MANUAL No.3071E R3Operation Manual for
TF-10
Oxygen Analyzer( Probe Transmitter )The person who operates the product

!

must

read

manual.

through

this

instructionSafety precautions!

WARNING(1) A voltage of 85 – 132V AC is applied to the power supply terminal of the receiver. Before
checking the wiring, always turn OFF the power. Failure to do so may cause an electricalshock.
(2) To prevent electrical shock hazards, always ground the grounding terminals firmly.
(3) If the sensor unit is removed while the plaint is being operated, the hot sample gas may spout
out from the furnace.

Therefore, do not remove the sensor unit during operation.

Ifremoval of the sensor unit is absolutely required, always observe the following cautions.

!

CAUTION(1) Carefully observe the following cautions when installing or removing the probe transmitter.
① Always wear heat-resistant gloves since parts close to the mounting seat are hot.
②

The hot sample gas and/or soot and dust may spout out from the opening of themounting seat. Do not get access to the opening.

③ The gas may also spout out from the calibration gas piping ports. Before installing or
removing the probe transmitter, attach stop plugs to the piping ports.

Restore thepiping to its previous state immediately after the probe transmitter has been installed.
④ The probe transmitter and sensor unit are hot. Always wear heat-resistant gloves toprevent burning hazards.
(2) The probe transmitter must be installed while the plant is stopped. Turn ON the probetransmitter one hour before starting the plant operation to raise its temperature.
If the temperature of the transmitter is not raised to its specified level, the sensor may bedamaged by the corrosive gas, causing the sensor to deteriorate earlier than usual.
(3) Always carefully install and/or remove the probe transmitter and sensor unit. Failure to doso may cause the ceramic parts inside the unit to break.
(4) Do not turn the terminal block with the sensor unit secured. The lead wires inside thesensor may be twisted, resulting in faulty wiring.

11. General description
1.1 Introduction“Model TF Zirconia Type O2 Analyzer “ is a unique oxygen analyzer emerged out of thestate-of-art fine ceramics technology. Down-sizing, minimal power consumption were attainedwith the integration of zirconia sensor and the ceramic heater. This Instruction Manual
described the installation, operation and inspection procedures of Model TF-10 for Model TF
Zirconia Type O2 Analyzer. We hope that this unit is operated after reading this Operating
Manual carefully prior to using it understanding the details of it thoroughly.
1.2 Product guarantee(1) Term:

Described in the final document.
Unless it is provided, the warranty term will last for one year after acceptance.

(2) Conditions: In the assumption that the product is properly stored and installed till the test
operation and adjustment after acceptance at the customer's site, the delivered
product shall be replaced or repaired without charge if any trouble orabnormality attributed to the poor design, manufacture or material which ourcompany is responsible for occurs though the product is properly used during
the above warranty term. Here, the proper operation method is as follows:① The operational conditions and installation conditions described in thespecifications and instruction manual shall be satisfied.
② Any excessive mechanical shock or vibration shall not be applied to theprobe transmitter.
③ Calibration of the analyzer and replacement of the consumable parts shallbe periodically carried out.
④ The operational state of the analyzer shall be checked and maintained.
(Note) The consumable and similar parts shall be outside the warranty range.
(3) Application: The warranty shall be limited only to those article delivered by us.
Warranty shall not be applicable to the losses incurred following to thefailure of our delivered articles(the losses or lost profits and others
incurred out of the controls or records by using the articles delivered from us,
the losses or lost profit and others of the equipment on which thearticles delivered from us are installed).

21.3 Table of contents

1. General description ･･･････････････････････････････････････････････････････････････

2

1.1 Introduction ･･･････････････････････････････････････････････････････････････････

2

1.2 Product guarantee ･････････････････････････････････････････････････････････････

2

1.3 Table of contents ･･････････････････････････････････････････････････････････････

3

1.4 General cautions ･･････････････････････････････････････････････････････････････

4

1.5 Outline of product and measuring principle ････････････････････････････････････････

5

1.6 Part names and functions ･･･････････････････････････････････････････････････････

8

2. After unpacking of unit ････････････････････････････････････････････････････････････ 12
2.1 Checking of accessories ････････････････････････････････････････････････････････ 12
2.2 Temporary storage of product ･･･････････････････････････････････････････････････

13

3. Installation ･･････････････････････････････････････････････････････････････････････

14

3.1 Installation conditions ･･････････････････････････････････････････････････････････

14

3.2 Installation procedures ･････････････････････････････････････････････････････････

15

3.3 Piping and wiring procedures ･･･････････････････････････････････････････････････

20

3.4 Inspection after installation ･･････････････････････････････････････････････････････ 23
4. Maintenance ････････････････････････････････････････････････････････････････････ 25
4.1 Cautions for maintenance ･･･････････････････････････････････････････････････････ 25
4.2 Maintenance and inspection items ･･･････････････････････････････････････････････

26

4.3 Troubleshooting ･･･････････････････････････････････････････････････････････････

27

4.4 Replacement parts ･････････････････････････････････････････････････････････････ 28
4.5 Replacement of parts ･･････････････････････････････････････････････････････････

29

5. References ･････････････････････････････････････････････････････････････････････

35

5.1 Standard specifications ･････････････････････････････････････････････････････････ 35

Request and information sheet to ENERGY SUPPORT CORP

3

1.4 General cautions!

• Always carefully install and/or remove the TF-10 probe transmitter and sensor unit. Failure to doso may cause the ceramic parts inside the unit to break.
• The following table shows the requirements for operating environment.

