Honeywell Elster EK280 User manual

73021209
Issue date 2019-01 (f)
From software version 2.51
Volume Conversion Device
EK280
Operating Instructions

Exclusion of liability
The information contained in this document is the property of Honeywell.
The following information may only be used for its intended purpose. This
document or its contents must not be copied, published or made accessible
to a third party in full or in part without the express consent of Elster GmbH.
All specifications and descriptions in these operating instructions have
been compiled following careful testing. In spite of this, errors cannot be
completely ruled out. Honeywell can therefore not provide any guarantee
that the content is complete or correct. The instructions must also not be
seen as a warranty of product features. Furthermore, features are also
described here which are only available as an option.
Honeywell cannot accept liability in any case for direct, special or
consequential damage suffered by third parties. The information and
specifications in this document may be amended without notice.
In view of extended product liability, the listed data and material
properties should only be regarded as reference values and must
always be checked for each individual case and corrected if
necessary. This is especially the case when safety aspects are
affected.
Further support is available from your local branch office or agent. The
address is available on the Internet or from Honeywell.
This manual or parts of it may only be disclosed or copied with written
consent from Honeywell.
If the product described here is improperly handled, repaired or changed by
unauthorized persons or if spare parts other than those supplied by
Honeywell are used, our warranty will be rendered void.
All rights reserved.
Copyright © 2019 Elster GmbH, D-55252 Mainz-Kastel. All rights
reserved.
Mainz-Kastel, January 2019

3
Contents
1General................................................................................................. 7
1.1 Information about this manual.......................................................7
1.2 Warranty provisions.......................................................................7
1.3 Customer service and and Technical Support (TAC) ...................7
1.3.1 Customer service and repairs ..............................................................8
1.3.2 Technical Assistance Center (TAC).....................................................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....................................................................10
1.7 Scope of delivery.........................................................................10
1.8 Spare parts and accessories.......................................................10
1.9 Storage........................................................................................11
2Safety ................................................................................................. 12
2.1 General........................................................................................12
2.2 Intended use................................................................................15
2.3 Personnel ....................................................................................16
2.4 Personal protective equipment....................................................17
2.5 Specific risks ...............................................................................18
2.6 Environmental protection.............................................................19
2.7 Operator's responsibility..............................................................19
3Technical data ...................................................................................20
3.1 General data................................................................................20
3.1.1 Dimensions ........................................................................................21
3.2 Power supply for EK280 without integrated power supply unit...22
3.2.1 Battery power supply for the basic device..........................................22
3.2.2 Battery power supply for the integrated modem.................................22
3.2.3 External power supply for the basic device........................................22
3.3 Power supply for EK280 with integrated power supply unit........23
3.3.1 Battery power supply for the basic device..........................................23
3.3.2 External power supply........................................................................23
3.3.3 Buffer batteries for the integrated modem..........................................23
3.4 Power supply for the EK280 with Power over Ethernet (PoE)....23
3.5 Pressure sensor ..........................................................................24
3.5.1 CT30 Type Pressure Sensor..............................................................24
3.5.2 Pressure Sensor Type 17002 ............................................................25
3.6 Temperature sensor....................................................................25
3.7 Digital inputs................................................................................25
3.7.1 LF pulse and signal inputs .................................................................25
3.7.2 HF pulse inputs (high frequency) .......................................................26
3.7.3 Encoder input.....................................................................................26

