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HGM2 Service Manual - Western Enterprises

1. For PSI set the switches as shown Models HGM2 HGM2HL Model HGM2HP 9 or z 1 5 2 v c z 1g 04 Switch Position e For KPa setthe switches as shown Models HGM2 HGM2HL Model HGM2HP PLPPLE PT oO SESE e For switches as shown Models HGM2 HGM2HL Model HGM2HP 9 g v e e L 4 Close the cover and reconnect power to the manifold Verify that during power up the status of the switches are displayed on the digits of the right bank display and the right most digit of the left bank display as a series of 1 s and 0 5 as follows 4 16 B20318 ECN 13116 0501 DIP SWITCH DISPLAY OPTION For PSI Models HGM2 HGM2HL Model HGM2HP Left Display Digit Right Display Digit Left Display Digit Right Display Digit 1 11111 1 11011 For KPA Models HGM2 HGM2HL Model HGM2HP Left Display Digit Right Display Digit Left Display Digit Right Display Digit 0 11111 0 11011 For BAR Models HGM2 HGM2HL Model HGM2HP Left Display Digit Right Display Digit Left Display Digit Right Display Digit 0 01111 0 01011 4 17 B20318 ECN 13116 05
2. GENERAL REPAIR PROCEDURES Be sure all pressure and electrical power is removed from the system prior to initiating any repair procedures WARNING e Do not shutdown the manifold until personnel have been advised of the intended service and all patients requiring medical gas are being supplied from portable supplies Patients still on the pipeline will not receive gas Replace parts with all components in the repair kit HOW TO OPEN THE MANIFOLD Disassembly 1 Using the 5 32 allen wrench provided with manifold remove the knob NOTE e Prior to removing the knob make note of the knob orientation When re attaching the knob it should be oriented in the same position as when it was removed 2 Turn the latch counter clockwise and open the door 3 The knob should be reattached with the door open to allow the four way valve to be rotated Reassembly 1 Reverse order of disassembly MANIFOLD CABINET COVER REMOVAL Disassembly 1 Open the manifold as explained in the How to open the manifold section NOTE Prior to removing the knob make note of the knob orientation When re attaching the knob it should be oriented in the same position as when it was removed 2 Disconnect the two wire harness terminal blocks from the manifold PCB 3 Using the appropriate screwdriver or 1 4 hex wrench remove the 4 screws 2 on each side holding the cover in place 4 Carefully pull the cover straight out to clear th
3. 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 easily 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 B20318 ECN 13116 0501
4. ou uum E H lt C C 7 Lo H am 7 ODO g Inlet Port 2 E 2 2 CA CYL 2 Outlet FIGURE A CYL 1 Outlet CYL 2 Outlet FIGURE B CYL 1 Outlet Inlet Port 2 AN AS SANS S CYL 2 Outlet FIGURE C FIGURE 2 11 Four Way Valve Gas is directed from inlet port 1 to outlet port CYL1 and from inlet port 2 to outlet port CYL2 only The seals in the valve prevent gas from traveling to the other ports With the valve in this position the gas from the right primary regulator is routed to the intermediate block and the gas from the left primary regulator is routed to the intermediate regulator Figure 2 11b shows the valve in the OFF position The OFF position is only used during shipment of the manifold Notice that the internal porting of the valve shown as dashed lines does not connect any of the inlet ports of the valve with the outlet ports Figure 2 11c shows the position of the valve ports when the left bank of cylinders is the Service bank and the right bank is the Secondary The only function the four way valve serves is to route the gas to the other components of the manifold PRESSURE SWITCH The pressure switch is used as a redundant safety feature to signal Secondary in Use The Switch Is a piston type with one common contact one normally closed contact and one normally open contact See Figures 2 12 and 2 13 When the manifold is pressur
