Pepperl+Fuchs 6000 SERIES Installation And Operation Manual
PROCESS AUTOMATION
INSTALLATION AND OPERATION MANUAL
6000 SERIES
PURGE/PRESSURIZATION SYSTEM
6000 Series Purge/Pressurization System
I/O Manual
With regard to the supply of products, the current issue of the
following document is applicable:
The General Terms of Delivery for Products and Services of
the Electrical Industry, published by the Central Association
of the Electrical Industry (Zentralverband Elektrotechnik und
Elektroindustrie (ZVEI) e.V.) in its most recent version as
well as the supplementary clause: "Expanded reservation of
proprietorship".
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6000 Series Purge/Pressurization System
I/O Manual
Contents
Safety note and symbols used ................................................................................................. 1
Symbols used ....................................................................................................................................1
General instructions regarding ATEX ...................................................................................... 2
Certication information ........................................................................................................... 3
Certication markings .......................................................................................................................3
Warning labels ...................................................................................................................................4
Conditions of Safe use ......................................................................................................................4
Purpose ......................................................................................................................................5
Description ................................................................................................................................. 5
6000 control unit .......................................................................................................................6
Electrical & pneumatic diagrams ............................................................................................. 8
6000 control unit power connections ..............................................................................................8
Electrical installation - power and I.S. wiring ................................................................................ 10
Pneumatic requirements ................................................................................................................. 12
Mounting instructions ............................................................................................................. 13
Manifold assembly, LH & RH mount ..............................................................................................13
EPV-6000 vent .................................................................................................................................. 14
6000 Control unit with housing "WH" ...........................................................................................15
Tightening the cover plate ..............................................................................................................16
6000 series component kit ..................................................................................................... 17
Identication of components .........................................................................................................17
Electrical diagrams ......................................................................................................................... 18
Electrical installation - power and I.S. wiring ................................................................................ 20
Component kit installation .............................................................................................................21
Mounting templates - user interface, EPCU, solenoid .................................................................22
Sequence of events ................................................................................................................. 23
Turning on power to the enclosure ................................................................................................23
Turning off power to the enclosure ...............................................................................................24
Operation of the 6000 series and component kit ................................................................. 25
Operation ..........................................................................................................................................25
Set-up procedures of 6000 series system ....................................................................................29
Operation of the 6000 series system .............................................................................................29
Start-up label located on 6000 series control unit .......................................................................30
The user interface ....................................................................................................................31
Programming menu ................................................................................................................. 32
Purge settings ..................................................................................................................................33
Units ..................................................................................................................................................33
Inputs ................................................................................................................................................34
Outputs .............................................................................................................................................38
Password ..........................................................................................................................................39
Language ..........................................................................................................................................39
Bypass control .................................................................................................................................39
Restore defaults ..............................................................................................................................39
Stats ..................................................................................................................................................40
Statistics ...........................................................................................................................................41
Alarm.................................................................................................................................................43
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6000 Series Purge/Pressurization System
Fault ..................................................................................................................................................43
Clear statistics ................................................................................................................................44
Clear fault ........................................................................................................................................44
Operation screen .............................................................................................................................44
I/O Manual
System dimensions ................................................................................................................. 45
6000 series control unit ..................................................................................................................45
EPV-6000 vent .................................................................................................................................. 46
6000 series component kit .............................................................................................................47
Temperature hub .............................................................................................................................48
Temperature sensor ........................................................................................................................49
6000 Manifold ...................................................................................................................................50
General specications ............................................................................................................51
Model number designators .....................................................................................................54
Accessories .............................................................................................................................55
Maintenance and repair ..........................................................................................................56
Alarm and fault conditions .....................................................................................................56
Dismantling and decommissioning .......................................................................................57
Establishing connection sizes, lengths & bends ................................................................. 58
Programming worksheet .........................................................................................................59
Notes .........................................................................................................................................66
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6000 Series Purge/Pressurization System
Warning
Note
Safety note and symbols used
It is strongly urged that you follow all instructions and
recommendations in this manual, in addition to all
applicable codes, standards, and local requirements.
Failure to do so voids all warranties, both implicit and
explicit, and relieves the manufacturer of all liability.
Symbols used
This symbol calls your attention to
instructions or requirements that must be
followed. Failure to observe the instructions
and information that this symbol calls
Attention
attention to may result in the failure of the
device and any devices or systems
connected to it.
This symbol draws your attention to
important information.
Note
I/O Manual
This symbol warns the user of potential
danger. Failure to observe this warning may
lead to personal injury or death and/or
property damage.
This symbol accompanies a list of tools you
will need to install the unit.
