Geotech BIOGAS 3000 User manual

BIOGAS 3000
OPERATING MANUAL

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TABLE OF CONTENTS
Manual guidelines.....................................................................................................................................8
Safety symbol........................................................................................................................................8
Hyperlinks .............................................................................................................................................8
Notes.....................................................................................................................................................8
Safety information ....................................................................................................................................9
Safety instructions ................................................................................................................................9
ATEX and IECEx Certification...............................................................................................................10
Marking...............................................................................................................................................10
Instructions Specific to Hazardous Area Installations .........................................................................11
Entity Parameters ...............................................................................................................................12
Range of environmental conditions ....................................................................................................13
Safety symbols used on the instrument..............................................................................................13
BIOGAS 3000 Overview...........................................................................................................................14
Features ..............................................................................................................................................14
Benefits...............................................................................................................................................15
Options ...............................................................................................................................................15
Main Applications ...............................................................................................................................15
Model Type Definitions.......................................................................................................................16
BG3K1 .............................................................................................................................................16
BG3K2 .............................................................................................................................................16
BG3K3 .............................................................................................................................................17
BG3K4 .............................................................................................................................................17
BG3KD.............................................................................................................................................18
BG3KE .............................................................................................................................................19
BIOGAS 3000 Internal Components........................................................................................................20
BIOGAS 3000 Module Features...............................................................................................................22
Physical Characteristics of the Module ...............................................................................................22
Definitions...........................................................................................................................................23
Installation ..............................................................................................................................................25
Pre-Installation Requirements ............................................................................................................25

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General ...........................................................................................................................................25
Packaging Contents.........................................................................................................................25
Storage of the System and Module.................................................................................................26
Ventilation Requirements ...............................................................................................................26
External Customer Connections..........................................................................................................27
Mounting the Enclosure......................................................................................................................28
Connecting the Gas Lines to the BIOGAS 3000 ...................................................................................29
Gas Sample Lines ............................................................................................................................29
Process Return................................................................................................................................30
Air In................................................................................................................................................31
Vent to Atmosphere........................................................................................................................31
Drain ...................................................................................................................................................31
Protective Cover .................................................................................................................................33
Cable Gland Selection and Cord Anchorage........................................................................................34
Cable Conductor Sizes and Insulation Requirements..........................................................................35
Cable Conductor Sizes.....................................................................................................................35
Cable Insulation Requirements .......................................................................................................35
Mains Wiring.......................................................................................................................................35
Protective Earthing and Mains Supply ............................................................................................35
How to Wire the Mains Supply .......................................................................................................36
Modbus Digital Output .......................................................................................................................38
Wiring the BIOGAS 3000 Modbus Outputs .....................................................................................39
Default Configuration of the BIOGAS 3000 Modbus Port ...............................................................40
Readable Parameters of the BIOGAS 3000 .....................................................................................41
4-20mA Outputs .................................................................................................................................47
General Information .......................................................................................................................47
Wiring the BIOGAS 3000 to a Current Sinking Input .......................................................................47
4-20mA Scaling ...............................................................................................................................49
Relays..................................................................................................................................................50
Profibus Digital Output .......................................................................................................................51
Configuration of the Profibus Module ............................................................................................51

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Wiring the Profibus Module............................................................................................................53
Readable Parameters of the Profibus Module................................................................................55
Profinet Digital Output........................................................................................................................59
Configuration of the Profinet Module.............................................................................................59
Wiring the Profinet Module............................................................................................................60
Readable Parameters of the Profinet Module ................................................................................62
Ethernet Digital Output.......................................................................................................................65
Configuration of the Ethernet Module............................................................................................66
Wiring the Ethernet Module...........................................................................................................66
Readable Parameters of the Ethernet Module ...............................................................................69
Heater Option .....................................................................................................................................72
Final Checks ........................................................................................................................................72
General Operating Instructions...............................................................................................................73
Switching the BIOGAS 3000 System On ..............................................................................................73
System Start-Up ..................................................................................................................................73
Language Selection .........................................................................................................................73
Time and Date.................................................................................................................................73
Interface Board Firmware Update ..................................................................................................74
Self-Test ..........................................................................................................................................75
Help Function......................................................................................................................................76
First Time Configuration .....................................................................................................................77
Gas Readings Screen...........................................................................................................................79
1. Time and date.......................................................................................................................79
2. Sample point status ..............................................................................................................79
3. Current operation.................................................................................................................80
4. Operation time remaining ....................................................................................................80
5. Cycle time remaining ............................................................................................................80
6. Pump flow rate .....................................................................................................................80
7. View alarms ..........................................................................................................................80
8. Catchpot full icon..................................................................................................................81
9. Service icon...........................................................................................................................81

