LANDTEC BG3K2, BG3KD, BG3KE Operating Manual

OPERATING MANUAL

OMBG3000 – Iss.A © Copyright 2016 –

Table of Contents

1 Manual guidelines ................................................................................. 9

1.1

Safety symbol ........................................................................................ 9

1.2

Hyperlinks .............................................................................................. 9

1.3

Notes ..................................................................................................... 9

2 Safety information .............................................................................. 10

2.1

Safety instructions ............................................................................... 10

2.2

ATEX and IECEx Certification ............................................................... 12

2.2.1

Marking ............................................................................................... 12

2.2.2

Instructions Specific to Hazardous Area Installations .......................... 13

2.2.3

Entity Parameters ................................................................................ 15

2.3

Range of environmental conditions .................................................... 15

2.4

Safety symbols used on the instrument .............................................. 16

3 BIOGAS 3000 Overview ....................................................................... 17

3.1

Features ............................................................................................... 17

3.2

Benefits ................................................................................................ 18

3.3

Options ................................................................................................ 19

3.4

Main Applications ................................................................................ 19

3.5

Model Type Definitions ....................................................................... 20

3.5.1

BG3K1 .................................................................................................. 20

3.5.2

BG3K2 .................................................................................................. 20

3.5.3

BG3K3 .................................................................................................. 21

3.5.4

BG3K4 .................................................................................................. 22

3.5.5

BG3KD .................................................................................................. 23

3.5.6

BG3KE .................................................................................................. 23

3.6

BIOGAS 3000 Internal Components ..................................................... 25

3.7

BIOGAS 3000 Module Features ........................................................... 27

© Copyright 2016 OMBG3000 – Rev1

3.7.1

Physical Characteristics of the Module ................................................ 27

3.7.2

Definitions ........................................................................................... 29

4 Installation .......................................................................................... 31

4.1

Pre-Installation Requirements ............................................................. 31

4.1.1

General ................................................................................................ 31

4.1.2

Packaging Contents ............................................................................. 32

4.1.3

Storage of the System and Module ..................................................... 32

4.1.4

Ventilation Requirements .................................................................... 33

4.2

External Customer Connections .......................................................... 33

4.3

Mounting the Enclosure ...................................................................... 34

4.4

Connecting the Gas Lines to the BIOGAS 3000 .................................... 36

4.4.1

Gas Sample Lines ................................................................................. 36

4.4.2

Process Return ..................................................................................... 37

4.4.3

Air In .................................................................................................... 38

4.4.4

Vent to Atmosphere ............................................................................ 38

4.5

Drain .................................................................................................... 38

4.6

Protective Cover .................................................................................. 41

4.7

Cable Gland Selection and Cord Anchorage ........................................ 42

4.8

Cable Conductor Sizes and Insulation Requirements .......................... 44

4.8.1

Cable Conductor Sizes ......................................................................... 44

4.8.2

Cable Insulation Requirements ............................................................ 44

4.9

Mains Wiring ....................................................................................... 45

4.9.1

Protective Earthing and Mains Supply ................................................. 45

4.9.2

How to Wire the Mains Supply ............................................................ 46

4.10

Modbus Digital Output ........................................................................ 48

4.10.1

Wiring the BIOGAS 3000 Modbus Outputs .......................................... 48

4.10.2

Default Configuration of the BIOGAS 3000 Modbus Port .................... 50

4.10.3

Readable Parameters of the BIOGAS 3000 .......................................... 50

OMBG3000 – Iss.01 © Copyright 2016

4.11

4-20mA Outputs .................................................................................. 57

4.11.1

General Information ............................................................................ 57

4.11.2

Wiring the BIOGAS 3000 to a Current Sinking Input ............................ 58

4.11.3

4-20mA Scaling .................................................................................... 60

4.12

Relays .................................................................................................. 61

4.13

Profibus Digital Output ........................................................................ 63

4.13.1

Configuration of the Profibus Module ................................................. 63

4.13.2

Wiring the Profibus Module ................................................................ 65

4.13.3

Readable Parameters of the Profibus Module .................................... 68

4.14

Profinet Digital Output ........................................................................ 72

4.14.1

Configuration of the Profinet Module ................................................. 72

4.14.2

Wiring the Profinet Module ................................................................. 73

4.14.3

Readable Parameters of the Profinet Module ..................................... 76

4.15

Heater Option ...................................................................................... 79

4.16

Final Checks ......................................................................................... 80

5 General Operating Instructions ........................................................... 81

5.1

Switching the BIOGAS 3000 System On ............................................... 81

5.2

Self-Test ............................................................................................... 81

5.3

First Time Run Set-up .......................................................................... 83

5.4

Gas Readings Screen ............................................................................ 85

5.5

Alarms .................................................................................................. 88

5.5.1

Notification .......................................................................................... 88

5.5.2

Viewing Alarms .................................................................................... 89

5.6

Stop Sampling ...................................................................................... 90

5.7

Menu ................................................................................................... 91

5.7.1

Settings Menu ...................................................................................... 92

5.7.2

Device Information Menu .................................................................. 108

5.7.3

Calibration Menu ............................................................................... 112


5.8

Help Function .................................................................................... 117

5.9

BIOGAS 3000 Sampling Process ......................................................... 118

5.9.1

BG3K1, 2, 3, 4, and D Variants ........................................................... 118

5.9.2

BG3KE Variants .................................................................................. 119

5.10

Switching the BIOGAS 3000 System Off ............................................ 120

6 Gas Check and Calibration ................................................................. 121

6.1

Introduction ....................................................................................... 121

6.2

Required Equipment .......................................................................... 122

6.2.1

Gas ..................................................................................................... 122

6.2.2

Flow Regulator ................................................................................... 122

6.3

Gas Mixtures ...................................................................................... 123

6.3.1

Adding a Mixture ............................................................................... 124

6.3.2

Deleting a Mix .................................................................................... 125

6.3.3

Edit O

2

in Fresh Air Mix ...................................................................... 126

6.4

Connecting a Gas Bottle to the BIOGAS 3000 .................................... 128

6.5

Gas Check and Calibration ................................................................. 131

6.6

Status Icons ....................................................................................... 133

6.6.1

Post Gas Check .................................................................................. 133

6.6.2

Post Calibration ................................................................................. 133

6.7

Disconnecting a Gas Bottle from the BIOGAS 3000 ........................... 134

7 Maintenance ..................................................................................... 136

7.1

Maintenance Schedule ...................................................................... 136

7.2

BIOGAS 3000 Consumable Products .................................................. 138

7.3

Emptying the Catchpot ...................................................................... 140

7.4

Replacing the Catchpot Filter ............................................................ 143

7.5

Replacing the Inline PTFE Filter ......................................................... 147

7.6

Pressure Test ..................................................................................... 150

7.6.1

Required Equipment .......................................................................... 150


7.6.2

Diagnostics Control Mode ................................................................. 150

7.6.3

General Set-Up .................................................................................. 152

7.6.4

Performing the Pressure Test ............................................................ 152

7.7

Cleaning and Decontamination ......................................................... 158

8 Service .............................................................................................. 159

8.1

General .............................................................................................. 159

8.2

Service Notifications .......................................................................... 159

8.3

Replacement BIOGAS 3000 Module for Service – Hot Swap ............. 160

9 Problem Solving ................................................................................ 163

9.1

Fault Detection .................................................................................. 163

9.1.1

Non-Critical Faults ............................................................................. 163

9.1.2

Critical Faults ..................................................................................... 165

9.2

System Will Not Power On ................................................................ 166

9.3

Module Will Not Power On ............................................................... 166

9.4

Module Lock-Up ................................................................................ 167

9.5

Under and Over Range Codes ............................................................ 167

9.6

Analog Outputs Not Working ............................................................ 168

9.7

Modbus Outputs Not Working .......................................................... 168

9.8

Low Flow / Flow Fail .......................................................................... 168

9.9

Fuses .................................................................................................. 169

9.10

User Calibration Explained ................................................................ 170

9.10.1

General .............................................................................................. 170

9.10.2

Factory Calibration ............................................................................ 171

9.10.3

User Zero Calibration ......................................................................... 171

9.10.4

User Span Calibration ........................................................................ 172

9.10.5

Trouble Shooting ............................................................................... 172

9.11

CH

4

Reading Low and O

2

Reading High .............................................. 174

9.12

Event Log ........................................................................................... 174


10 BIOGAS 3000 Warranty Terms and Conditions .................................. 176

11 WEEE Compliance .............................................................................. 179

12 Declaration of Conformity .......................... Error! Bookmark not defined.

13 Glossary of Terms .............................................................................. 180


Operating Manual

Manual guidelines

9

1 Manual guidelines

1.1

Safety symbol

Information in this manual that may affect the safety of users and others is in the following format:

Warning Warning text will be placed here.

Failure to follow this information may result in physical injury that in some cases could be fatal, cause damage to the equipment or to the environment, or invalidate the certification of the equipment.

1.2

Hyperlinks

Hyperlinks to other sections of this manual, websites or email addresses are in the following format: www.landtecna.com

1.3

Notes

Important/useful information and instructions are shown clearly throughout the manual in a note format.

For example:

 Note: For further information contact our technical support team at (800)

968-2026 or email [email protected]

.


10 Operating Manual

Safety information

2 Safety information

2.1

Safety instructions

Warning The BIOGAS 3000 comes with a guard that covers all accessible components with mains power. This guard must only be removed when power to the system is isolated. Failure to isolate the supply could result in an electric shock.

When opening the cabinet great care must be taken by the operator as mains voltages are present. It is the responsibility of the owner of the equipment to ensure that all personnel are adequately trained.

It is the responsibility of the owner of this equipment to complete a risk assessment on its installation, operation, and maintenance prior to it being used.

Anti-static precautions should be observed during installation, maintenance, and general operation of the equipment.

OMBG3000 – Iss.01

Inhaling toxic gases may be harmful to health and in some cases may be fatal. It is the responsibility of the user to ensure that he/she is adequately trained in the safety aspects of the gases being used and appropriate procedures are followed. In particular, where hazardous gases are being used, the gas exhausted from the system must be piped to an area where it is safe to discharge the gas, or returned to the process.

The equipment should not be altered in any way other than described within this operating manual. Alterations or changes outside of this operating manual could make the equipment unsafe and invalidate the ATEX/IECEx certification.

It is vital that the instructions in this operating manual are followed closely. Failure to comply could cause an injury to the operator.

© Copyright 2016


Safety information

11

The auto-drain pump will need replacing before 4,000 hours use. At 3,000 hours, a non-critical fault will appear on screen to advise the user that replacement is due. At

4,000 hours, a critical fault will occur and stop the system from operating until replaced.



Suitably trained personnel should carry out the installation in accordance with the applicable code of practice.



Repair and maintenance of this equipment should be carried out in accordance with the applicable code of practice and this operating manual.



Only LANDTEC approved components are to be used as replacement parts.



If the equipment is likely to be exposed to aggressive substances (e.g. acidic liquids, gases that may attack metals or solvents that may affect polymeric materials) then it is the responsibility of the user to take suitable precautions, e.g. regular checks are performed as part of routine inspections or establishing from the material’s datasheet that it is resistant to specific chemicals.

 Note: If there is any uncertainty, please contact our technical support team at (800) 968-2026 or email [email protected]

.



Safety information

2.2

ATEX and IECEx Certification

Warning The equipment is designed for use in potentially explosive atmospheres as defined by the classification.

The equipment can be configured to measure low levels of several gases, but may not be certified for use in potentially explosive atmospheres of these gases. It is the responsibility of the operator to determine the protection concept and classification of equipment required for a particular application and if these gases create a potentially explosive atmosphere.

The equipment should not be altered in any way other than described within this operating manual. Alterations or changes outside of this operating manual will invalidate the certification and could make the apparatus unsafe.

2.2.1

Marking

In reference to European ATEX Directive 2014/34/EU and the IECEx

International Certification Scheme, the BIOGAS 3000 has been certified according to the following designation:

II 3G

Ex nA nC IIA T1 Gc (-20°C ≤ Ta ≤ +50°C)

Nameplate 1 - BIOGAS 3000 markings can be found on the main enclosure of

the system:



Safety information

13

Nameplate 1 - BIOGAS 3000 markings

2.2.2

Instructions Specific to Hazardous Area Installations

1) The equipment may be used in zones 2 with flammable gases and vapors with apparatus groups IIA and with temperature classes T1.

2) The equipment is only certified for use in ambient temperatures in the range -4ºF to +122ºF and should not be used outside this range.

3) Installation shall be carried out in accordance with the applicable code of practice by suitably trained personnel.

4) There are no special checking or maintenance conditions other than a periodic check.

5) With regard to explosion safety, it is not necessary to check for correct operation.



Safety information

6) The equipment contains no user-replaceable parts and is not intended to be repaired by the user. Repair of the equipment is to be carried out by the manufacturer, or their approved agents, in accordance with the applicable code of practice.

 Note: Please contact our technical support team at (800) 968-2026 or email [email protected]

to receive equipment repair training.

7) Repair of this equipment shall be carried out in accordance with the applicable code of practice.

8) If the equipment is likely to come into contact with aggressive substances, e.g. acidic liquids or gases that may attack metals or solvents that may affect polymeric materials, then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected thus ensuring that the type of protection is not compromised.

9) The certificate number has an ‘X’ suffix, which indicates that special conditions of installation and use apply. Those installing or inspecting this equipment must have access to the contents of the certificate or these instructions. The conditions listed in the certificate are reproduced below:



All cable entry holes shall be fitted with either a certified cable gland or a certified stopping plug with minimum IP65 that is suitable for the application.



The equipment may only be used in areas with a low risk of mechanical impact.



Warning – in locations where high external humidity and internal temperature variations (e.g. frequent on-off cycles) may cause condensation inside the equipment, the interior should be periodically inspected.



The terminal blocks shall only be fitted with wires that have cross sectional area falling within the terminal blocks certificates limitations.

Refer to operating manual.



Safety information

15



Equipment has only been assessed for electrical safety. No nonelectrical assessment has been conducted and the manufacturer declares compliance for this under his own responsibility.

10) Cell replacement must only be carried out in the safe area or when a hazardous atmosphere is not present.

 Note: Additional instructions shall be supplied alongside any replacement cell related to the specific installation requirements.

11) Regarding the use of covers, jumpers, and end brackets, the instructions of the manufacturer must be followed.

2.2.3

Entity Parameters

The following ratings must not be exceeded on the listed circuits below:

Circuit Ur (rated voltage) Ir (rated current) Pr (rated power)

Relay coil

4-20mA

24Vdc

24Vdc

RS485 Modbus -7 to +12V

6A

20mA

83.3mA

144W

480mW

417mW

2.3

Range of environmental conditions



The system is only for use in ambient temperatures in the range of 0°C to 50°C (32⁰F to 122⁰F) without the use of the approved heater, and -

20°C to 50°C (-4⁰F to 122⁰F) with the use of the approved heater.



The BIOGAS 3000 is designed for use outdoors and has an IP65 rating.



The mains voltages (110-230V) can fluctuate up to ±10% of the nominal voltage.



The system is only for use in ambient pressures in the range 700 to

1200mbar (-4.5 -2.7 psi).



Safety information

2.4

Safety symbols used on the instrument

The following safety symbols are used on the BIOGAS 3000:

Protective conductor terminal

Function earth (ground) terminal

Caution, risk of electric shock

or

Caution

Caution, risk of hot surface

Warning Where the symbol or is used in the BIOGAS 3000, the operating manual must be consulted.


3 BIOGAS 3000 Overview

3.1

Features


BIOGAS 3000 Overview

17

The BIOGAS 3000, primarily for the AD Biogas and Bio-methane upgrading market has been designed to enable site operations to maximize gas production yield and protect expensive capital equipment from the damaging contaminant gases contained within the production process. The ATEX and

IECEx certified BIOGAS 3000 builds on field proven, robust gas analysis technology to offer cost effective online monitoring with local data outputs.



CH

4

, CO

2

& O

2

– standard measurements



H

2

S, H

2

and CO – optional measurements (choice of up to two)



Modular design enabling hot-swap for serviceability and onsite maintenance



User calibration function to maintain accuracy and ensure data reliability in extreme temperatures



ATEX and IECEx certified for use in potentially explosive gas atmospheres – Zone 2



ISO/IEC 17025 calibration for optimal accuracy



Ability to monitor the gas control process before and after desulphurization






Continuous monitoring option



Up to 4 sample points to monitor the complete gas control process



Gas return to process as standard



IP65 rated for weatherproofing



Built-in liquid level monitoring with a dedicated alarm to inform the user contents of the catchpot require emptying or an optional automated moisture removal drain



Gas alarms and fault notifications



6 x 4-20mA outputs



Modbus RTU communication



Optional Profibus and Profinet communication



Clear, visual and informative color display



Optional heater to extend operating temperature range to -4°F



Extended Warranty and Service pack options through approved global service centers

3.2

Benefits



Customizable to site requirements



Zero operational downtime for servicing



Product reliability and longevity



Protect expensive capital equipment from damaging gases



Maximize operational efficiency through optimizing the AD process



Operational within hazardous areas



Ease of operation, integration and installation




19



Minimal through-life costs



Local support for peace of mind

3.3

Options



H

2

S ranges from 0-50ppm to 0-10,000ppm



CO 0-1,000ppm



H

2

0-1,000ppm



Profibus replaces Modbus



Profinet replaces Modbus



110V or 230V heater



Auto-drain to empty contents of catchpot without user interaction



Hydrolysis tank measurement option to improve the life of the external sensor, if required

3.4

Main Applications



AD research



Agricultural waste AD (large scale)



Biogas upgrading



Farm waste AD (small scale)



Gas flaring



Mixed food waste AD



Sewage / waste water treatment AD




3.5

Model Type Definitions

3.5.1

BG3K1



The BG3K1 measures CH

4

, CO

2

, and O

2

as standard with a choice of up to two additional gases (one internal to the module and one external) and measures from one sample point.



It has user selectable sample and air purge intervals that are exhausted back to the process and atmosphere respectively.



