Elster EnCal 3000 Quad User manual

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

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Contact Information...................................................................................................................................... 3
Safety Information ........................................................................................................................................ 4
Gas quality measurement system EnCal 3000 Quad................................................................................... 5
1Process Gas Chromatography –General Introduction................................................................... 6
1.1 Analytical Principle................................................................................................................................6
1.1.1 Column .................................................................................................................................7
1.1.2 Detector................................................................................................................................8
1.1.3 Sample Injector .....................................................................................................................9
1.2 Process Gas Chromatography ..............................................................................................................10
2Functional Design ................................................................................................................................ 11
2.1 Introduction .......................................................................................................................................11
2.2 Enclosure...........................................................................................................................................12
2.3 Assembly of major components and internal components.......................................................................13
2.4 Channel .............................................................................................................................................14
2.5 Processor Board .................................................................................................................................18
2.6 Interconnection Board.........................................................................................................................21
2.7 Electrical connection to the Slave Unit ..................................................................................................22
2.8 Cabinet Heaters..................................................................................................................................23
2.9 Internal sample system .......................................................................................................................24
2.9.1 Double Block and Bleed Function ...........................................................................................26
2.9.2 Internal Sample Bypass ........................................................................................................26
2.10 Gas Connections.................................................................................................................................27
2.11 Breather ............................................................................................................................................28
2.12 Cable Glands ......................................................................................................................................29
2.13 External Switch ..................................................................................................................................29
3Technical Specifications ..................................................................................................................... 30
4Data Communication........................................................................................................................... 33
4.1 Local TCP/IP Data Communication .......................................................................................................33
4.2 Local Serial ModBus Data Communication .............................................................................................34
4.3 Remote Access ...................................................................................................................................35
4.4 ModBus Communication ......................................................................................................................36
5Hardware Installation......................................................................................................................... 37
5.1 Installation specifications.....................................................................................................................37
5.1.1 Weight and Dimensions ........................................................................................................37
5.1.2 Installation clearance............................................................................................................37
5.1.3 Wall mounting .....................................................................................................................38
5.1.4 Connection of utilities ...........................................................................................................39
5.1.5 Connections to the EnCal 3000 Interconnection board .............................................................40
5.2 Hardware Start-up ..............................................................................................................................43
APPENDIX 1: ZERTIFIKATES ENCAL 3000 .............................................................................................. 45
APPENDIX 2: DECLARATION OF CONFORMITY ENCAL 3000 .............................................................. 51

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Contact Information
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 Information
Electrical Safety
The EnCal 3000 Quad is a gas analyser designed to be installed in hazardous areas. For this purpose it is certified
according to:
ATEX II 2 G Ex-d IIB T4 and IECEx
In compliance with:
EN 60079-0: 2004
EN 60079-1: 2007
IEC 60079-0: 2004
IEC 60079-1: 2007
Detailed information on this certificate can be found in APPENDIX
Operation and maintenance of such equipment should only be done by experienced people. Apply in all circumstances
the following basic rules:
The flameproof enclosure may not be opened when an explosive gas
atmosphere may be present.
Before any start-up, verify all connections of the unit for tight sealing
WARNING!
ELECTROSTATIC HAZARD!
CLEAN WITH MOIST CLOTH ONLY
CASE MUST BE EARTHED
Important disclaimer:
If the equipment is used in a manner not specified by the manufacturer,
the protection provided by the equipment may be impaired.
Installation instructions mentioned in this manual are intended for information only. The installation of this equipment
must conform to any national, local, or company codes applicable to the location. Elster-Instromet assumes no
responsibility for compliance with these requirements. It is suggested that a review of the codes be made prior to
installation.

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Gas quality measurement system EnCal 3000 Quad
When running EnCal 3000 Quad is the meter is in two cases and can contain up to four analytical channels.
It represents the actual process gas represents
This option has been developed especially for extended analysis applications that cannot be solved with only
two channels. A possible example is the combination of an analysis C9 with the two standard channels and
the additional analysis of hydrogen and oxygen with a third channel, and the analysis of hydrogen sulfide
and carbonyl sulfide with a fourth channel. With the simultaneous use of up to four channels, it is possible to
analyze all components in a typical system.
The measuring unit of the analysis is conducted by measuring autonomy while using a PC program is
parameterized. Optionally, additional computers can be installed (see Figure 1).
This manual describes the Hardware of the Encal3000 Quad gas chromatograph (measuring unit). The other
subsystems are described in separate manuals.
The parameterization of the measuring unit is done with the PC program "RGC 3000". The parameterization
of the optional Encal3000 controller is done with the PC program "Gas Works".
Basic configuration EnCal 3000 Quad (Measuring unit and an optional Encal3000 controller)
Figure 1

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1Process Gas Chromatography –General Introduction
1.1 Analytical Principle
The analytical principle is shown in fig. 1-1:
fig. 1-1 Principle of a Gas Chromatography
A very small volume of sample gas (typically much less than 1 ml), which is a mixture of several components, is injected
into a stream of carrier gas, which takes the sample gas through the column. This column acts as a separator through
the difference in absorption rate of the different components of the sample gas, they are separated from each other
during their passage through the column and elute as individual components. The concentration of each component is
then measured at the end of the column by a detector. From the knowledge of the concentrations of each component,
any property of the gas can be calculated.

