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Honeywell ENCAL 3000 User Manual

Honeywell ENCAL 3000
141 pages
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GASCHROMATOGRAPH ENCAL 3000
HARDWARE MANUAL

Table of Contents

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Honeywell ENCAL 3000 Specifications

General IconGeneral
Hazardous Area ApprovalsATEX, IECEx
ApplicationsNatural gas custody transfer, process monitoring, and regulatory compliance
Communication ProtocolsEthernet
Measurement Range0-100%
AccuracyBetter than ±0.1% for energy measurement
Resolution0.01%
Response Time<30 seconds
Operating Temperature-20°C to +55°C
Operating Humidity5% to 95% RH non-condensing
Power Supply100-240 VAC
Battery LifeNot applicable
WeightVaries depending on configuration; consult datasheet

Summary

About this Manual and Device Delivery

Scope (Aim)

Describes the hardware of the gas chromatograph and its subsystems.

How to use this manual

Provides guidance on how to effectively use the manual for understanding the measuring system.

Symbols

Defines safety and warning symbols used in the document and on the device.

Device Delivery

Checking the delivery (list of supplied and required parts)

Instructions for unpacking and checking the received measuring instrument and components.

Transporting and storing the device

Guidelines to prevent transport damage and ensure correct storage conditions.

Intended Use and Operator Responsibility

Intended use of Device

Specifies the analysis of natural gas or similar gases as the device's intended purpose.

Responsibility of the device or system operator

Outlines operator duties regarding industrial safety and device maintenance.

Additional Technical Help and Repairs

Safety Information and Warnings

Information for handling the device

Details on device design for explosive atmospheres and relevant certifications.

Authorized (hardware) personnel

Specifies requirements for personnel performing hardware work on the device.

Information and warnings on the device housing

Highlights warning labels and their importance for safe operation.

Safety information about gases

Provides essential safety guidelines for handling various process gases.

Electrical information connecting with earth and emergency stop

Covers electrical safety, earthing, and emergency stop requirements.

Explosion protection

Details regulations and procedures for explosion-proof equipment handling.

Functional Design of EnCal 3000

Introduction /Enclosure/Hausing

Describes the device's on-line gas chromatograph function and its Ex-d housing.

Most important features and functions

Lists key features like compact design, stand-alone operation, and analytical capabilities.

Process Gas Chromatography – General Introduction

Analytical Principle

Explains the fundamental analytical technology used for gas mixture analysis.

Column

Details the separation column's role and different types used in gas chromatography.

Detector

Describes the thermal conductivity detector (TCD) and its function in analysis.

Sample Injector

Explains the sample injector's function in precisely introducing sample into carrier gas.

Result findig and presentation

Covers how chromatograms are generated and results are presented.

Housing Interior with Major Internal Components

The Channel

Details the subcomponents of a gas analysis channel, including modules and controllers.

Processor Board

Lists and illustrates the main components of the processor board.

Save parameters in the measuring unit

Explains how to protect parameters using configuration jumpers.

Processor Board installed

Describes the processor board's connection and cooling options within the device.

Interconnection Board

Outlines the functions of the interconnection board for power and data.

Internal sample system

Describes the functions of the internal sampling system, including pressure regulation.

Double Block and Bleed Function

Explains the DBB function for sealing gas streams and preventing mixing.

Internal Sample Bypass

Details the function of the sample bypass for refreshing dead volumes.

Hardware Installation

Installation specifications

Specifies compliance with national, local, and company codes for installation.

Design of the measurement point

Describes the typical measurement point setup and gas supply requirements.

Mechanical installation (assembly)

Provides guidance on professional installation for safe and problem-free operation.

Device dimensions

Presents detailed dimensions of the device in millimeters.

Place of use and installation site

Covers environmental influences and site requirements for installation.

Assembly hints

Offers general engineering rules for handling components and fitting parts.

Electrical installation

Details requirements for electrical connections, including safety standards.

Cable glands cables andwires

Explains the use and specifications of cable glands for electrical connections.

Making the electrical and signal connections

Provides instructions for connecting electrical and signal cables to the interconnection board.

Connections on the EnCal 3000 Interconnection board Version 1.x

Illustrates the layout and connectors of the Interconnection Board Version 1.x.

Connections on the EnCal 3000 Interconnection board Version 2.x

Illustrates the layout and connectors of the Interconnection Board Version 2.x.

