Oxygen Sensor QGO20.

000D27

Basic Documentation

The QGO20... and this Basic Documentation are intended for use by OEMs which
integrate the oxygen sensor in their products!

CC1P7842en Siemens Building Technologies

11.12.2003 HVAC Products
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 Contents
1 Safety notes..................................................................................................... 5

1.1 Warning notes ................................................................................................. 5

1.2 Engineering notes............................................................................................ 5
1.3 Installation and mounting notes....................................................................... 6
1.4 Electrical connection of the oxygen sensor ..................................................... 6
1.5 Commissioning notes ...................................................................................... 7
1.6 Standards and certificates ............................................................................... 8
1.7 Service notes................................................................................................... 8
1.8 Disposal notes ................................................................................................. 8

2 Overview.......................................................................................................... 9

3 Type summary............................................................................................... 10

4 Technical data ............................................................................................... 11

5 Description of functions ................................................................................. 12

5.1 Functioning principle of the measuring cell ................................................... 12

5.2 Impact of the cell’s temperature .................................................................... 14
5.3 Impact of the reference gas........................................................................... 15
5.4 Switching on and switching off ...................................................................... 16
5.5 Aging ............................................................................................................. 16

6 Mechanical design of the sensor ................................................................... 17

7 Mounting and connecting the sensor............................................................. 18

7.1 Mounting........................................................................................................ 18
7.2 Electrical connections.................................................................................... 19

8 Connection diagram ...................................................................................... 20

9 Dimensions.................................................................................................... 21

10 List of figures ................................................................................................. 22

11 Index.............................................................................................................. 23

12 Addendum ..................................................................................................... 24

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 1 Safety notes
1.1 Warning notes

To avoid injury to persons, damage to property or the environment, the following

warning notes should be observed!

Do not open, interfere with or modify the oxygen sensor!

• All activities (mounting, installation, service, etc.) must be performed by qualified

staff
• Before performing any wiring changes in the connection area of the QGO20...,
completely isolate the sensor from the mains supply (all-polar disconnection). En-
sure that the sensor cannot be inadvertently switched on again and check this by
making a voltage test
• Ensure protection against electric shock hazard by providing adequate protection
for the connection terminals
• During operation, the sensor’s connecting head must be kept closed; all 3 screws
must be securely tightened
• Ensure that wiring is in an orderly state and keep hot plant or sensor components
away from the cables
• Ensure that the hot QGO20... does not get into contact with explosive or inflamma-
ble gases
• There is a risk of burning since the measuring cell works at an operating tempera-
ture of 700 °C and other accessible parts can get very hot too (> 60 °C)
• To prevent injury caused by the hot immersion tube, remove the QGO20... from the
AGO20... only after the equipment has cooled down
• Fall or shock can adversely affect the safety functions. Such sensors must not be
put into operation. The measuring cell might no longer function, even without exhib-
iting any damage, so that dangerous situations could occur
• Make certain that the sensor’s inlet and outlet are always kept free from dirt
• Before cleaning the inlet and outlet, allow the QGO20... to cool down for at least 1
hour. When using compressed air for cooling (only after the sensor has completely
cooled down), pressures up to 0.5 bar are permitted. If this is not observed, the
sensor can be damaged in a way that inadmissibly high CO levels in the flue gases
can occur
• Air must not be allowed to join the flue gases between the burner and the measur-
ing equipment. Ensure that the sensor’s mounting flange is completely tight
• Mount the sensor such that the connecting part (head to flange) is free so that the
exchange of air is ensured. Otherwise, measurements might get distorted, possibly
leading to dangerous situations
• Ensure that there are no chemicals, such as solvent vapors, near the sensor

1.2 Engineering notes

• If the burner is shut down for no more than 1 or 2 weeks, do not switch off the
QGO20... and the associated control unit (RPO25..., LMV52..., PLL52)
• To ensure a good response, always use the QGO20... together with the AGO20...
• Flue gas temperatures at the QGO20... must not exceed 300 °C, since higher tem-
peratures can destroy the sensor
• Use the QGO20... only with natural gas or light oil since other types of fuel can de-
stroy the sensor, resulting from aggressive substances in the flue gases

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 1.3 Installation and mounting notes