4
3.8 Digital outputs..............................................................................27
3.8.1 Nominal data..................................................................................... 27
3.8.2 LF pulse or signal outputs................................................................. 27
3.8.3 HF pulse outputs............................................................................... 27
3.9 Interfaces.....................................................................................28
3.9.1 Serial optical interface....................................................................... 28
3.9.2 Serial electrical interface................................................................... 28
3.9.3 Integrated modem............................................................................. 28
3.9.4 Ethernet adapter ............................................................................... 29
3.10 Measurement conditions .............................................................29
3.10.1Environment...................................................................................... 29
3.11 Labelling ......................................................................................29
3.11.1Type label of the volume corrector.................................................... 29
3.11.2ATEX marking................................................................................... 30
3.11.3Device software identification............................................................ 31
4Construction and Function ..............................................................32
4.1 External view ...............................................................................32
4.2 Internal view ................................................................................32
4.3 Short description..........................................................................33
4.4 Connections.................................................................................33
5Assembly, Connection and Putting into Operation.......................34
5.1 Assembly.....................................................................................34
5.1.1 Assembly on a gas meter.................................................................. 35
5.1.2 Assembly on a pipeline ..................................................................... 35
5.1.3 Assembly on a wall ........................................................................... 36
5.1.4 Three-way valve................................................................................ 36
5.2 Connection ..................................................................................37
5.2.1 Connecting the gas meter................................................................. 38
5.2.2 Sealing the input terminals................................................................ 40
5.2.3 Connecting the temperature sensor.................................................. 40
5.2.4 Connecting the pressure pipe ........................................................... 42
5.2.5 Connecting the power supply............................................................ 43
5.2.6 Connect outputs of the EK280 .......................................................... 45
5.2.7 Earthing the EK280 housing.............................................................. 46
5.2.8 Earthing the cable connections of the EK280.................................... 47
5.2.9 Additional measures for installation in zone 2................................... 47
5.3 Putting into operation...................................................................48
5.3.1 Configuration of measurement parameters....................................... 48
5.3.2 Sealing.............................................................................................. 59
5.3.3 Closing the housing........................................................................... 60
5.3.4 Verifying assembly and connection................................................... 61
5.3.5 Programming a data transfer............................................................. 61
6Operation ...........................................................................................62
6.1 Safety...........................................................................................62
6.1.1 Personal protective equipment.......................................................... 62

5
6.2 Operating personnel....................................................................62
6.2.1 Instructed personnel...........................................................................62
6.2.2 Qualified personnel............................................................................62
6.2.3 Calibration officers .............................................................................63
6.3 Basic principles ...........................................................................63
6.3.1 Display...............................................................................................64
6.3.2 Button functions .................................................................................65
6.3.3 Data recall, display navigation ...........................................................66
6.3.4 Meaning of status symbols.................................................................67
6.3.5 Error messages when entering values...............................................68
6.3.6 Access rights......................................................................................69
6.4 Data register content...................................................................72
6.4.1 Access rights......................................................................................72
6.4.2 "Main" register (main display).............................................................72
6.4.3 "Cust." register (Customer) ................................................................74
6.4.4 "Admin" register (Administrator).........................................................76
6.4.5 "Serv." register (service) ....................................................................77
6.4.6 "Ctrl." register (Control)......................................................................78
7Maintenance ......................................................................................80
7.1 Safety ..........................................................................................80
7.1.1 Personnel...........................................................................................82
7.1.2 Personal protective equipment...........................................................82
7.1.3 Environmental protection ...................................................................82
7.2 Testing and changing device batteries........................................83
7.2.1 Changing and connecting device batteries ........................................83
7.2.2 Entering the battery capacity..............................................................85
7.2.3 Display remaining battery power........................................................86
8Faults..................................................................................................87
8.1 Safety ..........................................................................................87
8.1.1 Personnel...........................................................................................88
8.1.2 Personal protective equipment...........................................................88
8.1.3 Improper elimination of faults.............................................................88
8.1.4 Behaviour in the event of faults..........................................................89
8.2 Fault and other status messages................................................89
9Appendix............................................................................................95
9.1 List of spare parts and accessories.............................................95
9.1.1 Fastening elements............................................................................95
9.1.2 Pressure connections.........................................................................95
9.1.3 Temperature sensor pockets .............................................................95
9.1.4 Small parts and miscellaneous ..........................................................96
9.1.5 Documentation...................................................................................96
9.2 EC Declaration of Conformity......................................................97
9.3 ATEX Type Examination Certificate............................................98
9.3.1 Zone 0, 1............................................................................................98
9.3.2 Zone 2..............................................................................................106

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
illustrations used in this manual serve as a visual representation of the
described processes and are therefore not necessarily to scale and may
deviate from the actual design of the device.
i
The data and material properties indicated serve as
reference values. These must be verified on a case-by-case
basis and adjusted as necessary.
i
The EK280 Application Manual is available for you at
www.ek280.de (→„Docuthek“) for the commissioning of the
various communication and device applications.
In general, you can download the manuals in various
languages directly from the Honeywell Docuthek. Enter
"EK280" as search term.
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 and and Technical Support (TAC)
Our customer service team is responsible for providing technical
information and repairs. Our employees are constantly striving to acquire
new information and gain experience, and these are both valuable sources
for improving our products.

8 General
1.3.1 Customer service and repairs
–Phone: [phone] / 605-0
–Fax: [phone] / 605-390
–E-mail: [e-mail]
1.3.2 Technical Assistance Center (TAC)
Our Technical Support (TAC Technical Assistance Center) is at your
disposal in case of faults:
–Phone: [phone] / 605-123
–Website: www.elster-instromet.com/en/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.

