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HBAC2 Service Manual - Western Enterprises

Contents

1. Relief Power Supply Piping Connections Box Pipline we Piping Header Inlets Acetylene CGA 300 or 510 Carbon Dioxide CGA 320 Nitrous Oxide CGA 326 346 Hydrogen CGA 350 115 bd Oxygen CGA 540 Kc 580 Fj Helium CGA 580 Nitrogen CGA 580 Manifold 2 Control Manifold Outlet 1 4 tube compression fitting located on Settting the left side on top of the cabinet Relief Valve 1 2 NPT female pipe thread located on the right side on top of the cabinet FIGURE 1 2 Connection Location 1 2 B20193 ECN 11612 0112 ADJUSTMENT SPECIFICATIONS Primary Primary Pressure Change Over Intermediate Pressure Relief Line Regulator Regulator Switches Valve Regulator Low Side High Side Setting Setting HBAC2 120 125 200 min 170 175 205 215 75 80 HBAC2HL 120 125 200 min 170 175 205 215 75 80 HBAC2 Acetylene 50 55 110 max 85 90 120 125 10 15 HBAC2HP 220 225 300 max 270 275 305 315 150 170 Unit of measure all units are in psig N A Not Applicable Part of the optional fuel gas alarm kit This is the approximate setting This setting should be the midpoint of the changeover regulator settings 5 psig RECOMMENDED TOOLS AND TEST EQUIPMENT Volt Ohm meter Available from local source Isopropyl alcohol Available from local source Phillips screwdriver Available from local source Flat blade screwdriver Available from local sour
2. DESCRIPTION PART CGA 580 Nipple 15 8SF10 CGA 580 Nut 92 Inlet Block WMC 2 38 Pressure Switch WME 4 28 CGA 580 Adaptor B 70 1 4 Tube Connection WLF 3 3 1 8 NPT Street Tee BL 2HP 1 8 NPT Eblow BSL 2HP 1 8 x 1 4 NPT Adaptor ot show Female Wire Connector Right Side Inlet 5 12 B20193 ECN 11612 0112 INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HBAC2 HBAC2HL amp HBAC2HP Series Western Enterprises Repair Drawing Intermediate Block Components HBAC2 1 and 1A Series DESCRIPTION 400 PSI Gauge 1 8 NPT Bushing Intermediate Block 1 2 NPT Pipe Fitting 1 2 NPT Coupler Safety Relief Valve for HBAC2HL Series 300 psig for HBAC2HP Series 450 psig for HBAC2 Series 300 psig Pipe away Adaptor 1 8 NPT Plug 3 8 Tube x 1 4 NPT DESCRIPTION 400 PSI Gauge 1 8 NPT Bushing Intermediate Block 1 2 NPT Pipe Fitting HBAC2 1 Series 1 2 NPT Plug 1 8 NPT Plug 3 8 Tube x 1 4 NPT 5 13 PART G 15 400W BA 2HP WMC 2 36 WLF 1 15 BF 8HP WMV 8C 300 WMV 8V 450 WMV 8V 300 WMV 8 7 P 2HP WLF 3 30SS PART G 15 400W BA 2HP WMC 2 36 WLF 1 15 PC 8HP P 2HP WLF 3 30SS B20193 ECN 11612 0112 Western Enterprises Repair Drawing INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HBAC2 HBAC2HL amp HBAC2HP Series Gauge P
3. 60 WMG 3 4 400 psi 100 psi 3 8 2000 psi WMG 322 200 psi WMG 3 12 4000 psi WMV 2 56 itineri Master Valve WMS 1 59 CGA 326 Header Check Valve WMS 1 65 CGA 320 Header Check Valve WMS 1 62 CGA 346 Header Check Valve WMS 1 99 CGA 350 Header Check Valve WMS 1 100 CGA 510 Header Check Valve WMS 1 53 CGA 540 Header Check Valve WMS 1 54 CGA 580 Header Check Valve INDICATOR LAMP REPLACEMENT PARTS Square Style 8 42 0 Light Bulb 8 41 Bulb Receptacle 8 40 2 2 Red Green Lens 1010 Heater light Repair Kit 4 28 Pressure Switch Explosion Proof adjustable 150 375 psi HBAC2 HBAC2HL amp HBAC2HP WME 4 5 Explosion Proof Pressure Switch adjustable 30 300 psi Acetylene WME 4 29 Bracket for WME 4 28 switch POWER SUPPLY REPLACEMENT PARTS 11 31 Power Supply Assembly transformer PCB with dry contacts case and cable WME 8 1 Power Supply PCB for WMS 11 31 and WMS 11 36 includes dry contacts for remote alarms REMOTE ALARMS 24 VAC Service Visual 1 Gas 2
4. Intermediate Primary Regulator for HBAC2HP series Oxygen Air H2 Ar He N2 S N 21584 Change Over Primary Regulators WMSGS 11 119 Change over Primary Regulator for HBAC2 series Oxygen Air H2 Ar He N2 S N 21583 WMS 11 103 Change over Primary Regulator for HBAC2 amp HBAC2HL series CO2 20 5 gt 21583 WMS 11 115 Change over Primary Regulator for HBAC2 series Acetylene S N 21583 WMS 11 119 Change over Primary Regulator for HBAC2HP series Oxygen Air H2 Ar He N2 S N 21583 WMS 11 126 Change over Primary Regulator for HBAC2 series Oxygen Air H2 Ar He N2 S N 21584 WMS 11 125 Change over Primary Regulator for HBAC2 amp HBAC2HL series CO2 20 5 lt 21584 WMS 11 124 Change over Primary Regulator for HBAC2 series Acetylene S N 21584 WMS 11 126 Change over Primary Regulator for HBAC2HP series Oxygen Air H2 Ar He N2 S N 21584 Line Regulators WMS 11 19 Line Regulator for HBAC2 amp HBAC2HL series Acetylene and Liquefied Fuel Gas WMS 11 20 Line Regulator for HBAC2 series except Acetylene and Liquefied Fuel Gas manifolds WMS 11 39 Line Regulator for HBAC2HP series manifolds 5 1 B20193 ECN 11612 0112 PANEL MOUNT GAUGES 2 Diameter 1 4 NPT Back Port WIM GES El EU 30 psi WMG 3 14 300 psi 23 9
5. Line Pressure Regulator Intermediate Pressure Gauge Pre set Pressure Change over Pressure Regulator Regulator Left Cylinder Bank Pressure di Gauge m Right Cylinder Bank oH Heal Se ee ressure Gauge Line Pressure Intermediate Pressure Cylinder Pressure Check Valves Pressure Switch Pressure Switch FIGURE 2 5 Piping Schematic HBAC2 To Pipeline Distribution System s Relief Valve Line Pressure Gauge Line Pressure Regulator Intermediate Change over Pressure Pre set Pressure Reg ulator Regulator Left Cylinder Bank Pressure H Right Cylinder Bank G H mm Pressure Gauge Intermediate Pressure Line Pressure Cylinder Pressure Check Heater Check Pressure Switch Valve Valve Pressure Switch FIGURE 2 6 Piping Schematic HBAC2HL 2 6 B20193 ECN 11612 0112 To Pipeline Distribution System Line Pressure Gauge 1 Line Pressure Regulator Intermediate Pressure ee Gauge Change over Pressure Ex oe egulator egulator Left Cylinder Bank Pressure Right Cylinder Bank Gauge oe i _ Gauge Line Pressure I
6. WARRANTY Western Enterprises makes no warranty of any kind with regard to the material in this manual including but not limited to the implied warranties of merchantability and fitness for a particular purpose Refer to the Installation and Operating Instructions manual for warranty information i B20193 ECN 11612 0112 CAUTION e Failure to follow the following instructions can result in personal injury or property damage Never permit oil grease or other combustible materials to come in contact with cylinders manifold and connections Oil and grease may react with explosive force when ignited while in contact with some gases particularly oxygen and nitrous oxide Cylinder header and master valves should always be opened very s l o w l y Heat of re compression may ignite combustible materials Pigtails should never be kinked twisted or bent into a radius smaller than 5 inches Mis treatment may cause the pigtail to burst Do not apply heat Some materials may react and ignite while in contact with some gases particularly oxygen and nitrous oxide Cylinders should always be secured with racks chains or straps Unrestrained cylinders may fall over and damage or break off the cylinder valve which may propel the cylinder with great force Oxygen manifolds and cylinders should be grounded Static discharges and lightning may ignite materials in an oxygen atmosphere creating a fire or explosive force Welding s
7. CGA 580 Nipple 15 8SF10 CGA 580 Nut 92 Inlet Block WMC 2 37 Pressure Switch For HBAC2 Series WME 4 28 For HBAC2HP Series WME 4 28 CGA 580 Adaptor B 70 1 8 NPT Elbow BSL 2HP 1 4 x 1 8 NPT Adaptor B 4 2HP ot shown Female Wire Connector Right Side Inlet 5 10 B20193 ECN 11612 0112 Western Enterprises INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HBAC2 1 1A and 6 Series Repair Drawing Inlet Block Components Left Side Inlet DESCRIPTION Right Side Inlet CGA 580 Nipple CGA 580 Nut Inlet Block 1 8 Tube Connection Check Valve 1 4 Tube Connection 2 PART 15 8SF10 92 WMC 2 34 WLF 3 11 CVM 4FV WLF 3 30SS DESCRIPTION CGA 580 Nipple CGA 580 Nut Inlet Block 1 8 Tube Compression Fitting CGA 580 Adaptor 5 11 PART 15 8SF10 92 WMC 2 34 WLF 3 11 B 70 B20193 ECN 11612 0112 INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HBAC2HL Series Repair Drawing Inlet Block Components KEY DESCRIPTION PART Left Side Inlet 1 CGA 580 Nipple 15 8SF10 2 CGA 580 Nut 92 3 Inlet Block WMC 2 33 4 Pressure Switch WME 4 28 5 1 4 Tube Fitting WLF 3 30SS 6 Check Valve CVM 4F 7 8 9 1 4 Tube Fitting WLF 3 3 1 8 x 1 4 NPT Adaptor B 4 2HP 1 8 NPT Street Elbow BL 2HP ot shown Female Wire Connector WME 8 11 WILL 1
8. Clean all interior surfaces with isopropyl alcohol or 1 1 1 Trichloroethylene solvent 4 10 B20193 ECN 11612 0112 10 11 12 13 14 15 Apply Teflon tape to the 1 4 male pipe threads on the nipple Start the threads of the nipple into the outlet of line regulator Using a 3 4 hex wrench install the nipple to the outlet of the line regulator Using a 7 16 hex wrench reassemble the U bolt to the bracket When re tightening the 3 8 tube fittings the procedure outlined on page 4 2 shall be followed Using an 11 16 open end wrench reconnect the tubing When re tightening the 1 8 tube fitting the procedure outlined on page 4 2 shall be followed Using an 7 16 open end wrench reconnect the line pressure gauge tubing to the line regulator Reconnect the intermediate pressure relief valve to the building s vent line Reconnect the main supply line to the manifold at the 1 4 compression fitting Line Regulator Adjustment 1 Reinstall the manifold cover as explained at the beginning of this section CAUTION Be sure to backout the adjusting screw on the line regulator prior to pressurizing the system If the adjusting screw position was changed it may overpressurize causing something to burst or rupture 10 11 S l o w l y open one cylinder on the system Verify the cylinder pressure gauge indicates a minimum pressure of 1500 psig on Oxygen Air and Nitrogen systems or a mini
9. Audio Visual 2 Gases 3 Audio Visual 1 Gas WMS 11 36 Optional 115 to 24 VAC Power Supply for above Remote Alarms 5 2 B20193 ECN 11612 0112 INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HBAC2 amp HBAC2HP Series Hydrogen Manifolds Repair Drawing Components amp Miscellaneous Hardware See Page 5 5 for Part Numbers and Descriptions 5 3 B20193 ECN 11612 0112 gt INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HBAC2 Series Acetylene Manifolds Repair Drawing Components amp Miscellaneous Hardware See Page 5 5 for Part Numbers and Descriptions 5 4 B20193 ECN 11612 0112 INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HBAC2 amp HBAC2HP Series Hydrogen amp Acetylene Manifolds Components amp Miscellaneous Hardware Western Enterprises Repair Drawing KEY DESCRIPTION 1 Outlet HBAC2 1 Series Nut HBAC2 6 Series Tube Fitting HBAC2HP 6 Series Tube Fitting Outlet HBAC2 1 Series Nipple HBAC2 6 Series Tube Extender HBAC2HP 6 Series Tube Extender Line Regulator for HBAC2 1 Series for HBAC2 6 Series for HBAC2HP 6 Series Intermediate Block for HBAC2 1 Series for HBAC2 6 Series for HBAC2HP Series 10 32 Set Screw Inlet Tube Left Inlet 1 4 Tube Plug 1 8 Tube Bulkhead Fitting 1 8 Tubing for HBAC2 1 1A Series for HBAC2 6 amp HBAC2HP 6 Series
