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Elster Instromet EnCal 3000 Quad, Hardware Manual

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Elster Instromet EnCal 3000 Quad Hardware Manual Download Page 18

 

Elster GmbH 

 

 
 
 

___________________________________________________________________________________________________________ 

 

EnCal 3000 Quad– Hardware Manual  

 

              22/06/2017 

18/52 

 

 

Detector

Solenoid V1

Solenoid V2

Solenoid V3

Solenoid V4

Solenoid V5

inlet

Solenoid V6

outlet

sample

loop

 inject valve

Manifold block

Column vent

Reference vent

Sample vent

EGC/Ref vent

Sample

Injector

Analytical

column

Reference

column

Pump Manifold

Pressure

sensor

Pre

column

Pump

 sample valve

Pump valve

Backflush

valve

BF vent

 

 
 

Detector

Solenoid V1

Solenoid V2

Solenoid V3

Solenoid V4

Solenoid V5

inlet

Solenoid V6

outlet

sample

loop

 inject valve

 sample valve

Manifold block

Column vent

Reference vent

Sample vent

EGC/Ref vent

Sample

Injector

Analytical

column

Reference

column

Pump Manifold

Pressure

sensor

Pre

column

Backflush

valve

Pump

Pump valve

BF vent

 

 
 

fig. 2-4 Internal Gas Flow Circuit for each Analytical Channel with backflush of the EnCal 3000 

Quad,  

before activating backflush valve (top) and after activating backflush valve (below) 

 

Summary of Contents for EnCal 3000 Quad

Page 1: ..._________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 EnCal 3000 Quad Gas Chromatograph Hardware Manual 73022350 g 22 06 2017 ...

Page 2: ...nection Board 22 2 7 Electrical connection 23 2 8 Cabinet Heaters 24 2 9 Internal sample system 25 2 9 1 Double Block and Bleed Function 27 2 9 2 Internal Sample Bypass 27 2 10 Gas Connections 28 2 11 Breather 29 2 12 Cable Glands 30 2 13 External Switch 30 3 Technical Specifications 31 4 Data Communication 34 4 1 Local TCP IP Data Communication 34 4 2 Local Serial ModBus Data Communication 35 4 3...

Page 3: ...om the contracts concluded and the General Terms and Conditions applicable upon conclusion of the contract Warranty Conditions You will find our current Warranty Conditions in the General Terms and Conditions e g on our website www elster instromet com en general terms of business Contact Information Elster GmbH Manufacturer Steinern Str 19 21 55252 Mainz Kastel Germany Phone 49 6134 605 0 Email I...

Page 4: ...he process pressure shall be limited to 2 MPa to ensure that the pressure rise inside the flameproof enclosure remains below 10 kPa The functional pressure must be lower see chapter 3 and section 5 1 4 containing the specifications Before any start up verify all connections of the unit for tight sealing For information on the dimensions of the flameproof joints the manufacturer shall be contacted ...

Page 5: ...drogen and oxygen with a third channel and the analysis of hydrogen sulfide and carbonyl sulfide with a fourth channel With the simultaneous use of up to four channels it is possible to analyse all components in one system The measuring unit is the real gas chromatograph It performs the analysis by measuring technology autonomously It is possible to install additional optional Encal3000 controller...

Page 6: ..._________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 6 52 Basic configuration EnCal 3000 Quad Measuring unit and an optional Encal3000 controller Fig 1 Encal3000 Quad measuring system ...

Page 7: ...ly much less than 1 ml which is a mixture of several components is injected into a stream of carrier gas which takes the sample gas through the column This column acts as a separator through the difference in absorption rate of the different components of the sample gas they are separated from each other during their passage through the column and elute as individual components The concentration o...

Page 8: ...rption layer for the gas molecules flowing through the column Fig 1 2 Different types of gas chromatographic columns Various configurations are used depending on the components to measure Wall coated open tubular column the stationary phase is a thin liquid layer coated on the inner wall of the column for example type 5CB Packed column the stationary phase is coated on a packing which is equally d...

Page 9: ...nt of gas properties like heating value Relative density and Wobbe index The calculation of these parameters is based on the concentrations of the main gas components TCDs newer design in MEMS technology MEMS Micro Electro Mechanical System which are also used in the Encal3000 Quad are much smaller in terms of volume The components can be integrated at the same time much more accurately so that th...

