EXPLOSION PROTECTION SYSTEMS

E06-037

EXPLOSION PROTECTION SYSTEMS

FIKE RATE-OF-RISE DETECTOR (FRD)

INSTALLATION AND OPERATING INSTRUCTIONS
.
 TABLE OF CONTENTS
1. INTRODUCTION ..............................................................................................................1
1.1 FRD Theory ..............................................................................................................1
1.2 Activation Pressure History.......................................................................................2
1.3 Specifications............................................................................................................3
2. STANDARD MECHANICAL INSTALLATION ...................................................................4
2.1 Pressure Detector Location ......................................................................................4
2.2 Pressure Detector Handling......................................................................................4
2.3 Product Build Up.......................................................................................................4
2.4 Low Ambient Temperature Requirement ..................................................................4
2.5 Electrical Housing Mounting .....................................................................................4
2.6 Process Connections................................................................................................4
2.7 Product Impingement................................................................................................5
2.8 Rigid Mount...............................................................................................................6
2.9 Flush Mount ..............................................................................................................7
2.10 Flex Mount ................................................................................................................8
2.11 Hi-Temperature Flex Mount ......................................................................................9
3. MOUNTING ACCESSORIES..........................................................................................10
3.1 Air Purge – P/N E61-048 ........................................................................................10
3.2 Lateral Ferrule Clean-Out – P/N E61-049...............................................................10
3.3 2” NPT to 2” Tri-Clamp® – P/N 02-9081..................................................................11
4. WIRING ..........................................................................................................................11
4.1 General Wiring........................................................................................................11
4.2 Detector Configuration............................................................................................13
4.3 Circuit Wiring ..........................................................................................................14
5. CALIBRATION ................................................................................................................16
6. PERIODIC MAINTENANCE............................................................................................16
6.1 Routine Inspections ................................................................................................16
6.2 Diaphragm Cleaning ...............................................................................................17
7. COMPONENT PARTS....................................................................................................18
7.1 Rigid Mount Assembly ............................................................................................18
7.2 Flush Mount Assembly ...........................................................................................19
7.3 Flex Mount Assembly .............................................................................................20
7.4 Hi-Temp. Flex Mount Assembly..............................................................................21
8. REPAIR AND RETURN AUTHORIZATION ....................................................................22

FRD Table of Contents / Page 1 of 2

Manual P/N E06-037 Date: June 1, 2000
 FIGURES
Figure 1: FRD Settings .......................................................................................................... 1
Figure 2: Impingement in Centrifugal Equipment or Cyclones............................................... 5
Figure 3: Impingement in Elbows or bends............................................................................ 5
Figure 4: Rigid Mount ............................................................................................................ 6
Figure 5: Rigid Mount –Vertical / Horizontal Angular Restrictions.......................................... 6
Figure 6: Flush Mount............................................................................................................ 7
Figure 7: Flush Mount – Horizontal Restrictions .................................................................... 7
Figure 8: Flex Mount.............................................................................................................. 8
Figure 9: High-Temperature Flex Mount................................................................................ 9
Figure 10: Air Purge Accessory ........................................................................................... 10
Figure 11: Lateral Ferrule Clean-Out Accessory ................................................................. 10
Figure 12: 2” NPT to 2” Tri-Clamp® Accessory .................................................................... 11
Figure 13: Electrical Fittings ................................................................................................ 12
Figure 14: Control Panel DIP Switches................................................................................ 13
Figure 15: Wiring Schematic – Detection Circuit #1............................................................. 14
Figure 16: Wiring Schematic – Detection Circuit #2............................................................. 15
Figure 17: Rigid Mount Component List .............................................................................. 18
Figure 18: Flush Mount Component List.............................................................................. 19
Figure 19: Flex Mount Component List................................................................................ 20
Figure 20: Hi-Temperature Flex Mount Component List...................................................... 21

TABLES
Table 1: Activation Pressure Data ......................................................................................... 2

Table of Contents / Page 2 of 2 FRD

Date: June 1, 2000 Manual P/N E06-037
1. INTRODUCTION
This manual has been prepared to assist owners of Fike Explosion Protection (EP) Systems to install, operate
and maintain Fike Rate-of-Rise Pressure Detectors (FRD). These individuals should read the entire manual.
Specific sections will be of particular interest depending upon specific responsibilities.

1.1 FRD Theory

There are two basic concepts used in the detection of explosions.
• Threshold detection will produce an output signal when the measured pressure reaches an assigned
value.
• Rate-of-Rise detection will produce an output signal when the rate at which the pressure is increasing
reaches an assigned value.
The Fike Rate-of-Rise Detector or FRD utilizes both Threshold and Rate-of-Rise concepts. The Rate-of-Rise
portion of FRD is based on continuous process pressure measurement with real time comparisons made at
specified time intervals (dt). If the change in the measured pressure (dP) during the specified time interval (dt)
is greater than the Rate-of-Rise Set Point, dP/dtset, a supervised output signal is sent to the Explosion
Protection Control Panel, activating the system. Rate-of-Rise detection, with the correct selection of the
assigned value (dP/dtset), makes it possible for the system to differentiate pressure increases caused by a
combustion reaction from process pressure variations. This greatly reduces the possibility of nuisance
activation due to a relatively slow increase in process pressure.
The Threshold portion of FRD utilizes the same continuous process pressure measurement and will also
provide a supervised output signal to the control panel, if the measured pressure exceeds the Threshold
Activation Set Point. This Threshold Activation Set Point is derived from the Fike EP Designer Program, Fike
Combustion Models and information about your specific application. By incorporating the use of this
Threshold Activation, consideration is given to “Non-optimum” deflagrations. This type of deflagration,
characterized by a relatively slow initial rate of pressure rise, may be detected sooner by the Threshold
Activation Set Point than the Rate-of-Rise Set Point. There is also a Threshold Warning Set Point, based on
process operating pressure at maximum capacity (i.e. max. air and product). The Threshold Warning is used
to send the control panel a trouble alarm, indicating that the process has reached an unusually high pressure.
When either the Rate-of-Rise Set Point, dP/dtset, or the Threshold Activation Set Point, is reached, a signal is
sent from FRD to the Explosion Protection Control Panel. The control panel will activate the Fike Explosion
Protection System. For detector configurations and set points, refer to the Component Location Drawing,
which has specifically been prepared for your process protection system.

