Honeywell ENCAL 3000 Скачать руководство пользователя страница 1

Страница: 1 / 141

•

GASCHROMATOGRAPH ENCAL 3000

HARDWARE MANUAL

Содержание ENCAL 3000

Страница 1: ... GASCHROMATOGRAPH ENCAL 3000 HARDWARE MANUAL ...

Страница 2: ...ontract In no circumstances will the manufacturer accept liability for any direct special or consequential damage Subject to amendments in the course of further development Any such amendments will be included in the latest version without prior notice The latest version of this document is available in PDF format at www docuthek com Ensure that you use the appropriate version for your device The ...

Страница 3: ... Safety information about gases 19 2 5 Electrical information connecting with earth and emergency stop 20 2 6 Explosion protection 23 3 FUNCTIONAL DESIGN OF ENCAL 3000 25 3 1 Introduction Enclosure Hausing 26 3 2 Most important features and functions 27 4 PROCESS GAS CHROMATOGRAPHY GENERAL INTRODUCTION 28 4 1 Analytical Principle 28 4 1 1 Column 29 4 1 2 Detector 30 4 1 3 Sample Injector 31 4 1 4 ...

Страница 4: ...SIONING 79 7 1 Requirements for commissioning and operation 81 7 2 Hardware Start up 82 7 2 1 Checking the device settings and signals 83 7 3 Decommissioning 83 7 3 1 Dismantling 85 8 MAINTENANCE AND REPAIR 85 8 1 Troubleshooting Identifying hardware errors 86 8 1 1 Troubleshooting in the gas supply 88 8 1 2 Troubleshooting in the electrical supply and insulation 88 8 2 Maintenance and remote main...

Страница 5: ...5 ModBus Communication 104 10 TECHNICAL SPECIFICATIONS 105 11 POSSIBLE HARDWARE OPTIONS AND TYPE PLATES 108 11 1 Option HT Heaters installed 112 11 2 Option SC Single Channel analyser 113 11 3 Option QS Quad Slave 114 11 4 Option H2 Hydrogen carrier gas 115 12 ANNEX 116 12 1 Nomenclature Abbreviations 117 12 2 Definitions and explanations 120 12 3 CERTIFICATE EC Type Examination 125 12 4 DECLARATI...

Страница 6: ...onfigured with the PC program RGC 3000 and it is possible to install an additional optional Encal3000 controller See separat manuals The subsystems communicate with each other via Modbus see Figure 1 1 for basic configuration with measuring unit and an optional Encal3000 controller Figure 1 1 Parts of the Gas quality measurement system The enCal 3000 is suitable for worldwide use You should use a ...

Страница 7: ...llowing table shows the development of this document Revision Revision Revision Revision Date Date Date Date Description Description Description Description a to l 2008 until 2016 Historic development m August 04 2017 New Interconnection board n Feb 22 2018 New temperature range o August 20 2018 New CE Declaration and extension to Honeywell document design 1 1 1 How to use this manual It is essent...

Страница 8: ...ety and important for the functioning of the device If this information is ignored the result may be health impairment environmental or property damage and injuries or even death This information must be followed and given due consideration in all circumstances CAUTION Explosion Very serious health impairment Prohibited action Explosion or danger of explosion means that death and or injuries may b...

Страница 9: ... to comply with the WEEE directive of the EU In the interest of our environment the WEEE directive did not allow to dispose the device with household waste within the EU Device symbol This symbol on the device means that the power supply is 24 V DC Device symbol This symbol on the device designates the equipotential bonding connection PA or the terminal for the electrical connection to the equipot...

Страница 10: ...very electrical connection must be fitted with a cable gland of a suitable size or a blind plug There are not normally any openings on the device that do not have plugs or fittings glands The local display is included optional if ordered Fastening materials for example wall mounting bracket with screws are included as ordered 1 2 2 Transporting and storing the device Prevent transport damage incor...

Страница 11: ...on Intended use also includes compliance with all the information in this document and on the measuring instrument Any additional use or use other than that intended will be deemed to be misuse Claims of any kind due to damage as a result of misuse will be void ATTENTION Use the device only for its intended purpose as described in this docu ment If you use the device for other tasks or purposes pr...

Страница 12: ...el or components The operator must ensure that no earth potential shift takes place for example by using an equipotential bonding cable ATTENTION The operator must ensure that the installation and maintenance work described in this document is carried out correctly The operator is responsible for ensuring that the device remains in technically perfect safe condition throughout its period of operat...

Страница 13: ...operation We assume that users will have the appropriate language skills ATTENTION Always refer to the whole safety information in this documentation and on the device Also refer to the other relevant sections and the technical specifications Please contact your TAC if you have any questions or doubts A lack of warning signs does not release you from your personal responsibility for safety CAUTION...

Страница 14: ...val FM Approval FM Approval FM Approval 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 Detailed information on thi...

Страница 15: ... C D T6 Class I Zone 1 AEx db IIC T6 In compliance with IECEx IEC 60079 0 2011 IEC 60079 1 2014 ATEX EN 60079 0 2012 EN 60079 1 2014 FM standards Class 3600 2011 Class 3615 2006 Class 3810 2005 ANSI ANSI ISA 60079 0 2013 ANSI UL 60079 1 2015 Detailed information on this certificate can be found in ANNEX CAUTION The device may only be installed and used in the potentially dangerous zones specified ...

