Elster enCore FC1 User manual

FC1-OI-EN d 2015-12-17
i 2015-12-17
From Basic System version 03-03
Flow Computer
enCore
FC1
Manual
Operating Instructions

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Operating Instructions
enCore FC1

enCore FC1
Operating Instructions
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Elster GmbH
Schloßstraße 95a
D - 44357 Dortmund/Germany
Tel.:
[phone]
Fax:
[phone]
E-Mail:
[e-mail]

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Operating Instructions
enCore FC1
Contents
1General Information 8
1.1 The enCore/enSuite Concept 8
1.2 Scope of Delivery 9
2About these Instructions 10
2.1 Target Group Definition 11
2.2 The enCore FC1 Manual at a Glance 12
2.3 Text Labelling 12
2.3.1 Presentation of Safety and Risk Instructions 13
2.3.2 Paragraph Formats 14
2.3.3 Character Formats 15
2.3.4 Character Formats in Flow Charts 16
2.4 Limitation of Liability 17
2.5 Applicable Standards and Guidelines 18
3Safety 19
3.1 General Safety Instructions 19
3.2 Intended Use 21
3.3 Unauthorized Users 22
3.4 Operator Liability 22
4Design and Function 24
4.1 FC1 Flow Computer: Functional Description 24
4.1.1 Number of Streams and their Flow Directions 25
4.1.2 International Standards 25
4.2 Device Description 25
4.3 Operation Panel 27
4.3.1 Device Keys 28
4.3.2 Touch Screen 28
4.3.3 Operation and Navigation within the Display 29
4.3.4 Security Switch 29

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Operating Instructions
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4.3.5 LEDs 29
4.4 Interfaces (Rear Side of Device) 32
4.5 Available Process Boards 32
4.5.1 ExMFE5 Process Board 33
4.5.2 MFE7 Process Board 35
4.5.3 MSER4 Process Board 36
4.5.4 ESER4 Process Board 36
4.5.5 MFA8 Process Board 37
5Assembly Instructions 38
5.1 Line Connection 38
5.2 Power Supply and Grounding 40
5.3 Installation and Conversion of Process Boards 41
5.3.1 Insert a Process Board in a Free Board Slot 42
5.4 Connection Diagrams 46
5.4.1 General Recommendations for Signal and Data Cable 47
5.4.2 Pt100 (EEx i) via ExMFE5 Board 48
5.4.3 Pt100 (EEx d) via MFE7 Board 49
5.4.4 Analog Measurement Transmitter (EEx i) via ExMFE5 Board 50
5.4.5 Analog Measurement Transmitter (EEx d) via MFE7 Board 51
5.4.6 Analog Measurement Transmitter (EEx i) via MFE7 Board 52
5.4.7 HART Measurement Transmitter (EEx i) via ExMFE5 Board 53
5.4.8 HART Measurement Transmitter (EEx d) via MFE7 Board
(Internal Power Supply) 55
5.4.9 HART Measurement Transmitter (EEx d) via MFE7 Board
(External Supply Voltage) 56
5.4.10 HART Measurement Transmitter (EEx i) via MFE7 Board 58
5.4.11 HART Measurement Transmitter (EEx d) via MFE7 Board
(redundant) 60
5.4.12 HART Measurement Transmitter (EEx i) via MFE7 Board
(redundant) 62
5.4.13 Gas Meter (Turbine): Encoder Index, 2 LF/HF Sensors (EEx i)
via ExMFE5 Boards 64
5.4.14 Gas Meter (Turbine): Encoder Index, 2 LF/HF Sensors (EEx i)
via MFE7 Board 65

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5.4.15 Gas Meter (Turbine) SMRI Bi-directional: 2 HF Sensors, Flow
Direction Detection (EEx i) via MFE7 Board 67
5.4.16 Gas Meter (Turbine) SMRI Bi-directional:
Flow Direction Detection Internal (EEx i) via MFE7 Board 68
5.4.17 Q.Sonic Ultrasound Gas Meter: Serial RS485 (EEx d) via
MFE7 Board 70
5.4.18 Q.Sonic6 Ultrasound Gas Meter: Serial RS485 (EEx d) via
MFE7 Board 71
5.4.19 FLOWSIC600 Ultrasound Gas Meter: Serial RS485 (EEx d)
via MFE7 Board 72
5.4.20 Serial Interface through COM Port (CPU or MSER4-Board) 73
5.4.21 Analog Output over MFA8 Board (0/4 ... 20 mA) 75
5.4.22 Message Output over MFA8 Board 76
5.4.23 Pulse Output over MFA8 Board 78
6Device Configuration and Commissioning 79
6.1 Device Configuration 79
6.2 Commissioning the Measurement System 81
6.2.1 Checking Device Settings 82
6.2.2 Checking Measurement Input Values 82
6.2.3 Checking Output Signals 82
6.2.4 Checking Digital Communication (Modbus, etc.) 82
6.2.5 Checking Measurements and Calculations 82
6.2.6 Sealing (if necessary) 82
7Maintenance 83
7.1 Battery Replacement 83
7.1.1 Changing Batteries 84
7.2 Cleaning 86
7.3 Customer Service 87
7.4 Replacement Parts and Accessories 87
7.5 Warranty Conditions 88
8Decommissioning/Disposal 89
8.1 Storage 89

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Operating Instructions
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8.2 Disposal 90
9Technical Data 91
9.1 General Information 91
9.2 Input channels 92
9.3 Outputs 93
9.4 Interfaces for Digital Communication 93
9.5 Data Protocols 94
10 Index 95
11 Appendix 97

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Operating Instructions
enCore FC1
1 General Information
1.1 The enCore/enSuite Concept
enCore is the name of an Elster product platform for advanced measure-
ment devices. All enCore devices are based on the same hardware
components and software concepts. Both the hardware and software of
enCore devices have a modular design; the configuration of the process
board equipment and the arrangement of software components are variable.
On one hand, the software components consist of basic functionalities,
which are provided by the Basic System with its System Function Blocks
(abbreviated as: SFBs), and on the other hand consist of application-related
functionalities, which come with different Application Function Blocks
(abbreviated as: AFB). Owing to this modular design principle, each device
can be optimally adapted to individual requirements.
enSuite is the name of the PC software supporting all enCore devices along
with a number of other Elster devices. The enSuite software provides tools
for configuration, parameterization, diagnosis, software downloads and other
services.
Parameterization in enSuite
Please note that the changes that you make in parameterization
of enSuite become active in the device only when you activate the
action Transfer parameterization to device and after the enCore
device restarts (automatically).
Refer to volume “Configuration fo Device Software” of FC1
manual.

1 General Information
enCore FC1
Operating Instructions
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1.2 Scope of Delivery
The enCore FC1's scope of delivery includes:
•enCore FC1 electronic flow computer
•confirmation of conformity or factory test protocol
•dispatch list/delivery note
•FC1 manual:
−“Instructions for Use in Legal Metrology”
−“Operating Instructions”
•enSuite installation CD
•USB cable Type A/B
•accessories (plugs incl. housing)

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Operating Instructions
enCore FC1
2 About these Instructions
The present documentation are the Operating Instructions of the overall
documentation, and describe the assembly, installation, commissioning and
maintenance of the flow computer enCore FC1 (called FC1 below).
These instructions make it possible to work with the FC1 in a safe and
efficient manner.
Compliance with all the safety and handling instructions specified in these
Operating Instructions is a prerequisite to working with the FC1 in a safe
manner and using it properly, and for obtaining accurate measurement and
calculation results.
In addition, compliance is also necessary with the guidelines, standards,
local accident prevention regulations and general safety regulations that
apply for the FC1's area of application.
Manuals as product components
The volume “Use in Legal Metrology” and this “Operating
Instructions” are product components. Therefore, these must
always be kept in the immediate vicinity of the FC1 and easily
accessible to the installation, operational, maintenance and
cleaning personnel.
These two volumes are delivered in printed form with the device.
The illustrations in this manual serve to depict the facts that are being
explained, and therefore may differ from the actual design of the FC1
depending on the configuration of FC1 and enSuite.
The data and material properties that are presented below are
guidelines. They must be reviewed for each individual case and
corrected if required.

2 About these Instructions
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2.1 Target Group Definition
The present documentation is directed to qualified electricians in the fields of
switch cabinet construction and maintenance, as well as qualified personnel
with specialized knowledge in device assembly and commissioning.
The qualifications for different areas of activity are listed below:
•trained individual
A person, who has been instructed by the plant operator in an
informational session on the tasks assigned to him or her, and on
possible hazards in case of improper behavior.
•specialist personnel
A person who has the ability, because of his or her technical
training, knowledge and experience, as well as his or her
knowledge of the relevant regulations, to carry out the work
assigned to him or her at the FC1, and to recognize and avoid
possible hazards independently.
•gas specialist
A person who has the ability, because of his or her technical
training, knowledge and experience, as well as his or her know-
ledge of the relevant standards and regulations, to carry out work in
gas systems, and to recognize possible hazards independently. A
gas specialist receives training for the specific location in which he
or she works, and is acquainted with the relevant standards and
regulations.
•metrology expert
A person who has the ability and is authorized, because of his or
her technical training, knowledge and experience, to carry out
legally relevant tasks in gas systems within the scope of legal
metrology. A metrology expert is acquainted with the relevant
standards and legal regulations that apply in specific countries. In
the European the legally relevant tasks are executed by the
designated notified body.
•qualified electrician
A person who has the ability, because of his or her technical
training, knowledge and experience, as well as his or her know-

