LANDTEC BIOGAS 3000 User manual

OPERATING MANUAL

OMBG3000 –Iss.A
© Copyright 2016 –

© Copyright 2016
OMBG3000 –Rev1
Table of Contents
Manual guidelines ................................................................................. 91
1.1 Safety symbol ........................................................................................ 9
1.2 Hyperlinks.............................................................................................. 9
1.3 Notes ..................................................................................................... 9
Safety information .............................................................................. 102
2.1 Safety instructions ............................................................................... 10
2.2 ATEX and IECEx Certification ............................................................... 12
Marking ............................................................................................... 122.2.1
Instructions Specific to Hazardous Area Installations.......................... 132.2.2
Entity Parameters ................................................................................ 152.2.3
2.3 Range of environmental conditions .................................................... 15
2.4 Safety symbols used on the instrument .............................................. 16
BIOGAS 3000 Overview ....................................................................... 173
3.1 Features............................................................................................... 17
3.2 Benefits................................................................................................ 18
3.3 Options ................................................................................................ 19
3.4 Main Applications................................................................................ 19
3.5 Model Type Definitions ....................................................................... 20
BG3K1 .................................................................................................. 203.5.1
BG3K2 .................................................................................................. 203.5.2
BG3K3 .................................................................................................. 213.5.3
BG3K4 .................................................................................................. 223.5.4
BG3KD.................................................................................................. 233.5.5
BG3KE .................................................................................................. 233.5.6
3.6 BIOGAS 3000 Internal Components..................................................... 25
3.7 BIOGAS 3000 Module Features ........................................................... 27

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Physical Characteristics of the Module................................................ 273.7.1
Definitions ........................................................................................... 293.7.2
Installation .......................................................................................... 314
4.1 Pre-Installation Requirements............................................................. 31
General ................................................................................................ 314.1.1
Packaging Contents ............................................................................. 324.1.2
Storage of the System and Module ..................................................... 324.1.3
Ventilation Requirements.................................................................... 334.1.4
4.2 External Customer Connections .......................................................... 33
4.3 Mounting the Enclosure ...................................................................... 34
4.4 Connecting the Gas Lines to the BIOGAS 3000.................................... 36
Gas Sample Lines ................................................................................. 364.4.1
Process Return..................................................................................... 374.4.2
Air In .................................................................................................... 384.4.3
Vent to Atmosphere ............................................................................ 384.4.4
4.5 Drain .................................................................................................... 38
4.6 Protective Cover .................................................................................. 41
4.7 Cable Gland Selection and Cord Anchorage ........................................ 42
4.8 Cable Conductor Sizes and Insulation Requirements .......................... 44
Cable Conductor Sizes ......................................................................... 444.8.1
Cable Insulation Requirements............................................................ 444.8.2
4.9 Mains Wiring ....................................................................................... 45
Protective Earthing and Mains Supply................................................. 45
4.9.1
How to Wire the Mains Supply............................................................ 464.9.2
4.10 Modbus Digital Output ........................................................................ 48
Wiring the BIOGAS 3000 Modbus Outputs.......................................... 484.10.1
Default Configuration of the BIOGAS 3000 Modbus Port.................... 504.10.2
Readable Parameters of the BIOGAS 3000.......................................... 504.10.3