10. EUN 5 1 Panel Gauges tenti BP Ui eee te Le r a IE I edet eed 5 2 Valves and Gheck Valves ibn e RH RED d ert Urea Hd ep A EL Re ra ce Dt edu e 5 2 Indicator Lamp Replacement eret innen neret einen 5 2 Pressure SwItChes ede ond enden dede hec Ha obe tree isst esti 5 2 Power Supply Replacement Parts 5 2 Isemote Alarms inte it bete dt betreut deiude iret eed 5 2 SECTION 5 MAINTENANCE AND REPAIR PARTS Repair Drawings 5 3 Components and Miscellaneous Hardware HBAC2 Series Fuel Gas Manifolds 5 3 Components and Miscellaneous Hardware HBAC2 8 HBAC2HP Series except Fuel Gas 5 6 Components and Miscellaneous Hardware HBAC2HL Series 5 8 Inlet Block Components 2 8 HBAC2HP Series 5 10 Inlet Block Components HBAC2 Series Fuel 5 11 Inlet Block Components HBAC2HL Series 5 12 Intermediate Block 5 13 Gauge Plate 5 14 iv B20193 ECN 11612 0112 This page intentionally left blank v B20193 ECN 11612 0112 SECTION 1 INTRODUCTION amp GENERAL INFORMATION PRODUCT DESCRIPTION The automatic changeover manifold is designed to provide a reliable uninterrupted supply of gas t
11. Gas enters the regulator through the inlet port and fills the high pressure chamber and the port to the cylinder con tents gauge with gas See Figure 2 11 and 2 12 Gas in these areas is at the same pressure as the gas in the cyl inders The gas is sealed in this chamber by the seat holder and stem being pushed against the nozzle seal by gas pressure and the body spring An o ring seals between the nozzle and the regulator body The next area of the regulator is the low regulated pressure area of the regulator This chamber is sealed from the high pressure area by the seat nozzle assembly and the o ring around the nozzle and is isolated from the at mospheric pressure by the diaphragm sub assembly forming a seal around the body of the regulator The dia phragm is squeezed between the body of the regulator a slip ring washer and the regulator bonnet as the bonnet is tightened down on the body The third chamber of the regulator is open to atmospheric pressure This chamber contains the regulator bonnet adjusting screw pivot bonnet spring washer and the top side of the diaphragm sub assembly As the adjusting screw is turned in against the pivot the bonnet spring is compressed and puts a downward force on the diaphragm sub assembly The bottom of the diaphragm sub assembly is in direct contact with the seat holder and stem When the diaphragm is forced down by the spring the stem is pushed away from the nozzle and gas can then flow from the h
12. Intermediate Tubing Right Inlet PART D 8 WLF 3 30 WLF 3 30 WLF 5 4 WMS 11 24 WMS 11 19 WMS 11 20 WMS 11 39 WMS 11 48 WMS 11 49 WMS 11 51 WMC 6 58 WMS 11 45 WMS 11 71 WLF 3 32 WLF 3 33 WLF 6 19 WMS 11 47 WMS 11 29 DESCRIPTION Stem Locking Nut Change over to Block Tube 1 4 NPT Adaptor Control Knob Control Knob Screw 10 1 Self tapping Screw Outer Gauge Plate Case for HBAC2 1 Series for HBAC2 6 amp HBAC2HP 6 Series Screw Receptacle Inner Gauge Plate for HBAC2 1 Series for HBAC2 6 Series for HBAC2HP 6 Series Backplate Assembly Tee Mounting Bracket 3 8 16 Hex Nut 3 16 Hex Nut 3 16 Lock Washer 1 2 Nominal U bolt 3 16 24 x 1 3 4 Carr Bolt Case Lead Seal 8 Sht Metal Case Screw PART WMS 11 25 WMS 11 46 B 4HP RWC 3 19 RWC 3 60 WMC 6 39 WMC 8 2 WMC 8 14 WMC 6 35 WMS 8 7 WMS 1 12 WMS 5 4 WMS 11 28 WMC 6 7 WMC 6 6 WMC 6 1 1 WMC 6 12 WMC 6 13 WMC 6 10 WEM 1 27 WMC 6 23 Primary Int Regulator tem not pictured for HBAC2 1 Series for HBAC2 6 Sereis for HBAC2HP 6 Series See Maintenance amp Repair Parts list on page 5 1 10 32 Cap Screw Change over Regulator for HBAC21 Series for HBAC2 6 Series for HBAC2HP 6 Series WMC 6 59 Piping Schematics for HBAC2 1 HBAC2 1A and HBAC2 6 are shown on page 2 7 5 5 B20193 ECN 11612 0112 INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HBAC2 amp HBAC2HP Series Except Fuel Gas Western Enter
13. Start the threads of the compression fitting into the check valve Using an 9 16 open end wrench to tighten to effect a gas tight seal 4 When re tightening the fitting the procedure outlined on page 4 2 shall be followed Using an 9 16 open end wrench connect the inlet tubing to the 1 4 tube compression fitting located on the left side of the regulator 4 9 B20193 ECN 11612 0112 LINE REGULATOR REPLACEMENT Shutdown the manifold and remove cover as explained earlier in this section Removal 1 Mark the 3 8 tube compression fittings located on the intermediate block per the instructions on page 4 2 Using an 11 16 open end wrench disconnect the compression nut 2 Mark the 1 8 tube compression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the line pressure gauge tubing from the line regulator 3 Disconnect the intermediate pressure relief valve from the building s vent line 4 Disconnect the main supply line from the manifold at the 1 4 tube compression fitting 5 Using a 3 4 hex wrench remove the nipple from the outlet of the line regulator 6 Using a 7 16 hex wrench remove the U bolt from the bracket 7 Using a 3 8 hex wrench remove the nut and washer from the carriage bolt holding the intermediate block to the bracket and remove the bolt and the intermediate block 8 Secure the intermediate block in a vise or similar holding fixture 9 To remove the regulator from the in
14. against the diaphragm sub assembly As the pressure continues to build in the low pressure chamber more upward force will be exerted against the dia phragm and the diaphragm will push up against the bonnet spring compressing the bonnet spring As the dia phragm is gradually raised by the gas pressure the seat and nozzle gradually come closer together filling the low pressure chamber slowly and eventually the upward pressure exerted by the gas will be slightly greater than the downward pressure of the bonnet spring and the seat nozzle will close As gas is released from the low pressure chamber a proportional amount of gas will be let into the low pressure area from the high pressure chamber As the adjusting screw is turned in farther and the bonnet spring compressed the gas pressure required to lift the dia phragm increases resulting in a higher delivery pressure from the outlet port of the regulator LEGEND 1 Adjusting screw 2 Bonnet 3 Pivot 4 Adjusting spring 5 Diaphragm assembly 6 Body 7 Valve spring 8 Seat assembly 9 nozzle FIGURE 2 17 Line Pressure Regulator 2 11 B20193 ECN 11612 0112 This page intentionally left blank 2 12 B20193 ECN 11612 0112 FIELD TESTING amp TROUBLE SHOOTING SECTION 3 The manifold performance tests are used to verify the manifolds functional performance When used in con junction with the trouble shooting
15. bank are indicated on the gauges on the manifold front cover The Service supply is indicated by the position of the control knob The line pressure is indicated by the center gauge on the manifold front cover As the gas from the Service supply is depleted the gas pressure to the Service primary regulator will begin to fall Simultaneously the pressure to the pressure switch and the check valve and the line regulator also falls When the Service side pressure falls below the set point of the pressure switch the red replace depleted cylin ders light comes on and the green system normal light is extinguished Any remote alarms are activated at this time When the Service pressure falls to the set point of the intermediate regulator gas will flow from the interme diate regulator i e the Reserve supply begins to supply the system After replacing empty cylinders and opening the master valve and cylinder valves the cylinder pressure will actuate the pressure switch the red replace depleted cylinders light will be extinguished and the green system normal light will come on The operator should then turn the control knob to the opposite cylinder bank This will make the partially used Reserve bank the Service supply and the newly installed cylinders will become the Reserve sup ply 2 2 B20193 ECN 11612 0112 255 l LEGEND 1 Outlet adaptor 6 Ch
16. cylinder pressure Close the cylinder valve on the right bank of cylinders Observe the cylinder contents gauges the right cylinder bank gauge should begin to drop the left cylinder bank gauge should remain constant Observe the intermediate gauge as the right side pressure continues to drop As the cylinder pressure drops on the right side the intermediate area also loses pressure Verify that the pressure falls to the low set 3 2 36 37 38 39 40 41 42 43 44 45 46 point of the change over regulator see the specification chart in Section 1 Ad just the intermediate regulator as neces sary to obtain the required pressure S l o w l y open one cylinder valve on the right bank of cylinders Verify that the intermediate gauge has re turned to the set pressure of the intermedi ate primary regulator Rotate the control knob clockwise to make the left bank the service supply Close the cylinder valve on the left bank of cylinders Observe the cylinder contents gauges the left cylinder bank gauge should begin to drop the right cylinder bank gauge should remain constant Observe the intermediate gauge as the left side pressure continues to drop As the cylinder pressure drops on the left side the intermediate area also loses pressure Verify that the pressure falls to the set point of the intermediate regulator see the specification chart in Section 1 Close the outl