• Ensure that the relevant national safety regulations are complied with
• To facilitate mounting, both the QGO20... and AGO20... carry markings (refer to
Mounting Instructions M7842)
• The flue gas flow passing the measuring cell must be homogeneous, with no or
only little turbulence. When mounted too close to air dampers or pipe bends, faulty
measurements can occur
• The exchange of fresh air in the connection area of the sensor with the reference
air slots must be ensured and may never be covered up (by insulation or similar)
• On both the gas and air side, the sensor should not be exposed to corrosive gases
(NOx, etc.) since these can drastically reduce the sensor’s service life
• A number of faults can distort the measurements (this can lead to dangerous situa-
tions in connection with oxygen trim control):
- If the stack is not tight, false air can join the flue gases. In that case, the residual
oxygen content indicated by the sensor is higher than it actually is
- If the flue gas velocity is low, the sensor’s response is slower, since the flue
gases take more time to pass the measuring cell. In that case, it is recom-
mended to mount the sensor in an inclined position (refer to «Mounting»)
- The greater the sensor’s distance from the flame, the longer the dead time

Note For detailed information on mounting, refer to Mounting Instructions M7842.

1.4 Electrical connection of the oxygen sensor

It is important to achieve practically disturbance- and loss-free signal transmission:

• Do not run the sensor cable together with other cables, use a separate cable
• Observe the permissible length and specification of the sensor cables (refer to
«Technical data»)

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 1.5 Commissioning notes

• Prior to commissioning, check to ensure that wiring is in an orderly state

• To prevent the collection of condensate inside the QGO20..., do not put the burner
into operation before the sensor’s heating up phase is completed
• To avoid incorrect measurements, observe a heating up time of at least 2 hours
when first commissioning the plant, otherwise at least 1 hour

During the sensor’s heating up phase, temperature differences between the inner and
outer electrode generate thermo-electric voltages which, in that phase, falsify the ac-
quired oxygen value.
When commissioning the control system, the heating up times specified in «Engineer-
ing notes» must therefore be observed.
It is also recommended to keep the sensor activated during short burner off periods (1
to 2 days).

Prior to commissioning, make the following final checks:

- Check to ensure that the sensor is correctly fitted to the flange
- Ensure that the signal and power supply lines are correctly connected

Electronic circuit
- Activate the electronic circuit
- Wait until the sensor has reached its normal operating temperature, the residual
oxygen content is displayed on the associated control unit (RPO25..., LMV52...,
PLL52) and has stabilized. For more details, refer to the Basic Documentation of
the associated control unit (RPO25..., LMV52..., PLL52)

After the final mounting check, a first functional check can be made:

Functional check During the prepurge phase, the actual O2 value must be at a level of about 20.9 %. It
can be read off with the help of the handheld terminal AZW20.20 / AZL52...

Only with RPO25...: If set to measuring mode, the actual O2 value is also displayed di-
rectly by the RPO25...

It is also possible to make a functional check of the QGO20... based on a comparative

measurement.
Comparative measurement means that, during burner operation, the actual oxygen
value is measured with a flue gas analyzer and will then be compared with the value
acquired by the QGO20...

Note Flue gas analyzers measure «dry», the QGO20... measures «wet».
The conversion is made with the help of the conversion table contained in the Adden-
dum to this Basic Documentation.

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 1.6 Standards and certificates

ISO 9001: 2000 ISO 14001: 1996

Cert. 00739 Cert. 38233

Only in connection with Conformity to EEC directives

RPO25... - Electromagnetic compatibility EMC (immunity) 89 / 336 EEC
- Directive for gas appliances 90 / 396 EEC

Only in connection with Conformity to EEC directives

LMV52... / PLL52 - Electromagnetic compatibility EMC (immunity) 89 / 336 EEC
- Directive for gas appliances 0085BL0373

1.7 Service notes

Plants using the QGO20... must be serviced once a year. After no more than 3 months
of operation following commissioning, check the sensor’s internal resistance. If it ex-
ceeds 50 Ω, shorter the service interval to 3 months. Sensors having an internal resis-
tance of > 150 Ω should no longer be used for control tasks since their response is too
slow. For this reason, to ensure proper functioning, sensors with a resistance of
> 100 Ω should be replaced.

• Each time a sensor has been replaced, check wiring to ensure it is in an orderly
state
• Make certain that the sensor’s inlet and outlet are always kept free from dirt
• Check flange gasket on each service visit and replace if necessary
• Before cleaning, allow the QGO20... to cool down for at least 1 hour
• Check the flue gas collector AGO20... at regular intervals and clean if necessary
• After cleaning and heating up, check the O2 measurement and the proper function-
ing of the entire control equipment used in connection with the burner

1.8 Disposal notes

The oxygen sensor contains electrical and electronic components and may not be dis-
posed of together with household waste.
Local and currently valid legislation must be observed.

