Super System BAZOOKA PROBE Installation Manual

SSi

BAZOOKA PROBE™

U.S. Patent No. 5,635,044

USER’S MANUAL

Super Systems Inc help desk:

1-800-666-4330

Revision B June 23, 2010

TABLE OF CONTENTS

Page
INTRODUCTION …………………………………………..….……3

FEATURES …………………………………………………….4

SPECIFICATIONS ……………………………..………….5

INSTALLATION …………………………………………………….6

MAINTENANCE ……………………………………….……..…….7

TROUBLESHOOTING ……………………………..………….8

CONTROL SYSTEMS ………………………………..……….9

WARRANTY ………………………………………….….…….10

REVISION HISTORY ……….…………………….….…….11

BAZOOKA PROBE MANUAL Page 2 of 11

INTRODUCTION

Thank you for selecting the Bazooka Probe™ for your atmosphere control
applications.

The Bazooka Probe™ represents a dramatic change in sampling oxygen sensor
technology. It has been designed primarily for use in measuring systems as
applied to endothermic generators, but is also useful in applications where high
temperatures may have adverse effects on both life and performance, such as
sintering.

The Bazooka Probe™ is a descendant of the original Gold Probe™ with the same
patented electrode construction. It is the product of a team of design and
application engineers, each with over twenty years of atmosphere control
experience. The SSi engineering team has long recognized that the sensor is the
most critical component in the atmosphere control system and has traditionally
been the weakest link. Now, reliability, repeatability, and accuracy are assured
with the inclusion of the Bazooka Probe™.

BAZOOKA PROBE MANUAL Page 3 of 11

FEATURES

The Bazooka channels a small sample to the patented probe measuring point,
thence into an integral micro isolating well which then vents the sample to the
combustion chamber of the generator, or the interior hot wall, in the case of
furnaces.

There is no cool area where soot can be deposited.

There is a tiny buffering volume separating the probe from the sample exit, so
response is fast.

Flow restriction is negligible, so a sampling pump is not usually necessary.

With a low initial price and a liberal warranty, the Bazooka can also be rebuilt and
re-certified for a modest investment.

The Bazooka is a direct replacement for most existing sensors.
The 1” NPT sealing gland is easily plumbed into existing installations.

BAZOOKA PROBE MANUAL Page 4 of 11

Useful %C range – 0-100F DP (01 to 1.6%C)

Temperature range - 1350º to 1700ºF

Stability +/- 1 mvdc

Impedance – less than 10 k ohms @ 1700ºF

Useful output – 0 to 1250 mvdc

Length 22.95”
Weight 2.6 lbs
Insertion 16.25” max

Mounting – 1” NPT
Sheath dia. – 0.84”

SPECIFICATIONS

BAZOOKA PROBE MANUAL Page 5 of 11

INSTALLATION

Fig. 1 shows a suggested installation utilizing a 1” coupling welded to the
generator wall. The hole through the insulation must be at least 1 ¼” in
diameter and axially aligned with the coupling to avoid interference with the
Bazooka™ well which has an O.D. of 1.050”. For existing installations with larger
fittings, use a bushing to reduce the diameter to the 1” female required by the
probe gland. Provide for about 1 SCFH of reference air, 6-10 SCFH of burnoff air,
and 2 – 3 SCFH of sample from the endo manifold or sample from individual
retorts. The probe should be inserted to a depth such that, at equilibrium, the
probe temperature is between 1400ºF and 1700ºF, preferably at 1550ºF.
Insertion or removal must be limited to 2” per minute to avoid thermal shock.

Temperatures above 1500 °F will prevent sooting from the sample atmosphere.

1550 °F is an optimal temperature to ensure that the sheath is not exposed to
excessive temperatures, and this temperature will provide optimal life of the
sheath and its components.

BAZOOKA PROBE MANUAL Page 6 of 11

MAINTENANCE

Maintenance of the Bazooka™ probe follows the same general rules as for the
Gold Probe™/ Periodic burnoff is required to prevent buildup of carbon in the
sensing region of the probe. Simple systems to provide the appropriate probe
conditioning programs are available from SSi. For generators, the normal burnoff
cycle is 24 hours when operating at 40º dew point. Lower set points will usually
require more frequent burnoffs. Burnoff frequency can be determined by the
time required to burn off to a sensor reading near zero mV.

Typical burnoff times are two minutes at 6 cfh of burnoff air with 1 ½ minutes
allowed for probe recovery. Sample flow rates (from the Rx gas manifold) are
typically 2 SCFH.

BAZOOKA PROBE MANUAL Page 7 of 11

TROUBLESHOOTING

If problems are encountered in operation, it is necessary to verify the integrity of
the probe and its supporting equipment, the control instrument, signal
transmission lines, or the process, including the controlling elements, such as
solenoid or motor driven valves. If there is disagreement between the probe’s
indicated value and dew point analysis, the following simple tests can be
conducted to eliminate the probe as a source of problems. The probe must be at
temperature and under stable control.

