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Awite AwiFLEX XL Original Instruction Manual

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Original Instruction Manual
(Version: 18.0)

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Summary of Contents for Awite AwiFLEX XL

  • Page 1 Original Instruction Manual (Version: 18.0)
  • Page 2 Awite Bioenergie GmbH Grünseiboldsdorfer Weg 5 85416 Langenbach/Niederhummel, Germany Phone: +49 8761 / 72 162 - 0 Fax: +49 8761 / 72 162 - 11 Email: info@awite.com http://www.awite.com © 2022 Awite Bioenergie GmbH Errors and changes reserved...

  • Page 3: Table Of Contents

    Release of Potentially Toxic and Harmful Gases............21 5 Preparing the Gas Analysis System for Use................23 Transport and Storage....................23 Installation........................23 5.2.1 Main Switch Mains Disconnection Facility..............24 5.2.2 Terminal boxes for electrical connections..............24 5.2.2.1 Terminal Boxes AwiFLEX XL..................25 5.2.2.2 Connection Cable 100–240 V for Power Supply............25...
  • Page 4 5.2.6.1.2 Gas extraction fitting up to 16bar (PN16)..............31 5.2.6.2 Laying of Analysis Gas Lines..................32 5.2.6.3 Gas Inlets AwiFLEX XL....................33 5.2.6.4 Exhaust air – Discharge of the Measuring Gas............34 5.2.7 Installation of Humidity and Flow Sensor AwiFLOW..........35 5.2.8...
  • Page 5 Table of Contents Required Space......................52 Mechanical Connection....................54 Electrical Connection....................55 Maintenance........................56 8.6.1 Check non-return valve and solenoid valve............. 56 8.6.2 Procedure for checking the non-return valve and solenoid valve......56 9 AwiLAB Gas analysis........................58 Required Space......................59 Mechanical Connection....................59 Electrical Connection....................

  • Page 6: Preface

    Instruction Manual. Please operate and service your gas analysis system based on the information in this Instruction Manual. The Instruction Manual for the Awite – Gas Analysis System consists of two parts: Part A: Product Description, Installation and Operation...

  • Page 7: Identification

    Identification Identification This Instruction Manual is intended for Awite Bioenergie GmbH gas analysis systems of the respective series specified on the cover sheet. The type plate on the right hand side panel of the device indicates the device type, the required voltage supply and the rated output.

  • Page 8: Safety Instructions Part A

    Safety Instructions Part A Safety Instructions Part A The device is only designed for situations of intended use. A non-intended use can lead to personal injury and property damage. Only use the device as intended. The device measures combustible or explosive gases and is installed in their environment. There is a potential risk of spread or ignition of a hazardous atmosphere.
  • Page 9 In the event of the error messages "potentially dangerous atmosphere" or "risk of explosion" as well as with loose hose ends, porous hoses or other leaks that lead to an explosion hazard, disconnect the device from the gas supply and shut it down. Contact Awite or an Awite contract partner.
  • Page 10 Safety Instructions Part A The drain of the condensate trap is a secondary source of gas release. In case of poor ventilation, a hazardous explosive atmosphere may arise. Therefore please make absolutely sure to close the discharge tap after emptying the condensate traps. The device contains fuses that are under electrical voltage.
  • Page 11 Safety Instructions Part A Attention, General Hazard Point. Refer to the documentation. Disregarding this can lead to death or serious personal injuries or property damages. Warning of dangerous electrical voltage. Please also observe the safety instructions in Part B!

  • Page 12: Product Description

    20 mbar of underpressure or overpressure. The suitability for use in safety-critical applications must be assessed by the user for each case. Reliability data can be provided by Awite if required. WARNING The device is installed in the vicinity of combustible or explosive gases. Operating a non-explosion- protected device in a hazardous atmosphere can cause an explosion with personal injury and property damage.

  • Page 13: Device Category According To Atex Classification

    Product description Device Category According to ATEX Classification Applies only within the EU and in countries in which the ATEX Directive (2014/34/EU) also applies. The ATEX marking is located on the left outside of the casing. 4.2.1 Device category not intended for installation in an Ex-zone Marking per ATEX with II 2/- G IIA Gas-carrying pipes with inflammable or explosive gas of explosion group IIA (e.g.

