MODEL 4003 4000 CLASS I APPLICATIONS 90 Cubic …

1 SERIES 4000 TYPE X & EX[p]RAPID EXCHANGE PURGING SYSTEMINSTALLATION & OPERATION MANUALMODEL 4003 CLASS I APPLICATIONS90 Cubic Feet Cubic Meters MaximumModel 4003-FA-CI-VMLV ertical Mount ConfigurationModel 4003-FA-CI-HMTH orizontal Mount ConfigurationModel 4003-FA-CI-CKComponent Kit ConfigurationMODEL 4004 CLASS I APPLICATIONS250 Cubic Feet Cubic Meters MaximumModel EPV-3-SA-00-SMRequired AccessoryEnclosure Protection Ventw/ MODEL VSM-3 Vent Sensor Module installedPepperl+Fuchs Inc. Telephone (330) 486-0002 FAX (330) 425-4607 E-mail: "Terms & Conditions of Sale" information is printed on everyorder acknowledgement; copies are available upon reserve the right to make modifications and no guaranteeof the accuracy of the information contained herein is given. 2004 Pepperl+Fuchs Inc., Twinsburg, Ohio512802, Dwg No. 129-0217 (Supercedes 4000-IOM) Printed in EPSBEBCO EPSP epperl+Fuchs Inc. 1600 Enterprise Parkway Twinsburg, Ohio 44087-2245 (330) 486-0002 FAX (330) 425-4607 E-Mail.

2 Of ContentsPage 2 System Purpose and DescriptionPurpose, System Description, Important NotesPage 3 Identifying Your SystemDefines Specific Features of the SystemPage 4 General InformationSystem & Material Specifications, Spare Parts,Tools & Test Equipment, System AccessoriesPage 5 Enclosure & Device DesignDesign Requirements, Adjacent Enclosures,Device Ventilation, Temperature LimitationsPage 6 Getting StartedEstablishing Connection Sizes & DeterminingEnclosure Inlet & Outlet Connection LocationsPage 7 System Mounting DimensionsFace Plate & Component Dimension DiagramsPage 8VM & HM MountingFlange & Face Plate Mounted InstallationsPage 9CK & RCF MountingGCK Procedure, CK Configuration MountingProcedure & RCF Enclosure Mounting ProcedurePage 10 Pneumatic Tubing RequirementsProtective Gas Supply Requirements & PneumaticConnection RequirementsPage 11 Tubing InstallationSurface, Pipe, Frame & Panel Mount InstallationsPage 12 Tubing Connection DiagramsSurface, Pipe, Frame & Panel Mount InstallationConnection PointsPage 13 Electrical & Pneumatic DiagramsTypical Electrical & Pneumatic DiagramsPage 14 EPCU Conduit InstallationGeneral Information, Module Assembly RemovalProcedure & Typical Conduit Installation DetailsPurposeThe Pepperl+Fuchs Series 4000 Type X Enclosure Protection System spurpose is to allow the use of general purpose or non-rated electrical orelectronic devices, with exception to devices which produce excessiveheat, utilize combustible gas, or expose arcing contacts to the hazardousatmosphere, in Type 4 or 12 enclosures in the place of explosion proofType 7 enclosures.

3 Other purposes include heat, moisture and dustcontamination 4000 is a Rapid Exchange purging assembly which operateson a supply of compressed instrument air or inert gas. It is designedto regulate and monitor pressure within one or more sealed (protected)enclosures, in order to rapidly remove and prevent flammable vaporaccumulation within the enclosure(s). The system is designed toaccomplish the required air exchanges and maintain a "safe" pressureon one or more enclosures. An EPV-SM Enclosure Protection Ventwith Sensor Module is required for proper operation. This processreduces the hazardous (classified) area rating within the enclosure(s),in accordance with the NEC - NFPA 70, Article 500, NFPA 496, and EN 15 Required Hardware MountingRequired Enclosure Protection Vent & RequiredWarning NameplatesPage 16 Electronic Power Control UnitEPCU Description, Base Module Description, EPCUBase Module & Assembly Module PhotosPage 17 Electronic Power Control UnitEPCU Module Descriptions & Module PhotosPage 18 EPCU Features & SetpointsEPCU LED Display Indicators, EPCU Field AdjustableFunctions & SDT / RET Timer SettingsPage 19 EPCU Control OptionsPower & Alarm Control OptionsPage 20 Electrical Supply RequirementsGeneral Requirements, Enclosure PowerRequirements, System Grounding Options & TypicalEnclosure WiringPage 21 EPCU Wiring MethodsPower Source & Intrinsic Safe Wiring MethodsPage 22 Set-Up ProcedureImportant Notes & Helpful HintsPage 23 Set-Up Procedure (cont.)

