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Installation and Start-Up

3-1

INSTALLATION and START-UP

This chapter discusses how to install the Heated Acid Gas Sample Probe,
including:

• Safety considerations before working on the HAG Probe.

• Uncrating, inspecting, and storing the Sample Probe for damage be-

fore installing it.

• Installing the mechanical components and making the electrical

connections.

• Powering up the analyzer and Probe Heater.

Summary of Contents for ASR900

Page 1: ...id Gas Sample Probe Large Diameter Installation and Maintenance Guide With Essential Health and Safety Requirements PN 903 8663 Rev G Canada A DIVISION OF AMETEK PROCESS ANALYTICAL INSTRUMENTS Western...

Page 2: ...t Sam Houston Parkway North Suite A 400 Houston TX 77041 USA Tel 713 466 4900 Toll Free 1 800 634 8990 Fax 713 849 1924 CANADA AMETEK Canada 2876 Sunridge Way N E Calgary AB T1Y 7H9 Canada Tel 403 235...

Page 3: ...t the Heated Acid Gas Sample Probe 1 2 About the Analyzer Sample System 1 5 Working in This Manual 1 8 CHAPTER 2 SPECIFICATIONS 2 1 Probe Heater 2 1 Power Consumption 2 1 Electrical Requirements 2 1 A...

Page 4: ...ring Up the Probe Heater Assembly and Analyzer 3 20 CHAPTER 4 MAINTENANCE 4 1 Safety Considerations 4 1 Preventive Maintenance Schedule 4 2 Preparing the Analyzer and Probe for Maintenance 4 4 Changin...

Page 5: ...ages 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 ch...

Page 6: ...closures 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...

Page 7: ...f 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 an...

Page 8: ...ces 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 munici pal waste system r...

Page 9: ...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...

Page 10: ...quipment Unless Power Has Been Switched Off or the Area is Known to be Non Hazardous Risque d explosion Avant de d connecter l quipement coupez le courant o vous assurez que l emplacement est design n...

Page 11: ...2 Low Voltage Directive 2014 35 EU using the following standards EN 61010 1 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General requirements Pressure...

Page 12: ...being returned for repair are Canadian goods the name of the firm who purchased the goods and the shipment date The warranty shall not apply to any equipment or part thereof which has been tampered w...

Page 13: ...en replacing an existing Sample Valve and how to install the HAG Probe for new applications Chapter 3 This manual also describes in Chapter 4 general care and preventive maintenance including changing...

Page 14: ...a few degrees above The Probe Heater is protected from overheating by a temperature switch which will disconnect power if the Heater Assembly exceeds approximate ly 170 C 338 F If the temperature of...

Page 15: ...Overview 1 3 LEGEND SOL B SOL A SOL Z 8 7 6 5 1 2 3 4 12 9 10 11 MODEL 931 932 ANALYZER BACKPAN BY CUSTOMER BY CUSTOMER Figure 1 1 Zone 1 Model 931 Model 932 Analyzer Plumbing Schematic example...

Page 16: ...1 4 Heated Acid Gas Sample Probe Large Diameter Figure 1 2 HAG Sample Probe assembly drawing...

Page 17: ...duct Flow Restrictor in Solenoid Block Provides a consistent back pressure for setting the Aspirator Air which reduces sample rate fluctuations caused by pro cess pressure fluctuations The flow rate...

Page 18: ...Probe Flow Diagram Standard Applications JUNCTION BOX SAMPLE LINE VENT LINE PIPE ADAPTER SAMPLE PROBE VENT ISOLATION BALL VALVE SAMPLE ISOLATION BALL VALVE ASPIRATOR ASPIRATOR ADJUSTMENT SCREW HEATER...

Page 19: ...ER SAMPLE PROBE OPTIONAL SAMPLE DOUBLE BLOCK ISOLATION VALVE OPTIONAL VENT DOUBLE BLOCK ISOLATION VALVE OPPOSITE SIDE VENT ISOLATION BALL VALVE SAMPLE ISOLATION BALL VALVE JUNCTION BOX SAMPLE LINE VEN...

Page 20: ...ns that are necessary before continuing with the current procedure or information that is recommended by AMETEK Analyzer System 200 Configurator Software Navigation icon While working from the analyze...

Page 21: ...he Heater Assembly is the only part of the Sample Probe that is electri cally powered Power Consumption Maximum Power 150 W Electrical Requirements Supply Voltage 120 VAC 10 47 63 Hz 240 VAC 10 47 63...

