Pepperl+Fuchs 6000 SERIES User manual

INSTALLATION AND OPERATION MANUAL
6500 Purge and Pressurization System
PROCESS AUTOMATION
MANUAL

b
6000 Series Purge/Pressurization System I/O Manual
With regard to the supply of products, the current
issue of the following document is applicable:
The General Terms of Delivery for Products and
Services of the Electrical Industry, published by
the Central Association of the Electrical Industry
(Zentralverband Elektrotechnik und Elektroindustrie
(ZVEI) e.V.) in its most recent version as well as the
supplementary clause: "Expanded reservation of
proprietorship".

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6000 Series Purge/Pressurization System I/O Manual
Contents
1. Safety 1
1.1 Introduction 1
1.1.1 Contents 1
1.1.2 Target group, personnel 1
1.1.3 Symbols used 2
1.1.4 Pertinent laws, standards, directives, and further documentation 2
1.1.5 Declaration of conformity 2
1.1.6 Markings / Certifications 3
1.1.7 Responsibility of the operator and/or installer 4
1.1.8 General information on the ignition protection class – purging/pressurization system 4
1.1.9 Conditions of safe use 5
2. The 6500 purge and pressurization system – general explanation of the system 6
2.1 Standard vs. dilution applications 6
2.2 The 6500 system 7
2.3 6500 control unit 9
2.4 Technical specifications 10
2.5 Electrical connections 14
2.6 Dimensions 16
2.7 Mounting of the control unit – external, internal, internal with remote UIC mounting 20
3. EPV-6500 pressure relief vent 23
3.1 Introduction 23
3.2 Technical specifications 24
3.3 Electrical connections 26
3.4 Dimensions 27
3.5 Flow rate curves 28
3.6 Mounting of the EPV-6500 vent – Inside and outside 30
4. Manifold valves 31
4.1 6500-MAN-DV 31
4.2 6500-MAN-PV 31
5. Cable glands 6500-CBLG-... 32
6. Sequence of events 33
6.1 Turning on enclosure power 33
6.2 Turning off enclosure power 34

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6000 Series Purge/Pressurization System I/O Manual
7. Installation and operation - the 6500 purge and pressurization system 35
7.1 The ‘pxb’ and ‘pyb’ systems 35
7.2 For gas atmospheres 35
7.3 For dust atmospheres 35
7.4 For dust and gas atmospheres 35
7.5 Dilution applications 35
7.6 Setup procedures for standard applications 39
7.7 Operation for standard applications 39
8. Programming the 6500 purge/pressurization system 41
9. Stats 51
10. Model number designation 54
11. Connection sizes, lengths, and bends 55
12. Purge 6500 user-interface programming worksheet 56
13. Maintenance & repair 60
14. Alarm and fault conditions 60
15. Dismantling & decommissioning 61
16. P+F Purge & Pressurization Smart App 62
Contents (continued)

6500 Series Purge and Pressurization System I/O Manual
1
1 Safety
1.1 Introduction
1.1.1 Contents
This document contains information that you need in order 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
Disposal
Note!
Failure to follow these instructions may impair the safety protection and function of the equipment.
Note!
For full information on the product, refer to the instruction manual and further documentation on the Internet
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:
EC-type of examination
EU declaration of conformity
Attestation of conformity
Certificates
Control drawings
Additional documents
1.1.2 Target group, personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and dismounting lies with
the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation, commissioning,
operation, maintenance, and dismounting of the product. The personnel must have read and understood
the instruction manual and the further documentation.
Prior to using the product make yourself familiar with it. Read the document carefully.
Note
Note

6500 Series Purge and Pressurization System I/O Manual
2
1.1.3 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, whenever dangers may arise from your actions. It is
mandatory that you observe these warning messages for your personal safety and in order to avoid
property damages.
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.
1.1.4 Pertinent laws, standards, directives, and further documentation
Laws, standards, or directives applicable to the intended use must be observed. In relation to hazardous
areas, Directive 1999/92/EC must be observed.
The corresponding data sheets, declarations of conformity, EC Type-examination certificates, certificates
and control drawings if applicable (see data sheet) are an integral part of this document.You can find this
information under www.pepperl-fuchs.com.
Due to constant revisions, documentation is subject to permanent change. Please refer only to the most
up-to-date version, which can be found under www.pepperl-fuchs.com.
1.1.5 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 set of instructions an can be requested from the
manufacturer or obtained on line at www.pepperl-fuchs.com.
Warning
Note
Note

