Encal3000 Hardware Manual English FM ATEX O 2018-08-20

•
GASCHROMATOGRAPH ENCAL 3000

HARDWARE MANUAL
2018 Elster GmbH All rights reserved.
Elster GmbH is part of the Honeywell Group and the manufacturer of the device
described in the following. Use only documentation published by the manufacturer. The
amendment or translation of this manual requires the written consent of the
manufacturer.
The printed documentation supplied with the device represents the situation at the time
of delivery and may be regarded as accurate. All obligations on the part of the
manufacturer result only from concluded contracts and the General Terms and
Conditions in force on the date of the conclusion of contract. In no circumstances will
the manufacturer accept liability for any direct, special or consequential damage.
Subject to amendments in the course of further development. Any such

amendments will be included in the latest version without prior notice. The latest
version of this document is available in PDF format at www.docuthek.com.
Ensure that you use the appropriate version for your device.
The illustrations are designed to provide a visual depiction of the topics

covered. They may differ slightly from the actual design.
Contact
Elster GmbH (manufacturer)
Steinern Str. 19-21
55252 Mainz-Kastel, Germany
Tel.: +49 6134 605 0
E-mail: Customerfirst@Honeywell.com
Internet: www.elster-instromet.com
Honeywell Technical Assistance Center (TAC):
Tel.: +49 231 93 71 10 88
E-mail: ElsterSupport@Honeywell.com
Internet: www.elster-instromet.com
EnCal 3000 Hardware Manual 73022344 o 2

Table of contents
1 ABOUT THIS MANUAL AND DEVICE DELIVERY.............................................................................6
1.1 Scope (Aim)....................................................................................................................................................... 6
1.1.1 How to use this manual ...................................................................................................................7
1.1.2 Symbols....................................................................................................................................................8
1.2 Device delivery ............................................................................................................................................. 10

1.2.1 Checking the delivery (list of supplied and required parts) ........................................ 10
1.2.2 Transporting and storing the device ...................................................................................... 10
1.3 Intended use of Device ............................................................................................................................ 11

1.4 Responsibility of the device or system operator ......................................................................... 11
1.5 Additional technical help and repairs .............................................................................................. 12

2 SAFETY INFORMATION AND WARNINGS....................................................................................... 13
2.1 Information for handling the device ................................................................................................. 14
2.2 Authorized (hardware) personnel ....................................................................................................... 17
2.3 Information and warnings on the device housing ..................................................................... 18

2.4 Safety information about gases .......................................................................................................... 19
2.5 Electrical information connecting with earth and emergency stop ................................. 20
2.6 Explosion protection ................................................................................................................................. 23
3 FUNCTIONAL DESIGN OF ENCAL 3000 ..................................................................................... 25
3.1 Introduction /Enclosure/Hausing ..................................................................................................... 26
3.2 Most important features and functions.......................................................................................... 27

4 PROCESS GAS CHROMATOGRAPHY – GENERAL INTRODUCTION..................................... 28
4.1 Analytical Principle .................................................................................................................................... 28
4.1.1 Column .................................................................................................................................................. 29
4.1.2 Detector ................................................................................................................................................ 30
4.1.3 Sample Injector ................................................................................................................................. 31
4.1.4 Result findig and presentation.................................................................................................. 32
5 HOUSING INTERIOR WITH MAJOR INTERNAL COMPONENTS ............................................... 33
5.1 The Channel .................................................................................................................................................. 34
5.2 Processor Board .......................................................................................................................................... 39
5.2.1 Save parameters in the measuring unit................................................................................ 40
5.2.2 Processor Board installed ............................................................................................................ 41
5.3 Interconnection Board ............................................................................................................................. 41
5.4 Internal sample system ........................................................................................................................... 43

5.4.1 Double Block and Bleed Function ........................................................................................... 44
5.4.2 Internal Sample Bypass ................................................................................................................ 45
6 HARDWARE INSTALLATION .............................................................................................................. 45
6.1 Installation specifications ...................................................................................................................... 46

ABOUT THIS MANUAL AND DEVICE DELIVERY
6.2 Design of the measurement point ..................................................................................................... 46
6.3 Mechanical installation (assembly) .................................................................................................. 47

6.3.1 Device dimensions .......................................................................................................................... 49
6.3.2 Place of use and installation site (protection from environmental influences,
etc.) 50
6.3.3 Assembly hints .................................................................................................................................. 52
6.4 Electrical installation ................................................................................................................................ 53

6.4.1 Cable glands cables andwires ................................................................................................... 55
6.4.2 Making the electrical and signal connections .................................................................. 58
6.4.3 Connections on the EnCal 3000 Interconnection board Version 1.x .................... 60
6.4.4 Connections on the EnCal 3000 Interconnection board Version 2.x .................... 64
6.4.5 Electrical device test to verify correct installation ........................................................... 69
6.5 Fluidic installation...................................................................................................................................... 70

6.5.1 Fluid connections ............................................................................................................................ 70
6.5.2 Configuration with two Carrier Gases .................................................................................... 76
6.5.3 Connecting and replacing gas cylinders.............................................................................. 77
6.5.4 System tightness test .................................................................................................................... 79
7 COMMISSIONING AND DECOMMISSIONING .............................................................................. 79
7.1 Requirements for commissioning and operation ...................................................................... 81
7.2 Hardware Start-up ..................................................................................................................................... 82

7.2.1 Checking the device settings and signals ........................................................................... 83
7.3 Decommissioning ...................................................................................................................................... 83

7.3.1 Dismantling ......................................................................................................................................... 85
8 MAINTENANCE AND REPAIR ............................................................................................................ 85
8.1 Troubleshooting (Identifying hardware errors) ........................................................................... 86
8.1.1 Troubleshooting in the gas supply.......................................................................................... 88
8.1.2 Troubleshooting in the electrical supply and insulation.............................................. 88
8.2 Maintenance and remote maintenance ......................................................................................... 90

8.2.1 Visual inspection of the connections ..................................................................................... 91
8.2.2 Checking the gas connections with a tightness test ..................................................... 92
8.2.3 Checking the cylinder pressures (visual inspection) ..................................................... 93
8.2.4 Checking the inlet pressures (visual inspection) ............................................................. 93
8.2.5 Checking the flow rates (optional visual inspection) ..................................................... 94
8.2.6 Checking / Replacing the inlet filters and adapters ....................................................... 94
8.2.7 Checking the housing parts ....................................................................................................... 95
8.2.8 Inspecting the interior of the housing ................................................................................... 95
8.2.9 Inspecting and cleaning the breather valve ....................................................................... 96
8.3 Consumables (carrier and calibration gas cylinder)................................................................. 97

8.3.1 Spare and replacement parts for general maintenance work ................................... 97
8.4 Honeywell service work ............................................................................................................................ 98

9 DATA COMMUNICATION ................................................................................................................... 98
9.1 Data safety information and Warning.............................................................................................. 98
9.1.1 Security considerations for your network ............................................................................ 99
9.1.2 Implement stringent password guidelines ......................................................................... 99
9.1.3 Prevent unauthorized external access using a firewall. ............................................ 100
9.2 Local TCP/IP Data Communication .............................................................................................. 101
9.3 Local Serial ModBus Data Communication .............................................................................. 102
9.4 Remote Access.......................................................................................................................................... 103

9.5 ModBus Communication .................................................................................................................... 104
10 TECHNICAL SPECIFICATIONS ....................................................................................................... 105
11 POSSIBLE HARDWARE OPTIONS AND TYPE PLATES ............................................................. 108
11.1 Option HT: Heaters installed ............................................................................................................. 112
11.2 Option SC: Single Channel analyser .............................................................................................. 113
11.3 Option QS : Quad Slave ........................................................................................................................ 114

11.4 Option H2: Hydrogen carrier gas ..................................................................................................... 115
12 ANNEX .................................................................................................................................................. 116
12.1 Nomenclature/Abbreviations............................................................................................................ 117
12.2 Definitions and explanations ............................................................................................................ 120
12.3 CERTIFICATE EC-Type Examination ............................................................................................. 125

12.4 DECLARATION OF CONFORMITY ENCAL 3000..................................................................... 127
12.5 IECEx Certificate ENCAL 3000 ........................................................................................................ 128
12.6 FM Certificate of Conformity ............................................................................................................. 132

13 KEYWORDS AND FIGURES .............................................................................................................. 135
13.1 Keyword index ........................................................................................................................................... 135
13.2 List of figures ............................................................................................................................................. 139

1 About this Manual and Device delivery
1.1 Scope (Aim)

This user manual for the Gas quality measurement system EnCal 3000, hereinafter
referred to as the EnCal 3000, describes the Hardware of this gas chromatograph
(measuring unit). The other subsystems are described in separate manuals.
The measurement system consists in its basic configuration of a measuring unit and an
optional Encal3000 controller. The measuring unit is the real gas chromatograph. It
performs the analysis by measuring technology autonomously.
It is configured with the PC program "RGC 3000" and it is possible to install an additional
optional Encal3000 controller. (See separat manuals). The subsystems communicate
with each other via Modbus (see Figure 1.1 for basic configuration with measuring unit
and an optional Encal3000 controller).
Figure 1.1: Parts of the Gas quality measurement system
The enCal 3000 is suitable for worldwide use. You should use a manual in your mother
tongue or a language with which you are extremely familiar to ensure that you
understand all the information. The safety and warning information on the device are in
English or French. This information is stated in this document in the appropriate
language. In accordance with Honeywell's "Safety first" principle the maual starts after
the following introductory with this topic.

In general the manual is aimed at trained personnel in the gas industry or process
measuring sector. It contains the explosion-relevant information as well as a summary
of relevant safety and warning notices. In addition to general expertise, it enables the
enCal 3000 to be handled safely and efficiently.
Compliance with all given information and instructions is a requirement for safe working
practice and correct handling of the device. It will ensure the functions of the device,
deliver reliable measurement results, extend the service life of the device and save you
service and spare parts costs.
Furthermore, the directives, standards, local accident prevention regulations and

general safety regulations, which apply to the field of application of the device, must be
applied and obeyed..
Following table shows the development of this document.
Revision Date Description
a to l 2008 until 2016 Historic development
m August 04, 2017 New Interconnection board
n Feb. 22, 2018 New temperature range
o August 20, 2018 New CE Declaration and

extension to Honeywell document design
1.1.1 How to use this manual
It is essential that you read through the relevant section of this document before starting
work to ensure that you have a thorough understanding of the measuring system.
Safety information and warnings must be followed to the letter.

ATTENTION
A lack of symbols or information does not release you from your safety
duties or responsibility for safety.
CAUTION
If you use the device together with devices from other manufacturers or third-party
equipment, you must ensure that these are suitable components. These components
will have their own product documentation which also must be obeyed. Ensure that all
the technical documentation is available in the system and near the device.

1.1.2 Symbols
The safety and warning information in this document and on the device is designed to
help use the measuring instrument correctly. The signs, symbols and terminology are
defined in the following. Texts which are preceded by a sign of this type must be followed
to the letter. General safety rules and expertise in conduct in plants and in dealing with
gas are assumed to be known and are therefore not reproduced here in full.
Symbol in ducument Meaning
Attention denotes information which is relevant to safety

and important for the functioning of the device. If this
information is ignored, the result may be health impairment,
environmental or property damage and injuries or even
ATTENTION
death. This information must be followed and given due
consideration in all circumstances.
Explosion or danger of explosion means that death and/or

injuries may be suffered by several people and, in addition,
the plant, equipment and environment may suffer significant
damage if the appropriate precautions are not taken.
Very serious health impairment means that serious physical

CAUTION
injury, health impairment and, as a result, death may occur if
(Explosion/ Very serious health
impairment / Prohibited action) the appropriate precautions are not taken.
Prohibited action means that you must not complete the

action described unless the specified conditions and
requirements are satisfied and you are qualified for this work.

Symbol on device Meaning
The symbol on the device is a reminder to comply with all the

instructions and important information in the manual (in
this document). The appropriate parts are marked with the
Device symbol
other symbols in this table.
The symbol on the device is a reminder to comply with the

WEEE directive of the EU. In the interest of our environment
the WEEE directive did not allow to dispose the device with
Device symbol household waste within the EU!
This symbol on the device means that the power supply is

24 V DC.
Device symbol
This symbol on the device designates the equipotential

bonding connection (PA) or the terminal for the electrical
connection to the equipotential bonding system and earth.
Device symbol
This symbol on the device designates the connection for the
Device symbol functional earth (FE).
Denotes tips and recommendations which are interesting

and useful for a certain topic, but which have no bearing on
safety.

1.2 Device delivery
1.2.1 Checking the delivery (list of supplied and required parts)
Unpack the measuring instrument and any other components and check them for
signs of damage and missing or incorrect parts. Use your order documents and the
information in this manual as a guide for this purpose. The device is supplied ready-
assembled with all interior components and includes the required connections and
potential connections for gas, electricity and signals in standard operation unless
otherwise ordered. You should therefore check the following points:
• Every gas connection must be fitted with a Swagelok pipe fitting with a suitable
thread or a blind plug.
• Every electrical connection must be fitted with a cable gland of a suitable size
or a blind plug.
• There are not normally any openings on the device that do not have plugs or
fittings/glands.
• The local display is included (optional, if ordered).
• Fastening materials, for example wall mounting bracket with screws, are
included as ordered.
1.2.2 Transporting and storing the device
Prevent transport damage, incorrect storage. Please also refer to the liability
information at the start of this manual.
Store the device in a clean, dry location. Prevent dirt getting inside it. Pre-
vent material damage caused by the formation of condensation and
ATTENTION corrosion
The following applies to storage:
• The ambient conditions (see chapter „Technical spezifications“) must be

maintained.
• The packages may only be stored in enclosed rooms.
• Avoid mechanical impacts during storage.
• The storage time with a battery is up to one year, 2 years if the battery is then
replaced.

Do not expose the device to temperatures below or above temperatures

defined in the chapter “Technical spezifications”
CAUTION
If the device is transported in cold weather or extreme temperature fluctuations have

occurred, the EnCal 3000 must be returned to room temperature (temperature at the
place of use) slowly to prevent damage caused by the formation of condensation.
Do not remove transport guards and other safety devices, for example for
gas connections, before the device has been installed at its destination
CAUTION and if dirt can still ingress into it.
1.3 Intended use of Device

The device is designed and built exclusively for its intended use. This is the analysis of
natural gas or gas similar to natural gas (see details in Hardware section). Intended use
also includes compliance with all the information in this document and on the
measuring instrument. Any additional use or use other than that intended will be
deemed to be misuse. Claims of any kind due to damage as a result of misuse will be
void.
Use the device only for its intended purpose as described in this docu-
ment. If you use the device for other tasks or purposes, protection may be
adversely affected. This may result in dangerous situations.
ATTENTION
The device may only be installed and used in the potentially dangerous
zones specified on it.
1.4 Responsibility of the device or system operator

The operator of the device or system is subject to legal duties relating to industrial
safety. In addition to the safety information in this document, compliance with the
safety, accident prevention and environmental protection regulations valid for the field
of application of the device is mandatory. Furthermore, the operator is responsible for
keeping the device in technically perfect condition at all times.

The operator must use high-pressure reduction systems and safety

devices to ensure that the maximum inlet pressure, even in the event of a
fault; of the respective gas does not exceed the maximum permitted
value.
ATTENTION The following limits apply:

Sample gas/Calibration gas/ Verification gas: 0.40 MPa(g) (4.0 bar(g)).
Carrier gas: 0.55 MPa(g) (5.5 bar(g)).
The equipment shall not be used with process gases which contain
oxygen or any other oxidizer in concentrations greater than found in
CAUTION normal air.
The system operator must ensure that the electrical installation does not
give rise to any danger to personnel or components. The operator must
ensure that no earth potential shift takes place (for example by using an
ATTENTION
equipotential bonding cable).
The operator must ensure that the installation and maintenance work
described in this document is carried out correctly.
The operator is responsible for ensuring that the device remains in
ATTENTION
technically perfect, safe condition throughout its period of operation.
1.5 Additional technical help and repairs

If you have any questions, any points in this document are unclear or you require repair
work, the TAC or our customer service department will be delighted to help. The contact
details are provided at the start of this manual
Training classes
Honeywell holds technical training classes that are taught by process control systems
experts. For more information about these classes, contact your Honeywell
representative, or see http://www.automationcollege.com

SAFETY INFORMATION AND WARNINGS
2 Safety information and warnings
The safety and warning information in this manual (and on the device in English) is
designed to enable the device to be used correctly and prevent personal injury and
property damage.
The device complies with the relevant safety standards. If it is handled correctly, it does
not pose any danger which may adversely affect health or cause property damage.
To avoid risks, no changes or modifications may be made unless they have been
expressly approved by the manufacturer. Avoidable damage, for example caused by
inadequate device expertise, will render all liability claims void.
The safety and warning information must be read and obeyed in all
circumstances to ensure safe, flawless operation. We assume that users
CAUTION will have the appropriate language skills.
Always refer to the whole safety information in this documentation and

on the device. Also refer to the other relevant sections and the technical
specifications.
Please contact your TAC if you have any questions or doubts!

ATTENTION
A lack of warning signs does not release you from your personal
responsibility for safety
It is vorbidden to operate devices, or other parts used for measuring, if

they are damaged, have a modified housing or unsuitable connections
CAUTION since protection from explosions will no longer be guaranteed.
If you discover that the measuring equipment or other parts used for
measuring are damaged, shut down everything, disconnect everything
CAUTION from the gas and voltage supplies and secure them to prevent them being
used accidentally.
Direct contact with hot or cold surfaces can cause heat and ice burns.
Prevent this by using your personal protective equipment (for example,
CAUTION wear gloves).

