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USER MANUAL SWG 200-1 BIOGAS

USER MANUAL SWG 200-1 BIOGAS

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USER MANUAL SWG 200-1 BIOGAS

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.
Important notice!
This high quality electronic analyzer utilizes batteries that discharge even when the analyzer is not in use. Therefore it
is very important to charge the batteries (Li-Ion) every 6 months, even if the analyzer is not in use.
Failing to properly charge the batteries will void your warranty!
Save the original box and the packing material for use if the analyzer must be shipped in the future.

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 (+49) 71 32 99 62 0 (Reception)


Fon (+49) 71 32 99 62 61 (Service)
Fax (+49) 71 32 99 62 20
Email: info@mru.de
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 informa-
tion’s from this manual or any mis-use resulting from the use of this manual.

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USER MANUAL SWG 200-1 BIOGAS

1 CONTENT
1 CONTENT .......................................................................................................................................................... 4
2 INTRODUCTION ................................................................................................................................................. 7
2.1 The SWG 200-1 BIOGAS ........................................................................................................................... 7
2.1.1 Short description.................................................................................................................................. 8
2.1.2 Hardware ............................................................................................................................................. 8
2.1.3 Software .............................................................................................................................................. 8
2.2 Diagram BIOGAS site ............................................................................................................................... 9
2.3 The company MRU GmbH ...................................................................................................................... 10
2.4 Security advises ...................................................................................................................................... 11
2.4.1 Qualified staff .................................................................................................................................... 11
2.4.2 Planning and installation ................................................................................................................... 11
2.4.3 Operation........................................................................................................................................... 11
2.4.4 Maintenance ...................................................................................................................................... 11
2.4.5 Malfunctions ...................................................................................................................................... 11
3 OPERATION ..................................................................................................................................................... 12
3.1 Keypad ................................................................................................................................................... 12
3.2 Eventual problems after power-on ......................................................................................................... 13
3.2.1 Display contrast problem ................................................................................................................... 13
3.2.2 Software language problem............................................................................................................... 13
3.3 Operating ............................................................................................................................................... 14
3.3.1 Menu overview .................................................................................................................................. 14
3.3.2 Save changed configuration .............................................................................................................. 16
3.3.3 Selftest ............................................................................................................................................... 16
3.3.4 Set to zero ......................................................................................................................................... 17
3.4 Main menu measuring settings .............................................................................................................. 18
3.4.1 Automatic interval measurement....................................................................................................... 19
3.4.1.1 Setup of auto-measurement ..................................................................................................... 21
3.4.2 Reset to zero ...................................................................................................................................... 22
3.4.3 Selection of temperature measuring unit ........................................................................................... 22
3.4.4 Selection of interval auto-zero ........................................................................................................... 22
3.5 Main menu Xtras (settings) .................................................................................................................... 23
3.5.1 Set date and time .............................................................................................................................. 23
3.5.2 RS 232 settings .................................................................................................................................. 23
3.5.2.1 Continuous data transmission .................................................................................................. 24
3.5.2.2 Transmission protocol ............................................................................................................... 24
3.5.3 Analyzer settings ............................................................................................................................... 24
3.5.3.1 Setting display contrast ............................................................................................................ 25
3.5.3.2 Helping hints ............................................................................................................................ 25
3.5.3.3 Country (instrument language on display) ................................................................................ 25
3.5.3.4 Negative gas readings .............................................................................................................. 26
3.5.3.5 Reference temperature ............................................................................................................. 26
3.5.3.6 Hold delay after purge .............................................................................................................. 26
3.5.3.7 H2S sensor protection ............................................................................................................... 27
3.5.3.8 Basic System Settings ............................................................................................................... 27
3.5.3.9 Threshold sample gas ............................................................................................................... 28
3.5.4 Service values .................................................................................................................................... 29
3.5.5 Adjustment ........................................................................................................................................ 30

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USER MANUAL SWG 200-1 BIOGAS
3.5.5.1 Main adjustment menu............................................................................................................. 30
3.5.5.2 Adjustment electrochemical sensors ......................................................................................... 32
3.5.5.3 Infrared bench adjustment........................................................................................................ 33
3.5.5.4 Analog output (4-20 mA).......................................................................................................... 34
3.5.5.5 Sample gas flow measurement ................................................................................................. 34
3.5.5.6 Reset to zero............................................................................................................................. 34
3.5.5.7 Span gas scource nzl. Span ...................................................................................................... 34
3.5.6 Analog output configuration (4 – 20 mA) .......................................................................................... 35
3.5.7 Alarm output configuration ............................................................................................................... 36
3.6 Main menu Info ...................................................................................................................................... 38
3.6.1 Unit status ......................................................................................................................................... 38
3.6.2 Device options ................................................................................................................................... 38
3.7 General, functions .................................................................................................................................. 39
3.7.1 Quick input of numbers ..................................................................................................................... 39
3.7.2 Request user decision ........................................................................................................................ 39
3.8 Options................................................................................................................................................... 40
3.8.1 Sampling points switching ................................................................................................................. 40
3.8.1.1 Change interval time of automatic sampling point switching................................................... 41
3.9 Appendix ................................................................................................................................................ 42
3.9.1 H8 industrial analysers Modbus Slave specification ........................................................................... 42
3.9.1.1 General information ................................................................................................................. 42
3.9.1.2 Defined registers....................................................................................................................... 42
4 MOUNTING ..................................................................................................................................................... 47
4.1 Assembly 6U and gas connections # 200116 ......................................................................................... 47
4.2 Assembly 9U and gas connections # 200119 ......................................................................................... 48
4.3 Main control unit MCU 6U # 644416 ..................................................................................................... 49
4.4 Mounting plate 6U # 64417 ................................................................................................................... 52
4.5 Mounting plate 9U # 64405 ................................................................................................................... 53
4.6 Power supply connection of analyzer SWG 200-1 .................................................................................. 55
4.7 Analog output connection ...................................................................................................................... 56
4.8 Digital data transfer to Desktop PC ........................................................................................................ 58
4.9 Digital data transfer to notebook ........................................................................................................... 59
5 SERVICE........................................................................................................................................................... 60
5.1 Maintenance and service........................................................................................................................ 60
5.1.1 Cabinet ventilation ............................................................................................................................ 60
5.1.2 Sample gas filter (PTFE) # 60631 ....................................................................................................... 61
5.1.3 Span calibration gas filter # 56066 ................................................................................................... 61
5.1.4 Activated carbon filter # 11152 ......................................................................................................... 62
5.1.5 Purafil filter # 56795 .......................................................................................................................... 62
5.1.6 Replace O2 sensor # 58048B ............................................................................................................. 63
5.1.7 Replace NDIR bench # 62399BG ........................................................................................................ 63
5.1.8 Sample gas pump # 64656 ................................................................................................................ 64
5.2 Self test / Service .................................................................................................................................... 65
5.2.1 Self-test ............................................................................................................................................. 65
5.2.2 Set to zero ......................................................................................................................................... 65
5.2.3 Service values .................................................................................................................................... 66
5.2.4 Analog values .................................................................................................................................... 66

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USER MANUAL SWG 200-1 BIOGAS
5.2.5 NDIR values ....................................................................................................................................... 66
5.3 Current unit status ................................................................................................................................. 67
5.4 Errors ...................................................................................................................................................... 68
5.5 Manual for firmware update of MRU H8-Industrial analysers ................................................................ 70
5.5.1 System requirements ......................................................................................................................... 70
5.5.2 Important hints and warnings ........................................................................................................... 70
5.5.3 Update procedure .............................................................................................................................. 70
5.5.4 Possible causes and solutions in case of update failure: .................................................................... 70
5.6 Cable enumeration of main pcb of industrial analyzers.......................................................................... 71
5.6.1 Mainboard (pcb # 59351) .................................................................................................................. 71
5.6.2 Interface board (pcb # 60413) ........................................................................................................... 73
5.6.3 Alarm relays and auto-cal board (pcb # 60886) ................................................................................. 73
5.7 Schematics ............................................................................................................................................. 74
5.7.1 Gas flow diagram .............................................................................................................................. 74
5.7.2 Wiring diagram cabinet ..................................................................................................................... 75
5.7.3 Overview connectors ......................................................................................................................... 80
5.8 Spare part list ......................................................................................................................................... 81
5.9 Wearing part list..................................................................................................................................... 82
6 OPTIONS.......................................................................................................................................................... 83
6.1 Unit heater 500W with automatic regulation # 60997 ........................................................................... 83
6.2 Gas cooler # 64556 ................................................................................................................................ 85
6.2.1 Condensate pump # 11234............................................................................................................... 85
6.3 Sampling point switch ............................................................................................................................ 85
6.4 System safety set # 64555 ...................................................................................................................... 86
6.5 H2S high analysis # 64833 ..................................................................................................................... 86
6.6 H2 analysis # 64435 ............................................................................................................................... 86
7 APPENDIX ....................................................................................................................................................... 87
7.1 Technical Specifications.......................................................................................................................... 87
7.2 Declaration of confirmity ........................................................................................................................ 88

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USER MANUAL SWG 200-1 BIOGAS

2 INTRODUCTION
2.1 The SWG 200-1 BIOGAS

The following gas components can be measured and indicated:

Biogas analysis:
O2 Oxygen 0 – 25,00 % electrochemical cell (long-life)
CO2 Carbon dioxide 0 – 100 % NDIR bench
CH4 Methane 0 – 100 % NDIR bench

OPTIONAL :
H2 Hydrogen 0 – 1.000 ppm electrochemical cell
H2S(low) Hydrogen Sulphide 0 – 1.000 ppm electrochemical cell
H2S(high) Hydrogen Sulphide 0 – 10.000 ppm electrochemical cell

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USER MANUAL SWG 200-1 BIOGAS
2.1.1 Short description

The continuous gas analysis is based on extractive cold and dry method by using of electrochemical cells
and one multi-gas infrared bench (NDIR).
The SWG 200-1 shall be installed nearly to the gas sampling point, to have a short distance between
the analyzer and the gas sampling point, for decrease of analyzer response time, but still in safe area (hazardous
area instrument on special request). The length of the non-heated PTFE gas sample line for biogas sampling can be
up to 50 m. For sample gas line placed in low ambient temperature (winter time), a freezing protection of sample
line (user scope) and instrument cabinet heater (option) is required.
The SWG 200-1 is equipped with a partial sample conditioning system, see description below.
If biogas is humid, the option gas cooler is highly recommended.
For time sharing technique (alternate monitoring of biogas from up to max 4 different sampling points)
special non-heated solenoid valves will be used.
Optionally an instrument system safety package can be installed, also together with sample switching.
The SWG 200-1 is equipped with a digital data interface RS485 using Modbus RTU protocol or MRU
proprietary protocol. Additional 8 channel analog output (8x 4-20mA self powered current loops) will transfer
measured data to control panel (PLC) of cogeneration system or DCS
Display of analysis data and service data indication is direct in front of the SWG 200-1.
The SWG 200-1 is designed for continuous measurement and use automatic zero calibration
by clean ambient air sampling at least once a day, according to user free software settings.
Fresh and clean ambient air is required as zero gas.
The place of installation SWG 200-1 must be a dry, weatherproof ambient with temperature between
+5°C and +40°C.
!!! The use weather shade to protect unit from direct rain and sunlight is mandatory !!!

