LANDTEC BIOGAS 3000, BG3K2, BG3K4, BG3KD, BG3KE Operating Manual

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Page 1

OPERATING MANUAL

Page 2

OMBG3000 – Iss.A

Page 3

OMBG3000 – Rev1

Table of Contents

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

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

1.2 Hyperlinks .............................................................................................. 9

1.3 Notes ..................................................................................................... 9

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

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

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

Marking ............................................................................................... 12 2.2.1

Instructions Specific to Hazardous Area Installations .......................... 13 2.2.2

Entity Parameters ................................................................................ 15 2.2.3

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

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

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

3.1 Features ............................................................................................... 17

3.2 Benefits ................................................................................................ 18

3.3 Options ................................................................................................ 19

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

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

BG3K1 .................................................................................................. 20 3.5.1

BG3K2 .................................................................................................. 20 3.5.2

BG3K3 .................................................................................................. 21 3.5.3

BG3K4 .................................................................................................. 22 3.5.4

BG3KD .................................................................................................. 23 3.5.5

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

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

BG3KE .................................................................................................. 23 3.5.6

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OMBG3000 – Iss.01

Physical Characteristics of the Module ................................................ 27 3.7.1

Definitions ........................................................................................... 29 3.7.2

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

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

General ................................................................................................ 31 4.1.1

Packaging Contents ............................................................................. 32 4.1.2

Storage of the System and Module ..................................................... 32 4.1.3

Ventilation Requirements .................................................................... 33 4.1.4

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

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

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

Gas Sample Lines ................................................................................. 36 4.4.1

Process Return ..................................................................................... 37 4.4.2

Air In .................................................................................................... 38 4.4.3

Vent to Atmosphere ............................................................................ 38 4.4.4

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

Cable Conductor Sizes ......................................................................... 44 4.8.1

Cable Insulation Requirements ............................................................ 44 4.8.2

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

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

4.9.1

How to Wire the Mains Supply ............................................................ 46 4.9.2

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

Wiring the BIOGAS 3000 Modbus Outputs .......................................... 48 4.10.1

Default Configuration of the BIOGAS 3000 Modbus Port .................... 50 4.10.2

Readable Parameters of the BIOGAS 3000 .......................................... 50 4.10.3

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OMBG3000 – Rev1

4.11 4-20mA Outputs .................................................................................. 57

General Information ............................................................................ 57 4.11.1

Wiring the BIOGAS 3000 to a Current Sinking Input ............................ 58 4.11.2

4-20mA Scaling .................................................................................... 60 4.11.3

4.12 Relays .................................................................................................. 61

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

Configuration of the Profibus Module ................................................. 63 4.13.1

Wiring the Profibus Module ................................................................ 65 4.13.2

Readable Parameters of the Profibus Module .................................... 68 4.13.3

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

Configuration of the Profinet Module ................................................. 72 4.14.1

Wiring the Profinet Module ................................................................. 73 4.14.2

Readable Parameters of the Profinet Module ..................................... 76 4.14.3

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

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

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

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

Notification .......................................................................................... 88 5.5.1

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

5.5.2

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

5.7 Menu ................................................................................................... 91

Settings Menu ...................................................................................... 92 5.7.1

Device Information Menu .................................................................. 108 5.7.2

Calibration Menu ............................................................................... 112 5.7.3

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OMBG3000 – Iss.01

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

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

BG3K1, 2, 3, 4, and D Variants ........................................................... 118 5.9.1

BG3KE Variants .................................................................................. 119 5.9.2

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

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

6.1 Introduction ....................................................................................... 121

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

Gas ..................................................................................................... 122 6.2.1

Flow Regulator ................................................................................... 122 6.2.2

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

Adding a Mixture ............................................................................... 124 6.3.1

Deleting a Mix .................................................................................... 125 6.3.2

Edit O

in Fresh Air Mix ...................................................................... 126 6.3.3

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

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

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

Post Gas Check .................................................................................. 133 6.6.1

Post Calibration ................................................................................. 133 6.6.2

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

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

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

Required Equipment .......................................................................... 150 7.6.1

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OMBG3000 – Rev1

Diagnostics Control Mode ................................................................. 150 7.6.2

General Set-Up .................................................................................. 152 7.6.3

Performing the Pressure Test ............................................................ 152 7.6.4

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

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

8.1 General .............................................................................................. 159

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

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

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

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

Non-Critical Faults ............................................................................. 163 9.1.1

Critical Faults ..................................................................................... 165 9.1.2

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

General .............................................................................................. 170 9.10.1

9.10.2

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

User Zero Calibration ......................................................................... 171 9.10.3

9.11 CH4 Reading Low and O2 Reading High .............................................. 174

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

User Span Calibration ........................................................................ 172 9.10.4

Trouble Shooting ............................................................................... 172 9.10.5

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OMBG3000 – Iss.01

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

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

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

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

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Operating Manual

Manual guidelines

OMBG3000 – Rev1

Warning

Warning text will be placed here.

