mru NOVAplus biogas User manual

9472EN-BIO
NOVAplus biogas
USER MANUAL

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 2 / 84
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Original user manual
© 2022 by MRU
No part of this manual my be published in any form (print, fotocopy, 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: 2022-02-10-V1.20.EN

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 3 / 84
Table of content
1Information for product and safety............................................... 7
1.1. Safety manual .................................................................................................7
1.2. Safety precautions.........................................................................................7
1.3. Ensure safety ...................................................................................................8
1.4. Important general information.............................................................. 10
1.5. User guideline for rechargeable batteries......................................... 11
2Introduction.................................................................................... 12
2.1. Intended use ................................................................................................ 12
2.2. About us ........................................................................................................ 14
2.3. Packaging...................................................................................................... 15
2.4. Return of hazardous materials .............................................................. 15
2.5. Return of electronic equipment............................................................ 15
3Description...................................................................................... 16
3.1. Gas flow diagram........................................................................................ 16
3.2. Remote control unit (RCU)...................................................................... 17
3.3. Base unit ........................................................................................................ 18
Connectors depending on the options (gas cooler) ............................. 19
3.4. Gas sampling probes ................................................................................ 20
4Operating ........................................................................................ 21
4.1. Display............................................................................................................ 21
4.2. Keypad............................................................................................................ 22
4.3. Connection Remote control unit (RCU) to base unit..................... 23
Declaration of symbols..................................................................................... 23
4.4. Reset and Blink codes............................................................................... 25
4.5. Menu structure............................................................................................ 25
5First usage ....................................................................................... 27
5.1. Preparatory steps ....................................................................................... 27
5.2. Analyzer settings ........................................................................................ 27
5.3. Measurement settings.............................................................................. 28
5.4. Switch-On protection................................................................................ 29
5.5. Print-out settings........................................................................................ 29
5.6. Bluetooth settings...................................................................................... 30
5.7. Setting date and time ............................................................................... 30
5.8. Configuring Measurement Programs ................................................. 31
5.9. Setting CO limit value............................................................................... 31
5.10. Select fuel types and O2 reference...................................................... 32
Adding fuels to Fuel type selection............................................................. 32

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 4 / 84
Setting O2reference..........................................................................................32
5.11. Defining user fuels type ...........................................................................33
5.12. Defining measurement windows .......................................................... 34
5.13. Configuring zoom window......................................................................34
5.14. Changing measurement program names.......................................... 35
6Preparing measurement ................................................................36
6.1. Ensure power supply .................................................................................36
6.2. Automatic Auto off function...................................................................36
6.3. Measuring with grid power supply / Battery charging.................36
6.4. Battery charge condition .........................................................................36
6.5. Operating temperature ............................................................................37
6.6. Connections and tightness .....................................................................37
6.7. Automatic zero-point setting.................................................................38
6.8. Repeating the zeroing .............................................................................. 38
7Performing measurement .............................................................39
7.1. Select measuring program......................................................................39
7.2. Performing Biogas measurement.........................................................40
7.3. Flue gas measurement..............................................................................41
7.4. Setting CO-limit (only with optional flue gas measurement)..... 42
7.5. Storing measured values .........................................................................42
7.6. Terminate measurement..........................................................................42
7.7. Printing measurement results................................................................42
7.8. Last measurement values ........................................................................43
7.9. Pressure measurement.............................................................................44
7.10. Differential temperature measurement..............................................45
7.11. Performing measurements on CHP units (option) .........................46
7.12. Performing Auto-measurement (Option)..........................................47
Auto-measurement incl. data logger..........................................................47
Semi-continuous Auto-measurement incl. data logger.......................49
Selecting sites ......................................................................................................49
8Data Storage ...................................................................................50
8.1. Organizing data storage ..........................................................................50
8.2. Calling up information about data storage ......................................50
8.3. Site administration .....................................................................................51
Create new site....................................................................................................51
View sites...............................................................................................................52
Searching site.......................................................................................................52
Changing sites..................................................................................................... 53
Deleting sites ....................................................................................................... 54
Data transfer using SD card (option)...........................................................55
Importing sites ....................................................................................................55
Exporting sites .....................................................................................................57

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 5 / 84
Exporting combustion measurements........................................................ 57
Exporting differential pressure measurements ....................................... 58
8.4. Measurements in Data storage ............................................................. 58
Viewing Measurements.................................................................................... 58
Deleting Measurements................................................................................... 59
Transferring measurements to SD-Card (Option) .................................. 60
9Extras / Adjustments...................................................................... 61
9.1. User definable Logo print out................................................................ 61
9.2. Service calibration menu ......................................................................... 63
9.3. Default settings ........................................................................................... 64
9.4. Service values RCU / Service values Base unit ................................. 65
9.5. Performing leak test .................................................................................. 66
9.6. Contents SD card........................................................................................ 67
9.7. Contents Analyzer info ............................................................................. 68
Options list remote control ............................................................................ 68
Options list base unit........................................................................................ 68
9.8. Self diagnostics ........................................................................................... 69
10 Maintenance and care ................................................................ 70
10.1. Cleaning......................................................................................................... 70
10.2. Maintenance................................................................................................. 70
10.3. Service messages........................................................................................ 70
10.4. Check/replace optional water stop filter ........................................... 71
11 Appendix...................................................................................... 72
11.1. Technical data.............................................................................................. 72
General Data ........................................................................................................ 72
Gas conditioning and sampling.................................................................... 73
Measured values................................................................................................. 73
Calculated values................................................................................................ 76
Data communication......................................................................................... 77
11.2. Analysis and calculations......................................................................... 78
11.3. Text input ...................................................................................................... 79
11.4. Asking user for decision........................................................................... 79
11.5. Firmware update......................................................................................... 80
11.6. Troubleshooting ......................................................................................... 82
Troubleshooting the analyzer........................................................................ 82
12 Declaration of conformity ......................................................... 83

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 6 / 84

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 7 / 84
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.

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 8 / 84
1.3. Ensure safety
►Please read the user manual completely before the first use.
►Only use the analyzer for the intended use and within the parameters
specified in the technical data.
►Do not use any violence.
►Avoid falls.
►Do not put the analyzer into use, if the housing, power supply unit or
supply leads are damaged.
►Do not store the analyzer together with solvents. Do not use
desiccants.
►Only carry out maintenance and service work on this analyzer as de-
scribed in the User Manual. Observe the prescribed action steps.
►Operate the analyzer only in closed, dry rooms and protect it from
rain and moisture.
►When operating the analyzer on mains power, operate it only with
the mains adapter supplied
►The analyzer must not be located in the immediate vicinity of open
fire or great heat.
►Do not use the metal tube of the gas sampling probe or other metal-
lic parts / accessories as electrical conductors.
►Do not use the analyzer in or under water.
►The specified temperature range of the gas sampling probe must not
be exceeded, otherwise the probe tube and temperature sensor will
be destroyed.
►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.
►After measurement, vent the analyzer with ambient air and allow the
probe to cool. A hot probe could cause burns or ignite flammable
material.
►Electrochemical sensors are by their operating principle not only sen-
sitive to the gas they are intended for, but for other gases as well.
This cross sensitivity is compensated by MRU for the typical applica-
tion of flue gas analysis. However, unusual high concentration levels
of single gas components might lead to a reduced measurement ac-
curacy of other gas components and to a temporary change of the
sensitivity of sensors, which may require several hours recovery time.
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

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 9 / 84
Biogas or other similar gases (landfill gas, bio-methane, coal seam gas etc) is
containing flammable component CH4 and toxic component as well (H2S and
CO2).
Analyzers sample a certain volume of the biogas, and vent it to the am-
bient air.
For this reason, there are two aspects which must be considered:
1.) toxicity danger of sample gas
2.) flammable (explosion) danger of sample gas
1) Inhaling toxic gases is harmful to health and can even cause death in
some cases.
•It is the responsibility of analyzer user to ensure that person is
skilled and trained in safety aspects of gases being analyzed
and procedures to follow while using this instrument.
•Local regulations for possible exposition to toxic gases have to
be known by the user and obeyed by the user of the analyzer
•Using a personal gas detector inside the biogas plant is highly
recommended since H2S in higher (very dangerous concentra-
tion) cannot be detected by human nose. Only small concen-
trations around few ppm can be detected by human nose
•CO2 gas is heavier than air and therefore operator shall avoid
using portable biogas analyzer at underground levels. Beside of
that CO2 is also odourless!
•It is not allowed using the portable biogas analyzer in confined
space or rooms without sufficient ventilation.
•Sample gas exiting the analyzer will flow in the ambient air and
only outdoor use or forced ventilation rooms are suitable for
using the portable biogas analyzer
2) Regarding flammable gases (e.g. CH4 methane) and hazardous area
of operating the instruments, user must also be able to recognize the
area classification and be aware of using the instrument there. This area
classification is country specific, please observe and notice it.
•MRU instruments may be operated in hazardous areas zone 2
by skilled users obeying local guidelines e.g. by using LEL gas
detectors.

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 10 / 84
1.4. Important general information
This analyzer is not designed to be used for continuous measurements.
Before using the analyzer verify the condition of the various parts of the
analyzer, such as the probe, the ambient air conditions, the condensate
separator, star filter and the connectors for damage and/or blockages.
Depending on the state of the electrochemical sensors, the time taken
to reach the operating status after switching on is 1 to 3 minutes (zero-
ing) or 4 to 9 minutes with an installed 2-gas cuvette
When starting up the analyzer 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 analyzer to achieve correct measure-
ment values can be expected by 1.5 minutes!
Caution: Exposure to acids; aggressive gases such as sulphur; vapours
such as thinners, gasoline, 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; CO - 2 - 3
years and NO - 3 years.
The use of the analyzer for regulatory purposes is subject to special reg-
ulations (for example a periodical examination of the analyzer). Please
obtain the appropriate regulations from your local responsible author-
ity.

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 11 / 84
1.5. User guideline for rechargeable batteries
NOTE
The rechargeable batterie is installed inside the ana-
lyzer and is not accessible to the end customer. How-
ever, the following instructions must generally be ob-
served when handling lithium-ion rechargeable batter-
ies.
•This rechargeable battery can only be used in this analyzer.
•Do not throw the rechargeable battery into a fire, charge it at high
temperatures and store it in a hot environment.
•Do not deform, short-circuit or modify the rechargeable battery.
•The rechargeable battery must not be used in or under water.
•Do not expose the rechargeable battery to strong mechanical forces
and do not throw it.
•Do not cut or squeeze the connecting cables of the rechargeable
battery.
•Do not connect the (+) contact to the (-) contact or metal.
•Non-observance of the above guidelines can cause heat, fire and
explosions

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 12 / 84
2Introduction
•This manual enables you to understand and safely operate this MRU
Analyzer.
•Please read this manual with great vigilant and get familiar with the
product before using it.
•This analyzer 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
occur by not following the instructions in this manual.
•Always 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 analyzer over to others.
2.1. Intended use
The analyzer is used for:
•for BIOGAS simultaneous measurements of O2, CH4, CO2, H2S
and optional the BIOGAS pressure
•optional for combustion measurements of the engine: O2, CO,
NO, NO2and CO2(NDIR) including the calculation of: mg/m3,
NOx as mg/m3 NO2, true NOx-measurement NOx = NO + NO2,
referencing (normalisation) to user settable value
It can also be used (when optionals are activated or external equipment
is used) for a number of measurement tasks, such as:
•Flow velocity measurement
•Differential measurement of pressure and temperature
•Combustibles detection with external HC sensor
•Automatic measurement with data logging
You will find a list of all options for this analyzer on our web page or
you can contact MRU or our local representative. The NOVAplus BIO-
GAS Analyzer is available in different versions. This manual will describe
all versions indicating optionals and features not always available on all
versions.

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 13 / 84
The analyzer is specifically not intended as a safety device or personal
protective equipment.
The analyzer should not be used as a warning device to warn people
against the presence of harmful gases.
The analyzer must be used according to instructions for the intended
use.
Our analyzers are checked according to the following regulations:
VDE 0411 (EN61010) and DIN VDE 0701 before they leave the MRU
GmbH factory.
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.
MRU GmbH assures that the analyzer complies to the essential require-
ments of the legal regulations of the member states of the electro-mag-
netic compatibility (89/336/EWG)
WARNING
Risk from manipulations to the measuring device
Operational safety hazard
►Modifications or changes to the measuring device are
not allowed.

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 14 / 84
2.2. About us
The analyzer is produced by the MRU GmbH in Neckarsulm, Germany
(Founded in 1984), a medium sized company that specializes in devel-
oping, producing and marketing high quality emission monitoring
analyzers. 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)
Fuchshalde 8 + 12
74172 Neckarsulm - Obereisesheim
GERMANY
Tel [phone] (Front office)
Tel [phone] (Service)
Fax [phone]
Email: [email protected]
Site: www.mru.eu

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 15 / 84
2.3. Packaging
Save the original carton and packing materials to prevent damage in
transit in case you need to return the unit to the factory.
2.4. Return of hazardous materials
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.
2.5. Return of electronic equipment
MRU GmbH is required to accept the return, for proper disposal, of all
analyzers delivered after 13th of August 2005. Analyzers must be re-
turned to MRU prepaid.

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 16 / 84
3Description
3.1. Gas flow diagram
A partial volume of the biogas is sucked and analyzed using NDIR and electro-
chemical sensors on its ingredients.
Position
Description
Position
Description
B
Gas inlet
7
Filter
C
Differential pressure -
11
NDIR bench
D
Differential pressure
+
12
O2 sensor
E
Draft
13
CO sensor
F
Fresh air inlet
14
NO sensor
G
Gas outlet
15
NO2 sensor
H
Condensate outlet
16
SO2 sensor
K
Fresh air inlet for
zeroing
17
Sensor chamber
1
Gas cooler
18
Purge pump
2
Star filter unit
19
Filter
3
Hose pump
20
Pressure sensor
4
Non return valve
21
Pressure sensor
5
Filter
22
Air filter
6
Gas pump
23
Valve for zeroing

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 17 / 84
3.2. Remote control unit (RCU)
Position
Description
Position
Description
1
Keypad
2
Display
3
Cover
4
SD-card reader
(only by using a MRU-
SD-CARD we can assure
the compatibility of all
analyzer functions)
5
USB port
6
Eyes for shoulder strap
7
Analyzer feet
8
Fixing magnets
9
Contactless battery charg-
ing
10
Handle strip
11
Analyzer feet
12
Fixing magnets
13
Temperature connection 1
14
Temperature connection
2
15
Pressure connection 1
16
Pressure connection 2
(Diff. pressure)
17
AUX connector

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 18 / 84
3.3. Base unit
Position
Description
Position
Description
6
Aerial
16
Filter unit for gas cooler
7
ON-/OFF key button
16.1
Filter vessel
8
Built-in speed printer
16.2
Star filter
9
Gas outlet
16.3
Water stop filter (optional )
10
Connector T-gas
16.4
Filter holder on basic unit*
11
Charging socket
17
Connector T-Ambient air
(combustion air)
12
Condensate container
18
Charging frame for Remote
control unit
13
LED condensate container
X
Connectors see chapter
Connectors depending on
the options (gas cooler),
Page 19.
14
Fan gas cooler
15
Outlet for condensate

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 19 / 84
Connectors depending on the options (gas cooler)
Connector
2
3
4
5
Models
1 pressure sensor
standard
draft /
pressure -
gas inlet
pressure +
TRGI
Option pipe tests
according TRGI
draft /
pressure -
gas inlet
TRGI
pressure +
2 pressure sensors
Option Diff. Pres-
sure measurement
with 2nd internal
pressure sensor
draft
gas inlet
pressure -
pressure +
NOTE
* Note on filter holder
Please note that the filter holder differs without option-
ally installed water stop filter differs
1
Filter holder without water stop

USER MANUAL NOVAplus BIOGAS
MRU GmbH, D-74172 Neckarsulm 20 / 84
3.4. Gas sampling probes
The Analyzer is available with different probes, both with fixed and ex-
changeable probe tubes.
A complete list of available probes can be found in the current price list
of this analyzer.
Below are two different probe types
1
Probe tube
2
Probe cone (high grade steel)
3
Hose
4
Connector for sample gas measurement
5
Connector for draft measurement
6
Connector for temperature measurement
Probe
with 300 mm probe pipe
(fixed) and 2,7m sampling line
Probe
with 300 mm exchangeable probe
pipe and 2,7 m sampling line