AMETEK Process Instruments 903-8663 Heated Acid Gas Sample Probe Instruction Manual

903-8663 Heated Acid Gas Sample Probe

Product Information: Heated Acid Gas Sample Probe

The Heated Acid Gas Sample Probe is a specialized equipment
designed for use in hazardous locations. It is used to extract acid
gas samples for analysis. The probe features a heater to maintain
the sample temperature and ensure accurate measurements. The
product is manufactured by AMETEK Process Instruments and the model
number is PN 903-8663, Rev H. For more detailed information, please
refer to the installation and maintenance manual.

Product Usage Instructions

Preparing the Analyzer and Sample Probe for Maintenance

1. Disconnect mains AC power and any alternate power sources to
   the analyzer.

2. Open the covers or doors of the analyzer to access the
   components within the enclosures.

3. Follow the instructions provided in the manual to perform
   maintenance tasks on the analyzer and sample probe.

Changing Out Replaceable Parts

1. Gather the list of materials and special tools required for the
   replacement.

2. Follow the step-by-step instructions provided in section 3-9 of
   the manual to change out replaceable parts.

Examining and Caring For the Flamepaths

1. Read section 3-32 of the manual to understand how to examine
   and care for the flamepaths.

2. Follow the guidelines provided to ensure proper maintenance of
   the flamepaths.

HAG Probe Heater Directives and Standards

Section 4-3 of the manual provides information on the directives
and standards related to the HAG Probe Heater. Refer to this
section for detailed guidelines.

HAG Probe Valve Assembly Directives

Section 4-3 of the manual provides information on the directives
related to the HAG Probe Valve Assembly. Refer to this section for
detailed guidelines.

HAG Probe Heater Marking

Section 4-4 of the manual provides information on the marking of
the HAG Probe Heater. Refer to this section for detailed
guidelines.

Important Safety Warnings, Cautions, and Notes

The manual contains important safety warnings, cautions, and
notes that should be strictly observed. These instructions
emphasize critical information that should not be overlooked,
potential personal injury or environmental contamination risks, and
risks of equipment damage. It is important to read and follow these
instructions carefully.

Electrical Safety

The analyzer housings contain high voltages. Always shut down
power source(s) before performing maintenance or troubleshooting.
Only a qualified electrician should make electrical connections and
ground checks. Any use of the equipment not specified by the
manufacturer may impair the safety protection originally
provided.

Grounding

Instrument grounding is mandatory. Performance specifications
and safety protection are void if the instrument is operated from
an improperly grounded power source. Verify ground continuity of
all equipment before applying power.

Personnel and Equipment Safety Information

This section provides important safety information to avoid
personal injury and equipment damage during installation,
operation, maintenance, or servicing of the equipment. All safety
regulations, standards, and procedures at the analyzer location
must be followed. Review and follow the provided warnings and
cautions.

Hazardous Locations

Always disconnect mains AC power and/or alternate power sources
to the analyzer before opening any covers or doors on the analyzer
to check or perform maintenance on any components within the
enclosures.

INSTALLATION AND MAINTENANCE MANUAL
Heated Acid Gas Sample Probe
PN 903-8663, Rev H

Copyright Notice © 2023 AMETEK Process Instruments. All rights reserved. The information and descriptions in this document are the sole property of AMETEK Process Instruments and may not be copied, reproduced, disseminated, or distributed without explicit written permission from AMETEK Process Instruments. The statements, configurations, technical data, and recommendations in this document are believed to be accurate and reliable at the time of this publication, but AMETEK Process Instruments assumes no responsibility or liability for any errors or inaccuracies that may appear in this document. AMETEK Process Instruments is not responsible for any infringement of patents or other rights of third parties that may result from the use of this document. The content of this document is furnished for informational purposes only, is subject to change without notice, and does not represent a commitment or guaranty by AMETEK Process Instruments. AMETEK Process Instruments makes no warranty, express or implied, with respect to the content of this document. AMETEK Process Instruments shall not be liable for any loss or damage, including consequential or special damages, resulting from any use of this information, even if loss or damage is caused by AMETEK Process Instruments as a result of negligence or any other fault.
To obtain a PDF of this manual, visit our Products page at www.ametekpi.com.

Contents

Important Safety Warnings, Cautions, and Notes…………………………………………………………………v Electrical Safety ………………………………………………………………………………………………………………………….v Grounding …………………………………………………………………………………………………………………………………..v Personnel and Equipment Safety Information……………………………………………………………………..vi
Environmental Information ­ WEEE …………………………………………………………………………….. viii Special Warnings and Information …………………………………………………………………………………………ix
Equipment Used in Hazardous Locations………………………………………………………………………ix Electromagnetic Compatibility (EMC)…………………………………………………………………………………….x
OVERVIEW ……………………………………………………………………………………………………………..1-1 About the Heated Acid Gas Sample Probe…………………………………………………………………………1-2 About the Analyzer Sample System……………………………………………………………………………..1-5 Working in This Manual …………………………………………………………………………………………………………1-9
INSTALLATION AND START-UP………………………………………………………………………………..2-1 Safety Considerations ……………………………………………………………………………………………………………2-1 Pre-Installation Requirements ……………………………………………………………………………………………..2-2 Storage Prior to Installation …………………………………………………………………………………………..2-2 Uncrating and Inspecting the HAG Sample Probe …………………………………………………….2-2 Tools, Equipment and Supplies Required for Installation …………………………………………2-3 Installing the Heated Acid Gas Sample Probe……………………………………………………………………2-4 Installing the HAG Sample Probe in New Applications …………………………………………….2-5 Retrofitting the HAG Sample Probe ……………………………………………………………………………..2-9 Connecting the Aspirator Drive Gas Line…………………………………………………………………. 2-14 Connecting Signals and AC Power ……………………………………………………………………………. 2-17 Wiring Sample Probe Heaters Controlled by Analyzer…………………………………………2-17 Wiring Sample Probe Heaters Controlled by Standalone Temperature Controller (Retrofits)………………………………………………………………………………………………2-20 Powering Up the Probe Heater Assembly and Analyzer ……………………………………….. 2-22
MAINTENANCE AND TROUBLESHOOTING ……………………………………………………………….3-1 Safety Considerations ……………………………………………………………………………………………………………3-1 Aftermarket Excellence and Long-Term Commitment to Safety and Quality ………………3-2 Spare Parts Lists………………………………………………………………………………………………………………………3-3 HAG Sample Probe Spare Parts …………………………………………………………………………………….3-3 HAG Sample Probe Extended Maintenance Spare Parts…………………………………………..3-4 HAG Sample Probe Heater Assembly Spare Parts …………………………………………………. 3-4 Basic HAG Probe Sample/Vent Isolation Valve Kit and Replacement O-rings……… 3-4 Double Block Valve (Optional)……………………………………………………………………………….. 3-4

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Contents | iii

Diagnostic Flowcharts …………………………………………………………………………………………………………..3-5 Checking and Recording Operating and Set Point Temperatures…………………………..3-5 Possible Leaks in Sample Probe Valves ………………………………………………………………………..3-6 Probe-Related Alarms are Active ………………………………………………………………………………….3-6 Checking Flamepaths and Gaps……………………………………………………………………………………3-6
Preparing the Analyzer and Sample Probe for Maintenance…………………………………………..3-7 Changing Out Replaceable Parts …………………………………………………………………………………………3-9
Replacing Sample Probe Parts ………………………………………………………………………………………3-9 Replacing Probe Heater Parts ­ Extended Maintenance……………………………………….. 3-20
List of Materials and Special Tools Required ………………………………………………………..3-21 Examining and Caring For the Flamepaths…………………………………………………………………….. 3-32
SPECIFICATIONS……………………………………………………………………………………………………..4-1 Methodology…………………………………………………………………………………………………………………………..4-1 Heated Acid Gas (HAG) Probe Heater Specifications………………………………………………………..4-1 HAG Probe Valve Assembly Specifications …………………………………………………………………………4-2 HAG Sample Probe Approvals and Certifications ……………………………………………………………..4-3 Probe Heater Approvals and Certifications………………………………………………………………………..4-3
HAG Probe Heater Directives and Standards………………………………………………………………4-3
HAG Probe Valve Assembly Directives …………………………………………………………………………4-3 HAG Probe Heater Marking……………………………………………………………………………………………4-4

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Important Safety Warnings, Cautions, and Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as follows:
Important information that should not be overlooked.
An operating procedure which, if not strictly observed, may result in personal injury or environmental contamination.
An operating procedure which, if not strictly observed, may result in damage to the equipment.
Burn hazard. Hot surface. Do not touch, allow to cool before servicing.
Electrical Safety
High voltages are present in the analyzer housings. Always shut down power source(s) before performing maintenance or troubleshooting. Only a qualified electrician should make electrical connections and ground checks. Any use of the equipment in a manner not specified by the manufacturer may impair the safety protection originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specifications and safety protection are void if instrument is operated from an improperly grounded power source.
Verify ground continuity of all equipment before applying power.

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Contents | v

Personnel and Equipment Safety Information
This section describes important safety information to avoid personal injury and damage to the equipment while installing, operating, maintaining, or servicing the equipment. All safety regulations, standards, and procedures at the analyzer location must be followed. All personnel involved with installation, start-up, operation, maintenance, service, or troubleshooting of the analyzer must review and follow these Warnings and Cautions.
Hazardous Locations Always disconnect mains AC power and/or alternate power sources to the analyzer before opening any covers or doors on the analyzer to check or perform maintenance on any components within the enclosures.
If it is necessary to open the analyzer’s covers or doors while the circuits are live, test the area for flammable gases (and proceed only when the area is safe). To work on the analyzer with it powered up and its electronics enclosure(s) open, take appropriate precautions to avoid electrical shock. Hazardous voltages are present inside.
Refer to the analyzer User Manual for additional warnings when working on the analyzer and Heated Acid Gas Sample Probe.
Any adjustments or servicing of the analyzer while it is energized should be performed only by properly trained and qualified personnel.
For hazardous areas, all covers must be tightly fastened with all screws or latches while the circuits are live.
The Probe Heater Assembly is hot while it is powered up; take precautions to avoid burning yourself.
If potentially flammable gases or vapors are present, do not open any covers on the analyzer without first disconnecting mains AC power and/or alternate power sources to the analyzer.

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The Probe Heater Assembly is certified for use in hazardous classified areas and is rated T3, which means that it will not produce surface temperatures higher than 200 °C that could be an ignition source. This rating, however, is based on the maximum temperature that can be achieved with energy supplied by its electrical heater. An internal thermal switch disables the heater at 170 °C. In practice, this is the limiting factor, but those responsible for installation and maintenance of the overall probe assembly must take other factors into consideration.
Although the maximum process temperatures are stated as 210 °C (standard) and 450 °C (High Temperature version) these ratings apply to the probe and valve assemblies. In normal installations, the low sample flow and aspirator operation, combined with simple thermal losses, result in temperatures well below the dewpoint of the sample, so the heater must be added. However, if installed incorrectly, the use of external insulation and heat tracing could theoretically combine with high process temperature and process radiation to drive the surface of the heater assembly over 200 °C without any internal electrical heating being applied. To ensure this is not the case, the user must verify that the probe heater is being controlled at its set point and not being influenced by the process temperature. If the analyzer indicates the temperature is higher than the setpoint (greater than 170 °C), this indicates a problem.
When working on the analyzer/Heated Acid Gas Sample Probe, all safety policies and procedures for the hazardous area must be strictly followed. These policies and procedures are specified by the Owner Company and the local electrical inspection authority.
Any electrical connections, adjustments, or servicing of the analyzer/Heated Acid Gas Sample Probe while it is energized or de-energized should be performed only by properly trained and qualified personnel using materials and methods specified and approved by the Owner Company and the local electrical inspection authority.
For electrical-shock protection, the analyzer/Heated Acid Gas Sample Probe must be operated from a grounded power source that has a securely connected protective-ground contact.
Disconnect the power before removing any components from the analyzer or HAG Probe.

