mru SWG100 BIOGAS User Manual
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mru SWG100 BIOGAS User Manual

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SWG100 BIOGAS
USER MANUAL
9512EN- BIO

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  • Page 1 SWG100 BIOGAS USER MANUAL 9512EN- BIO...
  • Page 2 USER MANUAL SWG100 Page 2 of 158...

  • Page 3: Table Of Contents

    1.6. Packing ........................ 13 1.7. Return of hazardous waste ................13 1.8. Return of analyzer .................... 13 1.9. MRU Warranty conditions ................13 Analyzer Description ....................15 2.1. Intended use ...................... 15 2.2. Type plate ......................15 2.3. Possible applications and analyzer options ..........17 2.4.
  • Page 4 USER MANUAL SWG100 7.11. Power-On of analyzer ..................81 Operating the analyzer ....................82 8.1. General process of the measurement cycle ..........82 8.2. Protective measures for electrochemical H2S sensors ......85 8.3. Data Storage Menu...................87 8.4. Extra menu: Overview ..................91 8.5. Update the firmware ..................101 Service and maintenance ..................
  • Page 5 Submit damage claim to MRU immediately. NOTE: Damage claims not received by MRU within 3 days of receipt of shipment will not be accepted. The products described in this manual are subject to continuous development and improvement and it is therefore acknowledged that this manual may contain errors or omissions.

  • Page 6: General Information

    1 General Information 1.1. Weather and environmental conditions The SWG100 BIOGAS 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 7 USER MANUAL SWG100 It is important that the filter-units, listed in chapter 9.1 of the operation manual, are checked regularly and, if necessary, service parts are changed. Page 7 of 158...

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

    USER MANUAL SWG100 NOTE In case of not intended use the guarantee will void. Regular controls, inspections and the exchange from polluted and exhausted filters by the operator are also an important part of the determinations “not determined use”- see chapter 9.1 regular maintenance work.
  • Page 9 USER MANUAL SWG100 • CO gas is heavier than air and therefore operator shall avoid working at underground levels. Beware of that CO is also odorless! • It is not allowed to use the biogas analyzer in confined space or rooms without forced ventilation.
  • Page 10 Power down the system and disconnect from mains to avoid access to live parts by using a tool. MRU GmbH assures that the analyzer complies to the essential requirements of the legal regulations of the member states of the electro-magnetic compatibility (89/336/EWG) and to the low-voltage regulations (3/23/EWG).
  • Page 11 USER MANUAL SWG100 Battery cell The analyzer contains battery cells at the following positions: • Main board (1). Follow steps must be aware: WARNING Switch off the power of the device Before removing the battery the device must be switched off. WARNING Educated staff It is recommended that only trained staff exchange the battery...
  • Page 12 USER MANUAL SWG100 WARNING Replacement of empty or damage cells If and when necessary, these cells must be replaced with identical new ones from the same manufacturer. If a cell to be replaced is connected with other cells in series, it is recommended that the other cells be replaced with new ones at the same time.

  • Page 13: Packing

    Packing regulation of 12.07.1991 If your local waste facility does not accept MRU packing materials for disposal, you may return it to MRU or our local sales representative. Packing materials returned to MRU must be returned prepaid. 1.7. Return of hazardous waste...
  • Page 14 USER MANUAL SWG100 Page 14 of 158...

  • Page 15: Analyzer Description

    USER MANUAL SWG100 2 Analyzer Description 2.1. Intended use The instrument is intended for analyzing the composition of biogases / landfill gases and determine the concentration of several components like CH4, CO2, O2 and H2S. The instrument may optionally be equipped to monitor several sites in time sharing technique (cyclical one by one sampling).
  • Page 16 USER MANUAL SWG100 CH4/CO2 NDIR-bench Thermal conductivity detector. Page 16 of 158...

  • Page 17: Possible Applications And Analyzer Options

    Converter module of RS485 into Profibus • Cabinet heater for freeze protection Ask our sales representatives for available options and accessories or check out our MRU website. 2.4. Principle of operation • Sample gas from one or more sampling points is fed into the analyzer by dedicated ports.
  • Page 18 USER MANUAL SWG100 Picture above: Sample gas flow diagram. The picture below shows how the analyser should be piped. A ball valve and a prefilter is recommended. Page 18 of 158...

  • Page 19: Special Functions Of The Analyzer

    USER MANUAL SWG100 2.5. Special functions of the analyzer H2Slow sensor protection (optional) The instrument may be optionally equipped with a H sensor. As this sensor typically shows limited life time when experiencing high H S concentrations, some precautions are taken to protect the sensor: •...

