M&C CG Series User manual

Gas Converter CG®
CG-2/-2M, CG-2H-W/-2MH-W
Instruction Manual
Version 1.04.00

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Dear customer,
Thank you for buying our product. In this instruction manual you will find all necessary information about
this M&C product. The information in the instruction manual is fast and easy to find, so you can start
using your M&C product right after you have read the manual.
If you have any question regarding the product or the application, please don’t hesitate to contact M&C
or your M&C authorized distributor. You will find all the addresses in the appendix of this manual.
For additional information about our products and our company, please go to M&C’s website www.mc-
techgroup.com. There you will find the data sheets and manuals of all our products in German and
English.
This Operating Manual does not claim completeness and may be subject
to technical modifications.
© 12/2018 M&C TechGroup Germany GmbH. Reproduction of this doc-
ument or its content is not allowed without permission from M&C.
CG®is a registered trade mark.
Version: 1.04.00

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Table of Contents
1General information.................................................................................................................. 5
2Declaration of conformity......................................................................................................... 5
3Safety instructions.................................................................................................................... 6
4Warranty.................................................................................................................................... 6
5Used terms and signal indications.......................................................................................... 7
6Introduction............................................................................................................................... 9
7Application ................................................................................................................................ 9
8Operating principle of the conversion................................................................................... 11
8.1 Selection of the appropriate catalyst material..................................................................... 12
8.2 Selection of the appropriate catalyst temperature.............................................................. 12
8.3 Cross sensitivities and influence of interfering/carrier gas.................................................. 13
9Technical data......................................................................................................................... 15
10 Description.............................................................................................................................. 16
11 Receiving the CG…................................................................................................................. 18
12 Storage .................................................................................................................................... 18
13 Installation instructions.......................................................................................................... 18
14 Supply connections................................................................................................................ 19
14.1 Hose/tube connections ...................................................................................................... 19
14.2 Electrical connections........................................................................................................ 20
15 Starting-up............................................................................................................................... 21
16 Closing down .......................................................................................................................... 22
17 Determining the catalyst service life ..................................................................................... 22
17.1 Check of the efficiency....................................................................................................... 24
17.2 Conversion ppm --> mg/m3................................................................................................ 24
18 Maintenance............................................................................................................................ 25
18.1 Replacing the catalyst cartridge......................................................................................... 25
18.2 Replacing the o-ring seals ................................................................................................. 26
18.3 Checking for gas-tightness ................................................................................................ 27
19 Use of the temperature controller.......................................................................................... 28
19.1 Display and function keys.................................................................................................. 28
19.2 Operating state of the temperature controller..................................................................... 28
19.3 Changing the parameters of the temperature regulator...................................................... 29
19.4 Reset of the controller........................................................................................................ 30
20 Trouble shooting..................................................................................................................... 31
21 Spare part list.......................................................................................................................... 32
22 Appendix ................................................................................................................................. 32

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List of Illustrations
Figure 1 Functional diagram of CG-2 and CG-2M..........................................................................10
Figure 2 Functional diagram CG-2H-W and CG-2MH-W................................................................ 10
Figure 3 Notch to differentiate the two cartridge types ...................................................................12
Figure 4 CG-2 and CG-2M.............................................................................................................16
Figure 5 CG-2H-W and CG-2MH-W............................................................................................... 16
Figure 6 Pin configuration in the sub-D-plug X2............................................................................. 20
Figure 7 Catalyst life time depending on the NO2 concentration for varying flow rates and an
Oxygen concentration of 5 vol%...................................................................................... 23
Figure 8 Catalyst life time depending on the NO2 concentration for varying flow rates and an
Oxygen concentration of 10 vol%.................................................................................... 23
Figure 9 Catalyst life time depending on the NO2 concentration for varying flow rates and an
Oxygen concentration of 21 vol%.................................................................................... 23
Figure 10 Adapter for catalyst cartridge with handle......................................................................... 26
Figure 11 Wiring plan CG-2M, Drawing No.: 2224-5.04.0 ................................................................ 33
Figure 12 Wiring plan CG-2MH-W, Drawing No.: 2224-5.04.4.........................................................34
Figure 13 Wiring plan CG-2H-W, Drawing No.: 2224-5.04.5............................................................35

