mru Vario Luxx User manual

User Manual VARIO luxx SYNGAS
MRU GmbH, D-74172 Neckarsulm 1 / 50

User Manual VARIO luxx SYNGAS
2 / 50 MRU GmbH, D-74172 Neckarsulm
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Original user manual
© 2018 by MRU
No part of this manual my be published in any form (print, photocopy, electronic media or
any other publication form) without a written approval by the publisher.
All user trade marks and name mark descriptions, even those which are not marked as
such, are properties of the respective owners.
Edition: 2019-03-14, V03

User Manual VARIO luxx SYNGAS
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Content
1Introduction ...........................................................................................5
1.1. Intended use .........................................................................................................5
1.2. About us..................................................................................................................6
2Information for product and safety .....................................................7
2.1. Safety manual .......................................................................................................7
2.2. Safety precautions...............................................................................................7
3Description.............................................................................................8
3.1. Task...........................................................................................................................8
3.2. Gas flow diagram.................................................................................................8
3.3. The measuring instrument...............................................................................9
3.4. Connectors.......................................................................................................... 10
3.5. Probes................................................................................................................... 10
3.6. Gas sampling probe “TR”................................................................................ 11
3.7. Gas conditioning............................................................................................... 11
3.8. Electrochemical measuring principle ........................................................ 12
3.9. IR measurement ................................................................................................ 13
4Operation ............................................................................................ 14
4.1. Commissioning ................................................................................................. 14
4.2. Switch on............................................................................................................. 14
4.3. Switching on after automatic emergency stop...................................... 14
4.4. Switch off............................................................................................................. 14
4.5. Reset...................................................................................................................... 15
4.6. Operating panel................................................................................................ 15
5Settings................................................................................................ 16
5.1. Analyzer settings............................................................................................... 16
5.2. Setting time and date...................................................................................... 17
5.3. Configuration of measurement program................................................. 17
5.4. Gas flow measurement................................................................................... 19
5.5. Setting of CO purge limit ............................................................................... 20
6Measurement ...................................................................................... 21
6.1. Preparation of each measurement............................................................. 21
6.2. How to take a Measurement......................................................................... 23
7Maintenance and cleaning................................................................. 26
7.1. Cleaning and maintenance........................................................................... 26
7.2. Maintenance....................................................................................................... 26
8Data memory ...................................................................................... 27
8.1. Organization of the Data memory.............................................................. 27
8.2. Information about the data memory......................................................... 27
8.3. Site administration........................................................................................... 27
8.4. Data transfer via USB (CSV export).............................................................. 29
8.5. Export of measurements................................................................................ 29

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9Extras ................................................................................................... 30
9.1. Access key ............................................................................................................30
9.2. Internal Log Settings ........................................................................................30
9.3. Service values......................................................................................................31
9.4. Analog output setup (4 – 20 mA).................................................................31
9.5. Analog input setup (4 – 20 mA)....................................................................33
9.6. Info..........................................................................................................................34
9.7. Printer....................................................................................................................34
9.8. WIFI (WLAN) for remote control via MRU4win or VNC..........................36
10 Information on the instrument components ................................ 39
10.1. Firmware update ...............................................................................................39
11 Specifications................................................................................... 40
11.1. Technical data.....................................................................................................40
11.2. NDIR Measurements & TCD H2 .....................................................................40
11.3. Electrochemical-, temperature- and pressure sensors .........................40
11.4. Gas sampling and conditioning ...................................................................41
11.5. Calculated values and accessories...............................................................41
11.6. Data communication........................................................................................42
12 Appendix.......................................................................................... 42
12.1. Error diagnosis regarding the measuring instrument...........................42
12.2. Insert a static IP-address..................................................................................44
12.3. RS485 Extern (option) ......................................................................................48
12.4. Spare parts ...........................................................................................................49
13 Declaration of conformity............................................................... 50

User Manual VARIO luxx SYNGAS
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1Introduction
•This manual enables you to understand and safely operate
this MRU Analyzer VARIO Iuxx .
•Please read this manual with great vigilant and get familiar
with the product before using it.
•This analyzer may only be operated by competent person-
nel and for its intended use.
•Please pay special attention to all safety directions and
warnings to prevent personal injuries and damaging of the
product.
•We can’t be held responsible for any injuries and/or dam-
ages that occur by not following the instructions in this
manual.
•Always keep the manual near you when working with the
analyzer, to be able to read instructions as needed. Please
ensure to hand over all documents to when handing the
analyzer over to others.
1.1. Intended use
The Analyzer VARIO Iuxx is designed for the gas analysis of flue gases, as
they are emitted from gas/oil burners, engines, or heating and power appli-
ances.
The instrument is intended to support the user in control and indicative
measurements in an efficient, accurate and reliable way.
The analyzer is specifically not intended as a safety device or personal pro-
tective equipment; it should not be used as a warning device to warn people
against the presence of harmful gases.
The instrument was manufactured according relevant normatives and regu-
lations. It has to used within it’s intended use.
The Instrument must not be modified from the design or safety engineering.
Modifications of any kind by the user will render the declaration of conform-
ity.
This instrument meets the requirements of the valid
European and national regulations.
You can ind the declaration of conformity in the appendix.
Syntax
Please note that this manual makes use of the scientific notation of gases
(NO2), while the instrument itself and its screen shots display the gases in
upper case letter only, i.e. (NO2).