2.1.2 Hardware

The complete hardware is mounted into a steel cabinet (weight approx. 30kg, protection IP 54, with 4
fastening loops for wall mounting).
Lockable glass door
Local operation keyboard and back lighted LCD display for indication of measured data
Complete sample gas conditioning system with:
OPTION: system safety package using flame arrestor and shut-off solenoid valve
OPTION: multiple (2x,3x or 4x) sampling point switching using non-heated solenoid valves
OPTION: sample gas electric cooler (Peltier) with automatic condensate draining
Gas sampling pump
Filter elements for gas and ambient air
Flow meter with needle valve and internal sample flow volume measurement
Solenoid valve for auto-zero and for calibration
μ-processor electronic board
Sensors and amplifier electronics, infrared bench
RS485 interface for long distance data transfer (Modbus RTU)
8x analog outputs 4-20mA current loop, user free configurable

2.1.3 Software

Standard software for all aforementioned functions with self-check of all internal functions:
System self test and diagnosis
Peltier cooler automatic control with condensate monitoring and alarm (option)
Automatic interval measurement, user settable
Sample flow monitoring and alarm
Digital data transmission, including PC visualization software

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USER MANUAL SWG 200-1 BIOGAS
2.2 Diagram BIOGAS site

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USER MANUAL SWG 200-1 BIOGAS
2.3 The company MRU GmbH
Your 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. MRU GmbH
contact details are listed on the previous page.

Factory 1 (service department, development division, administration)

Factory 2 (Product division)

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USER MANUAL SWG 200-1 BIOGAS
2.4 Security advises
The following security advises have to be strictly observed.
They are an essential and indispensable part of the user’s documentation.
Not observing the security advises can mean loss of your right to claim under guarantee.

2.4.1 Qualified staff


Certain works at the device and its accessories are only to be done by especially qualified staff. Such are persons which
are authorized from the safety officer due to their education, knowledge and experience and which can recognize and
avoid possible danger.
2.4.2 Planning and installation
Installation design, assembly, installation and maintenance work are carried out only by trained and qualified persons
and is checked by responsible qualified staff.
Certain jobs, such as electrical installation, require special knowledge. The qualification of persons performing these
jobs must correspond to the degree of difficulty.
2.4.3 Operation
The device might cause danger, especially in case of not observing the security advises.
2.4.4 Maintenance
The SWG200-1 system components are operating equipment for use in industrial high voltage installations. During
installation, start-up and service wrong operational control or insufficient maintenance can cause severe injuries or
damage to persons or equipment.
To prevent equipment malfunctions, scheduled maintenance and inspections performed by qualified and servicing
staffs are required.

During maintenance work, make sure you switched off the power supply!
During maintenance work, take care of hot surfaces!
Attention, danger of skin burning! Wear safety gloves!

2.4.5 Malfunctions
Abnormal operating conditions must be regarded as serious indications for a functional degradation. Such indications
are:
heavy drift of measurement results
increased power consumption or power failure
increased temperatures inside the analyzer cabinet
unusual noises or smells

Quality Control Department MRU GmbH


USER MANUAL SWG 200-1 BIOGAS
3 OPERATION
3.1 Keypad

Position Symbol function


1 Save configuration key
2 Dependent on text/object
Main menu: measurement display
3 Dependent on text/object
Main menu: measurement settings
4 Dependent on text/object
Main menu: Data menu
5 Dependent on text/object
Main menu: Setting menu
6 Dependent on text/object
Main menu : Information menu
7 Help function
8 Print function (optional)
9 ESC function
10 ENTER function
11 Change value/setting
12 Change value/setting
13 Move selection cursor
14 Move selection cursor
USER MANUAL SWG 200-1 BIOGAS
3.2 Eventual pro
oblems affter powe
er-on
3.2.1 Display contrast problem

After power--on the unit, if


i you have trrouble readingg the display, you can channge display contrast by preessing
the or key: channge of displayy contrast occcur in 5 % steeps!

Analyzer display after pow


wer-on:

3.2.2 S
Software l
language p
problem

i you have noo installation of the languaage of the country of your origin, please press
After power--on the unit, if
or . This will swittch on the lannguage changge feature.
By means off key or you can search the laanguage required

……

Now press in order to accept thee new languagge setting. Thhe analyzer will
w restart with the selectedd language.

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USER MANUAL SWG 200-1 BIOGAS
3.3 Ope
erating
All fu
unctions no
ot describe
ed in this operation
o manual
m forr your SWG
G 200-1 BIO
OGAS are
n require
not ed for yourr stationary
y biogas measureme
m ents!

3.3.1 Menu overvieew


The structuree of this operating manuall is based upoon the structuure of the maiin menus.

Flowchart main menu


us

Switch on thhe mains switch in order too power-on annalyzer

• MRU logo display after


a power on
o
• self teest (automaticcally)
• set to zero (automaatically)
• start measurement
m t (automatically)

press or key to change display contrasst if required


press or keyy to change display
d languaage if requireed

preess : store acttual measurem


ment (for porttable analyzeer only)

preess , or : select maain settings menu


m

preess : select maain data mennu

preess : select maain Xtras mennu

preess .: select maain Info menuu

After power on, the analyyzer performss automaticallly the self test and setting to zero. Thenn the measureement starts and
a
the display shows
s the acttual measurinng values (main measuring menu).

By means off the keys , , , annd the menus of inteerest can be ddirectly selectted.

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USER MANUAL SWG 200-1 BIOGAS
Meassuring settin
ngs

Main settings
(Chaptter 3.4) give es access to
o:
• Auto-measurement (Chapter 3.4.1))
• Reset to zeero (Chapterr 3.4.2)
• Temperature unit (Chap pter 3.4.3
• Interval autto-zero (Chapter 3.4.4

Note: these
t functionns will be set during comm
missioning
and doo not need chaanging anymore

Main Xtras menu


u

Main Xttras
Chapterr 3.5) gives access to:
• RS232 settiings (Chapteer 3.5.2)
• Analyzer seettings (Chap
pter 3.5.3)
• Service valuues(Chapterr 3.5.4)
• Adjustmentt (Chapter 3 3.5.5)
• Analog outtput configuraation (Chaptter 3.5.6)

Note: these
t functionns will be set during comm
missioning
and doo not need chaanging anymoore
n informatio
Main on menu

Main innformation menu


(Chap. 3.6)
3 gives acccess to:
• Unit status (Chapter 3.6.1)
• Device optiions (Chapte
er 3.6.2)

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USER MANUAL SWG 200-1 BIOGAS
3.3.2 S
Save chang
ged config
guration

Analyzer will be poweredd on by pressing ON/OFF sw


witch
Pressing the - key will save only the
t eventual changed
c conffiguration.

Please carry out this procedure any tim


me you will chhange some configuration
c parameters.
It is not posssible to switchh-off the anallyzer by meanns of the - key
Only the connfiguration caan be saved or the set to zeero differentiaal pressure caan be selectedd.

Stand-by: Thhe device is reeady for meassurement – thhe temperaturre is hold to operation
o butt the pumps are
a switched-ooff.
Thhis mode can be selected also
a by the diggital input annd the RS232//RS485 interfaace.

After switch on, the analyyzer shows foor a few seconnds the MRU Logo on the display.
d

3.3.3 S
Selftest
t status (acctual voltage and temperatture values off
After power on, the displaays is showinng the analyzeer name and the
internal and external com
mponents).

During self test mode, the


t instrumennt is checkingg internal paraameters and act a
on differennt temperaturre controllers to bring the actual heaterrs/cooler to thheir
set point values.
v

As soon ass „ OK” will beb displayed anda all measuurement condditions are sattis-
fied, the innstrument sett to zero will automatically
a y start!

A prolonged in time (m
more than 30 minutes)
m quesstion mark “!” will obstruct
the instrum
ment to continue with autoomatic zeroinng. In this casse the operatoor
must act according
a to service
s manuaal.

16
USER MANUAL SWG 200-1 BIOGAS
3.3.4 S to zero
Set o

Set to zero iss carried out in the backgrround. For a sufficient


s accuuracy accordinng to analyzeers specificatioon, the infrareed
measuring teechnology reqquires a warm m up period of
o at least 30 minutes,
m depeendent on thee outside ambbient temperaa-
ture!
During this period
p of timee, flue gas meeasurement caannot be starrted. Still, all other
o menu ittems can be selected.
s
After finishinng set to zeroo, the analyzer starts autom
matically the measurement
m t and the maiin measuring menu will bee
displayed.

