OXYGEN PROBE
INSTALLATION AND OPERATION
MANUAL
Version Number 004
OXYGEN PROBE VER 003 Page 2 of 11
COPYRIGHT(C)
No part of this publication may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any language or computer language, in any form or
by any means, electronic, mechanical, magnetic, optical, chemical, manual, or
otherwise, without prior written permission of FURNACE CONTROL CORP.
DISCLAIMER:
The OXYGEN PROBE is to be used by the industrial operator under his/her direction.
Furnace Control Corp. is not responsible or liable for any product, process, damage or
injury incurred while using the OXYGEN PROBE. FURNACE CONTROL CORP. makes
no representations or warranties with respect to the contents hereof and specifically
disclaims any implied warranties or merchantability or fitness for any particular purpose.
For assistance please contact:
Furnace Control Corp.
a member of United Process Controls
TEL: +1 513 772 1000
FAX: +1 513 326 7090
Toll-Free North America +1-800-547-1055
erika.leeds@group-upc.com
www.group-upc.com
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
OXYGEN PROBE VER 003 Page 3 of 11
TABLE OF CONTENTS
INTRODUCTION.......................................................................................................................... 4
ACCURACY.................................................................................................................................. 5
INSTALLATION ........................................................................................................................... 6
FURNACE PREPARATION....................................................................................................... 7
PROBE INSTALLATION............................................................................................................ 8
Probe Wiring Information ........................................................................................................ 9
SPECIFICATIONS ..................................................................................................................... 10
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
OXYGEN PROBE VER 003 Page 4 of 11
INTRODUCTION
General
Congratulations, you have purchased an Oxygen Probe developed and manufactured
by Furnace Control Corp a member of United Process Controls.
This high temperature oxygen probe is specifically designed for atmospheres containing
free oxygen, such as combustion, incinerator, or kiln applications.
Principle of Operations
The relationship between oxygen probe voltage output and temperature and oxygen
content of the measured atmosphere is described below.
A closed end stabilized zirconia tube is used for the solid oxide electrolyte. The
reference electrode which is located at the bottom of the interior of the zirconia tube is
designed to be in contact with a continuous flow of air. The P02 at the air, i.e. 0.209atm.
The sensor shown in Fig.1 is located directly in the heated atmosphere to be measured
so that the electrode on the outside of the stabilized zirconia tube is exposed to this gas
atmosphere. The oxygen partial pressure in the atmosphere, P02, is determined from the
voltage output of the sensor, E, and the furnace temperature, T, by the well known
Nernst expression:
P02 = 0.209 x 10-E/0.0496T (Eq.1)
where E is the probe output in millivolts and T is the probe temperature in °K.
The % oxygen of the atmosphere is given by Eq.2:
%Oxygen = 20.9 x 10-E/o.0496T (Eq.2)
where E is the probe output in millivolts and T is the probe temperature in °K
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
OXYGEN PROBE VER 003 Page 5 of 11
ACCURACY
The voltage output should be measured with a precision of about ± 1mv. For example, if
the oxygen content of the atmosphere is1% oxygen and the temperature is 2400°F
(1316°C), a variation of ± 1mv corresponds to variation of ± 0.03% oxygen.
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
OXYGEN PROBE VER 003 Page 6 of 11
INSTALLATION
Probe Location
The general guideline is that the oxygen probe should be exposed to the gas
atmosphere that is representative of the atmosphere to be controlled or monitored (in-
situ vs. sampled exposure). The probe location should also be in a temperature range
where the probe is designed to operate, 1400°F (760°C) - 2500°F (1372°C). It should
be noted that the probe head should be in a location where the probe head temperature
will not exceed 200°F (93°C).
Note: Determine the proper probe length at the location selected to make sure that it
will not interfere with muffle components, radiant tubes, fan blades, gas ports, or any
other furnace components. The probe length is adjustable and the probe need not be
inserted to the maximum length.
WARNING!
Before proceeding, remove all combustible atmosphere from furnace, open all
doors and cool furnace to room temperature
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
OXYGEN PROBE VER 003 Page 7 of 11
FURNACE PREPARATION
After the location of the probe is determined to be acceptable, as described above, a
port with a female 1-inch NPT thread and 11/2-inch I.D. clearance is required. The use
of a probe mounting flange Part No. 1.2F-10, simplifies the task to prepare a port in the
furnace.
The “probe mounting flange” has a precision 1-inch NPT thread machined into it and
has an alloy pipe extension to line and support the furnace refractory. Use of this part is
strongly recommended to minimize problems and to simplify the installation of the
oxygen probe.
1. Saw or Torch-cut a 2 ½” diameter hole in the steel shell of the furnace at the
probe location determined above.
2. Using an insulation boring tool, bore a 2” diameter hole through the thermal
insulation, concentric with the 2 ½” hole in the steel sidewall and perpendicular to
the sidewall. Remove boring tool and core of insulation.
3. Insert “probe mounting flange” into hole in furnace sidewall. Flange should fit
flush against sidewall. If not, take necessary steps to remove interference
material.
4. Using the “probe mounting flange” as a template, mark location of the four
mounting holes on the furnace wall and remove the furnace flange.
5. Drill and tap the four holes with 3/8” NC thread.
6. Insert the “probe mounting flange” in the furnace sidewall hole with a gasket
between the flange and the furnace sidewall.
7. Secure the flange to the furnace sidewall with four (4) 3/8” NC hex head bolts
3/8” long. A 1” pipe plug should be used to close hole in probe mounting flange
allowing normal furnace operation until the oxygen probe is ready for installation.
Note: In new furnaces or newly rebricked furnaces it is important that the refractory be
fully dried and cured before the probe is installed. Binders and some mortar
components released during curing can affect probe accuracy and shorten the probe
life. It is strongly recommended to operate the furnace for at least 8 hours at 1700°F or
higher to flush out potentially detrimental refractory components
WARNING!