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Contents | vii

Warning Labels
These symbols may appear on the instrument to alert you of existing conditions.
Protective Conductor Terminal (BORNIER DE L’ECRAN DE PROTECTION) Schutzerde
Caution ­ Risk of electric shock (ATTENTION ­ RISQUE DE DÉCHARGE ÉLECTRIQUE) Achtung ­ Hochspannung Lebensgefahr
Caution ­ Refer to accompanying documents (ATTENTION ­ SE RÉFERER AUX DOCUMENTS JOINTS) Achtung ­ Beachten Sie beiliegende Dokumente
CAUTION ­ Hot Surface (ATTENTION ­ SURFACE CHAUDE) Achtung ­ Heiße Oberfläche
Environmental Information ­ WEEE
This AMETEK product contains materials that can be reclaimed and recycled. In some cases the product may contain materials known to be hazardous to the environment or human health. In order to prevent the release of harmful substances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reaches its “end of life”.
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a municipal waste system (residential trash). The Wheelie Bin marking on this product is a reminder to dispose of the product properly after it has completed its useful life and been removed from service. Metals, plastics, and other components are recyclable and you can do your part by doing one of the following steps:
· When the equipment is ready to be disposed of, take it to your local or regional waste collection administration for recycling.
· If you need further assistance in recycling your AMETEK product, contact us through our Customer Support page at www.ametekpi.com/customersupport/aftermarket.

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Special Warnings and Information
Equipment Used in Hazardous Locations
Refer to Chapter 4 ­ Specifications for details about the suitability of this equipment in hazardous areas.
Explosion Hazard ­ Do Not Disconnect Equipment Unless Power Has Been Switched Off or the Area is Known to be Non-Hazardous.
Risque d’explosion ­ Avant de déconnecter l’équipement, coupez le courant où vous assurez que l’emplacement est designé non dangereux.
All input and output wiring must be in accordance with wiring methods authorized for the area classification by the authority having jurisdiction. Ex d glands or stopping boxes (seals) must be installed on flameproof enclosures.

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Contents | ix

Electromagnetic Compatibility (EMC)
Read and follow the recommendations in this section to avoid performance variations or damage to the internal circuits of this equipment when installed in harsh electrical environments.
The various configurations of analyzers that use Heated Acid Gas Sample Probes, and ASR900 Heaters used on Heated Acid Gas Sample Probes, should not produce, or fall victim to, electromagnetic disturbances as specified in the European Union’s EMC Directive. Strict compliance to the EMC Directive requires that certain installation techniques and wiring practices are used to prevent or minimize erratic behavior of the Analyzer or its electronic neighbors. Below are examples of the techniques and wiring practices to be followed.
In meeting the EMC requirements, the various Analyzer configurations described in this manual rely heavily on the use of metallic shielded cables used to connect to the customer’s equipment and power. Foil and braid shielded I/O and DC power cables are recommended for use in otherwise unprotected situations. In addition, hard conduit, flexible conduit, and armor around non-shielded wiring also provides excellent control of radio frequency disturbances. However, use of these shielding techniques is effective only when the shielding element is connected to the equipment chassis/ earth ground at both ends of the cable run. This may cause ground loop problems in some cases. These should be treated on a case-by-case basis. Disconnecting one shield ground may not provide sufficient protection depending on the electronic environment. Connecting one shield ground via a 0.1 microfarad ceramic capacitor is a technique allowing high frequency shield bonding while avoiding the AC-ground metal connection. In the case of shielded cables the drain wire or braid connection must be kept short. A two-inch connection distance between the shield’s end and the nearest grounded chassis point, ground bar or terminal is highly recommended. An even greater degree of shield performance can be achieved by using metallic glands for shielded cable entry into metal Electronics Enclosures. Expose enough of the braid/foil/drain where it passes through the gland so that the shield materials can be wrapped backwards onto the cable jacket and captured inside the gland, and tightened up against the metal interior.
Inductive loads connected to the low voltage “Alarm Contacts” are not recommended. However, if this becomes a necessity, follow proper techniques and wiring practices. Install an appropriate transient voltage suppression device (low voltage MOV, “Transzorb,” or R/C) as close as possible to the inductive device to reduce the generation of transients. Do not run this type of signal wiring along with other I/O or DC in the sameshielded cable. Inductive load wiring must be separated from other circuits in conduit by using an additional cable shield on the offending cable.

x | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

In general, for optimum protection against high frequency transients and other disturbances, do not allow installation of this Analyzer where its unshielded I/O and DC circuits are physically mixed with AC mains or any other circuit that could induce transients into the Analyzer or the overall system. Examples of electrical events and devices known for the generation of harmful electromagnetic disturbances include motors, capacitor bank switching, storm related transients, RF welding equipment, static, and walkie-talkies.

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Overview
This manual describes how to retrofit a Heated Acid Gas (HAG) Sample Probe when replacing an existing Sample Valve, and how to install the HAG Probe for new applications (Chapter 2). This manual also describes (in Chapter 3) how to diagnose problems with the HAG Sample Probe and how to change out replaceable parts to ensure the HAG Sample Probe continues to operate at peak efficiency.

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Overview | 1-1

About the Heated Acid Gas Sample Probe
The Sample Probe is a heated probe that uses a dedicated temperature controller to heat and maintain the temperature of the sample gas above the sample dewpoint temperature. To do this, the analyzer uses a control loop with a temperature sensor to control the temperature of the Sample Probe.
The set points, Too Hot and Too Cold, depend on the application. The set point is usually set at 10 °C above the sample dewpoint temperature, to a maximum of 120 °C. The Too Cold set point is typically a few degrees below this and the Too Hot is typically a few degrees above.
The Probe Heater is protected from overheating by a temperature switch, which will disconnect power if the Heater Assembly exceeds approximately 170 °C/338 °F. If the temperature of the probe falls below the analyzer Too Cold parameter, the analyzer Microcontroller board will de-energize the flow control valve to allow zero gas to backpurge the entire sample system.
The aspirator draws sample gas from the process duct and through the analyzer sample system, and then returns it to the process duct (see Figure 1-1 for an example plumbing schematic). Valves contained within the probe allow for complete isolation of the sample system from the process duct.
Figure 1-1 is an example drawing only. For your system, refer to Final “As- Built” drawings in the Documentation Package folder shipped with the analyzer/probe.

1-2 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

MODEL 931/932 ANALYZER BACKPAN

Figure 1-1. Zone 1 931/ 932 Analyzer Plumbing Schematic (example).
PN 903-8663, Rev H

7

6

8

5

9

12

SOL B

SOL A

SOL Z 10
11 1 2

4 3

BY CUSTOMER

BY CUSTOMER

LEGEND

Overview | 1-3

Figure 1-2. HAG Sample Probe assembly drawing.
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PN 903-8663, Rev H

About the Analyzer Sample System
The components of the Heated Acid Gas Sample Probe and their functions are detailed below (see Figures 1-2, 1-3, 1-4.1, and 1-4.2).

Component

Function

HAG Sample Probe Sample Probe

The HAG Probe is made up of the following components: Extends into process duct to obtain a representative sample.

Sample Isolation Valve (Red handle)

Isolates the analyzer’s sample path from the Sample Probe that extends into the process duct.

Fiber Filter

Part of the Fiber Filter Assembly, which is the first filtration stage, this filter removes coarse particulate and some liquids.

Membrane Filter

The Sintered Disk, the third filtration stage, removes small quantities of low surface tension liquids (such as hydrocarbons) that are not extracted by the first and second filtration stages.

Aspirator

Provides flow to move the sample gas through the sample path, and the condensed sulfur (in the Sample Probe) back to the process duct.

Flow Restrictor

(in Solenoid Block) Provides a consistent back-pressure for setting the Aspirator Air, which reduces sample rate fluctuations caused by process pressure fluctuations. The flow rate obtained at a gauge pressure of 210 KPA (30 PSIG) is 30 L/min (1 SCFM).

CAUTION: To avoid plugging problems within the HAG Probe, do not remove this fitting or replace it with a general purpose fitting.

Vent Isolation Valve (Black handle)

Isolates the analyzer’s sample path from the process duct.

Double Block Valve Assembly (Optional)

This optional two-valve assembly (Sample and Vent) isolates the process gas from the upper portion of the HAG Probe, to allow for service on the upper portion and main Isolation Valves of the HAG Probe without having to remove the probe from the process. (Special applications only.)
Sample Isolation Needle Valve This needle valve (T-handle, below and closest to Red Sample Valve handle) can be closed to isolate the HAG Probe from the sample stream and to allow service to be performed on the upper sections of the HAG Probe.
Vent Isolation Needle Valve This needle valve (T-handle, below and closest to Black Vent Valve handle) can be closed to isolate the HAG Probe from the sample stream and the upper sections of the HAG Probe. Close this valve to allow service to be performed on the upper sections of the Probe.

Pipe Adapter

Threaded connection provides mounting of the Sample Probe to the process duct.

Probe Heater Assembly The Probe Heater maintains the temperature of the Sample Probe above the dewpoint temperature to prevent condensation of liquids.

Connection Tube

(Thermal Insulation Tube) This stainless steel tube encases the Heater Cartridge wires, ground wires, and RTD cable, and joins the Junction (terminal) Box to the Heater Assembly (heater block).

Junction Box

Contains the termination block for power, ground, and RTD wiring for the Heater Assembly.

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Overview | 1-5

JUNCTION BOX

CONNECTION TUBE

VENT LINE SAMPLE LINE

OPTIONAL CAL GAS MEMBRANE FILTER
CAL GAS
SAMPLE ISOLATION BALL VALVE
PIPE ADAPTER

HEATER BODY
ASPIRATOR DRIVE AIR ASPIRATOR ADJUSTMENT SCREW
ASPIRATOR
VENT ISOLATION BALL VALVE

Figure 1-3. Heated Acid Gas Sample Probe Flow Diagram, Standard Applications.

SAMPLE PROBE

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PN 903-8663, Rev H

JUNCTION BOX

CONNECTION TUBE

VENT LINE SAMPLE LINE

OPTIONAL CAL GAS MEMBRANE FILTER
CAL GAS
SAMPLE ISOLATION BALL VALVE
OPTIONAL SAMPLE DOUBLE BLOCK
ISOLATION VALVE
PIPE ADAPTER

HEATER BODY
ASPIRATOR DRIVE AIR ASPIRATOR ADJUSTMENT SCREW
ASPIRATOR
VENT ISOLATION BALL VALVE
OPTIONAL VENT DOUBLE BLOCK ISOLATION VALVE (OPPOSITE SIDE)

Figure 1-4.1. Heated Acid Gas Sample Probe Flow Diagram, with Optional Double Block Valve (Special Applications).

SAMPLE PROBE

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Overview | 1-7

SEE NOTE
Figure 1-4.2. Optional Double Block Valve (Special Applications) (100-2393).

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Working in This Manual
While working in this manual, icons in the outside page margins represent various kinds of information that serve as reminders or extra information about the topic, or navigation information when working from the analyzer Analyzer System 200 Configurator Software. See “Navigating in the Software” in the analyzer User Manual for more information.

Example:
See Fuse Legend inside analyzer’s Lower Enclosure.

Reminder icon: These reminders indicate related information about the topic, certain actions that are necessary before continuing with the current procedure, or information that is recommended by AMETEK.

Example:
Setup (tab)Gas Calibration <>

Analyzer System 200 Configurator Software Navigation icon: While working from the analyzer software, use these navigational aids to quickly access different software screens and change parameter settings. In this example, the user navigates to the Gas Calibration screen, where the analyzer’s Flow Control mode can be changed. See “Navigating in the Software” in the analyzer User Manual for more information.