  • Page 20: Physical Characteristic Of The Gas Analyzer

    USER MANUAL SWG100 2.6. Physical characteristic of the gas analyzer Top view Front view Reference: 1. Gas inlet (default x1/optional max.10) 4. Suspension for wall mounting 2. Cabinet lock Page 20 of 158...
  • Page 21 USER MANUAL SWG100 3. Operation unit with display Right side view Left side view Bottom view Page 21 of 158...
  • Page 22 USER MANUAL SWG100 1. Fan filter 4. Zero gas inlet 7. Cable gland M16 for IO 2. Sample gas outlet (Vent) 5. Condensate outlet 3. Calibration gas inlet 6. Cable gland M16 for power supply Page 22 of 158...

  • Page 23: Scope Of Supply And Delivery

    USER MANUAL SWG100 3 Scope of supply and delivery Your analyzer is delivered in a carton box and is protected with special edge protectors. Please do preserve the packing of your analyzer, for possible return shipment. Inside the attachments box are different fittings: Quantity Description Position...

  • Page 24: Sd-Card Content

    USER MANUAL SWG100 3.1. SD-card content Following content are on the SD-Card: • Ethernet-Converter manual • Profibus-Converter manual • GSD-Files for profibus-converter • SWG100-Bio manual (EN/DE) • SWG100-Bio ModBus/Profibus specification (EN/DE) The SD-card can be found in the SD-card slot in the device (see sketch below).

  • Page 25: Installation Manual

    USER MANUAL SWG100 4 Installation manual 4.1. Overview This manual explains how to install the analyzer mechanically and electrically. Page 25 of 158...
  • Page 26 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 adjustment gas outlet Connect sample gas outlet Page 26 of 158...

  • Page 27: Select Measurement Point

    USER MANUAL SWG100 4.2. Select measurement point The measuring point should be in an area where the flow no longer has any particular turbulence. That is: • Not directly before or after a pipe elbow. The measuring point must be at least 3 times the chimney diameter from a bend.

  • Page 28: Installation Of The Analyzer

    USER MANUAL SWG100 4.3. Installation of the analyzer The analyzer is equipped with adapters for the wall mounting. The dimensions for the wall mounting are in the appendix. NOTE The suspensions can be rotated by 90°. NOTE Dimensions see appendix 11.2 Mechanical dimensions ATTENTION Operation of the analyzer Only operate the analyzer in an upright position.
  • Page 29 USER MANUAL SWG100 General installation rules • Mount the device on a solid wall or steel rack. • Be sure, that the air circulation is not obstructed. • Let enough room for the tubing or piping. 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.
  • Page 30 USER MANUAL SWG100 Calibration gas inlet Zero gas inlet Condensate outlet Page 30 of 158...
  • Page 31 USER MANUAL SWG100 Reference: 1. Fitting for sample gas inlet G1/8 2. Fitting for sample gas outlet G1/4 3. Fitting with flow restrictor orifice gas inlet G1/8 for calibration gas inlet 4. Fitting filter for zero gas inlet G1/8. 5. Fitting for condensate outlet Page 31 of 158...

  • Page 32: Installation: Sample Gas Outlet (Vent)

    USER MANUAL SWG100 4.4. Installation: Sample gas outlet (VENT) WARNING Risk of poisoning Exhaust gases endanger health and can even lead to death. The sample gas flows out of the gas outlet and out of the analyzer again after the analysis is completed.

  • Page 33: Installation: Calibration Gas / Zero Gas And Condensate Outlet

    USER MANUAL SWG100 4.5. Installation: Calibration gas / zero gas and condensate outlet WARNING High pressure! Gas cylinder stands under high pressure! Can cause injuries or death. Only educated staff should install the device. WARNING High pressure • Only educated staff is allowed to install the gas cylinders on the analyzer.

  • Page 34: Option: Autocalibration By Using Several Gas Cylinders

    USER MANUAL SWG100 4.6. Option: Autocalibration by using several gas cylinders WARNING High pressure! Gas cylinder stands under high pressure! Can cause injuries or death. Only educated staff should install the device. WARNING High pressure • Only educated staff is allowed to install the gas cylinders on the analyzer.

  • Page 35: Connection Of Main Power Supply

    USER MANUAL SWG100 4.7. Connection of main power supply WARNING Hazardous Live Power down the system and disconnect from mains to avoid access to live parts by using a tool. The analyzer needs a main power supply of 100-140 V~, 50/60 Hz, 300VA. The power supply may be found on the DIN-rail.
  • Page 36 USER MANUAL SWG100 Hint: PROTECTIVE CONDUCTOR TERMINAL - a) Contact surfaces are metal Conductor cross sections for main power supply and protective conductor, which can be used: Type of electric line Conductor cross section min.-max. Solid 1,0-2,5 mm² (17-13 AWG) Stranded 1,0-2,5 mm²...

