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!

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Safety regulations
The analyzer may only be used as indicated in this manual. 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 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 analyzer shall not be placed near or directly exposed to open fire or heat.
The analyzer shall avoid dropping.
CAUTION
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.
1.7.Packing
Packing regulation of 12.07.1991
If your local waste facility does not accept 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.
1.8.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.
1.9.Return of analyzer
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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1.10. MRU guarantee conditions
MRU granted of the analyzer SWG100 BIOGAS a guarantee of 12 month.
1. 6 months on MRU spare parts.
2. The term of the guarantee conditions starts as of the invoice date.
3. Excluded from the guarantee conditions are damages, which occurred by:
•Improper use.
•Improper application.
•Improper mounting.
•Deliberate or negligent destructions.
•External influence for example fall, hits, solvents, acids, gases, by normal wear
or transport damages. This applies also for defects, which are caused from high
pollution and/or moisture (condensate) in the gas route or on the sensors.
4. As well excluded from the guarantee conditions are typical consumable- and spare
parts.
5. The guarantee condition denatured immediately, if no original consumable parts are
installed. The guarantee is only for original MRU consumable parts and sensors.
6. With the replacement of the type plate or the serial- number of the devices all
guarantee conditions will be invalid.
7. The service of a guarantee conditions will not enlarge the guarantee time. Demands
because of consequential damages are excluded.
8. The transport costs for round trip takes the consignor or the warrantee.
9. MRU reserves the right, to determine individual conditions or exceptions. These will
be separated informed.

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2. Important notes: Operating an ATEX analyser
DANGER
Maintenance work may only be carried out
after a successful clearance measurement.
This unit has an ATEX zone approval level II. The following instructions must be
observed to ensure that the unit operates safely:
•Weekly maintenance intervals.
•6-monthly replacement of the peristaltic pump hoses.
•Checking the compatibility.
•Correct commissioning of the unit.
•Correct opening of the unit.
The individual points are explained in more detail in the following sub-
chapters.
2.1. Weekly maintenance intervals
The weekly maintenance intervals serve as a check. The hoses
The hoses should be checked for damage, as well as the general condition of
the unit.
The unit should be opened weekly and the lines/hoses checked for leaks.
Especially moving parts, such as the hose pumps, should be checked weekly for
their condition.
2.2.Correct commissioning of the unit
The unit has a remote switch box. This box must be installed in a secured area.
The box must not be bypassed and only the mounted circuit breakers may be
used.

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2.3.Check / replace peristaltic pump hoses
DANGER
The hose pump hoses must be replaced every 6
months. Irrespective of their current condition.
The hose pump hoses must be completely replaced every 6 months. Even if
there is no obvious damage to the hoses.
2.4.Check material resistance
The unit has seals/hoses and fittings that are not necessarily resistant to all
substances in the measuring stream. Check whether the materials are resistant
to the respective contents.
2.5.Free measurement before opening the unit
Before opening the unit, a certified gas detector must be used to measure
whether there is an explosive atmosphere around the unit. The unit may only
be opened if the clearance measurement is successful.

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3. Analyzer Description
3.1.Intended use
The instrument is intended for analyzing the composition of biogases / biomethane /
landfill gases and determine the concentration of several components like CH4, CO2, O2
and H2S. The instrument may optionally be equipped to monitor several sites in time
sharing technique (cyclical one by one sampling).
In particular, the instrument is not foreseen to serve as a gas detector or as a safety
device.
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 determinations “not determined use”- see chapter 12 regular maintenance
work.
The ANALYZER-100BIO Ex. is an extractive measuring system. It has maximal 4 sample
gas inlets, to measure the gas concentration from 4 different sample points, one by one.
It has an internal gas pump to suck the sample gas from the sampling points. After the
measurement, the sample gas is vented through the sample gas outlet (Vent).
All sample points are equipped with a flow restrictor orifice, which allows also sampling
the gas from the higher-pressure gas pipe of the engine, while limiting the maximum
amount of gas in case of internal cabinet piping leakage.
Optional, the device can be equipped with a dilution unit, which allows the user to dilute
the sample gas. A dilution is necessary, if the analyzer should detect very high
concentrations of H2S (CH2S>10,000 ppm). This action enhances the life time of the
electrochemical detector. The dilution ratio is 1:50.
DANGER
Apply personality safety equipment, against high H
2
S 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.