Full explosion curve

Reduced explosion
pressure for dP/dt set
Pressure

Threshold Activation Set Point

dP/dt ≥ dP/dt set :

Rate-of-Rise Set Point dP
Operating pressure
Threshold Warning Set Point dt

Ignition Time (msec)

Figure 1: FRD Settings

FRD Page 1 of 21
Manual P/N E06-037 Date: June 1, 2000
1.2 Activation Pressure History
Another very helpful feature of the Fike Rate-of-Rise Detector is the Activation Pressure Recorder. This
standard feature of FRD captures and maintains a record or history of the system pressure readings before
and after an activation. This data will be available for printout by the Fike Certified Field Personnel that
service your Explosion Protection System after activation.
The pre-activation pressure history is captured at the rate of one pressure reading every millisecond. The
number of pre-activation pressure readings taken is determined by the Rate Setting selected specifically for
your application.
The post-activation pressure history is captured at either one pressure reading every 2.5 or 5.0 milliseconds.
The sampling rate is determined by the protected volume. Refer to Table 1 for more detailed information on
Activation Pressure Data collection and sampling rates.

ACTIVATION PRESSURE HISTORY

Pre-activation Post-activation
Rate Setting Number of Captured Time Protected Volume Number of Captured Time
(psi/sec) Data Points (ms) (m3) Data Points (ms)
20 41 41 10 or smaller 80 200
25 33 33 Greater than 10 80 400
30 27 27
40 21 21
50 16 16
70 12 12
100 8 8

Table 1: Activation Pressure Data

Page 2 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
1.3 Specifications
Sensing principle..................................Piezoresistive
Pressure range.....................................-9.0 to +6.0 psi. (15 psi. range)
Overpressure .......................................150 psig.
Vacuum resistance ..............................Full vacuum
Temperature range ..............................Ambient: 0°F to + 140°F
Process: See Individual Process Connection Type
Dynamic Rate-of-Rise function ............20 psi/sec to 100 psi/sec
Sampling rate .......................................200 µsec, 5 validation counts
Threshold function ...............................2 programmable Thresholds:
Threshold Warning
Threshold Activation
Pressure connection ............................2” Tri-Clover
Maximum Flange Pressure ..................550 psig. with Tri-Clover #13 MHHS Clamp @ 72°F, 2” Size
®
Contact Materials .................................O-ring: Teflon (Silicone Optional)
®
Diaphragm: Hastelloy C-276 & 316L Stainless Steel
Housing: 316L Stainless Steel
Sanitary Standard ................................3-A, #37-01
Process Connection Types – Allowable Process Temperature Range:
Rigid Mount – 0°F to 200°F
Flush Mount – 0°F to 200°F
Flex Mount – 0°F to 175°F
Hi-Temperature Flex Mount – 0°F to 450°F
Mounting Accessories (not available for Flush Mount):
Air Purge
Lateral Ferrule Clean-out
®
2” NPT to 2” Tri-Clamp
Enclosure Listings:
Class I, Group B, C and D
Class II, Group E, F and G
Class III
NEMA 3, 4X, 7 & 9
UL Classified Standard 1203
CSA Certified Standard C22.2-30
FM Class No. 3615
CENELEC – EExd II C IP 66
Temperature Compensated .................0°F to 200°F
Programming Port ................................RS 232

FRD Page 3 of 21
Manual P/N E06-037 Date: June 1, 2000
2. STANDARD MECHANICAL INSTALLATION

2.1 Pressure Detector Location

CAUTION: IMPROPER PLACEMENT OR WIRING OF THE PRESSURE DETECTOR MAY RESULT IN

NUISANCE ACTIVATION OR FAILURE OF THE SYSTEM TO RESPOND TO AN
EXPLOSION IN THE REQUIRED TIME.
Locate FRD on your equipment, from the Component Location Drawings, prepared specifically for your
installation. The location and orientation of FRD’s must be in accordance with these Component Location
Drawings. Orientation and general mounting information is discussed in more detail in the following sections.
• Examples of improper wiring are: incorrect conduit size or broken, stretched, spliced or unshielded cable.
• Examples of improper placement are mounting pressure detectors, containers or Explosion Isolation
Valves (EIV’s) outside the parameters of the Component Location Drawing.

2.2 Pressure Detector Handling

Handle the pressure detector with care in order to avoid damage to the diaphragm. Damage to the diaphragm
may result in a shift in the zero reading. This, in turn, could result in slower response, high base line readings
or failure of the Pressure Detector to operate.

2.3 Product Build Up

Care must be taken to assure that detectors are installed so that process material can not build up against the
diaphragm. Refer to Figure 5 or Figure 7 for angular mounting instructions intended to help reduce the
possibility of product build up.

2.4 Low Ambient Temperature Requirement

The allowable ambient temperature range is 0°F to +140°F. However, if the process pressure take-off is
expected to experience ambient temperatures below 32°F, the process pressure take-off and the entire
detector assembly must be insulated to prevent internal condensation and ice build up. A build up of ice at
this location could result in either the pressure take-off becoming blocked and not correctly sensing the
process pressure or the ice build up pressing against the diaphragm and causing a nuisance activation.