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1.2. About us
The analyzer is produced by the MRU GmbH in Neckarsulm, Germany
(Founded in 1984), a medium sized company that specializes in developing,
producing and marketing high quality emission monitoring analyzers.
MRU GmbH produces a wide range of instruments, from standard
analyzers up to tailor made industrial analyzers.
Plant 1: Sales, Service, R&D
Plant 2: Production
MRU GmbH
Fuchshalde 8 + 12
74172 Neckarsulm - Obereisesheim
GERMANY
Tel [phone] (Front office)
Tel [phone] (Service)
Fax [phone]
Email: inf[email protected]
Site: www.mru.eu

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2Information for product and safety
2.1. Safety manual
All general information and safety precautions of MRU products are listed in
the supplied separate safety manual.
Therefore this manual must be read and observed before the first use of the
instrument.
Instrument-specific safety and warning requirements in this manual are pre-
fixed before dangerous actions.
2.2. Safety precautions
The used categories of safety precautions are here explained once more.
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 infor-
mation.
The explanation of safety notices:
CAUTION
HOT – danger of burns and fire hazards from gas ex-
traction probe.
Physical harm and property damage can be caused.
►Cool down the probe tube.

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3Description
3.1. Task
Main task the instrument is designed for is the gas analysis of flue gases,
as they are emitted from gas/oil burners, engines, or heating and power
appliances.
The instrument is intended to support the user in control and indicative
measurements in an efficient, accurate and reliable way
The instrument provides a full set of all equipment and sensors required
for a emission control measurement:
•heated probe incl. heated filter
•heated sample line
•gas conditioning unit including filters and gas cooler
•gas pump and flow control
•gas sensors
Available accessories include sensors for temperature or flow measurement.
The user interface allows for a modern and intuitive way to operate the
instrument. Running a commercial LINUX operating system, it allows as
well for lot of options for data transfer and storage.
For an overview on all available options please refer to the company’s
home page or sales representatives.
3.2. Gas flow diagram
The analyzer draws a sample of the flue gases from the duct using a built-in
gas pump through the probe is cleaned and dried using a gas cooler
and built-in filter and analyses the extracted gas with electrochemical
and NDIR sensors.
Draft and temperature are measured at the tip of the sampling probe

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A
Fresh air inlet
B
Sample gas inlet
C
Condensate outlet
D
Diff. Pressure connector
E
Vent collection box
F
Vent outlet
1
Sample gas filter (PTFE)
2
Dust filter
3
Humidity sensor
4
Auto-zero solenoid valve
5
CO purging pump
6
Sample gas pump
7
CO purge solenoid valve
8
NOX protection filter
9
Box for electrochemical sensors
10
Vent pump
11
Infrared (NDIR) bank
12
Acrodisc PTFE filter
13
Sample flow sensor
14
Gas cooler
15
Diff. pressure sensor
In the case of the VARIO luxx SYNGAS, a device fan is mounted on the rear
side panel next to the fan of the gas cooler to remove quickly any explosive
gas mixtures from the inside of the unit.
3.3. The measuring instrument
The measuring instrument consists of a compact and robust metal
housing with shock-absorbing rubber corners. All electrical and pneumatic
connections are located on the both front sides of the instrument.
It is operated exclusively via the touch-sensitive touch screen.

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3.4. Connectors
1
Loudspeaker
2
Ethernet (LAN)
3
USB socket
4
Second USB socket (option)
5
RS485 (option)
6
Analog outputs 4 ... 20 mA
7
Mains power supply
8
Sample gas filter
9
Condensate outlet port
Hose connection DN 4/6
10
Sample gas outlet port (VENT)
Hose connection DN 4/6
11
Fresh air inlet port
12
Sample gas inlet port
13
Outlet fan of gas cooler
14
Outlet fan of gas cooler
15
Pressure-/diff. pressure
16
Pressure-/diff. pressure
(Absolute pressure)
17
Combustion air tempe-
rature
18
AUX socket
19
Display of flow rate
20
Needle valve for flow adjustment
3.5. Probes
The Analyzer is available with different probes, both with fixed and exchange-
able probe tubes.
•for high and less dust content
•for fuel temperatures up to 800 °C (stainless-steel probe tube),
•for fuel temperatures up to 1.200 °C (Inconel steel probe tube),
•for fuel temperatures up to 1.700 °C (ceramic probe tube)
•with and without heated pre-filter
•with and without heated gas sampling line
•probe tubes in different lengths, from 300mm to 2000mm
A complete list of available probes can be found in the current price list of this
analyzer.