2.1 Information for handling the device

The device is designed for installation in potentially explosive atmospheres and
certified to several approvals:
FM Approval
ATEX II 2 G Ex-db IIC T6 Gb and IECEx Ex-db IIC T6 Gb
Class I, Division 1. Groups B, C, D T6

Class I, Zone 1, AEx IIC T6 Gb
In compliance with:
IECEx:
IEC 60079-0 : 2011
IEC 60079-1 : 2014
ATEX:
EN 60079-0 : 2012
EN 60079-1 : 2014
United States standards

Class 3600 : 2011
Class 3615 : 2006
Class 3810 : 2005
ANSI/ISA 60079-0 : 2013

ANSI/UL 60079-1 : 2015
NEC:
Detailed information on this certificate can be found in ANNEX

ATEX Approval
ATEX II 2 G Ex-d IIC T6 Gb
IECEx Ex-d IIC T6 Gb

Class I, Division 1, Groups B, C, D T6
Class I, Zone 1, AEx db IIC T6
In compliance with:
IECEx:
IEC 60079-0 : 2011
IEC 60079-1 : 2014
ATEX:
EN 60079-0 : 2012
EN 60079-1 : 2014
FM standards
Class 3600 : 2011
Class 3615 : 2006
Class 3810 : 2005
ANSI:
ANSI/ISA 60079-0 : 2013
ANSI/UL 60079-1 : 2015
Detailed information on this certificate can be found in ANNEX
The device may only be installed and used in the potentially dangerous
zones specified on it.
CAUTION

The safety and warning information in this manual (and on the device in English) is
designed to enable the device to be used correctly and prevent personal injury and
• To avoid risks, no changes or modifications may be made unless

they have been expressly approved by the manufacturer
ATTENTION • A lack of warning signs does not release you from your personal
responsibility for safety.
It must be ensured (for example by an air-conditioned housing) that the

device is not exposed to any excessive temperatures during storage or
CAUTION operation. The temperature range is specified on the device.
The ambient conditions must comply with the technical specifications;

otherwise, an additional air-conditioned housing must be used. The
ATTENTION device may only be used in potentially corrosive atmospheres by
agreement and with the consent of your TAC.
When carrying out mechanical work (transport, assembly, etc.), use your
personal protective equipment (safety footwear, gloves, etc.) to avoid
CAUTION injury. Never lift weights which may jeopardize your health.

2.2 Authorized (hardware) personnel

The operator of the system or device is responsible for selecting the personnel. Suitable
personnel have been verified as possessing the required knowledge from this manual,
have received induction training and at least satisfy the requirements set out in this
document.
The manufacturer cannot accept any liability for damage and consequential damage
caused by untrained personnel.
Assembly, electrical installation, commissioning and inspection and

maintenance work (opening the housing) may only be carried out by
ATTENTION trained personnel authorized by Honeywell.
The appropriate personnel have the expertise set out in Annex A of EN IEC 60079-14
or has comparable expertise, including:
• General safety rules
• Care and use of reasonable safety equipment
• Electrical safety and explosion-protection rules
• Working on electrical circuits for systems with potentially explosive

atmospheres
• Working with high pressures and aggressive or hazardous media
• Safety and warning information from this manual
Suitable personnel must definitely have the ability to identify dangers

and risks, assess their work and avoid possible hazards.
CAUTION
Before starting work, everybody engaged to carry out hardware work on or

with the device must be familiar with the content of this manual. Any
ATTENTION unclear points and questions must be clarified before starting work.

2.3 Information and warnings on the device housing

There are warnings in English and/or French on the device. This information is also
repeated at the appropriate point in the documentation in the documentation language.
There is not sufficient space on the type label for this and there are therefore additional
warning signs on the housing. The figure below shows the possible locations on the
device and an example of a warning in English and French on an additional label.
The safety instructions for opening the device can be found on the top of the hood. The
gas inlets and outlets are also labelled with details of the maximum pressure values.
Figure 2.1: Warning and information labels on the device
Information on the device must be noted and obeyed in all circumstances.

You must have adequate language skills to understand their meaning.
ATTENTION

2.4 Safety information about gases

The measuring instrument requires various gases for operation and measurement with
different hazard potentials. Supply all gases to the device and remove all waste gases
from it through pipelines which comply with the listed switching, connection and
pipework plans in the relevant chapters.
When working on the gas pipelines, always ensure there is adequate

ventilation and protect yourself from gases which contain aggressive or
CAUTION toxic components.
When mixed with air, gases may form an explosive mixture or be toxic,
harmful or polluting.
CAUTION
Do not supply the device with any gas which contains more than 3.0%
v/v of oxygen. Il n’est pas autorisé de connecter un gaz contenant plus de
3 % d’oxygène (basé sur le volume).
It is not allowed to connect gasses that are flammable or explosive under
CAUTION exclusion of oxygen (i.e. acetylene (C2H2)). Il n’est pas autorisé de
connecter des gaz inflammables ou explosifs à l’exception de l’oxygène
(par exemple, l’acétylène (C2H2)).
Only natural gas and gases similar to natural gas (all components in gaseous
form) as specified in the technical specifications or approved calibration gases
ATTENTION may be used in the specified pressure range.
For other gases and pressures, please contact your TAC before use.
The equipment should not be installed in a location where it might be

subjected to external conditions which might cause electrostatic charges
CAUTION on non-conducting surfaces.
The breather valve is not part of the waste gas system and is in direct contact with the
ambient atmosphere. Gas will only escape from the breather valve in the event of a
fault. Take suitable precautions to discharge it. For example, for installations in a
building, this may take the form of a vent line into a safe ventilation area or appropriate
ventilation of the installation site.
The breather valve must not be sealed or blocked.

It may only be replaced by personnel authorized by Honeywell.
ATTENTION

Do not loosen or unscrew the breather valve in a potentially explosive

atmosphere.
CAUTION
A vent line does not need to be connected to the breather valve as no gas escapes
in normal operation.
ATTENTION
If a vent line is connected, it must be routed into a safe ventilation area as
specified below and must be protected from dirt and rain
The following specifications apply to a vent line (please contact your TAC if you are in
any doubt):
• The additional pressure drop caused by the pipeline depends on fittings, bends
and the material used. It must not allow the pressure inside the housing to rise
above 100 mbar (10 kPa). If a straight smooth pipe is used with a minimum
internal diameter of 8 mm and an inlet pressure of up to 3 bar, lengths of
around 40 m are possible. If you would like to use smaller diameters and
lengths of over 40 m, please contact your TAC.
• Completely separate pipeline, connection using the breather valve’s internal

thread.
DO NOT CONNECT THE BREATHER VALVE’S PIPELINE TO OTHER

PIPELINES.
CAUTION
2.5 Electrical information connecting with earth and emergency stop

Reference is made to the appropriate technical regulations regarding the installation,
commissioning, decommissioning and maintenance work in general. All national, local
or company standards and regulations which apply at the installation site of the device
must always be given due consideration and applied. For example, Directive 99/92/EC
(ATEX 137) governs the installation and operation of electrical systems in potentially
explosive atmospheres. Do not fail to comply with this Directive in territories in which it
applies.
Honeywell cannot accept any responsibility for compliance with provisions and
regulations unless the work was carried out by Honeywell. We recommend that you read
through the appropriate regulations again before installation.
Compliance with standards and directives on the following topics, in particular, is

mandatory:

• Electrical equipment for potentially explosive gas atmospheres
• Operation of electrical systems
• Testing and maintaining electrical systems in potentially explosive gas

atmospheres
• Erection of power installations with rated voltages below 1000 V – tests – initial
tests
• German Ordinance on Industrial Safety and Health
The place of use and installation must have a functioning, effective lightning
protection system to protect personnel and equipment.
The device must be connected by personnel authorized by the manufacturer in
ATTENTION
accordance with the instructions of this document.
CASE MUST BE EARTHED!

The housing and mounting base must be included in the local earthing system
and must not be opened or disconnect from erth in a potentially explosive
CAUTION atmosphere. The earth connection on the device (together with other connections
if necessary) must be used for this purpose
This device must not be operated without an equipotential bonding system/cable

or earthing or if this connection has been intentionally broken. No earth potential
CAUTION shift must take place.
The 24 V DC power supply (including mains fluctuations of ± 15%) must have a

safe electrical isolation. This may be provided, for example, by Quint-PS-100-
240AC / Quint-PS-24DC/24DC/10 / Siemens SITOP / Siemens Logo or
equivalent power supply units.
ATTENTION
Every device must be operated with a separate power supply. This is protected
externally by a fuse or a miniature circuit breaker.
Supply and communication cables (not supplied) which are shielded and comply
with local installation regulations must be used.
Use cables or wires and cable entries suitable at least up to 70°C (158°F / 343 K)
ambient temperature.
ATTENTION
Utilisez des câbles ou des fils et des entrées de câbles adaptés à une température
ambiante d'au moins 70°C (158°F / 343 K).

The installation personnel must ensure that the wiring is protected from
overloads and short-circuits and has the required overvoltage and overcurrent
ATTENTION protection. Connecting the device only when the power supply is off
Fuses and batteries may only be replaced by trained personnel authorized by

Honeywell. Les fusibles et les batteries ne peuvent être remplacés que par du
CAUTION personnel qualifié et autorisé par Honeywell.
The installation must comply with the local standards which apply to electrical
and explosion protection (e.g. DIN, EN, VDE, UL, etc.).
CAUTION All connected devices have increased insulation against mains voltage.
In addition to the SELV system, a PELV system may also be used.

The housing must be earthed using the equipotential bonding connection (PA) on
ATTENTION the underside of the housing.
The device does not have its own off switch. It must be operated using an isolating
device (switch or circuit breaker) and current limiting device (or a combination of
the two) to comply with ISO/IEC 60079-14 and ISO/IEC 61010-1. (Operating
ATTENTION
voltage of the isolating device at least 48 V DC.)
This isolating device (not supplied) must be located close to the device to comply with
explosion protection and electrical safety regulations, thus contributing to the formation
of the power-limited circuit. The isolating device must also isolate all the power supply
cables leading into the potentially explosive atmosphere. It must comply with the
requirements for the installation site as mentioned in the standard. One example of such
an isolating device is a C 5A circuit breaker.
Warning: this device is a Class A device (according to EN 55016-2-3). It may cause

radio interference in residential areas. In this case, the operator may be requested
ATTENTION to take suitable action at their cost
The enclosure is non-conducting and may generate an ignition capable level of

electrostatic charge under certain extreme conditions. The user should ensure
that the equipment is not installed in a location where it might be subjected to
external conditions which might cause a build-up of electrostatic charges on non-
ATTENTION
conducting surfaces. Additionally, cleaning of the equipment should be done only
with a damp cloth.

Cable glands and connections
There are four boreholes for electrical inlets and outlets on the device. The threaded bore
holes can be fitted as required with blind plugs, adapters or cable glands. These screw-
in parts must be suitable for the IIC Zone and have explosion-protection certification.
The enCal 3000 may only be connected using cable glands. These must comply
with local explosion-protection regulations and be installed or replaced by
authorized trained personnel. To comply with explosion-protection regulations,
ATTENTION they must be installed and sealed as specified by the manufacturer of the cable
glands. The relevant regulations must be observed during this process.
The cable inlets must satisfy or exceed the IP rating of the device. NEC-compliant
cable inlet equipment must be used in the USA. CEC-compliant equipment must
ATTENTION be used in Canada.
Cable glands may only be used with cables which have the following properties:
• Not sensitive to cold flow, impermeable to air and at least three metres long
(only suitable if cable and cable gland are designed for temperatures of at least
70°C )
(ne convient que si le câble et le presse-étoupe sont conçus pour des
températures de 70°C et plus)
• Terminal boxes, cable conduits if they are sealed:
- within 1xD outside the housing for ATEX and IECEx
2.6 Explosion protection
The regulations in the relevant national and international standards (for example
IEC/EN 60079-14, installation of explosion-protection equipment) must be
CAUTION followed to the letter.
Handling explosion-proof devices
The installation and connection work must be carried out using the circuit, connection
and pipework plans mentioned in the document. Follow the instructions set out below
carefully and ensure that you have completed all the required safety steps before you
work on the measuring unit or switch it on.
Work in potentially explosive atmospheres requires a license. You need a written

operator license (fire service license certificate), for example for the following:

• Transporting and/or using a PC or laptop through or in a potentially explosive

atmosphere.
• Opening the device in a potentially explosive atmosphere when the operating

voltage is live.
• Connecting the control and parameterization device or laptop in a potentially

explosive atmosphere.
DO NOT OPEN (THE DEVICE) WHEN AN EXPLOSIVE ATMOSPHERE IS PRESENT

DO NOT OPEN IF THE CONDITIONS DESCRIBED IN ISO/IEC 61010-1 ARE NOT
CAUTION COMPLIED WITH
The cable inlets must not be disconnected in any circumstances in this case.
Never work on live systems.
CAUTION
You require a written operator license for carrying out work in potentially
explosive atmospheres.
ATTENTION
Maintaining explosion protection
Please note: The test certificate for this device describes all the
conditions and regulations specified for the installation and operation of
ATTENTION the device to maintain explosion protection.
Only qualified personnel may operate and maintain explosion-proof devices.
These persons must only use explosion-proof, approved equipment and

ATTENTION
measuring instruments. Do not disconnect cable inlets and breather
valves in a potentially explosive atmosphere.
Switch off the device in any event when working on it. Comply with the following
procedure:
• Close all gas supplies.
• Switch off the supply voltage.
• Protect all open pipelines and connections from dirt.
ATTENTION! ELECTROSTATIC DANGER! ELECTROSTATIC HAZARD

Because of the potential electrostatic charging of the paint layer, the housing
should only be cleaned by using a damp cloth to prevent lectrostatic charging,
CAUTION
since otherwise sparks are possible

FUNCTIONAL DESIGN OF ENCAL 3000
Recommissioning must not be carried out in a potentially explosive gas

atmosphere and before you switch on the device, ensure that all the gas
connections are sealed and the earthing or protective conductor has been
CAUTION
installed correctly.
The used flame paths for this device are not intended for repair.
CAUTION
All removable covers and hoods for opening the housing must be
protected against accidental opening by security screws
ATTENTION
Danger of explosion
Danger of explosion in the event of incorrect installation and connection.

Before the device is switched on or switched back on, ensure that all the gas
CAUTION connections are sealed and the earthing or PE wire is correctly installed.
Do not operate or use damaged devices or devices with modified

housings or with an incorrect connection since explosion protection is no
CAUTION longer guaranteed in this case.
Safety information on the device:

DISCONNECT POWER BEFORE OPENING
CAUTION DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE IS PRESENT
If the device is not serviced or maintained correctly, there is a danger that

it will explode. Contact the manufacturer for repair work which affects the
CAUTION explosion protection and the flameproof properties of the device.
DO NOT OPEN THE DEVICE IF.
• IT IS IN A POTENTIALLY EXPLOSIVE ATMOSPHERE

CAUTION
• THE CONDITIONS DESCRIBED IN ISO/IEC 61010-1 ARE NOT
COMPLIED WITH
• YOU DO NOT HAVE THE PERMISSION OF THE MANUFACTURER
AND OF THE STATION OPERATOR TO DO SO
3 Functional Design of EnCal 3000

3.1 Introduction /Enclosure/Hausing

The EnCal 3000 is an on-line gas chromatograph. The device is fully automatic and is
enclosed in a tailor-made Ex-d housing which contains the electrical and analytical
equipment. The explosion-proof aluminium housing essentially consists of a low base
on to which a relatively high hood/cap is screwed using an M270 thread
It can be positioned close to the sampling unit. In the housing is place for up to two
analytical channels that are controlled by one processor board. The Encal 3000 Process
Gas Chromatograph (PGC) transfers the core laboratory technique to process
conditions. Once the cap is removed from the base, almost all the internal components
are directly reachable.
The EnCal 3000 (measuring unit) includes the analytical components, the stream
selection and all the electronic components required for autonomous automated
operation.It can analyse up to 5 gas streams sequentiallyChanges in ambient
temperature have no significant influence on the peak retention times. The device
therefore does not need an expensive temperature-controlled environment.
Maintenance work is only required once per year. Routine calibration takes place
automatically at a time programmed by the user and leads to significantly lower
consumption of carrier and calibration gases. This reduces operating expenses
compared to conventional gas chromatographs.
Figure 3.1: Housing complete with the (transparent)hood
Further information see technical data and the type labels on the device

3.2 Most important features and functions

• Compact EX-d design allows for the harshest conditions imaginable in natural
gas applications
• installation clearance Ø 55 cm x 70 cm height, weight <30 kg
• Complete stand-alone operation
• mount the device on a platform, a pole or to the wall
• Capillary and micro packed columns in combination with MEMS analytical

components
• Fast analysis (C6+ in less than 3 minutes)
• High analytical performance :
• Uncertainty < 0.1 % for a wide range of gases
• Repeatability < 0.005 %
• Up to 5 sample streams sequential without external stream selection
• All gas tubing (sample lines, cal. gas, vent lines, helium in and out) and all
electrical connections can be directly connected to the unit.
• Integrated sample system
• Internal data storage for the last 35 days of all data
• Suitable for extreme environmental conditions
• Two analytical modules (which do each a part of the total analysis, in parallel)
• Processor board
• Internal sample system (stream selection and pressure regulation)
• All electrical field connections (Ethernet, ModBus, analogue IN, digital I/O,
solenoid drivers), fuses, switches and jumpers
• Explosion proof certified for ATEX / IECEx / NEC

• IP 66 ingress protection against dust and precipitation (suitable for offshore
applications)
• Standard temperature range: 0 to +60 ° C (32 to 140 ° F), optional extension for
devices with ATEX/IECEx-Approval. 0 to 55°C (32 to 130°F) for devices with
FM-Approval 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
• For check or maintenance procedures of most parts, only the cap has to be
removed.
The following paragraphs give a general description of the main parts of the unit.

PROCESS GAS CHROMATOGRAPHY – GENERAL INTRODUCTION
4 Process Gas Chromatography – General Introduction
4.1 Analytical Principle

Gas chromatography in general is an analytical technology which is used to analyse gas
mixtures, i.e. to measure the concentrations of the different components of a gas.The
analytical principle is shown in figure 4.1
Figure 4.1: The analytical principle
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.