5. ESTERN AUTOMATIC CHANGEOVER MANIFOLD HGM2 HGM2HL amp HGM2HP SERIES SERVICE MANUAL WESTERN ENTERPRISES PRINTED IN USA B20318 ECN 13116 0501 SAFETY Statements in this manual preceded by the following safety signal words are of special significance Definitions on the SAFETY signal words follow DANGER 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 Means a hazard that may cause minor or moderate injury if the warning is ignored It also means 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 HGM2 HGM2HL and HGM2HP series manifolds This information is intended for use by technicians or personnel qualified to repair and service manifold equip ment The information contained in this document including performance specifications is subject to change without notice 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 Operation Instructions manual for warranty information B20318 ECN 13116 0501 CAUTION e
6. L amp R WMS 13 29 L amp R WMS 13 30 L amp R WMS 13 31 L amp R Primary Regulators RK 1038 Repair Kits for WMS 13 9 L amp R WMS 13 8 L amp R Primary Regulators 5 1 B20318 ECN 13116 0501 REGULATOR REPAIRS KITS continued Line amp Intermediate Regulator Kits RK 1160 Repair Kit for all line regulator and intermediate regulators VALVES AND VALVE REPAIR KITS 5 1 65 CGA 320 Check Valve Bushing 5 1 59 CGA 326 Check Valve Bushing WMS 1 62 CGA 346 Check Valve Bushing WMS 1 53 CGA 540 Check Valve Bushing WMS 1 54 CGA 580 Check Valve Bushing WMS 1 64 CGA 280 Check Valve Bushing WMS 13 14 Four Way Valve WMV 2 16 Master Valve RK 1041 Repair Kit for Low Pressure Check Valve RK 1085 Repair Kit for WMV 2 16 PRESSURE SWITCHES 4 4 All Gases except WME 4 4C For Oxygen Manifolds POWER SUPPLY REPLACEMENT PARTS 5 13 23 Power Supply Assembly transformer PCB with dry contacts case and cable 8 85 Power Supply PCB 8570D includes dry contact for remote alarms TRANSDUCERS WME 9 1A Inlet Transducer WME 9 2A Line Transducer for HGM2HP 9 Line Transducer for HGM2 HG
7. Teflon is a registered trademark of E du Pont de Nemours amp Co Inc Krytox is a register trademark of E du Ponte de Nemours amp Co Inc B20318 ECN 13116 0501 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 secondary supply to provide an uninterrupted supply of gas for the specific gas application The manifold control includes the following components and features green system normal and red replace depleted cylinders indicator lights digital readouts for both cylinder pressure and line pressure line pressure gauge internal dual line assembly and line relief valve Supply banks consist of a header with 24 stainless steel flexible pigtails with check valves individual check valve bushings master shut off valves and union connections for attachment to the control unit The main com ponents of the manifold are shown in Figures 2 1 through 2 3 Figures 2 4 and 2 5 show the piping schematics Fi
8. open the cylinder valve s l o w l y to allow the heat of compression to dissipate 6 Use only cleaning agents sealants and lubricants as specified in this instruction 4 1 B20318 ECN 13116 0501 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 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 gastight seal Assembly and Disassembly of Compression Fittings NOTE e Incorrect re assembly 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 the wrench until the marks line up which indicates that the fitting has been tightened to its original position A noticeable increase in mechanical resis tance will be felt indicating the ferrule is being resprung into sealing position Then snug the nut 1 12 of a turn 1 2 of a wrench flat past the original position Leak Testing
9. Failure to adhere to the following instructions may result in person injury or property damage e Never permit oil grease or other combustible materials to come in contact with cylinders manifold and connections Oil and grease may react and ignite when 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 recompression may ignite combustible materials Pigtails should never be kinked twisted or bent into a radius smaller than 3 inches Mistreatment may cause the pigtail to burst Do not apply heat Some materials may react 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 e Welding should never be performed near nitrous oxide piping Excessive heat may cause the gas to dissociate creating an explosive force ABBREVIATIONS C Common NFPA National Fire Protection Association CGA Compressed Gas Association OSHA Occupational Safety amp Health Administration FT LBS Foot Pounds PSIG Pounds per Square Inch Gauge IN LBS Inch Pounds SCFH Standard Cubic Feet per Ho
