mru SWG 100 biogas User Manual
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mru SWG 100 biogas User Manual

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MRU GmbH
SWG 100 User Manual
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  • Page 1 MRU GmbH SWG 100 User Manual Page 1 of 141...
  • Page 2 MRU GmbH SWG 100 User Manual Page 2 of 141...

  • Page 3: Table Of Contents

    1.6. Packing ........................9 1.7. Return of hazardous waste ..................9 1.8. Return of analyzer ...................... 9 1.9. MRU Warranty conditions ..................9 Analyzer Description ...................... 11 2.1. Intended use ......................11 2.2. Type plate ........................ 11 2.3. Possible applications and analyzer options ............. 12 2.4.
  • Page 4 MRU GmbH SWG 100 User Manual 10. Service and maintenance ..................87 10.1. Preparing and information about the maintenance ..........87 10.2. Regular maintenance work by the operator ............. 87 10.3. Position and overview of the service-parts............... 88 10.4. Troubleshooting ....................... 95 11.
  • Page 5 Note any damage to packaging accepting the shipment. Submit damage claim to MRU immediately. NOTE: Damage claims not received by MRU within 3 days of receipt of shipment will not be accepted. The products described in this manual are subject to continuous development and improvement and it is therefore acknowledged that this manual may contain errors or omissions.

  • Page 6: General Information

    These should be clarified with the manufacturer (MRU). Any additional protective measures for outdoor mounting have to be provided by the plant operator. The manufacturer (MRU) consults the plant operator in choosing appropriate protective measures. NOTE The SWG100Biogas analyser is designed for sampling biogas with condensate of max.

  • Page 7: Important Information About The User's Operation Manual

    MRU GmbH SWG 100 User Manual IMPORTANT In case of not intended use the guarantee will void. Regular controls, inspections and the exchange from polluted and exhausted filters by the operator are also an not determined use - see chapter 10.1 regular maintenance work.
  • Page 8 MRU GmbH SWG 100 User Manual Sample gas exiting the analyzer will flow in to the ambient air and only outdoor use or forced ventilation rooms are suitable for using the biogas analyzer. Flammable gas WARNING Flammable gas Biogas contains Methane (CH4), which can be flammable.

  • Page 9: Packing

    1.6. Packing Packing regulation of 12.07.1991 If your local waste facility does not accept MRU packing materials for disposal, you may return it to MRU or our local sales representative. Packing materials returned to MRU must be returned prepaid. 1.7.
  • Page 10 4. As well excluded from the guarantee conditions are typical consumable- and spare parts. 5. Use of original MRU consumable parts and sensors is required to maintain the warranty. 6. Removal of tampering of the serial number type plate will void the warranty.

  • Page 11: Analyzer Description

    MRU GmbH SWG 100 User Manual 2. Analyzer Description 2.1. Intended use The instrument is intended for analyzing the composition of biogases / landfill gases and determine the concentration of several components like CH4, CO2, O2 and H2S. The instrument may optionally be equipped to monitor several sites in time sharing technique (cyclical one by one sampling).

  • Page 12: Possible Applications And Analyzer Options

    Module with 4 channel analog outputs/inputs 4- relays Converter module of RS485 into Profibus Cabinet heater for freeze protection Ask our sales representatives for available options and accessories or check out our MRU website. 2.4. Principle of operation • Sample gas from one or more sampling points is fed into the analyzer by dedicated ports.
  • Page 13 MRU GmbH SWG 100 User Manual Picture above: Sample gas flow diagram. Page 13 of 141...

  • Page 14: Special Functions Of The Analyzer

    MRU GmbH SWG 100 User Manual 2.5. Special functions of the analyzer H2Slow sensor protection (optional) The instrument may be optionally equipped with a H sensor. As this sensor typically shows limited life time when experiencing high H S concentrations, some precautions are taken to protect the sensor: •...

  • Page 15: Physical Characteristic Of The Gas Analyzer

    MRU GmbH SWG 100 User Manual 2.6. Physical characteristic of the gas analyzer Top view Front view Reference: 1. Gas inlet (default x1/optional max.10) 4. Suspension for wall mounting 2. Cabinet lock 3. Operation unit with display Page 15 of 141...
  • Page 16 MRU GmbH SWG 100 User Manual Right side view Left side view Bottom view 1. Fan filter 4. Zero gas inlet 7. Cable gland M16 for IO 2. Sample gas outlet (Vent) 5. Condensate outlet 3. Calibration gas inlet 6. Cable gland M16 for power supply...

  • Page 17: Scope Of Supply And Delivery

    MRU GmbH SWG 100 User Manual 3. Scope of supply and delivery Your analyzer is delivered in a carton box and is protected with special edge protectors. Please do preserve the packing of your analyzer, for possible return shipment. Inside the attachments box are different fittings:...

  • Page 18: Sd-Card Content

    MRU GmbH SWG 100 User Manual SD-card content Following content are on the SD-Card: • Ethernet-Converter manual • Profibus-Converter manual • GSD-Files for profibus-converter • SWG100-Bio manual (EN/DE) • SWG100-Bio ModBus/Profibus specification (EN/DE) The SD-card can be found in the SD-card slot in the device (see sketch below).

