Installation manual EnSonic, 20/01/2004 - Elster
Contents
1. The electrical installation of the EnSonic is split in two parts 1 the field connections to the EnSonic measurement system 2 the indoor connections to the EnSonic measurement system and the M2000 Cabling required Although the measurement data from the EnSonic is present on a 2 wire RS485 serial interface with MODBUS protocol it is recommended to increase the number of data communication wires to facilitate the service of the instrument Therefore the following cabling should be present 1 Data communication a MODBUS port 2 main measurement data 5232 or 5485 2 x 2 shielded twisted pair b MODBUS port 1 configuration 5232 2 x 2 shielded twisted pair b Ultrasonic unit data amp configuration RS485 1 x 2 shielded twisted pair 2 Power supply nom 24 VDC max 120 W 5 A during startup 2 wires shielded 3 Heated tracing 220 VAC 3 wires shielded and armoured During normal operation MODBUS port 2 of the EnSonic is used to transmit the main measurement data to the M2000 For configuring and servicing the EnSonic system port 1 is used The electronic unit of the ultrasonic velocity of sound measurement unit can be serviced and configured by Instromet using the RS485 communication port of this unit however directly issueing commands to the unit will interrupt the normal operation of the EnSonic system All data communication cables may be combined into one 5 x 2 x 0 8 mm armoured shielded cable Since the elect2. TER2 terminal 2 is assigned to port 2 which is used for the communication with the M2000 It is recommended to use the 5485 communication protocol pin and 4 for this purpose the required protocol is selected using the EnSonic configuration software A twisted pair cable should be used TERI terminal 1 is assigned to port 1 which is used to configure and check the EnSonic Since this port operates in the RS232 mode only an additional RS232 485 converter may be installed depending on the cable length in the installation In this case a twisted pair cable should be connected to the RS232 485 converter instead of TER1 When the RS232 mode is used two twisted pair cables should be used The connection to the ultrasonic measurement unit is not described here since this unit is configured during the assembly of the EnSonic The measurement data from the ultrasonic unit is available via the Modbus registers of the EnSonic This connection is only to be made by qualified Instromet employees The shielding of the data communication cable should be properly connected following the installation instruction of the Eex d cable gland The intrinsic safe connection of the empty bottle detection should be checked the blue wire from the pressure switch mounted on the pressure reducing valve of the bottle with reference gas should be connected to the barrier located on the left side of the box Remark At the time of writing this document an altern
3. the EnSonic To make the connections the cover of the box should be removed using the proper tool Care should be taken when handling the relatively heavy cover The 24 VDC power supply is connected to the terminal block located on the left side of the temperature transmitter The polarity is indicated on the terminals Checking the actual polarity of the power supply before making the connections is recommended Page 6 of 18 10735 INST 004 E E3 Instromet The data communication wires are connected to the processor board of the EnSonic located directly above the 2VOS body Fig 2 shows the terminal lay out of this board k TER 2 Modbus Port 2 RS232 Gnd Rx amp Tx RS485 A amp B TER 1 Modbus Port 1 RS232 Gnd 900090 a E 6 ee O 5 gt UJ JJ gt 1 2 O O O O O O O O O O O O O O O O O O 1 1 1 1 24 VDC Fuse 5X20 A 13 15A 250V EnSonic computational unit Figure 2 Terminal lay out When making the connections the following should be taken into account 1 2 in the Eex d box the EnSonic computational unit is mounted upside down consequently the pin orientation shown in figure 2 must be regarded from left to right in the box pin 1 is on the left side of the terminal
4. 18 of 18 10735 INST 004
