Awite AWIFLEX Original Instruction Manual

Gas analysis system

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Original Instruction Manual

(Version 10.0)

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Page 1 Original Instruction Manual (Version 10.0)
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 © 2024 Awite Bioenergie GmbH Errors and changes reserved...
Page 3: Table Of Contents
Table of Contents Table of Contents 1 Preface..............................6 2 Identiﬁcation............................7 3 Safety instructions Part B......................... 8 4 Operation of the Gas Analysis System..................9 Measurement Process....................9 4.1.1 Interval Measurement (discontinuous)..............10 4.1.2 Continuous measurement (continuous)..............10 Operation........................10 Menu Navigation......................
Page 4 Table of Contents 4.12 Tab ‘Contact’........................23 5 Data transfer and remote access....................24 AwiRemote........................24 5.1.1 Remote access via PV browser...................24 5.1.2 Remote access via smartphone or tablet..............25 5.1.2.1 Procedure with VNC Viewer (Google and Apple)............26 Download - Update via USB-Stick................27 Alarm Limits........................27 6 Information security and data protection...................
Page 5 Table of Contents 8.3.1.8 Exchange of Calibration Gases.................. 54 8.3.2 Without Fixed Calibration Gas Connection.............. 55 AwiLAB Gas Analysis System..................55 8.4.1 Function AwiLAB Gas Analysis System..............55 8.4.2 Settings AwiLAB Gas Analysis System...............56...
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 B
Safety instructions Part B Safety instructions Part B Errors can occur where the unit sets to STOP (dangerous atmosphere inside) for safety reasons. If the gas analysis system is stopped and the error still persists, the cause of error has to be eliminated and acknowledged before the gas analysis system is activated again.
Page 9: Operation Of The Gas Analysis System
Operation of the Gas Analysis System The gas analysis systems are available in the AwiECO, AwiFLEX and AwiFLEX XL versions. The scope of operation depends on the design and the options of the analysis system. In the following chapter you will ﬁnd a special description of the operation of the analysis system AwiFLEX with its options.
Page 10: Interval Measurement (Discontinuous)
Operation of the Gas Analysis System 4.1.1 Interval Measurement (discontinuous) A measuring cycle consists of the following steps, which are repeated at each measuring point: 1. Suction of the sample, bypassing the sensors 2. Measurement: Sample gas is led via the sensors of the ﬁrst measuring channel 3.
Page 11: Menu Navigation
(exception: some sub-menus under the “Admin” tab (Chapter 4.7). A pulsating methane molecule, the Awite logo, indicates that the system is operating. During the measurement process, a green ﬁeld “Meas.” is displayed. In case of an error, a red (or yellow or orange) button is displayed (Chapter 7.2).
Page 12: Suction
Operation of the Gas Analysis System 4.4.2 Suction Analysis gas is sucked in via the bypass (e.g. from the fermenter). The display shows the remaining time of suction (Fig. 3). The number of the measuring point where measurement is currently taking place is displayed as well.
Page 13: Stop
Operation of the Gas Analysis System 4.4.5 Stop The gas analysis system is at Stop, the pump is switched oﬀ. If a serious fault occurs, the gas analysis system will be automatically stopped. ‘System state not safe’ is displayed in the status, and additionally above the fault list in the error window, as well as the cause ‘Pressure too high’...
Page 14 Operation of the Gas Analysis System Figure 5: Tab “History”, sub-menu “Graph”, displays the measuring value history as a graph The sub-menu “Table” (Fig. 6) displays the measured values in table format. In one column the histories of a measurement at a speciﬁc measuring point are displayed (for up to 9 days). You can scroll up and down in the table using the arrow keys.
Page 15 (maximum of 9 days). For continuously operating gas analysis systems, the storage interval can be pre-deﬁned by Awite based on customer requirements. Due to the large amount of data, the number of loaded table rows should be limited in the ﬁeld ‘Max. Number of Rows’.
Page 16: Tab 'Admin' - Settings
Operation of the Gas Analysis System Tab ‘Admin’ – Settings Not all systems oﬀer all sub-menus. Only ﬁelds highlighted in blue are active. The currently set user level is displayed in the right ﬁeld (Fig. 7). You can ﬁnd more information the user level in the (Chapter 4.7.3) Figure 7: ‘Admin’...
Page 17 The controller is displayed in green (Fig. 8). The controllers may only be operated manually if instructed to do so by Awite or with the necessary background knowledge. Figure 8: Admin > Controller Settings By clicking the MAN buttons, the controllers can be fully or partly switched to manual operation.
Page 18: User Level
Operation of the Gas Analysis System By clicking on MAN (6), the fuzzy control and the PI control are deactivated. Now a value between 0 and 100% can be entered. This sets the opening time of the valve at the selected point of air supply as part of the maximum possible switching time (Manual Control of the Air Supply AwiDESULF).
Page 19: Language
Operation of the Gas Analysis System 4.7.6 Language By clicking on Admin – Language opens a window which contains the available visualization languages. After choosing the desired language, conﬁrm your entry with “Yes‘ to restart the visualization server. 4.7.7 Expert Settings This setting particularly concerns the service personnel.
Page 20: Tab 'Admin' - Measurement Plan
Operation of the Gas Analysis System Tab ‘Admin’ – Measurement Plan The sub-menu “Measurement Plan” (Fig. 9) displays the measuring intervals of the single measuring points in an organized view. If a measuring interval is longer than 60 minutes, no empty green ﬁeld is shown in the corresponding hour column.
Page 21: Tab "Admin" - Cooler
Operation of the Gas Analysis System Tab “Admin” – Cooler The sub-menu “Cooler” (Fig. 10) shows the temperature values and states of both the cooler and the casing. “Setpoint” (Fig. 10) is the setpoint value temperature of the cooler, “Current value” (Fig.
Page 22: Ip Address - Change Network Settings
Operation of the Gas Analysis System 4.10.2 IP address - Change Network Settings Procedure: 1. Admin > User Level > Enter “1000” (Chapter 4.7.3) 2. Admin > Service > Network The current network settings are displayed here. The settings can be changed by clicking on ‘Settings’.
Page 23: Calibration Touchscreen
In this area you will ﬁnd help on how to operate the gas analysis system. By touching the respective tab, you receive information on the desired subject. 4.12 Tab ‘Contact’ Here you will ﬁnd the contact information for Awite Bioenergie GmbH.
Page 24: Data Transfer And Remote Access
10000. The port 10000 must be set as enabled. Both the functionality of the Internet access as well as incurred costs for Internet services and data transfer are within the responsibility of the customer. Awite assumes no liability nor any costs for this. Minimum speed for internet access: –...
Page 25: Remote Access Via Smartphone Or Tablet
5.1.2 Remote access via smartphone or tablet As a software for remote access via smartphone or tablet, Awite recommends the VNC viewer for Android and Apple iOS operating systems. These applications can be downloaded from Google Play Store, from the Apple App Store, or from Windows Marketplace, respectively.
Page 26: Procedure With Vnc Viewer (Google And Apple)
3. Initiate the connection with Connect 4. Enter password: The password is provided by the project manager / service technician or in case of loss under info@awite.com. If the “Save Password” option is checked, the password required later only needs to be entered once.
Page 27: Download - Update Via Usb-Stick
The copied data on the USB stick can be opened and evaluated with the program “AwiView”. Please ﬁnd more information on the AwiView programme online at www.awite.com “Update” button: Thus, a software update can be transferred to the gas analysis using a prepared USB stick. The copying process is started by clicking the “Update”...
Page 28 Data transfer and remote access Figure 12: Status Alarm Limits...
Page 29: Information Security And Data Protection
(ARM 7) compared to a normal PC. Other malware could be installed intentionally after logging in as ‘root’ via network port 22 (SSH) in the local network. Awite does not provide the root password and remote access via the Internet is specially secured.
Page 30: Local Network Access Protection
When connected to a network with an Internet connection, the device creates a secure tunnel to the remote maintenance server awitemote.awite.de. This is a semi-open reverse SSH tunnel. The device connects to the server after authentication. The respective device can only be accessed via the server using device-speciﬁc network ports.
Page 31: Error Messages
Yellow: Overvoltage (triggered if the voltage at the power-supply unit is > 27.5V, reason: overvoltage has damaged power-supply unit, counter measure: contact Awite) Red: Overcurrent (triggered when current is > 5/10 A, reason: faulty components in the device have caused a short circuit, counter measure: contact Awite) 1.
Page 32 Error Messages Figure 13: AwiProtect module with LEDs showing the current operational status...
Page 33: System Error Messages
Error Messages System Error Messages In the event of system errors, these are displayed via error messages. There are three types of errors, which are displayed by a button on the left hand side of the screen. – Current and not acknowledged errors (red button) –...
Page 34: List Of The Possible System Error Messages
Error Messages Figure 15: Error window displays a list of the errors that occurred 7.2.1 List of the possible system error messages Table 2: List of the possible system error messages with a short description of the error, possible causes and notes for determining or resolving the error Error Text Short descrip- Possible causes...
Page 35 Error Messages Error Text Short descrip- Possible causes Troubleshooting or Han- tion dling -9985 Switched oﬀ One of the sensors con- Switch gas analysis oﬀ and due to over- nected in series (most of on or contact service load of an- the time channel 1: CH4, other sensor CO2, O2) has an over-...
Page 36 Error Messages Error Text Short descrip- Possible causes Troubleshooting or Han- tion dling -9964 Reading log- Error when Problems with memory Please contact service file failed reading log ﬁle card (38) -9963 Writing log Error when writ- Memory card full Please contact service ﬁle failed ing to log ﬁle...
Page 37 Error Messages Error Text Short descrip- Possible causes Troubleshooting or Han- tion dling -9950 Bus: Socket Communication Communication with in- Please contact service failure (52) error bus ternal or external bus component failed -9949 Calibration Calibration Problems with optional Please contact service failed (53) failed automatic calibration...
Page 38 Error Messages Error Text Short descrip- Possible causes Troubleshooting or Han- tion dling -9944 Sensor de- Sensor faulty Measured value could Sensor used up > replace fective (58) not be accepted in the sensor scheduled time Sensor reacts too slowly -9942 Timeout: No Timeout: Time...
Page 39 Error Messages Error Text Short descrip- Possible causes Troubleshooting or Han- tion dling -9927 not ready Not all prerequi- Gas analysis system can- See causes (75) sites are met yet not run yet as certain pre- requisites are not met: –...
Page 40 Error Messages Error Text Short descrip- Possible causes Troubleshooting or Han- tion dling -9917 OK criterion End criterion Above or below thresh- not reached with error on old value (85) failure to reach: Error, as not reached -9912 Pressure too Pressure too Input pressure too high Check input pressure...
Page 41 Error Messages Error Text Short descrip- Possible causes Troubleshooting or Han- tion dling -9898 Pump is Pump faulty or 1. Pump faulty Check exhaust line for any defective outlet blocked blockage and exchange 2. Exhaust line blocked or outlet pump if necessary 3.
Page 42: Error Multi-Gas Sensor Infrafred
Error Messages Error multi-gas sensor InfraFRED The multi-gas sensor InfraFRED has LEDs (Fig. 16) that show the current status ("Tab. 3: List Status Conditions Multi-Gas Sensor InfraFRED") of the sensor. Errors can be transmitted as well here. Figure 16: Status LEDs Multi-Gas Sensor InfraFRED Table 3: List Status Conditions Multi-Gas Sensor InfraFRED State LED blue...
Page 43: Options
Options Options Awite gas analysis systems are modularly built and can be equipped with many options. Below you will ﬁnd information about the options available especially for your gas analysis system. Combi Package Microbiological Desulphurisation AwiDESULF Below, you will ﬁnd a description of the AwiDESULF combi-package microbiological desulphurisation option, i.e.
Page 44: Manual Control Of The Air Supply Awidesulf
Faulty oxygen sensor. When using manual control, 0.5 to 1% of the biogas amount should be fed in as air. The following table shows the air throughput. In the event of deviating counter pressures, please contact Awite about the air throughput.
Page 45 Options Table 7: Air ﬂow rate in the event of 25 mbar of counterpressure (opening pressure of the check valve) and a power frequency of 50 or 60 Hz. Compressor type Counterpressure Throughput at 50 Hz Throughput at 60 Hz AwiDESULF 300 25 mbar 37 m³/h...
Page 46: Flow Meter Awiflow
It is also possible to calculate and display the energy ﬂow Psn (in KW), an energy meter Esn (KWh) and the average caloriﬁc value Hsn (KWh/m³). All values refer to the Awite standard reference states according to standard DIN 51857:1995: –...
Page 47: Automatic Calibration
Options Procedure: 1. Admin > User Level > Enter “300” (Chapter 4.7.3) 2. Admin > Expert settings > reset all counters Automatic calibration For automatic calibration, the gas analysis system is ﬁrmly connected to the calibration gases using its own calibration gas connectors, or the calibration gases are only connected to the gas analysis system during the calibration process.
Page 48: Status
Options Figure 18: Admin > Calibration > Media, pop-up window for entering a gas concentration 8.3.1.2 Status Admin > Calibration > Status Under the ‘Status’ Tab (Fig. 19) the individual sensors as well as the respective gases used for calibration are listed.
Page 49 Options By clicking on the ﬁelds, the window ‘Extended Calibration Status’ (Fig. 20) will open. This window shows the setpoints and actual values of the measuring gas and the sensor for the sensor/medium constellations as well as the status of the calibration. The following messages are possible for the status of the calibration: If the calibration has not been completed yet, the following messages can be displayed in the Status display...
Page 50: Calibration - History
Options Figure 20: Admin > Calibration > Status > Extended Calibration Status 8.3.1.3 Calibration - History Admin > Calibration > History Under the ‘History’ Tab (Fig. 21) the calibration cycles are documented.
Page 51: Calibration - Settings
Options Figure 21: Admin > Calibration > History 8.3.1.4 Calibration - Settings Admin > Calibration > Settings In the ‘Settings’ Tab (Fig. 22) the measuring channels that are available in the device are displayed. Each measuring channel is calibrated separately. The display indicates which sensors in the corresponding measuring channel are connected in series: e.g.
Page 52 Options Option Remark Manually The calibration is started manually using the ‘Start’ button. Non- relevant items for manual calibration are displayed in rounded brackets, e.g. Interval -> (3d). Start Starts a manual calibration. The ‘Start’ button is only available if the calibra- tion is set to manual.
Page 53: Error Failed Calibration
Options Figure 22: Admin > Calibration > Settings 8.3.1.5 Error Failed Calibration If problems occur during the calibration, three diﬀerent error messages may be displayed. These errors cannot be deleted. They will be reset automatically after a successful calibration. Calibration partly failed, channel …: During calibration of multiple sensors at the same time, the calibration failed for some (not all) of the sensors.
Page 54: Display Of Measured Values During Calibration
8.3.1.8 Exchange of Calibration Gases It is necessary to use certiﬁed test gases (for the right composition please contact Awite). Please ensure to order new calibration gases well in advance, as the production of individual mixtures takes several weeks.
Page 55: Without Fixed Calibration Gas Connection
Function AwiLAB Gas Analysis System The extension AwiLAB is controlled by the gas analysis system AwiFLEX. Up to 7 measuring points / reactors can be connected to the AwiLAB. The produced gas is counted by a milligas counter or drum...
Page 56: Settings Awilab Gas Analysis System
Options point. When the gas bag is full, the remaining gas is released into the atmosphere. The gas composition is analyzed from the gas bag in the gas analysis system AwiFLEX. 8.4.2 Settings AwiLAB Gas Analysis System All settings for the AwiLAB can be made in the Admin > AwiLAB area. The individual measuring points / reactors can be selected in the tab ‘AwiLAB’...
Page 57 Options Figure 24: measuring point-speciﬁc settings AwiLAB 1. Under ‘Reset bag volume’, the current ﬁll level of the bags is displayed and can be set to zero. Caution: No actual emptying of the bag takes place. 2. The gas meters count the fully produced gas, even when the bag is full and the gas is released to the outside.
Page 58 Options Figure 25: Scaling Milligas Counter / Drum Gas Meter...