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3.2.Principle of operation
•Sample gas from one or more sampling points is fed into the analyzer by
dedicated ports. Internally mounted electric valves select one point at a time to
feed sample gas to the analysis unit.
•The instrument is equipped with a non-dispersive infrared (NDIR) bench for
analysis of CO2 and CH4. Two separate infrared detectors for each CO2 and CH4
are included, each operating with a different optical path length and stabilized
by referring to a reference detector. The IR source is a highly efficient and stable
IR emitter, pulsed at a frequency of several Hertz. By design 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
servicing the instrument).
•The instrument is optionally 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
typically of limited life time (several years) but may be easily replaced once the
end-of-life is reached.
•In regular time intervals (user settable), the instrument automatically switches
to purge the sensors with fresh (ambient) air for re-adjust the zero point.

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The picture below shows how the analyser should be piped. A ball valve and a prefilter is
recommended.

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3.3.Marking and range of application
The analyzer was designed for use in hazardous area with potentially explosive
atmosphere and was certificated by ATEX directive:
EX-Protection: [EX] II 3G Ex nA nC IIC T3 Gc
Certification no.: EPS 16 ATEX 1xxx X
The SWG100BIO-EX is operating in a temperature range of -20°C … +45°C with intern
cabinet heater.
The specifications of the analyzer are:
Main power supply:
230 VAC / 50 Hz
Power consumption:
36 VA
Protection class:
IP65
Fuses:
230 VAC/ 50Hz / 6 A
Data output interface:
4…20 mA / analog
outputs
RS485 Modbus RTU
3.4.Possible applications and analyzer options
The biogas analyzer SWG100 is the industrial measuring solution to be used at all
hazardous zone 2 areas of:
•biogas (anaerobic digestion) plants
•cogeneration heat and power engines (CHP)
•municipal or industrial waste water treatment sites
•coal seam gas sites (coal bed methane)
•food and animal waste processing plants
•biomethane (gas to grid) plants
•landfill sites
3.5.Features
This analyzer can be equipped with additional options and/or additional accessories to
full fill multiple other measuring tasks such as
•H2Slow measurement with protected EC cell using cutoff solenoid valve and
air purge pump.
•H2Shigh measurement with EC cell.
•H2 measurement with EC cell.
•CO measurement with EC cell.
•Multiple sampling point switchover from 2x up to maximum 4x sites.
•Module with 4 channel analog outputs/inputs 4-20mA, with 2x “fail safe”
alarm relays.
•Converter module of RS485 into Profibus.
•Cabinet heater for freeze protection.
Dilution-unit, to enhance the life-time of electrochemical sensors.
Ask our sales representatives for available options and accessories or check out our MRU
website.

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4. Overview of the SWG-100BIO Ex
4.1.Scope of supply and delivery
The delivery contains the follow components:
•SWG-100BIO Ex analyser, with a stainless-steel case.
•A stainless-steel thread filter for the zero-gas inlet, with a G1/8 inch male thread.
•Flow restrictor orifices for the sample gas inlets, with a G1/8 inch female thread.
The number of flow restrictors is depended from the number of gas sample
inlets.
•A fitting for the gas outlet (vent), with a G 1/4 inch male thread.
•Mounting material.
•Optional: Flame arresters for the sample gas inlets, with a G1/4 inch male thread.
4.2.Material required for the installation (not scope of supply)
Material for tubing or hosing the sample gas inlets and outlet.
•For the sample gas inlets: Flexible PTFE tube or stainless-steel tubing with a
diameter of 4/6 mm. It could be necessary to install a heated sample line on the
tubes, to protect the sample gas from freezing.
•For the sample gas outlet (Vent): Flexible PTFE tube with a diameter of 8/10
mm. It could be necessary to install a heated sample line on the flexible tube, to
protect the vent gas pipe for freezing.
•For the condensate outlet: Flexible tube with a diameter of 4/6 mm. It could be
necessary to heat the condensate tube to prevent that the condensate for
freezing.
Power supply lines and signal lines
•Cable for power supply: Cable type: H 07 RN-F 5 G 0,75 mm²
•Signal lines for 4…20 mA analog outputs.
•Signal lines for Modbus RTU digital transfer.
4.3.SD-Card content
Follow content is safed at the SD-Card:
•Ethernet-Converter manual
•Profibus-Converter manual
•GSD-Files for profibus-converter
•SWG100-Bio manual (EN/DE)
•SWG100-Bio ModBus/Profibus specification (EN/DE)

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4.4.Dimensions and views of the analyser
Top view:
Front view / left view / right view
Bottom view
642 mm
630 mm
223 mm
1
2
1
2
3
4
1
2
3
4
Reference:
1. Sample gas inlets G1/8 inch female thread.
2. Sample gas outlet G1/4 inch female thread
Reference:
1. Heat sink of gas cooler unit
2. Calibration gas inlet G1/8 inch female thread
3. Zero gas inlet G1/8 inch female thread
4. Condensate outlet G1/8 inch female thread
Reference:
1. Cable gland M16 for power supply
2. PE bolt for earthing cable
3. Cable gland M16 for I/O modules
4. Breather drain