The 4-20mA and Modbus outputs are updated at the end of each sample.



The following image is a simple block diagram of the system including the optional external gas sensor:

3.5.2

BG3K2




4

, CO

2

, and O

2

as standard with a choice of up to two additional gases (one internal to the module and one external) and measures from two sample points.













21

3.5.3

BG3K3




4

, CO

2

, and O

2

as standard with a choice of up to two additional gases (one internal to the module and one external) from three sample points.












The BG3K3 also has the option of measuring from the hydrolysis tank on sample point 1 and not passing this gas across the external sensor. This prolongs the life of the sensor. The following image is a block diagram if the system with this option selected:




Warning For this option, additional moisture filtration will be required external to the equipment on ‘Sample Gas 1’.

3.5.4

BG3K4




4

, CO

2

, and O

2

as standard with a choice of up to two additional gases (one internal to the module and one external) from four sample points.












The BG3K4 also has the option of measuring from the hydrolysis tank on sample point 1 and not passing this gas across the external sensor. This prolongs the life of the sensor. The following image is a block diagram if the system with this option selected:




23

Warning For this option, additional filtration will be required external to the equipment on ‘Sample Gas 1’.

3.5.5

BG3KD



The BG3KD measures CH

4

, CO

2

, O

2

and high and low range H

2

S as standard (high range internal to the module and low range external) from two sample points.






The system has bypass solenoids in order to divert high levels of H

2

S from the low range sensor, which will prolong its life.






The following image is a simple block diagram of the system:

3.5.6

BG3KE



The BG3KE measures CH

4

, CO

2

, and O

2

as standard with a choice of up to one additional gas (external to module only) from one sample point.



It measures CH

4

, CO

2

, and O

2

continuously that is exhausted back to the process.






The module has a minimum three-minute air purge every 24-hours. The duration and time of day this occurs is user-definable.



The external sensor has user selectable sample intervals that are exhausted back to the process. The external sensor cannot be subjected to the gas stream continuously.



After each defined cycle, the external sensor is subjected to a user definable air purge that is exhausted to the atmosphere.



The 4-20mA and Modbus outputs are updated continuously, with the external sensor data being refreshed at the end of each sample



The following images are two simple block diagrams of the system with one including the optional external gas sensor:

BG3KE with no external sensor

BG3KE with an external sensor




3.6

BIOGAS 3000 Internal Components

25

1

2

Figure 1 - BIOGAS 3000 door internals

1) Viewing window

2) Heater (110V or 230V)

3) Plastic wallet containing operating manual and calibration certificate


3



1

2 3 4

19

18

17

16 15 14

Figure 2 - BIOGAS 3000 internal components

1) BIOGAS 3000 module

2) Heater thermostat

3) Solenoid valves

4) Inline PTFE filter

5) Female QRC for calibration

6) Catchpot with liquid level switch

7) External sensor

8) Pumps

9) Auto-drain pump (or drain valve)

10) Calibration valve

13

11) Modbus terminals

12) Gas in/out valves

13) 4-20mA terminals

14) Relays

15) Mains supply terminals

16) Power supplies

17) Fuses

18) Protective cover

19) Interface PCB


5

6

7

8

12

9

10

11

3.7

BIOGAS 3000 Module Features

3.7.1

Physical Characteristics of the Module



27

Front View:

1

9

8

7

2

3

Reference:

1) Display

2) Soft keys

3) Help key

4) On/off key

4

5

5) Keypad

6) Return key (  )

6

7) Pump key

8) Backlight key

9) Menu key

Rear View:

10) Module mounting brackets

10

11) Rear label

11

Top View:

12

13

© Copyright 2016

14

12) Gas outlet

15

13) Power supply connector

14) Gas inlet

15) Communications connector

OMBG3000 – Rev1






29

3.7.2

Definitions

Front View

Reference

1) Display

2) Soft keys

3) Help key

4) On/off key

5) Keypad

6)

7)

Return key (

Pump key

9) Menu key

© Copyright 2016



8) Backlight key

)

Definition

Shows information to the user.

The function of the three soft keys on the keypad is determined by the screen the operator is in.

Where ‘?’ is shown on the display, the operator can press the help key for onscreen assistance.

Press the on/off key for two seconds to switch the module on and off.

Allows numeric entry from 0-9 and letters

A-Z.

Keys ‘2’, ‘4’, ‘6’ and ‘8’ allow the operator to navigate ‘up’, ‘right’, ‘left’ and ‘down’ respectively in certain menu items.

Key ‘0’ is also used as the space key when entering text.

The  accepts/confirms choices made by the operator for various functions and operations.

Not used in normal operation but is used to aid diagnostics and assist with maintenance. It does not control the pump.

Enables the operator to turn the backlight off and on.

Press the ‘menu’ key to navigate to the

‘menu’.

OMBG3000 – Rev1



Rear View

10) Module mounting brackets Securely holds the module to the backplate.

11) Rear label The serial number is the unique identification number for the BIOGAS

3000 module. The part number is the unique record for the internal configuration of the BIOGAS 3000 module at time of manufacture or last service.

Top View

12) Gas outlet The gas sample exits the BIOGAS 3000 module here.

13)

14)

Power supply connector

Gas inlet

Power supplied from the Interface PCB connects here.

The gas sample enters the BIOGAS 3000 module here.

15) Communications connector Connection point for the USB lead from the Interface PCB.



Installation

31

4 Installation

4.1

Pre-Installation Requirements

4.1.1

General

It is LANDTEC’s recommendation that the installation of the BIOGAS 3000 is carried out in accordance with this operating manual and the latest edition of

IEC 60079-14. Any electrical work should be carried out by a competent electrician and any relevant codes of practice should be followed.

In order to effectively install the BIOGAS 3000 system it is important that the site is ready and in a fit state. In particular, the following points should be noted:

Warning Power should NOT be applied before all piping and wiring has been completed and tested.

Only a qualified person should make electrical connections to the system.



This operating manual has been read and fully understood



A risk assessment has been performed that includes installation, operation, and maintenance of the system and the removal, where practicably possible, of any identified hazards



Applicable codes of practice identified



The BIOGAS 3000 system has been received on site, unpacked, packaging contents checked, and checked for obvious damage



A suitable location is determined for the installation of the instrumentation



Note: Refer to section Mounting the Enclosure for items that need to be

considered.



A suitable mains supply as detailed in this manual is installed



All required gas lines are installed



Installation

 Note: Inlet pressure to the BIOGAS 3000 system must not exceed 350 mbars (5psi). Where this is exceeded, additional pressure regulation is required.



Output data cable has been installed (if required) to the BIOGAS 3000 location.

 Note: Failure to comply with any of the above may result in additional time on site and additional costs.

4.1.2

Packaging Contents

Check the product box for the following items:



BIOGAS 3000 system



Key for enclosure locks



Operating manual – found in plastic wallet on the inside of the enclosure door



Customer wiring diagram – found in plastic wallet on the inside of the enclosure door



Calibration certificate – found in plastic wallet on the inside of the enclosure door



Compression fittings – found on the bulkheads on the enclosure base

(see annotations 4, 5, and 7-11 on Figure 3 - BIOGAS 3000 customer connections )



Particulate filter for air purge line (LANDTEC part number 2008277/S,

see section BIOGAS 3000 Consumable Products ).

4.1.3

Storage of the System and Module

The BIOGAS 3000 system and module should not be exposed to extremes of temperature. It is the user’s responsibility to ensure the system and module are kept within their ambient operating temperature range.



Installation

33

4.1.4

Ventilation Requirements

There is an enclosure breather fitted to the BIOGAS 3000 situated at the base

of the enclosure (see annotation 13 on Figure 3 - BIOGAS 3000 customer connections ). It is the user’s responsibility to ensure that there is a free

circulation of air around the cabinet.

Warning If the system is being installed indoors, it is our recommendation that a suitable gas leak detector is placed nearby to the system to inform operators of a leak before entering the room. This is not supplied by

LANDTEC or QED.

4.2

External Customer Connections

The installation will require the operator to connect a mains cable, output

cable, drain and gas pipes to the equipment. Figure 3 - BIOGAS 3000 customer connections identifies the available connection points on the BIOGAS 3000:

7

8

1

13 12

Figure 3 - BIOGAS 3000 customer connections

11 10 9

1) Customer cable entry – mains supply 8) Drain

2) Customer cable entry – not used 9) Vent to Atmosphere

3) Customer cable entry – data outputs 10) Sample Gas 4

4) Sample Gas 1

5) Sample Gas 3

6) Air In

7) Process Return

11) Sample Gas 2

12) Customer cable entry – relays

13) Breather Drain



Installation

 Note: There are four stopping plugs fitted to the enclosure for the customer’s cable entry. An M20 stopping plug must be removed from annotations 1-3 and 12 where a cable gland is to be placed. Where a cable entry point is not being used, the M20 stopping plug must remain in place in order to maintain the IP rating of the enclosure.

Warning The mains and output cables must enter the cabinet via

a cable gland (see Cable Gland Selection and Cord

Anchorage ) and the mains supply should be isolated (see

Mains Wiring ).

4.3

Mounting the Enclosure

The system is contained in one enclosure that is weatherproof and has a rating of IP65.

When considering the location of the equipment, the following must be considered:



Although the enclosure is IP65, it must be protected from the worst of the weather. For example, maintenance of the system will be made easier and safer if it is not exposed to driving rain



Allow easy access for routine maintenance to be undertaken



Allow easy viewing of the display through the viewing window



Any future changes in the area, for example plantation growth causing damage to pipework



Ensure there is no risk of damage from vehicles or animals in the area



Avoid positioning the enclosure in direct sunlight as this may increase the internal temperature of the cabinet to outside of the operating temperature range of the equipment.

 Note: If it is difficult to position the BIOGAS 3000 system out of direct sunlight, measures should be taken to protect the system, such as a basic cover to provide shade.

The enclosure is to be mounted to a solid brick wall or framework (preferably stainless steel) capable of holding the weight of the system. The weight of the



Installation

35 enclosure and contents will depend on the options that are fitted, but the maximum weight is 32kg. It is therefore recommended that the installation be undertaken by a minimum of two people.

Warning Although the wall mounting brackets are fitted and tested at manufacture, during transit it is possible that they could have worked loose. Prior to installation, ensure the wall mounting brackets are securely fitted to the BIOGAS 3000 system.

Four mounting brackets are supplied and fitted to each corner of the BIOGAS

3000. Suitable nut and bolt or rawl bolt arrangements will have to be defined by the operator for fixing to the wall or framework (it is recommended that these are stainless steel). The enclosure should be mounted as square and level as possible.

Dimensions of the enclosure are provided in Figure 4 - BIOGAS 3000 enclosure dimensions .

© Copyright 2016

Figure 4 - BIOGAS 3000 enclosure dimensions

OMBG3000 – Rev1


Installation

4.4

Connecting the Gas Lines to the BIOGAS 3000

 Note: The gas connections on the system are ¼ inch stainless steel bulkhead connectors with a compression fitting suitable for ¼ inch outer diameter tubing. It is recommended that stainless steel tubing be used where possible.

 Note: After installation, ensure all tube connections are tight and free

from leaks. See section Pressure Test .

4.4.1

Gas Sample Lines

Care should be taken in routing the sample lines, especially in cold environments. The sample lines may need insulating or even trace heating to prevent freezing of water within the pipe. This is not part of the BIOGAS 3000 system and is the responsibility of the operator.



The sample should be taken from a suitable location at the required monitoring point. It is recommended that a valve be incorporated in the assembly so that the gas can be shut off if the sample line is removed.

Figure 5 - Ball valve assembly



The line should connect to the upper surface of a horizontal pipe or on a vertical standing pipe. This will prevent excessive amounts of water entering the sample line.



Installation

37



An additional ball valve should be incorporated in to each sample line close to the BIOGAS 3000 system. This ball valve will be used to isolate the gas supply to the system as part of pressure testing the system during routine maintenance.



The sample tube should be connected to the bulkhead connectors labelled ‘SAMPLE GAS 1’, ‘SAMPLE GAS 2’, ‘SAMPLE GAS 3’, and

‘SAMPLE GAS 4’ where applicable – see annotations 4, 5, 10, and 11 on

Figure 3 - BIOGAS 3000 customer connections .

 Note: The maximum distance the BIOGAS 3000 can be from the sample point is 164 feet, (50 meters).

4.4.2

Process Return

This is the line where measured gas from the system is exhausted. It can be returned to the process or vented to atmosphere.

Care should be taken in routing the process return line, especially in cold environments. The process return line may need insulating or even trace heating to prevent freezing of water within the pipe. This is not part of the

BIOGAS 3000 system and is the responsibility of the operator.



The gas exhaust line should be returned to a suitable location at the required point. It is recommended that a valve be incorporated in the assembly so that the gas can be shut off if the sample line is removed.

See

Figure 5 - Ball valve assembly .

Warning The gas being exhausted at this point of the system will be flowing at approximately 300ml/min. If the sample gas is being vented to atmosphere, it should be routed to a safe and well-ventilated area.



An additional ball valve should be incorporated in to the piping close to the BIOGAS 3000 system, even when being vented to atmosphere. This ball valve will be used as part of pressure testing the system during routine maintenance.


38

Installation




The gas exhaust line should be connected to the bulkhead connector

labelled ‘PROCESS RETURN’ – see annotation 7 on Figure 3 - BIOGAS

3000 customer connections .

4.4.3

Air In

The air purge inlet requires uncontaminated air for the purge line. If uncontaminated air is available, the particulate filter should remain in place.

If uncontaminated air cannot be guaranteed at the location of the analyser, the particulate filter should be removed and a pipe should be connected in its place and terminated at a point where uncontaminated air is present.



The sample tube should be connected to the bulkhead connector

labelled ‘AIR IN’ – see annotations 6 on Figure 3 - BIOGAS 3000 customer connections .

4.4.4

Vent to Atmosphere

Warning When performing an air purge the gas that was previously sampled will be vented to atmosphere for a short period, typically 10 seconds. This equates to approximately 50ml of gas per air purge. In addition, when performing a user calibration, the calibration gas will be exhausted from this bulkhead. It is therefore recommended that the ‘Vent to Atmosphere’ line should be routed to a safe and well-ventilated area.



A ball valve should be incorporated in to the piping close to the BIOGAS

3000 system. This ball valve will be used as part of pressure testing the system during routine maintenance.



The sample tube should be connected to the bulkhead connector

labelled ‘VENT TO ATMOSPHERE’ – see annotation 9 on Figure 3 -

BIOGAS 3000 customer connections .

4.5

Drain

The system incorporates a catchpot and drain for removal of liquid to help

prevent water from entering the system (see annotation 6 on



Installation

39

Figure 2 - BIOGAS 3000 internal components). However, additional water

filtering may be required where the sample is heavily contaminated with water

(available from LANDTEC, see part number GA3KP.S15 in section BIOGAS 3000

Consumable Products ).

Care should be taken in routing the drain line, especially in cold environments.

The drain line may need insulating or even trace heating to prevent freezing of water within the pipe. This is not part of the BIOGAS 3000 system and is the responsibility of the operator.

Alternatively, the contents can be emptied in to a suitable container and disposed of in a safe manner.

If the auto-drain option is fitted, no manual draining of the system is required.



The drain line should be connected to the bulkhead connector labelled

‘DRAIN’ – see annotation 8 on Figure 3 - BIOGAS 3000 customer connections .



The drain line should be run to a position where it is safe to discharge the small amount of liquid that is removed from the sample gas.



The contents of the catchpot are drained under gravity. Therefore, any tubing needs to be lower than the drain compression fitting.



The drain connection on the system is a 6mm stainless steel bulkhead connector with a compression fitting suitable for 6mm outer diameter tubing. It is recommended that stainless steel tubing be used where possible.



The catchpot contains a liquid level (reed) switch. When the liquid reaches a certain level, the switch activates and informs the BIOGAS

3000 module. From here, an icon is displayed on screen and if

configured triggers a relay (see Configure Relays ).



Refer to the Emptying the Catchpot section of this operating manual for

how to drain the catchpot.



When taking a gas sample, ensure the drain ball valve (see annotation 9

on


40

Installation




Figure 2 - BIOGAS 3000 internal components is in the closed (horizontal)

position.

 Note: If the auto-drain option is fitted, there will be no drain valve fitted to the equipment.

Warning For the hydrolysis tank option chosen at manufacture, additional filtration will be required on sample point 1, as this does not pass through the system’s catchpot. See

LANDTEC part number GA3KP.S15 in section BIOGAS

3000 Consumable Products

The catchpot can hold approximately 90ml of liquid.

Dependent upon the application the liquid removed may be contaminated and should be discharged to an area where it is safe to do so.

This line may also vent sample gas for a brief period during each draining operation if the sample inlet and gas out valves are not closed.



Installation

41

4.6

Protective Cover

The BIOGAS 3000 has a protective cover fitted inside the main enclosure to cover areas where mains voltages are present. This cover must be removed in order to wire the mains supply to the BIOGAS 3000 system and to replace fuses.

Warning The cover must only be removed when power to the system has been isolated. Failure to isolate the power before removing the cover could result in an electric shock.

It is vital that after installation and prior to powering the equipment that the protective cover is replaced. Failure to replace the cover could result in an electric shock.

The cover is removed by unscrewing four M6 x 12mm button head screws with

a 4mm hexagon tool (see Figure 6 - Mains cover removal ). The cover and

screws must be kept safe once removed to ensure that they are not lost and can be refitted once installation is complete.

To fit the cover, simply align the holes in the protective cover with the four pillars fixed to the BIOGAS 3000 back plate and screw in to place using the

4mm hexagon tool.

 Note: For clarity, some images of the BIOGAS 3000 system in this operating manual may not include the protective cover.


42

Installation


Figure 6 - Mains cover removal

4.7

Cable Gland Selection and Cord Anchorage

To maintain the integrity and certification of the equipment a cable gland must be selected that:



is suitably certified – see section ATEX and IECEx Certification in this

operating manual for the equipment marking

 has a minimum rating of IP65

 shall be protected against abrasion and sharp bends at the point where the cord enters the equipment, by an inlet or bushing with a smoothly rounded opening

 has been fitted and tightened to the recommended torque set by the manufacturer.

