Spirax Sarco MPC1 User manual

IM-P054-08 CTLS Issue 6 1
MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
1. Safety information
2. General product information
3. Installation and
commissioning
4. Operation
5. Spare parts
6. Maintenance
© Copyright 2023
Printed in GB
0549750/6
MPC1, MPC2 and MPC2A
High E󰀩ciency Compressed Air Filter/Regulators
Installation and Maintenance Instructions
IM-P054-08
CTLS Issue 6

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
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.
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 EU Pressure Equipment Directive / UK Pressure Equipment (Safety)
Regulations 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.
1.2 Access
Ensure safe access and if necessar y a safe working platfor m (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. Safety information

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
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.
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.

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
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 other wise 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.
Please visit the Spirax Sarco product compliance web pages
https://www.spiraxsarco.com/product-compliance
for up to date information on any substances of concern that may be contained within this product .
Where no additional information is provided on the Spirax Sarco product compliance web page,
this product may be safely recycled and/or disposed providing due care is taken. Always check
your local recycling and disposal regulations.
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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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
2.1 General description
The 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.
2.1.1 How efficient is the MPC product range?
The 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.
2.1.2 Available types supplied as standard
MPC1 Metal bowl with manual drain and tamper-proof cap.
MPC2 Polycarbonate bowl with manual drain.
MPC2A Metal bowl with autodrain.
2.1.3 MPC optional extras - Selection table
Feature MPC1 MPC2 MPC2A
Polycarbonate bowl
Without drain OE
With manual drain S
Bowl guard OE
Metal bowl (no sight glass)
With manual drain SOE
With autodrain S
Tamper-proof cap With locking seal SOE OE
Pressure gauge
50 mm Ø OE OE
40 mm Ø SOE OE
Type 8 mounting bracket OE OE
FK21 fixing kit SOE OE
Aluminium locking ring SOE OE
S= Supplied as standard
OE = optional extra
= not available
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.
2.2 Sizes and pipe connections
¼" screwed BSP (BS 21-Rp, ISO 7)
2. General product information

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
Fig. 1 MPC2 high efficiency compressed air filter/regulator
MPC2
shown with optional pressure gauge
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)
2.4 Operating limits
Maximum pressure/temperature
Polycarbonate bowl 10 bar g @ 50 °C (145 psi g @ 122 °F)
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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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
3.2.2 FK21 fixing kit
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.
Dimensions (approximate) in millimetres
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.
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.
3.2 General information
3.2.1 Type 8 mounting bracket 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
Fig. 3 FK21 fixing kit
40
Fig. 2 Type 8 mounting bracket
5
12.712.7
10
38
64 51
29
31
30.5 Ø8.2
32
61.5
3. Installation and commissioning

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
E
without bowl guard
E1
with bowl guard
C
A
B
MPC2 high efficiency compressed air filter/regulator
Dimensions/weight (approximate) in mm and kg
Withdrawal
distance
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
3.3 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 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.
Fig. 4

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
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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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
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.

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
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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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
4.2 Performance selection (with primary 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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Air flow scfm
Secondary pressure bar g
Secondary pressure psi g
Air flow dm3/s
Use of the product in this region may reduce the oil removing efficiency.
Maximum recommended flow

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
Spare parts
The spare parts available are detailed below. No other parts are supplied as spares.
Available spares
Polcarbonate bowl, Metal bowl, Drain assembly (specify with or without drain) 1, 2
Element and 'O' ring set 2, 3, 4
Bowl guard assembly (MPC2 only) 5, 6, 7
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


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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
5. Spare parts
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 MPC2 high efficiency
compressed air filter/regulator.
Note:
In the interests of safety Spirax Sarco
recommend that a bowl guard (an
optional extra) should be fitted to
polycarbonate bowls.

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators
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.
6. Maintenance
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
8
2
4
3
9
1
Fig. 8

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators

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MPC1, MPC2 and MPC2A High Efficiency Compressed Air Filter/Regulators