Manual No.3010E R3OPERATION MANUAL FOROVEN O2 ANALYZER MODELTYPE CP-X

ＲＥＡＤ ＴＨＥ ＯＰＥＲＡＴＩＯＮ ＭＡＮＵＡＬ．

Safety Precautions
Obsereve the following precautions without fail for safe operation of the equipment.
WARNING
1. When connecting cables to the terminals of the analyzer or when servicing inside theanalyzer, take care to avoid electric shock. When servicing electrical parts, be sure to turnthe power off.
2. Connect the grounding wire to prevent accidents caused by electric shock.
3. When fabricating the gas inlet/outlet pipes or disconnecting pipes for maintenance inside
the analyzer, be sure to shut off the gas source valve to prevent accidents caused by gas
intoxication or oxygen deficiency.
4. To prevent gas intoxication and oxygen deficiency, test gas leaks after fabricating the gas
inlet/outlet pipes or performing maintenance service of piping inside the analyzer.
Route the gas outlet at a safe place provided with the atmospheric pressure.

CAUTION
1. To prevent electric shock, before you turn on the power switch always check that thepower supply wiring is correctly and securely connected, and that the supply voltage
matches the power source voltage of this device.
2. To prevent gas intoxication or oxygen deficiency, before you open the gas source valve
always check that the gas inlet and outlet pipes of the analyzer are correctly and securely
connected, and check that there is no gas source valve.
3. To prevent burns, do not touch the transmission unit, sensor unit (detector, etc.) and their
periphery during operation and shortly after operation because there portions are very hot.
4. Be sure to close the gas source valve to perform maintenance services of the piping system
when the sample gas contains toxic contents to prevent gas intoxication.
5. Observe the cautions and operation methods described in this manual to operate this equipment
safety. If the description is neglected during operation of the equipment, electric shock, gas
intoxication, oxygen deficiency, burns, damage or deterioration of this equipment or damage tothe final product (device, etc.) may be caused.

Table of Contents

1.

General ............................................................................................................... 1

2.

Theory of measurement ...................................................................................... 1

3.

Features of type CP-X O2 analyzer ..................................................................... 2

4.

Specofocations .................................................................................................... 3

5.

Names and functions of parts .............................................................................. 3

6.

Installation work ............................................................................................. 3

7.

Operation.............................................................................................................. 58.

Inspection and maintenance ................................................................................ 6

9.

Troubleeshooting .............................................................................................. 10

10. Attashed drawings ............................................................................................ 12

1. General
The reducing atmosphere oven O2 analyzer automatically measures the oven atmosphere inside a gives
the indication and signals of the measured value.

2.

Theory of measurement
The type CP-X oxygen analyzer introduces the gas to be measured between the sample gas intake port
fitted on the oven wall and the outlet. Partial pressure of oxygen in the introduced sample gas ismeasured with a sensor cell.
Fig. 1 Basic configurationig. 2 Principle of sensor cell operationE= PO2 (A ) 
RT
・In 

ｎF
 PO2 (S) (1)・・・・・・・

Where
E:

Electromotive force (mV)R:

Gas constantT:

Absolute Temperature

F:

Faraday constantn:4

PO2(A): O2 partial pressure in reference gas (0.206 atm)
PO2(S): O2 partial pressure in sample gas (atm)(Normal atmospheric air is used as the reference gas)

By substituting these values into the equation (1), the following equation is obtained.

E = 49.6  T  10 -3 log１０

0.206
PO 2 (S)・・・・・・・・・(2 )1Usually, the O2 partial pressure in the oven atmosphere which has been denatured by the supplied gas CH 4,
C3H6, C4H10 etc. falls within 10-19～10-21 atm.
Relationship between the oven atmosphere and carbon potential is expressed as follows.
In the oven atmosphere reaction CO + 1/2 O 2⇔CO2, the following equation holds:
1

PCO・PO 2 2= K 1 （K1：equilibrium constant）
PCO 2
 PCO 2 =1
1
 PCO  PO 2 2
K1

In the oven atmosphere reaction CO 2 + C ⇔2CO

PCO 2  ac
= K 2 (K2: equilibrium constant）
PCO 2

ac = K 2 

PCO 2
PCO 2

By substituting PCO 2 into the above equation, carbon potential ac is obtained as follows.

a c = K 2  PCO 2 1
11
 PCO  PO 2 2
K−1= K1  K 2  PCO  PO 2 2
Because PCO in the oven atmosphere remains constant, carbon potential can be obtained by measuring PO 2
in the oven atmosphere.

