Spirax Sarco MPC1 User manual

IM-P054-08 CH Issue 5 1
MPC1, MPC2 and MPC2A Spirax-Monnier
High Efficiency Compressed Air Filter /Regulators
Installation and Maintenance Instructions
IM-P054-08
CH Issue 5
0549750/5
1. Safety information
2. General
product information
3. Installation
and commissioning
4. Operation
5. Spare parts
and maintenance
Printed in the UK © Copyright 2006

IM-P054-08 CH Issue 52

IM-P054-08 CH Issue 5 3
1. Safety information
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended use/application.
The products comply with the requirements of the European Pressure Equipment
Directive 97 /23 /EC and fall within the category 'SEP'. It should be noted that
products within this category are required by the Directive not to carry the mark.
i) The products have been specifically designed for use on compressed air,
which is in Group 2 of the above mentioned Pressure Equipment Directive.
The products’ use on other fluids may be possible but, if this is contemplated,
Spirax Sarco should be contacted to confirm the suitability of the product for
the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are fitted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.
v) Remove protection covers from all connections and protective film from all
name-plates, where appropriate, before installation on steam or other high
temperature applications.
Safe operation of these products can only be guaranteed if they are properly
installed, commissioned, used and maintained by qualified personnel (see Section
1.11) in compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, as well as the proper use of tools
and safety equipment must also be complied with.
Directive 94 / 9 / EC (ATEX95) Declaration
The MPC1 is intended for use in potentially explosive environments as defined by
Equipment Group II Category 2.
• We have determined the MPC1 is a 'simple' mechanical product. It is therefore not
covered by the scope of the ATEX directive and consequently does not need to carry
any marking
As part of our conformity assesment, an ignition hazard analysis to EN 13463-1 was
conducted with the following outcome:
• We have determined the MPC1 does not have its own effective sources of ignition - even
in the event of rare failures.
Note: As defined by the European ATEX Standing Committee... "Electrostatic charges
caused by the flow-through of a medium are not considered as "own" ignition source in
the sense of directive 94 / 9 / EC."
The MPC1 may be used in a potentially explosive environment, as defined by Equipment
Group II Category 2, when used in accordance with its Installation and Maintenance
Instructions (IM-P054-08).
The MPC1 compressed air filter / regulator is ATEX compatible -

IM-P054-08 CH Issue 54
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and /or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high/low temperature,
radiation, noise, falling objects, and dangers to eyes and face.

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1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and /or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of some products
may reach temperatures of 90°C (194°F).
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation (refer to 'Maintenance instructions').
1.14 Freezing
Provision must be made to protect products which are not self-draining against
frost damage in environments where they may be exposed to temperatures below
freezing point.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this
product is recyclable and no ecological hazard is anticipated with its disposal
providing due care is taken.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and
Environment Law, when returning products to Spirax Sarco they must provide
information on any hazards and the precautions to be taken due to contamination
residues or mechanical damage which may present a health, safety or
environmental risk. This information must be provided in writing including Health
and Safety data sheets relating to any substances identified as hazardous or
potentially hazardous.

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2. General product information
2.1 General description
The Spirax-Monnier MPC range of (self-relieving) high efficiency oil removing filter/regulators
provide very high quality compressed air, with accurate pressure control, for pneumatic
actuators and general purpose systems.
How efficient is the MPC product range?
Spirax-Monnier coalescing filters when tested to BS 3928 or the D.O.P. test, are more
than 99.99% efficient.
In the sodium flame test (BS 3928) the element is challenged by a cloud of salt particles
of mass mean diameter of 0.6 micron.
In the American D.O.P. test, a cloud of droplets of mass mean diameter 0.3 micron is
used.
Available types supplied as standard
MPC1 ATEX compatible.
Metal bowl with manual drain and tamper-proof cap.
MPC2 Polycarbonate bowl with manual drain.
MPC2A Metal bowl with autodrain.
2.2 Sizes and pipe connections
¼" screwed BSP (BS 21-Rp, ISO 7)
2.3 Operating pressure ranges
All regulators can be adjusted to zero pressure, or above the figures shown. The operating
range is marked on the unit:
0.2 - 2.0 bar g (White) 0.3 - 4.0 bar g (Pink) 0.7 - 9.0 bar g (Black)
MPC optional extras - Selection table
S = Supplied as standard OE = optional extra = not available
Feature MPC1 MPC2 MPC2A
Polycarbonate bowl Without drain OE
With manual drain S
Bowl guard OE
Metal bowl With manual drain S OE
(no sight glass) With autodrain S
Tamper-proof cap With locking seal S OE OE
Pressure gauge 50 mm Ø OE OE
40 mm Ø S OE OE
Type 8 mounting bracket OE OE
FK21 fixing kit S OE OE
Aluminium locking ring S OE OE
Note: Airsets consist of an MPC with a 40 mm Ø pressure gauge, locking seal and FK21
fixing kit. A tamper-proof cap with locking seal is recommended as an optional extra for
MPC2 and MPC2A airsets.