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 2 Overview

The QGO20... is an oxygen sensor that is used to acquire the residual oxygen content
of flue gases in heat generating plants that burn natural gas or light fuel oil. In connec-
tion with the control unit (RPO25..., LMV52..., PLL52), QGO20... monitors and controls
the combustion process. For mounting the QGO20..., flue gas collectors type AGO20...
are available. They can be welded directly into the stack. The QGO20... in connection
with the AGO20... is suited for use on all types of heat generating plant which burn
natural gas or light fuel oil with flue gas temperatures up to 300 °C at the test point. The
units of the ECOGYR range or LMV52...-systems – especially when used in connection
with oxygen trim control – are designed to minimize emissions and to optimize the effi-
ciency of the combustion process, also on retrofit projects.

QGO...
RVW... RPO...

M
SA4

M
SA1

M 7842s02/0802

SA2

Figure 1: General overview with a modulating burner as an example

Figure 2: General overview of a dual-fuel burner

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 3 Type summary

Oxygen sensor QGO20.000D27

- Complete with flange gasket

Flange gasket for service 5 759 2021 0

Control unit for oxygen trim control

- Refer to Data Sheet 7847 and Basic Documentation P7847 RPO25.000B27
- Refer to Basic Documentation P7550 LMV52... with PLL52

Flue gas collectors

- For stack diameters up to 400 mm AGO20.001A
- For stack diameters above 400 mm AGO20.002A

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 4 Technical data

General unit data Operating voltage of measuring cell’s AC 230 V ±15 %

AC 120 V ±15 % (only with LMV52... / PLL52)
Mains frequency 50...60 Hz ±6 %
Power consumption max. 90 W, typically 35 W (controlled)
Perm. mounting position refer to Mounting Instructions M7842
Degree of protection IP 40, to be ensured through installation
Weight (net) approx. 0.9 kg
Signal lines
- Shielded 6-core cable twisted pairs
- Shielding connected to terminal GND of
the RPO25... / LMV52...
- Wire dia. min. 0.25 mm²
(e.g. LiYCY 6 x 2 x 0.2 / 22 or
LiYCY 6 x 2 x 0.2)
Measuring system zirconium dioxide measuring cell as an
oxygen ion conductor
Perm. flue gas velocity (only with AGO20...)1...10 m / s
Types of fuel fuel oil «EL» or natural gas «H»
Measuring range 0.2...20.9 % O2
Perm. cable length max. 100 m
Power supply lines (Sensor heating)
- Wire dia. min. 1 mm² (e.g. NYM3 x 1.5)
Required operating temperature of 700 °C ±50 °C
measuring cell

Environmental Transport DIN EN 60 721-3-2

conditions Climatic conditions class 2K2
Mechanical conditions class 2M2
Temperature range -25...+70 °C
Humidity < 95 % r.h.
Operation DIN EN 60 721-3-3
Climatic conditions class 3K5
Mechanical conditions class 3M2
Temperature range
- Flange max. 250 °C
- Connecting head max. 70 °C
- Flue gas ≤ 300 °C
Humidity < 95 % r.h.

Condensation, formation of ice and ingress of water are not permitted!

AGO20... Tube DN50, steel X5 CrNi 18 9

Tube length
- For AGO20.001A 180 mm
- For AGO20.002A 260 mm
Flange DN50, steel X5 CrNi 18 9

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 5 Description of functions
5.1 Functioning principle of the measuring cell

The measuring cell of the QGO20... is made of ceramics (ZrO2), stabilized with Y2O3.
At temperatures above 500 °C, oxygen ions can diffuse through the ceramics material.
It carries a porous platinum layer on both sides, which serve as electrodes.

Figure 3: Functioning principle of the measuring cell

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 The diffusion of ions starts when concentrations on both sides of the cell differ.
The diffusion of oxygen ions carries electrical charges that generate an electrical field
across the platinum electrodes.
When in equilibrium, the diffusion force compensates the force of the electrical field.
On the one hand, the porous platinum electrodes serve for the catalytic conversion of
the molecules into ions, and vice versa
(O2 ⇔ 20 + 2e), on the other, for the acquisition of voltage.
The voltage across the electrodes is the so-called Nernst voltage. The magnitude of
this voltage is dependent on the difference in oxygen concentration and the cell’s tem-
perature.

R x T O2-Ref.
VN = In
4xF O2

where VN = Nernst voltage

R = gas constant 8.3 J / K
F = Faraday constant 96.486 As
T = absolute cell temperature (K)
O2-Ref. = oxygen content of reference gas (air: 20.9 %)
O2 = oxygen content of measured gas

R µV
that is = = 21.5 K or
4xF

RxT
= 20.9 mV at T = 700 °C = 973 K
4xF

Figure 4: Nernst voltage as a function of the oxygen concentration at a cell temperature

of 700 °C

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 5.2 Impact of the cell’s temperature

The slope of the curve changes on a change of cell temperature.

