MANUAL No.3013E R2OPERATION MANUALFORSENSOR OF O2 ANALYZER
FOR PROCESSING
TYPE AS-210

1． General
1-1 Introduction
The PME oxygen analyzer is a very unique analyzer developed through the latest
ceramics production technologies. This operation manual describes instructions
for the AS-210 type sensor. Refer to the separate operation manual for theanalyzer. Read both manuals thoroughly to prolong the service life of ourproducts.

IMPORTANT

1-2 Precautions

・ When using the analyzer for the first time after unpacking
or after replacing the sensor, the sensor data (linearizer

no. and resistance at normal heater temperature , Pressure
correction coefficient) must be input and air-pointcalibration must be preformed.

・ Do not handle the analyzer violently and avoid installing it in a location
where vibrations may be caused.
・ Do not expose the sensor to water or volatile liquids.
・ The exhaust and sample gases must not contain corrosive gases.
・ If the exhaust and sample gases contain flammable gases, the measured valueof oxygen concentration will contain an error.

- 1 -1-3 Contents
1． General ..................................................................... 1
1-1 Introduction ................................................................ 11-2Precautions ................................................................. 1

1-3 Contents .................................................................... 2
1-4Product warranty ............................................................ 3

1-5

Outline of product .......................................................... 3

1-6 Nomenclature and functions .................................................. 6

2． Installation ................................................................ 72-1

Installation side ........................................................... 72-2 How to install sensor ....................................................... 83． Maintenance ................................................................ 10
3-1 How to replace sensor ...................................................... 10
3-2 Spare parts list ........................................................... 10
3-3 Troubleshooting ............................................................ 11- 2 -COUTION

1-4 Product warranty(1) Warranty term
ENERGY SUPPORT CORP. guarantees this analyzer against

defective parts and workmanship for one full year form the dateof delivery.
(2) Conditions

ENERGY SUPPORT CORP. will exchange or repair any defective design, parts, or
workmanship during the warranty if correctly used, installed and operated atyour site provided such defective parts are returned with postage prepaid tothe manufacturer or an authorized sales outlet.
Proper operation refers to abiding by the following conditions:① Operation and installation conditions specified in the specifications andthis operation manual shall be sufficiently observed.
② No excessive mechanical shock or vibration shall be given to the probe
generator.
③ Periodic calibration of the analyzer and the replacement of consumableparts shall be conducted properly.
④ Confirmation of appropriate operation and maintenance shall be conducted
properly.
Note: This warranty is not applicable to expendable and consumable parts.
(3) Scope of WarrantyThis warranty is limited to the analyzer manufactured and supplied by ENERGYSUPPORT CORP.

REFERENCE

1-5 Outline of product
The AS-210 type sensor has the following features.
・ O2 analyzer with a zirconia two-cell pump.
・ Low power consumption of the sensor (about 13w for normaluse)・ Can be calibrated using air (requires only span pointcalibration and no zero calibration)
・ Short warm-up time (about 3 minutes)
・ Easy maintenance・ Compact design- 3 -

Theory of oxygen analyzer with zirconia two-cell pump
１. Configuration and function (refer to the figure on the right)① HeaterThe zirconia element is heated to approximately 800℃.
② Sensing cell(1) Sets the oxygen concentration of the reference oxygen chamber toapproximately 100%.
(2) Measures the oxygen concentration of the gas detection chamber.
(For details on the theory, refer to the following description.)③ Pumping cell
Sets the oxygen concentration of the gas detection chamber to 0%.
(For details on the theory, refer to the following description.)④ Gas detection chamber
Incorporates the sample gas through the gas diffusion holes.
⑤ Reference oxygen chamber
Always kept at about 100% O2 by reference oxygen micro current.
２. Features of zirconia element caused by being heated at high temperature① When gases with different oxygen concentrations are place between theelectrodes, the oxygen ionic conduction occurs, generating an electromotiveforce.
(Oxygen concentration cell theory)② By passing the electric current between the electrodes, the oxygen ions movein the opposite direction of the electric current. (Oxygen pumping theory)
The sensing cell uses features ① and ② and the pumping cell ②.
３. Theory of sensing cell
① Micro current is passed between the electrodes of the sensing cell. By passing
the electric current between the electrodes, the oxygen ions in the gas
detection chamber move to the reference oxygen chamber so that the oxygen
concentration of the reference oxygen chamber becomes about 100% O2.
(Note) The number of the O2 ions that move from the gas detection chamberto the reference oxygen chamber is extremely small so it has no effecton the oxygen concentration in the gas detection chamber.
② Between the electrodes of the sensing cell, an electromotive force is generated
due to the difference in the oxygen concentrations of the gas detection chamber
and the reference oxygen chamber. It can be calculated from the following
equation.
The sensing cell measures this electromotive force generated between theelectrodes and sends signals to the pumping cell so that the electromotiveforce will be 350mV (i.e. so that the oxygen concentration in the gas detection
chamber will be 0% O2).

- 4 -

Electromotive force E =Oxygen concentration in gas detection chamber(sample gas concentration)――――――――――――――――――――――
Oxygen concentration in reference
oxygen chamber (100)approx. -53.2×log10Ｘ
450 = -53.2×log10 ――
100
Ｘ = approx. 0.003ppm ≒ 0%
４. Theory of pumping cell

The pumping cell receives signals from the sensing cell and passes electric
current between the electrodes so that the oxygen concentration in the gas
detection camber becomes 0% O2.
Since the electric current is proportional to the number of O2 ions (oxygenconcentration) discharged from the gas detection chamber, the oxygen
concentration of the sample gas (i.e. oxygen in the gas detection chamber) canbe measured by measuring the electric current.

