Elster EK280 User manual

Operating manual
Volume conversion device
EK280

Volume conversion device EK280
Operating manual: 73021209
Version: c
Issue date: 6.9.17
Software-Version: 2.50 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 Safety......................................................................................................12
2.1 General............................................................................................12
2.2 Intended use....................................................................................14
2.3 Personnel.........................................................................................15
2.4 Personal protective equipment........................................................16
2.5 Specific risks....................................................................................17
2.6 Environmental protection.................................................................18
2.7 Operator's responsibility..................................................................18
3 Technical data........................................................................................20
3.1 General data....................................................................................20
3.2 Power supply for EK280 without integrated power supply unit .......20
3.2.1 Battery power supply for the basic device...........................................20
3.2.2 Battery power supply for the integrated modem..................................20
3.2.3 External power supply for the basic device .........................................21
3.3 Power supply for EK280 with integrated power supply unit ............21
3.3.1 Battery power supply for the basic device...........................................21
3.3.2 External power supply.........................................................................21
3.3.3 Buffer batteries for the integrated modem...........................................21
3.4 Pressure sensor ..............................................................................22
3.4.1 CT30 Type Pressure Sensor...............................................................22
3.4.2 Pressure Sensor Type 17002..............................................................23
3.5 Temperature sensor ........................................................................23
3.6 Digital inputs....................................................................................23
3.6.1 LF pulse and signalinputs....................................................................23
3.6.2 HF pulse inputs (high frequency) ........................................................24
3.6.3 Encoder input......................................................................................24
3.7 Digital outputs..................................................................................25
3.7.1 Nominal data.......................................................................................25

4 General
3.7.2 LF pulse or signal outputs .................................................................. 25
3.7.3 HF pulse outputs................................................................................ 25
3.8 Interfaces.........................................................................................26
3.8.1 Serial optical interface........................................................................ 26
3.8.2 Serial electrical interface.................................................................... 26
3.8.3 Integrated modem.............................................................................. 26
3.9 Measurement conditions..................................................................27
3.9.1 Environment....................................................................................... 27
3.10 Labeling .........................................................................................27
3.10.1 Type label of the volume corrector ................................................... 27
3.10.2 ATEX marking.................................................................................. 28
3.10.3 Device software identification........................................................... 29
4 Construction and Function...................................................................30
4.1 External view....................................................................................30
4.2 Internal view.....................................................................................30
4.3 Short description..............................................................................31
4.4 Connections.....................................................................................31
5 Assembly, Connection and Putting into Operation ...........................32
5.1 Assembly .........................................................................................32
5.1.1 Assembly on a gas meter................................................................... 33
5.1.2 Assembly on a pipeline ...................................................................... 33
5.1.3 Assembly on a wall............................................................................. 34
5.1.4 Three-way valve................................................................................. 34
5.2 Connection.......................................................................................35
5.2.1 Connecting the gas meter .................................................................. 36
5.2.2 Sealing the input terminals................................................................. 38
5.2.3 Connecting the temperature sensor................................................... 38
5.2.4 Connecting the pressure pipe............................................................. 40
5.2.5 Connecting the power supply............................................................. 41
5.2.6 Connect outputs of the EK280............................................................ 43
5.2.7 Earthing the EK280 housing............................................................... 44
5.2.8 Earthing the cable connections of the EK280..................................... 45
5.2.9 Additional measures for installation in zone 2 .................................... 45
5.3 Putting into operation.......................................................................46
5.3.1 Configuration of measurement parameters........................................ 46
5.3.2 Sealing............................................................................................... 55
5.3.3 Closing the housing............................................................................ 57
5.3.4 Verifying assembly and connection.................................................... 57
6 Operation................................................................................................58
6.1 Safety...............................................................................................58
6.1.1 Personal protective equipment........................................................... 58
6.2 Operating personnel ........................................................................58
6.2.1 Instructed personnel........................................................................... 58
6.2.2 Qualified personnel ............................................................................ 58
6.2.3 Calibration officers.............................................................................. 59

