01/98

1355 Mendota Heights Road, Suite 200 Mendota Heights, MN 55120

Phone: (651) 451-1710 Fax: (651) 457-7684 http://www.durag.com






D-FW 230
Filter Monitor








D-FW 230

Table of Contents

1. Applications ........................................................................................................................................1
2. Principle of Operation........................................................................................................................1
3. Basic Characteristics.........................................................................................................................1
4. Functional Description ......................................................................................................................2
5. Description of System Components ................................................................................................2
6. Specifications .....................................................................................................................................6
7. Choosing the Measuring Point .........................................................................................................7
8. Mounting .............................................................................................................................................8
9. Installation...........................................................................................................................................9
10. Start-up............................................................................................................................................10
11. Maintenance....................................................................................................................................11
12. System Components and Accessories........................................................................................12
13. Technical Drawings .......................................................................................................................13


Figures and Tables

Fig. 1 System Components......................................................................................................................3
Fig. 2 Block Diagram................................................................................................................................4
Fig. 3 Control Unit ....................................................................................................................................5
Fig. 4 Choosing the Measuring Point.......................................................................................................7
Fig. 5 Mounting.........................................................................................................................................8
Fig. 6 Electrical Installation.......................................................................................................................9
Fig. 7 Dimensional Drawing of Control Unit...........................................................................................13
Fig. 8 Dimensional Drawing of Sensor with flange, according to DIN 2633 DN 38...............................13
Fig. 9 Dimensional Drawing: Sensor, 1 (G1), according to DIN ISO 228.............................................14
Fig. 10 Dimensional Drawing: Sensor with 1
1
/
2
" NTP ............................................................................14



D-FW 230 Page 1

1. Applications
The DURAG D-FW 230 filter monitor may be used for continuous monitoring of filter installations in flue
gas ducts or in duct work for dust extraction, etc. The filter monitor is placed on the clean-gas side, behind
a filter, and will report any defect. By using filter monitors at the most important emissions sources or
filters, appropriate action may be taken in the event of a malfunction, to prevent or limit damage, i.e., by
shutting down the defective filter chamber.
This system offers several advantages over comparable optical devices, including low purchase,
installation and maintenance costs, as well as extremely high performance.


2. Principle of Operation
The DURAG D-FW 230 filter monitor operates according to the principle of triboelectric measurement.
When dust particles collide with one another, they acquire an electrical charge. If these electrically
charged particles strike the measuring probe, the charge is transferred. The current flowing through the
probe is thus proportional to the number of particles colliding with it.
The result will accurately correspond to dust emissions, since it accounts not only for dust concentration,
but also the velocity of the particle flow. Dust concentration may be determined by calculating the particle
flow velocity.
In addition to dust concentration and particle flow velocity, the ability of the particles to give off an
electrostatic discharge is a decisive factor, and in turn contributes to the measured result. Humidity and
particle type play an important role in this case.


3. Basic Characteristics
In-situ measurement, directly behind or in the filter
Continuous measurement
Integration which may be freely activated or switched off
Compact design
Two main components: a sensor located directly in the flue gas duct and a control unit in an easily
accessible location
Control unit displays the measured value and operational status
Protection from dust or moisture penetration (IP65)
Rugged construction, no moving parts
Easy mounting, installation and operation
Performance may be easily monitored

D-FW 230 Page 2

4. Functional Description
The sensor records the electrical charge of the dust using a measuring probe inserted directly into the flue
gas duct. It then processes the signal into a 4-20 mA signal. In addition to the amplification of the input
signal, other necessary tasks are performed during signal processing, including rectification and damping
of the signal.
These operations are carried out entirely in the sensor, that is to say, possible interference is minimised
(signal processing takes place directly in the sensor, measured values are transmitted as interference-
resistant signals).
The measured value is compared in the control unit to a set limit value. In the event of limit exceedence,
signalling occurs by means of a relay.
A switch on the control unit allows the measurement signal to be uncoupled so that the limit value may be
set. The current limit value is then displayed and may be set using a potentiometer.
The measuring probe may be disconnected electrically from the amplifier chain in order to perform a zero-
test ("4mA" switch on the control unit). The unit cannot then display the dust content (measured value =4
mA).
An integration period may be added to smooth the measurement signal. The zero-test occurs
automatically without integration.


5. Description of System Components
Overview
A complete system features two groups of equipment and operations:
1. Sensor Measuring probe
Amplifier
20 mA output driver for the measurement signal
Setting the sensitivity
Selection of the integration period
Zero-test

2. Control unit Power supply
Connection terminals
Display of the measured value
Limit-value relay, with LED on the front panel
Switch and potentiometer for setting the limit value
Change-over switch for the integration period
Switch for checking the zero


D-FW 230 Page 3






Fig. 1 System Components
D-FW 230 Page 4

Sensor

The sensor consists of the measuring probe in the flue gas duct, the flange, the amplifier and cable.
Operations are carried out essentially by the measuring probe and the amplifier chain, which amplifies the
current from the sensor and converts it into a 4-20 mA signal.
The amplification is set digitally using a six-way DIL switch.
The signal from the pre-amplifier is rectified and integrated during signal processing. The two possible
integration periods are selected by means of the "OFF Int. ON" switch on the control unit.
A voltage-current conversion from 4 to 20 mA takes place as a final step before transmission to the
control unit.
The offset alignment of all amplifiers in the signal path may be checked thanks to a relay that electrically
uncouples the sensor ("4mA" switch on the control unit).



Fig. 2 Block Diagram
D-FW 230 Page 5

Control Unit
The Control Unit may be installed in an easy accessible position and includes the following functions:
Power Supply
Rated voltages 115 or 230 V-AC (as stated on type tag), 50/60Hz
Safety fuse 100mA at 230VAC, 200mA at 115VAC
Display:
A digital display indicates the current measured value or, if the " " switch is activated, the set limit
value.
" OFF Int. ON" Switch (Integration):
An integration period may be activated or deactivated.
" 4mA" Switch (Zero-test):
By activating the "4mA" switch, the measuring probe is separated from the amplifier. This aids in
checking the zero. In the case of an exactly set zero point, 4 mA will be displayed. The integration is
automatically deactivated during the zero-test.
" " Switch (Limit Value):
The " " switch brings up the set limit value on the display. This may be set to a desired value via the
potentiometer.
Limit-value Exceedence:
An exceedence of the set limit value is signalled via a relay, and also indicated by the LED on the front
panel.

Fig. 3 Control Unit
D-FW 230 Page 6

6. Specifications

Gas temperature -20-200C (-4..392F), optional 500C (932F)
Ambient temperature -20..50C (-4..122F)
Penetration depth of the
measuring probe
400mm (15.75 in.)
optional 80 mm (3.15 in.), 250 mm (9.84in.), 700 mm (27.56 in.).
Special length available upon request
Measured-value signal 4-20 mA, max load 500 Ohms
In case of overload, maximun of 28 mA
Limit-value contact Relay output for signalling limit exceedence: 250V-AC/ 100VA (resistive
load), threshold selectable using potentiometer on the front panel
Displays Digital display of the 20 mA signal
Indication of limit exceedence via LED
Integration period 2 sec. or 20 sec., selectable
Power supply 230 V-AC (optional 115V-AC), 50/60 Hz, 10 VA
Enclosure rating (electronics) IP65
Function test Manual zero-test
Cable length Length of connection cable between Sensor and Control Unit =2,80m.
Custom length up to 6m
Weigths Control Unit 3,0 kg
Sensor 1,9 .. 4,5 kg, depending on the used flange/socket-type and on
the length of the probe
Flow velocity of monitored gas >7m/sec.; at lower velocities, the dust concentration must be
correspondingly high.
D-FW 230 Page 7

7. Choosing the Measuring Point

The measuring point must be located on the clean-gas side of the flue gas duct, at least 2 m. beyond the
filter.
The length of the flow path prior to reaching the filter monitor must total at least 5x the diameter of the
channel.
If dust concentration is low, the selection of the measuring point is especially important in order to take full
advantage of the triboelectric measuring principle. The chosen measuring point must be located at a site
where both the flow velocity is high and the longest possible measuring probe may used.

The following diagram displays three potential measuring points behind a filter installation. Measuring
points 1 and 3 are unfavourable. Mounting the filter monitor at measuring point 2 is the best choice.



Fig. 4 Choosing the Measuring Point


In order to keep moisture away from the sensor isolator, the sensor should be mounted horizontally or
with a downward slope.
D-FW 230 Page 8

8. Mounting

A flange with a welded pipe socket is provided for mounting the sensor. Optionally, a corresponding
flange with pipe sockets may be supplied. For dimensional drawings, please see figures 8 through 10.


Flange/
Socket
Standard: DIN 2633 nominal size 32, row 1
alternative: socket with 1 (G1) female thread, according to DIN ISO 228
alternative: socket with 1
1
/
2
NPT male thread
The flange/socket is to be welded on such that the insulator projects 10 to 15 mm into
the flue gas channel.
d1 Diameter of the flue gas duct.
This dictates the length of the measuring probe. Penetration depth 50 to 70% of d1,
maximum 1000 mm.
d2 Interior diameter of the pipe socket
At least 36 mm. overall internal width
Fig. 5 Mounting

In stacks with flue gas temperatures over 150
0
C or weak insulation, thermal shields and/or insulating
gaskets should be employed. It must be ensured that the electronics housing is never heated above
50
0
C.
D-FW 230 Page 9

9. Installation

The electrical connections for the D-FW 230 are made in the control unit terminal box, on the 10-pole
terminal strip, as demonstrated in the connection plan. The cables for the power supply, recorder output
and switch output must be installed separately. The connection to the recorder should be shielded. The
grounded lead for the power supply is to be connected at the control unit housing. The electrical
connection from the sensor to the control unit is made using a cable and plug connection.

Contact Description
X11 Power supply
X12 Potential-free switch contact for the limit exceedence alarm
X13 No function
X14 Connection for measured-value recorder, range 20 mA, mass-related. If no
recorder is connected, contacts X14:1 and X14:2 must be bridged.
X15 Connection for current meter (for units manufactured 08/96 and after)


Fig. 6 Electrical Installation

Caution!
All installations involving the sensor and control unit must observe the relevant VDE regulations, and those
of the local public utilities.
D-FW 230 Page 10

10. Start-up

Caution: Operating voltage must be compared with that of the
nameplate!

Start-up may begin after proper mounting and installation. The filter monitor is aligned at the factory, so
that only the amplification and limit value need to be set.
Limit Value:
The limit value may be set anywhere between 4 and 20 mA. The " " switch is activated, and, by
turning the potentiometer, the display is set to the desired value.
Setting the Amplification:
The amplification is set using a six-way DIL switch in the sensor. The switch is accessible once the
sensor cover is opened. The amplification is to be set such that signal changes are already recognisable
during normal, interference-free operation.

S1:1 S1:2 S1:3 S1:4 S1:5 S1:6 Amplification

ON ON * * * * 67

ON * * * * * 45

* ON ON * * * 31

* ON * * * * 21

* * ON ON * * 14.5

* * ON * * * 10

* * * ON ON * 6.7

* * * ON * * 4.5

* * * * ON ON 3.1

* * * * ON * 2.1

* * * * * ON 1

* * * * * * 0.4 **


* OFF
** For all units manufactured 08/96 and after
D-FW 230 Page 11

11. Maintenance

If the measuring probe is ever damaged, it must be replaced.

Cleaning the Probe and the Insulator:
The probe is maintenance-free under normal operating conditions. Only in the case of a filter defect is the
sensor to be taken down. The probe/insulator may be cleaned with a cloth. If caking occurs due to high
relative humidity in the monitored gas, or adherent dust, cleaning must be performed at regular intervals.

Zero-Testing
The zero-point should be checked monthly. The 4 mA switch on the control unit must be activated, and
the zero-point should be at 4 mA, +/- 0.2 mA. If deviations occur, the zero may be adjusted as follows:
The potentiometers are located in the sensors evaluating electronics.
The settings must occur in the sequence P1, P3, P2 whereby the potentiometers P2 and P3 may only be
newly set in exceptional cases.

P1 Zero-point The zero-point of the evaluation electronics is aligned.
Settings: By activating the "4mA" switch on the control unit, the
measuring probe is electrically uncoupled.
The displayed measured value is set to minimum with potentiometer P1.
P3 4 mA The zero-point of the evaluation electronics is aligned to 4mA.
Settings: By activating the "4mA" switch on the control unit, the
measuring probe is electrically uncoupled
The displayed measured value is set to 4 mA with potentiometer P3.
P2 System sensitivity The sensitivity of the amplifier is selected.
Settings: DIL switch S1:6 set to ON, the rest OFF. The measuring points
MP3 and MP4 must be connected. A defined current will be fed through
these points.
The measured value is set to 20 mA with Potentiometer P2.
Potentiometer P2 must be set only if a repair has been made to the
sensor, and may only be performed by the repair service.
D-FW 230 Page 12

12. System Components and Accessories

Quantity Art-Code Description

1 D-FW230-System D-FW 230 filter monitor
consisting of the sensor and control unit
rated voltages 230V, 50/60Hz (optional 115V)
length of measuring probe: 400 mm
mounting: DIN-flange

1 D-FW230-G1 Option:
mounting: 1(1G) thread.

1 D-FW230-ST08 Option:
length of measuring probe: 80 mm.

1 D-FW230-ST25 Option:
length of measuring probe: 250 mm.

1 D-FW230-ST70 Option:
length of measuring probe: 700 mm.

1 upon request Option:
custom measuring probe lengths available upon request

Accessories / Replacement Parts

1 D-FW230-S Sensor for the D-FW 230 filter monitor
length of measuring probe: 400 mm
mounting: DIN-flange

1 D-FW230-B Control unit for the D-FW 230 filter monitor
rated voltages 230V, 50/60Hz (optional 115V)

1 D-FW230-FL Mounting materials:
flange with pipe socket for welding to the flue gas duct

1 D-FW230-DI
Mounting and incidental items:
gasket between sensor and flange on the flue gas duct


D-FW 230 Page 13

13. Technical Drawings


Fig. 7 Dimensional Drawing of Control Unit



Fig. 8 Dimensional Drawing of Sensor with flange, according to DIN 2633 DN 38
D-FW 230 Page 14





Fig. 9 Dimensional Drawing: Sensor, 1" (G1), according to DIN ISO 228







Fig. 10 Dimensional Drawing: Sensor with 1
1
/
2
" NTP