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Installation Manual

Purge and Pressurization System

5500 SERIES

PROCESS AUTOMATION

5500 Operating Instructions

Contents

1. Preface .......................................................................................................................... 4

2. Information on these operating instructions ............................................................. 4

3. Responsibility of the operator and/or installer .......................................................... 4

4. General information on the ignition protection class - pressurizing system ......... 5

4.1 Conditions of Safe Use .......................................................................................... 5

5. The 5500 Purge and Pressurization System .............................................................. 6

5.1 5500 Control Unit .................................................................................................. 6

5.1.1 Technical Speci cations ........................................................................................ 7

5.1.2 Electrical Connections ......................................................................................... 10

5.1.3 Dimensions ...........................................................................................................11

5.1.4 Hardware Kit ........................................................................................................ 14

5.1.5 Mounting of the Internal Control Unit ................................................................... 15

5.1.6 Mounting of the External Control Unit ................................................................. 16

5.2 EPV-5500 Vents .................................................................................................. 17

5.2.1 Technical Speci cation ........................................................................................ 17

5.2.2 Flow Rate Curves ................................................................................................ 18

5.2.3 Dimensions .......................................................................................................... 22

5.3 Manifold Valves ................................................................................................... 23

5.3.1 Technical Speci cations ...................................................................................... 24

5.3.2 Dimensions .......................................................................................................... 26

6. Installation and Operation of the 5500 System ....................................................... 28

6.1 For Gas Atmospheres ......................................................................................... 28

6.2 For Dust Atmospheres ......................................................................................... 28

7. Programming the 5500 control unit .......................................................................... 30

7.1 LED Indication ..................................................................................................... 30

7.1.1 Buttons ................................................................................................................ 31

7.2 The Purge Programming Settings ....................................................................... 34

7.2.1 Program 1 ............................................................................................................ 34

7.2.2 Program 2 ............................................................................................................ 35

7.2.3 Program 3 ............................................................................................................ 36

7.2.4 Program 4 ............................................................................................................ 36

7.2.5 Program 5 ............................................................................................................ 37

7.3 Purging Timer ...................................................................................................... 38

7.4 Minimum enclosure pressure ‘P1’ ........................................................................ 39

7.5 Alarm pressure ‘P2’ ............................................................................................. 39

7.6 Purging pressure ‘P3’........................................................................................... 39

7.7 Maximum internal pressure ‘P4’ .......................................................................... 40

7.8 4.8 Programming K2 ............................................................................................ 42

7.9 Shutdown timer for K1 ......................................................................................... 44

7.10 4.10 Number of PT100 temperature sensors used .............................................. 44

7.11 Temperature inputs PT1 and PT2 ....................................................................... 45

7.12 Bypass ................................................................................................................. 47

5500 Operating Instructions

7.13 Units .................................................................................................................... 48

7.14 TEMP ENABLED ................................................................................................. 48

7.15 CHANGE PASSWORD ....................................................................................... 49

8. Determining Purging Time ......................................................................................... 50

9. User Parameter Setting Sheet ................................................................................... 51

10. Type Codes .................................................................................................................52

11. Certi cation ................................................................................................................ 54

11.1 ATEX - UL/DEMKO 14ATEX1282X .................................................................... 54

11.1.1 External ............................................................................................................... 54

11.1.2 Internal ................................................................................................................54

11.2 IECEx - UL14.0019X............................................................................................ 54

11.2.1 External .............................................................................................................. 54

11.2.2 Internal ............................................................................................................... 54

11.3 cULus Class Divisions ......................................................................................... 54

11.4 Applied Standards ............................................................................................... 55

11.4.1 IECEx ................................................................................................................. 55

11.4.2 ATEX .................................................................................................................. 55

11.5 Certi cation Markings .......................................................................................... 56

11.5.1 Control Unit ........................................................................................................ 56

11.5.2 EPV-5500 Vent Unit ............................................................................................ 57

12. Troubleshooting ......................................................................................................... 57

5500 Operating Instructions

1. Preface

We are pleased that you have chosen a quality product from Pepperl+Fuchs.

These operating instructions will help you to meet the safety and protection requirements

for systems with explosion protection in equipment group II Zones 2 and 22, Class I

or II, Division 2 when installing, commissioning and using the 5500 controller and its

components.

This important safety and hazard information will help you to use the 5500 controller safely

and correctly.

We reserve the right to make technical changes.

Publisher with responsibility for content:

Pepperl+Fuchs

1600 Enterprise Pkwy

Twinsburg, Ohio 44087

2. Information on these operating instructions

Knowledge of the basic safety regulations and additional training and experience in the

area of explosion protection are essential for the safe handling and failure-free operation of

this 5500 controller.

These operating instructions contain important data and information to ensure the safe

use of the 5500 pressurizing system in hazardous areas and to meet the requirements of

Directive 94/9/EC.

These operating instructions, particularly the safety information, must be followed by all

personnel who work on the unit.

3. Responsibility of the operator and/or installer

The operator and/or installer undertake to ensure that only specialist, trained personnel

work on the 5500 pressurizing system and that they

• are familiar with the occupational safety and accident prevention regulations and have

been briefed regarding handling of the unit.

• have the additional knowledge of explosion protection that is required for work on

explosion protected components.

• are familiar with the relevant rules and regulations for the installation, operation and

maintenance of explosion-protected systems.

• have read the safety section and warnings in these operating instructions.

The operator and/or installer must also ensure that:

• The 2-wire RTDs for temperature sensors are suitable for the area classi cation,

Zone 2 or Zone 22, Class I Zone 2. Maximum length is 3 m.

• The bypass switch is suitable for the area classi cation, Zone 2 or 22, Class I Zone 2.

5500 Operating Instructions

4. General information on the ignition protection class -

pressurizing system

Pressurizing systems are one of the most versatile ignition protection classes. They are

based on the principle that in Zone 2/Class I Division 2 (gas) the gas mixture in the

ambient atmosphere, which may ignite under certain circumstances, is removed from

the housing by an initial purge process. After the purge phase, sufficient compressed

air is supplied to compensate for leaks in the housing and any installed equipment.

This permanent overpressure, achieved using compressed air, prevents any potentially

explosive atmosphere in the ambient air from entering the housing.

During the purge phase an internal pressure is achieved.

Any hotspots that may occur on individual components within the control cabinet are

monitored by temperature sensors (optional) and switched off safely if necessary. This

ensures that no unacceptably high surface temperatures can reach the exterior.

For applications in Zone 22/Class II Division 2 (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.

The purge and pressurizing system is particularly suitable for installed equipment that is

not approved for use in hazardous areas. It can then be used directly in the hazardous

area.

4.1 Conditions of Safe Use

The main control unit and the EPV vent are the only parts that have been evaluated for the

certi cations of the system.

For dust environments, the non-metallic membrane touchpad and display may pose

an 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 IEC60079-32-1 for further

information.

When mounting the 5500 purge control unit, the unit shall not have the membrane keypad

exposed to direct UV light sources and direct sunlight. Example methods of protection

include, but are not limited to, indoor applications away from UV sources and outdoor

locations under shading. As part of regular inspections, if damage to or deterioration

of the membrane keypad is detected the unit is to be taken out of service for repair or

replacement.

When the 5500 purge system is mounted to an enclosure, the complete installation

shall be evaluated to the appropriate standards and regulations applicable for the  nal

installation location.

The purge control unit has a temperature class (T6 or T4) that is dependent on ambient

temperature. This temperature shall be considered when mounted to an enclosure, or

inside of an enclosure.

All un-used entry points to the 5500 control unit shall be closed with a properly certi ed

IECEx, ATEX or cULus device suitable for the area of installation with the necessary

ingress protection.

5500 Operating Instructions

The bypass function shall only be enabled during setup or maintenance and only when the

area is known to be non-hazardous.

The device shall be installed in an area of not more than pollution degree 2 as de ned in

IEC/EN 60664-1

The device must be installed in accordance with the manufacturer’s installation drawing

number 116-B026. ‘

5. The 5500 Purge and Pressurization System

The 5500 series purge/pressurization system consists of the control unit with a user-

interface mounted in a 316 stainless steel enclosure and works in conjunction with the

EPV vents and pneumatic solenoid valves or manual valves to comprise the system.

The 5500 is a purge/pressurization controller and is not protected by pressurization.

5.1 5500 Control Unit

The 5500 control unit is a control device in ignition protection for Type Z & Ex pz purge

systems and is suitable for purge time and pressure monitoring in Class I or II, Division 2,

Zone 2 or 22.

It controls the volume of purge gas  owing into the explosion protected control cabinet

and maintains and monitors an overpressure relative to the ambient air when purging is

complete.

The 5500 control unit can be ordered for internal or external mount with different optional

cable glands/conduit  ttings for easy approved wiring methods.

The components of the 5500 series control unit:

• 5500 control unit

• Cable glands/conduit openings available

• Mounting bolts and sealing washers for attaching 5500 control unit to the enclosure

• Hardware for the reference pressure - bulkhead  tting, sealing washer, tubing

included

• Installation and instruction manual

5500 Operating Instructions

5.1.1 Technical Speci cations

Supply

Rated voltage 100 to 240 V AC, 48 ..62 Hz +-10%, single phase

20 to 30 V DC +- 10%

Overvoltage category 2

Power consumption 100 to 240 V AC – 2.3VA (without digital valve)

20 to 30 V DC – 2.5 W (without digital valve)

Fuse rating F2 AC: 2.0 A

DC: 3.15 A

Terminals L, N for AC

+- for DC

Input - Temperature

Number of sensors up to 2 RTDs per unit

Input type Temperature input

Sensor requirement PT100, 2-wire connection

Input accuracy +-2.5% of measurement value + PT100 error

Input - Bypass

Number of inputs 1

Input type Mechanical contact

Sensor requirement Passive contact (switch)

Outputs

Output I

Connection K1, terminals K1/NO, K1/NO

Output type Enclosure power, (1) SPST

Contact loading 6 A @ 250 V AC, 30V DC resistive load

Inrush current 6 A

Overvoltage Category 2

Output II

Connection K2, terminals K2 (NO, C, NC)

Output type Alarm, (1) DPST

Contact loading 3 A @ 250 V AC, resistive load, 3 A @ 30 V DC

Inrush current 3 A

Overvoltage Category 2

Output III

Connection Digital valve, terminals SV

Output type (1) SPST powered contacts from supply power

Fuse F1 0.08 A @ 250 V AC, 0.5 A @ 30 V DC

Inrush current 3 A

Fuse rating 80 mA / AC version, 500 mA / DC version

5500 Operating Instructions

Membrane Pad

LED indication K1: Green – Contact K1 is energized

K2: Amber – Contact K2 is energized

SV1/encl press.: Blue for safe pressure, Amber for valve on

Bypass: Amber when bypass is active

PT100 error: Red when fault in PT100 sensor

Pneumatic parameters

Protective gas supply Instrument grade air or inert gas

Regulated pressure

requirement

29 psig (2 bar)

Safe enclosure pressure for gas 0.3” H2O (0.7 mbar)

Safe enclosure pressure for

dust

0.65” H2O (1.6 mbar)

Ambient conditions

Ambient temperature -20 °C to +40 °C (-4 F to 104 F) at T6

-20 °C to +60 °C (-4 F to 140 F) at T4

Relative humidity 5 … 90%, noncondensing

Vibration resistance 5 … 100 Hz, 1 g, 12 m/s2, all axes

Impact resistance 30 g, 11 ms, all axes

Maximum altitude 1600 m

Mechanical speci cations

Protection degree Type 4X, IP 66

Mass 1.4 kg (3.1 lbs)

Dimensions 165 mm x 203 mm x 105 mm (6.5” x 8” x 4.2”)

Material

Housing 316 stainless steel

Pressure ports 316 stainless steel

Membrane pad Autotex F200XE

Connection Type Pneumatic

High press port 1/8” NPTF

Low press port 1/8” NPTF

RTD/Bypass Terminals

5500- bypass and temperature wiring notes

1.) The minimum wire strand in a stranded wire shall have a diameter of 0.1mm or grater

2.) Wire shall be copper only, rated 80°C minimum

3.) Minimum wire insulation thickness shall be 0.25mm for each conductor

4.) Terminal torque is 0.22Nm to 0.25Nm

5.) The wire strip length is 7mm

6.) There Shall be only one wire per terminal

Cable Glands (3) M12 x 1.5

Wire size: M12 diameter 3-6.5 mm / M20 diameter 10-14 mm

Material 316 stainless steel or nickel plated brass, o-ring EPDM

Conductor cross section min. 0.14 mm2

5500 Operating Instructions

Conductor cross section max. 1.5 mm2

Conductor cross section

stranded min.

0.14 mm2

Conductor cross section

stranded max.

1.5 mm2

Conductor cross section

stranded, with ferrule without

plastic sleeve min.

0.25 mm2

Conductor cross section

stranded, with ferrule without

plastic sleeve max.

1.5 mm2

Conductor cross section

stranded, with ferrule with

plastic sleeve min.

0.25 mm2

Conductor cross section

stranded, with ferrule with

plastic sleeve max.

0.5 mm2

Conductor cross section

AWG/kcmil min.

Conductor cross section

AWG/kcmil max.

5500 control power connection general wiring notes

1.) All applicable local and national wiring codes MUST be followed when wiring the system. Also see

IEC60079-14

2.) The power supply to this device shall have a separate disconnect. If placed in the hazardous area,

it shall be rated for the area it is being installed. Placing the disconnect into the purged enclosure is

not a “safe” are since power needs to be applied to the control unit before the purge cycle is complete.

3.) PE Ground wire to be same size as largest wire used to bring power into the enclosure. Terminate

using ring lug properly crimped at grounding stud in bottom of enclosure.

4.) All wire shall be copper only, rated 80°C minimum

5.) The minimum wire strand in a stranded wire shall have a diameter of 0.1mm or grater

6.) Wire strip length into  xed terminal block is 8mm

7.) Terminal torque is 0.5Nm to 0.6Nm

8.) There Shall be only one wire per terminal

9.) It is recommended to leave a bit of extra wire loop in housing.

Cable Gland ‘P_C’ (3) M20 x 1.5

Material 316 stainless steel or nickel plated brass, o-ring EPDM

Conduit ‘PSH’ (3) ½” NPTF

Material 316 stainless steel or nickel plated brass, o-ring EPDM

Conductor cross section min. 0.2 mm2

Conductor cross section max. 6 mm2

Conductor cross section

stranded min.

0.2 mm2

Conductor cross section

stranded max.

4 mm2

Conductor cross section

stranded, with ferrule without

plastic sleeve min.

0.25 mm2

5500 Operating Instructions

Conductor cross section

stranded, with ferrule without

plastic sleeve max.

2.5 mm2

Conductor cross section

stranded, with ferrule with

plastic sleeve min.

0.25 mm2

Conductor cross section

stranded, with ferrule with

plastic sleeve max.

4 mm2

Conductor cross section

AWG/kcmil min.

Conductor cross section

AWG/kcmil max.

5.1.2 Electrical Connections

External Mount

L(+)

SV1

Power

L(+)

SV1

N(-)

N(-) N(-)

Bypass

T1 T2

Internal Mount

Bypass T1 T2

L(+) C

SV1 K1

N(-) NO

L(+) L(+) K1

N(-)

N(-) N(-)

SV1

Power

Terminal Block Connections

L (+) N (-) SV1 K2 K1

5500 Operating Instructions

5.1.3 Dimensions

Dimensions - External Mounting

165

124

9017 90

16928

215

106

39.5

1 2

1 Low pressure port (atmospheric pressure)

2 High pressure port (enclosure pressure)

5500 Operating Instructions

For the external mount 5500 control unit, the display can be rotated in 90 degree rotation.

No screws are required. To rotate, remove cover and pop out the display. Position display

as desired and push back into the pin on the control unit. Do not rotate more than

+/- 90 degrees. When rotating display, be careful to not collapse the tubing by bending in

extreme angles.

5500 Operating Instructions

Dimensions - Internal Mounting

124

169

ø 6.4 x 3

58 16 90

60.7

106

39.5

110

168

215

1 Low pressure port (atmospheric pressure)

2 High pressure port (enclosure pressure)

5500 Operating Instructions

5.1.4 Hardware Kit

The hardware mounting kit is included. It comprises of

mounting hardware

pressure kit: Bulkhead  tting + O-ring, tubing + tubing inserts, straight connector, sintered

element for bulkhead  tting

5500 Operating Instructions

5.1.5 Mounting of the Internal Control Unit

Use the drawing below to mount the external control unit correctly.

Note

1) Internal studs may be added to enclosure for cleaner looking installation.

2) Pressure reference kit included. Required to measure ambient pressure

outside for the differential pressure sensor within the 5500 control unit. Tubing kit

connected to port labeled ‘Atmospheric Pressure’.

3) Key pad must be mounted in a vertical orientation only.

5500 Operating Instructions

5.1.6 Mounting of the External Control Unit

Use the drawing below to mount the external control unit correctly.

Note

1) RTDs - not included.

2) Pressure reference kit included. Required to measure ambient pressure

outside for the differential pressure sensor within the 5500 control unit. Tubing kit

connected to port labeled ‘Enclosure Pressure’.

3) Key pad must be mounted in a vertical orientation only.

5500 Operating Instructions

5.2 EPV-5500 Vents

The EPV-5500 vent works with the 5500 control unit and valve to provide a functional,

certi able purge and pressurized system for enclosures. As required by all pressurized

enclosure systems, the EPV-5500 vent functions as a pressure relief device and allows the

purge gas to exit the enclosure, yet provides a seal when the enclosure is pressurized and

operating. The vent also has a spark arrestor which is required for hazardous areas.

The components of the EPV-5500 vent:

• EPV-5500 vent with spark arrestor

• Sealing washer and nut for internal or external mounting

• Hex key for removing/attaching/rotating the vent cap

5.2.1 Technical Speci cation

Pneumatic parameters

Protective gas supply Instrument grade air or inert gas

Maximum pressure Depends on the integrity of the enclosure (strength)

Purge  ow rate See graphs

Flowrate for leakage

compensation

EPV-….-01:

approx. 21 scfh (593 l/hr) @ 0.25” wc (0.63 mbar)

approx. 58 scfh (1640 l/hr) @ 0.75” wc (1.9 mbar)

EPV-….-02:

approx. 14 scfh (395 l/hr) @ 0.25” wc (0.63 mbar)

approx. 34 scfh (961 l/hr) @ 0.75” wc (1.9 mbar)

EPV-….-03:

approx. 9.2 scfh (260 l/hr) @ 0.25” wc (0.63 mbar)

approx. 22 scfh (622 l/hr) @ 0.75” wc (1.9 mbar)

Breaking pressure EPV-….-01: 0.8” w.c. (2.0 mbar)

EPV-….-02: 1.4” w.c. (3.5 mbar)

EPV-….-03: 1.5” w.c. (3.8 mbar)

Ambient conditions

Ambient temperature -20 °C to +60 °C (-4 F to 140 F )

Storage temperature -20 °C to +60 °C (-4 F to 140 F)

Relative humidity 5 … 90 %, noncondensing

Vibration resistance 5 … 100 Hz, 1 g, 12 m/s2, all axes

Impact resistance 30 g, 11 ms, all axes

5500 Operating Instructions

Mechanical speci cations

Protection degree EPV-….-01/02: mounting only type 4x

EPV-….-03: Type 4X

Mass EPV-….-01/02/03: approx. 2.2 lb (1005 g)

Dimensions See dimension drawing

Material

Housing EPV-5500-AA...: 6061T6 anodized aluminum (body and cap)

EPV-5500-SS...: 6061T6 anodized aluminum (body), 316L

stainless steel (cap)

Spark arrestor 316L stainless steel

Installation Any orientation to enclosure

Not gravity dependent

Internal and external mounting possible

Mounting EPV-….-01:

mounting hole 1 ½” NPT knockout (50.8 mm)

hole sealing nut (provided)

EPV-….-02:

mounting hole 1 ½” NPT knockout (50.8 mm)

hole sealing nut (provided)

EPV-….-03:

mounting hole 1 ½” NPT knockout (50.8 mm)

hole sealing nut (provided)

5.2.2 Flow Rate Curves

The enclosure pressure vs.  ow rate curves below represent the EPV-5500....-01, 02, and

03 vents. This corresponds to the enclosure pressure and is independent on the valve

used, provided it can deliver the  ow rate required.

The curves below represent a completely sealed enclosure which may not be

representative of the customer enclosure. More  ow may be required to reach the

enclosure pressure in the enclosure due to leakages from gaskets, seals, windows,etc.

The EPV-5500-…-01 is usually used on large enclosures because it has a higher  ow rate

and lower back pressure within the enclosure than the other two versions. This can reduce

the time of purging while keeping the enclosure pressure low which is important for a large

enclosure. However, this vent will leak more pressure through its  ow control mechanism.

The EPV-5500-…-02 provides a better seal at the vent than the EPV-5500-…-01. The  ow

rate for purging will be less for the same enclosure pressure of the ‘-01’ version.

The EPV-5500-…03 gives the best seal for pressurization and should be selected for

a smaller enclosure, bottled air, or inert gas sources, and for increase conserving of

protective gas source. The  ow rate will is less than the ‘-01’ and ‘-02’ versions but provides

very low leakage.

There is no restriction of enclosure size for each vent, but leakage rate,  ow rate, and

enclosure pressure should be considered when applying these vents and the purge time

166 min.

5500 Operating Instructions

If you are using the EPV-5500…-01 you will use one of the following three curves to

determine your  ow rate. The size of your enclosure will determine which curve to use.

The  rst curve is for an enclosure up to 5 cubic feet, the second curve is for an enclosure

between 5-15 cubic feet and the third curve is for an enclosure 15 cubic feet and larger.

Once you determine which curve matches your application, you can determine your  ow

rate from the pressure reading.

1.9

1.8

1.7

1.6

1.5

1.4

1.2

1.1

1.3

56 7 8 910

CFM

P3, Inch/H2O

Vent Flow vs. Pressure (EPV-5500-...-01)

Enclosure up to 5 Cubic Feet

2.2

2.4

1.6

1.2

1.4

57 9111315

1.8

CFM

P3, Inch/H2O

Vent Flow vs. Pressure (EPV-5500-...-01)

Enclosure up to 5-15 Cubic Feet

5500 Operating Instructions

3.5

2.5

1.5

51015202530

CFM

P3, Inch/H2O

Vent Flow vs. Pressure (EPV-5500-...-01)

Enclosure 15 Cubic Feet and up

If you are using the EPV-5500…-02 you will use one of the following three curves to

determine your  ow rate. The size of your enclosure will determine what curve to use.

The  rst curve is for an enclosure up to 5 cubic feet, the second curve is for an enclosure

between 5-15 cubic feet and the third curve is for an enclosure 15 cubic feet and larger.

Once you determine which curve matches your application you can determine your  ow

rate from the pressure reading.

2.6

2.5

2.3

2.1

2.2

5678910

2.4

CFM

P3, Inch/H2O

Vent Flow vs. Pressure (EPV-5500-...-02)

Enclosure up to 5 Cubic Feet

5500 Operating Instructions

3.4

3.2

2.8

2.4

2.2

2.6

579111315

CFM

P3, Inch/H2O

Vent Flow vs. Pressure (EPV-5500-...-02)

Enclosure 5-15 Cubic Feet

5.5

3.5

2.5

51015202530

4.5

1.5

CFM

P3, Inch/H2O

Vent Flow vs. Pressure (EPV-5500-...-02)

Enclosure 15 Cubic Feet and up

5500 Operating Instructions

If you are using the EPV-5500…-03 then you will use the curve shown below.

257101215

SCFM

P3, Inch/H2O

Vent Flow vs. Pressure (EPV-5500-...-03)

5.2.3 Dimensions

73.2

98.5

49.5

57.2

127

57.2

23.4

3 4

11 ½ NPS thread

2 (3) hex key 0.050’’ (included)

3 Exhaust port

4 Inlet port

5500 Operating Instructions

5.3 Manifold Valves

The 5500-MAN…. manifold valve includes a solenoid valve for purging and a needle valve

for pressurization in one manifold design.

When the valve is energized, the solenoid valve is open and allows for a high  ow rate

of protective gas into the enclosure. The amount of  ow is controlled by the regulated

pressure supply of the protective gas to the manifold. When the valve is de-energized,

the  ow is through the internal needle valve and is adjustable by using the included hex

key (for CDUL valve) or slotted screw driver (EX01 and CD01 valve). The solenoid valve

is used for purging, leakage compensation, and temperature control with signals from the

5500 control unit that will have these set points set up by the user.

Mounting hardware includes 3/8” tube compression  ttings mounted on the manifold

for input and output  ow, 3/8” tube compression bulkhead  tting for getting  ow into

the enclosure and UL certi ed sealing washers with bolts to mount the manifold to the

enclosure.

Also included is 1 meter of 3/8” poly tubing with 3/8” poly tube stiffener inserts which

allows users to connect plastic tubing to compression  ttings without collapsing the tubing.

Stainless steel tubing can be used with existing  ttings.

For NEC, ATEX and IECEx applications, look at the model number key for the correct

model.

The 5500 valve system works with the 5500 control unit and EPV-5500 vents.

The 5500 system has UL certi cation for Class/Division installation.

The manifolds are optional and the user can use their own pneumatic system. These

valves are not part of the evaluation of the certi cation of the 5500 Control unit and EPV-

5500.. vent. They have their own certi cation.

1 Solenoid coil for purging

2 1/8’’ hex key adujstment for pressurization (hex key included)

5500 Operating Instructions

Tubing kit included Mounting hardware included

Manifold includes solenoid and manual needle valve

• 3/8” compression ferrule  ttings for inlet and outlet protective gas source

• 3/8” compression ferrule bulkhead  tting that attaches to enclosure – for protective

gas to inside enclosure

• 3/8” poly tubing, L=2meters

• Inserts for poly tubing to ferrule  tting connection. If stainless steel tubing is used,

inserts are not required.

• Hex key for pressurization valve included with 5500-MAN-CDUL version

Note

When ordering, please note the supply voltage of the 5500 control unit. Please

order manifold valves accordingly. Voltages are 24 V DC, 120 V AC, 220 V AC.

5500 MAN-CDUL manifold valves are only available with 60 Hz operation.

5.3.1 Technical Speci cations

General Speci cations

Operation mode For automatic purging

Series 5500

Hazardous environment Gas or dust

Supply

Rated power requirement 5500-MAN-CDUL

24 V DC 5.6 W

120 V AC 7.2 VA, 60 Hz

230 V AC 7.2 VA, 60 Hz

Rated power requirement 5500-MAN-CD01

24 V DC 4.6 W

120 V AC 6.8 VA, 60 Hz

230 V AC 6.8 VA, 60 Hz

Rated power requirement 5500-MAN-EX01

5500 Operating Instructions

24 V DC 2.6 W

120 V AC 3.1 VA, 50 ... 60 Hz

230 V AC 3.0 VA, 50 ... 60 Hz

Voltage tolerance ±10 %

Fuse rating on 5500 control unit

DC voltage 500 mA

AC voltage 80 mA

Pneumatic Parameters 5500-MAN-CDUL (only 60Hz for AC version)

Protective gas supply Instrument grade air or inert gas

Pressure requirement 20 psi (1.4 bar) to 120 psi (8.2 bar)

Purge  ow rate (solenoid valve) Cv ( ow coefficient) = 1.4

Pressurization  ow (needle valve) Cv ( ow coefficient) = 0.24

Pneumatic Parameters 5500-MAN-CD01

Protective gas supply Instrument grade air or inert gas

Pressure requirement 20 psi (1.4 bar) to 120 psi (8.2 bar)

Purge  ow rate (solenoid valve) Cv ( ow coefficient) = 1.4

Pressurization  ow (needle valve) Cv ( ow coefficient) = 0.24

Pneumatic Parameters 5500-MAN-EX01

Protective gas supply Instrument grade air or inert gas

Pressure requirement 25 psi (1.7 bar) to 115 psi (8.0 bar)

Purge  ow rate (solenoid valve) Cv ( ow coefficient) = 1.4

Pressurization  ow (needle valve) Cv ( ow coefficient) = 0.24

Mechanical Speci cation

Protection degree (connector) Type 7&9

Mass 2.8 lbs (1250 grams)

Dimensions see dimension drawing

Material

Housing Anodized aluminum

3/8” compression  ttings 316 stainless steel

Pressure ports 3/8” NPTF

Bulkhead  tting 316 stainless steel

Mounting bolts ¼-20, 316 stainless steel

Sealing washers

Pneumatic connection type Pneumatic

Input port 3/8” tube compression  tting

Output port 3/8” tube compression  tting

Electrical connection

5500-MAN-CD ½” NPTF thread connection w/ 24” (0.61 m)  ying leads

5500-MAN-EX01 3 meter cable

5500 Operating Instructions

Warning

During installation, ensure that no foreign bodies lie inside or can enter the valve.

The digital valve must be `EX’ rated for mounting in a hazardous area.

5.3.2 Dimensions

5500-MAN-CDUL

81.4

50.373.2

45.8

1/2"-14 NPT

ø6.5 (4x)

82.3

12.7

70.7

31.8

50.8

95.3

7.1

41.4

118

5500 Operating Instructions

5500-MAN-EX01

53.3

38.1 14.8

10.7

14.6

12.7 22.2

22.2

38.1

24.1

61.5

72.2 45.2

38.1 22.2

3/8" NPT (2x)

1/4-20UNC

8 (4x)

1/4-20UNC

9.5 (4x)

5500-MAN-CD01

53.3

38.1 14.8

10.9

12.7 22.2

22.2

3/8" NPT (2x)

14.6

24.1

61.5

38.1 22.2

50.5

76.2

56.6

1/4-20UNC

9.5 (4x)

1/4-20UNC

0.375 (4x)

5500 Operating Instructions

6. Installation and Operation of the 5500 System

The 5500 series control unit, vent, and manifold, can be universally mounted to the

customer enclosure. The control unit can be mounted within the enclosure or outside the

enclosure and can be to the left, right, top or bottom of the enclosure because the display

can be rotated for those positions. The EPV-5500 vent can be externally or internally

mounted with just the cap showing for exhaust of pressure.

The 5500 system is designed to allow the enclosure to be located in Zone 2 or 22, Class

I or II, Division 2 hazardous locations to operate safely by  rst making them safe internally

either by purging out the hazardous gas or manually cleaning out the dust hazard and

then pressurizing the enclosure so that the internal pressure prevents the hazardous

atmosphere from getting in. The 5500 control unit has a differential pressure sensor

within the unit that is pneumatically connected to the protective enclosure and will provide

pressure for evaluation of the enclosure pressure and the  ow through the enclosure

during purging.If pressure is lost then power can remain on. Take care that an indication

by an alarm or display has to notify operator of condition. If pressurized enclosure has

been opened or positive pressure has not been maintained, then purging for hazardous

gas or cleaning the enclosure out for dust atmospheres is required. The  ow measurement

is evaluated by using the pressure in the enclosure and the known measured  ow in the

graphs through one of the vents selected.

6.1 For Gas Atmospheres

If the protective enclosure has been opened or has been subjected to the hazardous

atmosphere, purging is required to  ush out the hazardous gas that may be inside the

protective enclosure. A protective gas is introduced into the enclosure so that the pressure

builds up and is exhausted through the enclosure. The measurement of  ow is achieved

by the 5500 control unit pressure sensor measuring enclosure pressure and using that

pressure for the  ow graphs of the vent selected and enclosure size. Each vent has an

enclosure pressure vs  ow curve for enclosure size that can be used to determine  ow

rate. This  ow rate is used to determine the purging time required to make the protective

enclosure safe.

NOTE: The  ow rate curves generated for each vent are measured on a completely sealed

enclosure with no leakage from the enclosure. In real applications, there will be some

leakage from the enclosure which will depend on the intergirity of the seals, door windows,

etc. As the enclosure pressure increases, the leakage may increase. Always plan on more

 ow from the protective gas to achieve enclosure pressure because of the leakage.

After purging, then the  ow into the enclosure can be reduced so that just a small  ow is

used for leakage compensation for pressurization of the enclosure.

6.2 For Dust Atmospheres

If the protective enclosure has been opened or has been subjected to the hazardous

atmosphere, then the enclosure must be manually cleaned of all combustible dust, closed

up, and pressurized before energizing power to the enclosure. For dust atmospheres a

higher pressure is required for pressurization and is re ected in the pressure range within

the 5500 programming setup.

Setting up the 5500 series system

1. Ensure that the system meets all electrical, mechanical, and pneumatic connections

before operation. Please refer to this manual and standards for explanation of

requirements.

2. Apply power to the 5500 series system.

3. Program the 5500 system using the User-interface on the front of the 5500 control

5500 Operating Instructions

unit. Please see ‘User-Interface Menu’ for instructions.

NOTE: This step is for intial set-up of the 55000 system. This procedure can be

skipped if the 5500 control unit has been programmed for the applicationwhere it will

be used.

4. Make sure the control valve is closed before applying pressure to the system.

5. Use a regulated pressure source to the valve. Set the regulated pressure to 30 psig

(2 bar) or lower. Do not exceed the maximum pressure for the valve and tubing being

used.

6. Select the user-interface display so that the enclosure pressure is showing. The

pressure should be below 0.1” wc (0.25 mbar). Slowly open the needle valve on the

control valve system so that the pressure is above P1. If one of the 5500-MAN… is

being used, the solenoid valve will energize for purging above P1.

7. Check the EPV vent to make sure air is coming out of it. If not, check for any

obstructions or improper installation

8. System is ready to operate.

Operating the 5500 Series System

1. Follow ‘Set-up procedures of the 5500 series system’ listed in this manual.

2. For Flush Program 1 through 4 (hazardous gas environments), purging is required.

a. Seal the pressurized enclosure.

b. Set enclosure pressure to a value above P1.

c. When using the 5500-MAN… the manifold valve is connected to SV1 output,

when enclosure pressure is greater than P1, SV1 energized the solenoid valve for

purging. For manual or other valves, initiate the purging valve.

d. Adjust the regulated pressure so that enclosure pressure is above P3 (Purging

starts).

e. For the 5500-MAN manifold, after purging, the needle valve can be re-adjusted

to users desire, but must be above P1 value.

3. For Flush Program 5 (hazardous dust environment), purging is not required.

a. The inside of the enclosure must be cleaned of all combustible dust.

b. The enclosure is sealed.

c. Adjust the enclosure pressure above P1. The minimum for P1 is 1.0” wc (2.5

mbar) for hazardous dust environments.

4. If enclosure pressure is above P1, power to the enclosure will be energized.

5. If enclosure pressure drops below P1, then power must be disconnected. If power is

to remain on, then an alarm must be initiated and located near an operator.

6. To energize the pressurized enclosure again, repeat above sequence.

Warning

All 5500 pressurization systems require EPV-5500... vents for pressure relief.

5500 Operating Instructions

7. Programming the 5500 control unit

Pencl > P1

Pencl < P4

Purge

Progress

Start

Timer

Purge

Complete

Safe Mode

Bypass ON

‘E’

only in menu

T-K1 < T3

t=0

To programm the 5500 control unit, use the membrane pad on the front of the unit.

Program settings are saved on non-volitale memory within the CPU, and settings are

unaffected by power down and reset function.

Default values are stored and can be restored.

7.1 LED Indication

LED Color Description

K1 Green Contact K1 is energized

K2 Amber Contact K2 is energized

P/SV Blue/amber Blue: safe pressure

Amber: valve on

BYPASS Amber Bypass is ON

PT100 Red PT100 is in fault mode

5500 Operating Instructions

7.1.1 Buttons

Button Description

To advance up

To advance down

The set button has three functions:

1. Hold for 5 seconds to enter the purge settings

2. Press to advance into the purge setting parameters you have selected

3. Press to enter the purge setting you have selected

: The reset button has two funtions:

1. When in the purge settings mode, the RESET exits out of the parameter menu

2. When in operation mode, when pressed for 5 seconds, will act like a power

interrupt. Any settings programmed will not be lost. The action of the reset happens

when the reset button is pressed a second time after the menu shows ‘RESET ?’ This

is NOT a restore to default settings.

The following table shows all the possible parameters and their default values:

Display Description Default values

PASSWORD / SET Enter password to

access Purge Settings

0000

PURGE / PROGRAM Up to 5 programs to

select

PURGE / TIME Time required for

purging

00:30

ENCLOSUR / PRESS P1 Enclosure pressure P1 0.3” (gas), 0.7” (dust)

0.75 mbar (gas), 1.75 mbar (dust)

ENCLOSUR / PRESS P2 Enclosure pressure P2 0.8” (2 mbar)

ENCLOSUR / PRESS P3 Enclosure pressure P3 3.0” (7.5 mbar)

ENCLOSUR / PRESS P4 Enclosure pressure P4 6.0” (15 mbar)

LEAKAGE / HYST Compensates for

excess leakages

0.5’’ H2O (1.25 mbar)

PROGRAM / K2 Various parameters to

activate K2 contacts

SHUT-OFF / DELAY Delay in turning K1 off

when P<P1

0 sec

NUMBER / OF PT100 Number of PT100s

being used

TEMP PT1 /SV1 SV1 turns on above

PT1

35 °C

TEMP PT2 / SV1 SV1 turns on above

PT2

35 °C

5500 Operating Instructions

Display Description Default values

TEMP PT1 / K2 K2 turns on above PT1 45 °C

TEMP PT2 / K2 K2 turns on above PT2 45 °C

TEMP PT1 / K1 K1 turns on above PT1 50 °C

TEMP PT2 / K1 K1 turns on above PT2 50 °C

BYPASS / N Y E N for no, Y for yes, E for

external bypass

UNITS / M I M for metric units, I for

imperial units

TEMP / ENABLED Temperature

monitoring on or off

CHANGE / PASSWORD Change existing

password

Restoring Default Settings

To restore default settings, proceed as follows:

• Hold the UP and DOWN buttons at the same time while power up the control unit.

Once power to the control unit is on, the default settings will be restored.

NOTE: If temperature sensor(s) are connected to the unit, then an error will occur for the

PT100 because the function is disabled as a default.

Adjusting the Contrast

To adjust the contrast, proceed as follows:

• Hold the UP and DOWN buttons for 3 seconds at the same time. The menu will show

the contrast level.

• Adjust the contrast by using the UP and DOWN buttons: use UP button to increase

the contrast. Use DOWN button to decrease the contrast.

5500 Operating Instructions

LCD Backlight

LCD backlight is always on. It cannot be turned off or adjusted.

PASSWORD

CHANGE

PASSWORD

TEMP

DISABLED

UNITS

M I

BYPASS

TEMP PT2

SV1

TEMP PT1

TEMP PT2

TEMP PT1

TEMP PT2

TEMP PT1

SV1

NUMBER

OF PT100

SHUT-OFF

DELAY

PROGRAM

ENCLOSUR

PRESS P1

ENCLOSUR

PRESS P2

ENCLOSUR

PRESS P3

ENCLOSUR

PRESS P4

LEAKAGE

HYST

Purge

Program

PASSWORD

SET

5 sec.

Power On

Operation

mode

At any time during

purge settings

SET

5 sec.

5500 Operating Instructions

7.2 The Purge Programming Settings

There are 5 program selections for the operation of the system. Programs 1 thru 4 are for

hazardous gas environments and require purging. The 5th program is for hazardous dust

environments that require cleaning the enclosure then pressurizing.

PROGRAM

SET

PROGRAM

PURGE

PROGRAM

7.2.1 Program 1

Program 1 is used in hazardous gas atmospheres.

Pre-Purge

• The purge valve (SV) is immediately energized regardless of enclosure pressure

• If enclosure pressure goes above P4 during purging, SV will shut off but will energize

when below P4. Oscillation of SV may be noticed.

• Setting the pressurization valve on the manifold will have to be done after purging or

the power to SV will have to be interrupted to set this pressure. The solenoid valve on

the manifold is immediately energized before this pressure can be set.

• Purge timer begins counting down when enclosure pressure is greater than P3 and

must remain greater than P3 to  nish a successful purging. If the pressure drops

below P3 at anytime, or for any length of time, the purge timer is reset and will not

begin counting down until pressure is greater than P3.

5500 Operating Instructions

Operation mode

• After the purge timer counts down, the SV will shut off and K1 is energized.

• If enclosure pressure drops below P2, the SV is energized and will stay energized

for the value of HYST (%, leakage compensation). If HYST is set to 0, then leakage

compensation is turned off.

• If enclosure pressure drops below P1, K1 remains on and an alarm shall be

implemented. K2 can be set to P- or Alarm to indicate below safe or operating

pressure.

• If enclosure pressure goes above P4, K1 remains. If K2 is setup as Alarm, then K2

will energize.

Note: If K1 is used to energize power to the enclosure, then if during operation of the

system if enclosure pressure is below P1, K1 will remain energized. An alarm is required

and must be located so an operator will be noti ed of the alarm.

7.2.2 Program 2

Program 2 is used in hazardous gas atmospheres.

Pre-Purge

• The purge valve (SV) is energized when enclosure pressure is greater than P1.

• If enclosure pressure goes above P4 during purging, the SV will shut off but will

energize when below P4. Oscillation of SV may be noticed.

• Setting the pressurization valve on the manifold will have to be done after purging or

the power to SV will have to be interrupted to set this pressure. The solenoid valve

is energized once enclosure pressure is above P1. Adjusting the pressurization valve

before the solenoid valve is energized will allow the enclosure pressure to be above

P1 when purging is completed. Fine adjustment of P1 can be achieved after purging

when solenoid valve is off.

• Purge timer begins counting down when enclosure pressure is greater than P3 and

must remain greater than P3 to  nish a successful purging. IIf the pressure drops

below P3 at anytime, or for any length of time during purging, the purge timer is reset

and will not begin counting down until pressure is greater than P3.

Operation Mode

• After the purge timer counts down, the SV will shut off and K1 is energized.

• If enclosure pressure drops below P2, the SV is energized and will stay energized

for the value of HYST (%, leakage compensation). If HYST is set to 0, then leakage

compensation is turned off.

• If enclosure pressure drops below P1, K1 remains on and an alarm shall be

implemented. K2 can be set to P- or Alarm to indicate below safe or operating

pressure.

• If enclosure pressure goes above P4, K1 remains. If K2 is setup as Alarm, then K2

will energize.

NOTE: If enclosure pressure is below P1 when K1 is used to provide power to the

enclosure during operation, K1 will remain energized. An alarm is required and must be

located so an operator will be noti ed of the alarm.

5500 Operating Instructions

7.2.3 Program 3

Program 3 is used in hazardous gas atmospheres.

Pre-Purge

• The purge valve (SV) is energized when enclosure pressure is greater than P1.

• If enclosure pressure goes above P4 during purging, the SV will shut off but will

energize when below P4. Oscillation of SV may be noticed.

• Setting the pressurization valve on the manifold will have to be done after purging or

the power to SV will have to be interrupted to set this pressure. The solenoid valve

on the is energized once enclosure pressure is above P1. Adjusting the pressurization

valve before the solenoid valve is energized will allow the enclosure pressure to be

above P1 when purging is completed. Fine adjustment of P1 can be achieved after

purging when solenoid valve is off.

Operation Mode

• After the purge timer counts down, the SV will shut off and K1 is energized.

• If enclosure pressure drops below P2, the SV is energized and will stay energized

for the value of HYST (%, leakage compensation). If HYST is set to 0, then leakage

compensation is turned off.

• If enclosure pressure drops below P1, K1 turns off immediately or after Shutdown

delay timer times out. K1 remains off until enclosure goes through a successful

purging

• If enclosure pressure goes above P4, K1 remains. If K2 is setup as Alarm, then K2

will energize.

7.2.4 Program 4

Program 4 is used in hazardous gas atmospheres.

Pre-Purge

• The purge valve (SV) is immediately energized regardless of enclosure pressure.

• If enclosure pressure goes above P4 during purging, the SV will shut off but will

energize when below P4. Oscillation of SV may be noticed.

• Setting the pressurization valve on the manifold will have to be done after purging or

the power to SV will have to be interrupted to set this pressure. The solenoid valve on

the manifold is immediately energized before this pressure can be set.

• Purge timer begins counting down when enclosure pressure is greater than P3 and

has to remain greater than P3 to  nish a successful purging. If the pressure drops

below P3 at anytime, or for any length of time during purging, the purge timer is reset

and will not begin counting down until pressure is greater than P3.

NOTE: If enclosure pressure is below P1 when K1 is used to provide power to the

enclosure during operation, K1 will remain energized. An alarm is required and must be

located so an operator will be noti ed of the alarm.

Operation Mode

• After the purge timer counts down, SV will shut off and K1 is energized.

• If enclosure pressure drops below P3, the SV is energized and will stay energized

for the value of HYST (%, leakage compensation). If HYST is set to 0, then leakage

compensation is turned off. However, Program 4 is usually used when a continuous

purging through the enclosure is required during operation mode.

5500 Operating Instructions

• If enclosure pressure drops below P1, K1 remains on and an alarm will sound. K2

can be set to P- or Alarm to indicate below safe or operating pressure.

• If enclosure pressure goes above P4, K1 remains. If K2 is setup as Alarm, then K2

will energize.

7.2.5 Program 5

Program 5 is used in combustible dust atmospheres.

Pre-Purge

• The purge valve (SV) does not come on during this operation. In a dust atmosphere

purging is not required, but the enclosure has to be cleaned out of all combustible

dust and then pressurized.

• Menu screen will show ‘CLEAN ENCLOSURE’. Enclosure should be cleaned and then

pressurized before pressing SET button.

• The enclosure pressure has to be above P1 (minimum 0.65” wc / 1.6 mbar for dust

atmospheres) in order for the SET button to work.

Operation mode

• After cleaning out and pressurizing the enclosure, the menu will show ‘CLEAN

ENCLOSURE’. To see the enclosure pressure press Down or Up button. Pressing the

SET button will energize K1.

• If enclosure pressure drops below P2, the SV is energized and will stay energized

for the value of HYST (%, leakage compensation). If HYST is set to 0, then leakage

compensation is turned off. Compensation for leakages is allowed in a dust

atmosphere because the enclosure is safe at this point.

• If enclosure pressure drops below P1, K1 remains on and an alarm will sound. K2

can be set to P- or Alarm to indicate below safe or operating pressure.

• If enclosure pressure goes above P4, K1 remains. If K2 is setup as Alarm, then K2

will energize.

Note: If enclosure pressure is below P1 when K1 is used to provide power to the enclosure

during operation, K1 will remain energized. An alarm is required and must be located so an

operator will be noti ed of the alarm.

5500 Operating Instructions

Sequence of events for purging and operation of the 5500 system for all 5 programs

Program12345

purging K1 SV K1 SV K1 SV K1 SV K1 SV

P<P1 off on off off off off off on off off

P1<P<P2 off on off on off on off on off off

P2<P<P3 off on off on off on off on off off

P3<P<P4 off on off on off on off on off off

P>P4 off off off off off off off off off off

Clean

activates

above P1

after purging

P<P1 on on on on off off on off on off

P1<P<P2 on on on on on on on on on on

P2<P<P3 on off on off on off on on on off

P3<P<P4 on off on off on off on off on off

P>P4 on off on off on off on off on off

Note: Shutdown timer, temperature, and bypass will affect status of K1 and SV. Please see

explanation of each to determine effects on K1 and SV.

7.3 Purging Timer

MIN:SEC

000:00

To program the purging timer, proceed as follows:

• Calculate the purging time using the formulas and examples in chapter 8 „Determing

Purging Time“.

• Enter the purging time using the UP and DOWN buttons and SET.

• To change purging time by one second increments, press the UP or DOWN button

once.

• To change purging time faster, hold down the button continuously. Purging time will

advance faster, the longer you hold the button down (in 5 seconds, 1 min, 5 min

steps).

Maximum purge time is 166:39.

5500 Operating Instructions

MIN:SEC

XX:XX

SET

PURGING

TIME

7.4 Minimum enclosure pressure ‘P1’

In accordance with the applicable standards and tolerances on the 5500 pressure sensor,

the minimum operating pressures are as follows:

• Gas environments: 0.25” wc / 0.7 mbar

• Dust environments: 0.65” wc / 1.6 mbar

When enclosure pressure drops below P1 during operation mode, the power has to be

interrupted. If not, an alarm has to be generated to address the problem.

7.5 Alarm pressure ‘P2’

If enclosure pressure drops below P2 during operation mode, the solenoid valve will

energize until pressure goes above P2+HYST. Therefore, leakage compensation has to be

implemented.

If leakage compensation is not used, the P2 can sound an alarm to indicate that pressure

is droping.

P2 can be adjusted to above P1 and Below P3 values.

7.6 Purging pressure ‘P3’

The purging timer starts when enclosure pressure is above P3. If the pressure is above

P3, purging will start and  nish uninterrupted. If the enclosure pressure is below P3, the

purging timer will not start. If the pressure drops below P3 during purging, the purging timer

will immediately reset to its beginning time and will not start timing down until pressure is

above P3. P3 can be adjusted to above P2 and below P4 values.

5500 Operating Instructions

7.7 Maximum internal pressure ‘P4’

If enclosure pressure is above P4, then the display will read ‘MAX’ to indicate maximum

pressure has been achieved. Regardless of the action of the solenoid valve (purging,

leakage compensation, temperature) the solenoid valve will de-energize and will not come

on until enclosure pressure goes below P4. This action may cause the solenoid valve to

osicallate on and off and should be noted as a maximum pressure problem if this happens.

If K1 was on before P4 was reached, it will remain on after enclosure pressure is above

P4. P4 is adjusted above P3. Maximum setting is 9.99” wc / 25 mbar.

P1-P4 MBAR

XX.X

SET

ENCLOSUR

PRESS P1-P4

Leakage Compensation hysteresis ‘HYST’

In operation mode there may be excess leakage of pressure from the enclosure because

a seal or gasket has caused a drop in regulated line pressure (protective gas sorce).

Leakage compensation option allows for the SV to turn on in order to compensate for

these unintentional leakages. Depending on the purge program used, the SV will energize

when below P2 and will de-energize when it is above P2 + hysteresis.

If leakage compensation is not required, set HYST to ‘0’.

Values for hysteresis HYST are as following:

Inches of wc mbar

0.2 0.5

0.4 1.0

0.6 1.5

0.8 2.0

1.0 2.5

1.2 3.0

5500 Operating Instructions

1.4 3.5

1.6 4.0

1.8 4.5

2.0 5.0

Example

units are in mbar, hysteresis = 1.5, then SV is on at P2 and turns off at P2 + 1.5

The HYST unit of measurement will be the units being used.

If HYST = 1.5 then this is 1.5 mbar.

HYST

0.5

SET

LEAKAGE

HYST

Pressure

SV1

off

SV1

off

Hysteresis

AUTOMATIC LEAKAGE COMPENSATION

5500 Operating Instructions

7.8 4.8 Programming K2

The K2 contact output can be programmed for various settings that are chosen by the

user.

For Type Z and Ex pz systems, power to the pressurized enclosure can remain on if

pressure goes below the minimum allowed pressure but an audible and/or visual alarm

must be generated to notify the operator of a problem.

K2 can be used to generate the signal for the alarm.

Below are the following users selectable settings for K2

K1 Switches simultaneously with K1

P1+ Switches on when pressure exceeds P1

P1- Switches off when pressure falls below P1

P2+ Switches on when pressure exceeds P2

P2- Switches off when pressure falls below P2

P3+ Switches on when pressure exceeds P3

P3- Switches off when pressure falls below P3

P4+ Switches on when pressure exceeds P4

P4- Switches off when pressure falls below P4

FT Switches on when purge timer starts and shuts off at the end of purging

Temp AL Switches on K2

Bypass Switches on when the bypass function is activated

All Alarms Comes on when P1-, P4, Bypass, Temp AL

5500 Operating Instructions

P1+

SET SET

PROGRAM

P1-

P2+

P2-

P3+

P3-

P4+

P4-

PURGE

TIMER

TEMP

MAX

BYPASS

ALARMS

5500 Operating Instructions

7.9 Shutdown timer for K1

The shutdown timer is used in the operation mode and allows K1 to remain on for the

duration of this setting when enclosure pressure drops below the minimum setting of P1.

If the pressure goes above P1 during the countdown, the timer is reset. If the pressure

remains below P1 for the duration of the countdown, K1 will shut off.

Shutdown timer is effective only for Program 3 where K1 will de-energize when enclosure

pressure is below P1. The other programs allow power to the enclosure to remain on when

pressure is below P1 but an alarm must be generated to the operator.

Default value is 0 seconds. Range is 0 to 60 seconds.

DELAY

SET

SHUT-OFF

DELAY

7.10 4.10 Number of PT100 temperature sensors used

The 5500 control unit allows up to two 2-wire PT100s to be connected to the unit for

monitoring and controlling temperatures in the pressurized enclosure.

Each sensor can be located up to three meters from the control unit input. Using two

PT100s allows various placements within the enclosure to capture the variation of heat in

locations where electronic devices are located.

In order for the temperature inputs to work, Number of PT100s and Temperature enabled

must be activated. A wrong number of PT100s selected will give a error on the PT100

input, the PT100 LED will light up, and TEMP AL will be activated if selected for K2.

5500 Operating Instructions

PT100

SET

PT100

NUMBER

OF PT100

7.11 Temperature inputs PT1 and PT2

To activate this function:

enter the number of PT100s into the menu with the correct number of sensors connected

to the input.

• Select ENABLED in the TEMP ENABLED selection menu.

• All values are entered in degrees C. F is not available.

TEMP PT1 SV1, TEMP PT2 SV1

When the temperature on the PT100(s) is greater than the user set value, the SV1 contact

is energized. The manifold will be energized and the purge  ow will begin to  ush out the

cabinet to allow for cooling. The SV1 contact remains energized until temperature falls to

3 °C below this set temperature.

TEMP PT1 K2, TEMP PT1 K2

If the temperature within the enclosure continues to increase because the SV1 valve is

not efficient enough to cool, this second trip point can be used to activate K2 when K2 is

programmed for TEMP AL (temperature alarm). This can be used to control a secondary

cooling device or as a warning. K2 (TEMP ALARM) contact remains energized until

temperature falls to 3 °C below this set temperature.

TEMP PT1 K1, TEMP PT2 K1

If the temperature rises above this set point. K1 will de-energize and the LCD will display

OVER TMP, indicating over temperature. A RESET must be done to get the system to

operate again. The RESET will work only when the temperature goes below the user-set

temperature value. Depending on the program used, the RESET will cause the system to

5500 Operating Instructions

re-purge or CLEAN out the enclosure.

Note: If TEMP ENABEL is off, the number of PT100s is ‘0’, and a PT100 is connected

to one or both of the inputs, the PT100 LED will turn on. This is to indicate that there

is something not correct with the temperature setup of this system. The system will still

operate, but the LED will remain illuminated until the issue is corrected.

SV1 TEMP

XXXC

SET

TEMP Pt1...2

SV1

K2 TEMP

XXXC

SET

TEMP Pt1...2

K1 TEMP

XXXC

SET

TEMP Pt1...2

PT K1

PT K2

PT SV1

SV1

Temp action

off

*K2 on

SV on

off

* Note: K2 is mapped to Any Alarm or Temp Max. For above action to take place.

time

AUTOMATIC TEMPERATURE CONTROL

5500 Operating Instructions

7.12 Bypass

The Bypass mode allows power to the enclosure to be energized when the enclosure

pressure is below the minimum pressure P1. This can be useful in commissioning the

enclosure or working on the enclosure when it is open.

The Bypass option has three modes of operation to choose from.

Mode Description

N No Bypass is not enabled

Y Yes Bypass is implemented using the purge settings menu. By

selecting ‘Y’, the system will go into bypass and will turn on

K1. In the ‘Y’ mode, K1 can be energized before the system

goes through a successful purge. This mode can be useful in

commissioning the enclosure during start up. This mode is on

when it is selected and the menu stays in the purge settings

mode. If the user exits from the purge settings mode, then

the Y’ is automatically changed to ‘N’ and K1 will de-energize.

Bypass LED is on

E External The bypass is implemented using the HW input on the control

unit and is only operational when the enclosure is safe and

pressure is above P1. The ‘E’ mode will not energize K1 if the

enclosure is not safe. Bypass LED is on.

Warning

Bypass should only be implemented when the area surrounding the pressurized

enclosure is known to be safe – non hazardous!

BYPASS

N Y E

SET

BYPASS

5500 Operating Instructions

7.13 Units

The units can be changed from ‘M’ metric to ‘I’ imperial. This affects the pressure readings

and M will read in mbar and I will read in inches of water column. The temperature settings

will always be in C.

BYPASS

M I

SET

UNITS

7.14 TEMP ENABLED

TEMP ENABLED allows for temperature alarm/control when ON. TEMP ENABLED and

NUMBER OF PT100 has to be selected for temperature alarm/control to be effective. If

one is selected and another is not, a TP100 LED fault LED will be on.

TEMP OFF

Y N

SET

TEMP

DISABLED

5500 Operating Instructions

7.15 CHANGE PASSWORD

To change the existing password, use the UP and DOWN buttons for each digit.

• Enter 4 digits.

• To cancel without saving a new password, press RESET. The existing password will

still be valid.

Note: There is no con rmation of key strokes when changing the password, so please note

what the password is when changing.

PASSWOR D

X _ _ _

SET

PASSWOR D

_ X _ _

SET

PASSWOR D

_ _ X _

SET

PASSWOR D

_ _ _ X

SET

CHANGE

PASSWOR D

5500 Operating Instructions

8. Determining Purging Time

To make sure the enclosure is safe from the hazardous atmosphere, the inside of the

enclosure has to be free of the hazardous atmosphere and pressurized before the

equipment inside can be powered.

The  rst step in this process is to get rid of the hazardous atmosphere within the

enclosure.

For a dust atmosphere, the inside of the enclosure must be cleaned out and then

pressurized. Because most vents on a pressurized enclosure have a spark arrestor,

purging is not the method used. The dust must be cleaned out manually or with some type

of vacuum that is rated for the area or in an area that is not rated when cleaning.

For gas atmospheres, the enclosure is purged by introducing a  ow of protective gas

(compressed air, or Inert gas) through the enclosure to make it safe. Depending on the

standards being used to evaluate the effectiveness of the purging operation, the volume

of protective gas through the enclosure will determine the amount of time for purging.

The exchange of protective gas is related to the volume of the enclosure, the number of

exchanges, and the  ow rate through the enclosure.

Below is an equation for determining the purging time:

(number of volume exchange) X (volume of the enclosure) /  ow rate = purging time

The number of volume exchange will depend on the item being purged and the standard it

is being evaluated:

# of exchanged NEC Zone

4 X n/a

5 n/a X

10 (motors) X X

Example:

P3 = 2.6” H2O 6.5 mbar

Vent = EPV-5500-...-02

graph for P3: EPV-5500-...-02, 5-15 ft3,

see section 5.2.2

Enclosure volume = 10 ft3 282 liters

Flow Rate from P3 (see graph) 11.3 scfm 320 liters/min

NEC (class/division) 4 volume exch. 4 volume exch.

Zone (ATEX, IECEX) 5 volume exch. 5 volume exch.

NEC: 4 x 10 ft3 / 11.3 scfm = 3.6 min 4 x 282 liters / 320 l/min = 3.6 min

Zone: 5 x 10 ft3 / 11.3 scfm = 4.5 min 5 x 282 liters / 320 l/min = 4.5 min

Motors: 10 x 10 ft3 / 11.3 scfm = 8.9 min 10 x 282 liters / 320 l/min = 8.9 min

5500 Operating Instructions

The 5500 control unit has a purge timer in the EPC_U and is user selectable through the

menu.

The purge timer is activated when the enclosure pressure goes above P3. The pressure

must always be above P3 for the timer to continue until it counts down to 000:00. If the

enclosure pressure drops below P3 for any amount of time, then the timer is reset to its

starting value and will not start counting down until pressure is above P3.

The  ow rate for P3 value can be found on the graphs for Vent  ow in section 5.2.2 „Flow

Rate Curves“. The  ow rate for P3 depends on the EPV-5500 vent that is used.

Please note that the more the enclosure leaks pressure, the more  ow rate into the

enclosure to achieve the P3 threshold.

Maxmimum purge time allowed on the 5500 system is 166:39 ( min:sec)

9. User Parameter Setting Sheet

Display Description User Settings

PASSWORD / SET Password

PURGE / PROGRAM Program 1-5

PURGE / TIME Time required for purging

ENCLOSUR / PRESS P1 Shutdown pressure P1

ENCLOSUR / PRESS P2 Alarm/signal pressure P2

ENCLOSUR / PRESS P3 Purge pressure P3

ENCLOSUR / PRESS P4 Maximum pressure P4

LEAKAGE / HYST Leakage comp and hysteresis

PROGRAM / K2 K2 program

SHUT-OFF / DELAY Shutdown timer for K1

NUMBER / OF PT100 Number of PT100’s being used

TEMP PT1 /SV1 SV1 turns on above PT1

TEMP PT2 / SV1 SV1 turns on above PT2

TEMP PT1 / K2 K2 turns on above PT1

TEMP PT2 / K2 K2 turns on above PT2

TEMP PT1 / K1 K1 turns on above PT1

TEMP PT2 / K1 K1 turns on above PT2

BYPASS / N Y E Bypass

UNITS / M I M for metric units, I for imperial units

TEMP / ENABLED Temperature monitoring on or off

5500 Operating Instructions

10. Type Codes

5500-SS- I -VAC-PSC-LSC

Wiring entrance for low voltage

connection

LSC (3) M12 Stainless low power

cable glands

LBC (3) M12 Nickel plated low

power cable glands

LNO No cable glands

Wiring entrance for power connection

PSC (3) M20 stainless power cable gland

PBC (3) M20 Nickel plated power cable gland

PSH (3) ½"NPTF Stainless steel conduit entrance

PNO No fittings or cable gland

Voltage requirement

VAC 100 to 240 VAC

VDC 20 to 30 VDC

Mounting Configuration

EExternal mounting

IInternal Mounting

Housing Material

SS 316 stainless steel

Ty p e of S y s t e m

Type Z & Ex pz, Zone 2 or 22, NEC Class I or II / Division 2

EPV - 5500 -AA- 01

Configuration

01 30 SCFM (850 l/min) max flow, brk press. 0.8" H2O (2 mbar)

02 20 SCFM (565 l/min)max flow, brk press. 1.4" H2O (3.5 mbar)

03 12 SCFM (340 l/min) max flow, brk. press. 1.5" H2O (3.8 mbar)

Material

AA EPV-…-01: 6061T Al (body & cap)

SS EPV-…-02: 6061T Al (body), 316 stainless steel (cap)

Series of vent

5500 5500 Series

5500 Operating Instructions

5500–MAN - EX 0 1 - 2 4VDC

Voltage Requirement

24VDC

120VAC

230VAC

Type of Approval

EX01 ATEX and IECEx certification

CD01 FM and CSA certification

CDUL UL and CSA certification (different body design),

only 60 Hz for AC models

Valve Type

MAN Manifold (includes purging and pressurization valves)

Typ e o f S ys te m

Type Z & Ex pz, Zone 2 & 22, NEC Class I & II / Division 2

5500 Operating Instructions

11. Certi cation

11.1 ATEX - UL/DEMKO 14ATEX1282X

11.1.1 External

II 3 G Ex ic nA nC [ic pz IIC Gc] IIC T4 Gc (-20 °C ≤ ta ≤ +60 °C)

II 3 G Ex ic nA nC [ic pz IIC Gc] IIC T6 Gc (-20 °C ≤ ta ≤ +40 °C)

II 3 D Ex ic tc [ic pD IIIC Dc] IIIB T80°C Dc (-20 °C ≤ ta ≤ 60 °C)

II 3 D Ex ic tc [ic pD IIIC Dc] IIIB T60°C Dc (-20 °C ≤ ta ≤ 40 °C)

11.1.2 Internal

II 3 G Ex ic nA nC [ic pz IIC] IIC T4 Gc (-20 °C ≤ ta ≤ +60 °C)

II 3 G Ex ic nA nC [ic pz IIC] IIC T6 Gc (-20 °C ≤ ta ≤ +40 °C)

II 3 D Ex ic tc [ic pD IIIC Dc] IIIC T80°C Dc (-20 °C ≤ ta ≤ 60 °C)

II 3 D Ex ic tc [ic pD IIIC Dc] IIIC T60°C Dc (-20 °C ≤ ta ≤ 40 °C)

11.2 IECEx - UL14.0019X

11.2.1 External

Ex ic nA nC [ic pz IIC GC] IIC T4 Gc (-20 °C ≤ ta ≤ +60 °C)

Ex ic nA nC [ic pz IIC GC] IIC T6 Gc (-20 °C ≤ ta ≤ +40 °C)

Ex ic tc [ic pD IIIC DC] IIIB T80°C C (-20 °C ≤ ta ≤ 60 °C)

Ex ic tc [ic pD IIIC Dc] IIIB T60°C DC (-20 °C ≤ ta ≤ 40 °C)

11.2.2 Internal

Ex ic nA nC [ic pz IIC GC] IIC T4 Gc (-20 °C ≤ ta ≤ +60 °C)

Ex ic nA nC [ic pz IIC GC] IIC T6 Gc (-20 °C ≤ ta ≤ +40 °C)

Ex ic tc [ic pD IIIC Dc] IIIC T80°C Dc (-20 °C ≤ ta ≤ 60 °C)

Ex ic tc [ic pD IIIC Dc] IIIC T60°C (-20 °C ≤ ta ≤ +40 °C)

11.3 cULus Class Divisions

Class I Division 2 Group A, B, C, D T4 (-20 °C ≤ ta ≤ +60 °C)

Class I Division 2 Group A, B, C, D T6 (-20 °C ≤ ta ≤ +40 °C)

Class II Division 2 Group F+G T4 (-20 °C ≤ ta ≤ 60 °C)

Class II Division 2 Group F+G T6 (-20 °C ≤ ta ≤ 40 °C)

5500 Operating Instructions

11.4 Applied Standards

11.4.1 IECEx

IEC 60079-0

IEC 60079-2

IEC 60079-11

IEC 60079-15

IEC 60079-31

IEC 61241-4

11.4.2 ATEX

EN 60079-0

EN 60079-2

EN 60079-11

EN 60079-15

EN 60079-31

EN 61241-4

5500 Operating Instructions

11.5 Certi cation Markings

11.5.1 Control Unit

5500 Operating Instructions

11.5.2 EPV-5500 Vent Unit

12. Troubleshooting

Problem Possible Reason Solution

Purge cycle does not start No air to system Check air supply, make

sure minimum pressure

available

Minimum pressure not high

enough

Check vent and enclosure

seals, check compensation

valve setting.

Control Unit in dust mode Program 5 was used

instead of programs 1-4.

Select proper program

www.pepperl-fuchs.com

PROCESS AUTOMATION –

PROTECTING YOUR PROCESS

Worldwide/German Headquarters

Pepperl+Fuchs GmbH

Mannheim · Germany

Tel. +49 621 776 2222

E-Mail: pa-info@de.pepperl-fuchs.com

Asia Pacific Headquarters

Pepperl+Fuchs PTE Ltd.

Singapore

Company Registration No. 199003130E

Tel. +65 6779 9091

E-Mail: pa-info@sg.pepperl-fuchs.com

Central/Western Europe &

Africa Headquarters

Pepperl+Fuchs N.V.

Schoten/Antwerp · Belgium

Tel. +32 3 6442500

E-Mail: pa-info@be.pepperl-fuchs.com

Middle East Headquarters

Pepperl+Fuchs M.E (FZE)

Dubai · UAE

Tel. +971 4 883 8378

E-Mail: pa-info@ae.pepperl-fuchs.com

North/Central America Headquarters

Pepperl+Fuchs Inc.

Twinsburg · Ohio · USA

Tel. +1 330 486 0002

E-Mail: pa-info@us.pepperl-fuchs.com

Northern Europe Headquarters

Pepperl+Fuchs GB Ldt.

Oldham · England

Tel. +44 161 6336431

E-Mail: pa-info@gb.pepperl-fuchs.com

Southern/Eastern Europe Headquarters

Pepperl+Fuchs Elcon srl

Sulbiate · Italy

Tel. +39 039 62921

E-Mail: pa-info@it.pepperl-fuchs.com

South America Headquarters

Pepperl+Fuchs Ltda.

São Bernado do Campo · SP · Brazil

Tel. +55 11 4341 8448

E-Mail: pa-info@br.pepperl-fuchs.com

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 demand-

ing 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.

2015_03_27_5500 Manual Installation Directions

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