mru MGAprime User manual

MGAprime
USER MANUAL
9452EN-PR

USER MANUAL MGAprime
2 / 126 MRU GmbH, D-74172 Neckarsulm
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Original user manual
© 2022 by MRU
No part of this manual my be published in any form (print, photocopy, electronic media or
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such, are properties of the respective owners.
Edition: 2022-09-01, V12.21.EN

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Note on electrochemical sensors
Electrochemical sensors are by their operating principle not only sensitive to
the gas they are intended 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 re-
quire several hours recovery time.
Especially concentration levels as high as several % for single gas compo-
nents 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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Table of Contents
1Information for product and safety..................................................... 8
1.1. Safety manual .......................................................................................................8
1.2. Safety precautions...............................................................................................8
2Introduction .......................................................................................... 9
2.1. Intended use .........................................................................................................9
2.2. About us ...............................................................................................................10
3Description .......................................................................................... 11
3.1. Task.........................................................................................................................11
3.2. Gas flow diagram...............................................................................................11
3.3. The Analyser........................................................................................................13
3.4. Connectors...........................................................................................................14
3.5. Probes....................................................................................................................15
3.6. Heated Gas sampling probe ..........................................................................15
3.7. Unheated Gas sampling probe.....................................................................17
3.8. Gas conditioning................................................................................................18
3.9. Gas supply............................................................................................................18
3.10. Gas sensors ..........................................................................................................18
3.11. Acid injection ......................................................................................................19
4Operation............................................................................................. 21
4.1. Commissioning ..................................................................................................21
4.2. Operating panel.................................................................................................21
4.3. Charging the battery ........................................................................................22
4.4. Switching on the analyser ..............................................................................23
4.5. Switching off the analyser ..............................................................................23
4.6. Turn Display.........................................................................................................23
4.7. Set the analyser to standby mode ...............................................................24
4.8. Back to homescreen / Back to measure .....................................................25
4.9. Create screenshots............................................................................................25
5Settings................................................................................................ 26
5.1. Open menu Settings.........................................................................................26
5.2. General settings .................................................................................................26
5.3. Settings Date and Time ...................................................................................27
5.4. Device settings ...................................................................................................28
5.5. Water monitoring ..............................................................................................31
5.6. Averaging.............................................................................................................34
5.7. Interval measurement......................................................................................35
5.8. Programs ..............................................................................................................39
5.9. Analog output setup (4-20 mA)....................................................................40
Setting channel ..........................................................................................................40
Setting lower / higher limit ....................................................................................41
Setting Analog outputs during zeroing .............................................................42
Pin assignment of the 4-20mA interface (Analog IN /OUT).........................43
5.10. Analog input setup (4-20mA)........................................................................43
5.11. Connecting analyser with WIFI (WLAN) .....................................................44
5.12. Getting information about the network....................................................45

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5.13. Assigning a fixed IP address.......................................................................... 46
5.14. Serial connectivity (RS485/USB)................................................................... 47
5.15. Default settings ................................................................................................. 49
5.16. Configuration of measurement program................................................. 50
Test program.............................................................................................................. 50
Measurement program........................................................................................... 50
Further measuring programs................................................................................ 50
Moving a value field................................................................................................. 50
Assign a measured value........................................................................................ 50
Setting zoom .............................................................................................................. 51
6Measurement ...................................................................................... 52
6.1. Prepare measurement .................................................................................... 52
Setting up the measuring point........................................................................... 52
Operating temperature .......................................................................................... 53
Power supply.............................................................................................................. 53
Opening the transport bag.................................................................................... 53
Plug in Temperatur sensor..................................................................................... 54
Switch-on, warm-up phase, zero point ............................................................. 55
Repeated Zero point................................................................................................ 56
Automatic zero point............................................................................................... 56
Use last valid zero point.......................................................................................... 57
Select Source zero point (gas) .............................................................................. 58
Charging state of the battery................................................................................ 59
Connections to the analyser ................................................................................. 59
Attach clip-on filter................................................................................................... 60
Controlling Filters ..................................................................................................... 60
Connecting Gas moisture bottle ......................................................................... 61
Connecting Acid Dosing Unit APE ...................................................................... 61
6.2. Take a measurement ....................................................................................... 64
Setting O2 reference and Fuel type.................................................................... 64
Setting CO purge limit ............................................................................................ 64
Starting the measurement..................................................................................... 65
Storing measured values........................................................................................ 66
Selecting channels for graphic display.............................................................. 66
Starting Auto-measurement................................................................................. 68
7Data memory ...................................................................................... 71
7.1. Organizing data memory............................................................................... 71
7.2. Managing sites .................................................................................................. 71
Adding a new site ..................................................................................................... 71
Changing site data ................................................................................................... 72
Deleting sites.............................................................................................................. 73
Recalling stored measurements .......................................................................... 74
Delete stored measurements ............................................................................... 74
7.3. Data transfer via USB (CSV export).............................................................. 77
8Extras ................................................................................................... 79