Pumping current (mA)

Sensor Element Construction

HeaterExhaust gas O2 concentration (%)

SensorHeaterExhaust gas

Exhaustgas

Heater temperature control

Pumping cell

Pumping current
Output signals

Gas detection
chamber

PumpingGas diffusion
holescurrent

Sensing cellcontroller
Micro current to generated
in reference oxygen

Reference oxygen chamber- 5 -Referencevoltage (450 mV)

1-6 Nomenclature and functions- 6 -2． Installation

IMPORTANT

2-1 Installation side
・ Avoid exposure to rain, water, and oil.

(This sensor is not designed for outdoor use. When using it
outdoors, a protective cover shall be provided.)・ Avoid direct sunlight or radiated heat from furnace. The ambient temperatureof the metal connector of the sensor shall not exceed 120℃.
・ Select a place with little humidity and dust.
・ Vibrations shall be transmitted as little as possible.
・ The central value of the gas to be measured shall be obtained.
・ Condensation occurs at the sensor mounting section depending on the sample
gas condition and ambient environment, resulting in the damage of the sensor.
If there is a fear of condensation, insulate the mounting adapter, pipes,etc.
・ The condensation adhered to the sensor will cause the sensor to be faulty.
Make sure that there will be no condensation around the sensor.
・ The air ratio of the gas to be measured must be 0.65 or more. If the measuring
gas contains an air ratio of 0.65 or less, or a large amount of CO and/or
H2, this may cause the sensor to break in a short time. Do not expose thesensor to the gas with high reduction ability.
・ If the sensor is used in the sampling system (the measuring gas is sampled
to the outside of the furnace and measured after the drain is removed), whereflammable gas, such as CO or H2 exists, measure the gas after performing thewater bubbling at room temperature and humidification.

- 7 -2-2 How to install sensor
Consult Engineering service of ENERGY SUPPORT if you use unspecified mounting
methods or you have any questions.
(1) When installing the sensor directly on the flueConnector
NCS-258Ad

PT3/4B socket※ Mounting adapter
AS-210 type sensor

Lead

If condensation may from on the mounting adapter,
Flue

Insulate the mounting adapter to avoid it.
(It is recommended to use the quick-releaseinsulation materials to facilitate sensor replacement.)(2) When taking the gas from the exhaust path in the flueConnector

AS-210 type sensor
Mounting adapter
Calibration gas entrance PT1/4

If condensation may from on the mounting adapter,
insulate the mounting adapter to avoid it.
Gas flow(It is recommended to use the quick-releaseinsulation materials to facilitate sensor replacement.)- 8 -(3) When exhaust gas is sampled and measured;
Various mounting methods are provided depending on the usage. It is theprecondition that drain is not mixed in the sampling gas.
This sensor element is the ceramics heated to approx. 800℃. The sensor isdamaged if drain is splashed on the sensor. If there is any fear of mixingof the drain, take measures to prevent mixing and select the proper mounting
method so that the sensor tip is not directly located at the flow of themeasured gas as shown in the figure below.

Sensor installation

Gas flow- 9 -3． Maintenance
3-1 How to replace sensor① Turn OFF the main power of the analyzer.
② Remove the connector.
③ Remove the hexagonal part of the sensor by turning it counterclockwise witha monkey wrench.
④ Replace the sensor with a new AS-210 type sensor.
⑤ Tighten the hexagonal part of the sensor by turning it clockwise with a monkey
wrench.
(Note)The tightening pressure shall be 0.2±0.1kgf.m. Tightening it more than thatwill deform the packing.
When the mounting adapter is hot (200℃ or higher), use a metal packing.
The tightening pressure shall be 4±0.5kgf.m.
⑥ Mount the connector.
⑦ Turn On the main power of the analyzer.
⑧ Wait about three minutes. Then enter the date of the new sensor through thekeys.
Input location for receiver

Input items
Linearizer no.
Heater resistance※1
Pressure correctioncoefficient※2RE-210

DTF-201R

CH2CH143

CH10CH192――DTF-101
SENSOR PARAMETER「LIN」
DISPLAY SELECT「RH0」
PRESSURE SET「β1」

The date is described in the inspection sheet.
※1：When the end of the Re-210 type receiver product number is D,
CH10 Heater resistance input is unnecessary.
(Receiver product number KX-621020-****D)※2：input Only KX-721045-B-*⑨ Perform air point calibration.
⑩ The sensor is ready for measurement.
3-2 Spare parts list
Part nameSensor

Part no.

Remarks

KX-721045-B(-*)

Connecting cable

KX-821100-LConnector

NCS-258-P

Packing

RX-331300-11- 10 -Connector on the cable end

3-3 Troubleshooting① When the mounting adapter or pipes are clogged・Remove the dust clogging it using a piece of wire or a rod.
② When the sensor becomes faulty due to adhered condensations
・Heat and insulate the mounting adapter up to about 200℃ using a heater orthe like.
③ When the indicated value is high・Check the screw section or packing of the mounting adapter to see if there
is a leak.
・Check if dust is clogging the adapter or pipe.

- 11 -- 12 -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