USER MANUAL MGAprime Table of Contents Information for product and safety ..........7 1.1. Safety manual ....................7 1.2. Safety precautions ..................7 Introduction ..................8 2.1. Intended use ....................8 2.2. About us ......................9 Description ..................11 3.1.
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USER MANUAL MGAprime 5.5. Operating the analyser in the extended temperature range ..32 Precautions for use in the extended temperature range ..... 32 Connecting heating box .................. 32 5.6. Operating analyser with NiHM-Battery ..........34 Measurement .................. 35 6.1.
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USER MANUAL MGAprime 8.1. History ......................64 8.2. System extensions ..................65 8.3. Connections ....................66 8.4. Setting Date / Time ..................66 8.5. Programs ....................... 66 8.6. Instrument leak test ................... 67 8.7. Default settings ................... 68 8.8. Internal log Settings .................. 68 Copying all log data ..................
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USER MANUAL MGAprime Appendix ..................91 13.1. Error diagnosis regarding the measuring instrument ....91 13.2. Switching off the analyser in case error ..........92 13.3. RS485 Extern (Option) ................93 13.4. Screw adapter onto HPI-Probe (Option) ..........94 13.5. Connecting analyser with MRU4win ............ 94 Connecting analyser with MRU4win via serial interface (RS 485).
USER MANUAL MGAprime Information for product and safety 1.1. Safety manual All general information and safety precautions of MRU products are listed in the supplied separate safety manual. Therefore, this manual must be read and observed before the first use of the instrument .
USER MANUAL MGAprime Introduction • This manual enables you to understand and safely operate this MRU Analyzer MGAprime. • Please read this manual with great vigilant and get familiar with the product before using it. • This analyser may only be operated by competent personnel and for its intended use.
(NO2). 2.2. About us The analyser is produced by the MRU GmbH in Neckarsulm, Germany (Founded in 1984), a medium sized company that is specialised in developing, producing and marketing high quality emission monitoring analysers.
USER MANUAL MGAprime Description 3.1. Task The main task of the analyser is to analyse flue gases, as they are emitting from incinerators or engines. • The analyser is optimized for this purpose and includes all components from the gas sampling probe to data processing.
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USER MANUAL MGAprime Fresh air inlet Sample gas inlet Condensate outlet Diff. Pressure connector Vent collection box Vent outlet Sample gas filter (PTFE) Dust filter Auto-zero solenoid valve Sample gas pump Double stage gas cooler Sample flow sensor Paramagnetic sensor...
USER MANUAL MGAprime 3.3. The Analyser The analyser consists of a compact and robust metal housing with shock-absorbing rubber corners. All electrical and pneu- matic connections are located on the both front sides of the instrument. It is operated exclusively via the touch-sensitive touch screen.
USER MANUAL MGAprime 3.4. Connectors Front side right Loudspeaker Ethernet (LAN) USB socket Second USB socket (option) RS485 (Option) Analog outputs 4 ... 20 mA Analog-inputs 4 … 20 mA Mains power supply Front side left Sample gas filter Condensate outlet port...
USER MANUAL MGAprime The connection drawings are also displayed in the menu Extras. ► Touch the menu Extras. A selection list appears. ► Press „Connections“. The left side of the analyser appears. ► Push „Right >>“. The right side of the analyser appears.
USER MANUAL MGAprime 3.6. Heated Gas sampling probe For interchangeable probe tube with flue gas temperature measure- ment using type K-thermoelement. Probe handle Probe tube Fast locking coupling Probe cone Cable plug (14-pin) Heated hose line Cable coupler (5-pin) Fast locking coupling Filter lock ►...
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USER MANUAL MGAprime ATTENTION When measuring with coiled heated hose line, the hose line is destroyed due to strong heat development. ► Roll out the heated hose line completely for each measurement. NOTE Please note that heating hoses with 110V and 230V are offered.
USER MANUAL MGAprime 3.7. Unheated Gas sampling probe Filter lock Fast locking coupling Cable coupler (5-pin) Cable plug (14-pin) Fast locking coupling Unheated hose line Probe cone Probe tube Probe handle ► Check the probe filter before and after every measurement.
USER MANUAL MGAprime Optionally, connect a hose (DN 4/6) to the condensate drain. A hose (DN 4/6, not longer than 5 m) can also be connected to the sample gas outlet for discharge. For subsequent filtering, a round filter is used on the front of the Analyze.