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OMBG3000 –Rev1
4.11 4-20mA Outputs .................................................................................. 57
General Information ............................................................................ 574.11.1
Wiring the BIOGAS 3000 to a Current Sinking Input............................ 584.11.2
4-20mA Scaling .................................................................................... 604.11.3
4.12 Relays .................................................................................................. 61
4.13 Profibus Digital Output........................................................................ 63
Configuration of the Profibus Module................................................. 634.13.1
Wiring the Profibus Module ................................................................ 654.13.2
Readable Parameters of the Profibus Module .................................... 684.13.3
4.14 Profinet Digital Output ........................................................................ 72
Configuration of the Profinet Module ................................................. 724.14.1
Wiring the Profinet Module................................................................. 734.14.2
Readable Parameters of the Profinet Module..................................... 764.14.3
4.15 Heater Option...................................................................................... 79
4.16 Final Checks ......................................................................................... 80
General Operating Instructions ........................................................... 815
5.1 Switching the BIOGAS 3000 System On............................................... 81
5.2 Self-Test............................................................................................... 81
5.3 First Time Run Set-up .......................................................................... 83
5.4 Gas Readings Screen............................................................................ 85
5.5 Alarms.................................................................................................. 88
Notification.......................................................................................... 885.5.1
Viewing Alarms.................................................................................... 89
5.5.2
5.6 Stop Sampling...................................................................................... 90
5.7 Menu ................................................................................................... 91
Settings Menu...................................................................................... 925.7.1
Device Information Menu.................................................................. 1085.7.2
Calibration Menu............................................................................... 1125.7.3

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5.8 Help Function .................................................................................... 117
5.9 BIOGAS 3000 Sampling Process......................................................... 118
BG3K1, 2, 3, 4, and D Variants ........................................................... 1185.9.1
BG3KE Variants .................................................................................. 1195.9.2
5.10 Switching the BIOGAS 3000 System Off ............................................ 120
Gas Check and Calibration ................................................................. 1216
6.1 Introduction....................................................................................... 121
6.2 Required Equipment.......................................................................... 122
Gas..................................................................................................... 1226.2.1
Flow Regulator................................................................................... 1226.2.2
6.3 Gas Mixtures...................................................................................... 123
Adding a Mixture ............................................................................... 1246.3.1
Deleting a Mix.................................................................................... 1256.3.2
Edit O2in Fresh Air Mix...................................................................... 1266.3.3
6.4 Connecting a Gas Bottle to the BIOGAS 3000.................................... 128
6.5 Gas Check and Calibration................................................................. 131
6.6 Status Icons ....................................................................................... 133
Post Gas Check .................................................................................. 1336.6.1
Post Calibration ................................................................................. 1336.6.2
6.7 Disconnecting a Gas Bottle from the BIOGAS 3000........................... 134
Maintenance ..................................................................................... 1367
7.1 Maintenance Schedule ...................................................................... 136
7.2 BIOGAS 3000 Consumable Products.................................................. 138
7.3 Emptying the Catchpot...................................................................... 140
7.4Replacing the Catchpot Filter ............................................................ 143
7.5 Replacing the Inline PTFE Filter ......................................................... 147
7.6 Pressure Test ..................................................................................... 150
Required Equipment.......................................................................... 1507.6.1

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Diagnostics Control Mode ................................................................. 1507.6.2
General Set-Up .................................................................................. 1527.6.3
Performing the Pressure Test ............................................................ 1527.6.4
7.7 Cleaning and Decontamination ......................................................... 158
Service .............................................................................................. 1598
8.1 General .............................................................................................. 159
8.2 Service Notifications.......................................................................... 159
8.3 Replacement BIOGAS 3000 Module for Service –Hot Swap............. 160
Problem Solving ................................................................................ 1639
9.1 Fault Detection .................................................................................. 163
Non-Critical Faults ............................................................................. 1639.1.1
Critical Faults ..................................................................................... 1659.1.2
9.2 System Will Not Power On ................................................................ 166
9.3 Module Will Not Power On ............................................................... 166
9.4 Module Lock-Up ................................................................................ 167
9.5 Under and Over Range Codes............................................................ 167
9.6 Analog Outputs Not Working ............................................................ 168
9.7 Modbus Outputs Not Working .......................................................... 168
9.8 Low Flow / Flow Fail .......................................................................... 168
9.9 Fuses.................................................................................................. 169
9.10 User Calibration Explained ................................................................ 170
General .............................................................................................. 1709.10.1
Factory Calibration ............................................................................ 171
9.10.2
User Zero Calibration......................................................................... 1719.10.3
User Span Calibration ........................................................................ 1729.10.4
Trouble Shooting ............................................................................... 1729.10.5
9.11 CH4Reading Low and O2Reading High.............................................. 174
9.12 Event Log ........................................................................................... 174