General 5
6.3 Basic principles................................................................................59
6.3.1 Display ................................................................................................60
6.3.2 Button functions ..................................................................................61
6.3.3 Data recall, display navigation.............................................................62
6.3.4 Meaning of status symbols..................................................................63
6.3.5 Error messages when entering values................................................65
6.3.6 Access rights.......................................................................................66
6.4 Data register content .......................................................................68
6.4.1 Access rights.......................................................................................68
6.4.2 "Main" register (main display)..............................................................68
6.4.3 "Cust." register (Customer) .................................................................70
6.4.4 "Admin" register (Administrator)..........................................................72
6.4.5 "Serv." register (service)......................................................................73
6.4.6 "Ctrl." register (Control) .......................................................................74
7 Maintenance........................................................................................... 77
7.1 Safety...............................................................................................77
7.1.1 Personnel............................................................................................79
7.1.2 Personal protective equipment............................................................79
7.1.3 Environmental protection.....................................................................79
7.2 Testing and changing device batteries............................................80
7.2.1 Changing and connecting device batteries..........................................80
7.2.2 Entering the battery capacity...............................................................82
7.2.3 Display remaining battery power.........................................................83
8 Faults ......................................................................................................84
8.1 Safety...............................................................................................84
8.1.1 Personnel............................................................................................84
8.1.2 Personal protective equipment............................................................85
8.1.3 Improper elimination of faults ..............................................................85
8.1.4 Behavior in the event of faults.............................................................85
8.2 Fault and other status messages ....................................................86
9 Appendix.................................................................................................91
9.1 List of spare parts and accessories.................................................91
9.1.1 Fastening elements.............................................................................91
9.1.2 Pressure connections..........................................................................91
9.1.3 Temperature sensor pockets...............................................................92
9.1.4 Small parts and miscellaneous............................................................92
9.1.5 Documentation....................................................................................92
9.2 EC Declaration of Conformity..........................................................93
9.3 ATEX Type Examination Certificate................................................94
9.3.1 Zone 1.................................................................................................94
9.3.2 Zone 2...............................................................................................109

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 operating manual is a prerequisite for safe working processes and
proper use of the device. Furthermore, the valid guidelines, standards, local
accident prevention regulations, and general safety regulations must be
complied with for the respective area 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, maintenance, and cleaning personnel at all times. The graphic il-
lustrations used in this manual serve as a visual representation of the de-
scribed processes and are therefore not necessarily to scale and may de-
viate from the actual design of the device.
The data and material properties indicated serve as refer-
ence values. These must be verified on a case-by-case ba-
sis and adjusted as necessary.
The EK280 Application Manual is available for you at
www.ek280.de (-> Documents) for the commissioning of
the various communication and device applications.
1.2 Warranty provisions
The current warranty provisions can be found in the general terms and
conditions online under: https://www.elster-instromet.com/en/general-
terms-of-business
1.3 Customer service
Our customer service team is responsible for providing technical infor-
mation 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: [e-mail]

8 General
1.3.2 Electronic hotline
In the event of faults, you can also contact the electronic hot-
line.
Tel. [phone] / 605-123
http://www.elster-instromet.com/de/support
E-Mail: [e-mail]
1.4 Meaning of symbols
1.4.1 Safety information
In this manual, safety information is denoted by the use of symbols. The
safety information 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
avoided, 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 se-
rious 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 well as in-
formation for ensuring efficient and smooth operations.
1.5 Limitationof liability
All of the information contained in this manual has been compiled under
consideration of valid standards and regulations, the latest technological
developments, and our many years of experience and expertise. The man-
ufacturer shall accept no liability 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
presented herein due to special designs, the selection of additional order-
ing 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
works on and with the device, particularly before putting the
device into operation! The manufacturer shall accept no lia-
bility for damages and losses arising from non-compliance
with the manual.
We reserve the right to make technical changes within the scope of improv-
ing usability and further development.
1.6 Copyright 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 permit-
ted without written consent from the manufacturer, except for internal pur-
poses. Contraventions to this provision shall result in damage compensa-
tion. We reserve the right to assert further claims.

10 General
1.7 Scope of delivery
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 may pre-
sent a risk to safety!
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 service 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 pro-
gram the EK280 volume conversion device via its data interfaces to per-
form 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 Operation" chapter.

General 11
1.9 Storage
CAUTION!
Exceeding or falling below the valid temperature range
for the batteries may impair performance.
If the valid temperature range of the batteries during stor-
age of the device is exceeded or fallen below, the perfor-
mance of the batteries may be impaired.
Therefore:
–For long periods of storage, please ensure that the valid
temperature range for the fitted batteries does not fall
below -25 °C or exceed +55 °C.
CAUTION!
Material damage caused by the formation of condensa-
tion.
Fluctuations in temperature during storage may cause con-
densation to form. This may lead to subsequent malfunc-
tions of the device.
Therefore:
–After storage or transport in cold weather conditions or
after having been exposed to strong temperature fluctu-
ations, the device should slowly be adjusted to the room
temperature before being put into operation.
–If condensation has formed, wait at least 12 hours be-
fore putting the device into operation.
If the power supply to the device is interrupted during stor-
age 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 Safety
2 Safety
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 opera-
tion of the device. A non-compliance with the safety information and in-
structions 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 operation 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 standards: 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 catego-
ry "II 1 G" or "II 2 G" have been marked on the ATEX la-
bel.
–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
housing.