  • Page 37: I/O Modules: Installation And Setting

    USER MANUAL SWG100 4.8. 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. • Reads one PT1000. •...
  • Page 38 USER MANUAL SWG100 analog output does not require power supply alarm relays Out1 and Out2 contacts are “fail safe” type:  open contact in case of alarm or power failure  closed contact for normal operation Plug connector definition: WARNING Electric voltage Power the system down and protect from reconnecting, before starting maintenance work.

  • Page 39: Operation Of The Analyzer (Hmi)

    5 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 • “air purging” or • “gas sampling” or • “measurement” Function key bar • F1 “sample point” •...
  • Page 40 USER MANUAL SWG100 Menu key: Will show all available functions in the window that is currently in use – also those which have an individual key on the key pad like the printer and the three function keys. Function Keys: Activates the functions seen on the display (2 function key bar) Page 40 of 158...

  • Page 41: Analyzer Commissioning Manual

    USER MANUAL SWG100 6 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 42: Configuration Of The Alarm Relays

    USER MANUAL SWG100 6.3. 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. Main board is offline (internal RS485 bus communication failure) Main board is in the “bootloader”...
  • Page 43 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 44: 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 RS485 (Modbus RTU) Plug connector definition for the system alarm relay Slit screws Stripping length: 7 mm...

  • Page 45: Autocalibration: Explanation Of The Software Operation

    USER MANUAL SWG100 Configuration at the analyzer Open the path XTRAS ENERAL ETTINGS Press F3 “Modbus”. The Modbus store settings will be open. The user can commission the slave’s settings. The following settings can be set: Baud rate. Slave address. Stop bits.
  • Page 46 USER MANUAL SWG100 NOTE Gas components In a SWG100BIO analyser the follow gas components can be set: H2S (ppm) CO2 (Vol.%) CH4 (Vol. %) O2 (Vol. %) With the user can set the gas concentrations for the different gas compositions. First select the gas component, then press OK.

  • Page 47: Binding To A Process Control System: I/O Modules

    USER MANUAL SWG100 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. An IO module has the following features: •...

  • Page 48: 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. Power supply for AO1+ transducer V12+ AO1- PT1000 PT1000 AO2+ PT1000 AO2- AO3+ Thermocouple AO3-...
  • Page 49 USER MANUAL SWG100 max. max. Internal Double Description Abbrevation external Load (for load (in occupancy Voltage outputs) inputs) max. AO1+ 500R max. AO1- 500R max. AO2+ 500R max. AO2- 500R max. AO3+ 500R max. AO3- 500R max. AO4+ 500R max. AO4- 500R AL1+...

  • Page 50: Analog Outputs 4-20 Ma

    USER MANUAL SWG100 7.3. 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. Reference: 1 Analog output 1 plus 2 Analog output 1 minus 3 Analog output 2 plus 4 Analog output 2 minus 5 Analog output 3 plus 6 Analog output 3 minus 7 Analog output 4 plus 8 Analog output 4 minus Information for connection:...
  • Page 51 USER MANUAL SWG100 Software-settings • Open the menu: (1). XTRAS NALOG OUTPUT CONFIGURATION • 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 52 USER MANUAL SWG100 • List of the installed analog output ports (1): At this list the operator can select, which analog-output should be configured. To select an analog-output, move the up/down arrow keys. • Details (2): Here the operator can open the configuration screen for the selected output port.
  • Page 53 USER MANUAL SWG100 Reference: Section (1): Shows the operator, which analog-output will be changed. Sample point (2): The operator can select the sample point. This means, that the analog-output signal from the choose sample point will be transmitted to the process control system. Meas.
  • Page 54 USER MANUAL SWG100 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 55 USER MANUAL SWG100 arrow keys and OK • In the last step the menu must be closed. Confirm the store message. The 4-20 mA output is now configuring. Page 55 of 158...

  • Page 56: 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. Reference: 1 Alarm Relay + 1 Alarm Relay - 2 Alarm Relay + 2 Alarm Relay - Information for connection: Conductor cross section:...
  • Page 57 USER MANUAL SWG100 Software-side • Open the menu: (1). XTRAS NALOG OUTPUT CONFIGURATION • 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 58 USER MANUAL SWG100 • List of the installed alarmoutput ports (1): At this list the operator can select, which alarm output should be configured. • Details (2): Here the operator can open the configuration screen for the selected alarm output. To open the details-menu, push or OK.
  • Page 59 USER MANUAL SWG100 Reference: Section (1): Shows the operator, which alarm-output will be change. Sample point (2): The operator can select the sample point. This means, that the alarm-output signal from the choose sample point will be transmitted to the process control system. Meas.
  • Page 60 USER MANUAL SWG100 Beeper Relays: Normally open Electric consumer: max. 1 • 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: .