USER MANUAL MGAprime 3.11. Acid injection CAUTION Phosphoric acid (10 %) Phosphoric acid (10 %) may cause burns. ► If you come into contact with acid, wash the area im- mediately using a lot of water. ► Note the safety data sheet for phosphoric acid (10%).
USER MANUAL MGAprime 4 Operation 4.1. Commissioning The analyser leaves the factory assembled and ready for use. ► Check the analyser regarding completeness and integrity. ► Connect the analyser to the mains. The analyser switches on. The operating system boots.
USER MANUAL MGAprime Power-on and reset Reserve Reserve LED display mains opera- tion/battery charging mode Reserve Current flow rate Current pump load Current temperatures heated hose Selected measuring pro- gram, e.g., Test or measure- ment program Current temperatures of Current temperatures of gas...
USER MANUAL MGAprime 4.4. Switching on the analyser ► Touch the ⏻ button (1) for 3 sec. minimum LED lights blue ► Release the ⏻ button (1). Analyzer runs up. 4.5. Switching off the analyser There are two possibilities to switch off the analyser.
USER MANUAL MGAprime 4.7. Set the analyser to standby mode The analyser is protected in standby mode. You cannot take measurements in standby mode. The actuators, for example pumps and gas coolers, are switched off as far as possible. Note that NDIR is not switched off. After you have left the standby mode, the analyser will start up again.
USER MANUAL MGAprime 4.8. Back to homescreen / Back to measure As soon as the back button is displayed, you have the option to go back to the homescreen or go back to the measurement, from any window. ► Press for one second ...
USER MANUAL MGAprime Settings After the analyser has been inspected and is ready for start-up it can be switched on and personalized settings can be entered. These settings can be changed at any time. 5.1. Analyser settings In the Settings menu, some analyser pre-sets may be configured: ►...
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USER MANUAL MGAprime For an overview on all available options please refer to the company’s home page or sales representatives See also chapter Activate NDIR- Fastmode function, page 41. Temperature unit Change of unit Hold delay Time in which Analog outputs maintain...
USER MANUAL MGAprime Ref. temperature Calculation of the values for a standard state at reference temperature Language Select analyzer language. Heated probe temper- 120°C – Default 160 °C ature 180°C Intervall auto-zero [h] See also Chapter Automatic zero point, Page 38.
USER MANUAL MGAprime Measurement program The measured value window can be freely set with regard to the displayed measured values. Further measuring programs The measurement window for gas analysis can be configured and adapted to your needs. The measuring window initially displays 12 measured values, by a scrolling gesture it will display more values.
USER MANUAL MGAprime You can replace the selected value field with the selected measured value. You can insert the selected measured value in place of the se- lected value field. The previously selected value field moves accordingly. ► Touch „replace“ or „insert“.
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USER MANUAL MGAprime ► Touch „Gas flow measurement“. A setting window appears. ► Change the desired parameters. ► Touch „CHOOSE UNITS“. A setting window appears. ► Change the desired unit. ► Go back. The change will be saved.
USER MANUAL MGAprime 5.5. Operating the analyser in the extended temperature range With the option "Operation at extended temperature range" you can carry out measurements up to -15°. NOTE Note that measurements with a connected Acid Dosing Unit APE are not recommended because phosphoric acid can freeze at low temperatures.
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USER MANUAL MGAprime ► Screw the heating box onto the analyser (1). The spacer bolts have internal threads. ► Connect the heating box to the external power supply (3). ► Plug the external power supply into a power socket. Ensure that the heating box is supplied with power during the entire measurement.
USER MANUAL MGAprime 5.6. Operating analyser with NiHM-Battery ► Please note that the following information is only relevant for you if an optional NiHM-Battery is installed in your analyser. The NiHM-Battery is mounted in the analyser instead of a LiIon-Battery.
USER MANUAL MGAprime Measurement 6.1. Prepare measurement CAUTION Acid from the condensate Acid burns may result from weakly acidic liquids from the condensate. ► If you come into contact with acid, wash the area im- mediately using a lot of water.
