mru VARIOluxx User manual

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 1 / 80

User Manual VARIOluxx
2 / 80 MRU GmbH, D-74172 Neckarsulm
Manufacturer:
Legal notices / Intellectual property rights comments
Original user manual
© 2020 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: 2020-02-24, V7.00.EN

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 3 / 80

User Manual VARIOluxx
4 / 80 MRU GmbH, D-74172 Neckarsulm
Table of content
1Information for product and safety ............................................. 7
1.1. Safety manual .................................................................................................7
1.2. Safety precautions.........................................................................................7
2Introduction................................................................................... 8
2.1. Intended use....................................................................................................8
2.2. About us............................................................................................................9
3Description................................................................................... 11
3.1. Task..................................................................................................................11
3.2. Gas flow diagram........................................................................................11
3.3. The measuring instrument ......................................................................12
3.4. Connectors....................................................................................................13
3.5. Probes.............................................................................................................14
3.6. Heated Gas sampling probe...................................................................15
3.7. Gas conditioning.........................................................................................15
3.8. Gas supply.....................................................................................................16
3.9. Gas sensors ...................................................................................................16
4Operation..................................................................................... 17
4.1. Commissioning............................................................................................17
4.2. Operating panel ..........................................................................................17
4.3. Charging the battery .................................................................................18
4.4. Switching on the analyzer ....................................................................... 19
4.5. Switching off the analyzer .......................................................................19
5Settings ........................................................................................ 20
5.1. Analyzer settings.........................................................................................20
5.2. Setting time and date ...............................................................................22
5.3. Configuration of measurement program ..........................................22
Test program........................................................................................................22
Measurement program ....................................................................................22
Further measuring programs .........................................................................22
Moving a value field..........................................................................................23
Assign a measured value.................................................................................23
Setting zoom........................................................................................................24
5.4. Gas flow measurement.............................................................................24
Parameter for gas flow measurement ........................................................24
5.5. Operating the analyzer in the extended temperature range......26
Precautions for use in the extended temperature range.....................26
Connecting heating box ..................................................................................26
5.6. Operating analyzer with NiHM-Battery..............................................27

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 5 / 80
6Measurement............................................................................... 29
6.1. Preparing measurement........................................................................... 29
Setting up the measuring point.................................................................... 29
Operating temperature.................................................................................... 30
Power supply........................................................................................................ 30
Switch-on, warm-up phase, zero point ...................................................... 30
Select Source zero point (gas)....................................................................... 30
Charging state of the battery......................................................................... 32
Connections to the analyzer........................................................................... 32
Filters....................................................................................................................... 33
Perform leak test ................................................................................................ 33
6.2. Take a measurement................................................................................. 34
Setting O2 reference......................................................................................... 34
Setting of CO purge limit ................................................................................ 34
Starting the measurement .............................................................................. 35
Storing measured values ................................................................................. 35
Starting Auto-measurement .......................................................................... 36
Displaying Auto-measurement graphical.................................................. 37
Stopping Auto-measurement........................................................................ 38
7Data memory ............................................................................... 39
7.1. Organizing data memory......................................................................... 39
7.2. Managing sites ............................................................................................ 39
Adding a new site............................................................................................... 39
Changing site data............................................................................................. 40
Deleting sites ....................................................................................................... 41
Recalling stored measurements.................................................................... 41
7.3. Data transfer via USB (CSV export) ...................................................... 42
8Extras............................................................................................ 45
8.1. History ............................................................................................................ 45
8.2. Access key ..................................................................................................... 46
8.3. Internal log Settings .................................................................................. 46
Copying all log data .......................................................................................... 46
Copying single log data................................................................................... 47
8.4. Service values............................................................................................... 49
8.5. Analog output setup (4 –20 mA)......................................................... 49
Setting channel ................................................................................................... 49
Setting lower / higher limit............................................................................. 50
Setting Analog outputs during zeroing ..................................................... 51
Pin assignment of the 4-20 mA interface (Analog IN/OUT)............... 52

