GfG G400-MP2 Operation Manual - User Manual

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GfG GESELLSCHAFT FÜR GERÄTEBAU MBH

▐

KLÖNNESTRASSE 99

▐

D-44143 DORTMUND

▐

TELEFON +49 / (0)2 31 / 5 64 00 –0

▐

FAX +49 / (0)2 31 / 51 63 13

INFO@GFG-MBH.COM

▐

WWW.GASMESSUNG.DE

▐

AMTSGERICHT DORTMUND HR B 2742

▐

ZERTIFIZIERT NACH DIN EN ISO 9001:2000

▐

ATEX QM ZERTIFIZIERT

Operation Manual

G400-MP2

Smart motorized pump for Microtector II series

Content

Page

INTRODUCTION

1.1

For your safety

1.2

Application and use

1.3

Special conditions for safe use

1.4

General description and design

1.4.1

Connection to Microtector II series

1.4.2

Sensor cover and inlet

OPERATIONAL HINTS

2.1

Turning pump on and off

2.2

Pump confidence signal

2.3

LowFlow - alarm

2.4

Minimum pump time

2.5

Pump monitoring and failure

2.6

Monitoring battery capacity

2.7

Information about pump

2.8

Power supply

2.8.1

Charging the battery pack

2.8.2

Replacement of batteries and battery pack

ANNEX

3.1

Cleaning

3.2

Inspection

3.3

Maintenance and regular function check

3.4

Service

3.5

Changing of filter

3.6

Spare parts and accessories

3.7

Technical data

3.8

EC-Type Examination Certificate

1. Introduction

1.1 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.
This manual must be carefully read by all individuals who have or will have the responsibility for using and
servicing this product. As any piece of complex equipment, the product will do the job designed to do, only,
if it is used and serviced in accordance with the manufacturer's instructions.
If the product is not used and serviced in accordance with the instructions in this manual the warranty will
be voided. Adjustments in the service mode must be done by experts only.

Before operating the pump check the charge status of the battery resp. of the rechargeable
battery as well as the readiness of operation of the detector (see chapter “Indication of battery
capacity”, page 5).

The above does not alter statements regarding GfG's warranties and conditions of sale and delivery.

1.2 Application and use

The smart motorized pump G400-MP2 is used for personal safety in atmospheric conditions in combination
with the portable gas detectors of the Microtetcor II series.

The smart pump G400-MP2 is approved for the use in explosion endangered areas and is subject to an EC-
Type Examination Certificate issued by DEKRA EXAM, according to directive 2014/34/EU with following
certificates:

For  the  application  in  group  I,  category  2G  depends  on  the  temperature  class  of  the  supply  module  used.
When using the rechargeable battery pack „NiMH II“, temperature class T4 is valid for ambient temperatures
from  –20°C  to  +55°C,  resp.  temperature  class  T3  when  using  the  rechargeable  battery  pack  “NiMH”.  Both
rechargeable battery packs come with a black casing and can be distinguished by means of an internal label
showing type and temperature class. When using the Alkaline batteries (grey housing), temperature class T4
is valid for ambient temperatures from -20°C to +45°C resp. temperature class T3 for ambient temperatures
of  -20°C to +55°C.  For  the  application  in  group  I,  category  M1  the  pump  G400-MP2  can  be  used  in
environments -20°C≤T

≤+55°C.

1.3 Special conditions for safe use

In  explosion  endangered  areas  the  pump  G400-MP2  must  be  used  properly,  i.e.  the  pump  with  a  gas
detector of the G400 series must be carried at your body and must not be laid down unattended, to prevent
an  electrostatic  charge  of  the  clip.  The  pump  must  be  attached  to  the  Microtector II  gas  detector  before
entering the explosion endangered are. It must not be removed from the detector in the hazardous area.
Always pay attention to the ignition protection with the temperature class of the gas detector.

