Ba CC28 en
Ba CC28 en
Ba CC28 en
CC28
Transmitter for flammable gases and vapours
GfG GESELLSCHAFT FÜR GERÄTEBAU MBH▐ KLÖNNESTRASSE 99▐ D-44143 DORTMUND▐ TELEPHONE +49 / (0) 2 31 / 5 64 00 –0 ▐ FAX +49 / (0) 2 31 / 51 63 13
[email protected] ▐ WWW.GASDETECTION.BIZ▐ AMTSGERICHT DORTMUND HR B 2742▐ CERTIFIED AS PER DIN EN ISO 9001:2000▐ ATEX QM CERTIFICATE
Content
Page
Warning:
The supply voltage must never exceed
30 V DC, not even in case of voltage peaks !
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For your Safety
According to § 3 of the law about technical working media, this manual points out the proper use of
the product and serves to prevent dangers. It must be carefully read by all individuals who have or
will have the responsibility for operating, using, servicing, maintaining and controlling this product.
Like any piece of complex equipment, this product will do the job designed to do, only, if it is
operated, used, serviced, maintained and controlled in accordance with GfG’s instructions.
The warranties made by GfG Gesellschaft für Gerätebau with respect to the product are voided, if it
is not operated, used, serviced, maintained and controlled as per GfG’s instructions. The above does
not alter statements regarding GfG Gesellschaft für Gerätebau's warranties and conditions of sale and
delivery.
Operational Hints
According to the relevant national regulations, gas warning instruments have to pass a function test,
done by a specialist, after having been installed but before put in operation. For Germany,
§ 56(2) "UVV Gase" (BGV B6 - formerly VBG 61) is applicable.
Before shipment, the transmitter has passed a function and display test, being calibrated with suitable
test gases. This does not, however, overrule the obligation of putting in operation with test gas
after the installation.
The transmitter CC28 (including CC28 D and CC28 DA) is approved for the use in explosion
endangered areas and is subject to an EC-Type Examination Certificate issued by EXAM BBG Prüf-
und Zertifizier GmbH, according to directive 94/9/EG (ATEX100a) with the following
Certificate: BVS 04 ATEX E 132 X
Labelling: ¯ II 2G EEx dem [ib] IIC T4 -20°C≤Ta≤+50°C
For the use in explosion endangered areas, with a measuring function for explosion protection, the
EXAM BBG Prüf- und Zertifizier GmbH issued an EC-type examination certificate for the transmitter
as per directive 94/9/EG.
Certificate: BVS 05 ATEX G 001 X
The test was based on the standards DIN EN 61779-1 "Electrical apparatus for detection and
measurement of combustible gases – General requirements and test methods" and DIN EN 61779-4
"Electrical apparatus for detection and mesurement of combustible gases – Requirements for the
operational behaviour of apparatus of group II with a detection range up to 100 % of the Lower
Explosion Limit" and the DIN EN 50271 „Electrical devices for the detection and measurement of
combustible gases, toxic gases or oxygen – Requirements and testing for warning devices using
software and/or digital technology“.
The EC-Type Examination Certificate BVS 05 ATEX G 001 X
! includes the following sensors, gases and detection ranges:
MK208-1, MK217-1, MK218-1 0 ... 100 %LEL CH4 (Methane), C3H8 (Propane)
0 ... 100 %LEL C2H4 (Ethylene), C3H8O (Isopropanol),
C3H6O (Aceton), C4H8O2 (Ethylacetate),
MK208-1, MK218-1 C6H14 (Hexane), C4H10O (Diethylether),
C9H20 (Nonane), C7H8 (Toluene)
MK217-1, MK218-1 0 ... 100 %LEL H2 (Hydrogen)
MK208-1, MK218-1 0 ... 4,00 %Vol. NH3 (Ammonia)
The functions marked (#) in this operation manual have not been part of the function and EC Type
Examination Certificate BVS 05 ATEX G 001 X.
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General Description
A fixed gas monitoring system consists of a transmitter and a controller (GMA), which are connected
by means of cable. The transmitter converts the gas concentration into an electrical signal and
transmits it over the cable to the controller for further processing.
Compared to the transmitter CC28, the model CC28 D provides an additional display, while the
CC28 DA features a display and a visual and audible alarm.
The comprehensive electronics allow easy operation and maintenance and also increases the
operational safety and accuracy. The special features of the transmitter are:
• Indication of concentration at display or at remote control
• Adjustment by means of touch keys or remote control, without opening of casing
• Compensation of temperature effects.
• Ex-Approval for use at temperatures from -20 to +50°C
• Function Approval for use at temperatures see sensor specification
• Smart Sensor system – sensor replacement by means of plug-in, pre-calibrated sensor
• Permanent status display (operation/fault) at transmitter
Detection Principle
The CC28 is operated on the detection principle "catalytic combustion" (fig. 1). 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
entering gas at its vatalytic layer. This increases the temperature at the sensor and results in 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) filament and is used for
compensation of environmental effects (e.g. temperature changes).
Gas
Active element
Fig. 1
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Design
CC28 D
Cable gland
Detection range
Display
Touch keys
Status display
Sensor casing
Potential equalization
Alarm LEDs
Connection for
Remote Control
CC28 DA
The type label shows the transmitter type. The sensor enclosure includes the sensor and the sensor
card, which carries the components for the sensor circuitry. For adjustment of electrical zeropoint and
sensitivity you can use either the built-in display or the remote control RC2. A secured key at the left
side of the transmitter allows a quick zero setting. The electronics on the main p.c.board converts the
sensor signal into a linear output signal of 4 .. 20 mA.
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Always connect the remote control RC2 only for servicing a transmitter without
! display.
The remote control RC2 may be used in explosion endangered areas.
As per EN 50014 table 4 for devices of group II the casing has been tested with an
! impact energy of 4 Joule (low degree of mechanical danger). Protect the casing
against very hard impacts.
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 transmitter at a place where the gases pass the sensor even in case of bad ventilation. If
necessary, use a smoke cartridge to check.
If the transmitter has to be installed at a position, where flow rates can be >3.0m/s, a wind protection
is necessary.
Generally a gas supply to the transmitter from below (sensor side) should be avoided.
Should the gas flow come from below, however, the displayed value may increased beyond the
tolerance as per EN61779-4.