5. DISCLOSURE LOANED SUBJECT TO DRAWING NUMBER AND THAT ALL COPIES RETURNED IMMEDIATELY ON DEMAND SKID_TOPVIEW INSTROMET B V Munstermanstraat 6 7064 KA Silvolde Tel 31 0 315 338911 Fax 338679 E mail info instromet nl 10735 INST 004 Page 15 of 18 ELST E3 Instromet Appendix C LED Status Indication EnSonic Processor board The 3 red LED s located on the processor board of the EnSonic computational unit provide full information about its current status Depending on the operation mode the following LED combinations are supported When in MAIN PROGRAM normal operation mode the following 3 condition groups can be distinguished Operating conditions LED1 LED2 LED3 Status definition Remark FLASH FLASH FLASH LED OK FLASH ED OK STATE WAIT STATE SERI Tr SSS pos for system power up FLASH LED UNKNOWN Unknown state Fault conditions LED1 LED2 LED3 Status definition Remark FLASH FLASH LED DATA FAULT Data fault FLASH FLASH LED INPUT BOARD Input board fault Warning conditions LED1 LED2 LED3 Status definition Remark When in BOOT PROGRAM mode used by Instromet to update the embedded software the following LED combinations are supported LED1 LED2 LED3 Status definition Remark FLASH LED PROGRAM CORRUPTED LED PROGRAM FLASH LED PROGRAM OK OK FLASH LED PROGRAM DOWNLOADING Downloading FLASH LED UNKNOWN Unknown
6. local regulations into account The skid is mounted using M12 bolts 4 pieces placed on a 450 x 750 mm rectangle the front of the EnSonic faces the short side of this rectangle The dimensions of the skid are presented in Appendix B When selecting a suitable place to install the EnSonic the following considerations should be kept in mind 1 the unit should be installed as close as possible to the sample point to minimize delay times due to long sample lines 2 although not frequently the reference gas bottle needs replacement so their must be some space available on the back of the EnSonic to handle the reference gas bottle 3 the sampled gas is vented from the top of the EnSonic so provisions must be taken to reduce the build up of high gas concentrations when necessary local regulations need to be followed 4 since the EnSonic internally operates at 50 C the maximum ambient temperature of the EnSonic is set at 30 C therefore in some installations the EnSonic may have to be shielded from direct sunlight After mounting the EnSonic skid the connection between the sample point for the line gas and the EnSonic should be made using the heat traced sample line mounted on the bottom of the unit This sample line contains 2 separate 1 8 tubings which are used for the line and the reference gas The length of the sample line may be reduced to 2 m to facilitate the installation An adapter set is included to connect the EnSonic to a system with 3
7. settings of the communication ports using the EnSonic configuration software and the M2000 configuration software Both ports should have the same settings baud rate 38400 The proper Modbus register configuration must be assigned to port 2 Two different settings can be configured and the setting of port 2 must resemble the setting expected by the M2000 The M2000 requires a so called stream number if the stream number is not set the M2000 is simply not polling the EnSonic unit for measurement data Use the M2000 configuration software to set the stream number After switching the 24 VDC power on and off the system has lost it s configuration and clock settings Both the M2000 and the EnSonic processor board come with a lithium battery to save their settings The battery back up must be switched on by setting a dip switch on the board which is normally done during assembly of the units The dip switch settings for the EnSonic and the M2000 are presented in appendix E The dip switches of the EnSonic are located on the processor board to set the dip switches of the M2000 the small black plastic cover on the side of the M2000 has to be removed carefully The EnSonic configuration software is not able to communicate with the EnSonic processor board Check the wiring and the COM port settings of the configuration software When in RS232 mode switch the TX and lines When in 5485 mode check the settings of the converters and or try to communi
8. state Summarizing when all three LED s are flashing the meter is working properly all the other combinations indicate a non standard condition Page 16 of 18 10735 INST 004 ELST E3 Instromet Appendix D LED Status Indication EnSonic Interface board The 2 red LED s located on the interface board of the EnSonic computational unit provide full information about its current status Depending on the operation mode the following LED combinations are supported LED1 LED2 jStatusdefintion 1 Remark Summarizing when both LED s are flashing the board and the communiation are working properly all the other combinations indicate a non standard condition 10735 INST 004 Page 17 of 18 B ELGTE1 Instromet Appendix E Dip switch settings The four dip switches of the EnSonic and the M2000 have the following functionality SWITCH 1 SECURITY SWITCH 2 SECURITY SWITCH 3 BOOT MODE RUN MODE SWITCH 4 BATTERY Security Modes SWITCH 1 OFF SWITCH2 OFF UNIT TOTALLY SECURE SWITCH 1 SWITCH2 OFF UNIT PARTIALLY SECURE SWITCH 1 OFF SWITCH2 ON UNIT PARTIALLY SECURE SWITCH 1 SWITCH2 ON UNIT NOT SECURE The security setting is determined by the user Boot run mode SWITCH OFF BOOT MODE set when uploading embedded software ON RUN MODE set for normal operation Battery SWITCH 4 OFF BATTERY OFF set during storage ON BATTERY ON set during normal operation Page