Manual guidelines

1.1 Safety symbol

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

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].

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Operating Manual

Safety information

OMBG3000 – Iss.01

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.

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.

Safety information 2

2.1 Safety instructions

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Operating Manual

Safety information

OMBG3000 – Rev1

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].

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Operating Manual

Safety information

OMBG3000 – Iss.01

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 ATEX and IECEx Certification

Marking 2.2.1

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:

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Operating Manual

Safety information

OMBG3000 – Rev1

Nameplate 1 - BIOGAS 3000 markings

Instructions Specific to Hazardous Area Installations 2.2.2

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.

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Operating Manual

Safety information

OMBG3000 – Iss.01

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.

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Operating Manual

Safety information

OMBG3000 – Rev1

Circuit

Ur (rated voltage)

Ir (rated current)

Pr (rated power)

Relay coil

24Vdc

144W

4-20mA

24Vdc

20mA

480mW

RS485 Modbus

-7 to +12V

83.3mA

417mW

 Equipment has only been assessed for electrical safety. No non-

electrical 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.

Entity Parameters 2.2.3

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

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).

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Operating Manual

Safety information

OMBG3000 – Iss.01

Protective conductor terminal

Function earth (ground) terminal

Caution, risk of electric shock

Caution

Caution, risk of hot surface

Warning

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

2.4 Safety symbols used on the instrument

The following safety symbols are used on the BIOGAS 3000:

Page 17

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Rev1

BIOGAS 3000 Overview 3

3.1 Features

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  H

, CO2 & O2 – standard measurements

S, H2 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

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Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Iss.01

 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

Page 19

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Rev1

 Minimal through-life costs  Local support for peace of mind

3.3 Options

 H

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

 CO 0-1,000ppm  H

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

Page 20

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Iss.01

3.5 Model Type Definitions BG3K1 3.5.1

 The BG3K1 measures CH

, CO2, and O2 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:

BG3K2 3.5.2

 The BG3K2 measures CH

, CO2, and O2 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.

 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:

Page 21

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Rev1

BG3K3 3.5.3

 The BG3K3 measures CH

, CO2, and O2 as standard with a choice of up

to two additional gases (one internal to the module and one external) from three sample points.

 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:

 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:

Page 22

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Iss.01

Warning

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

BG3K4 3.5.4

 The BG3K4 measures CH

, CO2, and O2 as standard with a choice of up

to two additional gases (one internal to the module and one external) from four sample points.

 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:

 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:

Page 23

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Rev1

Warning

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

BG3KD 3.5.5

 The BG3KD measures CH

, CO2, O2 and high and low range H2S as

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

 It has user selectable sample and air purge intervals that are exhausted

back to the process and atmosphere respectively.

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

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

 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:

BG3KE 3.5.6

 The BG3KE measures CH

, CO2, and O2 as standard with a choice of up

to one additional gas (external to module only) from one sample point.

 It measures CH

, CO2, and O2 continuously that is exhausted back to the

process.

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Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Iss.01

 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

Page 25

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Rev1

Viewing window

Heater (110V or 230V)

Plastic wallet containing operating manual and calibration certificate

3.6 BIOGAS 3000 Internal Components

Figure 1 - BIOGAS 3000 door internals

Page 26

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Iss.01

BIOGAS 3000 module

11)

Modbus terminals

Heater thermostat

12)

Gas in/out valves

Solenoid valves

13)

4-20mA terminals

Inline PTFE filter

14)

Relays

Female QRC for calibration

15)

Mains supply terminals

Catchpot with liquid level switch

16)

Power supplies

External sensor

17)

Fuses

Pumps

18)

Protective cover

Auto-drain pump (or drain valve)

19)

Interface PCB

10)

Calibration valve

1 2

19 4 5

Figure 2 - BIOGAS 3000 internal components

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Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Rev1

Front View:

Reference:

1) Display

2) Soft keys

3) Help key

4) On/off key

5) Keypad

6) Return key ( )

7) Pump key

8) Backlight key

9) Menu key

Rear View:

10) Module mounting brackets

11) Rear label

Top View:

12) Gas outlet

13) Power supply connector

14) Gas inlet

15) Communications connector

1 2 3 4 5

3.7 BIOGAS 3000 Module Features Physical Characteristics of the Module 3.7.1

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Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Iss.01

Page 29

Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Rev1

Reference

Definition

1) Display

Shows information to the user.

