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

© Copyright 2016
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

© Copyright 2016
OMBG3000 –Rev1
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

Operating Manual
Manual guidelines
9
© Copyright 2016
OMBG3000 –Rev1
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].

10
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.