Awite AwiECO User guide

PART A: PRODUCT DESCRIPTION, INSTALLATION AND OPERATION AWIECO AWITE BIOENERGIE
Original Instruction Manual
(Version: 12.0)
PART A: PRODUCT DESCRIPTION, INSTALLATION AND OPERATION AWIECO AWITE BIOENERGIE
Original Instruction Manual
(Version: 12.0)

Contact and Imprint
Please find the latest information online at WWW.AWITE.COM . For any questions, comments or
suggestions, please send an email to [email protected] .
Awite Bioenergie GmbH
Grünseiboldsdorfer Weg 5
85416 Langenbach Niederhummel, Germany
Phone: +49 8761 / 72 162 - 0
Fax: +49 8761 / 72 162 - 11
Email: [email protected]
http://www.awite.com
©2020 Awite Bioenergie GmbH
Errors and changes reserved
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Table of Contents
Table of Contents
1 Preface...................................................................................................................................... 5
2 Identification...............................................................................................................................6
3 Safety Instructions Part A.........................................................................................................7
4 Product description..................................................................................................................10
4.1 Intended Usage...................................................................................................... 10
4.2 Device Category According to ATEX Classification...............................................11
4.2.1 Device category not intended for installation in an Ex-zone.................................. 11
4.2.2 Device category intended for installation in an Ex-zone 2.....................................11
4.2.2.1 Safety device for monitoring the interior space......................................................12
4.3 Description of the Gas Analysis System and Dimensions..................................... 13
4.4 Ambient Conditions and Limits for Operation and Storage....................................16
4.4.1 Ambient Temperature.............................................................................................16
4.4.2 Ambient humidity....................................................................................................16
4.4.3 Installation height....................................................................................................16
4.4.4 Humidity and dust...................................................................................................16
4.4.5 Measuring gas pressure.........................................................................................16
4.4.6 Measuring gas, fresh air and exhaust air requirements.........................................17
4.5 Hazards from gas...................................................................................................17
4.5.1 Zone division.......................................................................................................... 18
4.5.2 Flame or explosion propagation over gas bearing lines........................................ 18
4.5.3 Leakage in the Measuring Gas Supply Line..........................................................18
4.5.4 Gas volume............................................................................................................ 18
4.5.5 Leaks in the Gas Analysis System........................................................................ 18
4.5.6 Release of Potentially Toxic and Harmful Gases...................................................19
5 Preparing the Gas Analysis System for Use..........................................................................20
5.1 Transport and Storage........................................................................................... 20
5.2 Installation...............................................................................................................20
5.2.1 Main Switch Mains Disconnection Facility............................................................. 21
5.2.2 Terminal boxes for electrical connections..............................................................21
5.2.2.1 Terminal box AwiECO............................................................................................22
5.2.2.2 Connection Cable 100–240 V for Power Supply....................................................22
5.2.2.3 Connection cable for DI (digital inputs) and DO (digital outputs)...........................22
5.2.2.4 Connection cable for AI (analogue inputs) and AO (analogue outputs).................23
5.2.3 Potential equalization..............................................................................................23
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Table of Contents
5.2.4 Data transmission of signals..................................................................................24
5.2.4.1 Profibus...................................................................................................................24
5.2.4.2 Analogue outputs....................................................................................................25
5.2.5 Information on Cable and Lines Routing................................................................25
5.2.6 Connection of analysis gas lines............................................................................26
5.2.6.1 Gas Inlets AwiECO.................................................................................................26
5.2.6.2 Extraction Points for Analysis Gas.........................................................................27
5.2.6.3 Laying of Analysis Gas Lines.................................................................................28
5.2.6.4 Exhaust air – Discharge of the Measuring Gas.....................................................28
5.2.7 Installation of Humidity and Flow Sensor AwiFLOW..............................................30
5.2.8 Initial Operation...................................................................................................... 32
6 Handling of the Gas Analysis System....................................................................................33
6.1 Maintenance........................................................................................................... 33
6.1.1 Cleaning..................................................................................................................33
6.1.2 Calibration...............................................................................................................34
6.1.3 Hydrogen sulphide filter..........................................................................................34
6.1.4 Detonation Flame Arrester.....................................................................................34
6.1.5 Connecting Tubes.................................................................................................. 34
6.1.6 Condensate traps................................................................................................... 35
6.2 Replacing a Fuse................................................................................................... 35
6.2.1 Specification Fuse F1 (Input Voltage 100–240 VAC).............................................35
6.2.2 Specification Fuse F2 (Power Supply Unit Output Voltage 24 VDC)..................... 35
6.3 Spare Parts List......................................................................................................35
6.4 Disposal.................................................................................................................. 36
6.5 Product Liability...................................................................................................... 36
7 Technical Data and Sensor Accuracy.................................................................................... 37
7.1 Technical Data........................................................................................................37
7.2 Accuracy, Service Life and Calibration of the Sensors..........................................37
8 Annex.......................................................................................................................................40
8.1 CE Declarations of Conformity...............................................................................40
8.1.1 CE Declaration of Conformity for Devices Not Intended to be Installed in an Ex-
Zone........................................................................................................................41
8.1.2 CE Declaration of Conformity for Devices Intended to be Installed in an Ex-
Zone........................................................................................................................42
8.2 IEC - Conformity Declaration................................................................................. 43
8.3 Certificat TÜV SÜD UL - CSA 61010-1-2012........................................................44
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Preface
1 Preface
PLEASE READ THE INSTRUCTION MANUAL AND SAFETY INSTRUC-
TIONS CAREFULLY BEFORE INSTALLATION AND OPERATION!
