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USER MANUAL SWG

Page 96 of 129

Spare part 3: PTFE filter

Reference:
1. Filter element
2. Filter glass
3. Holding ring
4. Filter holder

Unscrew the holding ring (3).
Remove the filter glass (2).
Unscrew the filter holder (4).
Exchange the exhausted filter element with a new one (1).

Spare part 5: Disc filter PTFE

Power the system down.
Open the service flap of the MCU.
Carefully pull the filter from the clamps.
Unscrew the fittings from the exhausted filter.
Exchange the exhausted filter with a new one.
To make the entire system gas-tight, Teflon tape must be inserted

between the filter and the screw connection.

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Summary of Contents for SWG 100 SYNGAS

Page 1: ...SWG 100 SYNGAS USER MANUAL ...

Page 2: ...t of this manual my be published in any form print fotocopy 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 2021 11 05 V1 00 EN ...

Page 3: ...8 3 4 Installation of pressure reducer unit 20 3 5 Connection of main power supply 22 3 6 I O modules Installation and setting 25 3 7 Installation Calibration gas zero gas and condensate outlet 27 4 Operation of the analyser HMI 0007 Fehler Textmarke nicht definiert 4 1 Display and keypad Fehler Textmarke nicht definiert 5 Binding to a process control system I O modules 0008 33 5 1 Position of the...

Page 4: ...enance works by the operator 88 8 3 Description of the analyser 89 8 4 Exchange the condensate pump head unit 97 9 Specification Modbus via RS485 specification 0016 100 9 1 General information 100 9 2 Analyser Status address 0 and some mirror addresses 104 9 3 Analyser System Alarm address 2 and some mirror addresses 104 10 Adjustment NDIR bench MGB Module 105 11 Technical specification 108 Append...

Page 5: ... 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 information The f...

Page 6: ...wed to use the analyser in confined space or rooms without forced ventilation Sample gas exiting the analyser will flow into the ambient air and only outdoor use or forced ventilation rooms are suitable for using the analyser Flammable gas WARNING Flammable gas Gas can contain flammable gas components Regarding flammable gases e g CH4 methane and operating instruments in the hazardous areas the us...

Page 7: ...t cabinet heater resp 10 C to 45 C with cabinet heater The analyser is designed for indoor mounting In case of outdoor mounting it is important that the analyser is sufficiently protected against rain sun and wind In case of outdoor mounting under extreme environmental conditions like high humidity salty sea air etc further protective measures are necessary These should be clarified with the manuf...

Page 8: ...l analysers delivered after 13th of August 2005 Analyzers must be returned to MRU prepaid 1 8 MRU Warranty conditions The SWG100 warranty is 12 months 1 The warranty on spare parts is 6 months 2 The term of the warranty conditions starts as of the invoice date 3 The warranty is void under the following conditions Improper use Improper application Improper mounting Deliberate or negligent destructi...

Page 9: ...d over all documents when passing on the analyser to third parties 2 1 Intended use The instrument is intended for analysing the composition of several gases The list shows the analyser components which can be determined by the analyser CO CO2 CH4 H2 O2 The analyzer comes with a sampling probe for the installation at the measurement point and a sampling line system In particular the instrument is ...

Page 10: ...be prevented or removed by regular servicing the instrument The instrument is optionally equipped with several electro chemical sensors ECS to detect gas components like oxygen O2 Those sensors offer a reliable and effective way to detect the target gases They are typically of limited lifetime several years but may be easily replaced once the end of life is reached In regular time intervals the in...

Page 11: ...800 x 180 Reference 1 Fan filter 2 Calibration gas inlet 3 Zero gas inlet 4 Condensate outlet 5 Cable gland for power supply 6 Filter unit 7 Cable gland for IO modul 8 Sample gas inlet G1 8 inner thread 9 Sample gas inlet for heated sampling line 10 Sample gas outlet VENT G1 4 inner thread 1 1 1 1 4 4 10 3 2 5 ...

Page 12: ...USER MANUAL SWG Page 12 of 129 11 H3PO4 inlet G1 8 inner thread ...

Page 13: ... inner thread 10 Fitting list scope of supply Position Description Article number 1 1 2 3 4 9 Fitting G1 8 inner thread to DN 6 4 hose 55764 2 10 Fitting G1 4 inner thread to DN 6 8 hose 55110 3 1 2 3 4 9 Cooper seal 4 SD Card 5 1 Filter mat 6 9 Fitting for heated sampling line read installed at the top if option is available 1 2 3 4 5 6 ...

Page 14: ... Following content are on the SD Card Ethernet Converter manual Profibus Converter manual GSD Files for profibus converter Analyser manual EN DE Analyser ModBus Profibus specification EN DE The SD card can be found in the SD card slot in the device see sketch below ...

Page 15: ...through the housing This prevents an explosive atmosphere from building up inside the housing The volume flow of the fan must be at least 10 l s If this volume flow is not reached a system alarm appears If the error is not corrected the device switches itself off 2 6 Internal LEL sensor The internal LEL sensor is an unit which monitored the entire inner housing If a certain gas concentration is ex...

