Elster EnCal 3000 Quad Hardware Manual

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

1 Process 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

2 Functional 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

3 Technical Specifications ..................................................................................................................... 30

4 Data 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

5 Hardware 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

Elster GmbH

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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:

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:

Important disclaimer:

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.

ATEX II 2 G Ex-d IIB T4 and IECEx

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

If the equipment is used in a manner not specified by the manufacturer,
the protection provided by the equipment may be impaired.

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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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1 Process Gas Chromatography – General Introduction

1.1 Analytical Principle

The analytical principle is shown in fig. 1-1:

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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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fig. 1-1 Principle of a Gas Chromatography

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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:

o High and low temperatures
o Dust and precipitation
o Electro-magnetic influence
o Wind
o Corrosive atmospheres
o Vibrations and shocks

 Complete stand-alone operation, no operator interference during normal operation:

o Automatic and continuous analysis of different streams
o Control and processing of analytical measurement executed internally, no peripheral device needed
o Automatic calibration and verification

 Standard maintenance limited to yearly intervals, without need for specifically trained people

o High reliability of the components
o High 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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2 Functional 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 :

o Uncertainty < 0.1 % for a wide range of gases
o Repeatability < 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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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

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.

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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

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This board has the following functions:

 Power supply input (24 VDC)
 DC/DC converter (18 – 36 VDC)
 Connection of Processor Board with Analytical

Modules

 Field data communication connectors
 Actuation of stream select solenoids
 Enclosure temperature regulation
 Internal DC/DC conversion for various circuits

fig. 2-9 Interconnection Board

2.6 Interconnection Board

The scheme below shows the overall electrical configuration of the EnCal 3000.

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fig. 2-10 Overall Electrical Configuration of the EnCal 3000 Quad

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2.7 Electrical connection to the Slave Unit

There are two electrical conduits between the Master and the Slave Unit, one for the power supply and one for the data
transfer from channel 3 and 4 to the processor board.

There are no customer connections in the Slave Unit, these are all made in the Master Unit.

For the data transfer there is an additional board called “wire connection board” connected to the interconnection board
in both units. It is connected to the connector used by the processor board which is not present in the slave unit and
which is stacked on top of this add on board in the master unit. The wire connections between these boards in both
units are straight forward one on one, and should not be changed by the customer.

The power connection to both units is made with a 3 way lever clamp terminal in the master unit.

fig. 2-11 Wire Connection board for the Encal3000 Quad

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2.8 Cabinet Heaters

The cabinet heaters are used for frost protection. They are attached directly to the mounting plates and provide
additional heat when the internal enclosure temperature goes below 10 °C (50 °F). Figure 2.9 shows the location of the
cabinet heaters. For an Encal3000 Quad these heaters have to be installed in both housings, the principle is illustrated
for one housing in the following picture.

fig. 2-12 Cabinet heaters location in the EnCal 3000

For the regulation of the heaters standard thermostats with a fixed setting are used. These thermostats are connected
to the interconnection board close to the connectors for the power supply of the heaters (see also fig. 5.5, connectors
J12 and J13).

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Stream purge

Pressure regulators

Stream selection block

Helium purge valve
(optional)

2.9 Internal sample system

The internal sample system has the following functions:

 Double block and bleed stream selection (up to 5 streams / 1 cal)
 Pressure regulator. Advised input pressure is 2 barg. Input pressure range is 1 to 5 barg
 Split of the helium and sample gas to the 2 analytical columns
 Combination of the vent lines of the 2 modules
 Purge of the cabinet with Helium (optional)
 Integrated fast loop function (stream purge)

Elster GmbH

fig. 2-13 Front view of the internal sampling/stream selection system

Helium Purging (optional)

Helium enters the manifold and is split to both analytical modules. Through a purge valve the helium can be vented into
the housing, to expel the air in the housing (activated by time relay 3). Additionally to this the column vent is released
into the housing which is nearly pure helium. If there is a leak in the housing no combustible mixture can be formed
because of the absence of air. The housing withstands the pressure of an explosion but by purging the housing with
Helium the chance of internal damage is also reduced significantly. The purge and the small amount of helium that is
vented into the housing also protects the internal components against moisture or other aggressive components entering
the housing through the breather.

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fig. 2-14 Flow diagram Sample Conditioning and Selection System

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2.9.1 Double Block and Bleed Function

After small particles are filtered out by the inlet filters in the inlet couplings, the pressure is reduced to approximately 0.8
barg. From the pressure regulators the gas will flow to the manifold. There are several valves mounted on the manifold.

