Hach 48685 User manual

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DOC023.97.80196
Sample Heater
02/2012, Edition 3
User Manual
Manuel d'utilisation

English..............................................................................................................................3
Français.........................................................................................................................20
2

Specifications
Specifications subject to change without notice.
Application For water samples. Do not use the application for concentrated acids,
bases or any type of volatile sample.
Output temperature precision ±1.5 ºC (2.7 ºF) under reference conditions 1
Display resolution 1 ºC (1 ºF)
Set point range 20 to 50 °C (68 to 122 °F) Refer to operating charts for more information.
Flow rate range 50-300 mL/min; Sample Heater internal volume is 39 mL
Power requirements for single
phase (with grounded neutral) only
120 Vac, 50/60 Hz, 11A
230 Vac, 50/60 Hz, 5.5A
Installation category II
Inlet pressure 689.5 kPa (100 psi) max. internal pressure. This rating is for the Sample
Heater and does not affect the Analyzer requirements.
Sample fittings Two ¼" OD Tubing Compression fittings
Weight Net—4.98 kg (11 lb)
Shipping—6.35 kg (14 lb)
Wetted parts 316 Stainless Steel
Ambient operating temperature 0 to 50 °C (32 to 122 °F)
Pollution Degree 2
Protection Class I
Maximum Altitude 2000 m (6560 ft)
Enclosure Rating NEMA 4X, IP 65
Compliance Information Listed for use in general locations to UL and CSA Standards by ETL. CE
certified.
Storage Temperature -20 to 70 ºC (-4 to 158 ºF) with fluids drained.
Humidity Maximum relative humidity 80% for temperatures up to 31 ºC decreasing
linearly to 50% R.H. at 40 ºC.
1Within proportional control range (see charts) and input temperature ±5 ºC, flow rate ±10%, 115 VAC, 60 Hz
±2 Hz and ambient temperature ± ºC. Instrument tuned at operating conditions (Autotune 3). Cal offset
adjusted to yield the set temperature at the point of use.
Sample heater operating range
Figure 1 shows in graph form the sample heater operating range in terms of sample output
temperature and minutes. Figure 2 shows in graph form the sample heater operating range in terms
of sample output temperature and line AC voltage.
English 3

Figure 1 Temperature-minutes
1 Sample output temperature, ºC 2 Minutes
Figure 2 Temperature-line AC voltage
1 Sample output temperature, ºC 2 Line voltage, VAC
**milliliters per minute
General information
In no event will the manufacturer be liable for direct, indirect, special, incidental or consequential
damages resulting from any defect or omission in this manual. The manufacturer reserves the right to
make changes in this manual and the products it describes at any time, without notice or obligation.
Revised editions are found on the manufacturer’s website.
4 English

Safety information
N O T I C E
The manufacturer is not responsible for any damages due to misapplication or misuse of this product including,
without limitation, direct, incidental and consequential damages, and disclaims such damages to the full extent
permitted under applicable law. The user is solely responsible to identify critical application risks and install
appropriate mechanisms to protect processes during a possible equipment malfunction.
Please read this entire manual before unpacking, setting up or operating this equipment. Pay
attention to all danger and caution statements. Failure to do so could result in serious injury to the
operator or damage to the equipment.
Make sure that the protection provided by this equipment is not impaired. Do not use or install this
equipment in any manner other than that specified in this manual.
Use of hazard information
D A N G E R
Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous situation that may result in minor or moderate injury.
N O T I C E
Indicates a situation which, if not avoided, may cause damage to the instrument. Information that requires special
emphasis.
Precautionary labels
This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential
injury. If on the instrument, refer to the instruction manual for operation or safety information.
This symbol indicates that a risk of electrical shock and/or electrocution exists.
Electrical equipment marked with this symbol may not be disposed of in European public disposal
systems after 12 August of 2005. In conformity with European local and national regulations (EU
Directive 2002/98/EC), European electrical equipment users must now return old or end-of-life
equipment to the Producer for disposal at no charge to the user.
Certification
Canadian Radio Interference-Causing Equipment Regulation, IECS-003, Class A:
Supporting test records reside with the manufacturer.
This Class A digital apparatus meets all requirements of the Canadian Interference-Causing
Equipment Regulations.
Cet appareil numèrique de la classe A respecte toutes les exigences du Rëglement sur le matériel
brouilleur du Canada.
FCC Part 15, Class "A" Limits
English 5

