© @% D779 MiniPurge® Manual ML 433 Important Note: It is essential for safety that the installer and user of the Expo system follow these instructions. Please refer to the standard for principles and definition. These instructions apply only to the pressurizing system. it is the responsibility of the manufacturer of the pressurized enclosure to provide instructions for the enclosure. Expo Technologies reserves the right to replace any component, with one ofthe equivalent functonalty M433 | v8 2eFeb-tTSection 1: System Specification MiniPurge® Control Unit Data - Reliof Valve Unit and Purge Outlet Valve with integral spark arrestor... Section 2: Quick User Guide Installation .. Operation of the System Section 3: Application Suitability Section 4: Description and Principle of Operation Section 5: Main Components Air Supply Filter / Regulator. Logic Air Supply Regulater... Minimum Pressure Sensor... Purge Flow Sensor Purge Timer Purge Complete Valve OR Gate Alarm Only Circuit (AO) Visual Indicators Power Interlock Switch ...... Alarm / Pressurized Switch... Purge Valve Purge Flow Restrictor CLAPS Sensor CLAPS Regulator Relief Valve Unit IPA Terminal Box. Section 6; Installation of the System.. Relief Valve Unit Air Supply Quality Pipe Work Multiple Enclosures Provision and Installation of Alarm Devices Power Supplies and their Isolation Power Interlock Switch Section 7: Commissioning .. Commissioning the System Normal Operation Section 8: Maintenance of the System... ssesesesnee 1 General maintenance 13 Additional maintenance checks.... stntntintsesenereinnetntntntatsenesesereneneees 13 Re-calibration of the Relief Valve Unit 13 Re-calibration of the Pressure Sensors .....sscitsitstieseneseesinnetintststntvese 14 Section 9: Fault Finding. 14 General Information 14 System purges correctly but trips and auto re-purges at the end of the purge time... 15 Relief Valve opens (continuously or intermittently) 15 System enters purging but purge indication does not occur. 16 Section 10: Recommended Spares List. 16 Section 11: Glossary.. Section 12: Drawings and Diagram: Section 13: Certifications... ML433 | vai iSection 1: System Specification 3X LCI ss/OV/ PC / PAIDI79 size PA = Power and Alarm Switches. 3= MiniPurge® Integral IPA Terminal Box Purge flow rate: 1500 Ni/min PC = Pressurized Control. Automatic leakage compensation (CLAPS} Approval / Certification 398 compensation (CLAPS) ATEX Certificate: ‘Sira 01ATEX1295X OV = Purge Outlet Valve is C€ 0518 © 1122) 60 pneumatically operated Ex [pxb] IIC TS Gb Ex [pxb] IIIC T85°C Db MiniPurge® Housing Tamp “20°C to +55°C 88 = Stainless Steel 316L IECEx Certificate: IECEx SIRO7.0027x Ex [pxb] IC T6 Gb Ex [pxb] IIIC T85°C Db Tamp -20°C to +55°C Pressurization Method LC = Leakage Compensation TUV INMETRO Certificate: TOV 12.1462x Ex [pxb] IC T6 Gb Ex [pxb] IIIC T85°C Db Tamb -20°C to +55°C ML433 | vai Page 1MiniPurge® Control Unit Data Action on Pressure Failure: Type of Operation: Leakage Compensation Capacity: Enclosure Material: Mounting Method: Temperature Limits: Compressed Air Supply: Supply Pressure Main Regulator: Logic Regulator and Gauge: Process Connections: Visual Indicators: JPA Terminal Box: Power Interlock Switch: Alarm Switch: Minimum Pressure Sensor: Purge Flow Sensor: CLAPS Sensor: Alarm and Trip (isolate power to pressurized enclosure), user adjustable Alarm Only. ‘Automatic leakage compensation using the Closed Loop Automatic Pressurization System (CLAPS System) 500 Ni/min initial maximum pressurized enclosure leakage. Stainless Steel 316L. Wall mounting straps. Fixing holes as per drawing, -20°C to +55°C Clean, dry, oil free air or inert gas. Refer to Air Supply Quality section in installation of the System. 4 to 8 barg (60 to 120 psi). Set at 4 barg, 40 um automatic drain supply inlet filter. Fitted and set to 2.3 barg (33 psi). Purge supply and outlet to pressurized enclosure ‘/2’ NPT female. Minimum supply line 13 mm (“/2) ID tube, inlet sized appropriately for flow rate. Reference points & signals ‘/g’ NPT female, minimum 6 mm pipe to be used. Alarm (Red@) / Pressurized (Green@). System Purging (Yellow@). Glass reinforced polyester box with terminals and accessible cable glands. Certified to 2 Watts power dissipation: Ex e IIC T6 Gb / Ex tb IIIC T85°C Db IP67 Tamb : -65°C to +55°C. DPNO switch, contact ratings 250 Vac 4 Amps (AC-15) / 24V DC 4A, Exd IIC T6 Gb / Ex th IIIC T80°C Db. SPCO switch, contactratings 250 Vac4 Amps (AC-15)/24VDC4A, Ex d IIC T6 Gb / Ex tb IIIC T80°C Db. Minimum: 0.5 mbarg. Maximum: 5.0 mbarg, Default Setting: 1.5 mbarg. Tolerance -0, +0.7 mbarg. Set at 6.4 mbarg (Tolerance: -0, +10%). Minimum: 6.0 mbarg. Maximum:15 mbarg. Default Setting: 10 mbarg. Tolerance: -0, +10% Note: there must be a 2.5 mbarg difference between the intermediate and CLAPS sensor calibration point. For example: Minimum pressure = 5 mbarg, intermediate pressure = 6.5 mbarg, CLAPS sensor = 9 mbarg. Purge Time Weight: User selectable, 3-off time increments available. 10, 15 or 20 Minutes (-0 + 25%). Maximum available purge time of 45 minutes. Default Setting 45 minutes. 