Witt MFA 9000 Bedienungsanleitung

Instruction Manual for

WITT-Analyser

MFA 9000

Issue: 15.10.2015

This issue is not subject to change management

Page 2 of 46

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8



: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

1 Table of contents

1Table of contents......................................................................................................... 2

2Notes on these operating instructions...................................................................... 4

2.1 Scope................................................................................................................................................... 4

2.2 Structure..............................................................................................................................................4

2.3 Rights to this manual...........................................................................................................................5

2.4 What symbols are used?.....................................................................................................................5

3Safety instructions and precautionary measures .................................................... 6

3.1 General safety guidelines.................................................................................................................... 6

3.2 Measurement of burnable gases......................................................................................................... 7

3.3 Liability for proper function or damage................................................................................................7

4Equipment description ............................................................................................... 8

4.1 Intended use of the analyser...............................................................................................................8

4.2 Functional description..........................................................................................................................8

4.2.1 Technical data of the analyser .................................................................................................9

5Set up and installation.............................................................................................. 10

5.1 Checking for transport damage.........................................................................................................10

5.2 Location for setting up....................................................................................................................... 10

5.3 Safety instructions for installation......................................................................................................10

5.4 Installation of gas pipes.....................................................................................................................11

5.5 Electrical installation..........................................................................................................................12

6Commissioning and operation................................................................................. 13

6.1 Safety instructions for commissioning and operation........................................................................13

6.2 Commissioning and operating of the analyser..................................................................................13

6.3 Calibration check / Calibration of the selected gas combination.......................................................14

6.4 Shut-down .........................................................................................................................................15

6.5 Malfunctions and rectification............................................................................................................15

6.5.1 Malfunction table .................................................................................................................... 15

7Operation of the analyser module ........................................................................... 17

7.1 The Front Panel.................................................................................................................................17

7.1.1 Process Alarm and System Error Indicators..........................................................................17

7.1.2 System Alarm Indicator (red) .................................................................................................17

7.1.3 System Maintenance Indicator (yellow) .................................................................................17

7.1.4 Operation Indicator (green)....................................................................................................17

7.1.5 RIGHT / Selection Key...........................................................................................................18

7.1.6 UP / Selection Key .................................................................................................................18

7.1.7 ENTER / Termination Key......................................................................................................18

7.2 Front Panel Menu..............................................................................................................................18

7.2.1 Warm up Screen ....................................................................................................................19

7.2.2 Operation Screen...................................................................................................................19

7.2.3 Top Level Main Menu.............................................................................................................20

7.3 Calibration .........................................................................................................................................20

7.3.1 Set Offset Gas Concentration................................................................................................20

7.3.2 Gain Gas Concentration.........................................................................................................21

7.3.3 Offset Calibration....................................................................................................................21

7.3.4 Gain Calibration......................................................................................................................22

Page 3 of 46

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8



: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

7.4 Diagnosis ...........................................................................................................................................22

7.4.1 Parameter Menu.....................................................................................................................22

7.4.2 Errors......................................................................................................................................23

7.5 Setup..................................................................................................................................................24

7.5.1 The Instrument Setup Menu...................................................................................................25

7.5.1.1 Unit Setup..................................................................................................................25

7.5.1.2 Measuring Gas Setup................................................................................................26

7.5.1.3 Response Time Setup...............................................................................................27

7.5.1.4 Multi Gas Mode List...................................................................................................28

7.5.2 The Relays Setup Menu.........................................................................................................28

7.5.2.1 Relay 1 Mode ............................................................................................................29

7.5.2.2 Relay 1 Threshold .....................................................................................................29

7.5.2.3 Relay 1 Hysteresis ....................................................................................................30

7.5.2.4 Relay 1 Failsafe / Not failsafe....................................................................................30

7.5.2.5 Relay 1 active/frozen during Calibration ...................................................................31

7.5.2.6 Relay 2 Mode ............................................................................................................31

7.5.2.7 Common Relay..........................................................................................................32

7.5.3 Analog Output Setup ..............................................................................................................33

7.5.3.1 Current Loop..............................................................................................................33

7.5.3.2 Analog Output 1 ........................................................................................................35

7.5.3.3 Analog Output 2 ........................................................................................................36

7.5.3.4 Adjust Loop................................................................................................................36

7.5.4Expert Setup...........................................................................................................................37

7.5.4.1 Parameter..................................................................................................................37

7.5.4.2 Access Modes...........................................................................................................38

7.5.4.3 Reset Functions ........................................................................................................39

7.5.4.4 Test of Relays, Analog Outputs and Connections ....................................................40

7.6 System Errors....................................................................................................................................41

8Servicing and maintenance......................................................................................42

8.1 Safety instructions for servicing and maintenance ............................................................................42

8.2 Repair advise.....................................................................................................................................42

8.3 Inspection and maintenance..............................................................................................................43

8.4 Check / replace filter in the gas inlet..................................................................................................43

9Technical Data...........................................................................................................44

9.1 Sensor Specifications ........................................................................................................................45

9.1.1 Performance ...........................................................................................................................45

9.1.2 Measuring gas / Carrier gas combinations and possible measuring ranges..........................45

9.1.3 Electrical (MFA 9000).............................................................................................................46

10 Attachment.................................................................................................................46

Page 4 of 46

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8



: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

2 Notes on these operating instructions

Thank you for having chosen a gas analyser from WITT-Gasetechnik! We are sure that you have

made the right choice.

With these operating instructions we would like to provide you with all information necessary for the

safe intended use of the equipment and to provide instruction for safe, correct setting up and instal-

lation, operation and checking of your analyser.

2.1 Scope

This document provides all instructions necessary for operation and maintenance of the WITT-

analyser.

Observation of the instructions given herein helps to maintain safe operating conditions, minimise

downtime through incorrect equipment operation and to ensure the service life and reliability of the

gas analyser.

Handling gases, in particular combustible and / or toxic gases, requires greatest care. For this rea-

son it is imperative that all personnel concerned read these operating instructions carefully and

completely before the gas mixer is installed and started-up so that problems / hazards during oper-

ation can be prevented.

A legible copy of these operating instructions shall be maintained at operating locations. Employ-

ees designated to operate the gas mixer shall be familiar with operating this equipment or shall

have been properly instructed to operate such equipment.

If unexpected malfunctions occur that you cannot rectify even with the assistance of these operat-

ing instructions, please contact your local service agent, or call WITT-Gasetechnik at the telephone

number given below to receive additional instruction on operation. Please state the serial number

of the analyser. The serial number is printed on the first page of these operating instructions or can

be read on the nameplate of the unit. Alternatively you can fax us a copy of the first page of these

operating instruction, together with a short problem description. Please make sure that you advise

of your company’s name and telephone number.

Our address is:

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8

D-58454 Witten

Germany

Tel.: +49 (0)2302 89010

Fax: +49 (0)2302 89013

Alternatively you can also contact us via e-mail (service@wittgas.com) or visit our homepage a

http://www.wittgas.com.

In the case of modification to the gas analyser these operating instructions cease to be applicable!

2.2 Structure

These operating instructions are sub-divided into several sections:

In the section “Notes on these operating instructions” the layout of the instructions manual is

explained and the terms and symbols used are explained.

In section “Safety instructions and precautionary measures” suggestions for safe usage of the

gas analyser are listed. You should pay particular attention to this sections as failure to ob-

serve the information given here can result in equipment damage and physical injury .

In section “Equipment description” the functions of the WITT analyser is explained based on

the functional scheme.

In section “Set up and installation” you will find information on the correct location for setting up

the analyser and notes on both the gas and the electrical installation.

Page 5 of 46

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8



: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

In section “Start-up and operation” you will learn how to proceed to analysis of your analysis

gas. Further you will learn how you can take the gas analyser out of operation e.g. for service

tasks.

In section “Operation of the analyser module” the handling of the integrated sensor / evaluator

unit is addressed.

Information on servicing tasks that you can perform yourself is given in the “Servicing and

maintenance” section. Here you will also find a failure location and correction table which will

help trouble-shooting in the event that any problems may occur.

As an appendix to these operating instructions you will find the technical data on the WITT gas

analyser, the schemes given in the technical data, along with drawings and a list of symbols.

This provides a short overview on the function and the controls of the gas analyser. You will

also find the numbers for the symbols on the function scheme and on the components them-

selves. With the aid of the list of symbols and the function scheme, you can identify compo-

nents in the gas analyser.

2.3 Rights to this manual

This manual is the copyright of WITT-GASETECHNIK GmbH & Co KG.

Without the prior written agreement of WITT-GASETECHNIK GmbH & Co KG these operating in-

structions are not permitted to be duplicated in whole or in part or be used in a manner contrary to

the company’s due interests.

It is only permitted to pass these operating instructions on to third parties in conjunction with the

gas analyser.

2.4 What symbols are used?

The warning symbol indicated hazards for personnel or the equipment.

It is imperative that these instructions are observed and followed.

The word “Warning” is placed in front of information indicating risk of personal injury or poten-

tially fatal hazards.

The word „Caution“ is placed in front of information indication potential equipment damage.

Note!

The pointing had marks general notes that explain operating procedures.

The „dot“ marks actions to be performed.

The „square“ is used to identify a list.

This symbol indicates that you should turn the page.

Option This symbol indicates possible alarm options or equipment options of the analyser.

Page 6 of 46

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8



: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

3 Safety instructions and precautionary measures

It is imperative to follow and observe the following safety instructions and precautionary measures.

They are intended to prevent hazards which might occur if the analyser is not operated properly. In

addition, all applicable national health and safety regulations and standards must be observed. For

example, on usage in Germany the „Unfallverhütungsvorschriften (UVV)“ and the safety regulations

issued by the “Berufsgenossenschaften” shall be observed, e.g.:

Unfallverhütungsvorschriften der gewerblichen Berufsgenossenschaften

(safety regulations issued by the german tradel associations)

a) BGV A1 Allgemeine Vorschriften(General regulations)

b) BGV A3 Elektrische Anlagen und Betriebsmittel (Electrical systems

and equipment)

c) BGR 500 Kap. 2.33 Gase (Gases)

No claim is made to the completeness of this list!

When handling the equipment the following shall be observed:

The operating instructions

All health and safety regulations and standards applicable in the country and the place of use.

All engineering rules and guidelines for safety and good workmanship.

The owner or user of the equipment should ensure that the analyser is operated by authorised per-

sonnel only. All employees designated to handle the analyser shall be properly instructed and ad-

vised of the applicable safety and health precautions. The WITT-analyser has been designed and

built according to the state of the art. It shall only be used for its intended purpose. Any operation

not conforming to the intended use or operation by inadequately trained personnel may result in

hazardous operating conditions.

3.1 General safety guidelines

Warning !

The equipment is only permitted to be operated by personnel who has properly instructed

to operate such equipment and who has read and understood these operating instructions.

Please ensure that all applicable national health and safety regulations and standards for the

safe handling of gases are observed (e.g. UVV’s (Unfallverhütungsvorschriften) = German

health and safety regulations).

For safety reasons all unauthorised modifications, or addition or removal of parts onto the

product are not permitted.

Any malfunction occurring during the operating of the analyser shall be corrected adequately

trained and qualified personnel only.

All maintenance and repair of the equipment shall be performed by adequately trained and

qualified personnel only.

During all maintenance and repair it must be ensured that the equipment is un-pressurised and

disconnected from electrical mains.

The material of piping, tubing, fittings, gaskets, and gasket and thread sealants, as well as the

material of all valves, gauges, regulators, and other accessories installed in the gas lines to

the analyser shall be suitable for service of the particular gas at the pressures and tempera-

tures involved.

The maximum allowable gas inlet pressures must not be exceeded. If necessary, safety relief

devices should be installed in the gas supply lines.

All electrical wiring to and from the analyser shall be visually inspected for external defects and

for evidence of possible internal damage. All gas lines hall be inspected for

evidence of possible internal or external damage and for leak tightness.

Page 7 of 46

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8



: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

All piping, tubing, and fittings shall be tested and proved leak tight on a regular schedule (e.g.

during every start-up) with inert gas to prevent the intake of ambient air during the measure-

ment. If a leak is detected, the defective item shall be immediately removed from service and

no employee may use it until repairs and tests necessary to render the equipment safe and

completely operative have been made. All repair shall be performed by personnel familiar with

proper practices only. When performing repair on the equipment the applicable national safety

and health regulations must be observed.

Please check also the sample gas supply lines.

Any operation not conforming to the intended purpose can result in hazardous operating conditions

which may lead to serious personal injury and / or loss or damage of equipment. Examples for op-

eration not conforming to the intended purpose are given below:

Use of the analyser with any other gases than those expressively listed in the Technical Data.

Use of the analyser with liquids.

Use of the analyser at ambient temperatures exceeding the temperature range specified in the

Technical Data.

Use of the analyser at gas inlet temperatures exceeding the temperature range specified in the

Technical.