The lower the temperature, the lower the Nernst voltage and the higher the displayed
oxygen concentration.
The higher the temperature, the higher the Nernst voltage and the lower the displayed
oxygen concentration.

Figure 5: Impact of the cell’s temperature on the oxygen value

To limit the error, the temperature in the RPO25... / PLL52 is also considered when cal-
culating the oxygen value and monitored for a minimum temperature.
The actual temperature is continuously acquired and serves as an input variable for
controlling the cell’s temperature and for calculating the actual oxygen content.

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 5.3 Impact of the reference gas

When the oxygen concentration of the reference gas changes, the point of intersection
of the straight line with the abscissa will change (20.9 %).

Figure 6: Nernst voltage as a function of the reference gas

Note The QGO20... is a device that does not measure the absolute but the relative oxygen
value.
The result is calculated based solely on the ratio of the partial pressures of the refer-
ence gas (ambient air) and the measuring gas.

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 5.4 Switching on and switching off

When switching the sensor on or off, temperature differences generate thermo-electric

voltages of up to 100 mV (both positive and negative).
These can produce erroneous measurements during the heating up phase .
It is recommended to observe the heating up times specified in «Engineering notes».

5.5 Aging

Due to aging, the characteristics “internal resistance“ and “response time“ may change.
The RPO25..., LMV52..., PLL52 measures these characteristics at regular intervals and
triggers an alarm should programmable limits be exceeded.

Assessment of aging with On the display, the following 2 values can be checked:
the help of the RPO25... / - Internal resistance: Max. 150 Ω
LMV52... / PLL52 / - Response time: Max. 25 seconds
AZL52... / AZW20.20
If one of these 2 limits is exceeded, the QGO20... must be replaced.

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 6 Mechanical design of the sensor

The function of the oxygen sensor is ensured by the following components:

1) Measuring cell
The measuring cell acquires differences in oxygen concentrations and delivers a
Nernst voltage.

2) Gas routing
Ensures exchange of the measuring gases in the vicinity of the measuring cell.

3) Heating element
The heating element maintains the cell’s temperature at 700 °C.

4) Thermocouple
The thermocouple acquires the temperature in the cell and delivers a signal of
about 40 µV / K, which is used for temperature control.

5) Connecting head
The connecting head contains the sensor´s connection terminals and the tempera-
ture compensation element . The compensation element delivers a current of about
1 µA / K which represents the temperature inside the head. The sum of head tem-
perature and thermocouple temperature gives the absolute temperature in the
measuring zone (normally 973 K).

4) Thermocouple
2) Gas routing
Flue gas
7842z07e/1203

Flue gas

3) Heating element
1) Measuring cell
5) Connecting head

Figure 7: Mechanical design of the oxygen sensor

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 7 Mounting and connecting the sensor
7.1 Mounting

To simplify mounting in the stack, different types of AGO20... flue gas collectors are
available.

The AGO20... provides 2 functions:

1. Collection of flue gases and passing them to the sensor (Figure 8), adapting the
sensor to the stack.
2. Serving as a flange for accepting and mounting the QGO20... It is welded gas-
tight directly into the end section of the flue gas pipe.

For mounting position, refer to Mounting Instructions M7842.

To reduce the response time in the case of low flow velocities, the AGO20... can also
be mounted in an inclined position (Figure 8).
It must be ensured that the hole closest to the sensor head protrudes into the stack.

Flue gas

Air

7842z05e/1203

Figure 8: Mounting position of QGO20...

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 7.2 Electrical connections

Figure 10 shows the connection of the QGO20... to the control unit RPO25... / PLL52.

Note The signal lines require shielded 6-core cables with twisted pairs.
The shielding is to be connected to terminal GND of the RPO25... / PLL52.
Recommended cross-sectional area: Min. 0.6 mm²

• Open the cover only when the main switch is off so that both live and neutral con-
ductors are disconnected
• There is a risk of burning since the measuring cell works at an operating tempera-
ture of 700 °C

B1
B1

M
M

B2
B2

Q4 Q5 Q4 Q5

M
M

G2
G2

U3
U3

L N M B1 B2 M U3 G2 GND Q4 Q5 B1 M B2 M G2 U3 GND Q4 Q5
7842a01/1203

PLL52...

RPO... LMV52...

Figure 9: Electrical connections

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 8 Connection diagram

QGO20... QGO20...