9. ELSTER 5 EnSonic Installation Manual Document code 10735 INST 004 EnSonic Installation Manual 10735 INST 004 ELST E3 Instromet Document EnSonic Installation Manual Document code 10735 INST 004 Date June 25 2003 Publisher Instromet International N V Rijkmakerlaan 9 B 2910 Essen Belgium Phone 32 3 670 0700 Fax 32 3 667 6940 Copyright 2003 Instromet International N V Essen Belgium Instromet International N V is a member of the Instromet group All technical and technological information contained in this manual including any drawings and technical specifications remain the property of Instromet International N V and may not be used other than for the operation of this product copied multiplied passed on or communicated to a third party without the prior written permission of Instromet International N V Trademarks Products listed are trademarks of their respective manufacturers Company names listed are trade names of their respective companies Revision History Revision Remark Date 002 First edition 25 06 2003 003 ACAD drawings implemented 4 07 2003 004 A number of issues added 20 01 2004 Page 2 of 18 10735 INST 004 Instromet E STE3 Preface This document describes the mechanical installation procedure for the EnSonic Energy Measurement system The overall system layout is presented in figure 1 Normally the EnSonic is installed in the hazardous area as close as pos
10. I s i atta Q x Lo om ono e e X lt I e I e e e e A I y Y NAME SKID ENSONIC FRONT VIEW REV DwN DATE CHD CH REQ COPYHOLDERS 0 5 01 07 03 MATERIAL BEAM 50x50x3 AMERICAN SCALE ROUGHNESS ACCORDING SHAPE AND POSITIONAL PROJECTION UNITS IN mm NEN 3634 TOLERANCES ACC NEN ISO 1101 THIS DRAWING IS A CONFIDENTIAL DISCLOSURE LOANED SUBJECT TO DRAWING NUMBER THE CONDITIONS THAT IT OR ANY INFORMATION CONTAINED THEREIN WILL NOT BE USED IN ANY WAY DETRIMENTAL TO OUR INTERESTS AND THAT ALL COPIES BE RETURNED IMMEDIATELY ON DEMAND SKI DF RONT INSTROMET B V Munstermanstraat 6 7064 KA Silvolde Tel 31 0 315 338911 Fax 338679 E mail info instromet nl Page 14 of 18 10735 INST 004 Instromet Figure B 3 Skid Frontview SE 1876102 idi B E E B m B EN A H H s k NAME SKID ENSONIC TOPVIEW REV DWN pare CHD CH REQ COPYHOLDERS 0 HMS 01 07 03 MATERIAL BEAM 50x50x3 AMERICAN SCALE ROUGHNESS ACCORDING SHAPE AND POSITIONAL PROJECTION UNITS IN mm NEN 3634 TOLERANCES ACC NEN ISO 1101 THIS DRAWING IS A CONFIDENTIAL
11. ative method to connect the data communication wires to the unit has been implemented To the left of the Power Supply terminals a number of terminals is available for the communication wires Upper row labeled 1 2 3 and 4 gt Port 2 Tx Rx amp Gnd and Port 2 RS485 A Lower row labeled 5 6 7 and 8 gt Port 1 Tx Rx amp Gnd and Port 2 RS485 B Which method will be used finally is not yet known 10735 INST 004 Page 7 of 18 e Eq Instromet Indoor connections The following connections should be made in the safe area The 220 VAC power supply should be properly connected to the power supply cable of the heated tracing Before supplying power the grounding of the cable should be checked A 24 VDC power supply should be connected to the 24 VDC power supply cable of the unit in the field Before powering the unit the polarity should be checked The following connections should be made to the M2000 all connectors are available on the backside of the unit see fig 3 1 a24 VDC power supply should be connected to the power input of the M2000 on the left side the power output is used to supply power to the relays connected to the digital outputs 2 the serial data communication cable should be connected to SKT1 female 9 pin sub D connector on the MPU board located on the right side a when in RS232 mode pin 2 TX RX and 5 GND must be used b when in RS485 mode pin 6 A and 9 B must be used 3 onthe outpu
12. c meter should be lit or blinking These LED s may be difficult to see since they are located on the far end of the board The green LED indicating a proper power supply should be lit continously The yellow LED should be blinking once per second indicating the transmission of data on the serial communication port The red LED should be blinking at high rate indicating the measurement rate of the ultrasonic unit The bright white LED on the sensor of the CO2 analyser should be blinking regularly and the small red LED which lites directly after startup should be switched off after a few seconds One or more LED s on the barrier of the empty bottle detection should be lit If any of these conditions is not met the power should be switched off immediatley and the cause of the error should be traced 3 The data communication between the unit in the field and the M2000 can be checked by watching the measurement results presented on the screen of the M2000 To achieve this the following keystrokes should be entered on the front panell of the M2000 a b Press the F4 button under the word Menu displayed the screen Press the upper or lower arrow key on the right side of the screen until the item GAS DATA is visible and highlighted Press the ENTER key to select this item In the displayed menu select RECEIVED to view the actually received calculation results use the arrow keys to view the different pages Although the data itsel