4.1.1 Column
The separation column, or column for short, of a gas chromatograph traditionally

consists of a relatively long spiral tube wound in a coil with a very small internal diameter.
The interior of this “column tube” is made of slow-reaction materials such as quartz glass
or stainless steel. These coating or filler materials are known as the “stationary phase”.
They are used as an adsorption layer for the gas molecules flowing through the column
and ensure the actual separation of the components. There are various types of
columns, see the figure below.
Typical dimensions of the used columns in the enCcal3000 have a length of several
meters and internal diameters of <0.1 mm. They are made of inert materials like fused
silica and stainless steel.
Figure 4.2: Different types of gas chromatographic columns
Various configurations exist:
• 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 capillary 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 (SCOT column): the stationary phase is

a coated packing, which itself is coated on the inner wall of the column (for
example type M5S mole sieve)
• Porous layer open tubular column: the stationary phase is a porous layer on
the inner wall of the column (for example type PPU)

4.1.2 Detector
The thermal conductivity detector (TCD), known as the detector for short, is a relatively
simple, very efficient, robust detector which is very widely used in the natural gas
industry. The most popular detector is the TCD: Thermal Conductivity 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 EnCal 3000 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.
Figure 4.3: Typical electrical TCD circuit

4.1.3 Sample Injector
The sample injector, also known as simply the injector, injects the sample into the
stream of carrier gas.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 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.
Figure 4.4: MEMS Sample Injector

4.1.4 Result findig and presentation
Two fluidically independent collums for reference gas and sample gas are used.
Differences in temperatue and thermal conductivity occur between them and let to
changes in the electrical evaluation circuit which are analysed. It results in the “signal
mountain” known as the peak in the chromatogram. The figure below shows examples
of what chromatograms look like.
Figure 4.5: Chromatograms
All the main gas components can therefore be recorded directly and can undergo
further processing.

HOUSING INTERIOR WITH MAJOR INTERNAL COMPONENTS
5 Housing interior with major internal components
Only the hood must be removed for inspections, maintenance work and the electrical
installation.
DO NOT OPEN THE DEVICE IF.
• IT IS IN A POTENTIALLY EXPLOSIVE ATMOSPHERE

CAUTION
• THE CONDITIONS DESCRIBED IN ISO/IEC 61010-1 ARE NOT
COMPLIED WITH
• YOU DO NOT HAVE THE PERMISSION OF THE MANUFACTURER
AND OF THE STATION OPERATOR TO DO SO
Turn the security screws as far as possible downwards to allow the hood to be removed.
As soon as the hood has been unscrewed and removed, almost all the internal
components are directly accessible:
When the device is open, there is a risk of damaging the internal

components and thus generating safety problems and malfunctions.
CAUTION
You should therefore complete the work with the appropriate care and
always obey the explosion protection regulations.
The open housing provides a view of the layout of the main components and internal
parts. The skid is designed to secure the various components. It enables most
components to be removed by unscrewing just a few screws.
Due to the long application time of the device and the different conditions of use,
individual components are used in different variants. The following figure shows the
exploded view of the different internal components of the Master Unit of the EnCal3000,
the individual parts and variations are explained in detail with the functionalities of each
component in the following paragraphs.

Figure 5.1: Exploded View on the Internal Parts of the EnCal 3000
The frame is used for mounting the components and allows the removal of all the direct
and individual components, with the exception of the interconnection board.
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.
5.1 The 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 Storage) 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 the EnCal
3000 two columns are used:
• HSA column (HaySep), for the analysis of N2, CH4, CO2 and C2H6
• 5CB column 4m or 8m, for the analysis of the higher hydrocarbons (C3H8 up to C8H18
or up to C9H20)
For devices build before 2008 the 5CB-4m channel was used for the analysis up to C6+
and the 5CB-8m channel just for the analysis up to C9. Since 2008 the 5CB-8m
becomes used for both options, the main reason for this change is that the separation
of the peaks especially for n-butane and neo-pentane is better for the 8m long column.
Another possible Channel configuration for the special application biogas is:
• M5A column (molesieve), 10m long, for the analysis of H2, O2 and N2.
• PPU column, 10m long, for the analysis of the hydrocarbons (CH4 up to n-C4H10) and
CO2
Another possible Channel configuration for the analysis of hydrogen and natural gas is:
• COX column, 1m long for the components (He), H2, N2, CH4, CO2 and C2H6
• 5CB column, 8m long for the higher hydrocarbons (C3H8 to C9H20)
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.
Figure 5.2: Overview of Channel Components
The next page shows the internal gas flow configuration of the channels.

Figure 5.3: Internal Gas Flow Circuit for each Analytical Channel of the EnCal 3000,
during Normal Operation (top) and sample Injection (below)

Pre
column
Analytical
column
Column vent
Detector
Reference vent
Manifold block
Solenoid V1 Reference
column
Solenoid V5
inlet
Solenoid V2
Injector
Solenoid V3
Solenoid V6
outlet Pressure
sensor
Backflush
Solenoid V4 valve
inject valve
EGC/Ref vent
sample
BF vent Pump Manifold Pump valve loop
Pump
sample valve
Sample vent
Sample
Pre
Analytical column
column
Column vent
Detector
Reference vent
Manifold block
Solenoid V1 Reference
column
Solenoid V5
inlet
Solenoid V2
Injector
Solenoid V3
Solenoid V6
outlet Pressure
sensor
Backflush
Solenoid V4 valve
inject valve
EGC/Ref vent
sample
Pump Manifold Pump valve loop
BF vent
Pump
sample valve
Sample vent
Sample
Figure 5.4: Internal Gas Flow Circuit for each Analytical Channel with backflush of the
EnCal 3000, before activating backflush valve (top) and after activating backflush
valve (below)

5.2 Processor Board

The main components of the board 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
Figure 5.5: Processor Board connections

5.2.1 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 all mainboard types. (see following figure) 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 below.
Figure 5.6: Save parameters in the measuring unit all bord versions

5.2.2 Processor Board installed
When installed in the EnCal 3000, 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 can be mounted to cool the processor in case of elevated ambient
temperatures.
Figure 5.7: Processor board with ribbon flat cables mounted in the EnCal 3000
5.3 Interconnection Board

This board in all variations has the following functions:
• Power supply input (24 VDC)
• DC/DC converter
• 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

Figure 5.8: Interconnection Board in different variations
The following diagram shows the overall electrical configuration EnCal3000 in a rough
overview.
Figure 5.9: Overall Electrical Configuration of the EnCal 3000

5.4 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)
Figure 5.10: 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.

Figure 5.11: Flow diagram Sample Conditioning and Selection System
5.4.1 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.

HARDWARE INSTALLATION
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.
5.4.2 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.
If there is a long sample line between the sample point and the Encal, or there is a
relatively high pressure in this line the bypass time can be increased up to 150 seconds.
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.
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. The vent outputs from both modules return
to the manifold and are combined to two venting outputs.
6 Hardware Installation
All safety and warning notes in this document must be observed before
further workis done
CAUTION

6.1 Installation specifications

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.
Installations in the US shall comply with the relevant requirements of the

National Electrical Code® (ANSI/NFPA-70 (NEC®). Europe installations
ATTENTION shall comply with the 60079-14 according the attached certificates
6.2 Design of the measurement point

A typical measurement point consists of up to five sampling lines from the gas
pipeline(s) to the measuring instrument. If the pipeline pressure is higher than the
maximum inlet pressure, a pressure reduction system must be installed and adjusted
upstream of the sample gas inlet.
The streams of gas are measured in sequence. Gases which have passed through the
device are fed into the waste gas.
The carrier gas and calibration gas are generally supplied from gas cylinders with
pressure reducers installed near the device. These auxiliary gases are used to maintain
operation and measurement accuracy. The gas supply will generally last for several years
of operation and can be increased if necessary by using a changeover valve. This option
is shown on the helium cylinders in the picture below.
All components and pipelines (made of stainless steel) should be installed permanently
and may require additional heating. The waste gases must not cause any backpressure
in the exhaust system and must not interfere with each other. To enable this, the gas
from the module vent (MV) must always be discharged separately. The power supply and
the communication cables must be connected and installed as usual in industrial
environments. The following diagram shows a typical system layout in simplified form:

Figure 6.1: System overview
Flow meters may be installed in the stream of waste gas as an option to provide further
control of the device.
6.3 Mechanical installation (assembly)

Professional installation is the only way to ensure that the device operates safely and
without problems. Always observe the general safety rules, particularly in a potentially
explosive atmosphere. Always use a gas detector for your own protection to check your
respiratory air for toxic or explosive gases when you are working on the device in areas
where such hazards exist. Do not carry out any unauthorized modifications or technical
changes.
If the product is modified or changed without authorization, its CE

declaration will immediately become void. This may result in a safety risk!
ATTENTION

There must be a minimum gap of 700 m above the base of the device and 100 mm in
front of the gas connections or a radius of 225 mm around the centre of the cover.
Select an installation height between 1.00 m and 1.50 m above the floor
which is suitable for maintenance work.
We recommend that you use larger gaps to make installation and maintenance work
easier. The following sketch shows these requirements.
Figure 6.2: Minimum installation gaps

6.3.1 Device dimensions
Please note that all dimensions in the following drawing are shown in mm. The relevant
dimensions (raw dimensions) are highlighted in bold. Some of them will change
depending on the types of fluid and electrical couplings used.
Figure 6.3: Side view with dimensions (without couplings and connections)
Depending on local regulations, the weight of the EnCal 3000 (28kg) may
exceed the allowable manual lifting limit for one person.
ATTENTION
Be sure the appropriate manpower or lifting equipment and protective
equipment such as safety shoes are available.

Figure 6.4: Plan view with dimensions (without couplings and connections)
6.3.2 Place of use and installation site (protection from environmental influences, etc.)
Obey the explosion-protection rules at all times when working with tools
or on items in hazardous zones
CAUTION
The EnCal 3000 must be installed as close as possible to the

process gas sampling point to avoid having long supply lines and to
ensure that you obtain current measurements.

The installation site must satisfy the required ambient conditions. If this
is not the case, for example outside buildings, the device must be
protected from direct sunlight and rain, for example by a metal roof or an
additional air-conditioned housing. Ensure that the device cannot be
ATTENTION
struck by a jet of water (for example when cleaning). Further information
is available from your TAC.
The measuring instrument weighs around 28 kg. Before installing it, ensure that the
installation surface is strong enough to support it. The EnCal 3000 can be installed on a
flat vertical surface (wall/measuring board) or on a horizontal surface.
Use the fastening holes provided in the

housing and, if necessary, additional
mounting plates (as shown) for this
purpose.
The drawings below and to the side show
the various installation options:
For example, the measuring unit can be

secured to a horizontal surface with four
screws using the four threaded blind holes
in the housing base plate.See drawing
to the side (dimensions in mm).
It can be installed vertically (wall/board

mounting) using a wall mounting bracket
secured as shown in the figures below (dimensions in mm).
Figure 6.5: Installation options 1

Use suitable fastenings and mating parts in each fastening hole (i.e. nuts and bolts or
anchorings which fill the holes as much as possible). Select them on the basis of the
material and the type of installation surface. Ensure that your fastenings will withstand
a combined vertical load of at least 1000 N.
Ensure that the device is installed in the correct position:

The device must always be operated in a horizontal position, with the analytical
modules and hood at the top.
ATTENTION The technical specifications and flawless operation will only be
guaranteed if the device is installed in the correct position.
Figure 6.6: Installation options 2
6.3.3 Assembly hints
The generally accepted rules of engineering for handling gases and/or electronic
components must be followed when carrying out the replacement work described below.
Many components are assembled with screws. Ensure that these screws are securely
tightened.
When fitting the replacement parts, ensure that they are in the correct
position (left/right/top/bottom). The following figures show these
positions where necessary.
ATTENTION Prevent dirt and/or moisture getting into the device as it could possibly
falsify the measurements or cause damage.
Surfaces which come into contact with gas must be free of grease, oil, solvents and
other impurities.

Screws which connect gas components must be additionally secured. Use

Loctite 243 thread lock and apply it to the thread flanks in the last third
CAUTION of the internal thread.
Coat other screws with “OKS 250” or, alternatively, spray them with Fin Super if you are
not using any thread lock product.
Always replace the affected seals if they are in a gas route. Apply a very
thin coating of Molykote 55 to all new O-rings/seals.
ATTENTION
Ensure that you conduct a tightness test after replacing parts coming
into contact with gas before you use the new parts.
CAUTION
You should not be or become electrostatically charged before or during

the work.
NOTE
Check that connectors and screws are secure when all the work has been
completed. Reassemble the device fully and fit the hood.
CAUTION
6.4 Electrical installation

The device does not have its own off switch.To comply with Electrical Safety Standards
IEC 60947-1 and IEC 60947-3, an external external off switch (not supplied) 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.
A functioning, effective lightning protection system must exist at the

place of use to protect personnel, equipment and the device.
CAUTION
All input, output signals and power connections shall be of non-

hazardous voltage and reinforced isolated from main
CAUTION

The power supply must be reinforced isolated from mains. Voltage range: 24 V DC.
Fluctuations, including mains fluctuations: ± 15%.It must be possible to supply a rating
of up to 120 W. Only one device may be operated on each power supply unit.
The overvoltage/overcurrent and electrical cable protection must be provided by the

power supply unit. Suitable external safety devices must shut down a current of 8.3 A or
over within 120 seconds, thus limiting the power supply.
The device must be connected to the equipotential bonding system at the place of use
and earthed. Use a suitable connection on the base (see Figure 6.7) to connect the
device to the local earth and the equipotential bonding system. If other metal parts are
connected to the device during the installation work, they must be expertly included in
the earthing and the equipotential bonding system. Use the appropriate connections or
install such connections.
The device will only operate correctly if all the system parts have the same earthing
potential. The wire cross-section for earthing is 6 mm² copper wire. The earthing cable
can be connected at various points on the base, depending on the installation
configuration. Generally, the underside is used with M5 threaded bolts, but the rear with
M8 threaded bolts may also be used, see figure 6.7.
When connecting the earthing cable, ensure that it has a good,

permanent, stable electrical contact. When making the contact and
ATTENTION selecting the fastening materials, comply with the appropriate
regulations, for example IEC/EN 60079-14.
Figure 6.7: Example of earthing points on the device

6.4.1 Cable glands cables andwires
There are four threaded bore holes which pass completely through the device base (2x
M20x1.5 and 2x M25x1.5) (see Figures 6.7 and 6.8). All the electrical connections can
be directly connected to the device here using cable glands.
Since most systems only require connections for data transfer and power supply
(24 V DC), the other threaded boreholes can be fitted with blind plugs, adapters or other
cable glands, for example for signal cables or signalling contacts. A local display or a
USB connection can also be screwed into one of these boreholes as an option.
These screw-in parts must have the correct IP rating and suitable explosion-protection
certification. To comply with the specified explosion-protection regulations, they must
be installed and sealed in their function as securing parts as specified by the
manufacturer of the cable glands.
The M25 cable glands used as standard are suitable for reinforced cable with a diameter
of 11 – 17 mm, while the M20 cable end glands can be used for reinforced cable with a
diameter of 6 – 12 mm. The following cable properties are required in order to comply
with the explosion-protection regulations:
• Not sensitive to cold flow, impermeable to air and at least three metres long.
• The cable and cable gland are suitable for temperatures of 70°C and higher.
(Le câble et le presse-étoupe conviennent pour des températures de 70°C et
plus.)
• Conduit stop boxes must be sealed between 1xD and 45 cm depending on the
regulations.
The device can also be fitted with bespoke cable glands, for example with ½" NPT
threads, using adapters. Please contact your TAC for further details if you wish to change
the standard equipment.
Figure 6.8: Position of the cable end glands on the housing base

Followind figure shows the number and position of cable glands (looking from the wall
towards the device). The relevant installation guidelines must be obeyed for routing the
cables. The insulation must at least comply with flammability class 1. Use screened
cables.
Figure 6.9: Position of the cable end glands on the housing base
The electrical inputs are sealed for reasons of explosion protection. In the
event of a replacement, the complete gland must be replaced. The
CAUTION residual cable in the device must then be cut and can no longer be used.
The replacement and extension of the electrical connections involve similar work to a
new installation. Proceed as described and
in any event, obey the explosion protection regulations.
Use only suitable and approved cable inlet equipment. The cable inlets
must satisfy or exceed the IP rating. NEC-compliant cable inlet
equipment must be used in the USA. CEC-compliant cable inlet
ATTENTION
equipment must be used in Canada.
Cable glands with a sealing system are typically required or, to fulfil the FM regulations,
seal all conduits within 18 inches. See below table for use of gland or conduit
Approval Glands / Conduits Additional info
ATEX Glands Use Barrier glands
IECEx Glands Use Barrier glands
NEC (US) Conduit seal within 18 inches (45 cm)

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 entry
devices and blanking elements of unused apertures shall be of a certified flameproof
type, suitable for the conditions of use and correctly installed. For connection of an
external earthling or bonding conductor a cable lug shall be used. The conductor shall
be mounted so that it is secured against loosening and twisting and that the contact
pressure is permanently maintained.
The prepared cables must be fed through the cable glands in the device base. All the
electrical interfaces, are located on a single terminal board and electrically isolated. The
screened cables must be connected in compliance with local conditions and
regulations. Also take note of the specifications of the cable gland manufacturer.
Cables, wires, cable glands, adapters and blind plugs are standard products
not manufactured by Honeywell which are required for operating the device.
The basic equipment can be extended or adapted by using other parts or
buying additional ones. We recommend that the data cables are separated
from the power supply cable.
Standard industrial 2-wire cable, wire cross-sections AWG 12-13 (2.5 - 4 mm²) can be
used for the power supply. (The use of an external junction box is responsibility of the
customer / installer) Armoured cable required for outdoor installation – OD between 12
and 25 mm Power rating 24 VDC / 120 W max nominal (ambient T > 0 °C or >32 °F). The
cable cross-section must be chosen sufficiently large.
A maximum rated operating current of 5 A should be considered for the power supply.
(Remember to take the cable voltage drop into account.) Ensure that the power supply
is capable of tripping the external circuit breakers or the internal 5 A fuse in the event of
a short-circuit.
Wire cross-sections of 0.14 mm² to 1.5 mm² are suitable for signals. When making your
selection, also note that the wire cross-section must satisfy the electrical and
mechanical requirements. For example, signal cables generally require wire cross-
sections of over 0.25 mm². In general, the connection cables can be routed to two
separate locations without additional Ex-rated junction boxes.
Various data communication cable are suitable for the connection between the enCal
3000 and other devices. They should be selected on the basis of the requirements at the
place of use. Honeywell generally recommends a signal cable with a conductor-to-
conductor capacitance of less than 120 pF/m and an inductance of less than
0.7 H/m.
The number of cores varies depending on the application, whereby the cores should be
twisted in pairs and screened jointly. The maximum cable length depends on the type of
signal and must not be exceeded. A cable type of category 5 (Cat 5) is recommended for
data communication links via Ethernet.