2) Soft keys

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

3) Help key

Where ‘?’ is shown on the display, the

operator can press the help key for onscreen assistance.

4) On/off key

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

5) Keypad

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.

6) Return key ( )

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

7) Pump key

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

8) Backlight key

Enables the operator to turn the backlight off and on.

9) Menu key

Press the ‘menu’ key to navigate to the ‘menu’.

Definitions 3.7.2

Front View

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Operating Manual

BIOGAS 3000 Overview

OMBG3000 – Iss.01

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.

12) Gas outlet

The gas sample exits the BIOGAS 3000 module here.

13) Power supply connector

Power supplied from the Interface PCB connects here.

14) Gas inlet

The gas sample enters the BIOGAS 3000 module here.

15) Communications connector

Connection point for the USB lead from the Interface PCB.

Rear View

Top View

Page 31

Operating Manual

Installation

OMBG3000 – Rev1

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.

Installation 4

4.1 Pre-Installation Requirements

General 4.1.1

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:

 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

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Operating Manual

Installation

OMBG3000 – Iss.01

 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.

Packaging Contents 4.1.2

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).

Storage of the System and Module 4.1.3

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.

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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.

Customer cable entry – mains supply

Drain

Customer cable entry – not used

Vent to Atmosphere

Customer cable entry – data outputs

10)

Sample Gas 4

Sample Gas 1

11)

Sample Gas 2

Sample Gas 3

12)

Customer cable entry – relays

Air In

13)

Breather Drain

Process Return

7 8 9

Ventilation Requirements 4.1.4

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.

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:

Figure 3 - BIOGAS 3000 customer connections

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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).

 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.

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

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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.

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.

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.

Figure 4 - BIOGAS 3000 enclosure dimensions

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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.

Gas Sample Lines 4.4.1

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.

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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 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).

Process Return 4.4.2

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.

 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.

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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.

 The gas exhaust line should be connected to the bulkhead connector

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

3000 customer connections.

Air In 4.4.3

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.

Vent to Atmosphere 4.4.4

 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

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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

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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.

 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.

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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.

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.

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.

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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

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

manufacturer.

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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.

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.

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Function

Type

Conductor Size

Voltage Rating

Current Rating

Mains supply

Tri-rated

0.14 – 4.0mm2 solid

0.14 – 2.5mm2 stranded

230Vac

3.15A

4-20mA outputs

Twisted pair

0.14 – 4.0mm2 solid

0.14 – 2.5mm2 stranded

24Vdc

20mA

Modbus outputs

Twisted pair

0.14 – 4.0mm2 solid

0.14 – 2.5mm2 stranded

12Vdc

83.3mA Relays

Tri-rated

0.2 – 2.5mm2

24Vdc

Warning

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

Function

Cable Insulation thickness (min)

Mains supply

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.

4.8 Cable Conductor Sizes and Insulation Requirements Cable Conductor Sizes 4.8.1

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

Cable Insulation Requirements 4.8.2

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

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4.9 Mains Wiring Protective Earthing and Mains Supply 4.9.1

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:

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

Figure 7 - BIOGAS 3000 electrical label

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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.

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).

How to Wire the Mains Supply 4.9.2

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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.

Wiring Diagram 1 - Mains

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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.

Warning

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

Ensure the power is isolated.

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

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.

Wiring the BIOGAS 3000 Modbus Outputs 4.10.1

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Terminal Colour

Wiring Information

Pair

Orange

Signal A (RS485) ‘+’

Pair one Blue

Signal B (RS485) ‘-‘

White

Logic Ground (0V) ‘LG’

Pair two

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

refer to section Cable Conductor Sizes and Insulation Requirements.

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

Wiring Diagram 2 – Modbus

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Node Address

Baud Rate

19200

Parity

Even

Stop Bits

Termination

Off

The BIOGAS 3000 acts as a slave.

The protocol is MODBUS RTU.

(Dec)

(Hex)

Parameter

Content Information

0000h

System status

0 – system OK 1 – system fault

0001h

Flow status

0 – flow OK 1 – flow fail

0010h

Communications status

0 – communications OK 1 – communications error

0011h

Catchpot status

0 – catchpot empty 1 – catchpot full

Default Configuration of the BIOGAS 3000 Modbus Port 4.10.2

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

 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.

