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Elster GmbH

___________________________________________________________________________________________________________

EnCal 3000 - Hardware Manual

22/02/2018

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Safety Information

Electrical Safety

The EnCal 3000 is a gas analyser designed to be installed in hazardous areas. For this purpose it is certified according
to:

ATEX II 2 G

Ex-db IIC T6 Gb

nd IECEx

Ex-db IIC T6 Gb

Class I, Division 1. Groups B, C, D T6
Class I, Zone 1, AEx IIC T6 Gb

In compliance with:

IECEx:

IEC 60079-0

: 2011

IEC 60079-1

: 2014

ATEX:

EN 60079-0

: 2012

EN 60079-1

: 2014

United States standards

Class 3600

: 2011

Class 3615

: 2006

Class 3810

: 2005

ANSI/ISA 60079-0 : 2013
ANSI/UL 60079-1 : 2015

NEC:

Detailed information on this certificate can be found in APPENDIX

Summary of Contents for EnCal 3000

Page 1: ..._____________________________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 EnCal 3000 Gas Chromatograph Hardware Manual 73022344 LC 22 02 2018 ...

Page 2: ...nternal sample system 23 2 8 1 Double Block and Bleed Function 25 2 8 2 Internal Sample Bypass 25 2 9 Gas Connections 26 2 10 Breather 27 2 11 Cable Glands 28 2 12 External Switch 28 2 13 Configuration with two Carrier Gases 29 3 Technical Specifications 30 4 Data Communication 33 4 1 Local TCP IP Data Communication 33 4 2 Local Serial ModBus Data Communication 34 4 3 Remote Access 35 4 4 ModBus C...

Page 3: ...Mainz Kastel Deutschland Germany Tel 49 0 61 34 605 0 www elster com Aftersales Service Germany International Elster GmbH Schlossstrasse 95a 44357 Dortmund Deutschland Germany Tel 49 0 231 93 71 10 88 e mail system Support DO elster com Aftersales Service International Elster Instromet N V Rijkmakerlaan 9 2910 Essen Belgien Belgium Tel 32 0 3 6 700 700 e mail aftersales elster instromet com Or you...

Page 4: ... hazardous areas For this purpose it is certified according to ATEX II 2 G Ex db IIC T6 Gb and IECEx Ex db IIC T6 Gb Class I Division 1 Groups B C D T6 Class I Zone 1 AEx IIC T6 Gb In compliance with IECEx IEC 60079 0 2011 IEC 60079 1 2014 ATEX EN 60079 0 2012 EN 60079 1 2014 United States standards Class 3600 2011 Class 3615 2006 Class 3810 2005 ANSI ISA 60079 0 2013 ANSI UL 60079 1 2015 NEC Deta...

Page 5: ...nnections of the unit for tight sealing For information on the dimensions of the flameproof joints the manufacturer shall be contacted WARNING ELECTROSTATIC HAZARD Because of the potential electrostatic charging of the paint layer the housing should only be cleaned by using a moist cloth to prevent charging CASE MUST BE EARTHED Important disclaimer If the equipment is used in a manner not specifie...

Page 6: ...ntroller The measuring unit is the real gas chromatograph It performs the analysis by measuring technology auton omously It is configured with the PC program RGC 3000 It is possible to install an additional optional Encal3000 controller The subsystems communicate with each other via Modbus see Figure 1 This manual describes the Hardware of the Encal3000 gas chromatograph measuring unit The other s...

Page 7: ...g 1 1 Principle of a Gas Chromatography A very small volume of sample gas typically 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 ...

Page 8: ... acts as an absorption layer for the gas molecules flowing through the column fig 1 2 Different types of gas chromatographic columns Various configurations exist 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 distributed throughout the ...

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 Encal 3000 are much smaller in terms of volume The components can be integrated at the same time much more accurately so that the an...

Page 10: ...isa tion of the measured concentrations will compensate for a large part of the fluctuations of these parameters However to reach repeatability for the heating value below 0 01 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 tradi tional fine mechanical technologies ...

Page 11: ...Control 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 indust...

Page 12: ... board The most important features are Compact EX d design Complete stand alone operation Capillary and micro packed columns in combination with MEMS analytical components Fast analysis C6 in less than 3 minutes High analytical performance o Uncertainty 0 1 for a wide range of gases o Repeatability 0 005 Up to 5 sample streams sequential without external stream selection Integrated sample system I...

Page 13: ...r all other check or maintenance procedures only the cap has to be re moved The compactness of the unit installation clearance Ø 55 cm x 70 cm height weight 30 kg allows it to mount the de vice on a platform a pole or to the wall Mounting holes at the back M8 and in the bottom M5 allow for fixation All gas tubing sample lines cal gas vent lines helium in and out and all electrical connections can ...

Page 14: ...ows 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 removed bottom the frame has to be removed from the enclosure base first This arrangement permits the service engineer to easily review the board in case malfunctions ...