13. cate via the RS232 mode to achieve this it may be necessary to connect a lap top directly to the unit in the field check for explosive atmospheres before doing this Some modern PC s or laptops mimic serial COM ports via one of their USB ports Be sure that the serial COM port is actually working Experience revealed that Edgeport USB to RS232 converters do function properly under Windows XP The M2000 configuration software is not able to communicate with the M2000 Communication via the infra red port can be time consuming The infra red adapter should be fixed properly to the M2000 Check the COM port settings of the configuration program and the M2000 baud rate 38400 Some modern PC s or laptops mimic serial COM ports via one of their USB ports Be sure that the serial COM port is actually working Experience revealed that Edgeport USB to RS232 converters do function properly under Windows XP 10735 INST 004 Page 11 of 18 ELST E3 Instromet Appendix A Specifications Skid Overall Dimensions 1900 x 800 x 600 mm Mounting 4 x M12 rectangle 450 x 750 mm Weight approx 80 kg Electrical Power supply EnSonic 21 28 VDC 2 5 A 60 Watt M2000 21 28 VDC Tracing 220 VAC Communication EnSonic data RS 485 or 5232 MODBUS RTU or ASCII EnSonic service RS 232 dedicated protocol US data amp service RS 485 dedicated protocol Cable requirements Data 5x2x90 8mm twisted pair shielded amp armo
14. e system The Eex d box containing the electronics should be de energized before opening Helated documents EnSonic User Manual code 10735 USER 001 dd 20 01 2004 EnSonic Programmer code 10735 ENSCNF 001 dd 25 01 2004 Model 2000 Programmer code 10735 M2KCNF 001 dd 25 01 2004 Model 2000 Gas Flow Computer code Model 2000 issue 6 202 09 02 dd 16 09 2002 10735 INST 004 Page 3 of 18 ELSTE3 5 empty bottle detection RE reference gas heat traced sample line 1 8 3 mtrs l sample system bod line gas P gt 40 bar hazardous area Figure 1 System Layout Page 4 of 18 one i Instromet Supervisory System e 9 digital in digital out 4 20 mA lt q Wobbe xxxx MJ Nm3 24 VDC 220 VAC safe area 10735 INST 004 ELST E3 Instromet 1 Mechanical installation The following items need to be mounted prior to making the electrical connections 1 the EnSonic Skid 2 the M2000 flow computer oince the M2000 is the only part that needs to be installed separately from the EnSonic measurement unit each chapter presents the installation of the M2000 as a separate subject in cases were no M2000 is used these sections may be skipped EnSonic Skid The EnSonic measurement system comes mounted on a skid enabling easy field installation The recommended way to install the system is to mount the skid on a concrete base taking
15. f should not be displaying proper or meaningfull values the trailer of the data should indicate If the trailer indicates ALM proper communication with the unit in the field is not established If the communication fails the settings of both communication ports should be checked using the configuration software 4 The 220 VAC power supply to the heated tracing can be switched on After a while the temperature of the tracing should rise If not the connections should be checked 10735 INST 004 Page 9 of 18 B ELSTER Instromet After successfully completing the first 2 of the above 4 steps a PC or laptop with the EnSonic configuration software should be connected to communication port 1 of the EnSonic processor board Depending on the use of a 5232 485 converter the Eex d box an additional 5485 232 converter may be necessary to make the proper connection When necessary and allowed a direct connection between a laptop and port 1 of the EnSonic processor board can be made in the field However check for the presense of explosive mixtures before doing this By running the EnSonic configuration software the performance of the system can easily be checked The software itself is described in more detail in the corresponding manual Using an infra red serial adapter and the M2000 configuration software the M2000 can easily be configured The M2000 configuration software is described in more detail in the correspond