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1.1.1 Column
A GC column is a relatively long spiral of tubing with very small internal diameter. Typical dimensions of the used
columns in the Encal3000 Quad are a length of several meters and internal diameters of <0.1 mm. They are made of
inert materials like fused silica and stainless steel. Every GC column has a so-called stationary phase inside, which acts
as an absorption layer for the gas molecules flowing through the column.
fig. 1-2 Different types of gas chromatographic columns
Various configurations are used depending on the components to measure:
Wall coated open tubular column: the stationary phase is a thin liquid layer coated on the inner wall of
the column (for example type 5CB)
Packed column: the stationary phase is coated on a packing, which is equally distributed throughout
the column (for example type HSA)
Support coated open tubular column: the stationary phase is a coated packing, which itself is coated
on the inner wall of the column (for example type M5S / molesieve)
Porous layer open tubular column: the stationary phase is a porous layer on the inner wall of the
column (for example type PPU)

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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
Encal3000 Quad 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 the two TCD’s (reference + measurement detector) are integrated in a so-called Wheatstone configuration,
which increases significantly the signal-to-noise ration of the measurement.
fig. 1-3 Typical electrical TCD circuit

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1.1.3 Sample Injector
The sample injection must assure a precise injection of sample into the flow of the carrier gas.
In principle the amount injected must be very precisely controlled, both in volume, pressure, temperature and flow (to
avoid viscosity effects) to guarantee a high level of repeatability of the analytical results, but in practice the
normalisation of the measured concentrations will compensate for a large part of the fluctuations of these parameters.
However, to reach a repeatability for the heating value below 0.01 %, these parameters do have effect and need to be
controlled to a high degree.
The used MEMS technology allows a fundamental improvement of the sample injection quality compared to the
traditional fine-mechanical technologies used for most of the current process GC’s on the market. The picture below
shows a typical MEMS sample injector, etched in silicon channel, with membrane valves to control flow directions.
This injector allows for a very precise control of the injection volume and temperature, on a remote base.
fig. 1-4 MEMS Sample Injector

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1.2 Process Gas Chromatography
The Encal3000 Process Gas Chromatographs (PGC) transfers the core laboratory technique to process conditions. Apart
from the analytical performance specifications, a PGC therefore needs to be designed to match the following
specifications:
Explosion safety.
Extreme environmental conditions:
oHigh and low temperatures
oDust and precipitation
oElectro-magnetic influence
oWind
oCorrosive atmospheres
oVibrations and shocks
Complete stand-alone operation, no operator interference during normal operation:
oAutomatic and continuous analysis of different streams
oControl and processing of analytical measurement executed internally, no peripheral device needed
oAutomatic calibration and verification
Standard maintenance limited to yearly intervals, without need for specifically trained people
oHigh reliability of the components
oHigh degree of protection to any contaminant (liquids, vapour or particles) in the sample gas
Analytical results available in industrial formats (for natural gas industry serial ModBus or ModBus TCP/IP)
Internal data storage of all data, including averages, calibration data, events and alarms, during the last 35
days, to permit the operator to retrieve data in the past in case the continuous analysis was interrupted for any
reason.
The EnCal 3000 Quad is designed to meet or exceed all of the above requirements. At the same time the unit uses
analytical technology which can compete with the highest standards used in the laboratory world, surpassing any PGC
currently used in the natural gas industry.

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2Functional Design
2.1 Introduction
The Encal 3000 Quad is the combination of two housings in one measurement System. In the two housings is place for
up to four analytical channels that are controlled by one processor board. This System is especially developed for
extended analysis applications which cannot be solved with just two channels. One possible example is the combination
of a calorific value analysis up to C9, the analysis of hydrogen, oxygen and the sulphur components hydrogen sulphide
and carbonyl sulphide. For the analysis up to C9 the two standard channels are used, for the analysis of hydrogen and
Oxygen a third channel and for the sulphur components a fourth channel is required. With up to four channels it is
possible to analyse all typical components of interest in one system.
The two housings are mounted on a metal plate to have a stable connection. The right housing, further referred as
“Master unit” contains the first two channels, the processor board for the control of the measurement system and the
sample selection. The left housing, further referred as “Slave unit” contains the third and optionally fourth channel
(depending in the application). Both housings have a separate power supply board (interconnection board). The slave
unit shares the output of the stream selection in the master unit and therefore no additional stream selection is needed.
The required gas connections between the two housings are preinstalled.
The most important features of the Encal3000 Quad are:
Compact EX-d design
Complete stand-alone operation
Capillary and micro packed columns in combination with MEMS analytical components
Fast analysis (extended analysis of higher hydrocarbons up to C12 within 5 minutes)
Highest analytical performance available on the market :
oUncertainty < 0.1 % for a wide range of gases
oRepeatability < 0.01 %
Up to 5 sample streams sequential without external stream selection
Integrated sample system
Internal data storage for the last 35 days of all data
Suitable for extreme environmental conditions
The following paragraphs give a general description of the main parts of the measurement system.