 Reference air flow 0.5 to 1.0 CFH

 Sample flow 2.0 to 3.0 CFH

 Check the probe resistance. It should be less than 10 kilohms. If

not, burn off the probe and retest.

 Test the speed of response after switching the control instrument to

manual control. First, record the mV output. Then short the probe for
5 seconds, remove the short and measure the time required to return
to within 1% of the original reading. If it exceeds 30 seconds,
conduct a burnoff and repeat the test after the reading has stabilized.

 Turn off the reference air supply for three minutes. Read the probe

millivolts, and then turn the air back on. If the reading changes
(immediately) by more than 25 mV, replace the probe. The substrate
is cracked or broken.

If these fundamental tests show that the probe is functional, check the following
possible reasons for disagreement:

 Contamination of the reference air supply with combustibles

 Air leak into the sample line. Check with a dew pointer at the probe

entry

 Faulty insulation in the signal lines

 Instrument out of calibration. Check with a DVM or calibrator that the

instrument reading matches the open loop probe or temperature
reading. When all else fails, call the SSi Gold Probe team at (800)
666-4330

BAZOOKA PROBE MANUAL Page 8 of 11

CONTROL SYSTEMS

If you are using the Bazooka Probe™ for the first time as a replacement in
an existing system, you will find that the performance is as good as or
better than you are accustomed to. If you plan on a new system to
upgrade your controls, you can rely on Super Systems to supply you
exactly what you need, from the simplest on/off controls to the most
sophisticated programmable PID control with computer interface.

Fig 2. Shows a typical generator control system with a separate
conditioning box available as a standard system from Super Systems.
SSi is positioned to provide a “plug and play” system that is operator
friendly. Components such as valves, flow meters, cable and tubing are
generally ordered with each system so that these items are available
when the system is installed. For details, please contact SSi or your SSi
representative.

CHILLED ENDO

FILTERED SAMPLE
OR BURNOFF AIR

BURNOFF SYSTEM

ENLARGED VIEW OF

GENERATOR INSTALLATION.

HOT FACE,
GENERATOR
COMBUSTION
CHAMBER.

FIG. 2 ENDOTHERMIC GENERATOR BAZOOKA SAMPLING AND CONTROL SYSTEM WITH CONDITIONING.

TO RETORT

REFERENCE AIR

CARBURETOR

(MIXING VALVE)

GENERATOR MANIFOLD

SSi

SUPER SYSTEMS INC.

CINCINNATI, OH

REFERENCE

BURNOFF

AIR

AIR

POWER

SENSOR CABLE AND
T/C EXTENSION WIRE.

MAIN

AIR

AIR/GAS MIXING PUMP

MAIN

GAS

SAMPLE

3-WAY VALVE

FILTER

GAS

ENDO TO FURNACE

CONTROL SYSTEM

SSi

SUPER SYSTEMS INC.

CINCINNATI, OH

TRIM
GAS

TRIM

AIR

CONTROL OUTPUTS

AIR

BAZOOKA PROBE MANUAL Page 9 of 11

WARRANTY

Super Systems, Inc. (SSi) as manufacturer of the Bazooka Probe™,
warrants it for a period of one year to be free from defects in material and
workmanship under normal use and service. SSi’s obligation under this
warranty is limited to repairing or replacing, at its option, the sensor
described herein, should failure occur within the warranty period. The
warranty period shall commence on installation of the sensor as certified
by receipt of the postage-free Registration Card accompanying the
sensor. If premature failure occurs, the sensor along with the Warranty
Claim Report must be returned in the complete, original packaging to SSi.
Upon receipt, SSi will conduct an examination as to the cause of failure,
at which time appropriate action will be taken.

For sensors operating at elevated temperatures, the warranty period is
prorated such that full warranty is granted for operation below 1850F; six
months warranty for temperatures between 1850F and 1950F; three
months warranty between 1950F and 2050F, and no warranty above
2050F.

There are no warranties, expressed or implied, by the distributors or
representatives for the Bazooka Probe™, except the expressed warranty
against defects described above. There will be no applicable warranty in
the event of breakage resulting from thermal or mechanical shock.
Additionally, there will be no applicable warranty for a probe which has
been subject to misuse, negligence or accidental damage.

This warranty cannot be honored unless the Registration Card is received
at SSi prior to the Warranty Claim Report, and the use and installation is
accomplished according to the techniques and procedures described in
the Bazooka Probe™ Manual. SSi shall in no way be liable for special or
consequential damages related to the use of this sensor.

BAZOOKA PROBE MANUAL Page 10 of 11

REVISION HISTORY

Rev. Description Date MCO #

- Initial Release 04-24-2001
A Added Revision History 07-11-2001 2008
A_01 Corrected grammatical and spelling errors 05-24-2002 2025
A_02 Address & general update 04-25-2005 2035
B Corrected some spelling errors; Added in optimal

temperature warning and general usage to the
Installation section; Added the “MCO #” column to the
Revision History

06-23-2010 2075

BAZOOKA PROBE MANUAL Page 11 of 11