Страница 16: ...CAUTION It must be ensured for example by an air conditioned housing that the device is not exposed to any excessive temperatures during storage or operation The temperature range is specified on the device ATTENTION The ambient conditions must comply with the technical specifications otherwise an additional air conditioned housing must be used The device may only be used in potentially corrosive ...

Страница 17: ...by trained personnel authorized by Honeywell The appropriate personnel have the expertise set out in Annex A of EN IEC 60079 14 or has comparable expertise including General safety rules Care and use of reasonable safety equipment Electrical safety and explosion protection rules Working on electrical circuits for systems with potentially explosive atmospheres Working with high pressures and aggres...

Страница 18: ...re therefore additional warning signs on the housing The figure below shows the possible locations on the device and an example of a warning in English and French on an additional label The safety instructions for opening the device can be found on the top of the hood The gas inlets and outlets are also labelled with details of the maximum pressure values Figure 2 1 Warning and information labels ...

Страница 19: ...lusion of oxygen i e acetylene C2H2 Il n est pas autorisé de connecter des gaz inflammables ou explosifs à l exception de l oxygène par exemple l acétylène C2H2 ATTENTION Only natural gas and gases similar to natural gas all components in gaseous form as specified in the technical specifications or approved calibration gases may be used in the specified pressure range For other gases and pressures...

Страница 20: ... over 40 m please contact your TAC Completely separate pipeline connection using the breather valve s internal thread CAUTION DO NOT CONNECT THE BREATHER VALVE S PIPELINE TO OTHER PIPELINES 2 5 Electrical information connecting with earth and emergency stop Reference is made to the appropriate technical regulations regarding the installation commissioning decommissioning and maintenance work in ge...

Страница 21: ...osphere The earth connection on the device together with other connections if necessary must be used for this purpose CAUTION This device must not be operated without an equipotential bonding system cable or earthing or if this connection has been intentionally broken No earth potential shift must take place ATTENTION The 24 V DC power supply including mains fluctuations of 15 must have a safe ele...

Страница 22: ...a combination of the two to comply with ISO IEC 60079 14 and ISO IEC 61010 1 Operating voltage of the isolating device at least 48 V DC This isolating device not supplied must be located close to the device to comply with explosion protection and electrical safety regulations thuscontributing to the formation of the power limited circuit The isolating device must also isolate all the power supply ...

Страница 23: ... Cable glands may only be used with cables which have the following properties Not sensitive to cold flow impermeable to air and at least three metres long only suitable if cable and cable gland are designed for temperatures of at least 70 C ne convient que si le câble et le presse étoupe sont conçus pour des températures de 70 C et plus Terminal boxes cable conduits if they are sealed within 1xD ...

Страница 24: ...ining explosion protection ATTENTION Please note The test certificate for this device describes all the conditions and regulations specified for the installation and operation of the device to maintain explosion protection ATTENTION Only qualified personnel may operate and maintain explosion proof devices These persons must only use explosion proof approved equipment and measuring instruments Do n...

Страница 25: ...that all the gas connections are sealed and the earthing or PE wire is correctly installed CAUTION Do not operate or use damaged devices or devices with modified housings or with an incorrect connection since explosion protection is no longer guaranteed in this case CAUTION Safety information on the device DISCONNECT POWER BEFORE OPENING DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE IS PRESENT CAUTION ...

Страница 26: ... Once the cap is removed from the base almost all the internal components are directly reachable The EnCal 3000 measuring unit includes the analytical components the stream selection and all the electronic components required for autonomous automated operation It can analyse up to 5 gas streams sequentiallyChanges in ambient temperature have no significant influence on the peak retention times The...

Страница 27: ... extreme environmental conditions Two analytical modules which do each a part of the total analysis in parallel Processor board Internal sample system stream selection and pressure regulation All electrical field connections Ethernet ModBus analogue IN digital I O solenoid drivers fuses switches and jumpers Explosion proof certified for ATEX IECEx NEC IP 66 ingress protection against dust and prec...

Страница 28: ... 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 passage through the column and elute as...

Страница 29: ...al dimensions of the used columns in the enCcal3000 have a length of several meters and internal diameters of 0 1 mm They are made of inert materials like fused silica and stainless steel Figure 4 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 exampl...

Страница 30: ...rement 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 th...

Страница 31: ...ice the normalisation 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 traditional fine mechanical t...

Страница 32: ... Differences in temperatue and thermal conductivity occur between them and let to changes in the electrical evaluation circuit which are analysed It results in the signal mountain known as the peak in the chromatogram The figure below shows examples of what chromatograms look like Figure 4 5 Chromatograms All the main gas components can therefore be recorded directly and can undergo further proces...

Страница 33: ...ble CAUTION When the device is open there is a risk of damaging the internal components and thus generating safety problems and malfunctions You should therefore complete the work with the appropriate care and always obey the explosion protection regulations The open housing provides a view of the layout of the main components and internal parts The skid is designed to secure the various component...

