Awite AwiFLEX XL User guide

PART A: PRODUCT DESCRIPTION, INSTALLATION AND OPERATION AWIFLEX XL AWITE BIOENERGIE
Original Instruction Manual
(Version: 18.0)

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
© 2022 Awite Bioenergie GmbH
Errors and changes reserved
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Table of Contents
Table of Contents
1 Preface................................................................................................................................................6
2 Identification......................................................................................................................................7
3 Safety Instructions Part A.................................................................................................................8
4 Product description........................................................................................................................12
4.1 Intended Usage............................................................................................................ 12
4.2 Device Category According to ATEX Classification................................................ 13
4.2.1 Device category not intended for installation in an Ex-zone..................................13
4.2.2 Device category intended for installation in an Ex-zone 2..................................... 13
4.2.2.1 Safety device for monitoring the interior space.......................................................14
4.3 Description of the Gas Analysis System and Dimensions.......................................15
4.4 Ambient Conditions and Limits for Operation and Storage...................................18
4.4.1 Installation location...................................................................................................... 18
4.4.2 Installation height......................................................................................................... 18
4.4.3 Ambient Temperature..................................................................................................18
4.4.4 Ambient humidity.........................................................................................................18
4.4.5 Mains voltage fluctuations...........................................................................................18
4.4.6 Overvoltage category.................................................................................................. 19
4.4.7 Wetness and degree of pollution in the environment............................................ 19
4.4.8 Measuring gas pressure.............................................................................................. 19
4.4.9 Measuring gas, fresh air and exhaust air requirements.......................................... 19
4.5 Hazards from gas..........................................................................................................20
4.5.1 Zone division.................................................................................................................20
4.5.2 Flame or explosion propagation over gas bearing lines........................................20
4.5.3 Leakage in the Measuring Gas Supply Line............................................................. 21
4.5.4 Gas volume....................................................................................................................21
4.5.5 Leaks in the Gas Analysis System...............................................................................21
4.5.6 Release of Potentially Toxic and Harmful Gases.......................................................21
5 Preparing the Gas Analysis System for Use................................................................................23
5.1 Transport and Storage................................................................................................. 23
5.2 Installation......................................................................................................................23
5.2.1 Main Switch Mains Disconnection Facility.................................................................24
5.2.2 Terminal boxes for electrical connections.................................................................24
5.2.2.1 Terminal Boxes AwiFLEX XL........................................................................................25
5.2.2.2 Connection Cable 100–240 V for Power Supply...................................................... 25
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Table of Contents
5.2.2.3 Connection cable for DI (digital inputs) and DO (digital outputs).........................25
5.2.2.4 Connection cable for AI (analogue inputs) and AO (analogue outputs)...............26
5.2.3 Potential equalization...................................................................................................26
5.2.4 Data transmission of signals....................................................................................... 27
5.2.4.1 Profibus...........................................................................................................................27
5.2.4.2 Analogue outputs.........................................................................................................28
5.2.5 Information on Cable and Lines Routing.................................................................. 28
5.2.6 Connection of analysis gas lines................................................................................ 29
5.2.6.1 Extraction Points for Analysis Gas.............................................................................. 29
5.2.6.1.1 Gas extraction fitting unpressurized and up to 400 mbar..................................... 29
5.2.6.1.2 Gas extraction fitting up to 16bar (PN16)................................................................31
5.2.6.2 Laying of Analysis Gas Lines.......................................................................................32
5.2.6.3 Gas Inlets AwiFLEX XL.................................................................................................33
5.2.6.4 Exhaust air – Discharge of the Measuring Gas.........................................................34
5.2.7 Installation of Humidity and Flow Sensor AwiFLOW............................................... 35
5.2.8 Initial Operation............................................................................................................37
6 Handling of the Gas Analysis System..........................................................................................38
6.1 Maintenance.................................................................................................................. 38
6.1.1 Cleaning.........................................................................................................................38
6.1.2 Calibration..................................................................................................................... 39
6.1.3 Hydrogen sulphide filter..............................................................................................39
6.1.4 Detonation Flame Arrester..........................................................................................39
6.1.5 Connecting Tubes.........................................................................................................39
6.1.6 Condensate traps......................................................................................................... 40
6.2 Replacing a Fuse.......................................................................................................... 40
6.2.1 Specification Fuse F1 (Input Voltage 100–240 VAC)............................................... 40
6.2.2 Specification Fuse F2 (Power Supply Unit Output Voltage 24 VDC)......................40
6.3 Spare Parts List..............................................................................................................40
6.4 Disposal..........................................................................................................................41
6.5 Product Liability............................................................................................................ 41