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8.1. Open menu Extras.............................................................................................79
8.2. History ...................................................................................................................79
8.3. System extensions.............................................................................................81
8.4. Connections ........................................................................................................82
8.5. Automatic device start.....................................................................................82
8.6. Instrument leak test..........................................................................................83
8.7. Printing measurement results.......................................................................86
Printing current measurement results................................................................86
Printing stored measurement results .................................................................86
9Service.................................................................................................. 88
9.1. Open menu Service...........................................................................................88
9.2. Service values......................................................................................................88
9.3. Performing Device selftest .............................................................................88
9.4. Internal log settings..........................................................................................90
Copying all log data..................................................................................................90
Copying single log data...........................................................................................91
Export NDIR - Factors................................................................................................92
10 Info.................................................................................................... 93
10.1. Open menu Info.................................................................................................93
10.2. Calling up device info.......................................................................................93
10.3. Device usage .......................................................................................................94
11 Maintenance and cleaning ............................................................. 95
11.1. Cleaning and maintenance............................................................................95
11.2. Service check.......................................................................................................95
12 Simple service work ........................................................................ 96
12.1. Information of the analyser components..................................................96
12.2. Updating the firmware ....................................................................................96
Update main firmware .............................................................................................96
Update firmware of single modules....................................................................99
13 Specifications................................................................................. 101
13.1. Specifications of NDIR technology ........................................................... 101
13.2. Sensors for Oxygen, Temperatures and Pressure................................ 102
13.3. Gas sampling and conditioning ................................................................ 102
13.4. Calculated values and accessories............................................................ 103
13.5. Data communication..................................................................................... 103
13.6. Technical data.................................................................................................. 103
13.7. Technical data Acid Dosing Unit APE....................................................... 104
14 Options........................................................................................... 105
14.1. Activate NDIR-Fastmode function ............................................................ 105
14.2. Gas flow measurement................................................................................. 106
Connect analyser to Pitot tube .......................................................................... 106
Parameter for gas flow measurement ............................................................. 107
14.3. Operating the analyser in the extended temperature range .......... 109

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Precautions for use in the extended temperature range..........................109
Connecting heating box.......................................................................................109
14.4. Operating analyser with Nickel -Metal-Hybrid (NiHM)-Battery.......110
14.5. RS485 Extern..................................................................................................... 111
14.6. Screw adapter onto HPI-Probe...................................................................112
15 Appendix ....................................................................................... 113
15.1. Error diagnosis regarding the measuring instrument........................113
15.2. Condensate alarm .......................................................................................... 114
Condensate self help .............................................................................................114
Start drying manually ............................................................................................115
15.3. Switching off the analyser in case error ..................................................117
15.4. Connecting analyser with MRU4win........................................................117
Connecting analyser with MRU4win via serial interface (RS 485)...........117
Connecting analyser with MRU4win via TCP/IP connection....................118
Creating analyser in MRU4win ...........................................................................119
15.5. Remote control of the analyser device via VNC ...................................122
15.6. General Instructions for the heated hose line.......................................123
Unrolling the heated hose line...........................................................................123
Bending radius of heated sampling lines .......................................................124
15.7. CxHy Calculation.............................................................................................124
15.8. Spare parts ........................................................................................................124
16 Declaration of conformity ............................................................ 125

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1Information for product and safety
1.1. Safety manual
All general information and safety precautions of MRU products are listed in
the supplied separate safety manual.
Therefore, this manual must be read and observed before the first use of the
instrument.
Instrument-specific safety and warning requirements in this manual are pre-
fixed before dangerous actions.
1.2. Safety precautions
The used categories of safety precautions are here explained once more.
DANGER
Identifies an immediate, impending hazard that, if
ignored, will result in severe bodily injuries or death.
WARNING
Identifies an immediate, impending hazard that, if
ignored, may result in severe bodily injuries, material dam-
age or death.
CAUTION
Identifies a possibly dangerous situation that, if
ignored, may result in minor injuries.
ATTENTION
Identifies a possibly harmful situation that, if ignored, may
result in damages to the device or its
surroundings.
NOTE
Identifies user tips and other especially important infor-
mation.
The explanation of safety notices:
CAUTION
HOT – danger of burns and fire hazards from gas ex-
traction probe.
Physical harm and property damage can be caused.
►Cool down the probe tube.

