Elster EnCal 3000 User manual

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EnCal 3000 – Hardware Manual 05/10/2016
EnCal 3000
Gas Chromatograph
Hardware Manual
73022344 LC 05.10.2016

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Contact Informat on...................................................................................................................................... 3
Safety Informat on ........................................................................................................................................ 4
Gas quality measurement system EnCal 3000............................................................................................. 6
1 Process Gas Chromatography – General Introduct on................................................................... 7
1.1 Analytical Principle ................................................................................................................................ 7
1.1.1 Column ................................................................................................................................. 8
1.1.2 Detector ................................................................................................................................ 9
1.1.3 Sample Injector ................................................................................................................... 10
1.2 Process Gas C romatograp y .............................................................................................................. 11
2 Funct onal Des gn ................................................................................................................................ 12
2.1 Introduction ....................................................................................................................................... 12
2.2 Enclosure ........................................................................................................................................... 13
2.3 Assembly of major components and internal components ....................................................................... 14
2.4 C annel ............................................................................................................................................. 15
2.5 Processor Board ................................................................................................................................. 19
2.6 Interconnection Board ......................................................................................................................... 21
2.7 Cabinet Heaters .................................................................................................................................. 22
2.8 Internal sample system ....................................................................................................................... 23
2.8.1 Double Block and Bleed Function ........................................................................................... 25
2.8.2 Internal Sample Bypass ........................................................................................................ 25
2.9 Gas Connections ................................................................................................................................. 26
2.10 Breat er ............................................................................................................................................ 27
2.11 Cable entries ...................................................................................................................................... 28
2.12 External Switc .................................................................................................................................. 29
2.13 Configuration wit two Carrier Gases .................................................................................................... 30
3 Techn cal Spec f cat ons ..................................................................................................................... 31
4 Data Commun cat on........................................................................................................................... 34
4.1 Local TCP/IP Data Communication ....................................................................................................... 34
4.2 Local Serial ModBus Data Communication ............................................................................................. 35
4.3 Remote Access ................................................................................................................................... 36
4.4 ModBus Communication ...................................................................................................................... 37
5 Hardware Installat on......................................................................................................................... 38
5.1 Installation specifications ..................................................................................................................... 38
5.1.1 Weig t and Dimensions ........................................................................................................ 38
5.1.2 Installation clearance ............................................................................................................ 38
5.1.3 Wall mounting ..................................................................................................................... 39
5.1.4 Connection of utilities ........................................................................................................... 40
5.1.5 Connections to t e EnCal 3000 Interconnection board ............................................................. 41
5.2 Hardware Start-up .............................................................................................................................. 44
APPENDIX 1: Poss ble hardware opt ons of the EnCal 3000............................................................... 46
APPENDIX 2: DECLARATION OF CONFORMITY ENCAL 3000 .............................................................. 53
APPENDIX 3: CERTIFICATE EC-Type Exam nat on................................................................................ 57

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Contact Informat on
Manufacturer:
Elster GmbH
Steinern Straße 19-21
55252 Mainz-Kastel
Deutschland / Germany
Tel. ++49 (0) 61 34 / 605-0
www.elster.com
Aftersales/ Service Germany & International:
Elster GmbH
Schlossstrasse 95a
44357 Dortmund
Deutschland / Germany
Tel. ++49 (0) 231 93 71 10-88
e-mail: [e-mail]
Aftersales /Service International:
Elster-Instromet N.V.
Rijkmakerlaan 9
2910 Essen
Belgien / Belgium
Tel. ++32 (0) 3 6 700 700
e-mail: [e-mail]
Or your local agent:
www.elster-instromet.com

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Safety Informat on
Electr cal Safety
T e EnCal 3000 is a gas analyser designed to be installed in azardous areas. For t is purpose it is certified
according to:
ATEX II 2 G Ex-d IIC T6 Gb
IECEx Ex-d IIC T6 Gb
Class I, Division 1, Groups B, C, D T6
Class I, Zone 1, AEx db IIC T6
In compliance wit :
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 t is certificate can be found in APPENDIX

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T e operation and maintenance of suc equipment s ould only be performed by qualified personnel.
Fuse replacement must only be performed by Elster GmbH aut orized personnel.
T e following basic rules must be observed in all circumstances:
T e flameproof enclosure may not be opened w en an explosive gas atmosp ere may be pre-
sent. T e process pressure s all be limited to 2 MPa to ensure t at t e pressure rise inside t e
flameproof enclosure remains below 10 kPa. T e functional pressure must be lower see c apter 3
and section 5.1.4 containing t e specifications. Before any start-up, verify all connections of t e
unit for tig t sealing.
For information on t e dimensions of t e flameproof joints t e manufacturer s all be contacted.
WARNING! ELECTROSTATIC HAZARD!
Because of t e potential electrostatic c arging of t e paint layer, t e ousing s ould only be
cleaned by using a moist clot to prevent c arging
CASE MUST BE EARTHED!
Important disclaimer:
If t e equipment is used in a manner not specified by t e manufacturer, t e protection provided
by t e equipment may be impaired. Gases w ic are flammable or explosive under exclusion of
oxygen. (E.g. acetylene C2H2) s ould not be fed to t e measuring device.
Installation instructions mentioned in t is manual are intended for information only. T e installation of t is equipment
must conform to any national, local, or company codes applicable to t e location. Elster-Instromet assumes no responsi-
bility for compliance wit t ese requirements. It is suggested t at a review of t e codes be made prior to installation.

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Gas quality measurement system EnCal 3000
The gas quality measurement system EnCal 3000 consists in its basic configuration of a measuring unit and
an optional Encal3000 controller.
The measuring unit is the real gas chromatograph. It performs the analysis by measuring technology auton-
omously.
It is configured with the PC program "RGC 3000". It is possible to install an additional optional Encal3000
controller. The subsystems communicate with each other via Modbus. (see Figure 1)
This manual describes the Hardware of the Encal3000 gas chromatograph (measuring unit). The other sub-
systems are described in separate manuals.
Basic configuration EnCal 3000 (Measuring unit and an optional Encal3000 controller)
Figure 1

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1Process Gas Chromatography – General Introduct on
1.1 Analyt cal Pr nc ple
Gas c romatograp y in general is an analytical tec nology w ic is used to analyse gas mixtures, i.e. to measure t e
concentrations of t e different components of a gas.
T e analytical principle is s own in fig. 1-1 :
f g. 1-1 Pr nc ple of a Gas Chromatography
A very small volume of sample gas (typically muc less t an 1 ml), w ic is a mixture of several components, is injected
into a stream of carrier gas, w ic takes t e sample gas t roug t e column. T is column acts as a separator t roug
t e difference in absorption rate of t e different components of t e sample gas, t ey are separated from eac ot er
during t eir passage t roug t e column and elute as individual components. T e concentration of eac component is
t en measured at t e end of t e column by a detector. From t e knowledge of t e concentrations of eac component,
any property of t e gas can be calculated.

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1.1.1 Column
A GC column is a relatively long spiral of tubing wit very small internal diameter. Typical dimensions of t e used col-
umns in t e Encal3000 ave a lengt of several meters and internal diameters of <0.1 mm. T ey are made of inert ma-
terials like fused silica and stainless steel. Every GC column as a so-called stationary p ase inside, w ic acts as an
absorption layer for t e gas molecules flowing t roug t e column.
f g. 1-2 D fferent types of gas chromatograph c columns
Various configurations exist:
Wall coated open tubular column: t e stationary p ase is a t in liquid layer coated on t e inner wall of
t e column (for example type 5CB)
Packed column: t e stationary p ase is coated on a packing, w ic is equally distributed t roug out
t e column (for example type HSA)
Support coated open tubular column: t e stationary p ase is a coated packing, w ic itself is coated
on t e inner wall of t e column (for example type M5S mole sieve)
Porous layer open tubular column: t e stationary p ase is a porous layer on t e inner wall of t e col-
umn (for example type PPU)

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1.1.2 Detector
In the natural gas industry, the most popular detector is the TCD: Thermal Conductivity Detector. It’s a relatively simple,
very efficient and very robust detector.
Another reason for the popularity of the TCD in the natural gas industry is the fact that gas chromatographs are used
mainly for the measurement 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 the analytical precision is for example 1 ppm for n-pentane.
Traditionally t e two TCD’s (reference + measurement detector) are integrated in a so-called W eatstone configuration,
w ic increases significantly t e signal-to-noise ration of t e measurement.
f g. 1-3 Typ cal electr cal TCD c rcu t

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1.1.3 Sample Injector
T e sample injection must assure a precise injection of sample into t e flow of t e carrier gas.
In principle t e amount injected must be very precisely controlled, bot in volume, pressure, temperature and flow (to
avoid viscosity effects) to guarantee a ig level of repeatability of t e analytical results, but in practice t e normalisa-
tion of t e measured concentrations will compensate for a large part of t e fluctuations of t ese parameters.
However, to reac repeatability for t e eating value below 0.01 %, t ese parameters do ave effect and need to be
controlled to a ig degree.
T e used MEMS tec nology allows a fundamental improvement of t e sample injection quality compared to t e tradi-
tional fine-mec anical tec nologies used for most of t e current process GC’s on t e market. T e picture below s ows a
typical MEMS sample injector, etc ed in silicon c annel, wit membrane valves to control flow directions.
T is injector allows for a very precise control of t e injection volume and temperature, on a remote base.
f g. 1-4 MEMS Sample Injector