Supporting test records reside with the manufacturer. The device complies with Part 15 of the FCC
Rules. Operation is subject to the following conditions:
1. The equipment may not cause harmful interference.
2. The equipment must accept any interference received, including interference that may cause
undesired operation.
Changes or modifications to this equipment not expressly approved by the party responsible for
compliance could void the user's authority to operate the equipment. This equipment has been tested
and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules.
These limits are designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates, uses and can
radiate radio frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference, in which case the user will be required to
correct the interference at their expense. The following techniques can be used to reduce
interference problems:
1. Disconnect the equipment from its power source to verify that it is or is not the source of the
interference.
2. If the equipment is connected to the same outlet as the device experiencing interference, connect
the equipment to a different outlet.
3. Move the equipment away from the device receiving the interference.
4. Reposition the receiving antenna for the device receiving the interference.
5. Try combinations of the above.
Product overview
D A N G E R
The Sample Heater Model 48685 is not designed for use with flammable or explosive samples. If a sample
solution other than water is used in this product, test the sample/product compatibility to assure user safety and
correct product performance.
Figure 3 shows the sample heater. The sample heater has a thermostatically controlled outlet
temperature and is designed for use with water analysis instruments that require an elevated and
controlled sample temperature.
6 English

Figure 3 Sample heater
The heater contains a heater module, temperature controller, temperature sensor, thermal cut-off
switch, circuit breaker and power-connection terminal. The housing consists of a gasket-sealed
plastic enclosure.
A single piece of stainless steel tubing cast in an aluminum block and two 700 watt electric heater
elements make up the heater module. The stainless steel tube has two stainless steel adapter fittings
brazed on each end.
The temperature controller is a Watlow EZ-ZONE PM Express with microprocessor-based auto-
tuning control.
Figure 3 shows the normal operating display, the control panel and the controller keys, and describes
the controller key functions.
The lower window displays the set-point temperature and the upper window displays the process
temperature. The operator enters the setpoint and the controller heats the sample to the setpoint.
The 1 indicator light is on when the heating element turns on. A thermocouple attached to the outlet
tube of the heater module makes up the temperature sensor. The sensor indicates the sample
temperature at the outlet. A thermostat mounted on the heater block protects the product and user
from a thermal run-away fault (Wire the instrument on page 11).
English 7

Figure 4 Sample heater display and control panel
1 Infinity key--clears and silences alarms. This key is
factory locked by default. When the menu is
unlocked, this key will clear and silence alarms,
back up one level, or if held for 2-3 seconds return
to the Operation Menu.
5 Lower display--shows setpoint temperature
2 Upper display--shows process temperature 6 Up and Down arrow keys--Adjusts the setpoint in
the lower display. In other unlocked pages, changes
the upper display to a higher or lower value, or
changes a parameter selection.
3 Output 1 indicator--shows output activity 7 Advance key--moves through parameter prompts
4 Temperature unit indicator (Celsius) 8 A/M key--toggle the control mode. Locked by
default. When the Operation Menu is unlocked, this
key will toggle the control mode, and set mode to
Manual when the A/M key is pressed for 3 seconds.
Product components
Make sure that all components have been received. If any items are missing or damaged, contact the
manufacturer or a sales representative immediately.
Installation
Mount the instrument
D A N G E R
Burn, electrical, fire and chemical hazards. Only qualified personnel should conduct the installation tasks in this
section of the manual.
Figure 5 and Figure 6 show the sample heater dimensions. The sample heater has four mounting
feet. Install the instrument vertically on a wall with the sample connections on the bottom. Refer to
the appropriate manual for more information.
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Figure 5 Sample heater (front view)
English 9

