MWG 0238 Ex

Operation Manual
Part Number 7004-238

1194 Oak Valley Drive, Suite 20, Ann Arbor, Michigan 48108 USA z www.gfg-inc.com
800-959-0329 z 734-769-0573 z 734-769-1888 fax
Content

Page

For your Safety 3

General Description 3
Detection Principle 4
Operational Notes 4
Design 5
Mounting Position of MWG 0238 Ex 6
Mounting 6
Installation of Electrical Connections 7
Putting into Operation 7
Check of Electrical Zeropoint 8
Check of Sensitivity 9
Signal Transmission 9
Service 9
Maintenance and Inspection 10
Functional Restrictions depending on Oxygen Concentration 10
Display Irritation due to Sensor Poisons 10
Trouble Shooting 11
Spare Parts 11
Accessories 11
Connection Diagram MWG 0238 Ex 11
Technical Data 12
Index 13
For your Safety
Like any piece of complex equipment, the GfG MWG 0238 Ex will do the job designed to do only, if it is used and
serviced in accordance with the manufacturer's instructions. This manual must be carefully read by all individuals who
have or will have the responsibility for using and servicing this product.
The warranties made by GfG with respect to the product are voided, if the product is not used and serviced in accordance
with the instructions in this manual. They are also voided, if function or parameter settings are effected without GfG's
authorization. The above does not alter statements regarding GfG's warranties and conditions of sale and delivery.

General Description
A fixed gas monitoring system consists of a transmitter (MWG) and a control module (GMA), which are connected by
means of a transmitter cable. The transmitter converts the gas concentration into an electrical signal, which is sent to the
GMA for evaluation.

GfG Gesellschaft
für Gerätebau

MWG 0238 Ex
(Ex) es 3n G5 T Y P E L A B E L I N S ID E

BVS Nr.: T6947/Z1

IBS / PFG-Nr.: 41300596 A 3

A 2
M E NU
100

ΧΗΑΝ Ν ΕΛ
80

o u t/N
60 A 1
A 3

in/M A2 40

A 1
U 20
FA U L T
%
ON

Φ ΑΥ Λ Τ
U
ΤΕ Σ Τ ΘΥ ΙΤ

ΜΕ Ν Υ ΜΕ Ν Υ

Measurement
Evaluation Alarm
Fig. 1

The MWG 0238 Ex is an "intelligent" transmitter. Its comprehensive electronic circuitry allows easiest handling and
servicing and increases the measurement reliability and accuracy. The MWG 0238 Ex is characterized by following
features:

• Easy calibration at site.

• Compensation of temperature effects.
• EX-protection for use in a temperature range from -20 to +40 °C
• Tested for function in the temperature range from -25 to +55 °C

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Detection Principle
The MWG 0238 Ex is operated on the detection principle "catalytic combustion" (fig.2). The gas/vapour-air mixture
enters the sensor chamber by diffusion through the sinter filter. Inside the sensor chamber there are an active and a passive
sensor filament. The heated active sensor burns (oxidizes) the gas entering. This increases the temperature at the sensor
and results a change of the electrical resistance, which is the measure for the gas concentration. The passive (reference)
sensor is exposed to the same ambient conditions as the active (detection) sensor and is used for compensation of
environmental effects (e.g. temperature changes).

Detection Principle - Catalytic Combustion

passive filament Sensor

Sinter metal

Gas

active filament

Fig. 2

Operational Notes
According to § 26 a "UVV Gase" (VBG 61) (German Regulation for Preventing Accidents), gas warning instruments have
to pass a function test, done by a specialist, after having been installed but before put in operation.

Before shipment, the MWG 0238 Ex passes a function and display test, being calibrated with suitable test gases. This
does not, however, overrule the obligation to arrange for another function test after putting the transmitter in
operation.

