mru MGAprime User manual

9452EN-PR
MGA
prime
USER MANUAL

MRU
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MGA prime Version 1
Legal notices / Intellectual property rights comments
Original user manual
© 2018 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.
All user trade marks and name mark descriptions, even those which are not marked as such,
are properties of the respective owners.
Edition: 2018-05-04, V01

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Content
1 Introduction ................................................................................................................................. 5
1.1 Intended use.......................................................................................................................................5
1.2 About us...............................................................................................................................................6
2 Information for product and safety ......................................................................................... 7
2.1 Safety manual ....................................................................................................................................7
2.2 Safety precautions............................................................................................................................7
3 Description ................................................................................................................................... 8
3.1 Task ........................................................................................................................................................8
3.2 Gas ow diagram..............................................................................................................................8
3.3 The measuring instrument............................................................................................................9
3.4 Connectors....................................................................................................................................... 10
3.5 Probes ................................................................................................................................................ 10
3.6 Gas sampling probe “TR”............................................................................................................. 11
3.7 Gas conditioning............................................................................................................................ 11
3.8 IR measurement ............................................................................................................................. 12
4 Operation.................................................................................................................................... 13
4.1 Commissioning............................................................................................................................... 13
4.2 Switch on .......................................................................................................................................... 13
4.3 Switch o / Reset ........................................................................................................................... 13
4.3.1 Switch o................................................................................................................................. 13
4.3.2 Reset.......................................................................................................................................... 13
4.4 Operating panel ............................................................................................................................. 14
5 Settings ....................................................................................................................................... 15
5.1 Analyzer settings............................................................................................................................ 15
5.2 Setting time and date .................................................................................................................. 16
5.3 Conguration of measurement program ............................................................................. 16
5.4 Gas ow measurement................................................................................................................ 18
6 Measurement ............................................................................................................................. 19
6.1 Preparation of each measurement.......................................................................................... 19
6.1.1 Power supply.......................................................................................................................... 19
6.1.2 Charging state of the battery........................................................................................... 19
6.1.3 Connections to the instrument ....................................................................................... 19
6.1.4 Operating temperature...................................................................................................... 20
6.1.5 Filter........................................................................................................................................... 20
6.1.6 Switch-on, warm-up phase, zero point......................................................................... 20
6.1.7 Instrument leak test............................................................................................................. 21
6.2 How to take a Measurement...................................................................................................... 21
6.2.1 Fuel type selection and O2reference............................................................................. 21
6.2.2 Store the measurement results ....................................................................................... 22
7 Maintenance and cleaning ...................................................................................................... 23
7.1 Cleaning and maintenance........................................................................................................ 23

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8 Data memory.............................................................................................................................. 24
8.1 Organization of the Data memory .......................................................................................... 24
8.2 Information about the data memory ..................................................................................... 24
8.3 Site administration........................................................................................................................ 24
8.4 Data transfer via USB (CSV export) .......................................................................................... 26
8.5 Export of measurements............................................................................................................. 26
9 Extras ........................................................................................................................................... 27
9.1 Access key......................................................................................................................................... 27
9.2 Internal Log Settings .................................................................................................................... 27
9.3 Service values.................................................................................................................................. 28
9.4 Analog output setup (4 – 20 mA)............................................................................................. 28
9.4.1 Setting of lower limit (4 mA):............................................................................................ 29
9.4.2 Setting of upper limit (20 mA): ........................................................................................ 29
9.4.3 Setting analog outputs during zeroing........................................................................ 29
9.4.4 Pin assignment of the 4-20 mA interface..................................................................... 30
9.5 Info ...................................................................................................................................................... 30
9.6 Options.............................................................................................................................................. 30
10 Information on the instrument components....................................................................... 31
10.1 Firmware update............................................................................................................................ 31
11 Specications ............................................................................................................................. 32
11.1 NDIR measured values................................................................................................................. 32
11.2 Technical data ................................................................................................................................. 32
11.4 Gas sampling and conditioning ............................................................................................... 33
11.4.1 Electrochemical-, temperature- and pressure sensors ........................................... 33
11.5 Calculated values........................................................................................................................... 34
11.5.1 Data communication........................................................................................................... 34
11.5.2 Analysis and calculations................................................................................................... 34
11.6 Fuel types.......................................................................................................................................... 35
12 Appendix..................................................................................................................................... 36
12.1 Error diagnosis regarding the measuring instrument...................................................... 36
12.2 Insert a static IP-address.............................................................................................................. 37
12.2.1 Settings for the software MRU4win............................................................................... 39
12.3 Spare parts ....................................................................................................................................... 41
13 Declaration of conformity........................................................................................................ 42

