Geotech Biogas 300 User manual

OPERATING MANUAL
Geotech
Sovereign House, Queensway, Leamington Spa, Warwickshire, CV31 3JR, UK
www.geotechuk.com [e-mail] [phone]

Geotechnical Instruments (UK) Ltd OMBG300 –Iss.03
Table of Contents
Manual guidelines................................................................................. 7
1.1 Document history .................................................................................7
1.2 Safety Symbol.......................................................................................7
1.3 Hyperlinks.............................................................................................7
1.4 Notes....................................................................................................7
Introduction .......................................................................................... 8
2.1 General.................................................................................................8
2.2 Safety Instructions................................................................................8
2.3 Range of Environmental Conditions....................................................10
2.4 Safety Symbols Used on the BIOGAS 300............................................10
BIOGAS 300 Overview ......................................................................... 11
3.1 Features..............................................................................................11
3.2 Options...............................................................................................12
3.3 Benefits ..............................................................................................12
3.4 Main Applications...............................................................................12
3.5 Key Components.................................................................................13
3.6 BIOGAS 300 Module Features.............................................................17
Physical Characteristics of the Module ...............................................17
Definitions ..........................................................................................18
Installation .......................................................................................... 19
4.1 Pre-Installation Requirements ............................................................19
General...............................................................................................19
Package Contents ...............................................................................20
Storage of the System and Module.....................................................21
Ventilation Requirements...................................................................21
4.2 External Customer Connections..........................................................21
4.3 Mounting the Enclosure .....................................................................22

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4.4Connecting the Gas Lines to the BIOGAS 300 .....................................25
Sample Line ........................................................................................25
Process Return....................................................................................26
4.5 Drain...................................................................................................27
4.6 Protective Cover .................................................................................28
4.7 Cable Gland Selection and Cord Anchorage........................................29
4.8 Cable Conductor Sizes and Cable Insulation Requirements ................30
Cable Conductor Sizes ........................................................................30
Cable Insulation Requirements...........................................................30
4.9 Mains Wiring ......................................................................................30
Protective Earthing and Mains Supply ................................................30
How to Wire the Mains Supply ...........................................................31
4.10 Modbus Digital Output .......................................................................33
Wiring the BIOGAS 300 Modbus Outputs ...........................................34
Configuration of the BIOGAS 300 Modbus Port ..................................36
Readable Parameters of the BIOGAS 300 ...........................................36
4.11 4-20mA Outputs .................................................................................37
Wiring the BIOGAS 300 to ‘Current Source’ Inputs .............................37
Wiring the BIOGAS 300 to ‘Current Sink’ Inputs .................................40
4-20mA Scaling ...................................................................................42
4.12 Security...............................................................................................42
4.13 Final Checks ........................................................................................43
General Operation Instructions ........................................................... 44
5.1 Switching the BIOGAS 300 System On ................................................44
5.2 Menu..................................................................................................44
Time and Date ....................................................................................45
Sample Duration.................................................................................46
User Calibration..................................................................................47

Geotechnical Instruments (UK) Ltd OMBG300 –Iss.03
Factory Settings ..................................................................................48
Last reading ........................................................................................48
Information ........................................................................................49
Diagnostics .........................................................................................50
Modbus Slave Add. (Address) .............................................................50
Standby ..............................................................................................51
5.3 Taking a Reading.................................................................................52
Detailed Instructions ..........................................................................52
Simple Instructions –Flow Chart ........................................................54
5.4 Switching the BIOGAS 300 System Off................................................55
Calibration .......................................................................................... 56
6.1 Calibration Introduction .....................................................................56
6.2 Required Calibration Equipment.........................................................56
Gas .....................................................................................................56
Flow Regulator....................................................................................57
6.3 Gas Check ...........................................................................................58
6.4 CH4User Zero Calibration ...................................................................59
Detailed Instructions for Bottled Nitrogen User Zero .........................59
Detailed Instructions for User Zero in Air............................................62
Simple User Zero Calibration Instructions –Flow Chart ......................64
6.5 CH4User Span Calibration...................................................................66
Detailed Instructions for User Span Calibration ..................................66
Simple User Span Calibration Instructions –Flow Chart .....................69
6.6 Connecting a Gas Bottle to the BIOGAS 300 System ...........................71
6.7 Disconnecting a Gas Bottle from the BIOGAS 300 System ..................73
6.8 Set-Up for Using Clean Ambient Air Zero............................................75
6.9 Set-Up Following Clean Ambient Air Zero...........................................77
Maintenance ....................................................................................... 79