2.5 Electrical Housing Mounting

Mount electrical housings and support brackets to building or structural support. Mounting to process
equipment or to any vibrating object may result in nuisance activations.

2.6 Process Connections

All process connections are to be installed by the customer in accordance with the Mounting Details, as
specified on the Component Location Drawings. Fike recommends that all process connection related items
be purchased from Fike only. However, for the Rigid Mount Option, the customer may supply the 2” process
®
pressure take-off, Tri-Clover clamp and gasket.

Page 4 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
2.7 Product Impingement
Care must be taken to assure that detectors are installed so that process material will not impinge upon the
diaphragm of the pressure detector. Examples of known areas of product impingement are illustrated below.

Figure 2: Impingement in Centrifugal Equipment or Cyclones

Figure 3: Impingement in Elbows or bends

FRD Page 5 of 21
Manual P/N E06-037 Date: June 1, 2000
 2.8 Rigid Mount
If the Rigid Mount pressure detector is to be mounted on the side (vertical) surface of the vessel or duct, the
detector should be mounted as shown on the left side of Figure 4. If the pressure detector is to be mounted
on the top (horizontal) surface of the vessel or duct, the detector should be mounted as shown on the right
side of Figure 4.
6 5/16"
Ref.
2 7/8"
5/16" Dia. Mounting Hole Ref.
(Typical 2 Places)

Mounting/Support
Bracket

Full Length
Min. bend radius 10" 27 1/4" Ref.
Pressure Detector Ass'y.
(P/N E61-056-5 or -6)

As close as Possible Min. bend

to vessel/duct radius 10"
3.25" Min./6" Max. 30°

Tri-Clover Clamp and Gasket

Process Pressure Take-Off. 2" Tri-Clamp As close as Possible

16 gauge or heavier ferrule, 6" long Max. to vessel/duct
Backing
Mount Process Ferrule may be welded to vessel/duct or 1.50" Min./4.25" Max.
Plate
Take-Off Flush welded to a 1/4" backing plate and then
to Vessel/Duct welded to the vessel/duct.
Backing
Plate Process Pressure Take-Off may be supplied
Cut Process Pressure
Vessel/Duct by Customer or Fike (P/N 02-9073).
Take-Off for mounting
flush to Vessel/Duct.

VERTICAL SURFACE MOUNT Vessel/Duct HORIZONTAL SURFACE MOUNT

Figure 4: Rigid Mount

Note: The centerline of the pressure detector shall be mounted no more than 30° off vertical. This
limitation applies even if the vessel/duct is inclined between vertical and horizontal. The left
side of Figure 5 shows a 30° limit when mounting on the side (vertical) surface of the vessel or
duct. The right side of Figure 5 shows a 30° limit when mounting on the top (horizontal)
surface of the vessel or duct.

Figure 5: Rigid Mount –Vertical / Horizontal Angular Restrictions

Page 6 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
2.9 Flush Mount
If the Flush Mount pressure detector is to be mounted on the side (vertical) surface of the vessel or duct, the
detector should be mounted as shown on the left side of Figure 6. If the pressure detector is to be mounted
on the top (horizontal) surface of the vessel or duct, the detector should be mounted as shown on the right
side of Figure 6.

6 5/16"
Ref.
Mounting/Support
Bracket
10" Ref. 2 7/8"
27 1/4" Ref.
Ref. 5/16" Dia.
Mounting Hole
(Typical 2 Places)
Mounting/Support
Bracket
Min. bend
radius 10" Pressure Detector
5/16" Dia. Mounting Assembly
13" Ref. Hole (Typ. 2 Places) (P/N E61-056-3 or -4)

Mount Flush to Min. bend R

Vessel/Duct radius 10" Tri-Clover Gasket

Vessel/Duct Process Weld Flange

2.25" Min. Mount Flush to

I.D. 2.25"
Pressure Detector vessel/duct
Min. I.D.
Process Weld Flange Assembly
(P/N E61-056-3 or -4)
Vessel Duct

VERTICAL SURFACE MOUNT HORIZONTAL SURFACE MOUNT

Figure 6: Flush Mount

Note: The centerline of the pressure detector shall be mounted no more than 90° off vertical. This
limitation applies even if the vessel/duct is inclined between vertical and horizontal. This is
shown in Figure 7.

Figure 7: Flush Mount – Horizontal Restrictions

FRD Page 7 of 21
Manual P/N E06-037 Date: June 1, 2000
2.10 Flex Mount
If the Flex Mount pressure detector is to be mounted on the side (vertical) surface of the vessel or duct, the
detector should be mounted as shown on the left side of Figure 8. If the pressure detector is to be mounted
on the top (horizontal) surface of the vessel or duct, the detector should be mounted as shown on the right
side of Figure 8.

5/16" Dia. Mounting Hole

(Typical 2 Places) 6 5/16"
Ref. 2 7/8"
Ref.

Mounting/Support
Bracket

Pressure Detector
Assembly
(P/N E61-056-7 or -8)

Full Length
39 1/4" Ref.

As close as Possible 30°

to vessel/duct
3.25" Min./6" Max. Tri-Clover Clamp and Gasket
(Typical 2 Places)

Process Pressure Take-Off. 2" Tri-Clamp As close as Possible

16 gauge or heavier ferrule, 6" long Max. to vessel/duct
Backing
Ferrule may be welded to vessel/duct or 1.50" Min./4.25" Max.
Mount Process Plate
welded to a 1/4" backing plate and then
Take-Off Flush welded to the vessel/duct.
to Vessel/Duct Process Pressure Take-Off may be supplied
by Customer or Fike. Cut Process Pressure
Backing Plate Take-Off for mounting
Vessel Duct flush to Vessel/Duct.