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MGA prime Version 1
Introduction
1 Introduction
yThis manual enables you to understand and safely operate this MRU
Analyzer MGAprime.
yPlease read this manual with great vigilant and get familiar with the
product before using it.
yThis analyzer may only be operated by competent personnel and for its
intended use.
yPlease pay special attention to all safety directions and warnings to
prevent personal injuries and damaging of the product.
yWe can’t be held responsible for any injuries and/or damages that oc-
cur by not following the instructions in this manual.
yAlways keep the manual near you when working with the analyzer, to
be able to read instructions as needed.
Please ensure to hand over all documents to when handing the analyz-
er over to others.
1.1 Intended use
The Analyzer MGAprime is designed for the gas analysis of ue gases,
as they are emitted from gas/oil burners, engines, or heating and power
appliances.
The instrument is intended to support the user in control and indicative
measurements in an ecient, accurate and reliable way
The analyzer is specically not intended as a safety device or personal
protective equipment; it should not be used as a warning device to warn
people against the presence of harmful gases.
The instrument was manufactured according relevant normatives and
regulations. It has to used within it’s intended use.
The Instrument must not be modied from the design or safety engineer-
ing.
Modications of any kind by the user will render the declaration of
conformity.
Syntax
Please note that this manual makes use of the scientic notation of gases
(NO2), while the instrument itself and it’s screen shots display the gases in
upper case letter only, i.e. (NO2).
This instrument meets the requirements of the valid
European and national regulations.
You can ind the declaration of conformity in the ap-
pendix.

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Introduction
1.2 About us
The Analyzer is produced by the MRU GmbH in Neckarsulm, Germany
(founded in 1984), a medium sized company that specializes in develop-
ing, producing and marketing high quality emission monitoring analyz-
ers. MRU GmbH produces a wide range of instruments, from standard
analyzers up to tailor made industrial analyzers.
Plant 1: Sales, Service, R&D
Plant 2: Production
MRU GmbH
Fuchshalde 8 + 12
74172 Neckarsulm - Obereisesheim
GERMANY
Fon [phone] (Zentrale)
Fon [phone] (Kundendienst)
Fax [phone]
Email: [email protected]
Internet: www.mru.eu

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Information for product and safety
2 Information for product and safety
2.1 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 rst use of
the instrument.
Instrument-specic safety and warning requirements in this manual are
prexed before dangerous actions.
2.2 Safety precautions
The used category’s of safety precautions are here explained once more.
Identies an immediate, impending hazard that, if ignored, will result in
severe bodily injuries or death.
DANGER
Identies an immediate, impending hazard that, if ignored, may result in
severe bodily injuries, material damage or death.
WARNING
Identies a possibly dangerous situation that, if ignored, may result in
minor injuries.
CAUTION
ATTENTION
Identies a possibly harmful situation that, if ignored, may result in dam-
ages to the device or its surroundings.
NOTE
Identies user tips and other especially important information.