17. pressure at the end of the two minute period Tighten the cap screw into the collar using a 5 32 Allen wrench The side of the cap screw should be against the right side of the stop bracket Once tight the knob should not be able to rotate clockwise Tighten the two remaining set screws using the 3 32 Allen wrench Create a slight flow of gas Turn the knob counter clockwise until the cap screw hits the left side of the stop plate Close the valve used to create the flow The pressure on the test gauge should indicate indicated the pressure listed in the Adjustment Specification chart in Section 1 Close the left cylinder valve Vent all remaining gas from the manifold Close the valve used to create the flow after the gas pressure has been exhausted from the manifold The label indicating service bank will need to be repositioned See the manifold cabinet cover removal reassembly procedure 4 7 B20193 ECN 11612 0112 PRESSURE SWITCH REPLACEMENT Removal 1 Shutdown the manifold and remove cover as explained earlier in this section 2 Label the three wires attached to the switch Remove the wires by grasping and pulling the connector Do not attempt to pull the wire This may pull the wire out of the connector 3 Usea 1 1 2 open end wrench to remove the pressure switch Replacement CAUTION Do not stand directly in front of the ports when performing the next step Eye protection should be worn to protect the servi
18. regulator Observe the intermediate gauge for two min utes Verify that the intermediate primary B20193 ECN 11612 0112 24 25 26 27 28 29 30 31 32 33 34 35 regulator does not exhibit creep or an in crease in pressure Verify that the right side cylinder contents gauge indicates a minimum of 1500 psig for Oxygen Nitrogen Air or gas mixtures systems Nitrous Oxide and Carbon Diox ide systems should indicate a minimum of 600 psig Verify that the line pressure gauge is indicat ing a minimum of 30 psig on all systems except acetylene Acetylene should indi cate a pressure between 10 and 15 psig Adjust to the proper line pressure if neces sary Create a slight flow of gas through the mani fold Observe the test gauge and verify the inter mediate regulator setting under a flow con dition Adjust the intermediate primary regulator as necessary to obtain the re quired pressure Verify that the line pressure regulator is func tioning properly by observing the line pres sure gauge for two minutes The gauge should indicate the same pressure at the end of the two minute period Create a slight flow of gas through the mani fold Verify that the line pressure regulator main tains a constant pressure by observing the line pressure gauge S l o w l y open one cylinder valve on the left bank of cylinders Observe the cylinder contents pressure gauges to verify
19. thread on the new gauge and reassemble in the reverse order of the removal procedure 2 Make sure gauge face is properly oriented through the front of the gauge plate 3 If the gauge needle is not on zero unscrew the gauge bezel and adjust the needle using a flat blade screwdriver 4 4 B20193 ECN 11612 0112 INTERMEDIATE PRIMARY REGULATOR REPLACEMENT NOTE Removal and Replacement procedures are to be followed for repair or replacement To ensure proper torques and that nothing is damage the regulator should always be removed from the system Shutdown the manifold and remove cover as explained earlier in this section Removal 1 Mark the compression fittings on both ends of the tubing per the instructions page 4 2 Using an 9 16 open end wrench disconnect the outlet tubing from the regulator at the compression fittings 2 Mark the compression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the gauge tubing from the regulator at the compression fitting 3 Using two 1 1 8 hex wrenches disconnect the regulator from the inlet block at the union connection 4 Remove the intermediate primary regulator from the control section and clamp the regulator assembly in a vise Replacement 1 Position the regulator assembly in the control section and hand tighten the inlet nut and nipple Do not tighten completely until all other connections have been made 2 When re tightening the fitt
20. valve into the regulator Using an 11 16 open end wrench to tighten to effect a gas tight seal 3 Install the regulator into the manifold as explained earlier in this section CHECK VALVE REPLACEMENT Left Side Removal 1 Shutdown the manifold and remove cover as explained earlier in this section 2 Mark the compression fittings on both ends of the 1 4 tubing per the instructions on page 4 2 Using an 9 16 open end wrench disconnect the inlet tubing from the regulator at the compression fittings 3 Using a 3 4 open end wrench to stabilize the assembly while using a 9 16 open end wrench to remove the compression fitting from the check valve 4 Using a 3 4 open end wrench remove the check valve from the inlet block Replacement CAUTION Do not stand directly in front of the ports when performing the next step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 1 Remove all old sealant from the inlet block and the compression fitting Blow out the inlet block and compression fitting with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 2 Apply Teflon tape to the 1 4 NPT male pipe threads on the check valve Start the threads of the check valve into the inlet block Using an 3 4 open end wrench to tighten to effect a gas tight seal 3 Apply Teflon tape to the 1 4 male pipe threads on the compression fitting
21. C CHANGEOVER MANIFOLD HBAC2HL Series Repair Drawing Components amp Miscellaneous Hardware KEY DESCRIPTION PART KEY DESCRIPTION PART Control Knob RWC 3 19 30 3 16 Lock Washer WMC 6 12 Control Knob Screw RWC 3 60 31 3 16 Hex Nut WMC 6 11 Gauge Plate Screw WMC 6 39 32 Strain Relief Bushing WME 8 34 Outer Gauge Plate WMC 8 2 33 7 Heater Cord WME 8 33 Case WMC 8 9 34 Case Wiring Harness WMS 11 72 Screw Receptacle WMC 6 35 35 Dual Light Lens WME 8 40 Inner Gauge Plate WMS 2 3 36 Dual Light Base WME 8 41 Backplate Assembly WMS 11 1 37 Dual Light Bulb WME 8 42 Tee Mounting Bracket WMC 6 7 38 Dual Light Label WME 8 54 3 8 16 Hex Nut WMC 6 6 Case Lead Seal WEM 1 27 3 16 24 1 3 4 Carr Bolt WMC 6 10 8 Sht Metal Case Screw WMC 6 23 1 2 Nominal U bolt WMC 6 1 Wire Nut WME 8 58 Power Supply Box WMS 11 31 Item not pictured 5 9 B20193 ECN 11612 0112 INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HBAC2 and HBAC2HP Series Repair Drawing Inlet Block Components KEY DESCRIPTION PART 1 CGA 580 Nipple 15 8SF10 2 CGA 580 Nut 92 3 Inlet Block WMC 2 34 4 Pressure Switch For HBAC2 Series WME 4 28 For HBAC2HP Series WME 4 28 Check Valve For HBAC2 4 amp HBAC2 8 Series CVM 4F For all others CVM 4FV 6 1 4 Tube Connection WLF 3 30SS 7 1 4 x 1 8 NPT Adaptor B 4 2HP Not shown Female Wire Connector WME 8 11 Left Side Inlet KEY DESCRIPTION PART
22. INNOVATOR HBAC2 HBAC2HP amp HBAC2HL SERIES SERVICE MANUAL AUTOMATIC CHANGEOVER MANIFOLD Western Enterprises Printed in U S A B20193 ECN 11612 0112 SAFETY Statements in this manual preceded by the following safety signal words are of special significance Definitions of the SAFETY signal words follow DANGER e Means a hazard that will cause death or serious injury if the warning is ignored WARNING Means a hazard that could cause death or serious injury if the warning is ignored CAUTION e Means a hazard that may cause minor or moderate injury if the warning is ignored It also may mean a hazard that will only cause damage to property NOTE Indicates points of particular interest for more efficient and convenient operation INTRODUCTION This manual provides the information needed to service the Western Enterprises HBAC2 HBAC2HL and HBAC2HP series manifolds This information is intended for use by technicians or personnel qualified to repair and service manifold equipment The information contained in this document including performance specifications is subject to change without notice
23. Indicator light is on but both banks are full Master valve header valves or cylinder valves on bank are closed Slowly open valves Red indicator light does not come on when one bank is empty and changeover occurs Bulb burned out Pressure switch wiring disconnected Pressure switch set at too low a pressure Replace bulb or lamp assembly Check connections Adjust pressure switch or return faulty unit for factory setting Green indicator light does not come on but both banks are full Bulb burned out Pressure switch wiring disconnected Replace bulb or lamp assembly Check connections Green indicator light comes on even though one bank of cylinders is empty RESERVE IN USE SIGNAL Remote alarm signal stays in one mode constantly regardless of changeover status Pressure switch wiring disconnected Pressure switch set at too low a pressure Power supply wiring is incorrect Flow demand too high Check wiring connections Adjust pressure switch or return faulty unit for factory setting Check wiring connections on both power supply terminal strips Reduce flow demand Remote alarm signals are opposite of manifold status Faulty connection to remote alarm unit Check input from alarm unit to terminal strip 3 4 B20193 ECN 11612 0112 SYMPTOM ABNORMAL LINE PRESSURE SIGNAL Low pressure alarm activated PROBABLE CAUSE Line p
24. NK CONTENTS continued Premature changeover to reserve bank PROBABLE CAUSE Flow demand too high Leaks in the manifold system Intermediate regulator set to open at too high a pressure REMEDY OR CHECK Reduce flow demand Leak test tighten reseal or replace fittings as necessary Adjust intermediate regulator per specifications No changeover PIPELINE DISTRIBUTION Pipeline not at desired pressure Closed cylinder or shutoff valves Intermediate regulator defective Empty reserve bank cylinders Line regulator not set correctly Open valves Replace or repair regulator Replace cylinders Readjust line pressure regulator Required gas flow not available Line regulator not set correctly Flow demand too high 3 7 Readjust line pressure regulator Consult factory B20193 ECN 11612 0112 This page intentionally left blank 3 8 B20193 ECN 11612 0112 SECTION 4 SERVICE PROCEDURES GENERAL MAINTENANCE 1 Main section a Daily record line pressure b Monthly 1 Check regulators compression fittings and valves for external leakage 2 Check valves for closure ability c Annually 1 Check relief valve pressures 2 Check regulator seats 2 Manifold header a Daily observe Nitrous Oxide and Carbon Dioxide systems for cylinder frosting or surface condensation Should excessive condensation or frosting occur it may be necessary to increase manifold c