The two most right valves are purge valves. The upper purge valve is the sample bypass valve (Activated by timed relay

2). The lower is a helium purge valve and activated by timed relay 3.

The stream and calibration valves form pairs that are actuated at the same time.

The valves left from the purge valves are used for the calibration. Next to the calibration valves there are 1 up to 5 pairs
used for the streams. Depending on the configuration the manifold can support up to 3 or up to 6 streams (including the
calibration gas stream). Unused positions on the manifold are blocked.

Gas will enter at the first (lower) valve which will guide the flow to the second (upper) valve in actuated situation.
The second valve guides the flow into a common channel. In deactivated situation, the input from the first valve is
blocked and the output is linked to the relieve port of this valve, which vents to the SBV vent. The input of the second
valve is also blocked so it is not possible to build up pressure between both valves. In case one or both valves would
leak, the pressure between the valves won’t rise above the pressure that is present in the common channel because of
the vent to the SBV vent, so mixing up the streams is not possible.

2.9.2 Internal Sample Bypass

The output from all second valves is combined on the common channel. Depending on which channel is activated, a
section of this channel and the deactivated valves, form a dead volume. The outputs from deactivated valves are
therefore relieved to a second common vent channel, which is blocked by the sample bypass valve. Activating this valve
will result in a flow from the activated valves, through the deactivated valves, to the bypass valve. This refreshes all
second valves and the common channels with the new gas, so all dead volumes are refreshed. Actuating the bypass
valve results in a flow that is approximately 15 times higher than the normal flow. The purge valve should be activated
for a short period (±30 seconds default) when a new stream is selected.

The new stream is selected one analysis prior to the injection, so during the analysis the new sample is already flushed
through the manifold. The best moment to activate the sample purge is ending 10 seconds before the injection and then
extended to the front depending on the purge duration. For long sample lines or higher sample line pressures the purge
time may be extended to where the new stream was selected. Keep in mind the purge time also applies to the
calibration gas which must be purged, but larger purge times and frequent purging will deplete the bottle faster. Further
information for the needed setting in the software can be found in the software manual.

The flow through the analytical modules will be reduced during the activation of the bypass, but will continue. Closing
the bypass valve will restore the normal flow to the analytical modules. After the sample gas has passed the manifold it
becomes split for the transport to the two analytical channels that are installed in the master unit. The vent outputs from
both modules return to the manifold and are combined to two venting outputs. The sample output from the manifold in
the Master Unit is connected with the inlet for the sample gas connection from the Slave Unit. In the Slave Unit the
sample gas flow is also split for the transport to the two analytical channels that are in the slave unit. The sample gas
flow can be also increased for the Slave Unit with an additional Purge Valve. The output gases from these channels are
combined again and become transported to the SBV connection of the Slave Unit.

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2.10 Gas Connections

Each gas connection consists of:

 Male Connector 1/8” with internal particle filter 2µ (adapter in following figure) and adaptation to 1/8” or 3 mm

for the carrier gas, calibration and sample gas inlets. This can be replaced without removing the cap of the
analyser

 Male Connector 1/8” with optional adaption to 3mm for output gas
 Adapter, fixed to the housing
 Tubing 1/16”, soldered to the adapter and connected at the other end with the internal sampling system. This

tubing serves as flame arrestor. Its length has to be bigger than 25 cm (19") and should not be shortened by

the customer

fig. 2-15 Gas Connection of the EnCal 3000 Quad

WARNING!! DO NOT LOOSEN THE CONNECTORS (AS DESCRIBED ABOVE) FROM THE
ENCAL 3000 HOUSING. THE SOLDERED TUBE WILL BE DAMAGED!! THE JOINT BETWEEN
CONNECTOR AND HOUSING IS AN INTEGRAL PART OF THE ENCAL 3000’s SAFETY
APPROVAL. IF THE CONNECTOR IS ACCIDENTALLY LOOSENED PLEASE SWITCH OF THE
ENCAL 3000 AND CONTACT THE MANUFACTURER OR YOUR LOCAL ELSTER-INSTROMET
AGENT.



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2.11 Breather

The breather at the back of the enclosure is needed to comply with the ATEX rule which restricts the pressure in the
enclosure to 100 mbar overpressure, in case of total leakage, i.e. if all gas inlet tubing would be internally disconnected
at the same time.