10. HGM2HL Model HGM2HP Left Display Digit Right Display Digit eft Display Digit Right Display Digit Left Display Digit Right Display Digit 11111 11110 01010 CIII e For KPA Models HGM2 Model HGM2HL Model HGM2HP Left Display Digit Right Display Digit Left Display Digit Right Display Digit Left Display Digit Right Display Digit 11101 11110 11191 11010 11105 10110 For BAR Models HGM2 Model HGM2HL Model HGM2HP Left Display Digit Right Display Digit Left Display Digit Right Display Digit Display Digit Right Display Digit 1100 HJQ 11100 111019 11100 10110 4 20 B20318 13116 0501 TRANSDUCERS HIGH PRESSURE Removal 1 Shutdown and open the manifold as explained in the How to shut down the Manifold and How to open the Manifold sections NOTE e This item may be replaced without shutting down the manifold completely To work on the manifold while it is still in service follow the steps in How to open the Manifold and How to deplete the Service Bank sections 2 Using a 7 8 open end wrench turn the high pressure transducer counter clockwise If gas is heard escaping stop rotating the transducer and wait for the trapped pressure to deplete 3 Clean any remnant of Teflon Tape from the port on the inlet block Replacement 1 Apply Teflon tape to the 1 4 NPT thread on the new transducer 2 Using a 7 8 open end wrench thread the transducer into the inlet
11. Pop the PCB off the door Replacement 1 2 3 Align the PCB on the standoffs and carefully press into place Install the two wire clips to the PCB Install the PCB cover and tighten the 4 hex nuts Reconnect power 4 15 B20318 ECN 13116 0501 ELECTRICAL POWER UP Circuit Boards with 6 DIP Switches 1 When power is applied to the manifold the displays will first cycle through a power up sequence before displaying the pressures This process takes about 16 seconds All of the Status indication lights will be lit e The lights will go out sequentially e The state of the DIP switches will be shown on the digits of the right bank display and the right most digit to the left of the left bank display as a series of 1 s and 0 s e The display will show all 8 e Each digit of the display will be lit individually 2 The displays and status indicators will then be allowed to operate normally AS OF MEASURE The HGM2 manifold can be configured to display PSI BAR The manifold is shipped with PSI as the default unit of measure To switch the units proceed to step 2 If PSI units are desired no changes are necessary and step 2 may be skipped Switches 2 To change the units perform the following steps Remove power to the manifold switches are only read during power up Open the door of the manifold Locate the switches at the bottom edge of the PC Board on the door
12. b 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 capacity 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 SAFETY PRECAUTIONS 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 pressurizing causing death or serious injury 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 5 After connecting the cylinder to the manifold
13. banks feeding LINE PRESSURE REGULATOR Gas leakage around regulator body bonnet Pipeline not at desired pressure Required gas flow not available Loose bonnet Intermediate regulator not set correctly Intermediate regulator set at too high a delivery pressure Flow capacity too high Loose bonnet Line regulator not set correctly Line regulator not set correctly Flow capacity too high 3 4 REMEDY OR CHECK Replace regulator seat and nozzle components Tighten bonnet Replace diaphragm Tighten screws Replace valve Replace valve Replace valve Tighten bonnet Adjust intermediate regulator per specifications Adjust intermediate regulator per specifications Reduce flow demand Tighten bonnet Set delivery pressure per specifications Set delivery pressure per specifications Reduce flow capacity B20318 ECN 13116 0501 Trouble Shooting SYMPTOM Electrical System No indicator lights or displays on front panel come on when power is hooked up Red indicator light s on but both banks are full Red indicator light does not come on when one bank is empty and changeover occurs Green indicator light does not come on even though both banks are full Display reads 0 even when pressure is present Display incorrect One or both of the red indicators are blinking PROBABLE CAUSE Power Input Master valve header valves or cylind
