mru AirFair OPTIMA 7 NDIR User manual

62876EN-NDIR
OPTIMA7 NDIR
USER MANUAL

MRU GmbH USER MANUAL OPTIMA 7 NDIR
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MRU GmbH USER MANUAL OPTIMA 7 NDIR
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1 TABLE OF CONTENTS
1TABLE OF CONTENTS ........................................................................................................................ 3
2INTRODUCTION ................................................................................................................................. 9
2.1 The OPTIMA 7 - NDIR ..................................................................................................................... 9
2.2 The company MRU GmbH ........................................................................................................... 10
2.3 Important general information (EN 50379) and VDI 4206 ....................................................... 11
2.4 Important information about the users/operation manual..................................................... 11
3SAFETY INFORMATION ................................................................................................................... 11
3.1 Safety regulations ....................................................................................................................... 11
3.2 Specific safety regulations.......................................................................................................... 11
3.3 Guideline for Li-Ion Batteries...................................................................................................... 12
4RETURNED GOODS .......................................................................................................................... 12
4.1 Return of hazardous waste ......................................................................................................... 12
5MEASUREMENT PRINCIPAL ............................................................................................................ 13
5.1 Gas flow diagram......................................................................................................................... 13
5.2 Electrochemical measured principle.......................................................................................... 14
5.3 Principle of the IR-bench............................................................................................................. 14
6ANALYSER DESCRIPTION ................................................................................................................ 16
6.1 Analyser front .............................................................................................................................. 16
6.2 Analyser Connectors - bottom side............................................................................................ 16
6.3 Analyser Connectors - top........................................................................................................... 17
6.4 Analyser Back............................................................................................................................... 17
6.5 Condensate separator................................................................................................................. 18
7ACCESSORIES................................................................................................................................... 19
Operation Manual –
Please carefully read and follow all instructions before operating the analyser.

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7.1 Exhaust gas sampling probe....................................................................................................... 19
8OPERATING THE ANALYSER ........................................................................................................... 20
8.1 The Display................................................................................................................................... 20
8.2 The Keypad .................................................................................................................................. 20
8.3 Menu configuration..................................................................................................................... 21
9FIRST USE OF THE INSTRUMENT..................................................................................................... 22
9.1 Analyser ready for operation...................................................................................................... 22
9.2 Analyser settings ......................................................................................................................... 22
9.2.1 Switch-ON protection..........................................................................................................................................23
9.2.2 Setting printer type and print-out ..................................................................................................................23
9.2.3 Bluetooth settings.................................................................................................................................................24
9.3 Setting time and date.................................................................................................................. 25
9.4 Configuration of measurement program .................................................................................. 25
9.4.1 Configuration of the measurement window (display content)............................................................26
9.4.2 Configuration of the zoom function ..............................................................................................................26
9.4.3 Change measurement program names........................................................................................................26
10 MAINTENANCE............................................................................................................................. 27
11 PREPARATION FOR EACH MEASUREMENT ................................................................................ 27
11.1 Power supply ............................................................................................................................... 27
11.2 Auto Off ........................................................................................................................................ 27
11.3 Measurement with battery charger/battery charging ............................................................. 27
11.4 Measurement with battery (Battery monitoring) ..................................................................... 27
11.5 Operation temperature............................................................................................................... 28
11.6 Condensate separator................................................................................................................. 28
11.7 Connectors and leak tightness ................................................................................................... 28
11.8 Power ON and zeroing ................................................................................................................ 29
12 HOW TO TAKE A MEASUREMENT ............................................................................................... 30
12.1 Selection of the measurement program.................................................................................... 30
12.2 Measured Value Display.............................................................................................................. 30
12.3 Test program................................................................................................................................ 31

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12.4 Storage the measuring results ................................................................................................... 32
12.5 Printing the measurement results ............................................................................................. 32
12.6 End of measurement ................................................................................................................... 32
12.7 Last measurement results........................................................................................................... 33
12.8 Pressure measurement ............................................................................................................... 33
12.9 Differential temperature measurement .................................................................................... 34
13 DATA STORAGE............................................................................................................................ 35
13.1 Organisation of the data memory.............................................................................................. 35
13.2 Information about the data memory ......................................................................................... 35
13.3 Site administration...................................................................................................................... 35
13.3.1 View and search sites...........................................................................................................................................36
13.3.2 New entry and change of sites .........................................................................................................................37
13.3.3 Delete sites ..............................................................................................................................................................38
13.4 Data transfer via SD Card (Option)............................................................................................. 38
13.4.1 Import of Sites ........................................................................................................................................................39
13.4.2 Export of Sites.........................................................................................................................................................40
13.4.3 Export of Gas Measurements ............................................................................................................................40
13.4.4 Export of Differential Pressure Measurements...........................................................................................40
13.5 Measurements in the data memory ........................................................................................... 41
13.5.1 View measurements.............................................................................................................................................41
13.5.2 Delete measurements .........................................................................................................................................42
13.5.3 Export measurements to a SD card (optional)............................................................................................42
14 EXTRAS / ADJUSTMENTS............................................................................................................. 43
14.1 Maintenance adjustment menu ................................................................................................. 43
14.2 Manufacturer default settings.................................................................................................... 43
14.3 Service values .............................................................................................................................. 44
14.4 Leak proof test............................................................................................................................. 45
14.5 Contents SD card ......................................................................................................................... 47
14.6 Analyser info................................................................................................................................ 47
15 TECHNICAL SPECIFICATIONS ...................................................................................................... 48
15.1 Lambda (Brettschneider formula).............................................................................................. 50
15.2 P.E.F. factor .................................................................................................................................. 50

