mru SWG100 CEM User manual

SWG100 User Manual
MRU GmbH, D-74172 Neckarsulm

MRU GmbH SWG 100 User Manual
MRU GmbH, D-74172 Neckarsulm
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SWG100 User Manual
MRU GmbH, D-74172 Neckarsulm
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
1.1. Packing ...................................................................................................................... 9
1.2. Return of hazardous waste........................................................................................ 9
1.3. Return of analyzer...................................................................................................... 9
1.4. MRU guarantee conditions......................................................................................... 9
2. Analyzer Description...................................................................................................... 11
2.1. Intended use ............................................................................................................ 11
2.2. Type plate ................................................................................................................ 11
2.3. Possible applications and analyzer options ............................................................. 12
2.1. Principle of operation ............................................................................................... 13
2.2. CO sensor protection (option).................................................................................. 14
2.3. Cabinet ventilation ................................................................................................... 14
2.4. 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. Mounting of the sample measurement point on the stack/chimney ......................... 20
5.3. Installation of the analyzer ....................................................................................... 22
5.4. Installation of the gas inlet/gas outlet and condensate connector (basic)................ 23
5.5. Installation of the sampling line and probe............................................................... 24
5.6. Installation of the gas connections OPTION LOW DUST PROBE WITH UNHEATED
SAMPLE GAS LINE.............................................................................................................. 25
5.7. Installation of the gas connections OPTION LOW DUST PROBE WITH UNHEATED
SAMPLE GAS LINE.............................................................................................................. 28
5.8. Installation of the gas connections OPTION LOW DUST PROBE WITH UNHEATED
SAMPLE GAS LINE.............................................................................................................. 33
5.9. Installation of the gas connections OPTIONS HIGH DUST PROBE WITH HEATED
SAMPLE LINE....................................................................................................................... 39
5.10. Connection of main power supply............................................................................ 44
5.11. I/O modules: Installation and setting........................................................................ 45
6. Operation of the analyzer (HMI)..................................................................................... 47
6.1. Display and keypad.................................................................................................. 47
7. Analyzer commissioning manual.................................................................................. 48
7.1. Check country and language ................................................................................... 48
7.2. Check date and time of the instrument .................................................................... 48
7.3. Configuration of the alarm relays............................................................................. 49
7.4. Configuration of the Modbus.................................................................................... 51
8Binding to a process control system: I/O modules ..................................................... 53
8.1. Position of the IO module inside the analyzer.......................................................... 53

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8.2. Pin assignment ........................................................................................................ 54
8.3. Analog outputs 4-20 mA .......................................................................................... 56
8.4. Alarm outputs........................................................................................................... 62
8.5. Analog inputs (4-20 mA) .......................................................................................... 67
8.6. Configuration of the external control (Option: IO module)........................................ 72
8.7. Mounting and installation of the gas cylinders for the auto calibration function ....... 78
8.8. Mounting and installation of the gas cylinders for the auto calibration function ....... 78
8.9. Cycle configuration .................................................................................................. 81
8.10. Administrator PIN code............................................................................................ 87
8.11. Power-On of analyzer.............................................................................................. 87
9. Operating the analyzer................................................................................................... 88
9.1. General process of the measurement cycle............................................................. 88
9.2. Data Storage Menu.................................................................................................. 91
9.3. Extra menu: Overview.............................................................................................. 95
9.4. Update the firmware............................................................................................... 105
10. Service and maintenance............................................................................................. 108
10.1. Preparing and information about the maintenance ................................................ 108
10.2. Regular maintenance works by the operator ......................................................... 108
10.3. Description of the analyzer .................................................................................... 109
10.4. Exchange of electrochemical sensors ................................................................... 114
11. Technical specification ................................................................................................ 117
12. APPENDIX ..................................................................................................................... 122
A. Specification Modbus via RS485 specification.......................................................... 122
12.1. Analyser Status (address 0 and some mirror addresses)...................................... 126
12.2. Analyser System Alarm (address 2 and some mirror addresses).......................... 126
12.3. Heated Sampling Line general remarks................................................................. 127
12.4. General Instructions for the heated sampling lines................................................ 129
13. Purchase options of the analyzer ............................................................................... 133
13.1. Option: Electric sample gas cooler......................................................................... 133
13.2. Option: Cabinet heater........................................................................................... 134
13.3. Option: O2 paramagnetic cell measurement 0-25,00% ......................................... 135
13.4. Option: Multiple sample point switching and monitoring (time sharing) ................. 136
13.5. Option: automatic calibration for using 2…5 (max.) gas cylinders ......................... 137
13.6. Option: Extra IO module with 4 channel 4-20 mA.................................................. 138
13.7. Option: CO electrochemical cell measurement 0-2000ppm/4000ppm................... 139
13.8. Option: RS485 to Profi-Bus converter.................................................................... 140
13.9. Option: RS485 to Ethernet converter..................................................................... 141
13.10. Option: NDIR-bench for CO2 analysis, 0-100% ................................................ 142
13.11. Option: NDIR-bench 103 mm ............................................................................ 143
13.12. Option: NDIR-bench 334 mmm ......................................................................... 144
13.13. Configuration of the ethernetmodule ................................................................. 145
13.14. Option: Connection the SWG100 with RS-485 converter to MRU4Win............. 151
14. Declaration of conformity ............................................................................................ 154