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10. Stop sampling .......................................................................................................................81
11. Non-critical fault warning .....................................................................................................81
12. Scroll left...............................................................................................................................81
13. View faults ............................................................................................................................81
14. Scroll right.............................................................................................................................82
15. Current view .........................................................................................................................82
16. Gas readings .........................................................................................................................82
Alarms.................................................................................................................................................82
Notification .....................................................................................................................................82
Viewing Alarms ...............................................................................................................................83
Stop Sampling .....................................................................................................................................84
Menu...................................................................................................................................................85
Settings Menu.................................................................................................................................85
Device Information Menu...............................................................................................................99
Calibration Menu ..........................................................................................................................102
BIOGAS 3000 Sampling Process ........................................................................................................107
BG3K1, 2, 3, 4, and D Variants ......................................................................................................107
BG3KE Variants .............................................................................................................................108
Switching the BIOGAS 3000 System Off........................................................................................109
Gas Check and Calibration ....................................................................................................................110
Introduction......................................................................................................................................110
Required Equipment.........................................................................................................................110
Gas ................................................................................................................................................110
Flow Regulator..............................................................................................................................111
Gas Mixtures.....................................................................................................................................111
Adding a Mixture...........................................................................................................................112
Deleting a Mix...............................................................................................................................113
Edit O2 in Fresh Air Mix.................................................................................................................114
Connecting a Gas Bottle to the BIOGAS 3000...................................................................................115
Gas Check and Calibration ................................................................................................................117
Status Icons.......................................................................................................................................119

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Post Gas Check..............................................................................................................................119
Post Calibration.............................................................................................................................119
Disconnecting a Gas Bottle from the BIOGAS 3000 ..........................................................................120
Maintenance.........................................................................................................................................122
Maintenance Schedule .....................................................................................................................122
BIOGAS 3000 Consumable Products.................................................................................................124
Emptying the Catchpot .....................................................................................................................126
Replacing the Catchpot Filter............................................................................................................129
Replacing the Inline PTFE Filter.........................................................................................................133
Pressure Test.....................................................................................................................................136
Required Equipment .....................................................................................................................136
Diagnostics Control Mode.............................................................................................................136
General Set-Up..............................................................................................................................138
Performing the Pressure Test .......................................................................................................138
Cleaning and Decontamination.........................................................................................................143
Service...................................................................................................................................................144
General .............................................................................................................................................144
Service Notifications .........................................................................................................................144
Replacement BIOGAS 3000 Module for Service –Hot Swap ............................................................144
Problem Solving ....................................................................................................................................147
Fault Detection .................................................................................................................................147
Non-Critical Faults.........................................................................................................................147
Critical Faults.................................................................................................................................148
System Will Not Power On................................................................................................................149
Module Will Not Power On ...............................................................................................................149
Module Lock-Up................................................................................................................................150
Under and Over Range Codes...........................................................................................................150
Analogue Outputs Not Working........................................................................................................150
Modbus Outputs Not Working..........................................................................................................151
Low Flow / Flow Fail..........................................................................................................................151
Fuses .................................................................................................................................................152

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User Calibration Explained................................................................................................................153
General .........................................................................................................................................153
Factory Calibration........................................................................................................................153
User Zero Calibration ....................................................................................................................153
User Span Calibration....................................................................................................................154
Trouble Shooting...........................................................................................................................154
Event Log ..........................................................................................................................................156
BIOGAS 3000 Warranty Terms and Conditions.....................................................................................157
WEEE Compliance.................................................................................................................................159
Declaration of Conformity.....................................................................................................................160
Glossary of Terms .................................................................................................................................162

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MANUAL GUIDELINES
Safety symbol
Information in this manual that may affect the safety of users and others is in the following format:
Information in this manual that may affect the safety of users and others will be in a box
indentical to this one.
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.
Hyperlinks
Hyperlinks to other sections of this manual, websites or email addresses are in the following format:
www.geotechuk.com
Notes
Important/useful information and instructions are shown clearly throughout the manual in a note
format.
For example:
Note: For further information please contact Technical Support at QED on [phone] or
email [email protected]o.uk.