The housing temperature may rise above the maximum ambient temperature.
Cable inlets and cables must be suitable for 70°C (158°F / 343 K) ambient
temperature or higher.
ATTENTION Les entrées de câbles et les câbles doivent être adaptés à une température
ambiante de 70°C (158°F / 343 K) ou plus.
See following examples:
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:
• Standard industrial data communication cable shielded twisted pair
• 3-wire for RS 485 communication
• 3-wire for RS 232 communication
• 2 serial ModBus ports are available, each of them independently user

configurable into RS 232 or 485
• (Pin lay-out and link locations see figures 5.8 and 5.9)
6.4.2 Making the electrical and signal connections
The following work cannot be carried out without opening the housing.
Please contact your TAC if you are not authorized to open the device
ATTENTION
The integrated circuits can be destroyed by electrostatic discharge.

When working on the device, it must be protected by an ESD guard
ATTENTION (e.g. one which complies with EN 61340-5-1). Avoid short-circuits
The cables are connected to the Interconnection board using plug connectors.
Compliance with the local/national installation guidelines (e.g. EN 60079-14) is
mandatory. The connection terminals in the interior are different for the voltage supply
and signals.
It must be ensured that enclosure IP 66 is maintained and therefore the parts used must
comply with this or a better (higher) rating. Openings which are not required must be
fitted with appropriate blind plugs.

• Ensure that the device is not live (power supply and signals) before
wiring work is completed. .
ATTENTION
The device must be connected to the equipotential bonding system at the

place of use and earthed. Use the equipotential bonding connection (PA)
CAUTION on the underside of the housing.
Check the voltage used at the place of use to ensure it is correct and suitable as
described in the following instructions. Ensure that the same earthing potentials are
always connected to each other.
The device will not work if the connections are reversed (polarity reversal
protection). In some cases, the fuse also triggers and must be replased. This
protective equipment (thermal trips and electrical fuses) cannot be
accessed without opening the housing. Please contact your TAC if you are
not authorized to open the housing and replace the protective equipment.
When making the contact and selecting the fastening materials, comply with the
appropriate regulations, for example IEC/EN 60079-14.
ATTENTION
When connecting the earthing cable, check that it has a good, permanent,
stable electrical contact. Use earthing points outside the device as
ATTENTION discriped bevore
Tighten the screws on any unused terminals.

Check that the connectors are secure when all the work has been
ATTENTION completed.
In addition to the wiring work, special parameterization may be required

e.g. for Modbus communication. Detailed information is given in the
software manual.

6.4.3 Connections on the EnCal 3000 Interconnection board Version 1.x
The drawing below shows the top lay-out of the Interconnection Board Version 1.x at
the bottom of the unit. It contains all the connectors for external cables (marked with
grey). For flame retardant wiring use cables according an ISO norm. To fulfill the FM
regulations always use cables / wiring according to UL94 V-1 or equal for installation.
All the wiring with the other electronic boards is done in the factory, and may not be
changed during field installation.
Figure 6.10: Interconnection Board V1.x: top view lay-out

Part Description
J1 Processor board connection
J2 Channel 1 Connector 1
J3 Channel 2 Connector 2
J4 I/O Flat cable to Processor board
J5 TCP/IP connection between Interconnection 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 stream selection (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 analytical channels Module (6,3A)
F107 Fuse additional cabinet heaters (5A)
LD101 LED (internal 12 V- circuit)
LD102 LED (activation valves stream selection)
LK 301-304 4 jumper for selection between RS232 and RS485
LK 305-307 3 jumper for selection of analogue input (4-20 mA or 0-10 V)

Power Supply Connection:
Power Supply is 24 VDC, with conductor size AWG 12-13 (2.5 – 4 mm²). The cable has to
be connected to connector J8. See picture below and Fehler! Verweisquelle konnte
nicht gefunden werden. for location and polarity. 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.
Figure 6.11: 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 J7. See picture below for location and wiring
scheme.
Figure 6.12: Location of Ethernet connector and wiring scheme

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).
Figure 6.13: Location of Serial ModBus connector (J6)
Figure 6.14: Modbus Connection and Link settings

6.4.4 Connections on the EnCal 3000 Interconnection board Version 2.x
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. For flame retardant wiring use
cables according an ISO norm. To fulfill the FM regulations always use cables / wiring
according to UL94 V-1 or equal for installation. All the wiring with the other electronic
boards is done in the factory, and may not be changed during field installation.
Figure 6.15: Interconnection Board V2.x: top view lay-out

Part Description
J1 Connection of Processor Board
J2 Connection for Analytical Module 1
J3 Connection for Analytical Module 2
J4 26-pin Connector for first part of data connection cable between IC-Board and
processor board
J5 34- pin Connector for first part of data connection cable between IC-Board and
processor board
J6 Ethernet cable connection
J7 Connection for TCP-IP communication
J8 Connection for Modbus-Communication
J9 Connection for Digital Inputs (passive)
J10 Connection for Analogue Inputs (0-10 V DC)
J11 Connection for 24V supply of external transmitters (24V, 25 mA)
J12 Connection for Analogue Outputs (4-20mA)
J13 14-pin Connector for supply of timed relays and Vents
J14 24V Power Supply Connection
J15-J16 Additional optional 24V supply
J17 Connection for communication cable used for parameterization of the regulation
for the internal heating
J18 Connection for temperature sensor for regulation of the internal heating
J19 Connection of over temperature protection for internal heating
J20-23 Power supply connection for internal heating
J24 Connector for data communication between Master and Slave housing
E1-E2 optional connector for shield of cables
F1 Fuse 5A for die analytical Modules
F2 Fuse 5A for heating circuit
LD1 LED 24V Power Supply
LD2 LED 12V Supply for analytical modules and Vents
LD3-6 LEDs Diagnostic of Analogue Outputs
LD7-8 LEDs Diagnostic of internal Heating
LK1-6 Jumper-Connections for RS232 and RS485
LK7-12 Jumper-Connections for data communication cable between IC-Board and

processor board

Power Supply Connection:
Power Supply is 24 VDC, with conductor size AWG 12-13 (2.5 – 4 mm²). The cable has to
be connected to connector J14. See picture below and Fehler! Verweisquelle konnte
nicht gefunden werden. for location and polarity. 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.
Figure 6.16: Location of Power Supply connector (J14)
Ethernet connection:
The Ethernet connection is used for connection with a PC or ModBus TCP/IP clients. It
uses 4 wires, connected to connector J7. See picture below for location and wiring
scheme.
Figure 6.17: Location of Ethernet connector (J7) and wiring scheme


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 LK1-3 and LK4-6
(see pictures below for location, wiring
scheme and link settings).
Figure 6.18: Location of Serial ModBus connector (J8)
Figure 6.19: Modbus Connection and Link settings

6.4.5 Electrical device test to verify correct installation
After concluding the electrical work, you should conduct a test to rule out the possibility
of errors, e.g. insulation faults in the supply voltage and communication. This test must
be carried out by the personnel responsible for the electrical installation. The operator
should obtain written confirmation that the device is in perfect electrical condition.
Do not conduct the tests in a potentially explosive atmosphere.
You will require the permission of the system operator to conduct the test
CAUTION
The use of a multimeter is required to conduct the test. You should check the following
points:
Test
Test step
point
Conduct a visual inspection of the interior of the device. There must be no loose wires.
1 All wires are connected as shown in the circuit diagram. Spare wires have been dealt
with correctly and routed safely.
The supply voltage is 24 V DC. ± 15% is available after switching on the terminals on
2.
the terminal board.
A rating of up to 120 W can be supplied. Connect a load resistor in parallel if

3.
necessary.
Cause a short-circuit and the supply voltage must be switched off within
4.
120 seconds.
Check all switches and fuses outside the device. Is everything accessible and can
5.
everything be switched off and on?
Conduct resistance measurements to ensure that all the electrical connections have
6
low resistance. Check the earthing as well.
Conduct resistance measurements to ensure that all the cables are adequately
7
isolated from each other and to earth.
If you find any discrepancies or errors during the test, repeat the appropriate items in
the installation procedure until all the points are error-free and OK. This concludes the
installation work. Seal the device again correctly.
Close the device.
Position the hood with the sealing ring and fully tighten the thread. Then
ATTENTION
turn the countersunk security screws upwards to the edge of the hood to
prevent the hood being removed accidentally or through ignorance.

6.5 Fluidic installation

The installation of the fluid interfaces / connections is described in the following.
Always remember :
The maximum pressure at the gas inlets on the device must not be exceeded so as
to prevent damage and dangerous situations.
This must be guaranteed on site by external protection which is not part of the
device. Refer to the information in chapter 2.4 when setting the maximum pressure.
ATTENTION
The required pipelines and safety devices must be fitted to comply with
current general regulations and the specifications in this manual.
6.5.1 Fluid connections
The device has multiple gas connections for various functions. They are always fitted
by the manufacturer. All gas and vent lines do have a 1/8” Swagelok connection to the
EnCal 3000. On request also 3 mm connections are available.
Figure 6.20: Fluidic connections

Connection Position on the device/Note
Sample gas streams 1 – 5 Right-hand sideIt is possible to measure up to 5 different

Inlet pressure1-4 barg (15-57 PSIg) gases in sequence.
CAL Calibration Gas Left-hand side, first connection

1-4 barg (15-57 PSIg) Used to maintain measurement accuracy.
Carrier 1: HE Helium Left-hand side, second connection

5-6 barg (71-86 PSIg) For transporting the measurement gas inside the device;
Recommended pressure 5.5 barg) waste gas is released into the housing.
Sample and blocking vent Left-hand side, third connection The unmeasured sample
(SBV) gas is released at ambient pressure.
Left-hand side, penultimate connection

Carrier 2:
Second carrier gas only needed to analyse biogas or
AR Argon 5-6 barg (71-86 PSIg)
hydrogen in natural gas. In standard applications this
Recommended pressure 5.5 barg
connection is not used and closed without piping inside
Purge vent Left-hand side last connection

(PV) Flushing or bypass gas is released at a high flow rate.
In the standard version, they take the form shown in the figure below.
Figure 6.21: Layout of the gas connections
Each gas inlet consists of the coupling (a 1/8" Swagelok pipe fitting) and an adapter
with an internal 2 µ filter. Inside the device, the gas connections are each soldered (at
the connector ) to a 1/16" pipe and connected to the internal sample gas system. This
pipe is used as a flame arrester and must not be reduced in size. It must be more than
25 cm (19") in length and its maximum internal diameter may be 0.015".

WARNING! DO NOT LOOSEN THE CONNECTORS FROM THE ENCAL 3000

HOUSING. THE SOLDERED TUBE WILL BE DAMAGED! THE JOINT BETWEEN
ATTENTION CONNECTOR AND HOUSING IS AN INTEGRAL PART OF THE ENCAL 3000’s
SAFETY APPROVAL
To prevent loosening the connectors use a second key wrench to prevent the coupling
from turning.
IF THE CONNECTOR IS ACCIDENTALLY LOOSENED PLEASE SWITCH OF THE

ENCAL 3000 AND CONTACT THE MANUFACTURER
CAUTION
The adapter can be replaced without removing the hood from the gas chromatograph
and is suitable for connecting a Swagelok pipe fitting (3 mm or 1/8").
Each gas outlet consists of the coupling (a 1/8" Swagelok pipe fitting) and a filterless
adapter. The adapter can be replaced without removing the hood from the gas
chromatograph and is suitable for connecting a Swagelok pipe fitting (3 mm or 1/8").
The external pipework required should be made of stainless steel and permanently
connected. The supplied sample gases must comply with the specifications or be pre-
filtered as the particulate filters in the adapters are only designed to protect the device
The breather valve (also known as a vent valve or short breater) on the rear of the housing
is used to allow an atmospheric pressure equalization process between the interior of
the device and the ambient area so as to comply with the ATEX regulations.
These state that the gauge pressure inside the housing must not exceed 100 mbar in
the event of a complete gas rupture, in other words, if all the gas supply lines inside the
housing were to be detached at the same time.
DO NOT UNSCREW THE BREATHER VALVE.

DO NOT CONNECT THE BREATHER VALVE’S PIPELINE TO OTHER PIPELINES.
CAUTION
The breather valve in the device is made from Stainless steel and sintered metal. It is
suitable for a IIC and for Class I/Division 1 environment in conjunction with capillary
flame arrestors with an ID of maximum 0.015” (0.38mm) and a length of minimal
250mm. It has an outlet connection of ¼” NPT
It must not be sealed or blocked, for example by water, condensation, ice, insects, dirt or
the like, as otherwise the pressure equalization process will be adversely affected. In the
case of outdoor installation, it may be protected, for example by connecting a gooseneck
pipe or a vent line.

PROTECT THE BREATHER VALVE FROM BLOCKAGES.

ATTENTION
If this optional pipeline is connected using the ¼ "NPT thread, it must have a minimum
internal diameter of 8 mm. With the pipeline connected (comply with the length details
in chapter 2.4), IP 66 protection is achieved and a vent line flow rate of around
10.5 l/min is possible
Figure 6.22: Breather as required by Explosion proof directives
Flame barriers can generally only be replaced by the manufacturer. Please

contact your TAC
ATTENTION
Surfaces which come into contact with gas must be free of grease, oil, solvents and
other impurities.
Gases must not be contaminated or falsified when being transported from the source
(pipeline or cylinder) to the measuring instrument. This applies to all gases. Route the
gas pipelines to the measuring instrument. Use the pipework diagram specified and
prepared by the system operator. Ensure that every pipeline and every gas route is fitted
with the required safety and shut-off equipment. All pipelines are to be kept as short as
possible. Use only tight, clean stainless steel gas pipes.
Prevent dirt and/or moisture getting into the device as it could possibly
falsify the measurements or cause damage. Controls and pipe couplings
with low dead spaces are to be given preference.

Never mix connection elements from various system suppliers

to connect gas appliances.
CAUTION
Before connecting to the device, ensure that the pipeline is clean inside, for
example by flushing it with gas for around 30 seconds. The flushing gas must be
ATTENTION discharged correctly and safely
The process gas is taken from the process pipeline. The tapping equipment should
have a temperature equalization system and pressure regulator and be as close as
possible to the device.
The integrated inlet filters are designed to protect the device and are not
a substitute for a primary filter system. A primary filter system is always
CAUTION
required if the gas specifications cannot be satisfied.
The volume and pressure of the sampling line determine how current the measurement
result is in addition to the dead time of the measuring instrument itself.
Additional shut-off valves and possibly additional pressure reducing systems, filters, gas
dryers, etc. must also be fitted in the pipeline if required so that the process gas sample
is transported to the device still complying with the required specifications.
Steps to prepare the process gas sampling line

line
Ensure that there is a shut-off valve* in the process gas pipeline system. Check that
1. the shut-off valve* is closed. A suitable pressure regulator* may also be required. If
there is a pressure regulator*, turn the regulator to its lowest setting.
2. Connect the process gas to the pipeline system.

Do not connect the measuring instrument yet.
Check that the pressure and other parameters are correct before you carefully open
3. the shut-off valves on the pipeline section so as to create a permitted gas flow above
the operating conditions.
4. Then flush for around 30 seconds** to clean the pipeline system. Discharge the gas at
the end of the pipeline correctly into the waste gas system using a hose.
5. Then close the pipeline shut-off valves again and restore the previous settings. The
precise pressure is set later after the device has been connected.
The pipeline is now ready for connection see steps below.
6.
Prevent the ingress of dirt and moisture if the connection is not made immediately.
* Not part of the measuring instrument and not included in the delivery; use only suitable standard types.
** This time must be extended accordingly in very long pipelines.

During normal measurement, all the gas flows through the device and is then
discharged as waste gas via other pipelines into safe venting areas outside buildings
due to the permanent flow of flammable gas. It must be discharged without any
backpressure. Therefore, the diameter of the pipeline must never be reduced.
A 6 mm pipeline is generally sufficient. If a great deal of gas passes through the bypass
or a high volume of flushing gas is to be used, a separate waste gas line should ideally
be installed for this gas to prevent return effects. The waste gas lines must be protected
from dirt and moisture.
If gas inlets or outlets are not used, they must be sealed using blind plugs.
ATTENTION
The pipeline at the breather valve (if connected) is not part of the waste
gas system and must never be connected to other waste gas lines
CAUTION
Steps to connect the waste gas line

Connect the waste gas to the relevant outlets. Always discharge the gas from (MV) separate.
1.
Avoid back pressure formation and mutual interference in the exhaust system.
Connect the pipelines immediately after you have removed the sealing elements (blind plugs or
2.
screw plugs) from the gas outlets on the device.
Since it is not possible to conduct a tightness test when the device is switched off, the waste gas
3. line must be checked for leaks with a gas detector during the flushing cycle. This test must be
carried out first of all once the device has been installed and is operating.
Steps to connect the measuring instrument to the process gas pipeline

Ensure that the required work described in the previous sections has been completed. In particular,
1.
the pipelines must have been flushed.
Ensure that the process gas pipeline is connected to the sample sensor and that the shut-off valve
2. in the process gas pipeline is closed. (If there is a pressure regulator, turn the regulator to its lowest
setting.)
3. Ensure that a process gas inlet pressure range according to chapter 2.4 can be set.
Remove the protection (sealing plugs or screw plugs) from the relevant inlets, ensuring that the
4. connection on the housing is not released since otherwise the pipes soldered to it will be damaged.
Therefore use a second wrench to limit the rotary movement on the connection coupling.
Connect the pipeline properly.