M B1 B2 M U3 G2 Q4 Q5 B1 M B2 M G2 U3 Q4 Q5

L N M B1 B2 M U3 G2 GND Q4 Q5 B1 M B2 M G2 U3 GND L N PE

7842s01/1203
PLL52...

RPO25... LMV52...

Legend B1 (+) Signal of oxygen measuring cell

B2 (+) Thermocouple voltage
G2 (-) Power supply temperature compensation element
GND Electrical ground for shielding
L Live conductor
M (-) Electrical ground for «B1» and «B2»
M (-)
N Neutral conductor
Q4 Sensor heating element (AC 230 V)
Q5 Sensor heating element (AC 230 V)
U3 (+) Signal of temperature compensation element
Protective earth (PE)

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 9 Dimensions

Dimensions in mm

80 244
QGO20...
64 140 104
53
C

ø45
7
A

7842m02/0499

L 90
AGO20...
115 64
53,5
C

51
A

7842m04/0499

Legend A Flue gas inlet

B Flue gas outlet
C Notch on the flange marking the flue gas outlet side
L 180 mm for AGO20.001A
260 mm for AGO20.002A

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 10 List of figures

Figure 1: General overview with a modulating burner as an example ............................ 9

Figure 2: General overview of a dual-fuel burner............................................................ 9

Figure 3: Functioning principle of the measuring cell.................................................... 12

Figure 4: Nernst voltage as a function of the oxygen concentration at a cell temperature

of 700 °C................................................................................................................ 13

Figure 5: Impact of the cell’s temperature on the oxygen value ................................... 14

Figure 6: Nernst voltage as a function of the reference gas ......................................... 15

Figure 7: Mechanical design of the oxygen sensor....................................................... 17

Figure 8: Mounting position of QGO20... ...................................................................... 18

Figure 9: Electrical connections .................................................................................... 19

Figure 10: Table with the different types of flue gas analyzers (figures in %)............... 24

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11 Index
C ions starts ..................................................................14
cell temperature ............................................ 14, 15, 18 L
cell temperature control ............................................ 15 life expectancy ..........................................................17
ceramic cell ............................................................... 14 M
commissioning ............................................................ 5 measuring cell .................................5, 7, 12, 13, 18, 21
commissioning notes .................................................. 8 measuring range .......................................................12
comparative measurement ......................................... 8 modulating burner .............................................7, 8, 19
connecting................................................................. 19 Montage ......................................................................7
connecting head........................................................ 18 mounting .........................................................8, 10, 19
connection................................................................... 7 mounting instructions ......................................7, 12, 19
control unit .................................................... 10, 11, 21 mounting position ................................................12, 19
conversion table.......................................................... 8 N
cross-sectional area.................................................. 21 Nernst voltage .........................................14, 15, 16, 18
D O
dead time .................................................................... 7 operating temperature.................................5, 8, 12, 21
diffusion force............................................................ 14 operating voltage.......................................................12
E oxygen sensor.......................................7, 9, 10, 11, 13
electrical connections................................................ 21 P
F platinum layer ............................................................13
false air ....................................................................... 7 porous platinum electrodes .......................................14
false air entry .............................................................. 7 R
Faraday constant ...................................................... 14 reference gas ......................................................14, 16
faults ........................................................................... 7 residual oxygen content ....................................7, 8, 10
flange ........................................................................ 19 response time......................................................17, 19
flange gasket......................................................... 9, 11 S
flue gas analyzer......................................................... 8 sensor ...............................................5, 7, 8, 17, 18, 19
flue gas collector ......................................................... 9 shielding ....................................................................21
flue gas collectors ......................................... 10, 11, 19 signal lines ................................................................21
flue gas velocity .......................................................... 7 storage ......................................................................12
functional check .......................................................... 8 T
G table with the different types .....................................26
gas constant.............................................................. 14 temperature compensation .......................................18
gas routing ................................................................ 18 temperature compensation element..........................18
H temperature control ...................................................18
heating element ........................................................ 18 terminal .....................................................................21
heating up phase .................................................. 5, 17 thermocouple ............................................................18
I transducer ...........................................................15, 16
inclined position .......................................................... 7 W
installing ...................................................................... 7 weight ........................................................................12

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 12 Addendum

7842d05e/0602

Natural gas

Light oil
CO2 wet

CO2 wet
CO2 dry

CO2 dry
O2 wet

O2 wet

O2 dry
O2 dry

Figure 10: Table with the different types of flue gas analyzers (figures in %)

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D-76437 Rastatt
Tel. +49 7222 598 0
Fax +49 7222 598 269
www.landisstaefa.com

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