mru SWG100 User Manual
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mru SWG100 User Manual

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SWG100
USER MANUAL
9512EN-SWG

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  • Page 1 SWG100 USER MANUAL 9512EN-SWG...
  • Page 2 USER MANUAL SWG100 2 / 158 MRU GmbH, D-74172 Neckarsulm...

  • Page 3: Table Of Contents

    USER MANUAL SWG100 Content Information for product and safety ..............6 1.1. Safety manual ......................6 1.2. Safety precautions ...................... 6 1.3. Weather and environmental conditions ............8 1.4. General important instructions for the plant operator ......... 9 1.5. Packing ........................... 9 1.6.
  • Page 4 16.9. Option: NDIR-bench 334 mmm ................ 134 16.10. Configuration of the ethernetmodule ............138 16.11. Option: Connection the SWG100 with RS-485 converter to MRU4Win 17. Declaration of conformity ................. 148 18. Charts ........................149 18.1. Gas flow chart ......................149...
  • Page 5 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. 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: Information For Product And Safety

    USER MANUAL SWG100 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. All information and safety precautions for the analyser in the Safety Manual also apply to the analyser.
  • Page 7 USER MANUAL SWG100 Toxicity danger of sample gas WARNING Toxic gas Sample gas can contain toxic substances, which are harmful for health and can even cause death. It is the responsibility of analyser user to ensure that person is skilled and trained in safety aspects of gases being analysed and procedures to follow while using this instrument.

  • Page 8: Weather And Environmental Conditions

    MRU. 1.3. Weather and environmental conditions The SWG100 analyser is designed for ambient temperatures of +5°C to +45°C (without cabinet heater) resp. -10°C to +45°C (with cabinet heater). The analyser is designed for indoor mounting. In case of outdoor mounting it is important that the analyser is sufficiently protected against rain, sun and wind.

  • Page 9: General Important Instructions For The Plant Operator

    1.5. 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 10 7. The service of a guarantee conditions will not enlarge the guarantee time. Demands because of consequential damages are excluded. 8. MRU is not responsible for the transport costs for the warranty or replacement. 9. MRU reserves the right, to determine individual conditions or exceptions. These will be separately communicated.

  • Page 11: Analyser Description

    USER MANUAL SWG100 Analyser Description • Read and observe the separately supplied Safety manual. • This manual enables you to understand and safely operate this MRU Analyzer. • Please read this manual with great vigilant. • Get familiar with the product before using it.
  • Page 12 USER MANUAL SWG100 lifetime of sensor (only limited by corrosion or dust, which can be prevented or removed by regular servicing the instrument). • The instrument is optionally equipped with several electro- chemical sensors ECS to detect gas components like oxygen .

  • Page 13: Physical Characteristic Of The Gas Analyzer

    USER MANUAL SWG100 2.3. Physical characteristic of the gas analyzer Top view Front view Reference Sample gas inlet for f Cabinet lock Display and operation Cabinet mounting 13 / MRU GmbH, D-74172 Neckarsulm...
  • Page 14 USER MANUAL SWG100 Right side Left side Bottom view Reference: 1. Fan filter 5. Cable gland for power supply 2. Calibration gas inlet (G1/8 inner thread) 6. Power switch 3. Zero gas inlet (G1/8 inner thread) 7. Cable gland for IO module 4.

  • Page 15: Scope Of Supply / Mounting Positions

    USER MANUAL SWG100 Scope of supply / mounting positions 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 back shipment. Inside the attachments box are different fittings:...
  • Page 16 • 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). 16 / MRU GmbH, D-74172 Neckarsulm...

  • Page 17: Installation Manual

    USER MANUAL SWG100 4. Installation manual 4.1. Overview This manual explains how to install the analyzer mechanically and electrically. 17 / MRU GmbH, D-74172 Neckarsulm...

  • Page 18: Select Measurement Point

    USER MANUAL SWG100 The installer must correctly assemble these parts during installation. The following diagram shows the sequence in which the installation should be carried out: Preparation of the measurement points Analyzer mounting Power supply Connect IO module to control room Connect sample gas outlet Connect adjustment, zero gas and condensate outlet.
  • Page 19 USER MANUAL SWG100 Over 3 times of diameter Core flow Above 3 times of diameter • For installations on a metal pipe, make sure that the wall thickness can support the weight of the probe. For this purpose the mounting flange is welded to the pipe.

  • Page 20: Installation Of The Mounting Flange

    USER MANUAL SWG100 4.3. Installation of the mounting flange The mounting flange is not scope of supply. The sketch below shows the necessary dimensions of the mounting flange. The mounting flange has the same dimensions as a DN65/PN6 flange (dimensions as DIN2573).
  • Page 21 USER MANUAL SWG100 4. flange alignment DN65 The flange holes should not be aligned horizontally or vertically, but at an angle of 45°. 21 / MRU GmbH, D-74172 Neckarsulm...

  • Page 22: Installation Of The Analyzer

    USER MANUAL SWG100 4.4. 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. Picture 1: Dimensions for the wall mounting. Min. 500 mm Min. 300mm Min.

  • Page 23: Connection Of Main Power Supply

    USER MANUAL SWG100 4.5. Connection of main power supply WARNING Electrical shock! Electricity could cause damage, injuries and even death! Only educated staff should install the device. The analyser needs a main power supply of 100-230 VAC/ 47-60 Hz. The power supply will be connected on the hat-rail.

  • Page 24: I/O Modules: Installation And Setting

    USER MANUAL SWG100 4.6. 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 25 USER MANUAL SWG100 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 26: Installation: Sample Gas Outlet (Vent)

    USER MANUAL SWG100 4.7. Installation: Sample gas outlet (VENT) The sample gas flows out of the gas outlet and out of the analyzer again after the analysis is completed. Because the sample gas can be toxic, environmentally harmful or explosive, it is important to discharge this gas into a secured environment.

  • Page 27: Installation: Calibration Gas / Zero Gas And Condensate Outlet

    USER MANUAL SWG100 4.8. Installation: Calibration gas / zero gas and condensate outlet Reference: 1. Calibration gas inlet G1/8 for DN4/6 mm hose. 2. Zero gas inlet G1/8 for DN4/6 mm hose. 3. Condensate outlet G1/8 for DN4/6 mm hose.

  • Page 28: Installation Of The Sampling Line And Probe

    USER MANUAL SWG100 4.9. Installation of the sampling line and probe This section describes the installation of the HD probe and the heating hose. ATTENTION Use clean, oil and waterfree air! NOTE For further information about the heated sampling line read the appendix.
  • Page 29 USER MANUAL SWG100 1. Screw the probe, with seal, onto the HP probe. 2. The HEATED SAMPLING LINE CONNECTOR must be fixed with the nut. 29 / MRU GmbH, D-74172 Neckarsulm...
  • Page 30 USER MANUAL SWG100 3. Connect the heated sampling line with the HEATED SAMPLING LINE CONNECTOR. Fix the heated sampling line with the two fixation clamps. 4. Put the heated sampling line into the HEATED SAMPLING LINE CONNECTOR. The HEATED SAMPLING LINE must be connected with the plug-side.
  • Page 31 USER MANUAL SWG100 5. Connect the flexible PTFE-tube with the gas inlet of the HD-probe. 6. Put the plug from the heated sampling line on the right position. 7. Connect the compressed air with the HD-probe. The pressure should be...
  • Page 32 USER MANUAL SWG100 8. screw the heating hose to the clamps shown. Reference: 1. L Hose brown 2. N Hose blue 3. Th+ Hose green 4. Th- Hose white 5. L probe violet 6. N probe yellow 7. Th+ probe green 8.

  • Page 33: Operation Of The Analyzer (Hmi)

    USER MANUAL SWG100 Operation of the analyzer (HMI) 5.1. 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 - Measurement value… SD-Card symbol - Indication green →...

  • Page 34: Analyzer Commissioning Manual

    USER MANUAL SWG100 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 35: Configuration Of The Alarm Relays

    USER MANUAL SWG100 6.3. Configuration of the alarm relays 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 > 20% to 50% LEL) Condensate alarm (contacts resistance <...
  • Page 36 USER MANUAL SWG100 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. Solid 0,2-2,5 mm² (30-12 AWG) Stranded 0,2-2,5 mm²...

  • Page 37: Configuration Of The Modbus

    USER MANUAL SWG100 6.4. 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) Plug connector definition for the system alarm relay...
  • Page 38 USER MANUAL SWG100 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 slaves settings. 38 / MRU GmbH, D-74172 Neckarsulm...

  • Page 39: Binding To A Process Control System: I/O Modules

    7.1. Position of the IO module inside the analyzer At the basic SWG100, one IO module is integrated. Optionally, an analyzer can be equipped with further IO modules (max. 10). The IO module(s) are installed on the hat-rail (position: see sketch below).

  • Page 40: Pin Assignment

    USER MANUAL SWG100 7.2. 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. 40 / MRU GmbH, D-74172 Neckarsulm...
  • Page 41 USER MANUAL SWG100 max. Internal max. external Double Description Abbrevation Load (for load (in Voltage occupancy outputs) inputs) max. AO1+ 500R max. AO1- 500R max. AO2+ 500R max. AO2- 500R max. AO3+ 500R max. AO3- 500R max. AO4+ 500R max.

  • Page 42: Analog Outputs 4-20 Ma

    USER MANUAL SWG100 7.3. 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 42 / MRU GmbH, D-74172 Neckarsulm...
  • Page 43 USER MANUAL SWG100 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 44 USER MANUAL SWG100 • Auto configuration (3): If the operator pushes this key ( ) the output pins would be configured by default values. • Test (4): The test-menu is for testing the analog outputs. To open the test- menu, push...
  • Page 45 USER MANUAL SWG100 activated, the set value will be transferred to the DCS. Test (8): Further to a test-menu. Alternate push F3. 45 / MRU GmbH, D-74172 Neckarsulm...
  • Page 46 (AO1+/AO1-) with the DCS. For this, use a wiring with a conductor cross section between In the next step output 1 must be configured at the SWG100. To do this, open the menu: EXTRAS/ CONFIGURATE ANALOG OUTPUTS. The following menu overview will be appeared (see screenshot below). To configure the IO1, select the first record (channel I/O 1/1 SP1 / CH4) in the list and open it.
  • Page 47 USER MANUAL SWG100 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 48: Alarm Outputs

    USER MANUAL SWG100 7.4. 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: Normally open Voltage supply: max.
  • Page 49 USER MANUAL SWG100 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 50 USER MANUAL SWG100 • Details (2): Here the operator can open the configuration screen for the selected alarm output. To open the details-menu, push • Auto configuration (3): If the operator pushes this key ( ) the output pins would be configured by default values.
  • Page 51 Connect the parts with the relay inside the IO module. • In the next step the alarm 1 must be configured at the SWG100. To do this, open the menu: EXTRAS/ ALARM OUTPUT CONFIGURATION. The following menu overview will be appeared (see screenshot below).
  • Page 52 USER MANUAL SWG100 • The follow screen appears. To configurate the channel 1, the red marked positions must be changed: 52 / MRU GmbH, D-74172 Neckarsulm...

  • Page 53: Analog Inputs (4-20 Ma)

    USER MANUAL SWG100 7.5. 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 54 USER MANUAL SWG100 2-wire transducer: Transducer Load: 50 Ohm Power supply for transducer 4-wire transducer Transducer Load: 50 Ohm Power supply for transducer 54 / MRU GmbH, D-74172 Neckarsulm...
  • Page 55 USER MANUAL SWG100 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 56 Example: Read 4-20 mA signal from an external temperature sensor An operator wants to read an external temperature sensor signal inside a a 7-30 SWG100. The temperature sensor gives a 4-20 mA signal out and needs VDC power source a two-wire transducer .
  • Page 57 USER MANUAL SWG100 • First the operator sees an overview, which shows with kinds of sensors are mounted at the IO-module. In this example, there is no transducer mounted at the SWG100. • To configure a new sensor, push •...

  • Page 58: Configuration Of The External Control (Option: Io Module)

    USER MANUAL SWG100 7.6. 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 analyzer. With the help of the external control follow operations can be done: •...
  • Page 59 USER MANUAL SWG100 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 60 USER MANUAL SWG100 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 Automatic sampling point switching...
  • Page 61 USER MANUAL SWG100 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). The different commands will be given by the changing of the current signal.
  • Page 62 USER MANUAL SWG100 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 63 USER MANUAL SWG100 Case 1: Stand-by The Stand-by modus will be activated if the input state is higher than the number modus has the following pass: - Purging with zero gas (for the configured duration) - Standby until the input state is below or equal the number of sample points (e.g.
  • Page 64 USER MANUAL SWG100 - status number=1 (for any time period, recommended max. 1 hour) After installation and power-up of the analyzer few steps should be processed in order to operate the instrument properly. 64 / MRU GmbH, D-74172 Neckarsulm...

  • Page 65: Mounting And Installation Of The Gas Cylinders For The Auto Calibration Function

    USER MANUAL SWG100 7.7. 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 66 USER MANUAL SWG100 Software side: Adjustment for the option auto-calibration: “ XTRAS DJUSTMENT ”. MENU ETUP AUTO CALIBRATION rea can be Arrow keys left/ right: With these keys the gas composition can be set. Arrow keys up/ down: Single positions for the different gas compositions can be selected.
  • Page 67 USER MANUAL SWG100 4. 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. - Start the auto- calibration immediately: Press (start now).

  • Page 68: Cycle Configuration

    USER MANUAL SWG100 7.8. Cycle configuration Path and default setting XTRA EASUREMENT CYCLE CONFIG “M .” When the menu EASUREMENT CYCLE CONFIG is selected the user definable setting for the measurement cycle will appear (see screenshot below). Screenshot shows default setting, when the „M...
  • Page 69 USER MANUAL SWG100 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...
  • Page 70 USER MANUAL SWG100 Configuration of the phase details In this chapter the different cycle phase details will be explained. Zeroing (Cycle phase details): EROING time 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 71 USER MANUAL SWG100 Stand-by (cycle phase details): mode time can be configured. In the cycle phase details the following times can be set: • 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 72 USER MANUAL SWG100 Example for the deactivation of a phase phase is grey out. 72 / MRU GmbH, D-74172 Neckarsulm...
  • Page 73 USER MANUAL SWG100 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 74 USER MANUAL SWG100 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. 6. Switch to the next point and select with the left/right arrow key measurement SP1.

  • Page 75: Administrator Pin Code

    USER MANUAL SWG100 7.9. 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 analyser.

  • Page 76: Operating The Analyser

    USER MANUAL SWG100 Operating the analyser This chapter has the follow structure: • In the first part it will be explained, how to start the analyser and the selftest menu. • Part three shows the submenu, which are listed at the EXTRA menu.
  • Page 77 USER MANUAL SWG100 If one of the internal RS485 bus participants are issuing alarm (faulty) status, the user can still leave the self-test manually by pressing F2='forward' (PIN code requested), even if not all sub-systems or the gas cooler are ready.
  • Page 78 USER MANUAL SWG100 However, once a measurement phase is completed, the display automatically switches to the actual measurement location. Configuration of the measurement window (display content) The measuring values selection and arrangement is user free configurable in both display modes.

  • Page 79: Data Storage Menu

    USER MANUAL SWG100 8.2. 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. NOTE DATA STORAGE The analyser makes use of an internal flash memory to store measurement values automatically.
  • Page 80 USER MANUAL SWG100 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 81 USER MANUAL SWG100 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. This function is only available, when a SD card is inserted and is not write protected.
  • Page 82 USER MANUAL SWG100 • Set default list: In this list all available measurement values and 2 asset lines are pictured. • Set small list: In this list the general measurement values are pictured. 82 / MRU GmbH, D-74172 Neckarsulm...

  • Page 83: Extra Menu: Overview

    USER MANUAL SWG100 8.3. 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 Structure: Baud rate...
  • Page 84 USER MANUAL SWG100 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 85 USER MANUAL SWG100 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 ( Averaging this chapter). Adjustment CH4 pellistor (see service manual) Hardware state &...
  • Page 86 USER MANUAL SWG100 Hardware state & tests: Adjustment of the average-time for CO2 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 87 USER MANUAL SWG100 NOTE Effect of the average time A smooth averaging time smooths the measurement signal but increase the response time of the measurement signal. 87 / MRU GmbH, D-74172 Neckarsulm...
  • Page 88 USER MANUAL SWG100 Default configuration -> E –> D Use the menu for the default configuration: EASUREMENT XTRAS EFAULT ETTINGS DEFAULT CONFIGURATION Analog output 4- Parameter 20mA Alarm output relay contact 20mA open CH4 [ % ] less than O2 [ % ]...
  • Page 89 USER MANUAL SWG100 Contents SD card Path: XTRAS CONTENT CARD Structure: 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. Open the file. User can view the stored screenshots.
  • Page 91 USER MANUAL SWG100 Device info Path: XTRAS EVICE INFO Structure: 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 Device details MAINBOARD Device details NDIR bench Device details I/O module 1-max.
  • Page 92 USER MANUAL SWG100 Power-Down of analyser Before the analyser 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 Press the key in any menu in order to prepare the analyser for the Power-Down.

  • Page 93: Update The Firmware

    USER MANUAL SWG100 8.4. Update the firmware The analyser and different installed options can be updated, if it is necessary. Following options can be updated: • The firmware from the analyser. • The firmware from the pcb- mainboard. • The firmware from the NDIR-bench.
  • Page 94 USER MANUAL SWG100 F2 = details 2. Press to open the details for the main device menu. 3. Press F2 = FW update . The analyser will start the update from the SD-card. Update the pcb-mainboard (Firmware- Open the path:...
  • Page 95 USER MANUAL SWG100 Update the IO modules (Firmware- Open the path: XTRA EVICE INFO F3 = sub.syst 2. Press UB SYSTEMS INFO F2 = details 3. Press , to open the details from the I/O module. Be sure, that the device is 4.

  • Page 96: Service And Maintenance

    USER MANUAL SWG100 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 9.1.-) the producer recommends a regular half year maintenance, which must carried by a qualified specialist.

  • Page 97: Description Of The Analyser

    USER MANUAL SWG100 9.3. Description of the analyser The sketch below shows the positions of all spare and consumable parts in the SWG- 100 CEM. The parts, marketed with a red circle is a spare part, the parts, marketed with a green circle is a consumable part.
  • Page 98 USER MANUAL SWG100 Content of the service-set Single components can be offered under their article number directly. ✓ ✓ Acid-gas filter (Purafil) 56795 ✓ ✓ Dust- and particle filter (2 µm PTFE) 65533 ✓ ✓ Dust- and particle filter (0,3 µm PTFE) 66088 ...
  • Page 99 USER MANUAL SWG100 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. Steps: Remove exhausted acid gas filter from...
  • Page 100 USER MANUAL SWG100 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 101 USER MANUAL SWG100 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 to low. Steps: Pull the exhausted filter-unit from the viton tube and exchange it with a new one.

  • Page 102: Exchange Of Electrochemical Sensors

    USER MANUAL SWG100 9.4. Exchange of electrochemical sensors The position of the electrochemical sensor in the SWG-100 is shown in the sketch below. This is the standard positions of the sensors. Every sensor is optional. If a sensor was not ordered, the place on the sensor chamber will be free.
  • Page 103 USER MANUAL SWG100 Screw the O2 sensor from the adapter. Remove the plug for the O2 sensor from the mainboard. sensor Screw the new O sensor in the adapter. Put the plug from the new sensor on the mainboard. The sensor is now ready for operation.

  • Page 104: Maintenance: Hd-Probe With Back Purge Function

    USER MANUAL SWG100 10. Maintenance: HD-probe with back purge function Over time, flat and O-ring seals must be replaced. The following service set can be ordered for maintenance. Image Name Ceramic filter 0,5µm D50/20x90 mm 55764 Sealing DURABOARD for ceramic...

  • Page 105: Positions Of The Components

    USER MANUAL SWG100 The service set is intended for a one-time use. All components are replaced after a complete service cycle. 10.1. Positions of the components 105 / MRU GmbH, D-74172 Neckarsulm...

  • Page 106: Preparations

    USER MANUAL SWG100 10.2. Preparations • Power the system down. • Remove the probe cover. • Unscrew the filter holder. Pull the locking device downwards. • Pull out the filter holder. 106 / MRU GmbH, D-74172 Neckarsulm...

  • Page 107: Maintenance: Filter Holder

    USER MANUAL SWG100 11. Maintenance: Filter holder Follow maintenance steps must be done, at the filter holder. • Unscrew the filter holder nut. Open Size Position-No.: 17 mm • Remove the exhausted ceramic filter and the two sealings. • Remove the exhausted O-rings and replace with new ones.
  • Page 108 USER MANUAL SWG100 • Install the new filter and new seals. Screw on the filter holder nut. Close Size Position-No.: 17 mm • To exchange the O-rings at the back-purge manifold, unscrew the upper nut and remove the manifold. •...
  • Page 109 USER MANUAL SWG100 109 / MRU GmbH, D-74172 Neckarsulm...

  • Page 110: Exchange The Seals

    USER MANUAL SWG100 12. Exchange the seals • Power the system down. • Remove the HD-probe from the flange adapter. To do this, remove the nuts. Open Size Position-No.: 17 mm • Remove the entire HD-probe from the stack carefully.
  • Page 111 USER MANUAL SWG100 • Unscrew the probe tube from the HD probe. And replace the old seal with a new one. NOTE • When assembling, lubricate the screws with ceramic paste to prevent them from seizing. 111 / MRU GmbH, D-74172 Neckarsulm...

  • Page 112: Technical Specification

    USER MANUAL SWG100 14. Technical specification Allgemein General Deutsch Angabe English Betriebstemperatur(ohne +5°C ... +45 °C / 41 °F ... 113 Operating temperature (w/o Frostschutzheizung) °F heating) Betriebstemperatur (mit optionaler -10 °C ... +45°C / 14 °F ... 113 Operating temperature (with Frostschutzheizung) °F...
  • Page 113 USER MANUAL SWG100 Deutsch Angabe English Benutzerschnittstelle Angabe User Interface Anzeigetyp Display type Anzahl gleichzeitig Number of siultaneously displayed angezeigter Messwerte values Tastatur mit Anzahl Tasten Keyboard with qty of keys Elektrische Aus-/Eingänge Electrical I/O Serielle Schnittstelle RS485 Serial interface...
  • Page 114 USER MANUAL SWG100 Messbereich 21 % Measuring Range Auflösung 0,1% Resolution Genauigkeit abs. ± 0,2 Vol% Abs. Accuracy Ansprechzeit T90 < 20s Response Time T90 Jahre erwartete Lebensdauer an Luft Years expected lifetime (@air) Nicht-dispersive Non-dispersive Infrared Infrarotmessung (NDIR) NDIR-bench...

  • Page 115: Appendix

    USER MANUAL SWG100 15. APPENDIX A. Specification 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 116 USER MANUAL SWG100 Defined registers to be read by the master protocol data numb. of register content address type registers Status & Device info Analyser Status (more details read below) System Alarm (more details read below) Serial number Analyser type...
  • Page 117 USER MANUAL SWG100 protocol data numb. of register content address type registers Status & measurement values of sample point 1 Analyser Status (more details read below) System Alarm (more details read below) O2 [%] CO2 [%] CH4 [ppm] H2S [ppm]...
  • Page 118 USER MANUAL SWG100 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 AUX-value read by IO-module 1 - Input 3...

  • Page 119: Analyser Status (Address 0 And Some Mirror Addresses)

    USER MANUAL SWG100 15.1. 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 Air Purging (zeroing) Gas Sampling (preparing measurement, not measurement!) Currently sampled sample point number (1..10, reads 0 while air purging)

  • Page 120: Heated Sampling Line General Remarks

    USER MANUAL SWG100 15.3. Heated Sampling Line general remarks To avoid washout effects of gas components in condensate, a heated sampling may be used. Heated sampling lines are available in different lengths to support different site configurations. Draft 1 shows a heated sampling line for a low dust probe (LD probe). This type of heated sampling line has no plug for the probe.
  • Page 121 USER MANUAL SWG100 Draft 2 shows a heated sampling line for a HD-probe. The heated sampling lines for HD- probes have an extra plug for the probe heat. 100 mm Heated sampling line length: 1000 mm Dependent from the order...

  • Page 122: General Instructions For The Heated Sampling Lines

    USER MANUAL SWG100 15.4. General Instructions for the heated sampling lines For the save operation of the sample line it is important that it is installed correctly. This includes the following points: • The bending radius as given below is maintained, •...
  • Page 123 USER MANUAL SWG100 Bending radius of heated sampling lines The picture below shows the minimal bending radius. Bending radius min. = 32 cm ATTENTION Falling below the bending radius will reduce life time of the sampling probe. Mounting rules for heated sampling lines...
  • Page 124 USER MANUAL SWG100 Lay the heated sampling line free and Do not fixing the heated sampling clean. line with glue or material, which coat the entire line. -> Overheating hazard!! Only direction changes, Do not hang the heated having the right check rail sampling line on a direction diameter.
  • Page 125 USER MANUAL SWG100 avoid that the heated sampling line gets twisted, assemble it parallel. Do not assemble the heated Use a special spring suspension. sampling line that the whole application can sag from its one weight. Rules for laying the heated sampling line in a cable duct...

  • Page 126: Purchase Options Of The Analyser

    USER MANUAL SWG100 16. Purchase options of the analyser In this chapter the different available options are explained. The chapter shows the position of the different options in the analyser. 16.1. Option: Electric sample gas cooler The gas cooler-unit is equipped with a peltier-element. It is for drying the gas feed of a dew point of 5°C.

  • Page 127: Option: Cabinet Heater

    USER MANUAL SWG100 16.2. Option: Cabinet heater The feature cabinet heater is necessary to operate the analyser at low ambient air temperatures (-1 temperature is fallen <18°C. The electrical power from the cabinet heater is 200 Watt. This option exists in a 230 VAC and an 115VAC variant.

  • Page 128: Option: O2 Paramagnetic Cell Measurement 0-25,00

    USER MANUAL SWG100 16.3. Option: O2 paramagnetic cell measurement 0- 25,00% 128 / MRU GmbH, D-74172 Neckarsulm...

  • Page 129: Option: Multiple Sample Point Switching And Monitoring (Time Sharing)

    USER MANUAL SWG100 16.4. 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. 3). The sample points are not measured simultaneously but one at a time (round robin technique).

  • Page 130: Option: Extra Io Module With 4 Channel 4-20 Ma

    USER MANUAL SWG100 16.5. 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 131: Option: Co Electrochemical Cell Measurement 0-2000Ppm/4000Ppm

    USER MANUAL SWG100 16.6. Option: CO electrochemical cell measurement 0- 2000ppm/4000ppm The H2S 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. The cut-off solenoid valve with air rising pump have the advantage, that the electrochemical sensor can be purge with ambient air, after the sensor has determined the sample gas.

  • Page 132: Option: Rs485 To Profi-Bus Converter

    USER MANUAL SWG100 16.7. Option: RS485 to Profi-Bus converter RS485 Profi-Bus converter Normally the analyser communication is Modbus RTU. If it is wanted, a RS485- Modbus/Profi-Bus converter can be installed at the DIN-rail. This hat-rail module will be explained in a separate manual.

  • Page 133: Option: Rs485 To Ethernet Converter

    USER MANUAL SWG100 16.8. Option: RS485 to Ethernet converter RS485 to Ethernet converter Normally the analyser 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 134: Option: Ndir-Bench 334 Mmm