6500 Series Purge and Pressurization System I/O Manual
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1.1.6 Markings / Certifications
Markings for the 6500 control unit: 6500-01-EXT1-…
ATEX UL/Demko 16 ATEX 1640X
 
 
 
 
IECEx UL 16.0003X
 
 
 
 
Markings for the 6500-01-PM01-…. and 6500-01-PM02-….
ATEX UL/Demko 16 ATEX 1640X
 
 
 
 
IECEx UL 16.0003X
 
 
 
 
Markings for the 6500 user-interface (UIC) for panel mount version
Part of ATEX UL/Demko 16 ATEX 1640X
 
 
 
 
Part of IECEx UL 16.0003X
 
 
 
 
Markings for the EPV-6500 pressure relief vent
DEMKO 15 ATEX 1622 X
II 2 G Ex ib [pxb] IIC T4 Gb
II 2 D Ex ib [pxb] IIIC T135 °C Db
II 2 G Ex ib [pyb] IIC T4 Gb
II 2 D Ex ib [pyb] IIIC T135 °C Db
-20 °C Ta 
IECEx UL 15.0147X
Ex ib [pxb] IIC T4 Gb
Ex ib [pxb] IIIC T135 °C Db
Ex ib [pyb] IIC T4 Gb
Ex ib [pyb] IIIC T135 °C Db
-20 °C Ta 

6500 Series Purge and Pressurization System I/O Manual
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1.1.7 Responsibility of the operator and/or installer (include cable gland, mounting, operation
of unit, purge supply requirement)
The operator and/or installer undertake to ensure that only specialist, trained personnel work on the 6500
purge/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 additional knowledge of explosion protection that is required for the work on explosion
protected components.
Are familiar with the relevant rules and regulations for the installation, operation and maintenance of
explosion-protected systems.
The operator and/or installer must also ensure that:
The 2-wire RTD for temperature measurement is suitable for the area classification, Zone 1 or
Zone 21, and maximum length of 3 meters
The bypass switch, if used, is suitable for the area classification, Zone 1 or 21
Cable glands must be suitable for the area classification, Zone 1, or 21, and IP ratings required.
1.1.8 General information on the ignition protection class – purging/pressurization system
Purging and pressuring systems are one of the most versatile ignition protection classes. They are based
on the principle that in Zone 1 (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 should be monitored by
temperature sensors and switched off safely if necessary. This ensures that no unacceptably high surface
temperatures can reach the exterior.
For applications in Zone 21 (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.
When dealing with containment systems and dilution applications, refer to the applicable standards for the
requirements. In some cases, dilution with compressed air is not possible and Nitrogen or some other type
inert gas is required.
Note!
When using an inert gas like nitrogen, an asphyxiation hazard can exist.
The purge and pressurizing system is particular suitable for installed equipment that is not approved for
the use in hazardous areas. It can then be used in the hazardous area when properly installed.
Note!

provides a solution for both at the same time but would have to be evaluated by the certification bodies for
approval.
Note
Note

6500 Series Purge and Pressurization System I/O Manual
5
1.1.9 Conditions of safe use
Danger!
Non-observance of conditions of safe use will result in personal injury or death.
6500 control unit
1. The purge control unit has an operating temperature class of 135 ºC (T4 temperature class). This
temperature shall be considered when mounted to an enclosure.
2. When the purge control unit is mounted to an enclosure, the complete unit shall be evaluated to IEC/

3. Intrinsically safe cables extending from the main enclosure must be provided with at least 0.25 mm
insulation thickness per conductive core to maintain segregation between intrinsically safe circuits.
4. The nonmetallic touchpad and display does not pose an electrostatic discharge hazard under normal
use conditions. Use only water damp cloth and allow to air dry for cleaning device. Do not use or install

5. In hazardous dust environment, regularly remove dust from the control unit enclosure and EPV vent to
prevent excessive temperature rise. See certificate for full information.
6. Cable glands and/or blanking elements used with this system shall be properly ATEX/IECEx rated for
the environment they are being used in, with the proper temperature ratings. Only the cable gland size
identified for a particular hole shall be fitted to the hole.
 For systems that incorporate the UIC in the lid of the enclosure, system shall not be mounted such that
the UIC is facing up.
8. Attention: The maximum cable length between the vent or UIC and the control unit is 245 ft


9. The relay contact circuits shall be externally fused at installation. Each circuit shall have a fuse that
is rated for the voltage type being used (AC or DC) with a breaking capacity of at least 1500 A. The
rating of the fuse for the enclosure power connections shall not exceed 11 A. for the Aux relay, it shall
not exceed 3 A.
EPV-6500 pressure relief vent
1. The EPV vent has an operating temperature class of 135 ºC (T4 temperature class).This temperature
shall be considered when mounted to an enclosure.
2. When the purge control unit is mounted to an enclosure, the complete unit shall be evaluated to IEC/

3. Cables used to connect to an EPV- vent must be provided with at least 0.25 mm insulation thickness
per conductive core to maintain segregation between intrinsically safe circuits.
4. In hazardous dust environment, regularly remove dust from the EPV vent to prevent excessive
temperature rise. See certificate for full information.
5. In hazardous dust environment, the connector end of the vent shall be protected from direct exposure
of a UV light source. See certificate for full information.
6. Only EPV-6000-xx-xx vents can be connected to any certified Model 6000 control system.
 Only EPV-6500-xx-xx vents can be connected to any certified 6500 control system.
Warning

6500 Series Purge and Pressurization System I/O Manual
6
2 The 6500 purge and pressurization system – general explanation
of the system
The Pepperl+Fuchs 6500 purge and pressurization controller allows for general purpose equipment to
operate in a Zone 1/21 hazardous area to achieve an Ex px rating, or Zone 2/22 rated equipment mounted
in an enclosure in a Zone 1/21 hazardous area to achieve an Ex py rating. The 6500 control unit and EPV-
6500 vent is certified for Ex px or Ex py applications.
2.1 Standard vs. dilution applications
The 6500 purge and pressurization system can be set up for standard or dilution applications. Standard
applications are pressurizing enclosures that have equipment within the pressurized enclosure that does
not contain any hazardous gas.
Dilution applications are enclosure systems that do not have a containment system within the enclosure.
Containment systems in this context are usually used in analyzer applications where a small stream of
hazardous gas enters the pressurized enclosure and is analyzed for its content.This containment, (within
the pressurized enclosure), is the piping, enclosure, and any other device that can hold the hazardous gas,
which has the potential to leak within the enclosure. Depending on the leakage rate and if it is normal or
abnormal potential will demand the type of purging required and the equipment needed.
Note!
If the leakage rate cannot be determined or it is unlimited, then inert gas is required and dilution cannot be
used.
Note

6500 Series Purge and Pressurization System I/O Manual
7
2.2 The 6500 system
The 6500 purge/pressurization system consists of the following devices:
6500 control unit:The control unit provides all the functions
including user-defined functions. The 6500 controls the actions
for the system and supplies the supporting devices.
EPV-6500 vent: The EPV-6500 vent provides pressure
relief to the pressurized enclosure and feedback to the
6500 control unit with pressure and flow information. The
EPV-6500 vent is intrinsically safe with I.S. power and signal
protection from the 6500 control unit.There are two families
of vents that are selected at the time of ordering and can
provide standard application parameters or are specific to
dilution applications.
6500 MAN-DV manifold system (optional):The 6500-
MAN manifold has a digital valve that is activated by the 6500
control system for purging and cooling and pressure control.
It is intrinsically safe and has a needle valve for adjusting the
pressure in the enclosure after purging or pressurization.

6500 Series Purge and Pressurization System I/O Manual
8
Warning!
When using other customer provided electrical valves, please follow the entity parameters of the valve and
the output of the 6500 control unit.
6500-MAN-PV proportional valve (optional): This valve is used for dilution applications when the EPV-6500
continuous vent is used. It can also be used for standard applications.The EPV-6500-MAN-PV is activated
by the 6500 control system and is intrinsically safe.
Warning!
When using other customer provided electrical valves, please follow the entity parameters of the valve and
the output of the 6500 control unit.
6500-CBLG cable glands: The 6500 control system does not come
with cable glands. Customers can supply their own approved
cable glands or order the power and I.S. cable glands from
Pepperl+Fuchs.
Warning!
When using customer supplied cable glands, check for the required certification and installation of
selected cable glands for proper installation.