4 Purging Set-UpPage 24 Operating InstructionsRapid Exchange Purging OperationPage 25 Trouble - Shooting ProceduresTrouble-Shooting ChartPage 26 Warranty & Liability StatementWarranty Notes, General Terms & LimitationsPage 27 System MaintenanceLong Term Maintenance Instructions & SchedulePage 28 Systems Identification & Application InformationImportant NotesOne (1) permanent file copy and one (1) operations copy of thisManual must be studied and retained by the operator of this s Agents are responsible for transferring this Manual to theuser, prior to contents of this manual have been arranged to allow the useof this product as a stand-alone device on equipment andenclosures supplied by the user or its agents. The Manual sparameters encompass a combination of both National FireProtection Association (NFPA) requirements and Pepperl+Fuchs,Inc. requirements. Pepperl+Fuchs therefore acknowledges theuse of NFPA 496 as a guideline, that we have enhanced certainNFPA requirements and that additional information has beencompiled to complete this document.

5 The Manual is intended as acomplete guide and must be considered, unless specifically statedotherwise, that all directives contained herein are Pepperl+Fuchsrequirements for safe, practical and efficient use of this system is not intended for use to protect enclosures or deviceswhich contain ignitable concentrations of gases or vapors. Thisexclusion generally applies to process or product analyzing specifications are subject to change without EPSP epperl+Fuchs Inc. 1600 Enterprise Parkway Twinsburg, Ohio 44087-2245 (330) 486-0002 FAX (330) 425-4607 E-Mail: Your SystemHELPFUL HINTWARNINGIMPORTANT NOTEThis Enclosure Protection System is offered in various configurations. For proper installation and operation, examine theSystem markings to identify the System Style, Area Classifications, Zone Ratings and Types, as noted assist you through the installation and operation of your pressurization / purge system, Pepperl+Fuchs, Incorporatedhas provided the following information boxes throughout this manual.

6 This information is intended to clarify certaindifferences between the MODEL styles and configurations and to warn the user / installer of potential dangers of electricalshock or enclosure over 4003-FA-CI Type X90 Cubic FEET / Cubic METER MAXIMUM ENCLOSURE VOLUMECLASS I, DIVISION 1, GROUPS B, C & D / ZONE 1 GROUPS , IIA, IIB + H2 TO NONHAZARDOUSSYSTEM START-UP INSTRUCTIONS1. WITH ENCLOSURE POWER DEENERGIZED & PURGING SYSTEM AIR SUPPLY ONSERIESMODEL NUMBER4003 - 3/8 Protective Gas Supply4004 - 1/2 Protective Gas SupplySYSTEM CLASS RATINGD efines CLASS rating for ProtectionSystem s method of useCI - CLASS I Purging systemSYSTEM STYLES ystem available in three stylesFA - Fully AutomaticSA - Semi-AutomaticSTD - StandardSYSTEM TYPEType XReduces the internalenclosure areaDivision/Zone ratingfrom Division 1/Zone1 to &DEFINITIONS(not shown) Affixed torear of systemmanifold the currentthird party approvalsfor this systemAREACLASSIFICATIOND efines the areaclassifications forwhich the system issuitable for TOTALENCLOSURE VOLUMED efines total protectedenclosure(s) volumecapacity for each 4003 - 90 CF / CMModel 4004 - 250 CF / 7 CMBEBCO EPSP epperl+Fuchs Inc.

7 1600 Enterprise Parkway Twinsburg, Ohio 44087-2245 (330) 486-0002 FAX (330) 425-4607 E-Mail: SpecificationsSystem Dimensions:See Page 7 Shipping Weights:15 - 22 lbs. (7 - 10 kg)Operating Temperature Range: -4 F - 104 F (-20oC to +40oC)Supply Pressure Range:80 - 120 psi max. ( - bar)Supply Requirements:* Clean Air or Inert GasSafe Pressure " ( mm) @ Safe PressureSafe Pressure Flowrate:** - SCFH ( - 99 l/hr)Maximum Exchange Pressure:** 3" - 5" (76 - 127 mm)Minimum Exchange Flowrate: MODEL 4003: ** 12 SCFM/720 SCFH (340 l/min / 20400 l/hr) MODEL 4004:** 30 SCFM/1800 SCFH (850 l/min / 50940 l/hr)Exchange Times: MODEL 4003:4 Volume Exchanges: 1 Cubic Ft. (85 l/min) MODEL 4004:4 Volume Exchanges:1 Cubic Ft. (212 l/min)System Supply Port: MODEL 4003:1/4" FPTM odel 4004:1/2" FPTE nclosure Supply Port:1/2" FPTE nclosure Reference Fitting:1/4" TubeEPCU Conduit Port Size:3/4" FPTEPCU Power Requirements: 85-240 VAC 50-60 Hz 1 EPCU Power Consumption:500 mAPower Relay Contacts:10 Amps @ 240 VAC10 Amps @ 28 VDCA larm Relay Contact:10 Amps @ 240 VAC10 Amps @ 28 VDCA larm Relay Contact:10 Amps @ 240 VAC10 Amps @ 28 VDCSAE240 VAC, 28 VDC*Protective gas supply must be filtered to 40 microns min.