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16 APPENDIX..................................................................................................................................... 51
16.1 Text input ..................................................................................................................................... 51
16.2 Asking the user for a decision (pop up window)....................................................................... 51
16.3 Firmwareupdate.......................................................................................................................... 52
16.4 Analysis and calculations............................................................................................................ 54
16.5 Errors ............................................................................................................................................ 55
16.5.1 Error diagnosis regarding the measuring device ......................................................................................55
16.5.2 Error diagnosis regarding the condensate separator ..............................................................................56
16.6 Declaration of conformity........................................................................................................... 57

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Inspect Shipment for Damage
Carefully inspect the entire shipment for damage in the presence of the shipper’s agent, removing
packaging material if necessary. Note any damage to packaging and/or goods on 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 ac-
cepted.
Important notice!
This high quality electronic analyser utilizes batteries that discharge even when the
analyser is not in use. Therefore it is very important to charge the batteries every 4 – 6
weeks, even if the analyser is not in use. When it is fully charged, the analyser
should be switched on and allowed to zero itself before being switched off again. (see
chap. 11.8)
Failing to properly charge the batteries will void your warranty!
Save the original box and the packing material for use if the analyser must be shipped in the future.
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. MRU encour-
ages customer feedback and welcomes any comments or suggestions relating to the product or
documentation.
Please forward all comments or suggestions to the Customer Feedback Department at the follow-
ing address:
MRU GmbH, Fuchshalde 8 + 12, 74172 Neckarsulm / Obereisesheim,
GERMANY
Fon ([phone] (Reception)
Fon ([phone] (Service)
Fax [phone]
Email: [e-mail], Homepage: www.mru.eu
This manual is intended solely as a guide to the use of the product.
MRU shall not be liable for any loss or damage whatsoever arising from content errors or misinter-
pretation of information’s from this manual or any mis-use resulting from the use of this manual.
Electrochemical sensors are by their operating principle not only sensitive to the gas they are in-
tended for, but for other gases as well.
This cross sensitivity is compensated by MRU for the typical application of flue gas analysis.
However, unusual high concentration levels of single gas components might lead to
•a reduced measurement accuracy of other gas components
•and to a temporary change of the sensitivity of sensors, which may require several hours
recovery time.

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Especially concentration levels as high as several % for single gas components may affect the
measurement of other gas components at ppm level. Those applications need to be discussed with
MRU in detail.

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2 INTRODUCTION
2.1 The OPTIMA 7 - NDIR
The OPTIMA 7 - NDIR flue gas analyser is used for: total measurement of up to 5 car exhaust gas
components:
CO / CO2/HC infrared (ndir) measurement
O2and NOx electrochemical measurement
Simultaneous measurement of:
HC as (n-Hex) 0 - 20.000ppm
CO20 - 20,00 %
CO 0 - 16,000 %
O20 - 21,00 %
NO 0 - 5.000 ppm
.

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2.2 The company MRU GmbH
Your analyser is produced by the MRU GmbH in Neckarsulm Germany (founded in 1984), a medi-
um sized company that specializes in developing, producing and marketing high quality emission
monitoring analysers. MRU GmbH produces a wide range of instruments, from standard analysers
up to tailor made industrial analysers. MRU GmbH contact details are listed on one of the previous
page.
Factory 1 (service department,sales department, development division, administration)
Factory 2 (Product division)