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Description
3 Description
3.1 Task
The instrument is designed for the gas analysis of ue gases, as they are
emitted from gas/oil burners, engines, or heating and power appliances.
The instrument is intended to support the user in control and indicative
measurements in an ecient, accurate and reliable way
The instrument provides a full set of all equipment and sensors required
for a emission control measurement:
yheated probe incl heated lter
yheated sample line
ygas conditioning unit including lters and gas cooler
ygas pump and ow control
ygas sensors
Available accessories include sensors for temperature or ow measurement.
The user interface allows for a modern and intuitive way to operate the
instrument. Running a commercial LINUX operating system, it allows as
well for lot of options for data transfer and storage.
For an overview on all available options please refer to the company’s
home page or sales representatives.
3.2 Gas ow diagram
The analyzer draws a sample of the ue gases from the duct using a built-
in gas pump through the probe is cleaned and dried using a gas cooler
and built-in lter and analyses the extracted gas with electrochemical
and NDIR sensors.
Draft and temperature are measured at the tip of the sampling probe.
A
B
C
D
E
F
2 3 5 2 6 7
11 9 2
4
810
1

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Description
A Fresh air inlet B Sample gas inlet
C Condensate outlet D Di. Pressure connector
E Vent collection box F Vent outlet
1 Sample gas lter (PTFE) 2 Dust lter
3 Auto-zero solenoid valve 4 Sample gas pump
5 Double stage gas cooler 6 Sample ow sensor
7Oxygen sensor
O2-ECS or O2 paramagnetic 8 Vent pump
9 Infrared (NDIR) bank 10 Acrodisc PTFE lter
11 Di. pressure sensor
3.3 The measuring instrument
The measuring instrument consists of a compact and robust metal hous-
ing 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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Description
3.4 Connectors
1 Loudspeaker 2 Ethernet (LAN)
3 USB socket 4 Second USB socket (Option)
5 RS485 (Option) 6 Analog outputs 4 ... 20 mA
7 Mains power supply 8 Sample gas lter
9Condensate 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 Outlet fan of gas cooler
15 Pressure-/di. pressure 16 Pressure-/di. pressure
(Absolute pressure)
17 Combustion air temperature 18 AUX socket
3.5 Probes
The Analyzer is available with dierent probes, both with xed and ex-
changeable probe tubes.
yfor high and less dust content
yfor fuel temperatures up to 800 °C (stainless-steel probe tube),
yfor fuel temperatures up to 1.200 °C (Inconel steel probe tube),
yfor fuel temperatures up to 1.700 °C (ceramic probe tube)
ywith and without heated pre-lter
ywith and without heated gas sampling line
yprobe tubes in dierent lengths, from 300mm to 2000mm
A complete list of available probes can be found in the current price list
of this analyzer.
16 1 2
4
5
6
8
9
10
11
12
13
15
14
7
17 18
3

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Description
3.6 Gas sampling probe “TR”
Heated probe with heated and exchangeable glass lter. The probe
tube includes a gas temperature sensor and is available in dierent
tube lenghts.
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
3.7 Gas conditioning
The sucked sample gas is dried and ltered before it is fed to the sensors.
A double stage sample gas cooler with Peltier element is used for dry-
ing. 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.
The VENT output delivers the sample gas after the analysis stage. If
For subsequent ltering, a round lter is used on the front of the measur-
ing instrument.
1
5
6
7
8
9
2 3 4

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Description
3.8 IR measurement
The instruments NDIR gas sensor is able to detect up to 8 dierent gases.
It is most advanced in terms of its long-term stability due to a dedicated
stabilization technology including a permanent zeroing by operating the
bench at two dierent gas pressure values.
Due to its low noise and being drift free, it is perfectly suited to long-
term measurements.
Principle of the IR-bench (NDIR)
1 IR source 2 Gas entry
3 Sample gas cell 4 Gas exit
5 Band pass lter 6 IR detector
An infrared source delivers IR radiation in the wavelength range between
1 and 10 um, which is relevant for the absorption of gas components to
be measured.
The target gas absorbs a portion of the IR radiation, which is detected by
a wavelength selective detectors and the end of the sample gas cell.
The absorption value is correlated with the gas concentration, while all
eects of cross sensitivity to other gases are corrected by an internal
software algorithm.
As the IR bench is operated successively at two dierent gas pressure
values, it is possible to eliminate all drift eects, which would otherwise
contribute to the absorption signal.
21 3 4 5 6

