mru SWG100 BIO-EX User Manual
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mru SWG100 BIO-EX User Manual

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SWG100 BIO-EX
USER MANUAL
9512EN-BIOEX

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  • Page 1 SWG100 BIO-EX USER MANUAL 9512EN-BIOEX...
  • Page 2 MRU GmbH SWG 100 BIO Ex User Manual Page 2...

  • Page 3: Table Of Contents

    Packing............................. 11 1.8. Return of hazardous waste ....................11 1.9. Return of analyzer ........................ 11 1.10. MRU guarantee conditions ....................12 Important notes: Operating an ATEX analyser ..........13 2.1. Weekly maintenance intervals ..................13 2.2. Correct commissioning of the unit ................13 2.3.
  • Page 4 MRU GmbH SWG 100 BIO Ex User Manual 7.6. Correct tubing of the SWG100BIO-Ex ................42 7.7. Flow restrictor orifice (#65114) ..................43 7.8. Installation of the power supply ..................45 7.9. Installation of the external switch-off circuit .............. 46 7.10.
  • Page 5 MRU GmbH SWG 100 BIO Ex User Manual 17. General information ..................138 17.1. Special informationen about the Modbus Slave function ........138 17.2. Special informationen about the Profibus Slave function ........139 18. Defined registers to be read by the master ............ 139 18.1.
  • Page 6 Packing List and have it signed by the shipper’s agent prior to 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.

  • Page 7: 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) is supporting the plant operator in choosing appropriate protective measures. 1.2. Installation instructions Installation instructions, which are described in chapter 7 of the operation manual, have to be strictly carried out.

  • Page 8: Important Information About The User's Operation Manual

    MRU GmbH SWG 100 BIO Ex User Manual 1.4. Important information about the user’s operation manual The users/operation manual is an important part of this delivery. It will explain how to use this analyzer properly and sets forth safety and environmentally friendly procedures.

  • Page 9: General Warnings

    MRU GmbH SWG 100 BIO Ex User Manual 1.5. General warnings DANGER Any maintenance action must be done only, when the atmosphere is verified to be not explosive. DANGER Apply personality safety equipment, against high H2S/CO concentrations before open the device.
  • Page 10 MRU GmbH SWG 100 BIO Ex User Manual 2) Regarding flammable gases (e.g. CH4 methane) and hazardous area of operating the instruments, user must also be able to recognize the area classification and be aware of using the instrument there. This area classification is country specific, please observe and notice it.

  • Page 11: Packing

    1.7. 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.

  • Page 12: Mru Guarantee Conditions

    7. The service of a guarantee conditions will not enlarge the guarantee time. Demands because of consequential damages are excluded. 8. The transport costs for round trip takes the consignor or the warrantee. 9. MRU reserves the right, to determine individual conditions or exceptions. These will be separated informed. Page 12...

  • Page 13: Important Notes: Operating An Atex Analyser

    MRU GmbH SWG 100 BIO Ex User Manual 2. Important notes: Operating an ATEX analyser DANGER Maintenance work may only be carried out after a successful clearance measurement. This unit has an ATEX zone approval level II. The following instructions must be observed to ensure that the unit operates safely: •...

  • Page 14: Check / Replace Peristaltic Pump Hoses

    MRU GmbH SWG 100 BIO Ex User Manual 2.3. Check / replace peristaltic pump hoses DANGER The hose pump hoses must be replaced every 6 months. Irrespective of their current condition. The hose pump hoses must be completely replaced every 6 months. Even if there is no obvious damage to the hoses.

  • Page 15: Analyzer Description

    MRU GmbH SWG 100 BIO Ex User Manual 3. Analyzer Description 3.1. Intended use The instrument is intended for analyzing the composition of biogases / biomethane / landfill gases and determine the concentration of several components like CH4, CO2, O2 and H2S.

  • Page 16: Principle Of Operation

    MRU GmbH SWG 100 BIO Ex User Manual 3.2. Principle of operation • Sample gas from one or more sampling points is fed into the analyzer by dedicated ports. Internally mounted electric valves select one point at a time to feed sample gas to the analysis unit.
  • Page 17 MRU GmbH SWG 100 BIO Ex User Manual The picture below shows how the analyser should be piped. A ball valve and a prefilter is recommended. Page 17...