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Fig. 1 MPC2 Spirax-Monnier high efficiency compressed air filter /regulator
MPC2
shown with optional
pressure gauge
2.4 Operating limits
Maximum Polycarbonate bowl 10 bar g @ 50°C (145 psi g @ 122°F)
pressure /temperature Metal bowl 17 bar g @ 80°C (246.5 psi g @ 176°F)
2.5 Materials
Part Material
Body Aluminium - anodised finish
Plastic bowl Polycarbonate or aluminium alloy
Bonnet assembly Polycarbonate or alluminium
Filter element Microfibre /stainless steel
Valve Nitrile

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3. Installation and commissioning
3.1 Specific product safety information
Polycarbonate bowls may be attacked by phosphate ester based fluids, solvents, chemical
cleaners, carbon tetrachloride, etc. These and any other substances should not be allowed
to come into contact with this component. Certain compressor lubricating oils also contain
additives harmful to polycarbonate. Where there is any doubt we recommend, in the interests
of personal safety, that bowl guards or metal bowls be fitted.
Dimensions /weight (approximate) in mm and kg
Unit Size A B C E E1 Weight
MPC1 ¼" 75 167 41 25 - 0.2
MPC2 ¼" 65 155 41 25 45 0.2
MPC2A ¼" 75 167 41 25 - 0.2
3.2 General information
Type 8 mounting bracket (Fig. 2) and
mounting ring for general installations
The filter /regulator can be mounted using
this zinc plated mild steel bracket and
aluminium mounting ring. Both items are
optional extras and must be specified when
placing an order.
Dimensions (approximate) in millimetres
FK21 fixing kit (Fig. 3)
The FK21 fixing kit is required to mount
the MPC2 onto the Spirax Sarco range of
PN pneumatic actuators. The fixing kit and
aluminium mounting ring are optional extras
and must also be specified when placing
an order.
Note: Before actioning any installation observe the 'Safety information' in Section 1.
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended installation.
Fig. 3 FK21 fixing kit
40
Fig. 2 Type 8 mounting bracket
5
12.7
12.7
10
38
64 51
29
31
E1 with bowl guard
Withdrawal distance: E without bowl guard
C
A
B
Fig. 4
MPC2 Spirax-Monnier high efficiency compressed air filter /regulator (Fig. 4)
30.5 Ø8.2
32
61.5

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3.3 Installation
3.3.1 The unit should be fitted in horizontal pipework with the bowl vertically downwards.
3.3.2 Adequate space should be provided around the unit to allow easy access for routine
servicing requirements (see Figure 4 for withdrawal distances).
3.3.3 Connect the unit so that the airflow is in the direction indicated by the arrow on the body.
3.3.4 The unit should be installed as close as possible to the equipment it is serving.
3.3.5 The body has two R " ports, one of which is available for fitting a pressure
gauge to register the secondary pressure. In the event that a pressure gauge is
not fitted, this port should be blanked off with the blank plug provided. Ensure
that the range of the pressure gauge corresponds with that of the main control
spring as indicated on the unit. The second port should not be used for any
purpose and is sealed with a factory fitted plug which should not be removed.
3.3.6 Do not overload the filter cartridge (see Section 4 - Operation) or there will be
a reduction in its efficiency and/or life. On heavily contaminated systems, it is
advisable to fit a conventional pneumatic filter (Spirax-Monnier International or
Miniature) immediately in front of the unit for maximum efficiency and life cycle.
3.3.7 The polycarbonate bowl may be fitted with a bowl guard, or replaced with a metal bowl.
3.4 Adjustment
- If a locking seal (18) is fitted, remove it to readjust the set pressure to the required value.
- Lift the locking ring (11).
- Turn the adjustment knob (10) clockwise to increase the pressure.
- Depress the locking ring (11) to lock.
Note: A metal tamper-proof cap (an optional extra) may be fitted over the adjustment
housing. It is recommended that all adjustments be made under flowing conditions. There
will be a slight increase in set pressure when the flow stops.
Fig. 5 Adjustment
18
10
11
Tamper-proof cap

