Spirax Sarco IPC6 Bedienungsanleitung

IM-P705-02 CTLS Issue 3 1

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

1. Safety information

2. General product

information

3. Installation

4. Commissioning

5. Maintenance

6. Fault finding

7. Approvals

3440450/3

IPC6 and IPC6 ATEX

Electro-pneumatic Convertor

Installation and Maintenance Instructions

IM-P705-02

CTLS Issue 3

IM-P705-02 CTLS Issue 3

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

IM-P705-02 CTLS Issue 3 3

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

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.

WARNING: The maximum process fluid temperature must be suitable for use if the

unit is to be used in any potential explosive atmosphere. For the device maintenance

in a potentially explosive atmosphere, we recommend the usage of tools which do

not produce and / or propagate sparks.

1.1 Explosion Proof Warnings

Please ensure the unit is being used and installed in conformity with local, regional, and national

explosion proof environment.

- Refer to "7. Approvals"

- Explosion proof type of cables and gaskets should be used, when explosion gases are present

at the installation site.

- Power should be turned of before removing the plug.

- There is risk of explosion due to static electricity charge. Static electricity charge may develop

when cleaning the product with a dry cloth. It is imperative to avoid static electricity charge

in the hazardous environment. If cleaning the surface of the product is needed, must use a

damp cloth.

- Under certain extreme circumstances, the non-metallic parts incorporated in the enclosure of

this equipment may generate an ignition capable level of electrostatic charge. Therefore, the

equipment shall not be installed in a location where the external conditions are conducive to

the build-up of electrostatic charge on such surfaces. In addition, the equipment shall only

be cleaned with a damp cloth.

- The enclosures are manufactured from of aluminium alloy. In rare cases, ignition sources

due to impact and friction sparks could occur. This shall be considered during installation,

particularly if the equipment in installed in a zone 0 location.

- When the product is used and maintained in a dusty environment, corresponding cleaning

measures should be taken regularly to prevent the accumulation of dust on the surface, but

compressed air must not be used for blowing.

- This equipment contains no user-replaceable parts and is not intended to be repaired by the

user. Repair of the equipment is to be carried out by the manufacturer, or their approved agents,

in accordance with the applicable code of practice.

- The installation, use and maintenance of the product should also comply with

GB3836.13-2013 Explosive atmospheres

Part 13: Equipment repair, overhaul and reclamation GB/T3836.15-2017 Explosive

atmospheres

Part 15: Electrical installations design, selection and erection GB/T3836.16-2017 Explosive

atmospheres

Part 16: Electrical installations inspection and maintenance GB50257-2014 Code for

construction and acceptance of electric device for explosive atmospheres and fire hazard

electrical equipment installation engineering GB15577-2018 Safety regulations for dust

explosion prevention and protection.

1. Safety information

IM-P705-02 CTLS Issue 3

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

1.2 Intended use

Referring to the Installation and Maintenance Instructions, product markings and Technical

Information Sheet, check that the product is suitable for the intended use / application. These

products comply with the requirements of the Directive 2014/34/EU (ATEX) for the use of equipment

in potentially explosive atmospheres.

1.3 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.

1.4 Lighting

Ensure adequate lighting, particularly where detailed or intricate work is required.

1.5 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.

1.6 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.

The convertor is suitable for installation in Zone 0 or Zone 1 or Zone 2 ( Gas ) Zone 20 or Zone 21

or Zone 22 ( Dust ).

1.7 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 opened and closed progressively to avoid system

shocks.

1.8 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.

1.9 Temperature

Allow time for temperature to normalise after isolation to avoid the danger of burns.

1.10 Tools and consumables

Before starting work ensure that you have suitable tools and/ o r consumables available.

Use only genuine Spirax Sarco replacement parts.

IM-P705-02 CTLS Issue 3 5

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

1.11 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 l/ ow temperature, radiation, noise, falling

objects, and dangers to eyes and face.

1.12 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.

1.13 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 carried out.

1.14 Residual hazards

In normal use the external surface of the product may be hot.

1.15 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.

1.16 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.

1.17 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.

IM-P705-02 CTLS Issue 3

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

2.1 Introduction

The IPC6 is a Electro-pneumatic convertor requiring an air supply between 1.5 and 8 bar g. It will convert a

4 -20mA signal into an air pressure signal. The IPC6 can be mounted directly onto a flat surface, or using

mounting kits for panel, wall or pipe mounting.

2.2 Label Description

-Model, Indicates the model number and additional symbols.

-Explosion proof, Indicates certified explosion proof grade.

-Ingress Protection, Indicates enclosure protection grade.

-Input signal, Indicates input signal range.

-Ambient temperature, Indicates the allowable ambient temperature for explosion proof.

-Output Pressure, Indicates the output pressure range.

-Supply Pressure, Indicates the supply pressure range.

-Serial number, Indicates manufactured month and year.

2. General product information

Fig. 1a Nameplate - Non-Explosion Proof

Fig. 1b Nameplate - ATEX / IECEx

IM-P705-02 CTLS Issue 3 7

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

2.3 Operating principle

The IPC6 is an electro-pneumatic device that converts a DC input signal to a pneumatic output. This device

is made up of two sections, the Primary Converting Section and the Pneumatic Relay Section. The Coil

and Suspension Spring, in the Primary Converting Section, is used as a Flapper. Together the Flapper and

Nozzle work to control the signal pressure. The signal pressure acts on the Upper Control Diaphragm, in

the Pneumatic Relay Section, which sets the output pressure. The output pressure is sensed by the Lower

Control Diaphragm, in the Pneumatic Relay Section, which maintains the output pressure.