Page 16: ...USER MANUAL SWG Page 16 of 129 3 Installation manual 0006 3 1 Overview This manual explains how to install the analyzer mechanically and electrically 6 1 2 3 4 6 6 5 ...

Page 17: ...llowing diagram shows the sequence in which the installation should be carried out Preparation of the measurement points see 3 2 Analyzer mounting see 3 3 Power supply see 3 5 Connect IO module to control room see 3 6 Connect sample gas inlet Connect zero gas outlet adjustment gas inlet and condensate outlet ...

Page 18: ...s to the core flow This is usually the centre of the pipe For installations on a metal pipe make sure that the wall thickness can support the weight of the probe For this purpose the mounting flange is welded to the pipe For installation on a brick fireplace it is advantageous to screw a steel plate with the correct hole diameter to the brick fireplace 3 3 Installation of the analyzer The analyzer...

Page 19: ...evice on a solid wall or steel rack Be sure that the air circulation is not obstructed Let enough room for the tubing or piping For outdoor installation Ensure that the analyzer is mounted on a rain and sun protected place weather shade For indoor installation Ensure that the analyzer is installed on a dry and clean place Be sure that the room is permanently vented with fresh air Connect the VENT ...

Page 20: ...nozzle is intended only for single use NOTE Use PTFE strips to tighten the fitting inside the thread NOTE The pressure reducer unit is equipped with a PTFE DN4 6 fitting Use a 1 8G outer thread fitting for using another fitting For safety reasons the gas inlet and the autocalibration inlet must be equipped with a pressure reducing unit This fitting prevents the gas flow from being limited in the e...

Page 21: ...on of the pressure reducer unit Install a copper seat to the pressure reducer unit Use PTFE strip for the outer thread of the pressure reducer unit Screw the pressure reducer unit into the sample gas inlet Use a 19 open end spanner Picture Flow restrictor orifice with intern filter Reference 1 Sample gas inlet 2 Calibration gas inlet max 4 1 Sinter filter O ring Nozzle Male connector G1 8 2 ...

Page 22: ...ndustrial area The shut off box belongs to the safety concept of the analyser The Remote Power Supply Box as optionally supplied by MRU has a switch off contactor K1 with 3 make contacts normally open The power contactor K1 is activated after the analyser is powered on by pushing the power on button until the green LED is light on In case of an alarm the power contactor K1 is deenergized The circu...

Page 23: ...ven death Only educated staff should install the device The analyser needs a main power supply of 100 230 VAC 47 60 Hz The power supply will be connected on the hat rail Exactly Reference For the circuit plan see sketch below 1 T1 Relay 2 L1 Relay 3 N2 Connector 4 L2 Connector 5 PE Connector 1 3 2 4 5 ...

Page 24: ...USER MANUAL SWG Page 24 of 129 ...

Page 25: ... outputs Reads one PT1000 Reads one thermo couple Reads current inputs signals for sensors with max 20 mA output signals Reads voltage input signals for sensors with max 30 V output signals External control of the analyser Connection of the I O module The option IO module can be found at the hat rail The position is shown at the sketch below Reference 1 Cable gland for IO module M16 2 Cable for IO...

Page 26: ...wer the system down and protect for reconnecting before start maintenance work Slit screws Stripping length 7 mm Tightening torque min max 0 5 0 6 Nm Conductor cross sections which can be used Type of electric line Conductor cross section min max Solid 0 2 2 5 mm 30 12 AWG Stranded 0 2 2 5 mm 30 12 AWG Solid with ferrule with or without plastic 0 25 2 5 mm Information for cables which go through t...

Page 27: ...NING As part of the safety concept a reducing unit must be installed on each Autocal input WARNING As part of the safety concept a reducing unit must be installed on each sample gas input Reference 1 Calibration gas inlet with calibration gas cylinder and pressure reducer max 500 mbar Detail A A B 1 ...

Page 28: ...USER MANUAL SWG Page 28 of 129 Reference 2 Zero gas inlet with G1 8 inner threads and connector for DN4 6 mm hoses 3 Calibration gas inlet with G1 8 inner threads and connector for DN4 6 mm hoses 2 3 ...

Page 29: ... the upper gas connection plate Optionally 4 can be installed Each calibration gas port is intended for one calibration gas cylinder and has a screw connection for DN4 6 mm hoses The pressure regulator must not be set to more than 500 mbar Installation zero gas inlet see detail A 2 The zero gas connection is located on the left side of the upper gas connection plate and is equipped with a screw co...

Page 30: ...burns The condensate output is located on the left bottom side of the analyser It is equipped with a DN4 6 mm screw connection The condensate from the gas coolers is discharged from the condensate outlet Since this condensate can have a deviating pH value and could therefore be acidic or basic it should be collected in an extra container ...

Page 31: ...ot be longer than 10 m and should be laid with almost no kinks The sample gas flows into the sample gas inlet and out of the analyser again after the analysis is completed Because the sample gas can be toxic environmentally harmful or explosive it is important to discharge this gas into a secured environment Therefore the following principle applies Never let sample gas escape into the installatio...

Page 32: ...USER MANUAL SWG ...

Page 33: ...ng features Transmit 4 20 mA output Trigger alarm outputs Reads one PT1000 Reads one thermocouple Reads current inputs signals for sensors with max 20 mA output signals Reads voltage input signals for sensors with max 30 V output signals External control of the analyzer 4 1 Position of the IO module inside the analyzer At the basic SWG100 one IO module is integrated Optionally an analyzer can be e...

Page 34: ...USER MANUAL SWG Page 34 of 129 4 2 Pin assignment The follow pin assignment plan shows where the different pins for the interfaces can be found and which pins has a double occupancy ...

Page 35: ...o AO3 max 500R No AO4 AO4 max 500R No AO4 max 500R No Alarmoutpu ts AL1 AL1 24 VDC No AL1 24 VDC No AL2 AL2 24 VDC No AL2 24 VDC No Analog Input 4 20 mA PWROUT V12 No GND No AL1 AI1 50R No AI1 50R RC1 AL2 AI2 50R No AI2 50R RC2 AL3 AI3 50R No AI3 50R RC3 AL4 AI4 50R No AI4 50R RC4 Remote control RC1 RC1 No RC1 AL1 RC2 RC2 No RC2 AL2 RC3 RC3 No RC3 AL3 RC4 RC4 No RC4 AL4 Analog Input 0 10V AVL1 AVL...

Page 36: ...erence 1 Analog output 1 minus 2 Analog output 1 plus 3 Analog output 2 minus 4 Analog output 2 plus 5 Analog output 3 minus 6 Analog output 3 plus 7 Analog output 4 minus 8 Analog output 4 plus Information for connection Conductor cross section Max Load for output 500 Ohm 1 2 3 4 5 6 7 8 ...

Page 37: ...eight At the list the user finds the information which analog signal is carry out at which analog output channel The follow list notation can be found example Reference 1 The number of the IO module 1 means first IO module 2 The value of the analog output 3 means the third analog output 3 The sample point from where the signal comes SP1 means the first sample point 4 The signal name CH4 means that...

Page 38: ...2 the output pins would be configured by default values Test 4 The test menu is for testing the analog outputs To open the test menu push F3 or OK The navigation inside the menu taken place with the up down arrow keys With the OK key the analog output can be edited The settings for an analog menu See the screenshot below Reference 1 Section 1 Shows the operator which analog output will be changed ...

Page 39: ...the transmit signal have This point cannot be changed 5 Minimum 4mA 5 Here the operator entering the equivalent measurement value for a current of 4 mA Maximum 20mA 5 Here the operator entering the equivalent measurement value for a current of 20 mA The IO module will create the linear relation 6 Return 6 Leave the menu Alternate push F1 7 Overwrite on 7 A function to simulate values If the overwr...

Page 40: ...ng the analog output 1 with the DCS Wiring the analog output AO1 AO1 with the DCS For this use a wiring with a conductor cross section between In the next step output 1 must be configured at the SWG100 To do this open the menu EXTRAS CONFIGURATE ANALOG OUTPUTS The following menu overview will be appeared see screenshot below To configure the IO1 select the first record channel I O 1 1 SP1 CH4 in t...

Page 41: ...USER MANUAL SWG Page 41 of 129 Set points here with arrow keys and OK In the last step the menu must be closed Confirm the store message The 4 20 mA output is now configuring ...

Page 42: ...dule has two alarm outputs The position of the alarm outputs are marked with the red labels Reference 1 1 Alarm Relay 2 1 Alarm Relay 3 2 Alarm Relay 4 2 Alarm Relay Information for connection Conductor cross section Relays type Normally open Voltage supply max 24 VDC 1 2 3 4 ...

Page 43: ...s carry out at which alarm output channel The follow list notation can be found example Reference 1 The number of the IO module 1 means first IO module 2 The value of the alarm output 2 means the second alarm output 3 The sample point from where the signal come SP1 means the first sample point 4 The signal name CH4 means that this alarm output monitors the CH4 channel This example means At the sec...

Page 44: ...he settings for an alarm menu See the screenshot below Reference 1 Section 1 Shows the operator which alarm output will be change 2 Sample point 2 The operator can select the sample point This means that the alarm output signal from the choose sample point will be transmitted to the process control system 3 Meas Item 3 At this point the operator selects the measurement item which should be monitor...

Page 45: ...the sample point 2 The SWG100 has one IO module Both alarm outputs are not connected Follow steps must be done Both alarm outputs are equipped with a potential free relay The maximal voltage of the power supply is 24 VDC So the operator must provide a 24 VDC power supply and a warning light which works with 24 VDC Connect the parts with the relay inside the IO module In the next step the alarm 1 m...

Page 46: ...USER MANUAL SWG Page 46 of 129 The follow screen appears To configurate the channel 1 the red marked positions must be changed ...

Page 47: ...A transducer in the analyzer directly The IO module has a separate 12 V power source for the supply of the transducer At the sketch below the inputs and the power supply for the transducer are marked Information Internal Load 50 Ohm Power supply for transducer 12VDC 200 mA The sketches below show how the common transducer can connect to the IO module V12 AI1 AI2 AI1 AI2 AI3 AI4 AI3 AI4 Power suppl...