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2.3 Important general information (EN 50379) and VDI 4206
This analyser is not designed to be used for continuous measurements.
Before using the analyser verify the condition of the various parts of the analyser, such as the
probe, the ambient air conditions, the condensate separator, star filter and the connectors for dam-
age and/or blockages.
When starting up the analyser it will take between 1 – 3 minutes to set to zero depending on the
condition of the sensors and of ambient.
The minimum zeroing time of the analyser to achieve correct measurement values can be ex-
pected by 1.5 minutes!
Caution: Exposure to acids; aggressive gases such as sulphur; vapours such as thinners, gaso-
line, alcohol and paint, etc. can damage, reduce the life of, or destroy the sensors.
The life of the sensors depends on how they are used, maintained and treated. Typical average life
expectations are: O2- 2 years and NO - 3 years.
The use of the analyser for regulatory purposes is subject to special regulations (for example a
periodical examination of the analyser). Please obtain the appropriate regulations from your local
responsible authority.
2.4 Important information about the users/operation manual
The users/operation manual is an important part of this delivery. It will explain how to use this ana-
lyser properly and sets forth safety and environmentally friendly procedues.
It is the responsibility of all users to read and familiarize themselves with this manual, paying par-
ticular attention to the safety instructions.
The most important safety details are listed in chapter 3 (Safety Information). Additional
safety details in other chapters are clearly marked with an attention sign.
3 SAFETY INFORMATION
The following safety procedures must to be followed at all times. They are a significant and essen-
tial part of this manual. Failure to follow safety procedures can result in the loss of your warranty
claims.
3.1 Safety regulations
1. The OPTIMA 7 - NDIR analyser may only be used as indicated in this manual.
2. Our analysers are checked according to the following regulations:
VDE 0411 (EN61010) and DIN VDE 0701 before they leave the MRU GmbH facto-
ry.
3. MRU technical products are designed and manufactured according to DIN 31000/ VDE 1000
and UVV = VBG 4 of the professional guilds for fine mechanics and electrical engineering.
4. MRU GmbH assures that the analyser complies to the essential requirements of the legal regu-
lations of the member states of the electro-magnetic compatibility (89/336/EWG) and to the
low-voltage regulations (3/23/EWG).
3.2 Specific safety regulations
1. Use only the battery charger supplied with the analyser for this instrument
2. No part of the analyser, including the metal probe tube and all other metal parts & accessories
are to be used as electric conductors.
3. The analyser is not to be used in or under water.
4. The analyser is not to be placed near or directly exposed to open fire or heat.

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5. The specified probe temperature range is not to be exceeded, as the probe, temperature sen-
sory mechanism and sensor could be damaged or destroyed.
6. The analyser shall void dropping.
7. Caution: Moisture, being pumped out of the condensates trap can be slightly acidic.
In case of skin contact IMMEDIATELY: clean affected parts of the body.
Avoid getting liquid in eyes.
Please carefully clean all parts that come into contact with the condensates.
8. After measurement, vent the analyser with ambient air and allow the probe to
cool. A hot probe could cause burns or ignite flammable material.
9. The fumes from certain materials (for. example, cleaners, petrol, spirit, varnish)
may damage the sensors of the analyser. Do not store or use these or other simi-
lar fluids near the analyser.
3.3 Guideline for Li-Ion Batteries
•The battery pack is not accessibly for end users
•Li-Ion rechargeable battery pack for OPTIMA 7 - NDIR Combustion Analyser
•Do not heat or throw the battery pack of in fire.
Do not charge and leave the battery pack at the high temperature.
•Do not deform, short-circuit, disassemble or modify the battery pack
•Do not allow the battery to be immersed in or wetted with water or sea water
•Do not subject the battery pack to a strong impact or throw it
•Do not cut, squeeze, tear at the cables of the battery pack
•Do not carry or store the battery pack together with material which have sharp edges or is
electrical conductive in the same custody
•Not letting (+) terminal come in contact with (-) terminal or metal
The above items may cause heat, fire and explosion
Your quality management MRU GmbH
4 RETURNED GOODS
Packing regulation of 12.07.1991
If your local waste facility does not except MRU packing materials for disposal, you may return it to
MRU or our local sales representative. Packing materials returned to MRU must be returned pre-
paid.
4.1 Return of hazardous waste
- Waste Disposal/Returns/Warranty -
MRU GmbH is required to accept the return of hazardous waste such as electro-chemical sensors
that cannot be disposed of locally. Hazardous waste must be returned to MRU prepaid.

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Return of analyser according to ElektroG:
MRU GmbH is required to accept the return, for proper disposal, of all analysers delivered after
13th of August 2005. Analysers must be returned to MRU prepaid.
5 MEASUREMENT PRINCIPAL
The analyser draws a sample of the exhauist gas from the duct using a built-in gas pump through
the probe is cleaned and dryed using condensate separator with built-in filter and analyzes the
extracted gas with NDIR and electrochemical sensors.
5.1 Gas flow diagram
Position
Description
1
Sampling probe
2
Condensate separator
3
Star filter
4
Pressure sensor
5
NDIR sensor
6
Electrochemical sensor (s)