Страница 34: ... has to be removed from the enclosure base first This arrangement permits the service engineer to easily review the board in case malfunctions would occur 5 1 The Channel A channel consists of the following subcomponents Analytical Module This is the heart of the EnCal 3000 it contains the column sample injector detector and the heaters for the columns and the injector AMI Analytical Module Interf...

Страница 35: ...B 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 biogas is M5A column molesieve 10m long for the analysis of H2 O2 and N2 PPU column 10m long for...

Страница 36: ...s not necessary within a year calibration cycle As the capacity of the attached filter is very low the filter should be changed with each recalibration For the carrier gas argon always an additional external humidity filter should be used Figure 5 2 Overview of Channel Components The next page shows the internal gas flow configuration of the channels ...

Страница 37: ...RIOR WITH MAJOR INTERNAL COMPONENTS EnCal 3000 Hardware Manual 73022344 o 37 Figure 5 3 Internal Gas Flow Circuit for each Analytical Channel of the EnCal 3000 during Normal Operation top and sample Injection below ...

Страница 38: ...mn 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 Figure 5 4 In...

Страница 39: ...components of the board are Arm9 Processor A Flash Memory 32 MB for local data storage The Ethernet Port Data communication ports COM1 4 for serial Modbus Analogue and Digital I O USB Port I O Controller for Communication to the analytical channels Pressure and Temperature Sensor Figure 5 5 Processor Board connections ...

Страница 40: ...n Jumper is at the same position for the all mainboard types see following figure 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 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 ...

Страница 41: ...the data communication signals Also 2 fans can be mounted to cool the processor in case of elevated ambient temperatures Figure 5 7 Processor board with ribbon flat cables mounted in the EnCal 3000 5 3 Interconnection Board This board in all variations has the following functions Power supply input 24 VDC DC DC converter Connection of Processor Board with Analytical Modules Field data communicatio...

Страница 42: ...Cal 3000 Hardware Manual 73022344 o 42 Figure 5 8 Interconnection Board in different variations The following diagram shows the overall electrical configuration EnCal3000 in a rough overview Figure 5 9 Overall Electrical Configuration of the EnCal 3000 ...

Страница 43: ...lection 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...

Страница 44: ...l valves mounted on the manifold The two most right valves are purge valves The upper purge valve is the sample bypass valve Activated by timed relay 2 The lower is a helium purge valve and activated by timed relay 3 The stream and calibration valves form pairs that are actuated at the same time The valves left from the purge valves are used for the calibration Next to the calibration valves there...

Страница 45: ...umes are refreshed Actuating the bypass valve results in a flow that is approximately 15 times higher than the normal flow The purge valve should be activated for a short period 30 seconds default when a new stream is selected If there is a long sample line between the sample point and the Encal or there is a relatively high pressure in this line the bypass time can be increased up to 150 seconds ...

Страница 46: ...adjusted upstream of the sample gas inlet The streams of gas are measured in sequence Gases which have passed through the device are fed into the waste gas The carrier gas and calibration gas are generally supplied from gas cylinders with pressure reducers installed near the device These auxiliary gases are used to maintain operation and measurement accuracy The gas supply will generally last for ...

Страница 47: ...safely and without problems Always observe the general safety rules particularly in a potentially explosive atmosphere Always use a gas detector for your own protection to check your respiratory air for toxic or explosive gases when you are working on the device in areas where such hazards exist Do not carry out any unauthorized modifications or technical changes ATTENTION If the product is modifi...

Страница 48: ...the gas connections or a radius of 225 mm around the centre of the cover Select an installation height between 1 00 m and 1 50 m above the floor which is suitable for maintenance work We recommend that you use larger gaps to make installation and maintenance work easier The following sketch shows these requirements Figure 6 2 Minimum installation gaps ...

Страница 49: ... in bold Some of them will change depending on the types of fluid and electrical couplings used Figure 6 3 Side view with dimensions without couplings and connections ATTENTION 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 sho...

Страница 50: ...e and installation site protection from environmental influences etc CAUTION Obey the explosion protection rules at all times when working with tools or on items in hazardous zones The EnCal 3000 must be installed as close as possible to the process gas sampling point to avoid having long supply lines and to ensure that you obtain current measurements ...

Страница 51: ...sure that the installation surface is strong enough to support it The EnCal3000 can be installed on a flat vertical surface wall measuring board or on a horizontal surface Use the fastening holes provided in the housing and if necessary additional mounting plates as shown for this purpose The drawings below and to the side show the various installation options For example the measuring unit can be...

Страница 52: ...less operation will only be guaranteed if the device is installed in the correct position Figure 6 6 Installation options 2 6 3 3 Assembly hints The generally accepted rules of engineering for handling gases and or electronic components must be followed when carrying out the replacement work described below Many components are assembled with screws Ensure that these screws are securely tightened A...

Страница 53: ...k that connectors and screws are secure when all the work has been completed Reassemble the device fully and fit the hood 6 4 Electrical installation The device does not have its own off switch To comply with Electrical Safety Standards IEC 60947 1 and IEC 60947 3 an external external off switch not supplied has to be located close to the analyser enabling an operator to close down the unit in cas...

