Bühler technologies BA 5000 User manual
Gas Analysis
Installation and Operation Instructions
Original instructions
Gas analyzer for measurement of IR-absorbing gases and oxygen
BA 5000
BE555000
11/2019
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2019
Document information
Document No..........................................................BE555000
Version...........................................................................11/2019
Part No.........................................................................9031067
BA 5000
Contents
1 Introduction..................................................................................................................................................................................................................... 3
1.1 Intended Use......................................................................................................................................................................................................... 3
1.2 Product versions .................................................................................................................................................................................................. 3
1.3 General information ..........................................................................................................................................................................................4
2 Safety instructions......................................................................................................................................................................................................... 5
2.1 Important notices................................................................................................................................................................................................ 5
2.2 General hazard warnings .................................................................................................................................................................................6
2.3 Analyzers in biogas plants................................................................................................................................................................................ 7
2.4 Analyzers in hazardous areas.......................................................................................................................................................................... 7
3 Transport and storage ..................................................................................................................................................................................................8
4 Installation and connection........................................................................................................................................................................................9
4.1 Description............................................................................................................................................................................................................9
4.1.1 Area of application.............................................................................................................................................................................. 9
4.1.2 Design .....................................................................................................................................................................................................11
4.1.3 Function ................................................................................................................................................................................................ 13
4.1.4 Technical specifications....................................................................................................................................................................19
4.1.5 Wiring diagrams................................................................................................................................................................................ 28
4.1.6 Dimensional drawings..................................................................................................................................................................... 38
4.1.7 Communication.................................................................................................................................................................................40
4.2 Installation ......................................................................................................................................................................................................... 44
4.3 Connecting ......................................................................................................................................................................................................... 46
4.3.1 Safety instructions ............................................................................................................................................................................46
4.3.2 Gas connections and internal gas path ......................................................................................................................................48
4.3.3 Electrical connection......................................................................................................................................................................... 50
5 Operation and control ................................................................................................................................................................................................ 52
5.1 Commissioning.................................................................................................................................................................................................. 52
5.1.1 General information..........................................................................................................................................................................52
5.1.2 Saftey instructions .............................................................................................................................................................................52
5.1.3 Preparation for commissioning .................................................................................................................................................... 54
5.1.4 Commissioning ...................................................................................................................................................................................55
5.1.5 System setup with several analyzers in parallel .......................................................................................................................57
5.2 Operation.............................................................................................................................................................................................................59
5.2.1 General information......................................................................................................................................................................... 59
5.2.2 User prompting.................................................................................................................................................................................. 59
5.2.3 Display and control panel ...............................................................................................................................................................60
5.2.4 Operating modes............................................................................................................................................................................... 63
5.3 Functions .............................................................................................................................................................................................................70
5.3.1 Diagnostics .......................................................................................................................................................................................... 70
5.3.2 Calibration............................................................................................................................................................................................81
5.3.3 Parameter ............................................................................................................................................................................................ 93
5.3.4 Configuration .....................................................................................................................................................................................98
5.3.5 Automatically executed functions of the H2S sensors...........................................................................................................113
5.4 Application note ...............................................................................................................................................................................................117
5.4.1 H2S sensor with 'small' measuring range..................................................................................................................................117
6 Maintenance and repair ...........................................................................................................................................................................................119