This Instruction Manual provides you with information to assist you in using the gas analysis system. The
Instruction Manual is part of the product and has to be kept throughout the service life of the product.
When subsequently passing on the gas analysis system to a third party, the customer has to provide the
Instruction Manual along with it. The new owner of the system has to be trained in the regulations referred
to. If you receive an amendment to the Instruction Manual at a later stage, this amendment is also part of
the Instruction Manual.
The device may only be used in a technically perfect condition and for its intended use, with awareness of
safety aspects and possible hazards and in full adherence with the Instruction Manual. Please operate and
service your gas analysis system based on the information in this Instruction Manual.
The Instruction Manual for the Awite – Gas Analysis System consists of two parts:
Part A: Product Description, Installation and Operation
Part B: Operation
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Identification
2 Identification
This Instruction Manual is intended for Awite Bioenergie GmbH gas analysis systems of the respective
series specified on the cover sheet. The type plate on the right hand side panel of the device indicates the
device type, the required voltage supply and the rated output.
The manufacturer's address is:
Awite Bioenergie GmbH
Grünseiboldsdorfer Weg 5
85416 Langenbach Niederhummel, Germany
Phone: +49 8761 / 72 162 - 0
Fax: +49 8761 / 72 162 - 11
Email: [email protected]
http://www.awite.com
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Safety Instructions Part A
3 Safety Instructions Part A
The device is only designed for situations of intended use. A non-intended use can lead to personal
injury and property damage. Only use the device as intended.
The device measures combustible or explosive gases and is installed in their environment. There is
a potential risk of spread or ignition of a hazardous atmosphere. Make sure to observe the rules
regarding explosion protection.
Biogas contributes to the greenhouse effect and thus to climate change. If possible, do not
discharge gas into the atmosphere.
The rated overpressure is 100 mbar. In case a precision pressure regulator is installed, this may
fail (snagged membrane). A higher pressure may cause damage and leaks, whereby an explosive
atmosphere could arise. Ensure that no more than 100 mbar pressure is reached. Set a pressure
regulator before the precision pressure regulator to max. 100 mbar . The risk for pressure control
systems for process gas with an input pressure above 100 mbar is to be considered separately,
because in case of failure, large amounts of gas could leak out.
Parts inside the device are under electrical voltage. Danger to life by electric shock! ALL installation
repair maintenance operations on the gas analysis system or on the whole plant must only be carried
out in a de-energized state and when the system is completely turned off. Observe electrical safety
regulations.
Biogas contains hydrogen sulphide. Gas leakage can lead to acute inhalation toxicity. At a
concentration of hydrogen sulphide of more than 22,000 ppm or room volumes that are less than
the standard container size (32 m³) or air exchange rates of less than once per hour, the risk of a
possibly even deadly poisoning caused by hydrogen sulphide needs to be assessed individually and
appropriate measures have to be taken. Avoid small room volumes and low air exchange rates.
An improperly performed installation, electric installation, initial operation, or maintenance of the
gas analysis system may cause hazards, especially due to gas and electrical current. These activities
must therefore only be performed by trained personnel. The specialist personnel must have read
and understood the Instruction Manual and follow its instructions.
„Hydrogen sulphide is toxic. Watch out for smell of rotten eggs. Ventilate the room and do not
enter."
„Carbon monoxide is toxic. A suitable gas warning sensor must be used, unless the ventilation is
sufcient."