25. Port Port Port High Pressure High Pressure hamber hamber FIGURE 2 11 Primary Change over Regulator FIGURE 2 12 Primary Intermediate Regulator 2 9 B20193 ECN 11612 0112 CHECK VALVES The check valves prevent gas from flowing backward from one bank to the opposite bank See Figures 2 13 and 2 14 Gas enters the check valve and pushes the check valve seat assembly away from the sealing surface of the valve body This allows the gas to flow to the outlet port of the valve When the gas flow stops the spring of the check valve pushes the valve seat down on the sealing surface preventing any gas flow backward through the valve Spring 1 Spring Seat j I x NS DONA X N AER N x SNS ACA AY JAY VN a AS Figure 2 13 CGA 580 nipple check valve Figure 2 14 Inline check valve PRESSURE SWITCH The pressure switch used to signal Reserve in Use is a diaphragm type with one common contact one normally closed contact and one normally open contact See Figures 2 15 and 2 16 When the manifold is pressurized to the normal pressures the diaphragm in the switch is pushed up The dia phragm pushes the activator of the switch up This action closes the normally open contact and opens the normally closed contacts As gas from the cylinder banks is depleted the diaphragm moves down releasing the force against t
26. Pte a etu e eid Cb dia ee bue eda ende ees 2 10 Line Pressure hRegulator 5 er eb ba ret rfe e inb eti i eres 2 11 SECTION 3 FIELD TESTING AND TROUBLE SHOOTING 3 1 Performance Verification Procedure 3 1 TROUDIG SHOOtING 3 4 SECTION 4 SERVICE PROCEDURES 4 1 General Maintenance 4 4 1 palety Precautioris 4 1 Cleaning Lubrication 7 4 2 General Repair Procedures 4 3 How to Shutdown the 4 3 Manifold Cabinet Cover EEEE EEEE Ennen 4 3 Gauge Replacement eire bte RO ears 4 4 Intermediate Primary Regulator 4 5 Change over Primary Regulator 4 6 Pressure Switch 4 8 Check 4 9 Line Regulator eae EA me a 4 10 Light Socket Replacement 4 12 Indicator Lamp Replacement 4 12 iii B20193 ECN 11612 0112 SECTION 5 MAINTENANCE AND REPAIR PARTS 5 1 Replacement Pigtails y sarera en aa 5 1 Regulators a r oed e
27. The gas pressure at all ports is the same as the pressure at the in let to the block Gas enters the lower right port of the intermediate block from the change over regulator The upper right port of the block is connected to the intermediate pressure relief valve for all gases except acetylene The port on the right end of the intermediate block is plugged The intermediate pressure gauge is connected to the left end of the block The lower left port is connected via tubing to the intermediate regulator The left top port connects to the inlet of the line pressure regulator The intermediate pressure relief valve prevents over pressurization of the intermediate controls of the manifold should the Service or Reserve primary regulator fail The relief valve setting is noted in the adjustment specifica tion chart in Section 1 The line pressure regulator further reduces the pressure to the final pressure delivered to the gas piping system The regulator has one inlet port and three outlet ports One outlet port is plugged Tubing is connected from the second port to the line pressure gauge to sense the pressure of the gas on the downstream side of the regulator The other port is the outlet and is located 180 from the inlet The gas flows from the line regulator outlet to the pipeline distribution system When both cylinder banks are full the switches complete the electrical circuit to the green system normal light Cylinder pressures for each
28. adjust the line regulator setting if it was modified during cover installation Close the cylinder valve on the right bank of cylinders Create a slight flow of gas through the mani fold Verify that the red light illuminates and the green light is extinguished when the mani fold changes over from service to reserve supply S l o w l y open one cylinder valve on the right bank of cylinders Rotate the control knob clockwise to make the left cylinder bank the service supply Observe the cabinet system status indica tors Verify that the green indicator is lit and the red indicator is off Close the cylinder valve on the left bank of cylinders Verify that the red light illuminates and the green light is extinguished when the mani fold changes over from service to reserve supply Close the outlet used to create the flow S l o w l y open all cylinder valves on the left and right banks of cylinders Rotate the control knob to select the bank of cylinders supplying the system before service was performed B20193 ECN 11612 0112 TROUBLE SHOOTING SYMPTOM CABINET INDICATOR LIGHTS No indicator lights on front panel come on when power is hooked up PROBABLE CAUSE Power Input Bulb burned out Internal wiring disconnected Only qualified repair personnel should make repairs REMEDY OR CHECK Check electrical power supply Replace bulb or lamp assembly Check all wiring connections Red
29. and right inlet blocks In mani folds incorporating a heater Nitrous Oxide and Carbon Dioxide HBAC2HL systems the gas flows through the heater and then through check valves On all other manifolds the gas flows directly to the check valves The thermostatically controlled heater warms the gas before entering the regulator preventing freeze up and loss of pressure due to the extreme low temperatures generated when these gases rapidly expand The gas on the right bank flows from the check valve into the intermediate primary regulator while gas from the left bank flows into the change over primary regulator Tubing is connected from the high pressure port on these regula tors to the cylinder pressure gauges to sense the pressure of the gas in the cylinders 2 1 B20193 ECN 11612 0112 Pressure is regulated in these primary regulators to the pressures noted in the adjustment specification chart in Sec tion 1 The intermediate primary regulator is set midway between the maximum and minimum settings of the change over regulator The position of the change over regulator knob determines which bank is in service When the regulator knob is rotated clockwise arrow pointing to the left the change over regulator setting is higher than the intermediate regulator setting Therefore the left bank will be in Service and the right bank will be in Re serve When the regulator knob is rotated counterclockwise arrow pointing to the right the change over r
30. ange over primary regulator 2 Line regulator 7 Intermediate primary regulator 3 Intermediate pressure gauge 8 Right side inlet 4 Left side inlet 9 Right side inlet pressure switch 5 Left side inlet pressure switch 10 Intermediate relief valve FIGURE 2 2 Internal Components HBAC2 2 3 B20193 ECN 11612 0112 LEGEND 1 Outlet adaptor 7 Heater assembly 2 Line regulator 8 Intermediate primary regulator 3 Intermediate pressure gauge 9 Right side inlet 4 Left side inlet 10 Right side inlet pressure switch 5 Left side inlet pressure switch 11 Intermediate relief valve 6 Change over primary regulator FIGURE 2 3 Internal Components HBACHL 2 4 B20193 ECN 11612 0112 LEGEND 1 Outlet adaptor 6 Change over primary regulator 2 Line regulator 7 Intermediate primary regulator 3 Intermediate pressure gauge 8 Right side inlet 4 Left side inlet 9 Intermediate relief valve 5 Explosion proof pressure switch connection Acetylene manifolds do not incorporate the relief valve FIGURE 2 4 Internal Components HBAC fuel gases 2 5 B20193 ECN 11612 0112 Distribution System aie Relief Valve Line Pressure Gauge
31. apacity b Monthly 1 Inspect valves for proper closure 2 Check cylinder pigtails for cleanliness flexibility wear leakage and thread damage Replace damaged pigtails immediately 3 Inspect pigtail check valves for closure ability c Every 4 Years 1 Replace pigtails WARNING Repairs to manifold high pressure regulators valve connections and piping should be made only by qualified personnel Improperly repaired or assembled parts could fly apart when pressurized causing death or serious injury SAFETY PRECAUTIONS 1 Examine all parts before repair Note Because manifold parts may be exposed to high pressure Oxygen and Nitrous Oxide and the condition of the unrepaired parts is unknown a repair inspection should be performed before exposing the parts to high pressure gas 2 Keep manifold parts tools and work surfaces free of oil grease and dirt These and other flammable materials may ignite when exposed to high pressure Oxygen or Nitrous Oxide 3 Use only proper repair tools and parts Parts for Western manifolds are shown in this instruction Special tools are called out as needed 4 Before connecting the cylinder to the manifold momentarily open and close the cylinder valve to blow out any dirt or debris except for hydrogen manifolds 5 After connecting the cylinder to the manifold open the cylinder valve S L O W L Y to allow the heat of compression to dissipate 6 Use only cleaning agents sealan
32. ce Needle nose pliers Available from local source Wire cutters Available from local source 3 32 5 32 hex key wrench Available from local source 5 8 hex socket wrench Available from local source 13 16 hex socket wrench Available from local source Set of combination wrenches Available from local source 1 4 thru 1 1 1 8 1 3 8 1 1 2 and 1 3 4 Liquid leak detector Available from Western Enterprises Part number LT 100 Teflon tape Available from Western Enterprises Part number MTT 1 or MTT 2 Krytox Lubricant Available from Miller Stevenson Chemical Co Inc Teflon is a registered trademark of E 1 du Pont de Nemours amp Co Inc 1 3 B20193 ECN 11612 0112 This page intentionally left blank 1 4 B20193 ECN 11612 0112 SECTION 2 THEORY OF OPERATION GENERAL INFORMATION This section concentrates on the basic theory of operation of the components of the automatic changeover manifold The first part of this section is an operating summary and traces the flow of gas through the various components of the manifold The second part of this section explains in detail the operation of the individual components contained in the manifold control section MANIFOLD OPERATION The automatic changeover manifold consists of a manifold control and two supply bank headers one service and one reserve supply to provide an uninterrupted supply of gas for the specific gas application The manifold control includes the following c