  • Page 61: 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. The IO module has a separate 12 V power source, for the supply of the transducer.
  • Page 62 USER MANUAL SWG100 Transducer Load: 50 Ohm Power supply for transducer 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 63 USER MANUAL SWG100 The structure of the menu “AUX input details”, for the channel “definable” is given at the screenshot below. Reference: Show the operator, which analog-input will be changed. The operator can select the sample point. This means, that the analog- output signal from the choose sample point will be transmitted to the process control system.
  • Page 64 USER MANUAL SWG100 Here the operator entering the equivalent measurement value, for a current of 4 mA. Here the operator entering the equivalent measurement value, for a current of 20 mA. The IO module will create the linear relation. Leave the menu. Alternate push F2. Example: Read 4-20 mA signal from an external temperature sensor An operator wants to read an external temperature sensor signal inside a SWG100.
  • Page 65 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 F1. •...

  • Page 66: 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 67 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 68 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 Analyzer is sampling the point SP1 (*1, *2) Analyzer is sampling the point SP2 (*1, *2)
  • Page 69 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 70 USER MANUAL SWG100 Status of Status external signal Description number source I [mA] Remote reset of all system alarms Analyzer is “stand-by” (*3) Page 70 of 158...
  • Page 71 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 72 USER MANUAL SWG100 Case 1: Stand-by The Stand-by modus will be activated if the input state is higher than the number of sample points (example: 4 sample points and input state 5…15). The Stand-by 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 73: Analyser States

    USER MANUAL SWG100 7.7. 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: mA-Signal Function...

  • Page 74: Cycle Configuration

    USER MANUAL SWG100 7.8. Cycle configuration Path and default setting XTRA EASUREMENT CYCLE CONFIG When the menu is selected the user definable setting for the “M .” EASUREMENT CYCLE CONFIG measurement cycle will appear (see screenshot below). Screenshot shows default setting, when the will be started the first „M .”...
  • Page 75 USER MANUAL SWG100 The second program is for applications where the different measurement points have different gas concentrations. A zeroing is recommended after every measurement point change. The screenshots below show the “One zeroing / cycle” and “One zeroing / sample point” in comparison.
  • Page 76 USER MANUAL SWG100 Configuration of the phase details In this chapter the different cycle phase details will be explained. Zeroing (Cycle phase details): In the cycle phase detail “ ” the zeroing time can be EROING configured. ZEROING Measuring site valves Valves closed Zeroing valve Valve open...
  • Page 77 USER MANUAL SWG100 • Phase duration: Entire Stand-by time (Purging time + Quiet time = Phase time). • Purging time: The time, to purge the analyser with ambient air, through the zero gas inlet. • Quiet time: The time, where the analyser is in the pure stand-by mode. STAND-BY Measuring site valves Valves closed...
  • Page 78 USER MANUAL SWG100 Activated/deactivated a phase The user has the opportunity to deactivate a phase in the measurement configuration cycle. This could be necessary for example if a sample point is temporarily not in use. The activation and deactivation of a phase can be done in the cycle phase details of the concerning phase.
  • Page 79 USER MANUAL SWG100 Following points must be done to configure the individual measurement cycle: 1. Open the measurement cycle config. menu: Path: XTRA MEASUREMENT CYCLE CONFIG 2. The default measurement cycle will appear. Open the cycle phase detail of the first zeroing and adjust the phase duration at 25 min. F1/F3 3.
  • Page 80 USER MANUAL SWG100 6. Switch to the next point and select with the left/right arrow key measurement SP1. Go in the cycle phase detail of the measurement SP1. Here adjust the duration-phase 10 min. and the pure measurement time: 5 min. F1/F3 F1/F3 7.

  • Page 81: Administrator Pin Code

    USER MANUAL SWG100 7.10. Administrator PIN code All functions and menus which may disturb the analyzer's normal measurement can be protected against unauthorized access by activating the administrator PIN code request. We highly recommend activating this function, when unauthorized persons could access the analyzer.

  • Page 82: Operating The Analyzer

    USER MANUAL SWG100 8 Operating the analyzer This chapter has the follow structure: • In the first part it will be explained, how to start the analyzer and the self-test menu. • Part three shows the submenu, which are listed at the EXTRA menu. •...
  • Page 83 USER MANUAL SWG100 • the gas pump is switched off • all analog outputs will deliver 2mA • all alarm outputs will have alarm status (open contacts) Usually the self-test will be left automatically as soon as all conditions for measurement are satisfied.
  • Page 84 USER MANUAL SWG100 Change sampling point displayed For analyzers with several measuring points can used the arrow keys up / down the displayed (not measured) measuring point can be changed. In this way you can get an overview very quickly over the last measured values for all points.