16 kg (351b) Relief Valve Unit and Purge Outlet Valve with integral spark arrestor Type: Page 2 RLV52iss/FS, Design number D779RLV. ML433 | véiBore: Purge Outlet Valve @ 52 mm, Relief Valve @ 52 mm. Relief Valve Lif-Off Pressure: Minimum: 20 mbarg. Maximum: 50 mbarg. Default: 30 mbarg (+0, -20%). Flow Rate: Range: 1000 or 1500 Ni/min Default: 1500 Ni/min. Material: Housing: Stainless steel 316L. Gasket: Silicone. Spark arrestor: Stainless steel mesh. Mounting Method Rectangular cut-out and fixing holes as per drawing, Weight: 4 kg (8.8 Ib) Section 2: Quick User Guide Installation The MiniPurge® system must be installed by a competent engineer, in accordance with relevant standards, such as IEC / EN 60079-14 and any local codes or practice. + Mount the purge system in accordance with the hook-up drawing. + Ensure the system js installed according to the full instructions in the “Installation of the System” section of this manual. + Allpipings must be clean and free of dirt, condensation and debris prior to connection to the purge system or pressurized enclosure. + Itis strongly recommended that a local isolation valve is installed on the air supply upstream of the purge system. Note: Most faults are due to restricted air supply, Inadequate supply pipe work or drop in air supply pressure during the purge process. Operation of the System Once the system is installed correctly, turn on the air supply. Refer to Commissioning section. Indicator Colour Status Alarm / Pressurized Red @ Low pressure alarm (enclosure pressure too low) Purging Black @ Purge flow too low or not in purge mode The purge system commences the purge cycle: + The purge air will enter the enclosure + The pressurized enclosure will obtain a positive pressure. + The Purge Outlet Valve will open within the Relief Valve Unit. + The air will then exit the Relief Valve Unit housing via the spark arrestor. Indicator Colour Status ‘Alarm / Pressurized Green @ _| Pressurized (minimum enclosure pressure achieved) Purging Black @ | Purge flow too low ML433 | vai Page 3Open the Purge Flow Restrictor Valve until the air flow reaches the required rate; the system will initiate the timed purge cycle. Start a stopwatch when the purging indicator turns yellow. Indicator Colour Status Alarm / Pressurized | Green @ Pressurized Purging Yellow @ Purge flow rate above minimum On completion of an uninterrupted purge cycle of the required length, the system will indicate purge complete. Stop the stopwatch when the purging indicator turns black Indicator Colour Status ‘Alarm / Pressurized Green @ —_| Pressurized and in leakage compensation mode Purging Black @ | No longer in purge mode Check stopwatch timing to verify that the actual purge time is equal to or greater than the required purge time. Note: The recorded purge time must never be less than the required purge time. ‘The system is now operating correctly in leakage compensation mode, If the system has not performed as expected, check the installation thoroughly and ensure it has been carried out according to the instructions. If an obvious problem has not been highlighted and corrected, follow the procedures in the Fault Finding section. Ifall checks have been carried out and the system stil does not perform as expected, contact your local distributor or Expo Technologies. Page 4 ML433 | véiSection 3: Application Suitability MiniPurge® systems are certified for use in hazardous locations, where the hazardous location is non- mining (above ground) and the hazard is caused by flammable gasses, vapours or dust. Depending on the model the systems may be used in IECEx and ATEX Zone 1(21) and/or Zone 2(22) - Categories 2 and 3 respectively MiniPurge® systems may be used for hazards of any gas group. Apparatus associated with the MiniPurge® system, such as intrinsically safe signalling circuits and flameproof enclosures containing switching devices may be limited in their gas group. The certification documentation supplied with any such devices must be checked to ensure their suitability, This system is primarily designed for use with compressed air. Where other inert compressed gasses are used (Nitrogen, for example) the user must take suitable precautions so that the build up of the inert gas does not present a hazard to health. Consult the Control of Substances Hazardous to Health (COSHH) data sheet for the gas used. Where a risk of asphyxiation exists, a warning label must be fitted to the pressurized enclosure, The following materials are used in the construction of MiniPurge® systems. If substances that will adversely affect any of these materials are present in the surrounding environment, please consult Expo Technologies for further guidance. Materials of Construction Stainless Steel ‘Aluminium Acrylic Mild (Carbon) Steel Nylon Silicone Brass Polyurethane Neoprene ABS Polycarbonate Polyester (glass filled) Section 4: Description and Principle of Operation The MiniPurge® system is pneumatic in operation, with electrical interfaces. Purge and pressurization is a method of protection used in Zone 1 (21) and/or Zone 2 (22) hazardous locations to ensure that the interior of an enclosure is free of flammable gas. Addition of a MiniPurge” system allows the electrical equipment within the enclosure to be used safely in a hazardous location. The principle of purge and pressurization is as follows: + Clean compressed air or inert gas is drawn from a non-hazardous location. + The interior of the pressurized enclosure is flushed to remove any hazardous gas or dust. + This is introduced into the pressurized enclosure to keep the internal pressure at least 0.5 mbarg above the external pressure. + Whilst pressurized, flammable gas cannot enter the enclosure from the environment. Prior to switching on the power to the electrical equipment, the enclosure must be purged to remove any flammable gas that might have entered the enclosure before pressurization. Purging is the process of removal contaminated air and replacement with air (or inert gas) known to be free from flammable gas. The duration of this purge process is normally ascertained by performing a