The breather used on the EnCal 3000 is an Ex-d certified device with IP 65 rating, and a vent flow of about 600 l/h at
100 mbar overpressure in the enclosure. It is sealed with Loctite to prevent loosening by unauthorised persons.

When installed outside it should be protected against dirt and rain, i.e. by connecting a swan neck tube to it, the
breather has a 3/8 NPT connection. Any tube connected should have an internal cross section of at least 28mm² 3/8”
tube or larger.

The breather should always vent atmospheric without large pressure fluctuations. The output of the breather must not
be blocked because the valve would not function properly otherwise!

fig. 2-16 EX breather as required by ATEX directive

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2.12 Cable Glands

Two cable glands can be connected to the enclosure base of the Master unit: 1 M25 and 1 M20 cable gland. For the
standard configuration see chapter 5 “Hardware installation”.

Most installations will use one for data communication cable (TCP-IP and/or Serial ModBus) and another for Power
Supply (24 VDC). Additionally also signal cables (such as alarm contacts, carrier gas control, etc) might be used as long
as they are combined in the same cable.

fig. 2-17 Location of Cable Glands at the right of the Enclosure Base

Cable glands with a sealing system are typically required. Installation directive EN 60079-14 recommends for Ex-d
devices with an internal volume > 2 dm3 the so-called “Barrier Glands”, incorporating compound filled seals around the
individual cores or other equivalent sealing arrangements. The cable glands and blind covers of unused openings must
be installed correctly and non-flammable.

2.13 External Switch

To comply with Electrical Safety Standards IEC 60947-1 and IEC 60947-3, an external switch has to be located close to
the analyser, enabling an operator to close down the unit in case of emergency. It has to be marked with "Disconnecting
Device". Practical implementation of this requirement will differ from site to site. In any case the external switch
installation has to comply with all national, local, and company codes applicable to the location.

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Hardware up to 4 parallel isothermal GC modules with narrow-bore capillary column

technology in combination with MEMS based analytical components

Analysis Output Extended analysis of any natural gas up to C9 (standard) or C

12

(optional)

Heating Value, Density, Wobbe Index

Component Range for natural gas (standard) possible additional components

N2 : 0.005 – 20 % CH4S, TBM: 0.0001 – 0.002 %
CH4 : 55 – 100 % THT: 0.0002 – 0.002 %
CO2 : 0.001 – 20 % C

10

: 0.0001 – 0.002 %

C

2

: 0.001 – 14 % C11, C12: 0.0001 – 0.001 %

C

3

: 0.001 – 6 % C6 H6, C6 H12: 0.0001 – 0.1%
i, n-C4 : 0.001 – 3 % C7 H8, C7 H14: 0.0001 – 0.1%
neo-C5 : 0.005 – 0.25 % H2 : 0.001 – 5 %
i, n-C5 : 0.001 – 0.25 % O2 : 0.005 – 4%
C

6

: 0.001 – 0.1 % H2S : 0.0002 – 1%
C

7

: 0.001 – 0.05 % COS : 0.0001 – 1%
C

8

: 0.001 – 0.02% He : 0.001 – 1 %
C

9+

: 0.001 – 0.01 % H2O: 0.001 – 0.05%
CH3OH: 0.005 – 0.1%

Concentrations outside this scope might be possible, but verification with Elster-
Instromet is needed.

Performance Uncertainty < 0.1 % for all calculated properties

Repeatability < 0.01 % for all calculated properties Linear dynamic range 10

6

Detection limit for C5: 1 ppm, Detection limit for C9: 2 ppm
Analysis time 5 minutes for C9 analysis or C12 analysis

Temperature range 0 °C to 55 °C (32 to 130 °F), extendable to -40 °C to 55 °C (-40 to 130 °F)

Approvals PTB Metrological Certificate (basis version)

Analytical

Dimensions Two combined Housings: Base Ø 37 cm x Height 37 cm (Ø 14” x Height 14”)

Installation Clearance 100 cm x 42 cm x Height 70 cm (40” x 17” x Height 28”)

Weight <60 kg for the complete Quad device

Approvals ATEX II2G Ex-d IIB T4 (IIC certification pending) and ICECx

NEC Class I, Div. I, Groups A,B, C & D (pending)

IP 66
Vibration and shock test acc. IEC 60068-2-31 and 64

Mechanical

3 Technical Specifications

Below the main technical specifications:

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Power Supply 24 VDC, 60 W nominal (120 W start-up peak) for non-heated version

