mru NOVAplus BIOGAS User manual

MRU GmbH USER MANUAL NOVAplus BIOGAS
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MRU GmbH USER MANUAL NOVAplus BIOGAS
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MRU GmbH USER MANUAL NOVAplus BIOGAS
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CONTENT
1CONTENT........................................................................................................................................ 3
2INTRODUCTION ............................................................................................................................. 9
2.1 The NOVAplus BIOGAS ................................................................................................................. 9
2.2 The company MRU GmbH........................................................................................................... 10
2.3 Important general information.................................................................................................. 11
2.4 Important information about the users/operation manual .................................................... 11
3SAFETY INFORMATION................................................................................................................ 11
3.1 Safety regulations ...................................................................................................................... 11
3.2 Specific safety regulations ......................................................................................................... 11
3.3 Guideline for Li-Ion Batteries ..................................................................................................... 12
4RETURNED GOODS ...................................................................................................................... 12
4.1 Return of hazardous waste......................................................................................................... 12
4.2 Return of analyzer according to ElektroG ................................................................................. 12
5MEASUREMENT PRINCIPAL ........................................................................................................ 13
5.1 Gas flow diagram with gas cooler.............................................................................................. 13
6ANALYZER DESCRIPTION ............................................................................................................ 14
6.1 Remote control unit (RCU) front ................................................................................................ 14
6.2 Remote control unit (RCU) Connectors - top............................................................................. 14
6.3 Remote control unit (RCU) bottom side (option)...................................................................... 15
6.4 Remote control unit (RCU) back side ......................................................................................... 15
6.5 Base unit with gas cooler (option) ............................................................................................. 16
6.6 Connectors depending on the options (gas cooler) ................................................................. 17
7ACCESSORIES............................................................................................................................... 18
7.1 Gas sampling probes (optional for flue gas measurements)................................................... 18
8OPERATING THE ANALYZER ....................................................................................................... 19
8.1 The Display .................................................................................................................................. 19
8.2 Keypad ......................................................................................................................................... 20
8.3 Connection RCU to base unit...................................................................................................... 21

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8.4 Reset and Blink codes ................................................................................................................. 22
8.5 Menu configuration .................................................................................................................... 23
9FIRST USE OF THE INSTRUMENT................................................................................................. 24
9.1 Analyzer ready for operation ..................................................................................................... 24
9.2 Analyzer settings......................................................................................................................... 24
9.2.1 Measurement settings.........................................................................................................................................25
9.2.2 Switch-ON protection..........................................................................................................................................25
9.2.3 Print-out settings...................................................................................................................................................26
9.2.4 Bluetooth settings ................................................................................................................................................26
9.3 Setting time and date ................................................................................................................. 26
10 MAINTENANCE AND CLEANING.................................................................................................. 27
10.1 Cleaning ....................................................................................................................................... 27
10.2 Service and Maintenance ........................................................................................................... 27
10.3 Service-Maintenance Plan .......................................................................................................... 27
11 PREPARATION FOR EACH MEASUREMENT ................................................................................ 28
11.1 Power supply ............................................................................................................................... 28
11.2 Auto Off........................................................................................................................................ 28
11.3 Measurement with battery charger/battery charging............................................................. 28
11.4 Measurement with battery (Battery monitoring)..................................................................... 29
11.5 Operation temperature .............................................................................................................. 29
11.6 Connectors and leak tightness................................................................................................... 29
11.7 Power ON, Self-diagnostic and zeroing..................................................................................... 29
11.8 Repeating the zeroing ................................................................................................................ 30
12 HOW TO TAKE A MEASUREMENT ............................................................................................... 31
12.1 Selection of the measurement program ................................................................................... 31
12.2 BIOGAS measurement ................................................................................................................ 31
12.3 Flue gas measurement (option) ................................................................................................. 32
12.1 CO-limit (only with optional flue gas neasurement) ................................................................ 33
12.2Storage the measuring results................................................................................................... 33
12.3 Printing the measurement results ............................................................................................. 33
12.4 End of measurement ................................................................................................................... 33

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12.5 Last measurement results .......................................................................................................... 33
12.6 Pressure measurement............................................................................................................... 34
12.7 Differential temperature measurement.................................................................................... 35
13 DATA STORAGE ........................................................................................................................... 36
13.1 Organisation of the data memory ............................................................................................. 36
13.2 Information about the data memory......................................................................................... 36
13.3 Site administration..................................................................................................................... 37
13.3.1 View and search sites...........................................................................................................................................37
13.3.2 New entry and change of sites.........................................................................................................................39
13.3.3 Delete sites ..............................................................................................................................................................39
13.4 Data transfer via SD Card (Option) ............................................................................................ 40
13.4.1 Import of Sites........................................................................................................................................................40
13.4.2 Export of Sites.........................................................................................................................................................41
13.4.3 Export of Flue Gas Measurements ..................................................................................................................41
13.4.4 Export of Differential Pressure Measurements...........................................................................................42
13.5 Measurements in the data memory........................................................................................... 42
13.5.1 View measurements.............................................................................................................................................42
13.5.2 Delete measurements .........................................................................................................................................43
13.5.3 Export measurements to a SD card (optional) ...........................................................................................43
14 EXTRAS / ADJUSTMENTS............................................................................................................. 44
14.1 User definable Logo print out .................................................................................................... 44
14.2 Maintenance adjustment menu................................................................................................. 46
14.3 Manufacturer default settings ................................................................................................... 46
14.4 Service values (RCU)/ Service values (Base unit) ...................................................................... 47
14.5 Leak proof test............................................................................................................................. 48
14.6 Contents SD card ......................................................................................................................... 49
14.7 Analyzer info................................................................................................................................ 50
15 TECHNICAL SPECIFICATIONS...................................................................................................... 51
15.1 General specifications................................................................................................................. 51
15.2 Gas conditioning ......................................................................................................................... 51
15.3 Measured values ......................................................................................................................... 52
15.4 Calculated values ........................................................................................................................ 55
15.5 Data communication................................................................................................................... 56
16 APPENDIX..................................................................................................................................... 58

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16.1 Text input..................................................................................................................................... 58
16.2 Asking the user for a decision (pop up window) ...................................................................... 58
16.3 Firmwareupdate NOVAplus BIOGAS ......................................................................................... 59
16.4 Analysis and calculations............................................................................................................ 61
16.5 Errors ............................................................................................................................................ 62
16.5.1 Error diagnosis regarding the measuring device......................................................................................62
16.6 Declaration of confirmity............................................................................................................ 63

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Inspect Shipment for Damage
Carefully inspect the entire shipment for damage in the presence of the shipper’s agent, removing packaging mate-
rial if necessary. Note any damage to packaging and/or goods on Packing List and have it signed by the shipper’s
agent prior to accepting the shipment. Submit damage claim to MRU immediately.
NOTE: Damage claims not received by MRU within 3 days of receipt of shipment will not be accepted.
Important notice!
This high quality electronic analyzer utilizes batteries that discharge even when the analyzer is not in use. Therefore
it is very important to charge the batteries (Li-Ion) every 6 months,
even if the analyzer is not in use.
Failing to properly charge the batteries will void your warranty!
Save the original box and the packing material for use if the analyzer must be shipped in the future.
The products described in this manual are subject to continuous development and improvement and it is therefore
acknowledged that this manual may contain errors or omissions. MRU encourages customer feedback and wel-
comes any comments or suggestions relating to the product or documentation.
Please forward all comments or suggestions to the Customer Feedback Department at the following address:
MRU GmbH
Fuchshalde 8 + 12
74172 Neckarsulm / Obereisesheim
GERMANY
Fon ([phone] (Reception)
Fon ([phone] (Service)
Fax [phone]
Email: [e-mail]
Homepage: www.mru.eu
This manual is intended solely as a guide to the use of the product.
MRU shall not be liable for any loss or damage whatsoever arising from content errors or misinterpretation of in-
formation’s from this manual or any mis-use resulting from the use of this manual.
Electrochemical sensors are by their operating principle not only sensitive to the gas they are
intended for, but for other gases as well.
This cross sensitivity is compensated by MRU for the typical application of gas analysis.
However, unusual high concentration levels of single gas components might lead to
•a reduced measurement accuracy of other gas components
•and to a temporary change of the sensitivity of sensors, which may require several
hours recovery time.
Especially concentration levels as high as several % for single gas components may affect the
measurement of other gas components at ppm level. Those applications need to be discussed
with MRU in detail.

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Intended use
The NOVAplus BIOGAS with optional flue gas measurement is only used for its application!
Safety instructions
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 ambient 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 as-
pects 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 concentration) cannot be detected by human nose. Only small concentrations
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 ven-
tilation 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
•Stationary instruments are not allowed to be mounted in hazardous areas; these instruments will
be placed in safe area only, but never in confined placed, always in outdoor area or room with
forced ambient air ventilation.
Only trained personnel should carry out installation of stationary instrument and/or maintenance, service and re-
pair. Opening the stationary analyzer cabinet can expose personnel to mains voltage!
MRU analyzer is not a personal safety device and the ambient
air monitoring feature is only indicative.
To enter in confined spaces or hazardous area, the persons
must be equipped with a certified personal safety gas detector

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2
INTRODUCTION
2.1
The NOVAplus BIOGAS
The NOVA BIOGAS 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 cal-
culation of: mg/m3, NOx as mg/m3 NO2, true NOx-measurement NOx = NO + NO2, referencing (normalisa-
tion) 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 optionals for this analyzer on our web page or you can contact MRU or our local repre-
sentative. The NOVAplus BIOGAS Analyzer is available in different versions. This manual will describe all versions
indicating optionals and features not always available on all versions.

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2.2
The company MRU GmbH
Your analyzer is produced by the MRU GmbH in Neckarsulm Germany (founded in 1984), a medium sized company
that specializes in developing, 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. MRU GmbH
contact details are listed on the previous page.
Factory 1 (service department, development division, administration)
Factory 2 (Product division)

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2.3
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.
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 measurement 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 regulations (for example a periodical examina-
tion of the analyzer). Please obtain the appropriate regulations from your local responsible authority.
2.4
Important information about the users/operation manual
The users/operation manual is an important part of this delivery. It will explain how to use this analyzer properly
and sets forth safety and environmentally friendly procedues.
It is the responsibility of all users to read and familiarize themselves with this manual, paying particular
attention to the safety instructions.
The most important safety details are listed in chapter 3 (Safety Information). Additional safety details in other chap-
ters are clearly marked with an
attention
sign.
3
SAFETY INFORMATION
The following safety procedures must to be followed at all times. They are a significant and essential part of this
manual. Failure to follow safety procedures can result in the loss of your warranty claims.
3.1
Safety regulations
1. The NOVAplus BIOGAS may only be used as indicated in this manual.
2. Our analyzers are checked according to the following regulations:
VDE
0411 (EN61010)
and
DIN VDE 0701
before they leave the MRU GmbH factory.
3. MRU technical products are designed and manufactured according to
DIN 31000/ VDE 1000
and
UVV = VBG 4
of the professional guilds for fine mechanics and electrical engineering.
4. MRU GmbH assures that the analyzer complies to the essential requirements of the legal regulations of the
member states of the electro-magnetic compatibility
(89/336/EWG)
and to the low-voltage regulations
(3/23/EWG)
.
3.2
Specific safety regulations
1. Use only the battery charger supplied with the analyzer for this instrument
2. No part of the analyzer, including the metal probe tube and all other metal parts & accessories are to be
used as electric conductors.
3. The analyzer is not to be used in or under water.
4. The analyzer is not to be placed near or directly exposed to open fire or heat.
5. The specified probe temperature range is not to be exceeded, as the probe, temperature sensory mecha-
nism and sensor could be damaged or destroyed.
6. The analyzer shall void dropping.
7. Attention:Caution: Moisture, being pumped out of the condensates trap can be slightly acidic.
In case of skin contact IMMEDIATELY: clean affected parts of the body.

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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.
8. Electrochemical sensors are by their operating principle not only sensitive to the gas they are in-
tended for, but for other gases as well. This cross sensitivity is compensated by MRU for the typi-
cal application of flue gas analysis. However, unusual high concentration levels of single gas
components might lead to a reduced measurement accuracy of other gas components and to a
temporary change of the sensitivity of sensors, which may require several hours recovery time.
Especially concentration levels as high as several % for single gas components may affect the measure-
ment of other gas components at ppm level. Those applications need to be discussed with MRU in detail.
3.3
Guideline for Li-Ion Batteries
•The battery pack is not Aplus for end users
•Li-Ion rechargeable battery pack for NOVAplus BIOGAS
•Do not heat or throw the battery pack of in fire.
Do not charge and leave the battery pack at the high temperature.
•Do not deform, short-circuit, disassemble or modify the battery pack
•Do not allow the battery to be immersed in or wetted with water or sea water
•Do not subject the battery pack to a strong impact or throw it
•Do not cut, squeeze, tear at the cables of the battery pack
•Do not carry or store the battery pack together with material which have sharp edges or is electrical con-
ductive in the same custody
•Not letting (+) terminal come in contact with (-) terminal or metal
The above items may cause heat, fire and explosion
Your quality management MRU GmbH
4
RETURNED GOODS
Packing regulation of 12.07.1991
If your local waste facility does not except MRU packing materials for disposal, you may return it to MRU or our
local sales representative. Packing materials returned to MRU must be returned prepaid.
4.1
Return of hazardous waste
- Waste Disposal/Returns/Warranty -
MRU GmbH is required to accept the return of hazardous waste such as electro-chemical sensors that cannot be
disposed of locally. Hazardous waste must be returned to MRU prepaid.
4.2
Return of analyzer according to ElektroG
MRU GmbH is required to accept the return, for proper disposal, of all analyzers delivered after 13th of August
2005. Analyzers must be returned to MRU prepaid.

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5
MEASUREMENT PRINCIPAL
A partial volume of the biogas is suckrd and analyzed using NDIR and electrochemical sensors on its ingredients.
5.1
Gas flow diagram with gas cooler
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

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6
ANALYZER DESCRIPTION
6.1
Remote control unit (RCU) front
6.2
Remote control unit (RCU) Connectors - top
1
Display
2
Keypad
1
Cover
2
SD-card slot
(only by using a MRU-SD-CARD
we can assure the compatibility
of all analyzer functions)
3
USB port

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6.3
Remote control unit (RCU) bottom side (option)
6.4
Remote control unit (RCU) back side
1
Eyes for shoulder strap
2
Handle strip
3
Contactless battery charging
4
Analyzer feet
5
Fixing magnets
1
Pressure connection 1
2
Pressure connection 2
(Diff. pressure)
3
AUX connector
4
Temperature connection 1
5
Temperature connection 2

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6.5
Base unit with gas cooler (option)
6
Aerial
13
LED condensate container
7
ON-/OFF key button
14
Fan gas cooler
8
Built-in speed printer
15
Outlet for condensate
9
Gas outlet
16
Star filter
10
Connector T-gas
17
Connector T-Ambient air (combustion air)
11
Charging socket
18
Charging frame for Remote control unit
12
Condensate container
X
Connectors see chap. 6.9

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6.6
Connectors depending on the options (gas cooler)
Connector
2
3
4
5
Models
1 pressure sensor
standard
draft /
pressure -
gas inlet
pressure +
2 pressure sensors
Option Diff. Pressure
measurement with
2nd internal pres-
sure sensor
draft
gas inlet
pressure -
pressure +

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7
ACCESSORIES
7.1
Gas sampling probes (optional for flue gas measurements)
The NOVAplus BIOGAS is available with different probes, both with fixed and exchangeable 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:
Probe Probe
with 300 mm probe pipe (fixed) with 300 mm exchangeable probe pipe
and 2,7 m sampling line and 2,7 m sampling line
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

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8
OPERATING THE ANALYZER
8.1
The Display
All information required to operate the analyzer is displayed as shown below.
1
Menu bar
2
Function key bar
3
Display panel
-Menu
-Measurement value,…
4
Zeroing active
5
SD-Card in the slot
-Indication green Read- and write access
-Indication yellow only Read access (SD-Card write protected)
Indication red SD-Card is damaged SD-Card is damaged
6
Blue: Bluetooth connection base unit to RCU
Red: No Bluetooth connection base unit to RCU
Yellow: Base unit is in the update mode
(Press ON-key at the base unit for changing to the measurement mode)
7
Battery charge condition base unit
8
Battery charge condition RCU

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8.2
Keypad
Description and function of the keys:
ON/OFF
By pressing the ON/OFF button the RCU will start up without delay.
By pressing the ON/OFF button the base unit and the RCU (if RCU is
placed in the charging doc) will start up.
The powering down of the unit is timely delayed to protect the sen-
sors if there is no fresh air inside the system. If there is no fresh air
inside the system the analyzer will recommend a purging of the sen-
sors.
Function Keys
Activates the functions seen on the display (2 function key bar)
Menu Key
Will show all available functions in the window that is currently in use
– also those which have an individual key on the key pad like the
printer and the three function keys.
ESC
Abort or return to the menu above
Arrow Keys
Jump in between lines, change values
OK
Confirmation key, select a marked menu point
Printer Key
Activates the print out of the measuring results in the measuring
screen in a pre-defined format.
Linefeed when there is no printable display condition.