madur electronics maMoS 100 User manual

STATIONARY GAS ANALYSER
Manual
Version: 8.8
09/2011
PC 10.5.0
m mos 10.3.6

www.madur.com Manual maMoS100/200/300/400
Contents
1. Introduction....................................................................................................................4
2. Package content............................................................................................................5
3. Monitor construction.....................................................................................................6
3.1. Casing.....................................................................................................................7
3.2. Gas channel............................................................................................................9
3.2.1. Gas dryer with filter......................................................................................10
3.2.2. Peristaltic um ............................................................................................11
3.2.3. Solenoid valve...............................................................................................12
3.2.4. Gas um ......................................................................................................12
3.2.5. Gas sensors..................................................................................................12
3.3. Electric connectors of the monitor....................................................................13
3.3.1. Digital in uts.................................................................................................13
3.3.2. Analogue out uts.........................................................................................14
3.3.3. Digital out ut (PWM)....................................................................................15
3.3.4. Relay out uts (o tional)...............................................................................16
3.4. Monitor ower su ly..........................................................................................17
3.5. Configuration ossibilities..................................................................................18
3.5.1. Ty es of the measured gases.....................................................................18
3.5.2. Additional and o tional equi ment............................................................19
4. Monitor installation.....................................................................................................20
4.1. Connecting the monitor.......................................................................................21
4.1.1. Connecting the electric wires......................................................................21
4.1.2. Connecting the gas hoses...........................................................................24
4.2. First start-u .........................................................................................................27
5. O eration......................................................................................................................27
5.1. Basic o eration....................................................................................................27
5.2. Monitor function...................................................................................................28
5.2.1. Cyclic work mode.........................................................................................28
5.2.2. Scheduled work mode..................................................................................30
5.3. Communication with monitor.............................................................................31
5.3.1. Monitor network (RS485).............................................................................32
5.3.2. Communication via USB ort......................................................................33
5.3.3. Communication via Ethernet.......................................................................37
5.4. MMC module. .......................................................................................................41
5.4.1. Possible flashing sequences of the MMC control diode lam ................44
5.4.2. Formatting SD / MMC card in FAT-16 file system.....................................44
5.5. U dating the monitor's firmware........................................................................45
5.5.1. The rocedure of u dating firmware..........................................................45
5.6. Flow velocity measurement................................................................................49
5.7. Re lacing the dryer filter.....................................................................................51
5.7.1. Re lacing the filter in MD2 dryer................................................................51
5.7.2. Re lacing the filter in MD3 dryer................................................................53
5.8. Re lacing the head of the eristaltic um ......................................................54
6. Presenting the results.................................................................................................54
6.1. Calculating the results.........................................................................................55
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6.2. Dis lays' work modes..........................................................................................55
7. Software used for o erating the monitor..................................................................57
7.1. Installation............................................................................................................57
7.2. O erating the MaMoSII.exe rogram.................................................................58
7.3. The functions of the MaMoSII.exe rogram......................................................59
7.3.1. Reconnect (restart transmission)...............................................................59
7.3.2. Program settings..........................................................................................60
7.3.3. Main settings.................................................................................................62
7.3.3.1. Calculations of the results.....................................................................63
7.3.3.1.1. Calculations of CO2.........................................................................63
7.3.3.1.2. Calculations of NOX........................................................................63
7.3.3.1.3. Fuel arameters...............................................................................64
7.3.3.1.4. Calculations of mg/m3....................................................................66
7.3.3.2. Stabilisation of internal tem erature....................................................67
7.3.3.3. Gas um .................................................................................................68
7.3.3.4. Results storage (SD card)......................................................................69
7.3.3.5. Dis lays....................................................................................................70
7.3.3.6. Results.....................................................................................................72
7.3.4. Results...........................................................................................................72
7.3.5. Memory card..................................................................................................74
7.3.5.1. Re ort's data ..........................................................................................75
7.3.5.2. Chart.........................................................................................................76
7.3.5.3. Columns...................................................................................................77
7.3.6. Memory card → Re ort settings.................................................................77
7.3.7. Dis lays.........................................................................................................78
7.3.8. Work cycles...................................................................................................79
7.3.8.1. Work mode...............................................................................................79
7.3.8.2. Duration of cycle's hases.....................................................................80
7.3.8.3. Scheduler.................................................................................................82
7.3.8.4. Gra hic section.......................................................................................82
7.3.8.5. In ut IN1 / IN2..........................................................................................83
7.3.9. Analogue out uts.........................................................................................83
7.3.9.1. Setting the voltage out uts....................................................................84
7.3.9.2. Setting the current out uts....................................................................85
7.3.9.3. Analogue out uts behaviour.................................................................87
7.3.10. Relays..........................................................................................................88
7.3.10.1. Out uts' settings...................................................................................89
7.3.11. 1- oint calibration for maMoS II monitor.................................................92
7.3.11.1. IR sensor calibration............................................................................93
7.3.11.2. Electrochemical sensor calibration....................................................94
7.3.12. Service mode...............................................................................................95
7.3.13. About the rogram.....................................................................................95
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www.madur.com Manual maMoS100/200/300/400
1. INTRODUCTION
maMoS is high qu lity g s monitor. The device is produced using the l test
technology. Due to the modul r design of maMoS it is possible to meet the individu l cli-
ent's expect tions by djusting it to performing p rticul r me surements, such s concen -
tr tion of v rious g ses, pressure, temper ture nd number of boiler p r meter me s-
urements.