8 **Enclosure integrity determines actual flow and pressure** With regulator set at 60 psi ( bar) min. during rapidexchangeMaterial SpecificationsRegulator Body:Zinc w/ Enamel FinishRegulator Handle:PolycarbonateEnclosure Pressure Gauge:Alum. w / Enamel FinishRapid Exchange Gauge: Poly Case & Nickel Plated TubeTube Fittings:316 SS Forged BodyTubing:316 SS 1/4" .035 WeldedFastener Hardware:Aluminum & Stainless SteelManifold Body:Anodized AluminumManifold Valves:316 Stainless SteelManufacturer ID Nameplate:Photo Anodized AluminumSystem Start Up Instructions :Silkscreened Lexan System Face Plate:316 14 Ga SS Tumble FinishSystem Mounting Flanges:316 SS Tumble FinishEPCU:Epoxy Painted Cast AluminumEnclosure Warning Nameplate:Silkscreened SSLexan is a registered trademark of the General Electric CompanyRecommended Spare PartsQty DescriptionPart # (supercedes)1 Enclosure Pressure Indicator-CI 510024(001001)1 System Regulator ( MODEL 4003) 510056(002037)1 System Regulator ( MODEL 4004) 510073(002137)1 Filtered Regulator ( MODEL 4003-VMF) 510057 (002040)1 Filtered Regulator ( MODEL 4004-VMF) 510074 (002140)1 Rapid Exchange Pressure Gauge 510079 (002305)1T-Bar Valve Key 510092 (002740)1 Installation & Operation Manual129-0218 Please call and reference part number above for currentspare parts pricing.

9 Immediate pricing is available to allconfirmed Tools & Testing Equipment1/2" chuck drill, Complete set of drill bitsComplete set of tubing, conduit bending, instrument fittingand electrical craftsman hand tools0-10" differential pressure indicator or monometer (connectedto the protected enclosure to measure maximum pressure) MODEL 4003:1/2" & 1 1/4" conduit knockouts " & " hole sawsModel 4004:1/2" & 1 1/2" conduit knockouts " & " hole sawsSeries 4000 System AccessoriesEnclosure Protection VentsONE REQUIRED WITH EACH SYSTEMFor use with MODEL 4003:EPV-3-SA-00-SMStraight w/ Sensor ModuleEPV-3-SA-90-SMRt Angle w/ Sensor ModuleFor use with MODEL 4004:EPV-4-SA-00-SMStraight w/ Sensor ModuleEPV-4-SA-90-SMRt Angle w/ Sensor ModuleAdditional ItemsSMK-3 System Mounting Kit - FlangeSMK-8mSystem Mounting Kit - FramePMK-3 Pipe Mounting KitILF-41/4" In-Line FilterILF-81/2" In-Line FilterRCF-41/4" Remote Mount Cube FilterRCF-81/2" Remote Mount Cube FilterGCKG auge Conversion KitRAHDiv.

10 1 Remote Alarm HornRAB-1 Div. 1 Remote Alarm BeaconLCKL Fitting Conduit KitTCKT Fitting Conduit KitWH-IS-4 EPCU Intrinsic Safe Wiring HarnessWH-HW-4 EPCU Hard Wire Wiring HarnessWH-AX-4 EPCU Auxiliary Wiring HarnessSRM-4000 Switch Resistor ModuleEWN-1 Enclosure Warning Nameplate-CIass IETWE nclosure Temperature Warning NameplateGSWNP rotective Gas Supply Warning NameplateCG-81/2 Cable Gland FittingGeneral InformationBEBCO EPSP epperl+Fuchs Inc. 1600 Enterprise Parkway Twinsburg, Ohio 44087-2245 (330) 486-0002 FAX (330) 425-4607 E-Mail: Design Requirements1. All windows must be shatterproof and sized as small All required markings must be placed on or near allenclosure doors and The enclosure must withstand an internal pressure of ten(10) inches of water without sustaining permanentdeformation and resist all corrosive elements in thesurrounding All lightweight objects in the enclosure, such as paper orinsulation, must be firmly The enclosure should be constructed from materials suchas metal or anti-static polycarbonate to meet or exceedType 4 or 12 performance requirements, but does notrequire third party The installation of obstructions or other barriers whichblock or impede the flow of protective gas must The creation of air pockets or other areas which trapflammable gases within the enclosure or devices must The enclosure should be located in an area where impacthazards are If the enclosure is nonmetallic and contains equipmentwhich utilizes or switches power loads greater than 2500VA, it must be constructed from substantiallynoncombustible materials.