Readable Parameters of the BIOGAS 3000 4.10.3

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

Read-Only Single Bit Registers

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(Dec)

(Hex)

Parameter

Content Information

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)

0020h

Time and date: year

e.g. 2016

0021h

Time and date: Month

1-12 34

0022h

Time and date: day

1-31

0023h

Time and date: hour

0-23

0024h

Time and date: minute

0-59

0025h

Time and date: second

0-59

0030h

Current sample point

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

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

513 to 519

0201h to 0207h

Alarm 2 to alarm 7 Status

Repeated as per alarm 1

768

0300h

Sample point 1 last reading: year

e.g. 2016

Read-Only 16-Bit Registers

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769

0301h

Sample point 1 last reading: month

1-12

770

0302h

Sample point 1 last reading: day

1-31

771

0303h

Sample point 1 last reading: hour

0-23

772

0304h

Sample point 1 last reading: minute

0-59

773

0305h

Sample point 1 last reading: second

0-59

1024 to 1029

0400h to 0405h

Sample point 2 last reading time and date

Repeated as per sample point 1

1280 to 1285

0500h to 0505h

Sample point 3 last reading time and date

Repeated as per sample point 1

1536 to 1541

0600h to 0605h

Sample point 4 last reading time and date

Repeated as per sample point 1 832

0340h

Last reading sample point 1: CH4

CH4 reading x 10 e.g. 61.1% would be 611

833

0341h

Last reading sample point 1: CO2

CO2 reading x 10 e.g. 38.7% would be 387

834

0342h

Last reading sample point 1: O

O2 reading x 10 e.g. 0.5% would be 5

835

0343h

Last reading sample point 1: Internal cell

Internal cell reading e.g. 3500

837

0345h

Last reading sample point 1: External cell

External cell reading e.g. 3500

839

0347h

Last reading sample point 1: Baro

Baro reading e.g. 1025

841

0349h

Last reading sample point 1: Flow

Pump flow reading e.g. 275

1088

0440h

Last reading sample point 2: CH4

CH4 reading x 10 e.g. 61.1% would be 611

1089

0441h

Last reading sample point 2: CO2

CO2 reading x 10 e.g. 38.7% would be 387

1090

0442h

Last reading sample

O2 reading x 10

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point 2: O

e.g. 0.5% would be 5

1091

0443h

Last reading sample point 2: Internal cell

Internal cell reading e.g. 3500

1093

0445h

Last reading sample point 2: External cell

External cell reading e.g. 3500

1095

0447h

Last reading sample point 2: Baro

Baro reading e.g. 1025

1097

0449h

Last reading sample point 2: Flow

Pump flow reading e.g. 275

1344

0540h

Last reading sample point 3: CH4

CH4 reading x 10 e.g. 61.1% would be 611

1345

0541h

Last reading sample point 3: CO2

CO2 reading x 10 e.g. 38.7% would be 387

1346

0542h

Last reading sample point 3: O

O2 reading x 10 e.g. 0.5% would be 5

1347

0543h

Last reading sample point 3: Internal cell

Internal cell reading e.g. 3500

1349

0545h

Last reading sample point 3: External cell

External cell reading e.g. 3500

1351

0547h

Last reading sample point 3: Baro

Baro reading e.g. 1025

1353

0549h

Last reading sample point 3: Flow

Pump flow reading e.g. 275

1600

0640h

Last reading sample point 4: CH4

CH4 reading x 10 e.g. 61.1% would be 611

1601

0641h

Last reading sample point 4: CO2

CO2 reading x 10 e.g. 38.7% would be 387

1602

0642h

Last reading sample point 4: O

O2 reading x 10 e.g. 0.5% would be 5

1603

0643h

Last reading sample point 4: Internal cell

Internal cell reading e.g. 3500

1605

0645h

Last reading sample point 4: External cell

External cell reading e.g. 3500

1607

0647h

Last reading sample point 4: Baro

Baro reading e.g. 1025

1609

0649h

Last reading sample point 4: Flow

Pump flow reading e.g. 275

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Address

(Dec)

(Hex)