16. ing manual It is good practise to upload and save the original settings of the EnSonic and the M2000 when the unit is working properly after the system has been powered up for the first time Page 10 of 18 10735 INST 004 Instromet E STE3 4 Troubleshooting This section describes some procedures to troubleshoot the EnSonic system After switching on the 24 VDC power supply the unit in the field does not start up properly or behaves irratically The voltage level of the power supply should be checked on the unit itself If the level falls below 21 Volts a lower resistance cable or a power supply with a higher voltage level should be used The three red LED s on the EnSonic processor board or the 2 LED s on the interface board do not blink simultaneously In Appendix C and D all possible LED states are presented Most likely one or more of the devices in the system is not communication properly with the processor or interface board Check the operation of the individual devices by looking at their status LED s or check their power supply The baud rates and HART addresses of the different devices can be set using the EnSonic configuration software However since these values are factory set errors are not likely to occurr in these settings There is no communication between the unit in the field and the M2000 Switch the A amp B wire of the RS485 communication either on the unit in the field or on the backside of the M2000 Check the
17. mm tubing The heated tracing should be properly terminated using the provided termination set The reference gas bottle should be properly strapped to the back side of the skid and the pressure reducing valve should be installed The blue wire of the pressure switch should not be damaged The outlet of the pressure reducing valve should be connected to the proper inlet of the heat traced tubing the length of this part of the tubing is not critical At this stage do not supply pressure to the system M2000 The M2000 display and control unit is mounted in the safe area and the M2000 manual should be consulted for the mechanical installation procedure All connectors power supply serial communication ports analog and digital outputs and digital inputs are located on the back side of the unit Since the twelve digital outputs are opto coupler based each digital output requires an additional relay to switch larger currents These relays have to be mounted on a different location close to the M2000 The M2000 is configured via the infra red serial port located on the front panel of the unit A serial infra red adapter can be fixed to the unit 10735 INST 004 Page 5 of 18 ELST E3 Instromet 2 Electrical Installation The guidelines in this section should be followed to ensure proper functioning of the complete system The unit should be properly grounded and connections should be made carefully to ensure long term failure free operation
18. owing checks should be performed immediately only for visibility reasons it is recommended to leave the cover of the Eex d box removed however check for the presense of explosive mixtures before energising the unit a e The three LED s on the EnSonic processor board should start blinking after a few seconds the LED s should be blinking simultaneously which indicates proper communication with the other devices in the system If one of the LED s is not lit or does not blink most likely a communication failure exists with one of the devices in the system The two LED s on the EnSonic interface board should blink simultaneously The LED s may be difficult to see since they are located on the far end of the board If one of the LED s is not lit or does not blink most likely a communication failure exists with one of the devices in the system Initially the screen of the PID controller should indicate Startup After a few seconds the upper line on the display should indicate UFL UnderFLow while the lower line shows the set temperature of 50 00 C This underflow condition is to be exepected since the temperature of the 2VOS body will initially be outside of the span of the temperature transmitter which ranges from 45 to 55 When the body temperature rises above the lower limit of the range the PID controller will start indicating the actual body temperature The three LED s on the processor board of the ultrasoni