Grounding points internal and external
will be identied with a ground symbol:
This symbol is used for AC power:
This symbol is used for DC power:
Pepperl+Fuchs GmbH
Lilienthalstraße 200
68307 Mannheim
Germany
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6000 Series Purge/Pressurization System
Note
Warning
Warning
I/O Manual
General instructions regarding ATEX
1. The guidelines
The guideline 2014/34/EU determines the essential
health and safety requirements relating to the design
and construction of equipment and protective systems
intended for use in potentially explosive atmospheres,
given in Annex II of the directive.
The guideline 1999/92/EG is addressed to the operator/
user of facilities in explosive areas and governs the
safety regulations of persons during installation, handling,
and maintenance.
Furthermore, local laws and rules for electrical
installations and accident prevention have to be
observed.
2. General information for this manual
Preconditions for handling and operating the series
6000 controller safely are basic knowledge of safety
regulations and additional training and experience in
explosion protection.
4. General information about pressurized enclosures
The pressurized enclosure is one of the most
multifunctional applicable types of protection. It is based
on a rst ush operation which removes potential,
ignitable gas mixtures of the local environment from
the enclosure. After the ush, the overpressure will
be maintained by adding as much pressurized air as
necessary to compensate for the leaks of the enclosure
or components. This constant overpressure status
protects against the diffusion of potentially explosive
atmospheres.
During the ush, the internal pressure will be up to
10-12mbar. In the operation phase, it is reduced to
2-3 mbar. Hot spots at single components inside the
enclosure are monitored by temperature sensors
(optional) and if required turned off. This assures that no
unacceptable surface temperature will occur.
For applications with hazardous dust, the purge process
is omitted because purging would raise explosive dust.
Instead of pre-purging, the interior of the housing is
inspected for dust and cleaned manually if dust is
present.
This user manual contains important information and
instructions to handle the series 6000 controller in
explosive areas safely and to operate it according to
guideline 2014/34/EU.
This user manual, in particular the safety instructions,
has to be observed by everybody who works with the
components.
3. Responsibilities of users and installers
This equipment shall only be used within its
intended purpose. Refer to the manual for proper
usage.
The user and/or the installer is obligated to let only
competent, trained persons work at the 6000 Control Unit
who
• are familiar with the regulations about safety and
accident prevention and briefed in handling of the
component.
• are trained to work on explosion protection
equipment.
• know the appropriate instructions and rules for
the installation, handling, and maintenance of
explosion protected equipment.
For this reason, the pressurized enclosure is especially
suited for the use of non-Ex certied equipment in Exareas.
The enclosure has to be prepared specially for the use of
Ex p:
• all walls have to be additionally armed
• the doors have to be specially constructed
• tested for mechanical stability
• tested for overpressure resistance
When using an inert gas like nitrogen, an
asphyxiation hazard can exist.
EN 60079-2 and IEC 60079-2 do not cover both gas
and dust hazard atmospheres. The 6000 system
provides a solution for both at the same time but
would have to be evaluated by the certication
bodies for approval.
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6000 Series Purge/Pressurization System
Certication information
Marking for the 6000 control unit,
6000-__-S2-__-CK-__
Marking for the 6000 Control
unit, 6000-__-S2-UN-WH-__ and
6000-__-S2-__-XD-__
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Marking for the 6000 user interface controller, 6000-UIC-01
Marking for the 6000-ISB-___ termination board,
DIN mounted
Marking for the 6000 vent, EPV-6000-__-__
Marking for the 6000-TSEN-01
Marking for the 6000-TEMP-01
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6000 Series Purge/Pressurization System
Warning
Warning
Warning
Warning
I/O Manual
Warning Labels
WARNING - Conduit seal must be installed within 18
inches of the explosion-proof enclosure. To prevent
ignition of ammable or combustible atmospheres,
disconnect power before servicing.
WARNING - FOR ENCLOSURES IN HAZARDOUS
DUST ENVIRONMENTS
This enclosure shall not be opened unless the area
is known to be free of ammable materials or unless
all devices have been de-energized. Power must not
be restored after the enclosure has been opened until
combustible dusts have been removed and the enclosure
repressurized.
WARNING - FOR ENCLOSURES IN HAZARDOUS
GAS ENVIRONMENTS
This enclosure shall not be opened unless the area is
known to be free of ammable materials or unless all
devices have been de-energized. Power must not be
restored after the enclosure has been opened until the
enclosure is completely purged of all hazardous gas and
the enclosure repressurized.
WARNING - FOR ENCLOSURES IN HAZARDOUS
DUST AND GAS ENVIRONMENTS
This enclosure shall not be opened unless the area
is known to be free of ammable materials or unless
all devices have been de-energized. Power must not
be restored after the enclosure has been opened until
combustible dusts have been removed and completely
purged of all hazardous gas and the enclosure
repressurized.
Conditions of Safe Use
1. Conduit seals shall be certied in type of explosion
protection ameproof “db”, or explosion-proof Class
I/II Div 1 as required for the installation location
and suitable for the conditions of use. They shall be
correctly installed to the explosion-proof/ameproof
enclosure or conduit extensions as required. All NPT
threads are to be minimum 5 thread engagement,
wrench tight.
2. Seals shall be installed within 18 in. (450 mm) of the
explosion-proof/ameproof “db” enclosure.
8. The non-metallic membrane touchpad and display is
a potential electrostatic discharge hazard. Use only
water damp cloth and allow to air dry for cleaning
device. Do not use or install in high charge areas.
See IEC 60079-32-1 for further information.
9. In hazardous dust environment, regularly remove dust
from the control unit enclosure to prevent excessive
temperature rise, including the solenoid valve.
10. Only pressure relief vent model EPV-6000-xx-xx
covered under the following certicates can be
used with devices covered by this certicate: For
ATEX applications: Certicate No. DEMKO 15
ATEX 1622X, DEMKO 07 ATEX 0705753X, or SIRA
09ATEX9337X. For IECEx applications: Certicate
No. IECEx UL 15.0147X, IECEx UL 08.0003X or
IECEx CSA 09.0007X. For cULus and cCSAus
applications: UL certication as part of le E184741
or CSA certication as part of 2205652 (LR90178).
11. For all applications, the 6000-TEMP-XX I.S.
temperature hub must be mounted in an enclosure
that is a minimum IP54. In hazardous dust
environment, the 6000-TEMP-xx temperature hub
has to be mounted in an enclosure that is certied
for the area classication. The pressurized enclosure
does not account for this type of enclosure because
power to this device is required before safe operation
within the pressurized enclosure. Maintain separation
of I.S. to non-I.S. wiring as required by local codes.
12. Caution must be used when handling or cleaning
products so there is no static charge buildup. Do not
wipe off the 6000-TSEN-xx sensor with dry cloth
or use in the presence of high charge generating
processes such as ionizers or electrostatic
equipment. See IEC 60079-32-1 for further
information.
13. The 6000 systems may also be provided with
previously certied items (operators, gable glands,
terminal box, etc.) as specied in the test reports.
14. Enclosure 6000-DPE-xx is only for I.S. termination
board 6000-ISB-xx and/or 6000-TEMP-xx.
3. When the purge control unit is mounted to an
enclosure, the complete unit shall be evaluated to
the current revision of IEC/EN 60079-2 or NFPA 496
as applicable. See certicates and/or Declaration of
Conformity for reference to relevant editions of these
standards.
4. The purge control unit has an operating temperature
class of 135 °C (T4 temperature class). This
temperature shall be considered when mounted to an
enclosure.
5. The device must be installed in accordance with the
manufacturer’s installation drawing number 116-B027.
6. Intrinsically safe cables extending from the explosionproof/ameproof "db" enclosure must be provided
with at least 0.25 mm insulation thickness per
conductive core to maintain segregation between
intrinsically safe circuits.
7. The cable entries may be used only in places
where they are protected against the inuence of
mechanical danger.
4
I.S. Termination Board, DIN Mounted:
6000-ISB-xx
1. In hazardous dust environments, the I.S. termination
board, DIN mounted: 6000-ISB-xx must be mounted
in an enclosure that is certied for the area
classication. The pressurized enclosure does not
account for this type of enclosure because power to
this device is required before safe operation within
the pressurized enclosure.
2. Only connect to the 6000 EPCU I.S. termination
connection.
3. All wiring to and from this board is for intrinsically
safe connections and must be properly routed and
managed per international, NEC, local codes, and
applicable standards.
4. See the latest revision of installation drawing 116B027 for other important installation information.
5. The 6000-CBLA-… is not certied to be used in a
Zone 21 location. Use approved cable glands for this
area classication.
6000 Series Purge/Pressurization System
Note
I/O Manual
Note:
• Peripheral devices such as optional SRM module and
I.S. solenoid were not evaluated by UL as part of the
intrinsically safe certication.
• When using third-party certication, ensure that you
match the entity parameters for intrinsically safe
devices as shown in control drawing 116-B027.
• SRM module is a simple apparatus and does not
require third-party certication.
EPV-6000 Vent
1. The EPV vent has an operating temperature class of
135 °C (T4 temperature class). This temperature shall
be considered when mounted to an enclosure.
2. When the purge control unit is mounted to an enclosure,
the complete unit shall be evaluated to IEC/EN 600792: 2014 (Ed. 6)
3. Cables used to connect to an EPV- vent must be
provided with at least 0.25 mm insulation thickness
per conductive core to maintain segregation between
intrinsically safe circuits.
4. In hazardous dust environments, regularly remove dust
from the EPV vent to prevent excessive temperature
rise. See certicate for full information.
5. In hazardous dust environments, the connector end of
the vent shall be protected from direct exposure of a UV
light source. See certicate for full information.
The 6000 series system features these main parts:
• Electronic processor (EPCU) housed in an
explosion-proof enclosure
• I.S. electrical/pneumatic manifold assembly
• I.S. user interface for programming and monitoring
the system
• 316L stainless steel (UNS S31603) type4X IP66
enclosure for EPCU and connections
• Pressure relief vent with ow and pressure
monitoring at the exhaust.
The user interface allows programming of up to 4 switch
inputs, temperature modules, enclosure power contacts,
2 auxiliary outputs, and various operational functions.
Through the user interface menus, conguration of the
standard information for setup and operation of a system
(purge time, ow rates, pressures, enclosure size, etc.)
are easily programmed. Additional features allow inputs
for system bypass, enclosure power on/off, temperature
overload and activation of rapid exchange ow for cooling
or auxiliary relay for separate cooling source, delay
power shutdown, and more. The two auxiliary contact
outputs can be congured to activate on most of the
input switches or any of the congured alarm states for
pressure, ows, and temperature.
6. Only EPV-6000-xx-xx vents can be connected to any
certied model 6000 control system.
Purpose
The purpose of the Pepperl+Fuchs 6000 series Type X
& Ex px, Zone 1 enclosure protection system is to allow
the use of general purpose or non-rated electrical or
electronic devices located in general purpose enclosures
instead of explosion-proof/ameproof, Type 7 or 9 / Ex
d enclosures or other means of protection for the rated
area. Other purposes include heat, moisture, and dust
contamination prevention.
Description
The 6000 series Type X & Ex px purge and
pressurization system protects general purpose
equipment mounted in a standard enclosure. This allows
the enclosure to be located and the equipment operated
in a hazardous area. The hazardous area classication
can be Class I, Class II, Division 1 / Zone 1, Zone 21.
The 6000 series operates by controlling and monitoring
compressed instrument air or inert gas through the
protected enclosure(s) so as to remove and prevent the
accumulation of ammable gas, vapors, or dust.
The power for the solenoid valve on the manifold unit,
inputs, the user interface controller (UIC), and EPV-6000
vent are provided by the EPCU through the internal
galvanically isolated intrinsic safety barrier. No additional
I.S. barrier is required.
The adjustable mounting bracket and the universally
mountable vent make the 6000 system easy to install
horizontally or vertically onto the enclosure. A component
kit is available for custom installations that t specic
customer needs.
The 6000 control unit can monitor multiple enclosures
and control and accept inputs from two (2) EPV-6000
vents.
The 6000 series provides a complete system for purging
and pressurizing enclosures for hazardous location
operation.
One (1) operations copy of this manual must be
studied and retained by the system operator in
addition to one (1) permanent le copy. User’s
agents are responsible for transferring this manual
to the user/operator prior to start-up.
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6000 Series Purge/Pressurization System
6000 Control Unit
Main unit
I/O Manual
I.S. wiring terminals
User interface controller
(UIC)
Bracket for mounting to the
enclosure
316L stainless steel
(UNS S31603)
Type 4X (IP66) rating
Removable electronics
Explosion-proof/flameproof
enclosure
3/4" conduit for power
connections
Cable glands for I.S. inputs/outputs
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6000 Series Purge/Pressurization System
6000 Control Unit
Manifold
I/O Manual
Manifold for
purging and
pressurization
Type 4X (IP66)
ttings for
enclosure ow
Needle valve for
pressurization of enclosure
(requires athead
screwdriver for adjustment)
Manifold with
I.S. solenoid
valve
Connection to
protective gas
supply
Rotating vent cap
Spark arrestor
Vent
The EPV-6000 vent
is required.
Mounts on vertical or horizontal
surface of the enclosure
Lock nut
Seal washer
I.S. temperature hub
Temperature
monitoring/control
accessories
I.S.
temperature
sensor
1.5 " NPT knockout
(Ø 2", 50.8 mm)
M12 (V1) connector
for I.S. connection
to control unit
Conduit plug
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6000 Series Purge/Pressurization System
Warning
Warning
Attention
Warning
Warning
Warning
I/O Manual
Electrical & pneumatic diagrams
Complete 6000 full control unit power
connections (-WH-)
General wiring notes
For power connections to the 6000 control unit and
relay contacts:
1. All applicable local and national wiring codes
MUST be followed when wiring to the unit.
2. Ground wire to be 14 AWG (2.08mm2). Strip
length of ground to mate with pigtail under wire
nut .437" to .5" (11.1mm to 12.7 mm).
3. If a single wire is used, the maximum wire gauge
to the pluggable terminal block is 14 AWG
(2.08mm2).
4. If jumpering from one terminal to another at
pluggable terminal block, the maximum wire
gauge is 16 AWG (1.31mm2) for both wires.
5. Minimum wire gauge to the pluggable terminal
Attention
Warning
Warning
block is 24 AWG (0.20mm2). (Based on
connector, not code. Follow all applicable
codes.)
6. Strip length of wires terminating into the screw
terminals on the pluggable terminal block to be
0.2" to 0.27" (5 mm to 7 mm).
7. Add extra wire length of 1.25" (31.75 mm) past
top of opening in explosion-proof/ameproof box
to pluggable terminal block (allows connector
to be moved out of the way when changing
electronics. Prevents repouring seals).
8. Wires are to be neatly tucked back down past the
lid threads before lid is placed on unit. The wires
must not loop past the high point of the plastic
cover. The wire nut should be tucked in last (If
not, it may be difficult to access when changing
electronics).
9. If using a single conduit seal, the other conduit
on the 6000 control unit will need a cap for
the end of the conduit with appropriate hazloc
certications (A standard 3/4" conduit cap will not
work).
10. Conduit seals with or without the 6000-CC3/4NPT plug must be within 18" (457.2 mm) of
internal explosion-proof/ameproof box, or within
15.25" (387.3 mm) from the end of the conduit
supplied with the 6000 unit.
11. When wiring to the terminal plug, it is easier
to remove the plug, terminate the wires, then
reconnect the plug.
12. When removing the pluggable terminal block, it
is recommended that the electronics module be
supported by pressing down on top of the EPCU
to counteract the lifting force required to remove
the connector.
13. Wire should be copper only, rated 90 °C
Attention
minimum. Minimum of 0.25" (6.3 mm) wire
insulation thickness required.
14. The minimum wire strand in a stranded wire
should have a diameter of 0.1 mm or greater.
15. The 6000-CC-3/4NPT plug is certied to be
used only with the 6000 control unit’s ¾” nipples
coming out of the housing. This plug is not
certied to be used on any other hazardous
location equipment.
16. Ensure that electrical, mechanical, and
pneumatic connections and requirements are
met to operate this system. Please refer to
this manual and applicable standards/codes,
including current editio9n of the EN/IEC 60079-
14. Electrical supply to the purge system shall be
supplied through a switch or circuit breaker and
suitably located and easily reached and must be
marked as the disconnect for the equipment.
1 7. Power must be removed from the system when
the Ex d enclosure cover is off, unless the area is
known to be non-hazardous.
WARNING – To prevent ignition of the ammable
atmospheres, the wiring method must ensure that
if any wire is disconnected and extended to the
opposite terminal, a 2-inch separation must be
maintained.
I.S. wiring notes
For wires going to the explosion-proof/ameproof
box on the I.S. side:
1. The wire strip length is to be between 0.2" and
Attention
0.27" (5 mm and 7 mm).
2. The wire's gauge depends on the number of
connections. Fewer wires allow for heavier
gauge and will still meet the conduit seal ll
requirement. See the applicable standards for ll
requirement.
3. The terminal blocks are rated for a wire size of
16 AWG (1.31 mm2 ) to 28 AWG (0.08 mm2 ).
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6000 Series Purge/Pressurization System
Warning
Warning
Warning
Attention
4. If multiple wires need to land to a single terminal
(e.g., the RS-485 bus), these wires must be
either crimped to a single pin or grouped in an
external junction box with one wire going into the
terminal.
5. The wires must have a minimum insulation
thickness of 0.01" (0.25 mm).
6. Add extra wire length of 1.25" (31.75 mm) past
top of opening in explosion-proof/ameproof box
to pluggable terminal block. (Allows connector
to be moved out of the way when changing
electronics. Prevents repouring seals.)
7. Conduit seal on I.S. wiring side must be within
18" (457.2 mm) of the explosion-proof/ameproof
box.
8. Wire should be copper only, rated 90 °C
minimum.
9. The minimum wire strand in a stranded wire
should have a diameter of 0.1 mm or greater.
I/O Manual
For wires going to the I.S. interface board in the main
housing or to the DIN-rail-mount I.S. board:
1. The wire strip length is to be between 0.16" and
0.24" (4 mm and 6 mm).
2. The terminal blocks are rated for a wire size of
16 AWG (1.31 mm2) to 26 AWG (0.081 mm2).
3. The only terminals that might have multiple
connections are the shield connections.
These must be crimped to a single pin before
connection to the board.
4. If cables are used (recommended for
connections to the vents and UIC), it is
recommended that the cables be shielded.
5. The wires must have a minimum insulation
thickness of 0.01" (0.25 mm).
6. Wire should be copper only, rated 90 °C
Attention
minimum.
7. The minimum wire strand in a stranded wire
should have a diameter of 0.1 mm or greater.
9
6000 Series Purge/Pressurization System
Note
Note
IS PWR 1+
IS PWR 1-
IS DATA 1A
IS DATA 1B
IS 1 SHLD
IS PWR 2+
IS PWR 2-
IS DATA 2A
IS DATA 2B
IS 2 SHLD
IS PWR 3+
IS PWR 3-
IS DATA 3A
IS DATA 3B
IS 3 SHLD
INPUT 1-
INPUT 1+
INPUT 2-
INPUT 2+
INPUT 3-
Temp
Module
Vent 1
Vent 2
Inputs
1 thru 4
Enclosure
Prewired
Electrical installation - power and I.S. wiring
I/O Manual
Power to
EPCU
GND
GND
GND
Prewired
L1
GND
N
BK
OR
GN
WT
BK/WT
BL/WT
RD/WT
GN/WT
OR/BK
BL
RD
WT/BK
RD/BK
User interface
connection
(pre-wired)
EPCU I.S. connector
I.S. solenoid valve
from manifold
(pre-wired)
Temperature module
connection
(when Vent 2 is used)
Vent 1 connection
Vent 2 connection or
Temperature Module
connection
Inputs 1 - 4, 5.0 V DC
Contacts
(2) N.O.
Aux
Output 1
(1) SPDT
Aux
Output 2
(1) SPDT
Connector color code for the user interface,
temperature module, and vent:
PWR + BN (brown)
PWR - BU (blue)
DATA_A WH (white)
DATA_B BK (black)
Requires standard explosion-proof seals to
explosion-proof/ameproof enclosure at a
Warning
maximum distance of 18" (457.2 mm).
When removing the terminal block from the
EPCU stack, place your hand on top of the
plastic to support the stack when lifting the
terminal block off the stack.
10
Manifold connection Vent connection
GND
'A' White
+1
-2
'+' Brown
'B' Black
'-' Blue
The EPCU is prewired to the I.S. terminal board.
Note
Both enclosure power contacts are switched at
the same time.
6000 Series Purge/Pressurization System
Warning
No wiring is to be in
the area between the
terminals
I/O Manual
I.S. wiring
Non- I.S. wiring
Incoming ground wires
should be terminated into
the supplied wire nut
WARNING: To prevent ignition of the ammable
atmospheres, the wiring method must ensure
that if any wire is disconnected and extended to
the opposite terminal, a 2" (50.8 mm) separation
must be maintained.
EPCU
Maintain a minimum space of 2" (50.8 mm)
between the I.S. wiring and the non - I.S. wiring.
Attention
Make sure that the wiring is neatly tucked into
the explosion-proof housing. Use wire ties if
necessary. As a rule, no wires are to be in the
area between the two terminals, as shown
above.
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6000 Series Purge/Pressurization System
Note
I/O Manual
Pneumatic requirements
Protective gas supply
The protective gas supply to the enclosure system must
be a clean, instrument quality compressed air or inert
gas ltered to a minimum of 40 microns. It must contain
no more than trace amounts of ammable gas, vapor, or
dust.
The protective gas supply compressor intake must
originate in a nonhazardous location. The suction
duct passing through a hazardous location and the
protective tubing and piping must be fabricated from
noncombustible materials suitable for the prevailing
hazardous and environmental conditions.
The protective gas supply provided must be able to
handle the ow and pressure requirements for purging
and pressurization (see page 66, Establishing connection
sizes, lengths & bends).
Needle valve
3/8" tubing
Protective
Plug
gas supply
EFC-6-SS
Pneumatic connections
The 6000 series system requires only two pneumatic
connections to the protective enclosure, one for the
exhaust for the vent mounting and the other for the
protective gas supply for purging and pressurization.
The vent requires a single 1 1/2" conduit knockout (Ø2"
[50.8mm]) hole in the enclosure. A lock ring with gasket
for sealing are provided. The control unit for the 6000
series provides a compression tting with a lock ring and
washer connected to a 3/8" tube. All tubing and ttings
are 316L (UNS S31603) stainless steel. A single hole
into the enclosure as noted on the mounting template will
provide the installation for this tting.
For replacement of this tubing use only 3/8" tubing with
wall thickness of 0.035" (0.9 mm).
The 6000 series control unit with the manifold can be
top, bottom, right, or left-hand mounted on the enclosure.
However, the manifold connections may have to be
reversed as shown below.
Needle valve
3/8" tubing
EFC-6-SS
Plug
Protective
gas supply
Plug
Solenoid
valve, EEx io
2/2 way
Supply
to enclosure
Pressurization adjustment
To adjust, use a at head screw driver inserted into the
needle valve of the manifold as shown. Turn clockwise to
decrease the ow, counter-clockwise to increase the ow.
The maximum number of complete rotations allowed is
ve (5).
Diagram shown is without plumbing. See the
diagrams on the following page for plumbing
Note
installation.
Unit must be powered to get a pressure reading.
When delivered, the system is in its default mode
(fully automatic [FA]). It may be easier to adjust
Note
safe pressure in standard (STD) or
semiautomatic (SA) mode so that the system
does not automatically begin purging when
energized.
Supply
to enclosure
MAXIMUM of ve (5) turns
Counterclockwise
rotation
increases ow
6000 control unit
housing
Plug
Solenoid
valve, EEx io
2/2 way
Flathead screwdriver
Clockwise
rotation
decreases ow
Needle valve
in manifold
12
6000 Series Purge/Pressurization System
Mounting Instructions
Manifold assembly – left-hand or right-hand mount
Left-hand mount*
*Reverse ttings for
right-hand mount
Protective gas
supply inlet
Protective gas to
enclosure
I/O Manual
3/8" SS tube
(included)
3/8" ferrule tting
(included)
1/4 - 20
at head screws
(4 included)
3/8" SS tube
(included)
3/8" ferrule tting
(included)
Wiring entry
EFC-6-SS
(included)
EFC-6-SS nut
(included)
13
6000 Series Purge/Pressurization System
Note
Warning
EPV-6000 vent
Tools:
1 1/2" NPT knockout (Ø 2" [50.8mm] hole ) for
vent
Vent mounted on the outside of the enclosure
Pressurized enclosure
I/O Manual
Locking nut w/grounding screw
(included)
Seal gasket (included)
Ø 2" (50.8 mm)
6000 control unit
I.S. wire tag
(included)
Vent mounted on the inside of the enclosure
Pressurized enclosure
6000 control unit
Vent cap
(included)
EPV-6000
Vent cable (included)
Ø 2" (50.8 mm)
Seal gasket (included)
Locking nut w/o ground
(included)
Vent cap (included)
I.S. wire tag
(included)
Vent is not gravity sensitive and can be installed
in any orientation.
14
Hex screws 0.05"(1.3 mm) (3)
*Bulkhead tting for reference
pressure
EPV-6000
*Reference tube
Cord grip CG-8
(optional)
Vent cable (included)
*Reference tubing and hardware included with EPV-6000-SS models
Cable to the vent is I.S. wiring and must be
properly isolated from other wiring.
6000 Series Purge/Pressurization System
6000 Control unit with housing "WH"
Tools:
Appropriate sized drill bits or knockout holes
1 1/16" open end box wrench
Bolts: 1/4-20 (provided),
hole clearance = 0.27" (6.86 mm) diameter
EFC-6-SS (provided):
hole clearance = 0.61" (15.54 mm) diameter
I/O Manual
Seal washer (3 included)
Lock washer (3 included)
1/4-20 pan head bolts
(3 included)
Grounding lug
(included)
Mounting bracket
(included)
6000 control unit
1/4-20 pan head
w/lock washer screws
(4 included)
Ø 0.61" (15.54 mm) hole
Ø 0.27" ( 6.86 mm)
hole (3x)
1/4-20 nuts (3 included)
Locking nut
w/grounding screw
(included)
Seal gasket
(included)
Vent cap
(included)
EPV-6000
Vent cable
(included)
Enclosure
EFC-6-SS nut (included)
EFC-6-SS (included)
1. Drill holes using template. Check the scale if
printing an electronic version.
2. Assemble tubing and tting to control unit. Install
on the "Out" port of the correct side.
3. Bolt mounting plate to the enclosure. Type 4X
washers must be mounted inside the enclosure.
Tighten to 60 – 80 in-lb (16.38 – 18.08 Nm).
3/8" stainless steel tube, 2.5" (65 mm) long (included)
3/8" ferrule tting (included)
4. Put 2 of the mounting screws in the back of the
control unit to align with the key holes in the
mounting plate.
5. Hang the control unit onto the plate. Slide the unit
towards the enclosure so that the EFC-6-SS tting
is in the proper location.
6. Tighten the 2 bolts. Put the other two mounting
bolts in place and tighten.
7. Place the EFC-6-SS bolt in position and tighten.
15
6000 Series Purge/Pressurization System
(2.5")
Warning
Tightening unit cover plate
The screws on the unit cover plate must be
tightened in the order shown on the diagram to
the right. The cover plate to the main housing
has positive stops so that the gasket is not over
tightened. Torque screws at 12 in-lb (1.36 Nm).
When rotating the UIC, torque down the 4 screws
at 4 in-lb (0.46 Nm) using a crisscross pattern.
Note
I/O Manual
45
1 2
63
Left-hand mounting template
ø15.5 mm
(.60")
ø 7. 0 mm
(.25")
ø 7. 0 mm
(.25")
ø 7. 0 mm
(.25")
19.0 mm
(.75")
60.0 mm
2.35"
Right-hand mounting template
ø 15.5 mm
(.60")
ø 7. 0 mm
(.25")
189.5 mm
(7.45")
(7.45")
114.5 mm
(4.50")
57.0 mm
(2.25")
189.5 mm
(4.50")
114.5 mm
(2.25")
57.0 mm
2.35"
60.0 mm
(2.5")
ø 7. 0 mm
(.25")
ø 7. 0 mm
(.25")
19.0 mm
(.75")
16
6000 Series Purge/Pressurization System
Attention
Attention
6000 Series component kit
Identication of components
I/O Manual
Optional pneumatic manifold
User interface (Included)
Cannot be mounted in a
hazardous dust environment.
with solenoid (Included)
EPV-6000 vent: required for 6000 control unit / component kit
Atmospheric reference kit (6000-ACC-514482)
for mounting vent inside the enclosure
EPV-6000
The EPV-6000 vent is required.
The reference kit comes with the EPV-6000-SS
vent but must be ordered when mounting the
EPV-6000-AA vent inside the enclosure.
Control unit and explosion-proof/
ameproof enclosure (Included)
6000 series component kit accessories
6000-DPE-01-xxx (Not Included)
Dust-proof enclosure to house the
6000-ISB-01 and 6000-TEMP-01 devices
6000-ISB-01 (Not Included)
DIN-mounted I.S. termination board.
See data sheet for specications
6000-CBLA-ISB-xxxt (Not Included)
Cable assembly for connection from the
6000 EPCU to the 6000-ISB-01. See
data sheet for specic lengths.
17
6000 Series Purge/Pressurization System
Warning
Warning
Warning
Warning
Warning
Warning
Warning
Attention
Warning
Warning
I/O Manual
Electrical diagrams
General wiring notes for component kit design
For power connections to the control unit and relay
contacts:
1. All applicable local and national wiring codes
MUST be followed when wiring to the unit.
2. Protective earth wire to be 14 AWG (2.08 mm2).
Strip length of earth to mate with pigtail under
wire nut .437" to .5" (11.1mm to 12.7 mm).
3. If a single wire is used, the maximum wire gauge
to the pluggable terminal block is 14 AWG
(2.08mm2).
4. If jumpering from one terminal to another at
pluggable terminal block, the maximum wire
gauge is 16 AWG (1.31 mm2) for both wires.
5. Minimum wire gauge to the pluggable terminal
Attention
block is 24 AWG (0.20 mm2). (Based on
connector, not code. Follow all applicable codes.)
6. Strip length of wires terminating into the screw
terminals on the pluggable terminal block to be
0.2" to 0.27" (5 mm to 7 mm).
12. When removing the pluggable terminal block, it
is recommended that the electronics module be
supported by pressing down on top of the EPCU
to counteract the lifting force required to remove
the connector.
13. Wire should be copper only, rated 90 °C
minimum.
14. The minimum wire strand in a stranded wire
should have a diameter of 0.1 mm or greater.
15. The 6000-CC-3/4NPT plug is certied to be
used only with the 6000 control unit’s ¾” nipples
coming out of the housing. This plug is not
certied to be used on any other hazardous
location equipment.
16. Ensure that electrical, mechanical, and
pneumatic connections and requirements are
met to operate this system. Please refer to
this manual and applicable standards/codes,
including current editio9n of the EN/IEC 60079-
14. Electrical supply to the purge system shall be
supplied through a switch or circuit breaker and
suitably located and easily reached and must be
marked as the disconnect for the equipment.
7. Add extra wire length of 1.25" (31.75 mm) past
top of opening in explosion-proof/ameproof box
to pluggable terminal block. (Allows connector
to be moved out of the way when changing
electronics. Prevents repouring seals.)
8. Wires are to be neatly tucked back down past the
lid threads before lid is placed on unit. The wires
must not loop past the high point of the plastic
cover. The wire nut should be tucked in last (if
not, it may be difficult to access when changing
electronics).
9. If using a single conduit seal, the other conduit
on the 6000 control unit will need a cap for
the end of the conduit with appropriate hazloc
certications. (A standard 3/4" conduit cap will
not work.)
10. Conduit seals or the 6000-CC-3/4NPT plug must
be within 18" (457.2 mm) of internal explosionproof/ameproof box, or within 15.25" (387.3 mm)
from the end of the conduit supplied with the
6000 unit.
11. When wiring to the terminal plug, it is easier
to remove the plug, terminate the wires, then
reconnect the plug.
1 7. Power must be removed from the system when
the Ex d enclosure cover is off, unless the area is
known to be non-hazardous.
I.S. wiring notes
For wires going to the explosion-proof/ameproof
box on the I.S. side:
1. The wire strip length is to be between 0.2" and
Attention
0.27" (5 mm and 7 mm).
2. The wire's gauge depends on the number of
Attention
connections. Fewer wires allow for heavier
gauge and will still meet the conduit seal ll
requirement. See the applicable standards for ll
requirement.
3. The terminal blocks are rated for a wire size of
16 AWG (1.31 mm2 ) to 28 AWG (0.08 mm2 ).
4. If multiple wires need to land to a single terminal
(e.g., the RS-485 bus) these wires must be
either crimped to a single pin or grouped in an
external junction box with one wire going in to
the terminal.
5. The wires must have a minimum insulation
thickness of 0.01" (0.25 mm).
18
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