6500 Series Purge and Pressurization System I/O Manual
9
2.3 6500 control unit
The 6500 control unit is the control of the pressurized
system and is suitable for zone 1 and 12, Ex pxb and Ex pyb
applications.
The 6500 control unit can be ordered for different mounting
configuration for different applications. This unit does not
come with cable glands, which allows customers to select
the type or brand of cable glands to use but they must be
approved for the area and application. Approved cable
glands are available through Pepperl+Fuchs.
The features of the 6500 control unit are:
User selectable for pxb or pyb applications
User-interface is intrinsically safe touch that can be ordered for remote mounting
Universal power requirement, 20 to 30 VDC / 100 to 240 VAC
316L stainless steel housing with IP66 ratings
External, Internal, UIC remote mounting options
Input for 2-wire PT100 RTD for automatic temperature control/monitoring
Automatic pressure control
Digital manifold with min/max set points for pressurization
Proportional valve using user configured set points
Automatic flow control for dilution applications with the proportional valve and EPV-6500 continuous
vent
User selectable input functions
Door switch (for immediate shutdown)
Bypass control with maintenance or commissioning selections
Enclosure contacts
Auxiliary contacts for alarms, low/max pressures, control valve
RS485 com port w/HART protocol available through PACTware or other AMS systems,
DTM/DD/EDDLs available
Bluetooth connectivity with APP programs available
Cable glands not included

6500 Series Purge and Pressurization System I/O Manual
10
2.4 Technical specications
General specifications
Operating mode User programmable
Number of volume exchanges 5 to 19
Hazardous environment Gas, dust, gas and dust Note: Gas and dust are

Electrical specifications
Supply
Rated power requirement Universal AC/DC power requirement
100 to 240 VAC / 50 to 60 Hz / 200 mA
20 to 30 VDC / 600 mA
Um = 250 V
Connections
EPCU Terminal blocks and grounding screw
UIC 4-pin micro connector and cable (provided), for the
6500-01-PM02, cable length is 5 meters.
Input type Intrinsically safe, maximum cable 60 meters at 50
pf/ft and 0.2µH/ft
Inputs
Input 1 Voltage free contact or namur proximity sensor
Input type Intrinsically safe
Switch input (IS)
Uo = 9.56 V
Io = 19.4 mA
Co = 3.6 µF
Lo = 90 mH
Po = 46 mW
Input RTD (1) 2-wire, PT100 RTD
RTD input (IS)
Uo = 5.88 V
Io = 3.34 mA
Co = 43 µF
Lo = 100 mH
Po = 5 mW
Input type Intrinsically safe, Ex ib
Output
AUX output
Output type Voltage free contact outputs, SPDT configuration
Inrush current 2 A
Contact loading 2 A @ 240 VAC, resistive, 2 A @ 24 VDC
Note: External fusing is required at 3 AC or DC /
1500 A breaking current, Um = 250 V
Enclosure output
Output type Voltage free contact outputs, 2 N.O. configuration
Inrush current 8 A
Continued on next page

6500 Series Purge and Pressurization System I/O Manual
11
Contact loading 8A @ 100-250 VAC resistive to 60 ºC

8A @ 20-30 VDC resistive to 60 ºC
5A @ 20-3
Note: External fusing is required at no more than 11
amps / 1500 A breaking current, Um = 250 V
COM output HART Com via RS485, DTM through PACTware,
Um = 250 V
Digital valve When used with the 6500-MAN-DV-01, intrinsically
safe
Internal resistance 
Limit Supply current
Supply voltage
Digital valve output (IS

Io = 109 mA
Co = 84 nF
Lo = 3 mH

Open loop voltage 24 VDC
Proportional valve When used with the 6500-MAN-PV-01, intrinsically
safe
Proportional valve output (IS)
Uo = 19.11 V

Co = 251 nF

Po = 345 mW
Current 4 to 20 mA
Max. load 
Indicators
LED indicators • Safe pressure / BLUE –
safe enclosure pressure is achieved
• Enclosure power / GREEN –
enclosure power is on / RED – power is off
• Rapid exchange / BLUE –
rapid exchange is active
• System bypass / AMBER –
Warning, system bypass is active
• Alarm / Fault / RED blinking –
Alarm is detected / RED solid – fault is
detected
• Key / Green – a button on the capacitive touch
display has been activated. Momentary indication.
Continued on next page
2.4 Technical specications (continued)