3. Features of CP-X type O2 analyzer(1)Maintenance-free
CP-X type O2 analyzer is subject to minimum drift and requires minimum maintenance in sampling.
(2)High sensitivity
High sensitivity enables detecting slight change in the oven atmosphere.
(3)Quick response(4)Measurement by means of the sample gas in the flue allows a shorter sample line, making it freefrom clogging.

24. Specifications
Model:

CP-X typeKS-16410□-□

Response time:

Within 10 seconds (90% response)

Operating temperature range:

Sensor unit -10～150℃

Power requirement:

AC100±10V 260VA

Warm-up time:

About 20 minutes

Insulation resistance:

Sensor unit 100KΩ or overDimensions:

See the drawing.

5. Names and functions of parts
5-1 Sensor unit

6. Installation work
6-1 Selection of gas sampling point
Select the sample gas intake point or the sensor unit mounting position, observing the following
conditions.
(1) Where the sampled gas shows the representative values.
(2) Where the gas is less likely to undergo quick change.
(3) Where a laminar flow of sample gas exists.
(4) Where the sensor unit is not subject to vibration or impact.
(5) Where maintenance service can be performed easily.
(6) Where ambient temperature is not higher than 150℃.

3

6-2 Wiring and piping (Reference)

Note: Piping and wiring shall be given due consideration to the following.
(1) Place signal wires (CELL R BR) and power wires (CMV, Heater, etc.) in a separate conduit.
(2) Do not use the cable exceeding 100m between the transmitter and receiver.
(3) As the terminal temperature in the transmitter goes up 70-80℃ above ambient, use R-compensatedwire connecting to the transmitter for thermocouple (R).
(4) Use shielded wires for signal lines.
(5) Make sure to ground the shield of the signal lines(6) Type CP-X transmitter① Use control copper tube (CUT φ10/φ8-6/φ4)and make the tube as short as possible andwithout sharp bend, and connectors if possible.
② Pipe so that diversion type sample gas is discharged through flair bend. Adjust so that flame
length is 2-5 cm at the flair bend for the gas flow volume of 2-4L/min. This flair length
specification is based on the RX sample gas, which discharged to atmosphere through control
copper tube. For other specification, install flow meter upstream of the transmitter.
③ Make sure to install a drain filter in the sample gas piping.
④ Connect instrument air for purging to the transmitter using control copper tube
(CUTφ10/φ8-6/φ4)

4

⑤ Burn out the transmitter internal for 3-5 minutes with the compressed air of 2-4L/min once per
week. (Depending on the soot condition in the transmitter, maintain furnace temperature risedue to soot burning at 850+30℃)⑥ As soot at the low temperature part in the transmitter cannot be burnt out, remove it from thecleaning hatch.

7. Operation
7-1 Inspection before operation
Check the following for the installations made in accordance to the instruction in 6. Installation work.
(1) Check the piping and wiring to see they are completed correctly in compliance to the drawings.
(2) Check with a DC500V megger to make sure of no earth leakage and insulation defect. Be sure to notconnect the control unit in this check.
*Across PR (R), CELL and case (ground): 100 KΩ or over*Across OUT and case (ground): 10 MΩ or over(3) Check to make sure that power voltage is 100 ±10V.