If the pump G400-MP2 is going to be used in underground or surface mines which are endangered by black
damp  and/or  combustible  dust  (device  category  I)  following  additional  conditions  apply:  A  mechanical
impact  must  be  avoided  because  the  G400-MP2  is  only  specified  for  a  lower  degree  of  mechanical  hazard
according to EN 60079-0. The pump G400-MP2 has  to be removed from hazardous areas immediately and
getting cleaned if it becomes soiled by oil and grease or hydraulic liquids.

ATEX Certificate:

BVS 07 ATEX E 011

Labelling:



II 2G

Ex ia IIC T4 Gb

-20°C≤Ta≤+55°C (NiMH-II)

Ex ia IIC T3 Gb

-20°C≤Ta≤+55°C (NiMH)

Ex ia IIC T4/T3 Gb -20°C≤Ta≤+45°/+55°C (Alkaline)

Labelling:



I M1

Ex ia I Ma

-20°C≤Ta≤+55°C

1.4 General description and design

The  pump  G400-MP2  is  a  very  small  and  handy  supplemental  module  for  the  gas  detector
Microtector II series.  It  allows  sampling  of gases from  a  safe  position,  without  being  exposed to  hazardous
atmospheres.  The  pump  provides  its  own  power  supply,  which  works  independent  from  that  of  the
Microtector II series.

Type label with date of manufacture

Example SN:1003xxxx

10=year / 03=month

1.4.1 Connection to Microtector II series

Plug the pump G400-MP2 on the gas detector Microtector II series and fix it by means of the knurled screws.
For permanent attachment to the Microtector II series you can fix the pump by means of 2 additional screws
(attached).  You  will  find  the  mounting  holes  for  the  additional  screw  below  the  red  sensor  cover.  For
accessing  the  holes,  slide  the  sensor  cover  upwards  –  push  the  lock  smoothly  with  a  screw  driver  –  and
remove it. Once the screws were mounted, fix the sensor cover again and slide it downwards.
For  removing  the  pump  from  the  Microtector  II  series,  unscrew  the  knurled  screws  as  well  as  the  possibly
mounted additional screws.

1.4.2 Sensor cover and inlet

For both turning device on
and

off

and

closing

gas

diffusion inlet slide sensors
cover

during

pump

operation.

The sampling inlet is at the
bottom of the pump body.
Here

you

can

fix

the

accessories  for  taking  gas
samples  (hose  adapter  with
sampling  line,  probe,  GfG
telescopic probe).

Sampling inlet:

Connection of accessories

for gas sampling

The sensor cover turns pump on and off and closes the diffusion inlets during sampling.

Sensor cover

2. Operational Hints

2.1 Turning pump on and off

Slide the blue sensor cover upwards to turn the pump on. The display of the Microtector II shows the actual
operational status of the pump.

With sufficient battery capacity the pump motor starts after a short delay
(approx. 1 second). The display of the Microtector II shows the battery
capacity.(*1)

NOTE!

If the blue sensor cover is slided upwards violently, it may slip over its lock and the diffusion inlets

are not properly covered. This may result in false detection, since ambient air could dilute the concentration
of the gas sample. Make sure, therefore, that the diffusion inlets are closed properly.

Slide the blue sensor cover downwards to turn the pump off.

The pump symbol vanishes and the remaining battery capacity of the pump is
shown in the display of the Microtector II.

The pump should be turned off after detection to prevent unnecessary
discharging of the batteries.

Zu (*1): Bei Verwendung der Versorgungseinheiten NiMH

F25

oder NiMH-II

A21

kann es insbesondere bei

relativ neuen Akkus zu einer erhöhten Batteriekapazitätsanzeige kommen. Im Extremfall kann bis zur Hälfte
der Betriebsdauer ein relativ voller Akku angezeigt werden. Danach sinkt die Batteriekapazitätsanzeige dann
deutlich schneller. Dieses Verhalten normalisiert sich mit dem Alter des Akkus bzw. mit der Anzahl der
Lade/Entladezyklen. Der Batteriealarm wird aber unabhängig von diesem Verhalten rechtzeitig ausgelöst.

