Ankersmid Sampling AHL Series User manual

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Ankersmid Sampling
User Manual
Heated sample lines Series AHL

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List of content
A. Used terms and signal indications…………………………………………………………………… 3
B. Electrical standards ……………………………………………………………………………………… 3
C. Safety instructions ………………………………………………………………………………………… 4
D. Warranty …………………………………………………………………………………………………… 5
E. Introduction ………………………………………………………………………………………………… 5
F.1. Serial number………………………………………………………………………………………… 5
F.2. Power supply ………………………………………………………………………………………… 5
G. Description……………………………………………………………………………………………………
H. Area of application………………………………………………………………………………………… 7
I.1 Installation/putting into operation ………………………………………………………………… 7
I.2. Shortening a heated line with self-limited heating tape…………………………………… 9
J. During operation …………………………………………………………………………………………… 14
K. Installation guidelines …………………………………………………………………………………… 15
L. Service ………………………………………………………………………………………………………… 17
M. Receipt and storage of goods………………………………………………………………………… 18

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A. Used terms and signal indications
QUALIFIED PE SONNEL Persons with necessary qualification, who are familiar with
installation use and maintenance of the product
NOTE The signal is used according to DIN 4844 and
EU Recommendation 91/C53/0
IMPO TANT Important information about the product or parts
referring to operating in hazardous areas
B. Electrical standards
CE – Certification
The product described in this operating manual complies with following EC directives:
EMV-Instruction
The requirements of the EC directive 89/33 /EWG “Electromagnetic compatibility“ are met.
Low Voltage Directive
This product corresponds to the electrical standard of safety regulations concerning the
low-voltage of the EC recommendation 73/23 EEC and the recommendation of
electromagnetic compatibility 89/336 EEC.
Declaration of conformity
The EU Declaration of conformity is available at Ankersmid Sampling.

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C. Safety instructions
Please read these operating instructions very carefully before start up and use of the
equipment.
• Please check before installing the equipment if the device is suitable for:
- the exposed pressure
- the exposed temperature
- the exposed ambient conditions (e.g.: rain, moist, dust,…)
• Attention must be paid to the requirements of IEC 364 (DIN VDE 0100) when
setting high-power electrical units with nominal voltages of up to 1000 V, together with
the associated standards and stipulations.
• Work on electrical equipment should only be carried out by trained specialists.
• Before connecting the equipment, be sure that the main voltage is equal to the voltage
mentioned on the type plate on the inside of the electrical box.
• Installation, maintenance, monitoring and repairs can be done by authorised personnel.
The entire hose is designed in adaptation to the valid regulations or Directives and reflects
the state of the art. EC conformity is indicated by the CE marking.
IMPO TANT:
This equipment is, in its standard version, not explosion-proofed!
Ex-proofed equipment is specially marked.

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D. Warranty
If the equipment fails, please contact your ANKERSMID SAMPLING dealer.
The warranty is covered for a period of 1 year countable from the first day of delivery
(as also specified in our normal terms and conditions of sale) when the apparatus (*) is
handled and assembled correctly, installed according good craftsmanship, treatment and
use or operation of the equipment.
The warranty covers repair at the factory at no cost, or the replacement at no cost of the
equipment free ex user location. In case of resend or reshipment, the device must be
properly packed or in his original protective packaging or in a sufficient adapted recipient.
NOTE:
Consumables are only covered by this warranty in case of production defaults.
E. Introduction
The Ankersmid heated lines are for continuously use in gas analysis processes with gases of
high humidity.
With the heated hose system you have acquired a high quality product to be used in
accordance with the relevant standards and regulations as well as the conditions set out
here. It is always our main objective that the products manufactured by us function to your
full satisfaction and meet the desired requirements. To ensure that this can be properly
implemented for your own benefit, please read the following carefully and observe the
instructions concerning installation and operation.
F.1 Serial number
The serial number is mentioned on the type plate on the device.
F.2 Power supply
Depending on the type of application the heated line can be operated on alternating current
of 110-120VAC, 50- 0Hz or 230-250VAC, 50- 0Hz.
The heated line is standard delivered with 230V wired. In case of 115V needed please
specify with the order.

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G. Description
The central element of the heated hose is the inner tube or hose core through which the
fluid flows. It is made of high-grade PTFE (as standard, also available is PFA, stainless steel)
with a smooth surface. Any integrated fittings are moulded into the hose structure with a
defined pressure and time period. The heating system consists of high-grade heat conductor
alloys combined with different insulating materials depending on temperature. The thermal
insulation is adapted to the temperature range and the specific heated hose type, and
finished on both sides with temperature resistant connection caps. The entire heated hose is
designed in such a way that the high flexibility of the pressure hose or the bending potential
of the tube is hardly affected.
The heated sample lines are manufactured according to the client’s specification and
completely confectioned in the factory at a fixed length.
Two different types of heated lines are available:
1) Regulated heated lines.
The sample line temperature is to be controlled by a Pt100 temperature controller.
The heater used in this type is ONE serial resistance, twisted around the tube. Due to
this construction we eliminate the occurrence of cold zones or spots in the heated line,
where a potential blockage could occur.
2) Self-limiting heated lines.
The heating element used in this type of heated line is an auto-regulated ribbon. The
heated line is secured closely to the sample carrier tube, thus eliminating the
occurrence of cold zones or spots in the heated line, and therefore also eliminating the
incidence of potential blockage.
The use of a heated line is shown in below standard flow chart:
Figure 2 Standard flow chart of a heated gas sample line
Diaphragm gas pump
Universal filter
Gas cooler
Peristaltic pump for
condensate removal
Gas sample probe
Heated sample line
Analyser

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H. Area of application
The heated hoses can be used in many industrial fields under the operating conditions
specified in the present instructions for installation and operation. The area of application
ranges from freeze protection, e.g., -20°C, via temperature maintenance to temperature
increases up to max. 200°C. The standard nominal voltage of the heated hoses is 230V
(other supply voltages are possible!). The maximum permissible ambient temperature
(environment) spans from –20°C to + 40°C.
Suitable temperature control devices (controller/cut-out unit) must be provided to ensure
that the max. Fluid temperature is not exceeded. The heating power depends on the hose
length and cross-section. You will find the exact data specified on the yellow type plate
attached to the electrical connecting cable.
NOTE
Different ambient temperatures along the hose route will result in different internal
temperatures. For regulated heated lines the decisive factor for temperature control is the
ambient temperature at the sensor location, and to avoid overheating the sensor should
therefore be installed at the point where the highest ambient temperature occurs.
Since the product is a heating system with a flexible range of application, all the relevant
Directives, rules and regulations need to be determined and complied with, including
monitoring of compliance. In addition, it is absolutely essential to observe the following
manufacturer’s information (instructions for installation and operation). Before putting the
system into operation, please check which regulations or internal works rules are applicable
in your case to ensure safe and trouble-free use of the heated hose.
I.1. Installation / putting into operation
1. Check the data on the type plate to make sure that the type, design, mains voltage,
power and operating temperature correspond to your specifications. Check visually if the
hose design corresponds to the one ordered by you. If in doubt, compare with your
documentation. Does the heated hose meet the conditions for the intended application or is
it unsuitable for this purpose?
2. If you use clamps or similar fasteners for supporting the hose, it must be ensured that
pressing does not reduce the external diameter by more than 10 % at the most. Above this
10 % limit, there is a risk of damage to heat conductors, control leads and sensor wires.
3. If there are control cores running through the hose, please observe the electrical load
capability of these cores.
4. Please ensure that you are using the correct type of temperature controller. Controller
rating, sensor type and temperature range must be compatible. Is the heated hose
connected to the correct controller? An accidentally reversed sensor, for example, will result
in heating up the hose until it is completely destroyed. There will be no such problems if
you employ the available Winkler hose controller systems.