User Manual VARIOluxx
6 / 80 MRU GmbH, D-74172 Neckarsulm
8.6. Analog input setup (4-20mA) ................................................................53
8.7. Getting information about the network.............................................54
8.8. Assigning a fixed IP address...................................................................54
8.9. Connecting analyzer with WIFI (WLAN) .............................................56
8.10. Printing measurement results ................................................................57
Printing current measurement results ........................................................58
Printing stored measurement results..........................................................58
9Info............................................................................................... 60
10 Maintenance and cleaning ...................................................... 61
10.1. Cleaning and maintenance .....................................................................61
10.2. Service check................................................................................................ 61
11 Simple service work ................................................................. 62
11.1. Information of the analyzer components ..........................................62
11.2. Updating the firmware..............................................................................62
12 Specifications ........................................................................... 64
12.1. Technical data..............................................................................................64
12.2. Specifications of NDIR technology.......................................................65
12.3. Sensors for Oxygen, Temperatures and Pressure...........................65
12.4. Gas sampling and conditioning ............................................................68
12.5. Gas cooler strategy ....................................................................................68
12.6. Calculated values and accessories........................................................69
12.7. Analysis and calculations ......................................................................... 69
12.8. Data communication................................................................................. 70
12.9. Fuel type list..................................................................................................70
13 Appendix .................................................................................. 71
13.1. Error diagnosis regarding the measuring instrument ...................71
13.2. Switching off the analyzer in case error .............................................73
13.3. RS485 Extern (Option)...............................................................................73
13.4. Connecting analyzer with MRU4win....................................................74
Connecting analyzer with MRU4win via serial interface (RS 485).....74
Connecting analyzer with MRU4win via TCP/IP connection...............75
Creating analyzer in MRU4win ......................................................................76
13.5. Remote control of the analyzer via VNC............................................ 78
13.6. Spare parts ....................................................................................................79
14 Declaration of conformity....................................................... 80

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 7 / 80
1Information for product and safety
1.1. 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
prefixed before dangerous actions.
1.2. 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
extraction probe.
Physical harm and property damage can be caused.
►Cool down the probe tube.

User Manual VARIOluxx
8 / 80 MRU GmbH, D-74172 Neckarsulm
2Introduction
•This manual enables you to understand and safely op-
erate this MRU Analyzer VARIOluxx.
•Please read this manual with great vigilant and get
familiar with the product before using it.
•This analyzer may only be operated by competent per-
sonnel 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
damages 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.
2.1. Intended use
The Analyzer VARIOluxx is designed for the gas analysis of flue gases,
as they are emitted from gas/oil burners, engines, or heating and power
appliances.
The analyzer 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
protective equipment.
The analyzer should not be used as a warning device to warn people
against the presence of harmful gases.
The analyzer was manufactured according relevant normatives and
regulations.
The analyzer must be used according to instructions for the intended
use.
WARNING
Risk from manipulations to the measuring device
Operational safety hazard
►Modifications or changes to the measuring device
are not allowed.

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 9 / 80
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).
2.2. About us
The analyzer is produced by the MRU GmbH in Neckarsulm, Germany
(Founded in 1984), a medium sized company that specializes in devel-
oping, 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

User Manual VARIOluxx
10 / 80 MRU GmbH, D-74172 Neckarsulm
MRU GmbH
Fuchshalde 8 + 12
74172 Neckarsulm - Obereisesheim
GERMANY
Tel [phone] (Front office)
Tel [phone] (Service)
Fax [phone]
Email: in[email protected]
Site: www.mru.eu

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 11 / 80
3Description
3.1. Task
The main task of the analyzer is to analyse
flue gases, as they are emitting from incinerators or engines.
•The analyzer is optimized for this purpose and includes
all components from the gas sampling probe to data
processing.
•The analyzer also performs other measurement tasks
such as pressure and temperature measurement or
measurement of flow velocity.
For an overview on all available options please refer to the company’s
home page or sales representatives.
3.2. Gas flow diagram
In combination with the gas sampling probe, the analyzer extracts a
partial volume of the flue gas from the combustion channel and
analyses it for its components by means of sensors (e.g. paramagnetic
(oxygen) sensor, electrochemical (oxygen) sensor or NDIR sensors).
Draft and temperature are measured at the tip of the sampling probe.

User Manual VARIOluxx
12 / 80 MRU GmbH, D-74172 Neckarsulm
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 sen-
sors
10
Vent pump
11
Infrared (NDIR) bank
12
Acrodisc PTFE filter
13
Sample flow sensor
14
Gas cooler
15
Diff. pressure sensor
3.3. The measuring instrument
The measuring instrument consists of a compact and robust metal
housing with shock-absorbing rubber corners. All electrical and pneu-
matic connections are located on the both front sides of the instrument.
It is operated exclusively via the touch-sensitive touch screen.

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 13 / 80
3.4. Connectors
Front side right
1
Loudspeaker
2
Ethernet (LAN)
3
USB socket
4
Second USB socket (option)
5
RS485 (Option)
6
Analog outputs 4 ... 20 mA
Analog-inputs 4 … 20 mA
7
Mains power supply
Front side left
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
Probe connection, electrical
15
Pressure-/diff. pressure
16
Pressure-/diff. pressure
(Absolute pressure)
17
Combustion air temperature
18
AUX socket

User Manual VARIOluxx
14 / 80 MRU GmbH, D-74172 Neckarsulm
The connection drawings are also displayed in the menu Extras.
►Touch the menu Extras.
A selection list appears.
►Press „Connections“.
The left side of the analyzer appears.
►Push „Right >>“.
The right side of the analyzer appears.
3.5. Probes
In combination with the analyzer, probes in different versions for high
and less dust content are offered.
•for fuel temperatures up to 800 °C (Stainless-steel probe tube),
•for fuel temperatures up to 1.100 °C (Inconel steel probe tube),
•for fuel temperatures up to 1.700 °C (Viton, Teflon)
•with and without heated pre-filter
•with and without heated gas sampling line
•probe tubes in different lengths
A complete list of available probes can be found in the current price list
of this analyzer.

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 15 / 80
3.6. Heated Gas sampling probe
For interchangeable probe tube with flue gas temperature measure-
ment using type K-thermoelement.
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
►Check the probe filter before and after every measurement.
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.
A hose (DN 4/6, not longer than 5 m) can also be connected to the
sample gas outlet for discharge.
For subsequent filtering, a round filter is used on the front of the
analyzer.

User Manual VARIOluxx
16 / 80 MRU GmbH, D-74172 Neckarsulm
3.8. Gas supply
The analyzer contains a gas feed pump (diaphragm pump).
The flow through the gas feed pump is measured and regulated to the
nominal value by the analyzer.
If the pump capacity is not sufficient to reach the flow of the nominal
value, an alarm is issued.
If the flow does not reach the nominal value despite an increase of the
pump capacity, the pump is switched off after a while to protect the
analyzer.
3.9. Gas sensors
The analyzer has three types of gas sensors:
1. The analyser works with electrochemical sensors to measure O2(oxy-
gen), CO (carbon monoxide), NO (nitrogen monoxide), NO2(nitrogen
dioxide), SO2(sulphur dioxide), H2S(hydrogen sulphide).
2. The analyzer works with a paramagnetic sensor for the
Measurement of O2(oxygen).
3. The analyzer works with a non-dispersive infrared absorption
measurement.
Depending on the installed NDIR module, this measuring principle
makes it possible to measure CO (carbon monoxide), CO2(carbon diox-
ide), CH4(methane) and C3H8 (propane).

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 17 / 80
4Operation
4.1. Commissioning
The analyzer leaves the factory assembled and ready for use.
►Check the analyzer regarding completeness and integrity.
►Connect the analyzer to the mains plug.
The analyzer switches on.
The operating system boots.
Blue LEDs for ON and power supply are switched on.
(In the event of an error, the Power LED lights red)
The device runs through a start routine of 30 minutes.
The start routine includes:
•self-test
•warm-up of the NDIR bench
•cool down of the stage gas cooler, indicated by the
symbol
•Zeroing, indicated by symbol.
The remaining time until the end of zeroing is
displayed.
4.2. Operating panel
All functions are controlled via the touch surface of the instrument. Dif-
ferent gestures are available in the individual menus and windows.

User Manual VARIOluxx
18 / 80 MRU GmbH, D-74172 Neckarsulm
4.3. Charging the battery
The analyzer has an integrated rechargeable battery.
►Connect the mains plug.
The battery will be charged as soon as it is connected to the
mains.
The blue LED (4) lights up.
►Charge battery for more than 8h is recommended after first start to
allow the battery to charge completely.
NOTE
Note that the analyzer can only be used in battery
operation to a limited extent.
►Do not carry out any measurements in battery mode.
►Carry out only data processing and setting work in
battery operation.
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 pro-
gram, 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

User Manual VARIOluxx
MRU GmbH, D-74172 Neckarsulm 19 / 80
4.4. Switching on the analyzer
►Touch the ⏻button (1) for 3 sec. minimum
LED lights blue
►Release the ⏻button (1).
Analyzer runs up.
4.5. Switching off the analyzer
There are two possibilities to switch off the analyzer.
►Touch the Context menu (19) on the display.
A selection list appears.
►Touch „Turn unit off“.
►Touch „YES“.
The analyzer shuts down.
Alternatively, you can switch off the analyzer as follows:
►Touch the ⏻button (1).
A dialog window appears.
►Touch „YES“.
The analyzer shuts down.

User Manual VARIOluxx
20 / 80 MRU GmbH, D-74172 Neckarsulm
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 pre-sets may be configured:
►Touch the menu „Settings“.
Country
Option
By changing the country, the
O2reference values settings
are lost. The fuel list is reset.
Similarly, country-specific
defaults and methods of
measurement are selected
as a result.
Ensure the correct setting of the country in
which you are performing the measurement
to ensure that all relevant ones are set
Language
Option
Select analyzer language
Modbus slave
Modbus address of the instrument for the
remote control via Modbus
Temperature
Heat. hose
120°C –
180°C
Default 160 °C
Temperature
Grip heating
120°C –
180°C
Default 160 °C
Combustion
analysis
ON/OFF
Setting combustion analysis to ON
allows for several calculation performed