Страница 54: ... equipotential bonding system If other metal parts are connected to the device during the installation work they must be expertly included in the earthing and the equipotential bonding system Use the appropriate connections or install such connections The device will only operate correctly if all the system parts have the same earthing potential The wire cross section for earthing is 6 mm copper w...

Страница 55: ...on regulations they must be installed and sealed in their function as securing parts as specified by the manufacturer of the cable glands The M25 cable glands used as standard are suitable for reinforced cable with a diameter of 11 17 mm while the M20 cable end glands can be used for reinforced cable with a diameter of 6 12 mm The following cable properties are required in order to comply with the...

Страница 56: ...hen be cut and can no longer be used The replacement and extension of the electrical connections involve similar work to a new installation Proceed as described and in any event obey the explosion protection regulations ATTENTION Use only suitable and approved cable inlet equipment The cable inlets must satisfy or exceed the IP rating NEC compliant cable inlet equipment must be used in the USA CEC...

Страница 57: ...2 5 4 mm can be used for the power supply The use of an external junction box is responsibility of the customer installer Armoured cable required for outdoor installation OD between 12 and 25 mm Power rating 24 VDC 120 W max nominal ambient T 0 C or 32 F The cable cross section must be chosen sufficiently large A maximum rated operating current of 5 A should be considered for the power supply Reme...

Страница 58: ...ently user configurable into RS 232 or 485 Pin lay out and link locations see figures 5 8 and 5 9 6 4 2 Making the electrical and signal connections ATTENTION The following work cannot be carried out without opening the housing Please contact your TAC if you are not authorized to open the device ATTENTION The integrated circuits can be destroyed by electrostatic discharge When working on the devic...

Страница 59: ... the fuse also triggers and must be replased This protective equipment thermal trips and electrical fuses cannot be accessed without opening the housing Please contact your TAC if you are not authorized to open the housing and replace the protective equipment ATTENTION When making the contact and selecting the fastening materials comply with the appropriate regulations for example IEC EN 60079 14 ...

Страница 60: ...ottom of the unit It contains all the connectors for external cables marked with grey For flame retardant wiring use cables according an ISO norm To fulfill the FM regulations always use cables wiring according to UL94 V 1 or equal for installation All the wiring with the other electronic boards is done in the factory and may not be changed during field installation Figure 6 10 Interconnection Boa...

Страница 61: ... VDC J10 Analogue inputs 0 10 V DC J11 Solenoids terminal for valves of stream selection 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 valves internal current supply circuit J15 Digital Inputs passive contact J17 Fan1 power supply connection 12 V DC J18 Fan2 power supply connection 12 V DC J19 Input F106 Fuse analytical channels Module 6 ...

Страница 62: ...ection 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 Figure 6 11 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 wires connected to connect...

Страница 63: ...s 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 Figure 6 13 Location of Serial ModBus connector J6 Figure 6 14 Modbus Connection and Link settings ...

Страница 64: ... bottom of the unit It contains all the connectors for external cables For flame retardant wiring use cables according an ISO norm To fulfill the FM regulations always use cables wiring according to UL94 V 1 or equal for installation All the wiring with the other electronic boards is done in the factory and may not be changed during field installation Figure 6 15 Interconnection Board V2 x top vie...

Страница 65: ...uts 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 parameterization of the regulation for the internal heating J18 Connection for temperature sensor for regulation of the internal heating J19 Connection of over temperature protection for internal heating J20 23 P...

Страница 66: ...tion 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 Figure 6 16 Location of Power Supply connector J14 Ethernet connection The Ethernet connection is used for connection with a PC or ModBus TCP IP clients It uses 4 wires connected to connecto...

Страница 67: ...HARDWARE INSTALLATION EnCal 3000 Hardware Manual 73022344 o 67 ...

Страница 68: ...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 LK1 3 and LK4 6 see pictures below for location wiring scheme and link settings Figure 6 18 Location of Serial ModBus connector J8 Figure 6 19 Modbus Connection and Link settings ...

Страница 69: ...s have been dealt with correctly and routed safely 2 The supply voltage is 24 V DC 15 is available after switching on the terminals on the terminal board 3 A rating of up to 120 W can be supplied Connect a load resistor in parallel if necessary 4 Cause a short circuit and the supply voltage must be switched off within 120 seconds 5 Check all switches and fuses outside the device Is everything acce...

Страница 70: ...te by external protection which is not part of the device Refer to the information in chapter 2 4 when settingthe maximum pressure The required pipelines and safety devices must be fitted to comply with current general regulations and the specifications in this manual 6 5 1 Fluid connections The device has multiple gas connections for various functions They are always fitted by the manufacturer Al...

Страница 71: ...sured sample gas is released at ambient pressure Carrier 2 AR Argon 5 6 barg 71 86 PSIg Recommended pressure 5 5 barg Left hand side penultimate connection Second carrier gas only needed to analyse biogas or hydrogen in natural gas In standard applications this connection is not used and closed without piping inside Purge vent PV Left hand side last connection Flushing or bypass gas is released at...

Страница 72: ...red as the particulate filters in the adapters are only designed to protect the device The breather valve also known as a vent valve or short breater on the rear of the housing is used to allow an atmospheric pressure equalization process between the interior of the device and the ambient area so as to comply with the ATEX regulations These state that the gauge pressure inside the housing must not...