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3.6. Gas sampling probe “TR”
Heated probe with heated and exchangeable glass filter. The probe
tube includes a gas temperature sensor and is available in different
tube lengths.
1
Probe handle
2
Probe tube
3
Fast locking coupling
4
Probe cone
5
Cable plug (14-pin)
6
Heated hose line
7
Cable coupler (5-pin)
8
Fast locking coupling
9
Filter lock
3.7. Gas conditioning
The sucked sample gas is dried and filtered before it is fed to the sensors.
A sample gas cooler with Peltier element is used for drying. The condensate
liquid appearing in the gas cooler is pumped to the condensate outlet by
means of a peristaltic pump. The condensate forms drops at the outlet of the
instrument.
Optionally, connect a hose (DN 4/6) to the condensate drain.
The VENT output delivers the sample gas after the analysis stage. If the op-
tion “Active VENT” is installed, a hose (DN 4/6) may be connected here to
pump feed the sample gas to the ambient.
For subsequent filtering, a round filter is used on the front of the measuring
instrument.

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3.8. Electrochemical measuring principle
The oxygen content of the sample gas is measured with a 2 electrode elec-
trochemical sensor.
Toxic gases like carbon monoxide (CO), nitrogen oxide (NO), nitrogen diox-
ide (NO2), Sulfur dioxide (SO2), and hydrogen sulphide (H2S) are measured
with 3 electrode sensors.
The electrochemical sensors are based on gas diffusion technology.
The advantage of this technology is that the signal generated is direct pro-
portionally and linear to the volume concentration (% or ppm) of the analy-
sis gas components.
The 3 electrodes are: S (sensing electrode), C (counter electrode) and
R (reference electrode).
When the gas being measured contacts the sensing electrode, it reacts
on the electrode surface either through oxidation (for example CO, H2S,
SO2, NO, H2) or reduction (like NO2, and Cl2).
Example: CO sensor:
CO reacts at the sensing electrode as follows:
CO + H2O -> CO2+ 2H+ + 2e-
and at the counter electrode, oxygen from air will be re-oxidized to water:
½ O2+ 2H+ + 2e- -> H2O
The generated current is measured by the integrated micro controller.
1
Sample gas
2
Particle filter
3
S-electrode
4
R- electrode
5
C- electrode
6
Connection pin
7
Electrolyte reservoir
8
Electrolyte
9
Capillary diffusion
barrier

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3.9. IR measurement
The instruments NDIR gas sensor is able to detect up to 8 different gases. It is
most advanced in terms of its long-term stability due to a dedicated stabili-
zation technology including a permanent zeroing by operating the bench at
two different gas pressure values.
Due to its low noise and being drift free, it is perfectly suited to long-term
measurements.
Principle of the IR-bench (NDIR)
An infrared source delivers IR radiation in the wavelength range between 1
and 10 um, which is relevant for the absorption of gas components to be
measured.
1
IR source
2
Gas entry
3
Sample gas cell
4
Gas exit
5
Band pass filter
6
IR detector
The target gas absorbs a portion of the IR radiation, which is detected by a
wavelength selective detectors and the end of the sample gas cell.
The absorption value is correlated with the gas concentration, while all ef-
fects of cross sensitivity to other gases are corrected by an internal software
algorithm.
As the IR bench is operated successively at two different gas pressure val-
ues, it is possible to eliminate all drift effects, which would otherwise con-
tribute to the absorption signal.