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BIOGAS 3000 Warranty Terms and Conditions .................................. 17610
WEEE Compliance.............................................................................. 17911
Declaration of Conformity .......................... Error! Bookmark not defined.12
Glossary of Terms.............................................................................. 18013

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Manual guidelines
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Manual guidelines
1
1.1 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, or
invalidate the certification of the equipment.
1.2 Hyperlinks
Hyperlinks to other sections of this manual, websites or email addresses are in
the following format:
www.landtecna.com
1.3 Notes
Important/useful information and instructions are shown clearly throughout
the manual in a note format.
For example:
Note: For further information contact our technical support team at (800)
968-2026 or email landtec_sup[email protected].

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Operating Manual
Safety information
OMBG3000 –Iss.01
© Copyright 2016
Safety information2
2.1 Safety instructions
Warning
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.

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Safety information
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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 LANDTEC 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: If there is any uncertainty, please contact our technical support
team at [phone] or email [email protected].

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Safety information
OMBG3000 –Iss.01
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2.2 ATEX and IECEx Certification
Warning
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.
Marking2.2.1
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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Safety information
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OMBG3000 –Rev1
Nameplate 1 - BIOGAS 3000 markings
Instructions Specific to Hazardous Area Installations2.2.2
1) The equipment may be used in zones 2 with flammable gases and vapors
with apparatus groups IIA and with temperature classes T1.
2) The equipment is only certified for use in ambient temperatures in the
range -4ºF to +122ºF and should not be used outside this range.
3) Installation shall be carried out in accordance with the applicable code of
practice by suitably trained personnel.
4) There are no special checking or maintenance conditions other than a
periodic check.
5) With regard to explosion safety, it is not necessary to check for correct
operation.

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Operating Manual
Safety information
OMBG3000 –Iss.01
© Copyright 2016
6) 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 [phone] or
email [email protected] to receive equipment repair
training.
7) Repair of this equipment shall be carried out in accordance with the
applicable code of practice.
8) 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.
9) 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 operating manual.

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Safety information
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OMBG3000 –Rev1
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.
10) 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.
11) Regarding the use of covers, jumpers, and end brackets, the instructions
of the manufacturer must be followed.
Entity Parameters2.2.3
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
2.3 Range of environmental conditions
The system is only for use in ambient temperatures in the range of 0°C
to 50°C (32⁰F to 122⁰F) without the use of the approved heater, and -
20°C to 50°C (-4⁰F to 122⁰F) 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 (-4.5 -2.7 psi).

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Safety information
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2.4 Safety symbols used on the instrument
The following safety symbols are used on the BIOGAS 3000:
Protective conductor terminal
Function earth (ground) terminal
Caution, risk of electric shock
or
Caution
Caution, risk of hot surface
Warning
Where the symbol or is used in the BIOGAS 3000,
the operating manual must be consulted.

Operating Manual
BIOGAS 3000 Overview
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BIOGAS 3000 Overview3
3.1 Features
The BIOGAS 3000, primarily for the AD Biogas and Bio-methane upgrading
market has been designed to enable site operations to maximize 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
desulphurization

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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
6 x 4-20mA outputs
Modbus RTU communication
Optional Profibus and Profinet communication
Clear, visual and informative color display
Optional heater to extend operating temperature range to -4°F
Extended Warranty and Service pack options through approved global
service centers
3.2 Benefits
Customizable to site requirements
Zero operational downtime for servicing
Product reliability and longevity
Protect expensive capital equipment from damaging gases
Maximize operational efficiency through optimizing the AD process
Operational within hazardous areas
Ease of operation, integration and installation

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BIOGAS 3000 Overview
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Minimal through-life costs
Local support for peace of mind
3.3 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
3.4 Main Applications
AD research
Agricultural waste AD (large scale)
Biogas upgrading
Farm waste AD (small scale)
Gas flaring
Mixed food waste AD
Sewage / waste water treatment AD

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3.5 Model Type Definitions
BG3K13.5.1
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:
BG3K23.5.2
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: