Elster EK280 User manual

3
Operating manual
Volume conversion device
EK280

Volume conversion device EK280
Operating manual: 73021209
Version: b
Issue date: 25.10.13
Software Version: 2.20 or later

General 3
Contents
1 General...................................................................................................... 7
1.1 Information about this manual ........................................................... 7
1.2 Warranty provisions ........................................................................... 7
1.3 Customer service ............................................................................... 7
1.3.1 Customer service and repairs ...............................................................7
1.3.2 Electronic hotline ...................................................................................8
1.4 Meaning of symbols ........................................................................... 8
1.4.1 Safety information .................................................................................8
1.4.2 Tips and recommendations ...................................................................9
1.5 Limitationof liability ............................................................................ 9
1.6 Copyright protection .......................................................................... 9
1.7 Scope of delivery ............................................................................. 10
1.8 Spare parts and accessories ........................................................... 10
1.9 Storage ............................................................................................ 11
2 Safet ...................................................................................................... 12
2.1 General ............................................................................................ 12
2.2 Intended use .................................................................................... 14
2.3 Personnel ......................................................................................... 14
2.4 Personal protective equipment ........................................................ 15
2.5 Specific risks .................................................................................... 16
2.6 Environmental protection ................................................................. 17
2.7 Operator's responsibility .................................................................. 18
3 Technical data ........................................................................................ 19
3.1 General data .................................................................................... 19
3.2 Power supply for EK280 without integrated power supply unit ....... 19
3.2.1 Battery power supply for the basic device ........................................... 19
3.2.2 Battery power supply for the integrated modem .................................. 19
3.2.3 External power supply for the basic device ......................................... 20
3.3 Power supply for EK280 with integrated power supply unit ............ 20
3.3.1 Battery power supply for the basic device ........................................... 20
3.3.2 External power supply ......................................................................... 20
3.3.3 Buffer batteries for the integrated modem ........................................... 20
3.4 Pressure sensor .............................................................................. 20
3.4.1 CT30 Type Pressure Sensor ............................................................... 20
3.4.2 Pressure Sensor Type 17002 .............................................................. 21
3.5 Temperature sensor ........................................................................ 22
3.6 Digital inputs .................................................................................... 22
3.6.1 LF pulse and signalinputs .................................................................... 22
3.6.2 HF pulse inputs (high frequency) ........................................................ 23

4 General
3.6.3 Encoder input ...................................................................................... 23
3.7 Digital outputs .................................................................................. 23
3.7.1 Nominal data ....................................................................................... 23
3.7.2 LF pulse or signal outputs ................................................................... 23
3.7.3 HF pulse outputs ................................................................................. 24
3.8 Interfaces ......................................................................................... 24
3.8.1 Serial optical interface ......................................................................... 24
3.8.2 Serial electrical interface ..................................................................... 24
3.8.3 Integrated modem ............................................................................... 24
3.9 Measurement conditions .................................................................. 24
3.9.1 Environment ........................................................................................ 24
3.10 Labeling ......................................................................................... 25
3.10.1 Type label of the volume corrector .................................................... 25
3.10.2 ATEX marking ................................................................................... 26
3.10.3 Device software identification ............................................................ 26
4 Construction and Function ................................................................... 27
4.1 External view ................................................................................... 27
4.2 Internal view ..................................................................................... 27
4.3 Short description .............................................................................. 28
4.4 Connections ..................................................................................... 28
5 Assembl , Connection and Putting into Operation ........................... 29
5.1 Assembly ......................................................................................... 29
5.1.1 Assembly on a gas meter .................................................................... 30
5.1.2 Assembly on a pipeline ....................................................................... 30
5.1.3 Assembly on a wall ............................................................................. 31
5.1.4 Three way valve .................................................................................. 31
5.2 Connection ....................................................................................... 32
5.2.1 Connecting the gas meter ................................................................... 33
5.2.2 Sealing the input terminals .................................................................. 35
5.2.3 Connecting the temperature sensor .................................................... 35
5.2.4 Connecting the pressure pipe ............................................................. 36
5.2.5 Connecting the power supply .............................................................. 37
5.2.6 Connect outputs of the EK280 ............................................................ 39
5.2.7 Earthing the EK280 housing ............................................................... 40
5.2.8 Earthing the cable connections of the EK280 ..................................... 40
5.2.9 Additional measures for installation in zone 2 ..................................... 41
5.3 Putting into operation ....................................................................... 41
5.3.1 Configuration of measurement parameters ......................................... 41
5.3.2 Sealing ................................................................................................ 51
5.3.3 Closing the housing............................................................................. 52