5. NEVER OPEN THE GAS SUPPLY IF THE COUPLING HAS BEEN DETACHED.
In this case; you should always contact your TAC.
Carefully open all the shut-off controls, valves and regulators in the process gas route to slowly
6.
increase the pressure up to operating conditions.

A tightness test must be conducted once the installation work has been
completed in full and when all the gas pipelines have been connected and
CAUTION
pressurized.
Since the test cannot be carried out on all parts when the device is
switched off, the tightness test for these parts must be carried out first of
all when the device is running.
6.5.2 Configuration with two Carrier Gases
For some applications like the analysis of biogas a use of different carrier gases for the
two analytical modules can be an advantage. In the application Biogas for the module
from type mole sieve Argon is used as carrier gas and for the second module from type
PPU Helium is used as carrier gas. In the following picture this configuration is shown.
The two connections for the two different carrier gases are marked on the housing.
Figure 6.23: Configuration with two Carrier Gases

6.5.3 Connecting and replacing gas cylinders
Regular automatic calibration/adjustment with a calibration gas is required for the

EnCal 3000 to operate correctly. A gas cylinder containing the calibration gas mixture is
required for this purpose. A gas cylinder containing helium or argon to act as the carrier
gas is also required for operation. These gas cylinder should be replaced as soon as the
outlet pressure can no longer be held at a stable level. This will generally take place at
around 0.5 MPa, depending on the regulator. The cylinder pressure should be
monitored, for example with a pressure gauge or contact pressure gauge. Further
options and details about the calibration gas mixture and carrier gas can be provided by
your TAC on request.
Some situations make it necessary to connect additional gas cylinders, for example for
a verification measurement. This work must be carried out as described in the steps
below.
Always follow the steps of the cylinder change according to local regulations and
the working steps in the Operating Instructions. Suivez toujours les étapes du
CAUTION changement de cylindre établies selon les normes locales en respectant les étapes
de travail inscrites dans les instructions de ce manuel.
Failure to comply may result in substantial damage to the device or the station. Le
non-respect de ces étapes peut entraîner des dommages importants à l’appareil ou
au système!
A suitable pressure reduction is required to connect a gas cylinder to the calibration gas
inlet of the EnCal 3000. Honeywell offers prefabricated panels with high pressure
reductions for this purpose.
Steps to connect the gas cylinder (parts marked with an asterisk (*) are not necessarily
included in the delivery and must be obtained before starting the work; use suitable
standard-compliant types only)
Observe the generally accepted rules of engineering for handling gases during all work
as described. Surfaces which come into contact with gas must be free of grease, oil,
solvents and other impurities.
Take action to prevent dirt and/or moisture getting into the device during
the replacement process.
ATTENTION

Steps to connect /replace a gas cylinder !Obey the explosion protection regulations!
1. Close the main valve on the gas cylinder.
2. Depressurize the connected gas pipeline.
3. Remove all equipment from the cylinder connector.
4. Close the connection thread on the valve with the screw cover.
5. Place the protective cap onto the gas cylinder and screw it tight.
6. Release the anti-tipping device and remove the gas cylinder.
7. Replace the cylinder with a new/different one.
8. Secure the new cylinder to prevent it tipping over and unscrew the protective cap.
9. Ensure that the main valve on the cylinder is closed. Only then remove the screw
cover (blind plug) from the valve connector.
Reconnect the equipment you removed in step 3 to the valve connector on the gas
10.
cylinder. Do not apply any oil or grease to the thread.
11. Ensure that the reconnected controls are closed.
Ensure that gas can flow in the parts you wish to flush. For this purpose, disconnect
12. the pipeline immediately upstream of the device while the gas cylinder is closed.
Ensure that the flushing gas is discharged safely (via a flow indicator).
13. Now slowly open the main valve on the gas cylinder.
14. Adjust the gas flow. Do not exceed the maximum pressure levels.
15. Now close the main valve on the gas cylinder again.
If the outlet pressure of the high-pressure reducer or cylinder pressure regulator has
16.
fallen almost to 0 MPa, open the gas cylinder briefly and then close it again.
Repeat the procedure described above several times to ensure that there is no more air
17. in the dead space of the regulator and the pipeline. Everything will be flushed after a
total of 5 filling and emptying cycles.
18. After the flushing cycle, reconnect the pipe to the appropriate gas inlet on the device.
Open the main valve on the gas cylinder. Set the outlet pressure to the operating
19.
pressure recommended in section 1 of the User Manual.
20. Carefully check the tightness by means of a tightness test.

COMMISSIONING AND DECOMMISSIONING
6.5.4 System tightness test
Leaks in the gas supply lines increase the danger of explosion and may
result in inaccurate measurement results.
CAUTION
Step Action: Tightness test
If the device is already operating, stop the gas consumption by switching off the
1.
power supply, for example.
Supply all inlet gas lines for the measuring equipment with gases at the
2.
maximum pressure values so that the pipelines contain a gas volume.
3. Check all the parts of the system for leaks using a gas detector.
• If you identify a leak, it must be sealed immediately.

• Shut off the gas supply for this purpose.
4.
• Seal the leak.
• Repeat the test described in step 3.
Do not complete any further action or work before the entire system is tight
5.
and item 4 no longer applies.
7 Commissioning and decommissioning
This 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
CAUTION instructions below carefully and make sure you have fulfilled all necessary
safety steps before powering up the EnCal 3000.
This chapter describes the main points for commissioning and decommissioning the
measuring instrument. All new devices are supplied with default parameter set. This
default parameter set should generally be sufficient.
It may be that in different ambient conditions in the field, additional adjustments may
be required and integration parameters or other parameters will have to be adjusted a
little. Furthermore, only the streams of gas and the carrier and calibration gas
properties will have to be adjusted. The information required for the standard
commissioning procedure is listed below in chronological order.

If, in addition, (integration) parameters have to be adjusted, the information required

for this purpose can be found in the software section and in the service manual.
Do not carry out any of the work described in this section if you do not have
permission and have not received the required training from the manufacturer
or its agents. (Honeywell can provide the required device-specific service and
CAUTION
commissioning training)
If the device is used for fiscal measurements, the presence of a calibration officer or its
representative is required for the final commissioning of the device. In this case, the
conditions set out in the relevant approval must also be satisfied.
For official (fiscal) operation, make sure that you also comply with the current
regulations relating to sealing and closing off the housing.
Finally, this section contains information which you should take into account if you no
longer wish to use the device or if you wish to use it at a different location.

7.1 Requirements for commissioning and operation

All the safety and warning information in chapters before has been complied with and
the device has been installed and connected as described before. There is no conden-
sation in the device. If you are in any doubt, wait for around 12 hours or contact your
TAC.
Refer to the regulations for explosion protection and the safety information,
particularly for commissioning the device in a potentially explosive atmosphere
CAUTION
Requrirements for 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 Helium inlet. 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 with a non-flammable
gas like the carrier gas Helium. 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. (calibration is already connected in the section above)
• Make a careful leak check of the total system.
• Make sure that the sample gas flow is nowhere blocked. To be able to
guarantee this the Encal3000GC has to use a separate Vent line which doesn’t
become blocked by any kind of restriction. The Vent lines PV and SBV can be
combined to one vent line.

7.2 Hardware Start-up

Mount the cap on the unit, hand-tight fixed. The marked screws in the following figure
are security screws. Screw out the security screws to prevent removing of the cap by
accident or ignorance.
Figure 7.1: Location of security screws to fix the cap after mounting on the base
Complete all the commissioning work in the specified sequence to avoid possible
damage and fault situations affecting the device.
Steps Hardware Start-

Start-up / Commissioning !Obey the explosion protection regulations!
1. Open the carrier gas cylinder (setting: 0.55 MPag).
2. Open the process calibration gas cylinder (setting: 0.4 MPag)
3. Open the process gas (recommended setting 0.2 MPag )
4. Switch on the power supply.
5. Connect with RGC 3000 (future steps in software manual)
The unit will automatically start-up (as defined in the software). 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.If you wish
to make any changes, please refer to software manual or contact your TAC.
The device can be fitted with an optional additional heating system for use in
temperatures below freezing. Further details of this option is listet in the annex.

Check one more time if all gas connections are leak tight connected and
all cable glands for electrical connection are securely tight. Check also
CAUTION one more time the different gas pressures for correct settings. Apply
power to the unit (24 VDC) by turning on the external switch.
7.2.1 Checking the device settings and signals
If you have completed the commissioning steps listed above, it may be necessary to
adjust the flow of some gases or adjust some other settings.
Since the default settings cannot take account of the site conditions which may differ
from the standard ones, it may be necessary to readjust the settings, for example the
flush times, in some cases.
This is also the case if the gas chromatograph was not supplied with the calibration gas
in which case the calibration settings must be repeated.
If the device is not working well after you have made changes, an extended (complete)
check of the current device parameters is required.
This can be carried out according to the hints in the software manual. For example, you
must check and adjust the bespoke alarm limits and settings for the sequence of
sample gases and the calibration and protocol settings.
Parameterized output signals can be measured using suitable measuring equipment.
The digital communication (Modbus, etc.) can be checked using suitable tools (for
example a protocol analyser).
7.3 Decommissioning
Please proceed in the following sequence to decommission the measuring instrument
if you wish to use it again later at a different location. Also refer to the information in
the section entitled “Dismantling” and particularly remember the following:
Data will be lost if there is no power supply and no internal power supply
from the battery (for example archive data and time settings). The device
ATTENTION will no longer start correctly. You will then require a Honeywell service visit.

Steps Decommissioning (temporary) !Obey the explosion protection regulations!
Switch off the voltages (supply and communication) and secure them against being
1.
switched on again.
Shut down all gas streams and depressurize all gas inlets. Ensure that you prevent the
2.
shut-off valves being reopened unintentionally by taking suitable precautions.
If you intend to remove the device in full, supplement the above steps with the
following:
Steps Decommissioning (long-

(long-term) !Obey the explosion
explosion protection regulations!
Allow the device to cool to ambient temperature and disconnect all the gas pipelines at
3.
the couplings. Immediately seal all outlets and inlets.
Cut all the cables near the cable glands in an area which does not contain a potentially
4.
explosive atmosphere and remove the device mechanically.
Comply with the storage and disposal instructions, regardless of whether you have
5.
completed all the above steps.
Removed devices should generally be stored in the same way as new devices. We
recommend replacing the battery by Honeywell service personnel before using again.
At the end of the period of use of this device, the manufacturer offers professional,
environmentally compatible disposal.
Send the device to the address specified on the type label. The EU-WEEE sign
with a crossed-out dustbin, which you will also find on the device, symbolises
that the device in the EU must not be disposed of with household waste. Instead,
you must return it to the local collection points for electrical waste, if you not
want send it back.
Outside the EU, it is essential that you comply with the current laws for
disposing of industrial waste, if you dispose of the device yourself

MAINTENANCE AND REPAIR
7.3.1 Dismantling
Follow the instructions below before finally removing the device to prevent dangers
through electric shock, leaking gases and explosions (in potentially explosive
atmospheres).
If the device contains hazardous media, they must be removed before its
dismantling.
ATTENTION
Do not dismantle the device without first shutting down all supplies such
as pressure and electricity (including communication).
CAUTION
Ensure that the supply voltage, communication and gases cannot be

activated again by accident so that no danger will occur as a result of the
dismantling work.
ATTENTION
Prevent the release of potentially pollutant substances.
Return the device to the condition in which it was delivered if you wish to use the device
again at a later time or return it to the manufacturer (transport guard, blind plugs,
covers, etc.).
8 Maintenance and repair
As the operator, you are responsible for ensuring that the installation and maintenance
work described in this document is carried out correctly. Honeywell will be delighted to
help you with this work. Please contact your TAC. To ensure long-term use, in addition to
the regular calibration work described in separat manual , the device must undergo
annual maintenance/cleaning and repair work if necessary. Renewed basic calibration
may also be required if, for example, the calibration gas cylinder is replaced. We
recommend that this work is carried out by the manufacturer or personnel contracted or
trained by it to rule out the possibility of malfunctions and to adapt the software
correspondingly. .
The operator is responsible for ensuring that the device remains in

technically perfect, safe condition throughout its period of operation.
ATTENTION

8.1 Troubleshooting (Identifying hardware errors)

This chapter contains troubleshooting guidelines to help with troubleshooting and
rectifying faults. The causes of these faults can be localized and rectified by checking
the input.
Honeywell can provide assistance with troubleshooting work. You’re TAC

or the service helpdesk can be contacted using the contact details at the
TIP start of this manual.
Step Action: Troubleshooting
1. Check that the process gas or sample gas is available at the correct pressure.
2. Check that the carrier gas is available at the correct pressure.
3. Check that the calibration gas is available at the correct pressure.
4. Check that the waste gas line is not blocked.
5. Check that the supply voltage is available with the correct values.
6. Check the supply cables and the housing earth.
7. If you can’t fix the faults with items 1 –6, please contact your TAC
The following describes action to prevent some faults. It is essential to comply with all
the safety regulations when troubleshooting, particularly the following:
The following hardware check should only be carried out in compliance

with explosion-protection procedures. Any housing opening may only
CAUTION take place if there is no potentially explosive atmosphere.

• The housing may only be opened by authorized/trained

personnel
CAUTION
• You require a written operator license.
• Use only explosion-proof, approved equipment.
• Do not open the device without having taken all the necessary
safety precautions.
• Do not disconnect cable inlets in a potentially explosive

atmosphere.Do not loosen or unscrew the breather valve.
• Only carry out work after disconnecting the power supply and
depressurizing the system, the gas atmosphere must not be
potentially explosive.
• Protect all open pipelines and connections from dirt.
• Before the device is switched on again, ensure that all the gas
connections are sealed and the earthing or PE wire is correctly
installed.

8.1.1 Troubleshooting in the gas supply
The following action can be taken if a fault occurs in the gas supply, (rectification of
the faults under items 1 – 4), e.g. abnormal calibration gas or carrier gas shrinkage.
Step Action: Gas supply fault rectification
Complete a tightness test by checking the entire gas route (from the
1.
cylinder/pipeline to the device) using a gas detector.
2. Seal any leaks properly.
3. Set the regulators and valves to the required values.
Disconnect blocked lines from the switched-off device and flush the pipeline with
4. non-flammable gas to remove any blockages and deposits while observing the
maximum admissible pressure.
5. Discharge the flushing gas properly.
Use suitable gas detectors for the tightness test. These must reliably
display even very small quantities of the possibly leaking process,
ATTENTION
calibration and carrier gases.
8.1.2 Troubleshooting in the electrical supply and insulation
You can take the following action if an error occurs in the electrical power supply
(rectification of the faults under items 5 and 6). Use a voltmeter to localize the error.
If the device is not supplied with electricity or the supply voltage/current is too low, you
cannot establish a connection.
The connection plugs on the edge of the terminal board must always be
inserted until they lock. Check that they are secure.
CAUTION
Tighten the screws on any unused terminals.
ATTENTION
24 V DC Fluctuations, including mains fluctuations ± 15%, for example

with Quint-PS-100-240AC / Quint-PS-24DC/24DC/10 / Siemens SITOP
Power / Siemens Logo or equivalent power supply units with safe electrical
supply isolation
A rating of up to 5 A/120 W can be supplied.

Step Action: Testing the electrical supply
1. Check all switchgear and fuses and replace any defective parts.
Check that the cable connection between the device and the electrical supply is
2. OK (no interruptions in the wiring). Ensure that a low-resistance electrical
contact is established. Reconnect the cores if necessary.
Check that voltage is being supplied to the inlet point and that the voltage is not
impaired or reduced by overload, insulation errors or defective components.
3.
Remove or replace these parts if necessary. Measure the idling voltage (without
connections). Replace or repair the electrical supply if it is defective.
Measure the idling voltage (without connections).

4.
Replace or repair the electrical supply if it is defective.
Check that the connection between the device and the equipotential bonding
5. system is OK (no interruptions in the wiring). Ensure that a low-resistance
electrical contact is established. Reconnect the earthing cable if necessary.
Only with authorization and in compliance with explosion-protection

procedures!
Measure the incoming idling voltage on the supply cable at the device.
(6.) To do so, switch off the electrical supply and disconnect the supply cable plug
from the PCB. Switch on the electrical supply again and measure the voltage in
the plug. If there is no voltage or if it is significantly lower than the idling voltage,
replace the cable after disconnecting it from the power supply.
If the problem has not been rectified after completing steps 1 – 5 (6), the error is
inside the device. Please contact your TAC to check the internal fuse. The
7.
housing must be opened to replace it and this should only be done by service
personnel or appropriately trained personnel for safety reasons.