  • Page 18: Marking And Range Of Application

    • Converter module of RS485 into Profibus. • Cabinet heater for freeze protection. Dilution-unit, to enhance the life-time of electrochemical sensors. Ask our sales representatives for available options and accessories or check out our MRU website. Page 18...

  • Page 19: Overview Of The Swg-100Bio Ex

    MRU GmbH SWG 100 BIO Ex User Manual 4. Overview of the SWG-100BIO Ex 4.1. Scope of supply and delivery The delivery contains the follow components: • SWG-100BIO Ex analyser, with a stainless-steel case. • A stainless-steel thread filter for the zero-gas inlet, with a G1/8 inch male thread.

  • Page 20: Dimensions And Views Of The Analyser

    MRU GmbH SWG 100 BIO Ex User Manual 4.4. Dimensions and views of the analyser Top view: Reference: 1. Sample gas inlets G1/8 inch female thread. 2. Sample gas outlet G1/4 inch female thread Front view / left view / right view...

  • Page 21: Position Of The Gas In And Outlets

    MRU GmbH SWG 100 BIO Ex User Manual 4.5. Position of the gas in and outlets Display (color, with backlight) Keypad Sample biogas inlet ports (1 to max 4 ), female G1/8” threads Cabinet lock Inlet cable glands M16 for I/O modules...

  • Page 22: Operating Unit: Display And Keypad

    MRU GmbH SWG 100 BIO Ex User Manual 4.6. Operating unit: Display and keypad NOTE Operation of the keypad is intrinsically safe. All commissioning can be carried out with the control-unit. The operating-unit can only be operated when the cabinet door is open.
  • Page 23 MRU GmbH SWG 100 BIO Ex User Manual All information required to operate the analyser is displayed as shown below. Number Symbol Description ESC: abort or return to the menu above Prepare Power-Down: Press this key before you disconnect mains. The analyser will store...

  • Page 24: Measurement Menu

    MRU GmbH SWG 100 BIO Ex User Manual 4.7. Measurement menu The measurement menu is the main root of the menus. Here you can see the current measurement values, the current sampling point number and the status of the zeroing process while it's active.

  • Page 25: Explosion Protection Systems Of Swg100Bio-Ex

    SWG 100 BIO Ex User Manual Explosion protection systems of SWG100BIO-EX The explosion protection of SWG100 Bio-EX is based on the nA and nC type of protection as indicated in the ATEX declaration. Following aspects have to be followed. Any action not in line with the guidelines below may violate the explosion protection of...

  • Page 26: Ch4 Measurement Of Inside Cabinet

    While the components internal to the instrument are verified to meet the type of protection, it is nevertheless required to monitor the cabinet to prevent explosive atmosphere being present. Therefore SWG100 BIO-EX implements a regular monitoring of the CH4 content inside the cabinet with the help of the CH4-NDIR bench used for biogas measurement.
  • Page 27 MRU GmbH SWG 100 BIO Ex User Manual Description of the CH4 cabinet monitoring The main parts of the system are following: • The CH4/CO2 NDIR- bench. • A solenoid valve, which feeds the atmosphere inside the case to the CH4/CO2 NDIR bench.
  • Page 28 MRU GmbH SWG 100 BIO Ex User Manual Screen after a delay was Switch off alarm. The user has 2 General menu: Menu- point added minutes before the SWG100BIO- to set the LEL Level Ex power down. Self test of the CH4/CO2 NDIR- bench The CH4/CO2 NDIR-bench being a part of the SWG100BIO-EX protection system, is required to be monitoring itself.

  • Page 29: Remote Power Supply Box

    The circuit diagram of above pictured device must be implemented by user as part of the safety concept. User can either use the remote power supply box as offered by MRU or install inside the power distribution cabinet a similar circuit (see diagram in chapter 7.9) using a power contactor and push-start button.