2.2 Pump confidence signal

During sampling a pump symbol is shown in the display of the Microtector II to indicate trouble-free
operation.

The trouble-free operation is indicated on the left side in the display of the
Microtector II by an animated pump symbol.

This symbol blinks when the pump does not work properly.

Further status indication about alarm or failure is given by means of audible, visual or vibration alarm of the
Microtector II.

2.3 LowFlow - alarm

During normal pump operation the gas flow is about 0.5l/min. If the gas flow is too low (<0.25l/min) or if
the power supply of the pump motor is interrupted, the Microtector II gives audible, optical or vibration.

Additionally the display shows „Pump Flow error!“
Reason for that can be that the way of gas is possibly blocked or the sampling
line is bent. For proper operation make sure that the gas way is free.

Attention:

During LowFlow alarm proper detection of the Microtector II cannot be ensured.

2.4 Minimum pump time

For  sampling  gases  out  of  sewers,  rooms  or  drains  a  hose  (with  or  without  telescopic  probe)  can  be  used
that  is  plugged  on  the  intake.  As  the  response  time  heavily  depends  on  the  inside  volume  of  the  intake
appliance  the  lengths  of  the  appliance  shall  be  as  short  as  possible.  For  the  minimum  pump  time  (T

min

seconds) you may use the following formula:

min

= 10s + 3s/m*L

hose

+ T

Tele

hose

= lengths of hose (inner diameter 5 mm) in meter

Tele

= 10s with telescopic probe, 0s without

2.5 Pump monitoring and failure

Display and alarms of the Microtector II are used to indicate the operational status of the G400-MP2 resp. to
trigger fault alarms. Instrument and pump communicate over three gilded contact springs in the middle of
the devices. The Microtector II monitors the communication link permanently.

When the data connection is disconnected, visual and audible alarm is
triggered and the display shows “Pump connection lost!”

This status has to be reset by the middle key (RESET).

When the data connection is disconnected only partially the status of the pump
cannot be monitored correctly. In this case remove the pump from the
Microtector II

Remedy:

Clean dirty contacts of the instrument and spring contacts of the

pump or call GfG-Service.

The circuitry of the G400-MP2 is permanently monitored. A failure being
detected triggers an audible and visual alarm.

Remedy:

Change batteries. In case of failure not being solved call GfG-

Service.

2.6 Monitoring battery capacity

The battery capacity of the pump is shown in the display of the Microtector II directly after switching on or
off (see chapter 2.1 „Turning pump on and off“). A sufficient battery capacity and trouble-free operation is
indicated on the left side in the display of the Microtector II by an animated pump symbol.

An  low  battery  of  the  pump  is  indicated  by
display  showing  „Pump  battery  low!“.  During
normal  measurement  display  reads  a  blinking
battery symbol.

When the battery of the pump is completely exhausted the display shows
„Pump battery empty! Open blind!“.

The sensor cover has to be slided downwards in order to allow diffusion mode.

2.7 Information about pump

The display of the Microtector II can show certain information about the pump.

Keeping middle key pressed opens the main menu of the Microtector II. Scroll
down with the left key and select menu-point “Pump” with the middle key.

Model, firmware version (FW) and serial number (SN) of the pump are shown.

Status shows actual operational status and error messages as well as battery
capacity.

Due to the fact that the charging status is calculated from the battery voltage, the value can vary when the
pump is turned on or off.

2.8 Power supply

The pump G400-MP2 can be powered by an alkaline battery module or by a rechargeable NiMH battery pack.
These power supply modules allow a continuous operation for up to 11 hours. The operational time may be
reduced, however, by increased load of the pump motor (e.g. bent sampling line / blocked filter/low ambient
temperature).
The pump G400-MP2 turns off automatically, if the battery voltage falls below the minimum level needed for
proper functioning. At least 15 minutes before automatic deactivation the battery alarm will be triggered

. In

this case the display shows “Pump battery weak!”

