Related Manuals for Pepperl+Fuchs Bebco EPS 5500 Series
Summary of Contents for Pepperl+Fuchs Bebco EPS 5500 Series
- Page 1 5500 Purge System User Manual Bebco EPS® 5500 Series Type Z and Ex pzc Purge and Pressurization System...
- Page 2 Phone: +49 621 776 - 0 E-mail: info@de.pepperl-fuchs.com North American Headquarters Pepperl+Fuchs Inc. 1600 Enterprise Parkway Twinsburg, Ohio 44087 Phone: +1 330 425-3555 E-mail: sales@us.pepperl-fuchs.com Asia Headquarters Pepperl+Fuchs Pte. Ltd. P+F Building 18 Ayer Rajah Crescent Singapore 139942 Phone: +65 6779-9091 E-mail: sales@sg.pepperl-fuchs.com https://www.pepperl-fuchs.com...
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Page 3: Table Of Contents
5500 S T erieS anual able of conTenTS Table of contents 1. Introduction .....................6 1.1. Content of this Document ................6 1.2. Target Group, Personnel................7 1.3. Symbols Used ....................8 1.4. Pertinent Laws, Standards, Directives, and Further Documentation ....9 1.5. - Page 4 5500 S T erieS anual able of conTenTS 4. Programming ..................40 4.1. User Interface ..................... 40 4.1.1 LED Indication ..................40 4.1.2 Buttons ....................41 4.1.3 Adjusting the Contrast ................41 4.1.4 LCD Backlight ..................41 4.2. Default Settings ................... 42 4.3.
- Page 5 5500 S T erieS anual able of conTenTS 6. Product Lifetime Care ................67 6.1. Maintenance and Repair ................67 6.2. Dismantling and Decommissioning ............. 67 6.3. Troubleshooting ................... 68...
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Page 6: Introduction
5500 S i erieS anual nTroducTion 1. Introduction 1.1. Content of this Document This document contains information required to meet the safety and protection requirements for systems with explosion protection in equipment Group II Zones 2 or 22, Class I or II, Division 2 when installing, commissioning, and using the 5500 control unit and its components. -
Page 7: Target Group, Personnel
i 5500 S i erieS anual nTroducTion nTroducTion In addition, the documentation may comprise the following parts, if applicable: Manufacturer declaration of conformity EU declaration of conformity Control drawings Additional documents 1.2. Target group, Personnel Responsibility for planning, assembly, commissioning, operation, maintenance, and dismounting of the 5500 series lies with the plant operator. -
Page 8: Symbols Used
5500 S i erieS anual nTroducTion 1.3. Symbols Used This document contains symbols to identify warning messages and information messages. Warnings You will always find warning messages whenever hazards could result from your actions. It is essential that you observe these warning messages to ensure your personal safety and to prevent property damage. -
Page 9: Pertinent Laws, Standards, Directives, And Further Documentation
A Declaration of Conformity is included with these instructions and can be requested from the manufacturer or obtained online at www.pepperl-fuchs.com. Additional documentation can also be provided for individual components. The product manufacturer, the Pepperl+Fuchs Group, 68307 Mannheim, has a certified quality assurance system that conforms to ISO 9001. ISO9001... -
Page 10: Product Description
5500 S P erieS anual roducT eScriPTion 2. Product Description 2.1. Introduction Purge and pressurization is one of the most versatile ignition protection classes. Purge and pressurization systems are based on the principle that in Zone 2/Class I Division 2 (gas), the gas mixture in the ambient atmosphere, which may ignite under certain circumstances, is removed from the housing by an initial purge process. -
Page 11: Technical Data: Control Unit
5500 S P erieS anual roducT eScriPTion Control Unit Components 5500 control unit Cable glands / conduit openings available Mounting bolts and sealing washers for attaching control unit to an enclosure Hardware for the reference pressure—bulkhead fitting, sealing washer, and tubing Manual 2.3.1 Technical Data: Control Unit Item... - Page 12 5500 S P erieS anual roducT eScriPTion Input Input I Temperature, up to 2 RTDs per unit Connection PT100, 2-wire-connection Input type temperature input Input accuracy 2.5% of measurement value + PT100 error Input II 1 Bypass Connection passive contact (switch) Input type mechanical contact Output...