Probe transmitter

Installation place

Indoor/outdoor

Ambient temperature (℃)-10 – 80

Ambient humidity (% RH)

90 or lessInstallation posture

Horizontal – vertical downward* The ambient temperature of the pump air type unit is 0 - 40℃.
• If any corrosive gas and/or organic gas not stated in the specification are included in the operating
environment, this may shorten the service life of the sensor.
• The number of installation flange vibrations shall be 100 Hz or less and the vibration amplitude shallbe 0.5G or less.
(The vibration amplitude shall be 0.2G or less if the probe length is 1500 mm or 1000 mm and thehorizontal mounting with the guide pipe is used.)• If the unit is installed in a place where the vibration level of the installation flange exceeds the above
level, the customer must take appropriate measures so that the vibration is not applied to the probetransmitter directly.
• The probe transmitter is vulnerable to thermal shock. Do not place the hot probe transmitter on
the cold floor directly.

4

1.5 Outline of productThis product provides the excellent features listed below.

• No standard gas bombs are required.
Theoretically, there are no zero-drifts. The zero gas calibration, as well as maintenance of thestandard gas bomb are not required.

• No reference air is required.
Since the reference air is self-produced inside the sensor, no reference air is required.
Additionally, since a pump is built-into the calibration unit, no calibration air source is required.

• Built-in automatic calibration requires no daily maintenance work.
Automatic calibration with the internal cycle timer is built-into the product as standard accessory.
One-push manual calibration is also possible.

• Less expensive construction cost
Only 100V AC power supply is required as utility. No instrument and factory air sources are
required.
Additionally, no special electric wires (thermocouple compensation conductors) are required.
Only two 4-core cables and one calibration air piping are required, ensuring less expensive
construction cost.

• Low power consumption
The power consumption is approximately 40W, ensuring economical system. Additionally, theunit becomes ready for measurement only 3 min. after the power has been turned ON.

• Small diameter, and compact and light weight design
A thick film sensor integrating the zirconia sensor and ceramic heater is assembled into the pipewith a diameter of 10 mm. This makes it possible to install the unit even though the insertion port
is small (φ21.7 or more).
If the insertion length is 500 mm, the weight of the sensor unit is approximately 1 kg and that ofthe probe transmitter is approximately 2.5 kg. This lightweight design ensures easy installationof this unit in a small boiler.

5Principle of Zirconia 2 Cell Pump Type Oxygen Analyzer
1. Construction and functions (Refer to figure at right)① Heater :Sensing element is heated to approx. 800℃
② Sensing Cell :(1) Set the oxygen concentration of reference oxygen chamber

to approx. 100%.
(2) Measure the oxygen concentration of gas detection
chamber.
(Refer to the following for detailed theory of operation.)③ Pumping Cell :Set the oxygen concentration of gas detection charmer to 0%.
(Refer to the following for detailed theory of operation.)④ Gas Detection Charmer :Gather the exhaust gas through the gas diffusion holes.
⑤ Reference Oxygen Chamber : The oxygen concentration is at approx. 100% with thereference oxygen electrical micro current.
2. Characteristics of the detection section when heated to a high temperature.
①

An electromotive force (EMF) is generated with an induced oxygen ion conduction whengasses of different oxygen concentration are placed between the electrodes.
(Oxygen Battery by Concentration Principle)② By flowing an electrical current through the electrodes, oxygen ions proportional to sucha current are transferred in the opposite direction to the electrical current.
(Oxygen Pumping Effect)
The sensing cell utilizes principles ① and ②, while the pumping cell utilizes principle ②.
3. Principle of the sensing cell①

A minute electrical current flow is applied between the electrodes of the sensing cell.
By flowing electrical current through the electrodes, oxygen in the gas detection chamberis transferred to the reference oxygen chamber becomes approximately 100%.
NOTE : As the amount of oxygen transferred from gas detection chamber to the reference
oxygen chamber is extremely small, the oxygen concentration in the gas detection
chamber is not affected.
②

An electromotive force determined by the equation shown below is generated between

the electrodes of the sensing cell owing to the difference in oxygen concentrations
between gas detection and reference oxygen chambers.
This electromotive force is measured in the sensing cell section and sends a signal tothe pumping cell so that this electromotive force will become 450mV (oxygen
concentration in

the gas detection chamber is 0%).

EMF = About -53.2 × Log10

Oxygen Concentration in Gas Detection Chamber
Oxygen Concentration in Reference Oxygen Chamber (100)X
100
X = 0.00348ppm ≒ 0%

450 = -53.2 × Log10

6

4. Principle of the pumping cellAn electrical current is applied between the electrodes of the pumping cell so that the oxygen
concentration of the gas detection chamber becomes 0% by receiving a signal from thesensing cell.
Because the oxygen concentration in the exhaust gas is proportional to the electrical current
that flowed, the oxygen concentration in the exhaust gas can be measured by measuring theelectrical current.