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Installation and Start-Up
Safety Considerations
Before installing the HAG Probe and powering up its Heater, review and follow all safety information in this chapter and under “Personnel and Equipment Safety Information” following the Table of Contents. This information describes procedures to follow to avoid personal injury and/or damage to the equipment. All regulatory agency and personnel safety procedures for your jurisdiction must be followed.
Take all appropriate safety precautions to prepare for replacing the existing Sample Valve with a HAG Probe.
This includes obtaining a “hot permit” plus meeting all other safety requirements, as required by company and hazardous areas safety policies.
Under normal operating conditions, lethal concentrations of H2S and other toxic gases from the process duct may be present within the sample system. The sample system is defined as all components in the analyzer system through which sample gas passes.
A breathing apparatus must be worn when installing/removing equipment from the sample gas extraction point. The sample stream is under positive pressure, and injury or death from inhaling toxic gases in the sample stream could result from attempting to install/remove equipment without the use of a breathing apparatus.

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Installation and Start-Up | 2-1

Pre-Installation Requirements

Storage Prior to Installation

If the HAG Probe is stored for any period of time prior to installation, store the equipment in an environment where it is not subject to dripping or splashing liquids, corrosive gases, high humidity, or excessive heat or cold. Recommended storage conditions include:

Temperature: Relative Humidity:

0 °C to 50 °C (32 °F to 122 °F) <70 %

Failure to comply with these storage conditions will void your warranty.

Uncrating and Inspecting the HAG Sample Probe

When lifting the HAG Sample Probe out of its shipping container, or when transporting it to the process pipe, do not use its isolation valve handles.

The Probe Heater Assembly is shipped detached from the Sample Probe Assembly. This allows for easier installation of the equipment. Upon receiving the Sample Probe and the Probe Heater assemblies, remove them from their shipping crates and examine their exteriors for any obvious damage.
If equipment is damaged or parts are missing, notify the carrier and contact AMETEK Service (www.ametekpi.com/customersupport/aftermarket) immediately. If damage is found, contact AMETEK Service to verify if damaged parts will require replacement prior to safely installing and operating the equipment.

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Tools, Equipment and Supplies Required for Installation
· Set of open-end wrenches for fittings.
· Set of metric hexagonal wrenches.
· Set of metric ball drivers.
· Wire cutters, strippers, and crimpers.
· Flat blade instrument screwdriver.
· High temperature thread lubricant (must not contain copper).
· Detergent-based leak detector (Snoop® or another suitable leak detection agent is permissible).
· A supply of 316 stainless steel 1/4-inch O.D. tubing for the Calibration and Aspirator Drive Air lines (unless they are integrated in the Sample Line). Supplied by customer/end user.

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Installation and Start-Up | 2-3

Installing the Heated Acid Gas Sample Probe
This section describes how to retrofit an existing Sample Valve with AMETEK’s HAG Sample Probe, and how to install a HAG Sample Probe in new applications. Refer to the appropriate section for your installation requirement.
The Sample Probe must be installed a minimum of two pipe diameters away from any process piping component that causes process turbulence, such as bends, valves, etc. Failure to comply with this recommendation may result in an excessively noisy and therefore, erroneous, output signal.
To avoid plugging, do not install the Sample Probe horizontally.
IMPORTANT Performing HAG Probe start-up and verification procedures requires working from analyzer’s System 200 Configurator Software. Familiarize yourself with the Software operations before installing the HAG Probe. See “Navigating in the Software” in the analyzer User Manual for more information.

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Installing the HAG Sample Probe in New Applications
For installation drawings, refer to the Final “As-Built” drawings in the Documentation Package folder shipped with the analyzer or the HAG Sample Probe.
To install the HAG Probe:
1. Prepare the HAG Probe for installation:
· Ensure the probe end is the proper length for the process duct being sampled from. If necessary, cut the probe end so that it extends 30­50 % into the process duct.
· Ensure the Sample (Red) and Vent (Black) isolation handles on the HAG Probe are closed.
Potentially lethal concentrations of H2S and/or other toxic gases are present in the process. Before proceeding, follow all necessary safety precautions, such as wearing a supply air apparatus.
2. Install the new HAG Probe:
Applications with a Threaded connection: Apply a thin bead of pipe sealant on the lower threads of the Sample Probe Pipe Adapter. Use care to avoid cross- threading the threads on the Sample Probe.
Applications with a Flange: Remove the existing flange blind and, using a gasket suitable for the application, connect the Sample Probe (comes with replacement flange assembly) to the flange on the process duct.
If mounting the HAG Probe on a vertical section of pipe, it is critical to position the probe with the Vent Valve (Black handle) angled downward slightly.
3. Lay out the Sample and Vent Lines between the probe and the analyzer.

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Installation and Start-Up | 2-5

4. Connect the Sample and Vent Lines to the HAG Probe.
The Sample Line fitting is on the same side of the HAG Probe as the Sample isolation valve (Red handle). The Vent Line fitting is on the same side of the HAG Probe as the Vent isolation valve (Black handle).
Do not install the Insulating Flex Pack on the HAG Probe at this time. This will be done after the analyzer and HAG Probe have been powered up and the Sample Probe fittings have been leak-checked (with no leaks).
5. Connect the Sample and Vent Lines to the Sample Inlet/Outlet Fittings on the analyzer:
Non-Shelter Installations: Route the Sample Line to the analyzer and connect it to the Sample Inlet fitting.
Route the Vent Line to the analyzer and connect it to the Vent Outlet fitting.
Shelter Installations: Route the Sample Line through the hole marked “Sample Line” on the side of the shelter and connect it to the Sample Inlet fitting.
Route the Vent Line through the hole marked “Vent Line” on the side of the shelter and connect it to the Vent Outlet fitting.
If the Sample and/or Vent Lines have extra length between the HAG Probe and the analyzer, properly secure them to avoid any sags or sharp bends (to prevent plugging).
6. Perform these procedures in the order listed to complete the installation and then return to this procedure:
a. Install the Aspirator Drive Gas Line (see “Connecting the Aspirator Drive Gas Line”).
b. Optional: Install the Zero/Cal gas line as per the analyzer and/or HAG Probe drawings. This line, which must be 316 stainless steel, is supplied by the customer/end user (unless it is integrated in the Sample Line).

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PN 903-8663, Rev H

7. Using a suitable detergent-based leak detection fluid (e.g., Snoop®), leak-check the threaded connections at the Pipe Adapter threads, flange assembly, and the Sample, Vent, and Aspirator Drive Gas line fittings on the HAG Probe and at the analyzer. Use the Aspirator Drive Gas to perform the leak check, and observe the Aspirator Drive Gas regulator for any noticeable pressure loss.
To avoid damaging the pressure transducer when leak-checking the sample system, use a maximum of 10 PSIG.
For detailed information about leak-checking fittings, refer to “Sample System Leak Check” in the analyzer User Manual.
8. If no leaks are present, secure the Heater Assembly on the top of the HAG Probe.
a. Ensure the joining surfaces (heat transfer) of the Heater Block (underside of the Heater Assembly and the top of the HAG Probe) are free of debris. Use a non-abrasive cloth to gently clean the joining surfaces, if necessary.
b. Place the Heater Assembly on the HAG Probe with the Junction Box positioned on the side where the conduit (North American installations) or cable (European installations) from the analyzer has been installed.
c. Apply a high-temperature thread lubricant to the threads of the four (4) M6 x 60 mm screws (300-8741, Figure 2-1), install the screws, and tighten them to secure the Heater Assembly to the HAG Probe.
The thread lubricant must not contain copper.
9. Complete the wiring, described under “Wiring Sample Probe Heaters Controlled by Analyzer,” and then return to this procedure.
10. Take all necessary safety precautions and apply power to the analyzer, described under “Powering Up the Probe Heater Assembly and Analyzer,” and then return to this procedure.
11. Install the Insulating Flex Pack on the HAG Probe to allow it to warm up quickly.
The procedure is complete.

PN 903-8663, Rev H

Installation and Start-Up | 2-7

Figure 2-1. Probe Heater Assembly.
2-8 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Setup (tab)
Gas Calibration <>
See Fuse Legend inside
analyzer’s Lower Enclosure.

Retrofitting the HAG Sample Probe
This section describes replacing an existing Sample Valve with a HAG Sample Probe. Refer to the drawings shipped with the Sample Probe.
To replace an existing Sample Valve with the HAG Sample Probe:
1. Prepare the probe end of the Sample Probe for installation by ensuring the probe is the proper length for the process duct being sampled from. If necessary, cut the probe end so that it extends 30­50 % into the process duct. Apply Teflon tape or a liquid thread sealant (must comply with company/ hazardous location policy) to the probe pipe threads and thread it into the bottom of the Pipe Adapter.
2. While working from the System 200 Configurator Software, view and record the analyzer’s current Flow Control Mode.
3. Manually Zero the sample system for 2­3 minutes to remove all residual gas in the sample system. Information on how to do this is described in the analyzer User Manual.
4. After the Zero is complete, isolate the analyzer sample system from the process duct by closing the isolation valve on the existing Sample valve.
5. Power down the analyzer and its temperature zone circuitry. Refer to the analyzer User Manual for safe power down instructions.
Hazardous Locations Before proceeding, test the area around the analyzer for flammable gases and proceed only when the area is safe.
Do not remove the cover of the Explosion-Proof Digital Communications Port on the front of the Lower Enclosure (931 or 932 Analyzers) and do not power up/down the analyzer or computer if there is an explosive gas atmosphere present.

6. Remove the Sample Line from the existing Sample Valve.
Potentially lethal concentrations of H2S and/or other toxic gases are present in the process. Before proceeding, follow all necessary safety precautions, such as wearing a supply air apparatus.

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Installation and Start-Up | 2-9

7. Prepare the HAG Probe for installation by ensuring its Sample (Red) and Vent (Black) isolation handles are closed.
8. Install the new HAG Probe (see Figure 2-2):
If mounting the HAG Probe on a vertical section of pipe, it is critical to position the probe with the Vent Valve (Black handle) angled downward slightly.
Apply a thin bead of pipe sealant on the lower threads of the Sample Probe Pipe Adapter and thread it into the replacement flange, being careful not to cross-thread the threads on the HAG Probe.
Remove the existing upper flange/Sample Valve assembly. Using a gasket suitable for the application, secure the HAG Probe/replacement flange assembly to the process duct flange. 9. Lay out the Sample and Vent Lines between the HAG Probe and the analyzer or its shelter.
10. Connect the Sample and Vent Lines to the HAG Probe.
The Sample Line fitting is on the same side of the Sample Probe as the Sample isolation valve (Red handle). The Vent Line fitting is on the same side of the HAG Probe as the Vent isolation valve (Black handle).
Do not install the Insulating Flex Pack on the Sample Probe at this time. This will be done after the analyzer and Sample Probe have been powered up and leak-checked (with no leaks).
11. Connect the Sample and Vent Lines to the Sample Inlet/Outlet fittings on the analyzer:
Non-Shelter Installations: Route the Sample Line to the analyzer and connect it to the Sample Inlet fitting.
Route the Vent Line to the analyzer and connect it to the Vent Outlet fitting.

2-10 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Installation and Start-Up | 2-11

Figure 2-2. HAG Probe Installation Details (example).
PN 903-8663, Rev H

TOP VIEW OF HORIZONTAL DUCT NOTE: ORIENTATION OF PROBE IS NOT CRITICAL
FOR HORIZONTAL MOUNTING, USER DEFINED IN FIELD.
SECTION THROUGH HORIZONTAL DUCT (HANDLES NOT SHOWN)

NOTE: ORIENTATION OF PROBE IS CRITICAL FOR VERTICAL MOUNTING, VENT VALVE MUST BE ANGLED DOWNWARD SLIGHTLY.
SIDE VIEW OF VERTICAL DUCT
NOTE: AMETEK RECOMMENDS THAT ALL NOZZLES FROM THE PROBE CONNECTION TO THE PROCESS PIPE BE STEAM TRACED AND INSULATED TO AVOID PLUGGING.