  • Page 14: Safety Device For Monitoring The Interior Space

    II 2G / EEx de IIC T4 for intended use as a safety or control device in order to detect methane / Zone 2 in accordance with the requirements of Directive 2014/34/EU, sections 1.5.5 through 1.5.8 is available at Awite.

  • Page 15: Description Of The Gas Analysis System And Dimensions

    Mounting dimensions [mm] Width Height Depth AwiFLEX XL The analysis gas lines are routed to the system from the left hand side via the condensate traps for the manual emptying of the system. Pressure-resistant pipes are recommended as analysis gas lines: –...
  • Page 16 Product description Figure 1: AwiFLEX XL including condensate traps on the outside The equipment shown here serves as an example, as the components are individually assembled according to customer requirements. 1. Main switch 12. Mounting brackets for 4 condensate traps 2.
  • Page 17 Product description Figure 2: Assemblies in the AwiFLEX XL gas analysis system The equipment shown here serves as an example, as the components are individually assembled according to customer requirements. 1. Main switch 18. Multi-gas sensor InfraFRED 2. Line filter 19.

  • Page 18: Ambient Conditions And Limits For Operation And Storage

    Product description Ambient Conditions and Limits for Operation and Storage Although the Awite gas analysis systems are designed for use under rough conditions, some requirements concerning the location and environmental conditions should be met in order to obtain a high accuracy of measurement and to avoid damaging the system. For the conditions not listed here, the specifications from IEC Standard 60359 apply to application group 1.

  • Page 19: Overvoltage Category Ii

    Pressure outside this range is not allowed because the sensors may be damaged and measured values may be changed. With higher or lower pressure, corresponding measures must be taken (pressure regulator, precision pressure regulator, available from Awite). NOTE The highest rated overpressure inside the unit is 100 mbar in measuring mode and 2 bar in inactive state (valve inside the device closed).

  • Page 20: Hazards From Gas

    Awite. Technical data can be adapted to new technological advances in the area of biogas by the manufacturer without any prior notice. Please contact Awite if you need information about possible additions to this Instruction Manual and whether it is the current version.

  • Page 21: Leakage In The Measuring Gas Supply Line

    Product description 4.5.3 Leakage in the Measuring Gas Supply Line A technically permanently leak-tight pipe is used. This is achieved by using a durable plastic tube or stainless-steel pipe and corrosion resistant screw connections with resistant sealing. Components like condensate traps that might be included in the measuring gas pipe also have screw connections. The pipes are technically permanently leak tight up to the first valve, which can be used to shut off...
  • Page 22 Product description In normal operation and when used as intended, these gases are not released. The risk of exposure hazards arising from release due to leaks is considered sufficiently low according to risk assessment.

  • Page 23: Preparing The Gas Analysis System For Use

    Preparing the Gas Analysis System for Use Preparing the Gas Analysis System for Use WARNING This is a complex measuring and control system. Incorrectly performed installation, electrical installation, initial operation, or maintenance can lead to hazards and possibly even to death due to electric shock or risk of explosion.

  • Page 24: Main Switch Mains Disconnection Facility

    Check the connections afterwards. The Awite gas analysis system includes a terminal box for external connection. The terminal box offers connections for the following components: –...

  • Page 25: Terminal Boxes Awiflex Xl

    Preparing the Gas Analysis System for Use 5.2.2.1 Terminal Boxes AwiFLEX XL Figure 3: Terminal box Gas Analysis System AwiFLEX XL The terminal box illustrated here serves as an example only, as the number of feed-through terminals depends on the respective system setup.

  • Page 26: Connection Cable For Ai (Analogue Inputs) And Ao (Analogue Outputs)

    Preparing the Gas Analysis System for Use 5.2.2.4 Connection cable for AI (analogue inputs) and AO (analogue outputs) Specifications Connection Cable: AWG21 (metric equivalent 0.5mm²) • 75°C / copper wire only (75°C / copper) • shielded / twisted in pairs •...

  • Page 27: Data Transmission Of Signals

    Preparing the Gas Analysis System for Use 5.2.4 Data transmission of signals There are various possibilities for data transmission. If the connection to the process control is done via a bus connection (e.g. Ethernet, Profibus DP, serial interface), the corresponding interface is found on the right hand side of the device casing.