USER MANUAL MGAprime ► Use a test gas humidifier for measurements (see chapter Connecting Gas moisture bottle, Page 45 or see chapter Connecting Acid Dosing Unit APE, Page 46) to prevent the gas cooler from drying out due to dry test gas. For a short time, you can also use dry test gas (for about 15 minutes).
USER MANUAL MGAprime Opening the transport bag NOTE Note that different transport bags are offered. A standard transport bag is offered, which is intended exclusively for the transport and not for the operation of the analyser. Optionally, an IP42 operating bag is available, which is designed for the operation of the analyser.
USER MANUAL MGAprime If the ambient air is contaminated during the last two minutes of zeroing, the zero point is extended by approx. three to ten minutes. If there is no serious zero point after the zero-point extension, a message appears in the display.
USER MANUAL MGAprime ► Set the desired interval auto-zero [h] in the menu Settings. See also Chapter 5.1 Analyser settings, S.26. NOTE Please note that a manually initiated zeroing sets a new time point grid. This depends on the set interval auto- zero [h] in the menu Settings.
USER MANUAL MGAprime NOTE Please note that for the O2 sensor, regardless of this setting, a zero point measurement is performed after each switch-on. Select Source zero point (gas) You can select whether zero-point gas is always sucked in via the fresh air inlet.
USER MANUAL MGAprime A window appears. ► Choose the desired option. The zero gas is sucked in either via the probe or the fresh air inlet. NOTE After switching on, the first zero point is always taken via the fresh air inlet.
USER MANUAL MGAprime ► Confirm the message. A zero point measurement is performed. An icon appears in the display. After the zero point measurement the NDIR-Fastmode is acti- vated. Charging state of the battery The battery symbol in the display indicates approximately the remaining capacity of the battery.
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USER MANUAL MGAprime NOTE ► Always connect a collection container to the condensate output (9). ► Ensure that the collection container has a sufficient empty volume. ► Dispose of acidic condensate and phosphoric acid in accordance with national and, if necessary, local dis- posal guidelines.
USER MANUAL MGAprime Attach clip-on filter If you operate the analyser without a heated hose, dirt may collect in the gas inlet. ► In this case, plug the supplied clip-on filter onto the gas inlet (12). Controlling Filters The filters (probe filter and round filter) must be checked before and after each measurement.
USER MANUAL MGAprime Connecting Gas moisture bottle NOTE Fresh air and dry test gas must always be humidified to prevent the gas cooler from drying out. To humidify the test gas you can, for example, connect a gas mois- ture bottle. If you are using an Acid Dosing Unit APE the humidification is replaced by the Acid Dosing Unit APE.
USER MANUAL MGAprime Connecting Acid Dosing Unit APE See also Chapter 3.11 Acid injection, Page 20. CAUTION Acid from the condensate Acid burns may result from weakly acidic liquids from the condensate. ► If you come into contact with acid, wash the area im- mediately using a lot of water.
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USER MANUAL MGAprime NOTE Always connect the collecting container. Please note that the volume of the supplied collecting container is sufficient for 2 hours of meas- uring operation. ► Empty the collecting container after two hours of measuring operation. ► Dispose of acidic condensate and phosphoric acid in accordance with national and, if necessary, local dis- posal guidelines.
USER MANUAL MGAprime Perform leak test The analyser device has an integrated leak test to check the tightness of the gas paths. ► Check all plug connections for correct fit. ► Check all hoses and hose connections (from the probe tip to the gas inlet of the analyser) for leaks.
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USER MANUAL MGAprime ► Press START LEAK TEST A message appears. ► Confirm with YES, that the APE tubes are removed. ► Seal the gas port. The leak test is performed. Or if the complete gas path is to be checked for leaks:...
USER MANUAL MGAprime 6.2. Take a measurement Setting O2 reference and Fuel type ► Touch the menu „Measure“. The measurement window appears. ► Touch the „Context menu“(19). A selection list appears. ► Touch „O2ref / Fuel type“. A window appears.
USER MANUAL MGAprime ► Set the desired CO threshold value. ► Touch “OK”. The setting is saved. The stored ppm value determines the CO shutdown threshold. If the measured value reaches this threshold, the second fresh air purge pump starts and the CO sensor is separated from the gas path by a valve.
USER MANUAL MGAprime ► Choose the desired site. The measured values are stored. The measurement continues until you switch off the analyser. See also Chapter Recalling stored measurements, Page 60. Selecting channels for Auto-measurement You can log a maximum of eight channels simultaneously.
