Summary of Contents for Pentair Goyen Mecair FFD
- Page 1 FFD MANUAL FILTER FAILURE DETECTOR PENTAIR CLEAN AIR SYSTEMS INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR...
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Page 2: Table Of Contents
FFD MANUAL FILTER FAILURE DETECTOR Installation and Operation Manual – Owner's Record TABLE OF CONTENTS INTRODUCTION .................................. Purpose of this Manual ................................Product Safety ....................................Danger from Process ................................Safety Procedures ..................................Limits of Use....................................Additional Information ................................. List of Abbreviations ................................Product Parts and Options .............................. - Page 3 5.2.2 Location Requirements ............................5.2.3 Cabling Guidelines ..............................5.2.4 Grounding the Sensor .............................. 5.2.5 Running Cables between Sensor and Power Supply ..................... 5.3 Mounting the Sensor ................................10 5.3.1 Safety Information ..............................10 5.3.2 Fitting the Sensor to the Stack ..........................10 5.4 Connecting the Sensor ................................
- Page 4 © Copyright by Pentair International Ltd. 2019 This manual is provided as an aid to owners of a Pentair Environmental Systems instrument and contains information proprietary to Pentair Environmental Systems. This manual may not, in whole or part, be copied, or reproduced without the express written consent of Pentair Environmental Systems.
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Page 5: Introduction
1 INTRODUCTION PURPOSE OF THIS MANUAL This manual contains all information necessary for the correct installation, setup, operation, and maintenance of the instrument(s). The procedures given in this manual must be carried out only by suitably trained and qualified personnel. PRODUCT SAFETY The following symbols are used throughout this manual to indicate procedures that, if not followed correctly, may result in personal injury or damage to the equipment. -
Page 6: Limits Of Use
WARNING! Risk of personal injury or injury to others. All personnel must be fully trained and adhere to local and, where applicable, site-specific health and safety laws and guidelines. It is the responsibility of the local organizations to enforce safe working practices at all times. WARNING! –... -
Page 7: Certification
2 CERTIFICATION CONFORMANCE AND RELATED STANDARDS Goyen | Mecair hereby declares that this instrument—within the limits specified in this manual—complies with the essential requirements and other provisions of the pursuant European Union Directives: Low Voltage Directive, EMC Directive, and ATEX Directive. -
Page 8: Product Description
3 PRODUCT DESCRIPTION 3.1 COMPONENTS – SENSOR VARIANTS Figure 1: FFD sensor Standard Sensor (up to 200°C) 3.2 OVERVIEW The FFD is a Filter Failure Detector 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 4–20 mA output from a single, integrated unit to deliver pragmatic and dependable identification of increases of dust emissions and for monitoring leaking or broken bags. -
Page 9: Sensor
3.3 SENSOR The sensor comprises a metal probe rod that protrudes into the stack and connects to the stack via the hexagonal body connected to the sensor enclosure, which contains the advanced electronics module. The sensor is fitted to the stack using a ½″... -
Page 10: Sensor Safety Description
4 SENSOR SAFETY DESCRIPTION 4.1 HAZARDOUS AREAS The sensor may be installed in a metal stack or duct containing hazardous dust, while any ancillary equipment must be installed in the designated Safe Area. The sensor unit is mounted to the ductwork such that the metal probe rod protrudes into the flow of the particulate to be monitored. -
Page 11: Special Conditions Of Safe Use For Sensor Body & Probe
e) Cable Glands and Stopping Plugs certified to EN 60079-0 (e.g. Dust-protected ta/tb/tc; Increased safety Ex e; Flameproof Ex d; Type of protection “n” Ex n) are acceptable provided they are fitted with the appropriate seal to the enclosure and maintain a minimum ingress protection of IP64. (This seal may be incorporated within the gland or plug.) f) The equipment must be powered from a nominal 24 V DC power supply that includes transient protection at no more than 119 V DC. -
Page 12: Sensor Installation
5 SENSOR INSTALLATION 5.1 SAFETY INFORMATION WARNING! – DANGER FROM PROCESS It is possible that the sensors are to be installed in ducting containing process particulate that is hazardous to health. Unless the process conditions are known to be entirely safe, suitable precautions such as the use of breathing apparatus or duct purging/ detoxifying must be employed before any entry is made into the duct for installation or maintenance purposes. -
Page 13: Grounding The Sensor
In summary, the cabling should be installed such that: Heavy vibration is minimized to prevent fatigue and failure. • It is not vulnerable to accidental damage. • It is away from sources of large electromagnetic fields (if possible). • 5.2.4 Grounding the Sensor For FDD sensors it is essential that the sensor body is grounded to the stack wall. -
Page 14: Mounting The Sensor
Support cables at appropriate intervals. Where possible, use cable trays. • NOTE: For EMC reasons (interference rejection and surge handling), all of the cable trays carrying signal cables should be electrically continuous (i.e. the sections should be interconnected by heavy-gauge electrical wiring) and they should be connected to Earth at multiple points along their length. -
Page 15: Connecting The Sensor
Standard toolkit REQUIRED TOOLS Spanner set (22/30 mm A/F) or adjustable spanner AND EQUIPMENT Drilling, welding tools and consumables Prepare the stack or duct to fit the sensor to as follows: 1. Drill a hole with an ID of at least ∅19 mm (¾″) suitable for a ½″ threaded sensor in the stack wall where the sensor unit is to be located. -
Page 16: Relay Outputs
5.4.3 Relay Outputs WARNING! The relays and PCB tracks are not mains rated! Any attempt to use the relays to switch mains could result in damage to the equipment and pose a threat to the operator! Referring to Figure 4 below, the contacts are shown in their normal (non-energized) state. Prepare a suitable cable as described above and connect to the terminals using the second, free cable entry gland. -
Page 17: Connecting The Power Supply
5.4.5 Connecting the Power Supply Figure 6: Connecting the sensor power supply The FFD sensor requires a power supply of between 16 V and 24 V DC @ 80 mA. NOTE: Keep the length of exposed screen (known as a ‘pigtail’) to an absolute minimum (long pigtails degrade EMC performance);... -
Page 18: Setting Up The Ffd
6 SETTING UP THE FFD 6.1 SAFETY INFORMATION WARNING! – HAZARDOUS VOLTAGES Be aware that during the setup procedure, the FFD may be connected to the mains supply! 6.2 CONTROL PANEL OVERVIEW Figure 7: FFD control panel overview The FFD can be set up and operated using the controls located on the raised sensor control panel (see Figure 7 above): two rotary controls (upper/lower) for calibration, •... -
Page 19: Setup Procedure
6.3 SETUP PROCEDURE NOTE: To avoid triggering an external alarm unit whilst setting up the FFD disconnect all connections from RELAY 1 and RELAY 2 (see section 5.4.3 on page 12) by unplugging the headers. The steps involved in setting up the FFD sensor are described in the following sections: STEP 1 –... -
Page 20: Figure 9: Setup Procedure - Step 2
STEP 2 – Capture Process Information Capture some representative information from the plant. It is essential that the plant is running normally during this time. NOTE: Do not carry out this step on start-up or during a bag-cleaning cycle. Figure 9: Setup procedure – Step 2 1. -
Page 21: Figure 11: Setup Procedure - Step 3 Reset Mode Slide Switch
3. Referring to Figure 11, move the MODE slide switch back to RUN 1. Figure 11: Setup procedure – Step 3 Reset MODE slide switch 4. It is now possible to calculate the dust level from the control settings. The dust level is found by reading the position of the upper rotary control and multiplying it by the position of the lower rotary control. -
Page 22: Changing The Sensor Sensitivity
The Early Warning Alarm (RELAY 2) is triggered at HALF the value set for RELAY 1, which in this example this equates to: 1500/2 = 750 units IMPORTANT NOTE: Take care to ensure that the alarm level is set to more than TWICE the calculated dust level, otherwise RELAY 2 will be triggered continuously. - Page 23 Referring to Figure 14 above, adjust the sensor sensitivity by moving the jumper on the JP2 link (marked SENSITIVITY) to HIGH or LOW as follows: For dust concentrations above approx. 2mg/m³ set the sensor sensitivity to LOW. • For dust concentrations below approx. 2mg/m³ set the sensor sensitivity to HIGH. •...
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Page 24: Operation
7 OPERATION 7.1 GENERAL OPERATION When the sensor setup is complete, the operation of the FFD may be monitored from the front panel by checking the STATUS LED. During normal operation, the system settings are as follows: The STATUS LED is illuminated GREEN to show that power is present, and no alarms exist. •... -
Page 25: Maintenance
8 MAINTENANCE 8.1 SAFETY INFORMATION WARNING! Refer all servicing and maintenance to qualified service personnel. WARNING! – EXPLOSION OR COMBUSTION RISK Observe the requirements in the certificates and the precautions and Special Conditions of Use documented in this manual. (Refer to the Equipment Marking Information, section 4.5 on page 7.) The equipment may be opened only when it is de-energized or the area has been designated as ‘safe’... -
Page 26: Sensor Handling In Hazardous Areas
8.3 SENSOR HANDLING IN HAZARDOUS AREAS 8.3.1 Removing the Sensor from the Stack WARNING! – NON-ISOLATED EQUIPMENT Do NOT electrically disconnect the enclosure from the stack (i.e. break the ground/earth connection) in the presence of hazardous dusts. Circulating currents in the ground system could create an ignition hazard. -
Page 27: Troubleshooting
3. Clean off any excessive build-up from the sensor enclosure using a stiff brush or a damp cloth (do not use a dry cloth!). 4. Check that the lock nut moves freely. 5. Apply a small amount of copper slip or grease to the threads to prevent binding. 6. -
Page 28: Technical Data
9 TECHNICAL DATA 9.1 PROCESS AND APPLICATION CONDITIONS Stack temperature range –20 to 200°C (–4 to 390°F) SENSOR – KEY DATA Flue gas velocity >4 m/s Dust level response <1 to 500 mg/m³ (dependent upon application) Application conditions Suitable for measurement in non-condensing flue gases. Note: not recommended for deployment downstream of ESPs or in applications with water droplets or mist at monitoring point. -
Page 29: Dimensioned Drawing - Sensor
9.2.1 Dimensioned Drawing – Sensor 9.3 SENSOR OPTIONS Rod lengths 100 mm (4″), 200 mm (8″), 250 mm (10″), 300 mm (12″), 400 mm (16″), 500 mm (20″), 600 mm (24″), 800 mm (32″), 1000 mm (40″). Note: Imperial measurements are nominal values. Stack connection ½″... -
Page 30: General Notices
GENERAL NOTICES COMPLIANCE Waste of Electrical and Electronic Equipment (WEEE) Directive (2012/19/EU) This symbol, if marked on the product or its packaging, indicates that this product must not be disposed of with general household waste. In the European Union and many countries, separate collection systems have been set up to handle the recycling of electrical and electronic waste. - Page 31 NOTES INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR...
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