mru SWG 100 biogas User manual

MRU GmbH SWG 100 User Manual
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MRU GmbH SWG 100 User Manual
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MRU GmbH SWG 100 User Manual
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Content
1. General Information.......................................................................................................... 6
1.1. Weather and environmental conditions...................................................................... 6
1.2. Installation instructions............................................................................................... 6
1.3. General important instructions for the plant operator................................................. 6
1.4. Important information about the user’s operation manual.......................................... 7
1.5. Safety Information...................................................................................................... 7
1.6. Packing ...................................................................................................................... 9
1.7. Return of hazardous waste ........................................................................................ 9
1.8. Return of analyzer...................................................................................................... 9
1.9. MRU Warranty conditions .......................................................................................... 9
2. Analyzer Description...................................................................................................... 11
2.1. Intended use ............................................................................................................ 11
2.2. Type plate ................................................................................................................ 11
2.3. Possible applications and analyzer options ............................................................. 12
2.4. Principle of operation ............................................................................................... 12
2.5. Special functions of the analyzer ............................................................................. 14
2.6. Physical characteristic of the gas analyzer .............................................................. 15
3. Scope of supply and delivery ........................................................................................ 17
4. SD-card content.............................................................................................................. 18
5. Installation manual ......................................................................................................... 19
5.1. Overview.................................................................................................................. 19
5.2. Installation of the analyzer ....................................................................................... 20
5.3. Connection of main power supply............................................................................ 22
5.4. I/O modules: Installation and setting........................................................................ 23
6. Operation of the analyzer (HMI)..................................................................................... 25
6.1. Display and keypad.................................................................................................. 25
7. Analyzer commissioning manual............................................................................ 26
7.1. Check country and language ................................................................................... 26
7.2. Check date and time of the instrument .................................................................... 26
7.3. Configuration of the alarm relays ............................................................................. 27
7.4. Configuration of the Modbus.................................................................................... 29
8Binding to a process control system: I/O modules ..................................................... 31
8.1. Position of the IO module inside the analyzer.......................................................... 31
8.2. Pin assignment ........................................................................................................ 32
8.3. Analog outputs 4-20 mA .......................................................................................... 34
8.4. Alarm outputs........................................................................................................... 40
8.5. Analog inputs (4-20 mA) .......................................................................................... 45
8.6. Configuration of the external control (Option: IO module)........................................ 50
8.7. Mounting and installation of the gas cylinders for the auto calibration function ....... 57
8.8. Cycle configuration .................................................................................................. 60
8.9. Administrator PIN code ............................................................................................ 66
8.10. Power-On of analyzer .............................................................................................. 66
9. Operating the analyzer.............................................................................................. 67
9.1. General process of the measurement cycle............................................................. 67
9.2. Data Storage Menu.................................................................................................. 70
9.3. Extra menu: Overview.............................................................................................. 74
9.4.Update the firmware................................................................................................. 83

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10. Service and maintenance.......................................................................................... 87
10.1. Preparing and information about the maintenance .................................................. 87
10.2. Regular maintenance work by the operator ............................................................. 87
10.3. Position and overview of the service-parts............................................................... 88
10.4. Troubleshooting ....................................................................................................... 95
11. Technical specification .............................................................................................. 96
11.1. Technical specification: Electrochemical sensors.................................................... 98
11.2. Technical specification: NDIR-benches ................................................................... 99
12. APPENDIX.................................................................................................................... 100
12.1. Modbus via RS485 specification............................................................................ 100
12.2. Analyser Status (address 0 and some mirror addresses) ...................................... 104
12.3. Analyser System Alarm (address 2 and some mirror addresses).......................... 104
12.4. Spare parts list....................................................................................................... 105
13. Purchase options of the analyzer.......................................................................... 108
13.1. Option: Electric sample gas cooler......................................................................... 108
13.2. Option: Cabinet heater........................................................................................... 109
13.3.Option: Flame arrester........................................................................................... 110
13.4. Option: Multiple sample point switching and monitoring (time sharing) ................. 111
13.5. Option: Gas detector (%LEL CH4) to monitor air inside analyzer cabinet ............. 112
13.6. Option: Extra IO module with 4 channel 4-20 mA.................................................. 113
13.7. Option: H2S electrochemical cell measurement 0-2000ppm/4000ppm ................. 114
13.8. Option: Extern condensate-trap ............................................................................. 115
13.9. Option: RS485 to Profi-Bus converter.................................................................... 119
13.10. Option: RS485 to Ethernet converter..................................................................... 120
13.11. Configuration of the Ethernet module .................................................................... 121
13.12. Option: Connection the SWG100 with RS-485 converter to MRU4Win ................. 128
13.13. Option: NDIR-bench for CH4/CO2 analysis, 0-100% / 0-100% ............................. 131
13.14. Option: H2 thermal conductivity detector measurement 0-100%........................... 132
13.15. Option: NDIR-bench for 0-3.000ppm CO2/0-3.000…30.000ppm CH4 .................. 133
13.16. Option: Dilution-unit for H2S and CO electrochemical sensors ............................. 134
14. Declaration of conformity ............................................................................................ 140

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Inspect Shipment for Damage
Carefullyinspect th
agent, removing packagingmaterial if necessary. Note any damage to packaging
acceptingthe shipment. Submit damageclaim to MRU immediately.
NOTE: Damage claims notreceived byMRU within3 days of receipt of shipment will
not be accepted.
The products described inthis manual aresubject tocontinuous development and
improvement and it is therefore acknowledged that this manual may containerrors
or omissions. MRU encourages customer feedback and welcomes any comments or
suggestions relating to the product or documentation.
Please forwardall comments or suggestions to the Customer Feedback
Department atthe following address:
MRU GmbH
Fuchshalde 8 + 12
74172 Neckarsulm / Obereisesheim
GERMANY
Fon ([phone] (Reception)
Fon ([phone] (Service)
Fax [phone]
Email: [email protected]
Homepage: www.mru.eu
This manualis intended solely as a guide to the useof the product.
MRU shall not beliable for any loss ordamage whatsoever arisingfrom content
errorsor misinterpretationof informa anymis-use
resulting from the useof this manual.
FOR MORE INFORMATIONS ABOUT COMPANY MRU PLEASE VISIT OUR WEBSITE
www.mru.eu

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1. General Information
1.1. Weather and environmental conditions
The SWG100 BIOGAS analyser is designed for ambient temperatures of +5°C to
+45°C (without cabinet heater) resp. -10°C to +45°C (with cabinet heater).
The analyser isdesigned for indoormounting. In case of outdoor mounting itis
important that the analyser is sufficiently protected against rain, sun andwind. In
case of outdoor mountingunder extreme environmental conditions like high
humidity, salty sea air, etc. further protective measures are necessary. These should
be clarified with the manufacturer (MRU).
Any additional protective measures for outdoor mounting have to be provided by
the plant operator. The manufacturer (MRU) consults the plant operator in
choosing appropriate protective measures.
NOTE
The SWG100Biogas analyser is designed for sampling biogas with
condensateof max. 14ml/min.
If the sample biogas will be very wet (high condensate of more
than 14ml/min), then to protect the SWG100-Biogas analyser
please consider special precautions to remove the condensate.
If you not have your own feasible solution for this topic, please ask
MRU.
1.2. Installation instructions
Installation instructions, which are described in chapter 3 of the operation manual,
have to be strictly adhered to.
WARNING
Please check correct installation before powering up the analyzer!
Please operatethe analyzer only in uprightposition!
1.3. General important instructions for the plant operator
To guarantee continuous operation of the SWG100 BIOGAS analyser, the functions,
processes and operation of the analyser have to be monitored regularly by the
plant operator especially in case of any initial installation. Thus, it will be possible
to take suitablemeasures to improve the availability and life time of the analyser.
As the plant operator gains more experience concerning the maintenance
requirements of the analyser, the monitoring frequency may be reduced to more
extendedperiodsoftime.
It is important that the filter-units, listed in chapter 10.1 of the operation manual,
are checked regularly and,if necessary, service parts are changed.

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IMPORTANT
In case of not intended use the guarantee will void. Regular controls, inspections
and the exchange from polluted and exhausted filters by the operator are also an
not determined use - see chapter 10.1
regularmaintenance work.
1.4. Import 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
procedures.
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 detailsare clearly marked with an attention sign.
1.5. Safety Information
The following safety procedures must be followed at all times. They are significant
and essential part of this manual. Failure to follow safety procedures can result in
the loss of yourwarranty claims.
Biogas or other similar gases (landfill gas, bio-methane, coal seam gas etc) is
containing flammable gas component CH4 and toxic gas component as well ( H2S
and CO2 ).
Analyzer is continuously sampling a certain volume (approx. 50l/h) of the sample
gas, and is venting it to ambient air.
For this reason, there are two aspects whichmust be considered:
Toxicity danger of sample gas
WARNING
Toxic gas
Sample gas can contain toxic substances, which areharmful for
health and can even causedeath.
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
whileusing this
instrument.
Local regulations for possible exposure to toxic gases has to be known and
obeyed bythe user of theanalyzer
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. Onlysmall concentrations around few ppm can bedetected
by human nose
CO2
gas is heavier thanair and therefore operator shall avoid working at
underground levels. Beware of that CO2 isalsoodorless!
It is not allowed to use the biogas analyzerin confined space or rooms
without forced ventilation.

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Sample gas exiting the analyzer will flow in to theambient air and only
outdooruse
or forced ventilation rooms are suitable for using thebiogas analyzer.
Flammable gas
WARNING
Flammable gas
Biogas containsMethane (CH4), which can be flammable.
Regarding flammable gases (e.g. CH4 methane) and operating-instruments in the
hazardous areas, the 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 adhere to it.
Stationary analyzers are allowed to be mounted in hazardous area zone 2
only if they have the certificate of compliance.These instruments shall
never be locatedin confined places or roomswithoutforced ventilation.
Only trained personnel should carryout installationof stationary instrument and/or
maintenance, service and repair. Opening the stationary analyzer cabinet can
expose personnel to injuriesand shocks from electrical voltage!

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Safety regulations
The analyzer may only be used as indicated in this manual. Our analyzers are
checked accordingto the following regulations:
VDE 0411 (EN61010) and DIN VDE 0701 before they leave the MRU GmbHfactory.
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 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).
Specific safety regulations
No part of the analyzer, or any other metal parts & accessories shall be used as
electric conductors.
The analyzer shall not be used in or under water.
The analyzershall not be placed nearor directly exposedto open fire or heat.
The analyzershall avoiddropping.
WARNING
Acid substances
Moisture or condensate, being pumped out of the condensate outlet
port 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
condensate.
1.6. Packing
Packing regulation of12.07.1991
If your local waste facility does not accept MRU packing materials for disposal, you
may return it to MRUor our local sales representative. Packing materials returned to
MRU must bereturned prepaid.
1.7. 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 toMRU prepaid.
1.8. Return of analyzer
MRU GmbH is required to accept the return, for proper disposal, of all analyzers
delivered after13th of August 2005. Analyzers mustbe returned to MRUprepaid.
1.9. MRU Warranty conditions
The SWG100 BIOGAS warranty is 12 months.
1. The warranty on spare parts is 6 months.
2. The term of thewarranty conditions starts as ofthe invoicedate.
3. The warrantyis void under thefollowing conditions:

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•Improperuse.
•Improperapplication.
•Impropermounting.
•Deliberate or negligent destructions.
•External influence like droping, impact, solvents, acids, gases, or transport
damages. This includes damage, which is caused by exposure to high
pollution and/or moisture(condensate) in thegas path.
4. As well excluded from the guarantee conditions are typical consumable- and
spare parts.
5. Use of original MRU consumable parts and sensors is required to maintain the
warranty.
6. Removalof tampering of the serial number type plate will void thewarranty.
7. The service of a guarantee conditions will not enlarge the guarantee time.
Demands becauseof consequential damages are excluded.
8. MRU is notresponsible for the transportcosts for the warranty or replacement.
9. MRU reserves the right, to determine individual conditions or exceptions. These
will be separately communicated.
MRU GmbH
01.09.2014

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2. Analyzer Description
2.1. Intended use
The instrumentis intended for analyzing the composition of biogases / landfill gases and
determine the concentration of several components like CH4, CO2, O2and H2S. Theinstrument
may optionally beequipped to monitorseveral sites in time sharingtechnique(cyclical one byone
sampling).
In particular, theinstrument is not foreseen to serveas a gas detector or safety device.
In case ofunintended use,the warranty is void. Regular controls, inspections and the replacement
of pollutedand exhausted filters by the operator are also an important partof properuse. See
chapter 10.1 regular maintenance work.
2.2. Type plate
The type plateof the analyzer contains important informationabout the analyzer. It can be found:
•The serial-no.
•The power supply.
•The installed measurement options.
•Date built.
The table below shows, which kind ofmeasurement options maybe installedin the analyzer.
1.
O2, H2S, H2,
CO
Electrochemical sensor
2.
CH4/CO2
NDIR-bench
3.
H2
Thermal conductivity detector.
Table information: See below

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2.3. Possible applications and analyzer options
The biogas analyzer SWG100 is the industrial measuring solution to be used
with:
biogas (anaerobicdigestion) plants
cogeneration heat andpower engines (CHP)
municipal or industrial waste water treatment sites
coal seam gas sites (coal bed methane)
food and animalwaste processingplants
biomethane (gas togrid) plants
landfill sites
This analyzercan be equipped with additional options and/or additional accessoriesto full fill
multiple othermeasuring tasks such as
CH4 and CO2NDIRmeasurement
O2measurementwith long-life ECcell
H2Slow measurement withprotected EC cell using cutoff solenoid valve and air
purge pump
H2Shigh measurement with EC cell
H2measurement with EC cell
CO measurement with ECcell
Electric gas cooler (Peltier) with automatic condensate draining pump
Multiple sampling point switchover from 2x up to a maximum of 10x sites
Module with 4channel analogoutputs/inputs4-
relays
Converter moduleof RS485 into Profibus
Cabinet heater forfreeze protection
Ask our sales representatives for availableoptions and accessories or checkout our MRU website.
2.4. Principle of operation
•Sample gas fromone or more sampling points is fed into the analyzer by dedicated ports.
Internally mountedelectric valves select one point at a time to feed sample gas to the
analysis unit.
•The instrumentis equipped with a non-dispersiveinfrared (NDIR) bench for analysis of CO2
and CH4 . Two separate infrared detectors for each CO2 and CH4 areincluded,each
operating with adifferentoptical path length and stabilized by referring to a reference
detector. The IRsource is a highly efficient and stable IR emitter, pulsed at afrequencyof
several Hertz. Bydesign NDIR technique offers good stability and selectivity together with
long life time of sensor (only limited by corrosion or dust, which can be prevented or
removed by regular servicingthe instrument).
•The instrument isoptionally equipped with a number of electro-chemical sensors ECS in
order to detect gas components like oxygen O2 or H2S . Those sensors offer a reliable and
effective way to detect the target gases. They are typicallyof limited life time (several years)
but may be easily replaced once the end-of-lifeis reached.
•In regular timeintervals the instrument automatically switches to purge the sensors with
fresh (ambient) air for re-adjustthe zero point.

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Picture above: Sample gas flow diagram.

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2.5. Special functions of the analyzer
H2Slow sensor protection (optional)
The instrument may be optionally equipped with a H2Slow sensor. As this sensortypically shows
limited life time when experiencing high H2S concentrations, some precautions are taken to
protect the sensor:
•The instrument isequipped with a cut-off solenoid valve and air purge pump to protect the
H2Slow sensor,without impacting the results of allother sensors.
•The purge unit is always activated after 3-10 minutesof active sensor measuringtime.
•Themeasuring timeofthe H2Slow sensor may be limited to less than 10 minutes by user
setting
•The H2Slow sensor mayoptionally not be includedin allmeasuring cyclesof sampling
points. Instead theuser may configure that the H2Slow sensor is activeonly added at some of
the measurement cycles.

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2.6. Physical characteristic of the gas analyzer
Top view
Front view
Reference:
1. Gas inlet (default x1/optional max.10) 4. Suspension forwall mounting
2. Cabinet lock
3. Operation unit with display
1
2
3
4

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Right side view Left side view
Bottom view
1. Fan filter 4. Zero gasinlet 7. Cable glandM16 for IO
2. Sample gas outlet (Vent) 5. Condensate outlet
3. Calibration gasinlet 6. Cable gland M16for power supply
1
2
3
4
5
1
6
7

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3. Scope of supply and delivery
Your analyzer is delivered in a carton box and is protected with special edge protectors. Please do
preserve the packing of your analyzer, for possible return shipment.
Inside the attachments box are differentfittings:
Quantity
Description
Position
1 piece
1/8 G outlet
thread for
DN4/6mm
Condensateoutlet (4)
1 piece
¼ G outlet
thread 90°
Sample gasoutlet
(VENT) (5)
2 pieces + 1
for every
extra
sample gas
inlet
1/8 G outlet
thread / DN
4/6mm
Sample gas inlet (1)
Calibration gas inlet (2)
1 piece
Filter1/8 G
outlet thread
Zerogasinlet (3)
1 piece
Cabinetkey
Cabinetlocks
2 pieces + 1
for every
extra
sample gas
inlet
Copper seals for
the restrictor
orifice.
Sample gas inlet (1)
Calibration gas inlet (2)

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4. SD-card content
Following contentare on the SD-Card:
• Ethernet-Converter manual
• Profibus-Convertermanual
• GSD-Files for profibus-converter
• SWG100-Bio manual (EN/DE)
• SWG100-Bio ModBus/Profibus specification (EN/DE)
The SD-card canbe found in theSD-card slot in the device (see sketch below).
SD-card

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5. Installation manual
5.1. Overview
In this manual the installationof the differentparts of the analyzer-system will be explained.
An entire analyzer-system consistsof these parts:
•The analyzer.
•A sample line.
The user has to install these parts correctly and put them together. The following flow chart shows
the order ofthe installation.
Preparing the measurement point
Installation of the analyzer
Installation of the sample line
Installation of the electrical main power supply

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5.2. Installation of the analyzer
The analyzer is equipped with adapters for the wall mounting. The dimensions for the wall
mounting are shown in picture below.
ATTENTION
Operation of the analyzer
Only operate theanalyzer in an upright position.
Only power thedevice upafter it is correctly mounted.
General installation rules
•Mount thedevice on asolid wall or steel rack.
•Be sure, thatthe air circulation is notobstructed.
•Let enough room for the tubing or piping.
For outdoor installation
Ensure that the analyzer is mounted ona rain and sun protected place (weather shade).
For indoor installation:
Ensure that the analyzer is installed on a dry and clean place. Be sure that the room is permanently
vented with fresh air.