Figure 6 Sample heater bottom and side view
1 .875" (22.23 mm) O.D. for ½" NPT conduit fitting 3 Sample inlet--0.25 (6.35 mm) O.D. tubing stainless
steel compression fitting
2 Sample outlet--0.25 (6.35 mm) O.D. tubing stainless
steel compression fitting
Sample connections
D A N G E R
The Sample Heater Model 48685 is not designed for use with samples that are flammable or explosive in nature.
If any sample solution other than water is used in this product, test the sample/product compatibility to assure
user safety and proper product performance.
CAUTION
The instrument is factory tested to withstand 100 psi. Pressures greater than 100 psi may result in operator injury
and instrument damage.
Sample connections are stainless steel compression type fittings sized for ¼" OD stainless steel or
rigid wall plastic tubing. No tubing is supplied with the sample heater. Sufficient tubing is normally
supplied with analyzers to allow for sample heater installation.
The heater tubing is ¼" OD stainless steel cast in position in the heater block. The threaded end
pieces are brazed to the tubing. Twisted tubing may cause irreversible damage to the instrument.
Keep the tubing from becoming twisted and prevent the ends from bending when tightening the
connecting tubing. Make sure to plumb the heater so that the heater tubing is free from stress and
vibration.
If a leak develops between the brazed-on end fitting and the tubing adapter, hold the end fittings
while tightening the tubing adapter fitting. Use a 5/16" wrench on the flats machined on the fitting.
To make the sample connections:
1. Put the tubing in the fitting assembly and push it firmly against the internal shoulder.
2. Loosen the compression nut and make sure the tubing passes through the ferrules.
10 English

3. Finger tighten the nut. Use a 9/16" wrench to hold the adapter fitting and a second 9/16" wrench
to tighten the nut 1¼ turns.
Note: Never tighten the tubing nut without holding the hex portion of the tubing adapter.
Test the sample connections
Make sure that all the tubing connections are correct. Switch the sample on and gradually increase
flow through the instrument. Make sure that no leaks exist. If leaks exist, tighten the connections in
small increments. If a leak continues, loosen the fitting. Make sure that the ferrule is correctly
installed and the fitting contains no foreign material. Tighten the fitting again.
Connect to AC power
D A N G E R
Potential Electrocution Hazard. Only qualified personnel should conduct the tasks described in this
section of the manual.
D A N G E R
To meet UL, CSA and other applicable instrument safety standards, an external power disconnect switch must be
installed. Install the device in a location and position that gives easy access to the disconnect device and its
operation.
D A N G E R
Connect equipment in accordance with local, state, and national electrical codes.
Table 1 Power configuration and approved use by model number
Sample heater model number Power connections Approved use
48685-00 (48685-60 on reference serial
number label)
115 VAC, 50/60 Hz line power
Note: The 115 VAC model cannot be
modified for 230 VAC operation.
United States, Canada
48685-02 (48685-62 on reference serial
number label)
230 VAC, 50/60 Hz line power for
single phase (with grounded neutral)
only
United States, Canada,
European Community and
other countries with 230 V
single phase
Wire the instrument
The instrument is designed to be hard-wired. A ½" NPT conduit opening (7/8" diameter) is provided
for electrical connection. Use the correct sealing hardware to keep the NEMA 4 rating.
Note: Do not apply power to the heater until sample flow has been established and sample is in the heater tubing.
Sample must be flowing through the heater at all times when the heater is on.
Requirements for the power cord installation
To use a power cord for the connection to AC mains, make sure that the:
• Cord is less than 3 m (9 ft) in length
• Cord wire gauge is less than 16 AWG
• Outer power cord insulation is suitable for end use location
• Cord has a 3-circuit cord plug that has a ground connection that is necessary for a supply
connection
• Cord wires have the correct size of spade tongue terminals on the connection end. The terminals
must have insulated barrels.
• Cord has a cord cable gland that has the correct rating for the installation location. The cable gland
must attach the cord and seal to the enclosure to keep environmental ratings within specifications.
• Cord plug serves as the power supply disconnect. Make sure that it is close to the instrument and
easily accessible by the operator.
English 11