In addition, the cable gland must have a means of anchoring the cable. The cord anchorage shall relieve the conductors of the cord from strain, including



Installation

43 twisting, where they are connected within the equipment, and shall protect the insulation of the conductors from abrasion. The protective earth conductor shall be last to take the strain if the cord slips in its anchorage.

Cord anchorages shall meet the following requirements:



The cord shall not be clamped by a screw that bears directly on the cord



Knots in the cord shall not be used



It shall not be possible to push the cord into the equipment to an extent that could cause a hazard



Failure of the cord insulation in a cord anchorage that has metal parts shall not cause accessible conductive parts to become hazardous live



It shall not be possible to loosen the cord anchorage without the use of a tool



It shall be designed so that cord replacement does not cause a hazard, and it shall be clear how the relief from strain is provided.

Warning A compression bushing shall not be used as cord anchorage.

Failure to meet the above requirements could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.



Installation

4.8

Cable Conductor Sizes and Insulation Requirements

4.8.1

Cable Conductor Sizes

Cable conductors must meet the following requirements, be suitable for the environment, and distance to the supply:

Function Type Conductor Size

Voltage

Rating

Current

Rating

Mains supply

4-20mA outputs

Tri-rated 0.14 – 4.0mm

0.14 – 2.5mm

2

2

solid

stranded

Twisted pair

0.14 – 4.0mm

0.14 – 2.5mm

2

2

solid

stranded

Modbus outputs

Twisted pair

0.14 – 4.0mm

0.14 – 2.5mm

2

2

solid

stranded

Relays Tri-rated 0.2 – 2.5mm

2

230Vac 3.15A

24Vdc

12Vdc

24Vdc

20mA

83.3mA

6A

Warning Failure to meet the above requirements could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.

4.8.2

Cable Insulation Requirements

In addition to the table below, the cable insulation must comply with a recognised standard and have a flammability rating of V1 or better:

Function

Mains supply

Cable Insulation thickness (min)

0.6mm

4-20mA outputs 0.2mm

Modbus outputs 0.2mm

Relays 0.2mm

Warning Failure to meet the above requirements could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.



Installation

45

4.9

Mains Wiring

4.9.1

Protective Earthing and Mains Supply

The safety of the equipment depends on it being effectively earthed via the mains supply.

The mains requirement for the system can be found on the side of the

enclosure and is shown on Figure 7 - BIOGAS 3000 electrical label :

Figure 7 - BIOGAS 3000 electrical label

The mains fuse rating (FS1) of the equipment is 3.15A.

The equipment must be provided with a double-pole switched and fused mains supply. The switch must be mounted as close to the equipment as practicably



Installation

possible so that it can be easily reached and clearly identified as the disconnecting device for the system.

The mains cable must be three core cable (live, neutral and earth) and enter

the enclosure via a cable gland (see Cable Gland Selection and Cord

Anchorage ) through the mains supply customer cable entry point (see

annotation 1 on Figure 3 - BIOGAS 3000 customer connections ).

4.9.2

How to Wire the Mains Supply

Warning Only a qualified person should make electrical connections to the system.

Ensure the power is isolated and the Protective Cover is

removed before wiring to the system.

Failure to connect a suitable earth to the system could result in serious injury.

The equipment must be provided with a double-pole switched and fused mains supply. The switch must be mounted as close to the equipment as practicably possible and clearly identified as the disconnecting device for the system.

Cable glands should meet the requirements of Cable

Gland Selection and Cord Anchorage .

Cable insulation and conductor sizes must meet the

requirements of Cable Conductor Sizes and Insulation

Requirements .

If using armored cable, the armor must not be used as the main earth connection for the BIOGAS 3000. If earthing of the armor is required, this must not be taken from the BIOGAS 3000.

All cables should be crimped with an appropriate insulated ferrule for the size of the cable being used. In addition, the cable insulation must be housed adequately within the protective sheath of the ferrule.



Installation

47

Terminals that are wired should be tightened to a minimum of 0.6N

 m. Failure to tighten to this requirement could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.

Refer to annotation 15 on

Figure 2 - BIOGAS 3000 internal components for the location of the mains

wiring terminals, and Wiring Diagram 1 - Mains for how to wire the mains

cable to the BIOGAS 3000 system. A label within the system identifies the appropriate inputs live (L), earth (E), and neutral (N).



Note: For cable conductor sizes and cable insulation requirements, please

refer to section Cable Conductor Sizes and Insulation Requirements .

© Copyright 2016

Wiring Diagram 1 - Mains

OMBG3000 – Rev1


Installation

4.10

Modbus Digital Output

If Modbus digital outputs are being used, the cable must enter the enclosure

via a suitably rated cable gland (see Cable Gland Selection and Cord

Anchorage

) and cable (see Cable Conductor Sizes and Insulation

Requirements ), through the data outputs customer cable entry point (see

annotation 3 on Figure 3 - BIOGAS 3000 customer connections ).

A label within the system identifies the appropriate outputs ‘+’, ‘-‘, and ‘LG’.

Refer to annotation 10 on Figure 2 - BIOGAS 3000 internal components for the

Modbus terminal connections.

Warning The BIOGAS 3000 Modbus terminals must only be used for standard Modbus communications. No other connections must be made as they could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.

4.10.1

Wiring the BIOGAS 3000 Modbus Outputs


Ensure the power is isolated.





Requirements .


All cables should be crimped with an appropriate insulated ferrule for the size of the cable being used. In addition, the cable insulation must be housed



Installation

49 adequately within the protective sheath of the ferrule.



The input voltage range to the BIOGAS 3000 Modbus terminals must not exceed -7 to +12V and the current must not exceed 83.3mA. Operating outside of this range will invalidate the ATEX/IECEx certification.

Wire the outputs in accordance with Wiring Diagram 2 – Modbus . For optimum

performance, it is recommended that screened twisted pair cable be used.

 Note: For cable conductor sizes and cable insulation requirements, please


When wiring the outputs the twisted pairs must be as follows:

Terminal Colour Wiring Information

Orange

Blue

White

Signal A (RS485) ‘+’

Signal B (RS485) ‘-‘

Logic Ground (0V) ‘LG’

Pair

Pair one

Pair two

© Copyright 2016

Wiring Diagram 2 – Modbus

OMBG3000 – Rev1


Installation

4.10.2

Default Configuration of the BIOGAS 3000 Modbus Port

The BIOGAS 3000 Modbus port has a default configuration of the following:

Node Address 1

Baud Rate

Parity

19200

Even

Stop Bits

Termination

1

Off

The BIOGAS 3000 acts as a slave.

The protocol is MODBUS RTU.

 Note: A termination resistor of 200 ohms is fitted internally between the positive and negative Modbus signals of the BIOGAS 3000, which must be the last connection on the ‘bus’. The termination resistor can be turned

‘On’ or ‘Off’ via the menu on the BIOGAS 3000 module (see Configure

Modbus Slave ). Similarly, the master device on the ‘bus’ should have a

termination resistor.

 Note: The node address, baud rate, parity, and termination are all configurable settings found within the menu of the BIOGAS 3000 module;

see section Configure Modbus Slave .

4.10.3

Readable Parameters of the BIOGAS 3000

Below is a table of addresses that can be read from the BIOGAS 3000.

Read-Only Single Bit Registers

Register

Address

(Dec) (Hex) Parameter

0 0000h System status

1

3

0001h Flow status

2 0010h

Communications status

0011h Catchpot status

Content Information

0 – system OK

1 – system fault

0 – flow OK

1 – flow fail

0 – communications OK

1 – communications error

0 – catchpot empty

1 – catchpot full



Installation

51



Installation

Read-Only 16-Bit Registers

Register

Address


0 0000h Run status


0 – running process

1 – running with non-critical fault

2 – stopped by user (outputs frozen)

3 – stopped by user (fixed at safe values)

4 – stopped with critical fault

(outputs frozen)

32 0020h Time and date: year e.g. 2016

33 0021h Time and date:

Month

1-12

34 0022h Time and date: day 1-31

35 0023h Time and date: hour 0-23

36 0024h Time and date: minute

0-59

37 0025h Time and date: second

48 0030h Current sample point

0-59

1-4

128 0080h Service due: year e.g. 2016

129 0081h Service due: month 1-12

130 0082h Service due: day 1-31

512 0200h Alarm 1 Status

513 to

519

0201h to

0207h

Alarm 2 to alarm 7

Status

0 – No alarm

1 – Triggered

2 – Triggered and in recovering zone

4 – Latched

8 – Muted

9 – Triggered alarm and muted

10 – Recovering alarm and muted

12 – Latched and muted

Repeated as per alarm 1

768 0300h

Sample point 1 last reading: year e.g. 2016



Installation

769 0301h

Sample point 1 last reading: month

770 0302h Sample point 1 last reading: day

771 0303h Sample point 1 last reading: hour

772 0304h Sample point 1 last reading: minute

773 0305h Sample point 1 last reading: second

1024 to

1029

1280 to

1285

1536 to

1541

832

833

0400h to

0405h

0500h to

0505h

0600h to

0605h

Sample point 2 last reading time and date



0340h Last reading sample point 1: CH

4

0341h Last reading sample point 1: CO

2

834 0342h Last reading sample point 1: O

2

835 0343h Last reading sample point 1: Internal cell

1-12

1-31

0-23

0-59

0-59

Repeated as per sample point 1



CH

4

reading x 10 e.g. 61.1% would be 611

CO

2


O

2


Internal cell reading e.g. 3500

837 0345h Last reading sample point 1: External cell

839 0347h Last reading sample point 1: Baro

External cell reading e.g. 3500

Baro reading e.g. 1025

841 0349h Last reading sample point 1: Flow

Pump flow reading e.g. 275

1088 0440h

1089 0441h

Last reading sample point 2: CH

4

Last reading sample point 2: CO

2

CH

4


CO

2


1090 0442h Last reading sample O

2

reading x 10

53



Installation

1091 0443h

1093 0445h

1095 0447h

1097 0449h

1344 0540h

1345 0541h

1346 0542h

1347 0543h

1349 0545h

1351 0547h

1353 0549h

1600 0640h

1601 0641h

1602 0642h

1603 0643h

1605 0645h

1607 0647h

1609 0649h point 2: O

2

Last reading sample point 2: Internal cell

Last reading sample point 2: External cell

Last reading sample point 2: Baro

Last reading sample point 2: Flow


4


2

Last reading sample point 3: O

2






4


2


2




Last reading sample point 4: Flow e.g. 0.5% would be 5





CH

4


CO

2


O

2






CH

4


CO

2


O

2








Installation

Read-Only 32-Bit Registers

Readings stored in two 16-bit read-only registers as a single precision real/floating point number:

55

Register

Address


33024 8100h

33026 8102h

33028 8104h

33030 8106h


4


2


2



CH

4

reading e.g. 61.1

CO e.g. 38.7

O

2

2

reading

reading e.g. 0.5


33034 810Ah

33038 810Eh





33042 8112h



33280 8200h

33282 8202h

33284 8204h


4


2


2

Last reading sample

CH

4

reading e.g. 61.1

CO e.g. 38.7

O

2

2

reading

reading e.g. 0.5

33286 8206h

33290 820Ah

33294 820Eh

33298 8212h point 2: Internal cell








33536 8300h


4

CH

4

reading e.g. 61.1

33538 8302h Last reading sample CO

2

reading



Installation

33540 8304h

33542 8306h

33546 830Ah

33550 830Eh

33554 8312h

33792 8400h

33794 8402h

33796 8404h

33798 8406h

33802 840Ah

33806 840Eh

33810 8412h point 3: CO

2


2






4


2


2




Last reading sample point 4: Flow e.g. 38.7

O

2

reading e.g. 0.5





CH

4

reading e.g. 61.1

CO

2

reading e.g. 38.7

O

2

reading e.g. 0.5





 Note: Floating-point numbers consist of two 16-bit words to give a 32-bit single precision floating point number. The first word (e.g. 33802) holds the sign in bit 15, the exponent in bits 14-7, part of the mantissa in bits 6-

0. The remaining part of the mantissa is in the next register (e.g. 33803) bits 15 – 0.



Installation

57

4.11

4-20mA Outputs

If analog outputs are being used, the cable must enter the enclosure via a

suitably rated cable gland (see Cable Gland Selection and Cord Anchorage ) and

cable (see Cable Conductor Sizes and Insulation Requirements ), through the

data outputs customer cable entry point (see annotation 3 on Figure 3 -

BIOGAS 3000 customer connections ).

The outputs on the BIOGAS 3000 power the loop (24V) to allow the customers system to sink it to ground (0V).

Relays within the equipment can be used to indicate the status of the 4-20mA

channel. Refer to section Configure Relays for more information.

 Note: There are various combinations of configuring the system and this operating manual will describe the most common method. If your system does not support this, please contact our technical support team at (800)

968-2026 or email [email protected]

.

4.11.1

General Information

There are two sets of terminals for the 4-20mA signals. One set is a bank of terminals that provide a common 0V or 24V. The other group are double-deck terminals that provide the analogue signal depending on the configuration of the common terminal.

For the common terminals, labels identify the appropriate terminals namely from left to right (‘0V’, ‘T1’ through ‘T6’, ‘24V’). ‘T1’ to ‘T6’ are commoned together using a 3-way bridge connector between either the ‘0V’ or the ‘24V’ terminal.

For the analog channels, labels identify the appropriate terminal on the double-deck namely:



Top deck: ‘CH1A’ through ‘CH6A’



Bottom deck: ‘CH1B’ through ‘CH6B’

Refer to annotation 13 in



Installation

Figure 2 - BIOGAS 3000 internal components for the terminal location and

Wiring Diagram 3 - 4-20mA circuit for the 4-20mA terminal identification.

4.11.2

Wiring the BIOGAS 3000 to a Current Sinking Input

For this method, the power to the loop is provided by the BIOGAS 3000. The

BIOGAS 3000 sources the current.







Requirements .





Wire the outputs in accordance with Wiring Diagram 3 - 4-20mA circuit . For

optimum performance, it is recommended that screened twisted pair cable be used.



Installation

59



Wiring Diagram 3 - 4-20mA circuit



Installation

4.11.3

4-20mA Scaling

The following table details the scaling on the 4-20mA channels:

Gas

CH

4

CO

2

O

2

H

2

S 0-50ppm

H

2

S 0-200ppm

H

2

S 0-500ppm

H

2

S 0-1,000ppm

H

2

S 0-5,000ppm

H

2

S 0-10,000ppm

H

2

0-1,000ppm

CO 0-1,000ppm

4mA Reading

0.0%

0.0%

0.0%

0ppm

0ppm

0ppm

0ppm

0ppm

0ppm

0ppm

0ppm

20mA Reading

100.0%

100.0%

25.0%

50ppm

200ppm

500ppm

1,000ppm

5,000ppm

10,000ppm

1,000ppm

1,000ppm



Installation

61

4.12

Relays

 Note: The relays are configurable for alarm notifications, sample point monitoring notifications, air purge notifications, catchpot full notifications, and 4-20mA signal notifications. The configuration is set-up

via the menu (see section Configure Relays ).







Requirements .



The maximum rated voltage of the relays to 24Vdc.

Exceeding this voltage will invalidate the ATEX/IECEx certification.





Installation

The system comes equipped with eight available relays. The relays are volt free changeover contacts. The maximum rated voltage is 24Vdc.

When being used for alarms and fault notifications the relays are normally energized (i.e. will de-energize when an alarm condition is triggered). This means wiring across connections 11 and 12 during a notification will complete

the circuit and de-energize the relay. Refer to Wiring Diagram 4 - Relays for

further information.

When being used for sample point indication, catchpot notifications and air purge notifications, the relays are normally de-energized (i.e. will energize when the condition is active). This means wiring across connections 11 and 14 during a notification will complete the circuit and energize the relay. Refer to

Wiring Diagram 4 - Relays for further information.

Wiring Diagram 4 - Relays

 Note: For terminal conductor sizes and cable insulation requirements,

please refer to section Cable Conductor Sizes and Insulation

Requirements .



Installation

63

4.13

Profibus Digital Output

The Profibus option for the BIOGAS 3000 is via a Modbus to Profibus converter module. The converter is a Profibus slave module and acts as an interface between the Modbus output of the BIOGAS 3000 and Profibus network.

Warning The Modbus to Profibus converter module for the

BIOGAS 3000 is not ATEX or IECEx certified and must be housed in a non-hazardous location or within a flameproof enclosure. This is the responsibility of the owner of the equipment.

The BIOGAS 3000 Modbus terminals must only be used for standard Modbus communications; no other connections must be made. Connections outside of this could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.

 Note: The Profibus module can be purchased as a post-sale accessory and upgraded on site by the user; see LANDTEC part number BG3K.S3 in

BIOGAS 3000 Consumable Products .

For wiring to the Modbus terminals from the Profibus module, see section

Modbus Digital Output .

4.13.1

Configuration of the Profibus Module

The Profibus module node address is currently set to ‘02’. This can be adjusted, if required, by using the small rotary switches underneath a cap found on the

front face of the module (see Figure 8 - Profibus module switch location ). The

‘0’ is set using switch ‘A’ and the ‘2’ is set using switch ‘B’ (see Figure 9 -

Profibus module switch identification ).

 Note: The Profibus configuration GSD file required for setting up the master Profibus communications is enclosed on the supplied CD.


64

Installation


Figure 8 - Profibus module switch location

Figure 9 - Profibus module switch identification

In addition, the Modbus port on the BIOGAS 3000 must be configured as followed:

Node Address 1

Baud Rate 9600

Parity

Stop Bits

Termination

Even

1

On


To configure the Modbus port on the BIOGAS 3000, refer to section Configure

Modbus Slave in this operating manual.



Installation

65

4.13.2

Wiring the Profibus Module







Requirements .


The power supply for the Modbus to Profibus converter module must not be taken from the BIOGAS 3000. Using the supply from the BIOGAS 3000 could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.