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7.1 Maintenance Schedule .......................................................................79
7.2 BIOGAS 300 Consumable Products .....................................................81
7.3 Emptying the Catchpot .......................................................................82
7.4 Replacing the Catchpot Filter..............................................................85
7.5 Replacing the Inline PTFE Filter...........................................................89
7.6 Pressure Test ......................................................................................91
General...............................................................................................91
Required Equipment...........................................................................91
Set-Up.................................................................................................91
Pressure Test ......................................................................................92
7.7 Cleaning and Decontamination...........................................................93
Service ................................................................................................ 94
8.1 General...............................................................................................94
8.2 Replacement BIOGAS 300 Module for Service –Hot Swap .................94
Problem Solving .................................................................................. 98
9.1 System Will Not Power On..................................................................98
9.2 Under and Over Range Codes.............................................................98
9.3 System Lock-Up ..................................................................................99
9.4 Modbus Outputs Not Working............................................................99
9.5 Analogue Outputs Not Working........................................................100
9.6 Flow Fail ...........................................................................................101
9.7 Fuses ................................................................................................102
9.8 User Calibration Explained................................................................103
General.............................................................................................103
Factory Calibration ...........................................................................103
User Zero Calibration........................................................................104
User Span Calibration .......................................................................104
Trouble Shooting ..............................................................................105

Geotechnical Instruments (UK) Ltd OMBG300 –Iss.03
9.9 CH4Reading Low...............................................................................106
BIOGAS 300 Warranty Terms and Conditions .................................... 107
WEEE Compliance.............................................................................. 109
Sample Certificate of Calibration ....................................................... 110
Declaration of Conformity ................................................................. 111
Glossary of Terms.............................................................................. 112

Operating Manual
Manual guidelines
7
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Manual guidelines
1.1 Document history
Issued by
Issue date
Change
control ID
Issue No.
Reason for change
CAM
23/04/15
N/A
01
First issue
1.2 Safety Symbol
Information in this manual that may affect the safety of users and others is in
the following format:
Warning
Warning text will be placed here.
Failure to follow this information may result in physical injury that in some
cases could be fatal, cause damage to the equipment or to the environment.
1.3 Hyperlinks
Hyperlinks to other sections of this manual, websites or email addresses are in
the following format:
www.geotechuk.com
1.4 Notes
Important/useful information and instructions are shown clearly throughout
the manual in a note format.
For example:
Note: For further information please contact your local distributor, or our
technical support team at Geotech on [phone] or email
technic[email protected].

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Operating Manual
Introduction
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Introduction
2.1 General
Welcome to the BIOGAS 300, a gas analyser that has been designed and
manufactured in the UK by Geotech, an ISO 9001, and ISO 17025 accredited
company whose products are distributed and supported worldwide. For more
information about Geotech and its history, please refer to our website
www.geotechuk.com.
The BIOGAS 300 is designed to measure methane concentrations generated in
small-scale anaerobic digesters. It has been developed to include the latest
design and technology to provide the user with a fast, simple to use and
accurate monitoring system.
This manual explains how to install, operate, and maintain the BIOGAS 300
range of systems.
Note: The BIOGAS 300 can be used in other applications that require the
measurement of methane. For further information please contact your
local distributor, or our sales team at Geotech on [phone] or
email [e-mail].
Note: Whilst robust in design, the BIOGAS 300 is a sensitive piece of
scientific equipment and is to be treated as such.
2.2 Safety Instructions
Warning
The BIOGAS 300 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.
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.
Inhaling toxic gases may be harmful to health and in
some cases may be fatal. It is the responsibility of the

Operating Manual
Introduction
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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.
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.
Only Geotech 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 part of routine inspections
or establishing from the material’s datasheet that it is resistant to
specific chemicals.
Warning
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.
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.
It is vital that the instructions in this operating manual
are followed closely. Failure to comply could cause an
injury to the operator.
Note: If there is any uncertainty, please contact your local distributor, or
our technical support team at Geotech on [phone] or email
technic[email protected].

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Operating Manual
Introduction
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2.3 Range of Environmental Conditions
The system is only for use in ambient temperatures in the range 0°C to
50°C.
The BIOGAS 300 is designed for use outdoors and has an IP65 rating.
The mains voltages (110-240V) can fluctuate up to ±10% of the nominal
voltage.
The system is only for use in ambient pressures in the range 750 to
1450mbar.
2.4 Safety Symbols Used on the BIOGAS 300
The following safety symbols may be used on the BIOGAS 300:
Protective conductor terminal
Caution, risk of electric shock
or
Caution
Caution, risk of hot surface
Warning
Where the symbol or is used in the BIOGAS 300,
the operating manual must be consulted.