  • Page 31: Sample Gas Measurement

    MRU GmbH SWG 100 BIO Ex User Manual 6. Sample Gas measurement 6.1. Cycle configuration Path and default setting XTRA EASUREMENT CYCLE CONFIG When the menu “M .” is selected the user definable setting for EASUREMENT CYCLE CONFIG the measurement cycle will appear (see screenshot below).
  • Page 32 MRU GmbH SWG 100 BIO Ex 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.
  • Page 33 MRU GmbH SWG 100 BIO Ex User Manual Zeroing (Cycle phase details): In the cycle phase detail “ ” the zeroing time EROING can be 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...
  • Page 34 MRU GmbH SWG 100 BIO Ex 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. •...
  • Page 35 MRU GmbH SWG 100 BIO Ex 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 36: H2Slow Sensor Protection (Optional)

    MRU GmbH SWG 100 BIO Ex User Manual 5. Leave the cycle phase detail and select the next phase. Select with the left/right arrow keys the phase “zeroing” and go in the cycle phase detail. Adjust the phase-duration at 15 min. and leave the cycle phase detail.
  • Page 37 MRU GmbH SWG 100 BIO Ex User Manual • The measuring time of the H sensor may be limited to less than 10 minutes by user setting • The H sensor may optionally not be included in all measuring cycles of sampling points.

  • Page 38: Analyzer Mounting And Installation

    MRU GmbH SWG 100 BIO Ex User Manual 7. Analyzer mounting and installation 7.1. Content of your order Your analyzer is delivered in a carton box and is protected with special edged protectors. Please do preserve the packing of your analyzer, for possible back shipment.

  • Page 39: Steps For The Mechanical Mounting And Installation

    MRU GmbH SWG 100 BIO Ex User Manual 7.4. Steps for the mechanical mounting and installation The graphic below shows the single steps, which must be done to mount the SWG100BIO Ex. analyzer correctly into the application Mounting the analyzer on a wall or a steel rack...

  • Page 40: Mounting The Analyser On A Wall Or Steel Rack

    MRU GmbH SWG 100 BIO Ex User Manual 7.5. Mounting the analyser on a wall or steel rack The analyzer can be mounted indoor or outdoor. The device is designed for the mounting on wall or on steel rack. The follow sketch shows the dimensions, which the analyzer needs for the correct mounting.
  • Page 41 MRU GmbH SWG 100 BIO Ex User Manual For outdoor installation Ensure that the analyzer is mounted on a rain and sun protected place (weather shade). For indoor installation: Ensure that the analyzer is installed on a dry and clean place. Be sure that the room is permanently vented with fresh air (forced ventilation).

  • Page 42: Correct Tubing Of The Swg100Bio-Ex

    MRU GmbH SWG 100 BIO Ex User Manual 7.6. Correct tubing of the SWG100BIO-Ex The analyzer uses two different fitting diameters. The position and the diameters of the different connectors will be shown in the sketch below: DANGER Explosion hazard Before starting the mounting and installation work, make sure to have a “hot permit”...

  • Page 43: Flow Restrictor Orifice (#65114)

    MRU GmbH SWG 100 BIO Ex User Manual 7.7. Flow restrictor orifice (#65114) To measure any biogas applications, the analyzer can be equipped with a flow restrictor orifice (see picture). Male connector G1/8“ Sinter filter Nozzle O-ring Picture: Flow restrictor orifice with intern filter.
  • Page 44 MRU GmbH SWG 100 BIO Ex User Manual Left-side CAUTION Be sure, that the heat sink has enough distance to the next wall. CAUTION Be sure that the Zero gas inlet feeds fresh, clean air. Heat sink: Do not cover the heat sink from the gas cooling- unit.

  • Page 45: Installation Of The Power Supply

    MRU GmbH SWG 100 BIO Ex User Manual 7.8. Installation of the power supply DANGER Explosion hazard Before starting the mounting and installation work, make sure to have a “hot permit” and monitor at all time the ambient atmosphere with a certified flammable gas detector.

  • Page 46: Installation Of The External Switch-Off Circuit

    MRU GmbH SWG 100 BIO Ex User Manual 7.9. Installation of the external switch-off circuit The remote power supply box itself is not explosion protected at all. Therefore it must be installed in safe area. WARNING Safety installation The external electric contactor K1 is a part of the safety installation.
  • Page 47 MRU GmbH SWG 100 BIO Ex User Manual Page 47...

  • Page 49: Connection Of The I/O Module

    MRU GmbH SWG 100 BIO Ex User Manual 7.10. Connection of the I/O module DANGER Explosion hazard Before starting the mounting and installation work, make sure to have a “hot permit” and monitor at all time the ambient atmosphere with a certified flammable gas detector.
  • Page 50 MRU GmbH SWG 100 BIO Ex User Manual Plug connector definition: WARNING Electric voltage Power the system down and protect for reconnecting, before start 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 51: Power Up And Commissioning The Analyser

    MRU GmbH SWG 100 BIO Ex User Manual Power up and commissioning the analyser After installation of the analyzer few steps should be processed in order to operate the instrument properly. The graphic below shows the few steps, which should be done, to power up the analyser correctly.