The monitor is in p rticul r designed for flue (boiler) g s n lysis, but it c n be
used for different purposes (such s producing biog s from g rb ge nd nim l excre-
ments) s well.
E ch maMoS monitor, ccording to its configur tion, en bles the user to me sure
concentr tions of one or more g ses. Addition lly the device c n present the me sure-
ment results on the liquid cryst l displ ys nd up to eight n logue outputs. Independently
of the built-in me surement equipment there is lso the possibility of re ding the me sure-
ment results nd ch nging the settings with the help of the computer progr m provided.
It is worthwhile devoting some time to re ding this m nu l. This will help the users
f mili rise themselves with the device nd its oper tion. Proper oper tion will ssure the
f ilure-free working of the device.
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2. PACKAGE CONTENT
Along with the monitor the following elements re enclosed in the p ck ge:
Picture 1. The CD containing the software used for o erating the monitor
Picture 2. Communication cable between PC com uter and the analyser
Picture 3. 4 screws used for mounting the analyser on the wall
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3. MONITOR CONSTRUCTION
The maMoS monitor h s been constructed s modul r device which ssures
the user of the possibility of cre ting ny desired configur tion.
On request the maMoS monitor c n be constructed of ny of the v il ble mod-
ules. The possibilities for the device re described in ch pter 3.5.
Picture 4. Complete maMoS 400 gas monitor with the MD2 gas dryer and with o tional ower
su ly unit.
Picture 5. Complete maMoS 400 gas monitor with the MD2 gas dryer
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There re four different types of maMoS monitors:
−maMoS100 – the monitor is equipped with single displ y (displ y #1).
−maMoS200 – equipped with two displ ys (displ y #1, displ y #2).
−maMoS300 – equipped with three displ ys (displ y #1, displ y #2, display
#3)
−maMoS400 – equipped with four displ ys (displ y #1, displ y #2, display #3,
display #4).
The number of the device's displ ys does not refer to the number of the sensors
which h ve been inst lled in the monitor s, besides displ ying the me surement results,
the monitor c n lso present the results of ddition l c lcul tions (such s st ck loss nd
boiler efficiency).
The following ch pters describe the elements forming e ch of the monitors.
3.1. Casing
The n lyser with the g s dryer nd option lly with the power supply unit is moun-
ted on one mounting pl te. The n lyser itself is inst lled in ROBUST 240 c sing (dimen-
sions: 240 x 360 x 120 mm). In the front of the n lyser there re: displ ys (th t show the
results from the g s sensors, temper ture, pressure sensors nd others), red diode th t in-
dic tes the work of the n lyser (inst lled over the displ ys) nd the key th t protects
g inst un uthorised turning on / off of the n lyser. Addition lly, s n option, the n lys-
er c n be equipped with d t -logger, th t llows to store the results of the me sure -
ments on MMC c rd. Afterw rds the results c n be viewed on PC computer.
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Picture 6. mamos front anel
Picture 7. Casing – bottom view
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3.2. Gas channel
Picture 8. The schematic diagram of the gas channel.
L bels used in the di gr m:
The ddition l g s ch nnel h s been fr med with violet.
