Elster EnCal 3000 Guide

2008 Elster GmbH 2008/2013
EnCal 3000 Controller
Technical Documentation
Function, Operation,
Commissioning and Maintenance

EnCal 3000
page ii
Copyright:
2008 Elster GmbH
GAS-WORKS and FLOW COMP are registered trademarks of
Elster.
Microsoft, Windows and Windows NT are registered trademarks
of Microsoft Corporation.
HART is a registered trademark of HART Communication
Foundation.
Elster GmbH
Schloßstraße 95a
D - 44357 Dortmund / Germany
Tel.: +49 (0) 2 31 - 93 71 10 0
Fax: +49 (0) 2 31 - 93 71 10 99
E-mail: [e-mail]

EnCal 3000 page iii
Contents
General Notes on the Structure of this Manual....................................................................................................................v
Safety and Warning Notes...................................................................................................................................................v
1Introduction..................................................................................................................................................................1
1.1 The EnCal 3000 Gas Quality Measuring System.................................................................................................1
1.2 The EnCal 3000 Controller ..................................................................................................................................3
1.3 The gas-net System Idea.....................................................................................................................................4
2Device View and Design..............................................................................................................................................5
3Operating the Device...................................................................................................................................................7
4Primer for Impatient Operators: What do I have to do to ... .......................................................................................15
4.1 ... view the process values of the second stream in case of a dual-stream EnCal 3000 Controller?.................15
4.2 ... view the error listing of the Gas Quality module?...........................................................................................15
4.3 ... accept gas quality errors?..............................................................................................................................16
4.4 ...to view the software versions?........................................................................................................................17
4.5 ... to view the device configuration ?..................................................................................................................17
4.6 checking all parameter settings? .......................................................................................................................18
4.7 .. view archives? ................................................................................................................................................19
5Functional Description...............................................................................................................................................21
5.1 Gas Quality Module(s).......................................................................................................................................21
5.2 Data Logging Module.........................................................................................................................................40
5.3 Monitoring Module .............................................................................................................................................43
5.4 Integrated RDT Module......................................................................................................................................56
5.5 System Module..................................................................................................................................................61
5.6 DSfG Module, Data Exchange Module..............................................................................................................70
6GW-GNET+...............................................................................................................................................................71
6.1 Creating and Exporting a Parameter Data Record: Brief Description ................................................................71
6.2 Importing and Editing a Parameterization: Brief Description..............................................................................73
6.3 Extras: GW-GNET+ Service Programs..............................................................................................................74
7Installation .................................................................................................................................................................75
7.1 Mounting the EnCal 3000 Controller..................................................................................................................75
7.2 Connecting the Lines.........................................................................................................................................75
8Commissioning..........................................................................................................................................................83
8.1 Parameter Protection against Unauthorized Access..........................................................................................83
8.2 Parameterization................................................................................................................................................83
8.3 Commissioning the Integrated RDT...................................................................................................................84
9Maintenance..............................................................................................................................................................87
9.1 Battery Replacement .........................................................................................................................................87
10 Technical Data: EnCal 3000 Controller......................................................................................................................89
11 Annex ........................................................................................................................................................................93

EnCal 3000
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11.1 Error Listing of the Gas Quality Module.............................................................................................................93
11.2 Menu Structure of the EnCal 3000 Controller....................................................................................................95
11.3 Certificate of Conformity ....................................................................................................................................96
11.4 ATEX Certificate EXMFE5.................................................................................................................................97
11.5 ATEX Certificate EXDE6..................................................................................................................................103
12 Bibliography.............................................................................................................................................................107
13 Index........................................................................................................................................................................109

EnCal 3000 page v
General Notes on the Structure of this Manual
This documentation describes the function, operation, commissioning and maintenance of the EnCal 3000 Controller.
This controller is part of the EnCal 3000 Gas Quality Measurement System, which also consists of the EnCal 3000 Gas
Chromatograph (GC). When mentioned within this documentation, “EnCal 3000”or “controller” always refers to the
EnCal 3000 Controller.
Tip: Chapter 4 provides brief instructions on how to accomplish regular tasks during routine tests in the station. It is
intended for the impatient reader who does not want to read the entire manual first just to accept an error. It is,
however, necessary to read the entire manual to comprehend the device’s mode of operation.
Three manuals describe the EnCal 3000 gas quality measuring system:
The manual on hand deals with the controller. The other two manuals deal with the hardware and the PC
parameterization software of the gas chromatograph.
The entire Technical Documentation must always be at hand in the station.
Safety and Warning Notes
Attention! The following safety and warning notes must be observed at any rate:
The EnCal 3000 Controller must neither be stored at temperatures below -20°C nor above +50°C.
A temperature between 0°C und +40°C must be guaranteed during operation.
The EnCal 3000 Controller must be installed outside hazardous area 2 as it is not an explosion-proof device.
The EnCal 3000 Gas Chromatograph, however, is explosion-proof.
The EnCal 3000 Controller can be equipped with hardware modules that are approved as associated
electrical apparatus of category ib according to DIN EN 50020 with intrinsically safe circuits (EXMFE5 /
EXDE6 input boards). It is therefore suitable for being connected to sensors, signal transmitters and pulsers
located in hazardous areas (e.g. zone 1). It is not permitted to connect intrinsically safe and non-intrinsically
safe circuits to these modules together.
The power supply of the EnCal 3000 Controller is 24 V DC and must be secured externally by 1 A.
Connect the earthing to PE of the power supply socket for equipotential bonding.
Observe the regulations of the relevant standards, in particular the regulations of DIN EN 50014, DIN EN
50020 and DIN EN 50029.
Observe the limit values stated in the respective certificates of conformity of the boards to be connected.
(Please refer to the annex for the certificates of conformity.)
Warning: This is a Class A device that may cause interferences in living areas; you may be asked for
appropriate measures at your expense if the device is installed in such areas.
!