The function test of the MWG 0238 Ex has been effected by "DMT-Gesellschaft für Forschung und Prüfung mbH,
Fachstelle für Sicherheit - Prüfstelle für Grubenbewetterung" for the use of warning from explosible gas mixtures, based
on the standards DIN EN 50054 "Electrical Devices for detection and measurement of combustible gases - General
requirements and test methods" and DIN EN 50057 "Electrical Devices for finding and measuring combustible gases -
Requirements of the operational behaviour of equipment of group II with a detection range of up to 100 % of the Lower
Explosion Limit".
The following ranges have been tested:
Gas Range

! CH4
C3H8 Propane
Methane 0 .. 100
0 .. 100
% LEL
% LEL
C9H20 n-Nonane 0 .. 100 % LEL
C2H5OH Ethanol 0 .. 100 % LEL

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Design
The design of the MWG 0238 Ex is shown in fig. 3.

MWG 0238 Ex - Design

1. Casing bottom

2. Casing top

3. Type label

4. Special screws
for fixing of
casing top

5. Cable gland
PG screwing

6. Sensor with
diffusion inlet

Fig. 3

The type label (Pos. 3) shows the transmitter type. The sensor sleeve (Pos. 10) includes the sensor and the sensor card,
which carries the components for the sensor circuitry. For adjustment of electrical zeropoint and sensitivity you find the
respective potentiometers behind the service lid (Pos. 7), together with test sockets for connecting a multi-meter to
measure the zeropoint and sensitivity signals (please also refer to fig. 6). The MWG casing contains the main p.c.board
and the calibration p.c.board. The electronics on the main p.c.board converts the sensor signal into an output signal of
either 4 .. 20 mA or 0,2 .. 1 mA. The calibration p.c.board carries the adjustment elements.

The type label (pos. 3) shows the transmitter type. The sensor is built into the sensor chamber (pos. 6). For adjustment of
the electrical zeropoint you will find a potentiometer below the casing top (pos. 2). The printed circuit board inside the
casing is sealed in epoxy resin.

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Mounting Position of MWG 0238 Ex
It is essential to exactly know the ambient conditions, which have to be taken into consideration before deciding on the
mounting position. To achieve representative measurement results, take care of

• the room ventilation and

• the gas density.

Install the MWG 0238 Ex at a place where the gases pass the sensor even in case of bad ventilation. If necessary, use a
smoke cartridge to check.

In case the gas to be measured has a higher density than air, the transmitter is to be installed close to the floor. For lighter
gases, with a lower density than air, the transmitter is being mounted close to the ceiling. The following chart shows the
density of the tested gases. More detailed information are available on request.

Type of gas rel. gas density Mounting

(air = 1) recommended
Methane CH4 0,55 close to ceiling
Propane C3H8 1,56 close to floor
n-Nonane C9H20 4,43 close to floor
Ethanol C2H5OH 1,59 close to floor

Furthermore, take the following into consideration as well:

• Rain water, hose water, dripping water, condensate and
• Dust in the atmosphere.

The MWG 0238 Ex is to a great extent protected against the entering of water and dust (IP 56). Special accessories are
available to provide additional protection for very difficult conditions. Please contact GfG for detailed information.

Warranty may be voided, if the sensor is exposed to ambient conditions which were
! unknown to GfG during planning, production or delivery.

Mounting
When deciding on the position for the transmitter, make sure that it is always accessible for service and maintenance. The
MWG 0238 Ex must be mounted with the sensor showing to the floor.

The MWG 0238 Ex is connected to the controller according to the Connection Diagram MWG 0238 Ex (page 11). For
mounting the transmitter remove the four special screws (pos. 4, fig. 3) and take the casing top off. Fix the casing by
means of two screws through the relevant borings.

The printed circuit boards inside the casing are potted in epoxy resin. In front of the potted block you will find the
terminals for the sensor and the connections to the controller.