  • Page 19: Installation Manual

    MRU GmbH SWG 100 User Manual 5. Installation manual 5.1. Overview In this manual the installation of the different parts of the analyzer-system will be explained. An entire analyzer-system consists of these parts: • The analyzer. • A sample line.

  • Page 20: Installation Of The Analyzer

    MRU GmbH SWG 100 User Manual 5.2. Installation of the analyzer The analyzer is equipped with adapters for the wall mounting. The dimensions for the wall mounting are shown in picture below. ATTENTION Operation of the analyzer Only operate the analyzer in an upright position.
  • Page 21 MRU GmbH SWG 100 User Manual Connect the VENT gas-outlet of the device to ambient by using adequate tube with min Ø8mm ID. Calibration gas inlet Zero gas inlet Condensate outlet Reference: 1. Fitting for sample gas inlet G1/8 2. Fitting for sample gas outlet G1/4 3.

  • Page 22: Connection Of Main Power Supply

    MRU GmbH SWG 100 User Manual 5.3. Connection of main power supply WARNING Electric voltage Power the system down and protect for reconnecting, before start maintenance work. The analyzer needs a main power supply of 100-230 VAC/ 47-60 Hz. The power supply may be found on the DIN-rail.

  • Page 23: I/O Modules: Installation And Setting

    MRU GmbH SWG 100 User Manual 5.4. I/O modules: Installation and setting The IO module is for monitors and allows for remote operating of the analyser. An IO module has the following features: • Transmit 4-20 mA output. • Trigger alarm outputs.
  • Page 24 MRU GmbH SWG 100 User Manual Plug connector definition: WARNING Electric voltage Power the system down and protect from reconnecting, before starting maintenance work. Slit screws Stripping length: 7 mm Tightening torque min.-max.: 0,5-0,6 Nm Conductor cross sections, which can be used: Type of electric line Conductor cross section min.-...

  • Page 25: Operation Of The Analyzer (Hmi)

    MRU GmbH SWG 100 User Manual 6. Operation of the analyzer (HMI) 6.1. Display and keypad All information required to operate the analyzer is displayed as shown below. Menu indication bar Function key bar Display area of - Menu SD-Card symbol - Indication green →...

  • Page 26: Analyzer Commissioning Manual

    MRU GmbH SWG 100 User Manual 7. Analyzer commissioning manual After the first start of the analyzer it is necessary to make some settings at the analyzer. These settings are: • Check the country and language. • Check the date and time of the instrument.

  • Page 27: Configuration Of The Alarm Relays

    MRU GmbH SWG 100 User Manual 7.3. Configuration of the alarm relays On the main PCB there is o contact. The following errors will turn the relay from NC to NO. Main board is offline (internal RS485 bus communication failure) Gas leakage inside analyzer cabinet (CH4 >...
  • Page 28 MRU GmbH SWG 100 User Manual Plug connector definition for the system alarm relay Slit screws Stripping length: 7 mm Tightening torque min.-max.: 0,5-0,6 Nm Conductor cross sections, which can be used: Type of electric line Conductor cross section min.-max.

  • Page 29: Configuration Of The Modbus

    MRU GmbH SWG 100 User Manual 7.4. Configuration of the Modbus The Mobdbus connector can be found on the PCB-mainboard (see sketch below). NOTE: for specification of Modbus (RTU) data transfer over RS485, please observe appendix. User RS-485 (Modbus RTU)
  • Page 30 MRU GmbH SWG 100 User Manual Configuration at the analyzer 1. Open the path XTRAS ENERAL ETTINGS 2. Press 3. The Modbus store settings will be open. The user can commission the settings. The following settings can be set: •...

  • Page 31: Binding To A Process Control System: I/O Modules

    MRU GmbH SWG 100 User Manual 8 Binding to a process control system: I/O modules The IO module is a necessary module for the signal forwarding, into a control room. This module is an interface for signal transmitting, remote operating and to read signals, from extern transducers.

  • Page 32: Pin Assignment

    MRU GmbH SWG 100 User Manual 8.2. Pin assignment The follow pin assignment-plan shows where the different pins for the interfaces can be found and which pins has a double occupancy. Page 32 of 141...
  • Page 33 MRU GmbH SWG 100 User Manual max. Load max. external Internal load Double Description Abbrevation (for Voltage (in inputs) occupancy outputs) AO1+ max. 500R AO1- max. 500R AO2+ max. 500R AO2- max. 500R AO3+ max. 500R AO3- max. 500R AO4+ max.