The input voltage range to the BIOGAS 3000 Modbus terminals must not exceed -7 to +12V and the current must not exceed 83.3mA. Operating outside of this range will invalidate the ATEX/IECEx certification.



Installation

Wire the outputs in accordance with Wiring Diagram 5 – Modbus to Profibus converter module wiring

. In addition, Wiring Diagram 2 – Modbus may also be

useful for wiring to the BIOGAS 3000 Modbus outputs.

For optimum performance, it is recommended that screened twisted pair cable be used.



 Note: If the distance between the BIOGAS 3000 and the Profibus converter module is greater than 200m, it may be necessary to add a termination resistor at the Profibus end to ensure noise-free communications. In this case, place a 200ohms (0.25W) resistor across the two data line terminals pins one and two on the Furse ESP SL06/I.

 Note: For further information please contact our technical support team at (800) 968-2026 or email [email protected]

.

When wiring the Modbus connections the twisted pairs must be as follows:


Orange

Blue

White




Pair

Pair one

Pair two



Installation

67

Wiring Diagram 5 – Modbus to Profibus converter module wiring



Installation

4.13.3

Readable Parameters of the Profibus Module

The data available to the Profibus network is two (16-bit) words, each word occupying two hex address locations as follows:

Module

Internal Name Parameter

0x0000 Sample Point 1 Last

Reading: Year

0x0002

0x0004

Sample Point 1 Last

Reading: Month

Sample Point 1 Last

Reading: Day

0x0006

0x0008

0x000A

0x000C

0x000E

0x0010

0x0012

Sample Point 1 Last

Reading:

Sample Point 1 Last

Reading:

Sample Point 1 Last

Reading: Second

Sample Point 1 Last

Reading: CH4 x 10

Sample Point 1 Last

Reading: CO2 x 10

Sample Point 1 Last

Reading: O2 x 10

Sample Point 1 Last

Reading: Internal Cell

0x0014

Example e.g. 0x07E0 (2016 dec) is 2016 or

High Byte 7x256 +Low Byte 0x224 e.g. 0x0259 (601 dec) is 60.1% or

High Byte 2x256 +Low Byte 0x89 e.g. 0x03E8 (1000 dec) is

1000ppm or High Byte 3x256

+Low Byte 0x232

0x0016

Sample Point 1 Last

Reading:

Sample Point 1 Last

Reading: Gas Flow

0x0018

0x001A

0x001C

Barometric Pressure

Sample Point 2 Last

Reading: Year

Sample Point 2 Last e.g. 0x0122 (290 dec) is

290ml/min or High Byte 1x256

+Low Byte 0x34 e.g. 0x03E1 (993 dec) is 993mbar or High Byte 3x256 +Low Byte

0x225 e.g. 0x07E0 (2016 dec) is 2016 or

High Byte 7x256 +Low Byte 0x224


0x001E

0x0020

0x0022

0x0024

0x0026

0x0028

0x002A

0x002C

0x002E

0x0030

0x0032

0x0034

0x0036

0x0038

0x003A

0x003C

0x003E

0x0040

© Copyright 2016

Reading: Month

Sample Point 2 Last

Reading: Day

Sample Point 2 Last

Reading: Hour

Sample Point 2 Last

Reading: Minute

Sample Point 2 Last

Reading: Second

Sample Point 2 Last

Reading: CH4 x 10

Sample Point 2 Last

Reading: CO2 x 10

Sample Point 2 Last

Reading: O2 x 10

Sample Point 2 Last


Sample Point 2 Last

Reading: External cell

Sample Point 2 Last

Reading: Gas Flow

Sample Point 3 Last

Reading: Year

Sample Point 3 Last

Reading: Month

Sample Point 3 Last

Reading: Day

Sample Point 3 Last

Reading: Hour

Sample Point 3 Last

Reading: Minute

Sample Point 3 Last

Reading: Second

Sample Point 3 Last

Reading: CH4 x 10

Sample Point 3 Last


Installation

69 e.g. 0x0259 (601 dec) is 60.1% or



+Low Byte 0x232 e.g. 0x0122 (290 dec) is


+Low Byte 0x34 e.g. 0x07E0 (2016 dec) is 2016 or



OMBG3000 – Rev1

0x004A

0x004C

0x004E

0x0050

0x0052

0x0054

0x0056

0x0058

0x005A

0x005C

70

Installation

0x0042

0x0044


Reading: CO2 x 10

Sample Point 3 Last

Reading: O2 x 10

Sample Point 3 Last


0x0046

0x0048

Sample Point 3 Last


Sample Point 3 Last

Reading: Gas Flow

0x005E

0x0060

0x0062

Sample Point 4 Last

Reading: Year

Sample Point 4 Last

Reading: Month

Sample Point 4 Last

Reading: Day

Sample Point 4 Last

Reading: Hour

Sample Point 4 Last

Reading: Minute

Sample Point 4 Last

Reading: Second

Sample Point 4 Last

Reading: CH4 x 10

Sample Point 4 Last

Reading: CO2 x 10

Sample Point 4 Last

Reading: O2 x 10

Sample Point 4 Last


Sample Point 4 Last


Sample Point 4 Last

Reading: Gas Flow

Alarm 1

OMBG3000 – Iss.01 e.g. 0x03E8 (1000 dec) is










+Low Byte 0x34

0= No Alarm,

© Copyright 2016


Installation

71

0x0064

0x0066

0x0068

0x006A

0x006C

0x006E

0x0080

Alarm 2

Alarm 3

Alarm 4

Alarm 5

Alarm 6

Alarm 7

Current sample Point

1=Triggered,

2=Triggered and in recovery zone

4 = Latched

8 = Muted

9 = Triggered alarm and muted

A = Recovering alarm and muted

1 to 4

The Profibus module updates the readings from the BIOGAS 3000 every 2.5 seconds.

Successful communication between the Modbus output and the Profibus module is indicated by the subnet status light ‘5’ on the module showing green. If for any reason the communications is intermittent or fails, the light flashes red or is permanently red, and the value being read is cleared to zero and not frozen with a previous value. Monitoring for an example the year, month and day for non-zero values will gain confidence that communications is ongoing.



Installation

4.14

Profinet Digital Output

The Profinet option for the BIOGAS 3000 is via a Modbus to Profinet converter module. The converter is a Profinet slave module and acts as an interface between the Modbus output of the BIOGAS 3000 and Profinet network.

Warning The Modbus to Profinet converter module for the

BIOGAS 3000 is not ATEX or IECEx certified and must be housed in a non-hazardous location or within a flameproof enclosure. This is the responsibility of the owner of the equipment.

The BIOGAS 3000 Modbus terminals must only be used for standard Modbus communications; no other connections must be made. Connections outside of this could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.

 Note: The Profinet module can be purchased as a post-sale accessory and upgraded on site by the user, see LANDTEC part number BG3K.S4 in

BIOGAS 3000 Consumable Products .

For wiring to the Modbus terminals from the Profibus module, see section

Modbus Digital Output .

4.14.1

Configuration of the Profinet Module

The Profinet module can be configured using the GSDML file supplied on the enclosed CD. Follow the instructions on the supplied installation sheet to configure the module for the Profinet sub-network.

In addition, the Modbus port on the BIOGAS 3000 must be configured as followed:

Node Address 1

Baud Rate 9600

Parity Even

Stop Bits

Termination

1

On




Installation

73

To configure the Modbus port on the BIOGAS 3000, refer to section Configure

Modbus Slave in this operating manual.

4.14.2

Wiring the Profinet Module







Requirements .


The power supply for the Modbus to Profinet converter module must not be taken from the BIOGAS 3000. Using the supply from the BIOGAS 3000 could make the equipment unsafe resulting in a hazard and invalidate the ATEX/IECEx certification.




The input voltage range to the BIOGAS 3000 Modbus terminals must not exceed -7 to +12V and the current


74

Installation

Operating Manual must not exceed 83.3mA. Operating outside of this range will invalidate the ATEX/IECEx certification.

Wire the outputs in accordance with Wiring Diagram 6 - Modbus to Profinet converter module wiring

. In addition, Wiring Diagram 2 – Modbus may also be

useful for wiring to the BIOGAS 3000 Modbus outputs.

For optimum performance, it is recommended that screened twisted pair cable be used.



 Note: If the distance between the BIOGAS 3000 and the Profinet converter module is greater than 200m, it may be necessary to add a termination resistor at the Profinet end to ensure noise-free communications. In this case, place a 200ohms (0.25W) resistor across the two data line terminals pins one and two on the Furse ESP SL06/I.


.

When wiring the Modbus connections the twisted pairs must be as follows:


Orange

Blue

White




Pair

Pair one

Pair two



Installation

75

Wiring Diagram 6 - Modbus to Profinet converter module wiring



Installation

4.14.3

Readable Parameters of the Profinet Module

The data available to the Profinet network is two (16-bit) words, each word occupying two hex address locations as follows:

Module

Internal Name Parameter

0x0000 Sample Point 1 Last

Reading: Year

0x0002

0x0004

Sample Point 1 Last

Reading: Month

Sample Point 1 Last

Reading: Day

0x0006

0x0008

0x000A

0x000C

0x000E

0x0010

0x0012

Sample Point 1 Last

Reading:

Sample Point 1 Last

Reading:

Sample Point 1 Last

Reading: Second

Sample Point 1 Last

Reading: CH4 x 10

Sample Point 1 Last

Reading: CO2 x 10

Sample Point 1 Last

Reading: O2 x 10

Sample Point 1 Last


0x0014

Example e.g. 0x07E0 (2016 dec) is 2016 or




+Low Byte 0x232

0x0016

Sample Point 1 Last

Reading:

Sample Point 1 Last

Reading: Gas Flow

0x0018

0x001A

0x001C

Barometric Pressure

Sample Point 2 Last

Reading: Year

Sample Point 2 Last e.g. 0x0122 (290 dec) is


+Low Byte 0x34 e.g. 0x03E1 (993 dec) is 993mbar or High Byte 3x256 +Low Byte

0x225 e.g. 0x07E0 (2016 dec) is 2016 or



0x001E

0x0020

0x0022

0x0024

0x0026

0x0028

0x002A

0x002C

0x002E

0x0030

0x0032

0x0034

0x0036

0x0038

0x003A

0x003C

0x003E

0x0040

© Copyright 2016

Reading: Month

Sample Point 2 Last

Reading: Day

Sample Point 2 Last

Reading: Hour

Sample Point 2 Last

Reading: Minute

Sample Point 2 Last

Reading: Second

Sample Point 2 Last

Reading: CH4 x 10

Sample Point 2 Last

Reading: CO2 x 10

Sample Point 2 Last

Reading: O2 x 10

Sample Point 2 Last


Sample Point 2 Last


Sample Point 2 Last

Reading: Gas Flow

Sample Point 3 Last

Reading: Year

Sample Point 3 Last

Reading: Month

Sample Point 3 Last

Reading: Day

Sample Point 3 Last

Reading: Hour

Sample Point 3 Last

Reading: Minute

Sample Point 3 Last

Reading: Second

Sample Point 3 Last

Reading: CH4 x 10

Sample Point 3 Last


Installation

77 e.g. 0x0259 (601 dec) is 60.1% or








OMBG3000 – Rev1

0x004A

0x004C

0x004E

0x0050

0x0052

0x0054

0x0056

0x0058

0x005A

0x005C

78

Installation

0x0042

0x0044


Reading: CO2 x 10

Sample Point 3 Last

Reading: O2 x 10

Sample Point 3 Last


0x0046

0x0048

Sample Point 3 Last


Sample Point 3 Last

Reading: Gas Flow

0x005E

0x0060

0x0062

Sample Point 4 Last

Reading: Year

Sample Point 4 Last

Reading: Month

Sample Point 4 Last

Reading: Day

Sample Point 4 Last

Reading: Hour

Sample Point 4 Last

Reading: Minute

Sample Point 4 Last

Reading: Second

Sample Point 4 Last

Reading: CH4 x 10

Sample Point 4 Last

Reading: CO2 x 10

Sample Point 4 Last

Reading: O2 x 10

Sample Point 4 Last


Sample Point 4 Last


Sample Point 4 Last

Reading: Gas Flow

Alarm 1

OMBG3000 – Iss.01 e.g. 0x03E8 (1000 dec) is










+Low Byte 0x34

0= No Alarm,

© Copyright 2016


Installation

79

0x0064

0x0066

0x0068

0x006A

0x006C

0x006E

0x0080

Alarm 2

Alarm 3

Alarm 4

Alarm 5

Alarm 6

Alarm 7

Current sample Point

1=Triggered,

2=Triggered and in recovery zone

4 = Latched

8 = Muted

9 = Triggered alarm and muted

A = Recovering alarm and muted

1 to 4

The Profinet module updates the readings from the BIOGAS 3000 every 2.5 seconds.

Successful communication between the Modbus output and the Profinet module is indicated by the subnet status light ‘5’ on the module showing green. If for any reason the communications is intermittent or fails, the light flashes red or is permanently red, and the value being read is cleared to zero and not frozen with a previous value. Monitoring for an example the year, month and day for non-zero values will gain confidence that communications is ongoing.

4.15

Heater Option

If purchased at the point of sale, the equipment will be fitted with a 100W heater (suitable for the relevant mains input voltage), control thermostat, and enclosure insulation. The thermostat is pre-set to 15°C (59⁰F) and cannot be adjusted.



Installation

4.16

Final Checks



Ensure all gas connections to the system are leak free – refer to section

Pressure Test of this operating manual for instructions on how to

perform this.



Ensure the gas inlet and gas outlet ball valves are open (refer to

annotation 12 on



Figure 2 - BIOGAS 3000 internal components) these must be in the

vertical position.



Ensure the drain ball valve, if fitted, is closed (see annotation 9 on



Figure 2 - BIOGAS 3000 internal components), this must be in the

horizontal position.



Ensure the calibration ball valve is closed (see annotation 10 on



Figure 2 - BIOGAS 3000 internal components), this must be in the

vertical position.



Turn the power on to the system. Within one minute of power being applied, the module will turn on and display the BIOGAS 3000 logo,

shortly followed by the ‘system self-test’ screen (see Screen 2 - System

Self-Test ).



The first time the module is started after the self-test has successfully completed, the ‘first time run set-up wizard’ will begin – please refer to

section First Time Run Set-up in this manual for details of this process.



It is strongly recommended that a known concentration of gas be passed through the system to ensure that it still reading correctly

following installation. Refer to the Gas Check and Calibration section of

this operating manual for further information on this process.

Note: For further information please contact our technical support team at

(800) 968-2026 or email [email protected]

.



General Operating Instructions

5 General Operating Instructions

81

Warning Do not open when an explosive atmosphere is present.

5.1

Switching the BIOGAS 3000 System On

1) The module will automatically turn on when power to the system is

switched on. If this does not happen, refer to the Problem Solving section

of this operating manual.

 Note: It can take up to one minute for the BIOGAS 3000 module to power on. If it does not turn on at the point power to the system is applied, please wait one minute before pressing any keys on the module.

2) If the power on is successful, the ‘LANDTEC BIOGAS 3000’ logo will appear on screen and then the ‘System Self-Test’ will commence.

Screen 1 - Power on

5.2

Self-Test

 Note: If the system has an invalid time and date setting, the operator will be prompted to correct this before a self-test commences.

When switched on the module will perform a pre-determined self-test sequence taking approximately sixty seconds. During the self-test, the




percentage complete is shown and remains on screen until the self-test is completed.

Screen 2 - System Self-Test

During this time, many of the system’s functions are tested, including:



Testing of the CH4, CO2, O2, reference, barometer, internal cell, external cell, and transducers is performed continuously over a short period to check for faults and instability



The pump is switched on and the system checked for blockages



The next service due date is checked



Valid communications to the Interface PCB is checked



Test whether the ‘first time run set-up’ is required.

If no faults are found, then the first time set-up or monitoring will begin.



Note: After completion, if any non-critical failures occur then Screen 3 -

Self-test finished with warnings screen is shown.

 Note: If the fault is ‘service overdue’ or a channel warning (non-critical) then the user can continue to the next stage by pressing the right soft key

‘Continue’. The BIOGAS 3000 will continue automatically after thirty seconds if continue is not pressed.






Note: If any critical faults occur, refer to section Critical Faults .

83

Screen 3 - Self-test finished with warnings

5.3

First Time Run Set-up

1) When switching on the module for the first time the system will detect the first time run conditions and run set-up mode. The BIOGAS 3000 is designed to be fully configurable by the end-user without LANDTEC support or configuration.

Screen 4 - First time run set-up

2) Press the right soft key to ‘Continue’.




3) Configure the time that the daily air purge will commence. For more

information on how to do this, refer to section Daily Air Purge .

 Note: This option will only be present on BG3KE variants.

4) Configure the sampling options for the various sample points. For more

information on how to do this, refer to section Sample Times .

 Note: On a BG3KE variant without an external sensor, this option is not present.

 Note: On a BG3KE variant with an external sensor, this screen will be specifically for the external sensor sampling option only as the rest of the system will measure continuously.

5) Customise the relay configuration. For more information on how to do

this, refer to section Configure Relays .

6) Configure alarms (if set during the relay configuration option). For more

information on how to do this, refer to section Configure Alarms .

7) Configure Modbus slave (if being used). For more information on how to

do this, refer to section Configure Modbus Slave .

8) Configure analogue outputs (if being used). For more information on how

to do this, refer to section Configure Analog Outputs .

9) Define whether an administrator passcode is required on the system. For

more information on how to do this, refer to section Admin Passcode .

10)

Once the first time run set-up is complete, you will arrive at Screen 28 -

Gas Check

. To perform this, refer to section Gas Check and Calibration . To

skip and begin monitoring, press the right soft key to ‘Exit’ (not recommended).




85

5.4

Gas Readings Screen

Screen 5 - Gas readings is considered the normal operating screen and all

options are carried out from this starting point:

2

17

3

16

4

5

6

15

7

14

8 9 10 11

Screen 5 - Gas readings

12 13

 Note: The data shown on this display will be dependent on the system variant and the option(s) that was selected at the point of sale.