  • Page 85: Protective Measures For Electrochemical H2S Sensors

    USER MANUAL SWG100 8.2. Protective measures for electrochemical H2S sensors The analyser measures H2S according to the electronic measuring principle. These are measuring cells that trigger an electrochemical reaction when they come into contact with the target gas. The cells are consumed over time and must therefore be replaced approximately every 2 years.
  • Page 86 USER MANUAL SWG100 Setting: Flushing when changing the measuring point Since the H2S accumulates in the measuring lines, it can be useful to flush the lines when changing the measuring point. A flushing phase can be set in the configuration measuring cycle menu, which is intended specifically for flushing the H2S sensors.

  • Page 87: Data Storage Menu

    USER MANUAL SWG100 8.3. Data Storage Menu 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. NOTE DATA STORAGE The analyzer makes use of an internal flash memory to store measurement values automatically.
  • Page 88 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 89 USER MANUAL SWG100 When entering the menu the measurements of the last 24 hours will be displayed. This interval can be changed by pressing the keys F1=more or F3='less'. 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).
  • Page 90 USER MANUAL SWG100 3. It appears a list of all configured csv-datas. With the keys F1, F2 and F3 the user can navigate through the configuration-menu. The single keys mean: • F1=insert: Insert an entry below the cursor-position. • F2=move: Move the entry from the cursor-position to another one.

  • Page 91: Extra Menu: Overview

    USER MANUAL SWG100 8.4. 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 General settings Path: XTRA ENERAL SETTINGS Structure: Device info: Extra / General settings LCD brightness 10% until 100% / default 60% / 5%...
  • Page 92 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 l/h Measurement cycle config.
  • Page 93 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 (see Averaging in this Adjustment CH4 pellistor (see service manual) Hardware state &...
  • Page 94 USER MANUAL SWG100 Hardware state & tests: Hardware Settings Gas pump ON or OFF Purge pump (optional) ON or OFF Solenoid valve H2S low (optional) ON or OFF Solenoid valve zero gas ON or OFF Solenoid valve cal. Gas ON or OFF Solenoid valve sample points able to skip to the next one...
  • Page 95 USER MANUAL SWG100 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 95 of 158...
  • Page 96 USER MANUAL SWG100 2. Open “averaging” with the F1-key. 3. Configuration of averaging time: In this menu is able to set the averaging left/ right arrow keys time with the and the keys. The fast averaging time : 20 s The smooth averaging time : 240 s NOTE...
  • Page 97 USER MANUAL SWG100 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 [ % ] less than O2 [ % ] more than H2S [ ppm ] 1000...
  • Page 98 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 99 USER MANUAL SWG100 Device info Path: XTRAS EVICE INFO Structure: Main device info Device info: Extra / Device info Main device info detail Sub systems info MAINBOARD Sub systems info NDIR bench Sub systems info I/O module 1-max. Device details MAINBOARD Device details NDIR bench Device details I/O module 1-max.
  • Page 100 USER MANUAL SWG100 Power-Down of analyzer Before the analyzer is disconnected from mains, it should be prepared for the Power-Down, because • operational data should be stored • eventually changed user settings should be stored • the sensors should be purged with fresh air Press the key in any menu in order to prepare the analyzer for the Power-Down.

  • Page 101: Update The Firmware

    USER MANUAL SWG100 • insert an SD card containing the backup file 'settings.usr' • press the menu key and select the function 'Import user settings' The analyzer will replace the current settings by the settings from the backup file. 8.5. Update the firmware The analyzer and different installed options can be updated if it is necessary.
  • Page 102 USER MANUAL SWG100 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- 3.
  • Page 103 USER MANUAL SWG100 F3 = sub.syst. to open the menu “ 2. Press ”. UB SYSTEMS INFO F2 = details, to open the details from the NDIR bench. Be sure, 3. Press that the device is “NDIR bench” to update the NDIR-bench. 4.

  • Page 105: 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.-) MRU recommends a regular bi-annual maintenance at a minimum, which must carry by a qualified technician.

