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ML557 v1 Issued 22/12/16 ©
Page 1 of 10
MiniEPS®
Environmental Pressurization System ML557
IMPORTANT NOTE It is essential for safety that the installer and user of the Expo system observe
the following instructions: Please refer to the standard for principles and definitions.
(N.B. These instructions apply only to the Pressurizing system. It is the responsibility of the manufacturer of the Pressurized Enclosure to provide appropriate instructions for the Enclosure.)
Contents 1. MiniEPS® - General System Specification 2. Application Suitability 3. Description and Principle of Operation 4. Main Components 5. Installation of the System 6. Commissioning 7. Maintenance of the System 8. Fault Finding 9. Recommended Spares List 10. Drawings and Diagrams 11. Declarations
ML557 v1 Issued 22/12/16 ©
Page 2 of 10
1. MiniEPS® - General System Specification
Technical Specifications Pressurization Medium: Compressed air or inert gas.
Clean, dry and free of corrosive gases or vapors. Temperature Range: -20°C to +60°C (-4°F to +140°F) Supply Pressure: 2-7 barg (29 to 116 psi) Supply Connection: ¼” NPT Maximum Flow Rate: 100 Nl/min (3.5 scfm) Low Pressure Sensor: ‘Alarm’ setting 1.25 mbar (0.5” wc) Local Indication: GREEN indicates pressure OK
RED indicates low pressure Remote Indication: Volt-free contact/switch, open on alarm
375VA @ 120/240V ac 2A @ 24V ac/dc
Overpressure protection: Integrated relief valve + Magnetic operation (patented) + Opening pressure 10 mbar max (4” wc)
Construction: 316L Stainless Steel Approvals The MiniEPS® conforms to UL 50 & 50E for enclosures and will maintain pre-existing UL Type 4X and IP66 enclosure integrity when installed in line with Manufacturer instructions.
ML557 v1 Issued 22/12/16 ©
Page 3 of 10
2. Application Suitability
The MiniEPS® is for use in non-hazardous area environments and has been designed for use in normal industrial conditions of ambient temperature, humidity and vibration. Please consult Expo before installing this equipment in conditions that may cause stresses beyond normal industrial conditions. This system is designed for use primarily with compressed air. Where other inert compressed gases are used (Nitrogen, for example), the user must take suitable precautions so that the buildup of inert gas does not present a hazard to health. Consult the Control of Substances Hazardous to Health (COSHH) data sheet for the gas used. Where risk of asphyxiation exists, a warning label must be fitted to the Pressurized Enclosure. The following materials are used in the construction of the MiniEPS®. If substances that will adversely affect any of these materials are present in the surrounding environment please consult Expo Technologies for further guidance.
Stainless Steel Polycarbonate Aluminium
Mild (Carbon) Steel Polyamide Polyurethane
Brass AB Silicone Rubber
Copper PVC
3. Description and Principle of Operation
The MiniEPS® is an environmental pressurization system, designed for non-hazardous areas that may contain dusty, dirty and/or corrosive atmospheres. It requires a supply of compressed or instrument air, or an inert gas to regulate the pressure within the enclosure. This prevents the accumulation of damaging gases and/or dusts, extending the life of the enclosure’s expensive electrical equipment and instrumentation. Due to the positive pressure inside the enclosure, corrosive or harmful elements remain outside. The pressurization system maintains a constant pressure of 1.25 mbar (0.5” wc) inside the enclosure, with an optional remote alarm output. It is designed for typical industrial enclosures up to 7m3 (250 cu ft) or larger, depending upon the leak rate of the enclosure.
4. Main Components 1. Air Inlet: Connection for supply gas, ¼” NPT. 2. Flow Control Valve: Used to control the flow of air into the enclosure. Protective cap ensures no dust can penetrate into enclosure and must be replaced after using the valve. 3. Visual Indicator: Turns from red to green when the enclosure is pressurized to the minimum set point of 1.25 mbar (0.5” WC). If pressure is lost the indicator will automatically return to red. 4. Relief Valve: Provides overpressure protection for the enclosure in case of regulator failure.
ML557 v1 Issued 22/12/16 ©
Page 4 of 10
5. Installation of the System
The MiniEPS® must be installed in the attitude shown in drawings 1ELC-PM-PS and 1ELC-SS-PS. Cut-out drawings for both the panel-mount and stainless steel housing variations are included at the rear of this manual, XBR-1TD0-038. The fixtures used to secure the MiniEPS® to the pressurized enclosure must conform to the enclosure manufacturer’s instructions where present. Ensure that the MiniEPS is located so that visual indicator is easily seen. Panel-Mount Installation
Ensure that the gasket is not damaged prior to installation
Cut aperture and clearance holes in enclosure as per drawing XBR-1TD0-038
Attach MiniEPS® to enclosure using 4 off suitable M5 fixings
Stainless Steel Housing Installation - General
Ensure that the gasket is not damaged prior to installation.
Installation is designed to be configured at the point of use. Remove the front panel of the MiniEPS® from the housing by undoing the 4 off screws.
One mounting gasket is provided with the MiniEPS® that can be used for either side or top mounting.
Stainless Steel Housing Installation - Side Mounting
Drill two off Ø17mm holes in the rear of the MiniEPS® using the pre-punched centre-marks as a guide.
Drill mounting holes in the enclosure as per drawing XBR-1TD0-038
Ensuring a clean surface, attach the self-adhesive gasket provided to the rear of the MiniEPS®, lining up the gasket holes with the holes drilled in the enclosure.
ML557 v1 Issued 22/12/16 ©
Page 5 of 10
Pass the alarm switch cable through either of the holes in the housing and through the cable gland provided. Attach the cable gland to the housing using the black plastic nut provided.
Re-attach the front panel to the housing.
Pull the cable slack through the cable gland being careful not to apply to much force. Tighten the cable gland to clamp the cable in place.
Fix the MiniEPS® to enclosure
Stainless Steel Housing Installation - Top Mounting
Drill two off Ø17mm holes in the bottom of the MiniEPS® using the pre-punched centre-marks as a guide
Drill mounting holes in the enclosure as per drawing XBR-1TD0-038
Cut the self-adhesive gasket to size referring to drawing XBR-1TD0-038 and attach to the base of the MiniEPS®
Ensuring a clean surface, attach the self-adhesive gasket provided to the base of the MiniEPS®, lining up the gasket holes with the holes drilled in the enclosure
Pass the alarm switch cable through either of the holes in the housing and through the cable gland provided. Attach the cable gland to the housing using the black plastic nut provided
Re-attach the front panel to the housing
Pull the cable slack through the cable gland being careful not to apply to much force. Tighten the cable gland to clamp the cable in place
Fix the MiniEPS® to the enclosure provided.
Attach the cable gland provided to either of the holes. Drill mounting holes in the enclosure as per drawing XBR-1TD0-038.
Fix the assembled MiniEPS® to your enclosure
ML557 v1 Issued 22/12/16 ©
Page 6 of 10
Compressed gas connection Connect compressed gas supply to bulkhead fitting using a suitable ¼” NPT fitting. The MiniEPS® system should be connected to a protective gas supply, which is suitable for pressurization. The supply pipe connection to the MiniPurge® must be appropriate for the maximum input flow rate for the application. The air supply must be regulated at a pressure less than the maximum stated inlet pressure. The air supply must be: clean, non-flammable and from a non-hazardous location. The air should be of Instrument Air Quality. Although the purge control system will operate with lower air quality, its operational life will be adversely affected. The equipment that is being protected by the MiniPurge® may also suffer because of poor air quality. With reference to BS ISO 8573-1: 2010, Instrument Air is typically specified as: Particle Class 1 In each cubic metre of compressed air, the particulate count should not exceed 20,000 particles in the 0.1 to 0.5 micron size range, 400 particles in the 0.5 to 1 micron size range and 10 particles in the 1 to 5 micron size range. Humidity or pressure dew point The dew point, at line pressure, shall be at least 10 °C below the minimum local recorded ambient temperature at the plant site. In no case, should the dew point at line pressure exceed +3 °C. Oil Class 2 In each cubic metre of compressed air, not more than 0.1mg of oil is allowed. This is a total level for liquid oil, oil aerosol and oil vapour.
The minimum air supply pressure should be 2 bar/ 30 psig / 0.2MPa. Ensure that the supply pipework is sufficiently sized to deliver leakage compensation flow to the enclosure and maintain minimum pressure. The compressed air / inert gas supply should have a dedicated local air pressure filter/regulator. Electrical Switch Connection The MiniEPS® is supplied with a single pole normally-open alarm switch and 2m flying lead (0.75mm2 CSA).
ML557 v1 Issued 22/12/16 ©
Page 7 of 10
Earthing The MiniEPS® should be earthed using the M6 earth stud provided; earth cable cross-sectional area must be suitable for the local installation standards.
6. Commissioning Proceed as follows:
Check that the system has been installed in accordance with this manual.
Disconnect the supply pipe from the inlet to the MiniEPS system and blow it through for at least 10 seconds per meter (3ft) of length to remove any debris or condensation.
It may be advisable to install an external shutoff valve with the same, or larger, thread size as
the MiniEPS inlet fitting upstream of the connection.
Unscrew the protective cap and open the Flow Control Valve (FCV) until the alarm/pressurized indicator just turns from red to green. Clockwise will reduce the flow and anti-clockwise will increase the airflow
If the FCV is opened fully and the indicator has still not turned green, check the air supply pressure at the inlet to the control unit while flow is taking place. It must be above the minimum 2 bar/ 30 psig/ 200kPa specified. Also check for leaks, open doors, missing glands or entry seals in the enclosure.
Once the enclosure is pressurized with the indicator showing green, replace the FCV cap.
Please note that this cap must be present to maintain the original enclosure standard of UL50e Type 4X or IP66.
7. Maintenance of the System
The maintenance recommended for the system consists of the following, supplemented by any additional local requirements imposed by the local Code of Practice. Initial Maintenance Expo recommends that the functionality of the flow control valve is inspected 6 months after installation. Routine Maintenance At least every two years, the following additional checks are recommended:
There are no unauthorized modifications
The flow control valve cap is present
Seals are undamaged
The source of air is uncontaminated
Adequate spares are carried
The action on pressure failure is correct
ML557 v1 Issued 22/12/16 ©
Page 8 of 10
Pressure Sensor Calibration If it is decided that the minimum pressure /purge flow sensor needs recalibrating it must be returned to Expo for this service.
8. Fault Finding
If the system does not behave in the manner described above there is a fault. Some of the more likely faults are dealt with below. If a cure cannot be affected by following the procedure shown below please call Expo (24 hour answering) or your supplier for further assistance. Possible Fault 1 – Relief Valve Opens Continuously/Intermittently
Is the Pressurized Enclosure
pressure too high?
Relief Valve opens
continuously or intermittently.
Call Expo
The Flow Control Valve (FCV) is too far open.
Adjust the FCV clockwise to reduce the
PE pressure
No
Yes
ML557 v1 Issued 22/12/16 ©
Page 9 of 10
Possible Fault 2 – Indicator Will Not Turn Green
Is the Sensor out of calibration or
faulty?
Pressurized indicator will not turn green
Call Expo
Supply pipe to the air inlet ≥
8mm I.D?
Excessive leakage from Enclosure?
Is the air supply pressure incorrect?
No
Check the air supply pressure at the inlet to the MiniEPS® is stable between 2-7 Barg / 30-100 psi
Yes
Replace pipe work No
Yes
Any significant leakage must be corrected. Check for leaks down the cables or conduit. Ensure leakage does not exceed 100 Nl/min (3 cfm)
Yes
No
The basic operation of the Pressure Sensor can be checked by unscrewing the 60mm diameter diaphragm housing and, by using a rubber pad, e.g. an eraser, block the 12mm threaded hole in the top of the valve module. The valve should operate and the indicator turns green. If this is correct, the sensor diaphragm needs recalibrating or replacing.
Yes
No
ML557 v1 Issued 22/12/16 ©
Page 10 of 10
9. Recommended Spares List Part Number Description
MGA-Z000-158 Flow Control Valve Cap Gasket S0030/606 Pressure sensor factory set to 1.25 mbarg S0015/109 Visual Pressure Indicator MCV-S000-093 Flow Control Valve Cap MGA-Z000-159 Flow Control Valve Cap Gasket
10. Drawings and Diagrams
The following drawings are attached: Title Drawing Number Sheet(s) 1ELC-PM-PS MiniEPS® Panel Mount General Arrangement 1 of 1 1ELC-SS-PS MiniEPS® ‘ss’ Housing General Arrangement 1 of 1 XBR-1TD0-038 MiniEPS® Installation Instructions 4 of 4
11. Declarations
See attached Declarations of Conformity: EXPO EU-Declaration of Conformity SC036 EXPO Declaration of conformity with UL50 & UL50E SC037
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A3
S:\Files\QA\CERTS\C-OF-C\SC036 MiniEPS EU DoC Issue0.docx
EU-Declaration of Conformity
With European Directives
Issued under the sole responsibility of
Expo Technologies Ltd Unit 2, The Summit, Hanworth Road
Sunbury on Thames TW16 5DB, UK
This is to declare that all models of the MiniEPS, Mini-Environmental Pressurization System,
are designed and manufactured in conformity with the following European Directives and standards:
Low Voltage Directive 2014/35/EU The MiniEPS Systems meet the electrical safety requirements of EN 61010-1:2010 Safety requirements for equipment for measurement, control and laboratory use. When installed and maintained according to the instructions provided by Expo Technologies, the MiniEPS Systems are able to maintain a minimum Degree of Protection of IP66 according to the requirements of EN 60529:1991. Electromagnetic Compatibility Directive 2014/30/EU The MiniEPS incorporate one more volt-free (“dry”) contacts which work in circuits specified by others. In normal operation these circuits are benign and not regulated by the scope of this Directive. Pressure Equipment Directive 2014/68/EU In normal operation and when installed according to the instructions provided by Expo Technologies, the MiniEPS Systems are designed for a maximum working pressure of 10mbar, therefore covered by Article 4, Paragraph 4 of this Directive.
MiniEPS systems are manufactured under Production Quality Assurance Notification SIRA 99 ATEX M043, issued by SIRA Certification Service, Notified Body No 0518. Signed for and on behalf of Expo Technologies Ltd.,
John Paul de Beer Date 21/12/2016 Managing Director Confidential Assessment file reference SC036
SC037 Minieps UL50 & UL50E 4X.Docx
Declaration of Conformity
With UL50 & UL50E Type 4X
Expo Technologies Ltd Unit 2, The Summit, Hanworth Road Sunbury on Thames TW16 5DB UK
This document confirms that
MiniEPS – Mini Environmental Pressurization Systems
are designed in compliance with the requirements
of standards UL50 & UL50E for enclosure Type 4X.
Product description The MiniEPS is an environmental pressurization system, designed for non-hazardous areas that may contain dusty, dirty and/or corrosive atmospheres. It requires a supply of compressed or instrument air, or an inert gas to regulate the pressure within the enclosure. This prevents the accumulation of damaging gases and/or dusts, extending the life of the enclosure’s expensive electrical equipment and instrumentation. Due to the positive pressure inside the enclosure, corrosive or harmful elements remain outside. When installed and maintained according to the instructions provided by Expo Technologies, the MiniEPS System is able to maintain the classification of the enclosure, in which it is installed, as UL50 & UL50E Type 4X.
Signed Date 22/Dec/2016 Managing Director Confidential Assessment file reference SC037
Expo Technologies Inc. 9140 Ravenna Road Unit #3TwinsburgOH 44087, USATel: +1 (440) 247 5314Fax: +1 (330) 487 0611 E-mail: [email protected]
Expo Technologies Ltd.Unit 2 The Summit, Hanworth Road
Sunbury on ThamesTW16 5DB, UK
Tel: +44(0)20 8398 8011Fax: +44(0)20 8398 8014
E-mail: [email protected]
Qingdao Expo M&E Technologies Co. Ltd329 Huashan Er Lu
Jimo City, Qingdao, Shandong Province266200, China
Tel: +86 532 8906 9858Fax: +86 532 8906 9858
E-mail: [email protected]
www.expoworldwide.com