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SAFETY INFORMATION
Safety instructions
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.
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 QED 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: For further information please contact Technical Support at QED on [phone] or

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email [email protected]o.uk.
ATEX and IECEx Certification
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.
Marking
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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Nameplate 1 - BIOGAS 3000 markings
Instructions Specific to Hazardous Area Installations
The equipment may be used in zones 2 with flammable gases and vapours with apparatus
groups IIA and with temperature classes T1.
The equipment is only certified for use in ambient temperatures in the range -20ºC to +50ºC
and should not be used outside this range.
Installation shall be carried out in accordance with the applicable code of practice by suitably
trained personnel.
There is no special checking or maintenance conditions other than a periodic check.
With regard to explosion safety, it is not necessary to check for correct operation.
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 QED on [phone] or email
[e-mail] to receive training on repairing the equipment and becoming an
approved repair agent.
Repair of this equipment shall be carried out in accordance with the applicable code of practice.

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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.
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 Cable Conductor Sizes.
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.
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.
Note: Regarding the use of covers, jumpers, and end brackets, the instructions of the
manufacturer must be followed.
Entity Parameters
The following ratings must not be exceeded on the listed circuits below:
Circuit
Ur (rated voltage)
Ir (rated current)
Pr (rated power)
Relay coil
24Vdc
6A
144W
4-20mA
24Vdc
20mA
480mW
RS485 Modbus
-7 to +12V
83.3mA
417mW

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Range of environmental conditions
The system is only for use in ambient temperatures in the range of 0°C to 50°C without the use
of the approved heater, and -20°C to 50°C 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.
Safety symbols used on the instrument
The following safety symbols are used on the BIOGAS 3000:
Protective conductor terminal
Caution, risk of electric shock
Function earth (ground) terminal
or
Caution
Caution, risk of hot surface
Where the symbol or is used in the BIOGAS 3000, the operating manual must be
consulted.

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BIOGAS 3000 OVERVIEW
Features
The BIOGAS 3000, primarily for the AD Biogas and Bio-methane upgrading market has been designed
to enable site operations to maximise 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.
CH4, CO2& O2–standard measurements
H2S, H2and 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 desulphurisation
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

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6 x 4-20mA outputs
Modbus RTU communication
Optional Profibus and Profinet communication
Clear, visual and informative colour display
Optional heater to extend operating temperature range to -20°C
Multi-lingual product with literature and technical support now available in German, Chinese,
and English.
Extended Warranty and Service pack options through approved global service centres
Benefits
Customisable to site requirements
Zero operational downtime for servicing
Product reliability and longevity
Protect expensive capital equipment from damaging gases
Maximise operational efficiency through optimising the AD process
Operational within hazardous areas
Ease of operation, integration and installation
Minimal through-life costs
Local support for peace of mind
Options
H2S ranges from 0-50ppm to 0-10,000ppm
CO 0-1,000ppm
H20-1,000ppm
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
Main Applications
AD research

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Agricultural waste AD (large scale)
Biogas upgrading
Farm waste AD (small scale)
Gas flaring
Mixed food waste AD
Sewage / waste water treatment AD
Model Type Definitions
BG3K1
The BG3K1 measures CH4, CO2, and O2as 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
The BG3K2 measures CH4, CO2, and O2as 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:

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BG3K3
The BG3K3 measures CH4, CO2, and O2as 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:
Note: For this option, you will need to fit the additional moisture filter supplied on ‘Sample Gas 1’.
BG3K4
The BG3K4 measures CH4, CO2, and O2as 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

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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:
Note: For this option, you will need to fit the additional moisture filter supplied on ‘Sample Gas 1’.
BG3KD
The BG3KD measures CH4, CO2, O2and 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 H2S 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:

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BG3KE
The BG3KE measures CH4, CO2, and O2as standard with a choice of up to one additional gas
(external to module only) from one sample point.
It measures CH4, CO2, and O2continuously that is exhausted back to the process.
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

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BIOGAS 3000 INTERNAL COMPONENTS
Figure 1 - BIOGAS 3000 door internals
1)
Viewing window
2)
Heater (110V or 230V)
3)
Plastic wallet containing operating manual and calibration certificate
1
2
3