33. ce technician Chips and or debris may be propelled into unprotected eyes 1 Remove all old sealant from thepipe fitting Blow out the inlet block with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 2 Apply Teflon tape to the 1 4 NPT male pipe threads on the fitting Start the threads of the fitting into the pressure switch Using a 1 1 12 open end wrench to tighten to effect a gas tight seal 3 Complete the adjustment instructions below prior to installing the signal wires to the pressure switch Pressure Switch Adjustment 1 Connect an ohmmeter to the normally closed and common electrical contacts on the switch The ohmmeter should register zero resistance 2 Begin pressurizing the manifold by opening one cylinder valve on the side of the manifold the switch is on At the actuation pressure the ohmmeter reading will jump from zero resistance to infinite resistance 3 Close the cylinder valve after at least 500 psig has been reached 4 Create a slight flow of gas out of the manifold while observing the test gauge and ohmmeter to determine Switch setting At actuation pressure the ohmmeter reading should drop from infinite resistance to zero resistance 5 Close the valve used to create the flow The test gauge will go up slightly higher than the flowing adjusted pressure 6 Liftthe adjustment cover on the pressure switch 7 Usinga flat blade screwdriver turn clockwise to raise the set poin
34. charts the technician can verify proper performance or rapidly identify the probable source of the problem PERFORMANCE VERIFICATION PROCEDURE 1 Remove the control section cover as ex plained in Section 4 2 gt Reinstall the control knob on the shaft of the change over primary regulator 3 Rotate the control knob counter clockwise to make the left cylinder bank the Reserve supply and the right bank the Service supply 4 the master valves located on the der headers prior to pressurizing the mani fold 5 l o w l y open one cylinder valve on the left bank of cylinders 6 S o w l y open one cylinder valve on the right bank of cylinders 7 Using a leak detect solution verify that there are no leaks present 8 the cylinder valves on the left and right banks of cylinders 9 Deplete the gas from the manifold The gas must be expelled through the exit of the manifold Do not attempt to bleed gas from the control inlet or headers This will cause gas to be trapped in the manifold by check valves 10 S l o w I y open one cylinder valve on the left bank of cylinders 11 Verify that the intermediate gauge indicates the low pressure setting as shown in the specification chart in Section 1 for the change over primary regulator 12 Observe the intermediate gauge for two min utes Verify that the change over primary regulator does not exhibit creep or an in crease in
35. der valve on the left bank of cylinders Verify that the ohmmeter returns to approxi mately zero 0 ohms resistance Rotate the control knob counterclockwise to make the right bank of cylinders the serv ice supply Close the cylinder valve on the right bank of cylinders Verify an ohmmeter reading of infinite resis tance as soon as the test gauge pressure drops to the value for the pressure switch setting indicated in the specification chart in Section 1 S I o w l y open one cylinder valve on the right bank of cylinders Verify that the ohmmeter returns to approxi mately zero 0 ohms resistance Close all cylinder valves and vent all remain ing gas from the manifold Remove the ohmmeter leads from the black and brown wires Close the outlet used to create the flow Remove the control knob from the change over regulator 3 3 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 Reinstall the manifold section cover as ex plained in Section 4 Connect the electrical power source and sup ply electrical power to the manifold Observe the cabinet system status indica tors Verify that the green indicator is off and the red indicator is lit S l o w l y open one cylinder valve on the left and right banks of cylinders Observe the cabinet system status indica tors Verify that the green indicator is lit and the red indicator is off Re
36. egulator setting is lower than the intermediate regulator setting Therefore the right bank will be in Service and the left bank will be in Reserve The intermediate regulator setting and the low pressure setting of the change over regulator determines at which pressure the manifold will switch from Service to Reserve Gas will flow through the regulator that has the high est setting When the change over knob is turned clockwise pointing left the change over regulator setting is greater than the intermediate regulator setting Therefore gas will flow from the left bank When the gas pressure on the left bank drops to the set pressure of the intermediate regulator the right bank will start to flow Conversely when the change over regulator knob is rotated counterclockwise pointing right the intermediate regulator setting is higher than the change over regulator set pressure Therefore gas will flow from the right bank When the gas pressure on the right bank drops to the set pressure of the change over regulator the left bank will start to flow When rotating the control knob you are altering the pressure setting of the change over regulator above and below the intermediate regulator setting If the knob is not rotated until it stops the manifold will not function correctly The outlet port of each of these regulators is connected via tubing to the intermediate block The intermediate block has six ports all connected to the same chamber
37. et used to create the flow Verify that the intermediate regulator is func tioning properly by observing the interme diate gauge for two minutes The gauge should indicate the same pressure at the end of the two minute period S l o w l y open one cylinder valve on the left bank of cylinders Verify that the test gauge has returned to the set pressure of the change over primary regulator Connect an ohmmeter across the black and brown wires of the wiring harness The ohmmeter should indicate approximately zero 0 ohms resistance If the ohmme ter does not indicate approximately zero 0 ohms connect the meter across the normally open N O and common C ter minals on the pressure switch The ohm meter should register approximately zero 0 ohms resistance when connected to the switch Adjust or replace the faulty B20193 ECN 11612 0112 47 48 49 50 51 52 53 54 55 56 57 58 59 60 switch See Section 4 for servicing the pressure switch Reconnect the ohmme ter to the black and brown wires Close the cylinder valve on the left bank of cylinders Loosen the union connection to the main supply line to create a slight flow of gas through the manifold Verify an ohmmeter reading of infinite resis tance as soon as the test gauge pressure drops to the value for the pressure switch setting indicated in the specification chart in Section 1 S l o w l y open one cylin
38. g Harness WMS 11 72 10 1 Washer head Screw WMC 6 39 32 Dual Light Lens WME 8 40 Outer Gauge Plate WMC 8 2 33 Dual Light Base WME 8 41 Case WMC 8 9 34 24 V Bulb 285 WME 8 42 Screw Receptacle WMC 6 35 35 Dual Light Label WME 8 54 Inner Gauge Plate ii Case Lead Seal WEM 1 27 for HBAC2 Series WMS 1 12 8 Sht Metal Case Screw WMC 6 23 for HBAC2 4 8 Series WMS 2 3 Power Supply Box WMS 11 31 for HBAC2HP Series WMS 5 4 Backplate Assembly WMS 11 1 Tee Mounting Bracket WMC 6 7 3 8 16 Hex Nut WMC 6 6 3 16 24 x 1 3 4 Carr Bolt WMC 6 10 1 2 Nominal U bolt WMC 6 13 3 16 Lock Washer WMC 6 12 not pictured 5 7 B20193 ECN 11612 0112 W E 5 INNOVATOR estern nterprises AUTOMATIC CHANGEOVER MANIFOLD HBAC2HL Series Repair Drawing Components amp Miscellaneous Hardware 8 See Maintenance amp Repair Parts list KEY DESCRIPTION PART KEY DESCRIPTION PART 1 1 8 Tube Fitting WLF 3 30 10 Intermediate Tubing WMS 11 47 Outlet Extender WMS 11 24 11 Primary Int Regulator Line Regulator WMS 11 20 12 Right Inlet WMS 11 69 Intermediate Block WMS 11 50 13 10 32 Cap Screw WMC 6 59 3110 32 Set Screw WMC 6 58 14 Stem Locking Nut WMS 11 25 Inlet Tube WMS 11 45 15 Change over Regulator iii Left Inlet WMS 11 54 16 Change over to Block Tube WMS 11 7 Heater WMS 11 42 17 1 4 NPT Adaptor B 4HP 1 8 Tubing WLF 6 17 BW N 5 8 20193 ECN 11612 0112 1 INNOVATOR Western Enterprises AUTOMATI
39. gher flow rates up to 250 can be obtained using the HBAC2HL series manifolds The HBAC2HL manifold includes an internal heater Installing a Nitrous Oxide or Carbon Dioxide manifold in a location which exposes it to ambient temperatures below 20 F 7 C is not recommended Air Argon 250 SCFH maximum at 80 psig delivery with a 12 psi pressure drop and 2000 psig inlet pressure 30 SCFH maximum at 80 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure Helium amp 250 SCFH maximum at 80 psig delivery with a 12 psi pressure drop and 2000 psig inlet pressure Hydrogen 30 SCFH maximum at 80 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure Acetylene 75 SCFH maximum at 15 psig delivery with a 5 psi pressure drop and 200 psig inlet pressure Power Source Requirements A 115 VAC to 24 VAC power supply is provided with the manifold to operate the alarm lights on the manifold Under normal operation the manifold will draw a maximum of 40 milliamperes 040 amperes HBAC2HL series Nitrous Oxide and Carbon Dioxide systems include 500 capacity heater The thermo statically controlled heater warms the gas before entering the regulator preventing freeze up The heater operates at 115 VAC and draws four amperes
40. he switch activator The contacts of the switch then return to the normally open and normally closed posi tions The switch completes the electrical circuit to the indicators on the front of the control section and to the remote alarm terminal strip in the power supply box Diaphragm FIGURE 2 15 Pressure Switch FIGURE 2 16 Switch Schematic 2 10 B20193 ECN 11612 0112 LINE PRESSURE REGULATOR The line pressure regulator used in the manifold is a single stage four port adjustable regulator Refer to Figure 2 17 It has one inlet port and three outlet ports The inlet port is piped to an intermediate pressure port in the mani fold block One outlet port is piped to the outlet of the manifold for connection to the main pipeline One port is con nected to the delivery line pressure gauge and the other outlet port is plugged Gas enters the regulator through the inlet port and with the adjusting screw backed away from the spring is sealed in the high pressure chamber of the regulator by the seat and nozzle As the adjusting screw is turned in it compresses the spring and puts a downward force on the diaphragm sub as sembly When the diaphragm is forced down by the spring it pushes on the stem of the seat assembly The seat is pushed away from the nozzle and gas can then flow from the high pressure chamber to the low pressure cham ber When the low pressure chamber fills with gas the gas will push upward