Vessel/Duct
VERTICAL SURFACE MOUNT HORIZONTAL SURFACE MOUNT

Figure 8: Flex Mount

Note: The centerline of Flex Mounted pressure detectors shall be mounted no more than 30° off
vertical. This limitation applies even if the vessel/duct is inclined between vertical and
horizontal. The left side of Figure 5 on page 6 shows the 30° limit when mounting on the side
(vertical) surface of the vessel or duct. The right side of Figure 5 on page 6 shows the 30° limit
when mounting on the top (horizontal) surface of the vessel or duct.

Page 8 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
2.11 Hi-Temperature Flex Mount
If the Hi-Temperature Flex Mount pressure detector is to be mounted on the side (vertical) surface of the
vessel or duct, the detector should be mounted as shown on the left side of Figure 9. If the pressure detector
is to be mounted on the top (horizontal) surface of the vessel or duct, the detector should be mounted as
shown on the right side of Figure 9.

5/16" Dia. Mounting Hole

(Typical 2 Places) 6 5/16"
Ref. 2 7/8"
Ref.

Mounting/Support
Bracket

Pressure Detector
Assembly
(P/N E61-056-9 or -10)

Full Length
45 1/4" Ref.

As close as Possible
30°
to vessel/duct
3.25" Min./6" Max.
Tri-Clover Clamp and Gasket
(Typical 2 Places)

Process Pressure Take-Off. 2" Tri-Clamp As close as Possible

16 gauge or heavier ferrule, 6" long Max. to vessel/duct
Backing
Mount Process Ferrule may be welded to vessel/duct or 1.50" Min./4.25" Max.
Plate
Take-Off Flush welded to a 1/4" backing plate and then
to Vessel/Duct welded to the vessel/duct.

Process Pressure Take-Off may be supplied Cut Process Pressure

Vessel/Duct Backing by Customer or Fike. Take-Off for mounting
Plate flush to Vessel/Duct.

Vessel/Duct
VERTICAL SURFACE MOUNT HORIZONTAL SURFACE MOUNT

Figure 9: High-Temperature Flex Mount

Note: The centerline of Flex Mounted pressure detectors shall be mounted no more than 30° off
vertical. This limitation applies even if the vessel/duct is inclined between vertical and
horizontal. The left side of Figure 5 on page 6 shows the 30° limit when mounting on the side
(vertical) surface of the vessel or duct. The right side of Figure 5 on page 6 shows the 30° limit
when mounting on the top (horizontal) surface of the vessel or duct.

FRD Page 9 of 21
Manual P/N E06-037 Date: June 1, 2000
3. MOUNTING ACCESSORIES
Mounting accessories are available for all standard process connections, with the exception of the Flush
Mount. Each accessory has a specific purpose, described in the following paragraphs.

3.1 Air Purge – P/N E61-048

The Air Purge Accessory is intended for use in installations where process material is likely to collect in the
process pressure take-off. The use of a low pressure, continuous flow of air is used to help prevent material
buildup that may cause false pressure readings. Such false pressure readings may result in either failure of
the system to recognize an impending explosion or false activation of the system.

Pressure Detector Ass'y.

Attaches Here using
R
Tri-Clover Clamp and Gasket 1/4" Air Tube
Attaches Here

Process Pressure Take-Off

Figure 10: Air Purge Accessory

3.2 Lateral Ferrule Clean-Out – P/N E61-049

The Lateral Ferrule Clean-Out Accessory has two primary uses. It may be used in installations where the
diaphragm of Pressure Detector assembly would otherwise have to be mounted in a location where it could be
subjected to impact by particles of material in the process stream. It may also be used to facilitate cleaning of
the process pressure take-off in installations where plugging may occur.

Pressure Detector Ass'y.

Attaches Here using
Tri-Clover R Clamp and Gasket
Solid
End Cap

Process Pressure Take-Off

Figure 11: Lateral Ferrule Clean-Out Accessory

Page 10 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
3.3 2” NPT to 2” Tri-Clamp® – P/N 02-9081
The 2” NPT to 2” Tri-Clamp® Accessory is required whenever installation is made using a 2” NPT Schedule 40
steel pipe instead of a 2” Tri-Clamp® ferrule for the process pressure take-off.

Process Pressure
Take-Off Pipe

Figure 12: 2” NPT to 2” Tri-Clamp® Accessory

4. WIRING

CAUTION: IMPROPER PLACEMENT OR WIRING OF THE PRESSURE DETECTOR MAY RESULT IN

NUISANCE ACTIVATION OR FAILURE OF THE SYSTEM TO RESPOND TO AN
EXPLOSION IN THE REQUIRED TIME.
Note: Two detection circuits are provided on the control panel. A maximum of one pressure detector
may be installed on each detection circuit.

4.1 General Wiring

4.1.1 Wiring shall be run in a dedicated conduit. It is required to run five wires to and from each pressure
detector. All field wiring shall be minimum 18 AWG stranded, shielded cable with drain wire. The
cable must be U.L. listed and meet minimum dielectric strengths and service temperatures suitable to
the application. Individual circuits shall be coded for identification. Drain wires shall be connected
and isolated through all connections and junction boxes and shall be grounded at the control panel
only. All control panel wire terminations shall be ring terminals. Strip and tin all wires for pressure
detector terminations. Junction boxes may be used only as pull points. All wire runs shall be
continuous from device to device. WIRE NUTS ARE NOT ACCEPTABLE.
Note: High voltage circuits may not be run in the same conduit as the low voltage circuits. The
wiring circuit to each Fike system component is low voltage. System component wiring shall
have dedicated conduit specifically for Fike systems. All conduit and fittings for the Fike
System shall be weather tight and in accordance with area classification and applicable
standards.

