Pepperl+Fuchs 7500 Series User manual

Manual
7500 Series
Bebco EPS®7500 Series Type Z and
Ex pzc Purge and Pressurization System

With regard to the supply of products, the current issue of
the following document is applicable: The General Terms
of Delivery for Products and Services of the Electrical
Industry, published by the Central Association of the
Electrical Industry (Zentralverband Elektrotechnik und
Elektroindustrie (ZVEI) e.V.) in its most recent version as
well as the supplementary clause: "Expanded reservation
of proprietorship."

3
7500 Series Manual
Table of Contents
1. Preface......................................................................................................................................6
1.1 Information on This Manual ......................................................................................................6
1.2 Responsibility of the Operator and/or Installer..........................................................................6
2. Safety........................................................................................................................................7
2.1 Introduction ..............................................................................................................................7
2.1.1 Contents................................................................................................................................7
2.1.2 Target Group, Personnel........................................................................................................7
2.1.3 Symbols Used.......................................................................................................................8
2.1.4 Pertinent Laws, Standards, Directives, and Further Documentation......................................8
2.1.5 Declaration of Conformity......................................................................................................8
3. General Information on Purge and Pressurization ..............................................................9
3.1 Conditions of Safe Use.............................................................................................................9
4. 7500 Series System Components........................................................................................10
4.1 Control Unit ............................................................................................................................10
4.1.1 Technical Data—Control Unit ..............................................................................................11
4.1.2 Terminal Connection Data...................................................................................................13
4.1.3 Electrical Connections.........................................................................................................13
4.1.4 Dimensions—Control Unit...................................................................................................14
4.1.5 Panel Cut-Out Dimensions..................................................................................................14
4.1.6 Pressure Kit.........................................................................................................................15
4.1.7 Torque Requirements..........................................................................................................15
4.1.8 Dimensions—7500-MTD* External/Panel Mount Systems..................................................16
4.1.9 External/Panel Mount Illustration.........................................................................................20
4.2 EPV-7500 Vents......................................................................................................................21
4.2.1 Technical Data—EPV-7500 Vents .......................................................................................21
4.2.2 Flow Rate Curves................................................................................................................23
4.2.3 Dimensions—EPV-7500 Vents ............................................................................................25
4.3 7500-MAN-MV-01 Manual Manifold .......................................................................................26
4.3.1 Technical Data—7500-MAN-MV-01 ....................................................................................26
4.2.2 Dimensions—7500-MAN-MV-01.........................................................................................27
4.4 Automatic Manifolds...............................................................................................................28
4.4.1 Technical Data—5500 Manifolds.........................................................................................29
4.4.2 Dimensions—5500 Manifolds .............................................................................................31
5. Installation and Operation ....................................................................................................33
5.1 For Gas Atmospheres.............................................................................................................33
5.2 For Dust Atmospheres............................................................................................................33
5.3 For Gas and Dust Atmospheres .............................................................................................33
5.4 Setting Up the System............................................................................................................34
5.5 Operating the System.............................................................................................................34
6. Programming .........................................................................................................................35
6.1 LED Indication........................................................................................................................36
6.2 Default Settings ......................................................................................................................36
6.3 Contrast and Back Light .........................................................................................................36

4
7500 Series Manual
6.4 Menu Structure.......................................................................................................................37
6.5 Purge Programming Settings..................................................................................................38
6.5.1 Program 1 ...........................................................................................................................38
6.5.2 Program 2 ...........................................................................................................................39
6.5.3 Program 3 ...........................................................................................................................40
6.5.4 Program 4 ...........................................................................................................................40
6.5.5 Program 5 ...........................................................................................................................41
6.5.6 Sequence of Events for All Programs ..................................................................................42
6.6 Purging Timer ........................................................................................................................42
6.7 Minimum Enclosure Pressure “P1” .........................................................................................43
6.8 Alarm Pressure “P2” ...............................................................................................................43
6.9 Purging Pressure “P3”.............................................................................................................43
6.10 Maximum Internal Pressure “P4”.............................................................................................43
6.11 Programming K2.....................................................................................................................45
6.12 Shutdown Timer for K1 ...........................................................................................................47
6.13 Bypass ...................................................................................................................................48
6.14 Units .......................................................................................................................................48
6.15 Change Password ..................................................................................................................49
7. Determining Purging Time....................................................................................................50
8. User Parameter Setting Sheet..............................................................................................51
9. Type Codes.............................................................................................................................52
10. Certications..........................................................................................................................54
11. Maintenance and Repair .......................................................................................................56
12. Troubleshooting.....................................................................................................................56
13. Dismantling and Decommissioning.....................................................................................56

5
7500 Series Manual
This page left blank intentionally.