The multi-paage (up to 5 windows)


w meaasuring displaay can be set individually.
This configuration shall be changed duuring commissioning job and must be sttored before tthe analyzer will
w be switchhed
off.

The instrumeent has also a “zooming” function of display:

, : change the
t displayedd page
, : toggle between
b 4 value indicationn (zoom) and 10 value dispplay
: store moomentary meaasuring valuees (assigned too currently seelected site)
/. : change to
t menu settings
.: change to
t menu dataa
: t menu Xtras
change to
: change to
t menu info

17
USER MANUAL SWG 200-1 BIOGAS
3.4 Ma
ain menu measurin
ng setting
gs

, :Seelection of thee relevant parameter for measurement


m
• setuup start/stop auto
a measureement
• starrt new reset to zero

• configuration meeasuring proggrams

• seleect measuringg program ,


• seleect temperatuure unit ,
• moddify reset to zero
z interval ,

18
USER MANUAL SWG 200-1 BIOGAS
3.4.1 A
Automatic
c interval measureme
m ent
By means off the option “automatic intterval measurrement” the analyzer
a is abble to record tthe continuouus measuring
values itself.. The user maay vary the setttings of the automatic
a proogram accordding to his neeeds.
Once activatted, this optioon generates measurementts and other functions
f oveer a longer period of time.
These functioons can storee the measureements.

EXAMPLE:
The cycle in semi-continuous mode (w > 10 minutees and mean values = OFFF) is as follow
when interval >= ws:

AIR PURGE E 1: 120 secc. fixed internal software value


v
WAIT: iss INTERVAL – 600 secondss,
( e.g. wait = 0 sec. whenn interval = 600
6 sec. or wait = 400 sec.
s when intterval = 1000 sec.)
AIR PURGE E 2: 120 secc. fixed internal software value
v
AUTO-ZERO O: 120 secc. fixed internnal software value
v
GAS MEAS SURE: 240 secc. fixed internnal software value
v
PROGRAMMED ACTIO ON: At the endd of the gas measure
m mmed action (store) will be performed
phasse the program

So the waitinng phase is thhe only phasee which is reaally being changed while chhanging the interval time.
The user cannnot change purge
p time, orr zeroing timee or gas meassurement time.
Due to a certtain limit of the internal memory,
m theree are also limits in the ratioo between thee duration of the total meaas-
T analyzer automaticallyy calculates and limits the total time allowance for thhe
urement andd the selectabble intervals. The
measuremennts respectiveely the minimaal measuring interval depeending on thee memory spaace available.
This means a shorter meaasuring intervval will also reesult in a shorrter total meaasuring time ((duration).

19
USER MANUAL SWG 200-1 BIOGAS
Ring buffer storage mode (first in – first out)

When the internal memory is used, the analyzer is able to store the measurements in ring buffer mode. This means,
when the memory is fully occupied, then the next measurement will overwrite the oldest one (first in – first out).

Set duration time to ‘unlimited’ and destination memory to ‘internal’ in order to use this storage mode.

Example:
Total memory: 8500 blocks
Occupied memory: 2500 blocks
Available memory: 6000 blocks
Duration: unlimited
Interval time: 5 seconds

Now the automatic measurement is started in ring buffer mode at 10:00 am.

The analyzer will store measurements every 5 seconds until the 6000 available memory blocks will be occupied (this
will happen at 6:20 pm - after 500 minutes). The next stored measurement will overwrite the first stored measurement
from 10:00 am and so on.

So the ring buffer mode will preserve the previously occupied memory and will use the available memory to stock
measurements from a certain period of time – in our example 8 hours and 20 minutes.
Continuous transmission of the measured values over RS 232 is also ensured during activated automatic measure-
ment. It is therefore easily possible to send data to a computer for storing and evaluation purposes, for example with
MRU Online View.

When a measurement is started the automatic measurement is generally inactive.


It has to be deliberately activated by the operator in order to avoid unintended storing.

We recommend calibrating the analyzer regularly. During long term measurements the sensors may “offset drift” a
little bit which results in a loss of accuracy. The phase of sensor stability depends on the surrounding conditions and
the gas concentration. A rule of thumb is that electrochemical sensors will not drift before 6 hours and the draft sensor
not before 1 – 2 hours.

Make sure that the probe and analyzer filters will not clog during long term measurements.

20
USER MANUAL SWG 200-1 BIOGAS

3.4.1.1 Se
etup of auto-measurem
ment

Available setttings: (Auto--measuremennt deactivatedd!)

, : change value,
v measurement on/off
auto-m
, : move cuursor, change the line
: measurinng values
: minimum
m value
: maximum value
: modify values,
v Quick input of num
mbers (Chaptter 3.7.1)
: end, bacck to settings

Duration: betweenn 1 and 6.0000 minutes or unlimited


u (seee above - ringg buffer storagge mode)
Interval: betw
ween 1 und 6.000
6 secondss
Note: Thhe duration tiime can never
er be lower ass the interval time!
t

Storage: swittch on/off stoorage in the memory


m
defines whether
w theree is supposedd to store meaasuring data after
a each intterval.

Mean valuess: calculatiion of the meean values of the


t past measuring intervaal.
These mean
m w be stored/printed-out innstead of the actual valuess
values will
Note: onnly continuouus measuremeent mode is available
av withh mean valuess ON!

If there is noot enough avaailable memory for the dessired auto meeasurement, thhe analyzer aautomatically will shorten the
duration andd / or extendss the interval time.
t

21
USER MANUAL SWG 200-1 BIOGAS
3.4.2 Reset to ze
ero

In case readiings with ambbient air are erroneous


e (foor example neegative readinng Æ caused by electronic drift), the opp-
erator can sttart a manuall reset to zeroo.
For reset to zero,
z the analyzer switches automatically from gas sampling
s to ambient air saampling and after
a taking a
new zero will switch backk to samplingg gas.
3.4.3 S
Selection o tempera
of ature meassuring unitt

, : select thhe temperaturre measuring unit betweenn [°C] or [°F]

3.4.4 S
Selection o intervall auto-zero
of o

, : select thhe interval duuration betweeen two auto-zero cycles


(available settings miinimal intervaal 1/2 hour upp to maximal interval 24 hoours)

It is recommended to set an interval time for auto-zzero cycle as small


s as posssible: this will increase the accuracy of
analyzer.

Low auto-zeero interval tim


me will also inncrease the life time of eleectrochemical cells)!

Electrochemical cells requuire ambient air


a purge from m time to time; the moisture of ambientt air will recover the electrro-
lyte from insside the cell.
Do not expose electrocheemical cells too very high cooncentration of
o gas!

22
USER MANUAL SWG 200-1 BIOGAS
3.5 Maiin menu Xtras
X (setttings)
At delivery, the
t analyzer has
h a standarrd pre-adjusteed configuratiion (factory default),
d whichh should coveer your needs in
the most casses. However,, this configuration is highly flexible andd individuallyy adjustable.

If operator would
w like to modify
m differeent configurations, we recoommend doinng this in a reeasonable way. The better the
configuration modificatioon is planned, the less correective action must be takeen and the easier the workk with the anaa-
lyzer can be carried out.

The new connfiguration wiill be stored after


a pressing the - keyy.
Press : in all othher main mennus for selection of the main settings menu

3.5.1 S date and time


Set

press

Allows operaator to set tim


me and date.

, : modify selected
s item (hours, minutes, seconds, day, month or
o year)
, : move seelection cursor

3.5.2 RS 232 setttings

, : move seelection cursor


, : toggle trransmission protocol
p or coontinuous data transmissioon setting

NOTE: reco
ommended setting for stationary instrumentt using MRU
U protocol ffor data transfer:
Contin. datta transm. O
ONTransmiss s. protocol IP

23
USER MANUAL SWG 200-1 BIOGAS
3.5.2.1 Co
ontinuous data
d transm
mission

If the continuous data traansmission is activated (ON


N), the measuured values will
w be transmiitted without request to thhe
serial interfaace RS232 (annalyzer is masster).
If the continuous data traansmission is deactivated (OFF),
( the trannsmission of the
t measuredd values havee to be requessted
by the PC (analyzer is slavve).

Cont. dataa transm. Master Slave


ON N analyzer P
PC
OFFF PC anaalyzer

3.5.2.2 Trransmission
n protocol

The analyzerr can use 2 different transm


mission protoocols. The receeiver have to use the seleccted protocol in order to ree-
ceive the datta successfullly.

Transmissioon protocol Suiitable MRU PC software


I.P. (industrrial protocol) MRRU 32-bit dataa logger softw
ware
O.V. (Online View protocol) MRRU Online Vieew
In case you would
w like to implement an own receiveer software you will need the protocol sspecification. MRU will proo-
vide you the necessary doocuments freee of charge.
Modbus sla ave
• the anallyzer is able to work as moodbus slave using the RS2332 or RS485 port p (possiblyy with externaal RS232/RS4885
adapter))
• supportss RS485 interrface with 2/44 wires (half/full duplex)
• supportss only the binnary Modbus protocol
p (RTU
U)
• the slavee modbus adddress is user definable
d from
m 0 to 238
• communnication param meter are useer definable as
a follows:
- 9600 baud
b
- 19200 baud
- even parity
p and 1 sttop bit
- no parity and 2 stopp bits
Further inforrmation see appendix
a chapter 3.9.1

3.5.3 A
Analyzer s
settings

, : select iteem of analyzeer to be modified (highlighhted item)


, : modify selected
s item
: set flow thresholds
: return too main settingg menu

24
USER MANUAL SWG 200-1 BIOGAS
3.5.3.1 Se
etting displlay contrastt

The display contrast


c is deepending on the ambient teemperature of
o analyzer (deefault = 0 % / 20°C).
Meaning:
Displaay contrast, 0 % is normal with a tempeerature of aboout 20°C.
Possibble setting: -550 % to + 50 %, (in steps oof 5 %)

3.5.3.2 He
elping hintss

Posssible settings: ON/OFF


Theere are a coupple of messagges which aree generated automatically by
thee analyzer andd which help an initial useer, but which may
m annoy ann
expperienced useer.
An experienced user can swittch off such m messages by setting
s this paa-
meter to OFF.
ram
e.g.

3.5.3.3 Co
ountry (insttrument lan
nguage on display)
d

This function alloows the changge of display llanguage. Folllowing lan-


guagges are pre-programmed inn the firmwarre of the analyzer:

, .: change the
t language (also countryy specific fuels, units, valuees,...)
, .: change the
t language (also countryy specific fuels, units, valuees,...)

ATTENTION N!
A change of language/country also chaanges the listt of fuel typess and there paarameters. Ass losses and efficiency
e are
calculated with
w fuel param meters, previoously stored measurement
m ts will be recaalculated mosst probably with other pa-
rameters andd will therefoore result in otther/wrong vaalues. In this case you should change thhe language/ccountry back in
order to see correct storage contents.
25
USER MANUAL SWG 200-1 BIOGAS

3.5.3.4 Negative ga
as readings
s

If the anaalyzer is operating for longg time withouut a new resett to zero,
the meassuring values could drift froom zero in booth directionss, negative
and posittive.
Negativee readings aree caused eitheer by electronnic drift or exccessive
cross-sennsitivity betweeen different gas componeents.

Switch on / off
o the negatiive gas readinngs with , keys.
Negative gass readings ONN visualise neegative drift on
o the displayy
Negative gass readings OFFF hide negattive drift on the display

3.5.3.5 Re
eference te
emperature

In differrent countriess, there are diifferent local regulatory of standard gass


conditioon. For exampple in Europe the norm cubbic meter of gas g is deter-
mined ata 0°C, other countries require higher teemperature foor norm cubicc
meter (oor feet)!
This settting has influuence on the calculation
c off gas concentrations in
mg/m3, e.g. CO [mg//m3].
Here thee
Standarrd setting: 0°C C

, : sellect 0°C, 15°C


C or 25°C

3.5.3.6 Ho
old delay affter purge

, : sellect min. 0 sec. to max. 225 sec in 15 seec. Steps

In addition to
t hold time during
d auto-zeero (back purrge), the analyyzer can add a hold periodd (user selectaable delay tim
me
up to max. 255
2 seconds) which will keeep last analoog output valuue even after the gas meassurement starrts.
This will ensure that analyzer is not beeing influenceed by the zeroo gas (ambiennt air) which w
was sampled during auto-
zero or backk purge.

26
USER MANUAL SWG 200-1 BIOGAS

3.5.3.7 H2
2S sensor protection
p

The electro-cchemical H2S sensor shoulld not be exposed for a lonng time to thee gas in orderr to avoid quick sensor fail-
ure. That’s why
w the sensoor measures after
a each zerooing only for a short intervval, then it wiill be taken ouut of the gas
and will be purged.
p The H2S
H sensor's measuring
m intterval can eithher be set at the
t analyzer (see below) or o can be set byb
an external signal.
s

Switch the H2S


H measurem ment interval after measurement with , keyss:
Selectable innterval between 3 and 15 minutes
m or with external signal.

The measureement window


w shows during “non-meaasurement”: hold
h togetherr with the lateest measured H2S value.

3.5.3.8 Ba
asic System
m Settings

F1

27
USER MANUAL SWG 200-1 BIOGAS
3.5.3.9 Th
hreshold sample gas

F3
t adjust the upper and low
This setting is necessary to wer sample gas
g flow limitss corresponding to the valuues of the neee-
dle valve in front
f of the analyzer.
Turn the neeedle valve unttil the desiredd flow is achieeved, than preess the - key to writte this value for the upper /
lower threshhold.

, : select uppper / lower threshold


t (higghlighted item
m)
: write thee actual valuee
: return too main settingg menu

, : adjust thhe value of thhe flow meterr at the analyzzer front at thhe analyzer.

28
USER MANUAL SWG 200-1 BIOGAS
3.5.4 S
Service values

If an analyzeer malfunctionn should occuur (e. g. messaage during caalibration: " O2 sensor not OK"), the maalfunction cann
mostly be recognised in the Service meenu.
The analogoous values (= not calculated rough valuees) of all senssors will be diisplayed.

Please contaact our after-ssales service in case of an error (see adddress / phonee number on ppage 3). In ordder to localizee
the defectivee part, our tecchnicians mayy ask you samme service vallues or ask ww ww.mru.eu ffor the worldw wide MRU ser-
vice departm
ments.
Make a printt-out of thesee values and inform MRU service
s departtment on requuest.

, : page turrning
, : move linnes (in the firsst and the last line, the listt will be moveed = scroll)
: switch between
b service values anaalog and infraared module
.: tests: only for service
s deparrtment
: trends..: only for service
s deparrtment
: Interna
al heating: only for service
s deparrtment
: back to the
t menu Xtrras

29
USER MANUAL SWG 200-1 BIOGAS
3.5.5 A
Adjustmen
nt

The adjustment menu is protected


p agaainst use of noon-authorizedd persons by a PIN code.
For PIN codee ask MRU service departm ment (see ww ww.mru.eu)
At wrong inpput of PIN codde, the analysser will returnn to main setttings menu.

3.5.5.1 M
Main adjustm
ment menu

Note: Thee adjustmennts tempera ature, presssure, AUX an


nd analog output
o are ffactory mad
de,
it is generally not necesssary to repe
eat them!

Before starting the adjusttment of gas measurementt, it is advisedd to carry outt a zeroing of this measureement.
Connect anaalyser’s inlet port
p to the gaas calibration facility as in the
t picture beelow.

Observe the flow of bypass calibrationn gas in the floow meter (4) and adjust reegulator (2) foor some 2 … 7 m/h.
Cal gas will be sucked by the gas pump and has noo pressure!
A small exceess of cal gas will be vent by
b the flow meter,
m insuringg that no falsee air will be ssucked by thee gas pump.
Pressurizing the electrochhemical sensoors will be dam
mage them!

1 test gas cylinder


2 pressuure reducer
3 T-connector
4 flow-mmeter
5 Calibrration gas inleet of analyserr

30
USER MANUAL SWG 200-1 BIOGAS

Recommended calibration gases


For adjustment, the following (analysis certified) calibration gas cylinders are recommended:

range recommended cal gas manufacturer


leak proof test Displayed O2 value = 0 … 0,1 % N2 = 100 %

electrochem.
sensors
O2 0 - 21,0 Vol-% O2 = 10 % (for linerity error)) 10%
H2S 0 - 200 ppm, overload up to 1.000 ppm H2S = 500 ppm rest N2 500 ppm

multi gas IR-bench # 62587, CO2, CH4


CO2 approx. 70 ... 90 % reading
CO2 0 … 100 % rest N2 Gas mixer
CH4 approx. 70 ... 90 % reading
CXHY equiv CH4 0 … 100 % rest N2 Gas mixer

NOTE:
Within the given gas concentra-
tion one chooses this cal gas with
values like the real gas values!

31
USER MANUAL SWG 200-1 BIOGAS

3.5.5.2 Adjustment electrochem


e mical sensorrs

, : select thhe “electrocheemical cell” menu


m by moving the cursor

: enter selected menu (highlighted line)


l

Adjustm ment menu


electroochemical sensors

Manual callibration:

, : seelect the gas to be calibratted

, : change the facctor with smaall steps ( 1diggit steps)

F2: O2 offset: zero point offfset correctioon of oxygen cell


c by meanss of N2 calibraation gas (sensor signal and
dispplay is decreassing to zero).
Wait until thhe oxygen value is stable, then
t press to adjust offset

F3: y:
modify change faactor

F4: IR: not active

F5 or ENTE
ER: end: end of adjustmennt with savingg.

32
USER MANUAL SWG 200-1 BIOGAS

3.5.5.3 In
nfrared bench adjustment

Before starting the adjusttment of gas measurementt, it is advisedd to carry outt a zeroing of this measureement

Adjustmment menu
Infrared bench

: activate NDIR bench adjustment


: end: retturn to adjusttment menu

, : select thhe gas (in thiss example CH44)

ENTER: conffirm
F1 : adjust: adjustment of o the system to the valuess of the cylindder values whhich are set. The
T gases whiich
cylinder values are zeero will not bee affected. Thhe reaction tim
me of the systtem is about 20 seconds.
The adjuustment of a gas
g only accoomplished if between
b curreent value and cylinder valuue none to larrge
differencce (factor 3) is
e.g. currrent 10ppm cylinder 10000 ppm => > no adjustmeent

F3: modify the


t values (vaalue calibratioon gas cylindeer)
F5 or ENTE
ER:: end of adjustment wiith saving.

ATTENTION N:
The adjustment is not retturnable by leeaving the addjustment mennu by means of the F5 -keey!

With the keyy F4 the display can be sw


witch between electrochemical and NDIR
R adjustment!

33
USER MANUAL SWG 200-1 BIOGAS

3.5.5.4 Analog
A outp
put (4-20 mA)
m

3.5.5.5 Sa
ample gas flow
f measu
urement

3.5.5.6 Re
eset to zero
o

Before starting the adjusttment of gas measurementt, it is advisedd to carry outt a zeroing of this measureement.

, : select linne “Reset to zero”


z

3.5.5.7 Sp
pan gas sco
ource nzl. Span

34
USER MANUAL SWG 200-1 BIOGAS
3.5.6 A
Analog output config
guration (4
4 – 20 mA)
This menu allows individuual configurattion of all 8 channels
c of analog outputt 4 – 20 mA.
To each of thhe analog outtput channelss you can assiign a measureed (calculatedd) componentt and according measuringg
range.

, : select the analog output channel


c (channnel 1 …8)

, :seelection of sam
mpling point (all or A,…)

, : selection of measurement
m t item

, : select thhe measuremeent item betw


ween all meassured and calcculated valuees
: selectionn of min/max values
: back to the
t Xtras mennu

35
USER MANUAL SWG 200-1 BIOGAS
3.5.7 Alarm output configuration

Potential free relay contact: 250Vac; 125Vdc; 1A


The SYS AL alarm output is not configurable, it is reserved for the system alarms.