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Safety Instructions Part A
The main switch serves as a mains disconnection facility to shut down the function and avoid hazards
caused by electricity. The device has to be installed in such a way that the main switch operation is
not impeded.
In case of a defect, gas leakage may occur. In case of insufcient ventilation, even small amounts can
lead to a hazard (poisoning, explosion) over a longer period of time. The device must therefore not
be installed in unvented shafts or poorly ventilated rooms.
Different electrical voltages may be present at the terminals in the terminal box. An incorrect
connection will lead to malfunction and hazards arising from electrical current. For information on
the allocation of the different terminals or the wiring in the terminal box please refer to the electric
diagram provided as part of the system.
Combustible gas could enter the device through the exhaust gas line and create an explosive
atmosphere there. Therefore, lead the exhaust lines separately and directly to the outside and have
nothing discharge into the exhaust gas line. In case of analysis gas recovery, ensure the exhaust gas
line is not longer than 20 m and have it lead the exhaust gas only into gas-bearing areas in which a
maximum underpressure or overpressure of 20 mbar prevails.
Gas which may be toxic, ammable or explosive ows through the exhaust gas line. Therefore,
the exhaust gas must not be released inside the building unless there is appropriately sufcient
ventilation.
The device conveys combustible gas. A continuous stay in the immediate vicinity of the device
may lead to a statistically increased risk of explosion. Therefore, no persons are allowed to stay
permanently in the vicinity of the device.
To ensure the safe and correct operation of the process analysis system, regular maintenance work
is an absolute necessity, as during this process wearing parts (such as seals) are replaced and the
whole system is checked thoroughly. Failure to comply increases the risk by gas leakage (danger of
explosion). The maintenance interval must therefore be observed.
The state of the gas analysis system must be checked on a regular basis, error messages need to
be addressed. In the event of the error messages "potentially dangerous atmosphere" or "risk of
explosion" as well as with loose hose ends, porous hoses or other leaks that lead to an explosion
hazard, disconnect the device from the gas supply and shut it down. Contact Awite or an Awite
contract partner.
"The drain of the condensate trap is a secondary source of gas release. In case of poor ventilation,
a hazardous explosive atmosphere may arise. Therefore please make absolutely sure to close the
discharge tap after emptying the condensate traps."
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Safety Instructions Part A
The device contains fuses that are under electrical voltage. Danger to life by electric shock. Replace
the fuses only in a non-energized state. Observe electrical safety regulations.
Leakages in the AwiCONTAINER may create a hazardous atmosphere. The ventilation grilles are
important in order to dilute the air in case of leakages. These must not be closed.
Carbon monoxide is odorless and toxic. It can accumulate in the AwiCONTAINER. A poisoning can
be deadly. With carbon monoxide-containing gas, install a suitable CO gas alarm sensor.
Leaking fuel gas mixture may cause an explosion hazard in the AwiCONTAINER. Install an
electrocatalytic gas warning sensor, except for biogas with low leakage ow (pressure at sampling
point max 20 mbar) or low ammable gas concentration (less than 4 % v v).
Gas warning sensors can deliver too low readings or even become unusable due to hydrogen
sulphide in the air. Calibrate gas warning sensors in according to manufacturer's recommendation
(every 6 months). If the ambient air contains hydrogen sulphide, shorten the calibration interval (to 3
months).
The gas analysis system contains icons with the following meaning:
Attention, General Hazard Point. Refer to the documentation. Disregarding this can
lead to death or serious personal injuries or property damages.
Warning of dangerous electrical voltage.
Please also observe the safety instructions in Part B!
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Product description
4 Product description
The following chapter contains information on the intended usage, the device category according to the
ATEX classification, the ambient conditions during operation and storage as well as safety information.
4.1 Intended Usage
WARNING
The device is only designed for situations of intended use. A non-intended use can lead to
personal injury and property damage. Only use the device as intended.
The gas analysis systems serve as analytical device for air, biogas, sewage gas, biomethane as well as
hydrogen up to 100vol% and hydrogen sulphide up to 5vol%. They are neither part of explosion protection
nor a warning device. They are used without any additional pressure reducing measures for measuring
biogas with a maximum of 20 mbar of underpressure or overpressure. The suitability for use in safety-
critical applications must be assessed by the user for each case. Reliability data can be provided by Awite
if required.
WARNING
The device is installed in the vicinity of combustible or explosive gases. Operating a non-explosion-
protected device in a hazardous atmosphere can cause an explosion with personal injury and property
damage. Do not place the device in a dangerous atmosphere unless a corresponding marking exists on
its housing.
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