  • Page 34: Analog Outputs 4-20 Ma

    MRU GmbH SWG 100 User Manual 8.3. Analog outputs 4-20 mA Hardware-side green labels. AO1+ AO1- AO2+ AO2- AO3+ AO3- AO4+ AO4+ Information for connection: Conductor cross section: Max. Load (for output): 500 Ohm Page 34 of 141...
  • Page 35 MRU GmbH SWG 100 User Manual Software-settings • Open the menu: Extras/Analog output configuration (1). • The overview screen appears. This menu shows, how much analog-outputs are available and how the analog outputs are occupied. At the overview screen all analog-outputs are listed. The amount of the analog-outputs is dependent from the amount of the installed IO-modules.
  • Page 36 MRU GmbH SWG 100 User Manual • List of the installed analog output ports (1): At this list the operator can select, which analog-output should be configured. To select an analog- output, move the up/down arrow keys. • Details (2): Here the operator can open the configuration screen for the selected output port.
  • Page 37 MRU GmbH SWG 100 User Manual value, for a current of 20 mA. The IO module will create the linear relation. Return (6): Leave the menu. Alternate push Overwrite on (7): A function to simulate values. If the overwrite function is activated, the set value will be transferred to the DCS.
  • Page 38 MRU GmbH SWG 100 User Manual 1. Example: 4-20 mA signal outputs to control room Starting position: A plan wants to read the measurement values from the CO2 channel to their DCS The SWG100 has only one IO module and three sample points. All outputs are free.
  • Page 39 MRU GmbH SWG 100 User Manual The follow screen appears. To configurate the channel 1, the red marked positions must be changed: • In the last step the menu must be closed. Confirm the store message. The 4- 20 mA output is now configuring.

  • Page 40: Alarm Outputs

    MRU GmbH SWG 100 User Manual 8.4. Alarm outputs Hardware side: Every IO module has two alarm outputs. The position of the alarm-outputs are marked with the red labels. AL1+ AL1- AL2+ AL2- Information for connection: Conductor cross section: Relays-type:...
  • Page 41 MRU GmbH SWG 100 User Manual Software-side • tion (1). Extras/Analog output configura Open the menu: • The overview screen appears. This menu shows, how much alarm-outputs are available and how the alarm outputs are occupied. At the overview screen all alarm-outputs are listed. The amount of the alarm-outputs is dependent from the amount of the installed IO-modules.
  • Page 42 MRU GmbH SWG 100 User Manual • List of the installed alarmoutput ports (1): At this list the operator can select, which alarm output should be configured. • Details (2): Here the operator can open the configuration screen for the selected alarm output.
  • Page 43 MRU GmbH SWG 100 User Manual Example: Alarm output to control room Starting position: A warning light should be installed inside the plan. It should be power up, if the over sample point 2 one IO H2S concentration is 550 ppm in the .
  • Page 44 MRU GmbH SWG 100 User Manual • The follow screen appears. To configurate the channel 1, the red marked positions must be changed: Page 44 of 141...

  • Page 45: Analog Inputs (4-20 Ma)

    MRU GmbH SWG 100 User Manual 8.5. Analog inputs (4-20 mA) Hardware-side: The analog inputs are on the top of the IO module. They are marked with a blue label. Through the help of the analog inputs, the IO module can read all common 4- 20 mA transducer in the analyzer directly.
  • Page 46 MRU GmbH SWG 100 User Manual 2-wire transducer: Transducer Load: 50 Ohm Power supply for transducer 4-wire transducer Transducer Load: 50 Ohm Power supply for transducer Page 46 of 141...
  • Page 47 MRU GmbH SWG 100 User Manual Software-side • Open the menu: (1). XTRAS UX INPUT CONFIGURATION • The overview screen appears. At the overview-screen, the installed AUX- inputs are listed. Every IO module has four AUX-inputs. At the default settings all AUX-inputs are deactivated (OFF at the overview-screen).
  • Page 48 MRU GmbH SWG 100 User Manual Example: Read 4-20 mA signal from an external temperature sensor An operator wants to read an external temperature sensor signal inside a SWG100. a 7-30 VDC power The temperature sensor gives a 4-20 mA signal out and needs...
  • Page 49 MRU GmbH SWG 100 User Manual • The follow screen appears. Here, the sensor can get an individual name. • At the toolbar, the operator can select the options: o Details (F1): Here the select analog-inputs can be configured. If pressed the follow screen appears.

  • Page 50: Configuration Of The External Control (Option: Io Module)

    MRU GmbH SWG 100 User Manual 8.6. Configuration of the external control (Option: IO module) This feature requires an I/O module (optional) and the function must be activated This feature can be used for the external control of the analyser. With the help of the external control follow operations can be done: •...
  • Page 51 MRU GmbH SWG 100 User Manual Connection of the external control via relay contact This feature can be used for externally controlled sampling point selection, zeroing and stand-by, using external potential free relay contacts, see also diagram in $4.4 The relay contacts build a 4-bit binary number: RC4 - RC3 - RC2 - RC1 open=0, closed=1.
  • Page 52 MRU GmbH SWG 100 User Manual Connection of the external control via 4-20 mA input signals The signal inputs built a 4-bit binary number: I4 I3 I2 I1: 0-11 mA=open=0; 11/12-20 mA=closed=1. Status of external signal Status number Description source...
  • Page 53 MRU GmbH SWG 100 User Manual Connection of the external control via one 4-20 mA input signal The user can control the analyzer with only the first 4-20mA input (see sketch below). The different commands will be given by the changing of the current signal.
  • Page 54 MRU GmbH SWG 100 User Manual Connection of the external control via Modbus A further option is, to control the external control via Modbus. To do this, follow steps must be done: • Connect the RS485 to Modbus converter to the Modbus connector found at the main pcb.
  • Page 55 MRU GmbH SWG 100 User Manual 3. If a valid input state (>0) is present, an arrow in the title line will appear. The analyzer is now slave and will perform the measurement until it gets another command from the master unit. Some external control settings can be configured.
  • Page 56 MRU GmbH SWG 100 User Manual (*2): Not only status numbers 4 to 15, but all status numbers larger than the number of installed sample points will start the sample points, then statu will purge the sensors, then it will close all solenoid valves and switch off the gas pump.