Page 48: ...ANUAL SWG Page 48 of 129 2 wire transducer 4 wire transducer 12VDC Field SWG100 Power supply for transducer Transducer T U T U Transducer 12VDC Power supply for transducer SWG100 Field Load 50 Ohm Load 50 Ohm ...

Page 49: ...elected with the up down arrow keys After one AUX input is selected the measurement item must be activated To do this turn the measurement item from OFF to definable configuration where the user can configure by himself contains some pre configurated settings like for temperature or pressure sensors given at the screenshot below Reference 1 Show the operator which analog input will be changed 2 Th...

Page 50: ...alent measurement value for a current of 20 mA The IO module will create the linear relation 7 Leave the menu Alternate push F2 Example Read 4 20 mA signal from an external temperature sensor An operator wants to read an external temperature sensor signal inside a SWG100 The temperature sensor gives a 4 20 mA signal out and needs a 7 30 VDC power source It will use a two wire transducer The temper...

Page 51: ... configured If F1 is pressed the follow screen appears This screen means that no transducer is configurated Meas Item is OFF default With the ON key F2 or the arrow right left key the operator can skip inside the menu o If the AUX input is activated the follow screen appears At this screen the operator can define the incoming signal Meas Item This is the skip menu point Push the right left arrow k...

Page 52: ...sampling point selection Stand by The commands will be given by a 4 bit binary number which will be built through four external signals The pins for the signal are shown in the sketch below It exists two different types to set the four pins Potential free relay contacts 4 20 mA signal inputs Through one 4 20mA input Through Modbus RTU The settings menu can be found at the path EXTRAS GENERAL SETTI...

Page 53: ...witching 0 0 0 1 1 Analyzer is sampling the point SP1 1 2 0 0 1 0 2 Analyzer is sampling the point SP2 1 2 0 0 1 1 3 Analyzer is sampling the point SP3 1 2 0 1 0 0 4 Analyzer is sampling the point SP4 1 2 0 1 0 1 5 Analyzer is sampling the point SP5 1 2 0 1 1 0 6 Analyzer is sampling the point SP6 1 2 0 1 1 1 7 Analyzer is sampling the point SP7 1 2 1 0 0 0 8 Analyzer is sampling the point SP8 1 2...

Page 54: ...e point SP2 1 2 0 0 1 1 3 Analyzer is sampling the point SP3 1 2 0 1 0 0 4 Analyzer is sampling the point SP4 1 2 0 1 0 1 5 Analyzer is sampling the point SP5 1 2 0 1 1 0 6 Analyzer is sampling the point SP6 1 2 0 1 1 1 7 Analyzer is sampling the point SP7 1 2 1 0 0 0 8 Analyzer is sampling the point SP8 1 2 1 0 0 1 9 Analyzer is sampling the point SP9 1 2 1 0 1 0 10 Analyzer is sampling the point...

Page 55: ...nection of the one 4 20 mA signal is a two wire connection Status of external signal source I mA Status number Description 4 0 Automatic sampling point switching 5 1 Analyzer is sampling the point SP1 1 2 6 2 Analyzer is sampling the point SP2 1 2 7 3 Analyzer is sampling the point SP3 1 2 8 4 Analyzer is sampling the point SP4 1 2 9 5 Analyzer is sampling the point SP5 1 2 10 6 Analyzer is sampli...

Page 56: ...ing 1 Analyzer is sampling the point SP1 1 2 2 Analyzer is sampling the point SP2 1 2 3 Analyzer is sampling the point SP3 1 2 4 Analyzer is sampling the point SP4 1 2 5 Analyzer is sampling the point SP5 1 2 6 Analyzer is sampling the point SP6 1 2 7 Analyzer is sampling the point SP7 1 2 8 Analyzer is sampling the point SP8 1 2 9 Analyzer is sampling the point SP9 1 2 10 Analyzer is sampling the...

Page 57: ... number of sample points e g 4 sample points and input state 1 4 Case 2 External control of a sample point Zeroing First the zeroing will be done The duration of the zeropoint can be set configurated at the analyzer chapter Gas sampling The gas sampling is for purging the entire system and give the analyzer enough time for response Response time To set the suction configurated at the analyzer Meas...

Page 58: ...ess or equal afterwards the selected sample point will be measured Not Example status number 1 for any time period recommended max 1 hour status number 15 for a few seconds recommended min 10 seconds status number 1 for any time period recommended max 1 hour After installation and power up of the analyzer few steps should be processed in order to operate the instrument properly ...

Page 59: ...l0009 5 1 Power up the analyser Open the case door of the analyser Power up the circuit breaker See figure below Detail A Reference 1 Circuit breaker for analyser 2 Circuit breaker for heated sampling hose optional 3 Circuit breaker for HD probe optional A 3 1 2 ...

Page 60: ...d language Check the date and time of the instrument Configuration of the alarm relays Configuration of the Modbus Configuration of the external control via relay contacts IO module Configuration of the analog outputs at the I O module Configuration of the AUX inputs at the I O module Configuration of the alarm outputs at the I O module Configuration of the auto calibration 5 3 Check country and l...