- Page 13 5500 S P erieS anual roducT eScriPTion RoHS Directive 2011/65/EU EN 50581:2012 Conformity Degree of protection EN 60529 Shock resistance EN 60068-2 Ambient conditions Ambient temperature -20 ... 40 °C (-4 ... 104 °F) at T6 -20 ... 60 °C (-4 ... 140 °F) at T4 Relative humidity 5 ...
- Page 14 5500 S P erieS anual roducT eScriPTion Marking II 3 (3) G Ex ic ec nC [ic Gc] [pzc Gc] IIC T4 Gc (-20 °C ≤ Ta ≤ 60 °C) II 3 (3) G Ex ic ec nC [ic Gc] [pzc Gc] IIC T6 Gc (-20 °C ≤...
- Page 15 5500 S P erieS anual roducT eScriPTion Bypass and Temperature Wiring Notes 1. The minimum wire strand in a stranded wire shall have a diameter of 0.1 m or greater. 2. Wire shall be copper only, rated at a minimum of 80 °C. 3.
- Page 16 5500 S P erieS anual roducT eScriPTion 4. For earth stud torque and terminal torque values, see Section 2.3.5 Torque Requirements— Control Unit. 5. All wire shall be copper only, rated at a minimum of 80 °C. 6. The minimum wire strand in a stranded wire shall have a diameter of 0.1 mm or greater. 7.
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Page 17: Electrical Connections
5500 S P erieS anual roducT eScriPTion 2.3.2 Electrical Connections External Mount L(+) N(-) Bypass Power N(-) N(-) N(-) L(+) N(-) L(+) Internal Mount L(+) N(-) Bypass Power N(-) N(-) N(-) L(+) N(-) L(+) Terminal Block L (+) N (-) -
Page 18: Dimensions
5500 S P erieS anual roducT eScriPTion 2.3.3 Dimensions Dimensions: External Mounting Low-pressure port (atmospheric pressure) Low pressure port (-): The atmospheric reference. This port shall always be connected such that High-pressure port (enclosure pressure) the air pressure present on this port is the atmospheric pressure surrounding the enclosure being protected by pressurization. - Page 19 5500 S P erieS anual roducT eScriPTion For the external-mount 5500 control unit, the display can be rotated 90 degrees. No screws are required. To rotate, remove the cover and pop out the display. Position the display as desired and push it back into the pin on the control unit. Do not rotate more than +/- 90 degrees.
- Page 20 5500 S P erieS anual roducT eScriPTion Dimensions: Internal Mounting Low-pressure port (atmospheric pressure) High-pressure port (enclosure pressure) Low pressure port (-): The atmospheric reference. This port shall always be connected such that the air pressure present on this port is the atmospheric pressure surrounding the enclosure being protected by pressurization.
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Page 21: Hardware Kit
5500 S P erieS anual roducT eScriPTion 2.3.4 Hardware Kit The hardware mounting kit is included. It contains the following: • Mounting hardware: screws, nuts, and sealing washers Hole size: 6.4 mm • Pressure kit: bulkhead fitting, O-ring and tubing inserts, straight connector, sintered element for bulkhead fitting Panel hole size 29/34 inch (11.5 mm ) 2.3.5... -
Page 22: Internal-Mounting The Control Unit
5500 S P erieS anual roducT eScriPTion 2.3.6 Internal-Mounting the Control Unit Note 1. RTDs are not included. 2. Pressure reference kit is included. Required to measure ambient pressure outside for the differential pressure sensor within the 5500 control unit. Tubing kit connected to port labeled “Atmospheric Pressure”. -
Page 23: External-Mounting The Control Unit
5500 S P erieS anual roducT eScriPTion 2.3.7 External-Mounting the Control Unit Note 1. RTDs are not included. 2. Pressure reference kit is included. Required to measure ambient pressure outside for the differential pressure sensor within the 5500 control unit. Tubing kit connected to port labeled “Enclosure Pressure”. -
Page 24: Epv-5500 Vents
5500 S P erieS anual roducT eScriPTion 2.4. EPV-5500 Vents EPV-5500 vents work with the 5500 control unit and manifold to provide a functional, certifiable purge and pressurization system for enclosures. As required by all pressurized enclosure systems, the EPV-5500 vent functions as a pressure relief device and allows the purge gas to exit the enclosure, yet provides a seal when the enclosure is pressurized and operating. - Page 25 5500 S P erieS anual roducT eScriPTion Ambient conditions Ambient temperature -40 ... 70 °C (-4 ... 140 °F) Relative humidity 5 ... 95 %, non-condensing Vibration resistance 5 ... 100 Hz , 1 g, 12 m/s², all axes Impact resistance 30 g, 11 ms, all axes Mechanical specifications...