  • Page 28: Analogue Outputs

    Preparing the Gas Analysis System for Use – Set switch on connector to ON/OFF. – Plug connector back into Profibus module, tighten safety screws, close device door 5.2.4.2 Analogue outputs The voltage supply for the analogue outputs takes place via the gas analysis system. A galvanic separation of the potentials at the recipient's end is necessary.

  • Page 29: Connection Of Analysis Gas Lines

    Preparing the Gas Analysis System for Use 5.2.6 Connection of analysis gas lines As a matter of principle, the following applies: When carrying out maintenance work on the gas line, the gas analysis system must be turned off and the ball valve at the measuring gas extraction point has to be closed off.
  • Page 30 Precision pressure regulator: If the system pressure at the extraction point exceeds 20 mbar of relative high pressure, then additional precision pressure regulators have to be used (provided by Awite) which produce a stable output pressure of approx. 5 mbar of relative high pressure at a maximum of 400 mbar of relative high pressure at input.

  • Page 31: Gas Extraction Fitting Up To 16Bar (Pn16)

    Preparing the Gas Analysis System for Use Figure 6: Schematic layout of the extraction points for analysis gas – Exemplary representation 5.2.6.1.2 Gas extraction fitting up to 16bar (PN16) For gas extraction from pipes with system pressures between 400mbar and 16bar relative overpressure, the gas extraction fitting 16bar (PN16) is used.

  • Page 32: Laying Of Analysis Gas Lines

    Preparing the Gas Analysis System for Use Please take into account the following important points when designing and setting up the extraction points: Type: Depending on the condition of the gas to be extracted, the gas extraction fitting 16bar (PN16) must be configured in different versions: Version for corrosive gases –...

  • Page 33: Gas Inlets Awiflex Xl

    5.2.6.3 Gas Inlets AwiFLEX XL Due to the high variability of AwiFLEX XL, there is no fixed allocation of the gas connections. Please refer to the included gas flow diagram for individual allocations. Figure 8: Gas inlets, exhaust air and condensate outlets for AwiFLEX XL...

  • Page 34: Exhaust Air - Discharge Of The Measuring Gas

    Preparing the Gas Analysis System for Use 5.2.6.4 Exhaust air – Discharge of the Measuring Gas The discharge of the measuring gas from the installation room of the gas analysis system occurs via a technically permanently leak-tight pipe, normally into the open environment, as the gas amount is very low.

  • Page 35: Installation Of Humidity And Flow Sensor Awiflow

    Preparing the Gas Analysis System for Use DANGER The device measures/rinses alternately with measuring gas and ambient air. Combustible gas could enter the device through the exhaust gas line. This creates an explosion hazard. Therefore, lead the exhaust gas lines separately to the outside and have nothing discharge into the exhaust gas line.
  • Page 36 flow conditioner may be necessary. For details and prices please contact Awite. There must also be sufficient space (approx. 650mm from the pipe) for installation or removal of the sensor. The sensor should be positioned in such a way that the measuring tips are centered in the pipe, the flow direction arrow points in the flow direction of the gas, and the...

  • Page 37: Initial Operation

    Preparing the Gas Analysis System for Use Recommendation for 45° or 90° angle on one level < 150mm 15 x pipe Ø 7.5 x pipe Ø Fig. 11 >= 150mm 10 x pipe Ø 5 x pipe Ø with flow conditioner 6 x pipe Ø...

  • Page 38: Handling Of The Gas Analysis System

    Handling of the Gas Analysis System Handling of the Gas Analysis System The gas analysis system may only be operated by personnel who have been authorized and instructed by the operator of the system. The instructions of this Instruction Manual have to be strictly adhered to. The state of the device has to be checked on a regular basis and error messages need to be addressed.

  • Page 39: Calibration

    If you require a higher accuracy of results, or in case of heavy use, a calibration interval of 3–6 months is recommended. The calibration can be carried out directly on-site by Awite or an Awite partner. Please contact Awite for further information.