  • Page 57: Mounting And Installation Of The Gas Cylinders For The Auto Calibration Function

    MRU GmbH SWG 100 User Manual 8.7. Mounting and installation of the gas cylinders for the auto calibration function Mounting and installation of the gas cylinders for the auto calibration function The auto calibration function allows the calibration of the analyzer. To use the auto calibration function it is necessary to install the calibration gas bottles on the analyzer.
  • Page 58 MRU GmbH SWG 100 User Manual The diagram above shows the necessary installations for the auto calibration. The mixed gas cylinder is installed on the left side of the analyzer. Software side: Adjustment for the option auto-calibration: Open the menu...
  • Page 59 MRU GmbH SWG 100 User Manual NOTE All gas concentrations are in percent! The factory from percent to ppm is: 1%= 10.000 ppm. 5. The user has the following options: - leave the menu: The set gas concentrations are stored and the auto calibration will start after the interval is reached.

  • Page 60: Cycle Configuration

    MRU GmbH SWG 100 User Manual 8.8. Cycle configuration Path and default setting XTRA EASUREMENT CYCLE CONFIG When the menu is selected the user definable setting for the EASUREMENT CYCLE CONFIG measurement cycle will appear (see screenshot below). Screenshot shows default setting, when the will be started the first „M...
  • Page 61 MRU GmbH SWG 100 User Manual The two auto-configurations, which can be selected. Depending on the analyser type, the first or the first and second phase cannot be deleted, deactivated or moved to another position. Delete a phase With a phase can be deleted. To do this, select the phase, which should be deleted and press Screenshot shows how a phase can be deleted.
  • Page 62 MRU GmbH SWG 100 User Manual Zeroing (Cycle phase details): EROING configured. ZEROING Measuring site valves Valves closed Zeroing valve Valve open Duration 2min to 1 h Recommendation 5min., in general not to be changed by user as depending only on analyzer internal setup...
  • Page 63 MRU GmbH SWG 100 User Manual • Phase duration: Entire Stand-by time (Purging time + Quiet time = Phase time). • Purging time: The time, to purge the analyser with ambient air, through the zero gas inlet. • Quiet time: The time, where the analyser is in the pure stand-by mode.
  • Page 64 MRU GmbH SWG 100 User Manual Example for a measurement cycle configuration In this chapter an individual measurement cycle should be created with the features described at the chapters below. The measurement cycle should have the following sequence: Following points must be done to configure the individual measurement cycle: 1.
  • Page 65 MRU GmbH SWG 100 User Manual 5. Leave the cycle phase detail and select the next phase. Select with the left/right arrow keys Adjust the phase-duration at 15 min. and leave the cycle phase detail. left/right arrow key 6. Switch to the next point and select with the measurement SP1.

  • Page 66: Administrator Pin Code

    MRU GmbH SWG 100 User Manual 8.9. Administrator PIN code All functions and menus which may disturb the analyzer's normal measurement can be protected against unauthorized access by activating the administrator PIN code request. We highly recommend activating this function, when unauthorized persons could access the analyzer.

  • Page 67: Operating The Analyzer

    MRU GmbH SWG 100 User Manual 9. Operating the analyzer This chapter has the follow structure: • In the first part it will be explained, how to start the analyzer and the self- test menu. • Part three shows the submenu, which are listed at the EXTRA menu.
  • Page 68 MRU GmbH SWG 100 User Manual Self-Test The first menu to be displayed after Power-On is the self-test menu. The analyzer won't leave this menu before all sub-systems will be connected and the gas cooler (option) has reached the target operation temperature.
  • Page 69 MRU GmbH SWG 100 User Manual For devices with just one measuring point the switching is additional possible with the arrow keys up / down. Change the displayed page Use the arrow keys left / right can be changed in both display modes the page. The new page number is displayed in the title bar for a moment just after the successful change.

  • Page 70: Data Storage Menu

    MRU GmbH SWG 100 User Manual 9.2. Data Storage Menu 'storage' The data storage menu can be reached by pressing in the measurement menu: The menu provides an overview of stored measurements of each sample point and of the memory usage.
  • Page 71 MRU GmbH SWG 100 User Manual General information about the data storage Data storage strategy is as follows: • The analyser may store up to 20,000 measurement points (including all relevant data). • At the end of each measurement cycle (per sampling point) the current values will be stored.
  • Page 72 MRU GmbH SWG 100 User Manual The CSV format is not exactly the same in all countries. The analyser selects a fitting format variation according to the selected country. Nevertheless the CSV output can be changed the Data Storage Menu.
  • Page 73 MRU GmbH SWG 100 User Manual • Set maximal list: In this list all available measurement values and all 9 asset lines are pictured. • Set default list: In this list all available measurement values and 2 asset lines are pictured.