Most combustible gases and vapours are subject to 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. A few gases have a density which is similar to that of air. For these
gases the transmitter should be mounted at the breathing height of approx. 1.5 m over the floor. The
following chart shows the relative density of some gases and vapours. More detailed information is
available on request.
-8-
The transmitter is to a great extent protected against the ingress of water and dust (IP 64). Special
accessories are available to provide additional protection for very difficult conditions. Please contact
GfG for detailed information.
Mounting
When deciding on the position for the transmitter, make sure that it is always accessible for service
and maintenance. The transmitter must be mounted with the sensor showing to the floor.
For connecting the transmitter to the controller refer to the connection diagram (page 28). For
mounting the transmitter remove the four special screws and take the casing top off. Fix the casing by
means of two screws.
The printed circuit board inside the casing is potted in epoxy resin (encapsulation "m"). The side-
mounted terminals (increased safety “e”) are used for connecting the controller.
Cable gland
1 2 3 4 Transmitter
Type label
24V Ground 4..20mA
Buzzer
GMA Controller
Sensor
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In case the transmitter is not operated on a GMA controller, the operational voltage of the mains unit
must not exceed 30 V DC.
Fix the casing top with the four special screws after installation.
The user must make sure that even in case of failure the voltage at the
! transmitter terminals does not exceed the max. fault voltage Um indicated on
the type label.
Um = 250 V AC resp. Um = 45 V DC
Putting in Operation
The transmitter CC28 has passed quality control for correct operation and display before delivery.
The calibration was carried out with the appropriate test gases. Depending on transport, mounting
and ambient conditions however variations may occur. Therefore the gas warning system has to be
taken into operation and function checked by the manufacturer or by a professional which is
authorized by the manufacturer, according to BGV B6 (former VBG61-gases), resp. BG Chemie
guideline T 023.
After having been turned on, the unit needs a few minutes for:
• the self-test, checking the program and the working memory,
• entering and evaluating of transmitter parameters with simultaneous memory check,
• entering and evaluating of sensor parameters with simultaneous memory check,
• warming-up the sensor.
Within 6 seconds during the warm-up period the transmitter checks the memory first. The current
interface provides 0 mA and both the yellow and the green LED are lit. Then the output signal turns
to 1.6 mA, the fault LED lights up and the operation LED flashes slowly. The display reads LoAd,
then AdJ. Once this is completed, the display of the CC28 D and CC28 DA resp. of the remote
control RC2 at the CC28 reads the unit, the type of gas, the detection range, the alarm thresholds and
the calibration gas concentration one after the other. If the automatic reset of the ambiguity alarm is
activated, this is indicated last, and the fault LED flashes rapidly.
Once the warm-up is completed after 2 minutes, the CC28 turns to detection mode automatically.
During this period the display reads a countdown of the seconds from 120.
If a fault is recognized during this time, the transmiter turns to fault mode. The current interface
provides 1.2 mA and the display indicates a fault message (SYS ERR.). The status and fault LEDs are
lit constantly. The alarm LEDs and the display illumination will flash alternately.
Once the sensor has been replaced after a sensor fault (SENS ERR.), the transmitter is automatically
re-started. In case of sensor replacement adhere to the safety notes for electrical connections in
explosion endangered areas (see page 7).
Note:
After the initial putting into operation resp. after a sensor replacement it might be possible that the
value falls below or exceeds the detection range (____ resp. ----). In this case the zeropoint of the
transmitter must be corrected by starting the automatic zeropoint adjustment (ZERO).
Should SCAL ERR. occur (resettable), re-calibrate the sensor (SPAN) or, if necessary, enter the
service menu to adapt the detection range of the sensor to the hardware.
Allow a warm-up time of at least 30 minutes before you check the zeropoint. Once the warm-up is
completed, the display should read 0. Otherwise activate the (automatic) zeropoint adjustment
(AutoCal adjustment see page 11).
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Detection Mode
In detection mode the display shows the current gas concentration.
The display reading is always identical with the display of the remote control connected!
The detection is provided by continuous monitoring. Exceeded thresholds (only for model CC28 DA)
and ambiguous sensor signals are recognized immediately and reported visually by the CC28.
Features of the electronics like parameter memory or sensor function are permanently monitored.
During trouble-free operation the green LED “ON“ is lit, the yellow fault LED is not lit.
To indicate that the CC28 is in detection mode the display alternates every minute to
! unit and type of gas.
ZERO
activated for 2 seconds, and all segments of the display (8.8.8.8) are shown. For the CC28 DA the
alarm LEDs and the buzzer are activated additionally.
Display of Operational Parameters
During detection mode press key briefly for the automatic indication of the following operational
INFO
SPAN
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Value in “measuring unit” means that the displayed figure stands for either % LEL or Vol.%. Reading in
Vol.% applies only to the gas ammonia.
Alarm Threshold (only for type CC28 DA)
The CC28 DA provides two alarm thresholds. An alarm is triggered, if the gas concentration exceeds
the preset limit value (adjustment in service menu). Exceeded thresholds are indicated by means of
the LED bar over the display, the display illumination and a buzzer. When the first threshold (A1) is
exceeded, the display illumination and the LED bar are alternating in low frequency. The display
reads the currect measurement value and A1 alternately.
Exceeding the second threshold (A2) activates the display illumination, the LED bar and the buzzer
alternating in high frequency. The display reads the current measurement value and A2 alternately.
Resetting the threshold alarms can be done automatically or manually, i.e. non-latching or latching
alarms, depending on the function setting in the service menu.
The function of the buzzer is fixed and cannot be changed: Activation by alarm 2, automatic reset
when the concentration has fallen below the second threshold, always resettable.
Pressing key allows to reset a latching alarm, if the gas concentration has fallen below the alarm
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threshold.
Ambiguity Alarm
Due to the detection principle it might be possible that a very high gas concentration dissipates the
oxygen in the cell, thus resulting in a lack of oxidation and a reduced signal, although the sensor is
exposed to a gas concentration which is clearly above its detection range. For avoiding false signal
evaluation, the CC28 provides a warning from ambiguous sensor signals.
This alarm is triggered by exceeding of 112 % LEL and by recognition of a defined rise of signal
(Delta Alarm).