purge test At the end of the purge cycle the system automatically switches to leakage compensation mode. The Purge Outlet Valve is closed and the airflow is reduced but remains high enough to compensate for the leakage of air from the enclosure whilst maintaining the minimum over pressure state. In the event of pressure failure within the pressurized enclosure the system will raise an alarm in the form of visual indicators and a volt free contact depending on the specification of the system. The default action ML433 | vai Pageson loss of pressurization is alarm and automatic disconnect of power (A&T - Alarm and Trip). This can be changed by the customer to Alarm Only (/AO), please refer to section tiled Main Components. ‘The MiniPurge® system incorporates a Closed Loop Automatic Pressurization System (CLAPS). This allows the system to detect a rise or fall of the enclosure’s internal pressure and adjust the leakage compensation rate accordingly. Pressure variations are more likely during sudden start up of large rotating electrical machines but can also be caused by changes in running temperature. This system has been specifically designed to maintain a stable intemal pressure within the enclosure. Pressure characteristics during purge and pressurization of a pressurised enclosure using a MiniPurge® system that incorporates a CLAPS system: Powor interlock switeh \ Minin pressure sitch LAPS Regulator | Pressure fe or presse sens sends ‘stm 'neator ahows re alm oa} Alm tnictor shows td and poor” (3 isconnectod (Alarm and Tip) "Sensor Pressure Farge Tens) (RCA S (Normal Opwraion) (Faun Condton eer perm (Cope Tins) “outside of CLAPS re Section 5: Main Components Air Supply Filter / Regulator The unit is provided with a 40 um liquid / dust filter element as a precaution. The user of the MiniPurge® system must ensure that air supply is to the quality stated in Air Supply Quality paragraph found in the Installation of the System section. The regulator is factory set to 4 barg (60 psig) and regulates the pressure of an air supply between 4 and 8 barg (60 to 120 psig). A pressure gauge is fitted down stream of the fitter; this should indicate no less than 4 barg (60 psig). During the purge cycle a pressure drop will be indicated on the gauge. Logic Air Supply Regulator This device provides the system with a stable air supply pressure to the logic system and allows consistent operation. The pressure level is factory set to 2.3 barg (33 psig) and can be verified by means of the integral pressure gauge. Minimum Pressure Sensor This monitors the pressure inside the pressurized enclosure. When the pressure is below the minimum required for safe operation, the pressure sensor causes the system to reset and the Alarm / Pressurized indicator turns Red @. The sensor is factory calibrated and set to operate in falling pressure at or above the minimum specified pressure. Page o ML433 | véiPurge Flow Sensor The Purge Flow Sensor monitors flow through the Purge Outlet Valve. At correct purge flow rates, above the minimum specified for purging, the sensor sends a signal that activates the purge timer. This sensor is factory calibrated to operate on falling flow rate at or above the minimum specified purge flow rate. Purge Timer When both the enclosure pressure and the purge flow rate are correct, the Purge Flow Sensor activates the timer to start the timing period. The purge time is set by opening/closing the pinch valve so that the sum of the open valves times equals or exceeds the required purge time. At least one valve must be open, and the screws must be at the appropriate limit of travel. Do not over tighten. The purging indicator will turn yellow during timing Purge Complete Valve This valve receives a signal from the purge timer that indicates the completion of the purge cycle and verifies that the pressurization signal is still present. If both conditions are satisfied a signal is sent to indicate that the purge is complete. This performs two functions: to tum on the electrical supply to the pressurized enclosure and to reduce the high purge flow rate to leakage compensation mode. It also provides a hold-on signal that maintains the leakage compensation mode with the power switch on, even when the purge timer has reset ready for the next purge cycle. OR Gate This device provides the Purge Complete Valve with the hold-on function referred to previously. When either the timed-out signal or the purge complete signal is present it allows the pilot signal to be sent to the purge complete valve. Alarm Only Circuit (/AO) If the pressure in the pressurized enclosure is too low the system will normally cut off electrical power to it. In certain circumstances, where local codes of practice allow, the system can be altered to provide a hold- on circuit that will maintain the electrical power supply to the pressurized enclosure while also providing a pressure failure alarm. The user must respond to the alarm and either restore the pressure to the pressurized enclosure or otherwise make the installation safe; for example, cut off the electrical supply. The decision to use the Alarm Only facility, and the allowable length of time for non-pressurized operation, is the responsibility of the user. Warning: It is potentially dangerous to energise the pressurized enclosure in an non-pressurized condition when it is known that there is potentially explosive gas or dust in the hazardous location. Visual Indicators Visual indicators are fitted to provide status information to the operator. Alarm / Pressurized Indicator Green" @ Pressurized Red @ Pressure Alarm (enclosure pressure low) ‘System Purging Indicator Black” @ Purge flow too low (not in purge mode) Yellow @ Purging (flow above minimum) * The Green @/ Black @ combination indicates normal operation of the pressurized enclosure after the initial purging cycle has been completed ML433 | vai Page7Power Interlock Switch This flameproof power switch is activated by the signal from the Purge Complete Valve. This activation can be used to tum on the electrical supply to the pressurized enclosure. The cable from the switch is terminated in the /PA terminal box. Alarm / Pressurized Switch This flameproof switch is operated by the pressurized signal. It allows a remote electrical system status indicator to show either pressurized or a pressure failure alarm. The cable from the switch is terminated in the /PA terminal box. Purge Valve This changeover valve selects between purge air flow or leakage compensation. Itis sized to allow sufficient air into the enclosure during purging based on: the specified air supply pressure range, the minimum specified purging outlet flow rate +10% and the expected leakage rate from the pressurized enclosure. At the end of the purge cycle, the purge valve closes in response to the “Purge Complete” signal, it remains in the closed position until the next purge cycle is initiated. Purge Flow Restrictor This valve restricts the purge flow to the minimum required flow rate. The Purge Flow Restrictor must be readjusted during commissioning. CLAPS Sensor This sensor monitors the pressure within the pressurized enclosure and sends a control signal to the CLAPS Regulator. The normal running pressure must be determined prior to system start-up so that the CLAPS Sensor may be set to the level required to control the CLAPS Regulator. CLAPS Regulator This is the regulator that controls the leakage compensation air flow into the enclosure after the purging is complete. It either increases or decreases the air flow into the enclosure as appropriate to maintain a stable Tunning pressure. The CLAPS Regulator must be set at the time of commissioning. Relief Valve Unit ‘The Relief Valve Unit allows the purge air to exit the enclosure safely via a built-in spark arrestor. This spark arrestor is designed to prevent the emission of arcs, sparks and incandescent particles produced within the pressurized enclosure Purge air passes through the Relief Valve Unit; the preset pressure differential across the appropriate orifice ensures that the purge flow sensor is activated once the selected purge flow has been attained. During the purge cycle a pneumatic cylinder operates the Purge Outlet Valve that lets the air from inside the enclosure exhaust through the Relief Valve Unit. When the system changes to leakage compensation mode, the Purge Outlet Valve is closed and the enclosure sealed ‘The Relief Valve Unit has an in-built relief valve. This is sized to ensure that, if the air supply pressure rises up from the specified maximum, the internal enclosure pressure will not exceed the specified maximum. working pressure of the pressurized enclosure. IPA Terminal Box ‘The Terminal Box is increased safety (Ex e) certified and incorporates the terminal connection points for the alarm and interlock switches. All contacts provided are volt free (dry), Page 8 ML433 | véiCable entry methods (for example conduit or cable glands) must be certified to IECEx, ATEX or INMETRO standards. The main requirement is that IP66 (or better) ingress protection must be provided by use of seals or washers. Section 6: Installation of the System The MiniPurge® is designed for use under normal industrial conditions of ambient temperature, humidity and vibration, Please consult Expo before installing this equipment in conditions thet may cause stresses beyond normal industrial conditions. The MiniPurge® system must be installed by a competent person in accordance with relevant standards, such as IEC / EN 60079-14, and any local codes of practice. The MiniPurge® control unit should be installed either directly on, or close to the pressurized enclosure. It should be installed such that the system indicators and certification labels are in view. All parts of the system carry a common serial number. If installing more than one system, ensure that this, ‘commonality is maintained within each system installed Relief Valve Unit To achieve effective purging, the points where air enters and exits the pressurized enclosure should normally be at opposite ends of the enclosure. The RLV unit must be mounted vertically and there should bea minimum clearance of 300 mm (12") around the spark arrestor (purge outlet) It is important that the interior and exterior of the spark arrestor is kept clean and debris is not allowed to accumulate; this might affect the calibration of the device. In particular the exterior of the spark arrestor should not be painted or blocked in any way. Air Supply Quality The MiniPurge® system should be connected to a protective gas supply, which is suitable for purging and pressurization. The supply pipe connection to the MiniPurge® must be appropriate for the maximum input flow rate for the application The air supply must be regulated at a pressure less than the maximum stated inlet pressure. The air supply must be: clean, non-flammable and from a non-hazardous location. The air should be of Instrument Air Quality. Although the purge control system will operate with lower air quality, its operational life will be adversely affected. The equipment that is being protected by the MiniPurge® may also suffer because of poor air quality With reference to BS ISO 