24 VDC, 180 W nominal (240 W start-up peak) for heated version (ambient < 0 °C)

Processor Board 16-bit processor 133 MHz, 32 MB Flash Memory

Interfaces Ethernet UTP 10 Base-T for ModBus TCP/IP and PC link

Two RS 232/485 ports (user selectable) for ModBus RTU
3 analogue I/O for local sensors (4-20 mA or 0-10 VDC)

Fuses F106 and F107 for 24V power supply

Battery back-up Lithium Button battery, Type CR 2032 Li-Mn 3V

Approvals EMC according to EN 61000-6-2 and EN 61000-6-4

Analyser ProTM: complete stand-alone operation, inclusive all calculations and generation of report

formats, without need for operator intervention. Calculations according to ISO 6976, GPA 2172,
ASTM D3588 or GOST 22667

PC RGC 3000: Windows based program for configuration, diagnostics and report generation
(Compatible with Windows XP, Windows Vista and Windows 7)

Data Logging History Log: local storage of last 35 days of all analytical data (analysis, events, alarms,

averages, last chromatogram, calibration data) according to API Report 21.1. All data available
on remote workstation in XML format

DCS Remote monitoring and trending of the system as an integral part of the Instromet

Supervisory Suite

Electrical

Software

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Location Outdoor installation, close to sample point. Only sun shade required

Mounting Wall mounted

Gas connections Swagelok 1/8” or on request 3mm

Electrical connections

Power Supply M20/M25 cable gland for armoured cable Ø 11-17 mm / 17-26 mm
Data Communication M20/M25 cable gland for armoured cable Ø 11-17 mm / 17-26 mm

Installation

Helium / Argon Quality 5.0 or better

Optional 2 bottles with automatic change system
Supply pressure 5.5 barg
Flow ± 4 ml/min per channel (max. 16 ml/min with four channels)

Calibration gas Composition preferably close to pipe line composition

Quality 2.0 or higher
(with a maximal uncertainty of 1% relative deviation for each component)
Supply pressure 1 to 4 barg nominal
Pressure peak protection up to 4 barg
Flow ± 30 ml/min

Gas Cylinders

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4 Data Communication

4.1 Local TCP/IP Data Communication

The main Data Communication Port of the EnCal 3000 Quad is the TCP/IP port, although 2 serial ModBus ports are also
available (see next paragraph). The TCP/IP Port (Ethernet UTP 10 Base-T) is necessary for connection with RGC 3000
(Windows based interface for configuration, diagnostics and report generation), but is also used by preference for
ModBus communication with Flow Computers, DCS systems, PLC and other ModBus hosts, if they are able to handle
ModBus TCP/IP. If not, ModBus serial to TCP/IP are easily available nowadays. For existing systems the 2 serial ModBus
ports can of course also be used.

The picture below shows a typical set-up:

fig. 4-1 Typical Data Communication Set-up for Ethernet Communication with the EnCal 3000 Quad

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4.2 Local Serial ModBus Data Communication

Flow computers or another ModBus host could also be directly connected to one of the 2 serial ModBus ports internally
integrated in the EnCal 3000 Quad.

fig. 4-2 Typical Data Communication Set-up for TCP/IP combined

with Serial ModBus Communication with the EnCal 3000 Quad

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4.3 Remote Access

The schematic below shows the different options for remote access to the EnCal 3000 Quad:

Through Internet:

 Or through a direct connection of the Ethernet switch with Internet (through cable or ADSL modem, or

wireless)

 Or through a VPN connection with the customer’s network, if the Ethernet switch or the local PC is integrated in

this network. In this case the customer has to give (if required only temporarily) a User Account and Login ID
to the remote PC.

If network connection is not available, telephone line connection is also possible:

 Or by using an Ethernet modem with dial-in capability
 Or by using the internal modem of the local PC, and a remote access program like PC Anywhere.

fig. 4-3 Remote Access to the EnCal 3000 Quad

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4.4 ModBus Communication

The picture below shows the ModBus Configuration screen for the EnCal 3000 Quad (see also Software Manual)

fig. 4-4 ModBus Configuration Screen

The ModBus registers are user configurable:

fig. 4-5 ModBus Register Details

 Register Type: Either Read Only (R) or Read/Write (R/W), and either bit (Status) or register size
 Register #: User selectable. For the Instromet protocol be aware of the following restrictions:

 0 – 4999 : 2 bytes per Registers
 5000 – 6999: 4 bytes Integers
 7000 – higher: 4 bytes Floating Point

The Modicon protocol always uses 4 registers

 Data Type: Bit when Status is defined, Integer (16 bit or 32 bit) or Float when Register is defined
 Parameter ID: Instruction set which is available in EnCal 3000 Quad.
 Channel: This column is reserved to define channel # or stream #, depending on the type of Parameter

ID defined

 Peak #: Component number, if applicable

For further details concerning the Modbus communication please refer to the Software Manual of RGC 3000.

