Cambridge Sensotec is a globally recognized manufacturer of high-performance gas analysers, known for its Rapidox range of oxygen analysis instruments. These analysers often incorporate zirconia oxygen sensors alongside electrochemical sensors to achieve precise measurements across a broad range of applications. Zirconia sensor technology allows Cambridge Sensotec’s instruments to measure oxygen from trace ppm levels up to 100% in demanding conditions. As an official distributor of Cambridge Sensotec analysers, BW Technology proudly offers these advanced solutions to customers worldwide, backed by expert support and service. By partnering with BW Technology, users gain access to Cambridge Sensotec’s cutting-edge gas analysis technology and a team dedicated to helping them implement it effectively.

Zirconia Oxygen Sensors: Features & Industrial Applications

Zirconia oxygen sensors (zirconium dioxide-based sensors) are renowned for their ability to deliver fast, accurate oxygen readings even in extreme environments. Unlike common electrochemical cells, zirconia sensors operate at high temperatures (requiring an internal heater up to ~700 °C) and can directly withstand harsh process conditions. This makes them particularly suitable for monitoring oxygen in inert atmospheres and high-temperature processes. For example, Cambridge Sensotec’s Rapidox zirconia analysers use robust, long-life zirconia probes (often with integrated thermocouples) to measure very low oxygen levels with rapid response times in environments up to 650 °C. A key advantage of zirconia sensors is that they can be installed in-situ, directly in the process stream, without the need for complex sampling systems – providing immediate readings even in vacuum or combustible atmospheres.

The performance benefits of zirconia O₂ sensors translate into reliable operation in a variety of industrial applications where other sensors might falter. These sensors excel at controlling and monitoring furnace or kiln atmospheres, ensuring optimal combustion and product quality in steel production and glass manufacturing. In fact, zirconia probes are commonly used to instantly measure oxygen levels in steel refining and molten metal processing without needing to extract samples. They are equally valuable in glass melt furnaces and ceramic kilns, where tight oxygen control prevents product defects and improves energy efficiency. Zirconia oxygen analysers are also widely used in exhaust gas analysis for combustion engines and boilers – for example, automotive oxygen “lambda” sensors and boiler flue gas monitors rely on zirconia technology to maintain the ideal air-to-fuel ratio. In the chemical and electronics sectors, zirconia-based analysers enable inert atmosphere monitoring (e.g. nitrogen or argon blanketing) to protect sensitive processes. Maintaining low residual O₂ levels is critical in processes like pharmaceutical production, semiconductor fabrication, and food packaging to prevent oxidation. Zirconia analysers such as the Rapidox series are ideal for these tasks, measuring oxygen in the ppm range to ensure an ultra-low O₂ environment. From furnace monitoring and gasification systems to laboratory gloveboxes and nitrogen generators, zirconia oxygen sensors provide the stability and accuracy needed to safeguard product quality and safety in aggressive conditions

BW Technology’s DBI 2000 Series vs. Eaton MTL G1010 – Next-Generation Oxygen Analyser

The Eaton MTL G1010 galvanic oxygen analyser (Crouse-Hinds series) was a benchmark instrument, offering a wide measurement range from 100% down to 0.1 ppm O₂ with version-specific galvanic sensors for different applications. It featured a panel-mounted display with auto-ranging readout, dual adjustable alarm contacts, and options for remote or even hazardous-area sensor installations. BW Technology’s DBI 2000 Series now builds on this proven foundation – delivering modern enhancements that make it a superior drop-in replacement for the G1010 in virtually all applications.

BW Technology’s DBI 2000 Series Gas Analyser is a compact, high-precision O₂ instrument designed for reliability and ease of use. Weighing only about 1 kg and housed in a durable glass-fiber reinforced enclosure, the DBI 2000 is built for panel mounting (standard 96×96 mm) to integrate seamlessly into industrial systems. It achieves rapid response times (T₉₀ ~3 seconds at percent levels) and excellent stability (drift <2% of reading per month) for dependable real-time oxygen monitoring. Maintenance is straightforward – the sensor cell is accessible via the rear of the analyser for quick replacements, and the unit’s robust design minimizes downtime. Multiple power supply options (110–240 V AC or 24 V DC) and both 0–5 V and 4–20 mA analogue outputs are supported, simplifying integration with virtually any control system.

