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Elster Instromet EnCal 3000 Quad Hardware Manual

Gas chromatograph
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EnCal 3000 Quad
Gas Chromatograph
Hardware Manual
73022350 g 22.06.2017
___________________________________________________________________________________________________________
EnCal 3000 Quad – Hardware Manual
22/06/2017

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Summary of Contents for Elster Instromet EnCal 3000 Quad

  • Page 1 EnCal 3000 Quad Gas Chromatograph Hardware Manual 73022350 g 22.06.2017 ___________________________________________________________________________________________________________ EnCal 3000 Quad – Hardware Manual 22/06/2017...

  • Page 2: Table Of Contents

    Elster GmbH Contact Information ............................3 Safety Information ............................4 Gas quality measurement system EnCal 3000 Quad ................... 5 Process Gas Chromatography – General Introduction ............... 7 Analytical Principle ..........................7 1.1.1 Column ..........................8 1.1.2 Detector ..........................9 1.1.3 Sample Injector ........................

  • Page 3: Contact Information

    Elster GmbH (Manufacturer) Steinern Str. 19-21 55252 Mainz-Kastel / Germany Phone: +49 6134 605 0 Info@elster.com Email: www.elster-instromet.com Website: Technical Assistance Center: Phone: +49 231 93 71 10 88 support@elster.com Email: www.elster-instromet.com Website: ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 3/52...

  • Page 4: Safety Information

    Safety Information Electrical Safety The EnCal 3000 Quad is a gas analyser designed to be installed in hazardous areas. For this purpose it is certified according to: ATEX II 2 G Ex d IIB T4 Gb and IECEx Ex d IIB T4 Gb...

  • Page 5: Gas Quality Measurement System Encal 3000 Quad

    Elster GmbH Gas quality measurement system EnCal 3000 Quad The EnCal 3000 Quad is a special version of the Encal3000. It contains two housings and can contain up to four analytical channels. This option has been developed especially for extended analysis applications that cannot be solved with only two channels.
  • Page 6 Elster GmbH Basic configuration EnCal 3000 Quad (Measuring unit and an optional Encal3000 controller) Fig. 1: Encal3000 Quad measuring system ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 6/52...

  • Page 7: Process Gas Chromatography - General Introduction

    The concentration of each component is then measured at the end of the column by a detector. From the knowledge of the concentrations of each component, any property of the gas can be calculated. ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 7/52...

  • Page 8: Column

    (for example type M5S / molesieve)  Porous layer open tubular column: the stationary phase is a porous layer on the inner wall of the column (for example type PPU) ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 8/52...

  • Page 9: Detector

    1 ppm for n-pentane. Traditionally the two TCD’s (reference + measurement detector) are integrated in a so-called Wheatstone configuration, which increases significantly the signal-to-noise ration of the measurement. fig. 1-3 Typical electrical TCD circuit ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 9/52...

  • Page 10: Sample Injector

    MEMS sample injector, etched in silicon channel, with membrane valves to control flow directions. This injector allows for a very precise control of the injection volume and temperature, on a remote base. fig. 1-4 MEMS Sample Injecto ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 10/52...

  • Page 11: Process Gas Chromatography

    The EnCal 3000 Quad is designed to meet or exceed all of the above requirements. At the same time the unit uses analytical technology which can compete with the highest standards used in the laboratory world, surpassing any PGC currently used in the natural gas industry.

  • Page 12: Functional Design

    Functional Design Introduction The Encal 3000 Quad is the combination of two housings in one measurement System. In the two housings is place for up to four analytical channels that are controlled by one processor board. This System has been especially developed for extended analysis applications which cannot be solved with just two channels.

  • Page 13: Enclosure

    The following paragraphs give a general description of the main parts of the measurement system. Enclosure The two enclosures of the Encal 3000 Quad are a custom EX design, with various specific features. Essentially the explosion proof enclosures are consisting of a low base, to which a relatively high cap is attached through a screw connection.

  • Page 14: Assembly Of Major Components And Internal Components

    This arrangement permits the service engineer to easily review the board in case malfunctions would occur. The detailed description of the functionalities of each component will be done in the following paragraphs. fig. 2-1 Exploded View on the Internal Parts of the EnCal 3000 Quad ___________________________________________________________________________________________________________ EnCal 3000 Quad–...

  • Page 15: Channel

    The Analytical Module uses different columns for different applications. In an EnCal 3000 Quad up to four columns can be selected, the following columns are possible: 1.) HSA-0,4m Channel for Nitrogen, Methane, Carbon Dioxide, Ethane and Ethylene...
  • Page 16 Elster GmbH fig. 2-2 Overview of Channel Components The next page shows the internal gas flow configuration of the channels. ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 16/52...
  • Page 17 Elster GmbH fig. 2-3 Internal Gas Flow Circuit for each Analytical Channel of the EnCal 3000 Quad, during Normal Operation (top) and sample Injection (below) ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 17/52...
  • Page 18 Sample vent Sample fig. 2-4 Internal Gas Flow Circuit for each Analytical Channel with backflush of the EnCal 3000 Quad, before activating backflush valve (top) and after activating backflush valve (below) ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 18/52...

  • Page 19: Processor Board

    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. ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 19/52...
  • Page 20 Elster GmbH fig. 2-6 Save parameters in the measuring unit When installed in the EnCal 3000 Quad, two flat cables are making the connection between the communication ports of the Processor Board and the Interconnection Board, which provides field connections (Phoenix connector) for the data communication signals.
  • Page 21 Elster GmbH fig. 2-7 Processor board with ribbon flat cables mounted in the EnCal 3000 Quad „Master“ ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 21/52...