Pumping Current (mA)

Construction of Sensor Element

Ａ

Ｂ Ａ

Ｂ

HeaterSensorExhaust Gas O2 Concentration（％）① HeaterＯ --ExhaustGas

Exhaust Gas
Gas
Diffusion
Holes

Ｏ --

Gas
Detection
Chamber

Heater Temperature Control③ Pumping Cell④

Pumping Current
Output Signal
Pumping Current
Controller② Sensing Cell
Reference Oxygen Generation
Minute Current⑤ Reference Oxygen Chamber
Ａ－Ａ

Ｂ－Ｂ

7

Reference Voltage(450mV)1.6 Part names and functions

KX-331023-A**(-*)

KX-331022-A**(-*)
3

Sample gas flow4

Filter cover5

Dimension L

6

Dimension A

7

Dimension B

8HD ball filter

92-hexagon socket head set screw

10

Sensor unit

11

Flange (Needs to be specified by separate part No.)12

R1/B calibration gas inlet

13

Terminal block14

Guide probe

15

Half-union MC-21, 7-6

16

Half-union MC-15-4

17

Wiring port G 3/4 x 2 pcs.

18

Sample gas flow

19Standard flange

20

TF-10 probe transmitter

21

Half-union MC-21, 7-6

8

Flange with dust-proof guide pipe

Flange with 1.5m-standard guide pipe

3

Sample gas flow

4

Sample gas flow

5

Flange with dust-proof guide pipe

6

Gas flow direction marking

7

TF-10 probe transmitter

8

Half-union MC-21, 7-6

9

Sample gas flow

10

Flange with 1.5m-standard guide pipe11

TF-10 probe transmitter

12

Half-union MC-21, 7-6

9

10

Sensor unit with terminal block

Sensor unit

3

Terminal block4

Nameplate5

Box nut, front ferrule, rear ferrule

6

Wiring port G3/4 x 2 pcs.

7

Mark band No.

8

Terminal block No.

9

Signal assignment

10

Box nut, front ferrule, rear ferrule11

G 1/2 male-screw

12

M3 crimp terminal

13

Mark band

Mark band
No.
1
2
3
4
5
6
7
8

Terminal Signal
block No. assignment
1
2
3
4
5
6
7
8

VS+
VSIP+
IPH+
HS+
S-

11

2. After unpacking of unit
2.1 Checking of accessories
List of product units and accessories
Name

Part No.

Q’ty

Remarks

TF-10 probe transmitter

KX-331022-A ** (- *)1(- *)：with Pressure
correction coefficient

HD ball filter

KX-391019

1

Accessory

HG3M3S3LSUS316

2

Accessory

Mori-coat 1000

KS-185352-6

1

Accessory

Hexagon bar spanner

1.5

1Accessory

Hexagon socket head stop
screw

Flange *Hexagon bolt

Hexagon nut

Flat washer

Spring washer

Flange packing

May vary depending on thespecification.

1

May vary depending on the

Accessoryflange size.
May vary depending on the May varyflange size.

depending

May vary depending on the on theflange size.

flange size.
May vary depending on theflange size.

Accessory

Accessoryflange size.
May vary depending on the

Accessory1

Accessory

The above table shows quantities for one set of units.
* Either the standard flange or flange with dust-proof guide pipe is to be delivered.
For details, see the final drawing of the oxygen analyzer.

122.2 Temporary storage of product!

When temporarily storing the product, take care for the following:• It is desirable to protect the product with styrene or similar in the box for storage.
• Store it at the place not directly exposed to sunlight.
• Store it at the surrounding temperature of -10 to 50℃ with the minimal temperature
variation.
• Store it at the place with minimal moisture and dust.
• Store it at the place not exposed to rain water.
• Store it at the place with minimal mechanical vibration.
• Store it at the place free of corrosive and dangerous gases.

13

3. Installation
3.1 Installation conditions!

This analyzer is a precision unit. To safely and correctly operate this unit, always take thefollowing conditions into consideration to determine an optimal installation place.
The unit must be installed in a place where;• It is not exposed to the high radiation heat.
• The electromagnetic field does not affect it.
• The humidity and dust are minimized.
• A variation in voltage is minimized.
• A vibration in power supply frequency is minimized.
• The ambient temperature is –10 - 50℃. (It is not exposed to the direct sunlight.)• The following requirements for operating environment must be satisfied.
Probe transmitter

Installation place

Indoor/outdoor

Ambient temperature (℃)-10 – 80

Ambient humidity (% RH)

90 or lessInstallation posture

Horizontal – vertical downward* The ambient temperature of the pump air type unit is 0 - 40℃.
• Corrosive gas does not exist.
• The number of installation flange vibrations shall be 100 Hz or less and the vibration amplitude shallbe 0.5G or less.
(The vibration amplitude shall be 0.2G or less if the probe length is 1500 mm or 1000 mm and thehorizontal mounting with the guide pipe is used.)
If the unit is installed in a place where the vibration level of the installation flange exceeds theabove level, the customer must take appropriate measures so that the vibration is not applied to theprobe transmitter directly.
• The resistance of the wiring between the probe transmitter and receiver shall be 5Ω or less in thego and back way.
For two CVVS 1.25sq-4c cables, the maximum length is 150 m or less.
For two CVVS 0.9sq-4c cables, the maximum length is 120 m or less.

