Description
Flexible Electrically Heated Sample Line for Gas and Liquid Transfer
The Thermon HSL2000 Heated Sample Line is a flexible heated sample-line system designed for the reliable transfer of gases and liquids where precise thermal regulation is required. Thermon describes the HSL2000 for manufacturing, laboratory and testing environments, including RATA testing, where consistent temperature control is important.
The HSL2000 uses either self-regulating or power-limiting heating cable to provide freeze protection and temperature maintenance. It can be configured for ordinary areas as well as hazardous locations, including Zone 1 and Zone 2applications.
Key Features
- Flexible heated sample line
- Designed for gas and liquid transfer
- Self-regulating or power-limiting heat tracing
- Maintains internal fluid or gas temperature from 0°C to 200°C
- Temperature stability of approximately ±1°C when used with a controller
- Custom power density from 5–20 W/ft (16–65 W/m)
- Typical heated lengths from 0.5–30 m (1.5–100 ft)
- Minimum bend radius of 100 mm (4 in.)
- Integrated temperature-sensor options
- Meta Aramid Felt insulation up to 1/2 inch
- Custom end connections
- Teflon and alloy tube options
- Suitable for ordinary and hazardous areas.
What Is the HSL2000?
The HSL2000 is a complete heated sample-line assembly that combines the process tube, heating cable, insulation, electrical leads and optional temperature sensor into one flexible product.
The basic construction consists of:
Process Tube → Heating Cable → Insulation → Outer Jacket
Optional components include temperature sensors and end connections.
This integrated design allows the sample line to be installed as a complete assembly rather than separately installing the tube, heat tracing and insulation.
Precise Temperature Regulation
Temperature control is one of the main purposes of the HSL2000.
Thermon specifies that the HSL2000 can maintain the internal fluid or gas temperature between:
0°C to 200°C
with approximately ±1°C stability when used with a controller.
This is important for samples that must remain within a specific temperature range during transportation.
For example, maintaining the sample above its condensation point can help prevent condensation and sample degradation between the collection point and the final destination.
Self-Regulating and Power-Limiting Heat Tracing
The HSL2000 can use either:
Self-Regulating Heat Cable
The heat output changes according to the surrounding temperature. As temperature increases, the heating cable reduces its thermal output.
Power-Limiting Heat Cable
The heating system provides controlled power output suitable for the application and temperature requirements.
Thermon specifically lists both self-regulating and power-limiting heating cables for the HSL2000.
Custom Power Density
The HSL2000 can be configured with different heating outputs.
Thermon specifies:
| Power Density | Approx. Metric |
|---|---|
| 5 W/ft | 16 W/m |
| 10 W/ft | 33 W/m |
| 15 W/ft | 49 W/m |
| 20 W/ft | 65 W/m |
The specification states that the power density and line length can be customized according to the application.
The appropriate watt density depends on the required temperature, ambient conditions, tube dimensions, insulation and installation environment.
Flexible Construction
The HSL2000 is designed to remain flexible during installation.
Thermon specifies a minimum bend radius of 100 mm (4 in.).
This makes the product useful for installations where the heated sample line must follow equipment, analyzer cabinets or other plant structures.
Typical applications can include:
- Analyzer installations
- Laboratory equipment
- Testing systems
- RATA testing
- Process sampling
- Industrial instrumentation
Temperature Sensors
The HSL2000 can incorporate an optional temperature sensor for closed-loop temperature control.
Thermon lists the following sensor options:
- RTD
- Thermistor
- Type K thermocouple
- Type J thermocouple
With an appropriate controller, the sensor can provide feedback to regulate the heating system and maintain the required sample-line temperature.
Compatible Temperature Controllers
Thermon identifies several controller options for the HSL2000, including:
- GHT2002J
- ExoTouch
- PID controllers
The controller should be selected according to the required temperature-control strategy, sensor type and installation environment.
Process Tube Options
The HSL2000 can be supplied with different process-tube materials.
Thermon’s HSL2000 specification identifies:
- Teflon
- Alloy options
The detailed configuration system also identifies a broader range of tube materials, including:
- 316 stainless steel welded
- 316 stainless steel seamless
- 304 stainless steel welded
- 304 stainless steel seamless
- Copper
- PFA Teflon
- Monel
- Titanium
- Alloy C276
- Alloy 825
- Alloy 20
- FEP Teflon
- Nylon
- Polyethylene
- PTFE Teflon.
The actual tube material should be selected according to the chemical compatibility, temperature and pressure of the sample.
