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EnCal 3000 Quad – Hardware Manual

16/09/2014

EnCal 3000 Quad

Gas Chromatograph

Hardware Manual

73022350 e 16.09.2014

Содержание EnCal 3000 Quad

Страница 1: ..._________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 EnCal 3000 Quad Gas Chromatograph Hardware Manual 73022350 e 16 09 2014 ...

Страница 2: ...oard 21 2 7 Electrical connection to the Slave Unit 22 2 8 Cabinet Heaters 23 2 9 Internal sample system 24 2 9 1 Double Block and Bleed Function 26 2 9 2 Internal Sample Bypass 26 2 10 Gas Connections 27 2 11 Breather 28 2 12 Cable Glands 29 2 13 External Switch 29 3 Technical Specifications 30 4 Data Communication 33 4 1 Local TCP IP Data Communication 33 4 2 Local Serial ModBus Data Communicati...

Страница 3: ...2 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 y...

Страница 4: ...ple Apply in all circumstances the following basic rules The flameproof enclosure may not be opened when an explosive gas atmosphere may be present Before any start up verify all connections of the unit for tight sealing WARNING ELECTROSTATIC HAZARD CLEAN WITH MOIST CLOTH ONLY CASE MUST BE EARTHED Important disclaimer If the equipment is used in a manner not specified by the manufacturer the prote...

Страница 5: ...en 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 analyze all components in a typical system The measuring unit of the analysis is conducted by measuring autonomy while using a PC program is parameterized Optionally additional computers can be installed see Figure 1 T...

Страница 6: ...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...

Страница 7: ...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...

Страница 8: ...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...

Страница 9: ...alisation 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 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 traditional fine mechanical technologie...

Страница 10: ...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...

Страница 11: ...e 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 interconnection board The slave unit shares the output of ...

Страница 12: ...edures 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 electrical connections can be directly connected to t...

Страница 13: ...ed 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 removed bottom the frame has to be removed from the enclosure ba...

Страница 14: ...trogen 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 Methylmercaptane an...

Страница 15: ...________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 15 51 fig 2 2 Overview of Channel Components The next page shows the internal gas flow configuration of the channels ...

Страница 16: ...__________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 16 51 fig 2 3 Internal Gas Flow Circuit for each Analytical Channel of the EnCal 3000 Quad during Normal Operation top and sample Injection below ...

Страница 17: ... 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...

Страница 18: ...comes used until the end of year 2014 are Processor AMD 133 MHz 16bit Flash Memory 32 MB for local data storage Ethernet card Data communication ports DB9 DB15 DB25 and Ethernet for TCP IP and serial ModBus communication and Analogue and Digital I O Pressure and Temperature measurement I O controller for data communication with the Analytical Channels fig 2 5a Processor board connections and dataf...

Страница 19: ...t cannot be override Changes in the parameters can only be transferred to the measuring unit if the jumper is not set The setting of the jumper can be checked on the display of the instrument status page See Section 3 2 of the software manual How to set the jumper is shown in Figure 2 6 Arm9 Processor DHCP Switch Configuration Jumper Digital I O COM2 COM1 Ethernet Port Analogue I O SD Card Serial ...

Страница 20: ...rd versions When installed in the EnCal 3000 Quad 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 8 Processor board with ribbon flat cable and fans mo...

Страница 21: ...s 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 9 Interconnection Board The scheme below shows the overall electrical configuration of the EnCal 3000 fig 2 10 Overall Electrical Con...

Страница 22: ...lave Unit these are all made in the Master Unit For the data transfer there is an additional board called wire connection board connected to the interconnection board in both units It is connected to the connector used by the processor board which is not present in the slave unit and which is stacked on top of this add on board in the master unit The wire connections between these boards in both u...

Страница 23: ...enclosure temperature goes below 10 C 50 F Figure 2 9 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 12 Cabinet heaters location in the EnCal 3000 For the regulation of the heaters standard thermostats with a fixed setting are used These thermostats are c...

Страница 24: ...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...

Страница 25: ...________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 25 51 fig 2 14 Flow diagram Sample Conditioning and Selection System ...

Страница 26: ...ves 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 1...

Страница 27: ...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...

Страница 28: ...d by ATEX directive The breather used on the EnCal 3000 is an Ex d certified device with IP 65 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...

Страница 29: ...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 and non flam...

Страница 30: ...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 limit for...

Страница 31: ...thium Button battery Type CR 2032 Li Mn 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 22667 PC RGC 3000 Windows based program for configuration diagnostics and report generation ...

Страница 32: ...land 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 channel max 16 ml min with four channels Calibration gas Composition preferably close to pipe line composition Quality 2 0 or higher with a...

Страница 33: ...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...

Страница 34: ...are Manual 16 09 2014 34 51 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 ...

Страница 35: ...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...

Страница 36: ...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...

Страница 37: ...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 ...

Страница 38: ...nCal 3000 Quad Hardware Manual 16 09 2014 38 51 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 ...

Страница 39: ...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...

Страница 40: ...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 streamselection 0 12 V DC J12 Power supply heater 1 24 V DC J13 Power supply heater 2 24 V DC J14 Dip Switch Power supply va...

Страница 41: ...ction to this internal cable is prepared with two additional connectors with 3 pins Just a two wire connection for and is required don t connect 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 conne...

Страница 42: ...nnection is used for connection with Serial ModBus clients like for example Flow Computers 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 an...

Страница 43: ...Purge the tubing before connecting to the EnCal 3000 for about 30 s Make the connection with inlet STR1 Check for leaks Repeat this procedure for the other streams if applicable 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 customer installer Power rating 60 W nominal 120 W start up pea...

Страница 44: ... 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 electrical connection are securely tight Chec...

Страница 45: ...lster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 45 51 APPENDIX 1 ZERTIFIKATES ENCAL 3000 ...

Страница 46: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 46 51 ...

Страница 47: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 47 51 ...

Страница 48: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 48 51 ...

Страница 49: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 49 51 ...

Страница 50: ...Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 50 51 ...

Страница 51: ...GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad Hardware Manual 16 09 2014 51 51 APPENDIX 2 DECLARATION OF CONFORMITY ENCAL 3000 ...

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