143.2 Installation procedures
Cautions for installation!

• This analyzer is a precision unit. When installing this unit, do not apply excessive impact
and/or load to it.
• This unit may be broken easily. Do not hit this unit when installing it.
(1) Installation of flange① Install the flange with the dust-proof guide pipe so that the covering part faces toward the
upstream side of the sample gas flow as shown in the Fig. below.
(The standard flange and flange with 1.5m-standard guide pipe have no orientations.)② The mounting posture should be in a range of vertical downward to horizontal.
③ Install the flange packing so that it does not deviate.
④ Always tighten the hexagon bolts and nuts evenly.

Vertical – horizontal

15

1
2
3
4
5

Flange packing
Standard flangeStandard flange
Flange packing
Flange with 1.5m-standard guide pipe

6

Flange with 1.5m-standard guide pipe

789Flange packing
Sample gas flow
Flange with dust-proof guide pipe

10Flange with dust-proof guide pipe

11
12
13

Rear ferruleBox nut
Front ferrule16

(2) Installation of probe transmitter① Remove the box nut of the half-union MC-21.7-6, rear ferrule, and front ferrule from theflange, and then mount them on the probe transmitter.
(Pay special attention to their mounting orientations.)② Gradually insert the probe transmitter so that the calibration gas inlet faces the upstreamside of the sample gas.
First, insert the filter cover of the probe transmitter into the hole in the half-union of theflange.
If the probe transmitter is inserted slantwise, it cannot be inserted correctly.
At this time, if the probe transmitter is inserted forcibly, this may cause the probetransmitter to break.
③ When the filter cover is inserted, gradually insert the probe transmitter until the box nut isin contact with the calibration gas inlet.
④ Set the box nut, rear ferrule, and front ferrule, and then tighten them temporarily.
⑤ The insertion length of the probe transmitter becomes the maximum level when the box
nut of the half-union is in contact with the calibration gas inlet of the probe.
This insertion length can be changed as shown in the Fig. below.
(If the probe transmitter is equipped with the guide pipe, the insertion length cannot bechanged.)
Before retightening the box nut, always adjust the insertion length.

Insertion length
Insertion length (L)Insertion length adjustable range
Length (L) is 500.:

Insertion length is 250 – 500 mm.

The above data is applied

Length (L) is 1000.:

Insertion length is 750 – 1000 mm.

only when using theLength (L) is 1500.:

Insertion length is 1000 – 1500 mm.

standard flange.

17

⑥ Tighten the box nut in the following manner.
<To newly tighten the box nut>
• Lightly tighten the box nut with a spanner until the probe is no longer turned by hand.
This point is determined as start point.
• Tighten the box nut 1 1/4 rotations from this start point.

1 1/4 rotations• After plant operation has been started, retighten the box nut further about 1/8 rotation.
<To retighten the box nut>
• Lightly tighten the box nut with a spanner until the box nut is no longer moved. From
this position, retighten the box nut further about 1/8 rotation.

18

(3)Warmer installation work after installation of the probe transmitter
Warmer installation work shall be performed after installation of the probetransmitter
The guide pipe and flange warmer shall be installed as illustrated below toprevent corrosion at lower temperatures due to condensation in the guidepipe or at the flange
To permit removal of the probe transmitter, the warmer at the flange
section is desirably detachable.

193.3 Piping and wiring procedures(1) Piping procedures
Carry out the piping work between the calibration gas outlet and calibration gas inlet of theprobe transmitter.

1

Calibration air inlet Rc 1/8

2

TF-10 probe transmitter

3

CVVS 1.25sq. -4C x 2 pcs.

4

DTF-101 receiver

5

Calibration gas piping cut 6/4

6

Calibration gas flow meter

7

Calibration air outlet Rc 1/4*1: A flexible conduit is used for this portion (probe length + 1 m) to easily inspect and pull out theprobe.

20

(2) Wiring procedures
Carry out the wiring work between the probe transmitter and receiver, between the receiverand instrument room, and between the receiver and calibration unit.

1
2
3
4
5
6
7
8

TF-10 probe transmitter
DTF-101 oxygen analyzer receiver
Output, DC 4 - 20 mA
Power shut-off/instrument error contact output
Concentration upper/lower limit alarm contact output
Hi range echo back contact output
Maintenance contact output
Remote range switch contact input
When the contact is ON (no-voltage contact), the Lo range is selected if short-circuit occurs (remote switch

setting).
9
10
11
12

*1:

Output hold contact input
When the contact is ON (no-voltage contact), the output signal is held.
Air solenoid valve
Calibration unit
Power supply AC 100V, 100VA

3-core wires are used for the wiring work.

Always install the grounding plate on the

grounding terminal of the receiver, and connect the grounding lines to it.
21

(3) Wiring on probe transmitter－20－
Carry out the cable wiring through the wiring port (2-G 3/4) under the terminal block.
Run two 4-core cables one-by-one through the wiring port.
Additionally, take appropriate dust-proof and drip-proof measures during installation work.
All the terminal screws are M4 screws.

1
2
3
4
5
6
7

Caution) Do not touch the M3 terminal for the sensor unit.
Terminal screws are M4 screws.
Inside of terminal box
Wiring port G3/4 x 2 pcs.
Mark band No.
Terminal block No.
Signal assignment
CVVS 1.25sq.-4c x 2 pcs.

Caution) Process the end of the cable sheath close to the wiring port and put only the leadwire in the terminal box.
Caution) Carefully carry out the wiring work so that the conductors are not short-circuited in
the terminal box.