7 Technical Data and Sensor Accuracy.......................................................................................... 42
7.1 Technical Data...............................................................................................................42
7.2 Accuracy, Service Life and Calibration of the Sensors............................................ 42
8 AwiDESULF combi-package for microbiological desulphurisation.........................................45
8.1 Intended Usage............................................................................................................ 52
8.2 Assumptions for Interpreting......................................................................................52
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Table of Contents
8.3 Required Space.............................................................................................................52
8.4 Mechanical Connection............................................................................................... 54
8.5 Electrical Connection................................................................................................... 55
8.6 Maintenance.................................................................................................................. 56
8.6.1 Check non-return valve and solenoid valve............................................................. 56
8.6.2 Procedure for checking the non-return valve and solenoid valve......................... 56
9 AwiLAB Gas analysis...................................................................................................................... 58
9.1 Required Space.............................................................................................................59
9.2 Mechanical Connection............................................................................................... 59
9.3 Electrical Connection................................................................................................... 59
10 AwiVac..............................................................................................................................................61
10.1 Required Space.............................................................................................................62
10.2 Assemblies in the AwiVac........................................................................................... 63
10.3 Mechanical Connection............................................................................................... 64
10.4 Electrical Connection................................................................................................... 65
11 AwiWarn...........................................................................................................................................66
11.1 Installation AwiWarn.....................................................................................................66
11.2 Required Space.............................................................................................................67
11.3 Electrical Connection................................................................................................... 68
11.4 Settings and calibration...............................................................................................69
12 Annex............................................................................................................................................... 70
12.1 Declarations of Conformity......................................................................................... 70
12.1.1 CE Declaration of Conformity for Devices Not Intended to be Installed in an Ex-
Zone................................................................................................................................71
12.1.2 CE Declaration of Conformity for Devices Intended to be Installed in an Ex-
Zone................................................................................................................................72
12.1.3 UKCA Declaration of Conformity for Devices Not Intended to be Installed in an
Ex-Zone...........................................................................................................................73
12.1.4 UKCA Declaration of Conformity for Devices Intended to be Installed in an Ex-
Zone................................................................................................................................74
12.1.5 IEC - Conformity Declaration......................................................................................75
12.2 Certificat TÜV SÜD UL - CSA 61010-1-2012.............................................................77
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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.
Line breakage, breakage of fittings and damage inside and outside the unit can lead to explosion
hazard and risk of poisoning. Regularly check pipes and fittings for changes (damage, corrosion,
brittleness, leaks, animal damage) or have maintenance carried out. Replace if necessary (use
only suitable materials and fittings).
Biogas contributes to the greenhouse effect and thus to climate change. If possible, do not
discharge gas into the atmosphere.
Excessive rated pressure on the gas analysis system can cause gas to escape. During shutdown,
when no gas is present at the sensors, the device can withstand a maximum of 2 bar overpressure
up to the first valve. If the system pressure at the gas extraction points is reduced by the
customer, it must be ensured that no more than 2 bar can reach the gas analysis system even in
the event of a fault.
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.
Carbon monoxide is odorless and toxic. In the event of a fault, it can accumulate in the device and
escape in a gush when it is opened. While opening the housing, ensure sufficient ventilation and
distance or monitor the environment for carbon monoxide.
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.
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Safety Instructions Part A
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
sufficient.
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 insufficient 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, flammable or explosive flows through the exhaust gas line. Therefore,
the exhaust gas must not be released inside the building unless there is appropriately sufficient
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.
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Safety Instructions Part A
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.
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.
The measuring point switch-over includes a diffusion opening to prevent the occurrence of a
dangerous atmosphere (explosion hazard) inside. Therefore check coarse dust filter for any dirt
on a regular basis and clean it in order to maintain its function.
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 flow (pressure at
sampling point max 20 mbar) or low flammable 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).
Disconnecting the connection cable between the AwiLAB and the milligas counter or the drum
gas meter, respectively, during operation may lead to faulty controls. This can cause excessive
pressure in the connected collecting gas bags, which could then lead to damage and thus to gas
leakage. Before conversion work, the gas analysis system must be de-energized.
AwiDESULF: In order to avoid gas leakage via the air supply line and thus a risk of explosion, a
leakage test of the air supply line with non-return valve must be carried out after installation and
initial operation of the system.
AwiDESULF PureOxygen: Pure oxygen can react explosively with oil and grease. Do not use
lubricants and sealants containing oil or grease in pure oxygen or enriched air.
AwiDESULF: Hot surface on the compressor, thus risk of burns. Do not touch.
The gas analysis system contains icons with the following meaning:
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