2.8.1 Charging the battery pack

Attention: The unit must not be charged in explosion endangered areas. Charging contacts must

be cleaned. (see appendix chapter 3.1 “Cleaning”)

The  rechargeable  NiMH  battery  pack  in  the  G400-MP2  has  to  be  recharged  by  means  of  the  blue  cradle
charger G400-DIC2.
A  trouble-free  charging  process  is  only  guaranteed  if  charger  lies  or  is  mounted  in  horizontal  position  and
when  Microtector  II  is  assembled  to  the  charger  correctly.  The  pump charger  is  powered  by  GfG’s  plug-in
mains  unit.  Alternatively  the  Pump  Charger  may  also  be  connected  to  a  car  charging  cable.  The
Pump Charger limits the voltage for the G400-MP2 to max. 6V.

The charging process is divided into quick and trickle charge. The right green LED signalizes the readiness of
the charger. The right yellow LED signalizes the charging process for the pump (constant light: quick charge,
blinking:  trickle  charge).  Charging  a  completely  discharged  battery  pack  takes  about  6-7  hours  for  quick
charge.  After  that the  charger  automatically  switches  to  trickle-charge  to  prevent  over-charge.  The  display
of the Microtector II does not show the charging status of the pump.

To  provide  maximum  capacity  of  the  battery  pack  it  is  necessary  to  charge  only  in  dependency  to  the
operational  time  and  frequency.  Do  not  use  charger  for  storing  the  Microtector  II  and  pump  for  several
weeks.

2.8.2 Replacement of batteries and battery pack

Note:

The pump must not be opened in explosion endangered areas. You must not replace
the alkaline or rechargeable battery module in hazardous areas.

Always turn the pump off before replacing the alkaline or rechargeable battery module. Watch out for the
correct polarity of the new 1.5V AA alkaline batteries (see battery holder). These batteries must always be
purchased from GfG as the manufacturer of the pump. In-house quality management ensures that only
batteries are used which comply with the requirements of the EC-Type Examination Certificate.
The correct battery types are:

DURACELL PROCELL MN1500 LR6 AA

INDUSTRIAL

DURACELL ID1500 AA (LR6)

Note

The batteries may only be replaced in safe areas. Watch out for correct polarity when inserting
the batteries (see picture inside the battery tray). With incorrect polarity the pump will not turn
on.

For replacing the batteries separate the battery
tray from the pump. Unscrew the fixing screws on
the front and pull the battery tray off.

Note:

•

Batteries must not be replaced in EX-areas

•

Watch out for correct polarity of the new
batteries! (see pictograph on inner side of
battery tray)

•

Watch out for correct inserting of battery tray!
(Characters on front must be readable.)

Tighten all screws after inserting the battery tray.

Please adhere to disposal notes!

3. Annex

3.1 Cleaning

Give the G400-MP2 pump a short sight check after use. Use a damp cloth to remove stains or soiling from the
casing. Never use solvents or cleaning agents! Especially attend that outer charging contact areas and charging
springs are clean. Bad contacts result in incorrect charging of the NiMH battery pack.

3.2 Inspection

Independently from maintenance the user has to do the following checks at least before every shift:

Visual check for damages

Check of battery capacity

Check of sampling performance

3.3 Maintenance and regular function check

Depending on applicational conditions and technical requirements the maintenance is to be effected in intervals
which are to be referred to the application. Maintenance includes measures which retain the nominal status of the
pump G400-MP2.

Visual check for damages

Check of filter condition

Check of pump battery capacity

Check of confidence signal

Check of sampling performance

Check of LowFlow alarm

In addition to the above we recommend to get the pump checked for proper functioning by an expert in
combination with the (at least) annual maintenance of the Microtector II series.

3.4 Service

Service should be done by the manufacturer. Only genuine spare parts must be used for service
and repair

Battery tray

3.5 Changing of filter

For  changing  the  filter,  separate  the  pump  from  the
Microtector  II  series  and  pull  the  lateral  blue  cover
backwards.  Use  a  tweezers  to  remove  the  filter  and
replace it by a new one.