Before proceeding, remove all combustible atmosphere from furnace, open all
doors and cool furnace to room temperature
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
OXYGEN PROBE VER 003 Page 8 of 11
PROBE INSTALLATION
Installation of the oxygen probe should only be attempted after a proper furnace port is
ready and all interconnecting wire, reference air tubing, and air supply are in place.
READ THESE INSTRUCTIONS COMPLETELY BEFORE ATTEMPTING THE
INSTALLATION.
Note: If you plan to install the oxygen probe in a furnace port previously used for
another probe or some other function, make certain that the threads are 1” pipe thread
(NPT), the I.D. is at least 1 ½” and that the hole is straight and open on the end.
Use extreme care when handling and installing the oxygen probe. It is susceptible to
thermal and mechanical shock and may be damaged if mishandled.
1. Carefully remove the oxygen probe from the shipping box and inspect for
damage by looking for broken ceramic pieces. It is not necessary to open the
probe cover for damage inspection. If damage is observed or is suspected, notify
the carrier who delivered the probe.
2. Remove 1” NPT plug from center of furnace flange or port, which has been
installed on furnace sidewall according to previous instructions.
3. Check the port I.D. for any obstruction and remove collected debris using
compressed air or brush.
4. Remove compression fitting body from the oxygen probe. Leave the nut and seal
rings or O-rings on the probe sheath. Put Teflon plumbers tape on pipe threaded
end of compression fitting. Thread compression fitting into furnace flange.
Tighten with wrench but do not exceed 20 ft.-lb.
If the furnace is 300°F or cooler, slide probe into compression fitting to the
desired depth. Make sure seal rings or O-ring is between compression fitting
body and nut. Hand tighten nut on probe sheath. Do not rotate probe while
tightening nut.
Note: It is preferable that the furnace be at 300°F or cooler for probe insertion; however,
if the temperature is above 300°F, the following instructions must be followed in the
sequence given or thermal shock may damage the probe.
5. Measure 6 inches from the end of the probe sheath and mark with a felt tip pen.
Mark the remainder of the oxygen probe in 1-inch graduations.
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OXYGEN PROBE VER 003 Page 9 of 11
6. Carefully insert probe into compression fitting to the first mark on the probe
sheath (6-inch mark). Make sure seal rings or O-ring is between compression
fitting body and nut. Wait 5 minutes while the probe warms up.
7. Insert probe at the rate of about 1-inch per minute.
8. Repeat step 7 above until probe is installed to proper length. Hand tighten
compression fitting nut on the probe sheath.
9. Connections for the probe signal and also integral thermocouple are made
through the black electrical connector located at the underside of the probe
cover. If you are using a probe cable supplied by the connector installed on the
end of the cable and T.C. extension wire, will mate with the connector on the
probe cover. Your new probe was shipped with a 10ft cable assembly.
Probe Wiring Information
The Gray colored shielded cable contains the probe mV output wires:
Black insulated wire is positive (+)
White/clear insulated wire is negative (-)
Thermocouple extension wires are contained in:
Green colored shielded cable for 'R' & 'S' thermocouples
Red insulated wire is negative (-)
Black insulated wire is positive (+)
Red colored shielded cable for 'B' thermocouples
Red insulated wire is negative (-)
Black insulated wire is positive (+)
10. Reference air connection is made through the brass ¼-inch tube fitting adjacent
to the electrical connector. Either soft plastic or copper tubing can be used.
Remove nut and ferrules from brass body or air fitting on the underside of the
probe cover. Place nut and ferrules on reference air tube and connect to air
fitting. Hand tighten nut on air fitting, and then turn ¾” with a wrench to set
ferrules on tubing. Once the ferrules are set on the tubing, hand tightening of the
nut is adequate.
CAUTION: DO NOT REMOVE AIR FITTING BODY OR VERIFICATION AIR
FITTING BODY FROM PROBE HEAD, OTHERWISE PROBE WILL MALFUNCTION.
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
OXYGEN PROBE VER 003 Page 10 of 11
SPECIFICATIONS
A patented*, ceramic sheathed, high temperature oxygen probe, specifically designed
for atmospheres containing free oxygen, such as combustion, incinerator or kiln
applications.
Continuous probe operating temp. 1400-2500°F
Probe head temperature limit 200°F maximum
Sensitivity ± 0.1mv
Accuracy ± 1.0mv, for example
@ 1% O2, 2400°F 1mv=.03%O2
Stability ± 1mv over probe life
Response time Less than 5 second
Impedance Less than 4000 ohms
Calibration None required
Probe construction high purity alumina sheath; Stabilized Zirconia
solid electrolyte; Pt-Rh alloy electrode; patented
woven refractory sleeve
Assembly thermal shock Some caution is advised, both Ceramic sheath
and Zirconia tube are temperature sensitive
Life About 2 years with normal use
Serviceability No field service required, completely re-buildable
at factory with substantial savings
Reference air required .2-1.0 SCFH ambient air
Thermocouple 26ga. type S standard
26ga. type B or R optional
Connections: Probe & T.C. AMP 4 pin CPC connector
Ref. Air ¼" O.D. tube fitting
Dimensions: Overall length 27"
Insertion length Variable from 6" to 20"
Probe diameter 1.00"
Mounting thread 1" male NPT
Probe Weight 3.5 Lbs.
Shipping Weight 7 Lbs
*Foreign Patents Pending;
US Patent No.4,814,061
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
OXYGEN PROBE VER 003 Page 11 of 11
Copyright © 2010, Furnace Control Corp., a member of United Process Controls. All rights to copy, reproduce and transmit are reserved.