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Installation of Electrical Connections
Procurement of cable and electrical connections must be done by a specialist only, obeying the applicable regulations.
Installation has to be done using a 3 conductor 18 AWG shielded (e.g. LIYCY 3 x 1.5 mm2). The cross section of the
cable depends on the cable length. For short distances (max. 200 m) it may be sufficient to use 20 AWG (0.75 mm2)
instead of 18 AWG (1.5 mm2). For longer distances the cross section must be 18 AWG (1.5 mm2). The cable length must
not be more than 1000 m.
The shield is fixed to the PG screwing. In case the MWG is mounted to electrically conductive undergrounds (e.g. steel
girder), a potential compensation is to be effected (fig. 5). If the MWG is installed in a room which is subject to Ex-
regulations, make sure that only the transmitter is installed in this area. The gas monitoring system resp. the mains supply
and the evaluation unit must be installed in the safe area.

Terminal connection of MWG 0238 Ex

31 30 32 2 0 3

Y ellow G reen Red 0.2 -1 m A G round 15 -30 V

Sensor GM A

Fig. 4

The shield is to be laid on the PG screwing. It is to be considered, whether the MWG is installed in a room which is
subject to the rules of explosion protection. In this case only the MWG may be mounted in that area; the evaluation unit
resp. the mains supply must be installed in safe area. Once you have mounted the MWG, close the casing and fix it with
the four special screws.

Installation and opening of the transmitter must always be done in gas-free air.
!
Putting into Operation
Once the MWG is installed, a skilled person can put it in operation. Before shipment, the MWG has been calibrated and
tested after a running-in time of several days. You do not have to wait for so long, but once you have started your new
MWG 0238 Ex, the catalytic combustion sensor needs a certain running-in time of approx. 15 - 30 minutes before you
can check the sensitivity. Allow another 10 minutes as warm-up time for the MWG. Should you notice that a re-
calibration is required, allow the transmitter to warm up for about 24 hours.
To check the "running-in", connect an external volt meter to the test sockets UM at the front of the GMA 300 controller or
press at GMA 100 controller (please refer to the operation manual of your GMA). The measured value in clean air
(without any combustible gas) must be 200 mV (±15 %) after the warm-up time is completed. Should the deviation
exceed the allowed tolerance, correct the zeropoint at the transmitter.

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Check of Electrical Zeropoint
The MWG 0238 Ex is calibrated and tested before shipment. Certain deviations, however, are possible due to transport,
mounting and ambient conditions. Allow a warm-up time of about 15 to 30 minutes before checking the electrical
zeropoint. Once the warm-up is finished, you can connect a volt meter to the test sockets UM of your GMA controller or
press at GMA 100 controller (please read the operation manual for your GMA) to check the electrical zeropoint.
Instead of UM you may also measure the current in the "0.2 - 1 mA line" directly at the transmitter (terminal 2, see fig. 4).
For checking the zeropoint make sure that the transmitter is operated in fresh air (without any combustible gases).

It is not allowed to open the transmitter in rooms with an explosible atmosphere. Any work
at the sensor must only be done, if the presence of explosible mixtures can be excluded for
! the duration of work.

Should the test socket "UM" show a value, which is beyond the allowed toleranz (0.2 V ±15%), the output signal of the
transmitter is to be re-adjusted.
At the potted block you find two sealed potentiometers. Never turn the red one (sensor voltage)! The potentiometer with
the green sealing lacquer is meant for adjusting the zeropoint (0.2 mA in the transmitter line or 0.2 V at test socket UM of
the GMA controller.
Adhere to the following procedure for checking the electrical zeropoint:
Is the detection point free from combustible or interfering gases ?

yes no Use calibration adapter to supply zero gas

(air without interfering gases) to the sensor.
The flow rate should be approx. 0.5 l/min.

Remove casing top of MWG.

Connect volt meter to U M at GMA or measure the current

at remote sensor (0.2 .. 1 mA line).

UM = 0.2 V (resp. 0.2 mA) ?

yes no Turn potentiometer "NULLPUNKT" at MWG

until UM = 0.2 V (resp. 0.2 mA for the
measured current).

Re-seal zeropoint potentiometer.

Re-fix casing top to MWG.

Check UN at GMA. U N should be 0 V.

Deviations can be adjusted at GMA controller.
Please refer to the operation manual of
your GMA control module.

Once the zeropoint adjustment is completed, re-seal the potentiometer.