8.2 Maintenance and remote maintenance
Maintenance consists of an inspection of the entire system and preventive checks as

well as cleaning the device. Check the possible ranges of consumables and look out for
signs of unusual damage which may have occurred since the installation and
commissioning work by following the steps described below. The regular maintenance
interval is one year. This monitoring work may be carried out more often to identify
discrepancies at an early stage.
Document all work completed, events which occur and general

operations in a maintenance report.
TIP
The regulations for explosion protection (for example IEC/EN 60079-14)

must be followed to the letter. In addition, the operator must check the
CAUTION function of all safety devices regularly, even outside the maintenance
interval if necessary.
The best thing for cleaning the device is a damp cloth with a mild detergent solution or
a mild cleaner such as those used for household purposes.
• Do not use any equipment for cleaning which charges statically

and may generate sparks.
CAUTION • Do not pour or spray water or cleaning products directly into the
breather valve or vent line.
• Do not use high-pressure cleaners or similar equipment for
cleaning
• If the device is installed in a potentially explosive atmosphere,

compliance with the explosion protection regulations is also
CAUTION mandatory.
• Furthermore, the operator must check all safety devices at regular
intervals, possibly independently of the maintenance work, to
ensure that it all functions correctly.

General maintenance procedures
Step Action: Testing the electrical supply

Check the device and the surrounding area (gas connections and pipelines) with a
1. methane detector. If you discover any leaks, close the gas supply, identify the leaks and
seal them. If this is not possible, notify the TAC.
Check the device for signs of damage and loose parts. Notify the TAC if you identify any
2. damage. Tighten any loose parts. Activate any existing loosening guards, for example on
the hood.
Check the vent line/breather valve. Ensure there is no dirt or blockage. If there is, clean it
3. or notify your TAC. Do not use liquids.
Check the fluid connections and electrical cables to ensure they are undamaged. If they
4. are damaged, replace any damaged components. If this is not possible or spare parts are
required or the housing must be opened, please notify the TAC.
Ensure all unused openings are sealed. If this is not possible or spare parts are required,
5.
please notify your TAC.
Read the cylinder pressure of the calibration gas and carrier gas on the pressure gauges.
Note: you can empty the cylinder up to a minimum pressure of 1 MPa, but the cylinder
6.
must then be replaced, regardless of the maintenance interval. Replace the auxiliary gas
cylinders if necessary.
7. Check the inlet pressures
Optional: check the flow rates. If you have flow meters available, compare the current
values with the values obtained during commissioning. If they are different, readjust the
8.
flow rates. If this is not possible with the current inlet pressure, the inlet filters may have to
be replaced. In this case, please contact your TAC.
Create a report on the completion of the work and the results of items 1 – 8 to document
9. your work and results
8.2.1 Visual inspection of the connections
Step Action: Visual connection inspection
Check the connections (fluid and electrical) and stainless steel pipelines or
1. cables to determine whether they are undamaged, complete and free of
corrosion.
If you find any damaged or corroded parts or notice that components are
2.
missing, immediately disconnect the gas and voltage supply.
Replace damaged and/or corroded parts and add missing components so that
3. all the unused openings are sealed. If you require any spare parts, you can simply
order them at your TAC.
Do not carry out any measurements or work using the

4.
device before the repair work has been completed.

8.2.2 Checking the gas connections with a tightness test
Leaks in the gas supply lines increase the danger of explosion and may
result in inaccurate measurement results.
CAUTION
Step Action: Tightness test
If the device is already operating, stop the gas consumption by switching off the
1.
power supply, for example.
Supply all inlet gas lines for the measuring equipment with gases at the
2.
maximum pressure values so that the pipelines contain a gas volume.
3. Check all the parts of the system for leaks using a gas detector.
• If you identify a leak, it must be sealed immediately.

• Shut off the gas supply for this purpose.
4.
• Seal the leak.
• Repeat the test described in step 3.
Do not complete any further action or work before the entire system is tight
5.
and item 4 no longer applies.
Tips to seal the leak
If you identify a leak, it must be sealed. You have some options to do this.
• Replace the seals. Switch off the gas supply for this purpose. You need the
corresponding replacement seal.
• Tighten the connections. In the course of time, connections may have come
loose easily and can be sealed again by retightening.
Take care not to block the flow of the line, this can happen if you tighten
the line connections too much. In this case the GCM module flashes red
CAUTION and in enSuite unusual pressures are displayed for EBC and PPC.

8.2.3 Checking the cylinder pressures (visual inspection)
Step Action: Reading the gauges
1. Read the calibration gas cylinder pressure on the pressure gauge.
If there is still a minimum pressure of over 1.0 MPa, the cylinder can remain in
2. use. Note: if the pressure is close to the minimum, the cylinder must be replaced
independently of the maintenance work if necessary.
3. Read the carrier gas cylinder pressure on the pressure gauge.
If there is still a minimum pressure of over 1.0 MPa, the cylinder can remain in
4. use. Note: if the pressure is close to the minimum, the cylinder must be replaced
independently of the maintenance work if necessary.
Please notify your TAC if you require a new gas cylinder. You may use the
5. device without calibration gas but not without carrier gas. In this case, the
results are less accurate.
8.2.4 Checking the inlet pressures (visual inspection)
Read the process gas inlet pressure of the sample gas streams (1 – 5) on the
1.
pressure gauges.
If the inlet pressure (PG) is not like specified (see chapter “Technical
2.
Specifications), adjust the pressure within this range
If you cannot complete step 2, disconnect the gas and voltage supply. Do not
3.
proceed with any further action or work unless step 2 is correct.
Attempt the repair work described in sections 5 and 6 of this manual. If

4.
necessary, notify your TAC.

8.2.5 Checking the flow rates (optional visual inspection)
In some systems, there are also variable area flow meters installed in the gas streams.
These are not absolutely essential since the flow rate is generally controlled via the
pressure, but provide an option for additional checks.
The flow rates are correct, the ranges are as described in section 2 of the User
1.
Manual.
The flow rates are incorrect, a process gas pressure alarm is active, the inlet
2.
pressures are already at maximum.
If the case described in step 2 applies, the gas and voltage supply must be
3. disconnected. Filters or flame barriers must be replaced. Do not complete any
further measurements unless step 2 is correct.
Attempt the repair work described in sections 5 and 6 of this manual. If

4.
necessary, notify your TAC.
8.2.6 Checking / Replacing the inlet filters and adapters
The inlet filters should be inspected at regular intervals to prevent errors caused by
blockages. If they must be replaced despite the upstream external filter system,
proceed as follows:
Steps to replace an inlet filter !Obey the explosion protection regulations!
Close the main valve on the gas supply line and relieve the pressure in the supply line
1
to the device.
When the residual gas has flowed through the device, switch off the electrical supply to
2.
the device.
Only carry out the following work when the device is depressurized and the ambient
3. conditions are similar to the interior.
Disconnect the gas pipe from the device. Ensure that no gas escapes.
Disconnect the Swagelok pipe fittings from the filter and

4.
replace it with a new filter
5. Refit the fittings and pipelines to the device.

6 Open the gas supply to the supply line.
7 It is essential that you conduct a tightness test. Ensure that no gas escapes.
8 If everything is tight, switch on the device or restart operations.

8.2.7 Checking the housing parts
• The housing may only be repaired by the manufacturer.

• Explosion-proof devices and equipment which have not been
CAUTION
repaired by the manufacturer must not be reused until they
have been inspected by an accredited expert and comply with
the design documents again.
Step Action: Checking the housing parts

Inspect the housing parts visually for signs of damage and leaks (ensure all
1.
parts are secure).
2. If any parts are loose, tighten them and secure them with thread lock.
Please notify your TAC if parts are damaged and, in this case, disconnect the gas
(3.)
and voltage supply.
Do not complete any further action or work until the damaged parts have been
(4.)
replaced.
8.2.8 Inspecting the interior of the housing
The housing hood may only be removed in a non-hazardous area in controlled

conditions as described in ISO/IEC 61010-1. If it is not possible to establish these
CAUTION conditions on site, the complete device must be removed while it is still sealed.
Step Action: Visual inspection of device interior
1. Disconnect the gas and voltage supply.
Only in an atmosphere which is not potentially explosive! Remove the

2. housing hood to ensure that there is no damage/corrosion, unused open
connections or loose wires.
Replace any defective components and connect any loose cables as shown in the
3.
circuit diagram. Please notify your TAC if you require any spare parts.
(4.)
replaced and the hood has been closed again.
Only connect the device to the power supply when all the required steps have
5.
been completed and are OK.

8.2.9 Inspecting and cleaning the breather valve
The breather valve (also known as the

vent valve) is made of sintered metal.
It is located in the rear section of the base
and must not be sealed or blocked to
ensure compliance with the ATEX
regulations, see figure.
Step Action: Monitoring the breather valve

Check whether the openings on the breather valve or the line connected to it are
1.
free of dirt and blockages.
If they are dirty or blocked, clean the components.

2. (See the following instructions.)Do not pour or spray water or cleaning
products into the breather valve.
Please notify your TAC if the breather valve cannot be cleaned and, in this case,
(3.)
disconnect the gas and voltage supply.
(4.)
replaced.
The following describes action you can take if the breather valve is dirty or blocked. The
breather valve must be removed for this purpose. This is only allowed in controlled
conditions outside the Ex Zone as described in ISO/IEC 61010-1.
Step Action: Cleaning the breather valve/vent line

1. Disconnect the gas and voltage supply and, if connected, detach the vent line.
If the dirt is located in the vent line, flush the line from the connection point to the
2a end with compressed air or a non-flammable gas, e.g. nitrogen, with the pressure
required to remove the foreign bodies.
If the dirt is located on the actual breather valve, you must unscrew the valve using a
2b
suitable tool (tool available from Honeywell).
Clean the component without liquid cleaning products. Use a vacuum cleaner or
3.
compressed air to remove the dirt from the outside or blow it out from the inside.
Apply Fin Super before you screw in the component so that the threads do not seize.
4. Screw the breather valve back into place. Ensure that the O-ring is undamaged. Only
use alternative lubricants after consulting your TAC.
5. Reconnect the vent line if applicable. Reconnect the gas and voltage supply.

8.3 Consumables (carrier and calibration gas cylinder)
A gas cylinder with the calibration gas is required to ensure that the enCal 3000 operates
correctly. A gas cylinder containing helium (and or argon) to act as the carrier gas is also
required for operation. These gas cylinders should be replaced as soon as the outlet
pressure can no longer be held at a stable level. Depending on the regulator, this should
be around 1.0 MPag. At a pressure below 2 MPa, you should keep a replacement cylinder
available. The required work should be carried out using the steps described in
“Connecting and replacing gas cylinders”.
Hints about the needed gas cylinders could be found in the technical
specifications
8.3.1 Spare and replacement parts for general maintenance work
The device requires hardly any consumables and has hardly any wear parts. Honeywell
therefore recommends the annual inspection primarily for preventive reasons and to
replace the auxiliary gases if they are close to being empty and to identify errors. Our
contact details can be found at the start of this manual. Spare and replacement gases
can also be ordered using these contact details.
For safety reasons, work which requires the device to be opened may only
be carried out by the manufacturer or by personnel trained or authorized
ATTENTION by it. Please contact us if the device suffers any damage or to arrange an
appointment for service work.
Do not take any safety risks by carrying out incorrect maintenance work
or using non-genuine spare and replacement parts. No liability can be
ATTENTION accepted for damage caused by the use of non-genuine, non-approved
spare and replacement parts or incorrectly completed maintenance work.

DATA COMMUNICATION
8.4 Honeywell service work
If you have the annual maintenance work carried out by a Honeywell service technician,
any errors can be rectified immediately. Naturally, you will also receive detailed
documentation of the work. Then you only have to archive these documents.
In any case, the following always applies:
DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE IS PRESENT

CAUTION
DISCONNECT POWER BEFORE OPENING
After several years of operation, additional maintenance and repair work may be required
due to wear and ageing. Examples of this include battery replacement (around 5 years)
and the replacement of blocked inlet filters. Furthermore, factory maintenance is
required if defects are identified during the annual maintenance work which cannot be
rectified or if the housing has suffered damage.
Depending on the nature of this work, it may require the housing to be opened or the
device to be completely dismantled or returned to the manufacturer.
The required work (with the exception of the complete replacement of the device) may
therefore only be carried out by Honeywell service staff or by personnel trained by
Honeywell.
For example, the housing can only be repaired by the manufacturer since the
dimensions of the explosion-protection gaps are not part of the public domain and are
only specified in the manufacturer’s design documents. Please contact your TAC if you
require such services.
9 Data Communication
9.1 Data safety information and Warning

Devices and therefore also the enCal 3000 are used in modern infrastructures and
network control systems with the aim of transferring process information such as meter
readings, measurements and messages to a central billing or control point. A connection
of this type constitutes a significant security risk which must be given due consideration
when designing the network.

DATA COMMUNICATION
9.1.1 Security considerations for your network
As soon as you identify a possible vulnerability in a Honeywell product, please report it

direct to Honeywell. A vulnerability is if an error or a weakness in the software can be
exploited to adversely affect or reduce the operation or security of the parameterization
or device software. Honeywell reviews all reports about vulnerabilities relating to
Honeywell products and services.
Report a vulnerability to Honeywell at:
https://honeywell.com/pages/vulnerabilityreporting.aspx.
or by e-mail to security@honeywell.com
ATTENTION
or contact your Honeywell Technical Assistance Center (TAC)
9.1.2 Implement stringent password guidelines
Since various types of attacks on passwords take place these days, Honeywell
recommends that best practices for password management are used. Here are a few
time-tested methods:
• Always change standard passwords.
• Use secure passwords.

(When assigning passwords, always use a combination of upper and lower case
letters, numbers and special symbols. Furthermore, protection increases with
the length of the password. A secure password always consists of at least eight
characters.)
Document any changes from time-tested methods.
If your system does not allow one of these time-tested methods to be used,
Honeywell recommends that this should be documented. For example, if special
symbols such as the equals sign “=” are not allowed in passwords.

DATA COMMUNICATION
9.1.3 Prevent unauthorized external access using a firewall.
To reduce the risk for your network, we recommend that you use a firewall or another
mechanism to restrict network traffic between the “external” central billing or control
system and the “internal” network of the gas metering systems. We also recommend
that you only allow protocols and ports which are actually used for data exchange with
the external network and that these are added, for example, to the firewall’s white list.
See the following data protocols with their TCP standard ports (Ethernet) and the
explanatory illustration.
Protocol Standard Description

port
HTTP 80 Hypertext Transfer Protocol allows, for example, access to an

enCore device via the remote operation panel.
MMS 102 Manufacturing Messaging Specification (pursuant to ISO

standard 9506) allows communication between enSuite and
enCore devices.
Modbus 502 Protocol for data exchange by user-defined registers between

TCP AMR and enCore devices using a standard TCP/IP network.
NTP 123 Network Time Protocol for the high-precision time

synchronization of enCore devices with an NTP time server.
Example of a router and firewall between the metering system and control room and
data exchange via Modbus TCP in a trustworthy network
Figure 9.1: Example of a router and firewall

DATA COMMUNICATION
9.2 Local TCP/IP Data Communication

The main Data Communication Port of the EnCal 3000 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, 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:
Figure 9.2: Typical Data Communication Set-up for Ethernet Communication

DATA COMMUNICATION
9.3 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.
Figure 9.3: Typical Data Communication Set-up for TCP/IP combined with Serial
ModBus Communication with the EnCal 3000

DATA COMMUNICATION
9.4 Remote Access

The schematic below shows the different options for remote access to the EnCal 3000:
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.
Figure 9.4: Remote Access to the EnCal 3000

DATA COMMUNICATION
9.5 ModBus Communication

The picture below shows the ModBus Configuration screen for the EnCal 3000
(see also Software Manual)
Figure 9.5: ModBus Configuration Screen
The ModBus registers are user configurable:
Figure 9.6: ModBus Register Details
For further details concerning the Modbus communication please refer to

the Software Manual of RGC 3000

TECHNICAL SPECIFICATIONS
10 Technical Specifications
The main technical data are noted on various type plates and labels on the device. They
are also listed below and can be found in total on the data sheet.
Installation
Installation close to the sampling point up to Ex Zone 1

Place of use If installed outdoors, the device may need a sun shade or have to be placed
in an air-conditioned housing
Wall mounting using a supplied bracket or

Installation
installation on a bench or platform
Mechanical
Base Ø 37 mm x height 37 cm (Ø 14" x height 14")

Dimensions
Installation Clearance: Ø 55 cm x Height 70 cm (Ø 20” x Height 28”)
Weight: 28 kg
Approvals ATEX II 2 G Ex-d IIC T6 Gb and IECEx Ex-d IIC T6 Gb

ATEX (EN 60079-0: 2012/EN 60079-1: 2014)
IECEx (IEC 60079-0: 2011 Sixth edition/IEC 60079-1:2014 seventh edit.)
INMETRO:
NEC Class I/Div. 1, Groups B, C & D
NEC Class I/Zone 1 AEx db IIC T6
Mechanical Vibration and shock test to IEC 60068-2-31 and -64

strength
Enclosure IP 66
Electrical
Electrical Safety Designed to be installed in hazardous areas.
Power supply 24 VDC, 50W nominal non-heated

(single supply) and 120 W nominal heated version (ambient < 0 °C)
Created for example with Quint-PS-100-240AC / Quint-PS-
Maximum
24DC/24DC/10 / Siemens SITOP / Siemens Logo or equivalent power
current/rating
supply units with safe electrical isolation
Battery back-up Button battery, Panasonic Type BR 2032 3V
EMC strength to EN 61000-6-2 and EN 61000-6-4

Interfaces / Inputs/Outputs
Inlets (up to 5 x process gas, 1(2) x carrier gas, 1 x calibration gas)

Gas connections Outlets ( process gas & gas measured) 1/8" or 3 mm Swagelok pipe fitting
Breather line Connection at breather valve: 1/4" NPT
(standard equipment, others on request)
Electrical M20/M25 cable gland for armoured cable per default Diameters Ø 5.5-
connections 12 mm / Ø 12.5-20 mm / Ø 17-26 mm
Optionally with adapters to NPT or other sizes
Ethernet Ethernet UTP 10 Base-T for ModBus TCP/IP and PC link

communication
Serial Two RS 232/485 ports (user selectable) for ModBus RTU

communication
Analog I/O 3 analogues I/O for local sensors (4-20 mA or 0-10 VDC)
Software
Analyser ProTM: complete stand-alone operation, inclusive all calculations and

generation of report formats, without need for operator intervention.
Calculations to ISO 6976, GPA 2172 or GOST 22667
PC RGC 3000: Windows based program for configuration, diagnostics and

report generation (Compatible with Windows XP/Vista/7/10)
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
Analytical
Hardware 2 parallel isothermal GC modules with narrow-bore capillary column

technology in combination with MEMS based analytical components
Analysis Output Full composition of any natural gas up to C6+ (standard) or C9+
(optional)Heating Value, Density, Wobbe Index
Only gases set out in the list of suitable gases below

