Witt MFA 9000 User manual

Copyright WITT-GASETECHNIK GmbH & Co KG, 2015, all rights reserved
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

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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.: [phone]
Fax: [phone]
Alternatively you can also contact us via e-mail ([e-mail]) 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

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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
H2
N2
0% - 100%
0% - 0.5%
98% - 100%
H2
Ar
0% - 100%
0% - 0.4%
99% - 100%
H2
air
0% -4%
0% - 0.5%
-
He
N2or air
0% - 100%
0% - 0.8%
97% - 100%
He
Ar
0% - 100%
0% - 0.5%
98% - 100%
CO2
N2or air
0% - 100%
0% - 3%
96% - 100%
CO2
Ar
0% - 60%
0% - 10%
-
Ar
N2or air
0% - 100%
0% - 3%
96% - 100%
Ar
CO2
40% - 100%
-
80% - 100%
CH4
N2
0% - 100%
0% - 2%
96% - 100%
CH4
Ar
0% - 100%
0% - 1.5%
97% - 100%
CH4
air
0% -4.4%
0% - 2%
-
O2
N2
0% - 100%
0% - 15%
85% - 100%
O2
Ar
0% - 100%
0% - 2%
97% - 100%
N2
Ar
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
Salinger Feld 4-8

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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

: [phone]
www.wittgas.com
Gas Safety- & Control Equipment
D-58454 Witten
Fax: [phone]
[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.