1.

Time and date

Displays the time and date and is continuously updated.

2.

Sample point status

This indicates to the user the current sample point being monitored.

Sample point 1

Sample point 2

Sample point 3




Sample point 4

Idle – waiting for next cycle to begin.

3.

Current operation

Details the current operation for the sample point and cycle:

Sampling from sample point

System air purge following sample

Idle – waiting for next cycle to begin

4.

Operation time remaining

This is the time remaining for the current operation.

5.

Cycle time remaining

This is the time remaining for the complete cycle. When it counts to zero, the next cycle will commence, thus starting at sample point 1 again.

6.

Pump flow rate

This is the pump flow rate in ml/min. If this drops below 75ml/min, the reading will have an amber background and the system will flow fail and stop sampling

after fifteen seconds – see Low Flow / Flow Fail for more information.

7.

View alarms

Accessed using the left soft key, it takes the user to the alarm summary screen.

See Alarms section.




87

8.

Catchpot full icon

Indicates to the user that there is liquid in the catchpot and it needs emptying.

9.

Service icon

An indication to the user that the module is due for service. See Service

section.

10.

Stop sampling

Press the middle soft key to stop the sample process and freeze the outputs at their last known value. This can be useful when maintenance on site may be

required. See Stop Sampling section.

11.

Non-critical fault warning

This icon displays when there is a non-critical fault present on the system. A non-critical fault is a fault that will not stop the system from functioning. See

Fault Detection for more information.

12.

Scroll left

Use key ‘4’ to scroll through the previously stored gas readings. This will display the readings in memory for the data being output for the particular sample point shown.

13.

View faults

Press the right soft key to view the faults summary screen.




14.

Module firmware/language

Displays the firmware version of the module and current language setting.

15.

Scroll right

Use key ‘6’ to scroll through previously stored gas readings. This will display the readings in memory for the data being output for the particular sample point shown.

16.

Current view

Indicates which sample point the data on screen is representing with a number in the eye. These icons are the same as the sample point status icons. An eye without a number represents live readings for the current sample point being monitored.

17.

Gas readings

Displays the readings for the gases available. Green text indicates the reading is live. Blue text indicates the reading is a stored reading against the sample point. If the gas channel is an external cell, “(external)” will be shown below the gas name.

5.5

Alarms

5.5.1

Notification

 Note: For information on how to set alarms, please refer to section

Configure Alarms .

When an alarm condition has been met, the alarming channel will become highlighted with a bell icon and the ‘View Alarm’ soft key becomes red. An example screen is shown below of a channel with an active alarm.




89

Screen 6 - Alarm notification

The following notifications are available on the BIOGAS 3000:

Icon Definition

The alarm is active and the associated relay has been de-energized.

The alarm is active but the channel is within its recovery zone. The associated relay remains de-energized until the recovery value is met.

This is the latched alarm indicator. This indicates a channel has alarmed and recovered. During this notification, the relay remains deenergized until the alarm notification has been acknowledged by the operator.

The alarm has been silenced by the operator and the associated relay is energized. The alarm condition on the system remains active in the background until the recovery condition is met.

5.5.2

Viewing Alarms

To view an alarm, from the ‘Gas Readings Screen’ press the left soft key to go

to Screen 7 - Alarms summary :




Screen 7 - Alarms summary

This screen will detail all alarm conditions set by the operator. It will detail the condition for the alarm to trigger, the status (inactive, triggered, latched, or recovering), the time and date of the alarm, and the associated relay.

Pressing key ‘4’ and key ‘6’ scrolls the user through the relays available for alarms. This will also summarize inactive alarms.

Pressing the left soft key (‘Mute’) on an active alarm will disable the alarm and re-energizes the associated relay until the condition is cleared.

Pressing the left soft key (‘Clear Latch’) on a latched alarm will unlatch the alarm, clearing its status and re-energizes the associated relay.

5.6

Stop Sampling

From the ‘Gas Readings Screen’, pressing the middle soft key will ‘Stop

Sampling’. At this point, the sampling process is stopped, all solenoid valves are closed, and the outputs are frozen at their last known value. The following screen will be presented to the user:




91

Screen 8 - Sampling Stopped

Pressing the left soft key will ‘Restart’ the sampling process and return the user to the ‘Gas Readings Screen’.

Pressing the middle soft key will fix the outputs to the pre-determined safe values. These are shown in the table onscreen.

Pressing the right soft key allows the user to edit the safe values. For more

information on this, please see Configure Analog Outputs .

5.7

Menu

The menu enables the operator to select options to set-up specific parameters and perform operational tasks.

The menu is divided in to three areas:

1) Settings – this menu appears from the ‘Gas Readings Screen’ when pressing the ‘Menu’ key

2) Calibration – this menu is accessed from either the ‘Settings’ menu or the

‘Device Info’ menu by pressing the middle soft key

3) Device Info – the device information menu is accessed from either the

‘Settings’ menu by pressing the left soft key.




5.7.1

Settings Menu

Depending on the option chosen at manufacture, the following options are available from the settings menu:

1) Sample Times

 Note: On a BG3KE with an external cell, this option will be for the external cell sample options as the rest of the system runs continuously.

 Note: On a BG3KE without an external cell, this option will be the daily air purge.

2) Configure Alarms

3) Configure Interface

4) Adjust Backlight

5) Set Time and Date

6) Admin Passcode

7) Daily Air Purge

 Note: This option is only available on BG3KE variants.

An example of the ‘Settings’ menu is shown below.

OMBG3000 – Iss.01

Screen 9 - Settings Menu

© Copyright 2016



93

Following a change to ‘Sample Times’, ‘Configure Interface’, or ‘Daily Air

Purge’, when returning to the ‘Gas Readings Screen’, the system will apply the new configuration once ‘Confirm’ is pressed using the left soft key.

Screen 10 - Confirm new configuration

5.7.1.1

Sample Times

This option allows the operator to define the duration of each sample point (or the external sensor if the system is a BG3KE).

1) From the ‘Settings’ menu press key ‘1’ to select the ‘Sample Times’ option.

A summary screen will be shown.

© Copyright 2016

Screen 11 - Configure Sample Times (Non-E variant)

OMBG3000 – Rev1



Screen 12 - Configure Sample Times (E variant)

2) Press the right soft key to ‘Exit’ without saving any changes.

3) To edit a parameter, press the middle soft key to enter ‘Edit’ mode.

4) Using the scroll keys, select a sample point to edit (highlighted in the table) and select the field with the  key.

 Note: In addition to each sample point being editable, the ‘Sample’ time is also an editable parameter. This is the total time of the cycle before sample point 1 (or external cell) is monitored again.

OMBG3000 – Iss.01

Screen 13 - Edit Sample Point Times

© Copyright 2016



95

5) Press key ‘1’ to edit the sample duration or key ‘2’ to edit the air purge duration.

6) Key in a suitable time for the system and store using the  key.

 Note: Both parameters have minimum and maximum values that can be entered. If a time is outside of this range, the user will be prompted to enter a more suitable time.

7) Once a parameter has been changed, the left soft key becomes available to ‘Save and Exit’. Once pressed, the user will be returned to the summary screen.

 Note: If changing a duration exceeds the ‘Sample’ time, the ‘Sample’ time will automatically be updated to accommodate the change.

8) Press the right soft key to ‘Exit’ back to the ‘Settings’ menu.

5.7.1.2

Configure Alarms

This option allows the operator to define alarm conditions for a gas on any given sample point.

The relays operate in fail-safe mode. This means the relay is normally energized. When an alarm condition is met, the relay de-energizes.

 Note: The quantity of available alarms will be dependent on the relay

configuration, see Configure Relays section. The relay configuration

should be determined before configuring the alarms.

1) From the ‘Settings’ menu press key ‘2’ to select the ‘Configure Alarms’ option.




Screen 14 - Configure Alarms


3) To ‘Edit’ a parameter, press the middle soft key to enter edit mode. Using the scroll keys, select a parameter to edit (highlighted in the table) and select the field with the  key.

Definitions

Term

SP

Definition

The sample point (1, 2, 3, 4, or All) for which the alarm condition is to be monitored.

Alarm to trigger above the value. >

< Alarm to trigger below the value.

Disabled Alarm is disabled and will not activate.

Normal When an alarm has occurred and the gas concentration reaches its recovery value, the alarm will deactivate.

Latched When an alarm has occurred and the gas concentration reaches its recovery value, the alarm will remain activate until cleared by the operator.

The gas concentration for which the alarm condition will Value become active.

Recovery The gas concentration for which the alarm condition will recover.

4) Use the scroll keys to select the chosen parameter and select using the  key, or use the keypad to enter the gas concentration for the value followed by the  key to confirm.




97

5) Once a parameter has been changed, the left soft key becomes available to ‘Save and Exit’. Once pressed, the user will be returned to the ‘Settings’ menu.

 Note: Alarm settings become active immediately.

 Note: When any alarm setting is updated all active alarms will reset.

5.7.1.3

Configure Interface

This option allows the operator to configure the various interface options with the system to the client’s side. There are three options in this sub-menu:

1) Configure Analog Outputs

2) Configure Modbus Slave

3) Configure Relays

To ‘Exit’ this screen press the right soft key to return to the ‘Settings’ menu.

Configure Analog Outputs

This option allows the user to configure the six 4-20mA analog outputs. The user can define a gas on any given sample point and set the safe-value that is

output should the customer select this option via the Stop Sampling feature.

 Note: The safe value is a gas concentration that will force the 4-20mA and

Modbus registers to pre-fixed values. This is to prevent erroneous errors or alarm conditions in the user’s remote system whilst maintenance is being performed on the BIOGAS 3000 or any other plant equipment.

1) From the ‘Configure Interface’ menu press key ‘1’ to select the ‘Configure

Analog Outputs’ option.




Screen 15 - Configure Analogue Outputs


 Note: If the user has accessed the ‘Configure Analogue Outputs’ screen via the ‘Stop Sampling’ screen, the user will be returned to the ‘Stop

Sampling’ screen.

3) To ‘Edit’ a parameter, press the middle soft key to enter edit mode. Using the scroll keys, select a parameter to edit (highlighted in the table) and select the field with the  key.

4) Use the scroll keys to select the chosen parameter and select using the  key, or use the keypad to enter the gas concentration for the safe value followed by the  key to confirm.

5) Once a parameter has been changed, the left soft key becomes available to ‘Save and Exit’. Once pressed, the user will be returned to the

‘Configure Interface’ menu.

Configure Modbus Slave

This option allows the user to configure the Modbus digital output of the

BIOGAS 3000. The user can change the following parameters:



Slave Address – this is the address of the BIOGAS 3000 on the bus



Baud Rate – Information is transferred in a communication channel at this rate. Modbus is typically 9600 or 19200




99



Data Bits – the number of bits used to represent one character of data.

This parameter cannot be changed



Parity – the parity bit is used as a simple error detection algorithm.

Setting parity to odd will result in an odd number of 1 bits



Stop Bits – this is the number of bits to identify the end of a byte. This is typically set to 1



Termination – this is used to enable/disable the termination resistor within the system. This is typically enabled for systems that are the first or last connection on the bus.


Modbus Slave’ option.

Screen 16 - Configure Modbus Slave


3) To ‘Edit’ a parameter, press the middle soft key to enter edit mode. Using the scroll keys, select a parameter to edit (option will be highlighted) and select the field with the  key.

4) Use the scroll keys to select the chosen parameter and select using the  key, or use the keypad to enter the numeric required followed by the  key to confirm.






Configure Relays

This option allows the user to configure the eight relays in the system. ‘Relay 8’ is the fault relay and cannot be changed.


Relays’ option.

Screen 17 - Configure Relays


3) Press key ‘1’ to change the ‘Mode’ of the relays. Available options are:



Alarms only – Relays are only used to indicate an alarm status (refer to

Configure Alarms for information on how to define alarm settings)



Indicate 4-20mA outputs sample point – This mode enables a relay for when the 4-20mA signal is valid for a given sample point. This is useful if a 4-20mA output is being used to obtain the gas reading for a single gas channel across all sample points




101

SP1 Solenoid

SP2 Solenoid

SP3 Solenoid

4-20mA Output

SP1 Relay

SP2 Relay

SP3 Relay

Figure 10 - 4-20mA notification



Indicates current sample point solenoid – This mode enables a relay for when a sample point is being monitored. This is useful if the operator needs to know when a sample point is being monitored

SP1 Solenoid

SP2 Solenoid

SP3 Solenoid

4-20mA Output

SP1 Relay

SP2 Relay

SP3 Relay

Figure 11 - Sample point notification

 Note: When enabling the relays for 4-20mA or sample point notification, the remaining available relays will automatically be defaulted to ‘Alarms’.

4) Press key ‘2’ to define whether a relay is used to indicate when an air purge is occurring. If this option is selected, this will automatically be defaulted to ‘Relay 5’.

5) Press key ‘3’ to define whether a relay is used to indicate when the catchpot contains liquid and needs emptying. If this option is selected, this will automatically be defaulted to ‘Relay 7’.




 Note: If the system was fitted with the auto-drain option at point of manufacture, this option will not be available in the ‘Configure Relays’ screen.



5.7.1.4

Adjust Backlight

This option allows the operator to set the brightness of the backlight and the timer for when it will auto dim. In addition, the backlight can also be controlled using the ‘backlight’ key at any time. Having a brighter backlight will improve the readability of the display in bright sunlight.

1) From the ‘Settings’ menu press key ‘4’ to select the ‘Adjust Backlight’ option.

Screen 18 - Adjust Backlight


3) Press key ‘6’ to increase the brightness of the display or use key ‘4’ to reduce the brightness.

4) Press key ‘1’ to set whether the backlight auto-dims after a timeout or is always on and controlled manually by the ‘Backlight’ key.




103

5) If ‘Auto Dim’ is enabled, press the middle soft key to edit the auto dim timeout. Use the keypad to enter a value and store using the  key.

6) Once the settings have been changed, the left soft key becomes available to ‘Save and Exit’. Once pressed, the user will be returned to the


5.7.1.5

Set Time and Date

This option allows the user to set the time and date on the system. The time and date is recorded alongside the reading taken for each sample point.

1) From the ‘Settings’ menu press key ‘5’ to select the ‘Set Time and Date’ option.

Screen 19 - Set Time and Date


3) Press the left soft key to toggle the date format. Available options are

DD/MM/YY, MM/DD/YY, and YY/MM/DD.

4) Press key ‘1’ to edit the date or key ‘2’ to edit the time.

5) Key in a suitable date or time for the system and store using the  key.

 Note: Invalid time or date entries will not be accepted.

6) Once the setting has been changed, it is stored immediately.




 Note: At this point, the new setting is written to the Interface PCB. If this is not successful, an error message is displayed and the setting will need to be entered again.

7) Press the right soft key to ‘Exit’. Once pressed, the user will be returned to the ‘Settings’ menu.

5.7.1.6

Admin Passcode

The administrator passcode protects against unauthorised changes to the system’s set-up. The following screens are passcode protected:



Sample Times



Daily Air Purge (if enabled)



Configure Alarms



Configure Analog Outputs



Configure Modbus Slave



Configure Relays



Admin Passcode



Calibration menu

1) From the ‘Settings’ menu press key ‘6’ to select the ‘Admin Passcode’ option.




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Screen 20 - Set Administrator Passcode


3) Press key ‘1’ to enable or disable the administrator passcode.

4) To ‘Edit’ the current passcode, press the middle soft key to enter edit mode. Using the keypad, enter a four-digit passcode and press the  key to commit the passcode.

5) Once committed, the right soft key becomes available to ‘Save and Exit’.

Once pressed, the user will be returned to the ‘Settings’ menu.

6) Alternatively, the operator can press the left soft key to ‘Cancel’ their changes. This option will also return the user to the ‘Settings’ menu.

Administrator Passcode Required Prompt

When trying to edit a parameter that is passcode protected, the user will be

prompted with Screen 21 - Administrator Passcode Required prompt .




Screen 21 - Administrator Passcode Required prompt

For the user to edit the setting, they must enter the correct passcode followed by the  key. Once the passcode has been entered once, it will not need entering again whilst remaining in the menus.

Once the user has returned to the ‘Gas Readings Screen’, any further changes to the passcode-protected settings will require the administrator passcode to be entered again.

5.7.1.7

Daily Air Purge

This screen allows the operator to define the settings for the daily air purge.

The daily air purge is only available on the continuous BG3KE variants to prolong the life of the O

2

sensor. All other variants receive an air purge after each sample point is monitored.

1) From the ‘Settings’ menu press key ‘7’ to select the ‘Daily Air Purge’ option.

 Note: For a BG3KE without an external sensor, the daily air purge will be option ‘1’ in the ‘Settings’ menu.




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Screen 22 - Daily Air Purge settings


3) Press key ‘1’ to edit the start time, key ‘2’ to edit the air purge duration, or key ‘3’ to edit the wait time.

 Note: The ‘Wait Time’ is the time the system waits before updating the outputs when sampling is recommenced after a daily air purge, gas check, calibration, or stopping the sampling process. It is important that a suitable time be entered to ensure the system readings have stabilized to avoid false alarms.

 All parameters have minimum and maximum values that can be entered.

If a time is outside of this range, the user will be prompted to enter a more suitable time.

4) Key in a suitable time for the system and store using the  key.

5) Once a parameter has been changed, the left soft key becomes available to ‘Save and Exit’. Once pressed, the user will be returned to the ‘Settings’ menu.




5.7.2

Device Information Menu

The device information menu contains information relating to the system. The following options are available from the ‘Device Info’ menu:

1) System Information

2) Event Log

3) Diagnostics

An example of the ‘Device Info’ menu is shown below.

Screen 23 - Device Information menu

5.7.2.1

System Information

This option allows the operator to view important information about their system, such as the serial number of the module, next service due date, and firmware version. This information may be required when contacting your local distributor or our technical support team for assistance.

1) From the ‘Device Info’ menu press key ‘1’ to select the ‘System

Information’ option.




109

Screen 24 - System Information

2) Press the right soft key to ‘Exit’ back to the ‘Device Info’ menu.

