mru SWG100 BIOEX User manual

9512EN-BIOEX
SWG100 BIO-EX
USER MANUAL

MRU GmbH SWG 100 BIO Ex User Manual
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MRU GmbH SWG 100 BIO Ex User Manual
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Content
1. General Information.............................................................................................7
1.1. Weather and environmental conditions.........................................................................7
1.2. Installation instructions ........................................................................................................7
1.3. General important instructions for the plant operator .............................................7
1.4. Important information about the user’s operation manual....................................8
1.5. General warnings....................................................................................................................9
1.6. Safety Information..................................................................................................................9
1.7. Packing..................................................................................................................................... 11
1.8. Return of hazardous waste............................................................................................... 11
1.9. Return of analyzer................................................................................................................ 11
1.10. MRU guarantee conditions............................................................................................... 12
2. Important notes: Operating an ATEX analyser ................................................13
2.1. Weekly maintenance intervals ........................................................................................ 13
2.2. Correct commissioning of the unit................................................................................ 13
2.3. Check / replace peristaltic pump hoses....................................................................... 14
2.4. Check material resistance ................................................................................................. 14
2.5. Free measurement before opening the unit ............................................................. 14
3. Analyzer Description..........................................................................................15
3.1. Intended use.......................................................................................................................... 15
3.2. Principle of operation......................................................................................................... 16
3.3. Marking and range of application.................................................................................. 18
3.4. Possible applications and analyzer options ............................................................... 18
3.5. Features................................................................................................................................... 18
4. Overview of the SWG-100BIO Ex .......................................................................19
4.1. Scope of supply and delivery........................................................................................... 19
4.2. Material required for the installation (not scope of supply)................................. 19
4.3. SD-Card content................................................................................................................... 19
4.4. Dimensions and views of the analyser......................................................................... 20
4.5. Position of the gas in and outlets................................................................................... 21
4.6. Operating unit: Display and keypad.............................................................................. 22
4.7. Measurement menu............................................................................................................ 24
5. Explosion protection systems of SWG100BIO-EX ............................................25
5.1. Electrical components........................................................................................................ 25
5.2. IP 65 cabinet........................................................................................................................... 25
5.3. CH4 measurement of inside cabinet............................................................................. 26
5.4. Remote Power Supply Box ............................................................................................... 29
6. Sample Gas measurement .................................................................................31
6.1. Cycle configuration............................................................................................................. 31
6.2. H2Slow sensor protection (optional)............................................................................ 36
7. Analyzer mounting and installation .................................................................38
7.1. Content of your order......................................................................................................... 38
7.2. Installation rules to guarantee explosion protection.............................................. 38
7.3. Prerequisites for installation ............................................................................................ 38
7.4. Steps for the mechanical mounting and installation.............................................. 39
7.5. Mounting the analyser on a wall or steel rack........................................................... 40

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7.6. Correct tubing of the SWG100BIO-Ex............................................................................42
7.7. Flow restrictor orifice (#65114)........................................................................................43
7.8. Installation of the power supply .....................................................................................45
7.9. Installation of the external switch-off circuit..............................................................46
7.10. Connection of the I/O module.........................................................................................49
8. Power up and commissioning the analyser ..................................................... 51
8.1. Power up the analyser ........................................................................................................52
8.2. Check country and language ...........................................................................................53
8.3. Check date and time of the instrument........................................................................53
8.4. Configure sampling points................................................................................................53
8.5. Configuration of the alarm relays ...................................................................................54
8.6. Configuration of the Modbus...........................................................................................56
9. Dilution-unit....................................................................................................... 58
9.1. Correct installation of the SWG100 ................................................................................58
9.2. Tubing of all sample gas inlets.........................................................................................58
9.3. Installation of the calibration gas cylinder ..................................................................58
9.4. Fine calibration of the dilution-unit...............................................................................59
9.5. Software-settings..................................................................................................................61
9.6. Setting the dilution cycle...................................................................................................61
10 Binding to a process control system: I/O modules .......................................... 63
10.1. Position of the IO module inside the analyzer ...........................................................63
10.2. Pin assignment ......................................................................................................................64
10.3. Analyser states.......................................................................................................................82
10.4. Configuration of the external control (Option: IO module) ..................................82
10.5. Configuration of the external control (Option: IO module) ..................................89
11. Operating the analyser...................................................................................... 93
11.1. General process of the measurement cycle................................................................93
11.2. Power-On of analyser..........................................................................................................94
11.3. Self-Test....................................................................................................................................94
11.4. Main menu measurement.................................................................................................95
11.5. Data Storage...........................................................................................................................97
11.6. Extra menu: Overview......................................................................................................100
11.7. Power-Down of analyzer.................................................................................................107
11.8. Backup/restore all individual user-settings..............................................................107
11.9. Default configuration.......................................................................................................108
11.10. Update the firmware....................................................................................................111
12. Service and maintenance ................................................................................ 114
12.1. Preparing and information about the maintenance.............................................114
12.2. Regular maintenance works by the operator..........................................................114
12.3. Position and overview of the service-parts ..............................................................116
12.4. Cleaning the surface of SWG100BIO-Ex.....................................................................121
12.5. Maintenance of the switch-off relay (K2) and the solenoid valve for CH4
supervision .........................................................................................................................................121
13. Exchange of electrochemical sensors............................................................. 123
14. Adjustment of the NDIR-bench....................................................................... 126
15.1. Troubleshooting ................................................................................................................133
16. Technical specification .................................................................................... 134

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17. General information.........................................................................................138
17.1. Special informationen about the Modbus Slave function ..................................138
17.2. Special informationen about the Profibus Slave function..................................139
18. Defined registers to be read by the master....................................................139
18.1. Analyser Status (address 0 and some mirror addresses)......................................143
18.2. Analyser System Alarm (address 2 and some mirror addresses) ......................144
19. APPENDIX..........................................................................................................145
19.1. Spare parts list.....................................................................................................................145
20. Declaration of conformity ...............................................................................147

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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 material 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.
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 welcomes 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: inf[email protected]
Homepage: www.mru.eu
This manual isintended 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 information’s from this manual or any mis-use resulting from
the use of 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 analyzer is designed for operating ambient temperatures of +5°C to +45°C (without
cabinet heater) resp. -20°C to +45°C (with cabinet heater).
The analyzer is for designed for use in hazardous Zone 2, see the conformity marking in
the corresponding section.
In case of outdoor mounting it is important that the analyser is protected against rain
and sun.
For 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) is supporting the plant operator in choosing
appropriate protective measures.
1.2.Installation instructions
Installation instructions, which are described in chapter 7 of the operation manual, have
to be strictly carried out.
WARNING
Please check correct installation before powering up the
analyzer! Please operate the analyzer only in upright
position!
1.3.General important instructions for the plant operator
To guarantee continuous operation of the ANALYZER100 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 suitable measures 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 extended periods of
time.
It is important that the filter-units, listed in chapter 14 of the operation manual, are
checked regularly and, if necessary, service parts are changed.
ATTENTION
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 important part of
the determination “not determined use”. See chapter 9 regular
maintenance work.

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1.4.Important information about the user’s 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 details are clearly marked with an attention sign.
Safety declarations
In this document the safety hints will be declared as follow:
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
information.
DANGER
Any maintenance action must be done only, when the
atmosphere is verified to be not explosive.

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1.5.General warnings
DANGER
Any maintenance action must be done only, when the
atmosphere is verified to be not explosive.
DANGER
Apply personality safety equipment, against high H2S/CO
concentrations before open the device.
Under special conditions the device can accumulate with toxic
gases.
•Measure the atmosphere, around the device, before
opening it.
•After the opening of the device, ventilate sufficiently.
1.6.Safety Information
The following safety procedures must always be followed. They are significant and
essential part of this manual. Failure to follow safety procedures can result in the loss of
your warranty 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).
Analyzers 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 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
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 working at
underground or confined spaces. Beside of that CO2 is also odorless!
•It is not allowed using the biogas analyzer in confined space or rooms
without forced 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 biogas analyzer

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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.
•Stationary analyzers can be mounted in hazardous area zone 2 only if they
have the certificate of compliance. These instruments shall never be located
in confined places or rooms without forced ventilation.
Only trained personnel should carry out installation of stationary instrument and/or
maintenance, service and repair. Opening the stationary analyzer cabinet can expose
personnel to injuries and shocks from mains voltage!