General 5
5.3.4 Verifying assembly and connection ..................................................... 52
6 Operation ................................................................................................ 53
6.1 Safety ............................................................................................... 53
6.1.1 Personal protective equipment ............................................................ 53
6.2 Operating personnel ........................................................................ 53
6.2.1 Instructed personnel ............................................................................ 53
6.2.2 Qualified personnel ............................................................................. 53
6.2.3 Calibration officers............................................................................... 54
6.3 Basic principles ................................................................................ 54
6.3.1 Display ................................................................................................ 55
6.3.2 Button functions .................................................................................. 56
6.3.3 Data recall, display navigation ............................................................. 57
6.3.4 Meaning of status symbols .................................................................. 58
6.3.5 Error messages when entering values ................................................ 59
6.3.6 Access rights ....................................................................................... 60
6.4 Data register content ....................................................................... 62
6.4.1 Access rights ....................................................................................... 62
6.4.2 "Main" register (main display) .............................................................. 62
6.4.3 "Cust." register (Customer) ................................................................. 64
6.4.4 "Admin" register (Administrator) .......................................................... 66
6.4.5 "Serv." register (service) ...................................................................... 67
6.4.6 "Ctrl." register (Control) ....................................................................... 67
7 Maintenance ........................................................................................... 70
7.1 Safety ............................................................................................... 70
7.1.1 Personnel ............................................................................................ 71
7.1.2 Personal protective equipment ............................................................ 71
7.1.3 Environmental protection ..................................................................... 71
7.2 Testing and changing device batteries ............................................ 72
7.2.1 Changing and connecting device batteries .......................................... 72
7.2.2 Entering the battery capacity ............................................................... 74
7.2.3 Display remaining battery power ......................................................... 75
8 Faults ...................................................................................................... 76
8.1 Safety ............................................................................................... 76
8.1.1 Personnel ............................................................................................ 76
8.1.2 Personal protective equipment ............................................................ 77
8.1.3 Improper elimination of faults .............................................................. 77
8.1.4 Behavior in the event of faults ............................................................. 77
8.2 Fault and other status messages .................................................... 78

6 General
9 Appendix ................................................................................................. 82
9.1 List of spare parts and accessories ................................................. 82
9.1.1 Fastening elements ............................................................................. 82
9.1.2 Pressure connections.......................................................................... 82
9.1.3 Temperature sensor pockets .............................................................. 83
9.1.4 Small parts and miscellaneous ........................................................... 83
9.1.5 Documentation .................................................................................... 83
9.2 EC Declaration of Conformity .......................................................... 84
9.3 ATEX Type Examination Certificate ................................................ 85
9.3.1 Zone 1 ................................................................................................. 85
9.3.2 Zone 2 ................................................................................................. 90

General 7
1 General
1.1 Information about this manual
This manual allows for safe and efficient use of the device.
Compliance with all safety information and instructions for use contained in this op
erating manual is a prerequisite for safe working processes and proper use of the
device. Furthermore, the valid guidelines, standards, local accident prevention regu
lations, and general safety regulations must be complied with for the respective ar
ea of application of the device.
This manual forms a constituent part of the product and must be stored within the
immediate vicinity of the device and be accessible to installation, service, mainte
nance, and cleaning personnel at all times. The graphic illustrations used in this
manual serve as a visual representation of the described processes and are there
fore not necessarily to scale and may deviate from the actual design of the device.
The data and material properties indicated serve as reference val-
ues. These must be verified on a case-by-case basis and adjusted
as necessary.
The EK280 Application Manual is available for you at .elster-
instromet.com/en/EK280.html (-> Documents) for the commission-
ing of the various communication and device applications.
1.2 Warrant provisions
The current warranty provisions can be found in the general terms and conditions
online under: http://www.elster instromet.com/en/AGB.html
1.3 Customer service
Our customer service team is responsible for providing technical information and
repairs. Our employees are constantly striving to acquire new information and gain
experience and these are both valuable sources for improving our products.
1.3.1 Customer service and repairs
 Tel. [phone] / 605 0
 Fax [phone] / 605 390
 E mail: [email protected]