  • Page 74: Extra Menu: Overview

    MRU GmbH SWG 100 User Manual 9.3. Extra menu: Overview General settings Measurement configuration Measurement cycle config. Analog output configuration Alarm output configuration Adjustment menu Default settings Content SD card Even viewer Device info General settings Path: XTRA ENERAL SETTINGS...
  • Page 75 MRU GmbH SWG 100 User Manual Measurement configuration Path: XTRA EASUREMENT CONFIGURATION Structure: Measurement configuration Extras/Measurement configuration Measurement configuration Temperature °C or °F / default °C Pressure hPa, mbar or mmHG / default hPa Sample flow 30 l/h...60 l/h / default 50 l/h / steps: 5 l/h Measurement cycle config.
  • Page 76 MRU GmbH SWG 100 User Manual Adjustment menu Path: XTRAS DJUSTMENT MENU Structure: Device info Extra/Adjusment menu Adjusment gas factor (see service manual) Adjusment gas nom. Value (see service manual). NDIR CO2/CH4 adjustment Averaging (see Averaging in this chapter). Adjustment CH4 pellistor (see service manual) Hardware state &...
  • Page 77 MRU GmbH SWG 100 User Manual Hardware state & tests: Hardware Settings Gas pump ON or OFF Purge pump (optional) ON or OFF Solenoid valve H2S low (optional) ON or OFF Solenoid valve zero gas ON or OFF Solenoid valve cal. Gas...
  • Page 78 MRU GmbH SWG 100 User Manual Adjustment of the average-time for CO2/CH4 NDIR-bench (optional) If the analyser is equipped with a CO2/CH4 NDIR-bench, the user has the possibility to set the average time. 1. Open the path: Extras/ Adjustment menu/ NDIR CO2/CH4 adjustment.
  • Page 79 MRU GmbH SWG 100 User Manual Default configuration Use the menu for the default configuration: -> E > D EASUREMENT XTRAS EFAULT ETTINGS DEFAULT CONFIGURATION Analog output 4- Parameter 20mA Alarm output relay contact 20mA open CH4 [ % ]...
  • Page 80 MRU GmbH SWG 100 User Manual Contents SD card Path: XTRAS CONTENT CARD Structure: Contents SD card Extras/Contents SD card General settings Overview of the stored datas on the SD card. Skip the cursor on the first position. Open the file. User can view the stored screenshots.
  • Page 81 MRU GmbH SWG 100 User Manual Device info Path: XTRAS EVICE INFO Structure: Page 81 of 141...
  • Page 82 MRU GmbH SWG 100 User Manual Power-Down of analyzer Before the analyzer is disconnected from mains, it should be prepared for the Power-Down, because • operational data should be stored • eventually changed user settings should be stored • the sensors should be purged with fresh air...

  • Page 83: Update The Firmware

    MRU GmbH SWG 100 User Manual 9.4. Update the firmware The analyzer and different installed options can be updated if it is necessary. Following options can be updated: • The firmware for the analyzer. • The firmware for the pcb- mainboard.
  • Page 84 MRU GmbH SWG 100 User Manual Update the analyzer (Firmware- 1. Open the path: XTRA EVICE F2 = details 2. Press to open the details for the main device menu. F2 = FW update 3. Press . The analyzer will start the update from the SD-card.
  • Page 85 MRU GmbH SWG 100 User Manual 4. The Update will start from the SD-card, if a firmware with the filename -card. Update the IO modules (Firmware-Update w Open the path: XTRA EVICE INFO F3 = sub.syst 2. Press UB SYSTEMS INFO F2 = details 3.

  • Page 87: Service And Maintenance

    For a reliable function and high measurement quality it is necessary to inspect and service the analyser regularly. Besides the regular routine control by the operator (see chapter 10.1.-) MRU recommends a regular bi-annual maintenance at a minimum, which must carry by a qualified technician.

  • Page 88: Position And Overview Of The Service-Parts

    MRU GmbH SWG 100 User Manual In the follow chapters there will be introduced some service parts, which are important for the reliable operation. These parts are independent from the regular checks and must be replaced in a minimum interval of minimum 6 months.
  • Page 89 MRU GmbH SWG 100 User Manual Content of the service-set (offer-number: 66174) Single components can be offered under their article number directly. Image Interval Quantity Offer- name number Acid-gas filter New state: purple beads Used: white beads 2 pieces 56795...
  • Page 90 MRU GmbH SWG 100 User Manual Position 1: Acid-gas filter (#56795) Required materials 2x Acid gas filter (#56795), contained in the service- set. Required tools: Needle-nose pliers. Exchange interval: Exchange necessary, if filter turns from purple to white. Mounting direction: Irrelevant...
  • Page 91 MRU GmbH SWG 100 User Manual Position 2 and 3: Dust- and particle filter (#65533 and #66088) Required materials : Dust- and particle filter (#65533 and #66088) contained in the service set. Required tools: needle-nose pliers. Exchange interval: Exchange necessary, if the filter gets dark or black.
  • Page 93 MRU GmbH SWG 100 User Manual Position 4: PTFE Filter (#51513) Required materials: PTFE filter (#51513) contained in the service set. Required tools: needle-nose pliers. Exchange interval: Exchange necessary, if gas flow is too low. Mounting direction: Irrelevant Steps: Pull the exhausted filter-unit from the viton tube and exchange it with a new one.
  • Page 94 MRU GmbH SWG 100 User Manual Position 6: Filter mats (#60320) Required materials: 2x filter mats (#60320) contained in the service-set. Exchange interval: Exchange necessary, if filter revolution is reduced. Steps: Open the filter-unit by pulling the blue lash. Replace the exhausted filter mat through a new one.