Parameter

Content Information

33024

8100h

Last reading sample point 1: CH4

CH4 reading e.g. 61.1

33026

8102h

Last reading sample point 1: CO2

CO2 reading e.g. 38.7

33028

8104h

Last reading sample point 1: O2

O2 reading e.g. 0.5

33030

8106h

Last reading sample point 1: Internal cell

Internal cell reading e.g. 3500

33034

810Ah

Last reading sample point 1: External cell

External cell reading e.g. 3500

33038

810Eh

Last reading sample point 1: Baro

Baro reading e.g. 1025

33042

8112h

Last reading sample point 1: Flow

Pump flow reading e.g. 275

33280

8200h

Last reading sample point 2: CH4

CH4 reading e.g. 61.1

33282

8202h

Last reading sample point 2: CO2

CO2 reading e.g. 38.7

33284

8204h

Last reading sample point 2: O2

O2 reading e.g. 0.5

33286

8206h

Last reading sample point 2: Internal cell

Internal cell reading e.g. 3500

33290

820Ah

Last reading sample point 2: External cell

External cell reading e.g. 3500

33294

820Eh

Last reading sample point 2: Baro

Baro reading e.g. 1025

33298

8212h

Last reading sample point 2: Flow

Pump flow reading e.g. 275

33536

8300h

Last reading sample point 3: CH4

CH4 reading e.g. 61.1

33538

8302h

Last reading sample

CO2 reading

Read-Only 32-Bit Registers

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

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point 3: CO2

e.g. 38.7

33540

8304h

Last reading sample point 3: O2

O2 reading e.g. 0.5

33542

8306h

Last reading sample point 3: Internal cell

Internal cell reading e.g. 3500

33546

830Ah

Last reading sample point 3: External cell

External cell reading e.g. 3500

33550

830Eh

Last reading sample point 3: Baro

Baro reading e.g. 1025

33554

8312h

Last reading sample point 3: Flow

Pump flow reading e.g. 275

33792

8400h

Last reading sample point 4: CH4

CH4 reading e.g. 61.1

33794

8402h

Last reading sample point 4: CO2

CO2 reading e.g. 38.7

33796

8404h

Last reading sample point 4: O2

O2 reading e.g. 0.5

33798

8406h

Last reading sample point 4: Internal cell

Internal cell reading e.g. 3500

33802

840Ah

Last reading sample point 4: External cell

External cell reading e.g. 3500

33806

840Eh

Last reading sample point 4: Baro

Baro reading e.g. 1025

33810

8412h

Last reading sample point 4: Flow

Pump flow reading e.g. 275

 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.

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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].

General Information 4.11.1

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:

Refer to annotation 13 in

 Top deck: ‘CH1A’ through ‘CH6A’  Bottom deck: ‘CH1B’ through ‘CH6B’

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Warning

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

Ensure the power is isolated.

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.

Figure 2 - BIOGAS 3000 internal components for the terminal location and Wiring Diagram 3 - 4-20mA circuit for the 4-20mA terminal identification.

Wiring the BIOGAS 3000 to a Current Sinking Input 4.11.2

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

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.

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

refer to section Cable Conductor Sizes and Insulation Requirements.

Wiring Diagram 3 - 4-20mA circuit

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Gas

4mA Reading

20mA Reading

CH4 0.0%

100.0%

CO2

0.0%

100.0%

0.0%

25.0%

H2S 0-50ppm

0ppm

50ppm

H2S 0-200ppm

0ppm

200ppm

H2S 0-500ppm

0ppm

500ppm

H2S 0-1,000ppm

0ppm

1,000ppm

H2S 0-5,000ppm

0ppm

5,000ppm

H2S 0-10,000ppm

0ppm

10,000ppm

H2 0-1,000ppm

0ppm

1,000ppm

CO 0-1,000ppm

0ppm

1,000ppm

4-20mA Scaling 4.11.3

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

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Warning

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

Ensure the power is isolated.

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.

The maximum rated voltage of the relays to 24Vdc. Exceeding this voltage will invalidate the ATEX/IECEx certification.

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).

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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.

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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.

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.

 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.

Configuration of the Profibus Module 4.13.1

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.

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Node Address

Baud Rate

9600

Parity

Even

Stop Bits

Termination

The BIOGAS 3000 acts as a slave.

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:

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

Modbus Slave in this operating manual.

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Warning

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

Ensure the power is isolated.

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.

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.

Wiring the Profibus Module 4.13.2

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Terminal Colour

Wiring Information

Pair

Orange

Signal A (RS485) ‘+’

Pair one Blue

Signal B (RS485) ‘-‘

White

Logic Ground (0V) ‘LG’

Pair two

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: For cable conductor sizes and cable insulation requirements, please

refer to section Cable Conductor Sizes and Insulation Requirements.