FRD Page 11 of 21
Manual P/N E06-037 Date: June 1, 2000
4.1.2 All wiring and installation materials must conform to the National Electrical Code and the local
authority having jurisdiction. All materials used in the process area shall meet National Electrical
Code or Codes applicable to the location. All seals, drains and other materials are provided by
installer.
Note: Mount electrical housing and support bracket to the building or structural supports. Do not
mount to the process equipment or to any vibrating object.
4.1.3 Install conduit and complete field wiring in accordance with the Field Wiring Diagrams. These
drawings are prepared specifically for your installation. Provide about 36 inches of wire inside the
control panel enclosure for final connection.
Note: In order to maintain the Class “A” wiring integrity, the wires going to terminals 13, 14, 17, and
18 should be run in one conduit. The wires for terminals 12, 15, 16 and 19 should be run in a
second conduit with an alternate route. The wires for terminals 34, 35 (Power) and 52
(Tran/Maint) will be run in both conduits.
4.1.4 Connect all field-wiring terminations according to the Field Wiring Diagrams prepared specifically for
your installation. (Diagrams located inside the control panel enclosure are for reference only.)
4.1.5 The customer is responsible for supplying conduit nipples, conduit seals, a breather drain, a tee,
connectors and either flexible or rigid conduit for each pressure detector. See Figure 13 for details.
Note: If a flexible standoff mounting is used, at least 12" of flexible conduit must be between the rigid
conduit/junction box and the pressure detector conduit seal.

3/4" Conduit Nipple

3/4" Electrical (Typical 3 Places)
3/4" Conduit Seal
(Typical 2 Places) Connection

Tee Conduit

Breather From
Return to Drain
Control Panel Control Panel
Pressure Detector
Electrical Housing
To To Transducer
Transducer
(Fike Assembled)
Tran/Mant

1 2 3 4
Tran/Mant Terminal
Power Terminal Block (Black)
Block (Black)
Detection Terminal
Block (Green)
1 2 3 4

1 2 3 4
Detection
Power

From Control Panel

Return to
Control Panel

Insulate Shields within

Electrical Housing

Figure 13: Electrical Fittings

Page 12 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
4.2 Detector Configuration
Note: Two detection circuits are provided on the control panel. A maximum of one pressure detector
may be installed on each detection circuit.
4.2.1 The Fike EP control panel is equipped with three DIP switches. Switch number one (1) allows the
control panel to release on any "Alarm" signal, or on a Cross Zone "Alarm" signal. Refer to the
Control Panel Installation and Operation Manual for further detail regarding Switch numbers two (2)
and three (3). The DIP switch package can be seen in Figure 14.

DIP SWITCH SELECTIONS

ON 1) ON = Release on Any Alarm
OFF = Release on Cross Zone Alarm
2) ON = Alarm Relay Transfers on Pre-Alarm
OFF = Alarm Relay Transfers on Release
1 2 3 3) ON = Continuity Causes Trouble
OFF = Continuity and Trouble Separate
DS1
Figure 14: Control Panel DIP Switches
4.2.2 DIP switch number "1" is shipped with the switch in the "ON" position. This will allow any switch
closure on either of the two detection circuits to cause an activation and thus put the system in an
"Alarm" state. This is called Normal detection.

CAUTION: DIP SWITCH NUMBER "1" SHOULD BE TURNED "OFF" ONLY AFTER CONSULTATION
WITH FIKE CERTIFIED FIELD SERVICE PERSONNEL FROM YOUR LOCAL AUTHORIZED
SERVICE CENTER OR FIKE CORPORATION IN BLUE SPRINGS, MO.
4.2.3 DIP switch number one (1) can be turned "OFF" to achieve a Cross Zone detection configuration. In
this configuration, detectors must be placed on each of the two detection circuits. Both detection
loops must be activated in order for the system to be put into an "Alarm" state. If only one detection
loop is activated, the control panel will latch into a "Pre-Alarm" condition until the control panel is reset
or the other detection loop is activated.

FRD Page 13 of 21
Manual P/N E06-037 Date: June 1, 2000
4.3 Circuit Wiring
4.3.1 Using the Field Wiring Diagram, note the pressure detector located on Detection Circuit 1, and the
location of the particular pressure detector on the actual process equipment.
4.3.2 Run conduit and wire from the Control Panel to the pressure detector location.
4.3.3 The conduit and wire returning from pressure detector to control panel should be in a separate conduit
from that going from control panel to pressure detector. This allows the full benefit of Class “A” wiring.
4.3.4 Repeat steps 4.3.1 through 4.3.3 for Detection Circuit 2.
4.3.5 Termination Procedures for Detection Circuit 1. (See Figure 15)
4.3.5.1 From Control Panel Terminal 34 to Power Terminal 1.
4.3.5.2 From Control Panel Terminal 35 to Power Terminal 2.
4.3.5.3 From Control Panel Terminal 52 to Tran/Maint Terminal 3.
4.3.5.4 From Control Panel Terminal 17 to Detection Terminal 1.
4.3.5.5 From Control Panel Terminal 18 to Detection Terminal 2.
4.3.5.6 From Tran/Maint Terminal 4 to Control Panel Terminal 52.
4.3.5.7 From Power Terminal 3 to Control Panel Terminal 34.
4.3.5.8 From Power Terminal 4 to Control Panel Terminal 35.
4.3.5.9 From Detection Terminal 3 to Control Panel Terminal 16.
4.3.5.10 From Detection Terminal 4 to Control Panel Terminal 19.
Note: Be sure to carry and insulate shield/drain wire through on all connections. The shield is to be
grounded only one time at the control panel. For installations using multiple cables (instead of
a single 5-wire cable), each cable is to be grounded one time.