58. Inspection and maintenance(1)Inspection of indicated value, recorder chart: once/3 days.
(2)Air purging from sensor unit and pipe line: once /week.
(3)Inspection for sticking material and clogging in sensor unit with the sensor unit disconnected:
Occasionally (guide line: once / 3 months).
(4)Take out the sensor unit and check the appearance with eyes.
Once/year.
Note :

1)In the event of a failure which may affect the measurement, replace the unit.
2)When removing the clogging in the sensor unit, pay great care to not damage the sensor cell.

(Replacement of sensor cell)
The sensor cell should be replaced in the following procedure after turning off the power to the electric ovenand the electric oven has cooled down enough.
a) Loosen the cell clip screw and remove thecell clip.
b) Apply spanners to the cell mounting
fixture and the spanners flat and loosen
the cell mounting fixture(counter-clockwise).When loosened, thefixture is to be removed by turning it
manually.
c) Mount a spare sensor cell in the reverse
order of the disassembly.
Note: Handled the sensor cell with great careas it may break when impact is applied.

68-1 Effects of sooting
Sooting causes the indication to lower below the normal measurement level, with the variation in the

OUTPUT

indication diminishing.

Sooting taking place
Burning out for at least one hour should be carried out at
TIME

every run of operation or once every three days
(whichever the more frequent).

When such a phenomenon as above is observed, carry out a burning out by means of air. (Carry out
burning out for a period at an interval which depends on the sooting condition.)
8-2 Burn-out procedure(1) Keep the temperature of the type CP-X sensor unit controlled at 850℃
(2) Shut off the sample gas.
(3) Supply 2～4L/min of burn-out air.
(4) Keep the supply of burn-out air until the cell output (voltage across CELL + and -) of the type CP-X

sensor unit becomes +10mV or below.
(5) Stop the burn-out air and supply 2～4L/min of sample gas to make measurement.
Note : Frequency of burning out
Frequency of burning out depends on the carbon potential of the sample gas and other factors, but
once per week is recommended as the guide line.
If the measuring instrument mentioned in (4) is not used, carry out burning out for about 30 minutes.
Burning out should be done to keep the sensor unit temperature within a range of 850 ±30℃.
78-3 Soot removal after disassembly

Case lid

Cell clip+
Sensor cell
Knurled nut

Cell clip－(Do not loosen)

Cell mounting fixture

Disassemble
Disassemble

Spring clamp

Disassemble

Sample gas outlet pipe
Next page8

(1) Shut off the sample gas.
(2) Supply 2～4L/min of burn-out air.
(3) Shut off the power to the type CP-X sensor unit and turn off the sensor unit heater power.
(4) Leave the sensor unit to stand for about 60 minutes.
(5) Undo the spring clamp of the type CP-X sensor unit and remove the case lid.
(6) Remove the cell clip from the sensor cell by using a + screw driver and a pair of long-nosed pliers.
(The upper one is the + cell clip.)(7) Loosen the cell mounting fixture with a spanner or a monkey wrench.
(Do not loosen the knurled nut which is for sealing of the sensor cell.)(8) Remove the sensor cell.
(9) Dismantle the sample gas outlet pipe and three blind plugs using a spanner or a monkey wrench.
(10)Remove soot from the inside of the sensor unit through the cell mounting seat, blind plug hole and thesampled gas outlet pipe, by using a pipe of 5mm in O.D. or the like.
Note: Supplying purge air (0.05～0.1MPa) during the soot removal in (10) will be effective.

Measurement condition can be obtained by reversing the procedure above.

8-4 About sensor unit
・Please download the Safety Data Sheet (SDS) for IsoWool Bulk (artificial mineral fiber) used in thetransmitter of this product from our homepage.

99. Troubleshooting(1) Response is excessively slow.
Response is excessively slow.

Is electricNOoven temperature

Adjust the electric oventemperature to normal level.

normal?
YESYESIs there leakage?

Repair the leaking part.

NONO

Is the STD inlet
plugged?

Apply a blind plug to
STD inlet.

YES

YES

Is there sooting

Remove the soot.

in the oven?

NO

Is the response

NO
Replace the sensor cellfrom sensor cell normal?

YES

Test by supplying O 2/N2 or
CO , Co2/N2 gas throughthe STD gas inlet.