14. line assembly for connection to the main pipeline The other two outlet ports are 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 assembly 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 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 diaphragm and the diaphragm will push up against the bonnet spring compressing the bonnet spring As the diaphragm 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 pressu
15. low pressure chamber a proportional amount of gas will be let into the low pressure area from the HSS high pressure chamber As the adjusting screw is turned me d OS in farther and the bonnet spring compressed the gas Po E pressure required to lift the diaphragm increases resulting i 7 PEERS in a higher delivery pressure from the outlet port of the regulator Gas from Primary Regulator Gas from Four Way Valve CHECK VALVES FIGURE 2 9 Check Valve The check valves prevent gas from flowing backward See Figure 2 9 Gas enters the check valve from the primary regulator 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 seali i hrough the valve FOUR WAY VALVE The four way valve assembly is used to route the gas from the primary regulators to either the intermediate block or the differential control valve The four way valve has two inlet ports on the back side of the valve and two outlet ports located 180 apart on the sides of the valve See Figure 2 10 Figure 2 11a shows the position of the valve ports when the right bank of cylinders is the Service bank and the left bank is the Secondary Outlet FIGURE 2 10 Four Way Valve 2 7 B20318 ECN 13116 0501 CYL 1 Outlet Inlet Port 1 4 Inlet Port 1
16. on the manifold front cover The Service supply is indicated by the position of the control knob The intermediate pressure is indicated by the center gauge located on the intermediate block The line pressure is indicated by the digital readout as well as the gauge located on the outer block 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 intermediate block and the line regulator also falls When the Service side pressure falls below the set point of the bank pressure transducer the red replace depleted cylinders 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 the check valve between the regulator and the intermediate block is pushed open by the pressure applied from the intermediate regulator The Secondary supply begins to supply the system After replacing empty cylinders and opening the cylinder valves the pressure transducer will extinguish the red replace depleted cylinders light 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 secondary bank the Service supply and the newly installed cylinders will b
17. operate the alarm lights on the manifold Under normal operation the manifold will draw a maximum of 40 milliamperes 040 amperes A five terminal remote alarm terminal strip is on the right side of the circuit board in the power supply box for remote alarm interfacing The top three terminals on this strip N C N O and C provide dry contacts for hookup to the hospital or clinic s medical gas alarm system Contacts are rated up to 3 amps 30 VDC or 2 amps 250 VAC Nitrous Oxide and Carbon Dioxide systems include a 500 SCFH capacity heater The thermostatically controlled heater warms the gas before entering the regulator preventing freeze up The heater operates at 115 VAC and draws four amperes Piping Connections Ad Relief Valve poor Vent Line Header Inlets Carbon Dioxide CGA 320 Box DElvetviBibslih Nitrous Oxide CGA 326 IR VaN Sey Pipeline Breathing Air CGA 346 Outlet Oxygen CGA 540 Helium CGA 580 Nitrogen CGA 580 Med CGA 280 Manifold j Control Manifold Outlet 1 2 NPT male pipe thread located 4 on the top center of the cabinet Relief Valve 1 2 NPT male pipe thread located on the top left side of the cabinet FIGURE 1 2 Connection Locations B20318 ECN 13116 0501 ADJUSTMENT SPECIFICATIONS Primary Intermediate Pressure Intermediate Line Line Regulator Pressure Switch Regulator Regulators Pressure Relief Valve Relief Valve 195 205 135 140 120 125 295 305 235 24