SWG100 User Manual
MRU GmbH, D-74172 Neckarsulm
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: [email protected]
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 INFORMATION 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 CEM 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.
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 CEM 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 of the operation manual, are checked
regularly and, if necessary, service parts are changed.
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 important part of the
determinations “not determined use”- see chapter 6 regular maintenance work.

SWG100 User Manual
MRU GmbH, D-74172 Neckarsulm
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.
Exhaust gas or other similar gases may contain flammable or toxic components (for example
CO and CO2).
Analyzers extract a certain volume of the sample gas and vent 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 exposition to toxic gases have to be known and obeyed
by the user of the analyzer.
•Using a personal gas detector inside the plant is highly recommended. Some gases
cannot be detected by the human nose and are very harmful for the human body.
•Some gases like CO2 gas is heavier than air and therefore operator shall avoid
working at underground levels. Beside of that CO2 is also odorless!
•It is not allowed using the 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 analyzer.

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Flammable gas
WARNING
Flammable gas
Combustion gas could contain flammable gases.
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 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 mains voltage!

SWG100 User Manual
MRU GmbH, D-74172 Neckarsulm
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
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.
1.1. Packing
Packing regulation of 12.07.1991
If your local waste facility does not except MRU packing materials for disposal, you may return it
to MRU or our local sales representative. Packing materials returned to MRU must be returned
prepaid.
1.2. 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.
1.3. 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.
1.4. MRU guarantee conditions
MRU granted of the analyzer SWG100 CEM a guarantee of 12 month.
1. 6 month on MRU spare parts.
2. The term of the guarantee conditions starts as of the invoice date.

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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. Analyzer Description
2.1. Intended use
The instrument is intended for analyzing the composition of combustion gases and determine
the concentration of several components like O2, CO, CO2, CH4 and/or H2 for example. 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 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 8 regular maintenance work.
2.2. Type plate
The type plate of the analyzer contains important information about the analyzer. It can be
found:
•The serial-no.
•The power supply.
•The installed measurement options.
•Date built.
The table below shows, which kind of measurement options may be installed in the analyzer.
1.
O2, H2S, CO, SO2, NO, NO2, CO2
Electrochemical sensor
2.
CO/CO2/CH4 or CO2
NDIR-bench.
3.
O2
Paramagnetic sensor..
Table information: See below

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2.3. Possible applications and analyzer options
The analyzer SWG100 CEM is the industrial measuring solution to be used
with:
This analyzer can be equipped with additional options and/or additional accessories to full fill
multiple other measuring tasks such as
•all fuel gas/ stack gas/ exhaust gas emission sites.
•diesel gensets/ biomass boilers.
•landfill gas/ natural gas boilers CHP`s.
•bagasse boilers/ palm oil plants.
•many other industries.
Instrument main features are:
•accurate measurements, incl. plug & play, pre-calibrated sensors, easy field
replaceable.
•up to 7 gas measurement with O2-CO-NO-NO2-SO2-CO2-CxHy
•no dilution of sample gas is required
•direct and continuous & discontinuous measurement, with pressure and temperature
compensation
•including condensate separator with automatic condensate draining pump
•automatic zeroing using clean ambient air and separate calibration inlet port
•internal sample flow monitoring and alarm of probe or internal filter cogging
•sampling from low suction -200mbar up to high pressure +200mbar gas pipe
•industry compatible rugged design, easy and fastest service
•ready to run delivery, minimum installation work
Ask our sales representatives for available options and accessories or check out our MRU
website.

