Summary of Contents for United Process Controls Oxyfire-LT
- Page 1 Oxyfire-LT Modular Oxygen Sensor Installation / Operation Manual © United Process Controls, Inc.
- Page 2 Oxyfire sensors are for use in combustion trim control only. Do not use with full-range air/fuel ratio control. United Process Controls, Inc. makes no warranties expressed or implied beyond the written warranty presented at initial purchase. United Process Controls, Inc. is not responsible for any product, process, damage or injury incurred while using the oxygen sensor.
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Page 3: Table Of Contents
VERIFICATION........................... 14 Method #1 ..........................14 Method #2 ..........................14 OXYFIRE-LT REPLACEMENT COMPONENTS ..............15 REPLACMENT PRECAUTIONS ..................16 ELECTROLYTE REPLACEMENT ..................17 TROUBLESHOOTING ........................ 19 ... - Page 4 The detector (especially at the tip) becomes very hot. Be sure to handle it with gloves. Oxyfire-LT may be heavy. Handle it with care. Do not drop it. Handle safely to avoid injury. Sensor Heater Only qualified personnel with knowledge of electrical equipment and safety procedures involving electrical equipment should be allowed to work on this equipment.
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Page 5: Introduction
OVERVIEW The Oxyfire-LT is a self-heated device that is mounted into the process flue with a flange interface. The º probe is internally heated to operate at a temperature of 600º... -
Page 6: System Configuration
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual E = Sensor Output in Millivolts T = Sensor Temperature in degrees Kelvin (degrees C + 273) = Oxygen concentration on the inside of the zirconia substrate (20.9%) 2_reference = Oxygen concentration on the outside of the zirconia substrate (unknown) - Page 7 United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual Insertion Rate 1 inch (25mm) per 5 minutes during a hot installation Sensor Outputs Two millivolt output signals (electrolyte and type K thermocouple) Interconnecting Cable Sensor to electronics 2-conductor twisted pair shielded Belden #6341PC cable...
- Page 8 United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual Table 1 Standard Part Numbers Part #: FO1 X -YYYY Sheath Style X Alumina Open End Alumina Closed SS 316 Closed End 7 Insertion Length YYYY 304.8 1200 457.2 1800 609.6 2400 3000 914.4...
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Page 9: Installation
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual 2 INSTALLATION APPLICATION CONFIRMATION Call your local MMI Representative or MMI directly when planning your sensor installation. The sensor location and depth of insertion are critical factors to consider and vary with different applications. -
Page 10: Wall Thickness
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual WALL THICKNESS Verify the exact thickness of the refractory in the crown or wall. A length of high temperature metal wire, formed like an “L”, should be inserted into the refractory hole. Hook the lengths of wire against the inside face of the refractory and mark the outside face of the furnace on the wire. -
Page 11: Cool Installation (100 ° F Or Lower)
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual COOL INSTALLATION (100 ° F or lower) If the installation is cool Apply Teflon tape or thread sealant to the sensor threads before installing. Insert the entire sensor at once and seal or tighten the port connection to avoid any air in- leakage. -
Page 12: Reference Air
2 psi. Sources for the air supply are regulated, clean plant instrument air or atmospheric air from a small pump. Each Oxyfire-LT sensor has a reference air inlet and outlet port. If necessary, but not required, the reference air outlet can be vented to a specified location. The reference air exhaust must not create back pressure nor can it be plugged. - Page 13 United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual Suitable ¼” tubing for the application, such as poly/teflon, copper, aluminum, or stainless steel should be run from the reference air supply to the sensor. 13 | P a g e...
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Page 14: Verification
Oxyfire-LT Installation/Operation Manual VERIFICATION The oxygen sensor does not require calibration with a certified calibration gas. The Oxyfire-LT includes a port and fitting for verification of the oxygen measurement and operation of the cell. There are two common methods used in the verification process. -
Page 15: Oxyfire-Lt Replacement Components
The Oxyfire-LT is designed for modularity and quick replacement of critical components. The sensor has three key components that can be purchased separately for replacement on-site. -
Page 16: Replacment Precautions
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual REPLACMENT PRECAUTIONS DO NOT REPLACE HOT COMPONENTS. The sensor must be removed from the process before any disassembly is accomplished. Please follow these instructions before replacing any component on the Oxyfire-LT The sheath must be inspected for sagging before replacing the Electrolyte Assembly. Severe sagging will cause concentricity interference issues with the electrolyte assembly installation. -
Page 17: Electrolyte Replacement
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual Inspect screw on terminals and replace accordingly Mounting surface Inspect all O-rings for integrity ELECTROLYTE REPLACEMENT 1. Remove the cap and inspect the threads on the Cap and on the Manifold base. 2. Disconnect the six screw-on terminals. - Page 18 United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual 4. Rotate the assembly aligning the two SHCS in the clearance holes. 5. Remove the assembly from the body. Clean out any debris before replacing the Electrolyte Assembly, inspect heater assembly to insure proper connection. If necessary, you may have to use 0.005"...
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Page 19: Troubleshooting
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual 6 TROUBLESHOOTING ITEMS REQUIRED The following items are required to troubleshoot the Oxyfire sensor. A digital multimeter (with DC millivolt ranges) Blade and Phillips screwdrivers Needle-nose pliers Verification gas or portable oxygen analyzer ... -
Page 20: Heater Troubleshooting
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual (+) wire and the (-) wire. This measurement should be fairly stable (see diagram on page 13 for wire color and location). iv. Using the charts in the appendix, look up the temperature and oxygen. Compare the readings to what you were seeing in the electronics. -
Page 21: Appendix
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual 7 APPENDIX OXYGEN CALCULATION A natural phenomenon occurs when zirconia oxide is heated above 550° C. and a reference gas is on one side and an unknown atmosphere containing the same component as the reference gas is on the other side. -
Page 22: Standard Oxyfire Sensor Wiring Connections
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual STANDARD OXYFIRE SENSOR WIRING CONNECTIONS 22 | P a g e... -
Page 23: Oxygen/Temperature/ Millivolt Chart
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual OXYGEN/TEMPERATURE/ MILLIVOLT CHART 23 | P a g e... -
Page 24: Useful Formulas
United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual USEFUL FORMULAS a. Fahrenheit to Celsius C = (5/9) x (F -32) Example: F = 100 C = 0.56 x 68 = 38 b. Celsius to Fahrenheit F = (C x 9/5) + 32 Example: C = 100 F = 100 x 1.8 + 32 = 212... - Page 25 United Process Controls, Inc. Oxyfire-LT Installation/Operation Manual NOTES 25 | P a g e...
- Page 26 Oxyfire-LT Installation/Operation Manual Reach us at www.group-upc.com United Process Controls brings together leading brands to the heat treating industry including Waukee Engineering, Furnace Control, Marathon Monitors and Process-Electronic. We provide prime control solutions through our worldwide sales and services network with easy-to- access local support.