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USER MANUAL MGAprime ► Press a measurand that you want to replace. A window appears. ► Select the desired measurand. ► Press OK. The measurand is replaced. You have the possibility to display two measurands simultaneously as a curve.
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USER MANUAL MGAprime ► Press the graphic symbol. A diagram appears. ► If necessary, touch to stop the graphical display. The measurement will be continued in the background. ► If necessary, touch to continue the graphical display. 54 / 104...
USER MANUAL MGAprime Starting Auto-measurement You can record the measured values for a defined period and have them displayed graphically. ► Touch the menu Measure. The measurement window appears. ► Touch the “Context menu” (19). A selection list appears.
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USER MANUAL MGAprime The Auto-measurement starts automatically. The Auto-measurement ends automatically. A protocol of the Auto-measurement appears ► Press the graphic symbol. A diagram appears. ► If necessary, press the gear wheel symbol to display other measurands in graphical form.
USER MANUAL MGAprime 8.8See also Chapter Internal log Settings, Page 68. Stopping Auto-measurement The Auto-measurement can be stopped manually at any time. ► Touch the context menu (19) while the measurement is recorded. A selection list appears. ► Touch „Stop logging“...
USER MANUAL MGAprime Data memory 7.1. Organizing data memory Base of the data memory of the analyser is a set of sites stored in the instrument. Every site exists of a unique site number and 12 freely usa- ble text lines which can have, e.g., the address, customer name etc.
USER MANUAL MGAprime Changing site data ► Touch the menu Sites. A selection list appears. ► Select the desired site. A window appears. ► Change the desired data. ► Touch „STORE“. The changes are stored. 59 / 104...
USER MANUAL MGAprime Deleting sites ► Touch the menu Sites. A selection list appears. ► Select the desired site. A window appears. ► Touch „Delete“. The site is deleted. Recalling stored measurements Stored measurement can be displayed individually for each site.
USER MANUAL MGAprime ► Touch „MEASUREMENTS“. A selection list appears. ► Touch the desired measurement. The measurement window appears. 7.3. Data transfer via USB (CSV export) The data exchange format is CSV. A character-separated values (CSV) file is a simple text format for a database table. The analyser uses a sem- icolon ‘;’...
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USER MANUAL MGAprime ► Insert a USB-stick into the analyser. ► Touch the menu Sites. A selection list appears. ► Select the desired site. A window appears. ► Touch „MEASUREMENTS“. The stored measurements are displayed. ► Select the desired measurements.
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USER MANUAL MGAprime ► Open the CSV-File with Excel. (Do not use Dat-files files or internal Log-files) 63 / 104 MRU GmbH, D-74172 Neckarsulm...
USER MANUAL MGAprime Extras 8.1. History ► Touch the menu Extras. A selection list appears. ► Touch „History“. A window appears. ► Touch „DATE“. A selection list appears. ► Choose the desired period time. The chosen time period is displayed graphically.
USER MANUAL MGAprime 8.2. System extensions You have the possibility to expand the analyser with options. For this you will receive an option file from the manufacturer. ► Copy the options file onto a USB stick. NOTE You can also save the option files in subfolders. The an- alyser will search the folder structure on the USB stick up to the second hierarchy level.
USER MANUAL MGAprime ► Select the desired Options. ► Press “LOAD CHECKED OPTIONS”. A message appears. ► Touch OK. The option was successfully set. 8.3. Connections You can view the connections on the display of the analyser See also chapter 3.4Connectors, Page 14.
USER MANUAL MGAprime ► Select the program you want to change the name for. A keybar appears. ► Enter the desired Program name. ► Exit the Extras menu. ► Touch Selected measuring program (8) See also Chapter 4.2 Operating panel, page 21.
USER MANUAL MGAprime 8.7. Default settings You can reset the analyser to factory default. NOTE Note that when the analyser is reset to the factory de- fault, all individual settings are lost. ► Touch the menu Extras. A selection list appears.
USER MANUAL MGAprime ► Touch „SERVICE:COPY INTERNAL LOGG TO USB STICK“. A window appears. The copy process is started. A Symbol appears in the Display. ► Touch „OK“: The directory [serial number] Logg was created on the USB-Stick.