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Head Office
M&C TechGroup Germany GmbH Rehhecke 79 40885 Ratingen Germany
Telephone: 02102 / 935 - 0
Fax: 02102 / 935 - 111
E - mail: [e-mail]
www.mc-techgroup.com
1 GENERAL INFORMATION
The product described in this manual has been built and tested in our production facility.
All M&C products are packed to be shipped safely. To ensure the safe operation and to maintain the
safe condition, all instructions and regulations stated in this manual need to be followed. This manual
includes all information regarding proper transportation, storage, installation, operation and mainte-
nance of this product by qualified personnel.
Please follow all instructions and warnings closely.
Please readthis manualcarefully before commissioning and operating the device. If you have any ques-
tions regarding the product or the application, please don’t hesitate to contact M&C or your M&C au-
thorized distributor.
2 DECLARATION OF CONFORMITY
CE - Certification
The product described in this operating manual complies with the following EU directives:
EMV-Instruction
The requirements of the EU directive 2014/30/EU “Electromagnetic compatibility“ are met.
Low Voltage Directive
The requirement of the EU directive 2014/35/EU “Low Voltage Directive“ are met.
The compliance with this EU directive has been examined according to DIN EN 61010.
Declaration of conformity
The EU Declaration of conformity can be downloaded from the M&C homepage or directly requested
from M&C.

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3 SAFETY INSTRUCTIONS
Please follow these safety directions and instructions regarding installation, commissioning
and operation of this device:
Read this manual before commissioning and operating the product. Make sure to follow all safety in-
structions.
Installation and commissioning of electrical devices must be carried out only by qualified skilled person-
nel in compliance with the current regulations.
The installation and commissioning of the device must conform to the requirements of VDE 0100 (IEC
364) ‘Regulations on the Installation of Power Circuits with Nominal Voltages below 1000V’ and must
be in compliance with all relevant regulations and standards.
Before connecting the device, make sure to compare the supply voltage with the specified voltage on
the product label.
Protection against damages caused by high voltages:
Disconnect the power supply before opening the device for access. Make sure that all extern power
supplies are disconnected.
Operate the device only in the permitted temperature and pressure ranges. For details please refer to
the technical data sheet or manual.
Install the device only in protected areas, sheltered from sun, rain and moisture. The product should not
be exposure to the elements.
The converter CG.. is NOT certified to be installed or operated in explosive hazardous areas.
Installation, maintenance, inspections and any repairs of the devices must be carried out only by quali-
fied skilled personnel in compliance with the current regulations.
4 WARRANTY
In case of a device failure, please contact immediately M&C or your M&C authorized distributor.
We have a warranty period of 12 months from the delivery date. The warranty covers only appropriately
used products and does not cover the consumable parts. Please find the complete warranty conditions
in our terms and conditions.
The warranty includes a free-of-charge repair in our production facility or the free replacement of the
device. If you return a device to M&C, please be sure that it is properly packaged and shipped with
protective packaging. The repaired or replaced device will be shipped free of delivery charges to the
point of use.

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5 USED TERMS AND SIGNAL INDICATIONS
DANGER!
This means that death, severe physical injuries and/or important ma-
terial damages will occur in case the respective safety measures are
not fulfilled.
W ARNING!
This means that death, severe physical injuries and/or important ma-
terial damages may occur in case the respective safety measures
are not fulfilled.
CARE!
This means that minor physical injuries may occur in case the re-
spective safety measures are not fulfilled.
CARE !
Without the warning triangle meansthat a material damage may occur
in case the respective safety measures are not met.
ATTENTI ON!
This means that an unintentional situation or an unintentional status
may occur in case the respective note is not respected.
NOTE!
These are important information about the product or parts of the op-
erating manual which require user’s attention.
SKILLED STAFF
These are persons with necessary qualification who are familiar with
installation, use and maintenance of the product.
Risk of fire hazard!
Highly flamable materials are present. There is an imminent fire haz-
ard.
High voltages!
Protect yourself and others against damages which might be caused
by high voltages.
Wear protective gloves!
Working with chemicals, sharpe objects or extremly high tempera-
tures requires wearing protective gloves.
Wear safety glasses!
Protect your eyes while working with chemicals or sharpe objects.
Wear safety glasses to avoid getting something in your eyes.
Wear protective clothes!
Working with chemicals, sharpe objects or extremly high tempera-
tures requires wearing protective clothes.