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2.1. Principle of operation
•Sample gas from the sampling point is fed into the analyzer. Internally mounted electric valves dispose
the gas flow to the analyzer unit. (See red line in the gas flow diagram.)
•The instrument is optionally equipped with a number of electro-chemical sensors ECS or a NDIR bench
detecting the different gas components. (See green rectangle.)
•In regular time intervals the instrument automatically switches to purge the sensors with fresh (ambient)
air for re-adjustment the zero point. (See the blue line in the gas flow diagram.)

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2.2. CO sensor protection (option)
The instrument may be optionally equipped with a CO sensor. As this sensor typically shows limited life time
when experiencing high CO concentrations, some precautions are taken to protect the sensor:
•The instrument is equipped with a cut-off solenoid valve and air purge pump to protect the CO sensor, without
impacting the results of all other sensors.
•If the CO concentration exceeds a preset limit, the sensor is purged with ambient air until the next zeroing
phase.
The picture below shows the position and the schematic of the sensor protection system:
2.3. Cabinet ventilation
As soon as the analyzer is powered up the cabinet is permanently ventilated by means of the integrated fan. This
will prevent any explosive atmosphere inside the analyzer in case of internal leakages. The fan is monitored and
the analyzer will not operate when the flow speed falls below a certain threshold (system alarm is triggered).
Sample gas flow
The analyzer supports multiple sample points to be monitored. Those points may differ in the pressure range
inside the gas pipe by several hPa. In order to establish a constant sample gas flow over all sites, the analyzer's
gas pump is regulated. In it's initial state the analyzer supports a pressure range as given in the technical data
sheet. For pressurized site the flow restrictor orifice (# 65114) must be screwed in the female 1/8in thread.
CO
Fresh air
Stack gas
Cut off solenoid valve
Air purge pump
Acid gas filter

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2.4. Physical characteristic of the gas analyzer
Front view
Reference
1Operation unit with display
2Gas inlet for flexible tube (without heated sample line) optional max. 3.
3Gas inlet for heated sample line.
4OPTION: Automatic calibration gas inlet (max. 5).
5Sample gas outlet (VENT)
1
2
3
4
4

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Right side view Left side view
Bottom view
Reference
1 Filter unit
2Calibration inlet
3Zero gas inlet
4Condensate outlet
5Ventilation
6M12 cable gland
710xM16 cable gland for IO
module (optional)
1
2
3
4
5
7
6
5

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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 back shipment.
Inside the attachments box are different fittings:
Description
Position
1/8 G outlet thread
for DN4/6mm
Condensate outlet (4)
Sample gas inlet (1)
¼ G outlet thread
90°
Sample gas outlet (VENT)
(5)
1/8 G outlet thread
/ DN 4/6mm
Calibration gas inlet (2)
Cabinet key
Cabinet locks

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4. SD-card content
Following content are on 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)
The SD-card can be found in the SD-card slot in the device (see sketch below).
SD-card

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5. Installation manual
5.1. Overview
In this manual the installation of the different parts of the analyzer-system will be explained.
An entire analyzer-system consists of these parts:
•The analyzer.
•A sample line.
•A sample probe with sample tube.
The user has to install these parts correctly and put them together. The following flow chart shows the order of
the installation.
Preparing the measurement point
Installation of the analyzer
Installation of the sample probe
Installation of the sample line
Installation of the electrical main power supply
Installation of the I/O ports

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5.2. Mounting of the sample measurement point on the stack/chimney
The sampling probe must be installed on the stack. All sampling probes can be installed on a DN65 flange.
Further general installation information can be found in the appendix.
1. The flange tube assembly must have some dimensions, to install the high dust probe correctly. The sketch
below shows the necessary dimensions.
2. The measurement point needs a hole with a diameter of 77 cm in the chimney/stack.
D=77 cm
Flange tube assembly