3) Use the left soft key to scroll the page down and the middle soft key to scroll the page up.

5.7.2.2

View Event Log

The BIOGAS 3000 incorporates the facility to log significant events performed on the system via the event log. This can be used as an aid to monitoring the use of the system and used as a diagnostic tool if there is a problem.

The system stores ten logs each able to store 10kb of memory made up of events; 10kb is approximately 80-100 single event entries. Applicable events are stored in the event log automatically and no user intervention is required.

When the tenth log file is full, the events of log file one are deleted and replaced with log file eleven.

1) From the ‘Device Info’ menu press key ‘2’ to select the ‘View Event Log’ option.




Screen 25 - View Event Log


3) Use keys ‘4’ and ‘6’ to scroll through the available logs.

4) Use keys ‘2’ and ‘8’ to navigate up and down through the log page.

5) Press the middle soft key to ‘Delete All’ logs.

5.7.2.3

Diagnostics

This option allows the operator to view the diagnostics screen. The operator may be requested to view this screen if they contact their local distributor or our technical support team for assistance.

1) From the ‘Device Info’ menu press key ‘3’ to select the ‘Diagnostics’ option.




111

Screen 26 - Diagnostics


3) Use the left soft key to scroll the page down and the middle soft key to scroll the page up.




5.7.3

Calibration Menu

The following options are available in the calibration menu:

1) Gas check

2) Restore to Factory

3) Fit New Cell

An example of the ‘Calibration’ menu is shown below.

Screen 27 - Calibration menu

5.7.3.1

Gas Check

The ability has been provided to perform a gas check and calibration on the gas channels of the system. This ensures the accuracy of the system in its current operating condition. To ensure optimum performance please ensure your

BIOGAS 3000 module is returned for service and calibration on time.

 Note: Selecting a mixture within this option will stop the sampling process and freeze the outputs at their last known value.

1) From the ‘Calibration’ menu press key ‘1’ to select the ‘Gas Check’ option.




113

Screen 28 - Gas Check

2) Press the right soft key to ‘Exit’ back to the ‘Calibration’ menu.



Note: For more information on calibration, please refer to section Gas

Check and Calibration in this operating manual.

5.7.3.2

Restore to Factory

This option will reset the gas analyser to all of its factory programmed settings and will clear all user defined calibration points.

 Note: Selecting this option will stop the sampling process and freeze the outputs at their last known value.

1) From the ‘Calibration’ menu press key ‘2’ to select the ‘Restore to Factory’ option.




Screen 29 - Restore to Factory settings

2) Press the right soft key to ‘Abort’ which does not reset the calibration data and will return the operator to the calibration menu.

3) Press the left soft key to ‘Continue’, which resets the calibration data and will return the operator to the calibration menu.

 Note: Restoring the system to factory settings will stop the sampling process and freeze the outputs at their last known value.

5.7.3.3

Fit New Cell

This option should be selected when the user has installed a new precalibrated external cell or external sensor module (cell complete with PCB). It over-writes the current factory calibration values with the data provided with the cell.

 Note: Selecting this option will stop the sampling process and freeze the outputs at their last known value.

1) From the ‘Calibration’ menu press key ‘3’ to select the ‘Fit New Cell’ option.




115

Screen 30 - Fit New External Cell confirmation

2) Press the right soft key to ‘Exit’ and return to the ‘Calibration’ menu.

3) If fitting a new cell or complete module, confirm the cell type and range, and press the left soft key to ‘Continue’.

Screen 31 - Input new Slope and Offset

 Note: Alongside the new cell or complete module there will be a calibration certificate containing the new slope and offset figures. Both of these values need entering in to the appropriate fields in the above screen.




4) Press key ‘1’ to edit the ‘Slope’ or key ‘2’ to edit the ‘Offset’. Use the keypad to enter the numeric value and confirm with the  key.

5) Press the left soft key to ‘Save’ the new configuration to memory.

Following this, a prompt will appear advising the user to perform a calibration.

Screen 32 - User calibration recommendation

 Note: After a new cell or complete module is fitted, it is recommended that as a minimum a user zero be performed. For optimum accuracy, a span calibration should be performed in addition to a zero.

6)

Pressing the left soft key for ‘Calibrate’ will take the user to the ‘ Gas

Check ’ screen. Pressing the right soft key to ‘Exit’ will return the user to

the ‘Calibration’ menu.




117

5.8

Help Function

In some screens, there is a help screen available. An available help screen is indicated by a ‘?’ in the top right hand corner of the screen:

Screen 33 - Help screen available

To access the help screen, press the ‘?’ key on the keypad. The user can scroll through pages using key the left and middle soft keys. To exit, press the right soft key.

© Copyright 2016

Screen 34 - Help screen example

OMBG3000 – Rev1



5.9

BIOGAS 3000 Sampling Process

5.9.1

BG3K1, 2, 3, 4, and D Variants

Start

Complete first time run set-up

Sample Point

1 monitored

Sample Point

2 monitored

Sample Point

3 monitored

Sample Point

4 monitored

Outputs updated

Outputs updated

System Air

Purge

BG3K2/3/4/D

System Air

Purge

BG3K3/4

Outputs updated

System Air

Purge

BG3K4

Outputs updated

System Air

Purge

BG3K1 BG3K4 BG3K2/D BG3K3

System waits for remaining cycle time

Flow Chart 1 - BG3K1, 2, 3, 4, and D




119

5.9.2

BG3KE Variants

Start

Complete first time run set-up

Sample Point

1 monitored continuously

Outputs updated

External

Sensor?

Yes

No

No

Time of daily air purge?

Yes

Outputs frozen at last reading

Wait interval duration

External sensor air purged

© Copyright 2016

Daily air purge commences

Flow Chart 2 - BG3KE

External sensor monitored

Outputs updated

OMBG3000 – Rev1



5.10

Switching the BIOGAS 3000 System Off

The BIOGAS 3000 system can only be turned off at the switched mains supply

that is installed in section Mains Wiring .

The BIOGAS 3000 module can be turned off independently to the system. To do this, press and hold the on/off key for approximately two seconds. This will close all solenoids, switch off all pumps, trigger the fault relay, and freeze the outputs at their last known value. Power will remain to the system.

Screen 35 - Power off


6 Gas Check and Calibration


Gas Check and Calibration

121


6.1

Introduction

The BIOGAS 3000 system is carefully calibrated at manufacture and when returned for service using a number of gas concentrations and temperature points. However, it is sometimes desirable to carry out a gas check on the equipment to prove its accuracy and rectify any inaccuracies with a calibration process between services.

The BIOGAS 3000 measures CH

4

, CO

2

, and O

2

as standard with optional additional gases and these channels can be user calibrated. This section will describe in detail the correct procedure to gas check and calibrate these gas channels.

 Note: This does not replace the factory service and calibration.

 Note: If this calibration is completed incorrectly, it may decrease the accuracy of the system.

Four important terms that are used within this section are:

Gas check: This is where a known concentration of gas is applied to the system and its responses are checked with no adjustment being made.

Calibration: This is when an adjustment is made to the modules readings after a gas check has been performed, by either a zero, span, or both.

Zero: The point at which the system is calibrated when there is none of the target gas present.

Span: The point at which the system is calibrated when there is a known concentration of the target gas present.

 Note: A more detailed explanation of user calibration can be found in

section User Calibration Explained .




6.2

Required Equipment

6.2.1

Gas

User calibration of the system will greatly improve the data accuracy in the range of the calibration gas used and the environmental conditions for which the BIOGAS 3000 is calibrated. This may cause less accurate readings of concentrations outside of this calibrated range.

Users should select the correct calibration gas for the expected gas levels on their particular application. In addition, nitrogen (N

2

) can be used for a zero calibration. If this is not available, then clean ambient air can be used.

Warning Calibration gases can be dangerous. For each gas used, the appropriate material safety data sheet must be read and fully understood before proceeding.

6.2.2

Flow Regulator

It is recommended that the regulator available via LANDTEC be used as it has been configured to deliver a fixed flow of 300ml/min and correct pressure relief to avoid damage to the system (see LANDTEC part number GA6.8 in

BIOGAS 3000 Consumable Products ). As the regulator’s flow is factory set it

only requires a few turns to open, no adjustment will be necessary.

 Note: If using a regulator that was not supplied by LANDTEC, please ensure that the flow rate is adjusted to a maximum of 300ml/min.

Suitable pressure relief should be ensured to protect the system from damage because of over-pressurization – typically 3-5psi (200-350mbar).

Warning When the system is being calibrated, in cases of overpressurization, the 1/16” port on the red pressure relief valve (supplied with the LANDTEC pressure regulator) will release gas to protect the BIOGAS 3000 module.

It is recommended that the exhaust tubing from the pressure relief valve emerge in a well-ventilated area.

Ensure there are no leaks in the tubing and connections before carrying out a user calibration.




123

The calibration of the BIOGAS 3000 should be carried out by trained personnel taking all necessary precautions when using dangerous, explosive, or toxic gases.

6.3

Gas Mixtures

The BIOGAS 3000 provides the user with the ability to add, edit, or delete gas mixtures that can be used for the gas check and calibration process. There are three default mixtures:



Fresh Air – assumed values of fresh air are CH

4

0.0%, O

2

20.8, and all other optional gasses 0ppm. CO

2

is not available to calibrate in air.

 Note: The oxygen concentration is editable between 20.8% and 21.0% -

see Edit O2 in Fresh Air Mix .



Nitrogen Zero – known values of CH

4

0.0%, O

2

0.0%, and all other optional gasses 0ppm. CO

2

is not available to calibrate in nitrogen.

 Note: A new mixture can be created which will allow the CO

2

channel to be zeroed if required.



60/40 Mix – default values of CH

4

60.0%, O

2

40.0%, with O

2

0.0% and all other optional gasses 0ppm.

 Note: The CH

4

and CO

2

values should be edited with the true bottle concentration.




Screen 36 - Gas Check

6.3.1

Adding a Mixture

In addition to the three default mixtures, the BIOGAS 3000 also supports the addition of three user definable mixtures. To add a mix:

1) In the ‘Gas Check’ screen, press the middle soft key to ‘Add’ a mix.

Screen 37 - Add gas mixture

2) Using the keypad, enter a name for the mixture. Pressing the left soft key toggles between letter and number entry. Press  when complete.




125

Screen 38 - Edit gas mix details

3) Using the scroll keys, select an editable field and press  the key to edit:



Name, Description and Bottle ID are text and number fields



Gas channels are number fields. Enter the gas concentration of the bottle in percent or ppm. A ‘-‘ will not perform an action on the channel. Entering a gas concentration will span the channel, entering a

‘0’ will zero the channel.

4) Press the middle soft key to ‘Save and Exit’.

 Note: The gas concentrations for the 60/40 Mix and the three customer definable mixtures are editable using the left soft key when highlighting the mix in the ‘Gas Check’ screen.

6.3.2

Deleting a Mix

 Note: The three default mixtures cannot be deleted.

To delete a gas mix in the ‘Gas Check’ screen:

1) Use the scroll keys to highlight the mix to be deleted.

2) Press the middle soft key to ‘Add/Delete’.




Screen 39 - Add or delete mix

3) Press the middle soft key to ‘Delete’.

4) Press the left soft key (Yes) to confirm deletion.

6.3.3

Edit O

2

in Fresh Air Mix

The concentration of oxygen in the fresh air mix is editable between 20.8 and

21.0%. To change the concentration used:

1) Highlight the ‘Fresh Air’ mix.

2) Press the left soft key to edit the ‘Oxygen Level’.

OMBG3000 – Iss.01

Screen 40 - Edit oxygen concentration

© Copyright 2016



3) Pressing the right soft key will ‘Cancel’ the edit.

127

4) Key in the concentration you wish to span the oxygen channel to in fresh air, followed by the  key to confirm. The operator will be returned to the

‘Gas Check’ screen.




6.4

Connecting a Gas Bottle to the BIOGAS 3000

This section explains how to connect a gas bottle to the BIOGAS 3000 system in preparation for a gas check or calibration.

Op. Image

1


Mains voltages are present within the BIOGAS 3000 system and great care needs to be observed. If there is any uncertainty, seek advice from a professional.

Pressurized gas bottles can be dangerous and great care needs to be taken when in use.

Alternatively, contact our technical support team at


to arrange a site visit. (Please note a charge may be applicable.)

Instruction

Ensure the drain valve is closed.

 Note: Auto-drain systems will not have a drain valve.

2 Ensure the gas inlet and gas outlet valves are closed.


3



129

Disconnect the QRC from the top of the catchpot.

4

 Note: Ensure the pressure regulator is turned off.

Attach the pressure regulator to the gas bottle and ensure it is adequately tightened.

5

Warning Ensure that the regulator is fitted to the bottle at arm’s length in case of a gas leak.

Ensure that no cross threading occurs during tightening of the regulator.

During the rare occasion that gas does leak from the seal, place the bottle and regulator on the floor and leave the area until the leak has stopped. DO NOT attempt to solve the leak as this could be dangerous.

Ensure that the gas bottle has adequate pressure (i.e. is not empty).




6 Attach the tubing from the gas bottle and regulator to the QRC.




131

6.5


After the BIOGAS 3000 system has been installed and pressure tested, it is recommended that a gas check be performed to ensure it is still accurate, as damage could have occurred during installation and/or transit.

In addition, a gas check can be performed as part of regular maintenance to validate the accuracy of the system and determine whether a user calibration is required.

The gas used for a check or calibration should be representative of the gas within the application, for example, 60% CH

4

balanced with 40% CO

2

.

The BIOGAS 3000 performs a gas check before providing the user with a decision. If the result of the check is that the instruments accuracy is good, a calibration may not need to be performed. At this point, the user can decide to record the results and exit. Alternatively, the accuracy may need improving and at this point, the user can decide to correct the errors by way of a user calibration. This will adjust the figures and record the calibration to memory.

The Flow Chart 3 - Gas Check and Calibration is a simple overview of the

process:

 Note: It is LANDTEC’s recommendation that a zero check and calibration is carried out before a span check and calibration.

 Note: When selecting a mixture in the ‘Gas Check’ screen, the sampling process will be stopped.




Start

Edit gas mix

Yes

Does gas mix need updating to match bottle?

No

Select gas mix

Sampling stops and outputs are frozen at their last known reading

Set calibration valve to ‘span’

Turn gas in and gas out valves off

Disconnect

QRC from catchpot

Turn gas in and gas out valves on

Fresh air or gas bottle?

Gas

Connect gas to QRC

Set calibration valve to ‘OFF’

Span O

2

only or span O

2

and zero others?

Air

Press

‘Check’

Reconnect

QRC

No

Wait for air purge

Yes

Gas concentration greater than ext. cell range?

Wait for countdown

Retry

Check

‘status’ of gases

Retry, Set

Calibration, or

Record

Record

Records gas check to the event log.

Does not calibrate system

Calibrate

Refer to

‘Problem

Solving’ section

No

Was calibration successful?

Yes

Updates calibration of system

Press

‘Reconnect’

Flow Chart 3 - Gas Check and Calibration

Turn off gas and disconnect

Gas

Fresh air or gas bottle?

Air




133

6.6

Status Icons

Below are a list of status icons used after the gas check and calibration processes and their definition:

6.6.1

Post Gas Check

Icon Definition

Channel has not been checked

Recommends a calibration be performed

Channel is outside of limits – see User Calibration Explained

Channel is within limits and may not need adjusting

6.6.2

Post Calibration

Icon Definition

Channel has not been checked

Channel was not calibrated due to an error – see User

Calibration Explained

Channel was calibrated OK




6.7

Disconnecting a Gas Bottle from the BIOGAS 3000

This section explains how to disconnect a gas bottle from the BIOGAS 3000 system following a gas check or calibration.

Op. Image

1

2


Mains voltages are present within the BIOGAS 3000 system and great care needs to be observed. If there is any uncertainty, seek advice from a professional.

Pressurized gas bottles can be dangerous and great care needs to be taken when in use.

Alternatively, contact or our technical support team at


to arrange a site visit. (Please note a charge may be applicable.)

No image

Instruction

Ensure the pressure regulator is turned off.

Ensure the drain, gas inlet and gas outlet valves are still closed.

3

OMBG3000 – Iss.01

Ensure the gas bottle supply is turned off and disconnect the tubing of the gas bottle and regulator from the QRC.

© Copyright 2016

4

5

6

No image



135

Reconnect the system tubing by connecting the QRC to the top of the catchpot.

 Note: Ensure that the coupling ‘clicks’ in to place.

Remove the regulator from the gas bottle and store both appropriately to avoid damage.

Open the gas inlet and gas outlet valves.

 Note: The drain valve is to remain closed.

Warning It is critical that the connections are fully secured to ensure that no gas leaks in to the main enclosure.

Once the BIOGAS 3000 tubing has been reconnected, it

is recommended that a Pressure Test be completed to

ensure that the system is leak free.


136

Maintenance


7 Maintenance

This section outlines the maintenance requirements which the operator needs to perform on the system and instructions for user replaceable components.


.


The use of non-LANDTEC approved parts being fitted to the equipment may cause a hazard and will invalidate the ATEX/IECEx certification.

The system should not be altered in any way other than described in this operating manual. Alterations outside of this operating manual could cause a hazard, make the equipment unsafe voiding the warranty and ATEX/IECEx certification.

7.1

Maintenance Schedule

 Note: This maintenance schedule is a minimum guide and dependent upon the application and usage of the BIOGAS 3000 system, may need to be adapted accordingly.

As a minimum, LANDTEC recommends that each month the following be undertaken to ensure the BIOGAS 3000 system is in its optimum working and safe condition:



Inspect the BIOGAS 3000 system for damage



Review the installation location for continued suitability (i.e. physical and environmental conditions)



Check the main enclosure gasket for damage to ensure the IP rating can be maintained



Ensure terminals have remained tightened to the recommended torque setting and there are no visible signs of corrosion



Empty the catchpot (see Emptying the Catchpot )



Maintenance

137



Inspect, and replace if required, the coalescing catchpot filter (see

Replacing the Catchpot Filter )



Inspect, and replace if required, the inline PTFE filter (see Replacing the

Inline PTFE Filter )



Perform a pressure test to ensure there are no leaks (see Pressure Test )



Perform a gas check to determine the accuracy of the system and if

required a calibration (see Gas Check and Calibration ).