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Check of Sensitivity
Before checking or adjusting the sensitivity, make sure that the electrical zeropoint has been set properly. Fix a test gas
adapter on the diffusion inlet for checking the sensitivity (please also refer to the operation manual of your GMA
controller) and select a suitable test gas. Then check which gas has been used for initial calibration of the transmitter. You
can see this information from the test report and from the type label at the transmitter. The test gas concentration should
be at least 20 % above the second alarm threshold. Please refer to the test report of the transmitter for the basic adjustment
of alarm thresholds and full scale. Do not use a test gas concentration with a balance of nitrogen.
Adhere to the following procedure to check the sensitivity:

Fix calibration adapter to remote sensor.

Supply test gas without pressure and with a flow rate of

approx. 0.5 l/min to MWG.

Within about 1 minute the display at the GMA controller must

have stabilized to the value of the test gas concentration supplied
to the remote sensor.

yes no Adjust the sensitivity at the controller.

Refer to the operation manual of your
GMA.

Disconnect test gas and calibration adapter.

Signal Transmission
Depending on the type of gas, the MWG 0238 Ex is characterized by different transmission of signals, i.e. the response
time, the signal value and the transmission curve may be different. For example: The transmitter provides an almost linear
signal for gases like propane, ethanol and nonane, but a non-linear one for methane.

Service
According to the German "Regulation for Explosion Protection", "UVV-Gase" and DIN 31051, service stands for
maintenance, inspection and repair of gas warning equipment. Regulation T023 of "BG Chemie" describes the relating
measures, among others requesting a regular function check.
This function check means:
• Check with alarm gas concentration
• Check of zeropoint and sensitivity (calibration)
• Check of response time
• Check of gas sampling and gas processing system (if any)
• Check of alarm signal activation
• Check of failure alarm
The check must be done by an expert, who has to report the result in written form.

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Maintenance and Inspection
Maintenance and inspection mean measures which ensure the planned status of the gas monitoring system. Maintenance
and inspection also mean a regular check and adjustment of zeropoint and sensitivity as well as a functional check of the
system. Generally the calibration intervals should not exceed 16 weeks. The function check is to be done before putting
the system in operation, and it has to be done at least once a year.

Depending on the ambient conditions, gas monitoring systems may show a different behaviour. It is important, therefore,
to do a visual check every day, particularly during the first few days after putting in operation (see T023).

• Check of gas processing system and filters (if any).

• Check of gas supply for soiling or obstacles (for correct measurement the gas supply to the sensor must not be
blocked).
Check with test gas.
• Sensors are subject to ageing and exhausting. Depending on their type and on their exposure to gas they are
more or less used up, so a sensitivity check can only be done with a suitable test gas after certain periods. The
sensitivity calibration is an expert calibration and is usually done by GfG's service or by authorized persons.
It is recommended to call GfG service for the above.

Functional Restrictions depending on Oxygen Concentration

Please note that measurement of gas and/or vapour concentrations in the range below 100 % LEL cannot be done
accurately, if the oxygen concentration is below 10 Vol.-%. In this case there is not sufficient oxygen to allow the
catalytic combustion at the sensor.

The EX-approval is not valid for operating the sensor in atmospheres with excessive oxygen concentrations.

Display Irritation due to Sensor Poisons

Certain parameters, known as „sensor poisons“ or „catalyst poisons", may affect the signal behaviour of the sensor. The
"sensitivity", i.e. the capability to emit signals, is being reduced. Sensor poisons are e.g. sulphur, lead and silicon vapours.
Usually these components are found very rarely or in very low concentrations only.
Please draw your special attention to any interfering gases, which might be present at your detection place and which
might affect the proper functioning of your gas monitoring system. Depending on the type of gas and its concentration,
this effect may be a slight loss of sensitivity or even a sudden death of the sensor.