8 General
1.3.2 Electronic hotline
In the event of faults, you can also contact the electronic hotline.
 Tel. [phone] / 605 123
 http://www.elster instromet.com/en/support_electronics.html
 E mail: [email protected]
1.4 Meaning of s mbols
1.4.1 Safet information
In this manual, safety information is denoted by the use of symbols. The safety in
formation is introduced by signal words which identify the level of risk.
This safety information must be complied with and care should be taken to prevent
accidents, personal injury, and material damage.
DANGER!
... indicates an imminently dangerous situation which, if not avoid
ed, could lead to death or serious injury.
WARNING!
... indicates a potentially dangerous situation which, if not avoided,
could lead to death or serious injury.
CAUTION!
... indicates a potentially dangerous situation which, if not avoided,
may lead to minor or slight injuries.
… indicates dangers resulting from electrical current. A non
compliance of the safety information poses a risk of serious or life
threatening injuries.
CAUTION!
... indicates a potentially dangerous situation which, if not avoided,
could lead to material damage.

General 9
1.4.2 Tips and recommendations
… provides useful tips and recommendations as ell as infor-
mation for ensuring efficient and smooth operations.
1.5 Limitationof liabilit
All of the information contained in this manual has been compiled under considera
tion of valid standards and regulations, the latest technological developments, and
our many years of experience and expertise. The manufacturer shall accept no lia
bility for damages resulting from:
 Non compliance of the manual
 Improper use
 Deployment of unqualified personnel
 Unauthorized modifications
 Technical changes
 Use of unauthorized spare parts
The actual scope of delivery may deviate from the information and graphics pre
sented herein due to special designs, the selection of additional ordering options, or
the latest technological developments.
The obligations stipulated in the delivery contract, the general terms and conditions
and delivery conditions of the manufacturer, and the statutory provisions valid at the
time of signing the contract, shall apply.
This manual should be read carefully before commencing all orks
on and ith the device, particularly before putting the device into
operation! The manufacturer shall accept no liability for damages
and losses arising from non-compliance ith the manual.
We reserve the right to make technical changes within the scope of improving usa
bility and further development.
1.6 Cop right protection
This manual is copyright protected and is intended for internal use only. A transfer
of this manual to third parties, a reproduction of any kind, whether partially or fully,
and the use and/or disclosure of its content, are not permitted without written con
sent from the manufacturer, except for internal purposes. Contraventions to this
provision shall result in damage compensation. We reserve the right to assert fur
ther claims.

10 General
1.7 Scope of deliver
The scope of delivery for the EK280 includes:
 Electronic volume conversion device EK280
 Dispatch list
 Design data sheet
 Manual
 Bag of accessories
1.8 Spare parts and accessories
WARNING!
Incorrect use of spare parts and accessories ma present a
risk to safet !
False or incorrect use of spare parts and accessories may impair
safety and lead to damage, malfunctions, or total failures.
Therefore:
– Only use original spare parts and accessories produced by
the manufacturer.
– The manufacturer should always be contacted in the event of
uncertainty.
A list of spare parts and accessories can be found in the appendix. Spare parts and
accessories can be ordered from an authorized retailer or from our customer ser
vice team directly.
The free "enSuite" program also belongs to the accessories for the EK280 and is
available under www.elster instromet.com. This can be used to program the EK280
volume conversion device via its data interfaces to perform advanced applications.
The EK280 can be supplied as a calibrated and non calibrated device and is also
available in a number of different models. Further details can be found under
www.elster instromet.com and in the "Assembly, Connection and Putting into Oper
ation" chapter.