6
7500 Series Manual
1 Preface
We are pleased that you have chosen a quality product from Pepperl+Fuchs.
This manual will help you meet the safety and protection requirements for systems with explosion
protection in equipment group II Zones 2 or 22, Class I or II, Division 2 when installing, commissioning,
and using the 7500 control unit and its components. This important information will help you use the 7500
purge and pressurization system safely and correctly.
We reserve the right to make technical changes.
Publisher with responsibility for content:
Pepperl+Fuchs GmbH
Lilienthalstraße 200
68307 Mannheim, Germany
1.1 Information on This Manual
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 the 7500 series purge and
pressurization system.
These operating instructions contain important data and information to ensure the safe use of the
7500 system in hazardous areas and to meet the requirements of Directive 2014/34/EU. This manual,
particularly the safety information, must be followed by all personnel who work on the system.
1.2 Responsibility of the Operator and/or Installer
The operator and/or installer undertake to ensure that only specialist, trained personnel work on the 7500
series purge and pressurization 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 this manual.

7
7500 Series Manual
2 Safety
2.1 Introduction
2.1.1 Contents
This document contains information that you need to use your product throughout the applicable stages of
the product life cycle. These can include the following:
Product identification
Delivery, transport, and storage
Mounting and installation
Commissioning and operation
Maintenance and repair
Troubleshooting
Dismounting and disposal
Warning!
Failure to follow these instructions may impair the safety protection and function of the equipment.
Note!
For complete information on the product, refer to the instruction manual and further documentation at
www.pepperl-fuchs.com.
The documentation consists of the following parts:
Present document
Instruction manual
Datasheet
Additionally, the following parts may belong to the documentation, if applicable:
EU declaration of conformity
Certificates
Control drawings
Additional documents
2.1.2 Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and dismounting lies with
the plant operator. In accordance with but not limited to IEC/EN 60079-14, only appropriately trained and
qualified personnel may carry out mounting, installation, commissioning, operation, maintenance, and
dismounting of the product. National laws and regulations must be observed and take precedence over
any aspects of IEC/EN 60079-14. The personnel must have read and understood the instruction manual
and any further documentation.
Note

8
7500 Series Manual
2.1.3 Symbols Used
This document contains symbols for the identification of warning messages and of informative messages.
Warning Messages
You will find warning messages in instances where danger may arise from your actions.You must observe
these warning messages for your personal safety and to avoid property damage. Depending on the risk
level, the warning messages are displayed in descending order as follows:
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and plants, or result in
their complete failure
Informative Symbols
Note!
This symbol brings important information to your attention.
Action
This symbol indicates a paragraph with instructions.You are prompted to perform an action or
a sequence of actions.
2.1.4 Pertinent Laws, Standards, Directives, and Further Documentation
NEC, CEC, and other national and local aws, standards, or Directives that are applicable to the intended
use and installation location must be observed. In relation to hazardous areas, Directive 1999/92/EC must
be observed.
The corresponding datasheets, EU Declaration of Conformity, EU Type Examination Certificates, NEC/
NFPA and CEC certificates, and control drawings, if applicable (see datasheet), are an integral part of this
document.You can find this information at www.pepperl-fuchs.com.
Due to constant revisions, documentation is always subject to change. Please refer only to the most up-to-
date version, which can be found at www.pepperl-fuchs.com.
2.1.5 Declaration of Conformity
All products were developed and manufactured under observance of the applicable European standards
and guidelines.
Note!
A declaration of conformity is included with these instructions and can be requested from the manufacturer
or obtained online at www.pepperl-fuchs.com.
Warning
Note
Note