22

3.4 Inspection after installation
Proper wiring from the transmitter of Model TF-10 probe transmitter to the receiver . If!

power is supplied to the wrong wiring, it will cause a sensor breakage or other serious
trouble.

In order to prevent trouble which results from wrong wiring, check the wiring by the following
procedure with the air selected as the measured gas when turning on the power supply for the firsttime for test operation and adjustment.
After verifying that the power supply of the receiver is off, check the following.
(1) Heater wiring check (H+),(H-),(S+),(S-)
Check the followings after confirmed the receiver power is OFF.
• Resistance is measured at terminal block of the receiver between (H+), (H-) and between(S+),(S-).
Reference value : Heater resistance (2.5-4) Ω + lead wire resistance in transmitter (0.5-3) Ω+ wiring cable resistance (0-5) Ω• Resistance is measured at terminal block of the receiver between (H+), (H-), and between (S+),(S-).
Reference value : Lead wire resistance in transmitter (0.5-2) Ω + wiring cable resistance(0-5) Ω(2) Signal Load Wiring Check(Vs+),(Vs-),(Ip+),(Ip-)
Turn the electrical power to ON by disconnecting the lead wires of (Ip+),(Ip-) at receiverterminal block. Warm-up of transmitter is complete in about 3 minutes, so the followings aremeasured at the lead wires disconnected at the receiver terminal board.

Take sufficient care to prevent the disconnected line from being short-circuited or!

grounded.

The EMF between (Vs+) and (Vs-) is measured.
Standard value: 0 to 150mV (Approx. 40mV)The EMF between (Ip+) and (Ip-) is measured.
Standard value: 0 to 100mV(Approx. 0mV)
(3) Heater polarity check
Followings are measured at terminal block of the receiver.
Voltage between (H-) and (H+) Standard value: 5 to 13V(approx. 10V)
Voltage between (S-) and (S+) Standard value: 5 to 13V(approx. 10V)
Potential of (H+) and (S+) must be the same.
Potential of (H-) and (H+) must be the same.

23

(4) Signal wiring polarity check
Turn the electrical power to OFF and connect the lead wires(Ip+) and (Ip-) disconnection inparagraph(2) on the receiver side
Then turn the electrical power to ON and the followings are measured at transmitter side after
elapsed 3 minutes.
Voltage between (Vs-) and (Vs+): Standard value: 300 to 600mV(approx. 450mV)
Voltage between (Ip-) and (Ip+): Standard value: 0.3 to 1.5V(approx. 1V)(5) Maintenance inspections and wiring checks during the sensor replacements will be easier
when the cable marking bands are attached on the transmitter and receiver cables at this timeafter completed the wiring checks.
Note: The standard values indicated in paragraph(1) through(4) above are those when thesensor is at an initial condition. Because that value may change with the use, therefore,
the wiring checks must be made using the sensor in an initial condition.
Check Sheet during initial installation(Refer to paragraph (1) to (4) on the previous
pages for details of the checks.)
Check items

(1)

(2)

(3)

(4)

Standard value

Heater +lead wire +cable resistance

H+/H-

2.5- 9ΩS+/S-

2.5- 9Ω

Lead wire +cable resistance

H+/S+5Ω or lessH-/S-

5Ω or lessSensor signal

Vs-/Vs+Approx. 40mV

H+/H-

Approx. 10V

S+/S-

Approx. 10V

H+/H-

Approx. 10V

H-/H+

Approx. 10V

Vs-/Vs+Approx. 450mV

Ip-/Ip+Approx. 1V

Heater wiring
Polarity

Sensor signal
Wiring polarity

Check 1 ()

Check 2 (This column is reserved for aconvenient use during checks.

24)

4. Maintenance
4.1 Cautions for maintenance!

WARNING(1) If the sensor unit is removed while the plaint is being operated, the hot sample gas may spout
out from the furnace.

Therefore, do not remove the sensor unit during operation.

Ifremoval of the sensor unit is absolutely required, always observe the following cautions.

!

CAUTION(2) Carefully observe the following cautions when installing or removing the probe transmitter.
① Always wear heat-resistant gloves since parts close to the mounting seat are hot.
②

The hot sample gas and/or soot and dust may spout out from the opening of themounting seat. Do not get access to the opening.

③ The gas may also spout out from the calibration gas piping ports. Before installing or
removing the probe transmitter, attach stop plugs to the piping ports.

Restore thepiping to its previous state immediately after the probe transmitter has been installed.
④ The probe transmitter and sensor unit are hot. Always wear heat-resistant gloves toprevent burning hazards.
(3) Always carefully install and/or remove the probe transmitter and sensor unit. Failure to doso may cause the ceramic parts inside the unit to break.
(4) Do not turn the terminal block with the sensor unit secured. The lead wires inside thesensor may be twisted, resulting in faulty wiring.
(5) Always apply the screw burning prevention agent (Mori coat 1000, Dow-coaning) suppliedwith the unit to the hexagon socket set screws securing the filter cover.

25

4.2 Maintenance and inspection items!

The following table shows the maintenance and inspection items necessary to ensure correctfunctions and precise measurement.
Before starting the maintenance and inspection work, always fully understand the contents
stated in the table.

