Elster EnCal 3000 Quad Hardware Manual
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Elster EnCal 3000 Quad Hardware Manual

Elster EnCal 3000 Quad Hardware Manual

Gas chromatograph
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EnCal 3000 Quad
Gas Chromatograph
Hardware Manual
73022350 e 16.09.2014
___________________________________________________________________________________________________________
EnCal 3000 Quad – Hardware Manual
16/09/2014

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Summary of Contents for Elster EnCal 3000 Quad

  • Page 1 EnCal 3000 Quad Gas Chromatograph Hardware Manual 73022350 e 16.09.2014 ___________________________________________________________________________________________________________ EnCal 3000 Quad – Hardware Manual 16/09/2014...

  • 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 ..............6 Analytical Principle ..........................6 1.1.1 Column ..........................7 1.1.2 Detector ..........................8 1.1.3 Sample Injector ........................

  • Page 3: Contact Information

    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 your local agent: www.elster-instromet.com ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 3/51...

  • Page 4: Safety Information

    Elster GmbH 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 and IECEx In compliance with:...

  • Page 5: Gas Quality Measurement System Encal 3000 Quad

    Elster GmbH Gas quality measurement system EnCal 3000 Quad When running EnCal 3000 Quad is the meter is in two cases and can contain up to four analytical channels. It represents the actual process gas represents This option has been developed especially for extended analysis applications that cannot be solved with only two channels.

  • Page 6: 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 16/09/2014 6/51...

  • Page 7: 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 16/09/2014 7/51...

  • Page 8: 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 16/09/2014 8/51...

  • Page 9: 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 Injector ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 9/51...

  • Page 10: 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 11: 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 is especially developed for extended analysis applications which cannot be solved with just two channels.

  • Page 12: Enclosure

    Elster GmbH 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. Once...

  • Page 13: Assembly Of Major Components And Internal Components

    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 14: Channel

    This enables to swap to channels without a need for reconfiguration, uploading the internal settings is sufficient to fully install a new channel in an existing unit. 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 15 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 16/09/2014 15/51...
  • Page 16 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 16/09/2014 16/51...
  • Page 17 Pump sample valve 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...

  • Page 18: Processor Board

     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 dataflow block scheme until Dec. 2014 ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 18/51...
  • Page 19 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 16/09/2014 19/51...
  • Page 20 2-7 Save parameters in the measuring unit all bord 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.

  • Page 21: Interconnection Board

    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 Configuration of the EnCal 3000 Quad ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014...

  • Page 22: Electrical Connection To The Slave Unit

    The power connection to both units is made with a 3 way lever clamp terminal in the master unit. fig. 2-11 Wire Connection board for the Encal3000 Quad ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 22/51...

  • Page 23: Cabinet Heaters

    For the regulation of the heaters standard thermostats with a fixed setting are used. These thermostats are connected to the interconnection board close to the connectors for the power supply of the heaters (see also fig. 5.5, connectors J12 and J13). ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 23/51...

  • Page 24: Internal Sample System

    Helium the chance of internal damage is also reduced significantly. 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 16/09/2014 24/51...
  • Page 25 Elster GmbH fig. 2-14 Flow diagram Sample Conditioning and Selection System ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 25/51...

  • Page 26: Double Block And Bleed Function

    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 16/09/2014 26/51...

  • Page 27: 2.10 Gas Connections

    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. THE SOLDERED TUBE WILL BE DAMAGED!! THE JOINT BETWEEN CONNECTOR AND HOUSING IS AN INTEGRAL PART OF THE ENCAL 3000’s SAFETY...

  • Page 28: 2.11 Breather

    3/8 NPT connection. Any tube connected should have an internal cross section of at least 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 16/09/2014 28/51...

  • Page 29: 2.12 Cable Glands

    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 16/09/2014 29/51...

  • Page 30: Technical Specifications

    He : 0.001 – 1 % : 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 <...
  • Page 31 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 16/09/2014 31/51...
  • Page 32 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 16/09/2014 32/51...

  • Page 33: 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 connection with RGC 3000...

  • Page 34: 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 35: 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) Or through a VPN connection with the customer’s network, if the Ethernet switch or the local PC is integrated in...

  • Page 36: 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 37: Hardware Installation

    : 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 ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 37/51...

  • Page 38: 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 16/09/2014 38/51...

  • Page 39: 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 40: Connections To The Encal 3000 Interconnection Board

    RS232 and RS485 4 jumper for selection of analoge input streamselection(0-12 V DC) LK 305-308 Power supply heater 1 (24 V DC) (4-20 mA or 0-10 V) Power supply heater 2 (24 V DC) ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 40/51...
  • Page 41 The Ethernet connection is used for connection with a PC or ModBus TCP/IP clients. It uses 4 wires, connected to connector J10. See picture below for location and wiring scheme. fig. 5-7 Location of Ethernet connector (J10) and wiring scheme ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 41/51...
  • Page 42 RS232 or RS485 communication through link settings 301 to 304 (see pictures below for location, wiring scheme and link settings). fig. 5-8 Location of Serial ModBus connector (J6) fig. 5-9 Modbus Connection and Link settings ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 42/51...

  • Page 43: Hardware Start-Up

    3-wire for RS 232 communication  2 serial ModBus ports are available, each of them independently user configurable into RS 232 or 485 (Pin lay-out and link location see figures 5.8 and 5.9) ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 43/51...
  • Page 44 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 16/09/2014 44/51...

  • Page 45: Appendix 1: Zertifikates Encal 3000

    Elster GmbH APPENDIX 1: ZERTIFIKATES ENCAL 3000 ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 45/51...
  • Page 46 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 46/51...
  • Page 47 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 47/51...
  • Page 48 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 48/51...
  • Page 49 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 49/51...
  • Page 50 Elster GmbH ___________________________________________________________________________________________________________ EnCal 3000 Quad– Hardware Manual 16/09/2014 50/51...

  • Page 51: Appendix 2: Declaration Of Conformity Encal 3000

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

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