Страница 73: ...ich come into contact with gas must be free of grease oil solvents and other impurities Gases must not be contaminated or falsified when being transported from the source pipeline or cylinder to the measuring instrument This applies to all gases Route the gas pipelines to the measuring instrument Use the pipework diagram specified and prepared by the system operator Ensure that every pipeline and ...

Страница 74: ... specifications Steps to prepare the process gas sampling li Steps to prepare the process gas sampling li Steps to prepare the process gas sampling li Steps to prepare the process gas sampling line ne ne ne 1 Ensure that there is a shut off valve in the process gas pipeline system Check that the shut off valve is closed A suitable pressure regulator may also be required If there is a pressure regu...

Страница 75: ...device 3 Since itis notpossibletoconducta tightness test when the device is switched off the waste gas line mustbe checkedforleaks with a gas detector during the flushing cycle This test must be carriedoutfirst of all once the devicehas been installed and is operating Steps to connect the measuring instrument to the process gas pipeline Steps to connect the measuring instrument to the process gas ...

Страница 76: ...t first of all when the device is running 6 5 2 Configuration with two Carrier Gases For some applications like the analysis 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 second module from type PPU Helium is used as carrier gas In the following pic...

Страница 77: ...CAUTION Always follow the steps of the cylinder change according to local regulations and the working steps in the Operating Instructions Suivez toujours les étapes du changement de cylindre établies selon les normes locales en respectant les étapes de travail inscrites dans les instructions de ce manuel Failure to comply may result in substantial damage to the device or the station Le non respect...

Страница 78: ... 3 to the valve connector on the gas cylinder Do not apply any oil or grease to the thread 11 Ensure that the reconnected controls are closed 12 Ensure that gas can flow in the parts you wish to flush For this purpose disconnect the pipeline immediately upstream of the device while the gas cylinder is closed Ensure that the flushing gas is discharged safely via a flow indicator 13 Now slowly open ...

Страница 79: ...ntire system is tight and item 4 no longer applies 7 Commissioning and decommissioning CAUTION This should be done by an experienced technician with a proven knowledge of electrical installations in explosion proof areas Always remember to make sure there is no hazardous condition present during installation Follow the instructions below carefully and make sure you have fulfilled all necessary saf...

Страница 80: ...l can provide the required device specific service and commissioning training If the device is used for fiscal measurements the presence of a calibration officer or its representative is required for the final commissioning of the device In this case the conditions set out in the relevant approval must also be satisfied For official fiscal operation make sure that you also comply with the current ...

Страница 81: ...before connecting to the EnCal 3000 for about 30 s Make the connection with Helium inlet Check for leaks Make sure the cal gas cylinder is tightly secured to the wall and the regulators tightly mounted on the cylinder Check the cal gas certificate The tube should be flushed once before it is connected to the Encal3000 with a non flammable gas like the carrier gas Helium Open carefully the cal gas ...

Страница 82: ...on regulations Obey the explosion protection regulations Obey the explosion protection regulations Obey the explosion protection regulations 1 Open the carrier gas cylinder setting 0 55 MPag 2 Open the process calibration gas cylinder setting 0 4 MPag 3 Open the process gas recommended setting 0 2 MPag 4 Switch on the power supply 5 Connect with RGC 3000 future steps in software manual The unit wi...

Страница 83: ...ttings must be repeated If the device is not working well after you have made changes an extended complete check of the current device parameters is required This can be carried out according to the hints in the software manual For example you must check and adjust the bespoke alarm limits and settings for the sequence of sample gases and the calibration and protocol settings Parameterized output ...

Страница 84: ...ions losion protection regulations 3 Allow the device to cool to ambient temperature and disconnect all the gas pipelines at the couplings Immediately seal all outlets and inlets 4 Cut all the cables near the cable glands in an area which does not contain a potentially explosive atmosphere and remove the device mechanically 5 Comply with the storage and disposal instructions regardless of whether ...

Страница 85: ...h to use the device again at a later time or return it to the manufacturer transport guard blind plugs covers etc 8 Maintenance and repair As the operator you are responsible for ensuring that the installation and maintenance work described in this document is carried out correctly Honeywell will be delighted to help you with this work Please contact your TAC To ensure long term use in addition to...

Страница 86: ...rocess gas or sample gas is available at the correct pressure 2 Check that the carrier gas is available at the correct pressure 3 Check that the calibration gas is available at the correct pressure 4 Check that the waste gas line is not blocked 5 Check that the supply voltage is available with the correct values 6 Check the supply cables and the housing earth 7 If you can t fix the faults with ite...

Страница 87: ...necessary safety precautions Do not disconnect cable inlets in a potentially explosive atmosphere Do not loosen or unscrew the breather valve Only carry out work after disconnecting the power supply and depressurizing the system the gas atmosphere must not be potentially explosive Protect all open pipelines and connections from dirt Before the device is switched on again ensure that all the gas co...

Страница 88: ...ble pressure 5 Discharge the flushing gas properly ATTENTION Use suitable gas detectors for the tightness test These must reliably display even very small quantities of the possibly leaking process calibration and carrier gases 8 1 2 Troubleshooting in the electrical supply and insulation You can take the following action if an error occurs in the electrical power supply rectification of the fault...