Page 15: ...20 For devices build before 2008 the 5CB 4m channel was used for the analysis up to C6 and the 5CB 8m channel just for the analysis up to C9 Since 2008 the 5CB 8m becomes used for both options the main reason for this change is that the separation of the peaks especially for n butane and neo pentane is better for the 8m long column Another possible Channel configuration for the special application...

Page 16: ...___________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 16 56 fig 2 2 Overview of Channel Components The next page shows the internal gas flow configuration of the channels ...

Page 17: ..._______________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 17 56 fig 2 3 Internal Gas Flow Circuit for each Analytical Channel of the EnCal 3000 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: ...e 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 at the same position for the old and the new mainboard 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...

Page 20: ...rd versions When installed in the EnCal 3000 a flat cable makes 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 Also 2 fans are mounted to cool the processor in case of elevated ambient temperatures fig 2 6 Processor board with ribbon flat cable and fans mounted...

Page 21: ...ower supply input 24 VDC DC DC converter 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 7 Interconnection Board The following diagram shows the overall electrical configuration EnCal3000 in a rough overview fig 2 8 Overall Electrical ...

Page 22: ...to the mounting plates and provide addi tional heat when the internal enclosure temperature goes below 10 C 50 F Figure 2 10 shows the location of the cabinet heaters fig 2 9 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 close to the connectors for the powe...

Page 23: ...n 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 th...

Page 24: ...___________________________________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 24 56 fig 2 11 Flow diagram Sample Conditioning and Selection System ...

Page 25: ...ample Bypass The output from all second valves is combined on the common channel Depending on which channel is activated a section of this channel and the deactivated valves form a dead volume The outputs from deactivated valves are there fore 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 t...

Page 26: ...d 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 12 Gas Connection of the EnCal 3000 Adapter includes 2µ filter WARNING DO NOT LOOSEN THE CONNECTORS AS DESCRIBED ABOVE FROM THE ENCAL 3000 HOUSING THE SO...

Page 27: ...tuations The outlet of the breather must not be blocked and protected against dirt and rain i e with a swan neck tube fig 2 13 Breather as required by Explosion proof directives The Sintered breather which is suitable for a IIC and for Class I Division 1 environment in conjunction with capillary flame arrestors with an ID of maximum 0 015 0 38mm and a length of minimal 250mm It has an outlet conne...

Page 28: ...es with an internal volume 2 dm3 the so called Barrier Glands incorporating compound filled seals around the individual cores or other equivalent sealing arrange ments The cable entry devices and blanking elements of unused apertures shall be of a certified flameproof type suit able for the conditions of use and correctly installed For connection of an external earthling or bonding conductor a ca ...

Page 29: ...lysis of biogas a use of different carrier gases for the two analytical modules can be an advantage In the application Biogas for the module from type mole sieve Argon is used as carrier gas and for the sec ond module from type PPU Helium is used as carrier gas In the following picture this configuration is shown The two connections for the two different carrier gases are marked on the housing fig...

Page 30: ... once the unit has reaches its operation temperature depending on the ambient temperatures Interfaces Ethernet UTP 10 Base T for ModBus TCP IP and PC link Two RS 232 485 ports user selectable for ModBus RTU 3 analogues I O for local sensors 4 20 mA or 0 10 VDC Battery back up Button battery Panasonic Type BR 2032 3V EMC according to EN 61000 6 2 and EN 61000 6 4 Electrical Analyser ProTM complete ...

Page 31: ...0 001 14 C3 0 001 6 C3 0 001 6 C4 0 001 3 C4 0 005 3 Neo C5 0 005 0 25 H2 0 001 5 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 05 C9 0 001 0 05 Concentrations outside this scope might be possible but verification with Elster Instromet is needed Performance Uncertainty 0 1 for all calculated properties Repeatability 0 005 RSD for all calculated properties...

Page 32: ...nsors optional M20 M25 cable gland for armoured cable per default Diameters Ø 5 5 12 mm Ø 12 5 20 mm Ø 17 26 mm Optionally with adapters to NPT or other sizes 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 8 ml min with 2 columns Calibration gas Composition preferably close to pipe line compositi...

Page 33: ...net UTP 10 Base T is necessary for connection with RGC 3000 Win dows based interface for configuration diagnostics and report generation but is also used by preference for ModBus communication with Flow Computers 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 serial ModBus ports can of cour...

Page 34: ...rdware Manual 22 02 2018 34 56 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 fig 4 2 Typical Data Communication Set up for TCP IP combined with Serial ModBus Communication with the EnCal 3000 ...

Page 35: ...net through cable or ADSL modem or wire less 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 d...

Page 36: ...er 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 availabl...

