BlueSens YieldMaster User manual

Rev. 170404001
Operating Manual
Betriebsanleitung

Copyright 2017 BlueSens. All rights reserved.
Information in thisdocument issubject to change without notice.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or
anymeanselectronic or mechanical, including photocopying and recording for any purpose other than
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BlueSens
Snirgelskamp 25
45699 Herten, Germany
+49 2366 / 4995-500

CONTENTS / INHALT
1 About this document 5
1.1 Function 5
1.2 Target group 5
1.3 Symbols used 5
2 For your safety 7
2.1 General information 7
2.2 Authorized personnel 7
2.3 Proper use 7
2.4 Misuse warning 7
2.5 General safety instructions 8
2.6 CE conformity 8
3 Product description 9
3.1 Yieldmaster 9
3.2 BCP-CH4 sensor 11
3.2.1 Measuring principle CH4 sensor 12
4 Installation 13
4.1 General information 13
4.2 Connecting the BCP-sensors and CounterBox to a PC 14
4.3 Preparing CounterBox 14
4.3.1 Option 1: connect the CounterBox to the BACCom12 14
4.3.2 Option 2: connect the CounterBox directly to the PC 15
4.3.3 Connect the BACCom12 to the PC 15
4.3.4 Settings of the Network Enabler Administrator for the BACCom 17
4.3.5 Connecting the sensors: option 1: connecting the BCP- sensors to the
BACCom12 25
4.3.6 Connecting the sensors: option 2: connecting the BCP-sensors dir-
ectly to the PC via USB 26
4.4 Installation of the Yieldmaster with one way valve and vessel 27
4.5 Installation with the preserving jar 32
4.5.1 Preparations for the measurement in the preserving jar 33
4.6 1-point calibration with the use of jars 38
4.6.1 Dismounting the flow adapter for preserving jars 41
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Contents / Inhalt

4.7 The compensating reservoir 42
5 Maintenance 44
5.1 1-point calibration 44
5.2 Recalibration 44
5.3 Filter change – coarse filter 45
5.3.1 Removing the filter cover 45
5.3.2 Changing the filter and seals (Z-XX-00052) 46
5.4 Minimization of dilution effects 47
5.5 Exchange of the Battery of the CounterBox 48
6 Appendix 49
6.1 Calibration table 49
7 Technical data 52
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Yieldmaster Operating Manual

1About this document
1.1 Function
This operating manual provides you with all of the necessary information for quick start-up
and safe operation of the Yieldmaster. Therefore, please read this operation manual before
starting operation.
1.2 Target group
This operating manual is intended for use by trained specialist personnel. The content of this
manual must be made available to the corresponding personnel and followed by them.
1.3 Symbols used
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicatesa hazardoussituation which, if not avoided, could result in
death or seriousinjury.
CAUTION
CAUTION indicatesa hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
Notice about a harmful situation, possible consequences: the product itself or sur-
rounding objectscould be damaged.
This symbol indicates helpful, additional information.
Rev. 170404001 5
About this document

1. Sequence of actions
Numbers indicate stepsto be performed in a certain sequence.
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Yieldmaster Operating Manual

2For your safety
2.1 General information
The Yieldmaster system wastested and readyfor operation when it left our plant.
Please read this operating manual carefully before installing the device and starting oper-
ation. The operating manual contains safety instructions that must be observed to ensure
safe operation.
The system maynever be operated in conditionsthat do not correspond to the specifications
on the type plate.
Maintenance and servicing mayonly be performed by speciallytrained personnel who are
familiar with the hazards inherent to the work aswellasthe guarantee terms.
2.2 Authorized personnel
All actions described in this operating manual may only be conducted by specialist personnel
who have been authorized bythe plant operator. Work on the device other than that
described in this manual may only be performed by personnel of the BlueSens gassensor
GmbH companyfor safetyreasonsand to ensure compliance with the terms of the guar-
antee.
2.3 Proper use
The Yieldmaster is an analysis system for simultaneousgasconcentration analysis(CH4and
other gases like CO2, O2, EtOH, H2also addable) and volume determination in the specified
concentration area and under the conditionsdescribed in the technicaldata. It is used to mon-
itor metabolism in biological processes such as fermentation. The BPC-sensors of the Yield-
master may only be used in well ventilated rooms.
DANGER
The sensor does not have an ATEX certificate and may therefore only be used in
well ventilated rooms.
2.4 Misuse warning
Partsof the Yieldmaster system maynot be used asa safetycomponent for monitoring
gassesin systemsor as a gaswarning device. It mayalso not be used in areassubject to explo-
sion hazards.
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For your safety