Shelter Installations: Route the Sample Line through the hole marked “Sample Line” on the side of the shelter and connect it to the Sample Inlet fitting.
Route the Vent Line through the hole marked “Vent Line” on the side of the shelter and connect it to the Vent Outlet fitting.
If the Sample and/or Vent Lines have extra length between the HAG Probe and the analyzer, properly secure them to avoid any sags or sharp bends (to prevent plugging).
12. Install the Aspirator Drive Gas Line (see “Connecting the Aspirator Drive Gas Line”) and then return to this procedure.
Install the Zero/Cal gas line as per the analyzer and/or HAG Probe drawings. This line, which must be 316 stainless steel, is supplied by the customer/end user (unless it is integrated in the Sample Line).
13. Using a suitable detergent-based leak detection fluid (e.g., Snoop®), leakcheck the threaded connections at the Pipe Adapter threads, flange assembly, and Sample/Vent Line fittings on the HAG Probe, and the Aspirator Gas Line fittings on the HAG Probe and at the analyzer. Use the Aspirator Drive Gas to perform the leak check and observe the Drive Gas pressure gauge for any noticeable pressure loss.
To avoid damaging the pressure transducer when leak-checking the sample system, use a maximum of 10 PSIG.
For detailed information about leak-checking fittings, refer to “Sample System Leak Check” in the analyzer User Manual.
14. If no leaks are present, secure the Heater Assembly on the top of the HAG Probe:
a. Ensure the joining surfaces (heat transfer) of the Heater Block (underside of the Heater Assembly and the top of the HAG Probe) are free of debris. Use a non-abrasive cloth to gently clean the joining surfaces, if necessary.
b. Place the Heater Assembly on the HAG Probe with the Junction Box positioned on the side where the conduit (North American installations) or cable (European installations) from the analyzer will be installed.

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PN 903-8663, Rev H

c. Apply a high-temperature thread lubricant to the threads of the four (4) M6 x 60 mm screws (300-8741, Figure 2-1), install the screws, and tighten them to secure the Heater Assembly to the Sample Probe.
The thread lubricant must not contain copper.
15. Complete the wiring, described under “Wiring Sample Probe Heaters Controlled by Standalone Temperature Controller (Retrofits),” and then return to this procedure.
16. Take all necessary safety precautions and apply power to the analyzer, described under “Powering Up the Probe Heater Assembly and Analyzer,” and then return to this procedure.
17. Install the Insulating Flex Pack on the HAG Probe to allow it to warm up quickly.
The procedure is complete.

PN 903-8663, Rev H

Installation and Start-Up | 2-13

Connecting the Aspirator Drive Gas Line
The drive gas can be instrument air, nitrogen, or steam, depending on the process.
The Aspirator Drive Gas Line, which must be 316 stainless steel 1/4-inch O.D., is supplied by the customer/end user (unless it is integrated in the Sample Line).
To install the Aspirator Drive Gas Line (see Figures 2-2, 2-3.1, and 2-3.2):
For plumbing details for new and retrofit installations, refer to the Sample/Vent Line, Conduit & Tube Installation drawing and other sample system drawings shipped with the analyzer or HAG Probe.
· To retrofit a Standard HAG Probe to an existing analyzer (not in a shelter): Plumb 316 stainless steel 1/4-inch O.D. tubing from the analyzer Solenoid Block to the Aspirator Drive Port fitting on the Sample Probe.
· To install a Standard HAG Probe to an existing analyzer in a shelter: Plumb 316 stainless steel 1/4-inch O.D. tubing from the “Aspirator Air” port on the shelter to the Aspirator Drive Port fitting on the Sample Probe.
For Retrofit Installations to an analyzer in a shelter: Plumb 316 stainless steel 1/4-inch O.D. tubing from the “Aspirator Port” inside the shelter to the analyzer. (For new applications, this will already have been done at the factory.)
· To replace an existing sample valve/probe with the Double Block HAG Sample Probe:
a. In Figure 2-3.1, identify the type of Solenoid Block that is installed on the analyzer and the location of the Aspirator Outlet (male) Fitting.
b. Remove the Aspirator Outlet Fitting from the Solenoid Block.
c. Retrieve the 1 SCFM Flow Restrictor (Part No. 301-2363) from the zip top bag, attached to the HAG Probe ball valve handle (Figure 2-3.2).
Install this Flow Restrictor in the Aspirator Outlet port on the Solenoid Block.
d. Plumb 1/4-inch O.D. stainless steel tubing from the Aspirator Drive Port fitting (1 SCFM Flow Restrictor) on the analyzer Solenoid Block to the Check Valve on the Sample Probe.
· To install a new Double Block HAG Probe to an existing analyzer in a shelter: Plumb 316 stainless steel 1/4-inch O.D. tubing from the “Aspirator Air” port on the shelter to the Aspirator Drive Port fitting on the Sample Probe.

2-14 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Figure 2-3.1. Solenoid Block Identification diagram, locating Aspirator Outlet Fitting (Customer Installation Instructions, WX-102888).
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Installation and Start-Up | 2-15

Figure 2-3.2. Double Block HAG Probe diagram, retrofits (100-2521).

2-16 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Connecting Signals and AC Power
Refer to Figures 2-1 and 2-4 while wiring the Probe Heater Assembly.
This procedure assumes the Heater Assembly has already been installed on the HAG Probe.
To ensure easy removal of the Heater Assembly in the future, use at least 60 cm (2 feet) extra conduit (North American installations) or cable (European installations) at the Heater Assembly Junction Box.
North American installations Flexible conduit suitable for the location can be used between the Heater Assembly Junction Box and any rigid conduit. An alternative is to use TEK cable for the entire distance.
European installations Heat resistant cable and Ex d cable glands must be used, suitable for 85 °C (185 °F).
Any electrical connections, adjustments, or servicing of the analyzer/ HAG Sample Probe while it is energized or de-energized should be performed only by properly trained and qualified personnel using materials and methods specified and approved by the Owner Company and the local electrical inspection authority.
Wiring Sample Probe Heaters Controlled by Analyzer
This wiring procedure is for HAG Probe installations used with AMETEK 931 or 932 Analyzers. For AMETEK 919 or 920 Analyzers with a HAG Probe, refer to the “919/920 Analyzers with Heated Acid Gas Sample Probe” Manual Supplement in the Documentation Package folder shipped with the analyzer. Also, refer to Final “As-Built” drawings in the Documentation Package folder shipped with the analyzer or HAG Probe.

PN 903-8663, Rev H

Installation and Start-Up | 2-17

To wire the Probe Heater Assembly:
1. The signal and power conductors can be run in separate or common conduit (North American/General Purpose installations) or cable (European/ Hazardous Location installations). Terminal Box entries are 1/2-inch NPT.
Refer to the Sample/Vent Line, Conduit & Tube Installation drawing, Customer I/O Board drawing, and other related wiring drawings shipped with the analyzer or HAG Probe.
Connect the conductors that supply power and a ground source from the Probe Heater to terminals on J107 of the Customer I/O board.
Connect the Probe Heater RTD to terminal J103 on the Customer I/O board.
2. Complete the wiring from the analyzer to the Terminal Block in the Probe Heater Junction Box (see Figure 2-4).
Tighten the screws to secure each wire to the appropriate Terminal Block location in the Junction Box.
3. Plug all unused cable entry ports with a plug certified for the hazardous area.
4. With the Junction Box o-ring (Part No. 300-8743, see Figure 2-1) in place on the Junction Box Cover, thread the Cover onto the Junction Box Body by hand and then tighten it using a suitable tool. Take care to avoid damaging the o-ring and the threads.
Tighten the set screw on the end of the Junction Box Cover.
Install an external ground connection, using the washer and ground screw on the Junction Box Body. A cable lug must be used to terminate the conductor so that it is secured against loosening and twisting, and that contact pressure is permanently secured.
5. Continue with “Powering Up the Probe Heater Assembly and Analyzer” later in this chapter.

2-18 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Figure 2-4. HAG Probe Heater wiring diagram (North American and European style), 931/932 Analyzers.
PN 903-8663, Rev H

Installation and Start-Up | 2-19

Wiring Sample Probe Heaters Controlled by Standalone Temperature Controller (Retrofits)
A separate, external Temperature Controller device must be installed and connected to provide signals and power to the HAG Probe Heater. This device can be supplied by AMETEK or by the customer/end-user.
The Temperature Controller must be able to accept a European Curve threewire Pt100 RTD (0.00385 alpha coefficient), provide PID control, and must also meet or exceed the following:
Temperature Range 40 °C to 120 °C, adjustable
Electrical Requirements Must be able to switch a 150 W load at either 120 VAC or 240 VAC.
To wire the Probe Heater Assembly to the standalone Temperature Controller:
1. Install the standalone Temperature Controller in a suitable location, as close as possible to the HAG Sample Probe, to ensure the RTD in the Sample Probe operates efficiently.
Hazardous Locations The Temperature Controller must be located in a remote safe area, or in a purged shelter/enclosure.
All electrical connections, materials, and methods (plus all safety policies and procedures) must be made in compliance with local wiring regulations and electrical code for the hazardous area, and be approved by the Owner Company.
2. The signal and power conductors can be run in separate or common conduit (North American/General Purpose installations) or cable (European/Hazardous Location installations). Terminal Box entries are 1/2-inch NPT.
For wiring gauge (AWG) and other requirements, refer to drawings/ documentation shipped with the HAG Probe, analyzer, and/or Temperature Controller.

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PN 903-8663, Rev H

Connect the conductors that supply power and a ground source from the Sample Probe to the appropriate terminals on the Temperature Controller.
Connect the Sample Probe RTD wires to the appropriate terminals on the Temperature Controller.
3. Complete the wiring from the analyzer to the Terminal Block in the Probe Heater Junction Box (see Figure 2-3).
Tighten the screws to secure each wire to the appropriate Terminal Block location in the Junction Box.
The procedure is complete.

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Installation and Start-Up | 2-21

Powering Up the Probe Heater Assembly and Analyzer
This section describes how to safely power up the analyzer, the Probe Heater Assembly, and the rest of the temperature zone circuitry for operation after installation or maintenance.
If the entire analyzer system (analyzer and HAG Probe) has been installed or reassembled, continue with this procedure; if not, complete the installation/electrical connections before continuing.
Hazardous Locations Before proceeding, test the area around the analyzer for flammable gases and proceed only when the area is safe.
Do not remove the cover of the Explosion-Proof Digital Communications Port on the front of the Lower Enclosure (931 or 932 Analyzers) and do not power up/down the analyzer or computer if there is an explosive gas atmosphere present.
Refer to the analyzer User Manual for additional safety and important information about the operation of the analyzer before and during power-up.
After the entire analyzer system has been installed (or maintenance has been completed) and the analyzer is ready to be put into service, power up the analyzer and its temperature zone circuitry:
1. Before powering up the analyzer: Systems without the optional Double Block Valve: Ensure the Vent Line valve (Black handle) and the Sample Line valve (Red handle) are closed, to isolate the process gas from the sample system.
Systems with the optional Double Block Valve: Ensure the upper Vent Line (Black handle) and Sample Line (Red handle) valves and lower Vent Line and Sample Line (T-handle) valves are closed, to isolate the HAG Probe from the sample stream.

2-22 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

See Fuse Legend inside
analyzer’s Lower Enclosure.

2. AMETEK 931 or 932 Analyzers: Close the main breaker (explosion-proof power disconnect switch, if used) that supplies AC power to the analyzer.
Retrofits (i.e., AMETEK 732 Analyzers): Turn the power switch on the rear panel to On.
3. Install the Insulating Flex Pack on the Sample Probe to allow the Sample Probe to warm up quickly.
4. Verify the Probe Heater Assembly is working.
Applications where the Probe Heater Assembly is controlled by the analyzer: This is part of the overall analyzer verification, as described under the section “Analyzer Start-Up and Verification” in the analyzer User Manual.
Upon power-up the “f: Probe temperature too low” alarm error message typically will be displayed due to a low Probe Heater Assembly temperature. For more information about this and other Probe Heater Assemblyrelated alarms, refer to “Analyzer Start-Up Diagnostics Checklist” and “Host Controller Board Error Conditions and Corrective Action” in the analyzer User Manual.
If it is suspected there is a shorted RTD, ensure AC power is making it to the Probe Heater. To do this, check the wiring by measuring across Terminals 4 and 5 in the Heater Assembly Junction Box.
Retrofit applications where the Probe Heater Assembly is controlled by a standalone external Temperature Controller: Check the Temperature Controller display to verify the temperature is increasing and stabilizes at the required temperature for the application.
5. Complete all other checks for starting up the analyzer, as described under the section “Analyzer Start-Up and Verification” in the analyzer User Manual.