The ambiguity alarm is indicated by the fault LED flashing quickly. The CC28 DA additionally
activates the display illumination, the LED bar and the buzzer, alternating in high frequency. The
display also flashes ---- (also refer to Exceeding Detection Range).
On principal the ambiguity alarm is latching and can only be reset by pressing key (or by
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pressing the AutoZero key at models without display). The measurement value must be within the
detection range.
Should such an alarm be triggered by a high gas concentration, make sure to check ther zeropoint and
the sensitivity of the sensor, once the alarm was reset. Take into consideration that zeropoint and
sensitivity may vary considerably during the first few days.
Sensor Life
Catalytic combustion sensors are subject to a limited lifetime. The expected lifetime of the sensor
used in the CC28 for combustible gases is approx. 3 to 5 years, depending on operational conditions.
A few months before the lifetime expires, the transmitter indicates that the sensor has to be replaced
with the next service. The message is indicated by the fault LED flashing regularly and by the the
alternating reading of CHNL
M SENS and the measurement value. If the sensor is not being replaced
within the next few months, the transmitter turns off the detection mode, when the sensor is
exhausted. The current interface provides an output of 1.2 mA, the yellow fault LED lights up and
the green operational LED shortly flashes in intervals.
Fault
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A fault of the transmitters is indicated by the constantly lit yellow fault LED, the current interface
provides 1.2 mA an error message is shown in the display (SYS ERR. or SENS ERR.).
Fault report is given, if:
• the sensor or the circuitry in the transmitter is defective;
• the sensor is missing;
• the self-test of the unit recognizes a failure.
For further causes see „Special Status and relevant Error Messages“ on page 21.
After the fault is cured, the yellow fault LED expires.
ZERO
During the whole procedure the current interface provides 2.02 mA and the fault LED
flashes slowly.
The display shortly reads CodE.
2. Enter the numeric access code 0011 (resp. 0055). Use keys and to change the
TEST INFO
ZERO SPAN
MENU
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3. After correct entering the display shows alternating the current measurement value and the
reading ZERo. When the measurement value remains constant for a defined time interval, the
display changes to read ZERo and ADJ for a few seconds, and the hardware internally
regulates its zeropoints. Once the regulation is completed successfully, the new zeropoint is
set, the AutoCal program is automatically terminated with the display reading SAUE, and the
transmitter returns to detection mode.
Notes:
If the current measurement value is beyond the allowed tolerances for the relevant access code, the
display reads fAi L shortly in step 3, and the transmitter returns to detection mode.
The AutoCal program can be shortened by long-term pressing key or the AutoZero key, while the
TEST
ZERO
measurement value is checked for constancy. Then the hardware starts to regulate/adjust the zeropoint
directly.
For leaving the AutoCal program without zeropoint adjustment, press key or the AutoZero key
TEST
ZERO
Once the quick adjustment is completed, remember to screw the lock screw
! and its gasket in again to its stop!
All error message have to be confirmed with or with the AutoZero key at the left side of the
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casing. After confirmation the transmitter returns to detection mode without zeropoint adjustment.
SPAN
as Vol.%) of the parameter (CL MAS). The value of the test gas concentration should, if possible, be
20% above the main alarm threshold.
Many combustible gases are also toxic. Handling toxic gases requires special
! safety precautions.
TLVs give hints for hazards caused by toxic gases. For particularly toxic matters,
e.g. benzene or ethylene oxide, a reference gas is recommended for calibration.
For checking, resp. adjusting the display sensitivity (span) a calibration adapter has to be attached to
the sensor holder. Via this adapter the calibration gas can be supplied to the sensor at atmospheric
pressure with a flow of approx. 0.5 l/min., while the display has to be observed. Is there a deviation
between the displayed value and the actual calibration gas concentration a span calibration is
necessary. If the reading is constant the adjustment can be done using the AutoCal feature. The
AutoCal program automatically adjusts the measuring signal to the calibration gas. Follow the order
below:
→ Before a calibration is started, make sure that the sensor is free from calibration gas
(display 0).
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1. Press key for at least 3 seconds to activate the AutoCal program. During the whole
INFO
SPAN
procedure the current interface provides 2.0 mA and, the fault LED flashes slowly. The
display shortly reads CodE.
2. Now enter the numeric access code 0011. Use keys and to change the figure at the
TEST INFO
ZERO SPAN
MENU
3. After correct entering, the display shows the current measurement value and the message
SPAN alternately. The transmitter now waits for a clear rise of concentration. When the
measurement value remains constant during a defined time interval (after a fixed time of
2 minutes), the value is used to update the sensitivity (display SAUE). This updates the
calibration data successfully. The transmitter, however, does not return to detection mode yet,
since the presently supplied test gas concentration would activate an alarm. The transmitter
remains in calibration mode until it recognizes a falling gas concentration and then a
stabilization of the display value. The display alternately reads ZERo and the current
measurement value. Once the value has stabilized, the transmitter returns to detection mode.
If the unit does not notice a reduced gas concentration resp. a stabilized measurement value, it
returns to detection mode after max. 3 minutes.
At any time the AutoCal program can be shortened by long-term pressing key . The display
INFO
SPAN
shortly reads SAUE and the measurement value is accepted directly as the sensitivity update.
To leave the AutoCal program without sensitivity adjustment, press key only briefly. The
INFO
SPAN
The error messages have to be confirmed with key . The transmitter returns to detection mode
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The standard service menu is activated with code 1100 . It allows to adjust the calibration gas
concentration and, with model CC28 DA, all values which are related to alarms.
The extended service menu is activated with code 5050 . It allows to also change the type of gas,
full scale and ambiguity alarm. This code should only be used by specially trained safety personnel.
Activation of the extended service menu is only possible, if it has been authorized by GfG during the
basic setting of the transmitter.
For transmitters with function test (labelling BVS 05 ATEX G 001 X): The extended
service menu allows adjustments which may become the function test void !
! If the full scale value of 100 % LEL is changed to a different value, or if the gas is
changed from a certified gas (see page 3) to a non-certified one, the function test becomes
invalid.
When using the keypad at the display or at the remote control follow the order below:
1. Press key for at least 3 seconds. The transmitter turns to service mode. The display shortly
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reads CodE.