9
7500 Series Manual
3 General Information on Purge and Pressurization
Purge and pressurization is one of the most versatile ignition protection classes. Purge and pressurization
systems 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, sufficiently compressed inert gas, usually air, is supplied to compensate
for leaks in the housing and any installed equipment. This permanent overpressure prevents any potentially
explosive atmosphere in the ambient air from entering the housing. During the purge phase, an internal
pressure is achieved.
For applications in Zone 22/Class II Division 2 (dust), the purge process is omitted because purging would
raise explosive dust into a cloud, creating a possible hazard. Instead of pre-purging, the interior of the
housing is inspected for dust and cleaned manually if dust is present.
Purge and pressurization systems are particularly suitable for installed equipment that is not approved for use
in hazardous areas. The equipment can then be used directly in the hazardous area.
3.1 Conditions of Safe Use
1. The main control unit and the EPV vent are the only parts that have been evaluated for the system’s
certifications.
2. All unused entry points to the 7500 control unit shall be closed with a properly certified IECEx, ATEX,
or cULus device that is suitable for the installation location and has the necessary ingress protection.
3. For dust environments, the non-metallic window may pose an electrostatic discharge hazard. To clean
the device, use only a water-damp cloth and allow to air dry. Do not use or install in high charge-
areas. See IEC60079-32-1 for more information.
4. When the 7500 series purge and pressurization system is mounted to an enclosure, the complete
installation shall be evaluated to the appropriate standards and regulations that are applicable for
the final installation location. These include, but are not limited to NFPA 496, IEC 60079-2, and IEC
60079-14. These standards shall be available at the site of installation. See certificates for applicable
editions.
5. The purge control unit has a temperature class (T6, T5 or T4) that is dependent on ambient
temperature. This temperature shall be considered when mounted to an enclosure, or inside of an
enclosure. See details on the certificate.
6. The bypass function shall only be enabled when the area is known to be non-hazardous.
7. In a hazardous dust environment, regularly remove dust from the unit to prevent excessive
temperature rise. See certificate for full information.

10
7500 Series Manual
4 7500 Series System Components
The 7500 series system consists of a control unit, an enclosure protection vent, and manual or automatic
manifold. The control unit has a touch screen display that is menu driven and will easily guide the user in
selecting pre-programmed and user-selected variables. The 7500 can be used with a digital valve/manifold
system like the 5500-MAN-... unit to make a fully automatic system. The enclosure pressure and leakage can
be monitored and, in the event of a loss in enclosure pressure, the solenoid valve can engage to restore the
defined pressure settings and/or alarm for the pressure drop. An easy-to-see display also has 4 LEDs for
system condition indication from a distance.
4.1 Control Unit
The 7500 control unit is a control device 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 flowing
into the explosion-protected control cabinet, and it maintains and monitors an overpressure relative to the
ambient air when purging is complete.
The 7500 control unit can be ordered as a stand-alone unit for panel mounting to your enclosure or mounted
to a panel with the 7500-MAN-MV-01 valve in a configuration.
Control Unit Components
7500 control unit
Mounting bracket, gasket, and screws for enclosure mounting
Manual
Warning!
The conduit hub extension, 7500-HUB-AA-01, can only be mounted once to the 7500 control unit. If
removed, it cannot be reinstalled. A new conduit unit must be purchased.