18. rings with the spring retainer Push the smaller o ring to the bottom of the bore it rests in Assemble the large o ring with the nozzle Insert the new seat holder and stem into the nozzle Place the spring filter and Teflon gasket over the seat holder and stem Place the spring retainer on the compensating spring The boss on the retainer will enter the internal diameter of the spring Grasp the flats of the nozzle with one hand and carefully guide the seat nozzle assembly into the body of the regula tor until the threads are engaged Rotate the nozzle clockwise and hand tighten Using the 13 16 hex socket and torque wrench tighten the nozzle to approximately 5 ft lbs torque Lubricate the outer regulator body to diaphragm sealing surface of the regulator body with a small amount of water Do not allow water to enter the low pressure chamber of the regulator Hold the bonnet upside down and place the pivot and bonnet spring in the bore provided The small diameter of the pivot should enter the internal diameter of the spring Place the washer in the large bonnet cavity beveled side up Lay the slip ring on top of the washer Insert the diaphragm sub assembly in the bonnet cavity The side marked UP should be against the slip ring Carefully place the bonnet on the regulator body Rotate the bonnet clockwise and tighten to 85 95 ft lbs torque Replacement 1 2 the inlet of the regulator to the bush
19. the Manifold sections NOTE This item may repaired replaced without shutting down the manifold completely To work on the manifold while it is still in service follow the steps outlined in How to Deplete the Secondary Bank section 2 Mark the compression fittings at the regulator outlet per the instructions on page 4 2 Disconnect the tubing at this compression fitting using an 11 16 open end wrench 3 Disconnect the union fitting between the intermediate regulator and the four way valve 4 Remove the intermediate regulator from the control section Disassembly 1 Remove the intermediate regulator following the instructions above 2 Rotate the adjusting screw of the regulator counter clockwise with a flat blade screwdriver and remove 3 Remove the bonnet by holding the body hex with a wrench to stabilize the assembly and using another wrench to loosen the bonnet The adjusting spring vibration dampaner and pivot will come off with the bonnet 4 Remove the diaphragm assembly and slip ring 5 Using a 1 socket wrench rotate the seat capsule counterclockwise and remove the seat capsule CAUTION e Do not stand directly in front of the body and 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 6 Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign mate
20. the manifold Verify an ohmmeter reading of infinite resistance as soon as the intermediate gauge pressure drops to the value for the pressure switch setting indi cated in the specification chart in Section 1 5 1 1 open one cylinder valve on the left bank of cylinders B20318 ECN 13116 0501 51 52 53 54 55 56 57 58 59 60 61 Verify that ohmmeter returns to approximately zero 0 ohms resistance Close all cylinder valves and vent all remaining gas from the manifold Remove the ohmmeter leads from the black and brown wires Close the bleeder valve Connect the switch wires to the manifold wiring harness Observe the cabinet style status indicators Verify that the green indicator is off and the red indicators are lighted S I o w I y open on cylinder valve on the left and right banks of cylinders Observe the cabinet status indicator Verify that the green indicator is lit and the red indicators are off Close the cylinder valve on the right bank of cylinders Open the bleeder valve to create a slight flow of gas through the manifold Verify that the red light illuminates and the green light is extinguished when the manifold changes over from service to secondary supply 62 63 64 65 66 67 68 69 70 71 3 3 S l o w l y open one cylinder valve on the right bank of cylinders Rotate the control knob counterclockwise