FROM 16 17 18 19 RETURN TO
GROUND AT CONTROL PANEL
CONTROL PANEL
CONTROL PANEL
TERMINALS TERMINALS

34 35 52 34 35 52
GROUND AT
CONTROL PANEL

SHIELD SHIELD

SHIELD SHIELD

SHIELD SHIELD

SHIELD SHIELD
TRAN/MAINT POWER DETECTION
1234 1234 1234

SHIELD SHIELD SHIELD SHIELD

SHIELD SHIELD

Figure 15: Wiring Schematic – Detection Circuit #1

4.3.6 Termination Procedures for Detection Circuit 2. (See Figure 16)

Page 14 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
4.3.6.1 From Control Panel Terminal 34 to Power Terminal 1.
4.3.6.2 From Control Panel Terminal 35 to Power Terminal 2.
4.3.6.3 From Control Panel Terminal 52 to Tran/Maint Terminal 3.
4.3.6.4 From Control Panel Terminal 13 to Detection Terminal 2.
4.3.6.5 From Control Panel Terminal 14 to Detection Terminal 1.
4.3.6.6 From Tran/Maint Terminal 4 to Control Panel Terminal 52.
4.3.6.7 From Power Terminal 3 to Control Panel Terminal 34.
4.3.6.8 From Power Terminal 4 to Control Panel Terminal 35.
4.3.6.9 From Detection Terminal 3 to Control Panel Terminal 15.
4.3.6.10 From Detection Terminal 4 to Control Panel Terminal 12.
Note: Be sure to carry and insulate shield/drain wire through on all connections. The shield is to be
grounded only one time at the control panel.

12
13
FROM RETURN TO
GROUND AT
CONTROL PANEL
CONTROL PANEL 14 15 CONTROL PANEL
TERMINALS TERMINALS

34 35 52 34 35 52
GROUND AT
CONTROL PANEL

SHIELD SHIELD

SHIELD SHIELD

SHIELD SHIELD

SHIELD SHIELD
TRAN/MAINT POWER DETECTION
12 3 4 12 3 4 12 3 4

SHIELD SHIELD SHIELD SHIELD

SHIELD SHIELD

Figure 16: Wiring Schematic – Detection Circuit #2

FRD Page 15 of 21
Manual P/N E06-037 Date: June 1, 2000
5. CALIBRATION
Calibration of a FRD pressure detector requires a high degree of accuracy. Due to this fact, Fike requires all
calibration be done only by Fike certified Field Service Personnel from either your local authorized service
center or Fike Corporation in Blue Springs, MO.
NOTE: The electrical enclosure lid and the Tri-Clover® clamp are both sealed with cable ties to deter
unauthorized access and serve as an indicator when either has been opened.

WARNING: BEFORE MAINTENANCE, INSPECTION, OR CALIBRATION OF THE PRESSURE

DETECTOR CAN BEGIN, BE SURE THAT FIKE EXPLOSION PROTECTION SYSTEM
CONTROL PANEL IS DISARMED.
6. PERIODIC MAINTENANCE

CAUTION: IF ASSISTANCE IS NEEDED WHEN PERFORMING ANY MAINTENANCE OR SERVICE

WORK ON FIKE EXPLOSION PROTECTION EQUIPMENT AND/OR SYSTEMS, CONTACT
YOUR LOCAL AUTHORIZED SERVICE CENTER OR FIKE CORPORATION, PRODUCT
SUPPORT SERVICES, IN BLUE SPRINGS, MO, (816) 229-3405 FOR INSTRUCTIONS.
Routine System Inspections shall be conducted in accordance with the requirements of the appropriate local
authority having jurisdiction and the National Fire Protection Association Standard Number 69, Explosion
Prevention System, Chapter 4 or Chapter 7, current edition.
The NFPA Standard Number 69 Inspection Schedule is provided as a minimum requirement for Fike
Explosion Protection Systems, which operate in moderate environments. These pressure detector
instructions are to be implemented in cooperation with complete system inspection instructions.
During initial system checkout or start-up, the Fike Factory Certified Field Personnel may determine that an
additional inspection is required due to process operational characteristics and/or historical inspection data
relative to the specific process.
It is extremely important to closely monitor the operational characteristics of your system during the first few
days and weeks after initial start-up.
Any maintenance/repair other than calibration requires the pressure detector be response tested to insure that
the detector can be classified as a Fike Explosion Protection Pressure Detector.

6.1 Routine Inspections

These inspections are to be performed by Fike Field Personnel or personnel trained and certified by Fike.
To perform an inspection, it is important to first obtain all pertinent data that relates to the specific system
being inspected. The required information includes:
• System Engineered Drawings
Component Location Drawing #__________ Field Wiring Diagram #__________
• Copy of manuals, specifications or documents referenced on system engineered drawings
• Inspection equipment
• Operating specifications on each component being inspected

Page 16 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
6.2 Diaphragm Cleaning

