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Om Mwg0238ex PDF
Om Mwg0238ex PDF
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
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
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:
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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).
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.
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.
-5-
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
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.
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.
31 30 32 2 0 3
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 ?
-8-
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:
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).
The EX-approval is not valid for operating the sensor in atmospheres with excessive oxygen concentrations.
-10-
Trouble Shooting
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.
yellow
31
green 30
red
32
brown 3
green
0
white 2
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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
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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