Gas group The gases must be technically free of dust and liquids. Concentrations
outside these ranges and other components on request
Analysis time 3 minutes for C6+ analysis, 5 minutes for biogas or C9 analysis

Analytical
Component Concentrations outside this scope might be possible, but verification

Range with Honeywell is needed
for natural gas for biogas
N2 : 0.005 – 20 % N2 : 0.005 – 15%
CH4 : 55 – 100 % CH4 : 60 – 100%
CO2 : 0.001 – 20 % CO2 : 0.001 – 10%
C2 : 0.001 – 14 % C2 : 0.001 – 14 %
C3 : 0.001 – 6 % C3 : 0.001 – 6 %
C4 : 0.001 – 3 % C4 : 0.005 – 3 %
Neo-C5 : 0.005 – 0.25 % H2 : 0.001 – 5 %
C5 : 0.001 – 0.25 % O2 : 0.005 – 4%
C6 : 0.001 – 0.1 % H2S : 0.0002 – 1%
C7 : 0.001 – 0.05 % COS : 0.0001 – 1%
C8 : 0.001 – 0.05%
C9+ : 0.001 – 0.05 %
Uncertainty < 0.1 % for all calculated properties
Repeatability < 0.005 % (RSD) for all calculated properties :
Detection limit for C5: 1 ppm; Detection limit for C9: 2 ppm
Ambient conditions
Ambient Atmospheric pressure

pressure
Temperature for devices with ATEX/IECEx-Approval: 0 °C to 60 °C (32 to 140 °F),

range extendable to -40 °C to 60 °C (-40 to 140 °F)
for devices with FM-Approval: 0 °C to 55 °C (32 to 130 °F),

extendable to -40 °C to 55 °C (-40 to 130 °F)
Humidity 0 – 100% RH

POSSIBLE HARDWARE OPTIONS AND TYPE PLATES
Gas Cylinders
Carrier gas 50 l gas cylinder(not always included in Honeywell package)

Helium / Argon Option: 2 cylinders with automatic changeover system
Quality 5.0 Supply pressure 5.5 barg
or better Flow ± 4 ml/min per column (max. 8 ml/min with 2 columns)
Ensure that only suitable standard-compliant types are used if you do not
source them from Honeywell. Cylinder pressure greater than 1.0 MPa(g)
required. At a pressure below 2 MPa, keep a replacement cylinder available.
Other accessories required: pressure regulators and connection lines.
Calibration gas 10 l gas cylinder (not always included in Honeywell package)

Quality 2.0 or Composition preferably close to pipe line composition
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
Ensure that only suitable standard-compliant types are used if you do not
source them from Honeywell. Cylinder pressure greater than 1.0 MPa(g)
required. At a pressure below 2 MPa, keep a replacement cylinder available.
Other accessories required: pressure regulators and connection lines
11 Possible hardware options and type plates
The EnCal 3000 can be delivered with several options. These options are described in
the following segments of this appendix.
Option Meaning Explanation
HT Heaters Frost protection has been added to keep the internals in the
installed housing above 0 degrees Celsius
SC Single
This a single channel analyser
Channel
QS Quad Slave This housing is the slave (2nd dome) housing of an EnCal
3000 Quad. It has no CPU board inside.
H2 Hydrogen This analyser is configured to work with Hydrogen as carrier

gas. As such it needs venting of the carrier to safe area.

Position of the type indication:
The main type label with the most impor-

tant details is located above the sample
gas inlets on the right-hand rear base area.
This information must be noted and ob-
eyed in all circumstances.
If the main type label cannot provide suffi-

cient space for all the details, the additi-
onal details can be read off an additional
type label which is also affixed to the
housing base.
The figure shows the positions

of the type labels.
Figure 11.1: Positions of the type labels

The type label will vary depending on the application and country of use for the device.
The language and specified standards or regulations will be adjusted accordingly. The
details on the affixed label or labels apply at all times and exclusively to the device. These
labels always contain the following data, possibly spread over multiple labels:
Example: Example for Type plate for devices with FM-Approval for Group C and D:

Example for Type plate for devices with FM-Approval for Group B:
Example for Type plate for devices with ATEX/IECEx Approval (extended to 60°C in
2018)
The images are showing the IIC version

11.1 Option HT: Heaters installed

The device has the option for an additional heating system (cabinet heaters) for use in
temperatures around freezing and below.
They are attached directly to the mounting plates and provide additional heat when the
internal enclosure temperature goes below 10 °C (50 °F). Figure 2.10 shows the location
of the cabinet heaters.
Figure 11.2: Cut-out of an EnCal 3000 showing heaters installed
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 Interconnection board
connectors in Version 2 they are located
close to the connectors for the power
supply of the heaters.

The heaters have a protection against overheating. When the protection is activated it
will cut the power to the heaters and stay open until the power of the analyser has been
switched off and on again.
If the protection activates more than once, please contact Elster for an intervention. See
below for an overview of the heater schematic:
11.2 Option SC: Single Channel analyser

Whenever option SC is on the nameplate of the analyser, this will indicate that this EnCal
will only have one channel installed in the housing. This is the case when, for instance,
the EnCal 3000 is used to measure a single component only (like H2S or THT).
Figure 11.3: Cut-out of an EnCal 3000 showing one channel installed

11.3 Option QS : Quad Slave

The Encal 3000 Quad is the combination of two housings in one measurement System.
The two housing each have an explosion safety approval label. 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.
Figure 11.4: EnCal 3000 Quad (right master / left slave)
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.
Figure 11.5: Quad with open covers

The other housing, further referred as “Slave unit” contains the third and optionally
fourth channel (depending in the application). It has no CPU board inside. It is labelled
as “QS” on the Safety approval label.
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.
11.4 Option H2: Hydrogen carrier gas

This analyser is configured to work with Hydrogen as carrier gas. Normally the carrier gas
is a non-explosive one (Helium / nitrogen / Argon) and it is purged inside the housing to
keep the atmosphere in the housing clean. However with hydrogen we cannot do that
since it might cause an explosive atmosphere. As such it needs venting of the carrier to
safe area.
There is a vent connection marked “column vent” that should be connected to a vent
going to safe area without restriction or back pressure.

ANNEX
12 Annex
The annex contains abbreviations and explanations of the terms used as well as
ceritfilates, certificates and declarations. Since the device is used in different areas and
regions, not all certificates are always appropriate. Current versions can always be found
in our Docuthek (www.docuthek.com).
The documents for the Encal3000 chromatograph can be found at the following link:
http://docuthek.kromschroeder.com/documents/index.php?menuid=31&topmenu=3
1&lang=en&selclass=&sellang=&folder=400079

ANNEX
12.1 Nomenclature/Abbreviations
The following abbreviations, definitions and terminology are used in the
documentation.
Short form Description
°C Temperature (Celsius) = TC = TK - 273.15 = 5⁄9 (TF - 32)
°F Temperature (Fahrenheit) = TF = 1.8 TC + 32 = 1.8 TK - 459.67
ATEX Atmosphère explosible (French for explosive atmosphere)
bar Pressure 1 bar = 0.1 MPa = 14.504 psi
C2H6 Ethane
C3H8 Propane
CH4 Methane
CO2 Carbon dioxide
CPU Central processing unit
d Relative density (density ratio of fuel and air)
DBB Double-block-and-bleed (valve block technology)
DC Direct current
DHCP Dynamic Host Configuration Protocol
Deutsches Institut für Normung e.V.

DIN
(German Institute for Standardization)
EN European standard
EN/IEC 60079-14 Standard on explosive atmospheres
EPC Electronic pressure control
FE Functional earth
GC Gas chromatograph
Hi/HiM/HiV Lower heating value; molar/Lower heating value; mass/Lower heating

value; volume
Hs/HsM/HsV Higher heating value; molar/Higher heating value; mass/Higher

heating value; volume

ANNEX
HTTP HyperText Transfer Protocol
Hz Frequency
i-C4H10 i-butane
i-C5H12 i-pentane
IECEx (IECEx SYSTEM) International explosion-protection (Ex) rating
IP Internet protocol
ISO International Organization for Standardization
K Temperature (Kelvin) = TK = 5⁄9 (TF + 459.67)

= TC + 273.15 (∆ 1K = ∆ 1°C)
m Mass
M (Mm) Molar mass (of the mixture)
m or mm Length in SI unit (metre) 1 m = 1000 mm = 39.73 in = 39.73"
MEMS Micro-electro-mechanical system
MLC Multi-level calibration
MPa Megapascal (pressure) 1 MPa = 10 bar = 145.04 psi
MPag Gauge pressure in megapascals
N2 Nitrogen (gas component)
NC Switch/output which is closed when de-energized (NC contact)
n-C4H10 n-butane
n-C5H12 n-pentane
NEC National Electrical Code (USA)
neo-C5H12 Neopentane
NO Switch/output which is open when de-energized (NO contact)
NPT National Pipe Thread (self-sealing (pipe) thread)
NTP Network Time Protocol

(standard for clock synchronization in computer systems)
P1-11K PTB calibration gas mixture (EnCal MLC gas)

ANNEX
PA Equipotential bonding system connection
PC Personal computer
PELV Protective extra-low voltage
PGC Process gas chromatograph
ppm Parts per million
RS 485 Interface standard for cable-based differential serial data transfer
SELV Safety extra-low voltage
SLC Single level calibration
TAC Honeywell Technical Assistance Center
TCD Thermal conductivity detector
TCP Transmission Control Protocol (Internet)
VDE German Association for

Electrical, Electronic & Information Technologies
WEEE Waste of Electrical and Electronic Equipment (directive of the EU)
Wi Inferior Wobbe index
Ws Superior Wobbe index

ANNEX
12.2 Definitions and explanations
List of the definitions and explanations used in this document, please refer also to the
user manual.
Term Explanation
Alarm Alarms are faults which jeopardize the correctness of the results. An
alarm is generated, for example, if a measurement is outside the
defined measuring range. The start and end of the alarm is entered in
the relevant error list with a time stamp. If the cause of the alarm no
longer exists, the alarm can be accepted and thus removed from the
error list.
Audit trail is a two-part protocol archive (parameter change archive) which

enables the user to conduct changes relevant to billing without
opening the SSW. These changes are monitored and documented in
the Fiscal section. If the SSW is opened, data are only included in the
General section.
Breather valve The breather valve, also known as the vent valve or flame barrier, is
designed to equalize the pressure on explosion-proof housings during
operation. This pressure equalization device is required during
operation and must not be sealed.
Calibration gas is kept in a cylinder permanently connected to the device and is an

integral part of the measuring instrument. This is a mixture with
officially defined properties and is required for automatic calibration.
Calibration officer or representative is a person with country-specific authorization who

may carry out officially protected work on gas systems which are to be
used for fiscal measurements.
Carrier gas (mobile The carrier gas (inert gas) carries the sample through the separation
phase) column. The most commonly used carrier gases are helium, nitrogen
and hydrogen. The selection depends on the measuring task.
Carrier gas is kept in a cylinder permanently connected to the device. This gas, for
example helium, carries the sample through the separation column of
the gas chromatograph.
Chromatogram is the visual representation of the measurement results from a

chromatograph

ANNEX
Term Explanation
DBB technology is a valve technology to seal gas streams. The series connection of 2
solenoid valves, between which there is a vent, ensures that gases
cannot mix even if the valves are leaking.
EnCore devices are representatives of a highly developed series of measuring

instruments based on the same hardware components and software
concepts. enCore is the name of the product platform. Both the
hardware and software have a modular design; the configuration is
variable (modular principle).
Error list is used by the user to identify faults and reproduce the history of the
fault. The start and end of a message is entered in the error list with a
time stamp and recorded in the logbook.
Gas chromatograph is a measuring instrument which uses gas chromatography. In an

or process gas industrial version, it is the low-maintenance and explosion-proof
chromatograph upgrade of the measuring instrument, known as a process gas
chromatograph.
Gas chromatography Process which allows the separation of a mixture of gaseous

substances due to the differing distribution of its individual
components using a carrier gas (mobile phase) and separation
columns (stationary phase).
HyperText Transfer HTTP allows, for example, access to an enCore device via the remote
Protocol operation panel.
Internal sampling is a gas manifold which defines a gas route using valves. The gas
system channels in this metal block also enable DBB technology to be used.
Logbook also known as the system audit trail is a log archive which can be used
by all software parts and records every extraordinary situation, for
example faults in the measuring equipment.

ANNEX
Term Explanation
Message is an event which applies to multiple evaluation cycles of the device. It

may be reset by a user with the appropriate user rights.
Network Time NTP for the high-precision time synchronization of enCore devices
Protocol. with an NTP time server.
Note is generated if a measurement violates a state defined by the user.

The start is entered in the error list with a time stamp and logged in
the logbook. Notes cannot be accepted and are automatically deleted
from the error list after the cause of the note has ended.
PELV PELV protective extra-low voltage systems which comply with

DIN EN 60079-14: the power supply to generate PELVs must ensure
that no short-circuit is possible between the primary voltage and the
extra-low voltage and its connections. It has a safe electrical isolation
point (safety isolation transformer) and complies with IEC 61558-2-6.
The circuits are earthed. All bodies of electrical equipment must be
connected to a common earthing (and equipotential bonding) system.
Place of use or installation site is the room or position at which the measuring
instrument is located. It must satisfy the defined requirements of the
manufacturers, authorities and operators.
Power-limited circuit A power-limited circuit is a circuit separated from other circuits by at

least BASIC INSULATION in which the direct voltage (U) is no greater
than 60 V. The current which can occur in the circuit is limited by
certain measures to a value of less than 200/U. These measures must
interrupt the circuit within 120 seconds if this value is exceeded.
Process gas is the gas which is to be analyzed or measured. It is supplied to the

measuring equipment in normal operation and is also known as the
operating gas or sample gas.
SELV SELV safety extra-low voltage systems which comply with

DIN EN 60079-14: the power supply to generate SELVs must ensure
that no short-circuit is possible between the primary voltage and the
extra-low voltage and its connections. It has a safe electrical isolation
point (safety isolation transformer) and complies with IEC 61558-2-6.
Live parts of circuits must not be earthed or connected to live parts or
PE wires of other circuits. All bodies of electrical equipment cannot be
earthed (for example for electromagnetic compatibility).

ANNEX
Term Explanation
Separation column is a capillary with a defined internal diameter and a defined length. It
(stationary phase) is clad internally with a material which separates the gas components
over time. Traditionally, this component is known as a “column”.
Current technology uses thin tubes on a coil or chips manufactured
using Micro-electro-mechanical system technology.
Signal is an event which is only output for a short time. Accepting by the user
is not required or possible and signals are also entered in the logbook.
Status LED indicates whether an error, in other words, an alarm or a warning is

active or has been active. It is simulated on the operation panel.
Test gas A gas mixture with known properties which can be supplied to the
measuring instrument through a sample inlet instead of the process
gas for verification purposes.
Time stamps are time details which relate to an event. They contain the time in
seconds since 1 January 1970, the local time zone and the local time
difference (additional deviation in minutes). The format for displaying
time stamps depends on the language selected on the device, for
example YYYY-MM-DD hh:mm:ss or DD.MM.YYYY hh:mm:ss.
Trained personnel is the designation for a person who, as a result of their technical
training, possesses skills and experience and who is familiar with the
relevant standards and regulations. Trained personnel can assess
their work and identify possible dangers. Hardware work on the device
requires, among others, the expertise described in EN/IEC 60079-14,
Annex A.
User management ensures that unauthorized changes are suppressed and authorized
changes are permitted.
User is a person who operates or parameterizes the device. The user is

identified by a user name and password.
Warning (message or Fault messages which do not falsify the results but are important for
signal) monitoring the measurement. The calculation is continued without
falsification. If the cause no longer exists, it can be accepted on the
operation panel and the entry thus removed from the error list.
Methane number According to the definition, the methane number specifies the percentage
methane content in a mixture of methane and hydrogen. It is used to
measure the knock resistance of gaseous fuels. If, therefore, a natural gas
knocks as strongly as a mixture comprising 85% methane and 15%
hydrogen, it has a methane number of 85.

ANNEX
Term Explanation
Wobbe index Ws is used to characterize the quality of fuel gases and is a calculated
variable for monitoring and regulating the heat output. A distinction is
made between a superior Wobbe index (Ws) and an inferior Wobbe
index (Wi). The unit is J/m³ or kWh/m³, depending on the unit used for
the superior and lower heating value.
WEEE directive serves to avoid waste of electrical and electronic equipment and to reduce
such waste, especially in household waste. It lays down minimum
standards for the treatment of WEEE in the EU. The Directive will enter
into force on 14 August 2018 for all electrical and electronic equipment
used for private and commercial purposes. To achieve this goal, used
electrical and electronic equipment is collected separately and the raw
materials obtained from it are recycled.
Peak is the maximum deflection of a signal. In a chromatogram, this is

illustrated with rising and falling edges, thus forming a “signal mountain”.
Modbus protocol Modbus TCP protocol for data exchange by user-defined registers
between AMR and enCore devices using a standard TCP/IP network.
Lower heating value (Colloquially energy content or energy value) is a heat variable. In
Hi contrast to the higher heating value, all the combustion products are
in gaseous form. This is why the higher heating value is higher than
the lower heating value. The lower heating value is quoted as a mass-
related heating value, for example in kilojoules per kilogram in (kJ/kg)
or as the heating value of the gas quantity over the measured volume,
for example in building services engineering in kWh/m³.
Higher heating value is a heat variable used to monitor the gas composition and energy
Hs content of fuel gases. The higher heating value can be specified in
molar, mass or volume, for example in kWh/m³.
Density/Density at Density or density at base conditions is a heat variable used to monitor

base conditions the gas composition and energy content of fuel gases. It is the quotient of
the mass of a gas sample and its volume in specified pressure and
temperature conditions or at base conditions in kg/m³.
Carbon dioxide (CO2) is an acidic, non-flammable, colourless and odourless gas comprising a
chemical compound of carbon and oxygen. The gas is also known as
carbonic anhydride or colloquially carbonic acid.
Cable To ensure greater differentiation between gas and electrical lines,

electrical lines are always referred to as “cables” in the following.