  • Page 106: Position And Overview Of The Service-Parts

    USER MANUAL SWG100 In the follow chapters there will be introduced some service parts, which are important for the reliable operation. These parts are independent from the regular checks and must be replaced in a minimum interval of minimum 6 months.
  • Page 107 USER MANUAL SWG100 Content of the service-set (offer-number: 66174) Single components can be offered under their article number directly. Image name Interval Quantit Offer- number Acid-gas filter New state: purple beads Used: white beads 2 pieces 56795 Life time: 2-6 month, dependent of gas concentrations.
  • Page 108 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. Mounting direction: Irrelevant Steps: 1. Remove exhausted acid gas filter from the clips.
  • Page 109 USER MANUAL SWG100 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. Required tools: needle-nose pliers.
  • Page 110 USER MANUAL SWG100 Plug the viton tubes on the filter unit. Push the filter unit on the clip. Page 110 of 158...
  • Page 111 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 too low. Mounting direction: Irrelevant Steps: Pull the exhausted filter-unit from the viton tube and exchange it with a new one.
  • Page 112 USER MANUAL SWG100 Position 6: Filter mats (#60320) Required materials: 2x filter mats (#60320) contained in the service-set. Exchange interval: Exchange necessary, when the fan speed is reduced. Steps: Open the filter-unit by pulling the blue lash. Replace the exhausted filter mat through a new one.

  • Page 113: Cleaning And Decontamination

    USER MANUAL SWG100 9.4. Cleaning and decontamination Outside of the Device: • Clean the Device with a damp cloth. • Avoid aggressive cleaning agents, as these can damage the surface. Inside the Device: • Power down the system before cleaning the inside. •...

  • Page 114: Technical Specification

    USER MANUAL SWG100 10 Technical specification Allgemein General Deutsch Angabe English Betriebstemperatur(ohne +5°C ... +45 °C / 41 °F Operating temperature (w/o Frostschutzheizung) ... 113 °F heating) Betriebstemperatur (mit optionaler -10 °C ... +45°C / 14 °F Operating temperature (with Frostschutzheizung) ...
  • Page 115 USER MANUAL SWG100 Schnittstellen Interfaces Deutsch Angabe English Benutzerschittstelle Angabe User Interface Anzeigetyp 3,5TFT Display type Anzahl gleichzeitig Number of siultaneously angezeigter Messwerte displayed values Tastatur mit Anzahl Tasten Keyboard with qty of keys Elektrische Aus- /Eingänge Electrical I/O Serielle Schnittstelle RS485 Serial interface Protokoll...
  • Page 116 USER MANUAL SWG100 Gehäuseverschraubung Messgaseingang G1/8 Screw joint sampling point Gasausgang G1/8 gas output Frischluft (für Nullpunktnahme) G1/8 Fresh air (for zeroing) Kalibriergas optional, G1/8 Calibration gas Page 116 of 158...

  • Page 117: Technical Specification: Electrochemical Sensors

    USER MANUAL SWG100 10.1. Technical specification: Electrochemical sensors Angaben zur Deutsch Messgenauigkeit English Elektrochemischer Sensor O2 Long Life Electrochemical Sensor Messbereich 0 .. 21 % Measuring Range Auflösung 0,01 % Resolution Genauigkeit abs. ± 0,2 Vol% Abs. Accuracy Ansprechzeit T90 <...

  • Page 118: Technical Specification: Ndir-Benches

    USER MANUAL SWG100 <15% (501…2500 ppm) Ansprechzeit T90 < 35s Response Time T90 Jahre erwartete Lebensdauer an Luft Years expected lifetime (@air) (abhängig von (Depending on chosen gewähltem Sensor) sensor) Elektrochemischer Sensor CO/4000 Electrochemical Sensor Messbereich 0-4000 ppm Measuring Range Auflösung 1 ppm Resolution...

  • Page 119: Appendix

    USER MANUAL SWG100 11 APPENDIX 11.1. Spare parts list Article Description – Serial number Gas cooler - #60467HT Required to dry the sample gas Condensate pump - #11230 Required to drain the condensate Sample gas pump - #65032 Used for sample gas pumping H2S solenoid valve - #65470 Required for cut-off sample gas supply to sensor.
  • Page 120 USER MANUAL SWG100 Power supply - #65325 Only for use in hazardous area Zone 2 Axial fan - #65097 For ventilation of analyzer cabinet Solenoid valve - #65470 Used for sampling point switching. CxHy gas detector - #65469 Required for monitoring the CH4 concentration inside analyzer cabinet Heater - #65425 Used for freeze protection of analyzer...
  • Page 121 USER MANUAL SWG100 I/O-Module #65179 + #65430 Used for analog output data transfer and sample point switching. I/O Module - #65179 Used for analog output data transfer Heater #65734 Used for freeze protection of analyzer cabinet installed in safe area Page 121 of 158...

  • Page 122: Mechanical Dimensions

    USER MANUAL SWG100 11.2. Mechanical dimensions Page 122 of 158...

