Pepperl Fuchs 3003-LPS-CI-YZ-VML Owners Manual

PROCESS AUTOMATION

INSTALLATION AND OPERATION MANUAL

MODEL 3003 TYPE Y, Z & Ex [nP]

®

RAPID EXCHANGE

PURGE SYSTEM

Model 3003 Installation and Operation Manual

Table of Contents

Page 2 System Purpose and Description

Purpose, System description, Important notes

Page 3 Identifying Your System

Defines specific features of the system

Page 3 General Information

System & material specifications, Spare parts, Tools
& test equipment, System accessories

Page 4 Enclosure and Device Design

Design requirements, Adjacent enclosures, Device
ventilation, Temperature limitations

Page 5 Getting Started

Establishing connection sizes, Determining enclosure
inlet & outlet connection locations

Page 6 VM & HM Mounting

Flange & face-plate mounted installations

Page 7 CK / RCF Mounting

GCK procedure, CK configuration mounting
procedure, RCF enclosure mounting procedure

Page 8 Required Hardware Mounting

Required enclosure protection vent, Warning
nameplates

Page 9 System Mounting Dimensions

Face plate & component dimensional diagrams

Page 11 Typical System Installation Details

Typical internal & external installation diagrams

Page 12 Pneumatic Tubing Requirements

Protective gas supply requirements, Pneumatic
connection requirements

Page 13 Tubing Installation

Surface, pipe, frame & panel mount installations

Page 14 Tubing Connection Diagrams

Surface, pipe, frame & panel mount installation
connection points, pneumatic diagrams

Page 15 Electrical Supply Requirements

Wiring requirements, Enclosure power & alarm signal,
Enclosure wiring methods & connections

Page 16 Conduit Installation

Electrical & WPS style conduit and connection parts

Page 17 Set-Up Procedure

Important notes, Class I purging set-up

Page 18 Operating Sequence

Class I purging operation

Page 19 Troubleshooting Procedures
Troubleshooting chart

Page 20 Warranty and Liability Statement

Warranty notes, General terms, Limitations

Page 21 Customer Notes

Page 22 System Maintenance

Regular maintenance, Long-term maintenance,

Maintenance schedule

Page 23 Systems Identification & Application Information

Purpose and Description

Purpose

Pepperl+Fuchs' Bebco EPS System allows the use of general­purpose or nonrated electrical or electronic devices, with
exception to devices that 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.

Description

Model 3003 is a Rapid Exchange purging system that operates
on a supply of compressed instrument air or inert gas. It
regulates and monitors pressure within one or more sealed
(protected) enclosures, in order to rapidly remove and prevent
flammable vapor accumulation within the enclosure(s). The
system accomplishes four air exchanges and maintains
a "safe" (0.25") pressure on one or more enclosures not
exceeding a total volume of fifteen cubic feet. An EPV-3
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 2.4.

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 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 that 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.

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice

2

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Model 3003 Installation and Operation Manual

3003 - LPS - CI - Y Z - VM - ##

N O T R E L E A S E D

LABEL P/N: 511081

All dimensions are in inches.

All outside corners R=0.1

Tolerances: 2-place dec. +/- .03

3.00

Identifying Your System

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.

Model 3003-WPS Type Y or Z

S

I

F

S

I

E

A

L

D

C

MIN. SUPPLY PRESSURE
MAX. SUPPLY PRESSURE

PURGE CONTROL FOR U SE IN HAZARDOUS LOCATIONS IN ACCORDANCE WI TH THE NATIONAL FIRE PROTECTION AS SOCIATION
STANDARD FOR PURGED AND PRE SSURIZED ENCLOSURES FOR ELE CTRICAL EQUIPMENT NFPA 496-199 6 4S11. THIS PRODUCT
MUST BE INSTALLED AND OPERATED IN COMP LETE ACCORDANCE WITH CONTROL DOCUMENT 3003 -IOM.
APPROVED BY FM APPROVA LS AS ASSOCIATED TYPE Y OR Z PRESSURIZ ATIONCO NTROL EQUIPMENT FOR USE IN HAZ ARDOUS
LOCATIONS. REDUCES T HE INTERNAL AREA OF A CONNECTED E NCLOSURE IN ACCORDANCE WITH DRAWIN G NUMBER 3003-IOM.

Series Model Number
System Style

LPS - less pressure switch

†

WPS - with pressure switch

WPSA - with pressure switch
Area Classification

CI - Class I Area
System Type

YZ - Div. 1 to Div. 2
Div. 2 / Zone 2 to Nonhazardous

Mounting Configuration
VML - vertical mount left left of enclosure
VMR - vertical mount right right of enclosure
HMT - horizontal mount top top of enclosure
HMB - horizontal mount bottom bottom of enclosure
CK - Component Kit - LPS style only

## - Additional factory installed accessories

† Does not have ATEX certification

80 PSI

120 PSI

90 CF / 2.5 CM Max. Encl. Volu me

REDUCES INTERNAL AREA CLAS SIFICATION AS FOLLOWS:

TYPE Z: CL . I, DIV.2 GR. C & D / ZONE 2,

GR. IIB TO NONHA ZARDOUS

TYPE Y: CL . I, DIV.1 GR. C & D / ZONE 1,

GR. IIB TO DIV. 2 / ZONE 2

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 an
EPV-3-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

80 psi supply pressure: 22.23 scfm/ 333.8 scfh

Material Specifications

Regulator body: Zinc w/ enamel finish
Regulator handle & bowl: Polycarbonate
Enclosure pressure gauge: Aluminum w/ enamel finish
Rapid Exchange gauge: Poly & nickel-plated
Tube fittings: 316 SS forged body
Tubing: 316 SS 1/4" .035 welded
Fastener hardware: Aluminum & SS
System face plate: 316 14 ga #3 brush SS
System mounting flange: 316 SS tumble finish
Manifold body: Anodized aluminum
Manifold valves: 316 SS
EXP pressure switch body: Anodized cast alum.
Manufacturer ID nameplate:
VM & HM configuration- Reversed silkscreen Lexan
CK configuration- Anodized aluminum
System Start up instructions :
VM & HM configuration- Silkscreened to face plate
CK configuration- Anodized auminum nameplate
Enclosure warning nameplate: Silkscreened SS

General Information

System Specifications

System dimensions: See pages 9 & 10
Shipping weight LPS/WPS & WPSA: 10 lb /15 lb
Operating temperature range: -20 °F - 120 °F
Supply pressure range: 80 -120 psi max.