Insulation
The HSL2000 uses Meta Aramid Felt insulation, with a specified thickness up to 1/2 inch.
The insulation helps retain the heat generated by the electrical heating cable and reduces thermal losses to the surrounding environment.
It also provides an additional layer of protection against contact with the heated assembly.
Outer Jacket
Thermon specifies outer-jacket options including:
- Corrugated Polyamide
- Braided Sleeving
The outer jacket provides mechanical and environmental protection while maintaining the flexibility required for installation.
End Connections
The HSL2000 can be customized with different end-connection configurations.
Options identified by Thermon include:
- Custom swaged fittings
- Compression-style fittings
- Optional quick connects
- Raw tube ends.
This allows the heated sample line to be configured according to the connection requirements of the sampling point and analyzer.
Heated Length
Typical HSL2000 heated lengths range from:
0.5 to 30 m (1.5–100 ft).
Because the heating cable and tubing configuration can be customized, the actual length should be selected according to the distance between the sample collection point and the destination.
Applications
CEMS
The HSL2000 can be used for heated sample transport in Continuous Emissions Monitoring Systems, where maintaining sample temperature can be important to prevent condensation and sample degradation.
RATA Testing
Thermon specifically identifies RATA testing as an application for the HSL2000.
Process Analyzers
The HSL2000 can transport gas or liquid samples between a sampling point and process analyzer while maintaining the required thermal conditions.
Laboratory Applications
The flexible construction makes it suitable for laboratory and testing environments requiring controlled sample temperature.
Manufacturing
Thermon identifies manufacturing environments as another application for the HSL2000.
Hazardous Area Applications
The HSL2000 can be configured for ordinary and hazardous areas.
Thermon specifically identifies applications in:
- Ordinary / non-classified areas
- Zone 1
- Zone 2
- Zone 21
- Zone 22
The exact certification and connection configuration should be selected according to the hazardous-area classification of the project.
HSL2000 Construction
| Component | Function |
|---|---|
| Process Tube | Transports gas or liquid sample |
| Self-Regulating / Power-Limiting Cable | Provides heating |
| Meta Aramid Felt | Thermal insulation |
| Power Leads | Electrical connection |
| Temperature Sensor | Temperature feedback |
| Outer Jacket | Mechanical/environmental protection |
| End Seals | Protects bundle ends |
| End Connections | Connects to process/analyzer equipment |
This integrated construction is based on Thermon’s HSL2000 product specification.
Electrical Configuration
Thermon specifies the HSL2000 for:
120 / 208 / 240 VAC
The heating configuration can be selected according to the required power density and available electrical supply.
For quotation and engineering, the following electrical information should be confirmed:
- Supply voltage
- Heating power
- Heated length
- Number of heating circuits
- Temperature-control method
- Sensor type
- Hazardous-area classification.
HSL2000 Product Specification
| Attribute | Specification |
|---|---|
| Brand | Thermon |
| Model | HSL2000 |
| Product Type | Heated Sample Line |
| Application | Gas & Liquid Transfer |
| Heat Tracing | Self-Regulating / Power-Limiting |
| Operating Temperature | 0–200°C |
| Temperature Stability | ±1°C with controller |
| Power Density | 5–20 W/ft (16–65 W/m) |
| Typical Heated Length | 0.5–30 m |
| Minimum Bend Radius | 100 mm |
| Voltage | 120 / 208 / 240 VAC |
| Temperature Sensors | RTD / Thermistor / Type K / Type J |
| Tube Material | Teflon / Alloy / Other configurations |
| Insulation | 1/2″ Meta Aramid Felt |
| Outer Jacket | Corrugated Polyamide / Braided Sleeving |
| End Connections | Swaged / Compression / Quick Connect / Raw Ends |
| Controllers | GHT2002J / ExoTouch / PID |
| Hazardous Area | Zone 1 / 2 / 21 / 22 configurations |
| Applications | CEMS / RATA / Manufacturing / Laboratory / Testing |
The specifications above are based on Thermon’s current HSL2000 product page and product datasheet.
Why Choose Thermon HSL2000?
The Thermon HSL2000 Heated Sample Line provides a flexible and customizable solution for transporting gases and liquids where precise temperature regulation is required.
Its combination of self-regulating or power-limiting heat tracing, flexible construction, integrated temperature-sensor options, custom power density, multiple tube materials and hazardous-area configurations makes it suitable for CEMS, RATA, process analyzers and industrial sampling applications.
For proper selection, the main parameters should include the sample medium, required temperature, ambient conditions, tube material, heated length, available voltage, heating power, sensor type and hazardous-area classification.