The installation and operation of the analyser in areas with an explosion hazard.

The warranty granted for the gas analyser shall be invalidated in case of any unauthorised or im-

proper modifications, or addition or removal of parts onto the product, without expressive written

authorisation from WITT-GASETECHNIK.

3.2 Measurement of burnable gases

Caution!

When gas mixing units for flammable gases are use, the Explosion Protection Guidelines

(EX-RL) must be complies with.

Measurement of burnable gas / air mixtures is only allowed, if their composition doesn’t ex-

ceed the lower explosion limit (LEL).

We recommend to protect the analysis gas source by using a flashback arrestor in addition.

3.3 Liability for proper function or damage

The liability for the proper function of the instrument is irrevocably transferred to the owner or oper-

ating organisation to the extent the instrument has been serviced or repaired by personnel not em-

ployed or authorised by WITT-Service or when the instrument was used in a manner not conform-

ing to its intended use, or if the operation did not follow the applicable national health and safety

regulations.

WITT-GASETECHNIK GmbH & Co KG cannot be held responsible for damages arising from failure

to observe these operating instructions.

Page 8 of 46

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8



: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

4 Equipment description

4.1 Intended use of the analyser

The analyser is intended to measure the concentration of one gas in a mixture of inflammable, non-

corrosive, and non-toxic gases. On burnable gas / air mixtures the burnable gas concentration

must be below lower explosion limit.

For possible gas mixtures see Technical Data respective Section 4.2.

The analyser is only suitable to be operated at the conditions specified in the Technical Data (Sec-

tion 9). All information given in chapter 3 of these operating instructions as well as the safety pre-

cautions shall be observed.

4.2 Functional description

Please note !

The functional description is given with the aid of the enclosed functional schemes (please

refer to section 0). You will also find the numbers for the symbols on the function scheme

on the components themselves. With the aid of the list of symbols and the function scheme,

you can identify components in the gas analyser.

The gas analyser is intended to measure the concentrations of the following gases (measuring gas)

in the specified carrier gases:

Measuring

Gas

Carrier Gas Basic range Smallest range

Smallest sup-

pressed zero range

0% - 100%

0% - 0.5%

98% - 100%

0% - 100%

0% - 0.4%

99% - 100%

air

0% -4%

0% - 0.5%

N2or air

0% - 100%

0% - 0.8%

97% - 100%

0% - 100%

0% - 0.5%

98% - 100%

CO2

N2or air

0% - 100%

0% - 3%

96% - 100%

CO2

0% - 60%

0% - 10%

N2or air

0% - 100%

0% - 3%

96% - 100%

CO2

40% - 100%

80% - 100%

CH4

0% - 100%

0% - 2%

96% - 100%

CH4

0% - 100%

0% - 1.5%

97% - 100%

CH4

air

0% -4.4%

0% - 2%

0% - 100%

0% - 15%

85% - 100%

0% - 100%

0% - 2%

97% - 100%

0% - 100%

0% - 3%

97% - 100%

The build in sensor measures the thermal conductivity of the supplied analysis gas. Based on this

result the concentration of the measuring gas is calculated.

Note!

It is imperative to select the correct measuring gas / carrier gas combination.

Otherwise the shown concentrations will be wrong.

Note!

If the anayser is configured in “Multi Gas Mode” (MGM) the change over to another measur-

ing gas / carrier gas combination listed above is easy done with few key press.

The analysis gas can be supplied to the analyser.

pressurised via the inlet port “Analysis Gas” on the rear for permanent analysing.

For allowed inlet pressures see Technical Data.

Option unpressurised with aid of a pump via the inlet port “Lance” on the rear for permanent

analysing. For allowed inlet pressures see Technical Data.

Page 9 of 46

WITT-GASETECHNIK GmbH & Co KG

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: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

The calibration gases are supplied via the inlet port “Calibration gas” on the rear.

The respectively required calibration gases must be connected to this inlet port if a calibration is

executed. For valid inlet pressures see Technical Data.

Change over amongst the inlet ports occurs by means of the ball valve (47) at the front of the ana-

lyser.

Via pressure regulator (49) the gas to be analysed is supplied to the analyser module (56). The gas

concentration is shown digitally in % or ppm on the display of the analyser.

The MFA also provides standardised output signals, 0-10 V and 4-20 mA corresponding to the

measured gas concentrations. The respective electrical interface is located at connector X1.