When using the optional inline filter, max. supply pressure is 80 psi

Capacity & filtration (VM only): 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 (2.8 - 99 l/hr)
Maximum exchange pressure: * 3" - 5" (7.6 - 127 mm)
Minimum exchange flowrate: ** 12 SCFM/720 SCFH
(340 l/m / 20390 l/hr)
Exchange time: 1 minute/3 ft
System supply port: 1/4" FPT
Enclosure supply port: 1/2" FPT
Enclosure reference fitting: 1/4" tube
Switch setting (WPS & WPSA only): 0.15" ± 0.02"
Switch conduit port size: 1/2" FPT
Switch contact ratings:
WPS style: 120 VAC @ 15 Amps
WPSA style: *** 120/220 VAC, 24 VDC @10 Amps,
125 VDC @ 50 mA

* Enclosure integrity determines actual flow rate
** With regulator set at 60 psi min. during exchange
*** Supply voltages 24 VDC and 240 VAC available upon request

3

(85 l/min)

Recommended Spare Parts

Qty Description Part # (supercedes)
1 Enclosure pressure indicator-CI 510023 (001000)
1 WPS style EXP pressure switch 510045 (001085)
1 WPSA style EXP pressure switch 510044 (001080)
1 System filtered regulator (VM only) 510057 (002040)
1 System regulator (HM & CK ) 510056 (002037)
1 Rapid exchange pressure gauge 510078 (002300)
1 T-bar valve key 510092 (002740)
1 Installation & operation manual 129-0198
1 Enclosure warning nameplate-CI 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

1 1/4" conduit knockout punch or 1.6875" hole saw

Complete set of tubing, conduit bending, instrument fitting and
electrical craftsman hand tools

0-10" differential pressure indicator or monometer (connected
to the protected enclosure to measure maximum pressure)

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice
Pepperl+Fuchs Group

www.pepperl-fuchs.com

USA: [phone]

[e-mail] [e-mail]

Germany: [phone]

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3

Model 3003 Installation and Operation Manual

Model 3003 System Accessories

Enclosure Protection Vents (one required with each system)

EPV-3-SA-00 Straight w/ spark arrestor
EPV-3-SA-90 Rt angle w/ spark arrestor

Additional Items

SMK-1 System mounting kit - flange
SMK-6m System mounting kit - frame / panel
PMK-1 Pipe mounting kit
ILF-4 1/4" in-line filter
RCF-4 1/4" remote mount cube filter
GCK Gauge conversion kit
GPSK-1 General-purpose switch kit
EPSK-1 Class I, Gr. C & D exp. proof switch kit
EPSK-1A Class I, Gr. A - D exp. proof switch kit
RAH Div. 1 remote alarm horn
RAB-1 Div. 1 remote alarm beacon
RAB-2 Div. 2 remote alarm beacon
LCK L fitting conduit kit
TCK T fitting conduit kit
EFC-4 1/4" flush connector
EFC-6 3/8" flush connector
EBC-4 1/4" bulkhead connector
EBC-6 3/8" bulkhead connector
EPC-13 1 1/4" pipe connector
NC-6-4 3/8" T x 1/4" P ninety connector
SC-6-4 3/8" T x 1/4" P straight connector
NC-6-8 3/8" T x 1/2" P ninety connector
SC-6-8 3/8" T x 1/2" P straight connector
ETW Enclosure temperature warning

Enclosure & Device Design

Enclosure Design Requirements

1. All windows must be shatterproof and sized as small as
possible.

2. All NFPA 496 required markings must be placed on or near
all enclosure doors and covers.

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.

6. The installation of obstructions or other barriers that block
or impede the flow of protective gas must be avoided.

7. The creation of air pockets or other areas that trap
flammable gases within the enclosure or devices must be
avoided.

8. The enclosure should be located in an area where impact
hazards are minimal.

9. If the enclosure is nonmetallic and contains equipment that
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) purged or pressurized in series with the protected

enclosure

b) purged or pressurized separately or

c) 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.

Total Volume Calculation

1. The total volume of all pressurized enclosures, devices and
wireways must be considered.

2. All enclosure, device, and wireway volumes must be
calculated without consideration of internally consumed
space.

Device Ventilation

1. Enclosed devices within the protected enclosure which do
not exceed 1.22 in
to the protected enclosure.

2. If the free volume of an internal device exceeds 1.22 in
must be protected by one of the following means:

a) ventilated on the top and bottom sides with 1 in

opening for each 400 in
protected enclosure, at a minimum diameter of 1/4"

b) purged in series with the protected enclosure or be

purged separately or

c) protected by other means; e.g., explosion proof

enclosures, hermetically sealed devices, or intrinsic safe
circuits.

3

of free volume do not require ventilation

3

it

2

3

of volume within the internal

of

Temperature Limitations

1. The enclosure must have no surface area that exceeds 80
percent of the flammable or ignitable substance’s auto­ignition temperature.