Страница 89: ...ut connections Replace or repair the electrical supply if it is defective 5 Check that the connection between the device and the equipotential bonding system is OK no interruptions in the wiring Ensure that a low resistance electrical contact is established Reconnect the earthing cable if necessary 6 Only with authorization and in compliance with explosion protection procedures Measure the incomin...

Страница 90: ...example IEC EN 60079 14 must be followed to the letter In addition the operator must check the function of all safety devices regularly even outside the maintenance interval if necessary The best thing for cleaning the device is a damp cloth with a mild detergent solution or a mild cleaner such as those used for household purposes CAUTION Do not use any equipment for cleaning which charges statica...

Страница 91: ...auges Note you can empty the cylinder up to a minimum pressure of 1 MPa but the cylinder must then be replaced regardless of the maintenance interval Replace the auxiliary gas cylinders if necessary 7 Check the inlet pressures 8 Optional check the flow rates If you have flow meters available compare the current values with the values obtained during commissioning If they are different readjust the...

Страница 92: ...stem for leaks using a gas detector 4 If you identify a leak it must be sealed immediately Shut off the gas supply for this purpose Seal the leak Repeat the test described in step 3 5 Do not complete any further action or work before the entire system is tight and item 4 no longer applies Tips to seal the leak If you identify a leak it must be sealed You have some options to do this Replace the se...

Страница 93: ...o the minimum the cylinder must be replaced independently of the maintenance work if necessary 5 Please notify your TAC if you require a new gas cylinder You may use the device without calibration gas but not without carrier gas In this case the results are less accurate 8 2 4 Checking the inlet pressures visual inspection Step Step Step Step Action Action Action Action Reading the gauges Reading ...

Страница 94: ...nd adapters The inlet filters should be inspected at regular intervals to prevent errors caused by blockages If they must be replaced despite the upstream external filter system proceed as follows Steps to replace an inlet filter Steps to replace an inlet filter Steps to replace an inlet filter Steps to replace an inlet filter Obey the explosion protection regulations Obey the explosion protection...

Страница 95: ...d 8 2 8 Inspecting the interior of the housing CAUTION The housing hood may only be removed in a non hazardous area in controlled conditions as described in ISO IEC 61010 1 If it is not possible to establish these conditions on site the complete device must be removed while it is still sealed Step Step Step Step Action Visual inspection of device interior Action Visual inspection of device interio...

Страница 96: ...ty or blocked The breather valve must be removed for this purpose This is only allowed in controlled conditions outside the Ex Zone as described in ISO IEC 61010 1 Step Step Step Step Action Action Action Action Cleaning the breather valve vent line Cleaning the breather valve vent line Cleaning the breather valve vent line Cleaning the breather valve vent line 1 Disconnect the gas and voltage sup...

Страница 97: ...placement parts for general maintenance work The device requires hardly any consumables and has hardly any wear parts Honeywell therefore recommends the annual inspection primarily for preventive reasons and to replace the auxiliary gases if they are close to being empty and to identify errors Our contact details can be found at the start of this manual Spare and replacement gases can also be orde...

Страница 98: ...d damage Depending on the nature of this work it may require the housing to be opened or the device to be completely dismantled or returned to the manufacturer The required work with the exception of the complete replacement of the device may therefore only be carried out by Honeywell service staff or by personnel trained by Honeywell For example the housing can only be repaired by the manufacture...

Страница 99: ...om or contact your Honeywell Technical Assistance Center TAC 9 1 2 Implement stringent password guidelines Since various types of attacks on passwords take place these days Honeywell recommends that best practices for password management are used Here are a few time tested methods Always change standard passwords Use secure passwords When assigning passwords always use a combination of upper and l...

Страница 100: ...atory illustration Protocol Protocol Protocol Protocol Standard Standard Standard Standard port port port port Description Description Description Description HTTP 80 Hypertext Transfer Protocol allows for example access to an enCore device via the remote operation panel MMS 102 Manufacturing Messaging Specification pursuant to ISO standard 9506 allows communication between enSuite and enCore devi...

Страница 101: ... 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 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 course also be used The picture below s...

Страница 102: ...s 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 Figure 9 3 Typical Data Communication Set up for TCP IP combined with Serial ModBus Communication with the EnCal 3000 ...

Страница 103: ...h 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 dial in capability Or by using the internal modem of th...

Страница 104: ...w shows the ModBus Configuration screen for the EnCal 3000 see also Software Manual Figure 9 5 ModBus Configuration Screen The ModBus registers are user configurable Figure 9 6 ModBus Register Details For further details concerning the Modbus communication please refer to the Software Manual of RGC 3000 ...

Страница 105: ...x Height 70 cm Ø 20 x Height 28 Weight 28 kg Approvals ATEX II 2 G Ex d IIC T6 Gb and IECEx Ex d IIC T6 Gb ATEX EN 60079 0 2012 EN 60079 1 2014 IECEx IEC 60079 0 2011 Sixth edition IEC 60079 1 2014 seventh edit INMETRO NEC Class I Div 1 Groups B C D NEC Class I Zone 1 AEx db IIC T6 Mechanical strength Vibration and shock test to IEC 60068 2 31 and 64 Enclosure IP 66 Electrical Electrical Safety De...