11
7500 Series Manual
4.1.1 Technical Data—Control Unit
General specifications
Equipment architecture max. enclosure size 450 ft3(12.7 m3)
Operating mode fully automatic (FA)
Series 7500
Hazardous environment gas or dust
Supply
Rated voltage Ur20 ... 30 V DC at 0.1 A
90 ... 250 V AC, 50 ... 60 Hz at 0.04 A without solenoid valve
Supply voltage can be line-to-line or line-to-neutral, single phase
OVC II
Power consumption max. 2.7 W / 7.3 VA without valve
Accuracy pressure readings: ± 2 %
timers: ± 5 %
Electrical specications
Connection screw terminals—see manual for specications on wire size and
torque values
Output
Output I
Connection K1, terminals, 1 x NO
Output type enclosure power contacts
Contact loading 5 A at 250 V AC , 5 A at 30 V DC, relays must be externally fused
inrush current: 50 A
Output II
Connection K2, terminals, 1 x NO
Output type alarm and control contacts
Contact loading 5 A at 250 V AC , 5 A at 30 V DC, relays must be externally fused
inrush current: 50 A
Output III
Connection K3, terminals, L1 powered contact
Output type solenoid manifold, contact
Inrush current 5 A
Contact loading 0.5 A at 250 V AC , 0.5 A at 30 V DC, relays must be externally fused
Indicators/settings
LED indicator K1: Green - Contact K1 is energized (enclosure contacts)
K2: Amber - Contact K2 is energized (alarm/control contacts)
P/SV: Blue - Safe pressure P1 (minimum enclosure pressure)
P/SV: Amber - Solenoid manifold is energized (purging/pressure
compensation)
Pneumatic parameters
Protective gas supply compressed air or inert gas, 5 µm lter, free from oil
Pressure requirement supply pressure: 20 ... 120 psig (1.4 ... 8.2 bar)
Safe pressure 0.25 in wc (0.63 mbar) minimum for gas
0.65 in wc (1.63 mbar) minimum for dust
Enclosure pressure 0 ... 10 in wc (0 ... 25 mbar)
Conformity
Ambient conditions
Ambient temperature -40 ... 70 °C (-40 ... 158 °F) at T4 / T80°C
-40 ... 65 °C (-40 ... 149 °F) at T5 / T75°C
-40 ... 50 °C (-40 ... 122 °F) at T6 / T60°C
Storage temperature -40 ... 80 °C (-40 ... 176 °F)
Altitude max. 2000 m
Relative humidity 5 ... 90 %, non-condensing

12
7500 Series Manual
Vibration resistance 5 ... 100 Hz , 1 g, 12 m/s2, all axes
Impact resistance 30 g, 11 ms, all axes
Mechanical specications
Connection type electrical: 2 x 1/2 inch NPTF (open from factory)
1 x M12 opening (plugged from factory)
pneumatic: high-pressure port - 1/8 in NPTF, low-pressure port - 1/8
in NPTF
Degree of protection Type 4X, IP66
No ratings for mounting to enclosure for 7500-MTD-BX...
Material lens: Makrolon®GP-V polycarbonate
screws: AISI 316 (1.4401), 304, or 18-8 stainless steel
housing: A380, A356, or 6061-T6 aluminum
mounting gasket: Bisco®HT-800 medium cellular silicone
mounting tabs: SAE 304 stainless steel
M12 plug: 6061-T6 aluminum
Mass 710 g (1 lb 10 oz)
Dimensions 150 x 100 x 50 mm (5.9 x 4 x 2 in)
Data for application in connection
with hazardous areas
Certicate
Marking II 3 G Ex ec nC [pzc] IIC T6...T4 Gc
II 3 D Ex tc [pzc] IIIC T60 °C ... T80 °C Dc
Directive conformity
International approvals
UL approval
cULus Class I, Division 2, Groups A, B, C, D T4 (-40 °C ≤ Ta ≤ 70 °C)
Class I, Division 2, Groups A, B, C, D T5 (-40 °C ≤ Ta ≤ 65 °C)
Class I, Division 2, Groups A, B, C, D, T6 (-40 °C ≤ Ta ≤ 50 °C)
Class II, Division 2, Groups F, G T4 (-40 °C ≤ Ta ≤ 70 °C)
Class II, Division 2, Groups F, G T5 (-40 °C ≤ Ta ≤ 65 °C)
Class II, Division 2, Groups F, G T6 (-40 °C ≤ Ta ≤ 50 °C)
IECEx approval Ex ec nC [pzc] IIC T6...T4 Gc
Ex tc [pzc] IIIC T60 °C ... T80 °C Dc
General information
Supplementary information Type Examination Certicate, Declaration of Conformity, and instruc-
tions have to be observed where applicable. For information see
www.pepperlfuchs.com.
4.1.2 Terminal Connection Data
Conductor cross section solid max. 0.2 mm²
Conductor cross section solid max. 6 mm²
Conductor cross section exible min. 0.2 mm²
Conductor cross section exible max. 4 mm²
Conductor cross section exible, with ferrule without plastic sleeve min. 0.25 mm²
Conductor cross section exible, with ferrule without plastic sleeve max. 4 mm²
Conductor cross section exible, with ferrule with plastic sleeve min. 0.25 mm²
Conductor cross section exible, with ferrule with plastic sleeve max. 4 mm²
Conductor cross section AWG min. 24
Conductor cross section AWG max. 10