2. Enter the numeric code1100 (resp. 5050). Use keys and to change the figure at the
TEST INFO
ZERO SPAN
MENU
ZERO SPAN
menu points.
To activate a selected menu point press key briefly. For parameter adjustment use keys
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and . For leaving the menu point briefly press key again.
TEST INFO QUIT
CL
MAS Setting of calibration gas concentration
Menu point L
MAS – Change of type of gas (only possible in extended menu)
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This function allows to select explicitly all parameters for different types of gas, which are stored in
the sensor. You can see only those gases which the sensor is scheduled for.
1. Activate of menu point L
MAS.
2. The display shows the presently set type of gas.
This reading can also be selscted in the standard service menu.
3. Use keys and to set the gas.
TEST INFO
ZERO SPAN
In the standard service menu the display shortly reads fAi L and then the presently set
type of gas (step 2).
4. Select the desired type of gas and confirm by pressing key briefly.
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If the type of gas has been changed several times before the user returns to a gas which was already
parameterized before, the transmitter takes over those parameters which were stored by the user
before.
If the type of gas has been changed and after a restart, the stored standard parameters (see table on
page 30) are taken over for a type of gas which is selected for the first time.
When the type of gas was changed, the zeropoint has to be adjusted in any case by means of the
AutoCal function. The sensitivity of the sensor for the new gas is to be checked as well and to be
adjusted by means of the AutoCal function, if necessary.
The different gases will be indicated either as shown in the list below.
C6H6 Benzene
Menu point SCAL – Adjustment of full scale deflection (only possible in extended menu)
The detection range can be set to 50, 75 or 100 % LEL. The detection range for ammonia (4 Vol.%)
cannot be changed.
Follow the 5 steps described below:
1. Activate menu point SCAL.
2. The display shows the presently set full scale value.
In the standard service menu the display reads "100" for 100 % LEL.
3. Use keys and for parameter adjustment.
TEST INFO
ZERO SPAN
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In the standard service menu the display shortly reads fAi L and then the current value (step
2).
4. For leaving menu point SCAL press key briefly.
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Notes:
The EC-Type Examination Certificate BVS 05 ATEX G 001 X is only valid for a detection range
with a full scale of 100 % LEL resp. 4.00 %Vol. NH3.
If the full scale value is changed from 100 % LEL to a different value, the function test becomes
invalid.
The change of the detection range is mainly a change of the current output. The standardized output
signal of 4 – 20 mA is used for the new, reduced detection range. The display indication does not
change. A detection range of 0 – 50 % LEL results in the figures from 0 to 50.0 in the display (i.e. the
reading remains at % LEL).
Overrange and underrange refer to a percentage of the detection range, i.e. with a detection range of
0 – 50 % LEL the ambiguity alarm is triggered at approx. 56 % LEL ! Alarm thresholds are indicated
in % LEL (not in % of detection range) !
After a reduction of the detection range make sure that the alarm thresholds are checked and, if
necessary, corrected. If alarm thresholds were adjusted to a value beyond the new full scale
deflection, they are automatically set to the current full scale value.
Should the circuitry recognize that the currently set detection range cannot be monitored any longer
(sensor too sensitive for the measurement circuit, see also SCAL ERR.), the display turns
automatically to the highest possible value when entering this menu point.
Menu point AM"B. – Adjustment of the automatic reset of the ambiguity alarm (only possible in
extended menu)
ZERO SPAN
In the standard service menu the display shortly reads fAi L and then the current status (step
2).
4. Press key briefly to leave menu point AM"B. .
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For the proper functioning of the automatic reset of the ambiguity alarm
! the zeropoint adjustment of the CC28 must have been done correctly.
Notes:
This function is only active for the gases methane, propane and hydrogen. Should adjustment
AM"B. oN be selected, but none of the above gases is measured, the display order does not include the
reading AM"B. after pressing the info key.
The activation of the automatic reset is blocked until the next zeropoint adjustment, if the sensor has
been replaced or if the type of gas has been changed in the extended service menu !
As Info the display reads: AM
"B. -oN- instead of AM"B. oN.
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The final reset is only enabled after a zeropoint adjustment has been done with the sensor plugged in.
MENU
2. The display reads the currently set value for the calibration gas concentration in % LEL (for
ammonia in Vol.%).
3. Use keys and to set the parameter.
TEST INFO
ZERO SPAN
MENU
5. If necessary, store the parameter: Select menu point SAUE and confirm with .
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MENU
Menu point A1, A2 – Adjustment of alarm thresholds (only visible at model CC28 DA)
The alarm thresholds can be set throughout the detection range; A1, however, cannot be set to a
higher value than A2. Setting a threshold to 0 de-activates the alarm. A2 can only be set to 0 when
A1 was also set to 0 before.
1. Activate menu point A1 resp. A2.
2. The display reads the presently set value for the alarm threshold.
3. Use keys and to set the parameters .
TEST INFO
ZERO SPAN
MENU
Menu point H1, H2 – Adjustment of hysteresis (only visible at model CC28 DA)
This function allows to adjust the hysteresis, i.e. the difference between activation and de-activation
of the alarm thresholds. The setting of the parameter is done in % LEL and is restricted to max. 5 %
LEL (for ammonia in Vol.%, max. 0.2 Vol.%).
Example:
At a CC28 with the detection range 0 .. 100 % LEL the hysteresis for alarm 1 was set to 4.0, i.e. the
alarm de-activation point for the alarm is 4 % LEL below the alarm threshold.
This results in the following alarm triggering:
Alarm 1 = 10 % LEL
Alarm activation ≥ 10 % LEL
Hysteresis H1 3 % LEL
Alarm de-activation ≤ 7 % LEL
ZERO SPAN
MENU
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Menu point F1, F2 – Adjustment of alarm functions (only visible at model CC28 DA)
ZERO SPAN
MENU
Menu point iNFo – Indication of sensor type (MK number), sensor serial number, software
version, serial number and code
1. Activate menu point iNFo.
2. One after the other the display reads the MK number (S.typ xxx), the sensor serial number
(S.nr xxxx), the software version (SoFT xxxx), the 8-digit serial number of the transmitter in
2 parts (F.nr- xxxx F.nr_ xxxx) and a code (CoDE xxxx).