21. the right bank by opening one 38 39 40 41 cylinder valve knob should point to the right bank Verify that the line pressure regulator is functioning properly by observing the line pressure gauge for two minutes The gauge should indicate the same pressure at the end of the two minute period Open the bleeder valve to create a slight flow of gas through the manifold Verify that the line pressure regulator maintains 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 cylinder pressure Close the cylinder valve on the right bank of cylinders Observe the cylinder contents readouts the right cylinder bank pressure should begin to drop the left cylinder bank reading 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 set point of the Intermediate regulator see the specification chart in Section 1 S l o w l y open one cylinder valve on the right bank of cylinders Verify that the intermediate gauge has returned to the set pressure of the primary regulator 42 43 44 45 46 47 48 49 50 3 2 Rotate the control knob counterclockwise to make the left bank the servic
22. 0 220 225 160 165 4 0 170 175 v2 02 HGM2HL 235 245 300 135 140 120 125 50 55 75 Units above are PSIG All testing must be done with full cylinders Primary regulator set pressure will vary with inlet pressures Software version is located on back of circuit board CAUTION e Resetting adjusting manifold components with cylinders that are not full may cause the manifold to function improperly B20318 ECN 13116 0501 RECOMMENDED TOOLS AND TEST EQUIPMENT Volt Ohm meter Isopropyl alcohol Phillips screwdriver Flat blade screwdriver Needle nose pliers Wire cutters 5 32 hex key wrench 5 8 hex socket wrench 13 16 hex socket wrench Set of combination wrenches 1 4 thru 1 1 1 8 1 3 8 1 1 2 and 1 3 4 Fluorolube S 30 lubricant Krytox 240 AC Liquid leak detector Teflon tape Available from local source Available from local source Available from local source Available from local source Available from local source Available from local source Available from local source Available from local source Available from local source Available from local source Manufactured by Occidental Chemical Corporation Niagara Falls New York Available from E I Du Ponte Wilmington Delaware Available from Western Enterprises Part number LT 100 Available from Western Enterprises Part number MTT 1 or MTT 2 Fluorolube is a registered trademark of Occidental Chemical Corporation
23. 01 ELECTRICAL POWER UP Circuit Boards with 7 Dip Switches Software version 4 0 x and 1 When power is applied to the manifold the displays will first cycle through a power up sequence before displaying the pressures This process takes about 12 seconds All three status indication lights will be lit The state of the DIP switches will be shown on the right bank display and right most digits of the left bank display A 1 represents each open switch a 0 for closed e The status lights will extinguish in the order green left red right red 2 The displays and status indicators will then be allowed to operate normally Each digit of the displays will read 8 A pressure switch status test will be conducted If the red and Switche green status lights are on the pressure switch is in an open state no inlet pressure wired incorrectly broken connection Otherwise no status lights will be on Each digit of the display will be lit individually Software version 2 02 1 When power is applied to the manifold the displays will first cycle through a power up sequence before displaying pressure This process takes approximately 16 seconds All three status indication lights will be lit The lights will turn off in the order green left red right red The state of the DIP switches will be shown on the digits of the right bank display and the right most digits of the left bank A 1 repr