6.1 Safety instructions...........................................................................................................................................................................................119
6.1.1 General safety instructions ........................................................................................................................................................... 119
6.1.2 Safety information for analyzers used in hazardous areas................................................................................................ 120
6.2 Cleaning the device.........................................................................................................................................................................................120
6.3 Maintenance of the gas path.......................................................................................................................................................................120
6.4 Replacing spare parts......................................................................................................................................................................................121
6.5 Replacing fuses .................................................................................................................................................................................................121
6.6 Replacing the fine safety filter .....................................................................................................................................................................121
6.7 Maintenance work on the bench-top unit............................................................................................................................................... 122
6.7.1 Emptying the condensation trap.................................................................................................................................................122
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6.7.2 Replacing the coarse filter .............................................................................................................................................................122
6.8 Replacement of the UV module .................................................................................................................................................................. 122
6.9 Replacing the electrochemical oxygen sensor........................................................................................................................................ 124
6.10 Replacing the hydrogen sulfide sensor..................................................................................................................................................... 124
6.11 Replacing the paramagnetic oxygen sensor...........................................................................................................................................126
7 Service and repair........................................................................................................................................................................................................127
7.1 Error and system messages.......................................................................................................................................................................... 127
7.1.1 Maintenance requests ....................................................................................................................................................................127
7.1.2 Faults....................................................................................................................................................................................................128
7.2 Spare parts/accessories.................................................................................................................................................................................130
7.2.1 Gas path ...............................................................................................................................................................................................131
7.2.2 Electronics...........................................................................................................................................................................................134
7.2.3 Pump....................................................................................................................................................................................................136
7.2.4 IR analyzer units................................................................................................................................................................................ 137
8 Disposal.........................................................................................................................................................................................................................166
8.1 Taking out of operation and disposal .......................................................................................................................................................166
8.1.1 Repair or changing of location .................................................................................................................................................... 166
8.1.2 Scrapping the analyzer .................................................................................................................................................................. 166
9 Attached documents .................................................................................................................................................................................................168
ii Bühler Technologies GmbH BE555000 ◦ 11/2019
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1 Introduction
1.1 Intended Use
Proper use within the context of this manual, means that the product may be used only for the applications described in the
catalog or the technical description, and only in combination with the equipment, components and devices of other manufac-
turers recommended or permitted by us. The product described in this manual has been developed manufactured, tested and
documented in compliance with relevant safety standards. When the handling rules described for the configuration, installa-
tion, proper operation and maintenance, as well at the safety guidelines are adhered to, therefore, there is normally no risk to
the health of persons or in respect to damage to property. This device was designed to ensure safe isolation of the primary and
secondary circuits. Low voltages that are connected must therefore also be generated with safe isolation.
WARNING
Dangerous contact voltage
After removing the housing or protection against direct contact or after opening the sys-
tem cabinet, certain parts of this device/system will be exposed that can carry hazardous
voltage. Therefore, only appropriately qualified persons are permitted to perform work
within this device. These persons must be thoroughly familiar with all sources of danger
and service activities in accordance with these operating instructions.
NOTICE
Observe the environmental conditions for the rack unit and bench-top unit
Ensure compliance with the environmental conditions listed in the technical specifica-
tions
• During operation
• In the event of maintenance
NOTICE
Environmental conditions for bench-top unit in accordance with IEC 61010-1-2010
According to IEC 61010-1-2010, the bench-top unit may only be used indoors.
1.2 Product versions
The BA 5000 gas analyzer is suitable for a wide variety of measurements and is therefore available in different versions. The
data on the label, among others, indicates which device version you have.
1. Data matrix code
2. CE conformity symbol
3. Name and address of manufacturer
4. Designation of origin
5. Measuring range(s)
6. Serial number
7. Order No. (MLFB number) of the device
8. Device name
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1.3 General information
This device left the factory in a safe and proper condition and has been tested. In order to maintain this condition and to ensure
safe operation, it should only be used in the manner described by the manufacturer. Furthermore, proper transportation, stor-
age, installation, operation and maintenance of the device are vital for ensuring correct and safe operation.
This manual contains the information required for the intended use of the described product.
It is addressed to technically qualified personnel who are specially trained or who have the relevant knowledge of automation
technology (measuring and control systems).
Knowledge and technically correct implementation of the safety notes and warnings contained in this manual are required for
safe installation and commissioning, as well as for safety during the operation and maintenance of the described product. Only
qualified personnel have the required professional knowledge for correctly interpreting the generally valid safety notes and
warnings in this manual in each specific case and to act accordingly.
This manual is an inherent part of the scope of delivery, despite the fact that it can be ordered separately for logistic reasons.
Due to the variety of technical details, it is not possible to consider every single detail for all versions of the described product
and for every conceivable case in the set-up, operation, maintenance and use in systems. For further information, or in the case
of problems which are not covered in enough detail in this document, please request the required information from your local
or responsible regional office.
NOTICE
In particular, before using the device for new research and development applications, we
recommend that you first contact us to discuss the application in question.
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2 Safety instructions
2.1 Important notices
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard Unplug from mains
Voltage warning Wear respiratory equipment
Warns not to inhale toxic gasses Wear a safety mask
Warns of corrosive liquids Wear gloves
General information
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2.2 General hazard warnings
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal,
– compliance with national installation regulations.
DANGER Toxic, corrosive gases
The measuring gas led through the equipment can be hazardous when breathing or
touching it.
a) Check tightness of the measuring system before putting it into operation.
b) Take care that harmful gases are exhausted to a save place.
c) Before maintenance turn off the gas supply and make sure that it cannot be turned
on unintentionally.
d) Protect yourself during maintenance against toxic / corrosive gases. Use suitable pro-
tective equipment.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Danger to life from oxygen deficiency
Oxygen is vital to humans. The breathable air should contain over 17 Vol.% oxygen. Signi-
ficantly lower concentrations will sooner or later result in death from suffocation.
System users and operators must ensure personal protection measures are taken in ac-
cordance with legal requirements if the oxygen concentration is too low.
CAUTION Damage to the unit
The sensor on the oxygen measurement system contains zirconium dioxide and plat-
inum and contaminants/catalyst poisons will destroy it (see chapter contaminants).
These therefore must not be present in the gas mixture being measured!
WARNING Improper use
A device in the standard version must never be used in hazardous areas. Explosive gas
mixtures (e.g. flammable gases together with air or oxygen in a potentially explosive ra-
tio) must not be measured with this analyzer.
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2.3 Analyzers in biogas plants
DANGER Danger of poisoning
This device is designed to measure hydrogen sulfide and dihydrogen sulfide, H2S)!
Hydrogen sulfide is highly toxic even in small concentrations! The odor threshold for hy-
drogen sulfide is very low at 0.02 vpm (20 vpb), but higher concentrations result in
numbing of the olfactory receptors in the nose so that the odor is no longer perceived.
Persons exposed to this gas in concentrations up to 100 vpm for several hours exhibit
symptoms of poisoning such as fatigue, headaches, lack of appetite, lack of concentra-
tion, irritation of the mucous membranes of eyes and respiratory tract, and throat irrita-
tions.
Inhalation of H2S concentrations of 500 vpm longer than 30 minutes can cause fatal
poisoning. Concentrations above 1 000 vpm cause death within a few minutes, concen-
trations above 5 000 vpm cause death within a few seconds!
When using this device in plant where there may be high concentrations of H2S and you
therefore need to take following continual precautions to prevent the effects of poison-
ing:
• Connect the gas outlet of the analyzer to a gas exhaust unit so that no gas can escape
into the environment!
• Before you begin maintenance on the analyzer, make sure that the H2S concentration
in the analyzer is close to 0 vpm. Before beginning work, always flush the gas path of the
analyzer and the gas sampler with ambient air or nitrogen for a duration of about 10
minutes .
• Check for leaks in the analyzer at regular intervals!
DANGER Danger of explosion
This device is used in biogas plants, among other places. When it is used in biogas plants,
you should expect that the sample gas will contain methane, which forms explosive mix-
tures with oxygen or air in certain concentrations. These conditions are possible with
certain operating states of the plant.
2.4 Analyzers in hazardous areas
WARNING Unsuitable device for the hazardous area
Danger of explosion
Only use equipment that is approved for use in the intended hazardous area and la-
belled accordingly.
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3 Transport and storage
Transport
The unit is sensitive to shock and vibration. Therefore, where possible, transport in the original packaging or large, sturdy pack-
aging at a minimum consisting of 3 layer carton, plastic or aluminium sheet. Line the inside of the packaging with padding at
least 10 cm thick on all sides.
The unit should be marked fragile for shipping.
Storage
During extended periods of non-use, protect the analyzer against moisture and heat.
Store the unit in a dry, ventilated, dust-free room. Cover the unit with suitable packaging to protect it from liquids and dirt
8 Bühler Technologies GmbH BE555000 ◦ 11/2019
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