mru MGAprime User manual

MGAprime
USR MANUAL
9452EN-PR

USER MANUAL MGAprime
2 / 123 MRU GmbH, D-74172 Neckarsulm
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Original user manual
© 2021 by MRU
No part of this manual my be published in any form (print, photocopy, electronic
media or any other publication form) without a written approval by the publisher.
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as such, are properties of the respective owners.
Edition: 2021-05-28, V11.00.EN

USER MANUAL MGAprime
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Table of Contents
1Information for product and safety............................................... 7
1.1. Safety manual .................................................................................................7
1.2. Safety precautions.........................................................................................7
2Introduction...................................................................................... 8
2.1. Intended use ...................................................................................................8
2.2. About us ...........................................................................................................9
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................................................................................. 23
4.4. Switching on the analyser ....................................................................... 23
4.5. Switching off the analyser....................................................................... 23
4.6. Turn Display.................................................................................................. 24
4.7. Set the analyser to standby mode ....................................................... 24
4.8. Back to homescreen / Back to measure............................................. 26
4.9. Create screenshots..................................................................................... 26
5Settings............................................................................................ 27
5.1. Open menu Settings ................................................................................. 27
5.2. General settings .......................................................................................... 27
5.3. Settings Date and Time............................................................................ 28
5.4. Device settings ............................................................................................ 30
5.5. Water monitoring....................................................................................... 33
5.6. Averaging...................................................................................................... 36
5.7. Programs ....................................................................................................... 38
5.8. Analog output setup (4-20 mA)............................................................ 39
Setting channel ................................................................................................... 39
Setting lower / higher limit............................................................................. 40
Setting Analog outputs during zeroing ..................................................... 41
Pin assignment of the 4-20mA interface (Analog IN /OUT)............... 42

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5.9. Analog input setup (4-20mA) ................................................................43
5.10. Connecting analyser with WIFI (WLAN) .............................................44
5.11. Getting information about the network.............................................45
5.12. Assigning a fixed IP address................................................................... 46
5.13. Serial connectivity (RS485/USB) ............................................................47
5.14. Default settings ...........................................................................................47
5.15. Configuration of measurement program ..........................................48
Test program........................................................................................................48
Measurement program ....................................................................................48
Further measuring programs .........................................................................48
Moving a value field..........................................................................................48
Assign a measured value................................................................................. 49
Setting zoom........................................................................................................49
6Measurement ..................................................................................50
6.1. Prepare measurement............................................................................... 50
Setting up the measuring point....................................................................50
Operating temperature ....................................................................................51
Power supply........................................................................................................ 51
Opening the transport bag.............................................................................52
Switch-on, warm-up phase, zero point ...................................................... 52
Repeated Zero point .........................................................................................53
Automatic zero point ........................................................................................54
Use last valid zero point...................................................................................55
Select Source zero point (gas).......................................................................55
Charging state of the battery.........................................................................56
Connections to the analyser...........................................................................57
Attach clip-on filter............................................................................................58
Controlling Filters...............................................................................................58
Connecting Gas moisture bottle................................................................... 59
Connecting Acid Dosing Unit APE................................................................60
6.2. Take a measurement .................................................................................62
Setting O2 reference and Fuel type............................................................. 62
Setting CO purge limit......................................................................................62
Starting the measurement ..............................................................................63
Storing measured values .................................................................................63
Selecting channels for graphic display .......................................................64
Starting Auto-measurement...........................................................................67
7Data memory ..................................................................................70
7.1. Organizing data memory.........................................................................70
7.2. Managing sites ............................................................................................70
Adding a new site...............................................................................................70
Changing site data.............................................................................................71