Page 61: ...erefore the instruments system clock should be set correctly Use the menu EXTRAS GENERAL SETTINGS DATE TIME In case the date time is not correct press the key F2 modify change date time and then press the key F2 store Note According to the selected country see previous chapter the analyser automatically switch the daylight saving time in spring and autumn This function is active for most European ...

Page 62: ...n 900U min 6 Sample flow alarm sample flow 20 l hr 7 Gas cooler high alarm temperature 10 C 8 Gas cooler low alarm temperature 2 C 9 Cabinet high temperature 55 C 10 Cabinet low temperature 5 C Errors 1 to 5 alarm will force a measurement stop all analog outputs are on hold or at 2mA depending on configuration Errors 6 to 10 will be displayed as warning message only analog outputs of active sampli...

Page 63: ...USER MANUAL SWG Page 63 of 129 Detail A Alarm Relais ...

Page 64: ... can be used Type of electric line Conductor cross section min max Solid 0 2 2 5 mm 30 12 AWG Stranded 0 2 2 5 mm 30 12 AWG Solid with ferrule with or without plastic 0 25 2 5 mm Information for cables which go through the cable gland M16 It is recommended to use only electric lines with ferrules Following analyzer errors will produce a system alarm open contact of System Alarm relay ...

Page 65: ... the system alarm relay Slit screws Stripping length 7 mm Tightening torque min max 0 5 0 6 Nm Conductor cross sections which can be used Type of electric line Conductor cross section min max Solid 0 2 2 5 mm 30 12 AWG Stranded 0 2 2 5 mm 30 12 AWG Solid with ferrule with or without plastic 0 25 2 5 mm Information for cables which go through the cable gland M16 It is recommended to use only electr...

Page 66: ...USER MANUAL SWG Page 66 of 129 Configuration at the analyser 1 Open the path EXTRAS GENERAL SETTINGS 2 Press F3 3 The Modbus store settings will be open The user can commission the slaves settings ...

Page 67: ...ompositions First select the gas component then press OK A blue screen will show up appeared With the arrow keys the gas concentration can be set After the gas composition is set the interval for the calibration can be set too NOTE All gas concentrations are in percent The factor from percent to ppm is 1 10 000 ppm Arrow keys left right With these keys the gas composition can be set Arrow keys up ...

Page 68: ...libration will start after the interval is reached Start the auto calibration immediately Press F2 start now During the auto calibration the stored gas concentrations are compared with the measure gas concentrations If the gas concentrations are not differing too much the The new gas factors will be stored after successful calibration ...

Page 69: ...ion is performed with the three function keys F1 F2 and F3 F1 Delete a phase F2 Make an Auto config F3 Insert a new phase OK View change phase details Left right Change the phase type 6 3 Auto configuration With F2 configurations One zeroing cycle One zeroing sample point The first program is for applications where the different measurement points have almost the same gas concentrations The zeroin...

Page 70: ...t left arrow keys the different phase types can be selected In the title With OK shown and changed 6 5 Configuration of the phase details In this chapter the different cycle phase details will be explained Zeroing Cycle phase details ZEROING configured ZEROING Measuring site valves Valves closed Zeroing valve Valve open Duration 2min to 1 h Recommendation 5min in general not to be changed by user ...

Page 71: ...ls configured In the cycle phase details the following times can be set Phase duration Entire Stand by time Purging time Quiet time Phase time Purging time The time to purge the analyser with ambient air through the zero gas inlet Quiet time The time where the analyser is in the pure stand by mode STAND BY Measuring site valves Valves closed Zeroing valve Valve closed Duration Phase duration 2 min...

Page 72: ... phase The user has the opportunity to deactivate a phase in the measurement configuration cycle This could be necessary for example if a sample point is temporarily not in use The activation and deactivation of a phase can be done in the cycle phase details of the concerning phase Example for the deactivation of a phase ivated phase is grey out ...

Page 73: ...n the measurement cycle config menu Path EXTRA MEASUREMENT CYCLE CONFIG The default measurement cycle will appear Open the cycle phase detail of the first zeroing and adjust the phase duration at 25 min Leave the cycle phase detail and select the second point Switch with the left right arrow keys until the measurement SP2 is selected Open with the OK key the cycle phase detail of the measurement S...

Page 74: ...hase duration at 15 min and leave the cycle phase detail Switch to the next point and select with the left right arrow key the measurement SP1 Go in the cycle phase detail of the measurement SP1 Here adjust the duration phase 10 min and the pure measurement time 5 min At last push F3 key for insert a new phase and select with the left right arrow adjust the Purging time at 3 min and the Quiet time...

Page 75: ...USER MANUAL SWG Page 75 of 129 Leave the menu and safe the adjustments The individual configuration is done ...

Page 76: ...systems will be connected and the gas cooler option has reached the target operation temperature During the self test phase the gas pump is switched off all analog outputs will deliver 2mA all alarm outputs will have alarm status open contacts Usually the self test will be left automatically as soon as all conditions for measurement are satisfied Then the first zeroing will be started If one of th...

Page 77: ...y Zoom Standard Two display modes are available standard view mode with 6 values per page up to 4 pages indicating up to 24 values zoom view mode with 2 values per page up to 6 pages indicating up to 12 values The indication mode can be swapped with the menu key and the selection of zoom view or standard view For devices with just one measuring point the switching is additional possible with the a...