  • Page 52: Power Up The Analyser

    MRU GmbH SWG 100 BIO Ex User Manual 8.1. Power up the analyser 1. Open the case door of the analyser. 2. Power up the circuit breaker. See figure below. Power up the circuit breaker. 3. Press the power switch of the remote power supply box. Wait until the system is ready for operation.

  • Page 53: Check Country And Language

    MRU GmbH SWG 100 BIO Ex User Manual 8.2. Check country and language Important note: In case the analyzer shows a language, you don't understand, you may swap the language to English by pressing the menu key and selecting the function 'Set English language'.

  • Page 54: Configuration Of The Alarm Relays

    MRU GmbH SWG 100 BIO Ex User Manual 8.5. Configuration of the alarm relays On the main PCB there is one “system alarm” relay with “fail safe” NC contact. The following errors will turn the relay from NC to NO.
  • Page 55 MRU GmbH SWG 100 BIO Ex 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 56: Configuration Of The Modbus

    MRU GmbH SWG 100 BIO Ex User Manual 8.6. 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 57 MRU GmbH SWG 100 BIO Ex User Manual Configuration at the analyzer 1. Open the path XTRAS ENERAL ETTINGS 2. Press “Modbus”. 3. The Modbus store settings will be open. The user can commission the slaves settings. Page 57...

  • Page 58: Dilution-Unit

    9.2. Tubing of all sample gas inlets See chapter 7.6. 9.3. Installation of the calibration gas cylinder For the calibration of the dilution-unit, MRU recommends a gas cylinder with a min. concentration of 500 ppm, from the target gas. Page 58...

  • Page 59: Fine Calibration Of The Dilution-Unit

    MRU GmbH SWG 100 BIO Ex User Manual 9.4. Fine calibration of the dilution-unit If the steps above are done, the device should look like in the sketch below: Max. x6 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 60 MRU GmbH SWG 100 BIO Ex User Manual • Adjustment of the dilution-unit. o Installation of the calibration gas cylinder, for the dilution-unit. This gas cylinder must have a min. concentration of 500 ppm of the target gas. o Open the path:...

  • Page 61: Software-Settings

    MRU GmbH SWG 100 BIO Ex User Manual 9.5. Software-settings • Threshold: The operator can change the threshold. If the value is above this threshold, the dilution will turn on. o The path for this setting is: XTRAS EASUREMENT CONFIGURATION o Marked the setting “threshold”...
  • Page 62 MRU GmbH SWG 100 BIO Ex User Manual • Change the dilution from “automatically” to “ON”. For every single measurement phase, the dilution can be activated permanently or to automatically, too. For example, it is possible to set the first sample point always to “ON”...

  • Page 63: Binding To A Process Control System: I/O Modules

    MRU GmbH SWG 100 BIO Ex User Manual 10 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 64: Pin Assignment