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5 Hardware Installation

5.1 Installation specifications

5.1.1 Weight and Dimensions

Weight: < 60 kg for complete Quad device
Dimensions: Analyser : two combined housings Ø 37 x H 37 cm (Ø 14.5" x H 14.5”)

Installation Clearance : 100 cm x 42 cm x H 70 cm (40" x 17” x H 28”)

5.1.2 Installation clearance

fig. 5-1 Mounting Dimensions and Installation Clearance I

fig. 5-2 Mounting Dimensions and Installation Clearance II

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Because the weight of the EnCal 3000 surpasses 55 kg, care must be taken when lifting
or transporting the unit. Make sure to carry the unit with at least 3 persons when no
means for lifting and carrying are available

5.1.3 Wall mounting

Elster GmbH

fig. 5-3 Wall Mounting Bracket Dimensions

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HE

STR1
STR2
STR3
STR4
STR5

CAL

AR

PV

SBV

5.1.4 Connection of utilities

Gas lines: HE Helium 5-6 barg (71-86 PSIg) Recommended pressure 5.5 barg

AR Argon 5-6 barg (71-86 PSIg) Recommended pressure 5.5 barg

(Second carrier gas only to analyse biogas or hydrogen
in natural gas. In standard applications this connection is
not used and closed without piping inside.)

STR1 Stream 1 1-4 barg (15-57 PSIg)
STR2 Stream 2 1-4 barg (15-57 PSIg)
STR3 Stream 3 1-4 barg (15-57 PSIg)
STR4 Stream 4 1-4 barg (15-57 PSIg)
STR5 Stream 5 1-4 barg (15-57 PSIg)
CAL Calibration Gas 1-4 barg (15-57 PSIg)

PV Purge Vent

SBV Sample + Block and Bleed Vent

All gas and vent lines do have a 1/8” (or optional 3 mm) Swagelok connections to the EnCal 3000

Following figure shows the location of the connections to the EnCal 3000 Quad.

fig. 5-4 Connections to the EnCal 3000 Quad

If the second carrier gas Argon is not needed for any channel than the connection for AR becomes plugged.

Power Supply cable

24 VDC / 240 W max
Conductor cross section: AWG 12-13 (2.5 - 4 mm²)
Armoured cable required for outdoor installation – OD between 12 and 25 mm

Data Communication

Ethernet : shielded twisted 4 wire cable or industrial CAT5
ModBus Serial : shielded twisted pair

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J1 Processor board connection
J2 Channel 1 Connector
J3 Channel 2 Connector
J4 I/O Flat cable to Processor board
J5 TCP/IP connection between Inter-

connection board and Processor board

J6 Modbus RS485/232 connections
J7 Ethernet connection
J8 Solenoids terminal power suppl. 24 V DC
J9 Power supply out (12 VDC / 24 VDC)
J10 Analogue inputs (0-10 V DC)
J11 Solenoids terminal for valves of

streamselection(0-12 V DC)

J12 Power supply heater 1 (24 V DC)
J13 Power supply heater 2 (24 V DC)

J14 Dip Switch Power supply valves

(internal current supply circuit)

J15 Digital Inputs (passive contact)
J17 Fan1 power supply connection (12 V DC)
J18 Fan2 power supply connection (12 V DC)
J19 Input
F106 Fuse for analytical channels Module
F107 Fuse for additional cabinet heaters
LD101 LED (internal 12 V- circuit)
LD102 LED (activation valves streamselection)
LK 301-304 4 jumper for selection between

RS232 and RS485

LK 305-308 4 jumper for selection of analoge input

(4-20 mA or 0-10 V)

5.1.5 Connections to the EnCal 3000 Interconnection board

The drawing below shows the top lay-out of the Interconnection Board at the bottom of the unit. It contains all the
connectors for external cables. All the wiring with the other electronic boards is done in the factory, and may not be
changed during field installation.

fig. 5-5 Interconnection Board : top view lay-out

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Power Supply Connection:

Power Supply is 24 VDC (tolerance band 18 – 36 VDC), with conductor size AWG 12-13 (2.5 – 4 mm²). An internal cable
is connected to the connector J8. This connection is done for the Master Unit and for the Slave Unit. An external
connection to this internal cable is prepared with two additional connectors with 3 pins. Just a two wire connection for +
and – is required, don’t connect a third wire for the ground. Instead of that the device should be grounded at the
bottom of one housing at a M5 connection or at a free M8 connection at the mounting plate.

fig. 5-6 Location of Power Supply connector (J8)

Ethernet connection:

The Ethernet connection is used for connection with a PC or ModBus TCP/IP clients. It uses 4 wires, connected to
connector J10. See picture below for location and wiring scheme.

fig. 5-7 Location of Ethernet connector (J10) and wiring scheme

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Serial ModBus connection

The Serial ModBus connection is used for connection with Serial ModBus clients like for example Flow
Computers. The EnCal features 2 Serial ModBus ports with identical output. They are both independently
configurable for RS232 or RS485 communication through link settings 301 to 304 (see pictures below for
location, wiring scheme and link settings).

Elster GmbH

fig. 5-8 Location of Serial ModBus connector (J6)

fig. 5-9 Modbus Connection and Link settings

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Electrical Installation in Hazardous Areas

The start-up should be done by an experienced technician, with a proven knowledge of electrical
installations in explosion proof areas. Always remember to make sure there is no hazardous condition
present during installation. Follow the instructions below carefully and make sure you have fulfilled all
necessary safety steps before powering up the EnCal 3000.

5.2 Hardware Start-up

Gas connections:

 Make sure the helium cylinder is tightly secured to the wall and the regulators are tightly mounted on the

cylinder. Check the helium and Argon quality (5.0 – equivalent to Zero Grade classification - or better). Do
not connect yet the tubing to the helium inlet at the EnCal 3000. Open carefully the helium regulator and
check the helium pressure at the outlet of the regulator. Adjust to 5.5 barg (80 psig). Purge the tubing
before connecting to the EnCal 3000 for about 30 s. Make the connection with inlet HE. Check for leaks.

 Make sure the cal gas cylinder is tightly secured to the wall and the regulators tightly mounted on the

cylinder. Check the cal gas certificate. The tube should be flushed once before it is connected to the
Encal3000. Open carefully the cal gas regulator and check the cal gas pressure at the outlet of the
regulator. Adjust to 1-4 barg (15-57 psig). Purge the tubing before connecting to the EnCal 3000 for about
30 seconds. After the connection a check for leaks is required.

 Check the stream gas pressure at the connection point with the EnCal 3000. Adjust to 1-4 barg (15-57

psig). Purge the tubing before connecting to the EnCal 3000 for about 30 s. Make the connection with inlet
STR1. Check for leaks. Repeat this procedure for the other streams if applicable.

 Make a careful leak check of the total system.

Power Supply cable:

 Standard industrial 2-wire cable.

(The use of an external junction box is responsibility of the customer / installer)

 Power rating 60 W nominal (120 W start-up peak) for non-heated version (ambient T > 0 °C or 32 °F).
 Power rating 180 W nominal (240 W start-up peak) for heated version (ambient T < 0 °C or 32 °F).
 For the location of the internal connector see figure 5.6.

Data communication cable:

 Ethernet cable (PC and/or ModBus TCP/IP clients) :

Standard straight cable, shielded twisted 4 wire cable or industrial CAT5 quality. For the location of the
Ethernet connector see figure 5.7.

 Serial Modbus :

o Standard industrial data communication cable twisted pair

 3-wire for RS 485 communication
 3-wire for RS 232 communication

o 2 serial ModBus ports are available, each of them independently user configurable into RS 232 or 485

(Pin lay-out and link location see figures 5.8 and 5.9)

Elster GmbH

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Check one more time if all gas connections are leak tight connected and all cable glands
for electrical connection are securely tight. Check also one more time the different gas
pressures for correct settings

Apply power to the unit (24 VDC) by turning on the external switch.

Mount the cap on the unit, hand-tight fixed. Turn up the security screws to prevent removing of the cap by accident or
ignorance.

fig. 5-10 Location of security screws to fix the cap after mounting on the base

The unit will automatically start-up. The start-up sequence takes about 5 minutes, including temperature and pressure
stabilisation, and system flushing. After this sequence the unit is ready for the software configuration.

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APPENDIX 1: ZERTIFIKATES ENCAL 3000

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APPENDIX 2: DECLARATION OF CONFORMITY ENCAL 3000

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