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4Operation
4.1. Commissioning
The instrument is delivered as a complete assembly ready for use.
►Check the instrument regarding condition and integrity after delivery.
►Connect the instrument to the power grid.
The instrument switches on and start the operating system.
Blue LEDs for ON and power supply are switched on.
(In the event of an error, the Power LED lights red)
The instrument runs a start procedure which includes:
•self-test
•warm-up of the NDIR bench
•cool down the double stage gas cooler, indicated by the symbol
•Zeroing, indicated by symbol
►Charge battery for more than 8h is recommended after first start to allow
the battery to charge completely. Operation of heated probe and sample
line is only supported when connected to power grid.
The battery is charged as soon as the connection to power grid is
established.
The blue LED will be blinking slowly.
Heating of probe and probe tube are unsupported in battery mode.
4.2. Switch on
►Touch the ⏻button for 3 sec. minimum
LED lights blue
►Release the ⏻button
LED lights red, analyzer runs up
4.3. Switching on after automatic emergency stop
After an automatic emergency shutdown without shutting down the operat-
ing system, you have to turn on the VARIOluxx SYNGAS as follows:
LED lights blue
Release the ⏻key
LED lights red, analyzer runs up
4.4. Switch off
►Touch the “Context menu” on the display
►“Turn instrument off”
Do you wish to turn instrument off?
►“YES”
“The system will shut down”
or
►Touch the ⏻button
Do you wish to turn instrument off?
“YES”
“The system will shut down”
„YES“.

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4.5. Reset
►Touch the ⏻button during flashing LED for 30 sec. minimum
►After change to continuous lighting, release the ⏻button
The instrument will switching off with reset
4.6. Operating panel
All functions are controlled via the touch surface of the instrument. Different
gestures are available in the individual menus and windows.
1
Power-on and reset
2
Reserve
3
Reserve
4
LED display mains operation/battery charging mode
5
Reserve
6
Current flow rate
7
Current temperatures heated hose
8
Selected measuring program, e.g. Test or measurement program
9
Current temperatures of NDIR bench
10
Current temperatures of gas cooler
11
Access to detailed information on the instrument components.
Especially for service or inquiry
12
Menu info
13
Menu contacts
14
Status bar: display of zero point, alarms, executed measuring program,
selected fuel, heat-up-, cool-down phase
15
Menu measure
16
Menu settings
17
Menu extras
18
Battery Charge indicator
19
Context menu with window-dependent additional functions

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5Settings
After the analyzer has been inspected and is ready for start-up it can be
switched on and personalized settings can be entered. These settings can
be changed at any time.
5.1. Analyzer settings
In the Settings menu, some analyzer presets may be configured:
Country
Option
By changing the country
the O2reference values
settings are lost. The fuel
list is reset. Similarly,
country-specific defaults
and methods of meas-
urement are selected as a result.
Ensure the correct setting of the country
in which you are performing the measure-
ment to ensure that all relevant ones are
set up
Language
Option
Select instrument language
Modbus slave
Modbus address of the instrument for the
remote control via Modbus
Temperature
heating hose
130°C -
+180°C
Combustion
analysis
ON/OFF
Setting combustion analysis to ON
allows for several calculation performed
by the instrument, which are fuel type
dependent, e.g. Lambda, heat loss.
Negative gas
readings
ON/OFF
Negative gas readings caused by tempera-
ture drift of a sensor are suppressed
(shown as zero) or displayed
VNC
ON/OFF
VNC Viewer for remote control via LAN

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Reference tem-
perature
Calculation of the values for a standard
state at reference temperature
Interval
auto-zero
Interval time after which the instrument
performs a zero-point
5.2. Setting time and date
In the Extras menu, you can check the date and time and, if necessary, set it.
When connected to the Internet, the time automatically synchronizes itself.
►The time and date can be set in the middle black number series by push-
ing up and down the gray number row.
►Accept the changes with ACCEPT.
5.3. Configuration of measurement program
The Analyzer provides in the Measure menu various measurement pro-
grams, which can be selected in the main window. Each measuring program
defines the properties of the measuring window:
►Measurement program
The measured value window can be freely set with regard to the displayed
measured values, of the underlying fuel. The purge limit of the CO sensor (if
available) can be set
►Test program
The measured value window shows predefined values and cannot be
changed. Can be used in instrument testing to obtain standardized displays,
e.g. can easily be checked with test gases.
►If so, further measuring programs
The measurement window for gas analysis can be configured and adapted
to your needs. The measuring window initially displays 12 measured values,
by a scrolling gesture it will display more values.

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Moving a value field
►Touch and hold the value field.
Value field will be framed.
►Move the value field to a different position.
The other value fields move automatically.
Assign a measured value
►Double touch the value field.
A list with of all available measured values is displayed.
►Choose the wanted value and “replace”.

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5.4. Gas flow measurement
Set up measurement window
With the flow measurement option are further measurements available:
•v-flow
•Flow rate
•Mass flow carbon
Parameter for gas flow measurement
►Choose the right context button - menu item “gas flow measurement”.

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5.5. Setting of CO purge limit
High CO gases can affect the lifetime of the electrochemical CO sensor.
Therefore, the VARIOluxx is equipped with a protective instrument (switch-
ing-off and purge) of the CO sensor. You can specify, however, which CO
value (CO limit) of the CO sensor protection is activated. To do so, use the
context menu of the measurement window.