V1 – ventil tion v lve of the m in ch nnel.
V2 – ventil tion v lve of the ddition l ch nnel.
P1 – g s pump.
P2 – g s pump ventil ting the ddition l ch nnel.
S1...Sn – g s sensors of the m in ch nnel.
S+ – g s sensor of the ddition l ch nnel.
F – Hydrophobic filter.
The elements in the direct cont ct with the ex mined g s cre te the g s system.
At first the g s s mple p sses through the dryer, where it is cooled (in order th t the w ter
v pour condenses) nd filtered. Afterw rds, the s mple is p ssed through the 3-w y
solenoid v lve nd the pump to e ch of the g s sensors for n lysis.
The maMoS n lysers c n be option lly equipped with n ddition l g s ch nnel.
In such c ses the g s s mple is p ssed to the sep r te sensor (or sensors) through the
ddition l ventil tion v lve. The sep r te outlet h s been inst lled in the ddition l g s
ch nnel not to disturb the me surement process performed in the m in ch nnel. As res-
ult the g s s mple c n be supplied to the sep r te sensor only when the concentr tion
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v lue is me sured – p rt from th t throughout the me surement cycle the sensor is vent-
il ted with the inert g s with use of n ddition l ventil tion pump. Independently of the d-
dition l ch nnel the sensors in the m in g s ch nnel re continu lly supplied with the g s
s mple (during the “MEASUREMENTS” st ge). This option c n be found p rticul rly use-
ful in c se H2S (hydrogen sulphide) sensor is used – these re very sensitive nd we r
out f st. Th nks to such solution they c n be sep r ted from the m in ch nnel, supplied
with g s only when the me surement h s to be performed nd ventil ted while the other
sensors perform the me surement process. It extends their lifetime, nd s result de-
cre ses the n lyser's m inten nce cost.
3.2.1. Gas dryer with filter
The g s dryer is inst lled on the outside of the monitor c sing on the b ckpl te of the
device. Its m in t sk is to remove moisture from the ex mined g s s mple. The dryer uses
Peltier element to cool the flue g ses to pproxim tely 12°C nd to condense the w ter
out of the g s s mple. The condensed w ter g thers in the tr nsp rent cont iner from
where it is pumped by me ns of the perist ltic pump. Moreover, the dryer is equipped with
repl ce ble inlet filter which removes the dirt from the g s s mple (Picture 9.).
Picture 9. mamos MD2 gas dryer
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Picture 10. mamos MD3R/S gas dryer
3.2.2. Peristaltic pump
A perist ltic pump is used to remove the condens te g thered in the dryer cont in-
er. The pump is inst lled on the right side of the c sing (Picture 11.). The pump's he d is
pl ced outside the c sing (or in the front of the MD3 g s dryer) to ensure e sy repl ce-
ment of pump's tubings nd he d.
The condens te is removed from the dryer cont iner nd tr nsported through the
el stic hose to the pump, which pumps it further to the ppropri te cont iner.
Picture 11. Peristaltic um head (casing right side)
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3.2.3. Solenoid valve
The monitor is equipped with three-w y solenoid v lve to m ke periodic l ventil-
tion of the device possible. The ventil tion process h s to be performed in order to zero
the sensors. During ventil tion the v lve cuts the g s inlet off nd the free ir is let in.
3.2.4. Gas pump
To gu r ntee the proper g s flow the monitor h s been equipped with di -
phr gm pump which pumps g s t r te of more th n 30l/h. As the pump works lmost
throughout the working-time of the monitor it we rs out in time. It is essenti l to check the
cont min tion level of the g s dryer's filter to extend the lifetime of the g s pump. High
cont min tion level exerts neg tive influence on the pump function. The pump efficiency
c n be set with the help of the m mos PC progr m (see ch pter 7.3.3.3. ).
3.2. . Gas sensors
The g s sensors re the l st element of the g s system. The maMoS monitor c n
be equipped with up to four sensors me suring concentr tions of different g ses. Both
electrochemic l nd NDIR (Non-dispersive Infr -red) sensors c n be used for performing
me surements. The type of sensor used depends on the me sured g s.
The types of the g ses the maMoS monitor c n me sure re presented in ch pter
3.5.1.