19. ronics the internal heating system and the stream selection valve of the EnSonic consume a reasonable amount of power the resistance of the 24 VDC power supply cable is of importance To ensure an input voltage of the system in the field of at least 22 VDC max 28 VDC a low resistance cable should be selected As an example when using a 24 VDC supply as power source the maximum voltage drop of 2 V 24 22 V combined with a current of 5 A during startup results in a maximum cable resistance of 0 2 per wire 0 4 total Increasing the input voltage to 28 VDC allows for a cable resistance of 0 6 per wire 1 2 total Although at least a 2 x 2 5 armoured shielded cable is recommended the power supply voltage present on the unit should always be checked If the remaining voltage drops below 22 VDC a lower resistance cable and or a higher voltage power supply needs to be installed The 220 VAC is used for the heated tracing of the sample line A 3 x 1 5 mm armoured shielded cable is recommended Field connections In the field the following connections have to be made to the EnSonic unit The 220 VAC power supply is connected to the heat tracing using the terminals in the Eex e box which is mounted in the lower left part of the EnSonic cabinet The heated tracing itself should be properly terminated using the provided termination set The data communication and 24 VDC power supply are connected to terminals located in the Eex d box of
20. sible to the gas sample point The gas pressure between 40 and 80 bar is led to the EnSonic using a heat traced tubing After being analyzed by the EnSonic the gas is vented into the atmosphere via the vent pipe on the right side of the unit The auto calibration system which supplies reference gas to the system on regular intervals to check the performance is shown on the left side of the unit During operation the bottle with reference gas is strapped to the back side of the unit The power supplies 24 VDC and 220 and the M2000 display and control unit are located in the safe area The cabling between the unit in the field and the safe area consists of a data a 24 VDC and a 220 VAC cable The data and 24 VDC cable may be combined In the safe area the measurement data is presented to the customer via a the analog and digital outputs of the M2000 display and control unit b the Instromet Supervisory System Or auser supplied dedicated data logging system When using the M2000 the user is able to initiate both the auto calibration and reset function of the EnSonic remotely via the digital contact inputs of the M2000 The mechanical installation of the system is described first the electrical connections are described secondly Note since the EnSonic is installed and operated in the hazardous area where explosive gas mixtures may be present the necessary safety precautions should be taken when handling installing or operating th
21. t module the following connections are available a digital outputs which need to be connected to the corresponding relays A1 B1 A12 B12 b analog outputs pin A13 B13 A14 B14 A15 B15 and A16 B16 LET al k E LE Hr r E F F B E F F Figure 3 Backpannel M2000 4 Three digital inputs are located on the input module A1 B3 and A3 two of these inputs need to be connected to the control system of the user Since the function assignment is software selectable using the M2000 configuration software the actual mapping of the connections to the digital input is not important Jumpers 6 8 amp 10 on the input board have to be fitted The connections should be made according to the figure in appendix F For the detailed specification of the in and outputs the manual of the M2000 has to be consulted Page 8 of 18 10735 INST 004 E STE3 Instromet Ls 3 Powering up the EnSonic After installing the unit and making the electrical connections the unit can be powered up using the following procedure 1 The 24 VDC power supply to the M2000 can be switched on and after a few seconds the M2000 should present readable information on it s screen If not the power supply should be switched off immediately and the error should be traced 2 The 24 VDC power supply to the EnSonic unit in the field can be switched on and the foll
22. ured 24 VDC 2x 2 5 shielded amp armoured See remarks about power supply before installing power supply cable 220 3 1 5 shielded amp armoured Page 12 of 18 10735 INST 004 Ep Instromet Appendix B Skid Dimensions Figure B 1 Skid 3D view NAME SKID ENSONIC 3D VIEW REV DWN DATE CHD CH REQ COPYHOLDERS HMS 01 07 03 MATERIAL BEAM 50x50x3 ec AMERICAN SCALE E ROUGHNESS ACCORDING SHAPE AND POSITIONAL PROJECTION UNITS IN mm NEN 3634 TOLERANCES ACC NEN ISO 1101 THIS DRAWING IS A CONFIDENTIAL DISCLOSURE LOANED SUBJECT TO THE CONDITIONS THAT IT OR ANY INFORMATION CONTAINED THEREIN WILL NOT BE USED IN ANY WAY DETRIMENTAL TO OUR INTERESTS AND THAT ALL COPIES BE RETURNED IMMEDIATELY ON DEMAND DRAWING NUMBER SKID 3D INSTROMET B V Munstermanstraat 6 7064 Silvolde Tel 31 0 315 338911 Fax 338679 E mail info instromet nl 2019481 35 10735 INST 004 Page 1 3 of 18 a b a ELSTER 5 w Figure B 2 Skid Topview m 2 N 560 0 3 20 0 5 fo e I 2
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