Page 78: ...ved over the top or under the bottom line then the next definable page will show up As soon as you have finished the configuration press the ESC key or press again the menu key and select the function Save measuring window You will be asked whether the changed settings shall be stored or discarded Select keep them in order to store your changes ...

Page 79: ...u The menu provides an overview of stored measurements of each sample point and of the memory usage NOTE DATA STORAGE The analyser makes use of an internal flash memory to store measurement values automatically Storage menu 1 View text 2 View graph 3 Extras Device info Main device menu Storage menu 1 View text 2 Export SD View graph 3 ...

Page 80: ...ts of the last 20000 90 222 days more than 7 months View stored measurements in text mode This function can be reached from the Data Storage Menu by selecting one or all sample points and by pressing F1 view text When entering the menu the latest stored measurement will be displayed With the keys F1 previous and F3 next the measurements can be browsed F3 will lead to the oldest measurement when th...

Page 81: ...ng F2 export SD The created files have names like The 1st line of the created file is a column header with the following information Sample point number Date Time and all measurements The following lines contain the data CSV configuration settings 1 F2 in the main menu 2 Open the context menu in the store menu Select the menu menu 3 It appears a list of all configured csv datas With the keys F1 F2...

Page 82: ...t In this list all available measurement values and all 9 asset lines are pictured Set default list In this list all available measurement values and 2 asset lines are pictured Set small list In this list the general measurement values are pictured ...

Page 83: ...et FW is offered Note You also may enter this menu by pressing the OFF key and leave it by pressing the ESC key without starting the purge cycle when you just want to store operational data and user settings Backup restore all individual user settings It s a quite amount of work to configure the analyser especially when the analyser provides several sample point and several IO modules and when the...

Page 84: ...irmware from the installed I O modules Overview Device update The structure below shows the princip of the menu In this menu new updates firmwares can be executed The analyser has a bus systems of different independent pcb All these pcbs can be selected and updated here The screenshots show an example of one update menu Extras Device info Main device info Sub system MGB Sub system IO module Firmwa...

Page 85: ...ctrochemical module 8 Broadcast virtual General steps for the firmware update 1 Copy the actual firmware for the analyser or the firmware from the option on a SD card Be sure that the firmware is in the mean root of the SD card All 2 Put the SD card on the card slot on the operation unit The card slot can be found inside the door see sketch below 3 If the SD card is recognized the analyser will ma...

Page 86: ... the SD card Update the pcb mainboard Firmware Open the path Extra Device info Press F3 sub syst SUB SYSTEMS INFO Press F2 details to open the details from the mainboard Be mainboard The Update will start from the SD card if a firmware with the fil card Update the NDIR bench Firmware Open the path Extra Device info Press F3 sub syst SUB SYSTEMS INFO Press F2 details to open the details from the ND...

Page 87: ...rmware with the card Update the IO modules Firmware Update with filena 1 Open the path EXTRA DEVICE INFO Press F3 sub syst SUB SYSTEMS INFO Press F2 details to open the details from the I O module Be module The Update will start from the SD card if a firmware with the card Or F3 ...

Page 88: ...portant to comply with the national directives which are the country specific 8 2 Regular maintenance works by the operator All inspections and maintenance works are dependent from individual operating conditions and site The specified intervals below are only benchmarks Review Recommended intervals Actions Moisture in the analyser Weekly Remove the moisture Call vendor specialist Dirt and deposit...

Page 89: ...USER MANUAL SWG Page 89 of 129 8 3 Description of the analyser 1 1 1 1 2 ...

Page 90: ...age 90 of 129 The sketch below shows the positions of all spare and consumable parts in the SWG 100 The parts marketed with a red circle is a spare part the parts marketed with a green circle is a consumable part 2 A 1 ...

Page 91: ...SER MANUAL SWG Page 91 of 129 Content of the service set Single components can be offered under their article number directly Reference Legend Red label Green label Spare parts Consumable parts 2 3 4 1 1 ...

Page 92: ...arts 1 PTFE filter element 12685 6month 2 Acid gas filter 56795 6 month 3 Disc filter PTFE 64459 6 month 4 Active coal filter 65034 6 month Consumable parts 1 Sample gas pump sealing set 65592 If necessary 2 Condensate hoses for pump out 13434 6 month 3 Condensate hoses for H3PO4 injection 13434 6 month Spare parts 1 2 3 4 Consumable parts 1 2 3 ...

Page 93: ...tubes from the exhausted acid gas filter If it is necessary use needle nose pliers 3 Plug the viton tubes on the new acid gas filters Be sure that the tubing is correct The single tubes are signed side Steps Pull the viton tubes from the filter unit If it is necessary pliers can be used to solve the tubes from the filter unit Remove the exhausted filter unit from the clip Plug the viton tubes on t...

Page 94: ...the clip Plug the viton tubes on the filter unit Push the filter unit on the clip Position 4 PTFE Filter 51513 Required materials PTFE filter 51513 contained in the service set Required tools needle nose pliers Exchange interval Exchange necessary if gas flow is to low Steps Pull the exhausted filter unit from the viton tube and exchange it with a new one If it necessary the tube can be solved fro...