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3.3. Electric connectors of the monitor
Picture 12. Location of the in uts, out uts and ower su ly connectors
The maMoS monitor h s number of electric connectors which en ble the user to
connect the monitor to power supply nd ddition l devices. All the inputs, outputs nd
power supply connectors re to be found inside the monitor on the device m in bo rd (Pic-
ture 12.). The wires should be connected s described in section 4.1.1. E ch of the in-
puts nd outputs c n perform sever l functions which c n be defined with the help of the
MaMoSII.exe softw re. The PC nd the dryer connector re to be found t the bottom of
the monitor c sing (Picture 7.).
3.3.1. Digital inputs
The monitor h s two digit l inputs which c n be configured by the user: In1 nd
In2. According to the settings the inputs c n be used for:
−rest rting the me surement cycle (which me ns borting the current cycle
reg rdless of its st ge nd st rting the new cycle with the ventil tion
process),
−controlling (switching on or off) ny of two rel ys
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−controlling (switching on or off) the PWM digit l output.
Picture 13. Digital in uts on the monitor.
Ch nges to the settings c n be m de with the help of the MaMoSII.exe softw re. The
volt ge r nge of e ch of the inputs is 0V ÷ 5V. The input is reg rded s ctive when its
volt ge is 0V (in p rticul r short-circuit with GND). A disconnected (or connected to
volt ge of +5V) input is reg rded s in ctive.
If the input h s been set to rest rt the me surement cycle the ctive st te (0V) h s
to l st t le st 2s to evoke the zeroing.
3.3.2. Analogue outputs
The monitor h s 8 n logue outputs which c n be configured by the user: U1 ÷ U4
nd I1 ÷ I4.
With the help of the softw re e ch of the outputs c n be ssigned to ny of the
me sured (or c lcul ted) v lue. In such c se sign l proportion l to the me sured qu nt-
ity will ppe r on the output. The MaMoSII.exe softw re lso en bles the user to define
the r nge of the presented v lue.
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Picture 14. Analogue out uts on the monitor.
The n logue output (U1 ÷ U4) sign l r nge is 0 ÷ 5V or 0 ÷ 10V (set with the help
of the MaMoSII.exe softw re), where s the current output (I1÷I4) sign l r nge is 0÷20mA
or 4÷20mA ( lso set with the help of the MaMoSII.exe softw re).
3.3.3. Digital output (PWM)
The monitor h s single digit l P M output (PV3). This is n open dr in output,
the ctive st te of the output me ns short-circuiting the PV3 ending to the ground potenti l
by intern l high-power N-MOS tr nsistor. This c n be used for switching n extern l rel y,
etc. The P M output c n be controlled vi n logue outputs or digit l inputs. It c n lso
proceed to the ctive st te when the monitor h s initi ted the me surement ph se. The
P M output function c n be defined with the help of the MaMoSII.exe softw re.
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Picture 15. The PWM out ut and the load connection.
One of the two connectors: 12V or VCC (+5V) (Picture 15.) c n be used for sup-
plying the receiver controlled vi the output. If the 12V supply is used the m ximum lo d
current mounts 500mA, where s for the 5V supply it is 200mA.
3.3.4. Relay outputs (optional)
Option lly the monitor c n be equipped with two independent SPDT rel ys Re-
lay #1 nd Relay #2 connected with connector s shown in Picture 16. The B ending is
common ending, the A ending is norm lly closed ending (NC) nd the C ending is nor-
m lly open ending (NO). The Relay #1 is connected with the A1, B1 nd C1 connectors,
where s the Relay #2 is connected with A2, B2 nd C2. The rel ys en ble the user to
switch volt ges up to 230V nd currents below 2A.
The rel ys c n:
−be controlled by one of the n logue outputs U1 ÷ U4, I1 ÷ I4 ( ccording to
the level of sign l on the n logue output the rel y either switches on or off
with cert in hysteresis).
−be controlled by the digit l input (the rel y follows the In1 or In2 digit l input
st te, which me ns it switches on when the input is ctive nd switches off
when it is in ctive).
−work ccording to the me surement cycle st ge (the rel y switches on in the
“MEASUREMENT" st ge nd switches off during other st ges)
−be perm nently switched off.
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The ch nges to the configur tion c n be m de with the help of the MaMoSII.exe
softw re.
Picture 16. Relay out uts.