ANNEX
12.3 CERTIFICATE EC-Type Examination

ANNEX

ANNEX
12.4 DECLARATION OF CONFORMITY ENCAL 3000

ANNEX
12.5 IECEx Certificate ENCAL 3000

ANNEX

ANNEX

ANNEX

ANNEX
12.6 FM Certificate of Conformity

ANNEX

ANNEX

KEYWORDS AND FIGURES
13 Keywords and figures
13.1 Keyword index
Carrier gas cylinder 76, 92

A
Checking the breather valve 95
Accessories 107 Checking the device settings 82
Action (prohibited) 8 Checking the digital communication 82
Additional heating 81, 111 Checking the output signals 82
Additional type label 108 Chromatogram 119
Alarm 119 Circuit breaker 22
Ambient conditions 13, 16, 106 Cleaning the breather valve 95
Ambient temperature 10, 21, 110 Cleaning the device 89
Analog I/O 105 Commissioning 79, 81
Approval (explosion protection) 110 Commissioning requirements 80
Approval file (enSuite) 79 Communication interfaces 105
Audit trail 119 Condensation 10, 80
Automatic calibration 76 Connecting the gas cylinder 76
Connection inspection 90
B
Connection line 107
Battery 11, 22, 83 Connection to earth 9
Breather 105 Consumables and wear parts 96
Breather line 105 Contact details 2
Breather valve 19, 86, 119 Correct handling 13
Customer service 12
C Cylinder pressure reducer 76
Cable 21, 83
Cable (terminology) 123
D
Cable gland 23, 24 Damage 13, 25
Cable protection (electrical) 57, 59 Danger (electrostatic) 25
Calibration Department 79 Danger of explosion 8, 25, 78, 91
Calibration gas 69, 76, 107, 119 Dangerous situation 11
Calibration gas adjustment 82 DBB technology 120
Calibration gas cylinder 76, 92 Decommissioning 82
Calibration officer 119 Default parameter set 79
Carbon dioxide (CO2) 123 Detection limit 106
Carrier gas 76, 81, 107, 119 Device dimensions 49, 104

Device weight 49, 51 G

Digital outputs 59, 88
Gas chromatograph 120
Dismantling 84
Gas chromatograph 6
Disposal 82
Gas chromatography 120
Docuthek 2
Gas connection 69, 72
Gas connections 25, 105
E
Gas cylinder 76
Earth cable 54, 59
-Pressure monitoring 76
Earth potential shift 12, 21
-Residual pressure 76
Earthing 21, 25, 54, 59, 86, 87
Gas flow adjustment 82
Electrical connections 58, 59, 88, 105
Gas inlet 69
Electrical installation 53
Gas pipeline 74, 78, 91
Electrical interfaces 58
-Material 52, 72
Electrical supply fault 87
Gas pressure ranges 69
EMC strength 104
Gas route 78, 91
enCore devices 99, 120
Gas specifications 73, 104
Equipotential bond 8, 12, 21, 22, 54, 59
Gas supply 52, 72
Error list 120
Gas supply fault 86
Ethernet communication 105
Explosion 50, 84, 86 H
Explosion protection 13, 17, 22, 24, 25, 80
Hardware error 85
Explosion-protection equipment 16, 23
Health impairment 8
Honeywell Service 97
F
Housing check 94
Filter system 73
Humidity 106
Fiscal use 79
-Relative 10
Flame arrester 72
HyperText Transfer Protocol 120
Flame barrier 69
Flow meter 47 I
Flow rate check 93
Industrial safety 12
Fluid connection of the measuring instrument 74
Inlet filter 73
Fluid installation 69, 75
Inlet pressure 12, 20
Flushing (gas pipeline) 73
Inlet pressure range 69
Functional earth (FE) 9
Inlet pressures 92
Functional earthing point 54
Inspection of device interior 94
Fuse 87
Installation gaps 52
Fuses 22
Installation guideline 58
Fuses (internal) 54, 59
Installation position 52

Installation site 22, 50, 121 O

Installation work 12, 17, 23, 25
Off switch 53
Insulation error 87
Opening the device 17, 18, 24, 25
Interfaces 21, 59, 88
Operating gas 121
Internal fuse 54, 59
Operating requirements 80
Internal sampling system 120
Operating voltage 22, 24
IP enclosure 104, 108
Operator 12, 17, 22
Operator license 86
K
Overcurrent protection 21
Knowledge (required) 7, 13, 17, 122
Overvoltage protection 21, 54, 59
L P
Language skills 13, 18
PA terminal 54, 59
Leak sealing 91
Password 98
Leaks 78, 86, 91
Peak 123
Liability 13, 17
PELV 22, 121
Lightning protection 53
Personal injury 13
Logbook 120
Personnel (authorized by Honeywell) 19, 23
Personnel (authorized) 17, 25
M
Personnel (selection) 17
Main type label 110 Personnel protection 53
Maintenance 89 Pipes blocked 91
Maintenance work 12, 85, 96 Place of use 50, 53, 57, 82, 104, 121
Manufacturer 2 Polarity reversal 59
Maximum gas pressure 12, 18 Power consumption (electrical) 54, 87, 110
Measuring cycle 106 Power supply 9, 13, 21, 54, 81, 110
Measuring range 104 Pressure regulator 107
Mechanical impacts 11 Process calibration gas 81
Message 121 Process calibration gas cylinder 80
Methane number 122 Process gas 92, 121
Minimum installation gap 48 Process gas chromatograph 120
Misuse 11 Process gas connection 73
Modbus 99, 105, 123 Process gas sampling line
Mounting plate 52, 54, 59 -Preparation 73
Production site 2, 109
N
Property damage 13
Network 98, 99 Protective equipment 50
Note 121 Protective equipment (personal) 13, 16
EnCal 3000 poChain GC Service Manual 137

Protective equipment (personal) 19 T
Technical Assistance Center (TAC) 2

R
Technical data 104
Recommissioning 25
Technical datacumentation 7
Repair 12, 85, 96
Temperature range 16, 23, 106
Repeat accuracy 106
Test gas 122
Requirement (essential) 17, 80
Tightness test 74, 75, 78, 86, 91
Time stamps 122
S
Trained personnel 7, 17, 22, 122
Safety information (device) 8, 13, 18, 24, 25 Transport guards 11
Safety responsibility 7, 13 Transporting the device 10
Safety rules 7, 17 Troubleshooting 85
Sample gas 92, 121 Type designation 108
Sample gas inlets 18, 108 Type label 18, 108
Sealing 79
SELV 22, 121 U
Separation column 29, 122
Uncertainty 106
Serial communication 105
Use (intended) 11
Serial number 108
Use (unintended) 13
Service helpdesk 2
User 122
Service life (device) 7
User management 122
Shut-off valve 73
Using the device 83
Sign 7, 8, 9, 13, 98
Signal 122 V
Software 98
Vent line 20
Spare parts 96
Visual inspection 89
Status LED 122
Storage 10, 16, 82 W
Storage period 11
Waste gas line 74, 85
Storage rooms 10
Waste gas line return effect 74
Supplies check 89
WEEE directive 9, 83, 123
Supply voltage 54, 59, 68, 87
Weight 16, 104
Switch 22
Switching on 86
Y
Symbol 8, 9
System operator 53 Year of manufacture 110

13.2 List of figures

FIGURE 1.1: PARTS OF THE GAS QUALITY MEASUREMENT SYSTEM .............................................................6
FIGURE 2.1: WARNING AND INFORMATION LABELS ON THE DEVICE ......................................................... 18
FIGURE 3.1: HOUSING COMPLETE WITH THE (TRANSPARENT)HOOD ....................................................... 26
FIGURE 4.1: THE ANALYTICAL PRINCIPLE ............................................................................................................ 28
FIGURE 4.2: DIFFERENT TYPES OF GAS CHROMATOGRAPHIC COLUMNS................................................. 29
FIGURE 4.3: TYPICAL ELECTRICAL TCD CIRCUIT .............................................................................................. 30
FIGURE 4.4: MEMS SAMPLE INJECTOR ............................................................................................................. 31
FIGURE 4.5: CHROMATOGRAMS .............................................................................................................................. 32
FIGURE 5.1: EXPLODED VIEW ON THE INTERNAL PARTS OF THE ENCAL 3000 .................................. 34
FIGURE 5.2: OVERVIEW OF CHANNEL COMPONENTS .................................................................................... 36
FIGURE 5.3: INTERNAL GAS FLOW CIRCUIT FOR EACH ANALYTICAL CHANNEL OF THE ENCAL
3000, DURING NORMAL OPERATION (TOP) AND SAMPLE INJECTION (BELOW) ................................. 37
FIGURE 5.3: INTERNAL GAS FLOW CIRCUIT FOR EACH ANALYTICAL CHANNEL WITH BACKFLUSH
OF THE ENCAL 3000, BEFORE ACTIVATING BACKFLUSH VALVE (TOP) AND AFTER ACTIVATING
BACKFLUSH VALVE (BELOW)...................................................................................................................................... 38
FIGURE 5.5: PROCESSOR BOARD CONNECTIONS ............................................................................................. 39

FIGURE 5.6: SAVE PARAMETERS IN THE MEASURING UNIT ALL BORD VERSIONS ................................. 40
FIGURE 5.7: PROCESSOR BOARD WITH RIBBON FLAT CABLES MOUNTED IN THE ENCAL 3000 .... 41
FIGURE 5.8: INTERCONNECTION BOARD IN DIFFERENT VARIATIONS ........................................................ 42
FIGURE 5.9: OVERALL ELECTRICAL CONFIGURATION OF THE ENCAL 3000 ....................................... 42
FIGURE 5.10: FRONT VIEW OF THE INTERNAL SAMPLING/STREAM SELECTION SYSTEM .................. 43
FIGURE 5.11: FLOW DIAGRAM SAMPLE CONDITIONING AND SELECTION SYSTEM ............................ 44
FIGURE 6.1: SYSTEM OVERVIEW .............................................................................................................................. 47
FIGURE 6.2: MINIMUM INSTALLATION GAPS ...................................................................................................... 48
FIGURE 2.14: SIDE VIEW WITH DIMENSIONS (WITHOUT COUPLINGS AND CONNECTIONS)............... 49
FIGURE 6.4: PLAN VIEW WITH DIMENSIONS (WITHOUT COUPLINGS AND CONNECTIONS) ................ 50
FIGURE 6.5: INSTALLATION OPTIONS 1 ................................................................................................................ 51
FIGURE 6.6: INSTALLATION OPTIONS 2 ................................................................................................................ 52
FIGURE 6.7: EXAMPLE OF EARTHING POINTS ON THE DEVICE ..................................................................... 54
FIGURE 6.8: POSITION OF THE CABLE END GLANDS ON THE HOUSING BASE......................................... 55
FIGURE 6.9: POSITION OF THE CABLE END GLANDS ON THE HOUSING BASE......................................... 56
FIGURE 6.10: INTERCONNECTION BOARD V1.X: TOP VIEW LAY-OUT ....................................................... 60
FIGURE 6.11: LOCATION OF POWER SUPPLY CONNECTOR (J8) ............................................................... 62
FIGURE 6.12: LOCATION OF ETHERNET CONNECTOR (J10) AND WIRING SCHEME ........................... 62
FIGURE 6.13: LOCATION OF SERIAL MODBUS CONNECTOR (J6) ............................................................. 63
FIGURE 6.14: MODBUS CONNECTION AND LINK SETTINGS......................................................................... 63
FIGURE 6.15: INTERCONNECTION BOARD V2.X: TOP VIEW LAY-OUT ....................................................... 64
FIGURE 6.16: LOCATION OF POWER SUPPLY CONNECTOR (J14)............................................................. 66
EnCal 3000 poChain GC Service Manual 139

FIGURE 6.17: LOCATION OF ETHERNET CONNECTOR (J7) AND WIRING SCHEME .............................. 66
FIGURE 6.18: LOCATION OF SERIAL MODBUS CONNECTOR (J8) ............................................................. 68
FIGURE 6.19: MODBUS CONNECTION AND LINK SETTINGS......................................................................... 68
FIGURE 6.20: FLUIDIC CONNECTIONS .................................................................................................................. 70
FIGURE 6.21: LAYOUT OF THE GAS CONNECTIONS .......................................................................................... 71
FIGURE 6.22: BREATHER AS REQUIRED BY EXPLOSION PROOF DIRECTIVES ......................................... 73
FIGURE 6.22: CONFIGURATION WITH TWO CARRIER GASES ........................................................................ 76
FIGURE 6.22: LOCATION OF SECURITY SCREWS TO FIX THE CAP AFTER MOUNTING ON THE BASE 82
FIGURE 10.1: EXAMPLE OF A ROUTER AND FIREWALL................................................................................. 100
FIGURE 10.2: TYPICAL DATA COMMUNICATION SET-UP FOR ETHERNET COMMUNICATION ..... 101
FIGURE 10.3: TYPICAL DATA COMMUNICATION SET-UP FOR TCP/IP COMBINED WITH SERIAL
MODBUS COMMUNICATION WITH THE ENCAL 3000 ................................................................................. 102
FIGURE 10.4: REMOTE ACCESS TO THE ENCAL 3000 ............................................................................... 103
FIGURE 10.5: MODBUS CONFIGURATION SCREEN ...................................................................................... 104
FIGURE 10.6: MODBUS REGISTER DETAILS ................................................................................................... 104
FIGURE 12.1: POSITIONS OF THE TYPE LABELS ............................................................................................. 109
FIGURE 12.2: CUT-OUT OF AN ENCAL 3000 SHOWING HEATERS INSTALLED .................................. 112
FIGURE 12.3: CUT-OUT OF AN ENCAL 3000 SHOWING ONE CHANNEL INSTALLED ....................... 113
FIGURE 12.3: ENCAL 3000 QUAD (RIGHT MASTER / LEFT SLAVE) ....................................................... 114
FIGURE 12.5: QUAD WITH OPEN COVERS ......................................................................................................... 114

EnCal 3000 pro Chain GC
October 2018
© 2018 Honeywell International Sàrl
www.honeywellprocess.com www.honeywellprocess.com

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•

GASCHROMATOGRAPH ENCAL 3000

Subject to amendments in the course of further development. Any such

The illustrations are designed to provide a visual depiction of the topics

Elster GmbH (manufacturer)

Steinern Str. 19-21

55252 Mainz-Kastel, Germany

Tel.: +49 6134 605 0

Honeywell Technical Assistance Center (TAC):

Tel.: +49 231 93 71 10 88

EnCal 3000 Hardware Manual 73022344 o 2

1.2 Device delivery ............................................................................................................................................. 10

1.3 Intended use of Device ............................................................................................................................ 11

1.5 Additional technical help and repairs .............................................................................................. 12

2.3 Information and warnings on the device housing ..................................................................... 18

3.2 Most important features and functions.......................................................................................... 27

5.3 Interconnection Board ............................................................................................................................. 41

5.4 Internal sample system ........................................................................................................................... 43

EnCal 3000 Hardware Manual 73022344 o 3

6.2 Design of the measurement point ..................................................................................................... 46

6.3 Mechanical installation (assembly) .................................................................................................. 47

6.4 Electrical installation ................................................................................................................................ 53

6.5 Fluidic installation...................................................................................................................................... 70

7.2 Hardware Start-up ..................................................................................................................................... 82

7.3 Decommissioning ...................................................................................................................................... 83

8.2 Maintenance and remote maintenance ......................................................................................... 90

8.3 Consumables (carrier and calibration gas cylinder)................................................................. 97

8.4 Honeywell service work ............................................................................................................................ 98

EnCal 3000 Hardware Manual 73022344 o 4

9.2 Local TCP/IP Data Communication .............................................................................................. 101

9.3 Local Serial ModBus Data Communication .............................................................................. 102

9.4 Remote Access.......................................................................................................................................... 103

11.2 Option SC: Single Channel analyser .............................................................................................. 113

11.3 Option QS : Quad Slave ........................................................................................................................ 114

12.2 Definitions and explanations ............................................................................................................ 120

12.3 CERTIFICATE EC-Type Examination ............................................................................................. 125

12.5 IECEx Certificate ENCAL 3000 ........................................................................................................ 128

12.6 FM Certificate of Conformity ............................................................................................................. 132

13.2 List of figures ............................................................................................................................................. 139

EnCal 3000 Hardware Manual 73022344 o 5

1 About this Manual and Device delivery

1.1 Scope (Aim)

Figure 1.1: Parts of the Gas quality measurement system

EnCal 3000 Hardware Manual 73022344 o 6

Furthermore, the directives, standards, local accident prevention regulations and

Following table shows the development of this document.

Revision Date Description

a to l 2008 until 2016 Historic development

m August 04, 2017 New Interconnection board

n Feb. 22, 2018 New temperature range

o August 20, 2018 New CE Declaration and

1.1.1 How to use this manual

Safety information and warnings must be followed to the letter.

EnCal 3000 Hardware Manual 73022344 o 7

Symbol in ducument Meaning

Attention denotes information which is relevant to safety

Explosion or danger of explosion means that death and/or

Very serious health impairment means that serious physical

Prohibited action means that you must not complete the

EnCal 3000 Hardware Manual 73022344 o 8