 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:

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Wiring Diagram 5 – Modbus to Profibus converter module wiring

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Module Internal Name

Parameter

Example

0x0000

Sample Point 1 Last Reading: Year

e.g. 0x07E0 (2016 dec) is 2016 or High Byte 7x256 +Low Byte 0x224

0x0002

Sample Point 1 Last Reading: Month

0x0004

Sample Point 1 Last Reading: Day

0x0006

Sample Point 1 Last Reading:

0x0008

Sample Point 1 Last Reading:

0x000A

Sample Point 1 Last Reading: Second

0x000C

Sample Point 1 Last Reading: CH4 x 10

e.g. 0x0259 (601 dec) is 60.1% or High Byte 2x256 +Low Byte 0x89

0x000E

Sample Point 1 Last Reading: CO2 x 10

0x0010

Sample Point 1 Last Reading: O2 x 10

0x0012

Sample Point 1 Last Reading: Internal Cell

e.g. 0x03E8 (1000 dec) is 1000ppm or High Byte 3x256 +Low Byte 0x232

0x0014

Sample Point 1 Last Reading:

0x0016

Sample Point 1 Last Reading: Gas Flow

e.g. 0x0122 (290 dec) is 290ml/min or High Byte 1x256 +Low Byte 0x34

0x0018

Barometric Pressure

e.g. 0x03E1 (993 dec) is 993mbar or High Byte 3x256 +Low Byte 0x225

0x001A

Sample Point 2 Last Reading: Year

e.g. 0x07E0 (2016 dec) is 2016 or High Byte 7x256 +Low Byte 0x224

0x001C

Sample Point 2 Last

Readable Parameters of the Profibus Module 4.13.3

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

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Reading: Month

0x001E

Sample Point 2 Last Reading: Day

0x0020

Sample Point 2 Last Reading: Hour

0x0022

Sample Point 2 Last Reading: Minute

0x0024

Sample Point 2 Last Reading: Second

0x0026

Sample Point 2 Last Reading: CH4 x 10

e.g. 0x0259 (601 dec) is 60.1% or High Byte 2x256 +Low Byte 0x89

0x0028

Sample Point 2 Last Reading: CO2 x 10

0x002A

Sample Point 2 Last Reading: O2 x 10

0x002C

Sample Point 2 Last Reading: Internal Cell

e.g. 0x03E8 (1000 dec) is 1000ppm or High Byte 3x256 +Low Byte 0x232

0x002E

Sample Point 2 Last Reading: External cell

0x0030

Sample Point 2 Last Reading: Gas Flow

e.g. 0x0122 (290 dec) is 290ml/min or High Byte 1x256 +Low Byte 0x34

0x0032

Sample Point 3 Last Reading: Year

e.g. 0x07E0 (2016 dec) is 2016 or High Byte 7x256 +Low Byte 0x224

0x0034

Sample Point 3 Last Reading: Month

0x0036

Sample Point 3 Last Reading: Day

0x0038

Sample Point 3 Last Reading: Hour

0x003A

Sample Point 3 Last Reading: Minute

0x003C

Sample Point 3 Last Reading: Second

0x003E

Sample Point 3 Last Reading: CH4 x 10

e.g. 0x0259 (601 dec) is 60.1% or High Byte 2x256 +Low Byte 0x89

0x0040

Sample Point 3 Last

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Reading: CO2 x 10

0x0042

Sample Point 3 Last Reading: O2 x 10

0x0044

Sample Point 3 Last Reading: Internal Cell

e.g. 0x03E8 (1000 dec) is 1000ppm or High Byte 3x256 +Low Byte 0x232

0x0046

Sample Point 3 Last Reading: External cell

0x0048

Sample Point 3 Last Reading: Gas Flow

e.g. 0x0122 (290 dec) is 290ml/min or High Byte 1x256 +Low Byte 0x34

0x004A

Sample Point 4 Last Reading: Year

e.g. 0x07E0 (2016 dec) is 2016 or High Byte 7x256 +Low Byte 0x224

0x004C

Sample Point 4 Last Reading: Month

0x004E

Sample Point 4 Last Reading: Day

0x0050

Sample Point 4 Last Reading: Hour

0x0052

Sample Point 4 Last Reading: Minute

0x0054

Sample Point 4 Last Reading: Second

0x0056

Sample Point 4 Last Reading: CH4 x 10

e.g. 0x0259 (601 dec) is 60.1% or High Byte 2x256 +Low Byte 0x89

0x0058

Sample Point 4 Last Reading: CO2 x 10

0x005A

Sample Point 4 Last Reading: O2 x 10

0x005C

Sample Point 4 Last Reading: Internal Cell

e.g. 0x03E8 (1000 dec) is 1000ppm or High Byte 3x256 +Low Byte 0x232

0x005E

Sample Point 4 Last Reading: External cell

0x0060

Sample Point 4 Last Reading: Gas Flow

e.g. 0x0122 (290 dec) is 290ml/min or High Byte 1x256 +Low Byte 0x34

0x0062

Alarm 1

0= No Alarm,

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0x0064

Alarm 2

1=Triggered,

0x0066

Alarm 3

2=Triggered and in recovery zone

0x0068

Alarm 4

4 = Latched

0x006A

Alarm 5

8 = Muted

0x006C

Alarm 6

9 = Triggered alarm and muted

0x006E

Alarm 7

A = Recovering alarm and muted

0x0080

Current sample Point

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.

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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.

Node Address

Baud Rate

9600

Parity

Even

Stop Bits

Termination

The BIOGAS 3000 acts as a slave.

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.

 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.

Configuration of the Profinet Module 4.14.1

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:

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Warning

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

Ensure the power is isolated.

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.

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

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

Modbus Slave in this operating manual.

Wiring the Profinet Module 4.14.2

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Terminal Colour

Wiring Information

Pair

Orange

Signal A (RS485) ‘+’

Pair one Blue

Signal B (RS485) ‘-‘

White

Logic Ground (0V) ‘LG’

Pair two

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: For cable conductor sizes and cable insulation requirements, please

refer to section Cable Conductor Sizes and Insulation Requirements.

 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.

 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:

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Wiring Diagram 6 - Modbus to Profinet converter module wiring

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Module Internal Name

Parameter

Example

0x0000

Sample Point 1 Last Reading: Year

e.g. 0x07E0 (2016 dec) is 2016 or High Byte 7x256 +Low Byte 0x224

0x0002

Sample Point 1 Last Reading: Month

0x0004

Sample Point 1 Last Reading: Day

0x0006

Sample Point 1 Last Reading:

0x0008

Sample Point 1 Last Reading:

0x000A

Sample Point 1 Last Reading: Second

0x000C

Sample Point 1 Last Reading: CH4 x 10

e.g. 0x0259 (601 dec) is 60.1% or High Byte 2x256 +Low Byte 0x89

0x000E

Sample Point 1 Last Reading: CO2 x 10

0x0010

Sample Point 1 Last Reading: O2 x 10

0x0012

Sample Point 1 Last Reading: Internal Cell

e.g. 0x03E8 (1000 dec) is 1000ppm or High Byte 3x256 +Low Byte 0x232

0x0014

Sample Point 1 Last Reading:

0x0016

Sample Point 1 Last Reading: Gas Flow

e.g. 0x0122 (290 dec) is 290ml/min or High Byte 1x256 +Low Byte 0x34

0x0018

Barometric Pressure

e.g. 0x03E1 (993 dec) is 993mbar or High Byte 3x256 +Low Byte 0x225

0x001A

Sample Point 2 Last Reading: Year

e.g. 0x07E0 (2016 dec) is 2016 or High Byte 7x256 +Low Byte 0x224

0x001C

Sample Point 2 Last

Readable Parameters of the Profinet Module 4.14.3

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

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Reading: Month

0x001E

Sample Point 2 Last Reading: Day

0x0020

Sample Point 2 Last Reading: Hour

0x0022

Sample Point 2 Last Reading: Minute

0x0024

Sample Point 2 Last Reading: Second

0x0026

Sample Point 2 Last Reading: CH4 x 10

e.g. 0x0259 (601 dec) is 60.1% or High Byte 2x256 +Low Byte 0x89

0x0028

Sample Point 2 Last Reading: CO2 x 10

0x002A

Sample Point 2 Last Reading: O2 x 10

0x002C

Sample Point 2 Last Reading: Internal Cell

e.g. 0x03E8 (1000 dec) is 1000ppm or High Byte 3x256 +Low Byte 0x232

0x002E

Sample Point 2 Last Reading: External cell

0x0030

Sample Point 2 Last Reading: Gas Flow

e.g. 0x0122 (290 dec) is 290ml/min or High Byte 1x256 +Low Byte 0x34

0x0032

Sample Point 3 Last Reading: Year

e.g. 0x07E0 (2016 dec) is 2016 or High Byte 7x256 +Low Byte 0x224

0x0034

Sample Point 3 Last Reading: Month

0x0036

Sample Point 3 Last Reading: Day

0x0038

Sample Point 3 Last Reading: Hour

0x003A

Sample Point 3 Last Reading: Minute

0x003C

Sample Point 3 Last Reading: Second

0x003E

Sample Point 3 Last Reading: CH4 x 10

e.g. 0x0259 (601 dec) is 60.1% or High Byte 2x256 +Low Byte 0x89

0x0040

Sample Point 3 Last

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Reading: CO2 x 10

0x0042

Sample Point 3 Last Reading: O2 x 10

0x0044

Sample Point 3 Last Reading: Internal Cell

e.g. 0x03E8 (1000 dec) is 1000ppm or High Byte 3x256 +Low Byte 0x232

0x0046

Sample Point 3 Last Reading: External cell

0x0048

Sample Point 3 Last Reading: Gas Flow

e.g. 0x0122 (290 dec) is 290ml/min or High Byte 1x256 +Low Byte 0x34

0x004A

Sample Point 4 Last Reading: Year

e.g. 0x07E0 (2016 dec) is 2016 or High Byte 7x256 +Low Byte 0x224

0x004C

Sample Point 4 Last Reading: Month

0x004E

Sample Point 4 Last Reading: Day

0x0050

Sample Point 4 Last Reading: Hour

0x0052

Sample Point 4 Last Reading: Minute

0x0054

Sample Point 4 Last Reading: Second

0x0056

Sample Point 4 Last Reading: CH4 x 10

e.g. 0x0259 (601 dec) is 60.1% or High Byte 2x256 +Low Byte 0x89

0x0058

Sample Point 4 Last Reading: CO2 x 10

0x005A

Sample Point 4 Last Reading: O2 x 10

0x005C

Sample Point 4 Last Reading: Internal Cell

e.g. 0x03E8 (1000 dec) is 1000ppm or High Byte 3x256 +Low Byte 0x232

0x005E

Sample Point 4 Last Reading: External cell

0x0060

Sample Point 4 Last Reading: Gas Flow

e.g. 0x0122 (290 dec) is 290ml/min or High Byte 1x256 +Low Byte 0x34

0x0062

Alarm 1

0= No Alarm,

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0x0064

Alarm 2

1=Triggered,

0x0066

Alarm 3

2=Triggered and in recovery zone

0x0068

Alarm 4

4 = Latched

0x006A

Alarm 5

8 = Muted

0x006C

Alarm 6

9 = Triggered alarm and muted

0x006E

Alarm 7

A = Recovering alarm and muted

0x0080

Current sample Point

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

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.

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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].

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Warning

Do not open when an explosive atmosphere is present.

General Operating Instructions 5

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

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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.

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

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.

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

Screen 4 - First time run set-up

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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).

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Sample point 1

Sample point 2

Sample point 3

2 3 4 5 6

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:

Screen 5 - Gas readings

 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.

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Sample point 4

Idle – waiting for next cycle to begin.

Sampling from sample point System air purge following sample

Idle – waiting for next cycle to begin

3. Current operation

Details the current operation for the sample point and cycle:

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.

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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.

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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 Notification 5.5.1

 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.

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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.

Screen 6 - Alarm notification

The following notifications are available on the BIOGAS 3000:

Viewing Alarms 5.5.2

To view an alarm, from the ‘Gas Readings Screen’ press the left soft key to go to Screen 7 - Alarms summary:

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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:

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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.

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Settings Menu 5.7.1

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.

Screen 9 - Settings Menu

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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.

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

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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.

Screen 13 - Edit Sample Point Times

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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.

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Term

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.

Value

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

Recovery

The gas concentration for which the alarm condition will recover.

Screen 14 - Configure Alarms

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. Using

the scroll keys, select a parameter to edit (highlighted in the table) and select the field with the  key.

Definitions

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.

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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.

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Screen 15 - Configure Analogue Outputs

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

 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

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 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.

1) From the ‘Configure Interface’ menu press key ‘2’ to select the ‘Configure

Modbus Slave’ option.

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. Using

4) Use the scroll keys to select the chosen parameter and select using the 

Screen 16 - Configure Modbus Slave

the scroll keys, select a parameter to edit (option will be highlighted) and select the field with the  key.

key, or use the keypad to enter the numeric required followed by the  key to confirm.

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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 Relays

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

1) From the ‘Configure Interface’ menu press key ‘3’ to select the ‘Configure

Relays’ option.

Screen 17 - Configure Relays

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

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