    MRU GmbH SWG 100 BIO Ex User Manual 10.2. 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. Power supply for AO1+ transducer V12+ AO1-...
  • Page 65 MRU GmbH SWG 100 BIO Ex User Manual max. Load max. external Internal load Condutor Double Descrip�on Abbreva�on (for Voltage (in inputs) cross sec�on occupancy outputs) AO1+ max. 500R 0,2-2,5 mm² AO1- max. 500R 0,2-2,5 mm² AO2+ max. 500R 0,2-2,5 mm²...
  • Page 66 MRU GmbH SWG 100 BIO Ex User Manual Analog outputs 4-20 mA Hardware-side Every IO module has four 4…20 mA outputs. The outputs are marked at with the green labels. AO1+ AO1- AO2+ AO2- AO3+ AO3- AO4+ AO4+ Information for connection: Conductor cross section: 0,2…2,5 mm²...
  • Page 67 MRU GmbH SWG 100 BIO Ex 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 68 MRU GmbH SWG 100 BIO Ex 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. •...
  • Page 69 MRU GmbH SWG 100 BIO Ex User Manual 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 70 MRU GmbH SWG 100 BIO Ex 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 71 MRU GmbH SWG 100 BIO Ex 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 72 MRU GmbH SWG 100 BIO Ex User Manual 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: 0,2…2,5 mm²...
  • Page 73 MRU GmbH SWG 100 BIO Ex User Manual Software-side • tion (1). Open the menu: Extras/Analog output configura • 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 74 MRU GmbH SWG 100 BIO Ex 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 or OK.
  • Page 75 MRU GmbH SWG 100 BIO Ex 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 H2S concentration is over 550 ppm in the sample point 2. The SWG100 has one IO module.
  • Page 76 MRU GmbH SWG 100 BIO Ex User Manual • The follow screen appears. To configurate the channel 1, the red marked positions must be changed: Page 76...
  • Page 77 MRU GmbH SWG 100 BIO Ex User Manual Analog inputs (4-20 mA) 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 78 MRU GmbH SWG 100 BIO Ex 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 78...
  • Page 79 MRU GmbH SWG 100 BIO Ex User Manual Software-side • Open the menu: Extras/Aux input configuration (1). • 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 80 MRU GmbH SWG 100 BIO Ex User Manual 3. Example: Read 4-20 mA signal from an external temperature sensor An operator wants to read an external temperature sensor signal inside a SWG100. The temperature sensor gives a 4-20 mA signal out and needs a 7-30 VDC power source.
  • Page 81 MRU GmbH SWG 100 BIO Ex 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 82: Analyser States

    MRU GmbH SWG 100 BIO Ex User Manual 10.3. Analyser states The IO module, of the analyser, can read out the status of the analyser. To set this feature, open the path: (see pictures below). XTRAS NALOG OUTPUT DETAILS Each 1 mA steps represent a function. The chart below shows the different states:...
  • Page 83 MRU GmbH SWG 100 BIO Ex User Manual • Through one 4...20mA input. The settings-menu can be found at the path: -> E XTRAS ENERAL SETTINGS XTERNAL CONTROL The user can set three different types for the external control. The types can be found at the sketch below.
  • Page 84 MRU GmbH SWG 100 BIO Ex 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 85 MRU GmbH SWG 100 BIO Ex 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...
  • Page 86 MRU GmbH SWG 100 BIO Ex 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. The offset-signal is 4 mA.
  • Page 87 MRU GmbH SWG 100 BIO Ex User Manual Configuration at the analyzer Open the path: XTRAS ENERAL SETTINGS “4 x mA” 2. Switch the menu-point “External control” from “OFF” to “Relays” “1 x mA” (dependent from the connected signal input.). When the external control is activated an arrow symbol will appear at the title line.
  • Page 88 MRU GmbH SWG 100 BIO Ex User Manual Case 2: External control of a sample point -Zeroing: First the zeroing will be done. The duration of the zeropoint can be set at the menu ext. crtl. (see point “configurated at the analyzer” in the same chapter).

  • Page 89: Configuration Of The External Control (Option: Io Module)

    MRU GmbH SWG 100 BIO Ex User Manual 10.5. 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 analyzer. With the help of the external control follow operations can be done: •...
  • Page 90 MRU GmbH SWG 100 BIO Ex 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. Connection of the external control via one 4-20 mA input signal The user has the opportunity to control the analyzer with only the first 4-20mA input (see sketch below).
  • Page 91 MRU GmbH SWG 100 BIO Ex User Manual Configuration at the analyzer Open the path: • XTRAS ENERAL SETTINGS • Switch the menu-point “External control” from “OFF” to “Relais”/“4x mA” “1 x mA” (dependent from the connected signal input.). When the external control is activated an arrow symbol will appear at the title line.
  • Page 92 MRU GmbH SWG 100 BIO Ex User Manual -Measurement: The measurement will be started after the response/ suction time is finished. It will be only abort, if the user changes the status of the external signal sources. The chart below shows the possible statues, which can be set at the analyzer: (*1): Whenever the selected sample point will be changed, then the analyzer will start a zeroing before measuring the new sample point.