2. Internal devices that exceed this temperature must be
protected by one of the following manners:

a) The device is enclosed in a chamber that is ATEX,

or FM listed as a hermetically sealed device

CULUS

that prohibits the entrance of a 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 be accessed only 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.

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice

4

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[e-mail] [e-mail]

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Model 3003 Installation and Operation Manual

Getting Started

Typical Single Protected Enclosure Connections

1/2"
PROTECTIVE
GAS SUPPLY

HEADER

ENCLOSURE

PROTECTION

SYSTEM

C

REFERENCE

SUPPLY

PROTECTED
ENCLOSURE

ENCLOSURE PROTECTION VENT

(Required)

A

Description

*Tubing or pipe diameter

Tubing & pipe must be fully reamed

Maximum tubing / pipe length and

maximum number of bends / elbows

B

A

System

supply tubing

3/8" O.D. tubing

or 1/4" I.D. pipe

20 feet

10 bends

B

Enclosure

supply

3/8" O.D. tubing

or 1/2" I.D. pipe

5 feet

5 bends

Enclosure

reference

1/4" O.D. tubing

fully reamed

20 feet

10 bends

E

C

D

Multi - enclosure

connections

1 1/4" I.D. pipe

fully reamed

10 feet

5 elbows

Optional remote

venting

1 1/4" I.D. pipe

fully reamed

30 feet

5 elbows

TYPICAL MULTIPLE PROTECTED ENCLOSURE CONNECTIONS

1/2"
PROTECTIVE
GAS SUPPLY

HEADER

ENCLOSURE

PROTECTION

SYSTEM

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.

B

SUPPLY

PROTECTED
ENCLOSURE

REFERENCE

D

PROTECTED
ENCLOSURE

C

D

PROTECTED
ENCLOSURE

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.

E

Determining Enclosure Inlet & Outlet Connection Locations

INLET

OUTLET

HELPFUL HINTS

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.

[e-mail]

Connections for heavier than

air gases and vapors

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice
Pepperl+Fuchs Group

www.pepperl-fuchs.com

OUTLET

INLET

Connections for lighter than

air gases and vapors

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5

Model 3003 Installation and Operation Manual

VM & HM 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.

Flange mounted systems are intended for mounting
adjacent to the protected enclosure and are also suitable
for 2" schedule 40 pipe mounting.

Dimensional mounting configuration diagrams are located
on pages 9 & 10.

Remove and save the clear plastic envelope containing the
enclosure warning nameplate.

Although all purge systems are factory tested and
calibrated, we strongly suggest a bench test of basic
functions prior to installation.

Flange Mounted Systems

First, determine the system mounting flange to system face
plate orientation for your installation (top or bottom for HM
configurations, left or right for VM configurations).

Surface mounting systems

1. Transfer hole pattern of system mounting flange to intended
enclosure or adjacent mounting surface.

2. Secure system mounting flange to system face plate using
the mounting hardware provided.

3. Check for obstructions hindering bolt fastening, drill and
ream the mounting holes before mounting the system.

4. Secure the system to the enclosure, or other mounting
surface, using one (1) SMK-1 mounting kit or equivalent

- four (4) 1/4" x 3/4" stainless steel bolts, nuts and lock
washers.

Pipe mounting systems

1. Secure system mounting flange to system face plate using
the mounting hardware provided.

2. Locate 2" schedule 40 pipe within five (5) feet of protected
enclosure.

3. Ensure system is mounted in a true vertical position, secure
the system to pipe, using one (1) PMK-1 mounting kit or
equivalent - two (2) 1/4" x 2" pipe stainless steel “U” bolts,
nuts and lock washers.

Face Plate Mounted Systems

HELPFUL HINTS

Frame mount (FM) and panel mount (PM) installations are
designed to mount through a cutout one half (1/2) inch
smaller than the overall height and width of the system
face plate, using clips and fasteners provided with a SMK­6m mounting kit. This design eliminates the need to drill
the system mounting bolt holes in the mounting surface.

FM installations are intended for operation adjacent to the
protected enclosure.

PM installations are intended for mounting through a
cutout directly in the protected enclosure surface. PM
installations require a GCK gauge conversion kit for proper
operation (see page 7 for conversion instructions).

1. Transfer panel cutout pattern to the intended surface.

2. Check for obstructions which could prohibit bolt fastening
or system pneumatic connections.

3. Cut panel cutout pattern on the intended surface.

4. Deburr all cutout surfaces.

5. Secure system to surface using SMK-6m mounting kit, or
equivalent - six (6) 5mm x 12mm stainless steel nuts, bolts,
mounting clips and lock washers.

6. Go to page 7 for RCF-4 installation (if provided).

Typical Surface, Pipe, Panel & Frame Mounted Systems

Model 3003-LPS-CI-Z-VM

Flange Mounted to

Flat Vertical Surface with

Model SMK-1 Fastener Kit

Subject to modifications without notice

6

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Model 3003-LPS-CI-Z-VM

Flange Mounted to
Vertical 2" Pipe Stand with
Model PMK-1 Fastener Kit

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Model 3003-LPS-CI-Z-VM

Frame or Panel Mounted

through Cutout in Suitable Surface

with Model SMK-6m Fastener Kit

Part No. 512785 Drawing No. 129-0198c 03/09

Model 3003 Installation and Operation Manual

CK & RCF Mounting

HELPFUL HINTS

The Model 3003 purging system is supplied in several
configurations to meet your installation needs. When
ordered as a VM or HM configuration, the system face
plate can be mounted directly through the surface of a
pressurized enclosure. See page 6 "Face Plate Mounted
Systems." When ordered as a CK configuration, the
system components mount directly through panel
cutouts (provided by others) adjacent or external to the
pressurized enclosure. In addition, the CK configuration
can also be mounted directly through the surface of a
pressurized enclosure when modified with Pepperl+Fuchs
GCK gauge conversion kit. See "Panel Mount Conversion
Procedure" below.