The figure indicated as CoDE is a (only temprorarily valid) code, which allows the activation of the
zeropoint adjustment without any limitations (refer to Check and AutoCal Adjustment of Zeropoint).
1. 2. Press key briefly to leave the service menu without storing of parameter
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changes.
Menu point SAUE – Leaving the service menu with with storing
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Notes:
When the type of gas is changed, confirming the menu point activates the storing immediately and
enables the parameters for this type of gas.
Apart from this exception you can change several parameters one after the other without storing in between.
One collective storing procedure at the end of the settings saves all parameters which have been changed in
the service menu.
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Sensor Replacement
The sensors MK 208-1, MK 217-1 and MK 218-1 are supplied with an EEPROM which stores the
sensor data (serial number etc.), the calibration data and the adjustable types of gases. The sensors are
fit to the transmitter by means of a plug connector.
For replacing the sensor unscrew the allen screw side-mounted at the impact protection (see picture
on page 5 sensor casing). Open the Transmitter casing and use suitable tool to push the sensor
downward. The new sensor slides in the casing from below; the sensor label must show forward. The
transmitter provides a lock against rotation, which makes sure that the sensor always fits properly.
Once the sensor is locked in place, secure it with the allen screw. When opening the casing take note
of the safety measures in Ex areas (see page 7).
Once the sensor has been removed, the yellow fault LED lights up and the current output signal falls
to 1.2 mA. At model CC28 D and DA the display reads SENS ERR.1 , and at the CC28 DA the alarm
LEDs flash slowly.
When the new sensor has been fit, the transmitter does an automatic re-start. The display reads RSET
and then TEST (memory test; current output signal of 0 mA). Then the warm-up period is started:
The display reads LoAd , the green LED flashes and the current interface provides an output signal of
1.6 mA. If all data of the new sensor match the stored data for the measurement task, the transmitter
turns automatically from warm-up to detection mode. Since the hardware zeropoints of the different
sensors resp. sensor types may differ considerably, a sensor replacement must always be followed by
a zeropoint adjustment ZERo (see page 11). There are no restrictions for the first zeropoint
adjustment after a sensor replacement. Zeroing is even possible at values far beyond the detection
range (____ resp. ----).
MENU
extended service menu (see page 14/15); menu point L MAS (appears immediately after the code)
shows the types of gases the new sensor is specified for. If the user selects a type of gas and confirms
his choice by pressing key , the transmitter is converted to this gas and re-started. Then the
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zeropoint ZERo and the sensitivity SPAN have to be set for the new type of gas (see page 11-14).
CHEC SCAL New sensors, no matter for which gas, are always pre-set to the detection range of 0 –
100 % LEL. During the warm-up period the transmitter recognizes, if the detection range which was
set last, and the pre-setting of the sensor for the measurement gas do not match. The green LED turns
from flashing slowly to a twin flash (2 short flashes). The yellow fault LED remains lit, the current
interface still provides 1.6 mA, and the display reads CHEC SCAL . For check and, if required,
change of the detection range setting directly from the fault status, you may press key (longer
QUIT
MENU
than 3 seconds) and enter the code 1100 or 5050 to enter the service mode (see page 14/15), which
allows to do the adjustment under menu point SCAL. After leaving the menu with SAUE the warm-
up procedure is continued.
Example:
If the detection range SCAL was set to 50 % or 75 %, a new and unused sensor will cause the display
to read CHEC SCAL .
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If the transmitter is set to 100%, but the fit sensor had already been used in another unit which was
set to 50 % or 75 %, the display will also read CHEC SCAL .
Notes:
After the sensor was put into operation for the very first time, or when the sensor has been replaced,
the transmitter may indicate an overrange resp. underrange (____ resp. ----). In this case the
automatic zeropoint adjustment (ZERO) has to be activated to correct the zeropoint.
Should SCAL ERR. occur (resettable), the sensor must be re-calibrated (SPAN) or, if necessary, the
detection range of the sensor must be adapted to the hardware in the service menu.
Allow a warm-up time of at least 30 minutes before you check the zeropoint. Once the warm-up is
completed, the display should have stabilized to read 0. Otherwise activate the (automatic) zeropoint
adjustment (Adjustment see page 11).
Once the sensor was replaced (no matter which service and adjustment interval is
being considered), you have to effect a complete service and adjustment according to
! DIN EN 50073 para. 6.4.3.
Transmission Characteristics
Depending on the type of gas the transmitter is subject to different transmission characteristics.
Different gases may show different response times. The transmission signal is always proportional to
the gas concentration
-22-
Special Status and relevant Error Messages
The table below describes those special status which cause the yellow fault LED to be lit
permanently. For a better diagnosis of a transmitter without display you should either read the error
messages below from the remote control RC2 or analyse the values from the current output.
green yellow
No Display
LED LED
Output Cause Action
01 "TEST" On On 0 mA Memory test when booting the system finishes automatically after 6
seconds
02 "Load" flashing On 1,6 mA Booting the system at start or after turns to sensor warm-up
Operational change of gas (see page 8) automatically
para.
" AdJ "
03 Countdown flashing On 1,6 mA Sensor warm-up period finishes automatically after 120
of seconds seconds.
10 "TEST" Off glows 0 mA Too low supply voltage increase supply voltage
flashing
11 "CHNL
M" flashing On 1,2 mA Sensor lifetime expired Replace sensor
"SENS" shortly
(single
flash)
12 "CHEC" Twin On 1,2 mA After sensor replacement: Replace sensor again or
"L flash Sensor is not specified for the gas select different gas; see page 19
MAS "
„Sensor Replacement“
13 "CHEC" Twin On 1,2 mA After sensor replacement: Check and, if necessary, change
"SCAL" flash Detection range setting of sensor and detection range SCAL
transmitter do not match for the gas See page 19 „Sensor Replacement“
14 " SYS " Off On 1,2 mA Fault during RAM access Re-start transmitter. If error is
"ERR.1" reported again, replace transmitter
15 " SYS " Off On 1,2 mA Fault during ROM access Re-start transmitter. If error is
"ERR.2" reported again, replace transmitter
16 " SYS " Off On 1,2 mA Fault during EEPROM access (internal) Re-start transmitter. If error is
"ERR.3" reported again, replace transmitter
17 " SYS " Off Off 1,2 mA Reserved Re-start transmitter. If error is
"ERR.4" reported again, replace transmitter
18 " SYS " " SYS " On 1,2 mA Fault during regulation of sensor voltage
"ERR.5" "ERR.5"
19 Off Off On 1,2 mA Fault during regulation of hardware Re-start transmitter. If error is
zeropoint reported again, replace transmitter
20 " SYS " Off On 1,2 mA Temperature measurement is not
"ERR.7" plausible
21 "SENS" "SENS" On 1,2 mA Sensor is missing
Fit sensor (automatic re-start)
"ERR.1" "ERR.1"
22 "SENS" Off On 1,2 mA Fault during EEPROM access (sensor) Replace sensor (automatic re-
"ERR.2" start)
23 "SENS" Off On 1,2 mA Wrong sensor/parameter memory
"ERR.3"
24 " ADv " Off On 1,2 mA Error A/D converter (sensor voltage) Re-start transmitter.