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Page 26: Flow Rate Curves
5500 S P erieS anual roducT eScriPTion 2.4.2 Flow Rate Curves The enclosure pressure vs. flow rate curves below represent the EPV-5500..-01, 02, and 03 vents. This corresponds to the enclosure pressure and is independent of the valve used, provided the valve can deliver the flow rate that is required. The curves below represent completely sealed enclosure, which may not be representative of the customer’s enclosure. - Page 27 5500 S P erieS anual roducT eScriPTion EPV-5500-...-01 Flow Rate Curve Inches WC SCFM mbar l/min 1.75 12.5 2.05 17.5 2.75 22.5 27.5 11.2...
- Page 28 5500 S P erieS anual roducT eScriPTion EPV-5500-...-02 Flow Rate Curve Inches WC SCFM mbar l/min 12.5 17.5 22.5 10.7 12.2 14.2...
- Page 29 5500 S P erieS anual roducT eScriPTion EPV-5500-...-03 Flow Rate Curve Inches WC SCFM mbar l/min 12.7 18.7...
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Page 30: Dimensions: Epv-5500 Vents
5500 S P erieS anual roducT eScriPTion 2.4.3 Dimensions: EPV-5500 Vents EPV-5500-...-01/02/03 1 1/2 NPS thread (3) Hex key 0.050" (included) 23.4 Exhaust port Inlet port 49.5 57.2 73.2 98.5 2.4.4 Torque Requirements: EPV-5500 Vents Hardware Torque Sealing washer and nut 0.25–1 turns past finger tight.* Set screws Secure vent cap evenly by threading in set screws. - Page 31 5500 S P erieS anual roducT eScriPTion For NEC, ATEX, and IECEx applications, see the type code for the correct model. The 5500 valve system works with the 5500 control unit as well as EPV-5500 vents. The 5500 control system is certified by UL for Class/Division installation. Users can also use their own pneumatic system or the 5500-MAN-MV-01 manual manifold.
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Page 32: Technical Data: 5500 Manifolds
5500 S P erieS anual roducT eScriPTion 5500 manifolds include the solenoid and manual needle valve, as well as the following: 3/8 inch compression ferrule fittings for inlet and outlet protective gas source 3/8 inch compression ferrule bulkhead fitting that attaches to enclosure—for protective gas to inside enclosure 3/8 inch poly tubing (2 m length) Inserts for poly tubing to ferrule fitting connection. - Page 33 5500 S P erieS anual roducT eScriPTion Fuse rating on 5500 control unit DC voltage 500 mA AC voltage 80 mA Pneumatic parameters 5500-MAN-CDUL (only 60 Hz for AC version) Protective gas supply 40 μm filtered air or inert gas Pressure requirement 25 psi (1.7 bar) to 115 psi (8.0 bar) Purge flow rate (solenoid valves)
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Page 34: Dimensions: 5500 Manifolds
5500 S P erieS anual roducT eScriPTion Electrical connection 5500-MAN-CD 1/2 inch NPT thread connection with 24 inch (0.61 m) 5500-MAN-EX01 3 m cable WARNING! During installation, ensure that no foreign bodies lie inside or can enter the valve. The digital valve must be rated for mounting in a hazardous area. - Page 35 5500 S P erieS anual roducT eScriPTion Bulkhead Fitting Ordering information 768LO_3/8 x 9/16-18 A (Tube OD) 9.52 mm (3/8 in) T (Straight thread UNF) 9/16-18 in 7.11 mm (0.28 in) 23.62 mm (0.93 in) W (Hex flat) 15/16 in 35.05 mm (1.38 in) 11.93 mm (0.47 in) 40.89 mm (1.67 in)
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Page 36: Torque Requirements: Manifolds
5500 S P erieS anual roducT eScriPTion 5500-MAN-EX01 24.1 14.6 3/8" NPT (2x) 12.7 22.2 38.1 14.8 53.3 22.2 1/4-20UNC 8 (4x) 1/4-20UNC 9.5 (4x) 5500-MAN-CD01 24.1 14.6 3/8" NPT (2x) 56.6 12.7 22.2 38.1 14.8 53.3 22.2 1/4-20UNC 9.5 (4x) 1/4-20UNC 0.375 (4x) -
Page 37: Installation And Operation
5500 S i erieS anual nSTallaTion and PeraTion 3. Installation and Operation The 5500 series control unit, vent, and manifold can be universally mounted to the customer enclosure. The control unit can be mounted within the enclosure or outside the enclosure. -
Page 38: For Dust Atmospheres
5500 S i erieS anual nSTallaTion and PeraTion 3.1.2 For Dust Atmospheres If the protective enclosure has been opened or has been subjected to the hazardous atmosphere, the enclosure must be manually cleaned of all combustible dust, closed, and pressurized before supplying power to the enclosure. For dust atmospheres, a higher pressure is required for pressurization and is reflected in the pressure range within the 5500 programming setup. -
Page 39: Operation
5500 S i erieS anual nSTallaTion and PeraTion 3.2. Operation Operating the System Follow the preceding instructions for setting up the system. For Flush Programs 1 through 4 (hazardous gas environments), purging is required. a. Seal the pressurized enclosure. b. -
Page 40: Programming
5500 S P erieS anual rograMMing 4. Programming 4.1. User Interface To program the control unit, use the membrane pad on the front of the unit. Program settings are saved on non-volatile memory in the CPU. Settings are unaffected by power down and reset function. -
Page 41: Buttons
5500 S P erieS anual rograMMing 4.1.2 Buttons Button Description To advance up To advance down The set button has three functions: 1. Hold for 5 seconds to enter the purge settings 2. Press to advance into the purge setting parameters you have selected 3. -
Page 42: Default Settings
5500 S P erieS anual rograMMing 4.2. Default Settings Display Description Default Values PASSWORD / SET Enter password to access purge settings 0000 PURGE / PROGRAM Up to 5 programs to select PURGE / TIME Time required for purging 00:30 ENCLOSUR / PRESS P1 Enclosure pressure P1... -
Page 43: Menu Structure
5500 S P erieS anual rograMMing 4.3. Menu Structure PROGRAM Power On BYPASS SHUT-OFF UNITS DELAY 5 sec. NUMBER TEMP ENABLED OF PT100 PASSWORD TEMP PT1 CHANGE PASSWORD PURGE PROGRAM (Cycles from CHANGE PASSWORD back to TEMP PT2 PURGE PROGRAM.) PURGE TIME TEMP PT1... -
Page 44: Purge Programs
5500 S P erieS anual rograMMing 4.4. Purge Programs There are 5 program selections for system operation. Programs 1 through 4 are for hazardous gas environments and require purging. The fifth program is for hazardous dust environments that require cleaning the enclosure, then pressurizing. -
Page 45: Program 1
5500 S P erieS anual rograMMing 4.4.1 Program 1 Program 1 is used in hazardous gas atmospheres. Sequence of Events for Program 1 HYST > 0 Purge valve P < P2 Purge Start P > P3 K1 ON P < P4 valve K1 ON P <... -
Page 46: Program 2
5500 S P erieS anual rograMMing 4.4.2 Program 2 Program 2 is used in hazardous gas atmospheres. Sequence of Events for Program 2 HYST > 0 Purge valve P < P2 P < P4 Purge Start P > P3 valve K1 ON K1 ON... -
Page 47: Program 3
5500 S P erieS anual rograMMing 4.4.3 Program 3 Program 3 is used in hazardous gas atmospheres. Sequence of Events for Program 3 HYST > 0 Purge valve P < P2 P < P4 Purge Start P > P3 valve K1 ON P <... -
Page 48: Program 4
5500 S P erieS anual rograMMing 4.4.4 Program 4 Program 4 is used in hazardous gas atmospheres. Sequence of Events for Program 4 HYST > 0 Purge valve P < P3 Purge Start P > P3 K1 ON valve P <... -
Page 49: Program 5
5500 S P erieS anual rograMMing 4.4.5 Program 5 Program 5 is used in combustible dust atmospheres. Sequence of Events for Program 5 Purge valve P < P3 Clean P > P1 K1 ON K1 ON enclosure P < P1 P >... -
Page 50: Purging Timer
5500 S P erieS anual rograMMing Program Purging P<P1 P1<P<P2 P2<P<P3 P3<P<P4 P>P4 Clean activates above P1 After purging P<P1 P1<P<P2 P2<P<P3 P3<P<P4 P>P4 Note Shutoff delay timer and bypass affect the status of K1 and SV. See the explanation for each to determine effects on K1 and SV. - Page 51 5500 S P erieS anual rograMMing To make sure the enclosure is safe from the hazardous atmosphere, the inside of the enclosure has to be free of the hazardous atmosphere and pressurized before the equipment inside can be powered. The first step in this process is to get rid of the hazardous atmosphere within the enclosure.
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Page 52: Pressure Settings
5500 S P erieS anual rograMMing The number of volume exchange depends on the item being purged and the standard it is being evaluated to. Number of exchanges Class/Division (NFPA 496) Zone (60079-2) 10 (motors) EXAMPLE Class/Division (NFPA 496) Zone (60079-2) 2.6 inches water 6.5 mbar... -
Page 53: Purging Pressure "P3
5500 S P erieS anual rograMMing 4.5.2.3 Purging Pressure “P3” The purging timer starts when enclosure pressure is above P3. If the enclosure pressure is above P3, purging will start and finish uninterrupted. If the enclosure pressure is below P3, the purging timer will not start. - Page 54 5500 S P erieS anual rograMMing Values for hysteresis HYST Inches WC mbar Example Units are in mbar, hysteresis = 1.5, then SV is on at P2 and turns off at P2 + 1.5 They HYST unit of measurement is the units being used. If HYST = 1.5, then this is 1.5 mbar.
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Page 55: Programming K2
5500 S P erieS anual rograMMing 4.5.3 Programming K2 The K2 contact output can be programmed for various settings that are chosen by the user. For Type Z and Ex pz systems, power to the pressurized enclosure may remain on if pressure goes below the minimum allowed pressure, but an audible and/or visual alarm must be generated to notify the operator of a problem. -
Page 56: Shutoff Delay Timer For K1
5500 S P erieS anual rograMMing 4.6. Shutoff Delay Timer for K1 The shutoff delay timer is used in the operation mode and allows K1 to remain on for the duration of this setting when enclosure pressure drops below the minimum setting of P1. -
Page 57: Number Of Pt100 Temperature Sensors Used
5500 S P erieS anual rograMMing 4.7. Number of PT100 Temperature Sensors Used The 5500 control unit allows up to two 2-wire PT100s to be connected to the unit for monitoring and controlling temperatures in the pressurized enclosure. Each sensor can be located up to 3 m from the control unit input. Using two PT100s allows various placements within the enclosure to capture the variation of heat in locations where electronic devices are located. -
Page 58: Temperature Inputs Pt1 And Pt2
5500 S P erieS anual rograMMing 4.8. Temperature Inputs PT1 and PT2 To Activate this Function Enter the number of PT100s into the menu with the correct number of sensors connected to the input. Select ENABLED in the TEMP ENABLED selection menu. All values are entered in degrees Celcius. -
Page 59: Bypass
5500 S P erieS anual rograMMing AUTOMATIC TEMPERATURE CONTROL Temp action *K2 on SV on PT K1 PT K2 PT SV time * Note: K2 is mapped to Any Alarm or Temp Max. For above action to take place. 4.9. -
Page 60: Units
5500 S P erieS anual rograMMing 4.10. Units The units can be changed from ‘M’ metric to ‘I’ imperial. This affects the pressure readings. “M” reads in mbar, and “I” reads in inches of water column. The temperature settings are always in Celsius. UNITS UNITS 4.11. -
Page 61: Change Password
5500 S P erieS anual rograMMing 4.12. Change Password To change the existing password, use the UP and DOWN buttons for each digit. Enter 4 digits. To cancel without saving a new password, press RESET. The existing password will still be valid. -
Page 62: User Parameter Setting Sheet
5500 S P erieS anual rograMMing 4.13. User Parameter Setting Sheet Display Description User Settings PASSWORD / SET Password PURGE / PROGRAM Program 1-5 PURGE / TIME Time required for purging ENCLOSUR / PRESS P1 Shutdown pressure P1 ENCLOSUR / PRESS P2 Alarm/signal pressure P2 ENCLOSUR / PRESS P3 Purge pressure P3... -
Page 63: Product Identification
5500 S P erieS anual roducT denTificaTion 5. Product Identification 5.1. Specific Conditions of Use The main control unit and the EPV vent are the only parts that have been evaluated for the certifications of the system. For dust environments, the non-metallic membrane touchpad and display may pose an electrostatic discharge hazard. -
Page 64: Type Codes
5500 S P erieS anual roducT denTificaTion 5.3. Type Codes Wiring entrance for low voltage connection (3) M12 Stainless low power cable glands (3) M12 Nickel plated low power cable glands No cable glands Wiring entrance for power connection (3) M20 stainless power cable gland (3) M20 Nickel plated power cable gland (3) ½"NPTF Stainless steel conduit entrance... -
Page 65: Markings (Labelling)
5500 S P erieS anual roducT denTificaTion – Voltage Requirement 24VDC 120VAC 230VAC Type of Approval EX01 ATEX and IECEx certification CD01 FM and CSA certification UL and CSA certification (different body design), CDUL only 60 Hz for AC models Valve Type Manifold (includes purging and pressurization valves) Type of System... - Page 66 5500 S P erieS anual roducT denTificaTion Control Unit, Internal Mount (DC) Control Unit, External Mount (DC) 68307 Mannheim, Germany / www.pepperl-fuchs.com 68307 Mannheim, Germany / www.pepperl-fuchs.com Model 5500-SS-I-VDC-xxx-xxx Model 5500-SS-E-VDC-xxx-xxx Type Z / Ex pzc PN: 51xxxx PN: 51xxxx Type Z / Ex pzc Type 4X IP66 Type 4X IP66...
- Page 67 When operating the 5500 system in conjunction with a hazardous area, do not modify the system. If there is a defect, the product may need to be replaced. Repairs can only be performed by a Pepperl+Fuchs specialist who is trained and authorized to repair the defect.
- Page 68 5500 S P erieS anual roducT ifeTiMe 6.3. Troubleshooting Problem Possible Cause Solution Purge cycle does not start No air to system Check air supply, make sure minimum pressure is available Enclosure pressure not high Check vent and enclosure seals; check enough compensation valve setting Control unit in dust mode...
- Page 69 HART Interface Solutions AS-lnterface Surge Protection Identification Systems Wireless Solutions Displays and Signal Processing Level Measurement Connectivity Pepperl+Fuchs Quality Download our latest policy here: www.pepperl-fuchs.com/quality www.pepperl-fuchs.com Subject to modifications © Pepperl+Fuchs DOCT-B3R8 • 01/2024 •...