General 9
… indicates dangers resulting from electrical current. A
non-compliance of the safety information poses a risk of
serious or life-threatening injuries.
CAUTION!
... indicates a potentially dangerous situation which, if not
avoided, could lead to material damage.
1.4.2 Tips and recommendations
… provides useful tips and recommendations as well as
information 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
manufacturer 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
ordering 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
liability for damages and losses arising from non-compliance
with the manual.
We reserve the right to make technical changes within the scope of
improving usability and further development.

10 General
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
permitted without written consent from the manufacturer, except for internal
purposes. Contraventions to this provision shall result in damage
compensation. We reserve the right to assert further claims.
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
present 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
program the EK280 volume conversion device via its data interfaces to
perform 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

General 11
found under www.elster-instromet.com and in the "Assembly, Connection
and Putting into Operation" chapter.
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 storage of the
device is exceeded or fallen below, the performance 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
condensation.
Fluctuations in temperature during storage may cause condensation to
form. This may lead to subsequent malfunctions of the device.
Therefore:
–After storage or transport in cold weather conditions or after having
been exposed to strong temperature fluctuations, the device should
slowly be adjusted to the room temperature before being put into
operation.
–If condensation has formed, wait at least 12 hours before putting the
device into operation.
If the power supply to the device is interrupted during
storage 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
operation of the device. A non-compliance with the safety information and
instructions 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
–EK280 with or without integrated power supply unit with
Ethernet Adapter:
Zone 2 for gases in temperature class T…
Verification for use in zone 0, 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 0, 1 as this
presents a risk of explosion!
Therefore:
–Before installing the device in zone 0, 1, please check that the EK280
is suitable for use in zone 0, 1.
–The EK280 should only be operated in zone 0, 1, if category "II 1 G"
or "II 2 G" have been marked on the ATEX label.
–If category "II 3 G" has been marked on the ATEX label, the EK280
should not be used in zone 0, 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 0, 1 and connecting devices which are not
certified as "associated equipment" present a risk of explosion.
Therefore:
–When using the EK280 in zone 0, 1, it should only be connected 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
device (see chapter 9.1.4 .)
When connecting and operating the EK280 in explosive gas
atmospheres, the corresponding standards must be
observed:
DIN EN 60079-0
DIN EN 60079-14
The device may only be used in zone 0, 1 or zone 2, if
installation has been carried out according to the separate
requirements stipulated under DIN EN 60079-14 and the
operating 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.

14 Safety
–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.
–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
immediately.
–The setting values and value ranges specified in this manual should
be complied with.

Safety 15
2.2 Intended use
This device is solely designed and constructed for the intended use
described 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 variables 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.

16 Safety
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
personnel.
The following qualifications are used in the manual to denote different
areas of responsibility:
–Instructed personnel
will be informed of the tasks assigned to them and possible risks
resulting from inappropriate behaviour, 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 independently 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.

Safety 17
–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 relevant standards and regulations.
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
impaired, e.g. by drugs, alcohol or medication, shall not be authorized to
perform such works.
–When selecting personnel, please observe the valid age and
professional guidelines for all of the gas-handling equipment.
2.4 Personal protective equipment
When working on the device inside a gas-handling plant, personal
protective equipment must be worn to minimize risks to health.
–During works on the device, the necessary personal protective
equipment 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.

18 Safety
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
following 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
temperatures. 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
irritation. Avoid physical contact with such liquid. In the event of
contact, rinse with large quantities of water. If the liquid enters the
eyes, immediately 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
responsible 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.

Safety 19
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
environmentally hazardous substances are accidentally released into
the environment. 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
hazardous 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
device will therefore be subject to legal obligations concerning occupational
safety.
In addition to the safety information contained in these instructions, the
valid 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 device is being integrated, are complied with.
–The operator must be familiar with the valid occupational safety
regulations 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
determine whether their prepared operating instructions are
compatible with current regulations and amend these if and when

20 Technical data
necessary.
–The operator must clearly regulate and define responsibilities for the
assembly, connection, putting into operation, and maintenance of the
device.
–The operator must ensure that all employees who use the device
have read and understood this manual. Furthermore, the operator
must provide training to personnel at regular intervals and inform
them of the potential 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
remains 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.
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
Mechanical ambient conditions accord. to
MID Directive:
class
M2
Electromagnetic ambient conditions accord.
to MID Directive:
class
E2