Buhler FF-HM-230 User manual

Analysentechnik
Installation and Operation Instructions
Original instructions
Moisture detector controllers
Type FF-
BE410002
09/2017
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2017
Document information
Document No..........................................................BE410002
Version......................................................................... 09/2017

Type FF-
Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended use .........................................................................................................................................................................................................2
1.2 Types .......................................................................................................................................................................................................................2
1.3 Contents................................................................................................................................................................................................................. 2
2 Safety instructions......................................................................................................................................................................................................... 3
2.1 Important advice................................................................................................................................................................................................. 3
2.2 General hazard warnings .................................................................................................................................................................................4
3 Transport and storage .................................................................................................................................................................................................. 5
4 Installation and connection ........................................................................................................................................................................................6
4.1 Mounting...............................................................................................................................................................................................................6
4.1.1 Mounting of moisture detector and adapter ............................................................................................................................. 6
4.1.2 Mounting of detector-controller..................................................................................................................................................... 6
4.2 Electrical connections ........................................................................................................................................................................................6
4.2.1 Controller type FF-19............................................................................................................................................................................7
4.2.2 Controller type FF-HM .........................................................................................................................................................................7
4.2.3 Controller type FF-..-U......................................................................................................................................................................... 8
5 Operation and control ..................................................................................................................................................................................................9
5.1 Adjusting the sensitivity ...................................................................................................................................................................................9
6 Maintenance.................................................................................................................................................................................................................. 10
6.1 Replacement of fuses.......................................................................................................................................................................................10
7 Service and repair.......................................................................................................................................................................................................... 11
7.1 Spare parts and accessories ............................................................................................................................................................................11
7.2 Troubleshooting .................................................................................................................................................................................................11
8 Disposal............................................................................................................................................................................................................................12
9 Appendices......................................................................................................................................................................................................................13
9.1 Technical Data.....................................................................................................................................................................................................13
9.2 Dimensions ..........................................................................................................................................................................................................13
10 Attached documents....................................................................................................................................................................................................15
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Type FF-
1 Introduction
1.1 Intended use
A moisture detector is a device which signals moisture in the gas flow of a sample gas treatment system. Here the electrodes
separated by a gap are located inside the Gas flow.
The circuit devices Type FF analyse the moisture detector FF-3-N and FF-40. These devices allow the analysis of moisture ingress
in the sample gas detected by the moisture detector, and to trigger an alarm.
1.2 Types
These operating instructions apply to the following devices. Please refer to the nameplate to identify your model.
Moisture detector and mounting adapter
FF-3-N moisture detector with cable break detection
FF-40 moisture detector with cable break detection, max. pressure 40 bar
Type G flowcell in PVDF
Type S flowcell in stainless steel
Controllers Voltage Connectible moisture detectors
FF-HM-230 for rail mounting 230/115 V AC for one FF-3-N moisture detector or FF-40
FF-HM-24 for rail mounting 24 V DC for one FF-3-N moisture detector or FF-40
FF-19 19" rack 24 V DC for one FF-3-N moisture detector or FF-40
FF-1-U inside small casing 230/115 V AC for one or two moisture detectors FF-1
FF-3-U inside small casing 230/115 V AC for one FF-3-N moisture detector or FF-40
FF-3-U-2 inside small casing 230/115 V AC for two separate FF-3-N or FF-40
The functionality and operability is identical for all controllers. Differences in the pin assignment are indicated accordingly.
Please note: proper functionality can only be guaranteed when using the specified moisture detectors with the controllers.
1.3 Contents
– Product documentation
– Optional (varies by order)
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Type FF-
2 Safety instructions
2.1 Important advice
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard General information
Warns of voltage Unplug from mains
Warns not to inhale toxic gasses Wear respiratory equipment
Warns of corrosive liquids Wear a safety mask
Warns of explosive areas Wear gloves
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2.2 General hazard warnings
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic, corrosive gases
The measuring gas led through the equipment can be hazardous when breathing or
touching it.
a) Check tightness of the measuring system before putting it into operation.
b) Take care that harmful gases are exhausted to a save place.
c) Before maintenance turn off the gas supply and make sure that it cannot be turned
on unintentionally.
d) Protect yourself during maintenance against toxic / corrosive gases. Use suitable pro-
tective equipment.
DANGER Potentially explosive atmosphere
Explosion hazard when used in explosive areas
The equipment is not suitable for use in explosive areas.
Never operate moisture detectors located in flammable or explosive gas mixtures on the
device.
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Type FF-
3 Transport and storage
The device should be only transported in the original case or in appropriate packing.