CAUTION: HANDLE THE PRESSURE DETECTOR WITH CARE IN ORDER TO AVOID DAMAGE TO
THE DIAPHRAGM. THE DIAPHRAGM MUST BE PROTECTED AGAINST IMPACT
DAMAGE.
The steps required to properly clean the pressure detector diaphragm are listed below.
Step 1: Turn the keyed “Disabled/Arm/Reset” switch, on the front of the control panel, to the “Disabled”
position.
Note: Do not use the internal board switches to disable and silence the system. These switches are
to be used by Fike Certified Field Personnel only. Use of these switches will result in latching
of the FRD alarm conditions, necessitating a field service call in order to reset the system.
Step 2: Verify the control panel is in the “Disabled” mode. The yellow ”Trouble” LED should be the only one
of the three large LED’s on the front of the panel to be lit. When looking at the smaller diagnostic
LED’s, numbers 6, 7, 8 and 17 should be on.
Step 3: Remove the Tri-Clover® clamp that holds the detector to the process pressure port.
Step 4: Remove the built-up material from the diaphragm by using a soft brush or cloth (I.E. toothbrush,
paintbrush).
Note: Never use a screwdriver or any other hard or sharp object to clean the device.
Step 5: Return the detector to the process pressure port.
Step 6: Tighten the Tri-Clover® clamp that holds the detector to the process pressure port.
Step 7: Make sure the red “Alarm” LED, at the Control Panel, is not lit.
Note: If red “Alarm” LED is lit, do not proceed until the reason for the alarm condition is
determined and removed.
Step 8: Reset the Explosion Protection System at the control panel. Turn the keyed “Disabled/Arm/Reset”
switch, on the front of the control panel, to the “Reset” position. The switch is spring loaded so that it
will automatically return to the “Armed” position.
Step 9: Only the green “Normal” LED should be lit.
Note: There may be a slight delay, while the ARM’s charge, until the green “Normal” LED lights.

FRD Page 17 of 21
Manual P/N E06-037 Date: June 1, 2000
7. COMPONENT PARTS

7.1 Rigid Mount Assembly

E61-056-5 has Grey Enclosure
E61-056-6 has White Enclosure

Note: Optional Silicone Tri-Clamp®

gasket available.
Refer to P/N 02-9797

Pressure Detector Base Assembly

E61-056-1 has Grey Enclosure
E61-056-2 has White Enclosure
Note: Base Assembly is Rigid Mount
Assembly without items 15 & 16.

R
16 02-9082 1 GASKET, TRI-CLAMP, 2" - TEFLON
15 02-8593 1 TRI-CLAMP R, 2"
14 02-9637 1 ENCLOSURE, PRESSURE DETECTOR - AL. GREY
13 02-9713 1 ENCLOSURE, PRESSURE DETECTOR - AL. WHITE
12 02-4777 1 CAUTION LABEL-SENSITIVE AREA - NOT SHOWN
11 02-4775 2 CAUTION LABEL - NOT SHOWN
10 02-4776 2 CABLE TIE 14" x .091", NYLON - NOT SHOWN
9 02-8063 1 1/2" x 3/4" REDUCER
8 H02-0055 4 SCREW, MACHINE, 4-40 X 1/4
7 02-9695 2 SHRINK TUBE, 1 1/2" WHITE
6 02-9051 1 HOSE, FLEXIBLE, 1/2 NPT x 18
5 E25-0008 1 TAG, PRESSURE DETECTOR, NAME PLATE
4 02-1807 4 LOCK WASHER, #8 EXT. TOOTH
3 02-9136 4 SCREW, MACHINE, 8-32 x .375, PAN HEAD, PHILLIPS
2 E10-0056 1 PCB ASSEMBLY- FRD POTTED
1 02-9691 1 PRESSURE TRANSDUCER, 2" TRI-CLOVERR
ITEM PART NUMBER QTY DESCRIPTION

Figure 17: Rigid Mount Component List

Page 18 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
7.2 Flush Mount Assembly 13 or 14 5 8
3 4
E61-056-3 has Grey Enclosure
2
E61-056-4 has White Enclosure
G

Note: Optional Silicone Tri-Clamp®

gasket available.
Refer to P/N 02-9797
6 7

15

16 1

17

R
17 02-9082 1 GASKET, TRI-CLAMP, 2" - TEFLON
16 02-9125 1 GASKET, 2.5 x 2.0 x .125 - TEFLON
15 E61-0016 1 HOLD DOWN, 2", FLUSH MOUNT
14 02-9637 1 ENCLOSURE, PRESSURE DETECTOR - AL. GREY
13 02-9713 1 ENCLOSURE, PRESSURE DETECTOR - AL. WHITE
12 02-4777 1 CAUTION LABEL-SENSITIVE AREA - NOT SHOWN
11 02-4775 2 CAUTION LABEL - NOT SHOWN
10 02-4776 2 CABLE TIE 14" x .091", NYLON - NOT SHOWN
9 02-8063 1 1/2" x 3/4" REDUCER
8 H02-0055 4 SCREW, MACHINE, 4-40 X 1/4
7 02-9695 2 SHRINK TUBE, 1 1/2" WHITE
6 02-9051 1 HOSE, FLEXIBLE, 1/2 NPT x 18
5 E25-0008 1 TAG, PRESSURE DETECTOR, NAME PLATE
4 02-1807 4 LOCK WASHER, #8 EXT. TOOTH
3 02-9136 4 SCREW, MACHINE, 8-32 x .375, PAN HEAD, PHILLIPS
2 E10-0056 1 PCB ASSEMBLY- FRD POTTED
1 02-9691 1 PRESSURE TRANSDUCER, 2" TRI-CLOVER R
ITEM PART NUMBER QTY DESCRIPTION

Figure 18: Flush Mount Component List

FRD Page 19 of 21
Manual P/N E06-037 Date: June 1, 2000
 13 or 14 5 8
7.3 Flex Mount Assembly 3 4