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Operation
4 Operation
4.1 Commissioning
The instrument is delivered as a complete assembly ready for use.
fCheck the instrument regarding condition and integrity after delivery.
fConnect the instrument to the power grid.
ÖThe instrument switches on and start the operating system.
ÖBlue LEDs for ON and power supply are switched on.
ÖThe instrument runs a start procedure which includes:
yself test
ywarm-up of the NDIR bench
ycool down the double stage gas cooler, indicated by the symbol
yZeroing, indicated by symbol
fCharge battery for more than 8h is recommended after rst start to
allow the battery to charge completely. Operation of heated probe and
sample line is only supported when connected to power grid.
ÖThe battery is charged as soon as teh connection to power grid is
established.
ÖThe blue LED will be blinking slowly.
Heating of probe and probe tube are unsupported in battery mode.
4.2 Switch on
fTouch the ⏻button for 3 sec. minimum
ÖLED lights blue
fRelease the ⏻ button
ÖLED lights red, analyzer runs up
4.3 Switch o / Reset
4.3.1 Switch o
fTouch the “Context menu”on the display
f“Turn instrument o”
ÖDo you wish to turn instrument o?
f“YES”
Ö“The system will shut down”
or
fTouch the ⏻button
ÖDo you wish to turn instrument o?
Ö“YES”
Ö“The system will shut down”
4.3.2 Reset
fTouch the ⏻ button during ashing LED for 30 sec. minimum
fAfter change to continuous lighting, release the ⏻button
ÖThe instrument will switching o with reset

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Operation
4.4 Operating panel
All functions are controlled via the touch surface of the instrument. Dif-
ferent gestures are available in the individual menus and windows.
1 Power-on and reset
2 Reserve
3 Reserve
4 LED display mains operation/battery charging mode
5 Reserve
6 Current ow rate
7 Current temperatures heated hose
8 Selected measuring program, e.g. Test or measurement program
9 Current temperatures of NDIR bench
10 Current temperatures of gas cooler
11 Access to detailed information on the instrument components.
Especially for service or inquiry
12 Menu info
13 Menu contacts
14 Status bar: display of zero point, alarms, executed measuring pro-
gram, selected fuel, heat-up-, cool-down phase
15 Menu measure
16 Menu settings
17 Menu extras
18 Battery Charge indicator
19 Context menu with window-dependent additional functions
1
2
4
5
7
1915
8910 6
1412 1311 18
3
16 17

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Settings
5 Settings
After the analyzer has been inspected and is ready for start-up it can be
switched on and personalized settings can be entered. These settings can
be changed at any time.
5.1 Analyzer settings
After the analyzer has been inspected and is ready for start-up it can be
switched on and personalized settings can be entered. These settings can
be changed at any time.:
Country Option By changing the country the
O2 reference values settings
are lost. The fuel list is reset.
Similarly, country-specic
defaults and methods of
measurement are selected as a result.
Ensure the correct setting of the country
in which you are performing the measure-
ment to ensure that all relevant ones are
set up
Language Option Select instrument languages
Modbus slave Modbus address of the instrument for the
remote control via Modbus
Temperature
heating hose
130°C -
+180 °C
Combustion
analysis
on/o Setting combustion analysis to ON
allows for several calculation performed
by the instrument, which are fuel type
dependent, e.g. Lambda, heat loss.

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Settings
Negative gas
readings
on/o Negative gas readings Caused by tem-
perature drift of a sensor are suppressed
(shown as zero) or displayed
VNC on/o VNC Viewer for remote control via LAN
Reference tem-
perature
Calculation of the values for a standard
state at reference temperature
Interval
auto-zero
Interval time after which the instrument
performs a zero-point
5.2 Setting time and date
In the Extras menu, you can check the date and time and, if necessary, set
it. When connected to the Internet, the time automatically synchronizes
itself.
fThe time and date can be set in the middle black number series by
pushing up and down the gray number row.
fAccept the changes with ACCEPT.
5.3 Conguration of measurement program
The Analyzer provides in the Measure menu various measurement
programs, which can be selected in the main window. Each measuring
program denes the properties of the measuring window:
yMeasurement program
The measured value window can be freely set with regard to the dis-
played measured values, of the underlying fuel. The purge limit of the CO
sensor (if available) can be set
yTest program
The measured value window shows predened values and cannot be
changed. Can be used in instrument testing to obtain standardized dis-
plays, e.g. can easily be checked with test gases.
yIf so, further measuring programs

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Settings
The measurement window for gas analysis can be congured and adapt-
ed to your needs. The measuring window initially displays 12 measured
values, by a scrolling gesture it will display more values.
Moving a value eld
fTouch and hold the value eld.
ÖValue eld will be framed.
fMove the value eld to a dierent position.
ÖThe other value elds move automatically.
Assign a measured value
fDouble touch the value eld.
ÖA list with of all available measured values is displayed.
fChoose the wanted value and“replace”.

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Settings
5.4 Gas ow measurement
Set up measurement window
With the ow measurement option are further measurements available:
yv-ow
yFlow rate
yMass ow carbon
Parameter for gas ow measurement
fChoose the right context button - menu item“gas ow measurement”.

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Measurement
6 Measurement
6.1 Preparation of each measurement
6.1.1 Power supply
The analyzer can be operated with an internal battery to warm up the
instrument or to use internal instrument functions. A mains connection
is required for the measurement including heated gas sampling probe and
heating hose.
6.1.2 Charging state of the battery
The battery symbol in the display indicates approximately the remaining
capacity of the battery.
From 2% remaining capacity, the charging indicator starts to ash red. If
the instrument is not connected to the mains power supply within one
minute, the analyzer switches o to prevent battery discharge.
Even when the battery is discharged, the instrument can be operated
completely on the power supply.
6.1.3 Connections to the instrument
fConnect the gas sampling probe to the instrument (gas plug and elec-
trical plug).
fConsider to connect a hose or collecting container if necessary to the
condensate outlet when appropriate.
fThe hose and any connected reservoir connected to the outlet must
not be closed against ambient or include an air outlet to avoid over-
pressure.
fPlease note that measuring gas may leak at the instrument side or at
the VENT outlet. Connect a pump to the VENT output to collect the
sample gas. If an “active VENT” option is installed, an internal gas pump
feeds the sample gas completely to the VENT outlet, where an evacuat-
ing gas hose should be connected.
fIn the case the option active vent is installed, note that the sample gas
at the exit may be diluted with ambient air and is therefore not ade-
quate to be reused in the process.
fEnsure that ambient fresh air can be sucked in at the fresh air inlet.
Consider to connect a hose leading to fresh ambient air, when the
instrument’s environment contains toxic gases or a high CO2 level.
Acid from the condensate
Acid burns may result from weakly acidic liquids from the condensate.
fIf you come into contact with acid, wash the area immediately using a
lot of water.
CAUTION
Risk due to toxic gases
There is a risk of poisoning.
Noxious gases are sucked in by the measuring device and released into
the ambient air.
fOnly use the measuring device in well ventilated spaces.
DANGER

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Measurement
fThe ow rate of the gas should be within the specied range. Other-
wise, please check probe and lter for clogging
fTemperatures of NDIR and heating hose should be within the specied
range in order to guarantee a sucient measuring accuracy.
In the Extras menu under “Connections” the connection drawings are
displayed:
6.1.4 Operating temperature
The internal gas cooler operates at 5°C, which is the dew point of the
sample gas to the sensors. Components along the gas line may be dam-
aged if they are colder than 5°C and condensation appears internally.
Therefore, if the Analyzer has been stored very cold below 0°C, it is essen-
tial to wait for the Analyzer to warm up in a warm environment in order
to avoid such condensation! In such cases, take a typical warm-up time
for the instrument of one hour into account, especially when wet ue
gases are to be measured.
If the operating temperature is not within the permissible range, a corre-
sponding message is displayed.
6.1.5 Filter
The probe lter and the round lter must be checked before and after
each measurement
6.1.6 Switch-on, warm-up phase, zero point
After switching on, the instrument can always be operated, even if no gas
analysis can take place during the warm-up phase. The instrument inde-
pendently performs the following actions during the warm-up phase: