VarTech Systems ESW Workstation Series Manual

Transcription

VarTech Systems ESW
Workstation Series Manual
VT150ESW, VT500ESW, VT550ESW,
VT190ESW, VT900ESW, VT950ESW
P h o n e : 2 2 5 - 2 9 8 - 0 3 0 0 | F a x : 225-297-2440 | s a l e s @ v a r t e c h s y s t e m s .c o m | w w w.vartechs y s t e m s . c o m
ToughStation™ ESW Series Industrial Computer
Model Number:
VT150ESW
VT500ESW
VT550ESW
VT190ESW
VT900ESW
VT950ESW
(15” display)
(15” display w/ C1/D2 Purge Unit)
(19” display)
Serial Number: ________________________________
* The Power Cube™ computer has become part of a new product family known as the ToughStation Series
industrial computers.
Copyright © 2009. All rights reserved.
No warranty of any kind is made with regard to this manual, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. We assume no responsibility for any errors that
may appear in this document. No commitment is made to update, nor to keep current the information contained in this document. No part of this document may be copied or reproduced in any form or by any means
without prior written consent.
ToughStation and Power Cube are trademarks of Vartech Systems, Inc. Other brands and trademarks are
the property of their respective owners.
Table of Contents
Page
Chapter 1 - Introduction and Overview
The ToughStation™ Power Cube Industrial Computer System.............. 1-1
Using this Manual ............................................................................... 1-1
Safety Information............................................................................... 1-2
Receipt of System Components .......................................................... 1-2
Technical Assistance ........................................................................... 1-2
Overview of Power Cube Series System Features................................... 1-3
Power Cube Technical Specifications ..................................................... 1-4
Chapter 2 - Installation
Installation Requirements ........................................................................ 2-1
Outdoor Installations ........................................................................... 2-2
Installing a ESW Series Industrial Computer...................................... 2-3
Hardware Requirements for Wiring .................................................... 2-4
Connecting Power to the Computer .................................................... 2-5
Chapter 3 - Set Up and Operation
Start Up Procedure................................................................................... 3-1
System Configuration and Resource Conflicts ........................................ 3-1
Adding Expansion Cards ......................................................................... 3-2
Installing an Expansion Card .............................................................. 3-2
Chapter 4 - Maintenance and Repair
Preventive Maintenance Schedule ........................................................... 4-1
Check Every Three Months................................................................. 4-1
Replacing the Battery .......................................................................... 4-2
Chapter 5 – (Optional) Purge Units
Class 1 / Div 1 Purge Unit Data…………………………………………5-1
Class 1 / Div 2 Purge Unit Data…………………………………………5-3
Appendix B - Product Warranty
Vartech Systems Support Service........................................................... A-1
Vartech Systems Limited Warranty........................................................ A-1
-i-
List of Figures
2-1.
Page
Mounting Dimensions and Hardware Assembly ................................................2-3
-ii-
Chapter 1
Introduction and Overview
The ToughStation™ ESW Series Industrial Computer System
Congratulations on the purchase of your new Tough Station™. The Power Cube
computers define a new category of computing available to industrial computer
users. Power Cube systems are completely integrated Pentium® class computers
contained within an environmentally protected NEMA 4x enclosure. The enclosure’s sophisticated closed-loop heat exchanger maintains a cool interior while
the fail-safe damping and isolation system protects against external shock and vibration.
Pentium processors and supporting chipsets guarantee high reliability and longterm compatibility with the software of today and tomorrow. Robust NEMA 4x
enclosures tolerate a wide range of operating temperatures and humidity levels.
These rugged features combine with ease of use. ToughStatons are easy to install,
easy to use, and easy to expand.
Using This Manual
This manual provides the information you need to install and operate an ESW
Series ToughStation. This manual covers these topics:
x
x
x
x
x
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Appendix A
Introduction and Overview
Installation
Set Up and Operation
Maintenance and Repair
Product Warranty
For future reference, record your ESW Series model and serial number inside the
front cover of this manual.
1-1
Safety Information
This manual uses the following caution and warning statements to draw your attention to important information.
Caution! If you do not follow instructions, there is a risk you may damage the equipment.
Warning! Hazardous voltages are present. If you do not follow instructions, there is a risk of
electrical shock and danger to personal health.
Receipt of System Components
When receiving your ToughStation™, carefully check the outside packing carton
for damage incurred during shipment. If any carton is damaged, notify the local
carrier and submit a report to Vartech. Remove the packing slip and check to
make sure all ordered components are present. Be sure that no spare parts or accessories are discarded with the packing material. Do not return any equipment to
Vartech without a Return Material Authorization number (RMA#).
See Appendix A.
Technical Assistance
If you encounter a problem with your ToughStation/Power Cube, review the configuration information for each step of the installation and operation procedures.
Verify that the computer’s settings and adjustments are consistent with component
manufacturer recommendations. If the problem persists, contact Vartech
Systems Technical Support between the hours of 8:00 am and 4:00 pm EST at
phone number (215) 773-3601. When calling technical support, please have the
following information on hand:
x
x
x
The ToughStation model and serial number.
Any error messages and the BIOS configuration. (if applicable)
The problem encountered and any corrective action taken.
1-2
Overview of ToughStation ESW Series System Features
The NEMA Enclosure
ToughStation enclosures are built to meet or exceed NEMA 4, 4x, 12 and 13 requirements. Dust, dirt, dripped or hose-directed water, oil and coolants are effortlessly shrugged off by the enclosure. The rugged aluminum heat exchanger and
heavy-gauge stainless steel door and ring are built to withstand the most corrosive environments. An optional purge system is available for use in Class 1, Division 1 or Division 2 environments.
Cooling System
ESW systems utilize a sophisticated closed loop thermal management system.
Heat generated internally is efficiently ejected through the use of bi-planar finned
aluminum heat exchangers and a forced convection plenum. Two fans provide air
circulation and are fitted with ball bearings for long life.
Shock Resistance
ToughStations have two levels of shock and vibration isolation. Failsafe exterior
elastometric isolators integrated into the heat sink casting provide the first level of
isolation for the entire chassis. The second level of protection utilizes individual
isolators for the Power Cube.
1-3
Power Cube Technical Specifications
Processor - 1.73 Ghz Intel Pentium Core 2 Duo Mobile Processor T5300 (Other processors are available upon request)
BIOS - Award Bios 4MB Flash memory
O/S – Microsoft XP Professional
System Memory – 2 DDR2 533/667 SDRAM sockets, 2GB standard, 4GB optional (~3.25
recognizable)
Chip Set – Intel 945GME northbridge
VGA – Built-in Integrated Intel 945GME Graphics
Hard Disk Drive
160GB Fast Access SATA drive
Power Input – 12 VDC, Optional: 12/24 VDC; AC by available brick; 6 to 32VDC without
DVD
Power Consumption – 40 watts max
Back I/O Ports – 1 PS2 mouse port
- 1 PS2 keyboard port
- 1 VGA port
- 1 DVI-I port
- 2 RS-232 COM ports
- 2 LAN ports
- 4 USB 2.0 ports
- 3 Audio jacks: line-in, line-out, mic-in
Front I/O Ports – 2 USB 2.0 ports
PCI Expansion – Optional 1 or 2 PCI Slots
DVD Drive (E-IDE / ATAPI) – DVD-R, DVD+R, DVD-RW, DVD+RW, DVD-R DL, DVD+R9,
CD-R CD-RW
Environmental - Temperature: Operational: + 5°C to + 60°C / + 41°F to + 140°F
Storage:
- 40°C to + 65°C / - 40°F to + 149°F
- Humidity: Operational: 10 ~ 80% (relative; non condensing)
1-4
Mounting –
VESA Mount Pattern (100mm) for flexible mounting options
Options: Shock Mount Bracket, Custom Brackets
Dimensions - 10.65” x 8.5” x 3”
Weight - 5 lbs
Warranty - 1 year standard, Optional 2 or 3 year
1-5
Chapter 2
Installation
Installing a ToughStation™ ESW Series industrial computer is simple and
straightforward. This chapter will give the basic information necessary for a successful installation. Be certain to read all the instructions before proceeding with
the installation.
Installation Requirements
ToughStations are supplied with mounting hardware for easy installation. When
considering a mounting location, keep in mind the weight of the unit, available
power connection and access to other peripheral equipment necessary for system
operation. If installing the computer outdoors, be certain to read the recommendations for outdoor installations on the next page.
ToughStations have their own circuit breaker designed to protect internal components. The power wiring to an ToughStation relies on the building/installation site
for power protection. A circuit breaker must be in line prior to the ToughStation.
ToughStations require 4 Amps maximum at 120VAC and 2 Amps maximum at
230VAC. The circuit breaker before ESWs should be selected based on the wire
gauge used to supply the ToughStation. 14-16 AWG wire and a 10-15A 2-pole
breaker are recommended.
ToughStations must be securely mounted to a structure that will hold a weight
equal to four times the unit’s weight of 91 pounds (43 kg). The computer enclosure must have complete vertical and lateral support. It is recommended that
metal framing channels and fittings be used (such as Unistrut™ or Superstrut™)
for ESW computer installations.
Caution! A ToughStation must be installed in a location capable of supporting four times the unit
weight of 91 pounds (43 kg). Failure to mount the unit in a suitable location could cause the unit to
become a hazard to personnel and equipment.
Attention! L’Ordinateur ToughStation Industriel doit être installé dans un endroit capable de
soutenir quatre fois le poids de l’ordinateur qui pèse 91 livres (43 kg.) Ne pas installer l’ordinateur
K6 dans une location appropriée peut résulter à des dommages à la personne et à l’équipement.
2-1
If it is planned to mount the ToughStation in a rack or cabinet, the following
requirements must be observed:
1. Verify there is sufficient airflow for safe operation within the rack or cabinet.
Verify the installation will not exceed the maximum ambient temperature of
122°F (50°C) when combined with other installed equipment.
2. Make certain the mounting hardware is not compromised by the rack or cabinet installation.
3. Verify that the connection of the equipment to the supply circuit does not
overload the circuit, and that a reliable earth ground is maintained for the
units power connection.
Outdoor Installations
ToughStations are dust and moisture proof; however, solar radiation from direct
sunlight can overheat the enclosure. Solar radiation will also degrade the display
window and keyboard covers (if so equipped), and reduce readability of the display due to glare. To minimize the impact of solar radiation, the following display
orientations are listed in order of preference:
x
x
x
x
Facing North is the preferred orientation. The majority of solar radiation is directed at the sides of the enclosure that have the smallest surface area. Minimum direct sunlight falls on the enclosure’s heat exchanger panels.
Facing East is fair. Morning solar radiation directly heats the enclosure’s display area.
Facing West is poor and should be avoided. Solar radiation directly heats the
enclosure’s heat exchanger panels for most of the day.
For Southern latitudes, facing South is the preferred orientation.
Caution! To avoid equipment damage, any ToughStation installed outdoors must be provided with
shielding from direct solar radiation. If shelter is not available, you must install the optional
sunshield.
Attention! Pour éviter d’endommager votre équipement, l’ordinateur ESW installé a l’extérieur doit
être couvert avec une protection contre les radiations solaires directes. Si un abris n’est pas
disponible, l’installation d’une protection solaire (optionelle) est nécessaire.
2-2
Installing the ESW Series Tough Station
Warning! The ESW enclosure must be installed by trained professionals following good
industrial practices for electrical equipment. When these instructions conflict with local laws
and requirements, local laws and requirements shall prevail.
Danger! L’enceinte du ESW doit être installée par un personnel qualifié familié avec la
pratique de l’industrie électrique. Si ces instructions sont en conflit avec les lois et
demandes locales, les lois et demandes locales sont prédominantes.
Tools and Materials Required for Installation
x a device or manpower capable of lifting at least 91 lbs (43 kg)
x ESW mounting hardware (included)
x metal framing channels (Unistrut™ or Superstrut™ recommended)
x conduit and connectors
x torque wrench and socket or end wrench
x carpenter’s level, measuring and marking instruments
Figure 2-1. Mounting Dimensions and Hardware Assembly
2-3
After gathering the necessary tools and determining the general location for the
unit installation, install the enclosure as follows:
1. Locate the approximate position at which the unit is to be installed. Make sure
to allow sufficient clearance for opening the door and installation of conduit
and/or cable connections. Mark the mounting surface where the top edge and
one side of the enclosure will be aligned.
2. The mounting points of the unit are located in a rectangular pattern 18.5” wide
by 21” high. The mount points are ¾” from the sides, and 1½” from the top
and bottom of the installed enclosure (see Figure 2-1). The standard unit
comes with four 3/8”-16 bolts that are sized to work with threaded wall anchors or channel nuts. Other mounting options, such as stands, are also available from Vartech.
3. There are four rubber isolator assemblies in the mounting kit. Each isolator
assembly is comprised of two parts: a donut-shaped part and a T-shaped part.
Insert a mounting bolt into the donut-shaped part and insert it into the large
holes on the front of the mounting flange on the back of the enclosure as
shown in Figure 2-1.
4. Install the T-shaped parts to the mounting holes on the rear of the enclosure
and seat the donut shaped part on it as shown in Figure 2-1. Note that the
T-shaped part will fit very tightly in the mounting hole.
5. Lift the unit into position and tighten bolts.
Caution! The ESW ToughStation weighs in excess of 91 pounds (43 kg). To prevent injury to
personnel or the computer, use appropriate lifting equipment or adequate manpower to position
the enclosure in the mounting brackets.
Attention! L’ordinateur ESW pèse plus de 91 livres (43 kg). Afin d’éviter de créer des dommages
à la personne et à l’ordinateur, utilisez un appareil de levage appropriés ou une force de bras
adéquate afin de positioner l’enceinte dans les taquets de soutient.
Hardware Requirements for Wiring
The factory recommends using the supplied connectors on the bottom panel of the
enclosure for routing power and signal lines, or the following NEMA 4 (IP66)
rated conduit connectors. The standard configuration includes two 1-inch tradesize liquid tight conduit fittings. Other configurations, including sealing fittings
and bulkhead connectors, are also available.
These standard connectors are intended to be used with flexible, nonmetallic conduit or tubing.
2-4
It is strongly recommended that ESW ToughStation installations include a flexible section of conduit (for example, three feet of conduit or two feet of tubing) to
allow the shock and vibration isolators a full range of motion.
Caution! The conduit connectors must be sealed against adverse environments. If the ESW
computer is not connected to a closed conduit system, the connectors must be sealed with a
suitable compound.
Attention! L’étanchéité des connecteurs de fils électriques contre toutes conditions defavorables doit
être assurée. Si l’ordinateur ESW n’est pas connecté à un circuit électrique fermé, l’étanchéité des
connecteurs doit être assurée avec un produit approprié.
Connecting Power to the Computer
Before making power connections, prepare the entry holes on the enclosure bottom panel.
1. Install the two supplied conduit connectors into the two hole openings on the
bottom of the unit.
Warning! To avoid potential electric shock, follow National Electric Code safety practices or your
local code when wiring and connecting this unit to a power source and to electrical sensors or
peripheral devices. Failure to do so could result in injury or death. Only qualified personnel
should perform wiring procedures on the ESW computer.
Danger! Pour éviter possible danger de choc électrique, suivez les pratiques de sécurité du Code
Electrique National ou de votre code local lorsque vous installez les fils électriques ou branchez cet
équipe-ment à une source d’électricité et à un senseur électrique ou un appareil périphérique.
Inobservation de ce règlement peut résulter à des dommages à la personne ou même à la mort.
Toute intervention sur l’ordinateur ESW doit être effectuée par un personnel qualifié.
Warning! Before proceeding, make sure that incoming electrical power has been disconnected and
there is no electrical power on the leads you will be connecting.
Danger! Avant de procéder, soyez sûr que tout courant électri-que a été disconnecté, et assurezvous que le cordon d’alimentation soit débranché.
2-5
After preparing the entry holes, connect incoming power as follows:
1. De-energize incoming electrical power (mains power). Route conduit/wiring
to the ESW enclosure.
2. Verify that a circuit breaker is installed in the line prior to the ESW computer.
The breaker size should be determined by the wire gauge used for installation.
The ESW requires a maximum of 4 Amps at 120VAC and 2 Amps at
230VAC.
3. Verify the power supply line voltage switch setting matches the incoming
power. The voltage switch is located on the bottom of the power supply. The
switch is factory-set to 110 VAC, 60 Hz
Caution! The incoming power switch must be set correctly before powering the ESW computer.
Failure to do so may cause serious damage to the equipment and or injury to personnel.
Attention! L’interrupteur doit être correctement ajusté avant de démarrer l’ordinateur ESW.
Ignorer cette commande peut résulter à de sérieux dommages à l’équipement ou à la personne.
4. Connect 110/220 VAC, 50/60 Hz power to the mains power terminal block
inside the enclosure. Make sure that the “L1/L,” “L2/N” and “GROUND”
leads are correctly connected to the marked positions.
Caution! For safe system operation, the neutral and ground wire must be properly connected.
Attention! Afin d’opérer l’équipement sans danger, les fils électri-ques neutres et la prise de
terre doivent être proprement connectés.
5. Secure the conduit connectors as recommended by the manufacturer.
2-6
Chapter 3
Set Up and Operation
Start Up Procedure
When all connections are secure and any additional cards or peripheral devices
are installed, begin system operation as follows:
1. For units with no external power switch, open the front door of the
ToughStation and turn on the “Power” switch on the internal power strip.
2. The Power Cube will boot up automatically. In the event that the unit does
not power up, press the power button on the front of the unit.
3. For units with touch glass installed, the glass is calibrated at the factory before
shipping. You should not have to align the unit. In the event you need to
align the unit, click on the ELO icon on the task bar. Click on the
“Alignment” box and touch the glass at the target areas to align.
4. If you buy your ToughStation with no Power Cube installed you will need to
load the Touch Drivers from the CD-rom provided.
System Configuration and Resource Conflicts
In units equipped with an ISA bus, incorrect utilization of system resources is the single most significant cause of problems at start up. Hardware interrupt (IRQ), port address and DMA channel
conflicts can be difficult to resolve unless you follow a systematic planned approach when installing
add-on cards and/or software. “Hacking” or trial-and-error resource assignment will almost always
lead to start up problems.
3-1
Adding Expansion Cards
This section explains how to install expansion cards in the Power Cube industrial
computer. Before installing any cards, make sure the card being installed does not
conflict with any other installed cards, or the system configuration. Make sure the
combined power consumption does not exceed the total output limit for the system board. Exceeding the power limits could damage the expansion card.
Electrostatic Discharge Precautions
The Power Cube system board and expansion cards contain components that
could be damaged by electrostatic discharge. To avoid such problems, follow
these precautions to minimize electrostatic discharge.
x
Always work in a static-free area. Before handling the assemblies, discharge
your body by touching a grounded, metal object. When possible, use
grounded electrostatic discharge wrist straps when handling sensitive components.
x
Handle all cards by their edges unless otherwise required. Do not touch the
components on the card unless absolutely necessary. Avoid touching any metal edge connectors.
x
If any assemblies are removed from the Power Cube, place them on an antistatic padded surface. Always store cards in their original, antistatic packaging
when they are not installed.
Installing an Expansion Card
Caution! These are only general procedures. Always refer to the documentation provided with your
card for specific installation information.
1. Configure any jumpers and DIP switches on the card as indicated by the card
manufacturer. See Figure 3-2 to determine which card hold-down(s) to use.
2. Use the “Mains Power” switch to turn off power to the Power Cube.
3. Loosen the end screw and remove the appropriate card cage rod. Insert the
metal fingers of the expansion card into one of the expansion slots. Make sure
the card is fully seated in the connector. Secure the expansion card in place
with the card bracket securing screw. Connect any necessary cables. Install
any additional cards as required.
4. Slip the appropriate card hold-down onto the card cage rod. Install the support
rod into the card cage at the expansion card location. Tighten screws in each
3-2
end of the rod. Move the card hold-down back or forth on the rod until it is at
the location desired along the length of the expansion card.
5. Adjust the height of the hold-down by slowly squeezing the ends together for
short cards, or spreading them apart for taller boards. Be careful to bend the
card hold-down slowly to prevent damage to the hinge joints. Tighten the card
hold-down locking device with the .050 Allen wrench (provided).
3-3
Chapter 4
Maintenance and Repair
ESW Series computers require very little maintenance. The enclosure is watertight but should be checked every three months to ensure that all components are
operating properly. The components that do require regular periodic inspection
are listed below. If the unit requires repair, assembly drawings are provided at the
end of this chapter for reference. Contact VarTech for spare part ordering information.
Preventive Maintenance Schedule:
ESW Series industrial computers are housed in stainless steel. The enclosure may
be cleaned with a variety of industrial cleaners or solvents, following manufacturer directions. To prevent discoloration or deterioration of the enclosure finish,
avoid prolonged contact with acids or strong solvents.
Check Every Three Months:
Internal Components
1. Fans:
x Verify that the CPU fan is operating.
x Verify that the power supply fan is operating.
x Verify that the heat exchanger fans are operating.
2. Verify that all cable and harness connectors are securely fastened.
3. Check that all circuit boards are seated correctly and that their hold-downs are
in place.
4. Check door seal for nicks, breaks or loosened mounting adhesive.
5. Check door latch and hinges for worn, damaged or loose parts.
6. Verify that all conduit and cable connections are secure.
7. Check all cables and harness wiring for nicks and frayed or damaged insulation. Closely check the area where the wiring crosses the enclosure’s hinge
line.
8. Verify that the cables and wiring harnesses are held clear of any sharp edges
and fold or loop correctly when the door is closed.
4-1
External Components
1. Check heat exchanger cooling fins for excess buildup of dust, dirt or other
materials that could reduce the system’s heat rejection. Clean the fins by
flushing them with air or water.
2. Check for loose mounting screws and worn or broken vibration isolators.
3. Check the front panel indicator label for peeling, cracking, lifting or delamination.
4. Check for a cracked or loose display window.
5. Check for torn, cracked or displaced keyboard or mouse pointer surfaces.
Replacing the Battery
A lithium coin-cell style battery provides power to the real-time clock and CMOS
memory. The battery has an estimated life expectancy of three to five years, depending on the operating environment. Warm, humid conditions will shorten battery life. When the battery starts to weaken, it loses voltage. When the voltage
drops below a certain level, the system settings stored in CMOS RAM (for example, the date and time) may be incorrect.
Before replacing the battery, contact Vartech for specific instructions on jumper
placement and system settings/BIOS information. The battery specification is given in the separate system board manual.
Caution! Danger of explosion if battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Dispose of used batteries according to
manufacturer instructions.
Attention! Un danger d’explosion existe si les piles sont installées incorrectement. Remplacer
uniquement avec piles identiques ou d’un type équivalent recommendé par le constructeur. Mettre
au rebut les piles usées conformément aux instructions du fabricant.
4-1
CLASS I APPLICATIONS
15 Cubic Feet Maximum
MODEL 2002
TYPE X
RAPID EXCHANGE® PURGING SYSTEM
INSTALLATION & OPERATION MANUAL
STD Style
(Standard)
FA Style
(Fully Automatic)
For Class 1 Division 1 ESW Workstations
5-1
Table of Contents
D1-Page 2
System Purpose and Description
Purpose, System Description, Important Notes
D1-Page 3
Identifying Your System
Defines specific features of the system
D1-Page 4
General Information
System & Material Specifications, System Accessories, D1-Page 17
Spare Parts, Tools & Test Equipment
D1-Page 18
Enclosure and Device Design
Design Requirements, Adjacent Enclosures, Device
D1-Page 19
Ventilation, Temperature Limitations
D1-Page 5
D1-Page 15
Electrical Supply Requirements
General Wiring Requirements, EPCU Power & Alarm
Signal, Enclosure Wiring Methods & Connections
D1-Page 16
Electrical Power Control Unit
General Layout & Conduit Connection Points
D1-Page 6
Installation Overview
Installation Diagram
D1-Page 7
D1-Page 20
Getting Started
Establishing Connection Sizes, Determining Enclosure
Inlet & Outlet Connection Locations
D1-Page 21
D1-Page 8
System Mounting
LH, RH, TM, BM & WM Configurations,
D1-Page 22
FM & PM Configurations
EPCU Power Rating
Power Rating Nameplate, Assembled Electronics
Electrical & Pneumatic Diagrams
LH, RH, TM, BM, WM, FM, & PM Configurations
Conduit Installation
EPCU Electrical Conduit, Optional Intrinsic Safety Barrier
Conduit and EPCU Conduit Connection Parts
Power Modules & Wiring Diagram
EPCU 120/220 VAC & 24-48 VDC Power Modules
Logic Module & Barrier Wiring
Optional ISB Wiring Requirements & Diagram,
EPCU Power Control Modes
Barriers & Field Adjustments
ISB Description & Factory Programming, LED Display
Indicators,Timer Functions & Settings
D1-Page 9
Hardware Mounting
Enclosure Protection Vent, Warning Nameplates
D1-Page 10
Mounting Plate Dimensions
Mounting Plate Dimension Diagrams
D1-Page 23
Set-Up Procedure
Rapid Exchange® Purging Set-up
D1-Page 11
Mounting Plate Dimensions (cont.)
D1-Page 24
Set-Up Procedure (cont.)
Rapid Exchange® Purging Set-up
D1-Page 12
D1-Page 25
Operating Sequence
Pneumatic Tubing Requirements
Class I Purging Operation
Protective Gas Supply Requirements, Pneumatic
Connection Requirements
D1-Page 26
Trouble - Shooting Procedures
D1-Page 27
Warranty and Liability Statements
Tubing Connection Points
Warranty Notes, General Terms, Limitations
LH, RH, TM, BM, WM, FM, & PM Configurations
D1-Pages 28 & 29 System Maintenance
Tubing Installation
LH, RH, TM, BM, WM, FM & PM Tubing Configurations D1-Pages 30 & 31 Customer Notes
D1-Page 13
D1-Page 14
Purpose
The Pepperl+Fuchs' Enclosure Protection System’s purpose is to
allow the use of general purpose or non-rated electrical or electronic
devices, with exception to devices which produce excessive heat,
utilize combustible gas, or expose arcing contacts to the hazardous
atmosphere, in Type 4 or 12 enclosures in the place of explosion proof
Type 7 enclosures.
Description
Model 2002 Rapid Exchange® purging system operates on a supply
of compressed instrument air or inert gas. It regulates and monitors
pressure of sealed (protected) enclosure(s), in order to rapidly remove
and prevent flammable vapor accumulation within the enclosure(s).
The system is designed to accomplish four air exchanges and
maintain a "safe" (0.25") pressure on one or more enclosures not
exceeding a total volume of fifteen cubic feet. An EPV-2 Enclosure
Protection Vent is required for proper operation. In addition, the
system includes an electrical power control unit (EPCU) that monitors
system operation and controls enclosure power. All start-up
requirements must be satisfied before the EPCU will energize power
to the enclosure(s). This process reduces the Hazardous (Classified)
Area Rating within the enclosure(s), in accordance with the NEC NFPA 70, Article 500, NFPA 496 and ISA 12.4.
D1-Page 32
Systems Identification & Application Information
Important Notes
One (1) permanent file copy and one (1) operations copy of this Manual
must be studied and retained by the operator of this System. User’s
Agents are responsible for transferring this Manual to the user, prior to
start-up.
The contents of this manual have been arranged to allow the use of this
product as a stand-alone device on equipment and enclosures
supplied by the user or its agents. The Manual’s parameters encompass
both National Fire Protection Association (NFPA) requirements and
Pepperl+Fuchs requirements. Pepperl+Fuchs therefore
acknowledges the use of NFPA 496 as a guideline, that we have
enhanced certain NFPA requirements and that additional information
has been compiled to complete this document. The Manual is
intended as a complete guide and must be considered, unless
specifically stated otherwise, that all directives contained herein are
Pepperl+Fuchs requirements for safe, practical and efficient use of
this product.
This System is not intended for use to protect enclosures or devices
which contain ignitable concentrations of gases or vapors. This
exclusion generally applies to process or product analyzing systems
equipment.
All specifications are subject to change without notice.
D1-2
This Enclosure Protection System is offered in various styles. For proper installation and operation, examine the System
Model Number Nameplate to identify the System Style, Area Classification, and Type, as noted below.
SYSTEM CLASS RATING
SYSTEM STYLE
STD - Standard
SA - Semi-Automatic
FA - Fully Automatic
SERIES
MODEL NUMBER
MAXIMUM
TOTAL
ENCLOSURE
VOLUME
Defines Class & Group rating for
Protection System’s method of use
CI - Class I Purging system (Groups C&D)
IB - Class I Purging system (Group B)
Model 2002-STD-CI Type X
SYSTEM TYPE
15 CUBIC FEET MAXIMUM ENCLOSURE VOLUME
CLASS I, DIVISION 1, GROUPS C & D TO NONHAZARDOUS
Type X
T3C
Defines total
protected
enclosure(s)
volume capacity for
this particular
system. Total
enclosure(s)
volume must be
calculated without
regard for
consumed volume
PURGE CONTROL FOR USE IN HAZARDOUS LOCATIONS. CLASSIFIED BY UNDERWRITERS LABORATORIES
INC . ®
IN ACCORDANCE WITH THE NATIONAL FIRE PROTECTION ASSOCIATION
STANDARD FOR PURGED AND PRESSURIZED ENCLOSURES FOR ELECTRICAL EQUIPMENT
NFPA 496- 2003
7L93
Reduces the internal
enclosure area
Division rating from
Division 1 to
nonhazardous
APPROVED BY FACTORY MUTUAL AS ASSOCIATED TYPE X PRESSURIZATION CONTROL
EQUIPMENT FOR USE IN HAZARDOUS LOCATIONS. REDUCES THE INTERNAL AREA
OF A CONNECTED ENCLOSURE IN ACCORDANCE WITH DRAWING NUMBER 129-0211.
AREA
CLASSIFICATION
Defines the area
classification for
which the system is
suitable for operation
APPROVAL
MARKINGS &
DEFINITIONS
Identifies the current
third party approvals
for this system
To assist you through the installation and operation of your Rapid Exchange® purge system, Pepperl+Fuchs has
provided the following information boxes throughout this manual. This information is intended to clarify certain
differences between the model styles and configurations and to warn the user / installer of potential dangers of electrical
shock or enclosure over pressurization.
HELPFUL HINT
IMPORTANT NOTE
WARNING
D1-3
General Information
Recommended Spare Parts
System Specifications
System Dimensions:
Shipping Weight (Lbs.):
Operating Temp. Range:
Supply Pressure Range:
Capacity & Filtration:
Supply Requirements:
Safe Press. Setpoint:
Safe Press. Flowrate:
Exchange Pressure:
Exchange Flowrate:
Exchange Time:
System Supply Port:
Enclosure Supply Fitting:
Enclosure Reference Fitting:
EPCU Conduit Port Size:
EPCU Power Requirements:
See Pages 10 & 11
STD - 45 / SA & FA - 47
-20° F - 120° F
80 - 120 PSI max.
1.5 Oz. @ 20 Microns
Clean Air or Inert Gas
0.25" @ Safe Press.
* 0.1 - 3.5 SCFH / Cubic Ft.
3" - 5"
** 4 SCFM / 240 SCFH
1 Minute / Cubic Ft.
1/4" FPT
1/4" Tube Fitting
1/4" Tube Fitting
1/2" FPT
120 VAC 60 Hz 1Ø
(European 220 voltage only)
240 VAC 50 Hz 1Ø
EPCU Power Consumption:
500 mA
Power Relay Contacts:
20 Amps @ 240 VAC
20 Amps @ 28 VDC
Alarm Relay N.O. Contact:
20 Amps @ 240 VAC
20 Amps @ 28 VDC
Alarm Relay N.C. Contact:
15 Amps @ 240 VAC
10 Amps @ 28 VDC
*
Enclosure integrity determines actual flow rate
**
With regulator set to 60 PSI min. during exchange
Qty
Description
1
1
1
1
1
1
1
1
1
1
1
1
Enclosure Pressure Indicator
1/4" Filter Regulator
Enclosure Pressure Control Valve
Rapid Exchange® Valve Body (STD Style)
1/4" Solenoid Valve Body (SA & FA Style)
Safe Pressure Switch
Rapid Exchange® Pressure Switch
Series 2000 Logic Module-Ver. 2.0
Series 2000 VAC Power Module
Series 2000 VDC Power Module
Installation & Operation Manual
Enclosure Warning Nameplate-CI
510023 (001000)
510057 (002040)
510116 (003440)
510118 (003460)
510075 (002220)
510356 (005200)
510358 (005210)
510279 (005000)
510304 (005020)
510305 (005021)
129-0211
513008 (EWN-1)
Reference part number above for current spare parts
pricing. Immediate pricing is available to all confirmed
customers.
Installation Tools & Testing Equipment
1/2" chuck drill
Complete set of drill bits
1/2" & 3/4" conduit knockout punch or 1" hole saw
Complete set of tubing, conduit bending, instrument fitting
and electrical craftsman hand tools
0 - 5" differential pressure gauge or manometer (connected
to the protected enclosure to measure maximum pressure)
Model 2002 System Accessories
Material Specifications
Filter Regulator Body:
Zinc w/ Enamel Finish
Regulator Handle & Bowl:
Polycarbonate
Enclosure Pressure Gauge:
Alum. w/ Enamel Finish
Rapid Exchange Gauge:
Poly Case & Brass Tube
Rapid Exchange Solenoid:
Brass w/ Enamel Finish
Tube Fittings & Valves:
316 SS Forged Body
Tubing:
316 SS 1/4" .035 Welded
System Nameplates:
Silkscreened Lexan® & SS
Fastener Hardware:
SS Screws & Bolts
Mounting Plate:
316 14 Ga #3 Brush SS
EPCU Enclosure Body:
Bead Blast Cast Alum.
Conduit & Fittings (SA & FA):
Galvanized Steel
Enclosure Warning Nameplate:
Silkscreened SS
Part # (supercedes)
Enclosure Protection Vents
ONE REQUIRED WITH EACH SYSTEM
EPV-2-SA-00
EPV-2-SA-90
Straight w/ Spark Arrestor
Rt Angle w/ Spark Arrestor
Additional Items
SMK -2, -3 or -10
RAH
RAB-1
LCK
TCK
SRM-4000
NJ...
System Mounting Kit
Div. 1 Remote Alarm Horn
Div. 1 Remote Alarm Beacon
L Fitting Conduit Kit
T Fitting Conduit Kit
Switch Resistor Module
P+F NAMUR Sensor
Factory Installed Items
Lexan® is a registered trademark of the General Electric Corporation
IS-A-1
IS-B-2*
IS-C-3*
RP1
RP2
L
Channel A Barrier
Channel B Barrier
Channel C Barrier
Redundant Safe Pressure Switch
Redundant Rapid Exchange® Pressure Switch
Key Lock Assembly
*Requires custom programming information
D1-4
Enclosure & Device Design
Enclosure Design Requirements
Total Volume Calculation
1. All windows must be shatterproof and sized as small as
possible.
1. The total volume of all pressurized enclosures, devices
and wireways must be considered.
2. All NFPA 496 required markings must be placed on or
near all enclosure doors and covers.
2. All enclosure, device and wireway volumes must be
calculated without consideration of internally consumed
space.
3. The enclosure must withstand an internal pressure of
five (5) inches of water without sustaining permanent
deformation and resist all corrosive elements in the
surrounding atmosphere.
4. All lightweight objects in the enclosure, such as paper or
insulation, must be firmly secured.
5. The enclosure should be constructed from materials
such as metal or anti-static polycarbonate to meet or
exceed Type 4 or 12 performance requirements, but
does not require third party approval.
Device Ventilation
1. Enclosed devices within the protected enclosure which
do not exceed 1.22 cubic inches of free volume do not
require ventilation to the protected enclosure.
2. If the free volume of an internal device exceeds 1.22
cubic inches it must be protected by one of the following
means:
a)
6. The installation of obstructions or other barriers which
block or impede the flow of protective gas must be
avoided.
7. The creation of air pockets or other areas which trap
flammable gases within the enclosure or devices must
be avoided.
b) purged in series with the protected enclosure or be
purged separately; or
c)
8. The enclosure should be located in an area where
impact hazards are minimal.
9. If the enclosure is nonmetallic and contains equipment
which utilizes or switches power loads greater than 2500
VA, it must be constructed from substantially
noncombustible materials, such as materials designed
to meet or exceed ANSI/UL94 ratings of 94 V-0 or 94 5V.
Adjacent Enclosures
1. Adjacent enclosures must be protected by one of the
following means:
a)
1. The enclosure must have no surface area which exceeds
80 percent of the flammable or ignitable substance’s
auto-ignition temperature.
2. Internal devices which exceed this temperature must be
protected by one of the following manners.
a)
purged or pressurized in series with the protected
enclosure;
protected by other means; e.g. explosion proof
enclosures, hermetically sealed devices or intrinsic
safe circuits.
2. Adjacent purged or pressurized enclosures must be
designed to meet all construction requirements above.
devices, hermetically sealed housings or intrinsic
safe circuits.
Temperature Limitations
b) purged or pressurized separately; or
c)
ventilated on the top and bottom sides with one (1)
square inch of opening for each four hundred (400)
cubic inches of volume within the internal protected
enclosure, at a minimum diameter of one (1) quarter
inch;
The device is enclosed in a chamber which is cUL or
FM listed as a hermetically sealed device which
prohibits the entrance of flammable or ignitable
substance, and maintains a surface temperature
below temperature limits.
b) It can be proven by testing that the devices will not
ignite the substance involved.
c)
The device is purged in a separate enclosure that
bears an ETW (Enclosure Temperature Warning
Nameplate). Devices may only be accessed after
power has been removed and the device has been
allowed to cool to safe temperature, or the area is
positively known to be nonhazardous.
D1-5
Typical Left Hand Configuration Installation Diagram
Model 2002-STD-CI-LH Shown
ENCLOSURE
PROTECTION
VENT
(required)
PROTECTED
ENCLOSURE
ENCLOSURE
SUPPLY TUBING
ENCLOSURE
REFERENCE
TUBING
ENCLOSURE
CONNECTION
FITTINGS
ENCLOSURE
PROTECTION
SYSTEM
SERVICE
VALVE
PROTECTIVE
GAS SUPPLY
SYSTEM
SUPPLY TUBING
ENCLOSURE
WARNING
NAMEPLATE
EPCU BREATHER
DRAIN FITTING
EPCU POWER & ALARM SIGNAL
WIRING CONDUIT & SEAL
D1-6
Getting Started
Establishing Connection Sizes, Lengths & Bends
TYPICAL SINGLE PROTECTED ENCLOSURE CONNECTIONS
ENCLOSURE PROTECTION VENT
(Required)
1/2"
PROTECTIVE
GAS SUPPLY
HEADER
C
REFERENCE
ENCLOSURE
PROTECTION
SYSTEM
PROTECTED
ENCLOSURE
SUPPLY
A
E
B
Description
A
B
C
System
Supply Tubing
Enclosure
Supply
Enclosure
Reference
D
1/4" O.D. Tubing 1/4" O.D. Tubing 1/4" O.D. Tubing
Fully Reamed
Fully Reamed
Fully Reamed
*Tubing or Pipe Diameter
Maximum Tubing / Pipe Length and
Maximum Number of Bends / Elbows
20 Feet
10 Bends
5 Feet
5 Bends
20 Feet
10 Bends
E
Multi - Enclosure Optional Remote
Venting
Connections
3/4" I.D. Pipe
Fully Reamed
3/4" I.D. Pipe
Fully Reamed
10 Feet
5 Elbows
30 Feet
5 Elbows
TYPICAL MULTIPLE PROTECTED ENCLOSURE CONNECTIONS
B
1/2"
PROTECTIVE
GAS SUPPLY
HEADER
ENCLOSURE
PROTECTION
SYSTEM
SUPPLY
D
PROTECTED
ENCLOSURE
D
PROTECTED
ENCLOSURE
PROTECTED
ENCLOSURE
REFERENCE
C
A
*NOTE: Tube and pipe sizes are trade sizes and are not equal in inside diameters.
DO NOT substitute tube for pipe with same trade size.
HELPFUL HINTS
To ensure adequate protective gas flow to protected enclosure(s), all piping and tubing must be fully reamed.
Precautions must be taken to prevent crimping and other damage to protective gas piping and tubing.
When protecting multiple enclosures with a single enclosure protection system, the enclosures must be
connected in series from the smallest to the largest to ensure adequate protective gas flow.
Determining Enclosure Inlet & Outlet Connection Locations
HELPFUL HINTS
INLET
OUTLET
OUTLET
Connections for Heavier than
Air Gases and Vapors
INLET
Connections for Lighter than
If flammable gases are lighter than air, the inlet
connection to each enclosure must enter near a
bottom corner. The outlet connection, for an optional
enclosure protection vent or piping to an adjacent
protected enclosure, must exit near an extreme
opposite top corner. See diagrams to the left.
If flammable gases are heavier than air, inlet and
outlet connections must be reversed.
In all cases, the most prevalent gas must determine
the location of inlet and outlet connections.
D1-7
System
Mounting
IMPORTANT NOTES
The system should be mounted at EYE LEVEL.
Care must be taken to ensure the system and all
protruding components are clear of all enclosure
accesses (doors and covers) and conduit, pipe, tubing
or cable entries.
LH, RH, TM, BM and WM configurations are intended
for mounting adjacent to the protected enclosure.
LH, RH, TM & BM configurations are also suitable for
2" schedule 40 pipe mounting.
Determine the mounting configuration of your system
using the diagrams on pages 10 & 11.
Remove and save the manila envelope (containing
the enclosure warning nameplate) which may be
taped to the outer surface of the mounting flange.
Although all Bebco systems are factory tested and
calibrated, we strongly suggest a bench test of basic
functions prior to installation.
Mounting LH, RH, TM, BM & WM Configurations
1 . Transfer hole pattern of System mounting plate to
intended surface.
2. Check for obstructions hindering bolt fastening, drill and
ream the mounting holes before mounting the system.
3. Secure the system to the enclosure, or other mounting
surface, using one (1) SMK-3 or equivalent - six (6) 3/8"
x 3/4" stainless steel bolts, nuts and lock washers.
*WM requires one (1) SMK-2 or equivalent - four (4) 3/8"
x 3/4" stainless steel bolts, nuts and lock washers.
Mounting FM & PM Configurations
HELPFUL HINTS
FM and PM configurations are designed to mount through a panel cutout one (1) inch smaller than the overall
height and width of the system mounting plate, using clips and fasteners provided with SMK -10. This design
feature eliminates the need to drill the system mounting bolt holes in the protected enclosure.
FM configurations are intended for mounting adjacent to the protected enclosure.
PM configurations are intended for mounting through a cutout in the protected enclosure surface.
1. Transfer panel cutout pattern to the intended surface.
4. Deburr all cutout surfaces.
2. Check for obstructions which could prohibit bolt fastening
or system pneumatic and electrical connections.
5. Secure system to enclosure using SMK-10, or equivalent
- ten (10) 1/4" x 3/4" stainless steel nuts, bolts, mounting
clips and lock washers.
3. Cut panel cutout pattern on the intended surface.
Typical Examples of Surface, Pipe, Panel & Frame Mounted Systems
Typical Surface Mounted System
Typical Pipe Mounted System
Typical Panel/Frame Mounted System
(Model 1002-LPS-LH Type Z shown)
(Model 1002-LPS-LH Type Z shown)
(Model 1002-LPS-PM Type Z shown)
D1-8
Hardware Mounting
Required Enclosure Protection Vent
Warning Nameplate(s)
All configurations must be mounted in a true vertical position.
An EWN (Enclosure Warning Nameplate) must be located in
a prominent position on or near all enclosure accesses
(doors and covers).
The vent must be located to provide access for routine
testing of the vent’s flapper assembly. A minimum 8"
clearance is required below the vent opening.
1. Determine the vent’s mounting configuration, i.e.;
-00 vertical mount or -90 side mount. (See photos below)
2. Determine vent location and layout vent mounting hole
on the protected enclosure. (As determined on page 7,
“Getting Started”)
3. Using a 1" hole saw or 3/4" conduit punch, drill and
deburr the enclosure protection vent mounting hole.
4. Remove the hub mounting nut from the vent hub and
place the hub, with O-ring intact, through the mounting
hole. The O-ring must be on the outside of the protected
enclosure.
5. Reinstall the hub mounting nut to the mounting hub from
inside the protected enclosure and tighten.
One (1) EWN is provided with each system, located in the
manila envelope taped to the mounting flange of the system.
Additional EWN’s are available from Pepperl+Fuchs.
All EWNs provide labeled spaces allowing the customer to
mark the protected enclosure with: 1) a T Code (temperature
identification number), 2) Class, Group and Division of
surrounding area, and 3) NFPA pressurization Type X, Y or Z,
as may be required by plant and local codes and is required
by NFPA 496.
An ETW (Enclosure Temperature Warning nameplate) must
be located in a prominent position on or near all enclosure
accesses (doors and covers) when the temperature of an
internal component exceeds 80 percent of the ignition
temperature of the flammable vapor, gas or dust involved.
An ETW warns the operator to deenergize all equipment for
a specified length of time, allowing the protected equipment
to cool before opening the protected enclosure. The length
of time required is determined by the customer and can be
factory or field engraved.
All EWNs and ETWs are furnished with an adhesive back, but
should also be riveted or screwed to the protected enclosure.
EPV - 2 - SA - 00
Vertical Mount
Enclosure Warning Nameplate - Class I
Enclosure Warning Nameplate - Class II
EPV - 2 - SA - 90
Side Mount
Enclosure Temperature Warning Nameplate
D1-9
Model 2002
SA & FA
Styles Only
13.75"
.375" O.D.
TYP. 6
10.75"
4.25"
3.5625"
.6875"
11"
22"
20"
SA & FA
Styles Only
13.75"
10.75"
4.25"
3.5625"
SA & FA
Styles Only
11"
.6875"
.375" O.D.
TYP. 6
2002-LH
(Left Hand Configuration)
11"
22"
21.3125"
11"
12"
SA & FA
Styles Only
2002-RH
(Right Hand Configuration)
23"
.375" O.D.
TYP. 6
10.75"
13.75"
4.25"
IMPORTANT NOTE
Dimensions DO NOT include Systems ordered with an
Area Classification of IB (Class I, Division 1, Group B).
Consult factory for mounting plate dimensions.
3.5625"
.6875"
SA & FA
Styles Only
11.5"
20.5"
2002-TM
(Top Mount Configuration)
D1-10
(cont.)
Model 2002
12"
IMPORTANT NOTE
Dimensions DO NOT include Systems ordered with an
Area Classification of IB (Class I, Division 1, Group B).
Consult factory for mounting plate dimensions.
23"
22.3125"
.6875"
3.5625"
11.5"
SA & FA
Styles Only
4.25"
13.75"
12.5"
6"
Add 2" to both
dimensions for
SA & FA Styles
10.75"
.375" O.D.
TYP. 6
2002-BM
(Bottom Mount Configuration)
20"
22"
SA & FA Style
11"
2002-WM
(Wall Mount Configuration)
.25" O.D.
TYP. 10
13.25"
Panel Cutout
12"
10.25"
1.25"
.375" O.D.
TYP. 4
9"
1"
2"
Panel Cutout
23"
24"
TYPICAL -WM
MOUNTING FLANGE
13"
2002-FM & 2002-PM
(Frame & Panel Mount Configuration)
P hone: 2 2 5 - 2 9 8 - 0 3 0 0 | F a x : 225-297-2440 | s a l e s @ v a r t e c h s y s t e m s .c o m | w w w.vartechs y s t e m s . c o m
D1-11
Protective Gas Supply Requirements
Pneumatic Connection Requirements
The protective gas supply to the protection system must be
a clean, instrument quality compressed air or nitrogen and
must contain no more than trace amounts of flammable gas,
vapor or dust.
ALL FITTINGS MAY BE CUSTOMER OR FACTORY FURNISHED
The protective gas supply compressor intake must originate
in a nonhazardous location. Suction duct passing through a
hazardous location and the protection system tubing and
piping must be fabricated from noncombustible materials
suitable for prevailing hazards and environmental conditions.
The protective gas supply must originate from a dedicated
instrument quality compressed air header (1/2" pipe or
larger), no farther than twenty (20) feet from the protection
system. Local compressors and gas cylinders should not be
used before consulting with Pepperl+Fuchs.
regulated from 120 psi maximum to 80 psi minimum.
1. For system supply, one (1) SC-4 1/4" Male Straight
Connector or one (1) NC-4 1/4" Male Elbow Connector
or equivalent fitting per system.
One (1) similar fitting which will connect the inert gas
supply tubing to the inert gas supply header connection
point and one (1) lot of 1/4" O.D., .035" wall thickness,
welded or seamless stainless steel tubing.
2. For enclosure supply, one (1) EFC-4 1/4" Flush
Connector, or one (1) EBC-4 1/4" Feed-Through
Connector or equivalent fitting per system.
3. For enclosure reference, one (1) EFC-4 1/4" Flush
4. One (1) lot of 1/4" O.D., .035" wall thickness, welded or
seamless stainless steel tubing.
5. For multiple enclosure connections, two (2) EPC-12 3/
4" Pipe Mounting Hubs or equivalent and 3/4" 150#
rated pipe couplings & unions per interconnection.
One (1) lot 150# rating 3/4" galvanized or aluminum pipe
and fittings, fully reamed and unrestricted.
PM Pneumatic Connection Requirements
NC-4
SC-4
SYSTEM SUPPLY FITTINGS
In addition to item numbers 1, 4 and 5 above, the
following fittings are required for all PM configurations.
1. For system supply on PM configurations, one (1)
additional EBC-4 or equivalent 1/4" Through Bulkhead
Fitting per system is required.
2. For atmospheric reference, one (1) PRB-4 or equivalent
1/4" female bulkhead fitting and stainless steel sintered
element is required.
EFC-4
EBC-4
ENCLOSURE SUPPLY & REFERENCE FITTINGS
PRB-4
SYSTEM ATMOSPHERIC REFERENCE FITTING
EPC-12
MULTIPLE ENCLOSURE CONNECTION FITTING
D1-12
Tubing Connection Points
LH, RH, TM, BM, WM & FM Configuration Connection Points
Enclosure
Pressure
Gauge
Rapid
Exchange®
Control
Valve
Enclosure
Reference
Inlet
Filter
Regulator
System
Supply
Inlet
Enclosure
Pressure
Control
Valve
Enclosure
Supply
Outlet
EPCU
Pressure
Reference
Tubing
Mounting
Plate
Flame
Arrestor
Fitting
Venturi
Orifice
Enclosure
Pressure
Gauge
Rapid
Exchange®
Solenoid
Valve
Enclosure
Reference
Inlet
Filter
Regulator
System
Supply Inlet
Enclosure
Pressure
Control
Valve
Enclosure
Supply
Outlet
EPCU
Pressure
Reference
Tubing
RESV
Conduit
Flame
Arrestor
Fitting
Mounting
Plate
STD Style
SA & FA Style
®
(with Rapid Exchange
Solenoid Valve)
Venturi
Orifice
(not visible)
PM Configuration Connection Points
Enclosure
Pressure
Gauge
Atmospheric
Reference
Inlet
Enclosure
Pressure
Control
Valve
EPCU
Atmospheric
Reference
Tubing
Flame
Arrestor
Fittings
Rapid
Exchange®
Control
Valve
Filter
Regulator
System
Supply Inlet
Enclosure
Supply
Outlet
RESV
Conduit
Mounting
Plate
HELPFUL HINT
Pneumatic Connections
are bolded.
D1-13
Tubing Installation
HELPFUL HINTS
All work must be performed by technicians qualified in pneumatic tubing and electrical conduit installation.
Pepperl+Fuchs recommends the use of .035" wall thickness, welded or seamless stainless steel tubing.
If flexible tubing is used, it must be installed in a manner which will protect it from damage and corrosion.
Tubing LH, RH, TM, BM, WM & FM Configurations
System Supply Connections
Enclosure Supply & Reference Connections
1. Select or install a protective gas supply header tap, fitted
with the proper tube size fitting and located within
twenty (20) feet of the enclosure protection system.
1. Choose location for the enclosure supply connection(s)
based on the requirements on page 7, “Getting Started”.
2. If a service valve is placed between the protective gas
supply header and the enclosure protection system, it
must be installed in close proximity of the protected
enclosure and be labeled in accordance with NFPA 496,
2003 edition.
3. Select the appropriate fittings required to connect the
protective gas supply to the protection system regulator
as determined on page 12, “Pneumatic Tubing
Requirements”.
4. Determine appropriate tubing route from the protective
gas supply header to the protection system regulator.
5. Bend tubing using industrial grade benders, check tubing
fit to ensure proper seating between the tubing and
fittings. Fully ream all tubing ends.
6. Install tubing and tighten all fittings to fitting
manufacturer’s specifications. Secure tubing to
appropriate structural supports as required.
2. Place the enclosure reference connection fitting directly
behind the enclosure protection system whenever
possible. For systems protecting multiple enclosures in
series, the enclosure reference connection fitting
must be placed on the last enclosure in the series.
(See page 7, “Getting Started”)
3. Drill and deburr enclosure supply and reference fitting
holes on the protected enclosure. Mount the fittings.
4. Determine appropriate route for the enclosure supply
and reference tubing.
Tubing PM Configurations
Enclosure Bulkhead Fittings
1. Select the fittings required to install the System Supply,
System Supply Bulkhead Fitting and Atmospheric
Reference Bulkhead Fitting, (see page 12, “Pneumatic
Tubing Requirements”).
2. Choose location for the system supply bulkhead fitting.
This fitting allows the protective gas supply to pass
through the wall of a protected enclosure to the protection
system’s regulator supply inlet connection.
3. Choose location for the atmospheric reference bulkhead
fitting. This fitting allows the enclosure pressure gauge
and Electrical Power Control Unit (EPCU) to reference
atmospheric pressure.
4. Drill and deburr system supply and reference bulkhead
fitting holes in the protected enclosure. Mount the
fittings.
System Supply & Reference Connections
supply header and the protection system, it must be in
close proximity of the protected enclosure and labeled
in accordance with NFPA 496.
gas supply header to the system supply bulkhead fitting.
4. Determine appropriate tubing route from the system
supply bulkhead fitting to the protection system regulator.
5. Determine appropriate tubing route from the atmospheric
reference bulkhead fitting to the enclosure pressure
gauge’s reference inlet connection.
manufacturer’s specifications. Secure tubing as required.
D1-14
General Wiring Requirements
WARNING
THIS DEVICE CONTAINS ELECTRICAL PARTS WHICH
CAN CAUSE SHOCK OR INJURY
All electrical connections, conduit and fittings on the protected
enclosure must be suitable for the hazardous location in which
they are installed. In addition, all conduit and wire must be
installed in accordance with NEC articles 500-1, 500-2 or 5003 as required and all relevant plant and local codes.
Conduit seals must be utilized on all electrical conduit
connections and poured with an approved compound prior
to operation of the protection system.
Exception: Do not use seals on conduit used as a protected
“wireway” to supply protective gas to adjacent protected
enclosures. The same conduit can be utilized for both
electrical and pneumatic service to an adjacent protected
enclosure(s), provided the conduit is oversized to allow a
minimum free clearance equal to or larger than the pipe size
required between multiple enclosures as stated on page 7,
“Getting Started”.
HELPFUL HINT
Pepperl+Fuchs recognizes it may be impractical to
pour all electrical conduit seals prior to installation in
the field. However, all conduit connections must be
sealed for proper testing and operation of the
Enclosure Protection System.
Therefore,
Pepperl+Fuchs recommends the use of temporary
seals such as duct seal or masking tape for bench or
shop testing, prior to final field installation.
Typical Enclosure Wiring Methods
In a general sense, protected enclosures should be wired
similar to explosion proof enclosures, in accordance with
Article 500 of the National Electric Code - NFPA 70.
Single conductor wiring should be placed in rigid metal
conduit, seal-flex conduit or other mediums approved for
use in the hazardous location surrounding the protected
enclosure. Additionally, NFPA 496 requires the use of
approved seals on all pressurized enclosure conduit wiring
entries, in accordance with NFPA 70. Furthermore, the use
of an approved seal is simply the most practical way to
prevent excessive leakage through conduit connections.
However, while explosion proof enclosures require conduit
seals on all cable entries, in accordance with NFPA 70. Other
methods of sealed cable entries that are suitable for hazardous
locations can be used, such as compression glands.
In conclusion, there are two primary goals. First, the installer
should ensure that all associated wiring and cable is protected
by pressurization or other means, such as explosion proof
conduit or intrinsic safety barriers. Secondly, the installer
should ensure that all associated conduit and wireways are
sealed to conserve protective gas, unless they are used to
supply protective gas to other enclosures or devices.
Typical Enclosure Wiring Connections
Conduit
Explosion
Proof Device
Seal
EPCU Power Requirements
The Electrical Power Control Unit's (EPCU) electrical power
source must originate from a circuit breaker or fused
disconnect suitable for the hazardous location in which it is
installed. The power source should be uninterrupted and the
switch must be located within fifty (50) feet of the protected
enclosure(s) and the enclosure protection system and be
properly marked. For EPCU power specifications see page
4, "System's Specifications".
Conduit
Alarm Signal Requirements
Conduit
Intrinsically
Safe Or Fiber
Optic Device
Seal
Gland
Fitting
Intrinsically
Safe Or Fiber
Optic Device
Cable
Pepperl+Fuchs strongly recommends use of the optional
alarm system contacts of the EPCU, connected to an alarm
system located in a constantly attended location to indicate
the failure of the enclosure protection system. For EPCU
alarm signal specifications see page 4, "System's
Specifications".
Independently
Pressurized
Device
Seal
Pressurized
Raceway
Protected Enclosure
Or Device
D1-15
Electrical Power Control Unit
General Layout & Electrical Conduit Connections
Power Mode
Selector Switch
EPCU Electrical Rating
Nameplate
Power Mode
Selector Switch
(Optional Mounting Hole
-Factory Use Only-)
Type 7
Explosion Proof
Enclosure
LED Display
Type 7
Explosion Proof
Screw Cover
1/2" NPT Conduit
Connection Ports
Typical 6
(See Important
Notes below)
Type 7
Explosion Proof
Breather Drain
(See Important
Notes below)
IMPORTANT NOTES
For proper moisture drainage of the Type 7 enclosure, the installer must 1) move the Type 7 breather drain to
one of the bottom conduit entrances or 2) use drain seals on all conduit connected to the bottom two conduit
entrances.
The Type 7 breather drain is not provided or required with PM configurations.
Top two conduit entrances will be dedicated for Intrinsic Safe wiring ONLY when the EPCU is supplied with
Pepperl+Fuchs' optional ISB Intrinsic Safety Barriers.
EPCU LED Displays
Alarm Only
Alarm & Bypass
D1-16
EPCU Power Rating
EPCU Electrical Power Rating Nameplate
The EPCU (Electrical Power Control Unit) of this Type "X" Rapid Exchange® purging system is offered in various styles. For
proper installation and operation, begin by examining the EPCU Electrical Rating Nameplate to identify the System Input
voltage and power requirements, enclosure power and alarm contact ratings and third party approval markings. Next, match
the LED display of your EPCU with one of the displays shown on page 16. The EPCU LED Display will help identify the options
featured on your system e.g. Normal Running mode or Conditional Bypass.
REQUIRED WARNING
STATEMENTS
EPCU SERIAL
NUMBER
MODEL 2000 ELECTRICAL POWER CONTROL UNIT
CAUTION: OPEN CIRCUIT BEFORE REMOVING COVER
ATTENTION: OUVRIR LE CIRCUIT AVANT D'ENLEVER LE COUVERCLE
SERIAL NO.
XXXXXX
CSA Encl. 3
CLASS I, DIV. 1, Gr C&D
CLASS II, DIV. 1, Gr E, F, G HAS
UL & FM APPROVALS ONLY
INPUT VOLTAGE & POWER REQUIREMENTS
ENCL POWER & ALARM CONTACTS
ARE RATED 120/240 VAC, 20 AMPS
120 SINGLE PHASE, 60 CYCLE, 1 AMP
240 SINGLE PHASE, 50 CYCLE, 1 AMP
AREA CLASSIFICATION
EPCU INPUT POWER
REQUIREMENTS
Defines the area classifications for
which the EPCU is suitable for
operation
Factory set at time of order
Assembled EPCU Electronics Module
Logic Module
120/240 VAC
Power Module
Power Module
Cable
Pressure Switch
Module
D1-17
Electrical & Pneumatic Diagrams
LH, RH, TM, BM, WM & FM Configurations
Electrical Power
Supply Conduit
Hub
Conduit Seal
Union
Union
Conduit Seal
Sintered
Vent
Breather
Drain
Venturi
Orifice
Electrical Power
Control Unit
Required Enclosure
Protection Vent
Enclosure
Reference
Tubing
Enclosure Reference
Bulkhead Fitting
Enclosure
Pressure Gauge
System
Supply
Rapid Exchange®
Pressure Gauge
System
Supply
Tubing
Enclosure Supply
Bulkhead Fitting
Enclosure Pressure
Control Valve
Regulator
System Supply
Connection Fitting
*Rapid Exchange®
Control Valve
Enclosure
Supply
Tubing
* Solenoid on
SA & FA Styles
Protected Enclosure
PM Configurations
Required Enclosure
Protection Vent
Electrical Power
Supply Conduit
Hub
Atmospheric Pressure
Reference Bulkhead
Fitting
Electrical Power
Conduit
Conduit Seal
Conduit Seal
Enclosure
Pressure
Reference
Enclosure
Pressure
Reference
Enclosure Pressure
Gauge
Electrical Power
Control Unit
Rapid Exchange®
Pressure Gauge
System Supply
Bulkhead Fitting
Inlet
Union
Electrical
Power to
Enclosure
Atmospheric
Reference
Tubing
System
Supply
Union
*Rapid Exchange®
Control Valve
System
Supply
Tubing
Enclosure
Supply
Discharge
Regulator
System Supply
Connection Fitting
* Solenoid on
SA & FA Styles
Enclosure Pressure
Control Valve
Protected Enclosure
D1-18
EPCU Electrical Conduit
EPCU Conduit Connection Parts
Unplug the four unlabeled conduit entrances located on the
sides and bottom of the EPCU enclosure (See page 16,
"EPCU Layout" for conduit entrance layout).
Fitting Kits Can Be FactoryFurnished
The installer must mount the Type 7 drain fitting supplied
with the system (except for PM configurations) in one of the
bottom conduit entrances of the EPCU, or utilize drain seals
on all conduit connected to the bottom two (2) conduit
entrances of the EPCU.
Following the instructions listed below, install all conduit,
fittings and seals (or drain seals if utilized) between the
EPCU, alarm system (if utilized) and the protected
enclosure(s). Plug all remaining EPCU conduit entrances.
1. Choose the location for the enclosure’s electrical conduit
connection(s) based on the requirements on page 15,
“Electrical Supply Requirements”.
1. To connect enclosure power from the EPCU to the
protected enclosure, one (1) LCK (L fitting Conduit Kit) or
equivalent conduit elbow, coupling and seal fittings.
2. For EPCU to enclosure wiring connection with one (1)
additional conduit connection path, one (1) TCK (T fitting
Conduit Kit) or equivalent conduit tee, coupling and seal
fittings.
IMPORTANT NOTE
Model LCK & TCK are offered primarily to OEM's
attempting to achieve a "field ready" installation. In
all cases, limited pipe fitting skills will be required.
Pre-cut 150# galvanized steel pipe nipples can be
acquired from local plumbing shops, but a hole saw or
punch and wrenches are required to install kits.
2. Drill and deburr enclosure conduit fitting holes in the
protected enclosure. Mount the fittings.
3. Determine appropriate route for the enclosure electrical
enclosure and alarm signal conduit.
4. Measure, cut and thread conduit, check conduit fit to
insure proper seating. Fully ream all conduit.
5. Install conduit and tighten all fittings to fitting
manufacturers specifications. Secure conduit to
6. Seal all conduit with an approved compound prior to
operation of the protection system.
Optional Intrinsic Safety Barrier Conduit
Systems supplied with optional Intrinsic Safety Barriers (ISB)
will be supplied with clearly labeled isolated conduit entries,
a solid body wireway with snap cover and plexiglass wiring
partitions. These accessories provide a fully isolated wiring
path to the barrier wiring terminal located on the lower left
corner of the EPCU Logic Module. All IS wiring must be
isolated.
TCK “T” Fitting
Conduit Kit
1. Choose the location for the enclosure’s IS conduit
3. Determine appropriate route for the IS conduit.
LCK “L” Fitting
Conduit Kit
D1-19
Power Modules & Wiring Diagram
EPCU 120/240 VAC Power Module Layout
Isolated Coil
Voltage Transformer
Power Control Switch
Cable Header
Pressure Switch
Cable Header
Voltage Input Selector
Header (factory set for
120 VAC power)
Logic Module
Cable Header
1 Amp Input Fuse
Redundant Safe
Pressure Relay
Rapid Exchange®
Solenoid Valve (RESV)
Relay
Alarm Relay
Enclosure
Power Relays
RESV Factory Wiring
Terminal
Power Module
Wiring Terminal
EPCU 120/240 VAC
Power Module
20 Amp Enclosure
Power Fuse
VAC & VDC Power Module Electrical Wiring Diagram
Field Wired
Power Module
Terminals
12
Isolated
Enclosure
Power Relays
Isolated
Alarm
Relay
NO
NO
12
12
12
20 AMP12
12
FUSES
1
2
3
EPCU Power
Supply Terminals
120 VAC
*240 VAC (Optional voltage)
4
In
Gnd Hot
Gnd Hot
Neu
Neu
* European Single Phase 240 VAC only.
Power and alarm terminals are feed-thru dry switch contacts.
Caution should be exercised to ensure that the EPCU wiring
is properly connected.
All terminal connections to the EPCU should be wired with
spade or round lugs.
NO
5
6
7
Out
In
Out
Enclosure
Power
Supply
Terminals
8
NC
9
10
NO Com NC
Remote Alarm
Relay Terminals
Using 12 gauge maximum to 16 gauge minimum wire only,
check EPCU power requirements (See page 15) and wire to
the EPCU power source and alarm system (if utilized). Then
route power source(s) through the EPCU power in and out
terminals to all non-rated devices within the protected
enclosure(s).
D1-20
Logic Module & Barrier Wiring
EPCU Logic Module & Pressure Switch Module
Barrier Fault & Active
Status Indicators
Primary
Microprocessor
Barrier C
Socket
Factory
Programing
Header
Primary Safe
Pressure Switch
Rapid Exchange®
Switch
Redundant
Controller
(GAL)
Barrier B
(Installed)
Power Module
Cable Header
Barrier A
Socket
EDT, SLT &
RET Timers
Barrier
Wiring
Terminal
Space for Optional
Redundant Safe
Pressure Switch
EPCU Pressure
Switch Module
Space for Optional
Redundant Rapid
Exchange® Switch
EPCU Power Control Modes
Pressure Switch
Calibration Access
LED Status
Display
EPCU Logic Module
Optional ISB Wiring Requirements
( - ) BLUE
( + ) BROWN
INTRINSICALLY SAFE AUXILIARY INPUTS
B
A
-
+
-
C
+
-
+
All optional intrinsic safety (IS) wiring must be isolated from
all other electrical wiring using the dedicated IS conduit
entrances and wireway of the EPCU, (See "Optional ISB
Conduit Installation" on page 19 for more details). In addition,
all wiring must be installed in accordance with the NEC and
all relevant local and plant codes.
The ISB Intrinsic Safety Barriers are designed to function in
conjunction with a customer furnished switch and SRM4000 Switch Resistor Module, or an NJ...NAMUR Sensor.
The customer supplied switch must have dry contacts which
contain no inductance or capacitance.
NORMAL RUNNING (NR) MODE
EPCU features an on-off push-button power control switch
to activate control functions. Switch must be depressed to
initiate start-up. After completion of start-up, safe pressure
must be lost or switch must be depressed to deenergize
enclosure power relays.
CONDITIONAL BYPASS (CB) MODE
EPCU features an on-off-bypass power control switch to
activate control functions. Switch must be set to "on" position
to initiate start-up. After enclosure power is energized, safe
pressure must be lost or switch must be set to "off" position
to deenergize enclosure power. After enclosure power is
energized, switch may be set to "bypass" position, to
temporarily latch enclosure power relays. A flashing LED
then indicates bypass engaged, and the enclosure can then
be accessed without deenergizing power (performed under
specific conditions). Following access, safe pressure must
be reestablished to resume normal operation. At that time,
the switch may be reset to the on position, without disruption
of enclosure power. Alarm relay normally deenergizes only
upon loss of safe pressure, but can be factory programmed
to deenergize when bypass is engaged, if specified at time
of order.
The SRM-4000 Switch Resistor Module and the NJ...NAMUR
Sensor are supplied with approximately ten (10) feet of
wiring. Using 16 to 18 gauge shielded wire, the cable lengths
can be extended to a maximum of 100 feet.
In all applications, the module of the Switch Resistor Module
Cable must be installed as close to the customer supplied
switch as possible for proper operation.
Wiring lugs are not recommended for Intrinsic Safety Barrier
wiring connections.
See page 22 for barrier operation and factory programing.
21D1-21
Barriers & Field Adjustments
Optional Intrinsic Safety Barriers Description
Field Adjustable Timer Functions
The EPCU Logic Module can accommodate up to three
intrinsic safety barriers, to interact with remote devices and
affect operation of the EPCU. The barriers are installed and
programmed by the factory at time of order, and they are
designed to function either in conjunction with a customer
furnished switch and a Pepperl+Fuchs furnished resistor
network cable, or a Pepperl+Fuchs furnished proximity
detector. Each barrier develops a low power signal, to create
a two wire closed loop circuit. Operational status of each
barrier is indicated by a green LED to show active (closed
switch) status, and by a red LED to show faulted (line
breakage) cable status. All barriers can be reprogrammed to
duplicate other barrier functions as required, upon specific
request.
EDT (Exchange Delay Timer) (FA Style only) provides a time
delay to prevent Rapid Exchange® solenoid valve from
energizing until safe pressure can be stabilized.
SLT (Solenoid Latching Timer) (FA Style only) provides a time
delay to keep the Rapid Exchange® solenoid valve energized
until Rapid Exchange® pressure is detected. If the pressure
is not detected by completion of the time cycle, the EPCU will
reset.
RET (Rapid Exchange® Timer) provides a time delay after
Rapid Exchange® pressure is detected, to allow four volume
exchanges (ten volumes for motors) prior to energizing the
enclosure power relays. If Rapid Exchange® pressure is lost
or interrupted during time delay cycle, the EPCU will reset.
Optional ISB Factory Programing
Barrier A Function - when switch opens
Disables start-up cycle
Deenergizes enclosure power and alarm relay
Functions parallel to safe pressure switch
EDT, SLT & RET Timer Settings
F
Rotary Switch
Body
Barrier B Function - when switch opens
Disables Rapid Exchange® cycle
Functions parallel to Rapid Exchange® pressure switch
Power Off:
Enclosure Power Relays Deenergized
Power On:
Enclosure Power Relays Energized
Safe Pressure:
Enclosure Pressure > 0.15" or 0.50" w.c.
Rapid Exchange: Enclosure Pressure > 2.0" w.c.
Timer Running: Rapid Exchange® Timer Active
Alarm Active:
Enclosure Pressure < 0.15" w.c.
Bypass Engaged: Control Bypass Active - CB Mode
1
2
D
3
C
4
B
5
A
Barrier C Function - when switch closes
Energizes Rapid Exchange® solenoid valve relay
LED Display Indicators
0
E
6
9
8
7
EDT & SLT Timer
POSITION TIME IN SECONDS
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
RET Timer
POSITION
TIME IN MINUTES
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
NOTE: Power must be removed from the EPCU via the local
disconnect for approximately 10 seconds for timer
adjustments to reset.
D1-22
Set-up Procedure
IMPORTANT NOTES
Regardless of any condition, the Type X Rapid
Exchange® System is designed to automatically
withhold power to the protected enclosure while
inducing Rapid Exchange®, for at least five (5) minutes.
Normal exchange times should be doubled if large
obstructions block inert gas flow.
To test the vent’s operation, gently prod the vent
flapper open with a soft pointed object, ( example:
eraser end of a pencil) ensuring that the vent valve
works freely. On vertically configured vents, this can
be accomplished from within the protected enclosure.
Side mounted -90 configured vents can be tested by
removing the pipe plug at the bottom of the mounting
tee. Multiple operations require only one test per day
if enclosure is not opened or left unattended.
The volume exchange rate is based on a four (4)
enclosure volume exchange. Multiply the required
exchange time by 2.5 for applications requiring a ten
(10) volume exchange (motors).
The Start-Up Instruction Nameplate Exchange Time
Slot will feature the standard factor for this system
"ONE MINUTE PER CUBIC FOOT", but the unit may
feature a set of direct factor nameplates with selfadhesive backing such as “TEN MINUTES”, for
application to the start-up instructions, dependent on
how the system was specified and purchased. Field
modification of this nameplate, to show a direct factor,
is acceptable as noted above if the method used to
mark the nameplate does not deface the instructions
listed. Materials used for the marking must be indelible
and withstand prevailing environmental conditions.
Model 2002 Rapid Exchange® Purging Set-up
1. Close the Enclosure Pressure Control Valve (all Styles)
and Rapid Exchange® Control Valve (STD Style only) fully
by turning clockwise (CW).
8. Close Enclosure Pressure Control Valve and Rapid
Exchange® Control Valve (STD Styles) or Remove the
two 1/2" combination wrenches from behind the handle.
2. Connect the inert gas supply to the System Supply Inlet
and set the Rapid Exchange® Pressure Gauge to 60 psi.
Note: The Rapid Exchange® Pressure Gauge may now
indicate a higher set pressure than was originally set, this
is normal for all Rapid Exchange® purging systems.
3. Temporarily connect a 0-5 inch water column pressure
gauge or manometer to the protected enclosure.
4. Check operation of Enclosure Protection Vent as detailed
above. (see "Important Notes")
5. Seal enclosure(s) and adjust Enclosure Pressure Control
Valve by opening slowly counterclockwise (CCW) to set
a “Safe” pressure on the Enclosure Pressure Gauge.
Note: If pressure setting is difficult to stabilize or set,
(see page 26, “Trouble-Shooting Procedures”).
6. STD Styles - Open Rapid Exchange® Control Valve fully
by turning 90° CCW and quickly ensure the Enclosure
Protection Vent opens.
SA & FA Styles - With the aid of an assistant having two
1/2" combination wrenches on hand, place left hand on
system mounting plate and pull Rapid Exchange® Manual
Operator firmly with right hand and quickly ensure the
Enclosure Protection Vent opens. If Enclosure Protection
Vent operates properly, have assistant carefully place
the open end of both wrenches behind handle to hold the
manual operator in the out position temporarily.
Note: The Enclosure Pressure Gauge should move
quickly off scale to the right, this is normal for all Rapid
Exchange® purging systems.
7. Readjust the regulator to 60 psi minimum, while inducing
Rapid Exchange®, the test gauge should then read
approximately 2 inches of pressure and should not
fluctuate. (insufficient enclosure pressure will cause the
Enclosure Protection Vent to "shuttle") DO NOT exceed
5 inches of pressure within the protected enclosure.
9. Set RET timer (see page 21 for timer location and
settings) for required exchange time based on System
exchange rate of ONE MINUTE PER CUBIC FOOT, five
(5) minute minimum.
10. Install and tighten cover of EPCU. Ensure the conduit is
sealed with approved compounds.
11. Depress the On-Off push-button (NR mode) or turn
selector switch to the On position (CB mode). Each LED
should illuminate fully for two seconds (self test), then all
LEDs should turn off except Power Off (solid red) and
Alarm Activated (flashing red) LEDs.
12. Turn Enclosure Pressure Control Valve slowly CW to set
the Enclosure Pressure Indicator to a "Safe" 0.25 inch
pressure. The Safe Pressure LED should be on, the
Alarm Active LED should turn off. Check for a 0.10 to
0.15 inch trip point by slowly stroking the indicator from
0.10 to 0.25 inch readings. The Safe Pressure and Alarm
Active LEDs should turn on and off when the indicator
reads between 0.10 and 0.15 inches.
Note: FA Style only - Rapid Exchange® Solenoid Valve
will engage automatically upon time out of the EDT
Timer. Should the operator require additional time to set
a stable Safe Pressure on the enclosure pressure
indicator, reset the EDT timer setting as described on
page 22.
Set-Up Procedure continued on page 24.
D1-23
Set-up Procedure (cont.)
Model 2002 Rapid Exchange® Purging Set-up
13. STD Style - Open Rapid Exchange® Control Valve fully
Protection Vent opens. The Rapid Exchange® and Timer
Active LEDs should be on. Check for trip point by turning
Rapid Exchange® Control Valve on and off. The Rapid
Exchange® and Timer Running LEDs should turn on and
off as exchange is engaged and disengaged, without
disturbing the status of the Safe Pressure LED.
SA Style - Place left hand on system mounting plate and
pull Rapid Exchange® Manual Operator firmly with right
hand, until solenoid latches (to hold valve open
automatically) then quickly ensure the Enclosure
Active LEDs should be on. Check for trip point by turning
EPCU power switch off and on (to reset unit). The Rapid
Exchange® and Timer Running LEDs should not turn on
until valve is more than half open. Allow System to run
through RET timer cycle and watch for solenoid to
disengage. The valve should be able to shut off without
disturbing the status of the Safe Pressure LED.
FA Style - Rapid Exchange® Solenoid Valve will engage
automatically upon time out of the EDT Timer, then
quickly ensure the Enclosure Protection Vent opens.
The Rapid Exchange® and Timer Active LEDs should be
on and SLT Timer will be running. Check for trip point by
turning EPCU power switch off and on (to reset unit). The
Rapid Exchange® and Timer Running LEDs should not
turn on until valve is more than half open. Starting again,
allow System to run through EDT, SLT and RET timer
cycles and watch for solenoid to disengage. The valve
should be able to shut off without disturbing the status
of the Safe Pressure LED.
14. Having ensured that the Safe Pressure and Timer Running
LEDs are functioning properly, Operating Procedures
located on page 25 may now be followed to step through
a complete start up cycle, ensuring that the System
functions normally during all phases of operation.
15. Cease testing and remove test equipment .
Model
Identification
Nameplate
Start - Up
Instruction
Nameplate
Rapid
Exchange®
Control
Valve
Enclosure
Pressure
Gauge
Rapid
Exchange®
Manual
Operator
Start - Up
Instruction
Nameplate
Rapid
Exchange®
Pressure
Gauge
Rapid
Exchange®
Pressure
Gauge
Enclosure
Pressure
Gauge
Enclosure
Pressure
Control
Valve
Bypass
Operating
Instructions
EPCU
Power
Selector
Switch
LED Status
Nameplate
EPCU Power
Selector
Switch
LED Status
Nameplate
System LED
Display
EXP EPCU
Enclosure
System LED
Display
EXP EPCU
Enclosure
EXP
Breather
Drain
Model 2002-STD-CB-LH
Front View
Model 2002-FA-CB-LH
Front View
D1-24
Operating Sequence
WARNING
Do not exceed a “Safe” pressure with the Enclosure Pressure Control Valve.
Operators must follow step-by-step sequence of the Start-Up Instructions Nameplate on the Protection System.
Do not use the Bypass Modes without first securing a "Hot Work" permit.
Never leave the system unattended in Bypass Modes.
Rapid Exchange® Purging Operation
With the inert gas supply on, RET Timer set properly
(STD and SA Styles), EDT, SLT and RET Timers set
properly (FA Styles), EPCU power and alarm system
energized (if utilized) .
7. Standby until the EPCU RET Timer completes the timing
cycle and energizes enclosure power. Safe Pressure
LED should stay on, Timer Running LED should turn off
and Power On LED should turn on.
1. Carefully read Start-Up Instruction Nameplate on system.
8. STD Style - Close Rapid Exchange® Control Valve fully
by turning 90° CW. The Rapid Exchange® and Timer
Active LEDs should be off.
2. Check operation of the Enclosure Protection Vent, EPV2, opening it manually several times (see page 23,
“Helpful Hint”).
3. Seal protected enclosure(s).
4. Depress the On-Off push-button (NR mode) or turn
selector switch to the On position (CB mode). Each LED
should illuminate fully for two seconds as a self test, then
all LEDs should turn off except Power Off (solid red) and
Alarm Activated (flashing red) LEDs.
5. Turn Enclosure Pressure Control Valve slowly CCW to
set the Enclosure Pressure Indicator to a "Safe" 0.25
inch pressure. The Safe Pressure LED should be on, the
Alarm Active LED should turn off.
6. STD Style - Open Rapid Exchange® Control Valve fully
Active LEDs should turn on.
SA & FA Styles - After completion of the RET timimg
cycle, Timmer Running LED should turn off and Power
on LED should turn on. At the same time, the Rapid
Exchange® Solenoid Valve should deenergize and the
Rapid Exchange® LED should turn off.
9. Ensure the Protection System Enclosure Pressure
Indicator maintains a “Safe” 0.25 inch pressure for one
(1) minute. Readjust Enclosure Pressure Control Valve
if required.
10. If "Safe" 0.25 inch pressure is lost, the EPCU will
deenergize enclosure power and activate alarm system
(if utilized).
SA Style - Place left hand on system mounting plate and
pull Rapid Exchange® Manual Operator firmly with right
hand, until solenoid latches (to hold valve open
automatically) then quickly ensure the Enclosure
Active LEDs should turn on.
FA Style - Rapid Exchange® Solenoid Valve will engage
automatically upon time out of the EDT Timer, then
quickly ensure the Enclosure Protection Vent opens.
The Rapid Exchange® and Timer Active LEDs should be
on and SLT Timer will be running.
Note: On all Styles, if the Safe Pressure or Timer
Running LEDs blink on and off or "flicker" during this
cycle, EPCU will reset RET timer.
D1-25
Problem or Fault
Possible Causes
Corrective Action
Enclosure pressure control
valve will not hold a safe .25
inch pressure.
Leakage around gasketing,
covers, seams, piping and
tubing connections, conduit
connections and electrical
conduit seals of the enclosure.
Tighten enclosure latches: Where tightening is not
feasible, and gasketing materials are not practical,
holes or gaps can be closed with silicone sealant
applied from inside the protected enclosure.
Enclosure pressure indicator
reading is difficult to stabilize.
Insufficient enclosure leakage
or opening of the venturi orifice
is crimped too small.
Remove the orifice, cut off the crimped end and
ream the tube, then recrimp and reinstall the tube
to note effect. As tube is shortened, reamed, and
recrimped, sensitivity decreases, allowing easier
adjustment of setpoint on the enclosure.
Enclosure Protection Vent
"Shuttles" or Flutters"
Excessive leakage
protected enclosure.
Check all points above and verify a minimum 60 psi
injection pressure reading on the Rapid Exchange®
Pressure Indicator during Rapid Exchange®.
from
Insuffcient protective gas
supply header pressure.
Enclosure Pressure Indicator
reads a "Safe" pressure but
the Safe Pressure LED is not
illuminated.
Conduit seal between EPCU and
protected enclosure is not
poured or is leaking pressure
back into the EPCU.
With a 0.0" - 5" water column test gauge installed
properly (see "Set-Up Procedures" page 23), slowly
increase the Rapid Exchange® Injection pressure
with the Rapid Exchange® valve engaged until this
effect is eliminated. Do not exceed 3 inches of
pressure within the protected enclosure.
EPCU breather drain is clogged
(all systems except PM
configurations).
With area positively known to be non-hazardous,
remove screw cover of the EPCU and attempt a
complete start-up procedure. If the system works
properly, check enclosure power conduit seal for
leakage and the EPCU breather drain for blockage.
If the system does not operate properly, calibrate
the Safe Pressure switch.
Safe Pressure switch is out of
calibration.
Calibrate by slowly adjusting CW to decrease the
setpoint, and CCW to raise the setpoint.
(Do not attempt to calibrate the switch until all efforts
to make the switch respond properly have failed)
Rapid Exchange® LED does
not iluminate when Rapid
Exchange® is engaged.
FA Style only - The Rapid
Exchange® solenoid continues
to cycle without starting the
RET timer.
Conduit seal between EPCU and
protected enclosure is not
poured or is leaking pressure
back into the EPCU.
EPCU breather drain is clogged
(all systems except PM
configurations).
Rapid Exchange ® Pressure
switch is out of calibration.
With area positively known to be non-hazardous,
remove screw cover of the EPCU and attempt a
complete start-up procedure. If the system works
properly, check enclosure power conduit seal for
leakage and the EPCU breather drain for blockage.
If the system does not operate properly, calibrate
the Rapid Exchange® Pressure switch.
With Rapid Exchange® engaged, calibrate by slowly
adjusting counterclockwise to decrease the
setpoint, and clockwise to raise the setpoint.
(Do not attempt to calibrate the switch until all efforts
to make the switch respond properly have failed)
Problems persists, or if the
system does not appear to be
operating properly.
Persisting problems.
Contact Pepperl+Fuchs Applications/Customer
Service Department at (330) 486-0002 for more
information.
This section covers the most common problems documented with these systems. Any problems not covered in this
section should be addressed directly to our factory. Please address all service needs to Pepperl+Fuchs, Inc. - Customer
Service Department at (330) 486-0002.
D1-26
Warranty Terms and Conditions
PEPPERL+FUCHS STANDARD 24-MONTH WARRANTY
1.
Limited Warranty. Pepperl + Fuchs, Inc. (“P+F”) warrants Purge Units and components for Purge Units manufactured by
P+F (“Product” or “Products”) to be free from defects in material and workmanship under Normal Use for a period of
twenty-four (24) months from the date of shipment of such Products from P+F’s warehouse or place of manufacture (or
from P+F’s authorized representative or distributor). Only the original purchaser of such Products (the “Customer”) shall
be entitled to the benefit of the foregoing Limited Warranty. No representative, agent or salesman of P+F is authorized to
give or provide any warranty or make any representation contrary to or in addition to the foregoing Limited Warranty.
2.
Inspection and Claims. Customer must inspect and test all Products upon receipt. All claims under the Limited Warranty
provided herein must be made within thirty (30) days of the discovery of the defect. Customer must obtain shipping
instructions from P+F prior to returning any Product, which Product must be returned at Customer’s expense in
accordance with P+F’s instructions.
3.
Limitations and Exclusions. “Normal Use” shall mean use and operation within rated capacities, at the correct voltage, and
with any required maintenance as provided in the applicable P+F Operating Manuals. The Limited Warranty provided
herein does not apply to (i) any Products which have been altered or modified in any way or disassembled by the
Customer or anyone else, (ii) any Products which have been subject to misuse, negligence or accident, or improperly
installed, changed, substituted or replaced, (iii) any part or component not manufactured by P+F, or (iv) any part or
component that is subject to wear or consumption. For parts or components not manufactured by P+F, the Customer or
any other user or owner shall have only the warranty provided by the manufacturer of such part or component. The
Limited Warranty set forth herein is also subject to the following:
(1) The Limited Warranty is limited to electronic and mechanical performance only, as expressly detailed in
the product specifications, and does not apply to cosmetic appearance;
(2) The Limited Warranty shall not apply to any cables attached to, or integrated with, any Products.
(3) The Limited Warranty shall not apply to any Products which are stored, or utilized, in harsh environmental
or electrical conditions outside P+F’s written specifications.
THE LIMITED WARRANTY SET FORTH HEREIN IS THE ONLY WARRANTY MADE BY P+F WITH RESPECT TO THE
PRODUCTS. IT IS EXPRESSLY AGREED AND UNDERSTOOD THAT P+F MAKES NO WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. EXCEPT FOR THE LIMITED WARRANTY SET FORTH
HEREIN, THERE IS NO OTHER WARRANTY, EXPRESS, IMPLIED OR STATUTORY; AND THERE IS NO AFFIRMATION OF
FACT OR PROMISE BY P+F WITH REFERENCE TO THE PRODUCTS. IN NO EVENT SHALL P+F BE LIABLE FOR
ACTUAL OR ANTICIPATED LOST PROFITS OR FOR INCIDENTAL OR CONSEQUENTIAL OR PUNITIVE DAMAGES OR
FOR DAMAGES RESULTING FROM BUSINESS INTERRUPTION, OR INJURY OR DEATH OF PERSONS, OR INJURY TO
PROPERTY. P+F’S LIABILITY ON ANY CLAIM OF ANY KIND ARISING OUT OF, CONNECTED WITH OR RESULTING
FROM THE DESIGN, MANUFACTURE, SALE, REPAIR OR OPERATION OF A PRODUCT, SHALL NOT EXCEED THE
PRICE ALLOCABLE TO THAT PRODUCT OR THE PART THEREOF WHICH GIVES RISE TO THE CLAIM. THE REMEDY
SET FORTH IN THIS LIMITED WARRANTY CONSTITUTES THE SOLE AND EXCLUSIVE REMEDY OF THE CUSTOMER.
P+F SHALL NOT BE LIABLE FOR PENALTIES OF ANY DESCRIPTION.
4.
Limitation of Remedies. In the event of P+F’s liability, whether on this Limited Warranty or based on contract, tort
(including, but not limited to, negligence and strict liability) or otherwise, Customer’s sole and exclusive remedy will be
limited to, at P+F’s option, the repair or replacement (f/o/b P+F’s place of manufacture) by P+F of any non-conforming
items for which claim is made by Customer in accordance with paragraph 2, or the repayment of the portion of the
purchase price paid by Customer attributable to the non-conforming item.
5.
Responsibility of Customer: Safety and Protection Precautions. P+F takes great care to design and build reliable and
dependable Products; however, some Products can fail eventually. Customer must take precautions to design its
equipment to prevent property damage and personal injury in the unlikely event of a failure. AS A MATTER OF POLICY,
P+F DOES NOT RECOMMEND THE INSTALLATION OF PRODUCTS AS THE SOLE DEVICE FOR THE PROTECTION OF
PERSONNEL OR PROPERTY AND, THEREFORE, THE CUSTOMER SHOULD BUILD IN REDUNDANCY OR DUAL
CONTROL USING APPROVED SAFETY DEVICES FOR THESE APPLICATIONS.
6.
Conflicts. In the event there is any conflict between the provisions of this Limited Warranty and any provisions contained in
any orders, offers, acceptances or other writings or statements provided or made by Customer to P+F, the provisions of
this Limited Warranty shall prevail, and the contract between P+F and the Customer shall be deemed formed only upon
the provisions set forth in this Limited Warranty, and any additional or conflicting provision inserted by Customer shall be
of no force or effect.
D1-27
System Maintenance
Regular Maintenance
Drain the Protection System Regulator frequently and clean System with non-solvent cleaning agents only.
Long Term Maintenance
Calibrate the enclosure pressure indicator to 0 inches by venting the purge pressure reference port and the protected
enclosure to atmosphere and adjusting the calibration screw in the lower center portion of the indicator’s face.
Fully open the enclosure pressure control regulator, to blow out any deposits around the tip of the valve and to ensure that
the enclosure protection vent is operating properly, then carefully readjust system according to the set-up procedure and
operating sequence on pages 23 through 25. Replace or tighten stem packing nut as required to prohibit stem packing
leakage.
Carefully disassemble the enclosure protection vent by loosening the two bottom hex nuts that hold the unit together.
(DO NOT REMOVE CAP NUTS ON TOP OF VENT BODY)
Carefully clean the flapper valve and vent body seats with warm soap and water, being careful not to extend the vent valve
beyond its normal opening point, and being careful not to exert any stress on the valve hinge.
Examine the entire Protection System and the protected enclosure(s), and replace any defective parts during routine
shutdown of the protected enclosure(s). Parts are available from Pepperl+Fuchs on immediate notice as required.
MAINTENANCE SCHEDULE
Date
Work Performed
Performed by
D1-28
Date
Work Performed
Performed by
D1-29
CUSTOMER NOTES
D1-30
CUSTOMER NOTES
D1-31
SYSTEMS IDENTIFICATION & APPLICATION INFORMATION
Date of Installation
Unit Serial #
Item
Customer P.O.#
Customer Project#
Service
Type
Features
Application
NOTES:
Local Sales Representative
D1-32
CLASS I APPLICATIONS
15 Cubic Feet Maximum
MODEL 1002
TYPE Y OR Z
RAPID EXCHANGE® PURGING SYSTEM
INSTALLATION & OPERATION MANUAL
LPS Style
(Less Pressure Switch)
WPS & WPSA Style
(With Pressure Switch)
CSA Approval applies to
WPS Style EXP Pressure Switch Only
For Class 1 Division 2 ESW Workstations
5-3
Table of Contents
D2- Page 2
D2-Page 13
System Purpose and Description
Purpose, System Description, Important Notes
D2-Page 3
Defines specific features of the system
D2-Page 4
General Information
System & Material Specifications, Spare Parts,
Tools & Test Equipment, System Accessories D2-Page 15
D2-Page 5
D2-Page 6
D2-Page 7
D2-Page 8
D2-Page 9
D2-Page 10
D2-Page 11
D2-Page 12
D2-Page 14
Enclosure and Device Design
Design Requirements, Adjacent Enclosures,
D2-Page 16
Device Ventilation, Temperature Limitations
Installation Diagram
D2-Page 17
Getting Started
Establishing Connection Sizes, Determining
Enclosure Inlet & Outlet Connection Locations D2-Page 18
System Mounting
LH, RH, TM, BM & WM Configurations, D2-Page 19
FM & PM Configurations
D2-Page 20
Hardware Mounting
Required Enclosure Protection Vent, Warning
Nameplates
D2-Page 21
D2-Page 22
D2-Page 23
D2-Page 24
Protective Gas Supply Requirements,
Tubing Installation
LH, RH, TM, BM, WM, FM & PM Tubing
Configurations
Tubing Connection Diagrams
LH, RH, TM, BM, WM, FM, & PM Configuration
Connection Points, Pneumatic Diagram
Wiring Requirements, Enclosure Power & Alarm
Signal, Enclosure Wiring Methods & Connections
Electrical & WPS Style Conduit and Connection
Parts
Set-Up Procedure
Class I Purging Set-up
Operating Sequence
Trouble-shooting Chart
Warranty and Liability Statement
Warranty Notes, General Terms, Limitations
System Maintenance
Regular Maintenance, Long Term Maintenance,
Maintenance Schedule
Customer Notes
Customer Notes
Systems Identification & Application
Information
Purpose
Important Notes
Pepperl+Fuchs' Bebco EPS System’s purpose is to allow
the use of general purpose or non-rated electrical or electronic
devices, with exception to devices which produce excessive
heat, utilize combustible gas, or expose arcing contacts to
the hazardous atmosphere, in NEMA (National Electrical
Manufacturers Association) 4 or 12 enclosures in the place
of explosion proof NEMA 7 enclosures. Other purposes
include heat, moisture and dust contamination prevention.
One (1) permanent file copy and one (1) operations copy of
this Manual must be studied and retained by the operator of
this System. User’s Agents are responsible for transferring
this Manual to the user, prior to start-up.
Description
Model 1002 is a Rapid Exchange® purging system which
operates on a supply of compressed instrument air or inert
gas. It is designed to regulate and monitor pressure within
one or more sealed (protected) enclosures, in order to
rapidly remove and prevent flammable vapor accumulation
within the enclosure(s). The system is designed to accomplish
four air exchanges and maintain a "safe" (0.25") pressure on
one or more enclosures not exceeding a total volume of
fifteen cubic feet. An EPV-2 Enclosure Protection Vent is
required for proper operation. This process reduces the
hazardous (classified) area rating within the enclosure(s), in
accordance with the NEC - NFPA 70, Article 500, NFPA 496
and ISA ds12.4.
The contents of this manual have been arranged to allow the
use of this product as a stand-alone device on equipment
and enclosures supplied by the user or its agents. The
Manual’s parameters encompass a combination of both
National Fire Protection Association (NFPA) requirements
and Pepperl+Fuchs, Inc. requirements. Pepperl+Fuchs
therefore acknowledges the use of NFPA 496 as a guideline,
that we have enhanced certain NFPA requirements and that
additional information has been compiled to complete this
document. The Manual is intended as a complete guide and
must be considered, unless specifically stated otherwise,
that all directives contained herein are requirements for safe,
practical and efficient use of this product.
This System is not intended for use to protect enclosures or
devices which contain ignitable concentrations of gases or
vapors. This exclusion generally applies to process or
product analyzing systems equipment.
All specifications are subject to change without notice.
D2-2
This Enclosure Protection System is offered in various styles. For proper installation and operation, examine the System
Model Number Nameplate to identify the System Style, Area Classification, and Type, as noted below.
SYSTEM STYLE
Systems are available in three styles, with or without
an explosion proof differential pressure switch, used
to detect loss of “safe” enclosure pressure
LPS - Less Pressure Switch
SERIES
MODEL NUMBER
MAXIMUM
TOTAL
ENCLOSURE
VOLUME
Defines total
protected
enclosure(s)
volume capacity for
this particular
system. Total
enclosure(s)
volume must be
calculated without
regard for
consumed volume
SYSTEM CLASS RATING
Defines Class rating for Protection
System’s method of use
WPS - With Pressure Switch Groups C & D
CI - Class I Purging system
WPSA - With Pressure Switch Groups A - D
Model 1002-LPS-CI Type Y or Z
SYSTEM TYPE
15 CUBIC FEET MAXIMUM ENCLOSURE VOLUME
Type Z
REDUCES INTERNAL AREA CLASSIFICATION AS FOLLOWS:
TYPE Y: CL. I, DIV. 2, GR. A-D / ZONE 2, GR. IIC TO DIV. 2 / ZONE 2
TYPE Z: CL. I, DIV. 2, GR. A-D / ZONE 2, GR. IIC TO NONHAZARDOUS
PURGE CONTROL FOR USE IN HAZARDOUS LOCATIONS. IN ACCORDANCEWITH THE NATIONAL FIRE
PROTECTION ASSOCIATION STANDARD FOR PURGED AND PRESSURIZED ENCLOSURES FOR
ELECTRICAL EQUIPMENT NFPA 496- 1993 7L93
APPROVED BY FACTORY MUTUAL AS ASSOCIATED TYPE Y & Z PRESSURIZATION CONTROL
EQUIPMENT FOR USE IN HAZARDOUS LOCATIONS. REDUCES THE INTERNAL AREA
OF A CONNECTED ENCLOSURE IN ACCORDANCE WITH DRAWING NUMBER 1002-IOM.
AREA
CLASSIFICATION
Defines the area
classification for
which the system is
suitable for operation
enclosure area
Division 2 to
nonhazardous
Type Y
enclosure area
Division 1 to
Division 2
APPROVAL
MARKINGS &
DEFINITIONS
Identifies the current
third party approvals
for this system
To assist you through the installation and operation of your pressurization / purge system, Pepperl+Fuchs, Inc. has
provided the following information boxes throughout this manual. This information is intended to clarify certain
differences between the model styles and configurations and to warn the user / installer of potential dangers of electrical
shock or enclosure over pressurization.
HELPFUL HINT
IMPORTANT NOTE
WARNING
D2-3
General Information
System Specifications
System Dimensions:
See Pages 10 & 11
Shipping Weight (Lbs.):
LPS - 10 / WPS - 15
Operating Temperature Range:
-20° F - 120° F
Supply Pressure Range:
80 - 120 PSI max.
Capacity & Filtration:
1.5 Oz. @ 20 Microns
Supply Requirements:
Clean Air or Inert Gas
Safe Pressure Setpoint:
0.25"
Safe Pressure Flowrate:
* 0.1 - 3.5 SCFH / Cu Ft
Exchange Pressure:
* 3" - 5"
Exchange Flowrate:
** 4 SCFM / 240 SCFH
Exchange Time:
1 Minute / Cubic Ft.
System Supply Port:
1/4" FPT
Enclosure Supply Fitting:
1/4" Tube Fitting
Enclosure Reference Fitting:
1/4" Tube Fitting
Switch Setting (WPS & WPSA Only):
0.15" ± 0.02"
WPS & WPSA Pressure Switch Wiring:
1/2" FPT
Switch Contact Ratings:
WPS Style:
120 VAC, 15 Amps
WPSA Style:
*** 120/240 VAC, 10 Amps, 28 - 125 VDC
* Enclosure integrity determines actual flow and pressure
** With regulator set to 60 PSI min. during exchange
*** WPSA style switch requires 120/240 VAC supply voltage
Exchange Flow rating is based on safety factors considered
after extensive factory testing and does not reflect actual
flow. Flow was measured upstream of System with an
electronic flowmeter on a five cubic feet enclosure. The
System was installed with tubing that exceeded the maximum
allowable linear length and quantity of bends listed in this
manual for System supply, enclosure supply and enclosure
reference connections. The System was tested in conjunction
with the EPV-2-SA-00 Enclosure Protection Vent, mounted
directly on the test enclosure.
ABS Traceable Certified Exchange Flow Measurements with
System regulator set at 60 psi, ambient temperature of 75° F
100 psi supply pressure:
80 psi supply pressure:
6.90 scfm / 414.00 scfh
6.71 scfm / 402.60 scfh
Material Specifications
Filter Regulator Body:
Zinc w/ Enamel Finish
Regulator Handle & Bowl:
Polycarbonate
Enclosure Pressure Gauge:
Alum. w / Enamel Finish
Rapid Exchange Gauge:
Poly Case & Brass Tube
Tube Fittings & Valves:
316 SS Forged Body
Tubing:
316 SS 1/4" .035 Welded
System Nameplates:
Silkscreened Lexan® & SS
Fastener Hardware:
Aluminum & Stainless Steel
Mounting Plate:
316 14 Ga #3 Brush SS
EXP Pressure Switch Body:
Anodized Cast Alum.
Enclosure Warning Nameplate:
Silkscreened SS
Recommended Spare Parts
Qty
Description
Part # (supercedes)
1
1
1
1
1
1
1
1
1
Enclosure Pressure Indicator-CI
System Filtered Regulator
Rapid Exchange® Pressure Gauge
Enclosure Pressure Control Valve Body
Rapid Exchange® Control Valve Body
Installation & Operation Manual
Group C - D Pressure Switch-CI
Group A - D Pressure Switch-CI
Enclosure Warning Nameplate-CI
510023 (001000)
510057 (002040)
510078 (002300)
510116 (003440)
510118 (003460)
129-0196
510044 (001080)
510045 (001085)
513008 (EWN-1)
Please call and reference the above part number for
current spare parts pricing. Immediate pricing is available
to all confirmed customers.
Installation Tools & Testing Equipment
1/2" chuck drill
Complete set of drill bits
3/4" conduit knockout punch or 1.125" hole saw
Complete set of tubing, conduit bending, instrument fitting
and electrical craftsman hand tools
0-10" differential pressure indicator or manometer (connected
to the protected enclosure to measure maximum pressure)
Model 1002 System Accessories
Enclosure Protection Vents
ONE REQUIRED WITH EACH SYSTEM
EPV-2-SA-00
EPV-2-SA-90
Straight w/ Spark Arrestor
Rt Angle w/ Spark Arrestor
Additional Items
SMK-2 or -8
EPSK-1
EPSK-1A
GPSK-1
RAH
RAB-1
RAB-2
LCK
TCK
PIAD
System Mounting Kit
Class I, Group C - D Pressure Switch Kit
Class I, Group A - D Pressure Switch Kit
Class I, General Purpose Switch Kit
Div. 1 Remote Alarm Horn
L Fitting Conduit Kit
T Fitting Conduit Kit
Purgeable Instrument Access Door
Lexan® is a registered trademark of the General Electric Company
D2-4
Enclosure & Device Design
Enclosure Design Requirements
Total Volume Calculation
1. All windows must be shatterproof and sized as small as
possible.
1. The total volume of all pressurized enclosures, devices
and wireways must be considered.
2. All NFPA 496 required markings must be placed on or
near all enclosure doors and covers.
2. All enclosure, device and wireway volumes must be
calculated without consideration of internally consumed
space.
3. The enclosure must withstand an internal pressure of ten
(10) inches of water without sustaining permanent
deformation and resist all corrosive elements in the
surrounding atmosphere.
4. All lightweight objects in the enclosure, such as paper or
insulation, must be firmly secured.
5. The enclosure should be constructed from materials
such as metal or anti-static polycarbonate to meet or
exceed NEMA 4 or 12 performance requirements, but
does not require third party approval.
Device Ventilation
1. Enclosed devices within the protected enclosure which
do not exceed 1.22 cubic inches of free volume do not
require ventilation to the protected enclosure.
2. If the free volume of an internal device exceeds 1.22
cubic inches it must be protected by one of the following
means:
a)
6. The installation of obstructions or other barriers which
block or impede the flow of protective gas must be
avoided.
7. The creation of air pockets or other areas which trap
flammable gases within the enclosure or devices must
be avoided.
b) purged in series with the protected enclosure or be
purged separately; or
c)
8. The enclosure should be located in an area where
impact hazards are minimal.
9. If the enclosure is nonmetallic and contains equipment
which utilizes or switches power loads greater than 2500
VA, it must be constructed from substantially
noncombustible materials, such as materials designed
to meet or exceed ANSI/UL94 ratings of 94 V-0 or 94 5V.
Adjacent Enclosures
1. Adjacent enclosures must be protected by one of the
following means:
a)
1. The enclosure must have no surface area which exceeds
80 percent of the flammable or ignitable substance’s
auto-ignition temperature.
2. Internal devices which exceed this temperature must be
protected by one of the following manners.
a)
purged or pressurized in series with the protected
enclosure;
safe circuits.
2. Adjacent purged or pressurized enclosures must be
designed to meet all construction requirements above.
safe circuits.
Temperature Limitations
b) purged or pressurized separately; or
c)
ventilated on the top and bottom sides with one (1)
square inch of opening for each four hundred (400)
cubic inches of volume within the internal protected
enclosure, at a minimum diameter of one (1) quarter
inch;
The device is enclosed in a chamber which is UL, FM
or CSA listed as a hermetically sealed device which
prohibits the entrance of flammable or ignitable
substance, and maintains a surface temperature
below temperature limits.
b) It can be proven by testing that the devices will not
ignite the substance involved.
c)
The device is purged in a separate enclosure that
bears an ETW (Enclosure Temperature Warning
Nameplate). Devices may only be accessed after
power has been removed and the device has been
allowed to cool to safe temperature, or the area is
positively known to be nonhazardous.
D2-5
Typical Left Hand Configuration Installation Diagram
Model 1002-WPS-LH Shown
ENCLOSURE
PROTECTION
VENT
(required)
PROTECTED
ENCLOSURE
ENCLOSURE
SUPPLY TUBING
SYSTEM
MOUNTING
BOLT
ENCLOSURE
PROTECTION
SYSTEM
PROTECTIVE
GAS SUPPLY
SYSTEM
SUPPLY FITTING
SERVICE
VALVE
ENCLOSURE
CONNECTION
FITTINGS
ENCLOSURE
REFERENCE
TUBING
ENCLOSURE
WARNING
NAMEPLATE
SYSTEM
SUPPLY TUBING
ELECTRICAL ALARM WIRING
CONDUIT & SEAL
D2-6
Getting Started
Establishing Connection Sizes, Lengths & Bends
TYPICAL SINGLE PROTECTED ENCLOSURE CONNECTIONS
ENCLOSURE PROTECTION VENT
(Required)
1/2"
PROTECTIVE
GAS SUPPLY
HEADER
C
REFERENCE
ENCLOSURE
PROTECTION
SYSTEM
PROTECTED
ENCLOSURE
SUPPLY
A
E
B
Description
A
B
C
System
Supply Tubing
Enclosure
Supply
Enclosure
Reference
D
1/4" O.D. Tubing 1/4" O.D. Tubing 1/4" O.D. Tubing
Fully Reamed
Fully Reamed
Fully Reamed
Tubing or Pipe Diameter
Maximum Tubing / Pipe Length and
Maximum Number of Bends / Elbows
20 Feet
10 Bends
5 Feet
5 Bends
20 Feet
10 Bends
E
Multi - Enclosure Optional Remote
Venting
Connections
3/4" I.D. Pipe
Fully Reamed
3/4" I.D. Pipe
Fully Reamed
10 Feet
5 Elbows
30 Feet
5 Elbows
TYPICAL MULTIPLE PROTECTED ENCLOSURE CONNECTIONS
B
1/2"
PROTECTIVE
GAS SUPPLY
HEADER
ENCLOSURE
PROTECTION
SYSTEM
SUPPLY
D
PROTECTED
ENCLOSURE
D
PROTECTED
ENCLOSURE
PROTECTED
ENCLOSURE
REFERENCE
C
A
HELPFUL HINTS
To ensure adequate protective gas flow to the protected enclosure(s), all piping and tubing must be fully reamed.
Precautions must be taken to prevent crimping and other damage to protective gas piping and tubing.
When protecting multiple enclosures with a single enclosure protection system, the enclosures must be
connected in series from the smallest to the largest to ensure adequate protective gas flow.
Determining Enclosure Inlet & Outlet Connection Locations
HELPFUL HINTS
INLET
OUTLET
OUTLET
Connections for Heavier than
INLET
Connections for Lighter than
If flammable gases are lighter than air, the inlet
connection to each enclosure must enter near a
bottom corner. The outlet connection, for the required
enclosure protection vent or piping to an adjacent
protected enclosure, must exit near an extreme
opposite top corner.
If flammable gases are heavier than air, inlet and
outlet connections must be reversed.
In all cases, the most prevalent gas must determine
the location of inlet and outlet connections.
D2-7
System Mounting
IMPORTANT NOTES
The system should be mounted at EYE LEVEL.
Care must be taken to ensure the system and all
protruding components are clear of all enclosure
accesses (doors and covers) and conduit, pipe, tubing
or cable entries.
LH, RH, TM, BM and WM configurations are intended
for mounting adjacent to the protected enclosure.
LH, RH, TM & BM configurations are also suitable for
2" schedule 40 pipe mounting.
Determine the mounting configuration of your system
using the diagrams on pages 10 & 11.
Remove and save the manila envelope (containing
the enclosure warning nameplate) which may be
taped to the outer surface of the mounting flange.
Although all purge systems are factory tested and
calibrated, we strongly suggest a bench test of basic
functions prior to installation.
Mounting LH, RH, TM, BM & WM Configurations
Surface mounting Systems
Pipe mounting Systems
1 . Transfer hole pattern of System mounting plate to
intended surface.
2. Check for obstructions hindering bolt fastening, drill and
ream the mounting holes before mounting the system.
3. Secure the system to the enclosure, or other mounting
surface, using one (1) SMK-2 mounting kit or equivalent
- four (4) 3/8" x 3/4" stainless steel bolts, nuts and lock
washers.
1. Locate 2" schedule 40 pipe, (vertical for LH & RH,
horizontal for TM & BM) within five (5) feet of protected
enclosure.
2. Ensure system is mounted in a true vertical position,
secure the system to pipe, using one (1) PMK-2 mounting
kit or equivalent - two (2) 3/8" x 2" stainless steel “U”
bolts, nuts and lock washers.
Mounting FM & PM Configurations
HELPFUL HINTS
FM and PM configurations are designed to mount through a panel cutout one (1) inch smaller than the overall
height and width of the system mounting plate, using clips and fasteners provided with the SMK-8 mounting
kit. This design feature eliminates the need to drill the system mounting bolt holes in the protected enclosure.
PM configurations do not require and do not include a venturi orifice on the enclosure reference connection.
FM configurations are intended for mounting adjacent to the protected enclosure.
PM configurations are intended for mounting through a cutout in the protected enclosure surface.
1. Transfer panel cutout pattern to the intended surface.
4. Deburr all cutout surfaces.
2. Check for obstructions which could prohibit bolt fastening
or system pneumatic connections.
5. Secure system to enclosure using SMK-8, or equivalent
- eight (8) 1/4" x 3/4" stainless steel nuts, bolts, mounting
clips and lock washers.
3. Cut panel cutout pattern on the intended surface.
Typical Examples of Surface, Pipe, Panel & Frame Mounted Systems
Typical Surface Mounted System
Typical Pipe Mounted System
Typical Panel/Frame Mounted System
(Model 1002-LPS-CI-Z-LH shown)
(Model 1002-LPS-CI-Z-LH shown)
(Model 1002-LPS-CI-Z-PM shown)
D2-8
Hardware Mounting
Required Enclosure Protection Vent
Warning Nameplate(s)
All configurations must be mounted in a true vertical position.
An EWN (Enclosure Warning Nameplate) must be located in
a prominent position on or near all enclosure accesses
(doors and covers).
The vent must be located to provide access for routine
testing of the vent’s flapper assembly. A minimum 8"
clearance is required below the vent opening.
1. Determine the vent’s mounting configuration, i.e.;
-00 vertical mount or -90 side mount. (see photos below)
2. Determine vent location and layout vent mounting hole
on the protected enclosure. (as determined on page 7,
“Getting Started”)
3. Using a 1.125" hole saw or 3/4" conduit punch, drill and
deburr the enclosure protection vent mounting hole.
4. Remove the hub mounting nut from the vent hub and
place the hub, with O-ring intact, through the mounting
hole. The O-ring must be on the outside of the protected
enclosure.
5. Reinstall the hub mounting nut to the mounting hub from
inside the protected enclosure and tighten.
One (1) EWN is provided with each system, located in the
manila envelope taped to the mounting flange of the system.
Additional EWN’s are available from Pepperl+Fuchs.
All EWNs provide labeled spaces allowing the customer to
mark the protected enclosure with: 1) a T Code (temperature
identification number), 2) Class, Group and Division of
surrounding area, and 3) NFPA pressurization Type X, Y or Z,
as may be required by plant and local codes and is required
by NFPA 496 section 2-11.
An ETW (Enclosure Temperature Warning nameplate) must
be located in a prominent position on or near all enclosure
accesses (doors and covers) when the temperature of an
internal component exceeds 80 percent of the ignition
temperature of the flammable vapor, gas or dust involved.
The ETW warns the operator to deenergize all equipment for
a specified length of time, allowing the protected equipment
to cool before opening the protected enclosure. The length
of time required is determined by the customer and can be
factory or field engraved.
All EWNs and ETWs are furnished with an adhesive back, but
should also be riveted or screwed to the protected enclosure.
EPV - 2 - SA - 00
Vertical Mount
Enclosure Warning Nameplate - Class I
Enclosure Warning Nameplate - Class II
EPV - 2 - SA - 90
Side Mount
Enclosure Temperature Warning Nameplate
D2-9
Model 1002
6"
4.25"
3.5625"
.6875"
.375" O.D.
TYP. 4
7.5"
4.25"
3.5625"
.6875"
.375" O.D.
TYP. 4
9.3125"
10"
14.3125"
15"
11"
1002-LPS-LH
11"
1002-WPS & WPSA-LH
7.5"
4.25"
3.5625"
.6875"
.375" O.D.
TYP. 4
6"
4.25"
3.5625"
.6875"
.375" O.D.
TYP. 4
14.3125"
15"
9.3125"
10"
11"
11"
1002-LPS-RH
1002-WPS & WPSA-RH
10"
10"
16"
11"
7.5"
6"
4.25"
.375" O.D.
TYP. 4
1002-LPS-TM
.6875"
3.5625"
.6875"
3.5625"
10.3125"
4.25"
15.3125"
.375" O.D.
TYP. 4
1002-WPS & WPSA-TM
D2-10
Model 1002
10"
10"
11"
.6875"
3.5625"
.6875"
3.5625"
16"
15.3125"
.5"
.375" O.D.
TYP. 4
10.3125"
4.25"
4.25"
6"
7.5"
.375" O.D.
TYP. 4
1002-LPS-BM
1002-WPS & WPSA-BM
9.25"
7.75"
6"
6"
10"
8"
15"
13"
.375" O.D.
TYP. 4
11"
1002-LPS-WM
9"
1"
2"
11"
TYPICAL -WM
MOUNTING FLANGE
.25" O.D.
TYP. 8
1002-WPS & WPSA-WM
3.25" 3.25"
Panel Cutout
12"
.25" O.D.
TYP. 8
Panel Cutout
16"
17"
3.5"
Panel Cutout
12"
Panel Cutout
11"
1.5"
12"
13"
13"
1002-LPS-FM & 1002-LPS-PM
(Frame & Panel Mount Configuration)
1002-WPS & WPSA-FM
(Frame Mount Configuration)
D2-11
Protective Gas Supply Requirements
a clean, instrument quality compressed air or nitrogen and
must contain no more than trace amounts of flammable gas,
vapor or dust.
ALL FITTINGS MAY BE CUSTOMER OR FACTORY FURNISHED
The protective gas supply compressor intake must originate
in a nonhazardous location. Suction duct passing through a
hazardous location and the protection system tubing and
piping must be fabricated from noncombustible materials
suitable for prevailing hazards and environmental conditions.
The protective gas supply must originate from a dedicated
instrument quality compressed air header (1/2" pipe or
larger), no farther than twenty (20) feet from the protection
system. Local compressors and gas cylinders should not be
used before consulting with Pepperl+Fuchs.
regulated from 120 psi maximum to 80 psi minimum.
1. For system supply, one (1) SC-4 1/4" Male Straight
Connector or one (1) NC-4 1/4" Male Elbow Connector
or equivalent fitting per system.
One (1) similar fitting which will connect the inert gas
supply tubing to the inert gas supply header connection
point and one (1) lot of 1/4" O.D., .035" wall thickness,
welded or seamless stainless steel tubing.
2. For enclosure supply, one (1) EFC-4 1/4" Flush
3. For enclosure reference, one (1) Mdel EFC-4 1/4" Flush
4. One (1) lot of 1/4" O.D., .035" wall thickness, welded or
seamless stainless steel tubing.
5. For multiple enclosure connections, two (2) EPC-12 3/4"
Pipe Mounting Hubs or equivalent and 3/4" 150# rated
pipe couplings & unions per interconnection.
One (1) lot 150# rating 3/4" galvanized or aluminum pipe
and fittings, fully reamed and unrestricted.
NC-4
SC-4
SYSTEM SUPPLY FITTINGS
PM Pneumatic Connection Requirements
In addition to item numbers 1, 4 and 5 above, the
following fittings are required for all PM configurations.
1. For system supply on PM configurations, one (1)
additional EBC-4 or equivalent 1/4" Through Bulkhead
Fitting per system is required.
2. For atmospheric reference, one (1) PRB-4 or equivalent
1/4" female bulkhead fitting and stainless steel sintered
element is required.
EFCEBC4
ENCLOSURE
SUPPLY & REFERENCE4FITTINGS
PRB-4
SYSTEM ATMOSPHERIC REFERENCE FITTING
EPC-12
MULTIPLE ENCLOSURE CONNECTION FITTING
D2-12
Tubing Installation
HELPFUL HINTS
All work must be performed by technicians qualified in pneumatic tubing and electrical conduit installation.
Pepperl+Fuchs recommends the use of .035" wall thickness, welded or seamless stainless steel tubing.
If flexible tubing is used, it must be installed in a manner which will protect it from damage and corrosion.
Tubing LH, RH, TM, BM, WM & FM Configurations
System Supply Connections
Enclosure Supply & Reference Connections
1. Choose location for the enclosure supply connection(s)
based on the requirements on page 7, “Getting Started”.
supply header and the enclosure protection system, it
must be installed in close proximity of the protected
enclosure and be labeled in accordance with section 211.4 of the NFPA 496, 1998 edition.
3. Select the appropriate fittings required to connect the
protective gas supply to the protection system regulator
as determined on page 12, “Pneumatic Connection
Requirements”.
2. Place the enclosure reference connection fitting directly
behind the enclosure protection system and at least one
foot away from the enclosure supply and enclosure
protection vent connections, whenever possible. For
systems protecting multiple enclosures in series, the
enclosure reference connection fitting must be placed
on the last enclosure in the series. (see page 7, “Getting
Started”)
3. Drill and deburr enclosure supply and reference fitting
holes on the protected enclosure. Mount the fittings.
gas supply header to the protection system regulator.
4. Determine appropriate route for the enclosure supply
and reference tubing.
Tubing PM Configurations
Enclosure Bulkhead Fittings
1. Select the fittings required to install the System Supply,
System Supply Bulkhead Fitting and Atmospheric
Reference Bulkhead Fitting, (see page 12, “Pneumatic
Tubing Requirements”).
2. Choose location for the system supply bulkhead fitting.
This fitting allows the protective gas supply to pass
through the wall of a protected enclosure to the protection
system’s regulator supply inlet connection.
3. Choose location for the atmospheric reference bulkhead
fitting. This fitting allows the enclosure pressure gauge
to reference atmospheric pressure.
4. Drill and deburr system supply and reference bulkhead
fitting holes in the protected enclosure. Mount the
fittings.
System Supply & Reference Connections
supply header and the protection system, it must be in
close proximity of the protected enclosure and labeled
in accordance with section 2-11.4 of the NFPA 496.
gas supply header to the system supply bulkhead fitting.
4. Determine appropriate tubing route from the system
supply bulkhead fitting to the protection system regulator.
5. Determine appropriate tubing route from the atmospheric
reference bulkhead fitting to the enclosure pressure
gauge’s reference inlet connection.
manufacturer’s specifications. Secure tubing as required.
D2-13
Tubing Connection Diagrams
LH, RH, TM, BM, & FM Configuration Connection Points & Pneumatic Diagram
Enclosure
Pressure
Gauge
Rapid
Exchange®
Control
Valve
Enclosure
Reference
Inlet
Regulator
Venturi
Orifice
System
Supply
Inlet
Enclosure
Pressure
Control
Valve
Enclosure
Supply
Outlet
LPS Style
Mounting
Plate
Required Enclosure
Protection Vent
WPS & WPSA Style
Optional EXP
Pressure Switch
Enclosure
Pressure Gauge
Sintered
Vent
Sintered
Vent
Venturi
Orifice
System
Supply
Regulator
Rapid Exchange®
Pressure Gauge
Reference
Enclosure Reference
Bulkhead fitting
Rapid Exchange®
Control Valve
Supply
Inlet
Enclosure Supply
Bulkhead fitting
Enclosure Pressure
Control Valve
Protected Enclosure
PM Configuration Connection Points & Pneumatic Diagram
Enclosure
Pressure
Gauge
Rapid
Exchange®
Control
Valve
Atmospheric
Reference
Inlet
Regulator
System
Supply
Inlet
Enclosure
Pressure
Control
Valve
Mounting
Plate
Required Enclosure
Protection Vent
Enclosure
Supply Outlet
HELPFUL HINT
Pneumatic Connections
are bolded.
Enclosure
Pressure Gauge
Atmospheric
Reference
Bulkhead
System
Supply
Inlet
Sintered
Vent
Rapid Exchange®
Control Valve
Rapid Exchange®
Pressure Gauge
Enclosure Pressure
Control Valve
System Supply
Bulkhead
Regulator
Protected Enclosure
D2-14
General Wiring Requirements
Typical Enclosure Wiring Methods
WARNING
Protected enclosures must be wired similar to explosion
proof enclosures, in accordance with Article 501-504 of the
1993 National Electric Code - NFPA 70.
THIS DEVICE CONTAINS ELECTRICAL PARTS WHICH
CAN CAUSE SHOCK OR INJURY
All electrical connections, conduit and fittings on the protected
enclosure must be suitable for the hazardous location in which
they are installed. In addition, all conduit and wire must be
installed in accordance with NEC articles 500-1, 500-2 or 5003 as required and all relevant plant and local codes.
Note: Do not use seals on conduit used as a protected
“wireway” to supply protective gas to adjacent protected
enclosures. The same conduit can be utilized for both electrical
and pneumatic service to an adjacent protected enclosure(s),
provided the conduit is oversized to allow a minimum free
clearance equal to or larger than the pipe size required between
multiple enclosures as stated on page 7, “Getting Started”.
Enclosure Power Requirements
The protected enclosure(s) electrical power source must
originate from a circuit breaker or fused disconnect suitable for
the hazardous location in which it is installed. The switch must
be located within fifty (50) feet of the protected
enclosure(s) and the protection system and be properly marked.
Alarm Signal Requirements
The WPSA style pressure switch requires a 120 VAC power
supply in addition to the alarm signal. The WPS and WPSA
Style systems alarm signal may originate from the protected
enclosure if the alarm signal is disconnected by the protected
enclosure’s circuit breaker or fused disconnect as stated in
Enclosure Power Requirements above.
Single conductor wiring must be placed in rigid metal conduit,
seal-flex conduit or other mediums approved for use in the
hazardous location surrounding the protected enclosure.
Although the 1998 edition of NFPA 496 does not require
conduit seals on pressurized enclosures in a division 2 area,
Pepperl+Fuchs strongly recommends the use of a conduit
seal as the most practical way to prevent excessive leakage
through conduit connections.
While explosion proof enclosures require conduit seals on all
cable entries, in accordance with NFPA 70, Sections 5015, protected enclosure cable entries can be sealed in
accordance with Section 501-5 which permits the use of
compression gland fittings or other sealed cable entry fittings,
as opposed to approved conduit seals, if the wiring method
is otherwise suitable for the hazardous location.
In conclusion, there are two primary goals. First, the installer
should ensure all associated wiring and cable is protected by
pressurization or other means, such as explosion proof
conduit or intrinsic safety barriers. Secondly, the installer
must ensure all associated conduit and wireways are sealed
to conserve protective gas, unless they are used to supply
protective gas to other enclosures or devices.
Typical Enclosure Wiring Connections
Conduit
The protected enclosure(s) alarm signal power may also originate
from outside of the protected enclosure. In this application, the
protected enclosure may be used as a “wireway” to pass alarm
signal wiring from the power source to the alarm device, if the
wiring is isolated and properly labeled. In addition, appropriate
conduit seals must be provided outside of the protected
enclosure separately.
Explosion
Proof Device
Seal
Conduit
Intrinsically
Safe Or Fiber
Optic Device
Seal
Gland
Fitting
IMPORTANT NOTE
NFPA 496 requires the use of an alarm or an indicator
to detect the loss of safe enclosure pressure. In
addition, the NFPA 496 requires that if an indicator
alone is utilized, a protective gas supply alarm must
also be installed between the last valve in the
protective gas supply and the protected enclosure.
Therefore, the protective gas supply to all LPS Style
systems must be equipped with the above mentioned
protective gas supply alarm. Exception: Systems
utilizing either an EPSK or GPSK enclosure pressure
loss alarm switch accessory will satisfy the above
mentioned NFPA requirement.
Intrinsically
Safe Or Fiber
Optic Device
Cable
Conduit
Seal
Independently
Pressurized
Device
Adjacent
Pressurized
Device
Pressurized
Raceway
Protected Enclosure
Or Device
D2-15
Electrical Conduit
WPS & WPSA Style Conduit
1. Choose the location for the enclosure’s electrical conduit
WPS and WPSA style systems provide electrical contacts
for audible or visual alarm devices that signal a loss of
protected enclosure pressure. WPS and WPSA style systems
are calibrated to alarm at 0.15" for Class I applications. The
switches are suitable for hazardous (classified) outdoor
locations. Wiring must be installed with a seal and conduit
fittings suitable for the area. Alarm circuit power may be
derived from the protected enclosure power source or an
intrinsically safe alarm signal source. All associated alarm
devices must be protected by suitable means (explosion
proof, purged or intrinsically safe).
WPS & WPSA Style
Conduit Connection Parts
Fitting Kits Can Be Factory Furnished
3. Determine appropriate route for the enclosure electrical
and power alarm signal conduit.
HELPFUL HINT
It may be impractical to pour all electrical conduit
seals prior to installation in the field. However, all
conduit connections must be sealed for proper testing
and operation of the Enclosure Protection System.
Therefore, the use of temporary seals such as duct
seal or masking tape for bench or shop testing, prior
to final field installation may be used.
Switch
Body
2. For WPS and WPSA Style EXP pressure loss alarm
switch connected to a remote mounted alarm, one (1)
TCK (T fitting Conduit Kit) or equivalent conduit tee,
coupling and seal fittings.
3. One (1) lot 150# rating 1/2” galvanized or aluminum pipe.
Electrical
Switch
Contacts
SetPoint
Calibration
Screw
Low Port
Sintered
Vent
Grounding
Screw
1/2"
Conduit
Port
1. For WPS and WPSA Style EXP pressure loss alarm
switch connected to an enclosure mounted alarm, one
(1) LCK (L fitting Conduit Kit) or equivalent conduit
elbow, coupling and seal fittings.
High Port
Tube
Fitting
WPS Style EXP Pressure Switch
With Cover Removed
Switch
Body
Low Port
Sintered
Vent
SetPoint
Calibration
Screw
Grounding
Screw
120 VAC
Power &
Electrical
Switch
Contacts
1/2"
Conduit
Port
High Port
Tube
Fitting
WPSA Style EXP Pressure Switch
With Cover Removed
TCK “T” Fitting Conduit Kit
LCK “L” Fitting Conduit Kit
D2-16
Set-up Procedure
HELPFUL HINTS
The term “Safe” pressure for purposes of this manual
is defined as a minimum .25 inch of water column
pressure.
Regulator may be in the locked position upon arrival.
To adjust regulator, pull handle to outward position.
To test the vent’s operation, gently prod the vent flapper
open with a soft pointed object, ( example: eraser end
of a pencil) ensuring that the vent valve works freely. On
vertically configured vents, this can be accomplished
from within the protected enclosure. Side mounted -90
configured vents can be tested by removing the conduit
plug at the bottom of the mounting tee. Multiple
operations require only one test per day if enclosure is
not opened or left unattended.
Class I Purging Set-up
1. Close the Enclosure Pressure and Rapid Exchange®
Control Valves fully by turning clockwise (CW).
2. Connect the inert gas supply to the System Supply Inlet
and set the Rapid Exchange® Pressure Gauge to 60 psi.
3. Temporarily connect a 0-10 inch water column pressure
gauge or manometer to the protected enclosure.
4. Check operation of Enclosure Protection Vent as detailed
above. (see "Helpful Hint")
5. Seal enclosure(s) and adjust Enclosure Pressure Control
Valve by opening slowly counterclockwise (CCW) to set
a “Safe” pressure on the Enclosure Pressure Gauge.
NOTE: If pressure setting is difficult to stabilize or set,
(see page 19, “Trouble-Shooting Procedures”).
6. Open Rapid Exchange® Control Valve fully by turning
90° CCW and quickly ensure the Enclosure Protection
Vent opens. Note: The Enclosure Pressure Gauge
should move quickly off scale to the right, this is normal
for all Rapid Exchange® purging systems.
7. Readjust the regulator to 60 psi minimum, while inducing
Rapid Exchange ® , until the test gauge reads
approximately 2 inches of pressure and does not
fluctuate. (insufficient enclosure pressure will cause the
Enclosure Protection Vent to "shuttle") DO NOT exceed
10 inches of pressure within the protected enclosure.
8. Install and tighten all bolts on the pressure loss alarm
switch (if utilized). Ensure the conduit is sealed with
approved compounds. Energize power to Switch and
alarm system (if utilized) and test the function of the
alarm system.
Pepperl+Fuchs Rapid Exchange Purging Systems are
designed to provide a pre-calibrated and certified volume
exchange rate. With the Rapid Exchange® pressure gauge
set at 60 psi minimum, the model 1002 will accomplish the
required volume exchanges at a rate of ONE MINUTE PER
CUBIC FOOT of enclosure volume.
NOTE: The volume exchange rate is based on a four (4)
enclosure volume exchange. Multiply the required exchange
time by 2.5 for applications requiring a ten (10) volume
exchange (motors).
Regardless of enclosure volume or system flow rate, it is
required that operators withhold power to the enclosure
while inducing the Class I enclosure volume exchange, for at
least five (5) minutes. Normal exchange times should be
doubled if large obstructions block inert gas flow.
The Start-Up Instruction Nameplate Exchange Time Slot will
feature the standard factor for this system "ONE MINUTE
PER CUBIC FOOT", but the unit may feature a set of direct
factor nameplates with self-adhesive backing such as “TEN
MINUTES”, for application to the start-up instructions,
dependent on how the system was specified and purchased.
Field modification of this nameplate, to show a direct factor,
is acceptable as noted above if the method used to mark the
nameplate does not deface the instructions listed. Materials
used for the marking must be indelible and withstand
prevailing environmental conditions.
IMPORTANT NOTE
Operators must secure wrist or stop watch to manually
time Exchange Cycle for all applications.
9. Cease testing and remove test equipment.
D2-17
Operating Sequence
WARNING
Do not exceed "Safe" pressure with the Enclosure Pressure Control Valve.
Operators must follow step-by-step sequence of the Start-Up Instructions Nameplate on the Protection System.
With the inert gas supply connected, enclosure power
deenergized and alarm system energized (if utilized).
1. Carefully read Start-Up Instruction Nameplate on system.
2. Check operation of the Enclosure Protection Vent (Model
EPV-2), opening it manually several times, (see page 17,
“Helpful Hint”).
3. Seal protected enclosure(s).
4. Open Enclosure Pressure Control Valve, by turning
CCW, to set Enclosure Pressure Gauge at “Safe”
pressure, the Pressure Loss Alarm Switch should then
activate to silence the alarm system (if utilized).
5. Ensure the Protection System Enclosure Pressure Gauge
maintains a “Safe” pressure for one (1) minute.
Model
Identification
Nameplate
6. Open Rapid Exchange® Control Valve fully by turning
90° CCW and quickly ensure the Enclosure Protection
Vent opens. Note: The Enclosure Pressure Gauge
should move quickly off scale to the right, this is normal
for all Rapid Exchange® purging systems.
7. Standby for the exchange time as specified on the StartUp Instruction Nameplate( five minutes minimum), then
close the Rapid Exchange® Control Valve fully.
8. Wait for the Enclosure Pressure Gauge to return to a
"Safe" pressure and energize the protected enclosure(s)
power via the local disconnect switch.
9. Ensure the Enclosure Pressure Indicator maintains a
“Safe” pressure before leaving system unattended.
Start - Up
Instruction
Nameplate
Enclosure
Pressure
Gauge
Rapid
Exchange®
Control
Valve
Rapid
Exchange®
Pressure
Gauge
Enclosure
Pressure
Control
Valve
Model 1002-LPS
Front View
EXP Pressure
Loss Alarm
Switch
Model 1002-WPS & WPSA
Front View
D2-18
Problem or Fault
Possible Causes
Corrective Action
Enclosure pressure control valve will
not hold a "Safe" .25 inch pressure.
Leakage around gasketing, covers,
seams, piping and tubing connections,
conduit connections and electrical
conduit seals of the enclosure.
Tighten enclosure latches: Where
tightening is not feasible, and gasketing
materials are not practical, holes or
gaps can be closed with silicone
sealant applied from inside the
protected enclosure.
Enclosure pressure gauge reading is
difficult to stabilize.
Insufficient enclosure leakage or
opening of the venturi orifice is crimped
to small.
Remove the orifice, cut off the crimped
end and ream the tube, then recrimp
and reinstall the tube to note effect. As
tube is shortened, reamed, and
recrimped, sensitivity decreases,
allowing easier adjustment of setpoint
on the enclosure pressure gauge.
Enclosure pressure loss alarm switch
does not appear to be operating.
Pressure switch is out of calibration.
Calibrate by slowly adjusting
counterclockwise to decrease the
setpoint, and clockwise to raise the
setpoint. (Do not attempt to calibrate
the switch until all efforts to make the
switch respond properly have failed)
Pressure switch has not been energized
(WPSA style systems only)
Verify 120 VAC has been applied to
power contacts of WPSA style system.
Persisting problems.
Contact Pepperl+Fuchs Applications/
Customer Service Department at
(330) 486-0002 for more information.
Problems persists, or if the system
does not appear to be operating
properly.
This section covers the most common problems documented with these systems. Any problems not covered in this
section should be addressed directly to our factory. Please address all service needs to Pepperl+Fuchs, Inc. - Customer
Service Department at (330) 486-0002.
D2-19
Warranty Terms and Conditions
PEPPERL+FUCHS STANDARD 18-MONTH WARRANTY
Subject to the conditions and requirements set forth herein, P+F warrants the products covered by the respective
warranties to be free from defects in material and workmanship under normal and proper usage for the respective time
periods listed above from the date of shipment from P+F (or from an authorized representative or distributor of P+F). In
addition, certain specific terms apply to various warranties.
THESE EXPRESS WARRANTIES ARE IN LIEU OF AND EXCLUDE ALL OTHER REPRESENTATIONS MADE — BOTH
EXPRESS AND IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE, OR THAT THE PRODUCTS ARE FREE OF ANY CLAIM OF ANY THIRD PERSON BY WAY OF
INFRINGEMENT OR THE LIKE, and are also in lieu of and exclude any promise, description, affirmation of fact, sample
model or representation, oral or written, which may be part of an order or made by a representative of P+F or otherwise.
This WARRANTY shall not apply to any product which has been subject to misuse, negligence, or accident, or to any
product which has been modified or repaired, improperly installed, altered or disassembled (except according to P+F’s
written instructions) or any product if the machinery, equipment, or production line to which the product is originally
connected or on which the product is originally installed is abandoned, changed, substituted, moved or replaced or if
the product is removed from such machinery, equipment or production line or other original application.
This WARRANTY is subject to the following conditions:
1)
This WARRANTY is limited to the electronic and mechanical performance only, as expressly detailed in the product
specifications and NOT to cosmetic performance.
2)
This WARRANTY shall not apply to any cables attached to, or integrated with the product. However, it shall apply to
cables sold separately by P+F.
3)
This WARRANTY shall not apply to any products which are stored, or utilized, in harsh environmental or electrical
conditions outside P+F’s written specifications.
4)
The WARRANTY is applicable only to products shipped from P+F subsequent to January 1, 1992.
5)
All claims under this WARRANTY must be made in writing within thirty (30) days of the date on which the defect is
(or, with reasonable diligence, should have been) discovered.
PRODUCTS TO WHICH STANDARD 18-MONTH WARRANTY APPLIES
Ultrasonic sensors, level controls, photoelectric sensors, read-write ID systems, encoders, counters, signal conditioners,
purge/pressurization systems and all products with electromechanical relays or circuit breakers.
CONSIDER SAFETY AND PROTECTION PRECAUTIONS
P+F takes great care to design and build reliable and dependable products; however, some products can fail eventually.
You must take precautions to design your equipment to prevent property damage and personal injury in the unlikely
event of failure. As a matter of policy, P+F does NOT recommend the installation of electronic controls as the sole
device FOR THE PROTECTION OF PERSONNEL in connection with power driven presses, brakes, shears and similar
equipment and, therefore, the customer should build in redundancy or dual control using approved safety devices for
these applications.
DELIVERY
Pepperl+Fuchs® Inc. will deliver its products F.O.B. from its warehouse, place of manufacture or other place from which
the products are actually shipped within the U.S.A.
Freight charges will be prepaid and added to invoice.
D2-20
System Maintenance
Regular Maintenance
Drain the Protection System Regulator frequently and clean System with non-solvent cleaning agents only.
Long Term Maintenance
Calibrate the enclosure pressure indicator to 0 inches by venting the purge pressure reference port and the protected
enclosure to atmosphere and adjusting the calibration screw in the lower center portion of the indicator’s face.
Fully open the enclosure pressure control regulator, to blow out any deposits around the tip of the valve and to ensure that
the enclosure protection vent is operating properly, then carefully readjust system according to the set-up procedure and
operating sequence on pages 17 and 18. Replace or tighten stem packing nut as required to prohibit stem packing leakage.
Carefully disassemble the enclosure protection vent by loosening the two bottom hex nuts that hold the unit together.
(DO NOT REMOVE CAP NUTS ON TOP OF VENT BODY)
Carefully clean the flapper valve and vent body seats with warm soap and water, being careful not to extend the vent valve
beyond its normal opening point, and being careful not to exert any stress on the valve hinge.
Examine the entire Protection System and the protected enclosure(s), and replace any defective parts during routine
shutdown of the protected enclosure(s). Parts are available from Pepperl+Fuchs on immediate notice as required.
Date
Work Performed
Performed by
D2-21
CUSTOMER NOTES
D2-22
CUSTOMER NOTES
D2-23
SYSTEMS IDENTIFICATION & APPLICATION INFORMATION
Date of Installation
Unit Serial #
Item
Customer P.O.#
Customer Project#
Service
Type
Features
Application
NOTES:
Local Sales Representative
D2-24
Vartech Systems Technical Support Service:
If you are ToughStation is not operating correctly, contact Vartech Systems for
technical support. To ensure the most efficient technical support, be prepared to
operate your ToughStation computer while discussing the problem with a Vartech
Systems technical support representative. We recommend writing down any error
messages reported by the system BIOS, as well as having a record of the system
settings stored in the BIOS. If you determine that a replacement component is
needed, contact the factory for a Return Material Authorization number (RMA#).
Vartech Systems provides a special shipping container for the return of the defective component.
Vartech Systems Technical Support phone numbers are: (215) 773-3601 Monday
through Friday, 8:00 am to 5:00 pm PST, excluding holidays. Fax: (215) 7733620.
Vartech Systems Limited Warranty:
Vartech Systems, Inc. warrants this product against defects in material or workmanship, provided the serial number appears on the product and is as originally
configured by the factory. For details, please refer to the Vartech Systems, Inc.
standard terms and conditions included with your purchase agreement.
If failure of the product has resulted from accident, abuse or misapplication, Vartech Systems shall have no responsibility under this Limited Warranty.
Corporate Headquarters
Vartech Systems Inc.
6399 Amp Dr.
Clemmons, NC 27012 USA

VarTech Systems ESW Workstation Series Manual

Transcription

Similar documents

MECCOMark Mini Enclosure

This set of letters is both from the IARDC (Illinois Attorney

MAMAC SYSTEMS® Convinced that all temp sensors are same?

Untitled - MBTA.com

Cabinet - YG Acoustics

E2-2 SOUNDEX Quick-Tech Multi Enclosure

Blower Package Pressure and Vacuum

fr qEFuttqr*rruAtr+fdFds \r`/

TrueLook

SRX725