8573-1: 2010, Instrument Air is typically specified as: Particle Class 1 In each cubic metre of compressed air, the particulate count should not exceed 20,000 particles in the 0.1 to 0.5 micron size range, 400 particles in the 0.5 to 1 micron size range and 10 particles in the 1 to 5 micron size range. Humidity or pressure dew point The dew point, at line pressure, shall be at least 10 °C below the minimum local recorded ambient temperature at the plant site. In no case, should the dew point at line pressure exceed +3 °C. Oil Class 2 In each cubic metre of compressed air, not more than 0.1mg of oil is allowed. This is @ total level for liquid oil, oil aerosol and oil vapour. ML433 | vai Page‘When an inert gas is being used to supply the purge system, risk of asphyxiation exists. Refer to Application Suitability section. Before connection of the air supply to the purge system, the supply pipe work should be flushed through with instrument quality air to remove any debris that may remain in the pipes. This must be carried out for at least 10 seconds for every meter of supply pipe. Unless a supply shut-off valve has been fitted to the MiniPurge® system, an external shut-off valve with the same, or larger, thread size as the Control Unit inlet fitting should be fitted by the installer to prevent any restriction of purge flow. The purge air from the MiniPurge® Control Unit should be piped within the pressurized enclosure to ensure purging of potential dead air spots. The purge system is fitted with an internal regulator factory set to 3 bar feeding the logic. Pipe Work If the MiniPurge® is not connected directly to the pressurized enclosure, pipe work and fittings used to connect the Control Unit to the pressurized enclosure should be either metallic or appropriate to the environment into which the system is installed. No valve may be fitted in any signal pipe connecting the Control Unit to the pressurized enclosure. This pipe work must be fitted in accordance with local codes of practice where relevant. Multiple Enclosures This system is suitable for the purge and pressurization of the primary pressurized enclosure and its associated terminal boxes. Provision and Installation of Alarm Devices When the pressure inside the pressurized enclosure is above the minimum, the Minimum Pressure Sensor returns a positive (pressurized) signal causing the alarm indicator on the control unit to change from red to green. ‘When the pressure falls below the minimum permissible the positive (pressurized) signal is removed. This absence of signal indicates a low pressure alarm condition and causes the alarm indicator on the control Unit to go from green to red. ‘There are volt free (dry) contacts available within the terminal box for remote usage. ‘The user must make use of this alarm facility in accordance with the local code of practice for Action on Pres- sure or Flow Failure. Most codes include the following recommendations: + Zone 1 Installations: Alarm and Automatic Trip of Power. + Zone 2 Installations: Alarm Only on pressure or flow failure with power being removed manually. Power Supplies and their Isolation All power entering the pressurized enclosure should have a means of isolation. This requirement also applies to any external power sources that are connected to the equipment such as volt-free (dry) contacts within the pressurized enclosure. This is commonly achieved using the Power Interlock Switch. Power Interlock Switch This switch is a Double Pole Normally Open, double-break switch: it provides two independent contacts that should be connected in series and used to isolate the power. This can be achieved using switchgear or other suitable switching device. These contacts are terminated and accessible to the user in the Ex e terminal box. Itis the responsibility of the user to ensure that the switch is only operated within appropriate technical limits. Page 10 ML433 | véiThe switch must be replaced after any short circuit that occurs within the main circuit; the switch is a piece of encapsulated equipment and as such it is not possible to check the state of the contacts. Technical modifications to the switch are not permitted. Prior to commissioning, check that the Ex e terminal box is clean, the connections have been made properly, the cables laid correctly and all screws in the terminals are secure. In all cases the application and isolation of power must be controlled by the MiniPurge® system using the power interlock signal. No switches are permitted between the power switch and the MiniPurg manual override circuit. system other than an authorized The safe use of this switch is the responsibility of the user, all electrical installations must conform to local codes of practice. Exception Power to apparatus that is already suitable for use in hazardous locations need not be isolated by the MiniPurge® system, Section 7: Commissioning Commissioning the System Note: The steps 11 and 15 to 21 represent detailed commissioning tests The following equipment is needed for this process: = Continuity meter = Gauge manometer (0 to 200 mbarg) + Differential manometer If, after commissioning, the system does not perform as expected, refer to the Fault Finding Section. Follow the steps as outlined: 1, Check all connections and that the Relief Valve Unit is fitted correctly with an unobstructed path to the purge exhaust. Close the Purge Flow Restriclor Valve. Fully open external supply shut-off valve where fitted Check that the internal logic pressure gauge reads 2.3 barg / 33 psi / 230 kPag Check that the pressure gauge on main air supply reads 4 barg / 60 psi / 400 kPag. Check that the Pressure Relief Valve is correctly set by disconnecting the minimum pressure sensing pipe at the bulkhead fitting on the input to the MiniPurge®. This will disable all of the pressure sensors. + Using a4 mm nylon tube, connect a manometer to the bulkhead fitting from which the minimum pressure sensing pipe was removed. + Open the Purge Flow Restrictor Valve very slowly, until the Pressure Relief Valve opens + Check the opening pressure is within calibration limits. Sa kON + This test can be carried out several times to ensure repeatability and compliance. Refer to the Maintenance of the System section if the Relief Valve needs recalibrating. 