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2.2 Enclosure
The two enclosures of the Encal 3000 Quad are a custom EX design, with
various specific features.
Essentially the explosion proof enclosures are consisting of a low base, to
which a relatively high cap is attached through a screw connection. Once
the cap is removed from the base, almost all the internal components are
directly reachable:
Up to two analytical modules in each housing (which do each a
part of the total analysis, in parallel)
One Processor board (only in the Master Unit)
Internal sample system in the Master Unit (stream selection and
pressure regulation)
All electrical field connections like Ethernet, ModBus, analogue IN,
digital I/O, solenoid drivers, switches and jumpers (only in the
Master Unit) and fuses (in both Units).
Only if the Interconnection Board, which connects the analytical channels and the Processor Board, has to be
exchanged, the unit has to be taken apart. For all other check or maintenance procedures, only the cap has to be
removed.
The device can be mounted to the wall. The mounting holes at the back of each housing are used for the connection of
the housings. In this steel connection are some holes with a size of 8.5 mm available for the connection to the wall.
The gas tubing (sample lines, cal gas and helium in and out, vent lines) and all electrical connections can be directly
connected to the Master Unit. Helium is connected also to the Slave Unit with the tubes between the two units. If Argon
is used as a second carrier gas for the Slave unit it is directly connected to it, all other gas tubing are connected to the
Master Unit.
The design of the enclosures is allowed for the extremists conditions imaginable in natural gas applications:
Explosion proof certified for ATEX II 2G Ex-d IIB T4 and IECEx (equivalent FM approval pending)
IP 66 ingress protection against dust and precipitation (suitable for offshore applications)
Standard temperature range: 0 to +55 ° C (32 to 130 ° F), optional extension
with internal heating to -20 ° C (-4 ° F), with internal heating and external insulation to -40 ° C (-40 ° F)
EMC certification according to EN 61000-6 - 2/4 (Industrial devices)
Vibration and shock test according to OIML D11 11- 1/2
Coating according to Shell specifications DEP 40.4800.30 for off-shore applications

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2.3 Assembly of major components and internal components
fig. 2-1 shows the exploded view of the different internal components of the Master Unit of the EnCal3000 Quad.
The components in the slave unit are in principle the same, except that, the pressure regulators for each stream and the
processor board are not installed because they are only needed in the Master Unit.
The frame is used for mounting the components. It allows the removal of all the direct and individual components, with
the exception of the interconnection board. The components can be removed directly and individually by unscrewing just
a few screws.
If the Interconnection Board must be removed (bottom), the frame has to be removed from the enclosure base first. This
arrangement permits the service engineer to easily review the board in case malfunctions would occur.
The detailed description of the functionalities of each component will be done in the following paragraphs.
fig. 2-1 Exploded View on the Internal Parts of the EnCal 3000 Quad