3.4. Monitor power supply
It is dvised to supply the maMoS monitor with AC volt ge of 24V +/-10%,
50/60Hz nd power of more th n 150W.
The power supply should be connected to the connectors pl ced on the m in
bo rd which re shown in Picture 17.. The loc tion is shown in Picture 12..
A monitor c n be ordered complete with n ppropri te power supply – shown in
Picture 4.
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Picture 17. Power su ly connectors
ATTENTION!
Connecting the su ly to the connectors other than shown in
the Picture 17. will cause the ermanent damage to the device.
3. . Configuration possibilities
Due to its modul r design, the maMoS monitor c n be configured in m ny differ-
ent w ys. Below ll the extr modules nd the g ses the monitor me sures h ve been lis -
ted.
3. .1. Types of the measured gases
The maMoS monitor c n me sure the concentr tion of up to four different g ses
using electrochemic l or NDIR (Non-dispersive Infr red) sensors. In the T ble 1. the
sensors which c n be used by the monitor h ve been listed.
Due to continu l development of the monitor, the sensor types nd their me sure-
ment r nges might ch nge. If the needed sensor or me surement r nge does not ppe r
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in the bove t ble it is dvis ble to cont ct to inquire fter current me s-
urement c p bilities.
Gas ty e Sensor ty e Measurement
range
O2 oxygen electrochemic l m x. 25 %
CO carbon monoxide electrochemic l 2000ppm ÷ 10 %
CO carbon monoxide NDIR 5% ÷ 100 %
CO2 carbon dioxide NDIR 5000ppm ÷ 100 %
H2S hydrogen sulphide electrochemic l 6000ppm
CH4 methane NDIR 5 % ÷ 100 %
NO nitric oxide electrochemic l 5000 ppm
NO2 nitrogen dioxide electrochemic l 1000 ppm
SO2 sulphur dioxide electrochemic l 5000 ppm
N2O nitrous oxide NDIR 5000 ppm
Table 1. Gas sensor ty es.
Ap rt from g s concentr tion, n ppropri tely equipped monitor c n lso me s-
ure temper ture, differenti l pressure nd tmospheric pressure nd c lcul te number of
uxili ry p r meters (such s: st ck loss, excess ir f ctor, flow velocity nd m ny others).
3. .2. Additional and optional equipment
The following modules c n be chosen s the ddition l equipment of the maMoS
monitor:
the ddition l g s ch nnel which sep r tes one or more sensors from the
m in g s ch nnel (see ch pter 3.2. ),
module for digit l recording of the me surement results – d t -logger. It
en bles the user to s ve me surement d t on fl sh memory c rd - MMC
(MultiMedia Card) / SD (Secure Digital),
repl cing the RS232C interf ce with RS485 interf ce which en bles the
device to oper te in network (up to 15 devices) nd extends the communic-
tion lines up to 100m,
repl cing the RS232C interf ce with USB interf ce to m ke oper ting with
computers not equipped with RS232C connector possible,
repl cing the RS232C interf ce with the Ethernet connector,
communic tion c ble of non-st nd rd length,
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RS48 Switch to communic te with sever l maMoS devices,
temper ture sensors: thermocouple (temper ture r nge up to 1000°C) or Pt
sensor (temper ture r nge up to 100°C),
tmospheric pressure sensor,
differenti l pressure sensor, r nge: -5 ÷ +20hP or -20 ÷ 20hP ,
differenti l pressure sensor with g s ch nnel flow control nd dryer's filter
cont min tion level control,
Pitot's tube - used for indirect me surements of g s flow velocity with the
help of the differenti l pressure sensor.
4. MONITOR INSTALLATION
Mounting the monitor upright on w ll will ssure correct function. The device
should be inst lled in pl ce not exposed to we ther conditions (r in, snow, sun expos-
ure, temper tures below 0°C nd bove 40°C). It is dvis ble to void high dust concen-
tr tion in the ir.
To tt ch the monitor to the w ll the user should m ke four holes in the w ll (di -
meter ∅ = 10mm). The pl cement of the mounting holes is presented in the below dr w-
ing.
Picture 18. Mounting holes lacement
Picture 19. Mounting holes lacement
The monitor should be tt ched to the w ll with screws (the set of needed screws
h s been enclosed with the monitor – see Picture 3.).
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