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2Introduction
•This manual enables you to understand and safely operate this MRU
Analyzer MGAprime.
•Please read this manual with great vigilant and get
familiar with the product before using it.
•This analyser may only be operated by competent personnel and for
its intended use.
•Please pay special attention to all safety directions and warnings to
prevent personal injuries and damaging of the product.
•We can’t be held responsible for any injuries and/or damages that oc-
cur by not following the instructions in this manual.
•Always keep the manual near you when working with the analyser, to
be able to read instructions as needed. Please ensure to hand over all
documents to when handing the analyser over to others.
2.1. Intended use
The Analyzer MGAprime is designed for the gas analysis of flue gases, as
they are emitted from gas/oil burners, engines, or heating and power
appliances.
The analyser is intended to support the user in control and indicative
measurements in an efficient, accurate and reliable way.
The analyser is specifically not intended as a safety device or personal pro-
tective equipment.
The analyser should not be used as a warning device to warn people against
the presence of harmful gases.
The analyser was manufactured according relevant standards and
regulations.
The analyser must be used according to instructions for the intended use.
WARNING
Risk from manipulations to the measuring device
Operational safety hazard
►Modifications or changes to the measuring device are
not allowed.
Syntax
Please note that this manual makes use of the scientific notation of gases
(NO2), while the instrument itself and its screen shots display the gases in
upper case letter only, i.e. (NO2).

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2.2. About us
The analyser is produced by the MRU GmbH in Neckarsulm, Germany
(Founded in 1984), a medium sized company that is specialised 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.
Building 1: Sales, Service, R&D
Building 2: Production
MRU GmbH
Fuchshalde 8 + 12
74172 Neckarsulm - Obereisesheim
GERMANY
Tel [phone] (Front office)
Tel [phone] (Service)
Fax [phone]
Email: [e-mail]
Site: www.mru.eu

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3Description
3.1. Task
The main task of the analyser is to analyse
flue gases, as they are emitting from incinerators or engines.
•The analyser is optimized for this purpose and includes all compo-
nents from the gas sampling probe to data processing.
•The analyser also performs other measurement tasks such as pressure
and temperature measurement or measurement of flow velocity.
For an overview on all available options please refer to the company’s home
page or sales representatives.
3.2. Gas flow diagram
In combination with the gas sampling probe, the analyser extracts a partial
volume of the flue gas from the combustion channel and
analyses it for its components by means of sensors (e.g., paramagnetic (oxy-
gen) sensor, electrochemical (oxygen) sensor or NDIR sensors).
Draft and temperature are measured at the tip of the sampling probe.
With paramagnetic oxygen sensor

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A
Fresh air inlet
B
Sample gas inlet
C
Condensate outlet
D
Diff. Pressure connector
F
Vent outlet
1
Sample gas filter (PTFE)
2
Dust filter
3
Auto-zero solenoid valve
4
Sample gas pump
5
Double stage gas cooler
6
Sample flow sensor
7
Paramagnetic sensor
8
Not used
9
Infrared (NDIR) bank
10
Acrodisc PTFE filter
11
Diff. pressure sensor
With electrochemical oxygen sensor
A
Fresh air inlet
B
Sample gas inlet
C
Condensate outlet
D
Diff. Pressure connector
F
Vent collection box
E
Vent outlet
1
Sample gas filter (PTFE)
2
Dust filter
3
Auto-zero solenoid valve
4
Sample gas pump
5
Double stage gas cooler
6
Sample flow sensor
7
Electrochemical O2 sensor
8
Sample gas outlet pump
9
Infrared (NDIR) bank
10
Acrodisc PTFE filter
11
Diff. pressure sensor

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3.3. The Analyser
The analyser consists of a compact and robust metal
housing with shock-absorbing rubber corners. All electrical and pneumatic
connections are located on the both front sides of the instrument.
It is operated exclusively via the touch-sensitive touch screen.

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3.4. Connectors
Front side right
1
Loudspeaker
2
Ethernet (LAN)
3
USB socket
4
Second USB socket (option)
5
RS485 (Option)
6
Analog outputs 4 ... 20 mA
Analog-inputs 4 … 20 mA
7
Mains power supply
Front side left
8
Sample gas filter
9
Condensate outlet port
Hose connection DN 4/6
10
Sample gas outlet port (VENT)
Hose connection DN 4/6
11
Fresh air inlet port
12
Sample gas inlet port
13
Outlet fan of gas cooler
14
Probe connection, electrical
15
Pressure-/diff. pressure
16
Pressure-/diff. pressure
(Absolute pressure)
17
Combustion air temperature
18
AUX socket
19
Connection acid injection
(Option)
20
Connection acid injection
(Option)

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3.5. Probes
In combination with the analyser, probes in different versions are offered.
•for fuel temperatures up to 800 °C (stainless-steel probe tube),
•for fuel temperatures up to 1.100 °C (Inconel steel probe tube),
•probe tubes in different lengths
A complete list of available probes can be found in the current price list of this
analyser.
•Probe adapter set HPI for existing probe tubes (see chapter .14.6)
for connecting ON-SITE existing 6- or 8-mm tubes to the probe handle
INSTEAD of the enclosed MRU probe tube.
But then no measurement of the flue gas temperature is possible with
this probe tube
3.6. Heated Gas sampling probe
For interchangeable probe tube with flue gas temperature measurement us-
ing type K-thermoelement.