Unit nameProbetransmitter

Calibration
unit

Inspection part
Inspection criteria andRecommended
and itemmethodfrequency
Air calibration Perform the air calibration Once a month.
using the manual,(One week aftersemi-auto, and auto
the unit has
calibration procedures.
been installed(For details, see the air
newly.)
calibration procedures.)
Sensor output Check CAL. DATE monitor Once every 3 –inspection
after the air calibration has 6 months
been performed.
If AIR IP  10mA, AIR IP
 2mA, or AIR VP 
3.0V, replace the sensor.
Sensor drift
Check CAL. DATE monitor Once every 3 –amountafter the air calibration has 6 months
inspection
been performed.
If A. DRIFT  0.5%, checkthat the calibration is
performed correctly.
When necessary, performthe calibration again.
Sample gas
Measure the 90% response Once every 3 –response time time between turning OFF 6 months
inspectionof the solenoid valve andchanging of the indication
value to the sample gas
value after the air
calibration has been
performed.
If T90  3 min., replace theHD ball filter.
Calibration air 1 L/min. (1 – 3 L/min.)Once every 3 –flow meter
6 months

26

Remarks

This data can bechecked using the
DISPLAY SELECT
during air calibration.

T90 may varydepending on thesample gas flow rate.
Normally, T90 isapproximately 90 sec.
at 2 m/s. If a negative
pressure is applied
inside the furnace, theair remaining inside thepiping may affect T90.
If no guide pipes areprovided and the gas
flow rate is 20 m/s,
3L/min. is required.
Normally, set this value
to 1L/min.

Sampled
gas varies.

YES

27

NO

Turn off power
supply.
After 10 seconds,
turn it on again.
Normal return

NO

Cell electromotive
force varies.

wiring and piping.

Check external

The indicated value
flickers.

YES

Replace sensor.

Normal returncalibration.

Apply gas

the air display.

Replace filter.

wiring and piping.

according toSensor has aged.
(To next page)

Check external

RemedyNO

Filter is clogged.

Transmitter error

Error occurrence

Check display ofsetting error.
(Refer to 6-3.)

Primary delay
time change(Refer to 5-3(2).)

NO

Indicated value isabnormal.

Slow response

Repaired by maker.

Receiver troubleNO

Turn off power
supply.
After 10 seconds,
turn it on again.
Normal return

NO

Error occurrence

Remedyaccording to the
air display. (Tonext page)

YES

Reset setting.

Setting on

NO

Reset purging.

Reset calibration.

Key operation is
impossible.

Purging on

Calibration on

Output signal
does not vary.

4.3 Troubleshooting

4.4 Replacement parts① Spare and consumable parts
Part name

Part No.

Recommended
replacement frequency

Flange packing

T1995-*

Every 1 year

HD ball filter

KX-391019

Every 1 year

Filter cover

KX-391018

Every 2 years

Hexagon socket
head set screw

HG3M3L3SSU316

Every 2 years

Remarks
This part may vary dependingon the flange size.
Replace this part if the sample
gas response is delayed.
The replacement frequency
may vary depending on
operating conditions.
The replacement frequency
may vary depending on
operating conditions.

② Other replacement parts
Name

Sensor unit withterminal block

Sensor unit
(This unit is not
equipped with theterminal block.
Therefore, theterminal block needs
to be mounted fromthe old unit to a newunit.)
Terminal head
(Terminal block)Part No.

KX-731027-A** (- *)

KX-731024-A**

KX-731019

Guide probe

KX-391020-**

Standard flange

KX-391017-*

Flange with
1.5m-standard guide KX-391026-*
pipe
Flange with
KX-391025-***dust-proof guide pipe

Replacement criteria• Replace this part if the sensor
error occurs.
• Replace this part if it is corroded
or damaged excessively.
• Replace this part regularly once
every 2 – 3 years as normal
maintenance routine.
• Replace this part if the sensor
error occurs.
• Replace this part if it is corroded
or damaged excessively.
• Replace this part regularly once
every 2 – 3 years as normal
maintenance routine.
• Replace this part if it is corroded
or damaged excessively.
• Replace this part if it is corroded
or damaged excessively.
• Replace this part if it is corroded
or damaged excessively.
• Replace this part if it is corroded
or damaged excessively.
• Replace this part if it is corroded
or damaged excessively.

28

Remarks** shows the length.
(- *)：with Pressure
correction coefficient** shows the length.

** shows the length.
** shows the size.
* shows the size.
*** shows the lengthand size.

4.5 Replacement of parts(1) Replacement of glass tube fuse
Removal: Turn the fuse holder counterclockwise 1/4 rotation while keeping it pressed.
Mounting: After the fuse has been replaced with a new one, turn the fuse holder clockwise 1/4
rotation while keeping it pressed.
(2) Removal of probe transmitter① Turn OFF the power to the receiver.
② Disconnect the wiring and piping from the terminal block of the probe transmitter.
③ Loosen the box nut of the flange half-union MC-21.7-6 and gradually pull out the probetransmitter backward. (If the probe transmitter is pulled out slantwise, the filter covercannot be pulled out. Always pull out the probe transmitter straight.)
Since the probe transmitter is hot, always carefully perform the above work to!

prevent burn hazards.