3.6 Spare parts and accessories

Description

Part No.

Battery tray without alkaline batteries

1450200

Alkaline battery (pack of 10)

1450204

NiMH-II A21 rechargeable battery pack

1450206

NiMH F25 rechargeable battery pack

1460206

Sensor cover blue

1450320

Filter (pack of 10)

1450321

Filter cover blue (pack of 10)

1450322

Hose intake 5cm

1450323

Sampling tube 30cm

1450324

Telescopic probe CrNi 1.36m

1000205

Special dust/water filter (pack of 3)

1000207

Special sampling line 3m, anti-static, with dust/water filter

1000208

Special sampling line 3m, anti-static, with dust/water filter and flow indicator

1000209

Viton hose (resistant against solvents and hydrogen sulfide)

1000217

Float probe

on request

Filter

behind

filter cover

Sensor cover

3.7 Technical data

Type:

G400-MP2

Pump performance:

0,50 l/min for 0 mm water column
0,35 l/min for 300 mm water column
max.100m hose length (depending on gas and hose)

Gas supply:

Sampling inlet during pump mode or
Diffusion inlet when pump is turned off

Display and alarm:

Messages appear in the display of the Microtector II. Acoustic and visual
alarms will be triggered by means of the Microtector II. Vibration alarm
(optionally) integrated in the battery pack.

Power supply:

1. NiMH-battery pack A21 (black case), 2100mAh rechargeable
2. NiMH-battery pack F25 (black case), 2500mAh rechargeable
       Im=600mA  (max. charging current)
       Um=6V DC  (max. voltage)                               or
3. Alkaline batteries (grey case), not rechargeable
       with 2x Mignon 1.5V type: DURACELL PROCELL MN1500 LR6 AA or
                                         INDUSTRIAL

DURACELL ID1500 AA (LR6)

Charging time of the NiMH
battery pack:

approx. 6-7h

Operational time:

Pump ON:           > 9h (NiMH battery pack F25)
                 approx. 9h (NiMH-II battery pack A21)
                 approx. 10h (Alkaline batteries)
Pump OFF: approx. 10 days (Gas Detector ON)
                 approx. 200 days (Gas Detector OFF)

Climate conditions:

for operation: -20...+55 °C | 5...95% r.h.

for storage: -25...+55 °C | 5...95% r.h. (recommended 0...+30°C)

Casing:

Material: Plastic and rubberized compund

Dimensions: 68 x 109 x 21 (57) mm (W x H x D)

Weight: 180g with alkaline battery pack or 195g with NiMH battery pack

Protection: IP40

Approvals and certificates:

Labelling and ignition

protection:



II2G Ex ia IIC T4

-20°C≤Ta≤+55°C for NiMH-II (black)

Ex ia IIC T3

-20°C≤Ta≤+55°C for NiMH (black)

Ex ia IIC T4/T3 -20°C≤Ta≤+45°C/+55°C for Alkaline (grey)



I M1 Ex ia I Ma

-20°C≤Ta≤+55°C

EC-Type Examination

Certificate:

BVS 07 ATEX E 011

(without measuring function)

Electro magnetic compatibility:

Production monitoring:

DIN EN 50270:2006 Radio shielding:

Type class I

Interference resistance: Type class II



0158

(by notified body – DEKRA EXAM GmbH)

Worldwide Supplier

of Gas Detection Solutions

205-202.34_BA_G400-MP2.doc,

Edition: 22. April 2016,

We reserve the right of modification, Firmware Version 2.01

GfG Gesellschaft für Gerätebau mbH
Kloennestr. 99, D-44143 Dortmund
Phone: +49(0)231 – 564 00-0
Fax: +49(0)231 – 51 63 13
E-Mail: info@gfg-mbh.com
Internet: www.gasdetection.biz

3.8 EC-Type Examination

Type Examination Certificate

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