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Goyen Mecair FFD

Pentair Goyen Mecair FFD Installation And Operation Manual

FFD MANUAL
FILTER FAILURE DETECTOR
PENTAIR CLEAN AIR SYSTEMS
INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD
iINSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
FFD MANUAL
FILTER FAILURE DETECTOR
Installation and Operation Manual – Owner's Record
TABLE OF CONTENTS
Purpose of this Manual ................................................................................................................................................................ 1
Product Safety
Danger from Process
Safety Procedures
Limits of Use.................................................................................................................................................................................
Additional Information
List of Abbreviations
Product Parts and Options
2 CERTIFICATION ................................................................................................................................................................... 3
Conformance and related Standards .......................................................................................................................................... 3
ATEX Standards
3 PRODUCT DESCRIPTION .................................................................................................................................................... 4
3.1 Components – 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 Installation ............................................................................................................................................................. 8
5.1 Safety Information ............................................................................................................................................................... 8
5.2 Prerequisites and Guidelines .............................................................................................................................................. 8
5.2.1 Choosing the Best Position for the Sensor ............................................................................................................. 8
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ii INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
5.2.2 Location Requirements ............................................................................................................................................ 8
5.2.3 Cabling Guidelines ................................................................................................................................................... 8
5.2.4 Grounding the Sensor .............................................................................................................................................. 9
5.2.5 Running Cables between Sensor and Power Supply ............................................................................................. 9
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 ........................................................................................................................................................ 11
5.4.1 Safety Information .................................................................................................................................................... 11
5.4.2 Sensor Connections ................................................................................................................................................. 11
5.4.3 Relay Outputs ........................................................................................................................................................... 12
5.4.4 4–20 mA Output ........................................................................................................................................................ 12
5.4.5 Connecting the Power Supply .................................................................................................................................. 13
6 Setting up 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 in a Hazardous Area ............................................................................................. 22
8.4 Cleaning the Sensor ............................................................................................................................................................ 22
8.5 Troubleshooting ................................................................................................................................................................... 23
8.5.1 General ...................................................................................................................................................................... 23
8.5.2 Alarms ....................................................................................................................................................................... 23
9 Technical Data .................................................................................................................................................................... 24
9.1 Process and Application Conditions ................................................................................................................................... 24
9.1.1 User Controls and Functions ................................................................................................................................... 24
9.2 Sensor Specification ............................................................................................................................................................ 24
9.2.1 Dimensioned Drawing – Sensor .............................................................................................................................. 25
9.3 Sensor Options .................................................................................................................................................................... 25
9.4 Cabling ................................................................................................................................................................................. 25
iiiINSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
GENERAL NOTICES ..................................................................................................................................................................... 26
Compliance ................................................................................................................................................................................... 26
Waste of Electrical and Electronic Equipment (WEEE) Directive (2012/19/EU)
RoHS Compliance Statement
List of Materials (ISO 14001)
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LIST OF FIGURES
Figure 1: FFD sensor
Figure 2: Fitting the sensor to the stack
Figure 3: Sensor PCB connections
Figure 4: Connecting the sensor relays
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Figure 5: Connecting the 4–20 mA output .................................................................................................................................. 12
Figure 6: Connecting the sensor power supply
Figure 7: FFD control panel overview
Figure 8: Setup procedure – Step 1
Figure 9: Setup procedure – Step 2
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Figure 10: Setup procedure – Step 3 Calibrate the unit
Figure 11: Setup procedure – Step 3 Reset MODE slide switch
Figure 12: Setup procedure – Step 4
Figure 13: Setup procedure – Step 5
Figure 14: Changing sensor sensitivity
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© 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. Goyen Controls Co Pty Ltd reserve the right to change product designs and specifications without notice. Issue 01 – May 2019
iv INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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.
WARNING!
Warnings alert the user to a procedure or practice which, if not followed correctly, can result in personal injury or injury of others.
CAUTION!
Cautions alert the user to a procedure or practice which, if not followed correctly, can result in damage to the system or ancillary equipment.
NOTES are used to highlight important information that assists the user in carrying out a procedure or in understanding the text.
Danger from Process
It is possible that the sensor is installed in ducting that contains process particulate (and other flue gas constituents) 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 purging/detoxifying, must be employed before entry is made into the duct for installation or maintenance purposes. If in doubt, consult your local Safety Officer and/or local safety procedures.
SAFETY PROCEDURES
Always observe the following safety precautions. Personnel installing, operating, or maintaining the equipment are responsible for their personal safety, and for the correct handling and use of the equipment in accordance with the safety procedures detailed in this manual.
Follow all warnings and instructions marked on the product and in this manual. These safety instructions must be followed to avoid possible personal injury, injury to others, and damage to the product.
If the equipment is used in a manner not specified in this manual, the protection provided by the equipment may be impaired.
Retain these instructions in a safe and known place for future use.
01INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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! – 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’ at that time.
WARNING! – ELECTRIC SHOCK
Only connect to an earthed supply. This unit is a Class 1 construction and must be connected to a Protective Earth connection (GND).
WARNING! – ELECTRIC SHOCK
This product must be connected to a power supply of the same voltage (V) and frequency (Hz) as indicated on the product rating plate and provided in the Technical Data section on page 24 of this manual.
A supply cable with adequate rating must be used. Temperature de-rating must be considered.
CAUTION!
Position the equipment to avoid excessive heat, vibration, humidity, and dust.
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 Technical Data section on page 24 of this manual. Operation outside these limits can result in damage to the equipment or failure to achieve the performance specified.
Pollution Degree 2
This equipment is designed for operation in Pollution Degree 2 environments (non-conductive, transient pollution where occasionally a temporary conductivity caused by condensation must be expected).
Overvoltage Category II
Overvoltage protection for CATII equipment or instruments intended to be supplied for wiring (applicable to both plug-connected and permanently connected equipment).
ADDITIONAL INFORMATION
List of Abbreviations
The following abbreviations and terms are used in this manual:
ACRONYM MEANING
BSPP
CCW
CW
ESP
SPCO
British standard pipe parallel (thread standard)
counter-clockwise (also anti-clockwise)
clockwise
Electrostatic precipitator
single pole, change-over (electrical switch)
Product Parts and Options
Please contact Goyen | Mecair or our local representative for more information on available spares kits, special tools, and accessories for your instrument.
02 INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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.
For details refer to the Declaration of Conformance for this instrument or system (available on request from Goyen | Mecair or our local representative).
ATEX Standards
In addition, the instrument has been designed to be compliant with the below standards.
EN 60079-0:2012 + A11:2013
Explosive atmospheres. Part 0: Equipment – General requirements
EN 60079-15:2010
Explosive atmospheres. Part 15: Equipment protection by type of protection “n”
EN 60079-31:2009 AND EN 60079-31:2014
Explosive atmospheres – Part 31. Equipment dust ignition protection by enclosure “t”
Specifies the general requirements for the construction, testing and marking of electrical equipment used in explosive atmospheres.
Specifies requirements for the construction, testing and marking for Group II electrical equipment with type of protection, “n” intended for use in explosive gas atmospheres. This standard should be read in conjunction with EN 60079-0.
Specifies requirements for design, construction and testing of electrical equipment and Ex components.
03INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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.
04 INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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 6 for details of ATEX-related conditions and requirements.
The FFD is suitable for use in applications of up to 200°C (390°F).
Adjustable Alarm Levels
Dual alarming enables operators to configure early warning and limit (high) 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 in the air stream and the sensing rod to induce a charge signature. The instrument extracts a specific frequency band and filters out the DC current caused by direct particle collisions. The technology outperforms conventional DC tribo-electric systems by extending the range over which the instrument has minimal cross-sensitivity to changing velocity while remaining unaffected by the build-up of particulate on the sensing rod, thereby minimizing signal drift.
BSPP threaded socket and is secured with a lock nut. The instrument requires 24 V DC, nom. Refer to
05INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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.
4.1.1 Hazardous Zone Classification
The instrument is suitable for use in the following Ex zones:
INSIDE STACK OUTSIDE STACK
Gas zone
Dust zone
4.2 CENELEC CODES
4.2.1 Gas Atmospheres
The marking for explosive gas atmospheres includes the following CENELEC codes (see also section 4.5 below):
• Ex nA IIB T6 Gc for the sensor enclosure.
• Ex nA IIB T3 Gc for the sensor body and probe when the maximum stack ambient is +200°C.
The nA applies to the non-sparking connections, and also signifies that the equipment is incapable in normal operation of producing sparks or hot surfaces that may cause ignition.
4.2.2 Dust Atmospheres
The marking for explosive dust atmospheres includes the CENELEC codes (see also section 4.5 below):
• Ex tc IIIC T80°C Dc for the sensor enclosure.
• Ex tc IIIC T200°C Dc for the sensor body and probe when the maximum stack ambient is +200°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.
Zone 2 Zone 2
Zone 22 Zone 22
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 which it is connected has been de-energized. This includes the plugging/ unplugging of the screw terminals from the PCB-mounted headers.
b) Neither the enclosure nor any of the labels attached to it are to be rubbed with a dry cloth or anything else that might
cause a build-up of electrostatic charge.
c) A connection must be made between the earth stud on the outside of the enclosure and the duct wall. The connection
shall be made as follows
• The cable shall have a cross-sectional area of at least 4 mm².
• 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 or gas is present, this connection shall be maintained during the withdrawal of the probe.
d) This equipment is suitable for an ambient temperature range of –20°C to +50°C and the standard range of atmospheric
pressure; the user/installer shall ensure that the process temperatures and pressures, including within the dust stack, do not cause these parameters to be exceeded.
06 INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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