  • Page 95: Troubleshooting

    MRU GmbH SWG 100 User Manual 10.4. Troubleshooting Error Possible causes Solutions Display does not work. - System is not power-up. - connect main power supply. - power up automatic fuse. - contact customer support. Analyzer powers down by - The fan is defective.

  • Page 96: Technical Specification

    MRU GmbH SWG 100 User Manual 11. Technical specification Allgemein General Deutsch Angabe English Betriebstemperatur(ohne +5°C ... +45 °C / 41 °F ... Operating temperature (w/o Frostschutzheizung) 113 °F heating) Betriebstemperatur (mit optionaler -10 °C ... +45°C / 14 °F...
  • Page 97 MRU GmbH SWG 100 User Manual Tastatur mit Anzahl Tasten Keyboard with qty of keys Elektrische Aus- /Eingänge Electrical I/O Serielle Schnittstelle RS485 Serial interface Protokoll Modbus RTU Protocol Typ Analogausgang 4 ... 20 mA Type of analog output Anzahl Ausgangskanäle...

  • Page 98: Technical Specification: Electrochemical Sensors

    MRU GmbH SWG 100 User Manual 11.1. Technical specification: Electrochemical sensors Angaben zur Deutsch Messgenauigkeit English Elektrochemischer Sensor O2 Long Life Electrochemical Sensor Messbereich 0 .. 21 % Measuring Range Auflösung 0,01 % Resolution Genauigkeit abs. ± 0,2 Vol% Abs. Accuracy Ansprechzeit T90 <...

  • Page 99: Technical Specification: Ndir-Benches

    MRU GmbH SWG 100 User Manual (abhängig von gewähltem Sensor) Elektrochemischer Sensor CO/4000 Electrochemical Sensor Messbereich 0-4000 ppm Measuring Range Auflösung 1 ppm Resolution Überlastbereich < 10000 ppm Overload Range Genauigkeit abs. Abs. Accuracy Ansprechzeit T90 < 40s Response Time T90...

  • Page 100: Appendix

    MRU GmbH SWG 100 User Manual 12. APPENDIX 12.1. Modbus via RS485 specification General information • The Modbus (slave function) requires the firmware version V1.01.70 dated 17.11.2014 or later. • The analysers are able to work as Modbus slave using the RS232 or RS485 port (possibly with external RS232/RS485 adapter) •...
  • Page 101 MRU GmbH SWG 100 User Manual • Defined registers to be read by the master. modbus profibus data register content address address type Status & Device info Analyser Status (more details read below) System Alarm (more details read below) Serial number...
  • Page 102 MRU GmbH SWG 100 User Manual H2 [ppm] (optional) Net calorific value [MJ/kg] Gross calorific value [MJ/kg] Net calorific value [MJ/m³] Gross calorific value [MJ/m³] CO [ppm] (optional) CH4 [ppm] (optional, when CH4 [%] also available) CO2 [ppm] (optional, when CO2 [%] also available)
  • Page 103 MRU GmbH SWG 100 User Manual Optional AUX values are not available via Profibus. protocol data numb. of register content address type registers AUX-values (read by up to 10 IO-modules) AUX-value read by IO-module 1 - Input 1 AUX-value read by IO-module 1 - Input 2...

  • Page 104: Analyser Status (Address 0 And Some Mirror Addresses)

    MRU GmbH SWG 100 User Manual 12.2. Analyser Status (address 0 and some mirror addresses) The Analyzer Status is a 32bit-word and must be interpreted bitwise. Description Power-On (until the first zeroing has been done) System-Alarm, see table below Air Purging (zeroing)

  • Page 105: Spare Parts List

    MRU GmbH SWG 100 User Manual 12.4. Spare parts list Article Description Serial number Gas cooler - #60467HT Required to dry the sample gas Condensate pump - #11230 Required to drain the condensate Sample gas pump - #65032 Used for sample gas pumping...
  • Page 106 MRU GmbH SWG 100 User Manual Axial fan - #65097 For ventilation of analyzer cabinet Solenoid valve - #65470 Used for sampling point switching. CxHy gas detector - #65469 Required for monitoring the CH4 concentration inside analyzer cabinet Heater #65425...
  • Page 107 MRU GmbH SWG 100 User Manual I/O-Module #65179 + #65430 Used for analog output data transfer and sample point switching. I/O Module - #65179 Used for analog output data transfer Heater #65734 Used for freeze protection of analyzer cabinet installed in safe area...

