Super Systems SuperOX User Manual
Oxygen Sensor
Operations Manual
TM
SuperOX
U.S. Patent No. 5,635,044
Super Systems Inc.
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060
800-666-4330
Fax: 513-772-9466
www.supersystems.com
Table of Contents
Introduction ..................................................................................................................................... 3
Specifications .................................................................................................................................. 3
Characteristics ................................................................................................................................ 3
Operating Theory ............................................................................................................................ 4
Installation ...................................................................................................................................... 5
Troubleshooting .............................................................................................................................. 7
Glass Tank/Glass Furnace Installation ........................................................................................... 9
Warranty.........................................................................................................................................12
Notes ..............................................................................................................................................13
Revision History .............................................................................................................................14
Super Systems Inc. Page 2 of 14 SuperOXTM Operations Manual
Introduction
-20
F
• Overall length: 26.5” (67.31 cm), 35.5”
NPT female
Sheath diameter: 1.00" (25.4 mm)
Thank you for selecting the Super Systems Inc. (SSi) SuperOXTM Sensor for your combustion
control application.
TM
SuperOX
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.
TM
SuperOX
, with its 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,
TM
repeatability and accuracy are assured with the use of SSi’s SuperOX
high temperature, in situ
sensor in your system.
Specifications
• Useful O
• Temperature range: 1200
• Stability: within +/- 1 mvdc
• Impedance: less than 5 kohms @ 1700
• Useful output: -50 to 1250 mvdc
Range: 10
2
to 100%
o
F to 2900
o
o
F
(90.17 cm), and 44.5” (113.03 cm)
• Weight: 3.0 lbs.
• Insertion to 18” (45.72 cm), 27” (68.58 cm),
and 36” (91.44 cm)
• Mounting: into 1" (25.4 mm)
•
Characteristics
The typical zirconia oxygen sensor consists of a closed end tube with the sensing portion at the
tip. The tube operates on the principle of yttria-stabilized zirconia. Figure 1 illustrates the
SuperOX
TM
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.
Super Systems Inc. Page 3 of 14 SuperOXTM Operations Manual
Figure 1
To the instrument technician, the sensor looks like a battery (see Figure 2). It displays a voltage,
EC, from which the carbon potential can be calculated. The probe thermocouple is shown next
to the sensing electrode.
Figure 2
The value of the internal resistance can be measured, as shown in Figure 3, by connecting a
shunt resistor across the sensor terminals, measuring the resultant voltage, Em, and carrying
out the simple calculation shown.
Figure 3
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 tenfold 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.
Super Systems Inc. Page 4 of 14 SuperOXTM Operations Manual
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 (ideally) a 3”
(76.2 mm) diameter hole through the wall and the insulation. A 1" (25.4 mm) coupling may then
be welded to the wall to provide the gas-tight entry. As the SuperOX
TM
has a 1" (25.4 mm) NPT
hub; use of conventional 1" (25.4 mm) fittings allows for appropriate installation. A combination
of 1" (25.4 mm) nipples and couplings allows for appropriate insertion depth.
Your SuperOXTM Sensor has been shipped with TeflonTM 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 (50.8 mm) directly, then at a rate of no faster than 4" (101.6 mm) per 5 minutes
in order
to avoid thermal shock fracture. Support the cover end of the sensor during installation.
The sensor requires a reference air supply. In addition, the SuperOX
TM
Sensor has been
designed with an optional cooling port that may 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 must be
dry, clean, and oil free.
Any
combustibles in the reference air will cause the sensor to read high in oxygen. Avoid the use of
lubricated compressed plant air. The air connection at the sensor should be made of 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.
Figure 4 and Figure 5 show installations in furnaces and glass tank regenerators.
These views show the installation of SuperOXTM probes in the walls of two different furnaces
furnace, utilizing a silicon protection tube which requires a 1 ½” (38.1 mm) coupling (or half
coupling) entry. This arrangement is typically used for extremely high temperature applications.
The wall is typically 13 ½” (342.9 mm) thick. Correct location of the sensor in the protection tube
may be accomplished by inserting a 1” (25.4 mm) coupling and appropriate length 1” (25.4 mm)
nipple between the sensor and the protection tube. There are three lengths of protection tubes
for use with sensors of 18” (45.72 cm), 27” (68.58 cm) and 36” (91.44 cm) lengths. When using
the unprotected sensor
NOTE: A protection tube is not required for use of the SuperOX
, a 1” (25.4 mm) coupling (or half coupling) can be used for direct entry.
TM
Sensor.
Super Systems Inc. Page 5 of 14 SuperOXTM Operations Manual
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