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Operating Instructions
enCore FC1
ledge of the relevant standards and regulations, to carry out work in
electrical systems, and to recognize and avoid possible hazards
independently. A qualified electrician receives training for the
specific location in which he or she works, and is acquainted with
the relevant standards and regulations.
2.2 The enCore FC1 Manual at a Glance
The FC1 manual is made up of four parts in all:
•“Use in Legal Metrology”
This volume focuses on the legally relevant properties and
functions of the FC1 flow computer.
•“Operating Instructions”
This volume describes the assembly, installation, commissioning
and maintenance of the FC1.
•“Configuration of Device Software”
This volume describes parameterizing devices of the enCore series
with the software system enSuite, the software download and
further services.
•“Basic System with SFBs”
This volume describes the basic system, which provides all basic
functions of the device software. The basic system e.g. manages
the system resources, the I/O boards or the connection to other
devices via digital protocols.
•Functionality of individual Application Function Blocks
Each volume describes the parameterization, function and
operation of each AFB. These volumes always describe the full
range of functions of the respective AFBs.
2.3 Text Labelling
Texts containing different contents are labelled differently. With the help of
following characteristics, you can identify which content of the text is pro-
vided to you:

2 About these Instructions
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Operating Instructions
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2.3.1 Presentation of Safety and Risk Instructions
Hazard Warnings
Hazard warnings indicate hazardous situations which may result in material
damage and bodily harm or even death if disregarded.
Hazard warnings are described below:
DANGER WORD!
Type of danger
Consequences in case of non-compliance
Avoiding danger
The danger word signals the hazard level:
•DANGER!
… indicates an imminently hazardous situation that leads to death
or severe injuries.
•WARNING!
… indicates a possibly hazardous situation that may lead to death
or severe injury.
•CAUTION!
… indicates a possibly hazardous situation that may lead to slight
or minor injuries.
•ATTENTION!
… indicates a possibly hazardous situation that may lead to
material damage.
Safety Instructions
Safety instructions include notes and information which if disregarded may
lead to functions not working correctly or not working at all.

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Safety instructions are described below:
Safety instruction (optional)
Safety instruction text
Tips and recommendations
Tips include notes and information that make it easier for the user to operate
the FC1.
Tips are described below:
Heading (optional)
Hint text
2.3.2 Paragraph Formats
►This triangle prompts you for an action.
This character will show you the immediate result of your action.
For the FC1 symbol, the result of your operation is shown in running
operation of the device after you have transferred an enSuite para-
meterization to the device and the FC1 is restarted with this para-
meterization.
Example
Multi-row examples are marked by two continuous blue lines and the
keyword “Example”.

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Operating Instructions
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2.3.3 Character Formats
Example Use
Time Service Names of the individual SFB and AFB soft-
ware elements of the FC1.
refer to chapter 2.3.3
Character Formats (p. 15)
References to additional information are
marked with an arrow. If the arrow refers to
information within document, these referen-
ces are formated as hyperlinks in blue font.
You directly go to corresponding text pas-
sage by clicking the blue text.
Tab Parameters Marking of graphic screen elements or
messages which you find again on the
screen. These include, for example, menu
items, marking of tabs and parameters.
[OK]
[F1]
Marking of buttons and keys are additionally
framed with square brackets.
<Modbus AFB > Place holders are specified in angle-
brackets and represent the corresponding,
current value of your system – as in the ex-
ample the name of the Modbus AFB.
[Group 1.]Modbus Optional information is specified in square
brackets. In the example, Group 1 is shown
only when a group has been created in your
device.
admin1 Texts which you enter in enSuite in the
corresponding field.
www.docuthek.com links (Hyperlink)

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Example Use
Date & time You can navigate through different displays
of FC1 via hyperlinks. In the example, you
change to the Date & time display.
Update date and time Actions are also marked in the FC1 display
as hyperlinks. You carry out a specific func-
tionality when you activate an action. In the
example, the system time of the device is
updated.
readme.txt All the alphabetical strings which depict
sheer ASCII character strings such as
identifier for physical quantities, directory or
file names.
Table 2-1: Character formats
2.3.4 Character Formats in Flow Charts
The individual elements are highlighted in the flow charts as shown in the
following. That way, they can be distinguished properly even on a black-and-
white printout:
Example Use
[V Input] enSuite parameters are presented with
square brackets and font color [green].
generated counters
Export values, e.g. generated Flow
Conversion AFB counters, have a
proportional font and blue font color.
“Event messages” Event-messages which are activated or
reset by an AFB are marked in quotation
marks and orange font.
Table 2-2: Character formats in flow charts

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2.4 Limitation of Liability
All specifications and instructions in these Operating Instructions were
compiled after taking into consideration the applicable standards and
regulations, the current state of the art and the knowledge and experience
we gained over the years.
The manufacturer assumes no liability for loss due to:
•non-compliance with these Operating Instructions
•unintended use
•use of the device by non-instructed personnel
•unauthorized device modifications
•technical changes
•use of non-authorized replacement parts
The actual scope of delivery may differ from the explanations and de-
scriptions included here in case of special device designs, the use of
additional order options or because of the latest technical changes.
The obligations arranged in the delivery contract apply, as do the General
Terms and Conditions, manufacturer delivery conditions and current legal
regulations that apply at the time the contract was concluded.
Read through these Operating Instructions carefully before
beginning any work to and with the FC1, especially before
commissioning the device!
The manufacturer assumes no liability for loss and malfunctions
that result from non-compliance with these instructions.
We reserve the right to make technical changes within the scope of im-
proving performance characteristics and continuous development of the
device.

0
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2.5 Applicable Standards and Guidelines
The construction, production and operation of the FC1 is based on the
following standards and guidelines:
•EN 12405-1
Gas meter – Conversion devices – Part 1: Volume conversion
•EN 61000-6-2
Electromagnetic compatibility – Immunity for industrial environ-
ments
•EN 61000-6-3
Electromagnetic compatibility – Emission standard for residential,
commercial and light-industrial environments
•EN 60079-0
Explosive atmospheres – Equipment – General requirements
•EN 60079-11
Explosive atmospheres – Equipment protection by intrinsic safety “i”
•EN 60079-17
Explosive atmospheres – Electrical installations inspection and
maintenance
•EN 60079-25
Explosive atmospheres – Intrinsically safe systems
•ISO 12213
Parts 1-3: Natural gas – Calculation of compression factor
•ISO 6976
Natural gas – Calculation of calorific values, density, relative
density, and Wobbe index from composition

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3 Safety
3.1 General Safety Instructions
WARNING!
Risk of explosion
A risk of explosion exists if the FC1 is improperly assembled
and connected!
•The FC1 must be installed outside of Ex zones 0, 1 and 2.
•Assemblies which are authorized as associated category ib
electrical equipment with intrinsically safe electrical circuits in
accordance with EN 60079-11 can be installed in the FC1,
e.g. input boards with the label ExMFE5. The FC1 is there-
fore suitable for connecting to transmitters, pulse and signal
sensors that are located in the potentially explosive area e.g.
in zone 1. A mixed connection of intrinsically safe and non-
intrinsically safe circuits is not permitted for these assemblies.
•Only measurement transmitters and pulse sensors of the in-
trinsically safe protection class [Ex ib Gb] II C may be
connected to the ExMFE5 assembly terminals provided for
that purpose.
•All signals from the potentially explosive area (zone 0,
zone 1, zone 2) must be regulated using suitable Ex isolators
if they are connected to some other assembly group that is
not the input board ExMFE5.
•The regulations in the relevant standards, especially
EN 60079-0, EN 60079-11, EN 60079-17 and EN 60079-25,
must be obeyed unconditionally.

Safety 3
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Safety and warning instructions
The following safety and warning instructions must be observed
unconditionally:
•Any individual appointed to perform work on or with the FC1
must read and understand these Operating Instructions
before beginning work. This also applies if the individual
concerned has already worked with such a device or a similar
one, or was instructed by the manufacturer.
•In order to avoid risks and to ensure that the FC1 performs in
an optimal manner, no changes or modifications that were not
expressly authorized by the manufacturer may be performed
on the device.
•The FC1 must not be exposed to temperatures below −25°C
or above +60°C during storage.
•A temperature that is between −10°C and +55°C must be en-
sured while the FC1 is being operated.
•The power supply in FC1 is over a 24 V DC, and this supply
must be protected externally using a 1A time-delay fuse.
•The grounding system is connected to the power supply
socket PE for potential equalization.
•The threshold values listed in the certificates of conformity
(e.g. EC type examination certificate ATEX) for the boards to
be connected to the device must be observed.
The threshold values that are listed in the certificate of conformity
for the applicable authorization must be observed while using the
device within the scope of legal metrology e.g. of EC type
examination certificate (MID).
For a description of the process boards refer to chapter 4.5
Available Process Boards (p. 32).