mru SWG100 BIOGAS User manual

9512EN- BIO
SWG100 BIOGAS
USER MANUAL

USER MANUAL SWG100
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USER MANUAL SWG100
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Content
1General 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.................8
1.5. Safety Information ..............................................................................................8
1.6. Packing ................................................................................................................ 13
1.7. Return of hazardous waste ........................................................................... 13
1.8. Return of analyzer............................................................................................ 13
1.9. MRU Warranty conditions ............................................................................. 13
2Analyzer Description................................................................................................ 15
2.1. Intended use...................................................................................................... 15
2.2. Type plate ........................................................................................................... 15
2.3. Possible applications and analyzer options............................................ 17
2.4. Principle of operation..................................................................................... 17
2.5. Special functions of the analyzer................................................................ 19
2.6. Physical characteristic of the gas analyzer .............................................. 20
3Scope of supply and delivery................................................................................ 23
3.1. SD-card content................................................................................................ 24
4Installation manual................................................................................................... 25
4.1. Overview............................................................................................................. 25
4.2. Select measurement point............................................................................ 27
4.3. Installation of the analyzer............................................................................ 28
4.4. Installation: Sample gas outlet (VENT) ...................................................... 32
4.5. Installation: Calibration gas / zero gas and condensate outlet ........ 33
4.6. Option: Autocalibration by using several gas cylinders...................... 34
4.7. Connection of main power supply............................................................. 35
4.8. I/O modules: Installation and setting........................................................ 37
5Operation of the analyzer (HMI) .......................................................................... 39
5.1. Display and keypad ......................................................................................... 39
6Analyzer commissioning manual ........................................................................ 41
6.1. Check country and language....................................................................... 41
6.2. Check date and time of the instrument.................................................... 41
6.3. Configuration of the alarm relays............................................................... 42
6.4. Configuration of the Modbus ...................................................................... 44
6.5. Autocalibration: Explanation of the software operation.................... 45
7Binding to a process control system: I/O modules........................................ 47
7.1. Position of the IO module inside the analyzer ....................................... 47
7.2. Pin assignment.................................................................................................. 48
7.3. Analog outputs 4-20 mA ............................................................................... 50
7.4. Alarm outputs ................................................................................................... 56
7.5. Analog inputs (4-20 mA)................................................................................ 61
7.6. Configuration of the external control (Option: IO module)............... 66
7.7. Analyser states .................................................................................................. 73
7.8. Cycle configuration ......................................................................................... 74
7.10. Administrator PIN code ............................................................................. 81

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7.11. Power-On of analyzer..................................................................................81
8Operating the analyzer............................................................................................82
8.1. General process of the measurement cycle.............................................82
8.2. Protective measures for electrochemical H2S sensors.........................85
8.3. Data Storage Menu...........................................................................................87
8.4. Extra menu: Overview .....................................................................................91
8.5. Update the firmware.....................................................................................101
9Service and maintenance.....................................................................................105
9.1. Preparing and information about the maintenance.......................... 105
9.2. Regular maintenance work by the operator.........................................105
9.3. Position and overview of the service-parts........................................... 106
9.4. Cleaning and decontamination ................................................................ 113
9.5. Troubleshooting.............................................................................................113
10 Technical specification .....................................................................................114
10.1. Technical specification: Electrochemical sensors........................... 117
10.2. Technical specification: NDIR-benches ..............................................118
11 APPENDIX..............................................................................................................119
11.1. Spare parts list ............................................................................................119
11.2. Mechanical dimensions...........................................................................122
12 Purchase options of the analyzer.................................................................. 123
12.1. Option: Electric sample gas cooler ...................................................... 123
12.2. Option: Cabinet heater ............................................................................ 124
12.3. Option: Flame arrester .............................................................................125
12.4. Option: Multiple sample point switching and monitoring (time
sharing) 127
12.5. Option: Gas detector (%LEL CH4) to monitor air inside analyzer
cabinet 128
12.6. Option: Extra IO module with 4 channel 4-20 mA.......................... 132
12.7. Option: H2S electrochemical cell measurement 0-
2000ppm/4000ppm...................................................................................................133
12.8. Option: RS485 Profi-Bus converter ......................................................134
12.9. Option: RS485 to Ethernet converter..................................................135
12.10. Configuration of the Ethernet module...............................................136
12.11. Option: NDIR-bench for CH4/CO2 analysis, 0-100% / 0-100% ...144
12.12. Option: H2 thermal conductivity detector measurement 0-100%
150
12.13. Option: NDIR-bench for 0-3.000ppm CO2/0-3.000…30.000ppm
CH4 151
12.14. Option: Dilution-unit for H2S and CO electrochemical sensors.152
13 Declaration of conformity ...............................................................................158

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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: [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 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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1General 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 is designed for indoor mounting. In case of outdoor mounting
it is important that the analyser is sufficiently protected against rain, sun and
wind. In case of outdoor mounting under 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 condensate of 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 operate the analyzer only in upright position!
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 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.

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It is important that the filter-units, listed in chapter 9.1 of the operation
manual, are checked regularly and, if necessary, service parts are changed.

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NOTE
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 9.1
regular maintenance work.
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.
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 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).
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 which must be considered:
Toxicity danger of sample gas
WARNING
Toxic gas
Sample gas can contain toxic substances, which are harmful
for health and can even cause death.
• 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 exposure to toxic gases has to be known
and obeyed by the user of the analyzer
• Using a personal gas detector inside the biogas plant is highly
recommended since
H2Sin higher (very dangerous) concentration cannot be detected by
human nose. Only small concentrations around few ppm can be detected
by human nose

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• CO2gas is heavier than air and therefore operator shall avoid working at
underground levels. Beware of that CO2is also odorless!
• It is not allowed to use the biogas analyzer in confined space or
rooms
without forced ventilation.
• Sample gas exiting the analyzer will flow in to the ambient air and
only outdoor use
or forced ventilation rooms are suitable for using the biogas analyzer.
no dangerous quantities poisonous or injurious gases or substances are
liberated under NORMAL CONDITIONS
List of poisonous or injurious gases which are normally present in the
sample gas (Biogas)
Gas
liberated quantities
sample gas (total)
<100ml/day
CH4 (methane)
<75ml/day
CO2 (carbon dioxide)
<55ml/day
H2S (hydrogen sulfide)
<0,5ml/day
H2 (hydrogen)
<1ml/day
NH3 (ammonia)
<1ml/day
Flammable gas
WARNING
Flammable gas
Biogas contains Methane (CH4), which can be flammable.
Regarding flammable gases (e.g. CH4methane) 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 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 electrical voltage!

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Safety regulations
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.
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.
WARNING
Hazardous Live
Power down the system and disconnect from mains to avoid
access to live parts by using a tool.