  • Page 108: Purchase Options Of The Analyzer

    MRU GmbH SWG 100 User Manual 13. Purchase options of the analyzer In this chapter the different available options are explained. The chapter shows: • The place of the options in the analyzer. • The characteristic of the options. •...

  • Page 109: Option: Cabinet Heater

    MRU GmbH SWG 100 User Manual 13.2. Option: Cabinet heater The feature cabinet heater is necessary to operate the analyzer at low ambient air temperatures (- temperature is fallen <18°C. The electrical power from the cabinet heater is 200 Watt.

  • Page 110: Option: Flame Arrester

    13.3. Option: Flame arrester It can be necessary to install separate flame arresters at the sample gas inlets. The flame arrester, which can be purchase by MRU, has permission for ATEX areas zone 2 (DIN EN ISO 16852). Page 110 of 141...

  • Page 111: Option: Multiple Sample Point Switching And Monitoring (Time Sharing)

    MRU GmbH SWG 100 User Manual 13.4. Option: Multiple sample point switching and monitoring (time sharing) The analyser is by default equipped with one sample point (see market above). It can be offered with several sample points (max. 10). The sample points are not measured simultaneously but one at a time (round robin technique).

  • Page 112: Option: Gas Detector (%Lel Ch4) To Monitor Air Inside Analyzer Cabinet

    MRU GmbH SWG 100 User Manual 13.5. Option: Gas detector (%LEL CH4) to monitor air inside analyzer cabinet With this option the CH4 concentration inside the analyser can be determined and monitored. This menu is only installed, if the gas detector is installed.

  • Page 113: Option: Extra Io Module With 4 Channel 4-20 Ma

    MRU GmbH SWG 100 User Manual 13.6. Option: Extra IO module with 4 channel 4-20 mA The analyser is by default equipped with one IO module (see market above). It can be offered with a different number of IO modules (max.10). Every single installed IO module can be driven independent from each other.

  • Page 114: Option: H2S Electrochemical Cell Measurement 0-2000Ppm/4000Ppm

    MRU GmbH SWG 100 User Manual 13.7. Option: H2S electrochemical cell measurement 0- 2000ppm/4000ppm The H S electrochemical sensor is offered with two different functions: • Without cut-off solenoid valve and air purge pump. • With cut-off solenoid valve and air rising pump.

  • Page 115: Option: Extern Condensate-Trap

    BIOGAS SWG100 Supplementary instruction: Version External condensate trap 13.8. Option: Extern condensate-trap The external condensate trap is a pre-filter unit, which is for wet and dirty sampling points with condensate higher than 14ml/min. Mounting of the external condensate trap The schematic above shows the tubing of the external condensate trap: Safety valve (not scope of PTFE-flexible tube: DN6/4 mm (max.
  • Page 116 MRU GmbH SWG 100 User Manual Installation of the mounting panel Exchanging the filter element 1. Close the safety valve at the gas inlet. CAUTION Risk of negative pressure inside the system. The following order must be considered: ► Shut the system down.
  • Page 117 MRU GmbH SWG 100 User Manual 3. Remove the filter unit from the retention fixture (see picture 1). 4. Unscrew filter the side glass from the external condensate trap (see picture 5. Unscrew the filter bracket (see picture 3). Filter element...
  • Page 118 MRU GmbH SWG 100 User Manual 6. Delete the exhausted filter and exchange it with a new one (see picture 4). Exhausted filter element. 7. Screw the filter bracket back in the filter unit (see picture 5). New filter element.

  • Page 119: Option: Rs485 To Profi-Bus Converter

    MRU GmbH SWG 100 User Manual 13.9. Option: RS485 to Profi-Bus converter RS485 Profi-Bus converter Normally the analyzer communication is Modbus RTU. If it is wanted, a RS485- Modbus/ Profibus converter can be installed at the DIN-rail. This hat-rail module will be explained in a separate manual.

  • Page 120: Option: Rs485 To Ethernet Converter

    MRU GmbH SWG 100 User Manual 13.10. Option: RS485 to Ethernet converter RS485 to Ethernet converter Normally the analyzer communication is Modbus RTU. If it is wanted, a RS485-Modbus/Ethernet Bus converter can be installed at the DIN-rail. This hat-rail module will be explained in a separate manual.