2
E61-056-7 has Grey Enclosure
G
E61-056-8 has White Enclosure

9
16
15

6 7

Note: Optional Silicone Tri-Clamp®

17

gasket available. Refer to P/N 02-

9797.
18

19

16
22 15
21
23

20

23 02-8116 2 WASHER, .25, FLAT

22 02-8115 2 NUT, .25-20UNC-2B
21 02-1479 2 BOLT, .25-20UNC-2A x 1.00, HEX HEAD
20 02-9137 2 GASKET, SOLID, 1.5 x .875 x .125 - NEOPRENE
19 E61-0017 1 BRACKET, MOUNTING, FLEX
18 E02-0042 2 STRAP, MOUNTING, 10" - NEOPRENE
17 02-9109 1 HOSE, FLEXIBLE, PVC, BRAIDED
R
16 02-9082 2 GASKET, TRI-CLAMP, 2" - TEFLON
R
15 02-8593 2 TRI-CLAMP, 2"
14 02-9637 1 ENCLOSURE, PRESSURE DETECTOR - AL. GREY
13 02-9713 1 ENCLOSURE, PRESSURE DETECTOR - AL. WHITE
12 02-4777 1 CAUTION LABEL-SENSITIVE AREA - NOT SHOWN
11 02-4775 2 CAUTION LABEL - NOT SHOWN
10 02-4776 2 CABLE TIE 14" x .091", NYLON - NOT SHOWN
9 02-8063 1 1/2" x 3/4" REDUCER
8 H02-0055 4 SCREW, MACHINE, 4-40 X 1/4
7 02-9695 2 SHRINK TUBE, 1 1/2" WHITE
6 02-9051 1 HOSE, FLEXIBLE, 1/2 NPT x 18
5 E25-0008 1 TAG, PRESSURE DETECTOR, NAME PLATE
4 02-1807 4 LOCK WASHER, #8 EXT. TOOTH
3 02-9136 4 SCREW, MACHINE, 8-32 x .375, PAN HEAD, PHILLIPS
2 E10-0056 1 PCB ASSEMBLY- FRD POTTED
1 02-9691 1 PRESSURE TRANSDUCER, 2" TRI-CLOVER R
ITEM PART NUMBER QTY DESCRIPTION

Figure 19: Flex Mount Component List

Page 20 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
 13 or 14 5 8
7.4 Hi-Temp. Flex Mount 3 4

Assembly 2

E61-056-9 has Grey Enclosure G

E61-056-10 has White Enclosure

16
15

6 7 17

Note: Optional Silicone Tri-Clamp® 18

gasket available.
19
Refer to P/N 02-9797.
22
21
23
16
20
15

23 02-8116 2 WASHER, .25, FLAT

22 02-8115 2 NUT, .25-20UNC-2B
21 02-1479 2 BOLT, .25-20UNC-2A x 1.00, HEX HEAD
20 02-9137 2 GASKET, SOLID, 1.5 x .875 x .125 - NEOPRENE
19 E61-0017 1 BRACKET, MOUNTING, FLEX
18 E02-0042 2 STRAP, MOUNTING, 10" - NEOPRENE
17 02-4770 1 HOSE, FLEXIBLE, HIGH TEMP, BRAIDED
R
16 02-9082 2 GASKET, TRI-CLAMP, 2" - TEFLON
R
15 02-8593 2 TRI-CLAMP, 2"
14 02-9637 1 ENCLOSURE, PRESSURE DETECTOR - AL. GREY
13 02-9713 1 ENCLOSURE, PRESSURE DETECTOR - AL. WHITE
12 02-4777 1 CAUTION LABEL-SENSITIVE AREA - NOT SHOWN
11 02-4775 2 CAUTION LABEL - NOT SHOWN
10 02-4776 2 CABLE TIE 14" x .091", NYLON - NOT SHOWN
9 02-8063 1 1/2" x 3/4" REDUCER
8 H02-0055 4 SCREW, MACHINE, 4-40 X 1/4
7 02-9695 2 SHRINK TUBE, 1 1/2" WHITE
6 02-9051 1 HOSE, FLEXIBLE, 1/2 NPT x 18
5 E25-0008 1 TAG, PRESSURE DETECTOR, NAME PLATE
4 02-1807 4 LOCK WASHER, #8 EXT. TOOTH
3 02-9136 4 SCREW, MACHINE, 8-32 x .375, PAN HEAD, PHILLIPS
2 E10-0056 1 PCB ASSEMBLY- FRD POTTED
1 02-9691 1 PRESSURE TRANSDUCER, 2" TRI-CLOVER R
ITEM PART NUMBER QTY DESCRIPTION

Figure 20: Hi-Temperature Flex Mount Component List

FRD Page 21 of 21
Manual P/N E06-037 Date: June 1, 2000
8. REPAIR AND RETURN AUTHORIZATION
Any component that is to be returned to Fike must be approved for return prior to shipment. In order for the
returned component to receive the correct attention for credit, repair or replacement whether under warranty
or at the owner's expense, an authorization number must be assigned by Fike. This number is obtained by
contacting the organization that normally services your Fike Explosion Protection System. If for any reason,
they are not available, contact may be made directly to Fike Corporation, Field Service Department. A
prearranged return authorization will expedite matters and assure that proper measures will be taken upon
receipt of the part(s).
A reference to the Material Return Authorization Number (MRA) should be included on the packing slip. If a
packing slip is not used, the MRA should be made through alternate means, such as marking on the outside of
the container. When preparing the component for shipment, please include your original Purchase Order
Number, Invoice Number or Fike Production Order Number. Include with the package the return shipment
information including return address and method of shipment as well as the name and telephone number of a
contact.
A specific statement describing the reason for the return will assist in examining the part(s). This statement
should also address symptoms and an operational history of the system in which the component was installed.
In the event the part being returned is a part of a larger assembly, the party assigning the Material Return
Authorization Number (MRA) will inform you whether the entire assembly or only the component in question
you should be returned.
The following is the address to be used for all authorized material returns.

Fike Corporation
704 South Tenth Street
Blue Springs, MO 64015
Attention: Explosion Protection
MRA # __________

Page 22 of 22 FRD
Date: June 1, 2000 Manual P/N E06-037
 704 South 10th Street
P.O. Box 610
Blue Springs, Missouri 64013 U.S.A.
(816) 229-3405
Fax: (816) 229-5082
http://www.fike.com