41. hould not be performed near nitrous oxide piping Excessive heat may cause the gas to dissociate creating an explosive force ABBREVIATIONS ___ Occupational Safety amp Health Administration CGA Compressed Gas Association PSIG ____ Pounds per Square Inch Gauge FT LBS __ Foot Pounds SCFH Standard Cubic Feet per Hour IN LBS Inch Pounds VAC Voltage Alternating Current N C Normally Closed VDC Voltage Direct Current N O Normally Open PCB Printed Circuit Board NPT National Pipe Taper Western Enterprises shall not be liable for errors contained herein or incidental or consequential damages in connection with providing this manual or the use of material in this manual ii B20193 ECN 11612 0112 TABLE OF CONTENTS SECTION 1 INTRODUCTION 1 1 Product Description te estote ap 1 1 Installation Information ea ae einer de eee eas aed 1 1 Manifold Specifications ee 1 2 Adjustment Specifications ce eet e P UR pe Ge UE 1 3 Recommended Tools and Test 1 1 3 2 THEORY OF OPERATION 2 1 General Information ed eee dee 2 1 Manifold Operation nnt t P b n te d ri Ea e eiit bere E rra ege Be 2 1 Primary Regulators t edi t eer orte e a ertet te lb riae 2 9 Check Valves eet di entera 2 10 Low Pressure Switches nn eaen rte epe d
42. igh pressure chamber to the low pressure chamber When the low pressure chamber fills with gas the gas will push upward against the diaphragm sub assembly As the pressure continues to build in the low pressure chamber more upward force will be exerted against the dia phragm and the diaphragm will push up against the bonnet spring compressing the bonnet spring As the dia phragm is gradually raised by the gas pressure the seat and nozzle gradually come closer together filling the low pressure chamber slowly and eventually the upward pressure exerted by the gas will be slightly greater than the downward pressure of the bonnet spring and the seat nozzle will close As gas is released from the low pressure chamber a proportional amount of gas will be let into the low pressure area from the high pressure chamber As the adjusting screw is turned in farther and the bonnet spring compressed the gas pressure required to lift the dia phragm increases resulting in a higher delivery pressure from the outlet port of the regulator Adjusting crew _ Adjusting crew Bonnet gt M Diaphragm Diaphragm Spring SZ x Low _ Cx Low Seat and X TP mb Pressure Seat Xx RET Pressure Nozzle AN _ NS Chamber Nozzle SN S Chamber SN NY EN Inlet Outlet Inlet Jie Outlet Port
43. ing the procedure outlined on page 4 2 shall be followed Using a 7 16 open end wrench connect the gauge tubing to the 1 8 tube compression fitting located on the left side of the regulator 90 from the regulator inlet 3 When re tightening the fitting the procedure outlined on page 4 2 shall be followed Using an 11 16 open end wrench connect the outlet tubing to the 3 8 tube compression fitting located on the top of the regulator 180 from the regulator inlet 4 Tighten the inlet nut and nipple connection using two 1 1 8 open end wrenches Intermediate Primary Regulator Adjustment 1 If not already done shutdown the manifold as explained earlier in this section remove the manifold cover attach a test gauge to the left side of the intermediate pressure block and remove the acorn nut from the intermediate primary regulator 2 S l o w l y open one cylinder on the right bank 3 Verify the cylinder pressure gauge indicates a minimum pressure of 1500 psig on Oxygen Air and Nitrogen systems or a minimum of 600 psig on Nitrous Oxide and Carbon Dioxide systems 4 Using a flat blade screwdriver turn the adjusting screw of the regulator in while observing the test gauge Set the regulator to the pressure indicated on the Adjustment Specification chart in Section 1 5 Create a slight flow of gas through the manifold 6 Readjust the regulator to the proper specifications if necessary 7 Close the valve used to create the flow The
44. ing the procedure outlined on page 4 2 shall be followed Using an 9 16 open end wrench connect the inlet tubing to the 1 4 tube compression fitting located on the left side of the regulator Connect the stop plate to the brackets using two screws Thread the set screw into the bonnet hand tight Place the collar onto the set screw Proceed to the adjustment section to set the regulator correctly Change Over Primary Regulator Adjustment 1 2 10 11 12 13 14 15 16 17 18 19 If not already done shutdown the manifold as explained earlier in this section and remove the manifold cover Reinstall the control knob on the regulator S l o w l y open one cylinder on the left bank Verify the cylinder pressure gauge indicates a minimum pressure of 1500 psig on Oxygen Air and Nitrogen systems or a minimum of 600 psig on Nitrous Oxide and Carbon Dioxide systems Turn the adjusting screw of the regulator in while observing the test gauge Set the regulator to the pressure high pressure setting indicated on the Adjustment Specification chart in Section 1 Create a slight flow of gas through the manifold Readjust the regulator to the proper specifications if necessary Close the valve used to create the flow The test gauge will go up slightly higher than the flowing adjusted pressure Verify that the regulator does not creep by observing the test gauge for two minutes The gauge must indicate the same
45. ired for installation This precaution will keep moisture and debris from the piping interior avoiding operational problems Overall Manifold Length Manifold depth 12 40 10 typ 21 Note All dimensions are approximate Total number of cylinders 4 6 8 10 12 Overall manifold length 3 11 5 7 7 3 8 11 10 7 Acetylene manifold length 4 5 6 7 8 9 10 11 13 1 Floor Figure 1 1 1 1 B20193 ECN 11612 0112 MANIFOLD SPECIFICATIONS Flow Capability Oxygen 250 SCFH maximum at 80 psig delivery with a 12 psi pressure drop and 2000 psig inlet pressure 30 SCFH maximum at 80 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure Nitrogen 250 SCFH maximum at 80 psig delivery with a 12 psi pressure drop and 2000 psig inlet pressure 30 SCFH maximum at 80 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure Nitrous Oxide amp flow capability of a Nitrous Oxide or Carbon Dioxide cylinder manifold will depend upon Carbon Dioxide conditions at the installation site demands of the delivery system and the number of cylinders in service Maximum capability is 35 SCFH at 80 psig delivery and 750 psig inlet pressure Hi
46. lace cylinder Reseal or replace Repair or replace Venting at relief valve Line regulator setting too high Overpressure due to creeping or faulty regulation by primary regulator Overpressure due to creeping or faulty regulation by line regulator Regulator freeze up Nitrous oxide or carbon dioxide Heater failure Nitrous oxide or carbon dioxide Set delivery pressure to specifications Replace regulator seat and nozzle components Replace regulator seat and nozzle components Reduce the flow demand or increase the number of supply cylinders Reduce the flow demand or increase the number of supply cylinders Gas leakage around regulator body or bonnet Loose bonnet Diaphragm leak on regulator Tighten bonnet Replace diaphragm Gas leakage around valve stem or packing nut on master valve or header valve LOSS OF RESERVE BANK CONTENTS Both banks feeding Valve packing leaks Faulty valve Intermediate regulator seat leak Intermediate regulator set to open at too high a pressure Flow demand too high Tighten packing nut Repair or replace valve Repair or replace regulator Adjust intermediate regulator per specifications Reduce flow demand Opposite bank feeding Faulty primary regulator and or intermediate regulator Replace regulator seat and nozzle components 3 6 B20193 ECN 11612 0112 SYMPTOM LOSS OF RESERVE BA
47. late Components DESCRIPTION Cylinder Contents Gauge for HBAC2 1 400 psi for other HBAC2 amp HBAC2HP Series 4000 psi for HBAC2HL and HBAC2 4 8 Series 2000 psi Line Pressure Gauge for HBAC2 1 1A 30 psi for other HBAC2 amp HBAC2HL Series 200 psi for HBAC2HP Series 400 psi Gauge Plate 1 8 Tube x 1 4 NPT Female 5 14 B20193 ECN 11612 0112
48. ly located a leak detector solution should be applied to all connections in the event of leaks at more than one connection Be certain to wipe fittings dry after testing to prevent corrosion Western s LT 100 leak detector dries clean and will not harm apparatus If a leak is detected at sealed connections replace the assembly which is joined by the leaking connection threaded connections union sealing surfaces may have burrs or nicks which may be polished out Be certain to clean parts before reassembly If the surface will not seal replace the union Elbows and tees may be cleaned of old sealant and resealed with Teflon tape Refer to cleaning sealing and lubricating instructions compression fittings sealing surfaces of fittings or brass ferrules may be damaged and must be replaced Refer to the parts list for appropriate tubing gasket seals leaks may occur at seals made by gaskets such as diaphragms or o rings Gas may leak to atmosphere or across the seal into the opposite pressure circuit External leaks are evidenced by application of leak detector while leaks across the seal are detected by faulty manifold function When replacing seals use care not to damage sealing surfaces 4 2 B20193 ECN 11612 0112 GENERAL REPAIR PROCEDURES Be sure all pressure and electrical power is removed from the system prior to initiating any repair procedures WARNING Do not shutdown the manifold until all personnel have been advi