  • Page 123: Purchase Options Of The Analyzer

    USER MANUAL SWG100 12 Purchase options of the analyzer In this chapter the different available options are explained. The chapter shows: • The place of the options in the analyzer. • The characteristic of the options. • How to install the option if it is necessary. 12.1.

  • Page 124: Option: Cabinet Heater

    USER MANUAL SWG100 The gas cooler-unit is equipped with a peltier-element. It is for drying the gas feed of a dew point of 5°C. it is recommended to use this option if the gas feed from the biogas has a high moisture content. This option must be purchased separate, because it is not contain in the basic version.

  • Page 125: Option: Flame Arrester

    USER MANUAL SWG100 12.3. Option: Flame arrester Page 125 of 158...
  • Page 126 USER MANUAL SWG100 It can be necessary to install separate flame arresters at the sample gas inlets. The flame arrester, which can be purchase by MRU, has permission for ATEX areas zone 2 (DIN EN ISO 16852). Page 126 of 158...

  • Page 127: Option: Multiple Sample Point Switching And Monitoring (Time Sharing)

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

  • Page 128: Option: Gas Detector (%Lel Ch4) To Monitor Air Inside Analyzer Cabinet

    USER MANUAL SWG100 12.5. Option: Gas detector (%LEL CH4) to monitor air inside analyzer cabinet With this option the CH4 concentration inside the analyser can be determined and monitored. This menu is only installed, if the gas detector is installed. Page 128 of 158...
  • Page 129 USER MANUAL SWG Konfiguration • Power the system down. • Unscrew the security screw on the exhausted LEL (low explosive level - combustible gases) sensor from inside cabinet (see sketch below.) Reference: 1. LEL gas detector. • Remove the exhausted LEL sensor from the pcb main board and replace it with a new one.
  • Page 130 Set the span point: To calibrate the span point, a calibration gas cylinder and a special calibration cap is needed. MRU recommends a calibration bottle with a CH4 concentration between 2-4 % in synthetic air. The concentration chart shows the CH4- concentration and the equivalent LEL concentrations.
  • Page 131 USER MANUAL SWG Figure: Installation of the calibration cap with a pressure gas can. • Wait until the gas concentration in the menu is steady. Change the factor until the gas concentration in the display is equal to the calibration gas bottle concentration.

  • Page 132: Option: Extra Io Module With 4 Channel 4-20 Ma

    USER MANUAL SWG100 12.6. Option: Extra IO module with 4 channel 4-20 mA The analyser is by default equipped with one IO module (see market above). It can be offered with a different number of IO modules (max.10). Every single installed IO module can be driven independent from each other. The different IO modules can be set in the menu “”...

  • Page 133: Option: H2S Electrochemical Cell Measurement 0-2000Ppm/4000Ppm

    USER MANUAL SWG 12.7. Option: H2S electrochemical cell measurement 0-2000ppm/4000ppm The H S electrochemical sensor is offered with two different functions: • Without cut-off solenoid valve and air purge pump. • With cut-off solenoid valve and air rising pump. 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 134: Option: Rs485 Profi-Bus Converter

    USER MANUAL SWG100 12.8. Option: RS485 Profi-Bus converter RS485 Profi-Bus converter Normally the analyzer communication is Modbus RTU. If it is wanted, a RS485-Modbus/ Profibus converter can be installed at the DIN-rail. This hat- rail module will be explained in a separate manual. Page 134 of 158...

  • Page 135: Option: Rs485 To Ethernet Converter

    MRU GmbH SWG 100 User Manual 12.9. Option: RS485 to Ethernet converter RS485 to Ethernet converter Normally the analyzer communication is Modbus RTU. If it is wanted, a RS485- Modbus/Ethernet Bus converter can be installed at the DIN-rail. This hat-rail module will be explained in a separate manual.