  • Page 121: Configuration Of The Ethernet Module

    MRU GmbH SWG 100 User Manual 13.11. Configuration of the Ethernet module • The following screen will appear. Select Z-Key at the register called • y (market with 2 in screenshot). Page 121 of 141...
  • Page 122 MRU GmbH SWG 100 User Manual current IP-address, which is saved at the module will appear. (2). Connect the Ethernetmodule with an USB- nfiguration to Z- settings will be written to the module. Page 122 of 141...
  • Page 123 MRU GmbH SWG 100 User Manual ATTENTION . It can happen that the following message will appear: Just confirm the message and test, whether the settings are set. Normally the message can be ignored. 5. The settings are saved at the module now.
  • Page 124 MRU GmbH SWG 100 User Manual F3=Modbus 2. Open the path Extras/General settings, at the analyzer. Push At this menu the Modbus slave parameters can be configurated. Example: Baud rate: 19200 Slave address: 238 Stop bits: 1 Parity: even Data bits: 8 Picture: The screenshot shows an example of a Modbus slave settings.
  • Page 125 MRU GmbH SWG 100 User Manual ts will be appeared. At this protocol the following adjustments must be set: 6. Working mode: MODBUS BRIDGE ON PORT#2 (1). 7. Baudrate (2): 8. Data Bits (2). 9. Parity (2). 10. Stop Bits (2).
  • Page 126 MRU GmbH SWG 100 User Manual • The baudrate, data bits, parity and stop bits must be the same like Connection the SWG100 with MRU4WIN 1. Open MRU4WIN. 3. Set the Modbus setting from Serial to TCP(2). Can be found...
  • Page 127 MRU GmbH SWG 100 User Manual • The slave ID can be found at the modbus settings (see screenshot). The port number (called Port at the setting) can be found at the Ethernet protocol (see chapter 1.1 point 6). 5. The new created device can be found at the left side of the MRU4WIN screen.

  • Page 128: Option: Connection The Swg100 With Rs-485 Converter To Mru4Win

    MRU GmbH SWG 100 User Manual 13.12. Option: Connection the SWG100 with RS-485 converter to MRU4Win It is possible to connect the SWG-100 to MRU4Win, via a RS-485 converter. For the connection a MRU4Win-license and a RS-485 converter (offer-number: #62543) is required.
  • Page 129 MRU GmbH SWG 100 User Manual • Normally the RS-485 converter should be recognized from the PC. For testing the connection, open the device manager of the PC. A new COM- port must appear. • Connect the RS-485 converter with the Modbus connector at the main-pcb at the SWG100.
  • Page 130 MRU GmbH SWG 100 User Manual • At this screen, the settings, for the SWG-100 can be set. The screen shot below shows an instance. Of course, it can be set other baud rates or settings. • Same settings •...

  • Page 131: Option: Ndir-Bench For Ch4/Co2 Analysis, 0-100% / 0-100

    MRU GmbH SWG 100 User Manual 13.13. Option: NDIR-bench for CH4/CO2 analysis, 0-100% / 0-100% This NDIR-bench is for biogas at AD plants. It detects in percent range. Page 131 of 141...

  • Page 132: Option: H2 Thermal Conductivity Detector Measurement 0-100

    MRU GmbH SWG 100 User Manual 13.14. Option: H2 thermal conductivity detector measurement 0-100% It can equip the analyzer with a thermal conductivity detector, with a measurement range from 0-100%. Page 132 of 141...

  • Page 133: Option: Ndir-Bench For 0-3.000Ppm Co2/0-3.000

    MRU GmbH SWG 100 User Manual 13.15. Option: NDIR-bench for 0-3.000ppm CO2/0- Page 133 of 141...

  • Page 134: Option: Dilution-Unit For H2S And Co Electrochemical Sensors

    MRU GmbH SWG 100 User Manual 13.16. Option: Dilution-unit for H2S and CO electrochemical sensors Page 134 of 141...
  • Page 135 MRU GmbH SWG 100 User Manual Dilution-unit The dilution-unit inside the analyser dilutes the sample gas flow with a fix ratio. The unit is preadjusted. The operator must do a fine calibration of the device, to improve the accuracy of the measurement.
  • Page 136 MRU GmbH SWG 100 User Manual Fine calibration of the dilution-unit If the steps above are done, the device should look like in the sketch below: Max. x10 gas inlets Follow steps must be done, for the fine calibration of the dilution-unit. The steps below show the entire adjustment on the example of a H2S-sensors.
  • Page 137 MRU GmbH SWG 100 User Manual 1. Installation of the calibration gas cylinder (gas cylinder for the undilute calibration). 2. Adjustment of the undilute electrochemical sensor. a. Open the path: XTRAS DJUSTMENT MENU DJUSTMENT GAS FACTOR b. Select the electrochemical sensor, which should be adjusted.
  • Page 138 MRU GmbH SWG 100 User Manual Dilutable gases and the actual values (2): This show the dilutable gases and the calculated undiluted actual gas concentration value (C pure d. To fine calibrate the dilution-unit select the dilutable gas and impinge the analyser with the calibration gas. Wait until the gas concentration will not change anymore.
  • Page 139 MRU GmbH SWG 100 User Manual The operator can change the dilution settings, from every measurement phase for this measurement phase. Other measurement phases are not affected. For example: If the SWG-100 has a sample gas junction, with three sample gas inlets and the dilution-setting from sample gas-inlet 1 is permanently activated (ON), the two other sample gas-inlets are further set to automatically.

  • Page 140: Declaration Of Conformity

    MRU GmbH SWG 100 User Manual 14. Declaration of conformity Page 140 of 141...
  • Page 141 MRU GmbH SWG 100 User Manual V01.02.EN Page 141 of 141...

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