  • Page 40: Condensate Traps

    The operating safety of the gas analysis system can only be maintained by using original parts or approved spare parts for every repair operation that is carried out and by adhering closely to the instructions in this manual and the repair instructions. Spare parts lists are available at Awite.

  • Page 41: Disposal

    Handling of the Gas Analysis System Disposal For a small fee, Awite is prepared to take back any Awite devices that need to disposed off and use them for further industrial processing. Product Liability Awite does not assume liability for damages caused by faulty measuring values.

  • Page 42: Technical Data And Sensor Accuracy

    Technical Data and Sensor Accuracy Technical Data and Sensor Accuracy Technical Data For technical data, please refer to the provided data sheets. Accuracy, Service Life and Calibration of the Sensors A warranty of 12 months including the electro-chemical sensors can only be guaranteed under the accurate adherence of the surrounding conditions.
  • Page 43 Technical Data and Sensor Accuracy Table 3: Measuring uncertainties without uncertainty of the calibration gas. The uncertainty wasdetermined at the calibration point. Values that have been conservatively extrapolated to themeasuring range end value are indicated in brackets (worst case) Measured physical Calibration Standard un-...
  • Page 44 Technical Data and Sensor Accuracy Measured physical Calibration Standard un- Standard un- Standard uncer- component unit point (measur- certainty u2 certainty u3 tainty u4 right ing range end at delivery after 1 year after calibration value) +/– 10°C +/– 10°C +/–...

  • Page 45: Awidesulf Combi-Package For Microbiological Desulphurisation

    The non-return valves are spring-closed. The electric connection for the compressor incl. motor protection switch is located in a terminal box. The valves are controlled directly from the Awite gas analysis system. CAUTION AwiDESULF: Hot surface on the compressor, thus risk of burns.
  • Page 46 AwiDESULF combi-package for microbiological desulphurisation Figure 13: Schematic setup of AwiDESULF 100 UL/CSA – Exemplary representation 1. Compressor 4. Outlet to fermenter 2. Bracket compressor 5. Non-return valves 3. Magnetic valve, closed in a de-energized 6. Terminal box state...
  • Page 47 AwiDESULF combi-package for microbiological desulphurisation Figure 14: Schematic setup of AwiDESULF 200 – Exemplary representation 1. Compressor 4. Outlet to fermenter 2. Bracket compressor 5. Non-return valves 3. Magnetic valve, closed in a de-energized 6. Terminal box state...
  • Page 48 AwiDESULF combi-package for microbiological desulphurisation Figure 15: Schematic setup of AwiDESULF 200 UL/CSA – Exemplary representation 1. Compressor 4. Outlet to fermenter 2. Bracket compressor 5. Non-return valves 3. Magnetic valve, closed in a de-energized 6. Terminal box state...
  • Page 49 AwiDESULF combi-package for microbiological desulphurisation Figure 16: Schematic setup of AwiDESULF 300/500 – Exemplary representation 1. Compressor 6. Outlet to fermenter 2. Bracket compressor 7. Magnetic valve, closed in a de-energized state 3. Air intake/filter 8. Terminal box with motor protection switch 4.
  • Page 50 AwiDESULF combi-package for microbiological desulphurisation Figure 17: Schematic setup of AwiDESULF 1000 – Exemplary representation 1. Compressor 6. Outlet to fermenter 2. Bracket compressor 7. Magnetic valve, closed in a de-energized state 3. Air intake/filter 8. Terminal box with motor protection switch 4.
  • Page 51 AwiDESULF combi-package for microbiological desulphurisation Figure 18: Schematic setup of AwiDESULF PureOxygen – Exemplary representation 1. Terminal box 4. Outlet to fermenter 2. Connection pure oxygen 5. Non-return valves 3. Magnetic valve, closed in a de-energized 6. Console state...

  • Page 52: Intended Usage

    – Max. reachable pressure with compressor: < 500 mbar An exemplary risk assessment for the addition of pure oxygen and air is available from Awite on request. Required Space For information on the required space, please refer to the following illustrations. For details on the functioning of the desulphurisation unit, please refer to Part B of the Instruction Manual.
  • Page 53 AwiDESULF combi-package for microbiological desulphurisation Figure 20: Required space for AwiDESULF 200 UL/CSA – Exemplary representation Figure 21: Required space for AwiDESULF 300/500 – Exemplary representation Figure 22: Required space for AwiDESULF 1000 – Exemplary representation...

  • Page 54: Mechanical Connection

    Material: flexible or solid plastic pipe 1” – Pipe lengths of 100m and more are possible at the specified cross-sections (please inform Awite in advance about the pipe lengths and the expected biogas volume flows so the right compressor can be chosen) –...

  • Page 55: Electrical Connection

    AwiDESULF combi-package for microbiological desulphurisation Electrical Connection DANGER Dangerous electrical voltage is present at the terminals in the terminal box and the cables fed. An incorrect connection may lead to electrical hazards and even death. For information on the allocation of the different terminals and the wiring in the terminal box, please refer to the electric diagram provided as part of the system.

  • Page 56: Maintenance

    The intake (suction) side of the compressor is fitted with a filter. The filter pads should be checked on a regular basis and replaced when dirty. Dirty filter pads lead to a reduced air flow, whereby the motor can be damaged. Only original filter pads must be used (available at Awite). Testing and Change interval AwiDESULF 100: The filter should be checked every 3 months, it must be exchanged after 12 months.
  • Page 57 At 2. to 3. no gas flow (detection limit 0.1 liter per second) and/or no methane may be detected (detection limit 1000 ppm). The gas flow can also be checked qualitatively (moisten fingers or use foam). The non-return valve must be removed and cleaned/replaced if necessary. A detailed risk assessment can be obtained from Awite upon request.

  • Page 58: Awilab Gas Analysis

    AwiLAB Gas analysis AwiLAB Gas analysis The product family AwiLAB was developed especially for laboratory applications in the biogas sector. In combination with the AwiFLEX gas analysis system, gas production and gas composition can be automatically controlled and checked during the substrate fermentation. The Fig.

  • Page 59: Required Space

    AwiLAB Gas analysis Required Space For information on the required space for the AwiLAB extension, please refer to the following illustrations. Figure 25: Required space for AwiLAB Mechanical Connection The reactors are 4/6mm connected to the milligas counters or the drum gas meters ( 4/6mmstainless steel hose connections).
  • Page 60 AwiLAB Gas analysis DANGER Disconnecting the connection cable between the AwiLAB and the milligas counter or the drum gas meter, respectively, during operation may lead to faulty controls. This can cause excessive pressure in the connected collecting gas bags, which could then lead to damage and thus to gas leakage. Before conversion work, the gas analysis system must be de-energized.

  • Page 61: Awivac

    AwiVac 10 AwiVac The AwiVac serves as a support for the gas analysis, especially in the negative pressure range down to minus 350mbar, or for the suction of the sample gas from measuring points that are more than 100 meters away from the installation site of the gas analysis system. It is thus possible to easily analyse the gas composition in the specified negative pressure or from more distant measuring points.

  • Page 62: Required Space

    AwiVac 10.1 Required Space The AwiVac consists of a stainless steel housing that is connected directly to the gas analysis system. For information on the required space for the AwiVac extension, please refer to the following illustrations. Figure 27: Required space for AwiVac NOTE The installation position must be observed as in image (Fig.

  • Page 63: Assemblies In The Awivac

    AwiVac 10.2 Assemblies in the AwiVac Figure 28: Assemblies in the AwiVac 1: Connection analysis gas inlet 6: Mounting plate 2: Connection analysis gas outlet 7: Cable clamps 3: Connection exhaust air 8: Non return valve RM20 4: Water trap 9: Micro membrane pump 5: Precision pressure regulator 10: Excess flow valve RZ21 / RZ22...

  • Page 64: Mechanical Connection

    AwiVac 10.3 Mechanical Connection There are three mechanical hose connections for 4/6mm on the outer side of the housing of the AwiVac (optionally, other connection versions are also possible). - Connection 1: Analysis gas inlet from gas analysis system - Connection 2: Analysis gas outlet to gas analysis system - Connection 3: Exhaust air The exhaust air is usually conducted outside, and this outlet must be designed exactly like in the case of the exhaust air from the gas analysis system.

  • Page 65: Electrical Connection

    AwiVac 10.4 Electrical Connection The power supply and control of the AwiVac takes place directly via the gas analysis system. The assignment can be found in the included electrical plan.

  • Page 66: Awiwarn

    If a hazardous atmosphere is detected, the power supply and all signal lines to the gas analysis system must be switched off for safety reasons in order to disconnect potential ignition sources. Certain Awite gas analysis systems with AwiWarn may therefore be located in an EX zone 2. Further information is available from Awite on request.

  • Page 67: Required Space

    AwiWarn 1. Unscrew the plastic protective cap on the upper side of the housing 2. Take the AwiWarn out of the cardboard box and screw the white protective sleeve off the measuring head 3. Protective cap and protective sleeve serve as transport protection, are no longer needed and can be disposed of 4.

  • Page 68: Electrical Connection

    AwiWarn Figure 30: Required Space AwiWarn 11.3 Electrical Connection The supply voltage must be supplied from external sources and must always be available. Even in the event of a gas alarm, it must not be switched off. In case of a gas warning, the power supply and all signal lines to the gas analysis system must be switched off...

  • Page 69: Settings And Calibration

    (zone 2) into the device, the AwiWarn needs to be calibrated at least once a year. More detailed information on this can be requested from Awite. The calibration of the AwiWarn can be carried out directly by Awite.

  • Page 70: Annex

    Annex 12 Annex 12.1 Declarations of Conformity The gas analysis system can optionally be designed to be installed in the potentially explosive zone 2. Which declaration applies to the respective device can be determined using the marking on the left side of the device.

  • Page 71: Ce Declaration Of Conformity For Devices Not Intended To Be Installed In An Ex-Zone

    Prozessanalyse-System, Process analysis system Typenbezeichnung, Type designation: Serie 10, Series 10 (AwiFLEX, AwiFLEX XL und AwiECO) Das bezeichnete Gerät inklusive Zubehör entspricht den aufgeführten EU-Richtlinien und Normen. The denoted device including accessories corresponds to the listed EU guidelines and standards.

  • Page 72: Ce Declaration Of Conformity For Devices Intended To Be Installed In An Ex

    Prozessanalyse-System, Process analysis system Typenbezeichnung, Type designation: Serie 10, Series 10 (AwiFLEX, AwiFLEX XL and AwiECO) Das bezeichnete Gerät inklusive Zubehör entspricht den aufgeführten EU-Richtlinien und Normen. The denoted device including accessories corresponds to the listed EU guidelines and standards.

  • Page 73: Ukca Declaration Of Conformity For Devices Not Intended To Be Installed In An Ex-Zone

    Grünseiboldsdorfer Weg 5 D-85416 Langenbach Product: Process analysis system Type designation: Series 10 (AwiFLEX, AwiFLEX XL und AwiECO) The denoted device including accessories corresponds to the listed UK legislation and standards. – Supply of Machinery (Safety) Regulations 2008 UK legislation: –...

  • Page 74: Ukca Declaration Of Conformity For Devices Intended To Be Installed In An Ex-Zone

    D-85416 Langenbach Product: Process analysis system Type designation: Serie 10 (AwiFLEX, AwiFLEX XL, AwiECO) The denoted device including accessories corresponds to the listed UK legislation and standards. – Equipment and Protective Systems Intended for use in Potentially UK legislation Explosive Atmospheres Regulations 2016 –...

  • Page 75: Iec - Conformity Declaration

    CSA/UL 61010 Certification The Awite AwiEco/AwiFlex devices are constructed and tested in order to fulfill all requirements of CSA-C22.2 no 61010-1:2012-05 and UL 61010-1:2012-05 (and also IEC 61010 and EN 61010). Intended use is the measurement of methane and biogas and the documentation is part of the certification.
  • Page 76 Annex A pressure test (40 mbar, twice of nominal pressure according IEC 61010) is made with each device before delivery, whereby a maximum permissible pressure loss of 5 mbar is allowed in 6 minutes (2 mL Gas; safety factor 20). The electrochemical sensors which are only periodically exposed to a permissible pressure loss of 8 mbar/min may not be exceeded (safety factor 3).

  • Page 77: Certificat Tüv Süd Ul - Csa 61010-1-2012

    Annex 12.2 Certificat TÜV SÜD UL - CSA 61010-1-2012...

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