  • Page 136: Configuration Of The Ethernet Module

    USER MANUAL SWG100 12.10. Configuration of the Ethernet module 1. Start the software “Easy setup”. • The following screen will appear. Select Z-Key at the register called “Products in alphabetical order” (market with 1 in screenshot). • Push the “Start” key (market with 2 in screenshot). Page 136 of 158...
  • Page 137 MRU GmbH SWG 100 User Manual Page 137 of 158...
  • Page 138 USER MANUAL SWG100 The following screen appears. To test the communication pushes the key “Test” (1). The current IP-address, which is saved at the module will appear. 3. Get back in the menu and push the key “Setup” (2). Connect the Ethernetmodule with an USB-port of a pc.
  • Page 139 MRU GmbH SWG 100 User Manual ATTENTION . It can happen that the following message will appear: Just confirm the message and test, whether the settings are set. Normally the message can be ignored. 5. The settings are saved at the module now.
  • Page 140 USER MANUAL SWG100 2. Open the path Extras/General settings, at the analyzer. Push F3=Modbus. 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. 3.
  • Page 141 MRU GmbH SWG 100 User Manual 6. Push “Setup”. A list with the actual adjustments will be appeared. At this protocol the following adjustments must be set: 6. Working mode: MODBUS BRIDGE ON PORT#2 (1). 7. Baudrate (2): 8. Data Bits (2).
  • Page 142 Here the type of the device must be set. Example: It is the Ethernetmodule assembled at a SWG100 Biogas, this device must be set. 4. In the menu the following points must be set: Page 142 of 158...
  • Page 143 MRU GmbH SWG 100 User Manual • IP-Address • Port number • Device • Slave-ID The slave ID can be found at the modbus settings (see screenshot). The port number (called Port at the setting) can be found at the Ethernet protocol (see chapter 1.1 point 6).

  • Page 144: Option: Ndir-Bench For Ch4/Co2 Analysis, 0-100% / 0-100

    USER MANUAL SWG100 12.11. Option: NDIR-bench for CH4/CO2 analysis, 0-100% / 0-100% This NDIR-bench is for biogas at AD plants. It detects CH and CO percent range. Page 144 of 158...
  • Page 145 MRU GmbH SWG 100 User Manual This chapter shows, how to adjust the different type of NDIR-benches. The procedure is for all kind of NDIR-benches the same. ATTENTION Close door During the entire adjustment, the cabinet door must be closed.
  • Page 146 USER MANUAL SWG100 Page 146 of 158...
  • Page 147 MRU GmbH SWG 100 User Manual Mounting the adjustment gas cylinder: The pressure reducer must be set at max. 500 mbar. The adjustment gas cylinder remains closed. WARNING High pressure! Gas cylinder stands under high pressure! Can cause injuries or death.
  • Page 148 USER MANUAL SWG100 3. Upper set point, with set gas cylinder value and factor 4. Manual execution of the zero point 5. Reset to standard adjustment. 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).
  • Page 149 MRU GmbH SWG 100 User Manual Set a new adjustment factor: Finally, pressing the OK key sets the new adjustment factor. This must be done for CH4 and for CO2. During the whole adjustment procedure, only the lower setpoint value is changed. The upper set point remains unchanged. This is only adjusted if the accuracy in the 100 % range is to be improved.

  • Page 150: Option: H2 Thermal Conductivity Detector Measurement

    USER MANUAL SWG100 12.12. Option: H2 thermal conductivity detector measurement 0-100% It can equip the analyzer with a H thermal conductivity detector, with a measurement range from 0-100%. Page 150 of 158...

  • Page 151: Option: Ndir-Bench For 0-3.000Ppm Co2/0-3.000

    MRU GmbH SWG 100 User Manual 12.13. Option: NDIR-bench for 0-3.000ppm CO2/0-3.000…30.000ppm CH4 Page 151 of 158...

  • Page 152: Option: Dilution-Unit For H2S And Co Electrochemical Sensors

    USER MANUAL SWG100 12.14. Option: Dilution-unit for H2S and CO electrochemical sensors Page 152 of 158...
  • Page 153 Tubing of all sample gas inlets See chapter 5.2. Installation of the calibration gas cylinder See chapter 7.11. For the calibration of the dilution-unit, MRU recommends a gas cylinder with a min. concentration of 500 ppm, from the target gas. Page 153 of 158...
  • Page 154 USER MANUAL SWG100 Fine calibration of the dilution-unit 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. 1. Installation of the calibration gas cylinder (gas cylinder for the undilute calibration).
  • Page 155 MRU GmbH SWG 100 User Manual Dilution factor (1): Means the dilution ratio. For example: the value 50 means a ratio from 1:50. Hence, 10,000 ppm pure H2S, for example, will dilute to 200 ppm. The mathematical basic formula is:...
  • Page 156 USER MANUAL SWG100 • Threshold: The operator can change the threshold. If the value is above this threshold, the dilution will turn on. • The path for this setting is: XTRAS EASUREMENT CONFIGURATION • Marked the setting “threshold” with the cursor. With the left/right arrow keys the value can be changed.
  • Page 157 MRU GmbH SWG 100 User Manual To change the dilution setting follow steps must be done: Open the path: • XTRAS EASUREMENT CYCLE CONFIG • Open the measurement phase, from the sample-point, which should be set. • Press the OK key, to turn into the detail menu of the measurement phase.

  • Page 158: Declaration Of Conformity

    USER MANUAL SWG100 13 Declaration of conformity V3.30 Page 158 of 158...

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