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Hot surface!
Contact may cause burn! Do not touch!

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6 INTRODUCTION
In combustion processes, such as, for example, in large furnaces in which the nitrogen dioxide content
amounts to more than 5 % of the nitrogen oxide emission, continuous measurement of nitrogen oxide
NOx consisting of nitrogen monoxide NO and nitrogen dioxide NO2is prescribed by law in Germany and
many other countries.
7 APPLICATION
The M&C gas converters CG... convert the NO2content of the sample gas by catalysis into NO. To do
this, the sample gas is conducted through a special stainless steel cartridge with a catalyst-filling based
on carbon-molybdenum. This conversion makes it possible to measure nitrogen oxides indirectly using
all commercially available NO-selective measurement instruments.
The converter is available in four versions: CG-2 and CG-2M with non heated gas inlet for ‘cold gas’
conversion and versions CG-2H-W respectively CG-2MH-W with heated gas inlet and outlet and a sec-
ond internal heating circuit for ‘hot gas’ conversion.
For test purposes, the catalyst can be bypassed via two 3/2-way solenoid valves out of PVDF with
version CG-2M and one solenoid valve out of stainless steel with version CG-2MH-W. The solenoid
valves can be controlled internally or externally. The versions CG-2 and CG-2H-W are delivered without
bypass valves.
The M&C gas converters CG-2 and CG-2M… are designed as compact, user-friendly and easy to ser-
vice 19" plug-in units for mounting in 19" cabinet systems or with a mounting bracket for wall-mounting.
The M&C gas converters CG-2H-W and CG-2MH-W are executed as a wall mounting unit easy to
mount.
The catalyst cartridge is filled and formatted at the works and is ready for use immediately. The ability
to select theappropriate catalyst filling andthe possibility of adjusting the cartridge temperature optimally
to the catalytic reaction by means of an electronic temperature controller provides a wide range of ap-
plications for the M&C gas converter CG... .
Version
19“-plug-in
Wall mounting
Bypass
‘Hot gas’-Conver-
sion
CG-2
x
optional
CG-2M
x
optional
x
CG-2H-W
x
x
CG-2MH-W
x
x
x
Table 1 Summary of possible versions

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Figures 1 and 2 show the functional scheme of the gas converter type CG..
A Temperature Status Alarm
B Connection for Power Supply
C Sample Gas Inlet
D Sample Gas Outlet
B 1.0 Temperature Controller
B 1.1 Temperature Alarm
B 1.2 Temperature Display
E 1 Tube Furnace
Y 1 3/2-Way-Solenoid-Valve (not with version CG-2)
Y 2 3/2-Way-Solenoid-Valve (not with version CG-2)
Figure 1 Functional diagram of CG-2 and CG-2M
A Temperature Status Alarm
B Connection for Power Supply
C Sample Gas Inlet
D Sample Gas Outlet
B 1.0 Temperature Controller
B 1.1 Temperature Alarm
B 1.2 Temperature Display
E 1 Tube Furnace
E2 Heating bar sample gas inlet and outlet
and Y1
Y 1 3/2-Way-Solenoid-Valve
(not with version CG-2H-W)
Figure 2 Functional diagram CG-2H-W and CG-2MH-W
D
C
A
B
Y2
Y1
E1
°C
350
350
B 1.2
B 1.1
B 1.0
CG-2
CG-2M