 Note: It is the operator’s responsibility to keep a record of when and what maintenance has been performed.

 Note: If you suspect the BIOGAS 3000 system to have been damaged and are unsure of the consequences of this, please contact our technical support team at (800) 968-2026 or email [email protected]

.

 Note: Inspection of the catchpot and inline filter may be required more frequently depending upon the application and the likelihood of liquid in the sample gas.

 Note: After performing a gas check or calibration, it may be necessary to perform a further pressure test on the equipment to ensure it has remained leak free.

Warning Dependent upon the application, the equipment can come in to contact with unsafe contaminants. It is therefore recommended that suitable PPE is identified and worn (such as gloves) and hands are washed thoroughly after maintenance is completed.


138

Maintenance


7.2

BIOGAS 3000 Consumable Products

Optional replacement parts may be purchased for the BIOGAS 3000 from your local distributor or LANDTEC directly:



Maintenance

Ref Description

A Catchpot with coalescing filter and built-in valve for systems without auto-drain

B Catchpot with coalescing filter and drainage tubing for systems with auto-drain

C BIOGAS 3000 Profibus option

D BIOGAS 3000 Profinet option

E Filter, Exhaust 1/4 MNPT (used as air purge filter)

F Inline PTFE filters (pack of 10)

Inline PTFE filters (pack of 30)

G Pre-calibrated external sensor module

H Check gas regulator used in conjunction with calibration gas canister. This valve controls the flow of gas – c/w safety valve.

I Pre-calibrated external sensor

J 5m length 4mm I.D tubing

K Calibration gas

L Coalescing filter for catchpot x 5

M Fuses

N External catchpot option

BG3K.S3

BG3K.S4

2008277/S

GA4.2

GA4.2(30)

Please contact us

GA6.8

Please contact us

GA3K.S6

Please contact us

GA3K.S1

Please contact us

GA3KP.S15

139

Part Number

BG3K.S1

BG3K.S2


140

Maintenance


7.3

Emptying the Catchpot


Mains voltages are present within the BIOGAS 3000 system and great care needs to be observed. If there is any uncertainty, seek advice from a professional or isolate the supply. Alternatively, contact your local distributor, or our technical support team at LANDTEC on

(800) 968-2026 or email [email protected] to arrange a site visit. (Please note a charge may be applicable.)

 Note: This process is only applicable for systems without auto-drain.

Op. Image

1

2

Instruction

From the ‘Gas Readings Screen’, press the middle soft key to ‘Stop

Sampling’.

 Note: If required, press the middle soft key once more to fix the outputs at their safe values.

Ensure the drain, gas inlet, and gas outlet valves are closed.


3

4 Open the drain valve to allow liquid to empty from the catchpot.

5

Warning The catchpot can hold approximately 90ml of liquid.

Dependent upon the application the liquid removed may be contaminated and should be discharged to an area where it is safe to do so.

This line may also vent sample gas for a brief period during each draining operation if the sample inlet and gas out valves are not closed.

Once the catchpot has emptied, close the drain valve.


Maintenance

141

Disconnect the QRC from the top of the catchpot.


142

Maintenance


6 Reconnect the system tubing by connecting the QRC to the top of the catchpot.

 Note: Ensure that the coupling ‘clicks’ in to place.

7



8 From the sampling stopped screen, press the left soft key to

‘Restart’ the monitoring process and return to the ‘Gas Readings

Screen’.

Warning Once all maintenance is completed, it is recommended

that a

Pressure Test

Pressure Test be completed to ensure that

the system is leak free.



Maintenance

143

7.4

Replacing the Catchpot Filter


Mains voltages are present within the BIOGAS 3000 system and great care needs to be observed. If there is any uncertainty, seek advice from a professional or isolate the supply. Alternatively, contact our technical support team at (800) 968-2026 or email [email protected]

to arrange a site visit.

(Please note a charge may be applicable.)

The coalescing catchpot filter should be replaced if showing signs of contamination. Failure to replace the filter will result in the gas flow being restricted or blocked to the BIOGAS 3000 module. In addition, it will cause a flow fail error.

Op. Image

1

2

No image

Instruction

Drain the catchpot of any

contents. Refer to Emptying the

Catchpot .

From the ‘Gas Readings Screen’, press the middle soft key to ‘Stop

Sampling’.


3 Ensure the drain, gas inlet, and gas outlet valves are closed.


144

Maintenance


4 Disconnect the gas in and gas out tubes from the catchpot assembly.

5 Remove the catchpot from its clip.

6

7

OMBG3000 – Iss.01

1) Unscrew the catchpot top by turning a quarter turn anticlockwise.

2) Lift the top from the body.

Unscrew the filter stop from underneath the filter.

 Note: Keep the filter stop safe.

© Copyright 2016

8

9

10

11


Maintenance

145

Remove the coalescing filter from the threaded bar and replace with new.

Replace the filter stop and tighten into place.

1) Align and fit the catchpot top to the body.

2) Tighten the catchpot top by turning a quarter turn clockwise.

Fit the catchpot back in to its clip.


146

Maintenance


12 Gently position the catchpot so that the drain tube is closest to the backplate and the female QRC is facing the front.

13 Once secure, reconnect the couplings to the catchpot top, ensuring the tubing is not trapped or kinked.

 Note: Ensure that the couplings ‘clicks’ in to place.

14





Screen’.


that a Pressure Test be completed to ensure that the

system is leak free.



Maintenance

147

7.5

Replacing the Inline PTFE Filter


Mains voltages are present within the BIOGAS 3000 system and great care needs to be observed. If there is any uncertainty, seek advice from a professional or isolate the supply. Alternatively, contact our technical support team at (800) 968-2026 or email [email protected]

to arrange a site visit.


The inline PTFE filter should be replaced if showing signs of contamination or saturated with liquid. Failure to replace the filter will result in the gas flow being restricted or blocked to the BIOGAS 3000 module. In addition, it will cause a flow fail error.

Op. Image

1

Instruction

From the ‘Gas Readings

Screen’, press the middle soft key to ‘Stop Sampling’.


2 Ensure the drain, gas inlet, and gas outlet valves are closed.


148

Maintenance


3 The inline PTFE filter is located above the catchpot.

4

5

6

Disconnect one side of the tubing from the filter by turning counter-clockwise.

Disconnect the remaining tubing length from the filter by turning counter-clockwise.

Connect the new filter to the tubing by turning clockwise.


7


Maintenance

149

Connect the remaining tube to the filter by turning clockwise.

8 Position the tubing assembly above the catchpot ensuring the tubing is not trapped or kinked.

9





Screen’.


that a Pressure Test be completed to ensure that the

system is leak free.


150

Maintenance


7.6

Pressure Test

After any maintenance operations in this section are performed, the system must be pressure tested to ensure it is leak free. In addition, a pressure test should be performed as part of routine maintenance. The following sections outline the required equipment, the set-up, and the procedure for the pressure test on the different systems available.


Failure to pressure test the system could result in gas leaking in to the enclosure causing a hazard.

7.6.1

Required Equipment

To perform the test procedure, the following equipment will be required:



0-200mbar pressure gauge with minimum of 10mbar increments



T-piece fitting suitable for tubing



A ball valve



Pressure application device, such as a manual pump



Fittings and tubing to connect to the system bulkheads

 Note: An additional two ball valves will be required if not installed on the

‘process return’ and ‘vent to atmosphere’ outlets as recommended during the installation.

7.6.2

Diagnostics Control Mode

The BIOGAS 3000 includes a feature that allows the user to toggle the condition of the solenoids, relays, and pumps in the system. During the pressure systems tests, the user will need to control the position of the solenoid valves in order to complete a comprehensive test. To enable diagnostics control mode:

1) From the ‘Gas Readings Screen’ press the ‘Menu’ key.

2) Press the left soft key for the ‘Device Info’ menu.



Maintenance

151

3) Press key ‘3’ for ‘Diagnostics’.

4) Press the ‘pump’ key to display ‘Diagnostics Control Mode’.

 Note: Entering this mode of operation will stop the sampling process.

Screen 41 – Diagnostics Control Mode

5) Using the scroll keys, navigate to the desired parameter. Pressing the  key will toggle the status of the hardware item between on and off.

6) Pressing the right soft key at any point will return the user to the ‘Device

Info’ menu.

 Note: After returning to the ‘Gas Readings Screen’ after being in diagnostics control mode, the sampling process will start from the beginning.


152

Maintenance


7.6.3

General Set-Up

The image below shows an example of how the equipment will look when performing the test procedure.

 Note: Due to the significant differences between models, each set-up will be slightly different to the image shown.

7.6.4

Performing the Pressure Test


Ensure the gas supply has been isolated at the source before disconnecting the tubing from the equipment.

The test is to apply 100mbar of pressure to each gas inlet, including air, in turn as per the table associated to the model types below. Solenoids are to be

toggled via the Diagnostics Control Mode . A successful test is a pressure drop

of less than 10mbar in a minute on each test point.

For each test, the ball valves on the ‘Process Return’ and ‘Vent to Atmosphere’ lines should be closed.



Maintenance

153

 Note: Ensure the drain valve is closed when performing the pressure test.

 Note: An additional two ball valves will be required if not installed on the

‘Process Return’ and ‘Vent to Atmosphere’ outlets as recommended during the installation.

7.6.4.1

BG3K1 and BG3KE without an External Sensor

Apply pressure to:

Air Purge

Sample Gas 1

Solenoid

1

OFF

ON

Solenoid

6

OFF

ON

 Note: Ensure the ball valves on the ‘Process Return’ and ‘Vent to

Atmosphere’ lines are opened once testing is completed.

 Note: When reattaching the sample pipes to the system, ensure all tube connections are tight and free from leaks.

 Note: If assistance is required, please contact our technical support team at (800) 968-2026 or email [email protected]

.


154

Maintenance


7.6.4.2

BG3K2


Solenoid

1

Air Purge OFF

Sample Gas 1 OFF

Sample Gas 2 ON

Solenoid

2

OFF

OFF

OFF

Solenoid

5

ON

OFF

OFF

Solenoid

6

OFF

OFF

ON





.



Maintenance

155

7.6.4.3

BG3K3

With hydrolysis option:


Air Purge

Sample Gas 1

Sample Gas 2

Sample Gas 3

Solenoid

1

OFF

OFF

OFF

OFF

Solenoid

2

OFF

OFF

OFF

OFF

Solenoid

3

OFF

OFF

OFF

ON

Solenoid

5

ON

OFF

OFF

OFF

Solenoid

6

OFF

OFF

OFF

ON





.


156

Maintenance


7.6.4.4

BG3K4

With hydrolysis option:


Air Purge

Sample Gas 1

Sample Gas 2

Sample Gas 3

Sample Gas 4

Solenoid

1

OFF

OFF

OFF

OFF

OFF

Solenoid

2

OFF

OFF

OFF

OFF

OFF

Solenoid

3

OFF

OFF

OFF

OFF

OFF

Solenoid

4

OFF

OFF

OFF

OFF

ON

Solenoid

5

ON

OFF

OFF

OFF

OFF

Solenoid

6

OFF

OFF

OFF

OFF

ON





.



Maintenance

157

7.6.4.5

BG3KD


Air Purge

Sample Gas 1

Sample Gas 2

Solenoid

1

OFF

OFF

OFF

Solenoid

2

OFF

OFF

OFF

Solenoid

3

OFF

OFF

ON

Solenoid

4

OFF

OFF

ON

Solenoid

5

ON

OFF

OFF

Solenoid

6

OFF

OFF

ON





.

7.6.4.6

BG3KE with an External Sensor


Air Purge

Sample Gas 1

Solenoid

1

OFF

ON

Solenoid

3

OFF

OFF

Solenoid

4

OFF

ON

Solenoid

6

OFF

OFF





158

Maintenance



.

7.7

Cleaning and Decontamination

The equipment must be isolated from the mains supply prior to cleaning or decontamination. The enclosure can be cleaned externally using a mild soapy water and non-abrasive cloth.

Should the need arise for the BIOGAS 3000 module to be returned for service, it is the responsibility of the owner to ensure that the module has been decontaminated or that LANDTEC has been made aware of any contaminants that may be present, prior to it being returned.

Warning Only the exterior of the enclosure should require cleaning. Cleaning the interior could result in injury due to mains power being present.

High-pressure jet washers should not be used to clean the enclosure.



Service

159

8 Service

8.1

General

The BIOGAS 3000 module should be regularly serviced to ensure correct and accurate operation. LANDTEC recommends a service and recalibration every 12 months .

It is recommended that only qualified engineers service the BIOGAS 3000 module. Failure to observe this will result in the warranty becoming invalid.

 Note: For further information on how to return your BIOGAS 3000 module for service, please contact our service team at (800) 968-2026 or email [email protected]

.

8.2

Service Notifications

The BIOGAS 3000 uses two icons on the ‘Gas Readings Screen’ to notify the user that the module is due a service:

The service is due in 28 days

The service is overdue

In addition to the icons on screen, the service due date is a readable parameter

in the Modbus, Profibus and Profinet registers, and is viewable in the System

Information screen.



Service

8.3

Replacement BIOGAS 3000 Module for Service – Hot Swap

The BIOGAS 3000 has been designed to avoid unnecessary downtime and a temporary BIOGAS 3000 module can be supplied during service upon request.

Below are instructions on how to swap out the BIOGAS 3000 module for service.


Mains voltages are present within the BIOGAS 3000 system and great care needs to be observed. If there is any uncertainty, seek advice from a professional or isolate the supply. Alternatively, contact our technical support team at (800) 968-2026 or email [email protected] to arrange a site visit.


Op. Image

1

Instruction

Power off the module by holding the on/off key for two seconds.

 Note: This will freeze the outputs at their last known value

2 Disconnect the gas inlet and gas outlet tubing from the top of the

BIOGAS 3000 module.

3

Disconnect the USB lead from the communications connector and the power supply lead from the power supply connector from the top of the BIOGAS 3000 module.


5

6

4

No image


Service

161

Remove the four screws securing the module mounting brackets to the pillars using a 4mm Allen key.

 Note: Keep the screws safe, as they will be required to secure the hot swap module.

Send the module to your distributor or our service team at

LANDTEC.

Align the new module with the four pillars and secure in place using the four screws and 4mm

Allen key. The screws must be tightened to 4N

 m.

7

Warning It is critical that the screws are torques to 4N

 m. Failure to tighten to this setting will invalidate the ATEX and

IECEx certification.

8

Reconnect the USB lead to the communications connector and the power supply lead to the power supply connector at the top of the BIOGAS 3000 module.

Reconnect the gas in and gas out tubing to the module.

 Note: Ensure that the couplings are fully pushed into the housing.

 Note: The yellow tubing should connect to the yellow


162

Service

Operating Manual port on the module.

9

Warning It is critical that the connections are fully secured to ensure that no gas leaks in to the main enclosure. It is

recommended that a Pressure Test be completed to

ensure the system is leak free.

Power on the module by pressing the on/off key for two seconds.

10

The hot swap module will preload the configuration from the

Interface PCB and run the

operator through a First Time Run

Set-up .

 Note: After replacing the BIOGAS 3000 module, LANDTEC recommends that a gas check be performed on the system to ensure it is still reading accurately. If required, a user calibration can also be performed; refer to

the Gas Check and Calibration section of this operating manual for more

information.



Problem Solving

163

9 Problem Solving

This section discusses various problems that may be encountered, and warnings or error messages that the operator may receive during general operation of the BIOGAS 3000. For further assistance please contact our technical support team at (800) 968-2026 or email [email protected]

.

9.1

Fault Detection

When switched on the instrument will perform a pre-determined self-test sequence taking approximately sixty seconds. During this time, many of the systems working parameters and settings are checked. In addition, during normal operation, similar parameters are checked to ensure the channels are valid.

There are two types of faults, critical and non-critical.

9.1.1

Non-Critical Faults

If a non-critical fault is detected after power on, a warning will be displayed in a summary screen:

© Copyright 2016

Screen 42 - Self-test with warnings

OMBG3000 – Rev1


Problem Solving

For non-critical faults at this stage, the user can continue by pressing the right soft key ‘Continue’. The BIOGAS 3000 will continue automatically after thirty seconds if continue is not pressed.

In addition to Screen 42 - Self-test with warnings , there will be a non-critical

fault icon present on the ‘Gas Readings Screen’ during monitoring:

A non-critical fault does not stop the sampling process and this will continue as normal. Examples of non-critical faults are a channel under-ranging or the service being due.

Pressing the right soft key on the ‘Gas Readings Screen’ will display the noncritical faults the system has detected.

Screen 43 - System Warnings (non-critical faults)

From this screen:



Pressing the left soft key will ‘Reset’ the system and power cycle the

BIOGAS 3000 module



Pressing the middle soft key will perform a system test. If the fault clears after this, monitoring will resume and the icon will be removed



Problem Solving

165



Pressing the right soft key will ‘Exit’ and returns the operator to the ‘Gas

Readings Screen’.

9.1.2

Critical Faults

If a critical fault is detected after power on, a warning will be displayed in a summary screen:

Screen 44 - System Fault

The difference between a non-critical fault and critical fault after the self-test is that the user cannot proceed until the fault is rectified. In addition, the fault relay is de-energized to inform the operator of a problem.

Examples of critical faults are a loss of communications to the Interface PCB and low flow. If a critical fault occurs during the monitoring process, the process will be immediately stopped, the outputs will be frozen at their last known value, the fault relay will be de-energised, and an error message posted on screen.

From this screen:



Pressing the left soft key will ‘Reset’ the system and power cycle the

BIOGAS 3000 module



Pressing the middle soft key will access the ‘Diagnostics’ screen. This may be required if seeking technical support



Problem Solving



Pressing the right soft key will perform a system test. If the fault clears after this, monitoring will resume, the message will be cleared, and the fault relay energized.