Operating Manual
BIOGAS 300 Overview
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BIOGAS 300 Overview
3.1 Features
Easy to self-install, operate, and maintain, the BIOGAS 300 is a cost effective
fixed system biogas analyser for CH4monitoring. It is ideal for 500kW or
reduced scale anaerobic digestion plants, from agricultural to food waste
applications. The BIOGAS 300 builds on field-proven gas analysis technology to
offer effective and simple online monitoring with Modbus data outputs.
Market leading reliability
0-100% CH4measurement as standard
Single sample point
Configurable sample duration
Simple ‘push-button’ operation
Easy to read LED transflective display
Modbus communication
Stores last reading for easy-viewing
Gas return to process as standard
IP65 ABS enclosure

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Operating Manual
BIOGAS 300 Overview
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3.2 Options
4-20mA analogue data output (replaces Modbus)
Loop-powered isolators are available for connecting to current sinking
inputs with the 4-20mA option.
3.3 Benefits
No training required
Low cost of ownership
Quick and easy installation
Compact self-contained system
Moisture removal included as standard
Zero service downtime with hot-swappable module
Clear servicing schedules
Field-proven technology
Simple user calibration
3.4 Main Applications
Small-scale anaerobic digestion projects
Food and animal waste
Food processing plants
Dairy plants

Operating Manual
BIOGAS 300 Overview
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3.5 Key Components
Figure 1 –BIOGAS 300 external components
1
2

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Operating Manual
BIOGAS 300 Overview
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Figure 2 –BIOGAS 300 internal components
Note: For clarity, the protective guard that covers the mains terminals
has been removed in this image.
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Operating Manual
BIOGAS 300 Overview
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Figure 3 - BIOGAS 300 front components
17
3
5

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BIOGAS 300 Overview
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Gas-in ball valve
Sample button
Catchpot
Inline PTFE filter
BIOGAS 300 module
Control harness
Communications harness
Pump (optional)
PLC (with 4-20mA option)
24vdc power supply (with 4-20mA option)
5vdc power supply
Sample button and gas-in ball valve (internal location)
Drain ball valve
Gas-out ball valve
Data output terminals (Modbus / 4-20mA / loop-powered isolators)
Mains input terminals
Local distributor information
Note: The data output terminals will be for Modbus, 4-20mA, or loop-
powered isolators depending on the option chosen at point of
manufacture.

Operating Manual
BIOGAS 300 Overview
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3.6 BIOGAS 300 Module Features
Physical Characteristics of the Module
Front view:
Reference:
Display
Menu key
Scroll up
Scroll down
Escape key
Return key
Rear view:
Manufacturer’s label
Serial number
Product option
number
Left side view:
Gas inlet port
Gas outlet port
USB port
1
2
3
4
5
6
7
8
9
10
11
12

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Operating Manual
BIOGAS 300 Overview
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Definitions
Front View
Reference
Definition
Display
Shows information to the user
Menu key
Press the ‘menu’ key to navigate to the
‘menu’from the standby screen.
Scroll up
Press ↑ to navigate through menu options.
Also used to increment values in certain
menu items.
Scroll down
Press ↓ to navigate through menu options.
Also used to decrement values in certain
menu items.
Escape key
Exits screens without saving changes. Also
used as a backspace key in certain menu
items.
Return key
The key accepts/confirms choices made
by the operator for various functions and
operations.
Rear View
Manufacturer’s label
This displays information regarding the
manufacturer, such as contact details.
Serial number
This is the unique identification number for
the BIOGAS 300 module.
Product option number
This is the unique record for the internal
configuration of the BIOGAS 300 module at
time of manufacture or last service.
Left Side View
Gas inlet port
Gas sample enters the BIOGAS 300 module
here. Also used as the connection point for
calibration gas.
Gas outlet port
Gas sample exits the BIOGAS 300 module
here.
USB port
Used by Geotech service team.

Operating Manual
Installation
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Installation
4.1 Pre-Installation Requirements
General
It is Geotech’s recommendation that the installation of the BIOGAS 300 is
carried out in accordance with this operating manual. 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 300 system it is important that the
site is ready and in a fit state. In particular, the following points should be
noted:
Warning
Power should NOT be applied before all piping and
wiring has been completed and tested.
Only a qualified person should make electrical
connections to the system.
This operating manual has been read and fully understood.
A risk assessment has been performed that includes installation,
operation, and maintenance of the system and the removal, where
practicably possible, of any identified hazards.
Applicable codes of practice identified.
The BIOGAS 300 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
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Note: Inlet pressure to the BIOGAS 300 system must not exceed 50
mbars (0.7psi) gauge on non-pumped versions. Where this is exceeded,
either a pumped BIOGAS 300 is required or additional flow restriction is
required.
Note: Inlet pressure to the BIOGAS 300 system must not exceed 350
mbars (5psi) gauge on pumped versions. Where this is exceeded,
additional pressure regulation is required.
Output data cable has been installed (if required) to the BIOGAS 300
location.
Note: Failure to comply with any of the above may result in additional
time on site and additional costs.
Package Contents
Check the product box for the following items:
BIOGAS 300 system
Padlock and key set
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
Three 6mm compression fittings –found in the bulkheads on the
enclosure base (see annotation 1, 2, and 3 on Figure 4 - BIOGAS 300
connection points).