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Installation and Start-Up | 2-23

6. After all temperature zones have reached normal operating temperatures (for 931 or 932 Analyzers, the normal operating temperatures are above the Too Cold set point; for retrofits with a standalone Temperature Controller, the temperature has stabilized at the required temperature), open the valves as listed below:
Systems without the optional Double Block Valve: Slowly open the Vent Line valve (Black handle) and then the Sample Line valve (Red handle) on the HAG Probe to allow sample gas into the sample system.
Systems with the optional Double Block Valve: Slowly open the lower Vent Line valve (T-handle) and then open the upper Vent Line valve (Black handle). Then, slowly open the lower Sample Line (T-handle) valve and then open the upper Sample Line valve (Red handle) to allow sample gas into the sample system.
After the valves have been opened, turn on the Aspirator Gas and adjust the sample gas flow rate to the recommended pressure listed on the system drawings shipped with the analyzer or HAG Probe.
The analyzer is ready to analyze sample gas.

2-24 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Maintenance and Troubleshooting

This chapter describes how to request technical support and authorization on returning equipment, and lists spare parts required for general and extended maintenance. This chapter also includes Diagnostic Flowcharts which can be used to check for possible problems with the Heated Acid Gas Sample Probe, and information about how to clean and replace Heated Acid Gas Sample Probe parts to keep the Heated Acid Gas Sample Probe and its Heater Assembly operating at peak efficiency.
Safety Considerations
Before working on the HAG Probe, read the entire procedure you will be performing to learn how to safely perform maintenance on the HAG Probe.
Personnel should be thoroughly familiar with the operation of the analyzer and HAG Probe before performing the maintenance procedures described in this chapter.
Before performing any maintenance on the HAG Probe and/or its Heater, review and follow all safety information in this chapter and under “Personnel and Equipment Safety Information” following the Table of Contents. This information describes procedures to follow to avoid personal injury and/or damage to the equipment. All regulatory agency and personnel safety procedures for your jurisdiction must be followed.
To prevent an explosion, test the area around the analyzer for flammable gases and proceed with maintenance only when the area is found to be safe (nonhazardous).
Generally, the HAG Probe and its Heater require limited maintenance. The “Diagnostic Flowcharts” section lists general maintenance to follow, to ensure continued and proper operation of the HAG Probe.

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Maintenance and Troubleshooting | 3-1

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Our goal is to make your experience with our products exceptional. We stand behind our analyzers with a broad service offering that provides a sense of security long after the initial purchase has been made. We commit to fulfilling your service needs with speed, quality, and professional consideration. From delivering on-site technical support to in-house repair at one of our service centers, our experienced technicians are knowledgeable and helpful. We also offer remote virtual support and a variety of training options. Scan the QR code or click the link below to request expert Aftermarket support for parts, repairs, service, training, and more:
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3-2 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Spare Parts Lists
The parts in the “HAG Sample Probe Spare Parts” list are essential to ensure the HAG Sample Probe operates at peak efficiency. The parts in the “HAG Sample Probe Extended Maintenance Spare Parts” lists are necessary only in the event of a failure.
Refer to associated drawings (located by Figure No.) for the location of the part and the quantity of individual parts to order.
To avoid lengthy maintenance delays, be sure to have on-site all parts that are being replaced prior to disassembling the Sample Probe valve assembly.
Content is subject to change without notice.

HAG Sample Probe Spare Parts

Description
Sintered Disk, 52 mm diameter (HAG Sample Probe)
Hi-Flow Filter Membrane, c/w Buna O-Ring (HAG Sample Probe)
O-Ring, Aflas, size 118 (HAG Sample Probe)
O-Ring, Aflas, size 121 (Valve Cover, HAG Sample Probe)
O-Ring, Silicone, 2-014 (Aspirator Insert, HAG Sample Probe)
O-ring, Viton, size 008 (Fiber Filter Assembly, HAG Sample Probe)
Fiber Filter Element (Fiber Filter Assembly, HAG Sample Probe)
O-Ring, Aflas, size 115 (Fiber Filter Assembly, HAG Sample Probe)

AMETEK Part No. 301-1713 301-1714 300-8722 300-8719 300-4651 300-4958 100-2193 300-6242

Figure No. 3-1.1 3-1.1 3-1.1 3-1.1 3-1.2 3-2 3-2 3-2

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Maintenance and Troubleshooting | 3-3

HAG Sample Probe Extended Maintenance Spare Parts
In the “HAG Sample Probe Heater Assembly Spare Parts” list, be sure to choose the appropriate Heater Cartridge (for 120 VAC or 240 VAC application).

HAG Sample Probe Heater Assembly Spare Parts

Description O-Ring, Silicone
Over-Temperature Switch
Heater Cartridge, 120 VAC OR Heater Cartridge, 240 VAC
Thermal Insulation Tube

AMETEK Part No. 300-8721
300-8637
300-8684 OR
300-8742
300-8733

Figure No. 3-4 3-4 3-4
3-4

Basic HAG Probe Sample/Vent Isolation Valve Kit and Replacement O-rings

Description
Sample/Vent Isolation Valve Assembly Kit
O-Ring, Aflas, size 121 (See * Note) (Ball Valve Assembly, 2 places)

AMETEK Part No. 300-9824 300-8719

Figure No. 3-1.1
3-1.1

• Note: Discard the four (4) o-rings (2 per kit) that come with the two (2) valve kits (300-

9824. and use four (4) replacement Aflas o-rings (300-8719). Be sure to order four (4) Aflas o-rings when ordering the two (2) Sample/Vent Isolation Valve Assembly Kits.

Double Block Valve (Optional)
Description Double Block Valve Rebuild Kit (see *Note)

AMETEK Part No. 301-2666

Figure No. 3-3

*Apply lube MS-LT-WL7 or STL-2 to lower 2­3 threads of valve body. Torque to 860 IN-LBS / 72 FT-LBS.

3-4 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Diagnostic Flowcharts
This section describes how to check different HAG Probe areas for possible problems, to reduce the occurrence of problems with the HAG Probe. Since most analyzer problems originate within the sample system, the primary objective of the Flow Charts is proper care of the sample system.
Preventing leaks in the HAG Probe and the rest of the sample system is critical to proper analyzer operation. Leak check the HAG Probe and the rest of the sample system whenever it has been dismantled for maintenance.

Setup (tab)
Temp Control

Maintenance details and assembly drawings are included in this chapter. Refer to the analyzer User Manual for additional information while performing maintenance.
Checking and Recording Operating and Set Point Temperatures
Approximately every six (6) months, check and record the HAG Probe operating Temperature and Setpoint temperatures (Temperature Control dialog box: Setup tabTemp Control). Ensure the operating Temperature is within proper range of the Setpoint temperature. Refer to the analyzer User Manual for descriptions of these settings.
Depending on process stream conditions, the suggested maintenance frequency may be shortened or extended.
If temperatures vary outside this range, inspect the Insulating Flex Pack on the HAG Sample Probe. If there is any exposed metal, take appropriate safety precautions and re-insulate it properly.

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Maintenance and Troubleshooting | 3-5

See “HAG Sample Probe
Extended Maintenance Spare Parts” for Isolation valve ordering numbers for your application.

Possible Leaks in Sample Probe Valves
The Sample/Vent Isolation (or optional Double Block) valves typically do not require regular maintenance. However, if it appears that leaks are originating from the HAG Probe Main Sample/Vent Isolation Ball Valves or from the optional Double Block Valves the valves assembly will have to be immediately replaced or rebuilt.

IMPORTANT Depending on the application for your analyzer, the Sample Probe may be either Basic or Extended Temperature.

To avoid further delays during maintenance, be sure to have on-site all required parts that are being replaced prior to disassembling the Sample Probe valve assembly. Twenty-four (24) hours of curing time is required for the liquid sealant.

Probe-Related Alarms are Active
The Heater Assembly temperature zone circuitry does not require regular maintenance. However, if problems arise with the Heater (Probe-related alarms are active), determine the origin of the problem and immediately replace the faulty part(s). These parts can include the Over-Temperature Switch, Heater Cartridge, and RTD.
Refer to the “Maintenance and Troubleshooting” chapter (see section “Host Controller Board Error Conditions and Corrective Action”) in the analyzer User Manual for information on specific alarms. See “Replacing Probe Heater Parts ­ Extended Maintenance” in this chapter.
IMPORTANT Be sure to have on-site the proper replacement parts prior to disassembling the Heater Assembly. Refer to the “HAG Sample Probe Heater Assembly Spare Parts” list in this chapter for part numbers.

Checking Flamepaths and Gaps
During each Probe Heater Assembly maintenance, use a feeler gauge to check the flamepath gap between the Heater Body and the Heater Cover (see Figure 3-4 for location). The gap must not exceed 0.04 mm; if the gap exceeds this value, contact AMETEK for advice. See “Examining and Caring For the Flamepaths” in this chapter for more information.

3-6 | Heated Acid Gas Sample Probe

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Preparing the Analyzer and Sample Probe for Maintenance
Preparing and powering down the analyzer, HAG Probe, and its temperature zone circuitry is necessary to ensure the safety of personnel and equipment. This section describes how to power down the analyzer for all maintenance requirements discussed in this chapter. This section refers to 931 or 932 Analyzers only. For 919 or 920 Analyzers, refer to the companion document “919/920 Analyzers with Heated Acid Gas Sample Probe” Manual Supplement shipped with the HAG Probe or analyzer.
Hazardous Locations Before proceeding, test the area around the analyzer for flammable gases and proceed only when the area is safe.
Do not remove the cover of the Explosion-Proof Digital Communications Port on the front of the Lower Enclosure (931 or 932 Analyzers) and do not power up/down the analyzer or computer if there is an explosive gas atmosphere present.

Follow appropriate regulatory and/or company procedures to lock out the analyzer while the HAG Probe or its Heater Assembly is being worked on.

Setup (tab)
Gas Calibration<>

To prepare and safely power down the analyzer, HAG Sample Probe, and its temperature zone circuitry:
1. Connect a serial cable between the computer and the analyzer’s Communications Port. Using the Configurator Software, change the Flow Control setting to `2′ (zero). Click Apply (next to Flow Control) to set the analyzer into zero Flow Control mode. Click the ManZero button to initiate a Manual Zero then click OK. Do not save the changes to EEPROM. Allow the Zero gas to flow for 2­3 minutes to remove all residual gas in the sample system.
The Aspirator Drive Gas should remain on during the Zero or Span procedure to ensure the sample gas pressure remains steady.

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Maintenance and Troubleshooting | 3-7

See Fuse Legend inside
analyzer’s Lower Enclosure.