General 11
1.9 Storage
CAUTION!
Exceeding or falling below the valid temperature range for the
batteries ma impair performance.
If the valid temperature range of the batteries during storage of the
device is exceeded or fallen below, the performance of the batter
ies may be impaired.
Therefore:
– For long periods of storage, please ensure that the valid tem
perature range for the fitted batteries does not fall below
25 °C or exceed +55 °C.
CAUTION!
Material damage caused b the formation of condensation.
Fluctuations in temperature during storage may cause condensa
tion to form. This may lead to subsequent malfunctions of the de
vice.
Therefore:
– After storage or transport in cold weather conditions or after
having been exposed to strong temperature fluctuations, the
device should slowly be adjusted to the room temperature be
fore being put into operation.
– If condensation has formed, wait at least 12 hours before put
ting the device into operation.
If the power supply to the device is interrupted during storage due
to the batteries being disconnected, the time and date have to be
reprogrammed.
The following rules apply for storage:
 The relative humidity should be a maximum of 93%.
 Do not store packages in the open air.
 The storage temperature should not fall below 25 °C and should not exceed
+55 °C.
 Avoid mechanical vibrations during storage of the device.

12 Safet
2 Safet
This chapter gives an overview of all of the most important safety aspects in order
to best protect personnel and to ensure a safe and smooth operation of the device.
A non compliance with the safety information and instructions for use specified in
this manual could result in serious damage.
2.1 General
The EK280 is an intrinsically safe device as per the ATEX Product Directive
94/9/EC and the ATEX Operating Directive 1999/92/EC EN, and is suitable for op
eration within the following explosive gas atmospheres:
 EK280 without integrated power supply unit or modem:
Zones 1 and 2 for gases in temperature class T4
 EK280 without integrated power supply unit and with modem:
Zones 1 and 2 for gases in temperature class T3
 EK280 with integrated power supply unit (with or without modem):
Zone 2 for gases in temperature class T6
Verification for use in zone 1 as per the respectively valid technical rules and stand
ards: see chapter 9.3: EC type examination certificate no. LCIE 11 ATEX 3027 X
DANGER!
Using the wrong model presents a risk of explosion!
The EK280 is available in different models for use in zones 1
and 2.
The model designed for zone 2 should not be used in zone 1 as
this presents a risk of explosion!
Therefore:
– Before installing the device in zone 1, please check that the
EK280 is suitable for use in zone 1.
– The EK280 should only be operated in zone 1, if category
"II 1 G" or "II 2 G" have been marked on the ATEX label.
– If category "II 3 G" has been marked on the ATEX label, the
EK280 should not be used in zone 1, but only in zone 2.
– The ATEX label is located on the top panel of the EK280 hous
ing.

Safet 13
DANGER!
The connection of non intrinsicall -safe or non-associated
equipment presents a risk of explosion!
Operating the EK280 in zone 1 and connecting devices which are
not certified as "associated equipment" present a risk of explosion.
Therefore:
– When using the EK280 in zone 1, it should only be connected
to certified associated equipment as per the ATEX Product Di
rective 94/9/EC.
– The EK280 should only be connected to the intrinsically safe
circuits of associated equipment whose electrical data corre
sponds to those requirements stipulated in the declaration of
conformity for the EK280 (see Appendix).
DANGER!
Using incorrect batteries presents a risk of explosion!
Connect only the prescribed Elster battery types to the device
(see chapter 9.1.4 .
When connecting and operating the EK280 in explosive gas at-
mospheres, the corresponding standards must be observed:
DIN EN 60079-0
DIN EN 60079-14
The device may only be used in zone 1 or zone 2, if installation
has been carried out according to the separate requirements
stipulated under DIN EN 60079-14 and the operating conditions
(see "Technical Data" chapter) as ell as the connection condi-
tions (see "Assembly, Connection and Putting into Operation"
chapter).
The device may be dangerous if unqualified personnel use it incorrectly or do not
use it according to its intended purpose.
 All of those persons who are charged performing works on or with the device,
must have read and understood the manual before commencing such works.
This shall also apply if the person in question has already worked with the same
or a similar device or has been trained by the manufacturer.
 Being familiar with the content of the manual is a necessary condition for pro
tecting personnel against risks, preventing errors from occurring, and therefore
ensuring a safe and smooth operation of the device.
 In order to avoid risks and to ensure optimal performance of the device, neither
modifications nor changes should be carried out without express consent from
the manufacturer.
 All operating instructions should be kept in a clearly legible condition on the de
vice. Damaged or illegible instructions should be replaced immediately.
 The setting values and value ranges specified in this manual should be com
plied with.