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5. If the heated hose is laid outdoors is must be protected against wind, because it would
otherwise be subjected to cooling and may then not be able to attain the desired
temperature. Likewise, the heated hose should not be exposed to rain or direct solar
radiation for any length of time. In such cases suitable covering must be provided for
protection.
. Observe all the following installation guidelines (wrong-right chart). These guidelines
were drawn up on the basis of many years of experience and fault analysis to avoid the
most common causes of failure.
7. Do not use the fitting to pull the heated hose. The fittings are resistant to pressure, but
more susceptible to tension forces.
Neither should the connecting cable be used for pulling the heated hose because it is not
suitable for this.
8. Are there any special rules or regulations applicable at the place of installation and has
the installation taken this into account?
9. The operator/customer must check if the material that comes into contact with the
media is resistant to the media to be heated.
10. Always monitor the first heating-up phases of the heated hose very carefully so that
any possible faults can be detected and, where appropriate, remedied at an early stage.
11. Check whether any nearby objects, plant components or other parts could cause
damage to the heated hose or impair its function and, where applicable, remove or
rearrange such items.
12. Any accessible (exposed) electro-conductive parts must be included into the
equipotential bonding measures.
The standard lines, temperature controlled by ATC-temperature controller, are equipped
with round connector plugs:
7-pin plug (max. 10A) 5-pin plug (>10A, max. 20A)
Colour code:
Temperature sensor (standard Pt100) = yellow
Power supply (standard 230VAC) = brown (L) / blue (N)

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I.2. Shortening a heated line with self-limited heating tape
NOTE
Working on electrical heated lines are only permitted by authorized staff
1.
Only cut the line on the non-powered side (opposites the electrical connection)
2.
Unscrew the hard end caps
3.
Remove the fixed adhesive tape of the corrugated cover and cut the cover carefully to the
required length

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4.
Remove the fixed adhesive tape from the insulation felt and cut the felt to the required
length
5.
Remove the fixed adhesive tape from the copper braid and cut carefully to the required length
CAUTION
Open and remove the subjacent hose clamp

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.
Remove the fixed adhesive tape and cut the heating cable to the required length

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7.
Refit the end seal fitting as follows:
CAUTION
Only use end seals which are especially designed for this type of heating tapes
① Uncover the braid by removing the jacket to 13mm length.
Remove the 13mm of exposed braid.
② Cut a V-shape at the end of the heating tape with a depth of 10mm.
③ Squeeze end seal from the side (see drawing) and fill with silicone.
④ Push end seal over the end of heating tape so that it overlaps the jacket.
⑤ The silicone will set up within 30 minutes with a complete cure after 24 hours.
CAUTION
Do not carry out any dielectric test or measurement of insulation resistance until the
silicone is completely cured.

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8.
Shorten the stainless steel pipe by using a saw or professional pipe cutter to the required
length. Please note that a small overlap is needed.
NOTE
Fix the heating wire, the copper braid, the insulation felt and the corrugated cover with an
adhesive tape.
IMPO TANT
Ensure that all fixings are connected with the stainless steel pipe to avoid a shift of the
materials.
9.
Screw on the hard end caps.
10.
Perform a final electrical inspection.

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J. During operation
1. Has the installation / putting into operation been carried out successfully in accordance
with the present instructions and guidelines?
2. Check the first heating-up phase exactly and monitor the further operation of the heated
hose.
3. Make sure that the fluid at the inflow or inlet point is not hotter than the max.
Permissible heated hose temperature, otherwise the heated hose could suffer damage at
this point.
4. Extreme movements or vibrations, shaking etc. should be avoided during operation of
the heated hose.
5. If you want to remove the heating hose, you should first check that the hose has cooled
down and that it is totally disconnected from the mains power supply.
. The fitting should never be used to pull the heated hose; the fittings are resistant to
pressure, but more susceptible to tension forces.
7. It can happen that a fitting becomes clogged up when the liquid hardens and that the
fitting only becomes unclogged after a certain heating-up period. Do not try to shorten this
waiting period by applying heat externally (e.g. using a burner etc.). This will damage the
heated hose, and waiting for a replacement delivery will certainly take longer!
8. If you notice any damage to the heated hose or abnormal functioning during operation,
the hose must be switched off and disconnected from the power supply immediately. For
this purpose a disconnection device (master switch) with a minimum contact gap of 3mm is
to be provided by the customer together with a 1 A or 20A fuse depending on the lead
cross-section. Any fault needs to be exactly analysed in order to determine the cause. Our
experienced specialists will be pleased to assist you.
9. Avoid exposing the hose to direct solar radiation for any length of time or, if unavoidable,
provide suitable protection.

