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Summary of Contents for Pepperl+Fuchs 1011 Series
- Page 1 PROCESS AUTOMATION INSTALLATION AND OPERATION MANUAL MODEL 1011 TYPE Z PURGE/PRESSURIZATION SYSTEM...
- Page 2 Model 1011 Installation and Operation Manual Table of Contents Purpose and Description Page 2 System Purpose and Description Purpose Purpose, System description, Important notes Pepperl+Fuchs Enclosure Protection System’s purpose is to Page 3 Identifying Your System allow the use of general purpose or non-rated electrical or Defines specific features of the system electronic devices, with exception to devices which produce excessive heat, utilize combustible gas, or expose arcing Page 3 General Information contacts to the hazardous atmosphere, in Type 4 or 12 S ystem & material specifications, System enclosures in the place of explosion proof Type 7 enclosures. accessories, Spare parts, Tools & test equipment Other purposes include heat, moisture and dust contamination...
- Page 3 Model 1011 Installation and Operation Manual Identifying Your System In addition, for small, tightly sealed enclosures, or to compensate for a fluctuating protective gas supply, it may be necessary to pre-regulate the protective gas supply to a This enclosure protection system is offered in various styles. constant 5 psi regardless of whether an enclosure protection For proper installation and operation, examine the system ven is installed. This will reduce the amount of "drifting" model number nameplate to identify the system style, area that can normally occur when maintaining a "Safe" pressure classification, and type, as noted below. 2.50 inside a protected enclosure. The pre-regulation can be accomplished by installing a TR-10G tamperproof regulator Model 1011 CII Type Z accessories or equivalent. 10 CUBIC FEET MAXIMUM ENCLOSURE VOLUME ** Enclosure integrity determines actual flow rate CLASS II, DIVISION 2, GROUPS F & G TO NONHAZARDOUS PURGE CONTROL FOR USE 1.00 IN HAZARDOUS LOCATIONS...
- Page 4 Model 1011 Installation and Operation Manual Model 1011 System Accessories Adjacent Enclosures Optional Enclosure Protection Vents 1. Adjacent enclosures must be protected by one of the EPV-1-SA-00 Straight w/ spark arrestor following means: EPV-1-SA-90 Rt angle w/ spark arrestor a) purged or pressurized in series with the protected Additional Items enclosure SMK-1, or -4 System mounting kit b) purged or pressurized separately or EPSK-1 Class I, Group C - D pressure switch kit c) protected by other means; e.g., explosion proof EPSK-1A Class I, Group A - D pressure switch kit enclosures, hermetically sealed devices or intrinsic safe EPSK-2 Class II, Group E - G pressure switch kit circuits GPSK-1...
- Page 5 Model 1011 Installation and Operation Manual Installation Overview Model 1002-WPS-LH Shown ENCLOSURE PROTECTION VENT PROTECTED ENCLOSURE ENCLOSURE SUPPLY TUBING SYSTEM MOUNTING BOLT ENCLOSURE PROTECTION SYSTEM PROTECTIVE GAS SUPPLY SYSTEM SUPPLY FITTING SERVICE VALVE ENCLOSURE CONNECTION FITTINGS ENCLOSURE ENCLOSURE WARNING REFERENCE NAMEPLATE TUBING SYSTEM...
- Page 6 Model 1011 Installation and Operation Manual Getting Started Typical Single Protected Enclosure Connections ENCLOSURE PROTECTION VENT (Optional) 1/2" PROTECTIVE GAS SUPPLY HEADER REFERENCE ENCLOSURE PROTECTED PROTECTION ENCLOSURE SYSTEM SUPPLY System Enclosure Enclosure Optional remote Multi - enclosure Description supply tubing reference supply connections...
- Page 7 Model 1011 Installation and Operation Manual System Mounting IMPORTANT NOTES Mounting FM & PM Configurations The system should be mounted at EYE LEVEL. 1. Carefully read the HELPFUL HINTS located below. Care must be taken to ensure the system and all protruding 2. Transfer panel cutout pattern to the intended surface. components are clear of all enclosure accesses (doors and 3. Check for obstructions which could prohibit bolt fastening covers) and conduit, pipe, tubing or cable entries.
- Page 8 Model 1011 Installation and Operation Manual Mounting Plate Dimensions (continued) 8" 8" 8.25" 8.25" 1011-LH 1011-RH (Left hand configuration) (Right hand configuration) 8.25" 8.25" 8" 8" 1011-TM 1011-BM (Top mount configuration) (Bottom mount configuration) 2.4375" 3.25" 1.25" .875" Panel Cutout .6875"...
- Page 9 Model 1011 Installation and Operation Manual Hardware Mounting Optional 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 The vent must be located to provide access for routine testing and covers). of the vent’s flapper assembly. A minimum 8" clearance is required below the vent opening. One (1) EWN is provided with each system, located in the manila envelope taped to the mounting flange of the system. 1. Determine the vent’s mounting configuration, i.e.; Additional EWNs are available from Pepperl+Fuchs. -00 vertical mount or -90 side mount. See photos below. All EWNs provide labeled spaces allowing the customer to 2. Determine vent location and layout vent mounting hole on mark the protected enclosure with: 1) a T Code (temperature the protected enclosure. (as determined on page 6, “Getting identification number), 2) Class, Group and Division of Started”) surrounding area, and 3) NFPA pressurization Type X, Y or Z, 3. Using a 0.875" hole saw or 1/2" conduit punch, drill and as may be required by plant and local codes and is required by deburr the enclosure protection vent mounting hole. NFPA 496. 4. Remove the hub mounting nut from the vent hub and place An ETW (enclosure temperature warning nameplate) must the hub, with O-ring intact, through the mounting hole. The...
- Page 10 (model ILFK) hazardous location and the protection system tubing and piping accessory. must be fabricated from noncombustible materials suitable for One (1) similar fitting which will connect the inert gas supply prevailing hazards and environmental conditions. tubing to the inert gas supply header connection point and The protective gas supply must originate from a dedicated one (1) lot of 1/4" O.D., .035" wall thickness, welded or instrument quality compressed air header (1/2" pipe or larger), seamless stainless steel tubing. no farther than twenty (20) feet from the protection system. 2. For enclosure supply, one (1) EFC-4 1/4" flush connector, Local compressors and gas cylinders should not be used or one (1) EBC-4 1/4" feed-through connector or equivalent before consulting with Pepperl+Fuchs. fitting per system. The protective gas supply to the protection system must be 3. For enclosure reference, one (1) EFC-4 1/4" flush connector, equipped with a tamper-proof regulator set at 5 psi maximum. or one (1) EBC-4 1/4" feed-through connector or equivalent Exception: If the protected enclosure(s) is equipped with an fitting per system. Enclosure Protection Vent, the protective gas supply to the 4. One (1) lot of 1/4" O.D., .035" wall thickness, welded or protection system must not exceed 120 psi maximum, 5 psi seamless stainless steel tubing. minimum. (See page 3, "System Specifications" for additional information concerning protective gas supply requirements.) 5. For multiple enclosure connections, two (2) EPC-10 1/2"...
- Page 11 Model 1011 Installation and Operation Manual Tubing Installation Tubing PM Configurations HELPFUL HINTS Enclosure bulkhead fittings All work must be performed by technicians qualified in 1. Select the fittings required to install the system supply, pneumatic tubing and electrical conduit installation. system supply bulkhead fitting and atmospheric reference Pepperl+Fuchs recommends the use of .035" wall bulkhead fitting. See page 11, “Pneumatic Tubing thickness, welded or seamless stainless steel tubing. Requirements.” If flexible tubing is used, it must be installed in a manner 2. Choose location for the system supply bulkhead fitting. This that protects it from damage and corrosion. fitting allows the protective gas supply to pass through the wall of a protected enclosure to the protection system’s regulator supply inlet connection. Tubing LH, RH, TM, BM & FM Configurations 3.
- Page 12 Model 1011 Installation and Operation Manual Tubing Connection Diagrams LH, RH, TM, BM & FM Configuration Connection Points & Pneumatic Diagram System Enclosure supply pressure inlet gauge Enclosure Enclosure reference pressure inlet control regulator Venturi orifice Enclosure supply Mounting outlet bracket Mounting plate...
- Page 13 Model 1011 Installation and Operation Manual Electrical Supply Requirements General Wiring Requirements Typical Enclosure Wiring Methods WARNING: THIS DEVICE CONTAINS ELECTRICAL Protected enclosures should be wired similar to explosion PARTS THAT CAN CAUSE SHOCK OR INJURY proof enclosures, in accordance with Article 500 of the National Electric Code - NFPA 70. All electrical connections, conduit and fittings on the protected enclosure must be suitable for the hazardous location in which Single conductor wiring should be placed in rigid metal conduit, they are installed. In addition, all conduit and wire must be seal-flex conduit or other mediums approved for use in the installed in accordance with NEC as required and all relevant hazardous location surrounding the protected enclosure. plant and local codes. Additionally, NFPA 496 requires the use of approved seals on all pressurized enclosure conduit wiring entries, in accordance Note: Do not use seals on conduit used as a protected with NFPA 70. Furthermore, the use of an approved seal is...
- Page 14 Model 1011 Installation and Operation Manual Set-up Procedure CLASS I VOLUME EXCHANGE TIME CHART HELPFUL HINTS MEASURED FLOW REQUIRED EXCHANGE TIME The term “Safe” pressure for purposes of this manual 0.10 SCFM / 6 SCFH 40 minutes per cubic foot is defined as follows: 0.25 SCFM / 15 SCFH 16 minutes per cubic foot Class I = a minimum .25 inch of water column pressure 0.50 SCFM / 30 SCFH 8 minutes per cubic foot Class II = a minimum 1.0 inch of water column pressure 0.75 SCFM / 45 SCFH 5.5 minutes per cubic foot Regulator may be in the locked position upon arrival. To adjust regulator, pull handle to outward position. 1 SCFM / 60 SCFH 4 minutes per cubic foot To test the vent’s operation, gently prod the vent flapper 2 SCFM / 120 SCFH 2 minutes per cubic foot open with a soft-pointed object, ( example: eraser end 3 SCFM / 180 SCFH 1.5 minutes per cubic foot of a pencil) ensuring that the vent valve works freely. On 4 SCFM / 240 SCFH or greater 1 minute per cubic foot vertically configured vents, this can be accomplished from within the protected enclosure. Side mounted NOTE: The volume exchange time chart is based on a four (4) -90 configured vents can be tested by removing the enclosure volume exchange. Multiply the required exchange...
- Page 15 Model 1011 Installation and Operation Manual Operating Sequence Class II Pressurization Operation WARNING! Do not exceed a “safe” pressure with the enclosure pressure control regulator. Operators must Start-Up Conditions follow step-by-step sequence of the start-up instructions nameplate on the protection system. Protection method: Type “Z” pressurization system Powering method:...
- Page 16 Enclosure pressure indicator Application involves a small, tightly sealed Pre-regulate the protective gas supply upstream of "drifts" up or down from the enclosure and/or a fluctuating protective the enclosure protection system to 5 psi maximum. "safe" pressure setting. gas supply. For dramatic fluctuations in the protective gas supply, it may be neccessary to utilize a self-relieving low flow precision regulator to pre-regulate the protective gas supply. Enclosure pressure loss Pressure switch is out of calibration. Calibrate by slowly adjusting counterclockwise to alarm switch does not appear decrease the setpoint, and clockwise to raise the to be operating. setpoint. (Do not attempt to calibrate the switch until all efforts to make the switch respond properly have failed) Problems persists, or if the Problems persist Contact Pepperl+Fuchs Applications/Customer system does not appear to Service Department at (330) 486-0002 for more be operating properly. information. This section covers the most common problems documented with this system. 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...
- Page 17 Model 1011 Installation and Operation Manual Warranty Terms and Conditions PEPPERL+FUCHS STANDARD 24-MONTH WARRANTY 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. 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. 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.
- Page 18 Model 1011 Installation and Operation Manual System Maintenance Regular Maintenance Drain the protection system regulator frequently and clean system with nonsolvent 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 14 and 15. 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...
- Page 19 Model 1011 Installation and Operation Manual Systems Identification & Application Information Date of installation _____________________________________________________ Unit serial #____________________________________________________________ Item ___________________________________________________________________ Customer P.O.# ________________________________________________________ Customer project# _____________________________________________________ Service ________________________________________________________________ Type __________________________________________________________________ Features ______________________________________________________________ Application ____________________________________________________________ Notes: _______________________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________...
- Page 20 – Pepperl+Fuchs has earned a strong reputation by supplying the world’s largest process industry companies with the broadest line of proven components for a diverse range of applications. Subject to modifications • © 2009 PEPPERL+FUCHS, INC. • Printed in USA • Part No. 512083 Drawing No. 129-0205a (TDOCT-1360_ENG) 03/09...