Super System M4511v5 Installation Manual

Copyright 2001

INSTRUCTION MANUAL

M4511v5

TM

SuperOX

OXYGEN SENSOR

Ver. 3.0

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

SSi

513-772-0060 800-666-4330 FAX [phone]

SUPER SYSTEMS INC.

7205 Edington Drive, Cincinnati, Ohio 45249

Page 1

Table Of Contents

Introduction. . . . . . . .

Specifications. . . . . .

Characteristics. . . . . .

Operating Theory. . .

Installation. . . . . . . . .

Troubleshooting . . .

Warranty. . . . . . . . . .

Notes . . . . . . . . . . . . . 7

 Revision History . . . 8

1

1

2

3

3, 4

5

6

Page 2

SuperOX SENSOR MANUAL

INTRODUCTION

Thank you for selecting the SuperOXTM Sensor for your combustion control

application.

SuperOX TM represents "state of the art" in oxygen sensor technology. It has been
designed for use in combustion control systems for glass, power, steel reheat, chemical
process and incineration applications.

SuperOXTM, with it's patented measuring electrode construction, 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 a control system and has traditionally been the weakest
link. Now, reliability, repeatability and accuracy are assured with the inclusion of SSi’s

SuperOXTM high temperature, in situ sensor in

your

system.

SPECIFICATIONS

Useful O2 Range- 10

-20

to 100%

Overall length- 18, 26.6, 30 and 36”

Weight- 3.0 lbs.

Temperature range- 1200oF to 2900oF

Insertion- to 18, 26.6, 30 and 36”

Stability- within +/- 1 mvdc

Mounting- into 1" NPT female

Impedance- less than 5 kohms @ 1700F

Sheath diameter - 0.75"

Useful output- -50 to 1250 mvdc

Page 3

A

H

A

SuperOX SENSOR MANUAL

CHARACTERISTICS

The typical zirconia oxygen sensor consists of a closed end tube with the sensing portion at the tip. The

TM

tube is yttria stabilized zirconia. Fig.1 illustrates the SuperOX

Sensor design with details omitted for
clarity. The tip of the tube is spring loaded into contact with the outer, negative platinum electrode,
which is in contact with the ceramic sheath. The inner, positive electrode is spring loaded into contact
with the inner zirconia surface. A thermocouple is positioned close to the inner electrode surface and
reference air bathes the sensing surface.

LUMINA SHEAT

­T/C

+

-

+

FIG. 1

ZIRCONI

To the instrument technician, the sensor looks like a battery (see Fig.2.) It displays a voltage, EC, from
which the carbon potential can be calculated. The probe thermocouple is shown next to the sensing

electrode.

R

p

+

E

c

THERMOCOUPLE

FIG. 2

­+

-

The value of the internal resistance can be measured, as shown in Fig.3, by connecting a shunt resistor
across the sensor terminals, measuring the resultant voltage, Em and carrying out the simple calculation

shown.

R

p

E

c

R = ((E /E ) - 1) x R

pc

m

R

s

s

E

m

FIG. 3

Page 4

SuperOX SENSOR MANUAL

BASIC OPERATING THEORY

Oxygen concentration of a conventional combustion atmosphere is measured by an in situ zirconia

sensor, which responds to oxygen according to the Nernst equation shown here. Because the equation is
logarithmic, (to the base 10), the coefficient 0.0496TR is the number of millivolts accompanying a ten-

fold change in concentration:

Ec= -0.02756TR log (PR /PF) millivolts

where TR is the temp in degrees Rankine and PF and PR are the % oxygen (O2) in the furnace and the
reference gas.

INSTALLATION

If your new sensor is to be installed in an existing entry port, be advised that the sensor is 100%
interchangeable with your current sensor.

For new installations in furnaces, an

entry fitting

must be provided at the furnace wall, to permit the

sensor to extend into the furnace chamber. The furnace is prepared by drilling a 1 1/2" diameter hole

must

through the wall and the insulation. The hole

be at right angles to the wall to avoid interference

with sensor insertion. A 1" coupling may then be welded to the wall to provide the gas-tight entry.

TM

Because the SuperOX

has a 1 " NPT hub, use of conventional 1" fittings allows for appropriate
installation. A combination of 1 " nipples and connectors allows for appropriate insertion depth. Figures
4a and 4b show typical installations in furnaces and glass tank regenerators.

Your SuperOX

TM

Sensor has been shipped with heavy Teflon

TM

pipe tape applied to the gland, so you
may insert it directly into the furnace. When installing in a hot furnace, insert the first two inches
directly, then at a rate of no faster than 1" per 5 minutes

in order to avoid thermal shock fracture.

Support the cover end of the sensor during installation.

If you already have a control system for your oxygen sensor, you have probably been provided with a

TM

reference air supply. The SuperOX

Sensor, however, to protect the connections, has been designed
with cooling fins that require an additional air supply. SSi provides a custom system, P/N 13017 that
supplies both requirements.

It is imperative to emphasize that the reference air be

clean.

Any combustibles in the reference air will
cause the sensor to read high in oxygen, resulting in insufficient air addition. Avoid the use of lubricated
compressed plant air. Air connection at the sensor should be silicone rubber tubing to avoid problems
related to the high temperatures normally encountered at the sensor connection block. Reference air
flow should be in the range of 0.2 to 2 CFH at no more than 2 PSI. Cooling air flow should be in the
range of 1 to 10 CFH at no more than 2 PSI.