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.

Dimensional component diagrams are located on pages 9
& 10.

Remove and save the clear plastic envelope containing the
enclosure warning nameplate.

Although all purge systems are factory tested and
calibrated, we strongly suggest a bench test of basic
functions prior to installation.

Panel Mount Conversion Procedure

Perform the following procedure to convert Enclosure
Pressure Gauge for Panel Mount (PM) installations.

1. Secure one model GCK gauge conversion kit. Kit includes
one (1) PRB-4 & SC-2 fitting and one (1) enclosure pressure
gauge gasket.

2. Remove enclosure pressure gauge and install gauge gasket
between gauge and mounting surface. Reinstall gauge.

3. Remove venturi orifice and run tee from high port located on
rear of enclosure pressure gauge, discard.

4. Remove sintered vent from low port located on rear of
enclosure pressure gauge.

5. Reinstall sintered vent into high port located on rear of the
enclosure pressure gauge.

6. Remove stainless steel orifice plug from low port located on
side of enclosure pressure gauge.

7. Reinstall stainless steel orifice plug into low port located on
rear of enclosure pressure gauge.

8. Install model SC-2 fitting into low port located on side of
enclosure pressure gauge.

9. Install model PRB-4 vent through enclosure surface (vent
end out) and connect tubing (furnished by others) between
SC-2 & PRB-4 fittings.

Part No. 512785 Drawing No. 129-0198c 03/09

Typical Panel Mount Conversion

Venturi

orifice

Run

tee

Standard

configuration

(prior to conversion)

High

port

Low
port

Sintered

vent

PRB-4

Sintered

vent

SC-2

Panel Mount

configuration

(after conversion)

CK Configuration Mounting Procedure

1. Transfer hole pattern of system panel cutout to intended
surface. See page 10 for dimensions.

2. Check for obstructions hindering component installation or
operation. Drill and ream the manifold holes.

3. Remove adhesive backing from system instruction
nameplate and place on intended surface, taking care to
align all holes of nameplate with corresponding manifold
mounting holes on intended surface.

4. Insure manifold mounting gasket and manifold valve stem
O-rings are installed onto manifold. Install manifold through
cutouts in intended surface.

5. Secure manifold to intended surface utilizing hardware
supplied with system. Do not overtighten.

6. Install Rapid Exchange injection pressure indicator into
appropriate threaded hole in manifold. Tighten and align.

7. Install enclosure pressure gauge, with gasket in place,
secure gauge with mounting hardware provided.

RCF Enclosure Mounting Procedure

The following instructions detail mounting an optional RCF-4
(remote cube filter) directly to the protected enclosure of a PM
system installation. Alternately, the RCF-4 can be installed "in­line" on the protective gas supply.

1. Determine the mounting location of the remote cube filter
(RCF-4).

2 . Transfer hole pattern (located on page 10) of RCF-4 to

intended enclosure surface.

3. Check for obstructions hindering bolt fastening or tubing
connections, drill and ream the mounting holes before
mounting the RCF-4.

4. Ensure the O-ring gasket supplied with the filter is placed
around the outlet port of the mounting cube mounted
directly to the protected enclosure surface. This O-ring will
seal filter to the enclosure to prevent air leakage.

5. Secure filter to intended mounting surface with mounting
hardware provided, confirm O-ring seal is properly
positioned. Tighten mounting hardware.

6. Follow tubing instructions located on pages 13 & 14.

Subject to modifications without notice
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[e-mail] [e-mail]

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7

Model 3003 Installation and Operation Manual

Required Hardware Mounting

Required Enclosure Protection Vent

All configurations must be mounted in a true vertical position.

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 5, “Getting
Started”).

3. Using a 1.6875" hole saw or 1.1/4" 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.

Required Warning Nameplate(s)

An EWN (Enclosure Warning Nameplate) must be located in a
prominent position on or near all enclosure accesses (doors
and covers).

One (1) EWN is provided with each system, located in the
manila envelope taped to the mounting flange of the system.
Additional EWNs 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.

The 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 - 3 - SA - 00

Vertical Mount

EPV - 3 - SA - 90

Side Mount

Enclosure Warning Nameplate - Class I

Enclosure Warning Nameplate - Class II

Enclosure Temperature Warning Nameplate

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice

8

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Model 3003 Installation and Operation Manual

1.0 (25.4)

8.5 (215.9)

9.5 (241.3)

0.63 (15.9)

3.38 (85.7)

0.25 ( 6.4) O.D

.

TYP 4

4.0 (101.6)

SERIAL#

Model 3003-LPS-CI Type Y OR Z

5.5 (139.7)

9.5 (241.3)

Panel Cutout

5 (127)

Panel

C

utout

9 (228.6)

4.0 (101.6)

1.5 (38.1)

9.75 (247.7)

10.75 (273.1)

1.0 (25.4)

0.63 (15.9)

3.38 (85.7)

0.25 ( 6.4) O.D
TYP 4

4.0 (101.6)

5.5 (139.7)

10.75 (273.05)

Panel Cutout 10.25 (260.4)

Panel

Cutout

5 (127)

4.0 (101.6)

1.5 (38.1)

CL

4. 0

(1 01. 6)

1. 5

(3 8.1 )

3. 75

(9 5.3 )

1. 63 (41.3)
sq ua re

5. 25

(1 33 .4 )

4. 38

(1 11 .1 )

CL

0.63 (15.9)

0.63 (15.9)

CL

0.17 (4.4) Ø TYP. 2

0.5 (12.7) Ø

4.75 (120.7)

3.13

(79.4)

0.5

(12.7)

4. 88

(1 23 .8 )

System Mounting Dimensions

Model 3003-LPS VM Configuration System & Flange Dimensions

IMPORTANT NOTE

Panel cutout dimensions
are to be used only
when installing a HM or
VM configuration in a
frame or panel mount
installation. See page 6
for more information.