  • Page 93: Operating The Analyser

    MRU GmbH SWG 100 BIO Ex User Manual Operating the analyser 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 94: Power-On Of Analyser

    MRU GmbH SWG 100 BIO Ex User Manual Administrator PIN code All functions and menus which may disturb the analyser’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 95: Main Menu Measurement

    MRU GmbH SWG 100 BIO Ex User Manual 11.4. Main menu measurement This menu is the root of all menus and will be shown automatically as soon as the self- test is finished. The title bar you can see on the left the current measurement cycle status...
  • Page 96 MRU GmbH SWG 100 BIO Ex User Manual Manual zeroing and selection of measurement points For analyzers with just one measuring point, the status of "measuring" by pressing the F1 key = "zero" will be canceled and the next manual zeroing be initiated.

  • Page 97: Data Storage

    MRU GmbH SWG 100 BIO Ex User Manual 11.5. Data Storage The data storage menu can be reached by pressing F2='storage' in the measurement menu: The menu provides an overview of stored measurements of each sample point and of the memory usage.
  • Page 99 MRU GmbH SWG 100 BIO Ex User Manual The analyser makes use of an internal flash memory to store measurement values automatically. Data storage strategy is as follows: • The analyser may store up to 20,000 measurement points (including all relevant data).

  • Page 100: Extra Menu: Overview

    MRU GmbH SWG 100 BIO Ex User Manual Export of measurements to SD card This function is used to export the measurements from the analyzer to a PC. The used format is CSV (comma-separated values). Many computer programs are able to read this format, e.g.
  • Page 101 MRU GmbH SWG 100 BIO Ex User Manual General settings Path: XTRA ENERAL SETTINGS Structure: General settings Extra/General settings LCD brightness until 100% default 60% / 5% steps General settings Country Diverse /default English Language Diverse default English Keyboard beep...
  • Page 102 MRU GmbH SWG 100 BIO Ex 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 Measurement cycle config.
  • Page 103 MRU GmbH SWG 100 BIO Ex 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).
  • Page 104 MRU GmbH SWG 100 BIO Ex User Manual Hardware state & tests: Number Hardware Settings Gas pump ON or OFF Purge pump (optional) ON or OFF Solenoid valve H2S low ON or OFF (optional) Solenoid valve zero gas ON or OFF Solenoid valve cal.
  • Page 105 MRU GmbH SWG 100 BIO Ex 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 107: Power-Down Of Analyzer

    MRU GmbH SWG 100 BIO Ex User Manual 11.7. 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 •...

  • Page 108: Default Configuration

    MRU GmbH SWG 100 BIO Ex User Manual 11.9. 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 109 MRU GmbH SWG 100 BIO Ex 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.
  • Page 110 MRU GmbH SWG 100 BIO Ex User Manual Device info Path: XTRAS EVICE INFO Structure: Device info Extra/Device info Main device info Main device info detail Sub systems info MAINBOARD Sub systems info NDIR bench Sub systems info I/O module 1-max. 10...

  • Page 111: Update The Firmware

    MRU GmbH SWG 100 BIO Ex User Manual 11.10. Update the firmware DANGER Explosion hazard Before update the firmware, make sure to have a “hot permit” and monitor at all time the ambient atmosphere with a certified flammable gas detector.
  • Page 112 MRU GmbH SWG 100 BIO Ex User Manual Update the analyzer (Firmware-Updates with filename “1106.fwb”) 1. Open the path: XTRA EVICE F2 = details 2. Press to open the details for the main device menu. F2 = FW update. The analyzer will start the update from the SD-card.
  • Page 113 MRU GmbH SWG 100 BIO Ex User Manual F2 = details, to open the details from the NDIR bench. Be sure, that the 3. Press device is “NDIR bench” to update the NDIR-bench. 4. The Update will start from the SD-card, if a firmware with the filename “1106ndir.fwb”...

  • Page 114: Service And Maintenance

    MRU GmbH SWG 100 BIO Ex User Manual Service and maintenance DANGER Explosion hazard Before starting the maintenance make sure to have a “hot permit” and monitor at all time the ambient atmosphere with a certified flammable gas detector. DANGER Apply personality safety equipment, against high H2S concentrations before open the device.
  • Page 115 MRU GmbH SWG 100 BIO Ex User Manual Review Recommended Actions intervals Moisture in the analyzer. Weekly Remove the moisture. Call vendor specialist. Dirt and depositions in analyzer. Weekly Remove the dirt, prevent further penetration of dirt. Inform vendor. Dirt and moisture in the filter- unit Weekly Exchange the filter-unit.

  • Page 116: Position And Overview Of The Service-Parts

    MRU GmbH SWG 100 BIO Ex User Manual 12.3. Position and overview of the service-parts Page 116...
  • Page 117 MRU GmbH SWG 100 BIO Ex User Manual Content of the service-set (offer-number: 66174) Single components can be offered under their article number directly. Image name Interval Quantity Offer- number Acid-gas filter New state: purple beads Used: white beads 2 pieces...
  • Page 118 MRU GmbH SWG 100 BIO Ex 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.
  • Page 119 MRU GmbH SWG 100 BIO Ex User Manual Plug the viton tubes on the filter unit. Push the filter unit on the clip. 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.
  • Page 120 MRU GmbH SWG 100 BIO Ex 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. Steps: Pull the exhausted filter-unit from the viton tube and exchange it with a new one.

  • Page 121: Cleaning The Surface Of Swg100Bio-Ex

    MRU GmbH SWG 100 BIO Ex User Manual 12.4. Cleaning the surface of SWG100BIO-Ex. DANGER Explosion hazard For cleaning the cabinet uses a wet and antistatic cloth to prevent electrostatic charge. The SWG100BIO-Ex is designed for explosive atmosphere class 2. If the cabinet and the window must be cleaned, it is necessary to use a wet and antistatic cloth to prevent an electrostatic charge of the cabinet.

  • Page 123: Exchange Of Electrochemical Sensors

    MRU GmbH SWG 100 BIO Ex User Manual Exchange of electrochemical sensors The position of the electrochemical sensor in the SWG-100 BIOGAS is shown in the sketch below. Depending form, the design of the electrochemical sensors design, there are different ways to exchange the sensor.
  • Page 124 MRU GmbH SWG 100 BIO Ex User Manual Exchange the sensors of the model A Required sensor: O2-Sensor (65824 position 1) CAUTION Do not disposal the sensor in the domestic waste! Exhausted chemical sensors are special waste! To exchange the sensor, following steps must be done: Unplug the sensor connection cable here •...
  • Page 125 MRU GmbH SWG 100 BIO Ex User Manual Exchange the sensors of the model B Affected sensors: H2S low Sensor (65825 position 2) H2 low sensor (65827 position 4). Caution Do not disposal the sensor in the domestic waste! Exhausted chemical...

  • Page 126: Adjustment Of The Ndir-Bench

    MRU GmbH SWG 100 BIO Ex User Manual Exchange the sensors from the model C Affected sensors: H2S high sensor (65826 position 2) H2S sensor (66060 position 4). CAUTION Do not disposal the sensor in the domestic waste! Exhausted chemical...
  • Page 127 MRU GmbH SWG 100 BIO Ex User Manual ATTENTION Close door During the entire adjustment, the cabinet door must be closed. ATTENTION The PIN-Code is: F1 – F3 – F2 – F2 – UP - DOWN 1. Select the menu:...
  • Page 128 MRU GmbH SWG 100 BIO Ex User Manual Mounting the adjustment gas cylinder: The pressure reducer must be set at max. 500 mbar. The adjustment gas cylinder still remains closed. close P=0 bar 4. Open NDIR cuvette menu: Open the menu...
  • Page 129 MRU GmbH SWG 100 BIO Ex User Manual 2). A blue window appears in which the target value can be entered (see 3). This must be done for both CH4 and CO2. Open adjustment gas cylinder: Open the adjustment gas cylinder. The actual value changes.
  • Page 130 MRU GmbH SWG 100 BIO Ex User Manual 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 131 MRU GmbH SWG 100 BIO Ex User Manual Software side: Adjustment for the option auto-calibration: 1. Open the menu “Setup auto-calibration”. It from: “ XTRAS DJUSTMENT MENU ETUP ” AUTO CALIBRATION 2. Select menu point “test gas composition” to set the gas composition from the calibration gas cylinder.
  • Page 132 MRU GmbH SWG 100 BIO Ex User Manual NOTE All gas concentrations are in percent! The factor 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 133: Troubleshooting

    MRU GmbH SWG 100 BIO Ex User Manual 15.1. Troubleshooting Possible causes Solutions Error 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 defect.