6500 Series Purge and Pressurization System I/O Manual
12
Display 2x20 LCD for configuration, monitoring, and status
of the 6500 system with back light and contrast
selecting
Pneumatic parameters
Protective gas supply Instrument grade air or inert gas
Pressure requirement For 6500-MAN-DV: 1.4 to 8.3 bar (20 to 120 psig)
- regulated.
For 6500-MAN-PV: 3.5 to 6.9 bar (50 to 100 psig)
-regulated.
Note: max pressure will depend on the vent model
used.
Safe pressure Gas: 0.88 mbar (0.35” wc)
Dust: 0.88 mbar (0.35” wc)
Gas+Dust: 0.88 mbar (0.35” wc)
Note: Gas and dust are not covered by the

Valve flows
EPV-6500-__-01, 03, 05 Standard vent series
Readout on display from 56 to 850 l/min (2 to 30
scfm) in increments of 28 l/min (1 scfm). Minimum
and maximum reading depend on type of vent and
supply pressure.
See data sheet for EPV-6500 series vent.
 Continuous (dilution) vent series

to 8 scfm) continuous reading. Maximum reading
depends on type of vent and supply pressure.
See data sheet for EPV-6500 series vent.
Communication output RS485, (PACTware available)
Ambient conditions
Ambient temperature 
Storage temperature 
Relative humidity 5 … 85%, noncondensing
Vibration resistance 5 … 100 Hz, 1g, 12 m/s², all axes
Impact resistance 30 g, 11 ms, all axes
Mechanical specifications
Connection types See mounting and cable gland requirements
Degree of protection IP66
Continued on next page
2.4 Technical specications (continued)

6500 Series Purge and Pressurization System I/O Manual
13
Materials
UIC display Makrolon FI cover, A380 aluminum anodized casing
Housing 316L stainless steel
Hardware 316L stainless steel
Mass Approximately 5.0 kg (11.0 lbs)
Cable gland requirements For the 6500-CBLG requirements, please see data
sheets available at www.pepperl-fuchs.com
I.S. cable glands Requires (5) M12-approved cable glands (see ac-
cessories section for approved cable glands)
Power cable glands Requires (2) M20 and (2) M12 approved cable
glands (see accessories section for approved cable
glands)
Terminal connections requirements
Grounding bonding wire 2.5 mm²
Internal and external ground screw Torque is 14 in-lb (1.5 NM).Wire should terminate
under the screw with a ring or fork lug.
I.S. and power terminals
Wire strip length 9 mm
Minimum wire strand in stranded wire 0.1 mm or greater
Type of wire Copper only, rated at 90 °C
Tightening torque, min/max 0.4 Nm / 0.5 Nm
Conductor cross section solid min/max 0.2 mm² / 2.5 mm²
Conductor cross section stranded min/max 0.2 mm² / 2.5 mm²
Conductor cross section stranded with ferrule
without plastic sleeve min/max
0.25 mm² / 1.5 mm²
Conductor cross section stranded with ferrule
with plastic sleeve min/max
0.25 mm² / 1.5 mm²
Conductor cross section stranded AWG/kcmil
min/max
24 / 14
Wire insulation 0.25 mm minimum thickness
2 conductors with same cross section,
solid min/max

2 conductors with same cross section,
stranded min/max

2 conductors with same cross section, stranded,
ferrules without plastic sleeve min/max
0.25 mm² / .34 mm²
Warning!
The Intrinsic safety entities listed in the table above are subject to the following considerations.
The parameters are valid when one of the two conditions below is given:
The total Li of the external circuit (excluding the cable) is < 1% of the Lo value or
The total Ci of the external circuit (excluding the cable) is < 1% of the Co value.
The parameters are reduced by 50% when both of the two conditions below are given:
The total Li of the external circuit (excluding the cable) is > 1% of the Lo value and
The total Ci of the external circuit (excluding the cable) is > 1% of the Co value.
2.4 Technical specications (continued)

6500 Series Purge and Pressurization System I/O Manual
14
2.5 Electrical connections
In the 6500 control unit terminal housing

6500 Series Purge and Pressurization System I/O Manual
15
Note!
Grounding points internal and external will be identified with a ground symbol.
Warning!
There is a metal divider for the I.S. and Non I.S. wiring terminals that shall not be removed.
Note
2.5 Electrical connections (continued)
6500 UIC cable connector
'A' white wire
'B' black wire
'+' brown wire
'-' blue wire

6500 Series Purge and Pressurization System I/O Manual
16
2.6 Dimensions
6500-01-EXT1-PNO-LNO External mount