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Deleting sites ....................................................................................................... 72
Recalling stored measurements.................................................................... 73
7.3. Data transfer via USB (CSV export) ...................................................... 73
8Extras ............................................................................................... 76
8.1. Open menu Extras...................................................................................... 76
8.2. History ............................................................................................................ 76
8.3. System extensions...................................................................................... 79
8.4. Connections.................................................................................................. 80
8.5. Automatic device start.............................................................................. 80
8.6. Instrument leak test................................................................................... 82
8.7. Printing measurement results................................................................ 84
Printing current measurement results........................................................ 85
Printing stored measurement results.......................................................... 85
9Service ............................................................................................. 87
9.1. Open menu Service ................................................................................... 87
9.2. Service values............................................................................................... 87
9.3. Performing Device selftest...................................................................... 88
9.4. Internal log settings................................................................................... 89
Copying all log data .......................................................................................... 89
Copying single log data................................................................................... 90
10 Info ............................................................................................... 92
10.1. Open menu Info.......................................................................................... 92
10.2. Calling up device info ............................................................................... 92
10.3. Device usage ................................................................................................ 93
11 Maintenance and cleaning......................................................... 94
11.1. Cleaning and maintenance ..................................................................... 94
11.2. Service check................................................................................................ 94
12 Simple service work.................................................................... 95
12.1. Information of the analyser components.......................................... 95
12.2. Updating the firmware ............................................................................. 96
13 Specifications .............................................................................. 98
13.1. Specifications of NDIR technology ...................................................... 98
13.2. Sensors for Oxygen, Temperatures and Pressure........................... 99
13.3. Gas sampling and conditioning ............................................................ 99
13.4. Calculated values and accessories .....................................................100
13.5. Data communication...............................................................................100
13.6. Technical data............................................................................................100
13.7. Technical data Acid Dosing Unit APE................................................101
14 Options.......................................................................................102
14.1. Activate NDIR-Fastmode function .....................................................102

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14.2. Gas flow measurement...........................................................................103
Parameter for gas flow measurement ......................................................103
14.3. Operating the analyser in the extended temperature range....104
Precautions for use in the extended temperature range...................104
Connecting heating box ................................................................................105
14.4. Operating analyser with Nickel -Metal-Hybrid (NiHM)-Battery
105
14.5. RS485 Extern...............................................................................................107
14.6. Screw adapter onto HPI-Probe............................................................108
15 Appendix....................................................................................109
15.1. Error diagnosis regarding the measuring instrument.................109
15.2. Condensate alarm ....................................................................................110
Condensate self help.......................................................................................110
Start drying manually......................................................................................111
15.3. Switching off the analyser in case error ...........................................113
15.4. Connecting analyser with MRU4win..................................................113
Connecting analyser with MRU4win via serial interface (RS 485)...113
Connecting analyser with MRU4win via TCP/IP connection.............114
Creating analyser in MRU4win ....................................................................115
15.5. Remote control of the analyser device via VNC............................118
15.6. General Instructions for the heated hose line................................119
Unrolling the heated hose line ....................................................................119
Bending radius of heated sampling lines ................................................120
15.7. CxHy Calculation.......................................................................................121
15.8. Spare parts..................................................................................................121
16 Declaration of conformity........................................................122

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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
prefixed 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
damage 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
extraction 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 warn-
ings to prevent personal injuries and damaging of the product.
•We can’t be held responsible for any injuries and/or damages
that occur by not following the instructions in this manual.
•Always keep the manual near you when working with the ana-
lyser, 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
protective 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.

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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).
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

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10 / 123 MRU GmbH, D-74172 Neckarsulm
MRU GmbH
Fuchshalde 8 + 12
74172 Neckarsulm - Obereisesheim
GERMANY
Tel [phone] (Front office)
Tel [phone] (Service)
Fax [phone]
Email: [email protected]
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
components 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 par-
tial volume of the flue gas from the combustion channel and
analyses it for its components by means of sensors (e.g., paramagnetic
(oxygen) 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 pneu-
matic 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 of-
fered.
•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.
3.6. Heated Gas sampling probe
For interchangeable probe tube with flue gas temperature measure-
ment using type K-thermoelement.
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.

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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
measurement.
NOTE
Please note that heating hoses with 110V and 230V are
offered.
►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 119.
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
measurement.

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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
condensate 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
nominal 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 an-
alyser.
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
measuring O2(oxygen) is installed, optionally H2(hydrogen) and
H2S (hydrogen 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 meas-
ure up to 8 gases with this measuring principle: CO (carbon mon-
oxide), CO2(carbon dioxide), NO (nitrogen monoxide), NO2(ni-
trogen dioxide), N2O (nitrous oxide), SO2(sulphur dioxide), CH4
(methane) and C3H8(propane).

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3.11.Acid injection
CAUTION
Phosphoric acid (10 %)
Phosphoric acid (10 %) may cause burns.
►If you come into contact with acid, wash the area im-
mediately 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 ef-
fects caused by slowly forming or saturating moisture films.

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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 suffi-
cient for two hours of measuring operation.
See also chapter Connecting Acid Dosing Unit APE, Page 60 to
connect the Acid Dosing Unit APE to the analyser.