Pentair Goyen Mecair FFD User manual

iINSTALLATION 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

ii INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................................................................................. 1
Purpose of this Manual................................................................................................................................................................ 1
Product Safety .............................................................................................................................................................................. 1
Danger from Process .......................................................................................................................................................... 1
Safety Procedures ........................................................................................................................................................................ 1
Limits of Use................................................................................................................................................................................. 2
Additional Information ................................................................................................................................................................. 2
List of Abbreviations............................................................................................................................................................ 2
Product Parts and Options.................................................................................................................................................. 2
2 CERTIFICATION................................................................................................................................................................... 3
Conformance and related Standards.......................................................................................................................................... 3
ATEX Standards ................................................................................................................................................................... 3
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
FFD MANUAL
FILTER FAILURE DETECTOR
Installation and Operation Manual – Owner's Record

iiiINSTALLATION 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

iv INSTALLATION 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)............................................................... 26
RoHS Compliance Statement............................................................................................................................................. 26
List of Materials (ISO 14001)............................................................................................................................................... 26
LIST OF FIGURES
Figure 1: FFD sensor ................................................................................................................................................................... 4
Figure 2: Fitting the sensor to the stack..................................................................................................................................... 10
Figure 3: Sensor PCB connections ............................................................................................................................................. 11
Figure 4: Connecting the sensor relays...................................................................................................................................... 12
Figure 5: Connecting the 4–20 mA output .................................................................................................................................. 12
Figure 6: Connecting the sensor power supply.......................................................................................................................... 13
Figure 7: FFD control panel overview ......................................................................................................................................... 14
Figure 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 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

01INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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.
1 INTRODUCTION

02 INSTALLATION 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 British standard pipe parallel (thread standard)
CCW counter-clockwise (also anti-clockwise)
CW clockwise
ESP Electrostatic precipitator
SPCO 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.

03INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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
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 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.
EN 60079-31:2009 AND EN 60079-31:2014
Explosive atmospheres –
Part 31. Equipment dust ignition protection
by enclosure “t”
Specifies requirements for design, construction and testing of electrical equipment and Ex
components.
2 CERTIFICATION

04 INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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.
3 PRODUCT DESCRIPTION

05INSTALLATION 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″BSPP threaded socket and is secured with a lock nut. The instrument requires 24 V DC, nom. Refer to
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.

06 INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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 Zone 2 Zone 2
Dust zone Zone 22 Zone 22
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.
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.
4 SENSOR SAFETY DESCRIPTION

07INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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. This requirement will be met if the power supply meets the requirements of the Low Voltage Directive.
g) If the equipment is likely to come into contact with aggressive substances (e.g. Acidic liquids or gases that may attach
metals or solvents that may attack polymeric materials relied upon for sealing), then it is the responsibility of the user
to take suitable precautions that prevent it from being adversely affected thus ensuring that the type of protection
(Dust exclusion Ex tc and Non-sparking device Ex nA) is not compromised.
4.4 SPECIAL CONDITIONS OF SAFE USE FOR SENSOR BODY AND PROBE
a) The ½″sensor body must be mounted in the dust stack so that the PTFE insulator is positioned within the wall of the
dust stack, to protect the insulator from a build-up of electrostatic charge and to protect it from any possible impact.
b) Neither the PTFE insulator of the ½″sensor body 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 electronic charge.
c) If the ½″Sensor Body and Sensor Probe are used with a Sensor Enclosure, then a connection shall be made between
the stud on the Sensor Enclosure and the dust stack 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/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 aggressive substances (e.g. Acidic liquids or gases that may attack
metals or solvents that may affect polymeric materials relied upon for sealing), then it is the responsibility of the user
to take suitable precautions that prevent it from being adversely affected thus ensuring that the type of protection
(dust exclusion) is not compromised.
e) The ambient temperature range within the dust stack in which the ½″Sensor Body and Probe are mounted must
be no more than –20°C to +200°C.
4.5 EQUIPMENT MARKING INFORMATION
WARNING! – ELECTRIC SHOCK
Potential Electrostatic Charging Hazard (see instructions).
WARNING!
Do not open when energized!
The FFD sensor unit has two labels applied to its enclosure: a serial number label and a label showing the ATEX-related
Ex/CE marking obtained by the manufacturer for this instrument.
The equipment in normal operation is incapable of producing arcs, sparks, or hot surfaces, which may cause ignitions, and
is designed to be installed and used in accordance with EN 60079-14:2014.
For details refer to the Special Conditions of Safe Use above.
ATEX
DUST ZONE ZONE 2/22
Certificate number: PCME15ATEX0002X
Certification code:
Outside stack (enclosure)
Ex nA IIB T6 Gc
Ex tc IIIC T80°C Dc
Ta = –20°C to +50°C
Inside stack (sensor body, probe)A
Ex nA IIB T3 Gc
Ex tc IIIC T200°C Dc
Ta = –20°C to +200°C
II 3G/D
Manufacturer’s name: PCME Ltd.
Manufacturing address: St Ives, Cambs, PE27 3GH, UK
Model number: as applicable
Year of manufacture: as applicable
AThe probe does not generate heat; therefore, the surface temperature is dependent upon the stack temperature, maximal +200°C (390°F).

08 INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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. If in doubt, consult your local Safety Officer and/or local safety procedures.
WARNING! – ELECTRIC SHOCK
Ensure that only the cables types specified are used for powering and interconnection of equipment.
5.2 PREREQUISITES AND GUIDELINES
5.2.1 Choosing the Best Position for the Sensor
When selecting a mounting location for the sensor, the following guidelines are based on the related standardsBand
should be taken into consideration to ensure optimum performance of the instrument, safety, and for compliance
purposes.
The best position for the sensor unit is in a section of ductwork where the particulate has an even distribution and
the flow is linear. This would ideally be in a vertical or horizontal section of duct that has no bends or obstructions
for at least three duct diameters downstream or upstream. In many applications, a compromise 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
performance:
• In the longest, straightest, unrestricted section of ductwork available.
• In metallic ductwork (for non-metallic ducts contact Goyen | Mecair).
• Away from ambient or radiated temperatures greater than +50°C (120°F).
• Where possible, the equipment should be mounted out of direct sunlight, precipitation, and away from
running water.
• Hazardous Zones: refer to the Sensor Safety Description on page 6 for details of ATEX-related special conditions
and requirements.
5.2.3 Cabling Guidelines
Cables should be fixed such that they are free from excessive vibration and not under strain. Cables should
be secured in accordance with good engineering practice (e.g. using cable trays where possible) and careful
consideration should be given to the positioning of cables so that they are not damaged easily.
Cables should be routed to avoid sources of large electromagnetic fields, such as heavy switching gear. Care taken
during the installation of the cables ensures a long, maintenance-free life and avoids possible damage to the sensor.
BThe definitive guide for isokinetic sampling port location is given in standards ISO 9096 and EN 13284-1.
5 SENSOR INSTALLATION

09INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
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. This is necessary for Ex safety.
In addition, poorly grounded sensors may pick up external noise producing false high readings.
Ensure the installation complies with the following requirements:
• The sensor may only be fitted to a metal duct or stack. (If the stack is not metallic or you are concerned that the
stack may not provide a suitably earthed shield for the sensor, please contact Goyen | Mecair.)
• The grounding strap (or earth wire) provided must be connected to ensure the sensor body is securely grounded
to the metallic stack wall. The sensor is electrically grounded to the ductwork by the mechanical connection made
between the sensor and the socket, and also by the external grounding strap.
NOTE: The grounding strap must be connected between sensor enclosure and stack wall. Relying on the stack
connection only is not acceptable in hazardous areas!
• When connecting the grounding strap between sensor enclosure and stack wall leave sufficient length so that the
sensor can be removed and placed on the ground or platform for maintenance without disconnecting.
• For threaded connections: Do NOT put PTFE tape around the thread (as this can compromise the sensor
grounding connection)!
• If necessary, remove excessive rust from the thread and socket and apply a copper-loaded grease.
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. Preferably, and if feasible, the two cables should be twisted together
loosely as they are laid. Alternatively, they may be clipped together at regular intervals along their length.
At the sensor end, the earth cable should be bonded to the sensor enclosure body, or to a point on the stack
immediately adjacent to the sensor head, using a low-resistance screw termination. At the power supply, the
earth cable should be bonded to the same mains earth point as is used to connect the power supply safety
grounding strap.
See below for information on cable lengths.
CABLE LENGTH GROUNDING WIRE CONDUCTOR AREA (mm²)
0–3 m (0–10 ft) not required
3–10 m (10–33 ft) 4
10–30 m (33–100 ft) 6
30–100 m (100–330 ft) 10
Above 100 m (330 ft) 16
5.2.5 Running Cables between Sensor and Power Supply
CAUTION!
Do NOT route cables where they may be at risk from lightning damage (e.g. over exposed roofs).
• To prevent water from entering the instrument, mount all instruments and accessories with the cable entry
glands facing downward.
• After inserting and connecting a cable, fasten the cable glands tightly onto the cable to form a seal. Leave a little
slack in the cores.
• Cable sheathing must always penetrate the cable entry gland fully, and the gland must be fastened tightly to it.
• Where a cable run approaches the instrument from above, it must be run underneath the instrument and then
curved up to the cable gland.
• Leave sufficient slack in the cable to allow the sensor unit to be removed and placed on the ground/platform
for servicing.

10 INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
• 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. Cable trays are
typically secured to grounded metal structures, which satisfies this requirement.
• The cable screen must be terminated correctly.
• Any unused cable glands must be blanked 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
in inaccurate measurements.
CAUTION!
Do NOT try to rotate the sensor by twisting its enclosure as this can seriously damage the sensor.
5.3.2 Fitting the Sensor to the Stack
Figure 2: Fitting the sensor to the stack
1 Sensor enclosure
2 Heat shield
3 Lock nut (30 mm A/F)
4 Insulator
5 Probe rod
6 Stack connection socket (threaded)
7 ½″BSPP thread
8 Hexagonal sensor body (22 mm A/F)
9 Earth stud assembly
10 Breather
11 M16 cable glands (2 off)

11INSTALLATION AND OPERATION MANUAL – OWNER'S RECORD FFD MANUAL – FILTER FAILURE DETECTOR
REQUIRED TOOLS
AND EQUIPMENT
Standard toolkit
Spanner set (22/30 mm A/F) or adjustable spanner
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.
2. Fit a suitable socket [6] (based on the sensor-to-stack connection [7]). This must be securely welded to the stack.
The socket [6] should be installed at a slight upward angle, so that the probe rod points downward allowing any
condensate to drain off into the stack.
NOTE: If the duct is not vertical, take care to ensure that the socket is slightly angled and does not point upward
to prevent water ingress. For more information on sensor location and pre-installation preparations
please contact Goyen | Mecair.
Alternatively, sockets can also be mounted on preformed 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 the earth stud assembly at the rear of its enclosure [9].
4. Tighten the lock nut [3] against the socket [6] to secure the sensor in position.
5.4 CONNECTING THE SENSOR
5.4.1 Safety Information
WARNING!
Ensure the cabling is not connected to the control unit power during wiring.
CAUTION!
Do NOT try to rotate the sensor by its enclosure as this can seriously damage the sensor.
5.4.2 Sensor Connections
The sensor connections can be found below the raised control panel which carries the sensor controls and status
indicator. Refer to Figure 3 below for their location and the type of connectors.
Connect the power supply last, leave the cable gland (on the right) closest to the power connector free for this
purpose (see also Figure 6 on page 13).
Figure 3: Sensor PCB connections

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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. 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 4–20 mA Output
Figure 5: Connecting the 4–20 mA output
The FFD is fitted with a non-isolated 4–20 mA output capable of driving a 250Ωload. Referring to Figure 5, connect
to the 4–20 mA terminals as shown.
The 4–20 mA output is scaled from 0–200% of the high (limit) alarm setting. If, for example, the alarm is set
to 400 units, an emission level of 800 units will give an output current of 20 mA.

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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); however, the signal wires may be longer.

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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,
• 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 enclosure cover lid with the 4 off screws. This prevents
accidental adjustment and unauthorized tampering.
6 SETTING UP THE FFD

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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 – Preparation
• STEP 2 – Capture Process 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 switch to RUN 1.
4. Switch ON power to the FFD sensor.
After an initial delay of approx. one second, the STATUS LED illuminates (ignore the colour of the LED, it is not important
at this point).
Figure 8: Setup procedure – Step 1

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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. To begin collecting information, set the MODE slide switch to SET. The STATUS LED starts flashing to indicate that data
is being collected.
2. Run the data collection process as long as required (up to two hours maximum).
In general, a longer collection period will provide a more accurate representation 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 flashing GREEN, do not adjust the lower control at this stage.
• If the STATUS LED is flashing RED, proceed as follows:
1. Referring to Figure 10, turn the LOWER rotary control CW, step-by-step through each setting (×1, ×10, …), until the
STATUS LED changes from flashing RED to flashing GREEN.
Figure 10: Setup procedure – Step 3 Calibrate the unit
2. Then slowly turn the UPPER rotary control CCW, until the STATUS LED changes from flashing GREEN to flashing RED.