49. move the cap screw from the regulator set screw collar 5 Using 3 32 Allen wrench loosen but do not remove the two remaining set screws in the collar Remove the collar from the regulator set screw 6 Using a flat head screw driver remove the two screws holding the stop bracket from the mounting bracket 7 Remove the four screws holding the mounting bracket to backplate 8 Remove the change over primary regulator from the control section 9 Remove the two screws holding the brackets to the regulator 10 Clamp the regulator assembly in a vise Replacement 1 2 Position the new regulator in a vise the vice need not be tightened Position the brackets on the new regulator The order of the brackets should remain the same Tighten the two screws to mount the brackets onto the regulator Mount the regulator onto the backplate using the 4 self tapping screws When re tightening the fitting the procedure outlined on page 4 2 shall be followed Using a 7 16 open end wrench connect the gauge tubing to the 1 8 tube compression fitting located in the front of the regulator 90 from the regulator inlet 4 6 B20193 ECN 11612 0112 8 9 10 When re tightening the fitting the procedure outlined on page 4 2 shall be followed Using an 11 16 open end wrench connect the outlet tubing to the 3 8 tube compression fitting located on the right side of the regulator 180 from the regulator inlet When re tightening the fitt
50. mum of 600 psig on Nitrous Oxide and Carbon Dioxide systems Turn the adjusting screw of the regulator in while observing the line pressure gauge Set the regulator to the desired pressure Create a slight flow of gas through the manifold Readjust the regulator to the proper specifications if necessary Tighten the union connection to the main supply line The line pressure gauge will go up slightly higher than the flowing adjusted pressure Verify that the regulator does not creep by observing the line pressure gauge for two minutes The gauge must indicate the same pressure at the end of the two minute period Close the cylinder valve Loosen the main supply line union and vent all remaining gas from the manifold Tighten the union connection to the main supply line after the gas pressure has been exhausted from the manifold 4 11 B20193 ECN 11612 0112 LIGHT SOCKET REPLACEMENT Removal 1 Shutdown the manifold and remove cover as explained earlier in this section 2 Label and disconnect the four connectors attached to the back of the light socket 3 Using a small flat blade screwdriver pry off the two metal clips securing the light socket to the manifold cover 4 Slide the defective socket out through the front of the manifold cover Replacement 1 The new light socket will have two sets of terminals labeled and B Insert the back of the new light socket through the rectangular opening in the fro
51. nt of the manifold cover approximately 3 4 with the terminal of the A set on the top 2 Grasp the back of the light socket on the sides and pull the socket in until the front of the socket is flush with the front of the manifold cover 3 Reattach the connectors to the terminals on the socket 4 Reinstall the manifold cover and connect electrical power to the manifold Test for proper function by following the Performance Verification Procedure in Section 3 INDICATOR LAMP REPLACEMENT Removal 1 Remove indicator lens cover by pulling lens cover forward A small depression is molded into the top and bottom of the lens cover to facilitate removal A flat blade screwdriver can be wedged in the depression and twisted to pry the lens cover off 2 Remove the faulty lamp by pulling the built in extractor The clear plastic tab marked lamp pull is the extractor Replacement 1 Insert the replacement lamp and push on the lamp until it snaps into place CAUTION e Too much force used to install the lamp could break the socket bezel and allow the socket to be pushed completely through the front of the manifold cover 2 Reinstall the indicator lens cover with the green lens above the red lens CAUTION e Too much force used to install the lens cover could break the socket bezel and allow the socket to be pushed completely through the front of the manifold cover 4 12 B20193 ECN 11612 0112 SECTION 5 MAINTENANCE am
52. ntermediate Pressure Cylinder Pressure lt lt lt Pressure Switch Check Valves Pressure Switch FIGURE 2 7 Piping Schematic HBAC2 Acetylene To Pipeline Distribution System E Relief Valve Line Pressure Gauge Line Pressure Regulator _ Intermediate Pressure Gauge Change over Pressure Regulator Left Cylinder Bank Pressure Gauge Line Pressure Intermediate Pressure Cylinder Pressure num Pre set Pressure Regulator Right Cylinder Bank ressure Gauge Pressure Switch Check Valves Pressure Switch FIGURE 2 8 Piping Schematic HBAC2 Hydrogen 2 7 B20193 ECN 11612 0112 DUAL LIGHT B BULB A BULB RED LENS GREEN LENS RED BLUE WHITE WHITE PRESSURE SWITCH PRESSURE SWIT 2 WHITE BROWN BLACK VAC RED RED BLUE BROWN 5 110 24 PRESSURE SWITCH REFLECTS UNPRESSURIZED SYSTEM TRANSSORMER FIGURE 2 9 Electrical Schematic less heater FIGURE 2 10 Heater Electrical Schematic 2 8 B20193 ECN 11612 0112 PRIMARY REGULATOR change over and intermediate The primary regulator s function is to reduce the cylinder pressure of the supply banks to a more usable regulated pressure
53. o a gas pipeline sys tem in a laboratory installation The manifold has an equal number of cylinders in its Service supply and Reserve supply banks automatically switching to the Reserve supply when the Service supply becomes depleted When the manifold changes to Re serve supply it sends a signal to the gas alarm system alerting the personnel of the need for the exhausted bank of cylinders to be replaced with full cylinders After new cylinders are in place and turned on no manual resetting of the manifold is necessary except for turning the control knob INSTALLATION INFORMATION Manifolds should be installed in accordance with guidelines stated by the National Fire Protection Association the Compressed Gas Association OSHA and all applicable local codes The carbon dioxide and nitrous oxide manifolds should not be placed in a location where the temperature will exceed 120 F 49 C or fall below 20 F 7 C The manifolds for all other gases should not be placed in a location where the temperature will exceed 120 F 49 C or fall below 0 F 18 C A manifold placed in an open location should be protected against weather conditions including di rect contact with rain snow and heavy moisture During winter protect the manifold from ice and snow In summer shade the manifold and cylinders from continuous exposure to direct rays of the sun Leave all protective covers in place until their removal is requ
54. omponents and features green system normal and red replace depleted bank indicator lights cylinder pressure gauges line pressure gauge and intermediate safety relief valve Supply banks consist of a header with 24 stainless steel inner core flexible pigtails with check valves individual header check valves mas ter shut off valves and union connections for attachment to the control unit The main components of the manifold are shown in Figures 2 1 through 2 4 Figures 2 5 2 6 2 7 and 2 8 show the piping schematics Figure 2 9 is the schematic diagram of the electrical system of the manifold Figure 2 10 is the heater schematic Pressure Gauges Control Knob Cabinet Lights RIGHT BANK LEFT BANK gt pum Master Valves Check Valves FIGURE 2 1 External Components The cylinder bank that supplies the piping system is known as the Service supply while the cylinder bank on stand by is referred to as the Reserve supply Gas flows from the cylinder through the pigtails check valves headers and shut off valves into the left and right inlets of the control section Gas flows into the manifold control and to the pressure switches located on the left
55. p REPAIR PARTS REPLACEMENT PIGTAILS 24 Stainless Steel Inner Core Flexible with Check Valve HPF 16CVFA 24 CGA 300 with flash arrestor for Acetylene Service HPF 320CV 2A CGA 320 for Carbon Dioxide CO2 Service 326 24 CGA 326 for Nitrous Oxide N20 Service 346 24 CGA 346 for Breathing Air Air Service 83 24 CGA 350 for Hydrogen H2 Service HPF 15CVFA 24 CGA 510 with flash arrestor for Acetylene Service 63 24 CGA 540 for Oxygen O2 Service 92 24 CGA 580 for Inert Gas Service Argon Helium and Nitrogen REGULATORS amp REGULATOR REPAIR KITS Intermediate Primary Regulators WMS 11 104 Intermediate Primary Regulator for HBAC2 amp HBAC2HL series CO2 20 S N gt 21583 WMS 11 120 Intermediate Primary Regulator for HBAC2 series Oxygen Air H2 Ar He N2 S N 21583 WMS 11 105 Intermediate Primary Regulator for HBAC2 series Acetylene S N 21583 WMS 11 120 Intermediate Primary Regulator for HBAC2HP series Oxygen Air H2 Ar He N2 S N 21583 WMS 11 122 Intermediate Primary Regulator for HBAC2 amp HBAC2HL series CO2 20 S N lt 21584 WMS 11 123 Intermediate Primary Regulator for HBAC2 series Oxygen Air H2 Ar He N2 S N 21584 WMS 11 121 Intermediate Primary Regulator for HBAC2 series Acetylene S N 21584 WMS 11 123
56. pressure 3 1 13 14 15 16 17 18 19 20 21 22 23 Verify that the left side cylinder contents gauge indicates a minimum of 1500 psig for Oxygen Nitrogen Air or gas mixtures systems Nitrous Oxide and Carbon Diox ide systems should indicate a minimum of 600 psig Verify that the line pressure gauge is indicat ing a minimum of 30 psig on all systems except acetylene Acetylene should indi cate a minimum of 10 psig or a maximum of 15 psig Adjust to the proper line pres sure if necessary Create a slight flow of gas through the mani fold Observe the test gauge and verify the change over regulator setting under a flow condition Adjust the change over primary regulator as necessary to obtain the re quired pressure Rotate the knob clockwise so the change over regulator is at its maximum setting Verify that the intermediate gauge indicates the high pressure setting as shown in the specification chart in Section 1 for the change over primary regulator Turn off the left cylinder valve and allow all gas to vent from the manifold Once gas has depleted close the outlet used to cre ate the flow Rotate the control knob to its fully counter clockwise position S l o w l y open one cylinder valve on the right bank of cylinders Verify that the intermediate gauge indicates the pressure setting as shown in the speci fication chart in Section 1 for the intermedi ate primary