Electrical device test to verify correct installation

Outlines the steps for testing electrical installation integrity using a multimeter.

Fluidic installation

Describes the installation of fluid interfaces and connections.

Fluid connections

Details the various gas connections on the device and their fittings.

Configuration with two Carrier Gases

Explains a configuration using different carrier gases for two analytical modules.

Connecting and replacing gas cylinders

Provides step-by-step instructions for connecting and replacing gas cylinders.

System tightness test

Details the procedure for conducting a system tightness test using a gas detector.

Commissioning and Decommissioning

Requirements for commissioning and operation

Lists prerequisites for commissioning, including safety and gas connection checks.

Hardware Start-up

Describes the sequence for starting up the device and initial configuration.

Checking the device settings and signals

Guidance on checking and adjusting device settings and output signals.

Decommissioning

Provides information on preparing the device for later use or return.

Dismantling

Instructions to follow before removing the device to prevent hazards.

Maintenance and Repair

Troubleshooting (Identifying hardware errors)

Guidelines for identifying and rectifying hardware faults in the device.

Troubleshooting in the gas supply

Specific steps to address faults related to the gas supply system.

Troubleshooting in the electrical supply and insulation

Steps to diagnose and resolve issues with electrical supply and insulation.

Maintenance and remote maintenance

Covers routine inspections, preventive checks, and cleaning procedures.

Visual inspection of the connections

Procedure for visually inspecting fluid and electrical connections for damage.

Checking the gas connections with a tightness test

Steps to perform a tightness test on gas connections to detect leaks.

Checking the cylinder pressures

Instructions for visually inspecting and checking calibration and carrier gas cylinder pressures.

Checking the inlet pressures

Procedure for reading and adjusting process gas inlet pressures.

Checking the flow rates

Optional checks for flow meters to verify gas stream rates.

Checking / Replacing the inlet filters and adapters

Guidance on inspecting and replacing inlet filters to prevent errors.

Checking the housing parts

Steps for visually inspecting housing parts for damage and leaks.

Inspecting the interior of the housing

Procedure for inspecting the interior of the housing for damage or loose wires.

Inspecting and cleaning the breather valve

Instructions for monitoring, cleaning, and maintaining the breather valve.

Consumables (carrier and calibration gas cylinder)

Information on gas cylinders required for operation and their replacement.

Spare and replacement parts for general maintenance work

Recommendations for annual inspections and replacement of auxiliary gases.

Honeywell service work

Information on services provided by Honeywell for maintenance and repair.

Data Communication

Data safety information and Warning

Highlights security risks associated with network connections for data transfer.

Security considerations for your network

Guidance on reporting vulnerabilities and implementing network security measures.

Implement stringent password guidelines

Recommends best practices for creating and managing secure passwords.

Prevent unauthorized external access using a firewall.

Advises on using firewalls to restrict network traffic and allow only essential protocols.

Local TCP/IP Data Communication

Describes the TCP/IP port for communication with PCs and other hosts.

Local Serial ModBus Data Communication

Explains the use of serial ModBus ports for communication with hosts.

Remote Access

Details various options for accessing the EnCal 3000 remotely.

ModBus Communication

Covers ModBus configuration settings and register details.

Technical Specifications

Possible hardware options and type plates

Option HT: Heaters installed

Describes the additional heating system for use in freezing temperatures.

Option SC: Single Channel analyser

Indicates that the analyser has only one installed channel.

Option QS : Quad Slave

Explains the EnCal 3000 Quad system combining two housings for extended analysis.

Option H2: Hydrogen carrier gas

Details the analyser configuration for using Hydrogen as a carrier gas.

Annex

Nomenclature/Abbreviations

Lists abbreviations, definitions, and terminology used throughout the documentation.

Definitions and explanations

Provides definitions for terms and concepts used in the manual.

CERTIFICATE EC-Type Examination

Presents the EC-Type Examination Certificate for the gas analyzer.

DECLARATION OF CONFORMITY ENCAL 3000

Contains the EU Declaration of Conformity for the EnCal 3000 device.

IECEx Certificate ENCAL 3000

Provides the IECEx Certificate of Conformity for explosive atmospheres.

FM Certificate of Conformity

Details the FM Certificate of Conformity for hazardous location electrical equipment.

Keywords and figures

Keyword index

An alphabetical index of keywords used in the manual for quick reference.

List of figures

A comprehensive list of all figures included in the hardware manual.

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