Box nut

Rear ferruleBox nut
Front ferrule29

(3) Mounting of probe transmitter(To install a new probe transmitter, see the section, Installation. This section describes how tomount the probe transmitter, which has been removed for the maintenance work.)① Gradually insert the probe transmitter with the calibration gas inlet and filter cover opening
faced toward the upstream of the sample gas.
(First, insert the filter cover of the probe transmitter into the hole in the half-union of theflange. If the probe transmitter is inserted slantwise, it cannot be inserted correctly. At
this time, if the probe transmitter is inserted forcibly, this may cause the probe transmitter tobreak.)② When the filter cover is inserted, gradually insert the probe transmitter by the previous
insertion distance (to a part where the ferrule of the half-union is tightened.)③

Tighten the box nut and reconnect the wiring and piping.

(4) Removal of 【 A 】, filter cover, and hexagon socket head set screws① Remove the probe transmitter. (See the steps above.)② Prepare the hexagon bar spanner (width across flat: 1.5) and Mori-coat 1000 (KS-185352-6)
supplied with the unit.
③ Remove the upper and lower hexagon socket head set screws with the hexagon bar
spanner. Move the filter cover to the top. The filter cover and 【A 】 can then be

removed.
The 【 A 】 cover is sandwiched only by the guide probe and filter cover.
(5) Mounting of 【A 】, filter cover, and hexagon socket head set screws① Prepare the hexagon bar spanner (width across flat: 1.5) and Mori-coat 1000 (KS-185352-6)
supplied with the unit.
② Put the 【A 】 inside the filter cover and insert it to the top of the guide probe while

carefully checking the orientation of the filter cover.
• If the 【A 】 rotates and deviates in the filter cover, the filter cover cannot be mounted.

To avoid such troubles, insert the top of the filter cover with it faced downward slightly.
This ensures easy mounting without deviation of the 【A 】.

• For the orientation of the filter cover, make the orientation of the probe calibration gas inlet
matched with the opening of the filter cover (sample gas upstream side).
【 A 】：HD ball filter (KX-331022-A)
orSintered wire mesh filter , spacer (KX-331023-A)

30

③ Set the hexagon bar spanner on the hexagon socket head set screw, apply the Mori-coat1000 to the M3 screw thread part of the hexagon socket head screw sufficiently, andassemble it to the probe.
• Always apply the Mori-coat 1000. (This may prevent the screw threads from being
burnt.)• If the hexagon bar spanner is tightened excessively, the spanner edge may be rounded.
Always carefully observe this caution.

1 Caution: Pay special attention to the orientation of the filter cover so that thecalibration gas inlet faces toward the upstream side of the sample gas.
2 Sample gas flow direction
3 Calibration gas inlet
4 Hexagon socket head set screw
5 HD ball filter
6 Filter cover31

(6) Removal of sensor① Turn OFF the power to the receiver.
② Disconnect the wiring from the terminal block of the sensor unit.
③ Loosen the box nut of the half-union MC-15-4 of the sensor unit.
④ Put the spanner on the sensor unit part having a width across flat of 18 mm. By turning thespanner, gradually shift and pull out the sensor unit backward.
Do not turn the terminal block with the sensor unit secured. The lead wires inside thesensor may be twisted, causing the sensor to malfunction.
Always set the spanner on the part with a width across flat of 18 mm and carefully turn the
spanner to pull out the sensor unit.
Since the probe transmitter is hot, always carefully perform the above work to prevent!

burn hazards.

Box nut
Width across flat: 18 mm

32

(7) Mounting of sensor unit
① Mount the front ferrule, rear ferrule, and box nut on the sensor unit while carefully checking
their orientations.
② Gradually insert the top of the sensor unit into the hole in the half union MC-15-4 of theprobe.
③ When the top of the sensor unit is inserted, gradually insert the sensor unit.
(Even though it is felt that the insertion is slightly hard when inserting the part located after
the stepped part of the sensor unit, insert it forcibly.)④ Insert the sensor unit until the stepped part of the sensor guide is in contact with the innersurface of the stepped part of the guide probe.
Both stepped parts are in contact with each other at the last of the insertion work. Insert
the sensor unit in the insertion direction.
⑤ Tighten the box nut. (After the box nut has been tightened, the gap between the box nut
and part with a width across flat of 18 mm becomes approximately 10 mm as shown in theFig. below.)⑥ Restore the wiring to the previous state.

1

Stepped part2

Rear ferrule3

Box nut

4

Front ferrule5

Approximately 10 mm

33

4.3 Start-up Operation
The basic operation procedure for starting the oxygen analyzer is shown below.

Start-up operation① Turn the power ON.
Turn the power ON.

After the external power switch and the power switch inside
the receiver are turned on, the receiver starts thecount-down timer for warming the sensor (WARM-UP
shown on LCD). After the set temperature has been

Input sensor unit datareached, the measurement mode starts.
After the power has been turned ON, input RH0 (normal

WARM-UPtemperature heater resistance value) of the sensor unit
using the DISPLAY SELECT key, and LIN (linearizer NO.)

Check the output range.

RANGE(H)O2vol%(Measurement starts.)

using the SENSOR PARAMETER key.
When pressure correction coefficient is available, enter β1(pressure correction coefficient) in addition to the above
data using the PRESSURE SET key operation.
② Check the range (H/L) using the MODE key.
Operating the key on the receiver, check the output signal
range.

4.4 Stopping Operation
Before turning the receiver off, check that the inside of

Stopping operation!
Turn the power OFF.

the transmitter and the sensor are in the air
environment. Otherwise sensor deterioration will result.

