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BAZOOKA PROBE
TM
OPERATIONS MANUAL
Super Systems Inc.
www.supersystems.com
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060
Fax: 513-772-9466
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Bazooka ProbeTM Operations Manual
Super Systems Inc.
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Super Systems Inc.
Super Systems Europe
Super Systems México
Super Systems China
USA Office
Corporate Headquarters
7205 Edington Drive
Cincinnati, OH 45249
Phone: (513) 772-0060
http://www.supersystems.com
Sistemas Superiores Integrales S de RL de CV
Calle 3 Int.: 11.
Zona Ind. Benito Juarez
Querétaro, Qro. Méx.
C.P.: 76120
Phone: +52 (442) 210 2459
http://www.supersystems.com.mx
Units 3 & 4, 17 Reddicap Trading Estate,
Sutton Coldfield, West Midlands
B75 7BU
UNITED KINGDOM
Phone: +44 (0) 121 329 2627
http://www.supersystemseurope.com
No. 335 XianXia Road
Room 308
Shanghai, CHINA
200336
Phone: +86 21 5206 5701/2
http://www.supersystems.com
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Bazooka ProbeTM Operations Manual
Super Systems Inc.
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Table of Contents
Introduction ..................................................................................................................................... 4
Features .......................................................................................................................................... 4
Specifications and Typical Probe Measurements ........................................................................... 5
Installation ...................................................................................................................................... 5
Maintenance .................................................................................................................................... 6
Control Systems .............................................................................................................................. 6
Troubleshooting .............................................................................................................................. 8
Warranty.......................................................................................................................................... 9
Revision History .............................................................................................................................10
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Bazooka ProbeTM Operations Manual
Super Systems Inc.
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Introduction
WARNING!
Follow all proper safety precautions. Use proper eye protection and hand protection at all
times.
Features
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 derived from 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™.
The Bazooka Probe™ channels a small sample to the patented probe measuring point. From
there, the sample enters 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.
See the
The Bazooka is a direct replacement for most existing sensors.
The 1” NPT sealing gland is easily plumbed into existing installations.
Warranty
section for more information on rebuild and warranty options.
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Bazooka ProbeTM Operations Manual
Super Systems Inc.
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Specifications and Typical Probe Measurements
Useful %C range
0°F to 100°F (-17.8°C to 37.8°C) Dew Point (0.1 to 1.6%C)
Temperature range
1350°F to 1700°F (732.2°C to 926.7°C)
Stability
±1 mvdc
Impedance
Less than 10 kohms at 1700°F (926.7°C)
Useful output
0 mvdc to 1250 mvdc
Part Number
Description
Typical Length
Insertion
Maximum
Mounting
Bazooka Probe™, GP133, Type S T/C
Bazooka Probe™, GP133, Type K T/C
Bazooka Probe™, GP205, Type K T/C
Bazooka Probe™, GP277, Type S T/C
Installation
IMPORTANT!
Zirconia is thermal shock sensitive. Insert into hot atmosphere no faster than 2” (51mm) per
minute (after first 4 inches or 101 millimeters).
The specifications for the Bazooka Probe™ are as follows.
Typical measurements for Bazooka Probes™ are as follows:
1713100
1713800
1713900
1711800
1711900
1712800
1712900
Bazooka Probe™, GP133, Type R T/C
Bazooka Probe™, GP205, Type S T/C
Bazooka Probe™, GP277, Type K T/C
23.0” (58.4cm) 16.2” (41.1cm) 1” NPT
23.0” (58.4cm) 16.2” (41.1cm) 1” NPT
23.0” (58.4cm) 16.2” (41.1cm) 1” NPT
29.2” (74.2cm) 22.4” (56.9cm) 1” NPT
29.2” (74.2cm) 22.4” (56.9cm) 1” NPT
36.4” (94.5cm) 29.6” (75.2cm) 1” NPT
36.4” (94.5cm) 29.6” (75.2cm) 1” NPT
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
(760°C) and 1700ºF (926.7°C), preferably at 1550ºF (843.3°C).
Temperatures above 1500 °F (815.6°C) will prevent sooting from the sample atmosphere.
1550 °F (843.3 °C) 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.
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Maintenance
Control Systems
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 60-90 seconds at 6-10 SCFH of burnoff air with 90 seconds allowed for
probe recovery. However, burnoff may require up to 20 SCFH. Sample flow rates (from the Rx
gas manifold) are typically 2 SCFH.
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.
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Bazooka ProbeTM Operations Manual
Super Systems Inc.
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ENDO TO FURNACE
AIR/GAS MIXING PUMP
(MIXING VALVE)
TO RETORT
MAIN
GAS
T/C EXTENSION WIRE.
SENSOR CABLE AND
CARBURETOR
MAIN
AIR
TRIM
GAS
GAS
TRIM
AIR
REFERENCE AIR
POWER
REFERENCE
OR BURNOFF AIR
FILTERED SAMPLE
BURNOFF SYSTEM
AIR
SUPER SYSTEMS INC.
CINCINNATI, OH
SSi
BURNOFF
AIR
CONTROL SYSTEM
FILTER
SSi
SUPER SYSTEMS INC.
CINCINNATI, OH
3-WAY VALVE
GENERATOR MANIFOLD
CHILLED ENDO
SAMPLE
AIR
FIG. 2 ENDOTHERMIC GENERATOR BAZOOKA SAMPLING AND CONTROL SYSTEM WITH CONDITIONING.
CONTROL OUTPUTS
GENERATOR INSTALLATION.
ENLARGED VIEW OF
HOT FACE,
GENERATOR
COMBUSTION
CHAMBER.
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Bazooka ProbeTM Operations Manual
Super Systems Inc.
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Troubleshooting
WARNING!
When troubleshooting, follow all proper safety precautions. Use proper eye protection and hand
protection at all times.
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.
If you experience problems and cannot find the solution after troubleshooting, please call SSi
Technical Support at (513) 772-0060.
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Bazooka ProbeTM Operations Manual
Super Systems Inc.
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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 1850°F (1010°C); six months warranty for temperatures
between 1850°F (1010°C) and 1950°F (1065.6°C); three months warranty between 1950°F
(1065.6°C) and 2050°F (1121.1°C), and no warranty above 2050°F (1121.1°C).
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.
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Super Systems Inc.
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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
to the Revision History
06-23-2010
2075
C
Burnoff Procedure (Maintenance section)
updated
06-23-2011
2080
D
Manual format updated to current format;
typical measurements added
02-10-2015
2157
temperature warning and general usage to the
Installation
wording updated as necessary; Bazooka Probe™
Bazooka ProbeTM Operations Manual
section; Added the “MCO #” column
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