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2.4 Channel
A channel consists of the following subcomponents:
Analytical Module. This is the heart of the EnCal 3000: it contains the column, sample injector, detector and the
heaters for the columns and the injector
AMI (Analytical Module Interface): electronic circuit which controls the analytical components of the Analytical
Module. It has its own EDS (Electronic Data Sheets) which stores the local configuration parameters
EPC: Electronic Pressure Control for adjusting the pressure of the analytical column
Channel Controller: electronic circuit which controls the communication between AMI and Processor Board, and
also controls the EPC (Electronic Pressure Control) and valves needed for the control of the internal gas flow
circuit.
Both AMI and Channel Controller have their own EDS (Electronic Data Sheets) which stores the local configuration
parameters. This enables to swap to channels without a need for reconfiguration, uploading the internal settings is
sufficient to fully install a new channel in an existing unit.
The Analytical Module uses different columns for different applications. In an EnCal 3000 Quad up to four columns can
be selected, the following columns are possible:
1.) HSA-0,4m Channel for Nitrogen, Methane, Carbon Dioxide, Ethane and Ethylene
2.) 5CB-8m Channel for higher hydrocarbons Propane to Nonane
3.) 5CB-4m Channel for higher hydrocarbons Nonane to Dodecane
4.) PPU-10m Channel for Hydrogen Sulphide, Carbonyl Sulphide, water vapour, methanol
5.) M5A-10m molesieve Channel for Helium, Hydrogen, Oxygen, Nitrogen and Carbon Monoxide
6.) 13CB-12 Channel for odorants like THT and TBM, Methylmercaptane and Dimethylsulphide (DMS)
7.) AL2O3-Channel for saturated hydrocarbons from Propane to n-Pentane and unsaturated hydrocarbons like
Propylene, Propadiene, i-Butene, 1-Butene, trans-2-Butene, cis-2-Butene and 1,3-Butadiene
8.) COX-1m for Helium, Hydrogen, Nitrogen, Methane, Carbon Monoxide, Carbon Dioxide and Ethane
In the biogas-application for the M5A column, two additional internal humidity filters are required, which are mounted on
the module. These filters are used to reduce humidity to a minimum. Humidity can penetrate by diffusion of air into the
analytical column.
Without the filter, this humidity would reach the analytical module and be absorbed by the column material. Therefore,
the retention times of the measured components would reduce always so that the separation of the measured
components is deteriorated and a heating up of the column would be required after about 3 months.
With the filters ensures that a heating up of the M5A column is not necessary within a year (calibration cycle). As the
capacity of the attached filter is very low, the filter should be changed with each recalibration. For the carrier gas argon
always an additional external humidity filter should be used.

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fig. 2-2 Overview of Channel Components
The next page shows the internal gas flow configuration of the channels.

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fig. 2-3 Internal Gas Flow Circuit for each Analytical Channel of the EnCal 3000 Quad,
during Normal Operation (top) and sample Injection (below)

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Detector
Solenoid V1
Solenoid V2
Solenoid V3
Solenoid V4
Solenoid V5
inlet
Solenoid V6
outlet
sample
loop
inject valve
Manifold block
Column vent
Reference vent
Sample vent
EGC/Ref vent
Sample
Injector
Analytical
column
Reference
column
Pump Manifold
Pressure
sensor
Pre
column
Pump sample valve
Pump valve
Backflush
valve
BF vent
Detector
Solenoid V1
Solenoid V2
Solenoid V3
Solenoid V4
Solenoid V5
inlet
Solenoid V6
outlet
sample
loop
inject valve
sample valve
Manifold block
Column vent
Reference vent
Sample vent
EGC/Ref vent
Sample
Injector
Analytical
column
Reference
column
Pump Manifold
Pressure
sensor
Pre
column
Backflush
valve
Pump
Pump valve
BF vent
fig. 2-4 Internal Gas Flow Circuit for each Analytical Channel with backflush of the EnCal 3000 Quad,
before activating backflush valve (top) and after activating backflush valve (below)

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2.5 Processor Board
The main components of the board that becomes used until the end of year 2014 are:
Processor (AMD 133 MHz 16bit)
Flash Memory 32 MB for local data storage
Ethernet card
Data communication ports (DB9, DB15, DB25 and Ethernet) for TCP/IP and serial ModBus communication, and
Analogue and Digital I/O
Pressure and Temperature measurement
I/O controller for data communication with the Analytical Channels
fig. 2-5a: Processor board connections and dataflow block scheme until Dec. 2014

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fig. 2-6b: Processor Board connections for main board used from January 2015
Save parameters in the measuring unit
Setting the "Configuration Jumpers" can protect the parameters on the measuring unit computer witch was loaded by
using the software RGC 3000. This configuration Jumper is at the same position for the old and the new mainboard.
If the jumper is set,the parameters inside the measuring unit cannot be override.
Changes in the parameters can only be transferred to the measuring unit, if the jumper is not set. The setting of the
jumper, can be checked on the display of the “instrument status” page. See Section 3.2 of the software manual. How to
set the jumper is shown in Figure 2.6.
Arm9
Processor
DHCP
Switch
Configuration
Jumper
Digital I/O
COM2
COM1
Ethernet
Port
Analogue
I/O
SD-Card
Serial Ports
COM3 + 4
I/O Controller
The main components for the new
mainboard which becomes used since
January 2015 are:
- Arm9 Processor
- A Flash-Memory 32 MB for local
data storage
- The Ethernet-Port
- Data communication ports (COM1-
4) for serial Modbus, Analogue and
Digital I/O
- USB Port
- I/O Controller for Communication to
the analytical channels
- Pressure- and Temperature Sensor
USB

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fig. 2-7 Save parameters in the measuring unit all bord versions
.
When installed in the EnCal 3000 Quad, a flat cable makes the connection between the communication ports of the
Processor Board and the Interconnection Board, which provides field connections (Phoenix connector) for the data
communication signals. Also 2 fans are mounted to cool the processor in case of elevated ambient temperatures.
fig. 2-8 Processor board with ribbon flat cable and fans mounted in the EnCal 3000