Page 10: ...malisation of the measured concentrations will compensate for a large part of the fluctuations of these parameters However to reach a repeatability for the heating value below 0 02 these parameters do have effect and need to be controlled to a high degree The used MEMS technology allows a fundamental improvement of the sample injection quality compared to the traditional fine mechanical technologi...

Page 11: ...ontrol and processing of analytical measurement executed internally no peripheral device needed o Automatic calibration and verification Standard maintenance limited to yearly intervals without need for specifically trained people o High reliability of the components o High degree of protection to any contaminant liquids vapour or particles in the sample gas Analytical results available in industr...

Page 12: ...ted on a metal plate to have a stable connection The right housing further referred as Master unit contains the first two channels the processor board for the control of the measurement system and the sample selection The left housing further referred as Slave unit contains the third and optionally fourth channel depending in the application Both housings have a separate power supply board interco...

Page 13: ...ken apart For all other check or maintenance procedures only the cap has to be removed The device can be mounted to the wall The mounting holes at the back of each housing are used for the connection of the housings In this steel connection are some holes with a size of 8 5 mm available for the connection to the wall The gas tubing sample lines cal gas and helium in and out vent lines and all elec...

Page 14: ...alled because they are only needed in the Master Unit The frame is used for mounting the components It allows the removal of all the direct and individual components with the exception of the interconnection board The components can be removed directly and individually by unscrewing just a few screws If the Interconnection Board must be replaced the frame has to be removed from the enclosure base ...

Page 15: ...annel for Nitrogen Methane Carbon Dioxide Ethane and Ethylene 2 5CB 8m Channel for higher hydrocarbons Propane to Nonane 3 5CB 4m Channel for higher hydrocarbons Nonane to Dodecane 4 PPU 10m Channel for Hydrogen Sulphide Carbonyl Sulphide water vapour methanol 5 M5A 10m molesieve Channel for Helium Hydrogen Oxygen Nitrogen and Carbon Monoxide 6 13CB 12 Channel for odorants like THT and TBM Methylm...

Page 16: ...________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 16 52 fig 2 2 Overview of Channel Components The next page shows the internal gas flow configuration of the channels ...

Page 17: ...__________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 17 52 fig 2 3 Internal Gas Flow Circuit for each Analytical Channel of the EnCal 3000 Quad during Normal Operation top and sample Injection below ...

Page 18: ... Pump Manifold Pressure sensor Pre column Pump sample valve Pump valve Backflush valve BF vent Detector Solenoid V1 Solenoid V2 Solenoid V3 Solenoid V4 Solenoid V5 inlet Solenoid V6 outlet sample loop inject valve sample valve Manifold block Column vent Reference vent Sample vent EGC Ref vent Sample Injector Analytical column Reference column Pump Manifold Pressure sensor Pre column Backflush valv...

Page 19: ...parameters in the measuring unit Setting the Configuration Jumpers can protect the parameters on the measuring unit computer witch was loaded by using the software RGC 3000 This configuration Jumper is on the mainboard see fig 2 6 If the jumper is set the parameters inside the measuring unit cannot be override Changes in the parameters can only be transferred to the measuring unit if the jumper is...

Page 20: ...uad Hardware Manual 22 06 2017 20 52 fig 2 6 Save parameters in the measuring unit When installed in the EnCal 3000 Quad two flat cables are making the connection between the communication ports of the Processor Board and the Interconnection Board which provides field connections Phoenix connector for the data communication signals ...

Page 21: ..._____________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 21 52 fig 2 7 Processor board with ribbon flat cables mounted in the EnCal 3000 Quad Master ...

Page 22: ...ns Power supply input 24 VDC DC DC converter 18 36 VDC Connection of Processor Board with Analytical Modules Field data communication connectors Actuation of stream select solenoids Enclosure temperature regulation Internal DC DC conversion for various circuits fig 2 8 Interconnection Board The scheme below shows the overall electrical configuration of the EnCal 3000 fig 2 9 Overall Electrical Con...

Page 23: ...ply becomes connected in each housing separately With the help of connections the interconnection boards are connected 1 to 1 in the two housings and transfer the data These wire connections should not be changed by the customer There are no customer connections for data transfer in the Slave Unit these are all made in the Master Unit The following figure shows the location of the plug connection ...