After a critical fault occurs, the system will perform a self-test every fifteen minutes on four occasions to check if the fault has cleared. In the event it is still present, the self-test will then occur every 24-hours until user intervention or the fault has cleared.

9.2

System Will Not Power On

Ensure the switched mains supply is turned on and check that the LEDs are illuminated on the 24Vdc and 12Vdc power supplies. If they are not, check the mains fuse (fuse 1) and replace if necessary.

Warning Do not remove fuses whilst energised.

If the problem persists, please contact our technical support team at LANDTEC on (800) 968-2026 or email [email protected]

9.3

Module Will Not Power On

Ensure there is power to the system by checking that the LEDs are illuminated on the 24Vdc and 12Vdc power supplies. If they are not, check the mains fuse

(fuse 1) and replace if necessary.

If they are illuminating, it can take up to one minute for the BIOGAS 3000 module to power on. If it does not turn on at the point power to the system is applied, please wait one minute before pressing any keys on the module.

If after one minute the module has not powered on, check the fuse for the supply to the module (fuse 2) and replace if necessary.

Finally, check fuse 3, which provides 12Vdc to the Interface PCB, which in turn supplies the power to the module.

Warning Do not remove fuses while energized.

If the problem persists, please contact our technical support team at (800) 968-

2026 or email [email protected]

.



Problem Solving

167

9.4

Module Lock-Up

In the rare event that the BIOGAS 3000 ‘locks up’ and will not recognize button presses, the system should automatically power cycle the module due to a loss of communications.

If this does not occur or fix the problem, isolate the supply to the system and leave the system switched off for 60 seconds. After this duration, turn the power back on and check the systems operation.



.

9.5

Under and Over Range Codes

If a reading is under range (i.e. below zero) it will display ‘less than’ chevrons

(<<<). This can occur if:



A channel has been incorrectly user calibrated



The BIOGAS 3000 module has been damaged (e.g. during transit)



The BIOGAS 3000 module has drifted out of calibration or it is due for factory calibration.

If a reading is over range (i.e. above the maximum allowed value) it will display

‘more than’ chevrons (>>>). This can occur:



For the same reasons as an under range error



If the channel is reading more than its acceptable limit (e.g. CH

4

> 100%)



Due to potential cross gas effects.

In most circumstances, a return to factory settings (see Restore to Factory ) and

performing a user calibration (see Gas Check and Calibration ) will resolve the

error. If the error is not cleared by performing these tasks, please contact our technical support team at (800) 968-2026 or email [email protected]

.



Problem Solving

9.6

Analogue Outputs Not Working

Please refer to section 4-20mA Outputs in this operating manual to ensure the

outputs have been wired correctly. If the wiring method is not suitable for the input systems configuration, please contact your our technical support team at


.

If the system is wired correctly, ensure the analogue outputs have been

configured correctly; refer to Configure Analog Outputs for more information.

Check that your 4-20mA input channel is being interpreted correctly; refer to

4-20mA Scaling .

Finally, check fuse 5, which is used to provide power to the 4-20mA loop.



.

9.7

Modbus Outputs Not Working

Please refer to section Configure Modbus Slave in this operating manual and

ensure that the configuration of the Modbus port is correct and that the wiring

is correct as per Wiring Diagram 2 – Modbus .

 Note: If the BIOGAS 3000 is last on the bus, ensure the termination is set to ‘On’. Likewise, if it is not, ensure the termination is set to ‘Off’.

In addition, also check that no two nodes on the bus have the same slave address. If this is the case, the BIOGAS 3000 slave address can be changed by

referring to section Configure Modbus Slave in this operating manual.



.

9.8

Low Flow / Flow Fail

If a flow fail occurs, this is classified as a critical fault and sampling will be stopped.



Problem Solving

169

A flow fail occurs when there is not enough gas flowing through the BIOGAS

3000 module. This can be for a number of reasons:



You are sampling against a vacuum outside of the range of the system



There are blockages in the system



There is a gas leak in the system.

Firstly, check that all gas in and gas out valves are open, the drain valve is closed, and the calibration valve is closed.

If the valves are in the correct position and the problem persists:



Ensure that the system is not operating against a vacuum outside of its operating range. Refer to the latest technical specification (available at www.LANDTECuk.com

) for further information.



Empty the catchpot of any contents (see Emptying the Catchpot ).



Replace inline PTFE filter (see Replacing the Inline PTFE Filter ).



Replace the catchpot filter (see Replacing the Catchpot Filter ).



Visually check for damaged pipes or obvious signs of leaks.



Perform a Pressure Test .



Retest the system.

If after performing the above steps the problem is still present, please contact our technical support team at (800) 968-2026 or email [email protected]

.

9.9

Fuses

Warning The use of alternative fuses may affect the safety of the apparatus and will invalidate the ATEX/IECEx certification.

Ensure the power is isolated and the Protective Cover is

removed before replacing fuses. Once replaced, the



Problem Solving

protective cover will need to be fitted.

Please refer to the following table for the designation and location of each fuse together with its type and rating:

Designation Circuit

FS1

FS2

FS3

Mains input

Power supplies

Heater

24Vdc pumps

Drain pump

Reed switch

4-20mA loop

Relay control

External sensor

Rated voltage

250v

250v

250v

FS4

Solenoids

250V

FS5

FS6

FS7

24Vdc supply

250V

BIOGAS 3000 module supply

12Vdc supply to

Interface PCB

250v

250V

Rated current

3.15A

1.25A

500mA

1A

2A

1A

1A

Type

20mm time delay, ceramic







 Note: Please contact our Technical Support team at (800) 968-2026 or email [email protected]

for further information.

9.10

User Calibration Explained

9.10.1

General

User calibration is a means of optimising the performance of the BIOGAS 3000 system to the current operating conditions such as temperature and pressure as well as correcting for analyser drift caused by the infrared source.

User calibration has two operations, zero and span, and each may be performed individually. However, for a complete user calibration both must be completed.



Problem Solving

171

Graph 1 - User calibration explained

9.10.2

Factory Calibration

When the BIOGAS 3000 module is factory calibrated, a stable gas curve is

generated (see curve 1 on Graph 1 - User calibration explained ). This curve is

then used to determine the gas concentration based on the infrared signal strength after being absorbed by the gas.

9.10.3

User Zero Calibration

A zero calibration is used to correct the entire curve for the infrared source and filter variations caused by aging and induced drift due to dirt and other contaminants. If done correctly, there is often no need to complete a span calibration, as the new curve will follow closely to the factory calibration curve

(curve 1 on Graph 1 - User calibration explained ).

The zero calibration is very sensitive and a rushed or poor calibration, (such as the target gas still being present), will result in a zero error; see point A on

curve 2 of Graph 1 - User calibration explained . This also produces an error

throughout the remainder of the curve proportional to signal strength, but the



Problem Solving

effect on the span is significant, see point B on Graph 1 - User calibration explained .

 Note: To perform an accurate user calibration it is critical that a good user zero has been performed. LANDTEC recommends that this be done with nitrogen in order to guarantee that none of the gas of interest is present.

 Note: To obtain a good zero it may be necessary to flow nitrogen for several minutes, especially if the BIOGAS 3000 system has been subjected to high levels of gas previously, in order to ensure there are no remains of the target gas present. On the BIOGAS 3000, this would result in leaving the system for several minutes before pressing ‘check’ during the gas check process.

9.10.4

User Span Calibration

A span calibration is used to optimize the analyser at the span calibration

concentration (see point C on Graph 1 - User calibration explained ) for the

current operational conditions. It corrects the span point but leaves the zero unadjusted (this will be left at the last user zero if this has been performed) and should be done at the concentration of interest in the particular application.

If the user zero is poor and the span calibration is good, it will correct the gas curve for the point of interest, but other points on the curve could be

incorrect, see curve 3 on Graph 1 - User calibration explained .

9.10.5

Trouble Shooting

9.10.5.1

User Zero Calibration Failed

Three possible reasons for this are that:



The BIOGAS 3000 module is trying to zero to a level which is outside the predetermined range set when the module was last factory calibrated



The gas is not stable i.e. it is still purging out the measured gas



The system is not seeing a flow of gas.



Problem Solving

173

To rectify this:



Ensure the BIOGAS 3000 module contains none of the gas that is being zeroed by flushing through with nitrogen, or clean ambient air if this is not available and repeat a user zero calibration



Ensure the correct zero calibration has been selected (nitrogen, fresh air, or a mix with none of the target gas present) and retry



Ensure the flow regulator on the gas bottle is open (if being used).


.

9.10.5.2

User Span Calibration Failed

Check the span target (see Gas Mixtures ) is set to the value given on the

calibration bottle. If not, correct and re-span the channel.

In addition, check that the flow regulator on the gas bottle is open.

If the problem persists, repeat an entire user calibration by zeroing the channel prior to performing a span calibration.

 Note: Always ensure that the on-screen reading has begun to stabilize before pressing ‘Check’. If you notice that the reading is still changing after the elapsed time, use the ‘Retry’ function and perform the span calibration again.

If after performing the above steps the problem is still present, please contact our technical support team at (800)968-2026 or email [email protected]

.

9.10.5.3

Channel Outside of Limits

A channel outside of its limits to be calibrated is indicated by the icon in the ‘User Calibration’ screen. The cause of this is either:



The channel is under-ranging or over-ranging



The current user reading is too far from the target



Problem Solving

In both scenarios, perform a Restore to Factory , followed by a zero or span

check.

If after performing the above steps the problem is still present, please contact our technical support team at (800)698-2026 or email [email protected]

.

9.11

CH

4

Reading Low and O

2

Reading High

If you believe that the CH

4

reading is lower than you expect or the O

2

reading is higher than you expect, there could be two reasons for this:



There could be a leak in the tubing and when sampling you could be

drawing in air and diluting the sample. Refer to the Pressure Test

section of this operating manual for instructions on how to pressure test the BIOGAS 3000 system.



The BIOGAS 3000 has drifted since its calibration and may be due a user

calibration; see section Gas Check and Calibration of this operating

manual for further information.


.

9.12

Event Log

The BIOGAS 3000 incorporates the ability to log significant events performed on the system via the event log. This can be used as an aid to monitoring the use of the system and used as a diagnostic tool if there is a problem.

The system stores ten logs, each able to store 10kb of event memory. 10kb is approximately 80-100 single event entries. Applicable events are stored in the event log automatically and no user intervention is required. When the tenth log file is full, the events of log file one are deleted and replaced with log file eleven.

Below are some examples of events recorded to the logs:




Alarm disabled



Starting air calibration



User requested shutdown from module



Flow has failed



Manufacturer’s service was overdue on [date]


Problem Solving

175



BIOGAS 3000 Warranty Terms and Conditions

10 BIOGAS 3000 Warranty Terms and Conditions

QED Environmental Systems, Inc. will repair or replace (at QED’s discretion) any goods supplied by the company in respect to defects arising within 12 months for components related to the system and 3 years for components related to the module from date of purchase or delivery, whichever is later, provided that:



The defect is due to faulty parts or workmanship provided by QED.



Proof of delivery/purchase must be provided to QED for any claims. This includes a QED sales order, invoice, or delivery note.



All warranty repairs can only be carried out by QED or its authorized agents. In certain circumstances, permission may be granted by QED for the owner to replace a supplied part under warranty.



Any repair or replacement component under warranty will not extend the warranty period of the system.



Products must have been returned for service and calibration as recommended by QED or its authorized agents.



Where replacement parts have been supplied by QED under warranty, the replaced parts must be returned to QED. If not returned, QED reserves the right to charge for the replacement part.



If no fault is found an investigation charge may apply.



Technical support MUST be notified in the event of a pending warranty claim. They will then issue a warranty reference number that must be included in any return. Failure to provide this will void any warranty claim.

The following is not included:



Normal wear and tear of parts that might wear out over time, or be consumed, is not covered. Parts not covered include, but not limited to, the, suppression diodes, PTFE filter, coalescing filter, electrochemical cells, and tubing.



A service is not part of a warranty claim.



Accidental damage, including dropping during installation.



Damage as a result of vandalism.




177



Faults arising from use of the equipment that is not in accordance with standard operating procedures laid out in BIOGAS 3000 Operating Manual.



Faults arising from use of the equipment in unsuitable applications.



Repairs or alterations carried out by parties other than QED, its authorized agents, or under the instruction of QED.



Any data stored on the equipment that may be lost.



A claim due to a failure in maintaining the system in accordance with the operating manual.



A claim as a result of poor quality or inadequate repairs.



Any business related losses such as income, profits, and contracts (as far as the law allows).

The following voids the warranty:



When non-approved LANDTEC parts have been used for repair or maintenance.



When parts are added, or alterations made, to the system outside the scope of the operating manual.



The BIOGAS 3000 module has been opened, unless by QED approved service centers (where applicable).



The BIOGAS 3000 system has been opened in poor weather conditions that have resulted in damage to any of its components.



The equipment has been stored or installed outside of the operating range and environmental conditions determined in the operating manual.



The equipment has not been maintained in accordance with the operating manual.

Service Warranty:



QED offers a three-month warranty period, following a QED service, to cover any defects that have arisen because of that service.




 Note: Warranty repair is only granted after an investigation by QED.

 Note: For assistance in determining if your equipment qualifies for warranty investigation, please contact our technical support team at


.

QED Environmental Systems, Inc. reserves the right to update these terms and conditions without notice.


11 WEEE Compliance


WEEE Compliance

179

The wheelie bin symbol displayed on electrical equipment supplied by

LANDTEC signifies that the apparatus must not be disposed of through the normal municipal waste stream but through a registered recycling scheme.

The Waste Electrical and Electronic Equipment Directive (WEEE) make producers responsible in meeting their obligations, with the fundamental aim of reducing the environmental impact of electrical and electronic equipment at the end of its life.

LANDTEC is registered with the Environmental Agency as a producer and has joined a recycling scheme provider that manage and report on our electrical waste on our behalf.

 Note: When your instrument is at the end of its life, please contact our sales team at (800) 968-2026 or email [email protected]

, who will advise you on the next step in order to help us meet our obligations.



Glossary of Terms

12 Glossary of Terms

Term

Air purge

Baro

CH

4

CO

2

CO

Catchpot filter

Definition

Process used to clear out gas from the tubing within the BIOGAS 3000 system and used as part of a user zero in air.

The atmospheric pressure at the given location, measured in milli bar (mb/mbar).

Methane

Carbon dioxide

Carbon monoxide

The filter used to drop water droplets from the sample gas into the catchpot.

Current source The BIOGAS 3000 supplies the source to the 4-20mA loop. Other configurations are available.

Electrochemical gas A method of gas detection that works based on a sensor chemical reaction with the target gas e.g. H

2

S.

External gas sensor An electrochemical gas sensor incorporated in to an assembly external to the BIOGAS 3000 module but part of the overall system. It allows an additional gas

Factory settings

Firmware to be monitored by the equipment.

Default settings pre-set at time of manufacture or service.

Firmware is the term by which the internal module software is known and is not accessible by the client.

This firmware is updated to the latest version when the analyser is returned to LANDTEC or an approved agent for servicing. In addition, the firmware can be updated by the end user using a LANDTEC approved power source and the LANDTEC Firmware Updater

Tool.

Hydrogen H

2

H

2

S

Hazard

Hazardous live

Hydrogen sulphide

A potential source of harm.

Capable of rendering an electric shock or electric burn.

Infrared source The component used to provide a source of infrared



Glossary of Terms

181 light that can be absorbed by the gas.

Infrared source drift The component used to provide a source of infrared light has changed its brightness, and may not have been fully compensated by the reference channel. This

Inline PTFE filter may be due to age or contamination.

The component used to help protect the BIOGAS 3000 module from water ingress.

A document that contains information about a Material safety data sheet

Modbus particular substance. Commonly known as MSDS.

Modbus is a serial communications protocol and is a means of connecting industrial electronic devices.

Polymeric materials Organic material, natural or synthetic, with high

Pump molecular weight made of repetitive structural units.

Examples include wool and PVC.

Used to draw the gas sample from the monitoring point to the BIOGAS 3000.

Reference channel An infrared channel that has no sensitivity to the gas of interest that is used as a baseline for the CH

4

and

CO

2

absorption.


LANDTEC BG3K2, BG3KD, BG3KE Operating Manual

OPERATING MANUAL

Table of Contents

1 Manual guidelines

2 Safety information

3 BIOGAS 3000 Overview

4 Installation

5 General Operating Instructions

SP1 Solenoid

SP2 Solenoid

SP3 Solenoid

4-20mA Output

SP1 Relay

SP2 Relay

SP3 Relay

SP1 Solenoid

SP2 Solenoid

SP3 Solenoid

4-20mA Output

SP1 Relay

SP2 Relay

SP3 Relay

6 Gas Check and Calibration

7 Maintenance

8 Service

9 Problem Solving

10 BIOGAS 3000 Warranty Terms and Conditions

11 WEEE Compliance

12 Glossary of Terms

Related manuals

Table of contents

LANDTEC BG3K2, BG3KD, BG3KE Operating Manual

OPERATING MANUAL

Table of Contents

1 Manual guidelines

2 Safety information

3 BIOGAS 3000 Overview

4 Installation

5 General Operating Instructions

SP1 Solenoid

SP2 Solenoid

SP3 Solenoid

4-20mA Output

SP1 Relay

SP2 Relay

SP3 Relay

SP1 Solenoid

SP2 Solenoid

SP3 Solenoid

4-20mA Output

SP1 Relay

SP2 Relay

SP3 Relay

6 Gas Check and Calibration

7 Maintenance

8 Service

9 Problem Solving

10 BIOGAS 3000 Warranty Terms and Conditions

11 WEEE Compliance

12 Glossary of Terms

Related manuals

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DIRTMAGCLEAN 5790

Geotech

BIOGAS 3000

Geotech

Biogas

Geotech

Biogas 300

LANDTEC

BIOGAS 5000

Elster

EnCal 3000

Eaton

Crouse-Hinds series MTL GIR6000 Biogas Analyser

QED

GA5000

SICK

Waste and recycling industry

Table of contents