VM Configuration

front view

VM Configuration

side view

Vertical Mount Flange

front view

Model 3003-LPS HM Configuration System & Flange Dimensions

HM Configuration

front view

HM Configuration

side view

Horizontal Mount Flange

front view

Model 3003-LPS CK Configuration System & Optional Remote Cube Filter Dimensions

0.39 (10)

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice
Pepperl+Fuchs Group

www.pepperl-fuchs.com

4.5 (114.3) Ø

Side view Front view

Front view

Pneumatic Manifold

CL

1.34
(34)

3.25 (82.6)

0.35 (9)

1.26 (32)

2.33 (59)

0.82 (20.8)

4.5 (114.3) Ø

0.59 (15)

6.38 (161.9)

0.218 ( 5.5) Ø TYP. 3

0.44 (11.1) Ø

0.66 (16.7) Ø TYP. 2

1.40 (35.4)

Model 3003 CK System

USA: [phone]

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Panel cutout pattern

Germany: [phone]

Enclosure Pressure Gauge

Side view

HELPFUL HINTS

Note: Two optional enclosure
pressure gauge positions are shown
on the model 3003 CK system
panel cutout pattern to the left. The
optional positions center gauge to
the right or bottom side of system
nameplate.

Only cut ONE 4.5" Ø hole in panel.

Copyright Pepperl+Fuchs

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Side view

Model RCF-4

Model RCF-4

Panel cutout pattern

9

Model 3003 Installation and Operation Manual

Model 3003-WPS-CI Type Y OR Z

8 (203.2)

14 (356)

Panel Cutout

7.5 (190.5)

Panel

C

utout

13.5 (242.9)

4.0 (101.6) 3.5 (88.9)

13 (330)

14 (356)

1.0 (25.4)

0.63 (15.9)

3.38 (85.7)

0.25 ( 6.4) O.D

.

TYP 4

4.0 (101.6)

8 (203.2)

15 (381)

Z

Panel Cutout 14.5 (368.3)

Panel

C

utout

7.5 (190.5)

4.0 (101.6) 3.5 (88.9)

14.25 (222.3)

15.25 (387.4)

1.0 (25.4)

0.63 (15.9)

3.38 (85.7)

0.25 ( 6.4) O.D
TYP 4

4.0 (101.6)

System Mounting Dimensions (continued)

Model 3003-WPS & WPSA VM Configuration System & Flange Dimensions

VM Configuration

front view

VM Configuration

side view

Vertical Mount Flange

IMPORTANT NOTE

Panel cutout dimensions are to be used only when
installing a HM or VM configuration in a frame mount
installation. See page 6 for more information.

Model 3003-WPS & WPSA HM Configuration System & Flange Dimensions

HM Configuration

front view

front view

HM Configuration

side view

10

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Horizontal Mount Flange

front view

Copyright Pepperl+Fuchs

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Part No. 512785 Drawing No. 129-0198c 03/09

Model 3003 Installation and Operation Manual

Typical System Installation Details

External To The Protected Enclosure

Enclosure reference tubing,

customer supplied

Flange mount HM

configuration with model

SMK-1 fastener kit

System supply inlet fitting

SC-6-4 or NC-6-4

Enclosure supply inlet fitting

SC-6-8 or NC-6-8

System supply tubing,

customer supplied

Enclosure reference fitting

EFC-4

Enclosure supply

fitting EFC-6

Required

enclosure protection vent

EPV-3-SA-90

Enclosure protection system

System mounting kit

SMK-1

Pressurized (protected)

enclosure

Internal To The Protected Enclosure

Panel mount CK configuration

with model RCF-4 remote cube filter

& model GCK gauge conversion kit

Atmospheric reference

tubing, customer supplied

Atmospheric reference
bulkhead fitting PRB-4

System supply inlet fitting

SC-6-4 or NC-6-4

System supply tubing,

customer supplied

System supply inlet fitting

SC-6-4 or NC-6-4

Optional accessory remote

cube filter model RCF-4

shown mounted to the

protected enclosure

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice
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Required

enclosure protection vent

EPV-3-SA-00

Pressurized (protected)

enclosure

Enclosure pressure

indicator w/ GCK installed

Start up instruction

nameplate

System pneumatic manifold

Optional

Enclosure supply outlet fitting

SC-6-8 or NC-6-8

Enclosure supply tubing,

customer supplied

11

Model 3003 Installation and Operation Manual

Pneumatic Tubing Requirements

Protective Gas Supply 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.

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.

The protective gas supply to the protection system must be
regulated from 120 psi maximum to 80 psi minimum.

SC-6-4 & SC-6-8

SYSTEM SUPPLY INLET & ENCLOSURE SUPPLY OUTLET

FITTINGS

NC-6-4 & NC-6-8

Pneumatic Connection Requirements

ALL FITTINGS MAY BE CUSTOMER OR FACTORY FURNISHED

1. For system supply, one (1) SC-6-4 3/8" tube x 1/4" NPT
male straight connector or one (1) NC-6-4 3/8" tube x 1/4"
NPT male elbow connector or equivalent fitting per system.

Note: Systems supplied with optional RCF-4 or ILF-4 filter

accessories require two (2) additional SC-4-6 or NC-6-4
connectors.

One (1) similar fitting which will connect the protective

gas supply tubing to the protective gas supply header
connection point and one (1) lot of 3/8" O.D., .035" wall
thickness, welded or seamless stainless steel tubing.

NOTE: 1/4" 150# rated pipe, couplings & unions, fully

reamed, can be utilized in place of the fittings and tubing
listed above.

2. For enclosure supply from the purge system, one (1) SC­6-8 3/8" tube x 1/2" NPT male straight connector or one
(1) NC-6-8 3/8" tube x 1/2" NPT male elbow connector or
equivalent fitting per system.

3. For enclosure supply into the protected enclosure, one (1)
EFC-6 3/8" flush connector, or one (1) EBC-6 3/8" feed­through connector or equivalent fitting per system.

4. For enclosure reference, one (1) EFC-4 1/4" flush connector,
or one (1) EBC-4 1/4" feed-through connectoror equivalent
fitting per system.

5. One (1) lot of 1/4" & 3/8" O.D., .035" wall thickness, welded
or seamless stainless steel tubing.

6. For multiple enclosure connections, two (2) EPC-13 1-1/4"
pipe mounting hubs or equivalent and 1-1/4" 150# rated
pipe couplings & unions per interconnection.

One (1) lot 150# rating 1-1/4" galvanized or aluminum pipe

and fittings, fully reamed and unrestricted.

EFC-4 & EFC-6

ENCLOSURE SUPPLY, ENCLOSURE REFERENCE &

SYSTEM SUPPLY BULKHEAD FITTINGS

EPC-13

MULTIPLE ENCLOSURE CONNECTION FITTING

EBC-4 & EBC-6

PM Pneumatic Connection Requirements

In addition to item numbers 1, 5, and 6 above, the following
fittings are required for all PM systems.

1. For system supply on PM installations, one (1) additional
EBC-6 or equivalent 3/8" 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.

PRB-4

SYSTEM ATMOSPHERIC REFERENCE FITTING

Part No. 512785 Drawing No. 129-0198c 03/09

12

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Model 3003 Installation and Operation Manual

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
that protects it from damage and corrosion.

Surface, Pipe or Frame Mounted Installations

System supply connections

1. Select or install a protective gas supply header tap, fitted
with the proper tube size fitting and located within twenty
(20) feet (6.1 m) of the enclosure protection system.

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.

3. Select the appropriate fittings required to connect
the protective gas supply to the System Supply Inlet
as determined on page 12, “Pneumatic Connection
Requirements.” Install fittings.

4. Determine appropriate tubing route from the protective gas
supply header to the System Supply Inlet.

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.

Enclosure supply & reference connections

1. Choose location for the enclosure supply connection(s)
based on the requirements on page 5, “Getting Started.”

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 5, “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.

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.

Panel Mounted Installations

IMPORTANT NOTE: The purge system's enclosure
pressure gauge must be modified for panel mount
installation prior to performing the following
instructions. Refer to page 7 "Panel Mount
Conversion Process" for additional information.

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 fitting and
the bulkhead connection.

System 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.

2. If a service valve is placed between the protective gas
supply header and the protection system, it must be in
close proximity of the protected enclosure and labeled in
accordance with NFPA 496.

3. Determine appropriate tubing route from the protective gas
supply header to the system supply bulkhead fitting.

4. Determine appropriate tubing route from the system supply
bulkhead fitting to the system supply inlet.

5. Determine appropriate tubing route from the atmospheric
reference bulkhead fitting to the enclosure pressure gauge’s
reference inlet connection.

6. Bend tubing using industrial grade benders, check tubing
fit to ensure proper seating between the tubing and fittings.
Fully ream all tubing ends.

7. Install tubing and tigghten all fittings to fitting manufacturer's
specifications. Secure tubing as required

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice
Pepperl+Fuchs Group

www.pepperl-fuchs.com

USA: [phone]

[e-mail] [e-mail]

Germany: [phone]

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13

Model 3003 Installation and Operation Manual

Tubing Connection Diagrams

Surface, Pipe & Frame Mounted Connection Points & Pneumatic Diagram

Regulator

System

supply

inlet

Mounting

plate

Regulator

filter

Enclosure

pressure

gauge

System

supply

Model 3003-LPS-CI-Z-VM

Shown

Optional EXP

pressure switch

Venturi

orifice

Regulator

Inlet

pressure gauge

Sintered

vent

Rapid Exchange

pressure gauge

Rapid

Exchange

manifold

body

Enclosure

supply
outlet

Venturi

orifice

Enclosure

reference

inlet

Enclosure

Rapid Exchange

control valve

Enclosure pressure

control valve

Sintered

vent

HELPFUL HINT

This information is intended for
systems mounted external or adjacent
to the protected enclosure. HM & CK
configuration connection points and
pneumatic diagrams are identical to the
VM configuration shown to the left.

Required enclosure

protection vent

Reference

Supply

Enclosure reference

bulkhead fitting

Enclosure supply

bulkhead fitting

Protected enclosure

Regulator

System

supply

inlet

Mounting

plate

Regulator filter

Enclosure

pressure

gauge

Panel Mount Connection Points & Pneumatic Diagram

Model 3003-LPS-CI-Z-VM

Shown w/ GCK installed

HELPFUL HINT

Pneumatic
connections are
bolded.

Rapid Exchange

manifold body

Enclosure

Enclosure

reference

Atmospheric

reference

System

supply

supply
outlet

Inlet

Inlet

Atmospheric

reference
bulkhead

System supply

bulkhead

HELPFUL HINT

This information is intended for systems
mounted internal to or through the
surface of the protected enclosure. HM
& CK configuration connection points
and pneumatic diagrams are identical to
the VM configuration shown to the left.

Required enclosure

protection vent

Enclosure

pressure gauge

Sintered

vent

Rapid Exchange

pressure gauge

Regulator

Protected enclosure

Rapid Exchange

control valve

Enclosure pressure

control valve

Part No. 512785 Drawing No. 129-0198c 03/09

14

Subject to modifications without notice
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Model 3003 Installation and Operation Manual

Electrical Supply Requirements

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 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 5, “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.

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.

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.

Typical Enclosure Wiring Methods

Protected enclosures must be wired similar to explosion proof
enclosures, in accordance with Article 500 of the National
Electric Code - NFPA 70.

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.
Additionally, NFPA 496 requires approved conduit seals on all
pressurized enclosure conduit wiring entries, in accordance
with NFPA 70. Furthermore, the use of an approved conduit
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 must
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

Explosion

Conduit

Seal

Conduit

Seal

Gland

fitting

Cable

Conduit

Seal

Pressurized

raceway

proof device

Intrinsically

safe or fiber

optic device

Intrinsically

safe or fiber

optic device

Independently

pressurized

device

Adjacent

pressurized

device

Part No. 512785 Drawing No. 129-0198c 03/09

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Protected enclosure

or device

Copyright Pepperl+Fuchs

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15

Model 3003 Installation and Operation Manual

Conduit Installation

Electrical Conduit

1. Choose the location for the enclosure’s electrical conduit
connection(s) based on the requirements on page 15,
“Electrical Supply Requirements”.

2. Drill and deburr enclosure conduit fitting holes in the
protected enclosure. Mount the fittings.

3. Determine appropriate route for the enclosure electrical and
power 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 appropriate structural
supports as required.

6. Seal all conduit with an approved compound prior to
operation of the protection system.

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.

WPS Style Conduit

WPS & WPSA style systems provide electrical contacts for
audible or visual alarm devices that signal a loss of protected
enclosure pressure. They are calibrated to alarm at 0.15"
(3.8 mm) 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 Style Conduit Connection Parts

Fitting Kits Can Be Factory Furnished

1. For 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.

2. For 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.

Switch

body

Setpoint

calibration

screw

Grounding

screw

1/2" conduit

port

Switch

body

Setpoint

calibration

screw

Grounding

screw

1/2" conduit

port

WPS Style EXP pressure switch

with cover removed

WPSA Style EXP pressure switch

with cover removed

Electrical

switch

contacts

Low port

sintered

vent

High port

tube

fitting

Low port

sintered

vent

Supply

power &

electrical

switch

contacts

High port

tube

fitting

TCK “T” fitting conduit kit

LCK “L” fitting conduit kit

16

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Part No. 512785 Drawing No. 129-0198c 03/09

Model 3003 Installation and Operation Manual

Set-up Procedure

HELPFUL HINTS

“Safe” pressure, for purposes of this manual,
is defined as a minimum .25 inch (6.4 mm) of water
column.

Regulator may be in the locked position upon arrival. To
adjust regulator, pull handle to outward position.

Carefully insert T-bar valve key to align valve stem tip of
both valves. Practice locking and unlocking key in the
RECV valve stem. Practice and familiarization of this
process should ease operation of the system.

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.

IMPORTANT NOTES: The Rapid Exchange control valve and
the enclosure pressure control valve are both operated by
utilizing the removable T-bar valve key supplied with the
system. The purge system is shipped with the T-bar valve
key locked in the Rapid Exchange control valve stem. To
remove the T-bar valve key, wrap your index and middle
finger around the T-Bar and place your thumb firmly against
the system face plate. Pull the T-bar valve key straight out
firmly. This will unlock and free the T-bar valve key for use
in the enclosure pressure control valve stem. When Set-up
or operating procedures are complete, replace the T-bar
valve key in the Rapid Exchange control valve stem and
push in firmly to lock in position. THE T-BAR VALVE KEY
LOCKS IN THE RAPID EXCHANGE CONTROL VALVE STEM
ONLY.

Operators must secure wrist or stop watch to manually
time exchange cycle for all applications.

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 (4.14 bar)minimum, the model 3003 will
accomplish the required volume exchanges at a rate of
ONE MINUTE PER 3 CUBIC FEET (85 l/min) of enclosure
volume.

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
for motors.

Regardless of enclosure volume or system flow rate,
Pepperl+Fuchs requires 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
protective gas flow.

Class I Purging Set-up

READ IMPORTANT NOTES BEFORE

PROCEEDING WITH SET-UP

1. Utilizing the T-bar valve key supplied with system (see
important notes), close Rapid Exchange control and
enclosure pressure valves fully by turning clockwise (CW).

2. Engage the protective gas supply to the system supply Inlet
and set the Rapid Exchange pressure gauge to 60 psi.

3. Temporarily connect a 0-10 inch (0-254 mm) 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, utilizing the T-bar valve key, 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, “Troubleshooting Procedures.”

6. Carefully remove T-bar valve key from enclosure pressure
control valve stem. Ensure enclosure pressure gauge"safe"
pressure setting is stable.

7. Utilizing the T-bar valve key supplied with system (see
important notes above), lock T-bar valve key into Rapid
Exchange control valve stem. Open 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.

8. Readjust the regulator to 60 psi (4.14 bar) minimum, while
inducing Rapid Exchange, until the test gauge reads
approximately 3 to 5 inches (76-127 mm) of pressure and
does not fluctuate. (Insufficient enclosure pressure will
cause the enclosure protection vent to "shuttle.") DO NOT
exceed 10 inches (254 mm) of pressure within the protected
enclosure.

9. Close Rapid Exchange control valve fully and ensure T-bar
valve key is firmly locked in Rapid Exchange control valve
stem.

10. Cease testing and remove test equipment.

Part No. 512785 Drawing No. 129-0198c 03/09

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17

Model 3003 Installation and Operation Manual

Operating Sequence

WARNING! Do not exceed a “safe” pressure with the
enclosure pressure control regulator.

Operators must follow step-by-step sequence of the start­up instructions nameplate on the protection system.

Class I Purging Operation

With the protective gas supply connected, enclosure power
deenergized and alarm system energized (if utilized).

1. Carefully read start-up Instructions on system.

2. Check operation of the enclosure protection vent ( EPV-3),
opening it manually several times. See page 17, “Helpful
Hint.”

3. Seal protected enclosure(s).

4. Unlock T-bar valve key from the RECV stem and place in
the EPCV stem. See important notes on page 17. Open
enclosure pressure control valve, by turning CCW, to set
enclosure pressure gauge at “safe” pressure, the pressure
loss alarm switch (if utilized) should then activate to silence
the alarm system.

5. Ensure the protection system enclosure pressure gauge
maintains a “safe” pressure for one (1) minute.

6. Carefully remove T-bar valve key from enclosure pressure
control valve stem. Ensure enclosure pressure gauge "safe"
pressure setting is stable.

7. Utilizing the T-bar valve key supplied with system (see
important notes, page 17), 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.

8. Standby for the exchange time as specified on the start-up
Instructions (five minutes minimum), then close the Rapid
Exchange control valve fully and ensure T-bar valve key is
firmly locked in Rapid Exchange control valve stem.

9. Wait for the enclosure pressure gauge to return to a "safe"
pressure and energize the protected enclosure(s) power via
the local disconnect switch.

10. Ensure the enclosure pressure indicator maintains a “safe”
pressure before leaving system unattended.

System

start-up

instructions

Enclosure

pressure

control valve

stem

T-bar

valve key

Rapid

Exchange

control valve

stem

Model 3003-LPS-CI-Z-VM

front view

Model identification

Rapid Exchange

pressure gauge

Enclosure

pressure gauge

System

face plate

18

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Part No. 512785 Drawing No. 129-0198c 03/09

Model 3003 Installation and Operation Manual

Troubleshooting Procedures

Problem or Fault Possible Causes Corrective Action

Enclosure pressure control
valve will not hold a "safe"
.25 inch (6.35 mm) pressure.

Enclosure pressure gauge
reading is difficult to stabilize.

Enclosure pressure loss
alarm switch (if utilized) does
not appear to be operating.

Problems persists, or if the
system does not appear to
be operating properly.

Leakage around gasketing, covers,
seams, piping and tubing connections,
conduit connections and electrical
conduit seals of the enclosure.

Insufficient enclosure leakage or opening
of the venturi orifice is crimped to small.

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.

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.

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)

Persisting problems. Contact Pepperl+Fuchs Applications/Customer

Service Department at [phone] for more
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

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice
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USA: [phone]

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Germany: [phone]

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19

Model 3003 Installation and Operation Manual

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 twenty­four (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.

20

Subject to modifications without notice
Pepperl+Fuchs Group

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USA: [phone]

Germany: [phone]

Copyright Pepperl+Fuchs

Singapore: [phone]

[e-mail]

Part No. 512785 Drawing No. 129-0198c 03/09

Model 3003 Installation and Operation Manual

Notes

Part No. 512785 Drawing No. 129-0198c 03/09

Subject to modifications without notice
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USA: [phone]

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Germany: [phone]

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21

Model 3003 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 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.

MAINTENANCE SCHEDULE

Date Work performed

Performed by

22

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Part No. 512785 Drawing No. 129-0198c 03/09

Model 3003 Installation and Operation Manual

Systems Identification & Application Information

Date of installation _____________________________________________________

Unit serial #____________________________________________________________

Item ___________________________________________________________________

Customer P.O.# ________________________________________________________

Customer project# _____________________________________________________

Service ________________________________________________________________

Type __________________________________________________________________

Features ______________________________________________________________

Application ____________________________________________________________

Notes: _______________________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

Part No. 512785 Drawing No. 129-0198c 03/09

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23

PROCESS AUTOMATION –
PROTECTING YOUR PROCESS

For over a half century, Pepperl+Fuchs has provided new concepts for the world of process automation. Our company
sets standards in quality and innovative technology. We develop, produce, and distribute electronic interface modules,
Human-Machine Interfaces and hazardous location protection equipment on a global scale, meeting the most demanding
needs of industry. Resulting from our world-wide presence and our high flexibility in production and customer service,
we are able to offer complete individual solutions – wherever and whenever you need us. We are the recognized experts in our
technologies – 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.

1

Worldwide/German Headquarters

Pepperl+Fuchs GmbH
Mannheim · Germany
Tel. [phone]

E-Mail: [e-mail]

2

Asia Pacific Headquarters

Pepperl+Fuchs PTE Ltd.
Singapore
Company Registration No. 199003130E
Tel. [phone]

E-Mail: [e-mail]

3

Central/Western Europe &
Africa Headquarters

Pepperl+Fuchs N.V.
Schoten/Antwerp · Belgium
Tel. [phone]

E-Mail: [e-mail]

4

Middle East Headquarters

Pepperl+Fuchs M.E (FZE)
Dubai · UAE
Tel. [phone]

E-Mail: [e-mail]

5

North/Central America Headquarters

Pepperl+Fuchs Inc.
Twinsburg · Ohio · USA
Tel. [phone]

E-Mail: [e-mail]

5

8

6

Northern Europe Headquarters

Pepperl+Fuchs GB Ltd.
Oldham · England
Tel. [phone]

E-Mail: [e-mail]

7

Southern/Eastern Europe Headquarters

Pepperl+Fuchs Elcon srl
Sulbiate · Italy
Tel. [phone]

E-Mail: [e-mail]

8

South America Headquarters

Pepperl+Fuchs Ltda.
São Bernado do Campo · SP · Brazil
Tel. [phone]

E-Mail: [e-mail]

6

1

3

7

4

2

www.pepperl-fuchs.com

Subject to modifications • © 2009 PEPPERL+FUCHS, INC. • Printed in USA • Part No. 512785 Drawing No. 129-0198c (TDOCT-1369_ENG) 03/09