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USER MANUAL MGAprime ► Touch „FILE BROWSER“. A selection list appears. ► Choose the desired log file. A window appears. The desired log file appears in the window. ► Touch „COPY TO EXTERN USB-STICK“. A window appears.
USER MANUAL MGAprime The directory [serial number] Logg was created on the USB-Stick. The log files are saved in the directory [serial number]. After copying, the display shows "File(s) successfully copied". ► Touch „OK“. 8.9. Analog output setup (4 – 20 mA) There are 8 Analog outputs (4-20 mA) available.
USER MANUAL MGAprime ► Choose the desired measurrand. ► Touch “OK“. The measurand is assigned to the desired channel. Setting lower / higher limit NOTE Setting lower limit (4mA) This setting determines the lower end value, corre- sponding to 4 mA. If the measured value falls below the set value, the Analog output stops at 4 mA.
USER MANUAL MGAprime ► Enter the desired values for the lower and higher limit. ► Touch „OK“. The lower and higher limit are assigned to the desired channel. ► Touch "Default" to set the default values for the lower and upper limits.
USER MANUAL MGAprime ► Touch the menu Extras. A selection list appears. ► Touch „Analog output setup (4-20mA)“. A window appears. ► Scroll to "Output during zeroing" ► Touch the field. ► Choose the desired option. Pin assignment of the 4-20 mA interface (Analog IN/OUT) ►...
USER MANUAL MGAprime ► Choose the desired channel. A window appears. ► Enter the desired values. ► Go back. The values appear in the selection list. The incoming measurand is displayed. 8.11. Connecting analyser with WIFI (WLAN) ►...
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USER MANUAL MGAprime NOTE Press the button REFRESH if no WLAN connection is displayed. ► Select the desired WLAN-Connection. A window appears. ► Enter the WLAN password. ► Touch „OK“. A connection to the WLAN network is established.
USER MANUAL MGAprime ► Use the displayed WLAN -IP for MRU4win (in this example 192.168.43.53). See also Chapter 13.5 Connecting analyser with MRU4win, Page 8.12. Getting information about the network ► Touch the menu Extras. A selection list appears.
USER MANUAL MGAprime 8.13. Assigning a fixed IP address ► Touch the menu Extras. A selection list appears. ► Touch „Network“. A window appears. ► Set the switch to "Static IP is active". The fields for „IP-Adress/Subnetmask“, „Gateway“...
USER MANUAL MGAprime ► Choose the desired option. The change takes effect after a restart 8.14. Serial connectivity (RS485/USB) You have a connection option to MRU4win via Bluetooth 8.15. Printing measurement results In the menu Printer, you can select the type of connection between an optional printer and the analyser.
USER MANUAL MGAprime Printing current measurement results ► Switch on the printer. ► Go to the menu Measurement. The measurement window appears. ► Touch the “Context menu” (19). A selection list appears. ► Touch „Print“. The measurement is printed out with a slight delay.
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USER MANUAL MGAprime ► Touch „MEASUREMENTS“. The stored measurements are displayed. ► Touch the desired measurement. The measurement window appears. ► Touch the context menu (19). A selection list appears. ► Touch „Print“. The measurement is printed out with a slight delay.
USER MANUAL MGAprime 8.16. Service values This screen displays a number of internal parameters and their values. In case of unexpected behaviour of the analyser it might be helpful to communicate those values to our worldwide service staff: https://www.mru.eu ► Touch the menu Extras.
USER MANUAL MGAprime Info In the menu Info, version information and installed options can be viewed. ► Touch menu info. A window appears. ► Touch „INFO“. A window appears. ► Touch „OPTIONS“. A window appears. 83 / 104...
USER MANUAL MGAprime 10 Maintenance and cleaning 10.1. Cleaning and maintenance The analyser needs only low maintenance effort for long value preservation: CAUTION Acid from the condensate Acid burns may result from weakly acidic liquids from the condensate. ► If you come into contact with acid, wash the area im- mediately using a lot of water.
USER MANUAL MGAprime 11 Simple service work 11.1. Information of the analyser components Information about analyser components is helpful in case of service or inquiries. ► Touch A selection list appears. ► Choose the desired component of the analyser.