2.5 General safety instructions
If the device isnot used correctly, or used for itsintended purpose, application-specific haz-
ards mayarise.
DANGER
If the device isincorrectlyinstalled or set, there isa danger of explosionsand pois-
oning.
After installation, check all connections for leaks.
NOTICE
Please note the safety instructions in all the following chapters.
2.6 CE conformity
The Yieldmaster conforms to the EMC Directive (89/336/EEC, 92/31/EEC and 93/68/EEC)
when applying the harmonized standardsEN50081–1, EN61000.
The low-voltage directive (72/23/EEC und 93/68/EEC) isnot applicable as no voltage greater
than 24 Visused. You can find the EC Declaration of conformityon one of the last page of this
manual.
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Yieldmaster Operating Manual

3Product description
3.1 Yieldmaster
The Yieldmaster is an analysis system for the simultaneousmethane (CH4) and volume
determination. The biogasanalyzer Yieldmaster is a highly developed measuring system con-
sisting of microprocessor controlled infrared-gassensors, precision volumenometers (Mil-
liGascounter®) and the related BlueVis bioprocessing software. It isconsisting of up to 12
sets of BCP-CH4 sensors(other sensorsfor CO2, O2, EtOH, H2also addable) and the same
number of MilliGascounters. The CH4 concentration will be detected by the BCP-CH4
sensors and the produced volume will be detected by the MilliGascounter.
The CH4 sensorsBCP-CH4 are connected to a multiplexer boxBACCOM12 for the meth-
ane measurement inside the vessel. Alternatively, the sensorscan be connected with power
supply for each sensor and USB adapter. The MilliGascounter are connected to the Coun-
terBoxfor the detection of the volume. The CounterBoxwill be connected to the BACCom12
for the power supply and the data transfer. Alternatively, the CounterBoxcan be connected
with power supplyand USB adapter directlyto the PC. The BACCom12 will transfer the meas-
urement data of the Methane and the volume to a PC. The BACCom12 can be connected to
a PC via a serial connection or an Ethernet connection. The BACCom12 also can be integ-
rated into your local area network (LAN) by the Ethernet connection.
Every MilliGascounter isprotected by a one-wayvalve. This device secures that no fluid from
the MilliGascounter could be sucked into the fermentation vessel due to change of pressure
during longer experiments. During the experiment, Methane is produced inside of the fer-
mentation vessel.
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Product description

AUp to 12 CH4-sensors, other
sensors(CO2, O2, EtOH, H2) also
addable
FMilliGascounter® with one-wayvalve
BWater bath with integrated ther-
mostat and water compensation
GStirrer
CMultiplexer BACCom12 with integ-
rated pressure sensor and Coun-
terBoxwith integrated temperature
sensor
HSpecial flow adapter POM with two
gassensorsfor use with preserving
jars
DControl unit for magnetic stirrer
plate (water resistant magnetic stir-
rer plate is inside the water bath
and not shown on image)
IHeating jacket for preserving jars
EBlueVis Software for data logging
and process management
JMilliGascounter® with compensating
reservoir device
KControl unit for heating jacket
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Yieldmaster Operating Manual

3.2 BCP-CH4 sensor
For the CH4-measurement BCP-CH4 sensorsare included in the Yieldmaster analysissys-
tem. The BCP-CH4 is designed for a particular mechanical connection that can only be
altered subsequently at the plant for a certain fee. Please note the respective instructionsif
you are using additional sensorsfor other gas components (such as O2, H2, CO2 etc).
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Product description

3.2.1 Measuring principle CH4 sensor
The sensor contains the IR light source, the detector and the evaluation electronics.
The infrared light beam is reflected bythe gas-filled measuring adapter and the light
weakened bythe analyte gasismeasured by the detector. The light-permeable sapphire disc
preventsthe sample atmosphere from escaping and contaminating the optical components.
The sensor head heatsthe measuring adapter so that no moisture can condensate. The
heating time lastsabout 1 hour both during initialstart-up and after each time the device is dis-
connected from the power supply. The sensor doesnot output anymeasurement valuesdur-
ing the heating-up period.
A Sensor head
B Detector
C Light source
D Seal
E Sapphire window
F Light beam
G Sterile filter
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Yieldmaster Operating Manual