Remove the clogging（sensor unit , piping）.

10

(2) Measurement indication is faulty.
Measurement indication is faulty.

NOIs the electric ovenSee para 8-2.

temperature stable?

YES

Is theNO
See para 8-3.

response time normal?

YES

YES

Is the lead wire

Repair the unstable connection.

connection unstable?

NO

YES

Is there clogging?

Remove the clogging.

NO

YES

Is there sooting

Remove the soot.

in the oven?

NO

Change in the sample gas.

11

10.Attashed drawings (Sensor unit)

12

13

EMF(mv)
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190

O2(%)
EMF(mv)
20.6
200
13.62492
210
9.011577
220
5.960293
230
3.942161240
2.607361
250
1.724519
260
1.140604
270
0.7544280
0.498963290
0.330016300
0.218274310
0.144367320
0.095485
330
0.063154340
0.04177350
0.027627360
0.018273
370
0.012086
380
0.007993
390

O2(%)
EMF(mv)
0.005287
400
0.003497
410
0.002313
420
0.00153430
0.001012440
0.000669
450
0.000443
460
0.000293
470
0.000194480
0.000128490
8.47E-05
500
5.60E-05
510
3.71E-05
520
2.45E-05
530
1.62E-05
540
1.07E-05
550
7.09E-06
560
4.69E-06570
3.10E-06
580
2.05E-06
590

O2(%)
EMF(mv)
1.36E-06
600
8.97E-07
610
5.94E-07620
3.93E-07630
2.60E-07
640
1.72E-07
650
1.14E-07660
7.51E-08670
4.97E-08680
3.29E-08690
2.17E-08
700
1.44E-08710
9.51E-09
720
6.29E-09730
4.16E-09740
2.75E-09
750
1.82E-09760
1.20E-09
770
7.96E-10780
5.27E-10
790

O2(%)
EMF(mv)
8.94E-14
1000
5.91E-141010
3.91E-141020
2.59E-141030
1.71E-141040
1.13E-141050
7.48E-15
1060
4.95E-15
1070
3.27E-151080
2.16E-15
1090
1.43E-15
1100
9.47E-161110
6.26E-161120
4.14E-161130
2.74E-161140
1.81E-161150
1.20E-161160
7.93E-171170
5.24E-171180
3.47E-171190

E - n = 10 − n

O2(%)
EMF(mv)
3.48E-10800
2.30E-10810
1.52E-10820
1.01E-10830
6.66E-11840
4.41E-11850
2.92E-11860
1.93E-11870
1.28E-11880
8.43E-12890
5.58E-12900
3.69E-12910
2.44E-12920
1.61E-12930
1.07E-12940
7.06E-13
950
4.67E-13960
3.09E-13970
2.04E-13980
1.35E-13
990

O2(%)
EMF(mv)
2.29E-17
1200
1.52E-171210
1.00E-171220
6.64E-18
1230
4.39E-18
1240
2.90E-18
1250
1.92E-18
1260
1.27E-18
1270
8.40E-19
1280
5.56E-19
1290
3.67E-19
1300
2.43E-19
1310
1.61E-191320
1.06E-191330
7.03E-20
1340
4.65E-201350
3.08E-20
1360
2.03E-20
1370
1.35E-20
1380
8.90E-21
1390


O2 
CP − X EMF− O2 EMF = −49.6 10−3  (273+ 850) log10
20.6%O2 O2(%)
5.89E-21
3.89E-21
2.58E-21
1.70E-21
1.13E-21
7.45E-22
4.93E-22
3.26E-22
2.16E-22
1.43E-22
9.43E-23
6.24E-23
4.13E-23
2.73E-23
1.80E-23
1.19E-23
7.89E-24
5.22E-24
3.45E-24
2.28E-24

The contents of this manual are subject to change without notice for improvement.
For inquiries regarding product handling, please contact us or our distributors.
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ENERGY SUPPORT CORPORATION
1, Aza Kamikobarii, Inuyama, Aichi 484-8505 Japan