7. Close the Purge Flow Restrictor Valve. 8. Remove the manometer and reconnect the minimum pressure sensing pipe to the bulkhead fitting. 9. Remove red plug from the top of the Minimum Pressure Sensor and connect a gauge manometer. 10.Connect a differential manometer to the test points on the flow sensor. ML433 | vai Page 1111.To check sensor calibration + The internal pressure in the pressurized enclosure must be below Relief Valve lift off pressure and above the CLAPS pressure + At this time the pressurized indicator should be green. + gradually open Purge Flow Restrictor Valve until purging indicator turns yellow. Note: For large volumes it may take a long time for the purge flow to start. + very slowly close Purge Fiow Restrictor Valve until the purging indicator turns back to black. + Take a reading from pressure gauge. 12.To set the purge flow rate: + Turn on the compressed air to the MiniPurge®. + Gradually open the Purge Flow Restrictor Valve until the black / yellow indicator changes to yellow. + The yellow indicator confirms the correct flow rate. + The differential pressure should be greater than 6.4 mbarg. + The relief valve is supplied with different orifice plates for the specified flow rate. This orifice plate is held in position by two M3 screws and can easily be changed by removing the large cover plate from over the outlet valve assembly and screws. Warning: When opening the Purge Flow Restrictor Valve, ensure the over pressure within the pres- surized enclosure does not exceed the pressure relief vaive setting. 13.The purge timer will start as soon as the Purging Indicator turns yellow. Check that the time delay between the indicator turning to yellow and returning to black is not less than the minimum time required for complete purging of the pressurized enclosure. Times in excess of minimum are permitted. 14.After the purge has been completed, the Purge Valve will close and the air flow into the pressurized enclosure will be controlled by the CLAPS Regulator. The initial setting may be too high or too low. 15.Gradually turn the CLAPS Regulator anti-clockwise to reduce enclosure pressure. 16.Reduce regulator until intermediate sensor causes contacts to open. 17.Check the manometer on the minimum pressure sensor. 18.Continue to reduce the CLAPS Regulator to test the minimum pressure sensor. 19.To check operation of Minimum Pressure Sensor, check readings on manometer as system will automatically re-purge when it reaches minimum pressure. 20.While the system re-purges, return the CLAPS Regulator to the initial setting. 21./f minimum pressure is below the set point, refer to the Recalibration section 2.1 the setting is too high, continual rising and falling of the enclosure pressure will be seen as the CLAPS Regulator automatically shuts off and reinstates the flow. The CLAPS Regulator should be adjusted to reduce the flow into the pressurized enclosure by turning the adjuster screw anti-clockwise. 23.If the initial setting is too low the CLAPS Regulator may not provide enough air flow causing a gradual decline in enclosure pressure. To increase the flow into the pressurized enclosure, adjust the CLAPS Regulator Relief Valve unit by turning the adjuster screw clockwise. 24.To test the CLAPS settings, create a leak in the system by removing a bolt or losening a gland plate in order to create a 15mm hole. Remember to replace bolt or retighten gland plate after testing 25.The setting of the CLAPS Sensor is factory calibrated to the normal working pressure expected in the pressurized enclosure, typically 10 mbarg. The pressure in the pressurized enclosure should be stabilized as close as possible to this figure. This can be checked by a manometer attached to the minimum pressure sensor. 26.Remove the air supply to the system, remove all test equipment and replace all plugs. Page 12 ML433 | véiNormal Operation For normal operation of the system, after commissioning has been carried out it is possible to turn the air supply valve on or off to start or stop the system. After this, the purge and pressurization sequence is automatic. Section 8: Maintenance of the System General maintenance The maintenance of the system outlined in this manual should be supplemented with any additional requirements set out in appropriate local codes of practice. The following checks should be carried out every 6 - 36 months dependent on environment according to IEC / EN 60079-17 + Tests outlined in the Detailed Commissioning section. + Ensure that the Relief Valve Unit is free from contamination prior to making any adjustment. To do this: + Remove large cover plate using a 8 mm spanner (wrench). + Check that the interior and all components are clean and free from contamination. + Replace large cover plate. + Check the condition of the air supply filter element. Clean or replace as necessary. Additional maintenance checks The following additional checks are