Description
SV 1 Solenoid valve 1
SV 2 Solenoid valve 2
SV 3 Solenoid valve 3
SV 4 Solenoid valve 4
SV 5 Solenoid valve 5
AL 1 Alarm 1
AL 2 Alarm 2
Sys AL Systemalarm

The alarm relays are not energized (potential free relay contact is open Æ fail safe condition) if one of the following
alarm conditions occurs:

Component Problem State on LCD


Reset to zero mode has not Components or sensors are not ready Self-test window or bar of reset to
finished. zero
1-st gas cooler temperature value > 10°C Message on display, measurement
halted
Condensate monitor Condensate pump defect Message on display, measurement
halted
Inside analyzer temperature value < 3,5°C or value > 55°C Message on display measurement
(T-sensor) halted
Inside analyzer temperature 51°C< value < 55°C Message on display every 16 seconds
(T-sensor) NO SYSTEM ALARM
Sample gas flow monitor value < 7 % of rated value Message on display every 16 seconds
regulated

The setup of the alarm outputs allows the configuration of two value alarm outputs for AL1 and AL2.

36
USER MANUAL SWG 200-1 BIOGAS

, : select alarm output (aalarm 1 or 2)


, : change component
c

.: value channge value


: >/< select > or <
: tests: onlyy for service department
d
: end backk to Xtras menu

37
USER MANUAL SWG 200-1 BIOGAS
3.6 Maiin menu Info
I
This menu coontains important data of the analyzer for the servicce departmentt.

3.6.1 Unit statuss


Information about the acttual temperatture componeents measured with the annalyzer.

3.6.2 Device opttions


The informattion about the actual devicce options will be displayeed.

example:

38
USER MANUAL SWG 200-1 BIOGAS
3.7 Gen
neral, fun
nctions

3.7.1 Q
Quick inpu
ut of numb
bers

, : select the deecimal place


, : increase or decrease
d the sselected digit
: abort the funnction, changges will be disscarded
: set the numbber in the fram
me to zero
: set the sign character
c (noot used)
: end of input,, input will bee saved

3.7.2 Request usser decisio


on
At several fuunctions the analyzer
a requeests for a useer decision.

, : select thhe line


/ : abort the function
:: end of innput, input will
w be saved

39
USER MANUAL SWG 200-1 BIOGAS
3.8 Options
3.8.1 Sampling points switching
SWG300-1 is using for sampling point switching, up to max.4 solenoid valves SV1, SV2, SV3 and SV4. These numbers
can be less if the user is using less sampling points.
The control on the sampling points switching solenoid valves is carried out automatically by the u-processor of main
control unit.

The user can:


- Select the interval time of one sampling point measurement in 0,5hours steps
- Choose between automatic sampling point switching or manual sampling point switching
- Manual sampling point switching is carried out by applying a 12-24 ac-dc voltage on the connector X4-O,
digital inputs IN1: pins 5-6 for selecting site A, IN2: pins 7-8 for selecting site B and IN3: pins 9-10 for se-
lecting site C

- The applied voltage on connector X4-O are binary coded like:

o 000 = Æ Auto-Switch mode, no voltage applied at any digital input, the analyzer is performing
automatic sampling point switching in interval time setup by user
o 001 = select sampling point A
o 010 = select sampling point B
o 011 = select sampling point C
o 100 = select sampling point D
o 101 = reserved
o 110 = Æ Stop mode, internal pumps are switched off Stop is displayed and 0mA is delivered by
analog output
o 111 = Æ Standby mode, analyzer is purging with ambient fresh air and analog output is set to
2mA
The analysis system will:
- always start with an automatic zeroing after selecting a new sampling point
- smallest, user selectable measuring interval (automatic mode) for one sampling point is 0,5 hours, maxi-
mum is 96 hours (4days)

40
USER MANUAL SWG 200-1 BIOGAS
3.8.1.1 Ch
hange interrval time off automaticc sampling point
p switch
hing

For automattic switching of


o sampling point,
p user cann change the interval timee of sampling point switching:
- press F4 key to select Xtraa.main menu
- select the linne: “Samplingg pnt interval””

, : change the
t interval between
b 0,5 and
a 96 hours in 0,5 hours steps
s

The actual saampling point is displayedd in the measuuring window


w:

(A) = sampling pooint A


(B) = sampling pooint B
(C) = sampling pooint C

41
USER MANUAL SWG 200-1 BIOGAS
3.9 Appendix
3.9.1 H8 industrial analysers Modbus Slave specification

3.9.1.1 General information

• Since firmware V1.56 (2009/09/25) the analyzer is able to work as modbus slave using the RS232 or RS485 port
(possibly with external RS232/RS485 adapter)
• supports RS485 interface with 2/4 wires (half/full duplex)
• supports only the binary Modbus protocol (RTU)
• the slave modbus address is user definable from 0 to 238
• communication parameter are user definable as follows:
- 9600 baud
- 19200 baud
- even parity and 1 stop bit
- no parity and 2 stop bits
• data types (used in table below):
A ASCII character
U 16 bit unsigned integer value (0…65535)
I 16 bit signed integer value (-32768...32767)
UL 32 bit unsigned integer value (0…4.294.967.295)
L 32 bit signed integer value (-2.147.483.648…2.147.483.647)
F 32 bit floating point value (reads -1E38, when not available)