13
7500 Series Manual
4.1.3 Wiring Requirements and Electrical Connections
Wiring Requirements
1. All applicable local and national wiring codes must be followed when wiring the system.
See IEC 60079-14 for more information.
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 in which it is being installed. Placing the disconnect into the purged enclosure is not
a "safe" area since power needs to be applied to the control unit before the purge cycle is complete.
3. The protective earth wire must be the same size as largest wire used to bring power into the enclosure.
Terminate using a ring lug that is properly crimped at the protective earth stud in the bottom of the
enclosure. The protective earth terminal torque is 12 in lb (1.36 Nm).
4. All wire shall be copper only, rated at a minimum of 80 °C.
5. The wire strip length into the fixed terminal block is 8 mm.
6. The terminal torque is 0.5 Nm to 0.6 Nm.
7. There shall be only one wire per terminal.
8. It is recommended to leave a bit of extra wire loop in the housing.
Electrical Connections
Warning!
When connecting line-to-line power and K1 and K2 are used to switch the power, the alarm function is not
available. For more information, see chapter 6.11.
Warning!
When powering the system line-to-line, both lines are present if K3 is used. In this event, both sides of the
relay contacts must be fused.
Caution!
Use ferrules with all stranded wire types.
Alarm/
Encl Encl
ValveL/L1/+
N/L2/-N/L2/-
Electrical Connections
Te rminal Block Connections
Te rminal Block
L /L1/+SV1Alarm/Encl
K2
Encl
K1
N /L2/-N /L2/-
Protective
earth

14
7500 Series Manual
4.1.4 Dimensions—Control Unit
1. High-pressure port 1/8-27 NPT
2. Low-pressure port 1/8-27 NPT
3. Protective earth stud, torque 12 in lb (1.35 Nm)
4.1.5 Panel Cut-Out Dimensions
149
136
97
84
4 x
R11
4 x
R4.5
48
13
34
10
7
10
20 20
19 19
4 x
M4 x .7
127 136
1/2-14
NPT
M12 x 1.5
4.5
17.522
84
75
44
1
2
3
137 ± 0.5
85 ± 0.5 4 x R5 ± 1

15
7500 Series Manual
4.1.6 Pressure Kit
The included pressure kit contains the following components:
Bulkhead fitting
O-ring
Tubing
Tubing inserts
Straight connector
Sintered element for bulkhead fitting
4.1.7 Torque Requirements
Hardware Torque
Main lid 12 in lb (1.36 Nm).
M4 screws for mounting bracket 12 in lb (1.36Nm).
Screws for mounting HUB 12 in lb (1.36 Nm).
M12 plug 15 in lb (1.70 Nm).
Panel mount bracket hardware Tighten evenly to a uniform gasket thickness of 1.3 mm to 1.7 mm
Set screws to mount control unit in panel Tighten until control unit is touching metal-to-metal around all edg-
es
Manifold mounting hardware Tighten hardware until gasket is compressed 0.64 mm to 0.96 mm
(use washers provided)

16
7500 Series Manual
4.1.8 Dimensions—7500-MTD-* External/Panel Mount Systems
7500-MTD-BXRW-01 Rectangular External Mount with Control Unit and Manifold

17
7500 Series Manual
7500-MTD-PMRW-01 Rectangular Panel Mount with Control Unit and Manifold

18
7500 Series Manual
7500-MTD-BXSW-01 Square External Mount with Control Unit and Manifold

19
7500 Series Manual
7500-MTD-PMSW-01 Square Panel Mount with Control Unit and Manifold

20
7500 Series Manual
4.1.9 External/Panel Mounting Illustration