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K. Installation guidelines
1
If the heated hose is too short, it will be bent
excessively at the connection ends.
Remedy:
Include a straight section (5 x hose diameter).
A large bending radius will increase the service
life of the hose.
Wrong Right
2
Hose is laid with a sagging part.
Remedy:
Supports or rollers with counterweight.
3
CAUTION:
The heating tube may be not operated in
the rolled up condition or lying on top of
each other, because otherwise the outside
coat (Corrugated tube) can be destroyed.
Pulling at the end of a rolled up hose will result
in torsional stress and a bending radius smaller
than permissible.
Remedy:
Unroll the hose ring without pulling at the hose.
Observe minimum bending radius (5x hose
diameter).
4
Compression along the longitudinal axis due to
wrong installation or during movement will
reduce the pressure resistance. Stretch
compensation by fixed hoses leads to their
destruction.
Remedy:
Bends at connection points.
Wrong Right

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5
Torsional movements will destroy the
heated hose. This is often due to wrong
installation, particularly to turning the
hose in the wrong direction when
connecting it up.
Remedy:
Ensure that the hose axes run parallel and that
the direction of motion is on one plane. Use a
counter-wrench during installation to prevent
twisting the hose.
Wrong Right
Corners are danger spots because of the
risk of kinks and bending stress.
Remedy:
Saddle support or roller with suitable diameter.
7
Excessive bending stress just behind the
connection points is damaging.
Remedy:
Pipe bends
Wrong Right
8
With hand-held equipment, the risk of kinks is
particularly great.
Remedy:
Depending on working position, fit bend or anti-
kink system (e.g., wire spiral).
9
If powdery substances, adhesives or other
materials with thermal insulation properties are
spilt onto the heated hose, overheating will
occur at these points.
Remedy:
Constant cleaning/removing of such materials
and eliminating the cause.
10
If heated hoses are laid in a closed channel or
duct, this will result in heat concentration.
Remedy:
The hoses must not be in contact with each
other. Additionally, adequate ventilation should
be provided.
11
Bundling of hoses or laying hoses in close
contact next to each other will lead to
overheating at the points of contact.
Remedy:
Always leave sufficient space between the
hoses.

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12
Heat concentration with overheating can also
be caused by wrapping other materials around
the heated hose. If the sensor area is
wrapped up, the remaining hose section will
cool down.
Wrong Right
13
When fixing the hose with clamps or similar it
must be ensured that the outer structure is
not squeezed.
L. Service
1. Should any defects become apparent on the outside of the heated hose or the
connecting mains lead, the heated hose must be disconnected immediately from the mains
supply, removed and sent back to our works for inspection. Never open the heated hose or
any of its components on your own initiative, i.e. unauthorized.
2. Inspection or maintenance of the heated hose should be carried out at regular intervals
in order to guarantee operational safety. The inspection intervals should be chosen in
relation to the operating conditions on site. However, inspections by a qualified electrician
should take place every months using suitable measurement and test equipment.
3. The service life of the heated hose will depend on the actual operating conditions.
Therefore it is not possible to make a generally valid statement about the length of the
service life. However, the service life will generally be shorter under severe operating
conditions as against occasional use under optimum conditions. For more information
please contact us directly for competent advice.
4. If a cut-out switches the hose off permanently, the cause has to be analysed before
putting the hose back into service and appropriate measures have to be taken to prevent
reoccurrence.
5. If you intend to use the heated hose for another purpose than originally planned, please
get in touch with our specialists to check if it is really suited to this. Unauthorized change of
use is not permitted.
. Any changes on the hose performed by the customer will endanger the operational
safety and will automatically result in the manufacturer’s warranty becoming invalid.
Before the service please take care that that the specific safety procedures pertaining to the
system and operational process are observed.
NOTE Power supply
It is necessary to switch of the power supply before any service, maintenance or repairs.
The heated hoses have been designed to withstand bending stress. However, non-
observance of the minimum bending radius or kinks or strong torsional movement will lead
to the destruction of the heated hose. The permissible bending radius depends on the
material and the nominal diameter (DN) of the heated hose.
As a general rule: Minimum bending radius > 5 x outer hose diameter

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M. eceipt and storage of goods
The arrived goods should be carefully unpacked as soon as possible in order to control the
good and correct condition.
The goods and the delivery note should be compared. If any difference is noted please
contact your Ankersmid Sampling contact person.
The delivery should be checked for any transport damage. If any anomaly is noted, please
contact the transport insurer immediately notifying of the damage.
The device should be stored in a frost-protected area.
NOTE Unpack before use
It is necessary to unpack the heated sample line before any use. It is not allowed to
operate the heated line when still packed or convolved!