Page 95: ...USER MANUAL SWG Page 95 of 129 Steps Open the filter unit by pulling the blue lash Replace the exhausted filter mat through a new one Close the cover from the filter unit ...

Page 96: ...r holder 4 Exchange the exhausted filter element with a new one 1 Spare part 5 Disc filter PTFE Power the system down Open the service flap of the MCU Carefully pull the filter from the clamps Unscrew the fittings from the exhausted filter Exchange the exhausted filter with a new one To make the entire system gas tight Teflon tape must be inserted between the filter and the screw connection 1 2 3 ...

Page 97: ...nge the condensate pump head unit Unscrew and remove the cover from the condensate pump The inner assembly of the condensate pump head is shown in the picture below The inner assembly of the condensate pump head is shown in the picture below ...

Page 98: ...the upper condensate pump hose Insert the pump roller assemble Press the part into the groove Insert the lower condensate pump hose Be sure that all parts are sit well and screw the cover at the condensate pump head Reference 1 Upper condensate pump hose 2 Pump roller assemble 3 Lower condensate pump hose 1 2 3 ...

Page 99: ...USER MANUAL SWG Page 99 of 129 ...

Page 100: ...inable as follows 9600 baud 19200 baud even parity and 1 stop bit no parity and 2 stop bits Multi byte values are transmitted in Motorola byte order Big Endian Only the CRC16 at the end of each frame is transmitted in Intel byte order Little Endian In case you need Little Endian byte order in the master s system 16bit values occurs only in the frame swap bytes 0 1 32bit values occurs only in the d...

Page 101: ...gs 24 FL 2 Case fan rotations rpm 26 FL 2 Gas pump rotations rpm 28 FL 2 P absolute hPa mbar firmware V1 04 60 or later 30 FL 2 P absolute inchHG firmware V1 05 01 or later 32 U32 2 T hose C F unit depends on user settings 34 U32 2 T probe C F unit depends on user settings 36 U32 2 not yet defined read zero 38 U32 2 not yet defined read zero Status current measurement values live values 40 U32 2 A...

Page 102: ...ings 96 U32 2 Flow vol unit depends on user settings 98 U32 2 not yet defined read zero Status measurement values of sample point 2 100 U32 2 Analyser Status more details read below 102 U32 2 System Alarm more details read below 104 FL 2 O2 106 FL 2 CO2 108 FL 2 CH4 ppm 110 FL 2 H2S ppm 112 FL 2 H2 ppm 114 FL 2 CO ppm 116 FL 2 NO ppm 118 FL 2 SO2 ppm 120 FL 2 NO2 ppm 122 U32 2 T gas C F unit depen...

Page 103: ...216 FL 2 AUX value read by IO module 4 Input 2 218 FL 2 AUX value read by IO module 4 Input 3 220 FL 2 AUX value read by IO module 4 Input 4 222 FL 2 AUX value read by IO module 5 Input 1 224 FL 2 AUX value read by IO module 5 Input 2 226 FL 2 AUX value read by IO module 5 Input 3 228 FL 2 AUX value read by IO module 5 Input 4 230 FL 2 AUX value read by IO module 6 Input 1 232 FL 2 AUX value read ...

Page 104: ...1 0000 Measuring sample point 1 32 0020h 0010 0000 Measuring sample point 2 48 0030h 0011 0000 Measuring sample point 3 18 0012h 0001 0010 Measuring sample point 1 System Alarm 9 3 Analyser System Alarm address 2 and some mirror addresses The Analyser System Alarm is a 32bit word and must be interpreted bitwise Bit Description Meas halted 0 Mainboard Offline some communication problems YES 1 Mainb...

Page 105: ...STMENT MENU and input the 6 symbols password gas selection 1 choose between a Zero gas inlet Sucks gas from zero gas inlet if activated b Calibration gas inlet Sucks gas from calibration gas inlet if activated c Sample gas Sucks gas from sample gas inlet if activated The screenshot below shows the different gas inlets and their position at the analyser Zero point If this symbol appears just wait u...

Page 106: ...erence 1 Sample gas channel with current values acutal value 2 Lower set point with set gas cylinder value and factor 3 Upper set point with set gas cylinder value and factor 4 Manual execution of the zero point 5 Reset to standard adjustment Preferences Enter the set point from the gas adjustment cylinder into the menu see 1 To do this mark the lower set value and press the left and or right arro...

Page 107: ... change If the value is adjustable the set value is shown in quotation marks Set a new adjustment factor Finally pressing the OK key sets the new adjustment factor During the whole adjustment procedure only the lower setpoint value is changed The upper set point remains unchanged This is only adjusted if the accuracy in the upper range is to be improved open P 500 mbar ...

Page 108: ...age Temperature Schutzart IP54 Protection Class Aufstellbedingungen geschützt vor direkter Sonneneinstrahlung und Regen Installation Requirements do not expose to direct sun light or rain Akku intern Pufferzeit für Sensor Bias NiMH 3 Monate 3 months Internal Battery Pack buffer time for sensor bias Stromversorgung 100 240 V 200 W Power supply Gewicht typisch mit Sensoren Gaskühler Ca 45 kg 99 lbs ...

