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INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR

PENTAIR CLEAN AIR SYSTEMS

FILTER FAILURE

DETECTOR

FFD MANUAL

INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD

Summary of Contents for Goyen Mecair FFD

Page 1: ...i INSTALLATION AND OPERATION MANUAL OWNER S RECORD FFD MANUAL FILTER FAILURE DETECTOR PENTAIR CLEAN AIR SYSTEMS FILTER FAILURE DETECTOR FFD MANUAL INSTALLATION AND OPERATION MANUAL OWNER S RECORD ...

Page 2: ...ts Sensor Variants 4 3 2 Overview 4 3 3 Sensor 5 3 4 Principle of Operation 5 4 SENSOR SAFETY DESCRIPTION 6 4 1 Hazardous Areas 6 4 1 1 Hazardous Zone Classification 6 4 2 CENELEC Codes 6 4 2 1 Gas Atmospheres 6 4 2 2 Dust Atmospheres 6 4 3 Special Conditions of Safe Use for Sensor Enclosure 6 4 4 Special Conditions of Safe Use for Sensor Body Probe 7 4 5 Equipment Marking Information 7 5 Sensor I...

Page 3: ... the FFD 14 6 1 Safety Information 14 6 2 Control Panel Overview 14 6 3 Setup Procedure 15 6 3 1 Changing the Sensor Sensitivity 18 7 Operation 20 7 1 General Operation 20 7 2 Alarm Operation 20 8 Maintenance 21 8 1 Safety Information 21 8 2 Preventative Maintenance Programme 21 8 3 Sensor Handling in Hazardous Areas 22 8 3 1 Removing the Sensor from the Stack 22 8 3 2 Opening the Sensor Enclosure...

Page 4: ... 8 Setup procedure Step 1 15 Figure 9 Setup procedure Step 2 16 Figure 10 Setup procedure Step 3 Calibrate the unit 16 Figure 11 Setup procedure Step 3 Reset MODE slide switch 17 Figure 12 Setup procedure Step 4 17 Figure 13 Setup procedure Step 5 18 Figure 14 Changing sensor sensitivity 18 Copyright by Pentair International Ltd 2019 This manual is provided as an aid to owners of a Pentair Environ...

Page 5: ...tituents hazardous to health This may take one or more of the following forms Particulate which is flammable or explosive Particulate which is toxic or in some other way hazardous to health Particulate contained within high temperature gas Take Precautionary Measures Unless the process conditions are known to be entirely safe suitable precautions such as the use of breathing apparatus or duct purg...

Page 6: ... CAUTION Failure to service or maintain the product fitting non approved parts or carrying out non approved alterations or servicing can be dangerous and could affect the safety of the product It may also invalidate the terms and conditions of the product warranty LIMITS OF USE To achieve optimum performance and safe operation the equipment must be operated within the limits detailed in the Techni...

Page 7: ...t with the below standards EN 60079 0 2012 A11 2013 Explosive atmospheres Part 0 Equipment General requirements Specifies the general requirements for the construction testing and marking of electrical equipment used in explosive atmospheres EN 60079 15 2010 Explosive atmospheres Part 15 Equipment protection by type of protection n Specifies requirements for the construction testing and marking fo...

Page 8: ...r for the continuous monitoring of fabric filter baghouses to identify bag filter degradation The instrument combines the benefits of Probe Electrification technology and dual local alarms with dual alarm relays and a scalable 4 20mA output from a single integrated unit to deliver pragmatic and dependable identification of increases of dust emissions and for monitoring leaking or broken bags 3 PRO...

Page 9: ...gh alarm levels providing flexible sensitivity to suit the process Dust levels are averaged or smoothed using a walking window filter to avoid triggering false alarms due to temporary spikes in dust levels e g during bag filter cleaning cycles 3 4 PRINCIPLE OF OPERATION The FFD sensor utilizes Probe Electrification measurement technology The sensor measures the interaction between the particulate ...

Page 10: ...00 C The tc applies to protection by enclosure and also signifies that the equipment is incapable in normal operation of producing sparks or hot surfaces that may cause ignition 4 3 SPECIAL CONDITIONS OF SAFE USE FOR SENSOR ENCLOSURE a All connections to the equipment must not be inserted or removed unless the area in which the equipment is installed is known to be non hazardous or the circuit to ...

Page 11: ...e cable shall have a cross sectional area of at least 4 mm The cable shall be connected using an anti vibration nut and washer or a similar arrangement of comparable integrity If the Probe is removed while a potentially flammable dust air mixture is present this connection shall be maintained during the withdrawal of the Sensor Body and Probe d If the equipment is likely to come into contact with ...

Page 12: ...ise must be made but the sensor should be fitted in a position that satisfies the majority of the below requirements NOTE The sensor must be fitted to metal ductwork in order to be electrically screened from interference signals see Grounding the Sensor below 5 2 2 Location Requirements When selecting a mounting location for the sensor the following should be taken into consideration for optimum p...

Page 13: ...Surge Protection Safety Grounding Cable To reduce the likelihood of damage from nearby lightning strikes or from electrical surges due to high power equipment run an additional earth cable or grounding cable between the sensor and the power supply The additional earth cable should follow exactly the same path as the sensor cable so as to ensure the closest possible electrical coupling between them...

Page 14: ...nked using an appropriate device When connecting the sensor the 4 off screws securing the enclosure cover lid should be coated with a small amount of copper grease before refitting and securing the lid Do not over tighten the screws 5 3 MOUNTING THE SENSOR 5 3 1 Safety Information CAUTION PROBE DAMAGE Take care when handling the sensor to avoid bending or damaging the probe Probe damage may result...

Page 15: ...ormed backing plates which are then mounted to the stack wall Next fit the sensor to the stack duct as follows 3 Referring to Figure 2 above insert the sensor into the socket 6 and secure it by turning the hexagonal sensor body 8 using a suitable spanner NOTE Ensure the cable glands 11 are facing downward and that the grounding strap earth wire securely connects the sensor to the stack duct via th...

Page 16: ...ve and connect to the terminals using the second free cable entry gland Both relays are of type SPCO are volt free and are not fail safe in operation i e they are not normally energized Figure 4 Connecting the sensor relays 5 4 4 4 20mA Output Figure 5 Connecting the 4 20mA output The FFD is fitted with a non isolated 4 20mA output capable of driving a 250Ω load Referring to Figure 5 connect to th...

Page 17: ...necting the Power Supply Figure 6 Connecting the sensor power supply The FFD sensor requires a power supply of between 16V and 24V DC 80 mA NOTE Keep the length of exposed screen known as a pigtail to an absolute minimum long pigtails degrade EMC performance however the signal wires may be longer ...

Page 18: ...ed using the controls located on the raised sensor control panel see Figure 7 above two rotary controls upper lower for calibration a MODE slide switch bottom left for calibrating the instrument and for setting the alarm delay period a tricolour STATUS LED at the top of the control panel to indicate the current system status alarms When the setup of the FFD is complete replace and secure the enclo...

Page 19: ... Information STEP 3 Determine the Dust Level STEP 4 Set the Alarm Levels STEP 5 Set the Alarm Delay STEP 6 Complete the Setup STEP 1 Preparation On the sensor control panel set the controls to the following positions before switching ON the system 1 Referring to Figure 8 below turn the LOWER rotary control fully CCW setting 1x 2 Turn the UPPER rotary control fully CW set to 10 3 Set the MODE slide...

Page 20: ...resentation of plant activity However 15 minutes is typically sufficient to provide a good representative sample NOTE If the FFD sensor is to be referenced against an isokinetic sample the collection period must be the same length as the sample run STEP 3 Determine the Dust Level Using the rotary controls determine the Dust level from the process data collected in STEP 2 above If the STATUS LED is...

Page 21: ...vels based upon the dust level calculated in STEP 3 above The STATUS LED on the FFD control panel is typically RED at this point 1 Decide the level at which the HIGH or limit alarm RELAY 1 should be triggered NOTE In general this will depend upon the type of plant as well as your local and national guidelines and or regulations 2 Program the FFD sensor with this value by adjusting the rotary contr...

Page 22: ...larm delay period of 1 minute For dynamic unstable processes set the MODE slide switch to RUN 2 for an alarm delay period of 2 minutes If you are not sure of the dynamics of your process set the alarm delay period to RUN 1 and if RELAY 2 is intermittently triggered increase the alarm delay to 2 minutes bysetting it to RUN 2 Figure 13 Setup procedure Step 5 STEP 6 Complete the Setup 1 Refit any con...

Page 23: ...nk marked SENSITIVITY to HIGH or LOW as follows For dust concentrations above approx 2mg m set the sensor sensitivity to LOW For dust concentrations below approx 2mg m set the sensor sensitivity to HIGH IMPORTANT NOTE If the sensitivity is changed at any point during the setup procedure data collection must be restarted repeat the setup procedure beginning with STEP 2 on page 16 ...

Page 24: ...r to suit the application RELAY 2 Early Warning alarm this alarm level is fixed at HALF the level of the high alarm setting The STATUS LED indicates the alarm status see table below for details STATUS LED MEANING EFFECT GREEN Emissions are below HALF of the high level setting i e below the early warning alarm threshold RELAY 1 OFF RELAY 2 OFF ORANGE Emissions are above HALF the high level setting ...

Page 25: ...Check for any specific health implications of process gas and or dust before commencing maintenance CAUTION Do not allow moisture to penetrate the unit CAUTION PROBE DAMAGE Take care when handling the sensor to avoid bending or damaging the probe Probe damage may result in inaccurate measurements CAUTION Do NOT try to rotate the sensor by its enclosure as this can damage the sensor CAUTION If a ca...

Page 26: ...NSOR WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD Refer to the Special Conditions of Safe Use on pages 6 and 7 for details CAUTION 1 Do not allow moisture to penetrate the unit 2 Do not use solvents or oil based cleaners to remove contamination or accumulations of dirt as these can damage the surfaces and the seals and insulator on the sensor The FFD is designed to require minimal servicing how...

Page 27: ...lse rapidly between GREEN and RED see also the table on page 20 The relays and 4 20mA output will remain in the state present before communication was lost Solution Switch OFF power to the FFD sensor wait five seconds then switch ON power to reset the sensor If this does not remedy the problem check the sensor and connecting cables for damage or water ingress Sensor not working On new installation...

Page 28: ...arm Level 1 adjustable from 2 to 10 000 units Alarm Level 2 fixed 50 of Alarm Level 1 Alarm delay period 1 or 2 minutes Data smoothing One minute data averaging 9 2 SENSOR SPECIFICATION FFD SENSOR Sensor variants Standard sensor 0 200 C up to 390 F Weight approx 1930 g 4 3 lb Probe rod material 316 Stainless Steel PTFE insulator Cable entries 2 M16 cable glands ENCLOSURE Ambient temperature rangeC...

Page 29: ...ee page 10 for details on mounting the sensor Hazardous zone classification ATEX zone 2 22 Cat 3G D Note NEMA equivalents Class I Division 2 and Class II Division 2 9 4 CABLING All cabling must be suitable for use in hazardous zones All cabling should be rated for use up to 65 C 150 F at least to allow for an ambient temperature of up to 50 C 120 F Cables supplied by Goyen Mecair meet these requir...

Page 30: ...ecycling of electrical and electronic equipment according to local government regulations RoHS Compliance Statement Goyen Mecair is compliant with EU Directive 2011 65 EU on the restriction of the use of certain hazardous substances in electrical and electronic equipment RoHS List of Materials ISO 14001 The information is being provided to comply with ISO 14001 Environmental Management which is pa...

Page 31: ...27 INSTALLATION AND OPERATION MANUAL OWNER S RECORD FFD MANUAL FILTER FAILURE DETECTOR NOTES ...

Page 32: ...AIRSYSTEMS com 2019 Pentair Clean Air Systems reserves the right to change product designs and specifications without notice Goyen FFD FILTER FAILURE DETECTOR Installation and Operation Manual Issue01 05 19 ...

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