"ERR.1" If error is reported again, replace
transmitter.
25 " ADv " " ADv " On 1,2 mA Error A/D converter (NTC) Re-start transmitter.
"ERR.2" "ERR.2" If error is reported again, replace
transmitter.
26 " ADv " Off On 1,2 mA Error A/D converter (sensor current) Re-start transmitter.
"ERR.3" If error is reported again, replace
transmitter.
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Messages in detection mode
green yellow
No Display Output Cause Action
LED LED
30 " ---- " On flashing 22 mA Gas concentration has exceeded Caution Explosion hazards!
permanent quickly detection range of transmitter Latching alarm. Measures see page
electronics. Ambiguity alarm! 9 and 10
31 " ---- " On flashing 22 mA Overrange (> 112 %) Caution Explosion hazards!
flashing quickly Ambiguity alarm! Latching alarm. Measures see page
9 and 10
32 Value On Off 20–22 mA Overrange Caution Explosion hazards!
alternating with (between 100 % and 112 %)
" ---- "
33 Value On Off 4–20 mA Gas concentration has reached resp. Reduce gas concentration!
alternating with exceeded the 2.alarm threshold. Latching alarm as standard.
" A2 "
34 Value On Off 4–20 mA Gas concentration haa reached resp. Reduce gas concentration!
alternating with exceeded the 1.alarm threshold. Non-latching alarm as standard.
" A1 "
35 Value On Off 4–20 mA Cautionary warning message: QUIT
Reset with
Hardware/sensor combination cannot
MENU
alternating with
a) Re-calibrate sensor (SPAN)
"SCAL" recognize full scale deflection
b) Adapt resp. Reduce detection
" ERR." range in service menu.
36 Value On flashing 4–20 mA Cautionary warning message: Replace sensor during next service
alternating with shortly End of sensor life within the next few
"CHNLM" (single months
"SENS" flash)
37 Value On Off 4–20 mA Normal detection mode
38 Value On Off 2.8–4 mA Detection range is deviated between
-7.5% and 0.0%
39 Value On On 2.8 mA Detection range is deviated between Adjust zeropoint
alternating with -8.0% and –25.0%
" ____ "
40 " ____ " On On 2.8 mA Detection range is deviated Adjust zeropoint and sensitivity
permanent < -25.0%
41 " ____ " On On 1.2 mA Measuring signal has fallen below Adjust zeropoint and sensitivity
permanent detection range of transmitter
electronics.
Repair
Repair comprises all repair and replacement work. It must only be done by the manufacturer and by
persons who are authorised by the manufacturer – i.e. by GfG Gesellschaft für Gerätebau mbH. Only
original spare parts and original assemblies are allowed to be used, which are tested and authorised
by the manufacturer.
-26-
Function Restrictions depending on Oxygen Concentration
Take note, that the measurement of gas and/or vapour concentrations in the range up to 100 % LEL
cannot be done accurately, if simultaneously the oxygen concentration is less than 10 Vol. %. In this
case the pellistor suffers from a lack of oxygen necessary for the „catalytic combustion“.
The Ex approval is not valid for using the transmitter in oxygen enriched atmospheres with
concentrations of more than 25 Vol.% oxygen.
Trouble Shooting
Failure Cause Solution
Zeropoint cannot be adjusted Sensor is faulty Replace sensor
Sensitivity cannot be adjusted Sensor is faulty Replace sensor
Output current is fallen to 0 mA Fuse is blown Replace fuse
Line is interrupted Re-connect
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Spare Part List
Part-No.
Cap and minor parts for 5 units 2800301
Casing top screws for 5 units 2800302
Casing bottom for CC28 2800303
Casing top with display for CC28 D and CC28 DA 2800304
Casing bottom without buzzer for CC28 and CC28 D 2800305
Casing bottom with buzzer for CC28 DA 2800306
Main module without alarm (Um=45V) for CC28 and CC28 D 2800307
Main module without alarm (Um=250V) for CC28 and CC28 D 2800308
Main module with alarm (Um=45V) for CC28 DA 2800309
Main module with alarm (Um=250V) for CC28 DA 2800310
Display module without alarm for CC28 D 2800311
Display module with alarm for CC28 DA 2800312
MK 208-1 Spare sensor for combustible gases 2800750
MK 217-1 Spare sensor for combustible gases 2800751
MK 218-1 Spare sensor for combustible gases on request
Accessories
Part No.
Remote control RC2 2800201
-28-
Connection Diagram CC 28 - with 4 .. 20 mA Output
brown
1
green 2
3
white 4
Shield laid on
screwing
24 V GND 4 – 20mA
GMA101 5 1 2
GMA100 5 1 2 with motherboard
from 1997
GMA104 55 53 54 connection to
58 56 57 multiplexer
61 59 60
64 62 63
GMA301 5 1 2
GMA304 55 53 54 connection to
58 56 57 multiplexer
61 59 60
64 62 63
GMA41 28 29 30
GMA81 (A) 1 2 3
GMA43 19 20 21 connection of up to 3
22 23 24 transmitters
25 26 27
19 20 21 connection of up to 4
GMA44 and transmitters
22 23 24
GMA84 25 26 27
28 29 30
GMA88 19 20 21 connection of up to 8
: : : transmitters
40 41 42
For connection to the GMA … controller please refer to the operation manual of the relevant GMA.