EnCal 3000 page 1
1 Introduction
1.1 The EnCal 3000 Gas Quality Measuring System
The basic configuration of the EnCal 3000 gas quality measuring system consists of the EnCal 3000 Gas
Chromatograph and the EnCal 3000 Controller (see Figure 1 below).
When running EnCal 3000 Quad is the meter is in two cases and can contain up to four analytical channels. (see Figure
2 below).
The gas chromatograph’s measuring technology performs the analysis independently.
You can install further controllers as an option. The subsystems communicate via Modbus with each other, with one
controller being the active unit (Modbus master) that controls the gas chromatograph (Modbus slave). The two optional
controllers act as passive units (Modbus listeners), i.e. they also read the communication at the Modbus and extract the
data relevant to them, but they do not send and process any commands.
The controllers serve as displays and data logging devices within the EnCal 3000 measuring system. As active unit the
controller also serves as control element for the gas chromatograph. It is therefore used to perform manual calibrations
or test gas runs.
As an option the EnCal 3000 Controller provides a hydrocarbon dew point calculation derived from the ISO 23874
standard and based on a C9+ analysis of the EnCal 3000 Gas Chromatograph.
The gas quality measurement system EnCal 3000 is described in 3 manuals
This manual deals with the controller.
Two other manuals are devoted to the hardware and the PC configuration software of the measuring element.

page 2 EnCal 3000
Controller
active unit
e.g. stream 1, 2
Gas Chromatograph
Controller (optional)
passive unit
e.g. stream 3, 4
Controller (optional)
passive unit
e.g. stream 5
Modbus ASCII/RTU
(RS232/485)
Modbus TCP
(ethernet 10Base-T)
ethernet 10Base-T
V.24 serial
V.24 serial
V.24 serial
parameterization:
gas chromatograph:
RGC 3000
controller:
Gasworks
PC for parameterization
Figure 1
Figure 2

EnCal 3000 page 3
1.2 The EnCal 3000 Controller
The EnCal 3000 Controller is part of the gas quality measuring system. Each controller can process one or two gas
streams, while it is also possible to assign one gas stream to several controllers. This makes it possible, for instance, to
distribute the data of one gas stream to several DSfG buses.
The EnCal 3000 Controller indicates the calibratable measurements superior heating value Hs, standard density rho and
the mole fraction of the gas components in the basic display of the operator panel. The font size of these measurements
is twice as large due to their significance. The EnCal 3000 Controller automatically invokes this basic display again 30
minutes after the last device operation.
The basic display shows the measurements of the first assigned gas stream in dual-stream operation. You can switch to
the corresponding display of the second assigned stream with a menu command.
The EnCal 3000 Controller is also equipped with a data logging function that logs important measurement variables. A
Long-term archive is available as a certifiable archive type, which logs the calibratable measurement variables cyclically
every 15 minutes. There is one separate certifiable Long-term archive available for each gas stream.
The data logging function logs the measurements provided by the gas chromatograph. It is also able to log further
measurement variables provided by operational supplementary functions. The measurement variables to be logged are
provided with a time mark of the data logging time and a classification criterion, the ordinal number. They are saved in a
storage area that is organized as ring storage. If the ring storage is full, each new data record overwrites the oldest one.
If the controller is the one taking on the active function within the Modbus communication with the gas chromatograph, it
can also be used to perform manual calibrations or test gas runs.
In addition to the displaying and data logging function the EnCal 3000 Controller offers a variety of operational
supplementary functions; for instance, for monitoring tasks and data communications. The certifiable functions are
isolated from each other and from the operational functions.
The controller monitors itself and all incoming measurements. If it detects an internal error or an error in the
communication with the gas chromatograph and if this error affects the accuracy of the measurement variables, this error
will be indicated by a red flashing status LED and additional clear text. During such an error the last two measurements
measured before the error will be maintained. After the error has been eliminated, the EnCal 3000 Controller switches
automatically back to the current online values.
The EnCal 3000 Controller is equipped with up to two digital data interfaces of the DSfG type (DSfG stands for Digital
Interface for Gas Metering Device), which is used by all devices in the Elster gas-net device family as described below.
The controller uses the interface labeled DSfG to provide other measuring instruments connected to the DSfG multidrop
connection and typically calibrated (e.g. flow computers) with the calibrated target variables Hs, rho and the entire
analysis.
For this, the EnCal 3000 Controller operates exactly according to the method specified by the DSfG regulations. If new
measurements are available, the EnCal 3000 Controller sends a New measurements attention telegram. Data sinks
being interested in the values due to this signal have to get hold of these values by themselves by means of query
telegrams. In the EnCal 3000 Controller the transferred calibrated data is provided with an additional signature, which is
checked for integrity in the receiver. This procedure ensures the accuracy of the transferred data.

page 4 EnCal 3000
1.3 The gas-net System Idea
is the generic term for an Elster device family. All gas-net devices, including future device types,
are characterized by uniformity in appearance, operation and parameterization.
Each gas-net device always covers a multitude of measurement and control functionalities.
EnCal 3000 Controllers also provide this functional variety. To keep the operation and parameterization of the devices
well-structured and user-friendly, the gas-net series is based on a modular concept. A module corresponds to a special
functionality. Each module has its own main display within the device’s menu assistance, and each module has its own
group of settings within the parameter data record.
A particular module can be employed in different device types. This yields a modular system that is advantageous to the
user as a particular module can always be operated and parameterized in the same way, no matter in which device type
it has been installed.