2. If the analyzer uses measured Pressure Compensation (optional), change the pressure compensation to fixed mode so that a “f: Sample gas pressure too low” alarm does not occur. To do this, view the Cell/Misc Parameters dialog box and enter a value in the Default Cell Pres (pressure compensation) field that is the same as, or approximately, the Measuring Cell pressure. Refer to “Cell/Miscellaneous (Compensation) Parameters” in the analyzer User Manual.
Systems without the optional Double Block Valve Close the Sample Line valve (Red handle) to isolate the HAG Probe from the sample stream.
Systems with the optional Double Block Valve Close the lower Sample Line valve (T-handle) and then close the upper Sample Line valve (Red handle) to isolate the HAG Probe from the sample stream.
Backpurge the analyzer sample system with Zero gas for 2­3 minutes.
3. Change the Flow Control setting to `1′ (shut-in/off). Click Apply (next to Flow Control) and then click OK.
Next, bleed down the sample system to atmospheric pressure (check gauge), then close the isolation valves:
Systems without the optional Double Block Valve Close the Vent Line valve (Black handle) to isolate the HAG Probe from the sample system.
Systems with the optional Double Block Valve Close the lower Vent Line valve (T-handle) and then close the upper Vent Line valve (Black handle) to isolate the HAG Probe from the sample system.
4. Disconnect AC power to the analyzer and power down the computer before performing maintenance on the analyzer.
Hazardous Locations Always disconnect mains AC power and/or alternate power sources to the analyzer before opening any covers or doors on the analyzer to check or perform maintenance on any components within the enclosures.

If it is necessary to open the analyzer’s covers or doors while the circuits are live, test the area for flammable gases (and proceed only when the area is safe). To work on the analyzer with it powered up and its electronics enclosure(s) open, take appropriate precautions to avoid electrical shock. Hazardous voltages are present inside.

5. Remove the Insulating Flex Pack (see Figure 2-2) from the Sample Probe to allow it to cool.

3-8 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Changing Out Replaceable Parts
This section describes replacing parts in the standard HAG Sample Probe and the optional Double Block HAG Sample Probe.
Performing preventive maintenance on the analyzer/HAG Probe requires working with the analyzer’s System 200 Configurator Software. Familiarize yourself with the Software before working on the analyzer and HAG Probe.

See “Spare Parts Lists”
in this chapter for spare parts ordering numbers.

Replacing Sample Probe Parts
This procedure discusses maintenance procedures to change out parts in the HAG Probe. The Sample/Vent Isolation valves and (optional) Double Block valves in the HAG Probe do not require regular maintenance.
It is necessary to change out the o-rings, Hi-Flow Membrane, Fiber Filter Element, and Sintered Disk:
· If evidence of contamination and/or leaks is present.

See “Spare Parts Lists”
in this chapter for extended maintenance spare parts ordering numbers.

It is necessary to change out the Sample/Vent Isolation valves or (optional) Double Block valves immediately if:
· Leaks are originating from any of these valves.
IMPORTANT Be sure to have the required parts ­ o-rings, Hi-Flow Membrane, Fiber Filter Element, Sintered Disk, and/or Sample/Vent Isolation valve or (optional) Double Block valve kits ­ on-site prior to disassembling the Sample Probe valve assembly.

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Maintenance and Troubleshooting | 3-9

Figure 3-1.1. Standard Heated Acid Gas Sample Probe Assembly.
3-10 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Figure 3-1.2. Optional Double Block Heated Acid Gas Sample Probe, Full Assembly.
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Maintenance and Troubleshooting | 3-11

Figure 3-1.3. Optional Double Block Heated Acid Gas Sample Probe, Partial Assembly.
SEE NOTE
Figure 3-1.4. Optional Double Block Valve (Special Applications) (100-2393).
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PN 903-8663, Rev H

The design of the HAG Probe allows for Regular Maintenance without having to remove the Probe from the sample stream.
However, if the main Sample/Vent Isolation valves or the optional Double Block valves need to be replaced (Extended Maintenance), additional steps are required, as described in this procedure.
“Part No.” refers to AMETEK Part Number.
All screws are metric (mm) unless otherwise noted.

To change out parts in the HAG Probe (Figures 3-1.1, 3-1.2, 3-1.3, 3-2, 3-3) as they apply to your HAG Probe:
This procedure assumes that all appropriate safety precautions have been met to power down the analyzer and HAG Probe, and the Electronics Enclosure is already open as described under “Preparing the Analyzer and Sample Probe for Maintenance” in this chapter.

1. Remove the Insulating Flex Pack (see Figure 2-2) from the HAG Probe.
The Heater Assembly may be extremely hot. Allow the heater and the probe to cool down to a temperature that allows safe handling before working on these parts.

2. To allow easy removal of the Heater Assembly loosen, remove, and pull back the Sample and Vent Lines from their fittings on the HAG Probe.
3. Remove the four (4) M6 x 60 screws that secure the Heater Assembly to the HAG Probe (Figure 3-3). Remove the Heater Assembly from the Probe and pull it back to allow room to work on the Probe.
Depending on your maintenance requirements, below, continue with the appropriate step:
· If you are replacing the o-rings, Hi-Flow Membrane, Fiber Filter Element, and Sintered Disk, and/or the Isolation Valves in the Sample Probe, continue with Step 4.
· If you are replacing parts in the Heater Assembly, continue with “Replacing Probe Heater Parts ­ Extended Maintenance” in this chapter. Return to this procedure when complete.

PN 903-8663, Rev H

Maintenance and Troubleshooting | 3-13

4. If the Probe has a Heat Transfer Skirt (typically used only with Probes that do not have the optional Double Block Valve): Remove the four (4) M6 x 16 screws that secure the Heat Transfer Skirt (2 places) to the Heat Transfer Plate. Remove the Heat Transfer Skirt.
5. Remove the four (4) M6 x 100 screws that secure the Heat Transfer Plate, Filter Body, and Filter Plate to the Valve Cover.
Carefully remove these parts and separate them.
6. To replace parts in the HAG Probe:
When removing and replacing o-rings and other parts, take care to avoid damaging the o-ring grooves or the probe body parts.

a. Using an o-ring removal tool remove the o-ring (Part No. 300-8722) from the Filter Plate.
Note the orientation of the Hi-Flow Membrane and remove it from the Filter Body. Remove the Sintered Disk from the recess in the Filter Body.
Remove the two (2) o-rings (Part No. 300-8719 and Part No. 300-8722) from the Valve Cover.
Remove the Aspirator Insert from the Filter Body and remove its o-ring (Part No. 300-4651).
Remove the Fiber Filter Assembly from the Filter Plate. Remove the M6 x 10 screw and separate the Fiber Filter Assembly parts (Figure 3-2).
Remove the o-rings from the Filter Assembly screw and Filter Holder. Remove the Fiber Filter Element.
b. Using a soft, non-abrasive cloth, clean all parts and chambers with Isopropanol or a similar aqueous, non-abrasive cleaning agent that does not harm aluminum or stainless steel.
c. Rinse all parts with pharmaceutical grade distilled water and allow them to air dry.
d. Insert new o-rings:
When inserting new o-rings, use your thumbs to push each one into its o-ring groove until it is completely seated in the groove.

i. Insert two (2) new o-rings (Part No. 300-8722), one (1) in the top surface of the Filter Plate and one (1) in the top surface of the Valve Cover.

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PN 903-8663, Rev H

Figure 3-2. Fiber Filter Assembly, Aluminum (100-2194).

ii. Insert one (1) new o-ring (Part No. 300-8719) in the o-ring groove in the top surface of the Valve Cover.
iii. Install one (1) new o-ring (Part No. 300-4651) on the Aspirator Insert and replace the Aspirator Insert in the Filter Body.
iv. Install one (1) new o-ring (Part No. 300-4958) on the M6 screw by rolling it up to the screw head. Install one (1) o-ring (Part No. 300-6242) on the Filter Holder.
Install a new Fiber Filter Element (Part No. 100-2193) between the Filter Cover and Filter Holder (note the orientation in Figure 3-2), reassemble the Fiber Filter Assembly, and then remove the excess Filter material.
Replace the Fiber Filter Assembly in the Filter Plate and secure it with the M6 x 10 screw.
e. Insert one (1) new Sintered Disk (Part No. 301-1713) in the recess in the Filter Body.
Remove the new Hi-Flow Membrane (comes with attached o-ring, Part No. 301-1714) from its shipping bag and centre it over the o-ring groove (o-ring side upward). Gently press one side of the o-ring into the o-ring groove, then repeat on the other side of the o-ring. Repeat this process on the other sides until the o-ring is completely in place.

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Maintenance and Troubleshooting | 3-15

7. Extended Maintenance: If required, replace the main Sample/Vent Isolation valves and/or the optional Double Block valves; otherwise, continue with Step 8 to reassemble the HAG Probe:
Potentially lethal concentrations of H2S and/or other toxic gases are present in the process stream. Before proceeding, follow all necessary safety precautions, such as wearing a supply air apparatus, to safely remove the Pipe Adapter section of the Probe.

When replacing the Double Block isolation valves (lower valves, T-handles) ­ see Step 7-b ­ the Pipe Adapter section of the Probe must be removed from the sample stream to replace these valves. In this case a flange blind must be temporarily installed (or the threaded connection must be capped) while the Sample Probe is being worked on.
a. HAG Probe without the optional Double Block valves: Remove the HAG Probe from the process duct and temporarily install a flange blind (or cap the threaded connection) while the Probe is being worked on.
HAG Probe with the optional Double Block valve: If only replacing the main (upper) Sample/Vent Isolation valves, close the Double Block valves (lower, T-handles), remove the Sample/Vent Isolation valves from the Probe. Continue with Step 7-b.
If also replacing the Double Block isolation valves (lower valves, T-handles) ­ see Step 7-b ­ the Pipe Adapter section of the Probe must be removed from the sample stream to allow replacement of these valves. In this case a flange blind must be temporarily installed (or the threaded connection must be capped) while the Sample Probe is being worked on. Continue with Step 7-b.
b. If possible, take the Sample Probe to a shop to work on it.
Remove the six (6) M6 x 40 mm screws that secure the Valve Cover and Isolation Ball Valves to the Pipe Adapter Assembly.
c. Remove the Isolation valves (and optional Double Block valves):
HAG Probe without the optional Double Block valves: i. Remove the Valve Cover and then remove the Isolation valves. Set
aside any parts that will be re-used.
ii. Using an o-ring removal tool, remove the four (4) o-rings from the top and bottom o-ring grooves of the Isolation valve. Take care to avoid damaging the grooves.

3-16 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

HAG Probe with the optional Double Block valves: i. Loosen and remove the two (2) M5 x 10 screws and eccentric lock-
washers (2 places), and set aside (Figure 3-1.4).
ii. Remove the two (2) needle valves and discard.
d. Using a soft, non-abrasive cloth, clean the interior chambers and surfaces of the remaining parts with Isopropanol or a similar aqueous, non-abrasive cleaning agent that does not harm aluminum or stainless steel.
e. Rinse all parts with pharmaceutical grade distilled water and allow them to air dry.
f. Install the new Isolation valves (Sample/Vent Isolation Valve Assembly Kit Part No. 300-9824 ­ * See IMPORTANT Note) (and optional Double Block valves, if used):
Installing the new isolation valves in the standard HAG Sample Probe: i. Replace the four (4) Aflas o-rings (Part No. 300-8719), two (2) in
each valve assembly.

• IMPORTANT Do not use the four (4) o-rings (2 per kit) that come with the two (2) Sample/Vent Isolation Valve Assembly Kit Part No. 300-9824. Discard these o-rings and use four (4) replacement Aflas o-rings (Part No. 300-8719), which are listed in the “Basic HAG Probe Sample/Vent Isolation Valve Kit and Replacement O-Rings” list in this chapter.
  ii. Properly orient each Isolation valve and place it on the Pipe Adapter Assembly.
  iii. Properly orient the Valve Cover and place it over the Isolation valve. Secure it to the Pipe Adapter Assembly with the six (6) M6 x 40 screws.
  Installing the new isolation valves (lower valves, T-handles) in the Double Block HAG Sample Probe: i. Obtain (2) Double Block Valve Rebuild Kits (Part No. 301-2666,
  comes with lube MS-LT-WL7).
  ii. Apply lube MS-LT-WL7 to lower 2­3 threads of each Valve Body and install the valves in the Pipe Adapter.
  iii. Torque each valve to 860 in-lb/72 ft-lb (6.01 ±1.0 Nm).

PN 903-8663, Rev H

Maintenance and Troubleshooting | 3-17

8. Reassemble the Sample Probe:
a. Using the alignment dowel pin and Aspirator Insert as a reference, place the Filter Plate on the Valve Cover.
b. Using the alignment dowel pin and Aspirator Insert as a reference, lower the Filter Body onto the Filter Plate. Take care not to bind the Aspirator Insert.
c. Properly orient the Heat Transfer Plate, place it on the Filter Body, and secure these parts to the Valve Cover with the four (4) M6 x 100 screws.
9. If the Probe has a Heat Transfer Skirt (typically used only with Probes that do not have the optional Double Block Valve), secure the Heat Transfer Skirt to the Heat Transfer Plate with the four (4) M6 x 16 screws.
10. Replace the Sample Probe on the process duct.
All regulatory agency, personnel safety procedures, and installation/ removal procedures must be followed during the installation/removal of the components that make up the sample system. A breathing apparatus must be worn when installing/removing the Sample Probe. The process duct may be under positive pressure, and injury or death from inhaling toxic gases in the process could result from attempting to install/remove the equipment without the use of a breathing apparatus.

If applicable, remove the flange blind (or remove the cap) and connect the Sample Probe to the process duct.
11. Using a suitable detergent-based leak detection fluid (e.g., Snoop®), leakcheck the threaded connections.
Do not use a leak detection fluid on hot fittings. If the analyzer/probe system is at operating temperature, the temperature zone circuitry must be powered down to allow the temperature zones to cool down before using a leak detection fluid on the fittings.

For detailed information about leak-checking fittings, refer to “Sample System Leak Check” in the analyzer User Manual.
Applications With a Threaded Connection: Leak-check the Pipe Adapter threads (where the Pipe Adapter enters the threaded connection on the process), the Isolation Needle Valves ­ T-handles (if the probe is a Double Block HAG Probe, and if these valves were replaced), and the Sample/Vent Line connection points on the Sample Probe.
Applications With a Flange: Leak-check the Pipe Adapter threads/replacement flange assembly, the Isolation Needle Valves ­ T-handles (if the probe is a Double Block HAG Probe, and if these valves were replaced), and the Sample/Vent Line connection points on the Sample Probe.

3-18 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

12. After the leak-check passes, and maintenance on the Heater Assembly is complete, replace the Heater Assembly (Figure 3-3):
a. Use a non-abrasive cloth to gently clean the joining surfaces (heat transfer) of the Heater Block and the Sample Probe.
b. Place the Heater Assembly on the Sample Probe.
c. Apply a high-temperature thread lubricant to the threads of the four (4) M6 x 60 screws (Part No. 300-8741, Figure 3-4), replace the screws, and tighten them to secure the Heater Assembly to the Sample Probe.
The thread lubricant must not contain copper.
13. Replace the Insulating Flex Pack on the Sample Probe.
14. Power up the analyzer for operation, as described under “Powering Up the Probe Heater Assembly and Analyzer” in Chapter 2.
The procedure is complete.

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Maintenance and Troubleshooting | 3-19

Replacing Probe Heater Parts ­ Extended Maintenance
This section describes Extended (Advanced) Maintenance, which is required only in the event of failure of one of the Heater components (Over-Temperature Switch, Heater Cartridge, or RTD). Replace the faulty component(s) as required.
Carefully read and understand all of the instructions before beginning disassembly and reassembly. The instructions are described in a sequence that will ensure the proper removal and replacement of all parts that make up the entire Heater Assembly. The instructions also include special Notes, Cautions, and Warnings to consider while working on the Heater Assembly.

See “Spare Parts Lists”
in this chapter for extended maintenance spare parts ordering numbers.

IMPORTANT If the Heater Assembly cover is removed for the purpose of replacing internal electrical parts or wires, always replace the internal o-ring (Part No. 300-8721).
Be sure to have the required parts (Over-Temperature Switch, Heater Cartridge, and/or RTD) on-site prior to disassembling the Probe Heater. ORDER THE O-RING AT THE SAME TIME YOU ORDER ALL OTHER PARTS.

While the Heater Assembly is removed for maintenance, take extreme care to avoid scratching or damaging the joining surfaces (flamepath) of the Heater Assembly and its cover, and the joining surfaces (heat transfer) of the Heater Assembly and the HAG Probe. Also, take care to avoid damaging the o-ring groove.
Gently clean these areas with a non-abrasive cloth.

If the Thermal Insulation Tube is removed, take extreme care to avoid damaging its threads and the threads in the Heater Block, and the Junction Box and its cover. After removing these parts, cover the threaded ends to avoid damaging them. Clean, defect-free threads are essential to ensure a flame-proof connection.

3-20 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

List of Materials and Special Tools Required While working on the Heater Assembly, certain special tools and materials are required. These include: · Soldering iron · Solder · High-temperature wire (for ground wire) · High- temperature thread lubricant (must not contain copper) · O-ring removal tools · Soft, non-abrasive cloth

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Maintenance and Troubleshooting | 3-21

Follow this procedure in the order listed to ensure a complete and proper job is done while changing out the Heater Assembly’s internal parts.
Before working on the HAG Probe and its Heater Assembly, perform a manual backpurge on the analyzer to remove any residual gas in the sample system. Then, close the Double Block valves (optional ­ if installed) and then the Sample and Vent line valves on the HAG Probe.

To replace parts in the Heater Assembly (Figure 3-3):
This procedure assumes that all safety precautions have been met to safely power down the analyzer and HAG Probe and its temperature zone circuitry and to prepare the analyzer for maintenance, as described earlier in this chapter.
This procedure also assumes that the Insulating Flex Pack has been removed from the HAG Probe, the Probe Heater Assembly has cooled down enough to ensure safe handling, and the Heater Assembly has been disconnected and pulled back from the HAG Probe, as described earlier in this chapter.
Do not proceed until these conditions have been met.

1. Loosen the set screw on the Junction Box Cover enough to allow the cover to be removed. Use a suitable tool to turn the threaded cover counterclockwise and remove it from the Junction Box Body. Take care to avoid damaging the o-ring and the threads.
Remove the ground screw and washer from the Junction Box Body and pull back the ground wire out of the way.
2. Record the tag locations of the field wires on the Terminal Blocks to use later when installing the new parts. These terminations can also be found in Figure 3-4.
Loosen the screws securing all of the field wires and the wires that make up the RTD cable on the Terminal Blocks in the Junction Box.
Remove and pull back the wires from the Terminal Blocks.
North American installations: Disconnect the conduit (or TEK cable, if used) and pull back the cable(s). If flexible conduit is used, pull it back.
European installations: Loosen the cable gland(s) and pull back the cable(s).

3-22 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

3. Remove the four (4) M6 x 60 screws that secure the Heater Assembly to the HAG Probe.
Follow appropriate regulatory and/or company procedures to lock out the analyzer while the Heater Assembly is being worked on.
4. Remove the Heater Assembly from the HAG Probe and take it to a shop to work on it.
The Heater Assembly can be removed from the HAG Probe without removing the Sample Probe from the sample stream.
The Heater Assembly should be worked on in a suitable shop or other area equipped with proper tools, equipment, and materials that are required for repairing explosion-proof devices.
5. Remove the eight (8) M6 x 16 screws that secure the Heater Assembly Cover to the Heater Block.
6. Remove the Heater Assembly cover and store it in a safe location, where the joining surface (flamepath) will not be scratched or damaged.
IMPORTANT When disassembling the Heater Assembly, retain all parts in a safe location to avoid losing or damaging them. These parts, with the exception of the parts being replaced, will be required when reassembling the Heater Assembly.

PN 903-8663, Rev H

Maintenance and Troubleshooting | 3-23

INTERNAL HEATER BLOCK WIRING DETAIL
BLOCK IS SHOWN TRANSPARENT
FOR CLARITY ONLY
1 21 32 43 54 5

Figure 3-3. Probe Heater Assembly, 120 V/240 V (100-1658-1A).
3-24 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

7. Remove the o-ring using an o-ring removal tool to avoid damaging the groove or the Heater Block joining surface.
Every time the Heater Assembly cover is removed, the internal o-ring must also be replaced. DO NOT INSTALL THE NEW O-RING AT THIS TIME. Instructions on when to install the o-ring are described later in this procedure.
Continue with Step 8 (Over-Temperature Switch), Step 9 (Heater Cartridge), and/or Step 10 (RTD) as necessary for the removal and replacement of these parts.
If replacing only one of these items, follow only the procedure for the appropriate step. If you are replacing two or more items, follow the procedure for each of the steps. Some steps for the different part replacement procedures may be the same and certain procedures, such as routing wires, can be done at the same time.
8. Replace the Over-Temperature Switch:
a. Loosen and remove the two (2) M3 x 6 screws and two (2) 3 mm Internal Toothlock Washers that secure the Over-Temperature Switch and its mounting bracket in place.
b. Using a soldering iron, remove the solder from the wires on the OverTemperature Switch and remove the two (2) wires.
Remove any excess solder from the bottom of the Heater Block.
c. Assemble the new Over-Temperature Switch (Part No. 300-8637) and install it in the Heater Block.
Do not fully tighten the two (2) M3 x 6 screws that are used to secure the Over-Temperature Switch at this time. The Over-Temperature Switch and Heater Cartridge wires must be soldered before securing the Over-Temperature Switch in place.

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Maintenance and Troubleshooting | 3-25

Figure 3-4. HAG Probe Heater wiring diagram (North American and European style), 931/932 Analyzers.
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PN 903-8663, Rev H

d. Solder the Heater Cartridge wire to the closest terminal on the OverTemperature Switch. Solder the other wire to the other terminal.
Carefully pull the wires back from the Junction Box end until there is no excess wire remaining inside the Heater Block.
e. Tighten the two (2) M3 x 6 screws to secure the Over-Temperature Switch in place.
f. Replace other parts or continue with Junction Box reassembly.
9. Replace the Heater Cartridge:
The Heater Cartridge can be either 120 V or 240 V. Install only the proper Heater Cartridge for your application.
a. Inside the Heater Block, near the Heater Cartridge, carefully cut the wire leading to the Over-Temperature Switch.
Do not cut the wire that runs from the Heater Cartridge to the Terminal Block. This wire is necessary to assist in the removal of the Heater Cartridge.
b. Remove the Heater Plug from the Heater Block.
c. Attempt to break the connection on the Heater Block side of the Thermal Insulation Tube.
If you are able to break the connection: i. Slowly and carefully turn the entire Junction Box/Thermal Insula-
tion Tube assembly to avoid twisting or breaking the wires while removing it from the Heater Block.
Take extreme care to avoid damaging the threads on the Thermal Insulation Tube and in the Heater Block. After removing the tube, cover the threaded ends to avoid damaging them. Clean, defect-free threads are essential to ensure a flame-proof connection.

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Maintenance and Troubleshooting | 3-27

ii. When the Thermal Insulation Tube is free from the Heater Block, carefully pull the Junction Box/Thermal Insulation Tube assembly away from the Heater Block. Take care to avoid damaging the wires.
iii. Use the wire on the Heater Cartridge to pull it out from the Heater Block.
If you are not able to break the connection: i. On the Junction Box, remove the plug opposite the Thermal Insula-
tion Tube.
ii. If not already done, remove the Terminal Block.
iii. Locate the wire from the Heater Cartridge and pull it through the port opposite the Thermal Insulation Tube. Then, use the wire to pull the Heater Cartridge through the Thermal Insulation Tube and Junction Box.
d. Using a soldering iron, remove the solder from the wire on the OverTemperature Switch that was cut earlier (the wire leading to the OverTemperature Switch). Pull back the wire from the Over-Temperature Switch.
Remove any excess solder from the bottom of the Heater Block.
e. Install the new Heater Cartridge.
If you were able to break the connection: i. Insert the new Heater Cartridge in the Heater Block.
ii. Separate the heater leads so that the shorter wire goes up through the Heater Block to the Over-Temperature Switch.
Solder the wire to the terminal the original wire was removed from on the Over-Temperature Switch.
Before continuing with the next step, be sure to inspect the threads on the Thermal Insulation Tube and in the Heater Block. If any threads have been damaged, replace the Thermal Insulation Tube only with an AMETEK-supplied Thermal Insulation Tube. DO NOT REPLACE WITH STANDARD ELECTRICAL CONDUIT.

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PN 903-8663, Rev H

iii. If the Thermal Insulation Tube (Part No. 300-8733) threads are damaged, replace it now. Apply a high-temperature grease/lubricant (approved for use with threaded flamepath joints) to the threads that will be installed in the Junction Box and thread it into the Junction Box.
Do not thread the other end into the Heater Block at this time.
iv. Route the other end of the Heater Cartridge wire, and the other wires and RTD cable, through the hole in the Heater Block, through the Thermal Insulation Tube, and into the Junction Box.
v. If required, carefully clean the threads in the Heater Block.
Apply a high-temperature grease/lubricant (approved for use with threaded flamepath joints) to the threads on the Thermal Insulation Tube that will be installed in the Heater Block and carefully thread it into the Heater Block.
If you were not able to break the connection: i. Orient the new Heater Cartridge as shown in Figure 3-3 and insert
it in the opening opposite the Thermal Insulation Tube on the Junction Box.
While holding the other wires and RTD cable that are routed from the Heater Cartridge and into the Junction Box (to ensure they are not pushed back and damaged), carefully push the Heater Cartridge into the Thermal Insulation Tube.
Using a small blunt instrument, carefully push the Heater Cartridge into the Heater Block until the wires are visible inside the Heater Block.
ii. Separate the heater leads so that the shorter wire goes up through the Heater Block to the Over-Temperature Switch.
Solder the wire to the terminal it was removed from on the OverTemperature Switch.
If necessary, adjust the Heater Cartridge so it is properly seated in the Heater Block.

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Maintenance and Troubleshooting | 3-29

iii. Pull the wire from the Heater Cartridge into the Junction Box, along with the other wires and RTD cable.
iv. Replace the plug that was removed from the Junction Box.
AMETEK recommends applying a small amount of high-temperature thread lubricant to the threads.
The thread lubricant must not contain copper.
f. Replace the Heater Plug in the Heater Block.
g. Replace other parts or continue with Junction Box reassembly.
10. Replace the RTD:
a. Disconnect the RTD wiring and remove the RTD from the Heater Block.
b. Remove the Heater Plug.
c. Install the new RTD (Part No. 300-4924) in the Heater Block.
Connect the new RTD wires to the old RED wires and pull the wires through the Thermal Insulation Tube from the Junction Box side.
Carefully pull the RTD cable back from the Junction Box end until there is no excess cable remaining inside the Heater Block.
d. Replace the Heater Plug.
e. Continue with Step 11 for final Junction Box assembly.
11. To allow for easier wiring inside the Junction Box, cut any excess wire leads to approximately 4″ (10 cm).
Wire the terminal strip as per your notes (or Figure 3-4).
12. Using a soft, non-abrasive cloth, clean the o-ring groove and the joining surfaces (flamepath) on the Heater Block and its cover. Take care to avoid dropping any contaminants into the Heater Block.
13. Insert the new Heater Assembly o-ring (Part No. 300-8721) by using your thumbs to push it into the o-ring groove in the Heater Block. Ensure it is properly seated in the groove.

3-30 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

14. Ensure the joining surfaces (flamepath) of the Heater Assembly Cover and the Heater Block are free of debris. Replace the Cover on the Heater Block and the eight (8) M6 x 16 screws that secure the Cover to the Heater Block.
AMETEK recommends applying a small amount of high-temperature thread lubricant to the threads. Tighten the screws.
The thread lubricant must not contain copper.
15. Reposition the conduit (North American installations) or cable(s) (European installations) to the Probe Heater Assembly, reconnect the field wires, and reassemble the Junction Box (Figure 3-3 and Figure 3-4):
a. Insert the field wires into the Terminal Block tag locations, according to your notes or Figure 3-4.
Tighten the screws to secure each wire to the appropriate Terminal Block tag location in the Junction Box.
b. With the Junction Box o-ring in place on the Junction Box Cover, thread the Cover onto the Junction Box Body by hand and then tighten it using a suitable tool. Take care to avoid damaging the o-ring and the threads.
Tighten the set screw on the end of the Junction Box Cover.
Reconnect the ground to the Junction Box Body using the ground screw and washer.
c. Tighten the conduit connectors (North American installations) or cable gland(s) (European installations).
16. If all maintenance on the Heater Assembly is complete, replace and secure the Heater Assembly on the Sample Probe, as described in the section “Replacing Sample Probe Parts.”
The procedure is complete.

PN 903-8663, Rev H

Maintenance and Troubleshooting | 3-31

Examining and Caring For the Flamepaths
The HAG Sample Probe Heater Assembly is designed with a flamepath that will prevent flame propagation from within the Heater Assembly to the outside, should an internal explosion occur. The minimum flamepath length must be at least 9.5 mm with a maximum surface roughness of 6.3 µm. The gap between the flange surfaces with the bolts tightened must not exceed 0.04 mm. Use A2 stainless steel fasteners with yield stress 450 MPa (65,300 psi).
The flamepaths on the Heater Assembly consist of:
· The Heater Assembly joining surfaces (Heater Body and the Heater Cover).
During each analyzer maintenance, use a feeler gauge to check the flamepath gap between Heater (Block) Body and the Heater Cover joining surfaces. The gap must not exceed 0.04 mm; if the gap exceeds this value, contact AMETEK for advice. See Warning below.
· All separable joints between the Heater Body and its Junction Box. These parts include the threads in the Heater Body and the Junction Box used to connect to the Thermal Insulation Tube, the threads on each end of the Thermal Insulation Tube, the larger diameter threads on the Junction Box and its Cover, and the o-ring groove. See Caution and Warning below.
If the Thermal Insulation Tube is removed, take extreme care to avoid damaging its threads and those in the Heater Block. Also, take care to avoid damaging the threads on the Junction Box and its cover. After removing these parts, cover the threaded end to avoid damaging the threads. Clean, defect-free threads are essential to ensure a flameproof connection.

When performing equipment maintenance in hazardous areas, all safety standards and procedures must be followed, as specified by the Owner Company, local electrical-inspection authority, and National/ EU regulations.

Do not apply power to the analyzer/HAG Sample Probe if there is damage (scratches, indentations, or wear) to any flamepath. Applying power to an analyzer with a damaged flamepath is dangerous and could result in serious injury or death and/or serious damage to equipment. Review this section for complete information about caring for the flamepaths.
Replace the parts immediately if damage or wear is apparent. Contact AMETEK immediately if there is any doubt about the integrity of any flamepath.

3-32 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

Specifications

The Heated Acid Gas (HAG) Probe is designed for applications in which process gas is to be returned to the process pipe, where the process gas contains only small quantities of particulate and entrained liquids.

Methodology
The heated sample probe simultaneously extracts a sample, maintains high integrity, prevents condensation, and provides a sample return point to create a truly closed-loop sampling process.

Heated Acid Gas (HAG) Probe Heater Specifications
The Heater Assembly is the only part of the Sample Probe that is electrically powered.

Specification Power Consumption Electrical Requirements
Ambient Temperature
Ingress Protection Cable/Cable Glands

Description
Maximum Power: 150 W
Supply Voltage: 120 VAC ± 10 %, 47­63 Hz 240 VAC ± 10 %, 47­63 Hz
-50 °C to +70 °C (-58 °F to +158 °F), -29 °C to +70 °C (-20.2 °F to +158 °F), typical operating conditions with AMETEK Insulating Flex Pack.
NEMA Type 4, IP 55
This typically applies to European/Hazardous Locations only.
Heat resistant cable and Ex d cable glands must be used, suitable for 85 °C (185 °F).

PN 903-8663, Rev H

Specifications | 4-1

HAG Probe Valve Assembly Specifications

Specification Typical Flow Rate Aspirator Drive Gas (Sample Transport)
Minimum Ambient Temperature Maximum Process Temperature
Minimum Probe Temperature Maximum Probe Pressure Process Connection
Physical Dimensions

Description

2 L/min (0.7 SCFM)

Instrument air, nitrogen, or steam, depending on the process.

Flow Rate:

<1.0 SCFM (30 L/min) at 30 PSIG (2.1 BARG) above the process pressure.

Air Quality (if used): As per ANSI/ISA S7.0.01 (1996) Quality Standard for Instrument Air.

-29 °C (-20.2 °F)

121 °C (250 °F) 210 °C (410 °F) -29 °C (-20.2 °F)

Sample Gas Temperature, Standard HAG Probe
Sample Gas Temperature, Optional Extended Temperature HAG Probe
Sample Gas Temperature

10.3 BARG (150 PSIG)

1-1/2″ M-NPT flange (typical). Various ANSI Flange Adapters available (e.g., 1-1/2″ to 3″ at 150 lb or 300 lb).

For details, refer to the Final “As-Built” drawings in the Documentation Package shipped with the analyzer or HAG Probe.

Height:

230 mm (9″)

Diameter:

126 mm (5″)

Clearance (each side):

51 mm (2″)

Weight:

Approximately 13.6 kg (30 lb)

4-2 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

HAG Sample Probe Approvals and Certifications Probe Heater Approvals and Certifications

HAG Probe Heater Directives and Standards

CSA
ATEX IECEx GOST RoHS

Class I, Division 1, Groups B, C, D; Ex d IIB + H2 T3 (Class I, Zone 1, Group IIB + H2) General Safety Requirements

CSA and UL Standards.

DEKRA Certificate No.:

KEMA 01ATEX2177 X; II 2 G Ex db IIB+H2 T3 Gb or II 2 G Ex db IIB+H2 T3

IECEx Certificate No.:

IECEx DEK 15.0035X; Ex db IIB+H2 T3 Gb or Ex db IIB+H2 T3

1ExdIIBT3

Complies with all relevant European Directives, GOST Pattern Approval

Restriction of Hazardous Substances Directive: 2011/65/EU (RoHS 2)

HAG Probe Valve Assembly Directives

PED

Pressure Equipment Directive:

2014/68/EU

Article 4, Paragraph 3

CRN

Canadian Registration Number:

0H06030.235

PN 903-8663, Rev H

Specifications | 4-3

HAG Probe Heater Marking
The Probe Heater Assembly is the only part of the Sample Probe that is electrically powered. A Probe Heater Assembly with CSA, ATEX, or IECEx certification is marked with the label shown below.

0344

II 2 G

Model: ASR900 Heater

Heat resistant cable & 1/2″

SN:

YR:

NPT Ex d cable glands shall

Certificate No: KEMA 01ATEX2177 X be used, suitable for 85°C.

IECEx DEK15.0035X Ex db IIB + H2 T3 CL. I, GRP. B,C,D; CL. I, ZONE 1 120 240 Vac, 47-63 Hz, 150W

DANGER:
Do not open when an explosive gas atmosphere is present.

Tamb. -50°C to +70°C Enclosure Type 4, IP 55

Ne pas ouvrir si une atmosphère gazeuse explosive peut être présente.

4-4 | Heated Acid Gas Sample Probe

PN 903-8663, Rev H

AMETEK Process Instruments delivers worldwide sales and service support through a network of direct and factory-trained global distribution channels.
AMETEK Service Assistance Program plans offer coverage up to 24 hours a day, 365 days of the year.
As worldwide experts in the manufacture of process analyzers and instrumentation, we have supplied solutions to industry since 1962, providing the widest range of analysis technology available.
Through process application consulting, we create custom-designed solutions that meet the needs of your specific application or process.

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SALES, SERVICE & MANUFACTURING

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© 2023, by AMETEK, Inc. All rights reserved. Printed in the U.S.A. One of a family of innovative process analyzer solutions from AMETEK Process Instruments. Specifications subject to change without notice.

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References

• AMETEK PROCESS INSTRUMENTS
• Aftermarket
• AMETEK PROCESS INSTRUMENTS

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