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1
Probe handle
2
Probe tube
3
Fast locking coupling
4
Probe cone
5
Cable plug (14-pin)
6
Heated hose line
7
Cable coupler (5-pin)
8
Fast locking coupling
9
Filter lock
►Check the probe filter before and after every measurement.
WARNING
Danger of burns and fire hazards from Heated hose line
Injuries and burns may result.
►Roll out the heated hose line completely for each measure-
ment.
NOTE
Please note that heating hoses with 110V and 230V are of-
fered.
►Check the voltage supply of the heating hose before
commissioning.
►You can operate a 230V heating hose with 110 volts, but
with limited heat capacity.
DANGER
Risk due to improper use
Risk of death due to electric shock
►Do not operate a 110V heating hose with 230V.
See also chapter 15.6 General Instructions for the heated hose line,
Page 123.
ATTENTION
When measuring with coiled heated hose line, the hose line is
destroyed due to strong heat development.
►Roll out the heated hose line completely for each measure-
ment.

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3.7. Unheated Gas sampling probe
1
Filter lock
2
Fast locking coupling
3
Cable coupler (5-pin)
4
Cable plug (14-pin)
5
Fast locking coupling
6
Unheated hose line
7
Probe cone
8
Probe tube
9
Probe handle
►Check the probe filter before and after every measurement.

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3.8. Gas conditioning
The sucked sample gas is dried and filtered before it is fed to the
sensors.
A sample gas cooler with Peltier element is used for drying.
The condensate liquid appearing in the gas cooler is pumped to the conden-
sate outlet by means of a peristaltic pump. The condensate forms drops at
the outlet of the instrument.
Optionally, connect a hose (DN 4/6) to the condensate drain.
A hose (DN 4/6, not longer than 5 m) can also be connected to the
sample gas outlet for discharge.
For subsequent filtering, a round filter is used on the front of the
Analyze.
3.9. Gas supply
The analyser contains a gas feed pump (diaphragm pump).
The flow through the gas feed pump is measured and regulated to the nom-
inal value by the analyser.
If the pump capacity is not sufficient to reach the flow of the nominal value,
an alarm is issued.
If the flow does not reach the nominal value despite an increase of the pump
capacity, the pump is switched off after a while to protect the analyser.
3.10. Gas sensors
The analyser has three types of gas sensors:
1. The aanalyser works with an electrochemical sensor for the
measurement of O2 (oxygen). If an electrochemical sensor for measur-
ing O2(oxygen) is installed, optionally H2(hydrogen) and H2S (hydro-
gen sulphone) can be measured with electrochemical sensors.
2. The analyser works with paramagnetic sensor for the
Measurement O2 (oxygen).
3. The analyser works with a non-dispersive infrared absorption
measurement.
Depending on the installed NDIR module, it is possible to measure up
to 8 gases with this measuring principle: CO (carbon monoxide), CO2
(carbon dioxide), NO (nitrogen monoxide), NO2(nitrogen dioxide),
N2O (nitrous oxide), SO2(sulphur dioxide), CH4(methane) and C3H8
(propane).

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3.11. Acid injection
The Acid Dosing Unit APE is optionally available.
CAUTION
Phosphoric acid (10 %)
Phosphoric acid (10 %) may cause burns.
►If you come into contact with acid, wash the area imme-
diately using a lot of water.
►Note the safety data sheet for phosphoric acid (10%).
Phosphoric acid (10 %) is injected into the analyser using the
Acid Dosing Unit APE
The injection of phosphoric acid (10 %) is necessary for a correct
measurement.
•The injection guarantees constant conditions in the gas cooler, so
that you can measure dry or humid flue gas.
•The use of phosphoric acid (10%) reduces losses of SO2, NO2on the
humid surfaces of the gas cooler.
Both effects increase measurement accuracy by preventing slow drift effects
caused by slowly forming or saturating moisture films.
Two pumps inject 24ml of phosphoric acid (10%) per hour during the
measurement.
A collecting bottle is included in the scope of delivery.
►Please note that the volume of the supplied collecting bottle is sufficient
for two hours of measuring operation.
See also chapter Connecting Acid Dosing Unit APE, Page 61 to con-
nect the Acid Dosing Unit APE to the analyser.

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NOTE
Observe the consumption of the phosphoric acid. If the
consumption of the phosphoric acid decreases, there may
be a defect in the supply of the phosphoric acid.
►If necessary, pull the plug-in couplings off the Acid Dos-
ing Unit APE.
►Plug the plug-in couplings back into the Acid Dosing
Unit APE.
►Repeat the process several times.