• Cord is wired according to Color codes for the power cord on page 12.
Color codes for the power cord
Table 2 shows the color codes for the power cord.
Table 2 Color codes for the power cord
Conductor Type North American IEC
Line conductor (Line 1 (Hot)) Black Brown
Neutral conductor (Line 2 (Neutral)) White Blue
Ground conductor Green Green with yellow stripe
Terminal block connections
Connect the ground line to the heater block terminal that shows the ground symbol (Figure 7).
Connect the hot and neutral power supply lines to TB1 (Figure 7). The terminal block accepts up to
12 gauge wire. The manufacturer recommends 16–12 AWG wire based on installation requirements.
The wiring insulation must be rated to 90 °C minimum.
Figure 8 shows the interior of the sample heater with connections.
Figure 7 Power connections at the J3 terminal block
1 Line 1 (Hot) 3 Ground
2 Line 2 (Neutral) 4 Top of instrument
12 English

Figure 8 Sample heater interior with connections
1 Power connections (top to bottom: Ground, Neutral,
Hot)
3 Circuit breaker for 115 V (230 V has two switches)
2 Thermostat reset switch
Operation
Sample heater start up
Before startup, find the required sample temperature and sample flow rate of the analyzer. Start the
sample flow through the heater, then apply power to the instrument. Adjust the sample conditioning
system on the analyzer and make sure there are no leaks.
Instrument power
Apply power at the external (user-supplied) switch and the display lights up. If the display does not
light, qualified service personnel must check the circuit breaker and the thermostat reset switch
inside the heater enclosure. The area that contains the circuit breaker is not user-serviceable.
Set the temperature
1. Push the UP or DOWN arrows to set the desired temperature. The lower display shows the
temperature setpoint (e.g., 50 °C).
English 13

2. Use the thermometer included with the Sample Heater to measure the temperature of the sample
in the analyzer sample cell. Put the thermometer in the cell and wait for the temperature to
stabilize. The difference between the temperature in the cell and the temperature shown on the
display is due to loss of heat between the cell and the heater. For operator convenience, enter a
calibration offset to adjust for the temperature loss (Enter the calibration offset on page 14). If
necessary, insulate the sample lines to decrease the amount of heat loss.
3. The factory sets the PID parameters for the heater. The factory-set values are appropriate for
most applications. If it is necessary to change the PID parameters, refer to Autotune
on page 14.
Enter the calibration offset
The calibration offset is the difference between the required analyzer set-point temperature and the
temperature in the sample cell. For example, if the required temperature is set to 50 ºC and the
measured temperature of the sample cell in the analyzer is 47 ºC, the calibration offset is -3 ºC.
Wide variations in the temperature of the incoming sample or sample flow rate may cause a
difference in the indicated process temperature. If temperature changes occur in the analyzer sample
cell, make sure that the temperature setting on the sample heater and the offset agree with the
required values.
If variations in the sample-intake temperature or flow cause temperature instability, change the offset
to adjust. Refer to Sample Heater Specifications on page 3 to find the capability for the operating
conditions.
To enter a calibration offset:
1. Push the ADVANCE key until CAL shows in the lower display. Push the DOWN arrow to
decrease the value of the CAL offset by 3 ºC.
Note: If no CAL offset value is entered, the CAL offset value will be 0.
2. Push the ADVANCE key.
The sample heater returns to normal operation. The process temperature and the setpoint
indicator should read the same temperature value.
Autotune
The Watlow EZ-ZONE PM ExpressMicroprocessor-based Auto-tuning Control has PID (proportional
band, resent/integral and rate derivative) control capability. The factory sets the PID parameters for
the heater. These values suit most applications. If it is necessary to change these parameters, follow
the procedure below. This procedure allows the controller to automatically tune the parameters.
Note: For successful auto-tuning, the setpoint temperature should be set at least 10 ºC above the inlet temperature.
1. Push the UP and DOWN arrows and hold them for 3 seconds to access the Loc menu.
2. Push the UP arrow and change the upper display to 5.
3. Push the INFINITY key. The display returns to the Operation menu.
4. Push the ADVANCED key and scroll to the AUto menu.
5. Push the UP arrow and highlight YES.
The upper display flashes tune and then YES while the sample heater does the auto-tune
procedure. The temperature must cross the auto-tune setpoint five times to complete the
procedure. The controller installs the appropriate PID parameters and saves them in nonvolatile
memory. The sample heater will auto-tune itself around 90% of the set temperature value.
Controller setup menu
The operational setup of the PID controller depends on specifics of the use-case. The manufacturer
has set the controller to operate with the manufacturer's sample heater.
14 English