24. ATIONS Flow Capability Oxygen 1200 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure 500 SCFH maximum at 50 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure Nitrogen 1200 SCFH maximum at 160 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure Nitrous Oxide The flow capability of a Nitrous Oxide cylinder manifold will depend upon conditions at the installation site demands of the delivery system and the number of cylinders in supply service Maximum capability is 500 SCFH at 50 psig delivery and 750 psig inlet pressure Installing a Nitrous Oxide manifold in a location which exposes it to ambient temperatures below 20 F 7 C is not recommended Breathing Air 1200 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure Helium 1200 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure Carbon Dioxide The flow capability of a Carbon Dioxide cylinder manifold will depend upon conditions at the installation site demands of the delivery system and the number of cylinders in supply service Maximum capability is 500 SCFH at 50 psig delivery and 750 psig inlet pressure Installing a Carbon Dioxide manifold in a location which exposes it to ambient temperatures below 20 F 7 C is not recommended Power Source Requirements A 115 VAC 24 VAC power supply is provided with the manifold to
25. Components and Miscellaneous Hardware HGM2 HGM2HP Series 5 3 Components and Miscellaneous Hardware HGM2HL 5 5 Left Primary Regulator Components u u a 5 7 Right Primary Regulator 5 5 8 Check Valve sua Ee CERA FE a trenes nennen 5 9 Intermediate Regulator Components u 5 10 Right Left Line Regulator Components 5 11 Power Supply Components UL paway og b ped de aat bove saxea e tovto ER EL SERRE RUE EPOR 5 12 iv B20318 ECN 13116 0501 This page intentionally left blank B20318 ECN 13116 0501 SECTION 1 INTRODUCTION amp GENERAL INFORMATION PRODUCT DESCRIPTION The automatic changeover manifold is designed to provide a reliable uninterrupted supply of gas to a hospital or clinic s medical gas pipeline system It is designed to meet NFPA 99 type 1 facility requirements The manifold has an equal number of cylinders in its Service supply and Secondary supply banks automatically switching to the Secondary supply when the Service supply becomes depleted When the manifold cha
26. HGM2HL WMGCG 3 4 400 psi Intermediate gauge REGULATORS Primary Regulators 5 13 27 Right Primary Regulator for HGM2 Air He 5 13 4 Right Primary Regulator for HGM2 Oxygen and Medical Mixture 5 13 29 Primary Regulator for HGM2HL amp 5 13 31 Primary Regulator for HGM2HP Air He N gt 5 13 26 Left Primary Regulator HGM2 Air He No 5 13 8 Left Primary Regulator for HGM2 Oxygen and Medical Mixture 5 13 28 Primary Regulator for HGM2HL amp 5 13 30 Primary Regulator for HGM2HP Air He N gt Line and Intermediate Regulators WLR 13 60R Right Line Regulator for 2 HGM2HL series manifolds WLR 13 200R Right Line Regulator for HGM2HP series manifolds WLR 13 60L Left Line Regulator for HGM2 amp HGM2HL series manifolds WLR 13 200L Left Line Regulator for HGM2HP series manifolds WLR 13 125 Intermediate Regulator for HMG2 8 HGM2HL series manifolds WLR 13 225 Intermediate Regulator for HGM2HP series manifolds REGULATOR REPAIR KITS Primary Regulator Kits RK 1037 Repair Kits for WMS 13 26 L amp R WMS 13 27 L amp R WMS 13 28
27. M2 WLR 13 60L HGM2 WMV 4C 75 HGM2HP WLR 13 200L HGM2HP WMV 4C 250 Inlet Union WMS 1 40 5 3 B20318 ECN 13116 0501 Western Enterprises Automatic Changeover Manifold HGM2 amp HGM2HL Series Repair Drawing Components amp Miscellaneous Hardware KEY DESCRIPTION 29 Case 30 Outlet Union 31 8 Sht Metal Case Screw WMC 6 Case Wiring Harness WMS 13 25 Switch Wiring Harness WMS 1 13 Power Supply Box WME 13 23 Manifold PCB WME 8 84 Item not pictured 5 4 B20318 ECN 13116 0501 Western Enterprises Repair Drawing KEY 1 DESCRIPTION Outlet Nut Outlet Nipple Intermediate Regulator 4 way to Intermediate Tube Inter Reg to Block Tube Left Relief Tube Four Way Valve Pressure Switch Left Primary Regulator Right Primary Regulator Left Inlet Block Right Inlet Block Left Primary to 4 way Tube Right Primary to 4 way Tube Relief Tubing Right Prim Reg Left Line Regulator Assembly PART D 7 D 20 See Page 5 1 WMS 13 19 WMS 13 20 WMS 13 15 WMS 13 14 WME 4 4 See Page 5 1 See Page 5 1 WMS 13 33 WMS 13 27 WMS 13 17 WMS 13 18 WMS 13 16 WMS 13 60L Automatic Changeover Manifold HGM2HL Series Components 8 Miscellaneous Hardware KEY DESCRIPTION 17 18 19 20 21 22 5 5 Right Line Regulator Assembly Intermediate Gauge Line Pressure Gauge Inlet Transducer Line Transducer Ball Valve Ball Valve O Ring Relief Union Relief Outlet Tube Backplate Assemb