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Trouble Shooting

Failure Reason Solution

Zeropoint cannot be adjusted Faulty sensor Replace sensor
Measurement value at control unit cannot be Faulty sensor Replace sensor
set to test gas concentration
Output current has fallen to 0 mA Faulty electronics Replace electronics
Cable cut Re-fix connection

Spare Parts
Part No.
Spare sensor MWG 0238 Ex MK 91 2238401
Spare electronics (potted block) with connections for MWG 0238 Ex 2238301

Accessories
Part No.
Screw-on calibration adapter (flow rate 0.5 l/min ± 0.1 l/min) 200209

Spare parts and accessories should be stored at ambient temperatures of 0 ... 30°C. Storage time should not exceed 5
years. For storing of spare sensors make sure that the ambient atmosphere is free from corrosive components and sensor
poisons.

Connection Diagram MWG 0238 Ex

Sensor MK 91

yellow
31
green 30
red
32
brown 3
green
0
white 2

24 V GND 0.2 - 1 mA Shield laid on

GMA 300 5 1 2 PG screwing
GMA 011 5 1 2
GMA 100 5 1 2 with back panel 2 from model 97 (blue)
GMA 100 3 0 2 with back panel 1 until model 96 (no colour)

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Lower Explosion Limit (LEL) of Tested Gases
Gas LEL acc. to EN 50054 LEL acc. to Redeker/Schön
(Edition 1991) (6. Extension)
Methane, CH4 5,0 Vol.-% 4,4 Vol.-%
Propane, C3H8 2,0 Vol.-% 1,7 Vol.-%
n-Nonane, C9H20 0,7 Vol.-% 0,7 Vol.-%
Ethanol, C2H5OH 3,3 Vol.-% 3,5 Vol.-%

Technical Data

Transmitter
Type: MWG 0238 Ex
Sensor Type: MK 91
Sensor Life: > 5 years
Gas: Combustible gases and vapours,
e.g. methane, propane, ethanol, n-nonane (see test report)
Range: 0 .. 100 % LEL
Response Time T90: < 30 s (depending on type of gas)
Detection Principle: Catalytic combustion
Gas Supply: Diffusion or
via calibration adapter (flow rate 0.5 l/min ± 0.1 l/min)
Supply Voltage: 15 .. 30 V DC
Output Current: 0.2 .. 1 mA
Climate Conditions
Storage Temperature: 0 .. 30 °C
Operational Temperature: -20 .. +40 °C (EX-protection)
-25 .. +55 °C (function tested)
Humidity: 5 .. 90 % r. h.
Atmospheric Pressure: 950 .. 1100 hPa
Climate Effect acc. to EN 50057
Temperature -10 .. +40 °C (20 °C) ± 3 % of full scale or ± 10 % of indication
Temperature -25 .. +55 °C (20 °C) ± 7 % of full scale or ±15 % of indication
Pressure 950 .. 1100 hPa (1013 hPa) ± 5 % of full scale or ±15 % of indication
Humidity 5 % .. 90 % (55 %) ± 5 % of full scale or ± 15 % of indication
Casing
Casing Material: Anti-static compound
Cable Gland: PG 11 screwing
Cable Type: 3 conductor 18 AWG shielded; LIYCY 3 x 1,5 mm
Cable Length: up to 1000 m
Dimensions: 110 x 75 x 55 mm (WxHxD)
Weight: approx. 600 Gramm
Casing Protection: IP 56
Approval
Classification: (Ex) es 3n G5
Type Certificate: BVS-Nr. T6947/Z1
Function Test: IBS/PFG-Nr. 41300596

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Index

Design, 5. Safety, 3
Detection Principle, 4 Sensitivity Check, 9
Dust, 6 Service, 9
Electrical Connections, 6 Technical Data, 12
Inspection, 10 Trouble Shooting, 11
Installation, 6 Type Label, 5
Maintenance, 10 Ventilation Conditions, 5
Mounting, 6 Water, 6
Mounting Position, 5 Zeropoint Check, 8
Operational Notes, 4
Putting in Operation, 7

Edition November 20019 - We reserve the right of modification

(MWG 0238EX-US)

1194 Oak Valley Drive, Suite 20, Ann Arbor, Michigan 48108 USA z www.gfg-inc.com
800-959-0329 z 734-769-0573 z 734-769-1888 fax

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