For users comparing the DBI 2000 and the Eaton MTL G1010, here are several ways the DBI 2000 Series surpasses the G1010 in features and performance:

• Measurement Range & Sensor Flexibility: Both analysers cover oxygen from trace ppm levels up to high percentages. The G1010 employed multiple galvanic sensor types (e.g. “N”, “E”, “L” cells) to optimize accuracy for different gases and ranges – including sensors for CO₂ or H₂S-rich streams and for ultra-low ppm detection. The DBI 2000 Series matches this versatility with its own suite of easily interchangeable sensor cells (DN, L, and E types) tailored to various ranges and background gases. This means users can monitor everything from %O₂ in flue gas to ppm O₂ in pure inert gas with one platform, simply by choosing the appropriate sensor cell.

• Fast Response & Stable Accuracy: The DBI 2000 delivers swift, accurate readings, achieving a T₉₀ response in about 3 seconds at percent-level O₂ (and ~20 s at ppm levels) while maintaining excellent stability over time. This real-time responsiveness meets or exceeds the performance of the legacy G1010 (which also emphasized fast reaction to oxygen changes). In practice, DBI 2000 users can trust that sudden shifts in oxygen concentration will be detected almost immediately, without the signal drift that plagues older analysers. Consistently low drift (on the order of 1 ppm per month) means calibration intervals can be extended, maximizing uptime.

• Integration & Output Options: The DBI 2000 is engineered for easy integration into modern systems. It supports user-selectable analog outputs (both 0–5 V and 4–20 mA included standard) and offers flexible power input choices (universal 110–240 V AC or 24 V DC). By contrast, the G1010 provided a single analog output that had to be specified (voltage or current) when ordering the unit. The DBI’s all-in-one design simplifies installation and allows one analyser model to suit a variety of control schemes and locations – whether it’s a fixed control panel or a mobile skid, no special versions or add-ons are required to interface with your system.

• Maintenance & Longevity: Long sensor life and low maintenance were hallmarks of the G1010 (its galvanic O₂ sensors could last up to 5 years and it featured simple one-point calibration). The DBI 2000 continues this tradition while making maintenance even more convenient. Its sensor module is rear-mounted and designed for quick swap-out, meaning minimal downtime when a cell replacement is needed. Both analysers boast robust build quality, but the DBI 2000’s updated design and components ensure long-term reliability with minimal drift or degradationfile-q9ip7ucizpntbcotkmyxcd. In short, DBI 2000 owners can spend more time focusing on their process and less on instrument upkeep – an important consideration for any continuous monitoring application.

• Modern Support & Future-Proofing: As a new-generation product supported by BW Technology, the DBI 2000 Series comes with full technical backing, readily available spare sensors, and ongoing product development. Users searching for the Eaton MTL G1010 (a design introduced in years past) will find that the DBI 2000 not only meets the G1010’s specifications, but exceeds them in usability and support. With BW Technology as the manufacturer and Cambridge Sensotec’s official distributor, customers have a direct line to expert assistance. This ensures the DBI 2000 Series remains a future-proof solution for oxygen analysis, whereas legacy G1010 units may face obsolescence or limited availability over time.

Conclusion – The Optimal Oxygen Analysis Solution

In today’s demanding industrial landscape, having the right oxygen analyser can make all the difference in safety, efficiency, and product quality. Cambridge Sensotec’s Rapidox analysers (featuring state-of-the-art zirconia sensor technology) and BW Technology’s own DBI 2000 Series together provide a comprehensive toolkit to tackle any oxygen measurement challenge – from ultra-low ppm monitoring in inert atmospheres to robust %O₂ tracking in exhaust gases. As an official distributor and partner, BW Technology is uniquely positioned to deliver these solutions to a global audience, with the expertise to help you select and integrate the ideal analyser for your needs.

Ready to upgrade your oxygen monitoring capabilities? Whether you were initially considering the Eaton MTL G1010 or simply need the best-in-class analyser for your application, BW Technology’s DBI 2000 Series offers a superior, modern solution. Contact our team to learn more or visit our Products page to explore the full range of Cambridge Sensotec analysers and BW Technology’s gas analysis products. Let us help you achieve safer, more efficient operations with the power of advanced oxygen sensor technology.