3.9.1.2 Defined registers

Available data with modbus command 3/Read Holding Register (since V1.62 also 4/Read Input Reg.):
PLC- protocol data numb. of
register content
address address type registers
Device info / status
40001 0 U 1 Analyzer type
40002 1 U 2 Firmware version (main and sub version)
40004 3 U 1 Time since power-on in 15-minutes steps (e.g. 4 = 1h)
40005 4 - 7 Reserved for further device info / status
40012 11 U 1 Country ID (intern. phone no. * 10, e.g. D=490)
40013 12 U 1 Fuel type number (country dependend)
40014 13 U 1 Currently select. O2-reference in 0.1%, e.g. 30 = 3.0%
40015 14 A 4 Serial number, digits 1-8 (zero terminated if shorter)
40019 18 U 2 Analyzer status - part 1 / part 2
Meas. gas values
40021 20 F 2 O2 [%]
40023 22 F 2 CO2 [%]
40025 24 F 2 CO [ppm]
40027 26 F 2 NO [ppm]
40029 28 F 2 NO2 [ppm]
40031 30 F 2 NOx [ppm]
40033 32 F 2 SO2 [ppm]
40035 34 F 2 H2S [ppm]
USER MANUAL SWG 200-1 BIOGAS
PLC- protocol data numb. of
register content
address address type registers
40037 36 F 2 H2 [ppm]
40039 38 F 2 CH4 [ppm]
40041 40 F 2 C3H8 [ppm]
40043 42 F 2 C6H14 [ppm]
40045 44 F 2 H2O [%]
40047 46 F 2 NH3 [ppm]
40049 48 F 2 reserved [ppm/%]
40051 50 F 2 reserved [ppm/%]
40053 52 F 2 reserved [ppm/%]
Other meas. values (no gases)
40055 54 F 2 T-Gas [°C]
40057 56 F 2 T-Amb. [°C]
40059 58 F 2 Draft [hPa]
40061 60 F 2 Differential pressure [hPa]
40063 62 F 2 Flow speed [m/s]
40065 64 F 2 AUX [variable]
40067 66 F 2 Revolutions [rpm]
40069 68 F 2 reserved [variable]
40071 70 F 2 reserved [variable]
40073 72 F 2 reserved [variable]
40075 74 F 2 Flow volume [l/s]
Analyzer’s internal meas. values
40077 76 F 2 T-Sensor [°C]
40079 78 F 2 Sample gas flow [l/h]
40081 80 F 2 T-Cooler-1 [°C]
40083 82 F 2 T-Cooler-2 [°C]
40085 84 F 2 T-Hose [°C]
40087 86 F 2 reserved [variable]
40089 88 F 2 reserved [variable]
40091 90 F 2 reserved [variable]
Calculated gas values
40093 92 F 2 CO [mg/m³]
40095 94 F 2 NO [mg/m³]
40097 96 F 2 NO2 [mg/m³]
40099 98 F 2 NOx [mg/m³]
40101 100 F 2 SO2 [mg/m³]
40103 102 F 2 H2S [mg/m³]
40105 104 F 2 H2 [mg/m³]
40107 106 F 2 CH4 [mg/m³]
40109 108 F 2 C3H8 [mg/m³]
40111 110 F 2 C6H14 [mg/m³]
40113 112 F 2 H2O [mg/m³]
40115 114 F 2 NH3 [mg/m³]
40117 116 F 2 reserved [mg/m³]
43
USER MANUAL SWG 200-1 BIOGAS
PLC- protocol data numb. of
register content
address address type registers
40119 118 F 2 reserved [mg/m³]
40121 120 F 2 reserved [mg/m³]
40123 122 U 2 Analyser status - part 1 / part 2 (repetition)
40125 124 F 2 CO/ref.O2 [mg/m³]
40127 126 F 2 NO/ref.O2 [mg/m³]
40129 128 F 2 NO2/ref.O2 [mg/m³]
40131 130 F 2 NOx/ref.O2 [mg/m³]
40133 132 F 2 SO2/ref.O2 [mg/m³]
40135 134 F 2 H2S/ref.O2 [mg/m³]
40137 136 F 2 H2/ref.O2 [mg/m³]
40139 138 F 2 CH4/ref.O2 [mg/m³]
40141 140 F 2 C3H8/ref.O2 [mg/m³]
40143 142 F 2 C6H14/ref.O2 [mg/m³]
40145 144 F 2 H2O/ref.O2 [mg/m³]
40147 146 F 2 NH3/ref.O2 [mg/m³]
40149 148 F 2 reserved/ref.O2 [mg/m³]
40151 150 F 2 reserved/ref.O2 [mg/m³]
40153 152 F 2 reserved/ref.O2 [mg/m³]
40155 154 F 2 CO/0%O2 [ppm]
40157 156 F 2 NO/0%O2 [ppm]
40159 158 F 2 NO2/0%O2 [ppm]
40161 160 F 2 NOx/0%O2 [ppm]
40163 162 F 2 SO2/0%O2 [ppm]
40165 164 F 2 H2S/0%O2 [ppm]
40167 166 F 2 H2/0%O2 [ppm]
40169 168 F 2 CH4/0%O2 [ppm]
40171 170 F 2 C3H8/0%O2 [ppm]
40173 172 F 2 C6H14/0%O2 [ppm]
40175 174 F 2 H2O/0%O2 [ppm]
40177 176 F 2 NH3/0%O2 [ppm]
40179 178 F 2 reserved/0%O2 [ppm]
40181 180 F 2 reserved/0%O2 [ppm]
40183 182 F 2 reserved/0%O2 [ppm]
40185 184 F 2 CO [mg/s]
40187 186 F 2 NO [mg/s]
40189 188 F 2 NO2 [mg/s]
40191 190 F 2 NOx [mg/s]
40193 192 F 2 SO2 [mg/s]
40195 194 F 2 H2S [mg/s]
40197 196 F 2 H2 [mg/s]
40199 198 F 2 CH4 [mg/s]
40201 200 F 2 C3H8 [mg/s]
40203 202 F 2 C6H14 [mg/s]
40205 204 F 2 H2O [mg/s]
44
USER MANUAL SWG 200-1 BIOGAS
PLC- protocol data numb. of
register content
address address type registers
40207 206 F 2 NH3 [mg/s]
40209 208 F 2 reserved [mg/s]
40211 210 F 2 reserved [mg/s]
40213 212 F 2 reserved [mg/s]
40215 214 F 2 CO/ref.O2 [ppm]
40217 216 F 2 NO/ref.O2 [ppm]
40219 218 F 2 NO2/ref.O2 [ppm]
40221 220 F 2 NOx/ref.O2 [ppm]
40223 222 F 2 SO2/ref.O2 [ppm]
40225 224 F 2 H2S/ref.O2 [ppm]
40227 226 F 2 H2/ref.O2 [ppm]
40229 228 F 2 CH4/ref.O2 [ppm]
40231 230 F 2 C3H8/ref.O2 [ppm]
40233 232 F 2 C6H14/ref.O2 [ppm]
40235 234 F 2 H2O/ref.O2 [ppm]
40237 236 F 2 NH3/ref.O2 [ppm]
40239 238 F 2 reserved/ref.O2 [ppm]
40241 240 F 2 reserved/ref.O2 [ppm]
40243 242 F 2 reserved/ref.O2 [ppm]
40245 244 U 2 Analyser status - part 1 / part 2 (repetition)
40247 246 F 2 CO [mg/kWh]
40249 248 F 2 NO [mg/kWh]
40251 250 F 2 NO2 [mg/kWh]
40253 252 F 2 NOx [mg/kWh]
40255 254 F 2 SO2 [mg/kWh]
40257 256 F 2 H2S [mg/kWh]
40259 258 F 2 H2 [mg/kWh]
40261 260 F 2 CH4 [mg/kWh]
40263 262 F 2 C3H8 [mg/kWh]
40265 264 F 2 C6H14 [mg/kWh]
40267 266 F 2 H2O [mg/kWh]
40269 268 F 2 NH3 [mg/kWh]
40271 270 F 2 reserved [mg/kWh]
40273 272 F 2 reserved [mg/kWh]
40275 274 F 2 reserved [mg/kWh]
40277 276 F 2 CO [mg/MJ]
40279 278 F 2 NO [mg/MJ]
40281 280 F 2 NO2 [mg/MJ]
40283 282 F 2 NOx [mg/MJ]
40285 284 F 2 SO2 [mg/MJ]
40287 286 F 2 H2S [mg/MJ]
40289 288 F 2 H2 [mg/MJ]
40291 290 F 2 CH4 [mg/MJ]
40293 292 F 2 C3H8 [mg/MJ]
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USER MANUAL SWG 200-1 BIOGAS
PLC- protocol data numb. of
register content
address address type registers
40295 294 F 2 C6H14 [mg/MJ]
40297 296 F 2 H2O [mg/MJ]
40299 298 F 2 NH3 [mg/MJ]
40301 300 F 2 reserved [mg/MJ]
40303 302 F 2 reserved [mg/MJ]
40305 304 F 2 reserved [mg/MJ]
Other calculated meas. values (no gases)
40307 306 F 2 Exc air (unitless)
40309 308 F 2 Dewpoint [°C]
40311 310 F 2 Losses [%]
40313 312 F 2 Effic. [%]
40315 314 F 2 Losses condens. [%]
40317 316 F 2 Effic condens. [%]
40319 318 F 2 CO/CO2 [%]
40321 320 F 2 Flow volume [l/s]
40323 322 F 2 reserved [variable]
40325 324 F 2 reserved [variable]
40327 326 F 2 reserved [variable]
Industrial protocol in modbus frame
41001 1000 U 1 Length of Ind.-Protocol (*) in words (e.g. 52 = 104 bytes)
41002 1001 - x Data block in industrial protocol format (*)

(*) Start address of industrial protocol:


The data block in industrial protocol format is brought up to date, when the start register with address 1001 is read. If
the data block must be read in several steps (see max. modbus frame length), then the leading part should always be
read first, followed by the succeeding parts, in order to assemble a complete and consistent industrial protocol frame

Important:

The flow-monitoring (flow meter with needle valve at the front of the analyzer) must be:
• 50 to 60 l/h (devices with electrochemical cells)
• 30 to 40 l/h (devices with NDIR benches)
during the measurement!

Adjust by means of the needle valve!

If it is not possible to adjust this rate, it is necessary to check first the filters (including probe) and than the gas pump
and hoses.

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USER MANUAL SWG 200-1 BIOGAS

4 MOUNTING
4.1 Assembly 6U and gas connections # 200116

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4.2 Assembly 9U and gas connections # 200119

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USER MANUAL SWG 200-1 BIOGAS
4.3 Main control unit MCU 6U # 644416

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4.4 Mounting plate 6U # 64417

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4.5 Mounting plate 9U # 64405

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Important:

The flow-monitoring (flow meter with needle valve at the front of the analyzer) must be:
• 50 to 60 l/h (devices with electrochemical cells)
• 30 to 40 l/h (devices with NDIR benches)
during the measurement!

Adjust by means of the needle valve!

If it is not possible to adjust this rate, it is necessary to check first the filters (including probe) and than the
gas pump and hoses.

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USER MANUAL SWG 200-1 BIOGAS
4.6 Power supply connection of analyzer SWG 200-1
The power supply cable is feed through the connection plate and screwed to the internal safety fuse, see picture
below:

POSITION DESCRIPTION REMARKS


1 Internal safety fuse (2x) 10 A (B) # 60726
2 External safety fuse (2x) provided by user

Power supply wiring


If the device has no power supply, check the automatic circuit breakers.
If they were released during normal operation:
- disconnect heated sampling line and power-on system
- does analyzer start?
- if yes: you have a short circuit in the heated sampling line power cable (need to be re-
placed)
- if no: you have a short circuit inside analysis system (contact MRU or a qualified electrical service engineer)

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USER MANUAL SWG 200-1 BIOGAS
4.7 Analog output connection
Backside control unit

connector X4-O digital interface


connector X3-O analog output

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USER MANUAL SWG 200-1 BIOGAS
Mounting the analog output cables at the connector X3-O:

Plug of the connector X3-O from the contact strip. Use a flat tip screwdriver for unscrewing the 2 fixing screws.

Equip the cable end of the analog cables (0,25 mm2 up to 0,75 mm2) with wire end ferrule (DIN46228) and fasten
them by means of a flat tip screwdriver.
(see picture below)

Plug the connector to the contact strip X3-O and fasten the 2 fixing screws.

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USER MANUAL SWG 200-1 BIOGAS
4.8 Digital data transfer to Desktop PC

POSITION DESCRIPTION # REMARKS


1 Interface connection X4-O
2 Shielded 4-wire data cable Length < 1.000 m
twistet pair, AWG
3 RS 232 extension cable
4 RS 485 converter # 59795
4a Converter jumper settings SW1 = DTE, SW2 = T ON/R ON
4b Power supply unit 230 Vac / 9 Vdc, 200 mA
4c RS 232 adapter
5 Desktop PC with serial interface connector RS 232

4 wire cable twisted pair from SWG 200-1 X4-O connector to RS 485 converter

SWG 300-1 RS 485 converter


R+ 1 = T+
R- 2 = T-
T- 3 = R-
T+ 4 = R+
Shield (earth) The shield must be connected at the PE mounting rail at the SWG!

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USER MANUAL SWG 200-1 BIOGAS
4.9 Digital data transfer to notebook
In case your notebook does not support RS232 serial port, you need to interconnect a RS232/USB converter (see be-
low).

POSITION DESCRIPTION # REMARKS


1 Interface connection X4-O
2 Shielded 4-wire data cable Length < 1.000 m
twistet pair, AWG
3 USB converter # 60157
4 RS 485 converter # 59795
4a Converter jumper settings SW1 = DTE, SW2 = T ON/R ON
4b Power supply unit 230 Vac / 9 Vdc, 200 mA
4c RS 232 adapter
5 Notebook with USB interface connector

4 wire cable twisted pair from SWG 200-1 X4-O connector to RS 485 converter

SWG 300-1 RS 485 converter


R+ 1 = T+
R- 2 = T-
T- 3 = R-
T+ 4 = R+
Shield (earth) The shield must be connected at the PE mounting rail at the SWG!