Safety 13
DANGER!
The connection of non intrinsically-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 con-
nected to certified associated equipment as per the
ATEX Product Directive 94/9/EC.
–The EK280 should only be connected to the intrinsically-
safe circuits of associated equipment whose electrical
data corresponds 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 de-
vice (see chapter 9.1.4 .)
When connecting and operating the EK280 in explosive gas
atmospheres, the corresponding standards must be ob-
served:
DIN EN 60079-0
DIN EN 60079-14
The device may only be used in zone 1 or zone 2, if instal-
lation has been carried out according to the separate re-
quirements stipulated under DIN EN 60079-14 and the op-
erating conditions (see "Technical Data" chapter) as well as
the connection conditions (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.

14 Safety
Being familiar with the content of the manual is a necessary condition
for protecting 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 device. Damaged or illegible instructions should be replaced imme-
diately.
The setting values and value ranges specified in this manual should be
complied with.
2.2 Intended use
This device is solely designed and constructed for the intended use de-
scribed below.
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 allocate the measured quantities to tariffs. Furthermore, the
device can also be used to measure, record and monitor additional varia-
bles depending on the configuration 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 considered 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
variables affecting the gas volume in the entire system.

Safety 15
2.3 Personnel
WARNING!
Risk of injury 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 per-
sonnel.
The following qualifications are used in the manual to denote different are-
as of responsibility:
Instructed personnel
will be informed of the tasks assigned to them and possible risks result-
ing 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 perform their assigned tasks on the device and are able to
independently identify and prevent possible risks.
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 in-
dependently identify possible 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 subject 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 rele-
vant standards and regulations.

16 Safety
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 authorized to work on or with the device. People whose reactivity is im-
paired, e.g. by drugs, alcohol or medication, shall not be authorized to per-
form such works.
When selecting personnel, please observe the valid age and profes-
sional guidelines for all of the gas-handling equipment.
2.4 Personal protective equipment
When working on the device inside a gas-handling plant, personal protec-
tive equipment must be worn to minimize risks to health.
During works on the device, the necessary personal protective equip-
ment 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.

Safety 17
2.5 Specific risks
The residual risks arising from the risk assessment will be listed below.
Please observe the safety and warning information specified in the follow-
ing chapters to reduce risks to health and to prevent dangerous situations
from arising.
WARNING!
Misuse of batteries may present a risk of injury.
Special care must be taken when handling batteries.
Therefore:
–Do not throw batteries into the fire or expose these to high tempera-
tures. 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 irri-
tation. Avoid physical contact with such liquid. In the event of contact,
rinse with large quantities of water. If the liquid enters the eyes, im-
mediately rinse with water for 10 minutes and seek medical attention.
WARNING!
Risk of fire from highly flammable substances!
Highly flammable substances, liquids or gases could catch fire and lead
to serious 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 re-
sponsible 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.

18 Safety
2.6 Environmental protection
CAUTION!
Environmentally hazardous substances!
If environmentally hazardous substances are handled incorrectly this
may cause significant damage to the environment, particularly if they are
improperly disposed of.
Therefore:
–The instructions below should be observed at all times.
–Appropriate measures should be taken immediately if environmental-
ly hazardous substances are accidentally released into the environ-
ment. 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 haz-
ardous waste and be disposed of in municipal waste collection points or by
a waste specialist.
2.7 Operator's responsibility
The device will be used in the commercial sector. The operator of the de-
vice will therefore be subject to legal obligations concerning occupational
safety.
In addition to the safety information contained in these instructions, the val-
id safety, accident prevention, and environmental protection regulations for
the area of application of the device, must be adhered to. In particular:
The operator must ensure that the valid safety, accident prevention, and
environmental protection regulations for the entire plant in which the de-
vice is being integrated, are complied with.
The operator must be familiar with the valid occupational safety regula-
tions 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 device. 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 deter-
mine whether their prepared operating instructions are compatible with
current regulations and amend these if and when necessary.
The operator must clearly regulate and define responsibilities for the as-
sembly, connection, putting into operation, and maintenance of the de-
vice.

Safety 19
The operator must ensure that all employees who use the device have
read and understood this manual. Furthermore, the operator must pro-
vide training to personnel at regular intervals and inform them of the po-
tential 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 re-
mains 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 functionality and completeness.

20 Technical data
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 supply for EK280 without integrated power supply unit
3.2.1 Battery power supply 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 measure-
ment 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 Battery power supply for the integrated modem
Data
Value
Unit
Voltage
3.9
V
General nominal capacity
16.0
Ah