4Installation
4.1 General information
The Yieldmaster is protected by packaging on its wayto its application location. This secures it
against the usualtransport strains. However, before installation, check whether the device
hasbeen damaged due to improper transport or improper storage. If the device isdamaged
in anyway, operation without hazards isnot possible and the device maynot be installed and
taken into operation.
Check whether the enclosed materials such assealsand screw-caps are suitable for your pro-
cessconditions(pressure, temperature, etc.).
The installation should only be performed under supervision bya specialist and in compliance
with all applicable worksafetyrules. After the installation checkthe system for gas tightness.
CAUTION
The sterile filter is not intended for repelling fluids. Never install the sensor such
that fluid can run into the measuring adapter. If water has penetrated the meas-
uring adapter, allow it to dryout for at least 12 hours at max. 80 °C in a drying cab-
inet or on a hot plate. Protect the measuring adapter from penetration by liquids.
After installation, checkthat the system isgas-tight.
CAUTION
Read the installation instructionscarefullyto prevent damage to the device. Pro-
ceed step-by-step. Only use the original plugs, cables and power adapters.
Never connect or disconnect plugs when the device isconnected to the power
supply. The device doesnot have an on/off switch; it starts operation assoon asit
isconnected to the power supply. Improper operation can result in damage to the
device.
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Installation

4.2 Connecting the BCP-sensors and CounterBox to a PC
The Yieldmasteris a modular system with various types of mechanical and electronic con-
nections. In the first step the BCP-sensorsand the CounterBoxare connected to the PC .
4.3 Preparing CounterBox
It ispossible to connect the CounterBoxto the BACCom12 with a M12 to BACCom con-
nection cable. In that case the CouterBoxissupplied with power from the BACCom and the
data is transferred via the BACCom aswell. The other option isto connect the CounterBox
directlyto the PC via the Apapter cable M12 5pin to USB (RS232) (Article number Z-KA-
00032). In the latter case, the CounterBox needsa seperate power supply. See the following
chapters for detailsabout the preparing the CounterBox.
The CounterBoxcould be used with a Lithium battery, to avoid the loss of data
during a blackout. The measured volume will be stored for about 10 days. See
"Exchange of the Battery of the CounterBox" on page48 for detailsabout the use
of the battery. The installation of a batteryis recommended before measuring.
4.3.1 Option 1: connect the CounterBox to the BACCom12
If you want to connect the CounterBoxto the BACCom12 connect both devicesvia con-
nection cable BACCom CouterBoxM12M8 (article Number Z-KA-00049). The CounterBox
will send all the data to the BACCom12 . For this connection type the CounterBoxwill get the
power from the BACCom12 an will not need a separate power supply.
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Yieldmaster Operating Manual

4.3.2 Option 2: connect the CounterBox directly to the PC
The second option isto connect the CounterBoxdirectlyto the PC. In that case connect the
adapter cable M12 5pin to USB(RS232) (Article number Z-KA-00032) to the BACComCB
and connect the power supply to the cable. Use original equipment only to prevent damages
to the device.
Connect the adapter cable M12 5pin to USB (RS232) to the PC.
4.3.3 Connect the BACCom12 to the PC
Select the communication type with the “Communication” switch on the back of the BACCom
12. If you would like to use the RS-232 via USB serialconnection, select “RS-232” or select
“Ethernet” if you would like to use a connection via Ethernet.
Plug in the Ethernet cable into the Ethernet-port or the RS-232 connector to the RS-232-port
(RS-232 connection not shown).
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Installation

Connect a PC to the Ethernet cable or to the RS-232 connection (not shown on image).
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Yieldmaster Operating Manual

4.3.4 Settings of the Network Enabler Administrator for the BACCom
In the first step, install the Network Enabler Administrator (NEA). Run program "neadm_
setup_Ver2.10_Build_07072710.exe" and follow the instructions.
After that, open NEA, set IP address and COM port. After opening the program the
BACCOM has to be searched first. Run a Broadcast Search (Menu: Configuration/Broadcast
Search).
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Installation

If the BACCom iscorrectly connected a Model NE-4110S will be found.
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Yieldmaster Operating Manual

A configuration mask isopened bya double-click on the line with the corresponding module.
To set the networkparameters go to the tab Network and clickthe check boxModify.
Then the network address can be changed. Should other networkparameters have to be
changed also click on the corresponding Modifycheckboxand enter the desired values.
Leave the configuration mask with OK; the new networkparameters are transferred.
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Installation

NOTICE
For the proper function no settings other than the network settings maybe
changed.
After the configuration hasbeen stored in the BACCom, go to COM Mapping in the left Func-
tion field and then in the menu COM Mapping to Add Target.
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Yieldmaster Operating Manual