Страница 106: ...r intervention Calculations to ISO 6976 GPA 2172 or GOST 22667 PC RGC 3000 Windows based program for configuration diagnostics and report generation Compatible with Windows XP Vista 7 10 Data Logging History Log local storage of last 35 days of all analytical data analysis events alarms averages last chromatogram calibration data according to API Report 21 1 All data available on remote workstatio...

Страница 107: ...biogas N2 0 005 15 CH4 60 100 CO2 0 001 10 C2 0 001 14 C3 0 001 6 C4 0 005 3 H2 0 001 5 O2 0 005 4 H2S 0 0002 1 COS 0 0001 1 Uncertainty 0 1 for all calculated properties Repeatability 0 005 RSD for all calculated properties Detection limit for C5 1 ppm Detection limit for C9 2 ppm Ambient conditions Ambient pressure Atmospheric pressure Temperature range for devices with ATEX IECEx Approval 0 C t...

Страница 108: ...elative deviation for each component Supply pressure 1 to 4 barg nominal Pressure peak protection up to 4 barg Flow 30 ml min Ensure that only suitable standard compliant types are used if you do not source them from Honeywell Cylinder pressure greater than 1 0 MPa g required At a pressure below 2 MPa keep a replacement cylinder available Other accessories required pressure regulators and connecti...

Страница 109: ...e sample gas inlets on the right hand rear base area This information must be noted and ob eyed in all circumstances If the main type label cannot provide suffi cient space for all the details the additi onal details can be read off an additional type label which is also affixed to the housing base The figure shows the positions of the type labels Figure 11 1 Positions of the type labels ...

Страница 110: ... use for the device The language and specified standards or regulations will be adjusted accordingly The details on the affixed label or labels apply at all times and exclusively to the device These labels always contain the following data possibly spread over multiple labels Example Example for Type plate for devices with FM Approval for Group C and D ...

Страница 111: ...PLATES EnCal 3000 Hardware Manual 73022344 o 111 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 ...

Страница 112: ...at when the internal enclosure temperature goes below 10 C 50 F Figure 2 10 shows the location of the cabinet heaters Figure 11 2 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 Inte...

Страница 113: ... the protection activates more than once please contact Elster for an intervention See below for an overview of the heater schematic 11 2 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 componen...

Страница 114: ...r board This System is especially developed for extended analysis applications which cannot be solved with just two channels Figure 11 4 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 connection The right housing further referred as Master unit...

Страница 115: ...refore no additional stream selection is needed The required gas connections between the two housings are preinstalled 11 4 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 the housing clean However with hydrogen we canno...

Страница 116: ...arations Since the device is used in different areas and regions not all certificates are always appropriate Current versions can always be found in our Docuthek www docuthek com The documents for the Encal3000 chromatograph can be found at the following link http docuthek kromschroeder com documents index php menuid 31 topmenu 3 1 lang en selclass sellang folder 400079 ...

Страница 117: ...4 psi C2H6 Ethane C3H8 Propane CH4 Methane CO2 Carbon dioxide CPU Central processing unit d Relative density density ratio of fuel and air DBB Double block and bleed valve block technology DC Direct current DHCP Dynamic Host Configuration Protocol DIN Deutsches Institut für Normung e V German Institute for Standardization EN European standard EN IEC 60079 14 Standard on explosive atmospheres EPC E...

Страница 118: ...f the mixture m or mm Length in SI unit metre 1 m 1000 mm 39 73 in 39 73 MEMS Micro electro mechanical system MLC Multi level calibration MPa Megapascal pressure 1 MPa 10 bar 145 04 psi MPag Gauge pressure in megapascals N2 Nitrogen gas component NC Switch output which is closed when de energized NC contact n C4H10 n butane n C5H12 n pentane NEC National Electrical Code USA neo C5H12 Neopentane NO...

Страница 119: ... ppm Parts per million RS 485 Interface standard for cable based differential serial data transfer SELV Safety extra low voltage SLC Single level calibration TAC Honeywell Technical Assistance Center TCD Thermal conductivity detector TCP Transmission Control Protocol Internet VDE German Association for Electrical Electronic Information Technologies WEEE Waste of Electrical and Electronic Equipment...

Страница 120: ...eather valve also known as the vent valve or flame barrier is designed to equalize the pressure on explosion proof housings during operation This pressure equalization device is required during operation and must not be sealed Calibration gas is kept in a cylinder permanently connected to the device and is an integral part of the measuring instrument This is a mixture with officially defined prope...

Страница 121: ...stamp and recorded in the logbook Gas chromatograph or process gas chromatograph is a measuring instrument which uses gas chromatography In an industrial version it is the low maintenance and explosion proof upgrade of the measuring instrument known as a process gas chromatograph Gas chromatography Process which allows the separation of a mixture of gaseous substances due to the differing distribu...

Страница 122: ...ential bonding system Place of use or installation site is the room or position at which the measuring instrument is located It must satisfy the defined requirements of the manufacturers authorities and operators Power limited circuit A power limited circuit is a circuit separated from other circuits by at least BASIC INSULATION in which the direct voltage U is no greater than 60 V The current whi...

Страница 123: ... format for displaying time stamps depends on the language selected on the device for example YYYY MM DD hh mm ss or DD MM YYYY hh mm ss Trained personnel is the designation for a person who as a result of their technical training possesses skills and experience and who is familiar with the relevant standards and regulations Trained personnel can assess their work and identify possible dangers Har...

Страница 124: ...es using a standard TCP IP network Lower heating value Hi Colloquially energy content or energy value is a heat variable In contrast to the higher heating value all the combustion products are in gaseous form This is why the higher heating value is higher than the lower heating value The lower heating value is quoted as a mass related heating value for example in kilojoules per kilogram in kJ kg o...

Страница 125: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 125 12 3 CERTIFICATE EC Type Examination ...

Страница 126: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 126 ...

Страница 127: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 127 12 4 DECLARATION OF CONFORMITY ENCAL 3000 ...

Страница 128: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 128 12 5 IECEx Certificate ENCAL 3000 ...

Страница 129: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 129 ...

Страница 130: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 130 ...

Страница 131: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 131 ...

Страница 132: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 132 12 6 FM Certificate of Conformity ...

Страница 133: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 133 ...

Страница 134: ...ANNEX EnCal 3000 Hardware Manual 73022344 o 134 ...

Страница 135: ...linder 76 92 Calibration officer 119 Carbon dioxide CO2 123 Carrier gas 76 81 107 119 Carrier gas cylinder 76 92 Checking the breather valve 95 Checking the device settings 82 Checking the digital communication 82 Checking the output signals 82 Chromatogram 119 Circuit breaker 22 Cleaning the breather valve 95 Cleaning the device 89 Commissioning 79 81 Commissioning requirements 80 Communication i...

Страница 136: ...on of the measuring instrument 74 Fluid installation 69 75 Flushing gas pipeline 73 Functional earth FE 9 Functional earthing point 54 Fuse 87 Fuses 22 Fuses internal 54 59 G Gas chromatograph 120 Gas chromatograph 6 Gas chromatography 120 Gas connection 69 72 Gas connections 25 105 Gas cylinder 76 Pressure monitoring 76 Residual pressure 76 Gas flow adjustment 82 Gas inlet 69 Gas pipeline 74 78 9...

Страница 137: ...k 98 99 Note 121 O Off switch 53 Opening the device 17 18 24 25 Operating gas 121 Operating requirements 80 Operating voltage 22 24 Operator 12 17 22 Operator license 86 Overcurrent protection 21 Overvoltage protection 21 54 59 P PA terminal 54 59 Password 98 Peak 123 PELV 22 121 Personal injury 13 Personnel authorized by Honeywell 19 23 Personnel authorized 17 25 Personnel selection 17 Personnel ...

Страница 138: ...s LED 122 Storage 10 16 82 Storage period 11 Storage rooms 10 Supplies check 89 Supply voltage 54 59 68 87 Switch 22 Switching on 86 Symbol 8 9 System operator 53 T Technical Assistance Center TAC 2 Technical data 104 Technical datacumentation 7 Temperature range 16 23 106 Test gas 122 Tightness test 74 75 78 86 91 Time stamps 122 Trained personnel 7 17 22 122 Transport guards 11 Transporting the ...

Страница 139: ...5 7 PROCESSOR BOARD WITH RIBBON FLAT CABLES MOUNTED IN THE ENCAL 3000 41 FIGURE 5 8 INTERCONNECTION BOARD IN DIFFERENT VARIATIONS 42 FIGURE 5 9 OVERALL ELECTRICAL CONFIGURATION OF THE ENCAL 3000 42 FIGURE 5 10 FRONT VIEW OF THE INTERNAL SAMPLING STREAM SELECTION SYSTEM 43 FIGURE 5 11 FLOW DIAGRAM SAMPLE CONDITIONING AND SELECTION SYSTEM 44 FIGURE 6 1 SYSTEM OVERVIEW 47 FIGURE 6 2 MINIMUM INSTALLAT...

Страница 140: ...P AFTER MOUNTING ON THE BASE82 FIGURE 10 1 EXAMPLE OF A ROUTER AND FIREWALL 100 FIGURE 10 2 TYPICAL DATA COMMUNICATION SET UP FOR ETHERNET COMMUNICATION 101 FIGURE 10 3 TYPICAL DATA COMMUNICATION SET UP FOR TCP IP COMBINED WITH SERIAL MODBUS COMMUNICATION WITH THE ENCAL 3000 102 FIGURE 10 4 REMOTE ACCESS TO THE ENCAL 3000 103 FIGURE 10 5 MODBUS CONFIGURATION SCREEN 104 FIGURE 10 6 MODBUS REGISTER ...

Страница 141: ...www honeywellprocess com EnCal 3000 pro Chain GC October 2018 2018 Honeywell International Sàrl www honeywellprocess com ...

Результаты поиска

Содержание ENCAL 3000

Отзывы:

Honeywell ENCAL 3000, Руководство по оборудованию, Страница: 1 / 141

Результаты поиска

Содержание ENCAL 3000

Отзывы: