WARNING Check the supply voltage is correct before connecting the instrument.

Do not expose to water or moisture: use the controller only within the operating
limits avoiding sudden temperature changes with high atmospheric humidity to
prevent formation of condensation.
Warning: disconnect all electrical connections before any kind of maintenance.
Fit the probe where it is not accessible by the End User.
The instrument must not be opened.
Consider the maximum current which can be applied to each relay (see
Technical Data).
Ensure that the wires for the probes, loads and the power supply are separated
and far enough from each other, without crossing or intertwining.

ANALOG INPUTS

Input No Sensor Range Signal

AI1 O2 0-30%
AI2 CO2 0-100%
AI3 CH4 0-100% 0.25V-4V
AI4 H2S 0-2000ppm
AI5 Temperature 0-100°C

DIGITAL OUTPUTS

Sr No Output No Name Terminal

1 DO00 Sampling Solenoid
2 DO01 Purge Gas Solenoid
3 DO02 Suction Pump
4 DO03 Dilution Pump
5 DO04 Chiller Drain Solenoid
6 DO05 Temperature Control Solenoid
7 DO06 Hooter
8 DO07 Span gas solenoid
Connection Details

POWER SUPPLY Mean Well RS 35-24

230VAC----------------24VDC and 230V AC ----------+12VDC AND -12VDC

CONTROLLER TO HMI COMMUNICATION

Ethernet

DATA LOGGING

Pen Drive Connectivity Behind HMI

Kindly do the wiring connections as per above details. Also note that malfunction
due to wrong power supply given to the controller is not covered under
warranty. Wrong Connections between controller and display may damage the
display permanently.
Operation Logic:

The PLC can be

operated in two
modes- MANUAL
and AUTO
selectable by the
parameter in
SETTINGS in MENU
switch present on
the main screen.
Setting screen for
Auto/Manual
process selection. Settings screen
Press NEXT key from settings to navigate till above screen.

In Manual Mode
the user has to
select switches on
HMI to further
sample the gas. On
pressing SAMPLE
OFF, the sampling
for the gas will start
accordingly. If the
sampling has to be
stopped then the
same switch should
HOME Screen
be selected again. Also if manual purging has to be done then one PURGE OFF
switch can be selected to manually purge the sensors.
(Please Note: In manual mode once the sampling stops the purging will start
automatically, which will run for 1 minute and after that it will switch off
automatically.)
In Auto Mode the user has to enter the sampling time. Under ON time of
SAMPLING TIME user has to enter the time duration (in minutes) for which
sample should be taken to the system.
After that OFF time i.e. the purge time (in minutes). So in AUTO mode the
logic will run according to the ON time and OFF time entered by user. Firstly, it
will take the sample for the duration mentioned in the ON time, then it will purge
for the duration mentioned in the OFF time. This cycle will keep on repeating in
AUTO mode unless and until user switches from AUTO to MANUAL.

Alarm Logic:

There are total 4 gas sensors. For each sensor there are two alarm conditions. For
this the user has to enter high value and low value for alarm under SETTINGS in
MENU.
(Please Note: the high and low value for O2, CO2, CH4 are in percentage and for
H2S it is in ppm)
Once the gas conc. Goes above or below the range entered under the HIGH and
LOW value the status will be indicated on HOMESCREEN under the particular gas.

Also if hooter has to be operated under high value condition then the user has to
select ACK switch of gas for which hooter should sound.
PARAMETERS (SETTABLE):

Sr No Parameter Value
1 O2 High Value 30%
2 O2 Low Value 0%
3 CO2 High Value 100%
4 CO2 Low Value 0%
5 CH4 High Value 100%
6 CH4 Low Value 0%
7 H2S High Value 2000ppm
8 H2S Low Value 0ppm
9 Operating Mode Auto/Manual
10 Temperature Hysteresis 2
11 Temperature Setpoint 4
12 Chiller Drain On Time 10
13 Chiller Drain Off Time 15
14 Sampling On Time 60
15 Sampling Off Time 60
Operation:

When the Controller is powered ON, you can see the following display on your
screen.

MENU SCREEN:

Menu screen has the following switches for Navigation purpose.

Home: Main screen which displays all the sensor’s current value, Alarm indication
and alarm acknowledgement.

SETTINGS SCREEN:

It will navigate to the

settings screen of O2
and CO2 parameters.
To move to other
settings touch the
NEXT key or BACK key
accordingly. Also you
can navigate BACK
from BACK switch(i.e
3rd switch) from HMI and NEXT switch(i.e. 4th switch) respectively.
 To exit from
settings screen
touch HOME to
go to HOME
screen or MENU
respectively.

DIAGNOSTICS SCREEN:

Touch “Start
Diagnostics” switch to
enter into diagnostics
mode. You can Turn ON
and OFF the relays by
touching the respective
output.
TRENDS SCREEN:

It will display
graph for all the
sensor values.

Port Settings for Modbus Communication: -

1) Driver Modbus RTU

2) Baud rate 9600
3) Parity None
4) Media RS485
5) Stop Bit 1

Modbus Addresses:

Sr No Parameter Address
1 O2 Sensor Value (%)
2 CO2 Sensor Value (%)
3 CH4 Sensor Value (%)
4 H2S Sensor Value (ppm)
MECHANICAL SPECIFICATIONS:

Allen Bradley Micro830 PLC

Allen Bradley C400 HMI:

Item Description Item Description

1 Touch, function keys display 6 Mounting slots

2 Power status indicator 7 RS-232 serial port

3 24V DC power input 8 USB host port

4 10/100 MBit Ethernet port 9 Diagnostic status indicator

5 RS-422 or RS-485 port 10 Replaceable RTC battery

Input Voltage 24VDC Relative Humidity 0-95%

Operating Temperature 0-50°C Power Consump. Max3.5W

Technical Specifications:
Sr.no Parameters to Analyzer Specification
A GENERAL
1 Service / Location Field
2 Tag No. / Quantity
3 Tag Plate
4 Area Classification Unclassified
6 Model No: BG 112/ Chemtron
7 Make: Chemtron/ Chemtron
8 Stream Selection Automatic
B General Specification
1 Microcontroller based Multi Channel analyzer
Type
system for measuring gas composition in biogas
2 Components to Measure CH4, CO2, O2 & H2S
3 Analyzer Housing Material M.S with Powder coating
4 Panel Dimensions (H x W x D) (1385x609x304 ) mm
5 Mounting Free standing panel
6 Mounting Accessories Inclusive ( Wiring and piping to brought till panel)
7 Weather Protection Suitable for Outdoor application,IP-55
8 Software Standard Software
9 Power Supply 230VAC,50Hz
C Sensing Unit
1 System Type Sample Type
2 Technique / Type of Sensor
For CO2 & CH4 Non Dispersive Infra Red(NDIR)
For H2S Electrochemical
For O2 Electrochemical
3 Analyzer Range
CH4 0 - 100% Vol.
CO2 0 - 100% Vol.
H2S 0 - 2000 PPM
O2 0 - 30%
4 Multipoint sampling system Provided
5 No. of Stream One
6 Suction Pump Diapharagm Pump
7 Process connection 1/4" tube fitting
8 Wetted Part SS 316/ Teflon
9 Isolation Valve for Stream 1/2" NPT(F)
Quantity As required
10 Non Return Valve NA
11 Tubing & Tube Fittings 1/4" tube fitting
Material SS 316/ Teflon
12 Tubing for Calibration gas/ SS316 1/4" tube fitting
13 Flow Indicator Present in the system
14 Pressure Indicator Not required
15 Temperature Indicator Displays Dew Point of treated gas stream
16 Processed Gas (Recycled / Vented) Provided
D Transmitter / Converter Electronics
1 Output Modbus and 4 nos.(4-20)mA Analop output
2 Comm. Protocol RS 485 , Modbus Protocol
3 Alarm High Alarm Indicators
4 Local Indicator Touchscreen HMI
5 Display type TFT Display
6 Display Size 113 x 138 x 43 mm
8 Meter Scale Unit Engineering unit as specified
11 Electronic Calibration Range As per service condition specified
E Characteristics
1 For NDIR technique
Overall Accuracy ± 1% of full scale or Better
Zero/Span drift ± 1% of full scale in 24 hours.
Response Time < 5 sec. for 90% response
Repeatability ± 2 % of reading
2 For Electrochemical technique
Overall Accuracy ± 2% of full scale or Better
Zero/Span drift 1% of full scale
Response Time < 15 sec. for 90% response
Repeatability ± 2% of full scale or Better
3 For Paramagnetic technique
Overall Accuracy NA
Zero/Span drift NA
Response Time NA
Repeatability NA
4 Linearity +/-' 2 % of full scale
5 Rangeability +/-' 2 % of full scale
6 Warm up Time < 3min
7 Single Cycle Time for each stream 5 mins
8 Stability < 3 min
9 Relative Humidity 90% non condensing
10 1 yr for NDIR(depending on moisture and Conc of
Sensor Life Expectancy
Biogas)
11 Electromagnetic Compatibility Shall be as per IEC 801
F Calibration System
1 Calibration gas cylinder (0.5 Ltr Canister) Optional
Capacity Mini. For 1 year
2 Purging gas (Automatic/Manuel ) Auto
Purging gas Medium Instrument Air
Pressure / Temperature ambient/ ambient
3 Zero Calibration Type (Automatic / Manuel
Manual
)
Zero Calibration gas Instrument Air
Pressure / Temperature ambient/ ambient
 Pressure / Temperature ambient/ ambient
G Options
1 Sample Conditioning System confirmed for dust and moisture (Chiller Unit).
2 Touch Pad/Key pad oper. Keypad
3 Power consumption 250 W
4 Booster Pump Provided
6 Earthing Provided
7 Surge/Lightning Protection Provided
9 Other Accessories NONE
1 Training Provided
2 Painting Powder Coating
3 Performance Test Provided
4 Warranty 12 months
5 Max. distance b/w sample tapping point & up to 200 meter is 1/4 inch line is used for
analyzer for good response time sampling line
6 Analyzer shall be provided with Suitable brass,
Double compression cable gland with PVC
Cable gland & Accessories
shroud, plug and other accessories certified for
IP55
F As per MR & Vendor approved QAP to cover
Inspection & Testing
minimum requirement
G As per General Supplier Document Requirement
Documents to be Submitted
List
H Delivery 30 to 45 Days
I Optional Spare As per MR
1 Mandatory spare Included (Calibration Gas)
2 Commissioning spare NA
3 2 year operational spares Calibration Gas