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4. Operation
4.1 Operating principals
These units filter out solid contaminants and remove oil and water liquids and aerosols, by
coalescing.
Contaminated air flows to the inside of the filter cartridge. The cartridge contains a labyrinth
of micro fibres which will trap solid particles down to sub micron size. Fine liquid mist and
aerosols on their journey through the depth of the element, will strike one or other of the
fibres and will be retained on them by inter-molecular forces.
As the droplets migrate through the element due to the air flow, they will join (coalesce) with
others, growing in size. A specially designed porous plastic sock forms the outer layer of
the filter cartridge. This encourages further coalescing, so that the droplet mass is sufficient
to allow it to gravitate to the sump of the filter from which they can be drained manually.
The porous plastic sock also reduces the possibilty of re-entrainment.
With the adjustment knob (10) rotated fully anticlockwise, the valve return spring (17) will
keep the main valve (12) shut. Clockwise rotation of the adjustment knob will compress the
main control spring (15), deflect the diaphragm assembly (14) downwards, opening the main
valve (12). As air flows to the downstream (13) side of the filter/regulator, the secondary
pressure increases. The secondary pressure is sensed on the underside of the diaphragm.
As the controlled pressure varies, so does the force on the underside of the diaphram.
When this force (proportional to the secondary pressure) equals the compression in the
main control spring, the main valve will shut. Any fall in the secondary pressure will cause
the main valve to open sufficiently to meet the air flow requirements and maintain the set
secondary pressure.
Any appreciable rise in the secondary pressure from its set value will cause the diaphragm and the
pushrod (16) to lift. This will allow air to escape through the centre of the push rod to atmosphere.
When excess pressure has vented, the orifice in the pushrod will reseat on the main valve.
Ensure that the bowl is regularly drained by means of the quick action drain valve (9).
Do not exceed the maximum flowrate (for any given pressure) as shown in Section 4.3 or
there is every chance that some of the coalesced liquids will be re-entrained and carried
on downstream.
4.2 Performance selection (with proimary pressure 10 bar)
For any specified primary filtration pressure, there is a maximum recommended air flowrate.
Keeping within this, will ensure that the element performance maintains the stated high
efficiency levels, particularly for the removal of oil and water contaminants.
4.3 Maximum secondary flow at peak performance
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Use of the product in this region may reduce the oil removing efficiency.
Air flow scfm
Secondary pressure bar g
Secondary pressure psi g
Air flow dm3/s

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Fig. 6 Operation
Stainless steel screen
Chemically resistant foam sock
Boroscilicate microfibre
Support medium
10
11
14
12
13
9
17
16
15
Optional extra
18
Optional extra
Tamper-proof
cap

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5. Spare parts and maintenance
5.1 Spare parts
The spare parts available are detailed below. No other parts are supplied as spares.
Available spares
Polcarbonate bowl,
Metal bowl, (specify with or without drain) 1, 2
Drain assembly
Element and 'O' ring set 2, 3, 4
Bowl guard assembly (MPC2 only) 5, 6, 7
Note: In the interests of safety Spirax Sarco
recommend that a bowl guard (an optional extra)
should be fitted to polycarbonate bowls.
How to order spares
Always order spares by using the desciption
given in the column headed 'Available spares'
and state the size and type of unit.
Example: 1 - Element and 'O' ring set for
a Spirax-Monnier MPC2 high efficiency
compressed air filter /regulator.
5.2 Maintenance
To service the filter (no tools required):
- Isolate the main air supply.
- Release the pressure by turning the main
control knob (8) fully anticlockwise, remove
the bowl guard if fitted and depress the
drain valve (9).
- Remove the bowl (1) and unscrew the filter
element assembly (2, 3 and 4).
- Clean the bowl using soap and water and
dry with a lint free cloth.
- Reassemble in reverse order, ensuring that
the element 'O' ring (4) is fitted.
- The bowl should be firmly hand tightened.
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






Optional extra
Tamper-proof
cap with
Locking seal
Optional extra
Mounting ring
Optional extra
Type 8 or FK21
mounting
bracket
Optional extra
Pressure gauge
(Not available
for the MPC1)
Optional extra
Bowl guard
(MPC2 only).
Optional extra
Metal bowl
8
2
4
3
6
9
1
7
5
*
Note: Not available as spares.
*
*
Fig. 7 Spares and optional extras