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USER MANUAL SWG 200-1 BIOGAS
5 SERVICE
5.1 Maintenance and service
5.1.1 Cabinet ventilation
The analyzer cabinet has several built-in fans to evacuate the inside heat. The fans are equipped with filter matting.
The filters prevent inside enclosure from dust being ventilated through.
It is necessary to check these filters every week, until you are able to estimate your local interval of filter replacement.

Filters of wall mounted part (before fan of gas cooler):

• remove the cover


• clean – if necessary – the filter grid with compressed air
• replace the filter matting art. no.60319 (5 pieces) if the colour is changing from white to grey or brown.

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USER MANUAL SWG 200-1 BIOGAS
5.1.2 Sample gas filter (PTFE) # 60631

Replace the dust and particle filter element (art-no. 60631) of the filtering unit (art. No. 11179) if the colour is chang-
ing from white to brown.
Unscrew the filter case and replace the filter cartridge art-no. 60631.
Do not loose or forget the sealing O-ring.

OK DIRTY

The filter elements placed at the front of the analyzer should be changed latest at the yearly routine service.

5.1.3 Span calibration gas filter # 56066

The filter element (art. no. 56066), placed inside the analyzer, should be checked latest at the yearly routine service
and changed if it is necessary.
Pay attention to the arrow at the filter housing (see flow direction!)

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USER MANUAL SWG 200-1 BIOGAS
5.1.4 Activated carbon filter # 11152

The filter element (art. no. 11152), placed inside the analyzer, should be checked latest at the yearly routine service
and changed if it is necessary.

5.1.5 Purafil filter # 56795

The filter element (art. no. 56795), placed at the front of the analyzer, should be checked latest at the yearly routine
service and changed if it is necessary.

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USER MANUAL SWG 200-1 BIOGAS
5.1.6 Replace O2 sensor # 58048B
Remark: sensors can contain acid. Pay attention to security indications for manipulation!
In case of a leakage of the sensor, wear protection gloves!
The condition of the electro-chemical sensors is checked at every auto-zero cycle. If the sensor is not ok, an alarm
message is indicated in the display and system alarm relay will be triggered. The measurement will continue but with-
out O2 measurement.
To find out whether a sensor is faulty or not, please pay attention to the chapter 4
"service-values"!

Unlock connection cable of oxygen cell (art.no 58048B), unscrew the O2-cell out of the adapter plate.
The O-ring sealing and the filter paper (art. no. 56872) of the sensor manifold should be changed too!

5.1.7 Replace NDIR bench # 62399BG

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USER MANUAL SWG 200-1 BIOGAS
5.1.8 Sample gas pump # 64656
The tightness of the sample gas pneumatics is checked at the yearly routine service, e.g., by purging the measuring
instrument with nitrogen (N2).
The O2 indication in the display must be lower than 0,1%.
If indication is higher than 0,2%, the pump or parts of the sampling system can have a leakage or droplet of dirt.

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USER MANUAL SWG 200-1 BIOGAS
5.2 Selff test / Se
ervice
The SWG2000-1 is equippeed with a selff-diagnosis prrogram.
All internal functions
f are monitored annd displayed if
i necessary
Switch on analyser: internal, au utomatic ch heck of starrt conditions

5.2.1 S
Self-test

If you have exclamation


e m
mark:
Item correct valu
ue If valu
ue is not OK

U-mains 10,0 ... 16,1 V Check voltage from internal switched power suppply unit!

T-sensor +5 ... +40 °C


C Check ambient temperature of analyzer to be in bbetween this operating rangee!

T-cooler 5,0°C Secondd value 5,0 °C (MRU gas cooler) is too highh:
If this
t value cannnot be reached,, check (replace)
- fan of gaas cooler
- peltier ellement of gas cooler
c
NDIR bench warm-up If warmm-up display iss missing (blanc)
- chheck power suppply of multigaas ndir bench MRU
M
- chheck RS485 wires from main control unit too ndir bench MRU
R-condensat 500 k Check electrical connnection to conddensate monitooring electrodees of gas coolerr
MRU
Check operation of 12Vdc condensate pump #554467

If no exclamation mark iss displayed annd all values are


a displayed with O.K. (all measuring cconditions aree ready), thenn
the analyzer will continuee automaticallly with zero setting.
s

5.2.2 S to zero
Set o
During this phase,
p the analyzer is purgged with ambient air and all
a sensors aree checked for plausible signal values. If
values are noot OK an erroor message will
w be displayeed.
In case of ann error message, change too the Settingg menu and select Servic ice values.

Item corrrect value If value


v is not OK
O

E
Electrochemic
cal cell O2 1000 mv … 512 mV
m Reeplace expired sensor
M gas NDIR bench CO22
Multi Trrim offset potentiometer
M gas NDIR bench CH44
Multi Trrim offset potentiometer
E
Electrochemic
cal cell H2 Reeplace expired sensor
E
Electrochemic
cal cell H2S Reeplace expired sensor

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USER MANUAL SWG 200-1 BIOGAS
5.2.3 S
Service values

Service pro
ogram: V values of e. g. the sensors, temperaturre sensors, ettc. are displayyed. Afterwarrds,
The mV
the mV values are inndicated, whicch restrict thee “OK” range
e:

Scroll serv
vice data: ,

If an analyseer malfunctionn should occuur (e. g. messaage during caalibration: " O2 sensor not OK"), the maalfunction cann
mostly be interpreted in the
t Service meenu.
The analogoous values (= signal beforee analog to diggital converteer) of all sensors and internnal measuredd items will bee
displayed.

5.2.4 A
Analog values
Item value comme
ents
O2 199,922 mV
T-cooler 179,722 mV
Sample flow 16,755 mV
U-Mains 118066 mV
T-PCB 20533 mV
T-sensor 20322 mV
R-Condens 5000 mV
5.2.5 NDIR value
es
Item value comme
ents
CH4 32830 dig
CO 33303 dig
CO2 28520 dig
Reference 40723 dig
T-detector 5028 dig
T-bench 2443 dig
P-absolute 15402 dig
VCC 107 dig

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USER MANUAL SWG 200-1 BIOGAS
5.3 Current unit status
Information about the acttual temperatture componeents measured with the annalyzer.

Main in nformation menu


• Unit status

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USER MANUAL SWG 200-1 BIOGAS
5.4 Erro
ors
Error diagnoosis regarding the measurinng device

No Effecct or indication
Erro Cause
C Solution
003 Flue gas
g measurem ment Set to zero is carried
c out Wait until seet to zero will
cannoot be started inn the backgroound terminate

015 Measuurement is poossible O2-sensor


O is exhausted
e Change 02-ssensor
but O2-values
could be out of rannge of
the sppecifications

019 The data flow was inter- The


T connection was in- The transmisssion has to
ruptedd teerrupted; wroong PC be started onnce again,
comport was selected;
s after restarting the PC
wrong
w cable was
w used; transmissionn program.
PC
P resource haave con-
fllicts
020 see noo. 019

022 Set too zero cannot be A semi-continuuous auto- You don’t neeed more
launchhed manuallyy matic
m measureement is in resets to zeroo during the
progress
p and executes
e semi-continuuous auto-
periodical
p reseets to zero. matic measuurement. It
would disturrb.

026 Press any keyy and unplug


RS 485 cablee in order to
fetch back thhe control

027 Clock has lost timee and Clock


C has lost time and Set clock recommended
date date.
d

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USER MANUAL SWG 200-1 BIOGAS
028 Firmw
ware damagedd, Firmware dammaged, Please contaact service
operating conditionns not operating
o condditions not department
ensuree ensure
e www.mru.euu
see MRU woorldwide

033 Analyyzer is too warm Ambient


A tempperature is Conditioningg the location
tooo high of the analyzzer

034 The analyzer cannoot be Maybe


M the connnection Check cable connection
configgured via PC confi-
c was
w interrupteed or the or look for a new confi-
guratiion program (only
( configuration program is guration program or
for MRU partners) n compatible to the
not analyzer firm
mware
analyzer’s
a firm
mware.

042 Not coorrect measurring Low gas flow Check needlee valve
valuess
Check filter and
a samplingg
line system

043 Not coorrect measurring The


T gas flow is higher Check needlee valve or
valuess thhan the upper limit set increase the upper flow
by
b the user. limit in extraa menu

044 Condeensate alarm,, mea- The


T water in the gas The condenssate pump is
surem
ment is halted cooler cannot be sucked defective, coontact service
out
o department
www.mru.dee
see MRU woorldwide

045 Analyyzer is too warm Ambient


A tempperature is Conditioningg the location
tooo high of the analyzzer

046 Gas coooler alarm, mea-


m The
T gas coolerr does not The gas cooler is defec-
surem
ment is halted reeach a sufficient tem- tive, contact service de-
perature.
p partment
www.mru.euu
see MRU woorldwide

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USER MANUAL SWG 200-1 BIOGAS
5.5 Manual for firmware update of MRU H8-Industrial analysers
5.5.1 System requirements
• Operating system MS Windows XP or later
• Pentium PC or later

• One available RS232 port. It should be a real RS232 port. A RS232-USB adaptor may work, but may fail as well.

5.5.2 Important hints and warnings


• Most probably stored measurements and sites get lost during a firmware update!

• After the update the analyser must be switched off, as soon as it has reached the self test window! Please discon-
nect mains (unplug cable or switch off the master switch), analysers with battery additionally need to be switched
off by pressing the keys F1 and F4 simultaneously. Now you can restart the analyser and use it with its new
firmware.

• Please start the update only with a reliable mains connection.

5.5.3 Update procedure


• Please do not switch-on the analyser yet and disconnect mains! Connect the analyser with a 0-modem-cable (at
least five-wire crossed) to the PC’s RS232 port.

• Start the PC-program “MRU_UPLOADER.EXE”.

• Select the COM-port, which is connected with the analyser by clicking on “RS232” and then on the appropriate
“COMx”.

• Load a firmware file by clicking on “file” / “load file” and selecting a file.