Page 22: ...20 2 F to 158 F typical operating conditions with AMETEK Insulating Jacket Cable Cable Glands This typically applies to European Hazardous Locations only Heat resistant cable and Ex d cable glands mus...

Page 23: ...SIG Pressure Equipment Directive 2014 68 EU Article 4 Paragraph 3 Canadian Registration Number 0H06030 235 Process Connection 1 1 2 M NPT flange typical Various ANSI Flange Adapters available e g 1 1...

Page 24: ...ECEx Certificates and Marking For installation sites with potentially explosive gas atmospheres that require ATEX and IECEx certification AMETEK s ATEX and IECEx certifi cates for the Probe Heater Ass...

Page 25: ...Specifications 2 5...

Page 26: ...2 6 Heated Acid Gas Sample Probe Large Diameter...

Page 27: ...Specifications 2 7...

Page 28: ...2 8 Heated Acid Gas Sample Probe Large Diameter...

Page 29: ...Specifications 2 9...

Page 30: ...shown below DANGER II 2 G 0344 Ne pas ouvrir si une atmosph re gazeuse explosive peut tre pr sente Do not open when an explosive gas atmosphere is present Heat resistant cable 1 2 NPT Ex d cable glan...

Page 31: ...he Heated Acid Gas Sample Probe including Safety considerations before working on the HAG Probe Uncrating inspecting and storing the Sample Probe for damage be fore installing it Installing the mechan...

Page 32: ...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 leth...

Page 33: ...etached from the Sample Probe Assembly This allows for easier installation of the equipment Upon re ceiving the Sample Probe and the Probe Heater assemblies remove them from their shipping crates and...

Page 34: ...any process piping component that causes process turbu lence such as bends valves etc Failure to comply with this recom mendation may result in an excessively noisy and therefore errone ous output sig...

Page 35: ...d 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 Threa...

Page 36: ...nt 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 Sampl...

Page 37: ...ater 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...

Page 38: ...Acid Gas Sample Probe Large Diameter Prior to installing the Probe Heater Assembly on the Sample Probe the silicone o ring and Probe Heater Assembly Cover must be in place NOTE Figure 3 1 Probe Heate...

Page 39: ...tem Information on how to do this is described in the analyzer manual 4 After the Zero is complete isolate the analyzer sample system from the process duct by closing the isolation valve on the existi...

Page 40: ...robe 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 Pr...

Page 41: ...OBE NOTE TOP VIEW OF HORIZONTAL DUCT SIDE VIEW OF VERTICAL DUCT ORIENTATION OF PROBE IS NOT CRITICAL FOR HORIZONTAL MOUNTING USER DEFINED IN FIELD ORIENTATION OF PROBE IS CRITICAL MUST BE ANGLED DOWNW...

Page 42: ...k check 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...

Page 43: ...read 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...

Page 44: ...ation drawing and other sample system drawings in the Supplemental Information section of the analyzer or HAG Probe manual Non Shelter and Retrofit Installations Plumb 316 stainless steel 1 4 O D tubi...

Page 45: ...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 p...

Page 46: ...m the analyzer to the Terminal Block in the Probe Heater Junction Box see Figure 3 3 Tighten the screws to secure each wire to the appropriate Terminal Block location in the Junction Box 3 Plug all un...

Page 47: ...Installation and Start Up 3 17 Figure 3 3 HAG Probe Heater wiring diagram North American and European style Model 931 932 Analyzers...

Page 48: ...emperature 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 Haz...

Page 49: ...mperature 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 Jun...

Page 50: ...1 or Model 932 Analyzers and do not power up down the analyzer or computer if there is an explosive gas atmosphere present Refer to the analyzer manual for additional safety and important information...

Page 51: ...d 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...

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Page 53: ...ce 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 des...

Page 54: ...be Depending on process stream conditions the suggested Preventive Maintenance frequency may be shortened or extended Replace the o rings Hi Flow Membrane Fiber Filter Element and Sintered Disk in the...

Page 55: ...Conditions and Corrective Action in the analyzer manual for information on specific alarms See Replacing Parts in the Probe Heater Assembly in this chapter IMPORTANT Be sure to have on site the prope...

Page 56: ...osion Proof Digital Communications Port on the front of the Lower Enclosure Model 931 or Model 932 Analyzers and do not power up down the analyzer or computer if there is an explosive gas atmosphere p...

Page 57: ...then click OK Bleed down the sample system to atmospheric pressure check gauge Close the valve on the Vent Line side 4 Disconnect AC power to the analyzer and power down the computer before performing...

Page 58: ...uble 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 Every six months If evidence of...

Page 59: ...Maintenance 4 7 Figure 4 1 Large Diameter Heated Acid Gas Sample Probe Assembly...

Page 60: ...he Insulating Jacket 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...

Page 61: ...f the Hi Flow Membrane and remove it from the Filter Body Remove the Sintered Disk from the recess in the Filter Body Remove the 2 o rings P N 300 8719 and P N 300 8722 from the Valve Cover Remove the...

Page 62: ...iii Install 1 new o ring P N 300 4651 on the Aspirator Insert and replace the Aspirator Insert in the Filter Body iv Install 1 new o ring P N 300 4958 on the M6 screw by roll ing it up to the screw h...

Page 63: ...all necessary safety precautions such as wearing a supply air apparatus a HAG Probe without the optional Double Block valves Remove the HAG Probe from the process duct and temporarily install a flang...

Page 64: ...ve 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 Is...

Page 65: ...th from inhaling toxic gases in the process could result from attempting to in stall remove the equipment without the use of a breathing apparatus If applicable remove the flange blind or remove the c...

Page 66: ...n the Sample Probe c Apply a high temperature thread lubricant to the threads of the 4 M6 x 60 screws P N 300 8741 Figure 4 4 replace the screws and tighten them to secure the Heater Assembly to the S...

Page 67: ...the internal o ring P N 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 TIM...

Page 68: ...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...

Page 69: ...he 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 chap...

Page 70: ...ter 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 to...

Page 71: ...Maintenance 4 19 1 2 3 4 5 1 2 3 4 5 INTERNAL HEATER BLOCK WIRING DETAIL BLOCK IS SHOWN TRANSPARENT FOR CLARITY ONLY Figure 4 4 Probe Heater Assembly...

Page 72: ...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...

Page 73: ...Maintenance 4 21 Figure 4 5 HAG Probe Heater wiring diagram North American and European style Model 931 932 Analyzers...

Page 74: ...ridge 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...

Page 75: ...on remove the solder from the wire on the Over Temperature Switch that was cut earlier the wire leading to the Over Temperature Switch Pull back the wire from the Over Temperature Switch Remove any ex...

Page 76: ...ulation 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...

Page 77: ...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...

Page 78: ...es into the Terminal Block tag locations accord ing to your notes or Figure 4 5 Tighten the screws to secure each wire to the appropriate Terminal Block tag location in the Junction Box b With the Jun...

Page 79: ...n 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 Insulatio...

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Page 81: ...ith questions regarding the installation operation or maintenance of the Heated Acid Gas Sample Probe carefully review the contents of this manual If you are unable to find an explanation for your pro...

Page 82: ...site charge for this visit can be deducted from the start up charge if you select that option START UPS Your decision to buy an AMETEK analyzer is greatly appreciated After the time and money spent on...

Page 83: ...meter HAG Sample Probe 4 8 301 1714 100 2196 Hi Flow Filter Membrane c w Buna O Ring HAG Sample Probe 4 8 300 8722 100 2196 O Ring Aflas size 118 HAG Sample Probe 4 8 300 8719 100 2196 O Ring Aflas si...

Page 84: ...e Vent Isolation Valve Kit and Replacement O rings Part No Drawing No Description QTY 300 9824 100 2196 Sample Vent Isolation Valve Assembly Kit 2 300 8719 100 2196 O Ring Aflas size 121 See Note Ball...

Page 85: ...he standard drawings included in the main body of this manual Drawings that are job specific are located in the Supplemental In formation section of the analyzer manual and in the Documentation Packag...

Page 86: ...6 2 Heated Acid Gas Sample Probe Large Diameter Heated Acid Gas Sample Probe Assembly 100 2196...

Page 87: ...Drawings 6 3 Probe Heater Assembly 120 V 240 V 100 1658 1A 1 2 3 4 5 1 2 3 4 5 INTERNAL HEATER BLOCK WIRING DETAIL BLOCK IS SHOWN TRANSPARENT FOR CLARITY ONLY...

Page 88: ...6 4 Heated Acid Gas Sample Probe Large Diameter Double Block Valve Assembly 100 2393 SEE NOTES 1 2...

Page 89: ...Drawings 6 5 Fiber Filter Assembly 100 2194...

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Page 91: ...nformation S 1 SUPPLEMENTAL INFORMATION This chapter consists of any additional information that supports the op eration maintenance and safe use of this probe such as a Documentation Package or Manua...

Page 92: ...S 2 Heated Acid Gas Sample Probe Large Diameter This page intentionally left blank...

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