Turn the power switch of the receiver off.
When inspecting the terminals of the analyzer or!

receiver or performing maintenance work
accompanying disconnection of wiring, turn theexternal power switch (source power switch) off.

34

5. References
5.1 Standard specifications
1. Measuring Range : 0～10/0～25%O2 Range (Wet base)(The measurement range should be switched with the receiver key)
Calibration range : 0～25%O2
2. Power Supply: AC100V±10% 50/60Hz
max.100VA

3. Output Signal: DC4～20mA (Isolated, max. loading resistance of 600Ω)The output signal is hold (retained) if an error occurs or duringcalibration.

4. Calibration gas: Air one-point calibration (1～3L/min./1set)

5. Control Unit:□ pump air type (Instrument air is not required.)□ Instrument air port installation type (Instrument air is required.)
Instrument air

Amount of Fine Powder: 0.1mg/Nm3 or lessDiameter of Fine Powder : 10μm or lessContent of Impure Oil: 1ppm or less

Dew Point at Normal Air : -17℃ or lessPressure: 0.2～0.7Mpa

6. Probe Length:□500mm below Flange □1000mm below Flange □1500mm below Flange

7. Flange size:□ Considerable to□ Considerable toJIS5K65AFF

JIS10K65AFF

8. Guide pipe

□ Others (Special): If the probe is 1500 mm long, the 1500 mm-standard guide pipe isprovided.
If the dust amount exceeds 1g/Nm3, the guide pipe for large dust amountcorresponding to the probe length is provided.

9. Stand□ Supplied:□ Not Supplied; □ Wall mount type

□ Stand

Calibration Unit ; □ Wall mount type

□ Stand

10. Method of mount : Receiver3511. Installation□ Standard□ Indoor

Place
Transmitter℃-10～80Humidity%RH

max.90
Horizontal-Vertical
downward direction.
□ Indoor

Place

Calibration
Unit□ Outdoor

Temperature

Mounting attitude

Receiver□ Special□ Outdoor

Temperature℃-10～50Humidity%RH

max.90□ IndoorPlace□ Outdoor

Temperature℃-10～50 (0～40) ※Humidity%RH

max.90※ (The allowable ambient temperature of the pump air type is 0 - 40℃)
12. Conditions of measuring gas□ Waste gas after general combustion□ Others□ Standard□ Special

Your specification

Flow rate

20m/sec. or lessm/sec.

m/sec.

Pressure±5kPa(Variation in draft
is ±3 kPa.)

kPa

kPa

max.550℃

℃

℃

g/m3N

g/m3N

Temperature
Dust concentration□ 1g/m3N or less
□ 1～30g/m3N

O2

0～25%

%

%

CO

───

ppm

ppm

CO2

0～20%

%

%

H2O

0～25%

%

%

SOx

max.2000ppm

ppm

ppm

NOx

max. 500ppm

ppm

ppm

HCl

max.1000ppm

ppm

ppm

N2

Bal.

%

%

Notes 1.If the SOx and HCl concentrations are 500 ppm or more, the analyzer is determined
as consumable one year after starting of operation.
(The material (SUS316) of the probe and flange are corroded at a low temperature.)
2.Components other than those stated above shall not be included. In particular, if
corrosive and/or toxic components (F,Cl,Si,Pb,Zn,Sn,As, etc.) exist, the sensor may
deteriorate in a short time. Never use this analyzer under such operating conditions.

36

13. Calibration method: Air one-point auto calibration (To make the manual calibration
valid, it is necessary to change the receiver system settings.)(The zero gas calibration is not required since the zero drift
is not included in the measuring principle.)

14. Response time

: Within 5 sec. However, if the probe is 1.5 m long, the responsetime is 7 sec. or less.
(The above response time is obtained from the 90%-response
performance test when the gas is switched between the airand standard gas (approximately 4% O2).)

15. Repeatability: ±0.5% F.S.

16. Linearity: ±1.0% F.S. (F.S.=25%)±2.0% F.S. (F.S.=5,10%)

17. Span drift: ±2.0% F.S./month (F.S.=25%, AIR point)
However, the span drift is ±2.0% F.S./week for one month after
operation has been started.

18. Zero drift: ±0.1% O2/year (N2 point)

19. Warming-up time

: Approx.3 min.

20. Contact inputs: Remote range switch, remote output hold,remote auto calibration, etc. 1a×5
(To change the settings, it is necessary to change the receiversystem settings.)

21. Contact outputs: (1) Self-diagnosis error, power shut-down, 1b×1
(2) Air solenoid valve drive, concentration upper/lower limit alarm,
Hi range echo back, maintenance, 1a×4
(To change the settings, it is necessary to change the receiversystem settings.)

22. Sampling method: Direct duct insertion method (Principle : Zirconia 2-cell pump method)

23. Wiring between transmitter and receiver :The wiring resistance shall be 5Ω or less in both in and out directions.
CVVS 1.25 sq.-4c×2

max.150 m or less

CVVS 0.9 sq.-4c×2

max.120 m or less

Piping：Control copper pipe cut φ6/4
(Wiring and piping materials shall be prepared by the customer.)37

The contents of this manual are subject to change without notice for improvement.
For inquiries regarding product handling, please contact us or our distributors.
Inquiry form URL：https://www.energys.co.jp/english/inq/all.php
ENERGY SUPPORT CORPORATION
1, Aza Kamikobarii, Inuyama, Aichi 484-8505 Japan