According to EN 50014 table 4 for devices of group II the casing has been tested
! with an impact energy of 4 Joule (low degree of mechanical danger).
Protect the casing against very hard impacts.
-29-
Terminal Diagram MWG CC28
3 – wire connection
1
U= 15.0 V - 30.0 V *
2 CC28
R1 3
I = 4 - 20 mA
4
4 – wire connection
1
U= 15.0 V - 30.0 V *
2 CC28
3
R1
I = 4 - 20 mA
4
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Sensor specification
MK208-1 Catalytic combustion sensor for combustible gases and vapors (according to EN 61779-4)
Response time t50: ≤ 5 s (CH4), ≤ 5 s (C3H8), *1 with wind protection: ≤ 8 s (CH4), ≤ 8 s (C3H8), *1
t90: ≤ 9 s (CH4), ≤10 s (C3H8), *1 with wind protection: ≤15 s (CH4), ≤17 s (C3H8), *1
Flow rate 0...6m/s: max. ±3% of detection range or ±10% of display (regarding to 0 m/s) *2, *4
Pressure 800...1100 hPa: max. ±3% of detection range or ±7% of display (regarding to 1000 hPa) *4
Humidity 5%...90% r.F.: max. ±5% of detection range or ±10% of display (regarding to 50% r.F. and 40°C) *4
Temperature -25...+55°C: max. ±5% of detection range or ±15% of display (regarding to 20°C) *4
Cross sensitivities Methane – Measuring range (#) *3 Propane – Measuring range *3 Nonane – Measuring range (#) *3 .
at 50%LEL: . . 0,35 %Vol. C9H20: = 100%
2,20 %Vol. CH4 : = 100% 0,85 %Vol. C3H8 : = 100% 2,00 %Vol. H2 : ca.328%
2,00 %Vol. H2 : ca.131% 2,00 %Vol. H2 : ca.160% 1,25 %Vol. C3H6O: ca.231%
1,25 %Vol. C3H6O: ca. 97% 1,25 %Vol. C3H6O: ca.111% 2,20 %Vol. CH4 : ca.224%
1,15 %Vol. C2H4 : ca. 96% 2,20 %Vol. CH4 : ca.107% 1,15 %Vol. C2H4 : ca.213%
0,85 %Vol. C3H8 : ca. 96% 1,15 %Vol. C2H4 : ca.101% 0,85 %Vol. C3H8 : ca.210%
1,10 %Vol. C4H8O2: ca. 92% 1,10 %Vol. C4H8O2: ca. 95% 1,10 %Vol. C4H8O2: ca.201%
1,00 %Vol. C3H8O: ca. 87% 1,00 %Vol. C3H8O: ca. 93% 1,00 %Vol. C3H8O: ca.193%
0,85 %Vol. C4H10O: ca. 87% 0,85 %Vol. C4H10O: ca. 87% 0,85 %Vol. C4H10O: ca.180%
0,50 %Vol. C6H14: ca. 74% 0,50 %Vol. C6H14: ca. 69% 0,50 %Vol. C6H14: ca.143%
0,55 %Vol. C7H8: ca. 72% 0,55 %Vol. C7H8: ca. 67% 0,55 %Vol. C7H8: ca.132%
at 2 %Vol NH3: 0,35 %Vol. C9H20: ca. 57% 0,35 %Vol. C9H20: ca. 49% 2,00 %Vol. NH3: ca.100%
2,00 %Vol. NH3: ca. 57% 2,00 %Vol. NH3: ca. 49%
Special notes: This sensor is not suitable for the detection of hydrogen and for the use in hydrogenous areas. The sensor responds to
hydrogen, but is only suitable for warning of this gas. Permanent exposure to hydrogen may result in a permanently
rising signal.
Expected lifetime: 5 years
MK217-1 Catalytic combustion sensor for combustible gases and vapors (according to EN 61779-4)
Response time t50: ≤ 5 s (CH4), ≤ 7 s (C3H8), *1 with wind protection: ≤ 9 s (CH4), ≤ 9 s (C3H8), *1
t90: ≤10 s (CH4), ≤12 s (C3H8), *1 with wind protection: ≤18 s (CH4), ≤21 s (C3H8), *1
Flow rate 0...6m/s: Max. ±3% of detection range or ±10% of display (regarding to 0 m/s) *2, *4
Pressure 800...1100 hPa: Max. ±3% of detection range or ±7% of display (regarding to 1000 hPa) *4
Humidity 5%...90% r.F.: Max. ±5% of detection range or ±15% of display (regarding to 50% r.F. and 40°C) *4
Temperature -10...+40°C: Max. ±5% of detection range or ±15% of display (regarding to 20°C) *4
Cross sensitivities Methane – Measuring range (#) *3 . Propane – Measuring range *3 . Hydrogen – Measuring range (#) *3
at 50%LEL: 2,20 %Vol. CH4 : = 100% 0,85 %Vol. C3H8 : = 100% 2,00 %Vol. H2: = 100%
2,00 %Vol. H2 : ca.115% 2,00 %Vol. H2 : ca.188% 2,20 %Vol. CH4 : ca. 86%
0,85 %Vol. C3H8 : ca. 65% 2,20 %Vol. CH4 : ca.162% 0,85 %Vol. C3H8 : ca. 53%
Special notes: When the sensor was exposed to a gas concentration which was considerably higher than 100%LEL, the zeropoint and
the sensitivity of the sensor have to be checked, once the gas concentration has disappeared.