Page 37: ...all comply with the relevant requirements of the National Electrical Code ANSI NFPA 70 NEC Europe installations shall comply with the 60079 14 according the attached certifi cates 5 1 1 Weight and Dimensions Weight 30 kg Dimensions Analyser Ø 37 x H 37 cm Ø 14 5 x H 14 5 Installation Clearance Ø 50 x H 70 cm Ø 20 x H 28 5 1 2 Installation clearance fig 5 1 Mounting Dimensions and Installation Clea...

Page 38: ...Hardware Manual 22 02 2018 38 56 5 1 3 Wall mounting fig 5 3 Wall Mounting Bracket Dimensions Depending on local regulations the weight of the EnCal 3000 28kg may exceed the allowable manual lifting limit for one person Be sure the appropriate manpower or lifting equipment and protective equipment such as safety shoes are available ...

Page 39: ...am 2 1 4 barg 15 57 PSIg STR3 Stream 3 1 4 barg 15 57 PSIg 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 Swagelok connection to the EnCal 3000 On request also 3 mm connections are available fig 5 4 Connections to the EnCal 3000 Power Supply cable 24 VDC 1...

Page 40: ...onnection J2 Channel 1 Connector J3 Channel 2 Connector J4 I O Flat cable to Processor board J5 TCP IP connection between Inter connection board and Processor board J6 Modbus RS485 232 connections J7 Ethernet connection J8 Solenoids terminal power suppl 24 V DC J9 Power supply out 12 VDC 24 VDC J10 Analogue inputs 0 10 V DC J11 Solenoids terminal for valves of stream selection 0 12 V DC J12 Power ...

Page 41: ... polarity Just a two wire connection for and is required don t con nect a third wire for the ground Instead of that the device should be grounded at the bottom of one housing at a M5 connection or at a free M8 connection at the mounting plate fig 5 6 Location of Power Supply connector J8 Ethernet connection The Ethernet connection is used for connection with a PC or ModBus TCP IP clients It uses 4...

Page 42: ...ction is used for connection with Serial ModBus clients like for example Flow Comput ers The EnCal features 2 Serial ModBus ports with identical output They are both independently 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 J6 fig 5 9 Modbus Connection and ...

Page 43: ...ction point with the EnCal 3000 Adjust to 1 4 barg 15 57 psig Purge the tubing before connecting to the EnCal 3000 for about 30 s Make the connection with inlet STR1 Check for leaks calibration is already connected in the section above Make a careful leak check of the total system Power Supply cable Standard industrial 2 wire cable The use of an external junction box is responsibility of the custo...

Page 44: ...e 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 connected and all cable glands for electri...

Page 45: ...appendix Option Meaning Explanation HT Heaters installed Frost protection has been added to keep the internals in the housing above 0 degrees Celsius SC Single Channel This a single channel analyser QS Quad Slave This housing is the slave 2nd dome housing of an EnCal 3000 Quad It has no CPU board inside H2 Hydrogen This analyser is configured to work with Hydrogen as carrier gas As such it needs v...

Page 46: ...____________________________________________ EnCal 3000 Hardware Manual 22 02 2018 46 56 Example for Type plate for devices with FM Approval for Group B Example for Type plate for devices with ATEX IECEx Approval extended to 60 C in 2018 The images are showing the IIC version ...

Page 47: ...gure 1 Cut out of an EnCal 3000 showing heaters installed For the regulation of the heaters standard thermostats with a fixed setting are used These thermostats are connected to the interconnection board close to the connectors for the power supply of the heaters see also fig 5 5 connectors J12 and J13 The heaters have a protection against overheating When the protection is activated it will cut t...

Page 48: ...18 48 56 Option SC Single Channel analyser Whenever option SC is on the nameplate of the analyser this will indicate that this EnCal will only have one channel installed in the housing This is the case when for instance the EnCal 3000 is used to measure a single component only like H2S or THT Figure 2 Cut out of an EnCal 3000 showing one channel installed ...

Page 49: ...analytical channels that are controlled by one processor board This System is especially developed for extended analysis appli cations which cannot be solved with just two channels Figure 3 EnCal 3000 Quad right master left slave With up to four channels it is possible to analyse all typical components of interest in one system The two housings are mounted on a metal plate to have a stable connect...

Page 50: ...t of the stream selection in the master unit and therefore no additional stream selection is needed The required gas connections between the two housings are preinstalled Option H2 Hydrogen carrier gas This analyser is configured to work with Hydrogen as carrier gas Normally the carrier gas is a non explosive one Helium nitrogen Argon and it is purged inside the housing to keep the atmosphere in t...

Page 51: ...mbH ___________________________________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 51 56 APPENDIX 2 IECEx CERTIFICATE OF CONFORMITY ENCAL 3000 ...

Page 52: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 52 56 ...

Page 53: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 53 56 ...

Page 54: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 54 56 ...

Page 55: ...ster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 55 56 APPENDIX 3 CERTIFICATE EC Type Examination ...

Page 56: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Hardware Manual 22 02 2018 56 56 ...

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