Your final installation should resemble that shown in Fig. 4.

Page 5

SuperOX SENSOR MANUAL

This view shows the installation of a 26.6” SuperOX in the wall of a furnace, utilizing a silicon protection
tube which requires a 1 ½” coupling (or half coupling) entry. This arrangement is typically used for
extremely high temperature applications. The wall is typically 13 ½” thick. Correct location of the sensor
in the protection tube may be accomplished by inserting a 1” coupling and appropriate length 1” nipple
between the sensor and the protection tube. There are three lengths of protection tubes for use with
sensors of 26.6”, 30” and 36”. When using the un-protected sensor

, a 1” coupling (or half coupling) can

be used for direct entry.

1 1/2" COUPLING,

GAS TIGHT WELD

SiC PROT. TUBE,

P/N 20188

SUPEROX

INSERTION-26.6"

HOT FACE
FURNACE WALL.

1 3/4" DIA. HOLE

FIG. 4

The standard SuperOX, Ver. 2.0 is provided with a 5’ high temperature cable, as illustrated in FIG.5, so
that a plug may be mounted for interconnection with the customer’s measurement and control
instrumentation. Alternatively, (and preferably), the customer may feed his instrument interconnection
cable through the cord connector, and make connections directly to the internal connector.

Wire designation:

White (Sensor +)
Black (Sensor -)
Green (Thermocouple +)
Red (Thermocouple - )

Page 6

SuperOX SENSOR MANUAL

TROUBLE SHOOTING

When trouble arises with an oxygen control system, it is important to establish where the problem is
located; the sensor, signal transmission lines, the control instrument, or the combustion chamber itself.
Several simple tests can help to isolate the problem quickly. It is most important to first understand the
nature of the fault. Aside from erratic behavior like cycling, or failure to stabilize at the set point, the
most common symptom is non-conformity of the work pieces to quality assurance specifications.

To evaluate most faults, the recommended tools are:

1. A good 3 1/2-digit millivoltmeter with at least 10 meg Ω input impedance and 0 to 1999 mV

range,

2. A temperature calibrator and

3. A simulator to output 0 to 200 millivolts at less than 50 meg Ω output impedance.

Sensor troubleshooting

: In order to establish the source of problems in your installation, first

the temptation to remove the SuperOX

TM

Sensor from the furnace.

All of the following

resist

meaningful questions must be answered while your sensor is at temperature, and exposed to a normal

atmosphere under manual

control:

1. Are the connections from the T/C extension wire and sensor cable clean and firmly attached

at the correct sensor and control instrument terminals? Note that the shield wire in the
sensor cable should be connected to ground at the control instrument end only!

2. Is the sensor impedance less than 50  at temperatures above 1550



F? Conduct the test

shown in Fig. 3 using a shunt resistor of about 10 . Measure the voltage EC before
shunting, then EM with the shunt in place. Calculate RP. If it exceeds 50 , proceed to step 6
below.

3. How quickly does the sensor react to a change in O

concentration? Read the sensor

2
millivolts with the controller or the digital meter. Short the sensor for 5 seconds, remove the
short and measure the time required to return to within 1% of the original reading. If it
exceeds 60 seconds, proceed to step 6, below.

4. Is there a leak in the zirconia substrate? To test this property, turn off the reference air for

one minute. Measure the sensor mV as indicated by the controller or a digital voltmeter. Turn
the air back on and measure the mV again. If there is a difference greater than 5 mV,
replace the sensor.

TM

5. Should it be necessary to remove your SuperOX

carefully. UNDER NO CIRCUMSTANCES

should it be removed faster than 1" per 5

Sensor from a hot furnace, do so

minutes.

6. Failing resolution of your atmosphere control problems our technical support staff is available

Mon. - Fri. 7:00 a.m. to 7:00 p.m. You may call us at [phone].

Page 7

SuperOX SENSOR MANUAL

WARRANTY

TM

Super Systems Inc. (SSi), as manufacturer of the SuperOX

Sensor, warrants it to
be free from defects in material and workmanship for a period of six months 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 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.

There are no warranties, expressed or implied, by the distributors or representatives

TM

for the Superox

Sensor, 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
sensor that has been subject to misuse, negligence or accident.

In order to receive warranty coverage, user must mail the Registration Card when

the sensor is installed, according to the techniques and procedures described in the

TM

Superox
received in the original packaging with the Warranty Claim Report. SSi shall in no way
be liable for special or consequential damages related to the use of this sensor.

Sensor Manual. This warranty cannot be honored unless the sensor is

Page 8

SuperOX SENSOR MANUAL

We suggest that you use this space to keep a record of installation date, test data and experiences with

your SuperOX

TM

Sensor.

NOTES

Page 9

SuperOX SENSOR MANUAL

Revision History

Rev. Description Date

- Initial Release 03-21-2001
A Added Revision History 07-11-2001
B Revised Fig 5 Drawing, changed Step 8 to read Step 6 02-19-2002
C Changed “eight inches” to “two inches” Page 2 Installation Instructions 06-04-2003

D Changed company address 05-15-2005
E Corrected air flow parameters under Installation 6-23-2011

SSi SUPER SYSTEMS INC.

7205 Edington Drive, Cincinnati, Ohio 45249・

513-772-0060 800-666-4330 FAX [phone]