The measured gas concentrations can also be recorded through the RS 232 C interface (connect-

or X2).

Option To achieve a faster reaction to fluctuating measuring gas concentrations in the analysis gas a

bypass can be installed after the pressure regulator ex factory. The bypass causes a higher flow

rate of the analysis gas which causes faster reaction.

A flow guard (58)is installed in the outlet of the analyser to continuously monitor the analysis gas

flow. In case that the flow fall short of a pre-defined threshold limit (e. g. due to a leak in the sample

gas supply line), an alarm will be triggered.

Option The alarm signals (e.g. min. / max. concentration alarm, analysis gas fow alarm) will be exported

through volt free contacts.

Note!

In order to supply sample gas to the analyser (e.g. from a WITT gas mixer or a gas mixture

receiver) it is necessary to install a suitable gas line between the equipment where the gas

sample is taken from and the corresponding analysis gas inlet port of the gas analyser. The

installation of a suitable gas pipeline has to be performed by the customer. The gas inlet

pressures must be within the inlet pressure limits specified in the technical data section.

Proper pressure reducers should be installed in the gas supply lines to the analyser, if nec-

essary.

Note!

The analyser needs to be calibrated during initial start-up and on a regular schedule during

operation. To calibrate the gas analyser, proper calibration gases for calibration point 1 and

calibration point 2 must be supplied to the analyser.

Note!

Provisioning of proper calibration gas cylinders (see Technical Data), and installation of the

cylinders to the gas analyser are a customer responsibility. The calibration gas inlet con-

nector is located on the rear of the analyser (labeled “calibration gas”). The pressure cylin-

ders must be equipped with proper cylinder pressure reducers. The calibration gas inlet

pressure must not fall short of the minimum inlet pressure and must not exceed the maxi-

mum inlet pressure specified in the Technical Data.

All built-in pressure regulators are factory-set to the delivery status.

4.2.1 Technical data of the analyser

The technical data of the gas analyser are specified in the attached Technical Data sheets (please

refer to section 9).

Page 10 of 46

WITT-GASETECHNIK GmbH & Co KG

Salinger Feld 4-8



: +49 (0)2302 89010

www.wittgas.com

Gas Safety- & Control Equipment

D-58454 Witten

Fax: +49 (0)2302 89013

[email protected]

5 Set up and installation

In this section you will find information on the proper location for setting up the gas analyser, and

notes on both the gas and the electrical installations.

5.1 Checking for transport damage

Please note !

Never transport the system in a tilted position. Perform a visual inspection for external

damage and damage to cables (nicks, damage to the insulation).

The gas analyser is supplied ready to use. It must be correctly transported.

5.2 Location for setting up

Please note !

Never expose the instrument to direct sunlight or large amounts of heat.

Please note !

Do not operate the instrument in an environment with increased electromagnetic activity

(outside the standardised limits).

Please note !

Observe safety distances when setting up.

The analyser should remain accessible for servicing.

place the undamaged instrument on a solid surface in a place protected from the weather and

secured against accidents.

during setting up observe the ambient conditions specified in the Technical Data (section 9)

(e.g., ambient temperature, a safety zone, humidity, dust, altitude).

5.3 Safety instructions for installation

Warning !

Prior to initial commissioning and after modification, repairs, or expansion of the system /

unit, the safety checks required by BGV A3 (reference to DIN VDE 0100, DIN VDE 0701, DIN

VDE 0702, etc.) are to be performed and logged. The checks encompass the inspection,

testing, and measuring of the effectiveness of protective measures (e.g. emergency stop

devices, interlocks, pressure switches, etc.).

If the operating organisation is not in a position to perform a check, a check in accordance

with DIN VDE 0702 can be performed by WITT Service.

Warning !

In accordance with BGV A3 a protective earth connection (PE connection ) of protection

class 1 must be provided.

Warning !

Following initial commissioning and after modification, repair, or expansion of a system /

unit, the connections and joints are to be checked for leaks to the atmosphere with inert

gas. For this process only use suitable leak testing procedures (never test with a naked

flame). If you find leaks, rectify them immediately; the applicable safety regulations are to be

observed during this process.

Warning !

The material for the gas pipes (pipes from the gas supply to the inlets on the gas analyser),

all fittings installed there (e.g. shut-off valves, manometers, etc.) and all sealing elements

there must be designed for the related type of gas.

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