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USER MANUAL MGAprime A window appears. ► Touch „LOAD FROM USB-STICK“. The firmware is copied to the analyser. The button"PERFORM FIRMWARE UPDATE" becomes active when the copy process is complete. ► Touch „PERFORM FIRMWARE UPDATE“. The firmware is updated.
USER MANUAL MGAprime Specifications The technical data listed here may differ depending on the analyser configuration. • means: included in the standard scope of each analyser O means: optional possible, availability depends on device configuration 12.1. Specifications of NDIR technology...
USER MANUAL MGAprime 12.2. Sensors for Oxygen, Temperatures and Pressure Electrochemical Sensor Long Life Measuring Range 0 - 25 Vol.% Resolution 0,01 Vol.% Abs. Accuracy ± 0,25 Vol.% Response Time T90 < 40s Years expected lifetime at air 5 Years...
User Manual MGAprime Gas outlet (Vent port) • passiv 3 mm active (req for long VENT lines or Optional pressurized Vent) 12.4. Calculated values and accessories Measurement values available as mg/Nm Ref, mg/kWh NOX: mg/Nm Velocity based on differential pressure...
User Manual MGAprime Appendix 13.1. Error diagnosis regarding the measuring instrument Fault indication Possible causes Repair Gas cooler is faulty! Gas cooler faulty. Contact MRU service depart- The system will shut ment. down. Undervoltage!!! Battery is discharged. Connect instrument to power The System will shut grid.
USER MANUAL MGAprime Fault indication Possible causes Repair Condensate or wa- ► To continue the operation, it has to be en- ter has been de- sured that no water will be fed to the sen- tected behind the sors. gas cooler stage. To ►...
L 32 bit signed integer value (-2.147.483.648…2.147.483.647) F 32 bit floating point value (reads -1E38, when not availa- ble)- Further information about the defined registers on demand (www.mru.eu) and on the device supplied USB stick! 93 / 104 MRU GmbH, D-74172 Neckarsulm...
USER MANUAL MGAprime 13.4. Screw adapter onto HPI-Probe (Option) With the adapter you have the possibility to use heated probe tubes from other manufacturers. The adapter is available in 3/8-inch and 3/4-inch sizes. When screwing the adapter onto the HPI probe, pay attention to the size of your probe tube.
User Manual MGAprime Please note that the Modbus slave ID is a consecutive number. If the number 1 is already assigned, assign "Modbus Slave ID" 2 etc. to the analyser. ► You can now create the analyser in MRU4win. See also Chapter Creating analyser in MRU4win, Page 96.
USER MANUAL MGAprime If the number 1 is already assigned, assign "Modbus Slave ID" 2 etc. to the analyser. ► You can now create the analyser in MRU4win. See also Chapter Creating analyser in MRU4win, Page 96. Creating analyser in MRU4win Modbus devices are not automatically identified in MRU4win.
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User Manual MGAprime ► Choose “Name” A selection list appears. ► Choose “1113 Device”. ► Set "Slave ID" to 1. ► Note that the slave ID must match to the "Modbus Slave ID" of the analyser. For example, if the analyser has the "Modbus Slave ID" 2, the "Slave ID"...
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USER MANUAL MGAprime ► Set under "General” a check mark at "Activate Modbus". ► Go to “Livemeasurements”. The analyser appears in the column of available analyzers. ► Click on the "Connect-Icon” The analyser is connected. 98 / 104...
User Manual MGAprime 13.6. Remote control of the analyser device via VNC Activate WLAN-Hotspot (android) ► Install VNC viewer ► ► Configure VNC viewer Connect to device ► Activate VNC on analyser ► ► Use remote control via Android device...
USER MANUAL MGAprime 13.7. General Instructions for the heated hose line For the save operation of the sample line it is important that it is in- stalled correctly. This includes the following points: • The bending radius as given below is maintained, •...
User Manual MGAprime Bending radius of heated sampling lines The picture below shows the minimal bending radius. Bending radius min. = 32 ATTENTION Falling below the bending radius will reduce life time of the sampling probe. 101 / 104 MRU GmbH, D-74172 Neckarsulm...
USER MANUAL MGAprime 13.8. CxHy Calculation The calculation for CxHy is: • if CH and C are present: CxHy = CH • if only one HC - channel is available, CxHy is equal to it. 13.9. Spare parts Part number...
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