• Now press and hold down the F1 key and connect mains (plug cable or switch on the master switch). Hold the F1
key down until the PC indicates the message “MRU unit (H8-generation) recognized”. Now you can release the F1
key.

• The update usually takes less than one minute. The unit’s display stays empty during the uploading process. When
the update has finished, the unit starts its program as usual. Please bear in mind now the important hints and
warnings written above concerning switching-off and data loss!

5.5.4 Possible causes and solutions in case of update failure:


• Cable problems: cable defective, wrong cable or cable not properly plugged
• Another software runs on the used PC reserving the selected RS232 port: Close all running programs and restart
MRU_UPLOADER.EXE.

• A serial mouse uses the one and only RS232 port: Use another PC or another mouse.

You have not selected the COMx port which is connected to the analyser: Change the COM-port selection.

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USER MANUAL SWG 200-1 BIOGAS
5.6 Cable enumeration of main pcb of industrial analyzers
5.6.1 Mainboard (pcb # 59351)

23

22

21
24

20

19

18

17
1

16 2

3
15
4

14 5

7
13
8

12 11 10 9

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USER MANUAL SWG 200-1 BIOGAS

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5.6.2 Interface board (pcb # 60413)

5.6.3 Alarm relays and auto-cal board (pcb # 60886)

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USER MANUAL SWG 200-1 BIOGAS
5.7 Schematics
5.7.1 Gas flow diagram

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5.7.2 Wiring diagram cabinet

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5.7.3 Overview connectors

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USER MANUAL SWG 200-1 BIOGAS
5.8 Spare part list
Article Parts Quantity Remarks
number

200116A Cabinet 6U incl. MCU19-6U


# 64416 BIOGAS
63209 Rack holder spare key 1
63210 Cabinet spare key (key no.3524) 2
60467 Gas cooler 1
11230 Hose pump 115/230 Vac 1
60726 Automatic circuit breaker 10 A / 230 V 2
60325 Power socket 250 Vac, 16 A 1
61355 Blower 230 V 1
62298 PTFE filter complete with filter element 1
56879 Filter element PTFE for filter # 562298 1
55542 Filter grid with mat 120 x 120 mm 1

64416 Main control unit 6U BIOGAS complete


parts
59671 Display screen 1
61563 Keypad 1
62722 Flow meter 7 – 70 l / h with needle valve 1
acid-proof
59059 PTFE filter D = 73 mm 1
59672 Display 1
59351 Main printed circuit board 1
58058 Pressure sensor 0 – 25 hPa 1
56795 In-line filter, SOx/Nox Purafil 2
58809 Solenoid valve 3/2-way, 12 V 3
59535 Switched power supply 12 Vdc 1
52392 Gas pump 230 Vac 1
55248S H8 with Q 14,7456 Mhz, Rev. F pcb 1
60143 Interface pcb 1
59770 Analog outputs 4 – 20 mA pcb 1
60886 Autocal / alarm pcb 1
61657 Solid state relay 4 – 30 Vdc / 230 Vac / 4 A 1
56066 Dust filter complete 3
54105 Pump 2002 1
10411 Z-diode 4,3 V 1

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USER MANUAL SWG 200-1 BIOGAS
Article Parts Quantity Remarks
number
64273 O2/H2S measurement
parts
58048 O2 sensor 1
10720 H2S sensor 1
64388 O-ring 15 x 3,0 2

62587BG CO2/CH4 NDIR measurement

5.9 Wearing part list


Article Parts Quantity Remarks
number
Wearing part set
SWG 200-1 Biogas
61169BG Wearing part set
parts
56879A PTFE filter element (1 packing unit = 5 pieces) for 1
insert filter unit art. no. 11179
53619 Anti vibration device for pump 4
56066 Fine dust filter 2
56087 Filter tab for fine filter # 56066 (1 pack = 50 tabs) 1
64459 Filter Acrodisc PTFE D= 56 mm 1
51513 Filter Acrodisc PTFE, 1,0 μm , Ø 18 mm 2
56795 Inline filter Purafil 2
60320 Filter mat 120 x 120 mm, 1 pack = 5 pieces 1

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USER MANUAL SWG 200-1 BIOGAS

6 OPTIONS
6.1 Unit heater 500W with automatic regulation # 60997
To protect unit from freezing during winter, for larger 9U cabinet

General
Unit heater serves to heat switch cabinets so that water condensation and malfunctions are prevented as well as to
increase the overall functional capacity of the cabinet. The heater is composed of an aluminium profile with two a
built-in tube heating.

Safety Instructions
References marked as ! ensures the avoidance of danger and protection of personal health and safety.
Function
The desired temperature is regulated through a bimetallic release that is continuously adjustable to variable set-point.
The control light indicates the operating status of the heater.

Technical Data
Rated Voltage : 230-250 V AC
Rated Power : 500 W
Range of Adjustment : 5° - 45°C
Working Temperature : -20° - +100°C
Storing Temperature : -20° - +70°C
Protection Type : IP 20
Connection Line (Junction) : Silicone Cable 3G1
EMV : EN 55014
Dimensions LxWxH : 290x140x100 mm
Weight : 1.6 kg

Commissioning
The unit heater is exclusively meant for permanent locations where cable connections must be protected against me-
chanical damage.
! Protect the unit heater from:
- Direct sun light - Vibrations
- intense radiated heat - corrosive chemicals
- strong electro-magnetic fields - mechanical impacts

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USER MANUAL SWG 200-1 BIOGAS

The unit heater is delivered operable from the manufacturer.


To effectively bring this equipment into operation, the following measures must be taken:
! Mount the unit heater to a mounting plate
Connect the lead-in. Check the connection with the switch diagram shown in the opposite margin.

!The electrical connections can only be carried out by a skilled electrician and in compliance to cur-
rent regulations.

Handling and Cleaning


The unit heater is a high quality appliance and must be handled carefully. To clean, use a dry, soft, lint-free cloth. In
case of heavy dirt, use a neutral, polyester-friendly cleaning fluid on a soft cloth.
Do not use insecticides or chemical products such as gasoline or low viscosity chemicals to clean the housing.
! Disconnect voltage before cleaning.

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USER MANUAL SWG 200-1 BIOGAS
6.2 Gas cooler # 64556

Parts:
1 - # 60464 Electric gas cooler -> no service possible!
2 - # 11234 Condensate draining pump

6.2.1 Condensate pump # 11234

Lock the hose holder by turn it behind

Change condensate hose, if it is contaminated or leakage (hose set # 53702).


Lay condensate hose with holder around the pump head – latch first the lower side, thereafter the other.
Turn round the hose fixation and put on the hoses at the pump head.

6.3 Sampling point switch


Using non-heated solenoid valves mounted inside analyzers cabinet, with automatic control from MCU19-6U or with
manual control by user’s PLC
2x (dual) site monitoring # 64835
2x (dual) site monitoring, including safety set # 64836
3x (triple) site monitoring # 64837
3x (triple) site monitoring, including safety set # 64838
4x (quadruple) site monitoring # 64839
4x (quadruple) site monitoring, including safety set # 64840

For operation see chapter 3.8.1

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USER MANUAL SWG 200-1 BIOGAS

6.4 System safety set # 64555


With flame arrestor at gas inlet, HC gas detector inside instrument
With LEL display and alarm message on display and solenoid valve automatic shut-off of sample gas supply

6.5 H2S high analysis # 64833


Using electrochemical cell, 0 – 10.000 ppm
With H2S sensor cut-off valve and purging pump for sensor protection and longer life

6.6 H2 analysis # 64435


Using electrochemical cell, 0 – 1.000 ppm

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USER MANUAL SWG 200-1 BIOGAS

7 APPENDIX
7.1 Technical Specifications
General specifications SWG200-1
Oxygen O2 Electrochemical cell (long-life)
Carbon dioxide CO2 NDIR bench (multi-gas)
Methane CH4 NDIR bench (multi-gas)
Hydrogen Sulphide H2S (low) Electrochemical cell (optional)
Hydrogen Sulphide H2S (high) Electrochemical cell (optional)
Hydrogen H2 Electrochemical cell (optional)
Calorific (heating) value MJ/m3 calculated
Operating temperature: + 5° …+ 40°C,
relative humidity of air max 90 %, non condensing
Storage temperature. - 20° … + 50°C
Power supply 230 VAC / 100 W,
with option cabinet heater add 500W
Internal main fuse 10 A automatic
Warm-up time 1h minimum
Response time T90 60 seconds from analyzer inlet port
Noise of output signal < 0,5% of measuring range
Detection limit < 1% of measuring range
Linearity error < 2% of measuring range
Repeatability 1% of full scale
Temperature influence max 2% of measuring range per 10°K
Span drift with AUTOCAL: negligible
without AUTOCAL: <2% of measuring range / 2 weeks
Zero drift with AUTOZERO: negligible
Display full graphic LCD display with backlight
Resolution depends on range selection, ppm or %
8x analog outputs: 4 – 20 mA self powered,
max 500R load resistor, user free configurable
Output signals
RS485 digital data transmission,
Modbus RTU or MRU protocol (user selectable)
Alarm relays 3x potential free NO contacts
1x system alarm, 2x value alarm free settable
Sample gas conditioning max. 100mbar gas inlet pressure (other on request)
optional: gas cooler with constant dew point = + 5°C
and condensate draining pump
filtering particle size < 1μ
Sample gas monitoring Internal sample flow monitoring and alarm
Calibration by software and use of:
mixture calibration gas cylinder for CO2+CH4 required,
separate gas cylinder for H2S is required
clean and fresh ambient air for zero setting
Indoor enclosure 6U height 345 x 600 x 575 mm (H x W x D)
(for clean and cool ambient condition)
Weight up to 30kg
Protection class IP54

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USER MANUAL SWG 200-1 BIOGAS
7.2 Declaration of confirmity

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USER MANUAL SWG 200-1 BIOGAS

Technical changes may be made without notice! English


Date of issue: 20131010

89

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