Spirax Sarco IPC6: An Electro-Pneumatic Converter for Industrial Control
The Spirax Sarco IPC6 is a versatile electro-pneumatic converter designed to translate electrical control signals into proportional pneumatic output signals. This function is crucial in many industrial automation systems where electrical controllers need to interface with pneumatically actuated devices such as control valves.
Key Functionality: The core purpose of the IPC6 is to receive an electrical input, typically a 4-20 mA current signal (though a 0-10 Vdc input is available for some safe area versions), and convert it into a corresponding pneumatic pressure. This allows for precise control of pneumatic equipment based on an electronic control system’s logic.
Core Features and Specifications:
- Signal Conversion: Converts a 4-20 mA (or 0-10 Vdc for specific models) input to a proportional pneumatic output.
- Output Pressure Ranges: Offers various output pressure ranges to suit different final control element requirements, with common examples including:
- 0.2 – 1.0 bar g (3 – 15 psi g)
- 0.2 – 1.8 bar g (3 – 26 psi g)
- 0.4 – 2.0 bar g (6 – 29 psi g)
- Mounting Options: Provides flexibility in installation with options for wall mounting, DIN rail mounting, or 2″ pipe mounting (with an optional kit). Wall and DIN rail mounting kits are typically included.
- Field Reversible: The output can be configured to be directly or inversely proportional to the input signal, offering adaptability to different control strategies.
- Supply Air Pressure: Requires a supply air pressure typically ranging from a minimum of 1.5 bar g (21.8 psi g) to a maximum of 8.0 bar g (116 psi g).
- Operating Principle: Employs a two-section design:
- Primary Converting Section: Utilizes a coil and suspension spring as a flapper, which, along with a nozzle, controls the signal pressure.
- Pneumatic Relay Section: The signal pressure acts on an upper control diaphragm, setting the output pressure, which is then sensed and maintained by a lower control diaphragm.
- Enclosure Rating: Features an IP65 enclosure rating, indicating protection against dust ingress and low-pressure water jets.
- Operating Temperature: Designed to operate within a wide temperature range, typically from -40 °C to +70 °C (-40 °F to 158 °F).
- Materials of Construction: Key components include an aluminium body and housing, zinc-plated steel trim, nitrile diaphragm, and nickel-plated brass orifice.
- Hazardous Area Options: ATEX/IECEx certified intrinsically safe versions (e.g., IPC6 ATEX) are available for use in potentially explosive atmospheres. These versions meet stringent safety standards such as Ex ia IIC T4 Ga / Ex ia IIIC T135 °C Da.
- Pneumatic Connections: Typically features ¼” NPT pneumatic connections.
- Electrical Connections: Utilizes EN 175301-803 electrical connectors.
- Air Consumption: Has a low average air consumption, typically around 0.17 Nm³/h (0.10 SCFM).
- Linearity and Hysteresis: Offers good performance with linearity around ±0.5% FS and hysteresis of 0.25% FS.
Applications:
The Spirax Sarco IPC6 is widely used across various industries for controlling pneumatic actuators, particularly control valves, based on signals from electronic control systems like PLCs or DCS. Its applications are prevalent in any process requiring the modulation of fluid flow or pressure through pneumatic means, driven by an electrical signal. This includes, but is not limited to, systems in:
- Steam and condensate management
- Process control in manufacturing
- HVAC systems
- Automated industrial machinery
In essence, the IPC6 serves as a critical link between the electronic “brain” of a control system and the pneumatic “muscle” that performs the physical action in an industrial process. Its reliability, range of options, and availability of hazardous area certifications make it a suitable component for a diverse set of industrial control applications.