Page 24: ...re 2 11 shows the location of the cabinet heaters For an Encal3000 Quad these heaters have to be installed in both housings the principle is illustrated for one housing in the following picture fig 2 11 Cabinet heaters location in the EnCal 3000 For the regulation of the heaters standard thermostats with a fixed setting are used These thermostats are connected to the interconnection board see also...

Page 25: ...tion system Helium Purging optional Helium enters the manifold and is split to both analytical modules Through a purge valve the helium can be vented into the housing to expel the air in the housing activated by time relay 3 Additionally to this the column vent is released into the housing which is nearly pure helium If there is a leak in the housing no combustible mixture can be formed because of...

Page 26: ...________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 26 52 fig 2 14 Flow diagram Sample Conditioning and Selection System ...

Page 27: ...are therefore relieved to a second common vent channel which is blocked by the sample bypass valve Activating this valve will result in a flow from the activated valves through the deactivated valves to the bypass valve This refreshes all second valves and the common channels with the new gas so all dead volumes are refreshed Actuating the bypass valve results in a flow that is approximately 15 ti...

Page 28: ...daption to 3mm for output gas Adapter fixed to the housing Tubing 1 16 soldered to the adapter and connected at the other end with the internal sampling system This tubing serves as flame arrestor Its length has to be bigger than 25 cm 19 and should not be shortened by the customer fig 2 15 Gas Connection of the EnCal 3000 Quad WARNING DO NOT LOOSEN THE CONNECTORS AS DESCRIBED ABOVE FROM THE ENCAL...

Page 29: ...d by ATEX directive The breather used on the EnCal 3000 is an Ex d certified device with IP 66 rating and a vent flow of about 600 l h at 100 mbar overpressure in the enclosure It is sealed with Loctite to prevent loosening by unauthorised persons When installed outside it should be protected against dirt and rain i e by connecting a swan neck tube to it the breather has a 3 8 NPT connection Any t...

Page 30: ... the right of the Enclosure Base Cable glands with a sealing system are typically required Installation directive EN 60079 14 recommends for Ex d devices with an internal volume 2 dm3 the so called Barrier Glands incorporating compound filled seals around the individual cores or other equivalent sealing arrangements The cable glands and blind covers of unused openings must be installed correctly a...

Page 31: ...10 i n C5 0 001 0 25 O2 0 005 4 C6 0 001 0 1 H2S 0 0002 1 C7 0 001 0 05 COS 0 0001 1 C8 0 001 0 02 He 0 001 1 C9 0 001 0 01 H2O 0 001 0 05 CH3OH 0 005 0 1 Concentrations outside this scope might be possible but verification with Elster Instromet is needed Performance Uncertainty 0 1 for all calculated properties Repeatability 0 01 for all calculated properties Linear dynamic range 106 Detection li...

Page 32: ...20 mA or 0 10 VDC Fuses F1 and F2 each 5A for 24V power supply Battery back up Lithium Button battery Panasonic Type BR 2032 3V Approvals EMC according to EN 61000 6 2 and EN 61000 6 4 Analyser ProTM complete stand alone operation inclusive all calculations and generation of report formats without need for operator intervention Calculations according to ISO 6976 GPA 2172 ASTM D3588 or GOST 31369 P...

Page 33: ...gland for armoured cable Ø 11 17 mm 17 26 mm Data Communication M20 M25 cable gland for armoured cable Ø 11 17 mm 17 26 mm Installation Helium Argon Quality 5 0 or better Optional 2 bottles with automatic change system Supply pressure 5 5 barg Flow 4 ml min per column max 16 ml min with four columns Calibration gas Composition preferably close to pipe line composition Quality 2 0 or higher with a ...

Page 34: ...CP IP Port Ethernet UTP 10 Base T is necessary for connection with RGC 3000 Windows based interface for configuration diagnostics and report generation but is also used by preference for ModBus communication with Flow Computers DCS systems PLC and other ModBus hosts if they are able to handle ModBus TCP IP If not ModBus serial to TCP IP are easily available nowadays For existing systems the 2 seri...

Page 35: ...are Manual 22 06 2017 35 52 4 2 Local Serial ModBus Data Communication Flow computers or another ModBus host could also be directly connected to one of the 2 serial ModBus ports internally integrated in the EnCal 3000 Quad fig 4 2 Typical Data Communication Set up for TCP IP combined with Serial ModBus Communication with the EnCal 3000 Quad ...