Expected lifetime: 5 years
MK218-1 Catalytic combustion sensor for combustible gases and vapors (according to EN 61779-4)
Response time t50:
≤ 5 s (CH4), ≤ 6 s (C3H8), *1 mit Windschutz: ≤ 8 s (CH4), ≤12 s (C3H8), *1
t90:
≤ 9 s (CH4), ≤12 s (C3H8), *1 mit Windschutz: ≤18 s (CH4), ≤25 s (C3H8), *1
Flow rate 0...6m/s:Max. ±3% of detection range or ±10% of display (regarding to 0 m/s) *2, *4
Pressure 800...1100 hPa: Max. ±3% of detection range or ±7% of display (regarding to 1000 hPa) *4
Humidity 5%...90% r.F.: Max. ±5% of detection range or ±15% of display (regarding to 50% r.F. and 40°C) *4
Temperature -10...+50°C: Max. ±5% of detection range or ±15% of display (regarding to 20°C) *4
Cross sensitivities Methane – Measuring range (#) *3 . Propane – Measuring range *3 . Nonane – Measuring range (#) *3 .
at 50%LEL: 2,20 %Vol. CH4 : = 100% 0,85 %Vol. C3H8 : = 100% 0,35 %Vol. C9H20: = 100%
2,00 %Vol. H2 : ca.121% 2,00 %Vol. H2 : ca.195% 2,00 %Vol. H2 : ca.333%
1,15 %Vol. C2H4 : ca. 82% 2,20 %Vol. CH4 : ca.153% 2,20 %Vol. CH4 : ca.265%
0,85 %Vol. C3H8 : ca. 69% 1,15 %Vol. C2H4 : ca.120% 1,15 %Vol. C2H4 : ca.223%
1,10 %Vol. C4H8O2: ca. 64% 1,10 %Vol. C4H8O2: ca. 91% 0,85 %Vol. C3H8 : ca.182%
1,00 %Vol. C3H8O: ca. 63% 1,00 %Vol. C3H8O: ca. 90% 1,10 %Vol. C4H8O2: ca.172%
0,85 %Vol. C4H10O: ca. 62% 0,85 %Vol. C4H10O: ca. 89% 1,00 %Vol. C3H8O: ca.170%
0,55 %Vol. C7H8: ca. 58% 0,55 %Vol. C7H8: ca. 81% 0,85 %Vol. C4H10O: ca.167%
1,25 %Vol. C3H6O: ca. 54% 1,25 %Vol. C3H6O: ca. 78% 0,55 %Vol. C7H8: ca.152%
0,50 %Vol. C6H14: ca. 52% 0,50 %Vol. C6H14: ca. 73% 1,25 %Vol. C3H6O: ca.146%
0,35 %Vol. C9H20: ca. 40% 0,35 %Vol. C9H20: ca. 55% 0,50 %Vol. C6H14: ca.137%
at 2 %Vol NH3: 2,00 %Vol. NH3: ca. 45% 2,00 %Vol. NH3: ca. 60% 2,00 %Vol. NH3: ca.113%
Special notes: When the sensor was exposed to a gas concentration which was considerably higher than 100%LEL, the zeropoint and
the sensitivity of the sensor have to be checked, once the gas concentration has disappeared.
This sensor is not suitable for detection of aceton. The sensor responds to aceton, but is only suitable for warning of this
gas. Permanent exposure to aceton may result in a considerable loss of sensitivity.
Expected lifetime: 5 years
*1 For other gases longer response times are valid, especially for nonane.
*2 At flow rates >3 m/s a wind protection is necessary. Generally it should be avoided that the
gas is supplied to the transmitter from below (sensor side).
*3 The cross sensitivities can vary depending on sensor and are dependent on gas concentration and
age of sensor. Other combustible gases which are not listed, are expected to cause an increase of
signal.
*4 This specification is valid for methane and propane.
-31-
Technical Data
3
Transmitter CC28
Transmitter type: CC28 ; CC28 D and CC28 DA
Sensor type: MK 208-1 ; MK 217-1 and MK 218-1
Expected sensor life: 5 years - for normal industrial applications (see sensor specification)
Gas: Combustible gases and vapours,
e.g. Methane, Propane, Hexane, Nonane (see test report)
Detection range: e.g. 0 .. 100 % LEL (see test report)
Response time: see sensor specification
Alarm: only CC28 DA: visual and audible (90dB @ 10cm)
Detection principle: Catalytic combustion
Gas supply: Diffusion or
via flow adapter (flow rate 0.5±0.1 l/min)
Supply voltage: 15 .. 30 V DC
Max. supply current: 150 mA
Max. fault voltage: 250 V AC resp. 45 V DC (see type label)
Output current: 4 .. 20 mA (max. load 150 Ohm)
Climate Conditions
Short-term storage temperature: -25 .. +60°C
Recommended storage temperature: 0 .. +30°C
Operational temperature (ambient): -20 .. +50°C for use in Ex-hazardous areas
-25 .. +55°C for use in non-Ex areas
see Sensor specification in case of using of MK217 or MK218
Humidity range: 5 .. 90% r.h.
Atm. Pressure range: 800 .. 1100 hPa
Flow rate: 0 to 6 m/s (>3 m/s with wind protection, mounting position see page 6)
Climate Effect as per EN 61779
Pressure 800 .. 1100 hPa (1000 hPa) ± 5% of range or ±30% of display
Humidity 20% .. 90% r.h. (50%) ± 7% of range or ±15% of display
Temperature -25 .. +55°C (20°C) ±10% of range or ±20% of display
Flow rate 6 m/s (0 m/s) ± 5% of range or ±10% of display
Casing
Stability: Protect the casing against very hard impacts (> 4 J)
Casing material: anti-static compound
Dimensions: 100 x 167.5 x 55 mm (WxHxD) (H with sensor: 193 mm)
Weight: approx. 800 g ( with display )
Protection: IP 64
Cable gland: screwing M16 x 1.5 max. cross section 3 x 1.5 mm2
Cable type and length: LIYCY 3 x 0.75 mm2 for up to 200 m or
LIYCY 3 x 1.5 mm2 for up to 1000 m
Approvals and Certificates
Labelling: ¯ II 2G Y 0158
Ignition protection classification: EEx dem [ib] IIC T4 -20°C≤Ta≤+50°C
EC-Type Examination Certification: BVS 04 ATEX E 132 X (electrical Ex-Protection)
Function test: BVS 05 ATEX G 001 X (measuring function)
EMC test: EN 50270 : 1999
Radio shielding: Type class I
Interference resistance: Type class II
-32-
Annex
Internal Memory CC28
Every transmitter is pre-programmed with the data of the most important gases and their additional
parameters. In most cases, therefore, the user does not need to change the configuration. The
following information is stored in the internal memory of the transmitter:
If the transmitter is operated with a sensor for which no data are entered yet in this list, defined
settings are being used.
The user can adapt these settings individually and store them in the transmitter.
-33-
EC-Type Examination Certificate
-34-
-35-
-36-