The tables show the values in the upper and lower displays and give information about the values.
The values shown are default values. If necessary, use the UP and DOWN arrows to change a value
and then move to the next step.
1. Push and hold the up and down arrow keys for approximately 3 seconds to go to the Lockout
menu. Make the upper display show 5 to allow read and write access.
5Operations menu and setup menu with full R/W access
Lockout menu
2. Push ADVANCE.
Sensor type set to Thermocouple
Sensor type
3. Push ADVANCE.
J-type thermocouple as input measuring device
Linearzation
4. Push ADVANCE.
Temperature input and display units in whole numbers
Decimal
5. Push ADVANCE.
Temperature input and display units in Celsius
Display units
6. Push ADVANCE.
The lower range set point limit is 20 ºC
Range Low
7. Push ADVANCE.
The upper range set point limit is 50 ºC
Range High
8. Push ADVANCE.
English 15

Output set to heating
Function of Output 1
9. Push ADVANCE.
PID proportional-integral derivative
Heat Algorithm
10. Push ADVANCE.
Alarm set to off
Alarm type
11. Push ADVANCE.
Ramp action set to off
Ramp action
12. Push ADVANCE.
Set maximum value output 1 range
Power scale high output 1
13. Push ADVANCE.
Active process value
Upper or Left display
14. Push ADVANCE.
Active Set Point
Lower or Right display
15. Push ADVANCE.
Set to 1
Zone Address–Standard Bus Communication
16. Push ADVANCE and then the DOWN arrow until the upper display shows 2.
16 English

2A/M button disabled, set point R/W only.
Lockout Menu
17. Push INFINITY.
The sample heater returns to normal operations.
Sample heater operation menu
The upper display window shows the process temperature. The lower display window shows the
temperature setpoint. The 1 indicator lamp is on when the heater is on. No other display indicators
show.
If necessary, use the up and down arrow keys to change a value shown in the display, then move to
the next step.
1. To go to the Lockout menu, push and hold the up and down arrow keys for approximately
3 seconds. Change the upper display to 5.
5Operations menu and setup menu with full R/W access
Lockout menu
2. Push INFINITY.
The sample heater enters the operation menu.
3. Push ADVANCE.
Make sure that this is set to no. (To initially tune the
heater, select YES. Refer to Autotune on page 14.)
Autotune
4. Push ADVANCE.
Make sure that this is set to Auto
Control Mode Active
5. Push ADVANCE.
Set to 9
Heat Proportional Band
6. Push ADVANCE.
Set to 109
Time Integral
7. Push ADVANCE.
English 17

Set to 18
Time Derivative
8. Push ADVANCE.
Set to 7
Time Base Output 1
9. Push ADVANCE.
Set to -3
Calibration Offset
The calibration offset is shown in the upper display window. The value entered here corrects for
any temperature offsets that exist in the sampling application. Change this value to make the
process display agree with the assessment of the process temperature. Refer to Enter the
calibration offset on page 14.
10. Push the INFINITY key to go to the Operation menu.
11. Push and hold the UP and DOWN arrow keys for approximately 3 seconds to go to the Lockout
menu.
12. Change the upper display to 2, then push INFINITY.
The sample heater returns to normal operation.
Maintenance
Instrument maintenance and cleaning
The manufacturer designed the instrument to be maintenance-free except for exterior cleaning. If the
instrument exterior becomes dirty, clean the exterior surfaces with a damp cloth.
18 English

Troubleshooting
WARNING
Multiple hazards. Do not disassemble the instrument for maintenance or service. If the internal components must
be cleaned or repaired, contact the manufacturer.
Common problems
Problem Possible solutions
The PID display does not
light • Make sure the external power switch is in the On position
• Check the wiring connections
• Make sure the circuit breaker is in the On position
• Make sure the thermostat cutoff is not tripped (Wire the instrument on page 11).
If the cutoff has tripped, the middle button will snap down when lightly pressed.
The PID display is on but
the process temperature
does not drive to the set
temperature
• Make sure the sample flow rate and temperature are within the operational
range
• Check all electrical connections
• Make sure the temperature controller setup is correct
• Make sure the temperature of the sample temperature is not higher than the set
temperature of the heater
English 19