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5.2 Electrochemical measured principle
The oxygen content of the sample gas is measured with a 2 electrode electrochemical
sensor.
Toxic gases like carbon monoxide (CO), nitrogen oxide (NO), nitrogen dioxide (NO2), sul-
phur dioxide (SO2), and hydrogen sulphide (H2S) are measured with 3 electrode sensors.
The electrochemical sensors are based on gas diffusion technology.
The advantage of this technology is that the signal generated is direct proportionally and
linear to the volume concentration (% or ppm) of the analysis gas components.
The 3 electrodes are: S (sensing electrode), C (counter electrode) and R (reference elec-
trode).
When the gas being measured contacts the sensing electrode, it reacts on the electrode surface
either through oxidation (for example CO, SO2, NO) or reduction (like NO2, and Cl2).
Example: CO sensor:
CO reacts at the sensing electrode as follows:
CO + H2O -> CO2+ 2H+ + 2e-
and at the counter electrode, oxygen from air will be re-oxidized to water:
½ O2+ 2H+ + 2e--> H2O
The sensor supplies a constant current signal (µA-range) that is monitored and analyzed. The cur-
rent intensity is dependant upon the volume concentration of the sample gas, while other parame-
ters like temperature and cross sensitivity are calculated by the analyser.
5.3 Principle of the IR-bench
A regulated infrared source (IR) provides light in the range of 2 to 8 microns (µm). The infrared
light is directed through the sample cell to the optical detector. The source is electronically modu-
lated with no chopper wheels and no moving parts.
The residual infrared energy, not absorbed by the sample gas, is guided to the optical detector. It
passes an optical narrow band pass.
Infrared light passed through the filter is collected by a pyro-electric detectors. It produce a voltage
that is proportional to light intensity.
Unlike electrochemical sensors, the NDIR measurement shows no ageing due the gas concentra-
tion measured.
It’s lifetime is only limited by the lifetime of the IR source.
Pos.
1
Sample gas
2
Particle filter
3
Sensing Electrode
4
Reference Electrode
5
Counter Electrode
6
Connection pin
7
Electrolyte reservoir
8
Electrolyte
9
Capillary diffusion barrier

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6 ANALYSER DESCRIPTION
6.1 Analyser front
6.2 Analyser Connectors - bottom side
Note:
If during zeroing T air (5) is disconnected, then value of T gas at the end of zeroing will be used. In
this case, the measuring value will be displayed green coloured.
If T air (5) will be connected during the measurement, then true T air measurement will occur and
the display color changes from green to black.
1
Display
2
Condensate separator
3
Key pad
1
Sampling probe connection
Condensate separator
2
Pressure connection 1 (Draft)
3
Pressure connection 2
(Differential pressure)
4
Connector AUX (optional)
5
Temperature connection 1 /
T-Ambient air (combustion
air)
6
Temperature connection 2 /
T-gas

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6.3 Analyser Connectors - top
6.4 Analyser Back
1
Fixing magnets
2
Gas outlet
3
Handle strip
4
Analyser feet
Important!
During measurement the gas outlet must not be covered
1
Cover
2
IR-interface
3
SD-card reader
(only by using a MRU-SD-
CARD we can assure the
compatibility of all analyser
functions)
4
USB-port and charging port

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6.5 Condensate separator
Remove the condensate separator by pulling it towards you (1) out of the groove of the OPTIMA 7
- NDIR housing, then pull it downwards (2).
The condensate show glass is screwed into the plug. The complete condensate separator can eas-
ily be taken apart for cleaning or for exchanging the star filter. (Condensate separator details are
included in the service manual)
After cleaning a leaknes check (see chap. 14.4) must be done!

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7 ACCESSORIES
7.1 Exhaust gas sampling probe
The OPTIMA 7 - NDIR is available with an exhaust gas sampling probe, flexible, 400 mm, with 2,5
m Viton sampling line and benzine on-line filter
1
Probe hose
2
Probe
3
Viton hose
4
Hose connector
5
Hose bush
6
Benzine filter

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8 OPERATING THE ANALYSER
8.1 The Display
All information required to operate the analyser is displayed as shown below.
8.2 The Keypad
Description and function of the keys:
ON/OFF
Press to start the analyser without delay. The power off
function will be delayed to protect the sensors. If there is
not enough ambient air the analyser will recommend the
purging of the sensors.
Function Keys
Activates the functions seen on the display (2 function
key bar)
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.
ESC Key
Abort or return to the menu above
Arrow Keys
Jump in between lines, change values
OK Key
Confirmation key, select a marked menu point
Printer Key
Activates the printer function in the measurement and
1
Menu bar
2
Function key bar
3
Display panel
- Menu
- Measurement value
- …
4
Zeroing active
5
SD-Card in the slot
- Indication green
Read- and write access
- Indication yellow
only Read access
(SD-Card write protected)
6
Battery charge condition