    USER MANUAL SWG100 16.9. Option: NDIR-bench 334 mmm NDIR bench for 0-3.000ppm CO/0-20,00%CO2/0-3.000ppm CH4. NDIR bench for 0-1.000 to 30.000ppm CO/0-10 to 20,00% CO2/ 0-1.000 to 30.000ppm CH4. 134 / MRU GmbH, D-74172 Neckarsulm...
  • Page 135 USER MANUAL SWG100 ATTENTION Close door During the entire adjustment, the cabinet door must be closed. ATTENTION The PIN-Code is: F1 F3 F2 F2 UP - DOWN XTRAS DJUSTMENT MENU 1. Select the menu: and input the 6 symbols password.
  • Page 136 USER MANUAL SWG100 Mounting the adjustment gas cylinder: The pressure reducer must be set at max. 500 mbar. The adjustment gas cylinder remains closed. close P=0 bar XTRAS DJUSTMENT MENU 4. Open NDIR cuvette menu: Open the menu ADJUSTMENT . Here the values should now be close to zero. The...
  • Page 137 USER MANUAL SWG100 Preferences: Enter the set point from the gas adjustment cylinder into the menu (see 1). To do this, mark the lower set value and press the left and / or right arrow key (see 2). A blue window appears in which the target value can be entered (see 3).

  • Page 138: Configuration Of The Ethernetmodule

    USER MANUAL SWG100 16.10. Configuration of the ethernetmodule • The following screen will appear. Select Z-Key at the with 1 in screenshot). • Push t 138 / MRU GmbH, D-74172 Neckarsulm...
  • Page 139 USER MANUAL SWG100 The following screen appears. To test the communication pushes the -address, which is saved at the module will appear. Ethernetmodule with an USB- (3). A screen appears, allowing to set the TCP protocol. After a correct TCP...
  • Page 140 USER MANUAL SWG100 The settings will be written to the module. 140 / MRU GmbH, D-74172 Neckarsulm...
  • Page 141 5. The settings are saved at the module now. Adjustment of the SWG100 with the ethernetwork After the settings are configurated the analyser can be connected with the Ethernet. 1. Connect the Ethernet module with the network. For the connection use a LAN cable.
  • Page 142 USER MANUAL SWG100 F3=Modbus 2. Open the path Extras/General settings, at the analyser. 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 143 USER MANUAL SWG100 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). 143 / MRU GmbH, D-74172 Neckarsulm...
  • Page 144 USER MANUAL SWG100 • • The baudrate, data bits, parity and stop bits must be the same like at the SWG100. After the settin Connection the SWG100 with MRU4WIN 1. Open MRU4WIN. 3. Set the Modbus setting from Serial to TCP(2).
  • Page 145 5. The new created device can be found at the left side of the MRU4WIN screen. Activated it and start the logging. 16.11. 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 146 Connect the RS-485 converter with the Modbus connector at the main-pcb at the SWG100. A (+) B (-) • Open the menu: Extras/general infos at the SWG100. • the F2-key. • At this screen, the settings, for the SWG-100 can be set. The screen shot below shows an instance.
  • Page 147 The device will appear at the left side. For connection, press the connection symbol in the list. • The PC is now connected with the SWG100. To start a log, press the Start Logging button at the upper right side. 147 /...

  • Page 148: Declaration Of Conformity

    USER MANUAL SWG100 17. Declaration of conformity 148 / MRU GmbH, D-74172 Neckarsulm...

  • Page 149: Charts

    USER MANUAL SWG100 18. Charts 18.1. Gas flow chart Electrical diagram 149 / MRU GmbH, D-74172 Neckarsulm...
  • Page 150 USER MANUAL SWG100 150 / MRU GmbH, D-74172 Neckarsulm...
  • Page 151 USER MANUAL SWG100 151 / MRU GmbH, D-74172 Neckarsulm...
  • Page 152 USER MANUAL SWG100 152 / MRU GmbH, D-74172 Neckarsulm...
  • Page 153 USER MANUAL SWG100 153 / MRU GmbH, D-74172 Neckarsulm...
  • Page 154 USER MANUAL SWG100 154 / MRU GmbH, D-74172 Neckarsulm...
  • Page 155 USER MANUAL SWG100 155 / MRU GmbH, D-74172 Neckarsulm...
  • Page 156 USER MANUAL SWG100 156 / MRU GmbH, D-74172 Neckarsulm...
  • Page 157 USER MANUAL SWG100 157 / MRU GmbH, D-74172 Neckarsulm...
  • Page 158 USER MANUAL SWG100 V1.20.EN 158 / MRU GmbH, D-74172 Neckarsulm...

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