  • Page 134: Technical Specification

    MRU GmbH SWG 100 BIO Ex User Manual Technical specification Allgemein General Deutsch Angabe English Betriebstemperatur (ohne +5°C ... +45 °C / 41 °F ... Operating temperature Frostschutzheizung) 113 °F (without heating) Betriebstemperatur (mit optionaler -20 °C ... +45°C / 14 °F...
  • Page 135 MRU GmbH SWG 100 BIO Ex 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 136 MRU GmbH SWG 100 BIO Ex User Manual Jahre erwartete Lebensdauer an Luft Years expected lifetime (@air) Elektrochemischer Sensor H2S low200 Electrochemical Sensor Messbereich 0-200 ppm Measuring Range Auflösung 1 ppm Resolution Überlastbereich < 1000 ppm Overload Range ±5 ppm / 5% (0 …...
  • Page 137 MRU GmbH SWG 100 BIO Ex User Manual Genauigkeit abs. Abs. Accuracy Ansprechzeit T90 < 40s Response Time T90 Jahre erwartete Lebensdauer an Luft (abhängig von Years expected lifetime (@air) gewähltem Sensor) (Depending on chosen sensor) Elektrochemischer Sensor Electrochemical Sensor...

  • Page 138: General Information

    MRU GmbH SWG 100 BIO Ex User Manual General information • The Modbus/Profibus Slave function requires the analyser firmware version V1.11.00 dated 12.07.2016 or later. • ® Big-Endian Multi byte values are transmitted in Motorola byte order ( ). Only ®...

  • Page 139: Special Informationen About The Profibus Slave Function

    Special informationen about the Profibus Slave function • The Profibus Slave function requires a modbus/profibus-converter "Seneca HD67561", which is configured and installed in the analyser. • Usually MRU sets the Profibus ID to 84. Defined registers to be read by the master modbu profibus data...
  • Page 140 MRU GmbH SWG 100 BIO Ex User Manual v-gas [m/s] (unit depends on user settings) Flow vol. [m³/s] (unit depends on user settings) Net calorific value [MJ/m³] Status & measurement values of sample point 1 Analyser Status (more details read below)
  • Page 141 MRU GmbH SWG 100 BIO Ex User Manual AUX-value read by IO-module 2 - Input 4 AUX-value read by IO-module 3 - Input 1 AUX-value read by IO-module 3 - Input 2 AUX-value read by IO-module 3 - Input 3...
  • Page 142 MRU GmbH SWG 100 BIO Ex User Manual Note: User definable modbus values are not available via Profibus! (at least not with the delivered Profibus configuration) Since firmware V1.19.00 the user can configure a user definable modbus value list according to the configuration of the measurement window. This happens by a command at once.

  • Page 143: Analyser Status (Address 0 And Some Mirror Addresses)

    MRU GmbH SWG 100 BIO Ex User Manual 18.1. Analyser Status (address 0 and some mirror addresses) The Analyser 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...

  • Page 144: Analyser System Alarm (Address 2 And Some Mirror Addresses)

    MRU GmbH SWG 100 BIO Ex User Manual 18.2. Analyser System Alarm (address 2 and some mirror addresses) The Analyser System Alarm is a 32bit-word and must be interpreted bitwise. Meas. Description halted Mainboard Offline (some communication problems) Mainboard is in bootloader mode CH4 ambient >...

  • Page 145: Appendix

    MRU GmbH SWG 100 BIO Ex User Manual APPENDIX 19.1. Spare parts list Article Description – Serial number Condensate pump - #11230 Required to drain the condensate Sample gas pump - #65032 Used for sample gas pumping H2S solenoid valve - #65470 Required for cut-off sample gas supply to H sensor.
  • Page 146 MRU GmbH SWG 100 BIO Ex User Manual Display and operation unit #65133 Control unit for the user. I/O-Module #65179 + #65430 Used for analog output data transfer and sample point switching. I/O Module - #65179 Used for analog output...

  • Page 147: Declaration Of Conformity

    MRU GmbH SWG 100 BIO Ex User Manual 20. Declaration of conformity Page 147 of 150...
  • Page 148 MRU GmbH SWG 100 BIO Ex User Manual Page 148...
  • Page 149 MRU GmbH SWG 100 BIO Ex User Manual Page 149 of 150...
  • Page 150 MRU GmbH SWG 100 BIO Ex User Manual EN_V3.0_BIO-EX Page 150...

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