14 Safet
2.2 Intended use
This device is solely designed and constructed for the intended use described be
low.
The volume conversion device EK280 is used to convert the gas volume read from
a gas pipe under measurement conditions, into base conditions, as well as to allo
cate the measured quantities to tariffs. Furthermore, the device can also be used
to measure, record and monitor additional variables depending on the configura
tion set by the user.
Intended use also refers to compliance with all of the information contained in this
manual. Any use beyond the intended use and/or other types of use, shall be con
sidered as misuse and can result in dangerous situations. The manufacturer shall
not be held liable for any claims for damages resulting from misuse of this device.
WARNING!
Danger resulting from misuse.
Misuse of the device may lead to dangerous situations.
Therefore:
– Only use the device according to its intended use.
– Do not use the device to regulate the gas flow or other varia
bles affecting the gas volume in the entire system.
2.3 Personnel
WARNING!
Risk of injur to unqualified personnel.
Improper use of the device may lead to significant personal injury
or material damage.
Therefore:
– All works should solely be carried out by qualified personnel.
The following qualifications are used in the manual to denote different areas of re
sponsibility:
 Instructed personnel
will be informed of the tasks assigned to them and possible risks resulting from
inappropriate behavior, in a training session provided by the operator.
 Qualified personnel
who, on the basis of their specialist training, knowledge and experience, as well
as their awareness of the relevant statutory provisions, are in a position to per
form their assigned tasks on the device and are able to independently identify
and prevent possible risks.

Safet 15
 Gas specialists
who, on the basis of their specialist training, knowledge and experience, as well
as their awareness of the relevant standards and regulations, are in a position to
perform works on gas handling equipment and to independently identify possi
ble risks. The gas specialist will be specially trained in the respective area and
will be familiar with the relevant standards and regulations.
 Calibration officers
who, on the basis of their specialist training, knowledge and experience, as well
as their awareness of the relevant standards and regulations, are in a position to
perform the works subject to calibration regulations on gas handling equipment.
The calibration officer will be trained on works on devices and installations sub
ject to calibration regulations and will be familiar with the relevant standards and
regulations.
 Electricians
who, on the basis of their specialist training, knowledge and experience, as well
as their awareness of the relevant standards and regulations, are in a position to
perform the works on electrical installations and to independently identify and
prevent possible risks. The electrician will be specially trained in the respective
area and will be familiar with the relevant standards and regulations.
WARNING!
Risk to unauthorized persons!
Unauthorized persons, who do not meet the aforementioned criteria, will not be
familiar with the risks in the working area.
Therefore:
– Please keep unauthorized persons away from the working area.
– In cases of doubt, approach said person and direct them out of the working
area.
– Interrupt the works if unauthorized persons enter the working area.
Only those persons who can be trusted to reliably execute their works shall be au
thorized to work on or with the device. People whose reactivity is impaired, e.g. by
drugs, alcohol or medication, shall not be authorized to perform such works.
 When selecting personnel, please observe the valid age and professional guide
lines for all of the gas handling equipment.
2.4 Personal protective equipment
When working on the device inside a gas handling plant, personal protective
equipment must be worn to minimize risks to health.
 During works on the device, the necessary personal protective equipment must
be worn inside the respective plant at all times
 The notices relating to personal protective equipment mounted in the working
area must be followed at all times.

16 Safet
2.5 Specific risks
The residual risks arising from the risk assessment will be listed below. Please ob
serve the safety and warning information specified in the following chapters to re
duce risks to health and to prevent dangerous situations from arising.
WARNING!
Misuse of batteries ma present a risk of injur .
Special care must be taken when handling batteries.
Therefore:
– Do not throw batteries into the fire or expose these to high temperatures.
There is a risk of explosion.
– Do not charge batteries. There is a risk of explosion.
– Liquids that are produced as a result of misuse may lead to skin irritation.
Avoid physical contact with such liquid. In the event of contact, rinse with
large quantities of water. If the liquid enters the eyes, immediately rinse with
water for 10 minutes and seek medical attention.
WARNING!
Risk of fire from highl flammable substances!
Highly flammable substances, liquids or gases could catch fire and lead to seri
ous or fatal injuries.
Therefore:
– Do not smoke within the danger zone or within close proximity to this zone. No
naked flames or ignition sources are permitted within this zone.
– Have a fire extinguisher close to hand.
– Suspicious substances, liquids or gases should be reported to the responsi
ble member of staff immediately.
– Work should be stopped immediately in the event of a fire. You should leave
the danger zone until it is given the all clear.