recommended at least every 3 years: Cheek that: + Apparatus is suitable for use in the hazardous location. + There are no unauthorised modifications. + The air supply is uncontaminated. + The interlocks and alarms function correctly. + Approval labels are legible and undamaged. + Adequate spares are carried. + The action on pressure failure is correct. Re-calibration of the Relief Valve Unit Warning Incorrect adjustment of the Relief Valve Unit can lead to significant over pressure and result in damage to the enclosure. If maximum pressure setting Is reached, stop adjustment and reduce the pressure. To perform the following adjustments, an 8 mm spanner (wrench) and a 2.5 mm hex key will be required Ensure that the Relief Valve Unit is free from contamination prior to making any adjustment. To do this: + Remove large cover plate using a 8 mm spanner (wrench), + Check that the interior and all components are clean and free from contamination. + Replace large cover plate To adjust the lift off pressure of the Relief Valve: + Attach test equipment as described in the Commissioning Section. + Remove small cover plate. + Whilst holding the central adjustment screw in position using the hex key, loosen the retaining nut. + Adjust the hex key clockwise to increase, or anti-clockwise to reduce the lift off pressure, ML433 | vai Page 13+ Before testing, retighten the locking nut whilst holding the adjustment screw in place + Carry out the commissioning tests to check the correct setting of the relief valve after adjustment + The adjustment is sensitive and it is recommended that a */, turn (maximum) adjustments are applied between tests. Allen screw and locknut Re-calibration of the Pressure Sensors ‘The brass nozzle on the sensor is sealed into position using Loctite thread sealant. If the thread has seized up, remove to a safe area and heat slightly to soften prior to making any adjustment. This prevents potential damage to the brass of the nozzle. + Disconnect pipe work from the sensor, including pipe located below the sensor. + Remove sensor by unscrewing anti-clockwise. + The nozzle is located under the sensor. + The adjustment is sensitive, turn the nozzle in '/g of a turn steps. + Turn clockwise to reduce the pressure setting and anti-clockwise to increase. = Replace sensor, screwing clockwise. + Reconnect all pipe work Section 9: Fault Finding General Information Ifyou are having problems that cannot be corrected using one of the methods described, please call Expo or your supplier for further assistance. If the system is less than 12 months old, parts under warranty should be returned to Expo for investigation. A full report of the fault and the system serial number should accompany the parts. Itis common for problems with the MiniPurge® system to be caused by contamination of the air supply with cil, water or dirt, To prevent these problems, the air supply must contain a dust filter and a water filter. This will ensure that the air is instrument quality and protect both the purge system and the equipment being purged. This filtration system is not provided by Expo and must be sourced separately. Contamination can enter the system from a number of sources. To prevent this, it is essential that the procedures described in the installation section are carried out prior to first use of the system. These procedures should also be carried out following any disconnection and re-connection of the pipe work. Failure to perform these procedures may cause damage to the system that will not be covered by the warranty. ‘The system has been designed for ease of fault finding and many of the components fitted are plug-in or chassis mounted. Check components by substitution only after establishing that such action is necessary. Before carrying out the fault finding procedures, ensure that: + Both the main air pressure to the system and for Motor Purge Systems, the regulated pressure to the logic manifold are as specified on the settings sheet, Page 14 ML433 | véi+ Air pressure does not drop below the minimum supply pressure during purging: the majority of faults reported are due to insufficient air supply during the purge cycle. System purges correctly but trips and auto re-purges at the end of the purge time. This is a result of the pressure within the pressurized enclosure being below the minimum pressure sensor setting. The pressure can be checked using a manometer. The most common causes of this problem are outlined below. Fault Location Cause Solution Pressurised Enclosure There is debris on the face of the Relief Valve disk held in place by the magnet + Remove debris and ensure RLV disk is clean Enclosure leaking excessively. + Ensure all doors and covers are closed and that all conduit and cable glands are properly sealed + Seal any other leaks. Pressure sensing tube damaged, + Replace tubing. CLAPS Regulator The CLAPS Regulator setting is too low. + Increase the setting of the CLAPS regulator to raise the pressure in the pressurised enclosure after purging + Todo this, turn clockwise. MiniPurge® Control Unit the Minimum Pressure Sensor setting has drifted above the CLAPS setting The Minimum Pressure Sensor needs re-calibrating, + Refer to Re-calibration of Pressure Sensors in the Maintenance section Relief Valve opens (continuously or intermittently) Fault Location Cause Solution Pressurised Enclosure Enclosure pressure is too high due to CLAPS Regulator being open to far Adjust the CLAPS Regulator. Relief Valve Unit Debris on the Relief Valve disk allowing air to leak from the valve. Remove Relief Valve cover and clean the valve disk, ML433 | vai Page 15System enters purging but purge indication does not occur. Fault Location Cause Solution Air Supply Insufficient flow rate due to inadequate air supply pressure. Often due to pressure drop in the supply pipe. Sialic pressure of 5 barg must be maintained during purge + Check air supply pressure at the inlet to the control unit + Ensure that the supply pipe bore is suitable for the flow rate Pressurized Enclosure Excessive leakage from the pressurized enclosure. + Check around the enclosure while purging is taking place. + Total leakage at purge outlet valve should not exceed 10% of purge flow sensor setting. + Check for leakage down cables and conduit Pipe Work Tubing from Relief Valve flow sensing point not air tight. + Ensure fitting nuts are tightened + Check for tube damage. + Repair as necessary. Relief Valve Unit Relief Valve opening during purge + Check enclosure pressure on start up is less than Relief Valve lift off pressure. MiniPurge Control Unit Flow sensor setting incorrect, + Check the pressure is correct on the flow sensor. Section 10: Recommended Spares List Part Number Description $0016/250 Filter kit for main air supply filter/regulator $0030/606 Purge flow sensor factory set to 6.4 mbarg $0030/016 Minimum Pressure sensor, must be factory set to the value as stated on the Customer Test and Inspection Sheet s0030/588 CLAPS Sensor must be factory set to the value as stated on the Customer Test and Inspection Sheet $0015/018 Pressure gauge (Air Supply Pressure), 0 - 10 barg $0015/135 Miniature gauge (Logic Pressure), 0-4 barg Note. The system's Pneumatic Timer may be replaced with the Expo Electronic Timer. Please contact Expo Technologies’ Sales Team for further details. Page 10 ML433 | véiSection 11: Glossary Acronym Definition AT Alarm and Trip AO Alarm Only CLAPS Closed Loop Automatic Pressurization System cu Control Unit, ET Electronic Timer FcV Flow Control Valve Is Intrinsically Safe Lc Leakage Compensation PA Power and Alarm RLV Relief Valve Unit Section 12: Drawings and Diagrams Title Drawing Number Number of Sheets D779 Control Unit D779-GA 2 Typical Claps Hook-up Diagram SYS-M000-007 1 P and | Diagram D779-Pl 1 Circuit Diagram AGM-PA00-019 1 D779 EEx e Box Layout AGE-WC00-120 1 Manual Override Switch Hook-up ‘AGE-WC00-117 1 ‘Size 3 MotorPurge Relief Valve XBR-RTDO-010 1 MiniPurge® X LC Sequence Diagram XBR-7TDO-040 1 System Status Indication TP-518-058-WD 1 Section 13: Certifications Download the certificates at www.expoworldwide.com/downloads. 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With EU-Declaration of European Conformity Directives Issued under the sole responsibilty of Expo Technologies Ltd Unit 2, The Summit, Hanworth Road ‘Sunbury on Thames TW16 5DB, UK This is to declare that “Purge Controllers: Sub-MiniPurge, MiniPurge, Super-MiniPurge, Super-MiniPurge 1800/3500/7000/7000X”, are manufactured in conformity with the following European Directives and standards: Electromagnetic Compatibility Directive 2014/30/EU MiniPurge Systems with a /PO suffix in the type number are non-electrical and are outside the scope of the EMC Directive. MiniPurge Systems with suffices /PA or /IS incorporate one or more volt-ree (‘dry’) contacts which work in Circuits Specified by others. In normal operation these circuits are “benign” and no CE mark is appropriate. MiniPurge Systems with Electronic Timer (Option JET) are designed to conform to the EMC Directive, in compliance with EN 61000-6-4:2007 and EN 61000-6-2:2005 (Intertek Report EM10048000). MiniPurge Systems are intended for use in potentially explosive atmospheres (Hazardous Areas) and are therefore excluded from the Low Voltage Directive. Pressure Equipment Directive 97/23/EC. MiniPurge Systems are classified as not higher than category | under Article 9 of this Directive and intended for use in potentially explosive atmospheres (Hazardous Areas) and are therefore excluded from the Pressure Equipment Directive. ATEX Directive 2014/34/EU Equipment for explosive atmospheres MiniPurge Systems are designed to conform to the ATEX Directive in fulfilment of the essential health and safely requirements set out in Annex Il, and in compliance with: EN 60079-0; 2012 +A11:2013 EN 60079-2: 2014 MiniPurge Systems are certified by SIRA Certification Service, Hawarden Industrial Park, Hawarden CHS 3US, England, under EC Type-Examination Certificate SIRA 01ATEX1295X, in compliance wit EN 60079-0: 2012 EN 60079-2: 2014 According to the model, MiniPurge Systems are rated and shall be marked as follows: MiniPurge, Type X & Type Y models Group II Category 26 & 2D. ©) 1122) GD MiniPurge, Type Z models Group II Category 36.&3D 1123) GD MiniPurge systems are manufactured under Production Quality Assurance Notification SIRA 99 ATEX M043, issued by SIRA Certification Service, Notified Body No 0518. Signed for and on behalf of Expo Technologies Lid., John Paul de Beer Date 16/08/2016 Managing Director Confidential Assessment file reference SCO04 S\Files\QA\CERTSIC-OF-C\Minipurge CE $C004 Issue9.doc Page 54 ML433 | vaiExpo Technologies USA Expo Technologies UK Expo Technologies China Expo Technologies Inc. Expo Technologies Lid. Qingdao Expo M&E Technologies Co. Lid 9140 Ravenna Road Unit #3 Unit 2 The Summit, Hanworth Road 329 Huashan Er Lu Twinsburg, Sunbury-On-Thames, Jimo City, Qingdao, OH 440878, USA TW16 5DB, UK 266200 China T: +1 440 247 5314 T: #44 20 8398 6011 T: +86 532 8906 9858 F: +4 330 487 0011 F: +44 20 8398 8014 F: +86 532 8906 9858 E: sales.na@expoworldwide.com E: sales@expoworldwide.com E: gingdao@expoworldwide.com www.expoworldwide.com