If the device is not used for some time, protect it against heat and humidity. Store the device in a roofed, dry, and dust free
room. Temperature should be between –20 °C and 40 °C (-4 °F and 104 °F).
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Type FF-
4 Installation and connection
4.1 Mounting
4.1.1 Mounting of moisture detector and adapter
The flow adapter is equipped with internal threading, G1/4 or NPT1/4 (flow adaptor marked with NPT), for the gas connections
and G1/4 for the moisture sensor. The drawing you find on the backside of the attached data sheet. As well the fittings as the
moisture detector must be used with Teflon sealing or an O-ring to assure proper sealing of the sample stream. Please assure
that the wires are guided tension free.
If there’s particulate or aerosols in the sample gas, a filter has to be installed upstream the detector. Otherwise the particulate or
aerosols can build a layer on the detectors surface inhibiting its function.
The wire should NOT be put into one cable channel with power switching cords. The function can be influenced otherwise.
It might be necessary to adjust the position of the humidity sensor in strongly fluctuating ambient or component temperatures
in order to ensure the necessary tightness in the system.
4.1.2 Mounting of detector-controller
Controller type FF-19
This type is designed as an insert for 19"-housings. The bus connector is a DIN 41612 type B. Used pins of columns a and c are
plated through.
Before inserting the FF-19 into the housing, set the jumpers.
Controller types FF-HM
The type FF-HM is designed for standard 35 mm rail mounting according to DIN EN 50022.
Controller types type FF-..-U
For mounting disassemble the cover by loosening the 4 black screws. The holes for the mounting screws are below the black
screws. Mounting dimensions are 165 mm x 79 mm (6.5" x 3.1"). They are made for screws M4, the screws head should be at least
6 mm (0.24") in diameter.
4.2 Electrical connections
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
WARNING High voltage
Damage to the device in case of insulation testing
Do not proceed insulation tests with high voltage to the device as a whole!
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Type FF-
Insulation test
The device is equipped with extensive EMC protection. If insulation tests are carried out the electronic filter devices will be dam-
aged. All necessary tests have been carried out for all concerned groups of components at the factory (test voltage 1 kV or 1.5 kV
respectively, depending on the device).
Moisture and broken-wire alarms are signaled via two independent dry contacts.
They are made fail-safe in the FF-HM and FF-19 types: The relays switch when power is turned on and no moisture is detected,
they fall off when power fails, moisture or a broken wire is detected. Relays are used in the opposite logic with the types FF-..-U
(switched in the alarm case).
The devices have three LEDs (FF-3-U-2: five LEDs) for POWER, BROKEN WIRE and MOISTURE.
Alarms are monostable; they switch back after the cause for the alarm is removed.
Using the FF-HM or FF-19 type a hold function can be chosen by setting/wiring a jumper. The alarm will stay until the internal or
externally connected reset button is pressed.
4.2.1 Controller type FF-19
Note the drawing 47/075-06-4.
This type can only be used with a 24 V DC power supply. NOTICE!The grounding to PE has always to be attached!
The detector FF-40 is connected to PIN 30 and 31, the shield to PIN 2.
Connect the cable to the FF-3-N. Root strands white and brown to PIN 30 and 31, and shielding to PIN 2.
For FF-3-N and FF-40 the jumper J2 is set to 2-3.
When using older models (FF-1) jumper J2 has to be set to 1-2. Otherwise the controller would signal a broken wire.
Alarm hold function:
To select this function, jumper J1 has to be set to 2-3. An external reset switch or contact can be connected to PIN 26 and 27 of the
bus connector.
NOTICE!When using a detector without broken wire-detection, the broken wire alarm is not used. The relay contact may then
be used to look for power supply failure.
When installing the FF-3-N or FF-40 detector, both relays are used. A power supply failure may be seen by combining both alarm
outputs with an AND function since in working condition EITHER moisture alarm OR broken wire alarm is given.
4.2.2 Controller type FF-HM
Note the drawing 41/073-01-4 and 41/074-01-4.
On the upper terminal are the connections for power supply and alarm relay outputs, on the lower terminal the moisture de-
tector and the external reset switch are connected.
The type FF-HM-230 is suitable for 230 V AC and 115 V AC. The jumpers are factory set to 230 V AC. To change it to 115 V AC discon-
nect the jumper between terminals 9-10 and set jumpers to terminals 8-9 and 10-11. The power supply is connected to terminals
12-13 (PE is 7).
The type FF-HM-24 is only suitable for 24 V DC. The power supply is connected to terminals 12-13. NOTICE!Even with this control-
ler, PE has always to be connected to terminal 7!
Connecting the moisture detector:
The detector FF-40 is connected to terminals 25-26, the shield to 24.
Connect the cable to the FF-3-N. Root strands white and brown to terminals 25-26, and shielding to terminal 24.
When using models FF-3-N and FF-40, terminals 22 and 23 stay open to ensure broken wire detection.
When using older models (FF-1), a jumper must be set between terminals 22 and 23.
Hold function:
To enable this function, a jumper has to be set between terminals 20 and 21. An external reset switch or contact may be connec-
ted to terminals 14 and 15. The shield of this wire is connected to terminal 16.
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Type FF-
NOTICE
To prevent malfunction, the wires to the reset switch have to be shielded!
4.2.3 Controller type FF-..-U
Note the drawing 41/065-07-4.
After opening the housing you will see the switch for the voltage adjustment next to the fuses, which must first be set to your
voltage.
The power supply is connected directly next to the switch (refer to board labelling).
The moisture detector for protective elements FF-3-U-2 and FF-1-U attach to the 5-pin terminal X3 with the white and brown con-
ductors according to the connection diagram. On protective element type FF-3-U the moisture detector attaches to the 3-pin ter-
minal X3. Connect the shielding with care.
The signal relay for Type FF-3-U and FF-1-U connect to the 6-pin terminal above the switch, on Type FF-3-U-2 they connect to a 12-
pin terminal. Please also refer to the connection plans FF-U in the appendix.
Please be sure to sufficiently tighten the screw connections.
NOTICE!With these types both output relays will trigger in the event of a cable break, so also that of the moisture alarm.
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5 Operation and control
NOTICE
The device must not be operated beyond its specifications.
It might be necessary to adjust the position of the humidity sensor in strongly fluctuating ambient or component temperatures
in order to ensure the necessary tightness in the system.
5.1 Adjusting the sensitivity
NOTICE
If the moisture detector controller works in combination with a sample gas cooler, please
wait for at least 5 minutes until the cooler has reached its working temperature.
At the moisture detector controllers FF-HM 230 (24), FF-19 and ER-145/A/Ex sensitivity is reduced by turning the potentiometer
counter clockwise. Turn until the alarm turns off. (We recommend disabling the hold function during adjustment. Otherwise
the reset switch has to be pressed during the whole procedure).
At the FF-..-U the setting of sensitivity is quite the same. But first the enclosure must be opened. The potentiometer is on the up-
per right, next to the terminal block for the moisture detector.
The FF-3-U-2 has for the second moisture detector a Potentiometer on the upper left.
When switching on the power supply the alarm may happen to come on. This has to be taken into account for the design of the
whole system’s control. No other settings need to be done.
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6 Maintenance
During maintenance, remember:
– The equipment must be maintained by a professional familiar with the safety requirements and risks.
– Only perform maintenance work described in these operating and installation instructions.
– When performing maintenance of any type, observe the respective safety and operation regulations.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Toxic, corrosive gases
The measuring gas led through the equipment can be hazardous when breathing or
touching it.
a) Check tightness of the measuring system before putting it into operation.
b) Take care that harmful gases are exhausted to a save place.
c) Before maintenance turn off the gas supply and make sure that it cannot be turned
on unintentionally.
d) Protect yourself during maintenance against toxic / corrosive gases. Use suitable pro-
tective equipment.
The devices work free of maintenance. In case of failure see the table in chapter Troubleshooting [> page11].
The controllers are internally fused by Ø5x20 fuses. To replace the fuses, turn off the power supply (see chapter Troubleshooting
[> page11]). The fuses have to be replaced by the same type.
The following fuses are used:
Controller type Quantity Value Dimensions Part number
FF-19 and FF-HM-24 1 100 mA slow Ø 5 x 20 mm 91 10 0000 44
FF-..-U and F-HM-230 2 32 mA slow Ø 5 x 20 mm 91 10 0000 37
6.1 Replacement of fuses
Replacement of fuses at types FF-19 and FF-..-U
– Disconnect power supply and disassemble insert / open housing.
– Disassemble fuse cover; take fuse out.
– Insert new fuse and reassemble fuse cover.
– Insert FF-19 again / close housing
Replacement of fuses at types FF-HM
– Disconnect power supply.
– With a matching tool press the lashes on the sides away from the sides carefully. Take the front away from the housing.
– Below the upper PCB there are the fuses (one for the FF-HM-24, two for the FF-HM-230).
– Press the front against the housing for reassembling until it fits in.
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Type FF-
7 Service and repair
This chapter contains information on troubleshooting and correction should an error occur during operation.
Repairs to the unit must be performed by Bühler authorised personnel.
Please contact our Service Department with any questions:
Tel.: [phone] or your agent
If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected
by the manufacturer. Please send the equipment inside suitable packaging to:
Bühler Technologies GmbH
- Reparatur/Service -
Harkortstraße 29
40880 Ratingen
Germany
Please also attached the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable
to process your repair order.
You will find the form in the appendix of these instructions, or simply request it by e-mail:
[email protected].
7.1 Spare parts and accessories
Item no. Description
41 11 100 FF-3-N moisture detector (without cable)
41 11 1000 FF-3-N moisture detector (with cable)
41 89 699 FF-40 moisture detector
40 11 000 Type G flowcell (PVDF)
40 11 000I Type NPT1/4 flowcell (PVDF)
40 11 005 Type S flowcell (stainless steel)
41 11 020 Controller FF-HM-230
41 11 030 Controller FF-HM-24
41 11 017 Controller FF-1-U
41 11 015 Controller FF-3-U
41 11 016 Controller FF-3-U-2
41 11 012 Controller ER-145/A, 230 V
41 11 014 Controller ER-145/A, 115 V
41 11 040 Controller FF-19
7.2 Troubleshooting
Problem / Failure Possible cause Solution
No display – no power – check power supply; check connections
– fuse blown – check fuse and change it if necessary
No moisture detection – sensitivity too low – set sensitivity
– moisture detector dirty – disassemble and clean detector
Alarm cannot be reset – sensitivity too high – set sensitivity
– moisture detector completely drowned – disassemble and dry detector or flush with
clean dry air
Tab.1: Troubleshooting
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8 Disposal
Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of use for disposing of elec-
tronic components and devices during disposal.
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Type FF-
9 Appendices
9.1 Technical Data
Moisture detector FF-3-N FF-40
Material: PVDF,1.4571, epoxy resin, 1.4576, PTFE PE, 1.4571, epoxy resin, 1.4576
Cord length: Standard 4 m, 4 x 0.34² Standard 4 m, 2 x 0.25²
Max. operating pressure: 2 bar 40 bar
Operating temperature: 3 °C to 50 °C 3 °C to 50 °C
Cable break detection: yes yes
Type FF-3-N is suitable for ATEX areas (II 2G Ex ib IIC T5 Tamb 3...50 °C)
(Only when using ER-145/A/Ex, refer to operating instructions)
Adapters Type G Type S
Material: PVDF 1.4571
Controllers FF-HM-230 FF-HM 24 FF-19 FF-x-U ER-145/A/Ex
Supply voltage: 230/115 V AC
50/60 Hz ±10%
24 V DC ±10 % 24 V DC ±10 % 230/115 V AC
50/60 Hz ±10%
230/115 V AC
48/62 Hz ±10%
Max. switching output current: 230 V/2 A 24 V AC/DC 2 A 24 V AC/DC 2 A 230 V/2 A AC: 250 V/5 A
DC: 150 V/5 A
Protection class: IP 40
Terminals IP 20
IP 40
Terminals IP 20
IP 20
when built-in
IP 65 IP 40
Terminals IP 20
Ex protection class: - - - - II(1)G [EEx ia Ga] IIC
Max. lead length: 4 m 4 m 4 m 4 m 70 m
Dimensions (WxHxD/mm) 70 x 75 x 109 70 x 75 x 109 8TE x 3HE x 170 94 x 180 x 81 22.5 x 99 x 120
Connection: Terminals Terminals Multi-pole con-
nector
DIN 41612 style B
Terminals Terminals
9.2 Dimensions
FF-3-N FF-40 Flowcell
23.2
≈ 70
G1/4
21
M 12x1
SW17
Flange seal
1.5 mm
9
≈ 30
G1/4
19
SW19
45
33
Ø4.2 G1/4
G1/4
NPT 1/4 (only PVDF)
20
30
18.5
6
Ø19
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FF-HM230 FF-19 FF-x-U ER-145/A/Ex
70
75
Housing depth 109
Housing depth 170
Power
Reset
Moisture alarm
Cable break
alarm
Sensitivity
controller
Housing depth 81
94
180
Housing depth 120
22.5
99
Cable break
Condensate
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Type FF-
10 Attached documents
– Connections diagrams:
47/075-06-4 (type FF-19)
41/073-01-4 (type FF-HM 230)
41/074-01-4 (type FF-HM-24)
41/065-07-4 (types FF-..-U)
– Declaration of Conformity KX410001
– RMA - Decontamination Statement
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