Safet 17
2.6 Environmental protection
CAUTION!
Environmentall hazardous substances!
If environmentally hazardous substances are handled incorrectly this may cause
significant damage to the environment, particularly if they are improperly dis
posed of.
Therefore:
– The instructions below should be observed at all times.
– Appropriate measures should be taken immediately if environmentally haz
ardous substances are accidentally released into the environment. In cases
of doubt, please inform the responsible local authority about the damages.
The following environmentally hazardous substances are used:
 Batteries
Batteries contain toxic heavy metals. They must be treated as special hazardous
waste and be disposed of in municipal waste collection points or by a waste special
ist.

18 Safet
2.7 Operator's responsibilit
The device will be used in the commercial sector. The operator of the device will
therefore be subject to legal obligations concerning occupational safety.
In addition to the safety information contained in these instructions, the valid safety,
accident prevention, and environmental protection regulations for the area of appli
cation of the device, must be adhered to. In particular:
 The operator must ensure that the valid safety, accident prevention, and envi
ronmental protection regulations for the entire plant in which the device is being
integrated, are complied with.
 The operator must be familiar with the valid occupational safety regulations and
must also be able to conduct a risk assessment to determine risks arising from
the specific working conditions in the respective area of application of the de
vice. The operator must then implement this in the form of operating instructions
for the operation of the device.
 Throughout the entire life cycle of the device, the operator must determine
whether their prepared operating instructions are compatible with current regula
tions and amend these if and when necessary.
 The operator must clearly regulate and define responsibilities for the assembly,
connection, putting into operation, and maintenance of the device.
 The operator must ensure that all employees who use the device have read and
understood this manual. Furthermore, the operator must provide training to per
sonnel at regular intervals and inform them of the potential risks.
 The operator of the entire plant in which the device is to be integrated, must
provide personnel with the necessary protective equipment.
Furthermore, the operator is responsible for ensuring that the device remains in a
perfect functioning order at all times. The following therefore apply:
 The operator must ensure that the installation and maintenance works described
in this manual are carried out correctly.
 The operator must regularly have all safety mechanisms checked for their func
tionality and completeness.

Technical data 19
3 Technical data
3.1 General data
Data Value Unit
Width (incl. cable glands) 230 mm
Height (incl. cable glands) 180 mm
Depth 115 mm
Permissible ambient temperature range 25 ... +55 °C
Permissible gas temperature range 30 ... +60 °C
3.2 Power suppl for EK280 without integrated power suppl unit
3.2.1 Batter power suppl for the basic device
Data Value Unit
Voltage 3.6 V
General nominal capacity 16.5 Ah
Usable capacity 13.0 Ah
Minimum number of batteries required 2 units
Minimum operating life (at standard measurement
conditions)
5 years
The standard measurement conditions are defined as follows:
Data Value
Measurement cycle 30 seconds
Mode input 1 Pulse input
Display active 60 minutes per month
Interface or modem active 30 minutes per month
Ambient temperature 10 ... +50°C
3.2.2 Batter power suppl for the integrated modem
Data Value Unit
Voltage 3.9 V
General nominal capacity 16.0 Ah

20 Technical data
3.2.3 External power suppl for the basic device
Data Value Unit
Supply voltage 7.5 …8.5 V
Supply current, maximum 40 mA
3.3 Power suppl for EK280 with integrated power suppl unit
3.3.1 Batter power suppl for the basic device
Batteries for switching to battery mode in the event of a power failure: see chapter
3.3.1 "Battery power supply for the basic device"
3.3.2 External power suppl
Data Value Unit
Supply voltage 230 V ~
Power consumption, maximum 10 W
3.3.3 Buffer batteries for the integrated modem
The buffer batteries can optionally be connected to the integrated power supply unit
to ensure that data continues to be transmitted, even in the event of a power failure.
Data Value Unit
Voltage 3.6 V
General nominal capacity 13.0 Ah
Usable capacity 8.0 Ah
Minimum number of batteries required 2 units
3.4 Pressure sensor
3.4.1 CT30 T pe Pressure Sensor
Data Value Unit
External thread M12 x 1.5
Usable thread length approx. 10 mm