  • Page 22: Interconnection Board

     Internal DC/DC conversion for various circuits fig. 2-8 Interconnection Board The scheme below shows the overall electrical configuration of the EnCal 3000. fig. 2-9 Overall Electrical Configuration of the EnCal 3000 Quad ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017...

  • Page 23: Electrical Connection

    Interconnection boards and in the device. Above the connection on the Interconnection Board is visible, the lower part of the figure shows the position of connection in the real device. fig. 2-10 Internal data connection for the Encal3000 Quad ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 23/52...

  • Page 24: Cabinet Heaters

    (see also fig. 5.5, connectors J20 - J23). They are located close to the connectors for the power supply of the heaters (see following figure). fig. 2-12 Power supply (white connectors) for cabinet heaters ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 24/52...

  • Page 25: Internal Sample System

    The purge and the small amount of helium that is vented into the housing also protects the internal components against moisture or other aggressive components entering the housing through the breather. ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 25/52...
  • Page 26 Elster GmbH fig. 2-14 Flow diagram Sample Conditioning and Selection System ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 26/52...

  • Page 27: Double Block And Bleed Function

    The sample gas flow can be also increased for the Slave Unit with an additional Purge Valve. The output gases from these channels are combined again and become transported to the SBV connection of the Slave Unit. ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 27/52...

  • Page 28: 2.10 Gas Connections

    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 3000 HOUSING.

  • Page 29: 2.11 Breather

    28mm² (3/8”) tube or larger. The breather should always vent atmospheric without large pressure fluctuations. The output of the breather must not be blocked because the valve would not function properly otherwise! ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 29/52...

  • Page 30: 2.12 Cable Glands

    "Disconnecting Device". Practical implementation of this requirement will differ from site to site. In any case the external switch installation has to comply with all national, local, and company codes applicable to the location. ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 30/52...

  • Page 31: Technical Specifications

    : 2 ppm Analysis time 5 minutes for C analysis or C analysis Temperature range 0°C to 55°C (32°F to 130°F), extendable to -40°C to 55°C (-40°F to 130°F) Approvals PTB Metrological Certificate ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 31/52...
  • Page 32 API Report 21.1. All data available on remote workstation in XML format Remote monitoring and trending of the system as an integral part of the Instromet Supervisory Suite ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 32/52...
  • Page 33 Gas connections Swagelok 1/8” or on request 3mm Electrical connections Power Supply M20/M25 cable gland for armoured cable Ø 11-17 mm / 17-26 mm Data Communication M20/M25 cable gland for armoured cable Ø 11-17 mm / 17-26 mm ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 33/52...

  • Page 34: Data Communication

    Data Communication Local TCP/IP Data Communication The main Data Communication Port of the EnCal 3000 Quad is the TCP/IP port, although 2 serial ModBus ports are also available (see next paragraph). The TCP/IP Port (Ethernet UTP 10 Base-T) is necessary for...

  • Page 35: 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 ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual...

  • Page 36: Remote Access

    Elster GmbH Remote Access The schematic below shows the different options for remote access to the EnCal 3000 Quad: Through Internet:  Or through a direct connection of the Ethernet switch with Internet (through cable or ADSL modem, or wireless) ...

  • Page 37: Modbus Communication

    Elster GmbH ModBus Communication The picture below shows the ModBus Configuration screen for the EnCal 3000 Quad (see also Software Manual) fig. 4-4 ModBus Configuration Screen The ModBus registers are user configurable: fig. 4-5 ModBus Register Details  Register Type: Either Read Only (R) or Read/Write (R/W), and either bit (Status) or register size ...

  • Page 38: Hardware Installation

    : 100 cm x 42 cm x H 70 cm (40" x 17” x H 28”) Installation Clearance 5.1.2 Installation clearance fig. 5-1 Mounting Dimensions and Installation Clearance I fig. 5-2 Mounting Dimensions and Installation Clearance II ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 38/52...

  • Page 39: Wall Mounting

    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 ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 39/52...

  • Page 40: Connection Of Utilities

    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 STR1 STR2...

  • Page 41: Connections To The Encal 3000 Interconnection Board

    LEDs Diagnostic of internal Heating and Vents LK1-6 Jumper-Connections for RS232 and RS485 24V Power Supply Connection LK7-12 Jumper-Connections for data communication J15-J16 Additional optional 24V supply cable between IC-Board and processor board ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 41/52...
  • Page 42 The Ethernet connection is used for connection with a PC or ModBus TCP/IP clients. It uses 4 wires, connected to connector J7. See picture below for location and wiring scheme. fig. 5-7 Location of Ethernet connector (J7) and wiring scheme ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 42/52...
  • Page 43 LK1 left RS232 Like shown in the above picture LK2 left RS232 LK3 left RS232 LK4 left RS232 LK5 left RS232 LK6 left RS232 fig. 5-9 Modbus Connection and Link settings (J8) ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 43/52...

  • Page 44: Hardware Start-Up

    Standard straight cable, shielded twisted 4 wire cable or industrial CAT5 quality. For the location of the Ethernet connector see figure 5.7.  Serial Modbus: Standard industrial data communication cable twisted pair  3-wire for RS 485 communication  3-wire for RS 232 communication ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 44/52...
  • Page 45 Apply power to the unit (24 VDC) by turning on the external switch. 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. ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 45/52...

  • Page 46: Appendix 1: Certificates Encal 3000

    Elster GmbH APPENDIX 1: CERTIFICATES ENCAL 3000 ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 46/52...
  • Page 47 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 47/52...
  • Page 48 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 48/52...
  • Page 49 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 49/52...
  • Page 50 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 50/52...
  • Page 51 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 22/06/2017 51/52...

  • Page 52: Appendix 2: Declaration Of Conformity Encal 3000

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

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