Page 109: ... I O Modul optional 4 Number of output channels per I modul optional Typ Analogeingang 4 20 mA Typ of analog input Anzahl Eingangskanäle pro I O Modul optional 4 Number of input channels per I modul optional Anzahl Alarmausgänge pro I O Modul über Relais 2 Number of alarm ouput signal via relays Systemalarm Ausgang Relaiskontakt system alarm output relay contact Gas Ein und Ausgänge Gas input and ...

Page 110: ...USER MANUAL SWG Page 110 of 129 12 Appendix ...

Page 111: ...urge Probe internally heated Probe tube is exchangeable Filtering with sinter filter cartridge For lines with and without heating hose With back purge function With calibration gas inlet ATTENTION Use clean oil and waterfree air NOTE For further information about the heated sampling line read the appendix ...

Page 112: ...ulkhead connector Reference 1 Front ferrule 2 Back ferrule 3 Nut 4 Tube insert 5 PTFE hose Install the cable set for the probe Connect the compressed air with the HD probe The pressure should be female coupling NS 7 2 Screw the sample tube in the sample gas probe Be sure that the seal is between the sample gas probe and the sample probe 1 2 3 4 ...

Page 113: ...ated sampling line 2 Harness from heated sampling line Reference Heated sampling line number 1 10 1 L Hose brown 2 N Hose blue 3 Th Hose green 4 Th Hose white 5 L probe violet 6 N probe yellow 7 Th probe green 8 Th probe white 9 L purge grey 10 N purge black 1 2 ...

Page 114: ...USER MANUAL SWG Page 114 of 129 ...

Page 115: ... 2 Sealing DURANOARD for ceramic filter 55110 If necessary 3 Flat gasket 3 4 54899 If necessary 4 Seal gasket for mounting flange DN 65 PN6 52556 If necessary 5 O Ring 80 x 3 0 mm Viton 500 61578 If necessary 6 O Ring 60 x 3 0 mm Viton 500 59104 If necessary 7 O Ring 22 x 3 0 mm Viton 500 55648 If necessary 8 Ceramic compound 1 tube of 50g 64977 If necessary Spare parts 7 8 The service set is inte...

Page 116: ...USER MANUAL SWG Page 116 of 129 Positions of the components 3 4 ...

Page 117: ...USER MANUAL SWG Page 117 of 129 Preparations Power the system down Remove the probe cover Unscrew the filter holder Pull the locking device downwards Pull out the filter holder ...

Page 118: ...e steps must be done at the filter holder Unscrew the filter holder nut Remove the exhausted ceramic filter and the two sealings Remove the exhausted O rings and replace with new ones Install the new filter and new seals Screw on the filter holder nut Open Size 17 mm Position No 1 ...

Page 119: ...UAL SWG Page 119 of 129 To exchange the O rings at the backpurge manifold unscrew the upper nut and remove the manifold Inside the manifold are two O rings which must be replaced Close Size 17 mm Position No 1 ...

Page 120: ...he seals Power the system down Remove the HD probe from the flange adapter To do this remove the nuts Remove the entire HD probe from the stack carefully The graphite seal can now remove and replace with a new one Open Size 17 mm Position No 1 ...

Page 121: ...ER MANUAL SWG Page 121 of 129 Unscrew the probe tube from the HD probe And replace the old seal with a new one 13 NOTE When assembling lubricate the screws with ceramic paste to prevent them from seizing ...

Page 122: ... cable duct along the line The heated sampling line shall be supported close to the analyser cabinet and probe housing for example by using a separate stilt There are no extreme temperature variations along the line as placed in the mid of the line Unpacking of the heated sampling line A wrong and careless use of the sample line may cause damage Especially on very long heated sampling lines the ri...

Page 123: ...Page 123 of 129 Bending radius of heated sampling lines The picture below shows the minimal bending radius ATTENTION Falling below the bending radius will reduce life time of the sampling probe Bending radius min 32 cm ...

Page 124: ...shing hazard Only use clips which have the right side Do not fixing the heated sampling line with glue or material which coat the entire line Overheating hazard Lay the heated sampling line free and clean Do not hang the heated sampling line on a direction change without a check rail Only use direction changes having the right check rail diameter Do not choose the heated sampling line too short fo...

Page 125: ...ng layout Do not assemble the heated sampling line when it is twisted To avoid that the heated sampling line gets twisted assemble it parallel Do not assemble the heated sampling line that the whole application can sag from its one weight Use a special spring suspension ...

Page 126: ...UAL SWG Page 126 of 129 Rules for laying the heated sampling line in a cable duct Wrong Right Do not lay heated sampling lines in a closed cable duct Overheating hazard Use cable ducts where the air can get out ...

Page 127: ...USER MANUAL SWG Page 127 of 129 ...

Page 128: ...USER MANUAL SWG Page 128 of 129 20 12 2021 14 11 21 f 0 31 O Produkte SWGx00_1131 Referenz Gaslaufpläne GLP_SWGx00Syngas_1131_211202 sch Sheet 1 1 ...

Page 129: ...USER MANUAL SWG Page 129 of 129 ...

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