57. prises Repair Drawing Components amp Miscellaneous Hardware See Maintenance amp Repair Parts list KEY DESCRIPTION KEY DESCRIPTION PART 1 4 Tube Fitting WLF 3 30 9 Intermediate Tubing WMS 11 47 Outlet Extender WMS 11 24 10 Primary Int Regulator Line Regulator for HBAC2 Series for HBAC2 Series WMS 11 20 for HBAC2 4 8 Series for HBAC2HP Series WMS 11 39 for HBAC2HP Series Intermediate Block Right Inlet for HBAC2 Series WMS 11 49 for HBAC2 Series WMS 11 68 for HBAC2 4 8 Series WMS 11 50 HBAC2 4 8 Series WMS 11 68 for HBAC2HP Series WMS 11 51 for HBAC2HP Series WMS 11 68 3110 32 Set Screw WMC 6 58 10 32 Cap Screw WMC 6 59 Inlet Tube WMS 11 45 Stem Locking Nut WMS 11 25 Left Inlet Change over Regulator for HBAC2 Series WMS 11 52 for HBAC2 Series for 2 4 8 Series WMS 11 53 for HBAC2 4 8 Series for HBAC2HP Series WMS 11 52 for HBAC2HP Series 1 8 Tubing WLF 6 17 Change over to Block Tube 5 11 46 1 4 NPT Adaptor B 4HP 5 6 B20193 ECN 11612 0112 INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HBAC2 amp HBAC2HP Series Except Fuel Gas Western Enterprises Repair Drawing Components amp Miscellaneous Hardware DESCRIPTION PART KEY DESCRIPTION PART Service Control Knob RWC 3 19 30 3 16 Hex Nut WMC 6 11 6 32 Flat Head Screw RWC 3 60 31 Case Wirin
58. ressure regulator improperly adjusted Closed master valves header valves or cylinder valves Empty cylinders Primary regulator setting too low Faulty line pressure gauge Faulty alarm pressure switch REMEDY OR CHECK Readjust line pressure regulator Slowly open valves Replace with full cylinders Set delivery pressure to specifications Replace line pressure gauge Readjust or replace pressure switch as necessary High pressure alarm activated LOSS OF CYLINDER CONTENTS Audible or inaudible gas leakage unknown origin Line regulator setting too high Regulator freeze up Nitrous oxide or carbon dioxide Faulty line pressure gauge Faulty alarm pressure switch Leakage at manifold piping connections Leakage at manifold tubing connections Leakage in downstream piping system Readjust line pressure regulator Reduce the flow demand or increase the number of supply cylinders Add an internal heater to convert the manifold from a HBAC2 to a HBAC2HL Replace line pressure gauge Readjust or replace pressure switch as necessary Tighten reseal or replace Tighten reseal or replace Repair as necessary 3 5 B20193 ECN 11612 0112 SYMPTOM LOSS OF CYLINDER CONTENTS continued Audible or inaudible gas leakage unknown origin continued PROBABLE CAUSE Leakage at cylinder valve Gauge leaks Regulator leaks REMEDY OR CHECK Rep
59. sed of the intended service and all systems requiring industrial gas are being supplied from portable or alternate supplies Replace parts with all components in the repair kit HOW TO SHUTDOWN THE MANIFOLD 1 Turn off the piping system isolation valve if present If an isolation valve is not present the entire gas system will be reduced to atmospheric pressure WARNING Do not shutdown the manifold until all personnel have been advised of the intended service and all systems requiring industrial gas are being supplied from portable or alternate supplies 2 Turn off right and left supply bank cylinder valves 3 Deplete gas from the system The gas must be expelled through the exit of the manifold Do not attempt to bleed gas from the control inlet or headers This will cause gas to be trapped in the manifold by check valves 4 Disconnect electrical power from the manifold at the main power source MANIFOLD CABINET COVER REMOVAL Disassembly 1 Cut lead seal wire with wire cutters and remove 2 Remove the control knob on the front of the cabinet Peal back the service arrow label and remove screw with a Phillips screwdriver 3 Using a flat blade screwdriver or a 5 16 hex wrench unscrew the four screws holding the gauge plate to the cabinet Remove the cover plate 4 Unscrew the electrical connector at the bottom of the unit and unplug the cord 5 Unscrew the three screws attaching the cover to the backplate using an appropria
60. t or counterclockwise to lower the set point The pressure switch should be set per the Adjustment Specification chart in Section 1 8 Cycle between actuation and re actuation signals and make adjustments as required to achieve the signal setting The setting should be made on descending pressure Make adjustments response to the reading obtained in step 4 WARNING Be sure power is off when electrical connections are made Current flowing through the wires may shock the service technician 9 After the setting has been made connect the signal wires to the appropriate contacts on the pressure switch 4 8 B20193 ECN 11612 0112 CHECK VALVE REPLACEMENT Right Side Removal 1 Shutdown the manifold and remove cover as explained earlier in this section 2 Remove the intermediate regulator as explained earlier in this section 3 Put the regulator in a vice 4 Using an 11 16 open end wrench remove the check valve nipple from the regulator body Replacement CAUTION Do not stand directly in front of the ports when performing the next step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 1 Remove all old sealant from the regulator Blow out the regulator with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 2 Apply Teflon tape to the 1 4 NPT male pipe threads on the check valve Start the threads of the check
61. te screwdriver 6 Carefully pull the cover straight out to clear internal components 7 Locate and disconnect the three male female wire terminals to detach the cover electrical wiring from the pressure switch wiring 8 Lift the cover completely off the backplate Reassembly Reverse order of disassembly Connect internal wiring by matching up color coded wires 4 3 B20193 ECN 11612 0112 GAUGE REPLACEMENT Removal CAUTION careful not to kink or damage the tubing connected to the gauges Damaged tubing may burst when pressurized 1 Shutdown the manifold and remove cover as explained earlier in this section 2 Pull the mounting plate up so that it provides easy access to the gauge screws on the underside of the gauge plate 3 Mark the compression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the tubing from the defective gauge When re tightening the fitting the procedure outlined on page 4 2 shall be followed 4 Using a 3 8 hex wrench remove the two nuts holding the gauge brackets Slide the gauge brackets off of the screw posts 5 Slide the gauge out through the front of the gauge plate 6 Using a 3 4 hex wrench remove the compression fitting from the gauge Use a 9 16 open end wrench to stabilize the gauge 7 Remove the old sealant from the 1 4 NPT female pipe thread on the compression fitting Replacement 1 Apply Teflon tape to the 1 4 NPT male pipe
62. termediate block grasp the bonnet of the regulator and rotate the regulator counterclockwise Replacement 1 Secure the intermediate block in a vise or similar holding fixture 2 Remove all old sealant from the regulator inlet nipple Clean all interior surfaces with isopropyl alcohol or 1 1 1 Trichloroethylene solvent CAUTION Do not stand directly in front of the ports when performing the next step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 3 Remove all old sealant from the intermediate block Blow out the intermediate block with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 4 Apply Teflon tape to the 1 4 male pipe threads on the regulator inlet nipple Start the threads of the nipple into the intermediate block 5 Position the inlet of the regulator over the nipple and rotate the regulator clockwise to tighten the threads The inlet of the regulator is stamped IN 6 Grasp the bonnet of the regulator and rotate the regulator clockwise until tight The bonnet of the regulator must be parallel to the test gauge on the left end of the intermediate block 7 Remove the intermediate block from the vise and using the carriage bolt reinstall the intermediate block to the bracket on the backplate Assemble the nut and washer to the carriage bolt Tighten loosely 8 Remove all old sealant from the union nipple
63. test gauge will go up slightly higher than the flowing adjusted pressure 4 5 B20193 ECN 11612 0112 10 11 12 Verify that the regulator does not creep by observing the test gauge for two minutes The gauge must indicate the same pressure at the end of the two minute period Close the cylinder valve Create a flow of gas through the manifold and vent all remaining gas from the manifold Close the valve used to create the flow Install the acorn nut on the intermediate primary regulator CHANGE OVER PRIMARY REGULATOR REPLACEMENT NOTE Removal and Replacement procedures are to be followed for repair or replacement To ensure proper torques and that nothing is damage the regulator should always be removed from the system Shutdown the manifold and remove cover as explained earlier in this section Removal 1 Mark the compression fittings on both ends of the 1 4 tubing per the instructions page 4 2 Using 9 16 open end wrench disconnect the outlet tubing from the regulator at the compression fittings 2 Mark the compression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the gauge tubing from the regulator at the compression fitting 3 Mark the compression fittings on both ends of the 1 4 tubing per the instructions on page 4 2 Using an 9 16 open end wrench disconnect the inlet tubing from the regulator at the compression fittings 4 Using 5 32 Allen wrench re
64. ts and lubricants as specified in this instruction 4 1 B20193 ECN 11612 0112 CLEANING LUBRICATION AND SEALING Clean metal parts of the manifold with isopropyl alcohol or 1 1 1 Trichloroethylene solvent prior to assembly Dry thoroughly Do not clean o rings with this solvent Freon TF is acceptable Teflon Tape Application Threaded pipe connections should be sealed with Teflon tape Remove the old sealant from both male and female threads Apply Teflon tape to the male pipe thread Approximately 1 1 2 turns of tape should be sufficient Do not cover the first thread with tape Assemble the fittings wrench tight to effect a gas tight seal Assembly and Disassembly of Compression Fittings NOTE Incorrect reassembly of fittings may initially seal however they may start to leak over time Mark the fitting and nut prior to disassembly Before re tightening make sure the assembly has been inserted into the fitting until the ferrule seats in the fitting Retighten the nut by hand Torque the nut with a wrench until the marks line up which indicates that the fitting has been tightened to its original position Then snug the nut 1 12 of a turn 1 2 of a wrench flat past the original position Leak Testing There are four types of manifold piping connections sealed soldered threaded unions and elbows compression tubing connections and gasket diaphragms and o rings When a leak is suspected and cannot be easi

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