Fig. 2 IPC6

Flapper and nozzle

Upper control diaphragm

Lower control diaphragm

Primary converting

section

Pneumatic relay

section

Out In

Fig. 1c Nameplate - CCC / NEPSI / ATEX / IECEx

Flapper and nozzle

Upper control diaphragm

Lower control diaphragm

Primary converting

section

Pneumatic relay

section

Out In

Fig. 2 IPC6

Fig. 1c Nameplate - CCC / NEPSI / ATEX / IECEx

IM-P705-02 CTLS Issue 3

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

3/4

19.1

1 1/2

38.1

20.9 14.9

Fig. 3 Mounting Kit (Included with Unit)

Use two M6

Screws for

Mounting

(not included

in mounting kit)

DIN

EN-50045

DIN

EN-50022

DIN

EN-50035

15.6

53/64

20.9

19/32

14.9

Fig. 4 DIN Rail Mounting Kit (Included with Unit)

114

21 15 16

34.5

123

3. Installation

The IPC6 is supplied with a wall mounting kit and a DIN Rail Mounting Kit.

Mounting Kit PMK is available when installing the unit on a 2" pipe, see Figure 5.

Fig. 3 Mounting Kit (Included with unit)

Mounting Kit

Includes the following:

Two 10-32 x 5/16" Screws

Mounting Bracket Two ¼" NPT Pipe Plugs

Two 5 mm thick washers

Fig. 4 DIN Rail Mounting Kit (Included with unit)

Din Rail

Mounting

Configuration

shown with

Model IPC6

and DIN EN-50045

3/4

19.1

1 1/2

38.1

20.9 14.9

Fig. 3 Mounting Kit (Included with Unit)

Use two M6

Screws for

Mounting

(not included

in mounting kit)

DIN

EN-50045

DIN

EN-50022

DIN

EN-50035

15.6

53/64

20.9

19/32

14.9

Fig. 4 DIN Rail Mounting Kit (Included with Unit)

114

21 15 16

34.5

123

Use two M6

Screws for

Mounting (not

included in

mounting kit)

DIN

EN-50035

DIN

EN-50045

DIN

EN-50022

IM-P705-02 CTLS Issue 3 9

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

21/

11/32

8.6

Fig. 5 Mounting Kit (Sold Separately)

Pneumatic Connection

- Clean all pipelines to remove dirt and scale before installation.

- Apply a minimum amount of pipe compound to the male threads of the fitting only.

- Do not use teflon tape as a sealant.

- Start with the third thread back and work away from the end of the fitting to avoid contaminating the

convertor.

- Install the convertor in the air line.

- The inlet and outlet ports are labeled on the ends of the convertor.

- Tighten connections securely.

- Avoid undersized fittings that will limit the flow through the convertor and cause pressure drop down

stream.

Electric Connection

Make connections as shown in Figure 6.

Note:

Oil free air is required.

Use a filter to remove dirt and liquid in the air line ahead of the convertor.

The user is responsible for insuring that the environment in which the unit will be installed and the operating

gas are compatible with the materials in the convertor.

Fig. 5 Mounting Kit (Sold Separately)

Mounting Kit PMK

includes the following:

Mounting Bracket 2" Pipe Clamp

Two 10-32 x 5/16" Screws

2" Pipe Mounting Configuration shown

with Model IPC6

IM-P705-02 CTLS Issue 3

IPC6 and IPC6 ATEX Electro-pneumatic Convertor

Fig. 6

4. Commissioning

4.1 Equipment required for calibration:

Pneumatic Supply capable of delivering up to 10 bar g.

-Current Supply capable of delivering up to 60 mA.

-Pressure gauge capable of a digital readout up to 3 bar g with an accuracy of 0.1%.

-Digital ammeter capable of a readout up to 60 mA with an accuracy of 0.02%.

4.2 Full range operation

Caution:

Over-ranging the Zero Screw can damage unit.

Forward acting mode adjustment

1. Connect the input signal to the convertor as shown in Fig. 6.

Forward Acting Calibration-Zero

2. Apply the minimum input signal and adjust the Zero screw for minimum output pressure.

Turn screw clockwise to increase pressure and counterclockwise to decrease pressure.

Forward Acting Calibration-Span

3. Apply the maximum input signal and adjust the Span screw for maximum output pressure.

Turn screw clockwise to increase pressure and counterclockwise to decrease pressure.

4. Repeat steps 2-3 until the desired output range is obtained.

Reverse Acting Mode Adjustment

5. Connect the input signal to the convertor as shown in Fig. 6.

Reverse Acting Calibration-Zero

6. Apply the minimum input signal and adjust the Zero screw for maximum output pressure.

Turn screw clockwise to increase pressure and counterclockwise to decrease pressure.

Reverse Acting Calibration-Span

7. Apply the maximum input signal and adjust the Span screw for minimum output pressure.

Turn screw clockwise to decrease pressure and counterclockwise to increase pressure.

8. Repeat steps 6-7 until the desired output range is obtained.

Split range operation

All units have the capability to be split ranged or set for any output in the range as long as the Output Span

is equal to or greater than the minimum Span.

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