Page 36: ...ternet through cable or ADSL modem or wireless Or through a VPN connection with the customer s network if the Ethernet switch or the local PC is integrated in this network In this case the customer has to give if required only temporarily a User Account and Login ID to the remote PC If network connection is not available telephone line connection is also possible Or by using an Ethernet modem with...

Page 37: ...ther bit Status or register size Register User selectable For the Instromet protocol be aware of the following restrictions 0 4999 2 bytes per Registers 5000 6999 4 bytes Integers 7000 higher 4 bytes Floating Point The Modicon protocol always uses 4 registers Data Type Bit when Status is defined Integer 16 bit or 32 bit or Float when Register is defined Parameter ID Instruction set which is availa...

Page 38: ...allation 5 1 Installation specifications 5 1 1 Weight and Dimensions Weight 60 kg for complete Quad device Dimensions Analyser two combined housings Ø 37 x H 37 cm Ø 14 5 x H 14 5 Installation Clearance 100 cm x 42 cm x H 70 cm 40 x 17 x H 28 5 1 2 Installation clearance fig 5 1 Mounting Dimensions and Installation Clearance I fig 5 2 Mounting Dimensions and Installation Clearance II ...

Page 39: ...nCal 3000 Quad Hardware Manual 22 06 2017 39 52 5 1 3 Wall mounting fig 5 3 Wall Mounting Bracket Dimensions Because the weight of the EnCal 3000 surpasses 55 kg care must be taken when lifting or transporting the unit Make sure to carry the unit with at least 3 persons when no means for lifting and carrying are available ...

Page 40: ...SIg STR4 Stream 4 1 4 barg 15 57 PSIg STR5 Stream 5 1 4 barg 15 57 PSIg CAL Calibration Gas 1 4 barg 15 57 PSIg PV Purge Vent SBV Sample Block and Bleed Vent All gas and vent lines do have a 1 8 or optional 3 mm Swagelok connections to the EnCal 3000 Following figure shows the location of the connections to the EnCal 3000 Quad fig 5 4 Connections to the EnCal 3000 Quad If the second carrier gas Ar...

Page 41: ...Modbus Communication J9 Connection for Digital Inputs passive J10 Connection for Analogue Inputs 0 10 V DC J11 Connection for 24V supply of external transmitters 24V 25 mA J12 Connection for Analogue Outputs 4 20mA J13 14 pin Connector for supply of timed relays and Vents J14 24V Power Supply Connection J15 J16 Additional optional 24V supply J17 Connection for communication cable used for paramete...

Page 42: ... 3 pin plug connector but only two wire connection and are needed Don t connect a third wire for the ground Instead of that the devices should be grounded at the bottom of each housing at a M5 connection or at a free M8 connection at the mounting plate fig 5 6 Location of Power Supply connector J14 Ethernet connection The Ethernet connection is used for connection with a PC or ModBus TCP IP client...

Page 43: ...tly configurable for RS232 or RS485 communication through link settings 301 to 304 see pictures below for location wiring scheme and link settings fig 5 8 Location of Serial ModBus connector J8 Position in J8 Signal Jumper Setting Port Type Remarks 1 A LK1 right RS485 2 B LK2 right RS485 3 0 LK3 right RS485 4 A LK4 right RS485 Like shown in the above picture 5 B LK5 right RS485 6 0 LK6 right RS485...

Page 44: ... the stream gas pressure at the connection point with the EnCal 3000 Adjust to 1 4 barg 15 57 psig Purge the tubing before connecting to the EnCal 3000 for about 30s Make the connection with inlet STR1 Check for leaks Repeat this procedure for the other streams if applicable Do a leak test of the total system Power Supply cable Standard industrial 2 wire cable The use of an external junction box i...

Page 45: ...oving of the cap by accident or ignorance fig 5 10 Location of security screws to fix the cap after mounting on the base The unit will automatically start up The start up sequence takes about 5 minutes including temperature and pressure stabilisation and system flushing After this sequence the unit is ready for the software configuration Check one more time if all gas connections are leak tight co...

Page 46: ...lster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 46 52 APPENDIX 1 CERTIFICATES ENCAL 3000 ...

Page 47: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 47 52 ...

Page 48: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 48 52 ...

Page 49: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 49 52 ...

Page 50: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 50 52 ...

Page 51: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 51 52 ...

Page 52: ...GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 22 06 2017 52 52 APPENDIX 2 DECLARATION OF CONFORMITY ENCAL 3000 ...

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