28. M2HL MANIFOLD PCB WME 8 84 Manifold PCB HGM2 SERIES PRINTED CIRCUIT BOARD CALIBRATED WME 8 84A PCB Calibrated for HGM2 Air He N WME 8 84B PCB Calibrated for HGM2HL WME 8 84C PCB Calibrated for HGM2HP Air He No O gt 5 2 B20318 ECN 13116 0501 Western Enterprises Automatic Changeover Manifold HGM2 amp HGM2HP Series Repair Drawing Components amp Miscellaneous Hardware Not Shown KEY DESCRIPTION PART KEY DESCRIPTION PART Outlet Nut D 7 17 Right Line Regulator Assembly Outlet Nipple D 20 HGM2 WLR 13 60R Intermediate Regulator See Page 5 1 HGM2H WLR 13 200R 4 way to Intermediate Tube WMS 13 19 18 Intermediate Gauge WMG 3 4 Inter Reg to Block Tube WMS 13 20 19 Line Pressure Gauge Left Relief Tube WMS 13 15 HGM2 WMG 3 3 Four Way Valve WMS 13 14 HGM2HP WMG 3 4 Pressure Switch 20 Inlet Transducer WME 9 1A HGM2 HGM2HP WME 4 4 21 Line Transducer HGM2 9 oxygen WME 4 4C HGM2 WME 9 3A Left Primary Regulator See Page 5 1 HGM2HP WME 9 2A Right Primary Regulator See Page 5 1 22 Ball Valve WMV 5 12 Left Inlet Block WMS 13 4 li Ball Valve O Ring RO 016E Right Inlet Block WMS 13 3 Relief Union WLF 3 12 Left Primary to 4 way Tube WMS 13 17 Relief Outlet Tube WMS 13 21 Right Primary to 4 way Tube _ WMS 13 18 Backplate Assembly WMS 13 24 Relief Tubing Right Prim Reg WMS 13 16 Bleeder Valve 203 Left Line Regulator Assembly Line Relief Valve HG
29. Open the bleeder valve slightly to relieve pressure from 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 4 7 B20318 ECN 13116 0501 5 6 8 Close the bleeder valve Using a allen wrench turn the knurled adjustment screw on the pressure switch clockwise to raise the set point or counterclockwise to lower the set point The pressure switch should be set per the Adjustment Specification chart in Section 1 Cycle between actuation and re actuation signal and make adjustments as required to achieve the signal setting The setting should be made on descending pressure Make adjustments in response to the reading obtained in step 4 WARNING e Be sure power is off when electrical connections are made Current flowing though the wires may shock the service technician or damage the Ohmmeter After the setting has been made connect the signal wires to the appropriate contacts on the pressure switch CHECK VALVE REPAIR INTERMEDIATE Removal 3 Open and shutdown the manifold as explained in the How to open the manifold and How to shut down the mani fold sections Mark the compression fittings per the instructions on page 42 Disconnect the tubing at the compression fittings from the four way valve and the intermediate block using an 11 16 open end wrench Remove the che
30. Pee ert eie EE Ee 4 7 Check Valve Repair Intermediate u ehem n nhe nnne 4 8 Check Valve Repair Primary Regulator a 4 10 Four Way Vale Replacement 4 10 Intermediate Pressure Regulator Repair a 4 11 Line Regulator Re pails e eee drei Otis tes yuaya pakay CEST tn he 4 13 PCB Replacement yu l de eren eee dp ey e Ya une dea xa veo Uude ee Ya dune Ed 4 15 Electrical Power Up Circuit Boards with 6 DIP Switches 4 16 Electrical Power Up Circuit Boards with 7 DIP Switches HH 4 18 Transducer Replacemeltz E e dee piece petere a pese eb ter 4 21 B20318 ECN 13116 0501 SECTION 5 MAINTENANCE AND REPAIR PARTS 5 1 Replacement Pigtails ete iis e e Ee eo eerie Ee dade 5 1 GAUGES 4E 5 1 Regulators and Repair KiS eico 26020 Rar 0520 00029 RA RE 5 1 Valves and Valve Repair AS AR DARA Rere IRA E ETE eA 5 2 Pressure u u un r ea a de ce edd oe ev aude a aus ee edad ace Hav gee TAO N iaa 5 2 Power Supply Replacement Parts 5 2 M A S 5 2 Circuit Board u ccm 5 2 SECTION 5 MAINTENANCE AND REPAIR PARTS Repair Drawing 5 3
31. V Nipple Item included in repair kits Repair Kit PART RWS 6 5 RWS 1 8 RWS 3 47 5 5 RWS 3 81 RWS 1 3 WMV 4 7 WMV 4C 300 WMV 4C 450 P 4HP B20318 ECN 13116 0501 Western Enterprises Automatic Changeover Manifold HGM2 HGM2HL 8 HGM2HP Series Repair Drawing Right Regulator Components KEY DESCRIPTION PART KEY DESCRIPTION PART Nut WMC 6 30 14 Valve Spring Preset Adjusting Screw RWS 3 3 for HGM2 9 Series RWS 6 5 Regulator Bonnet RWS 2 3P for all other models RWS 1 8 Bonnet Bushing RWC 3 12 15 O Ring RWS 3 47 Bushing Retainer RWC 3 14 16 Filter S 5 Pivot RWC 2 8P 17 Spring Retainer RWS 3 81 Bonnet Spring RWS 1 12 18 Regulator Body RWS 1 3 Washer RWS 3 26 19 Pipe Away Adaptor WMV 4 7 Slip Ring RWS 3 17 20 Relief Valve Diaphragm Assembly RWS 3 28 HGM2 HGM2HL WMV 4C 300 Nozzle HGM2HP WMV 4C 450 for HGM2 9 Series RWS 5 1 90 Elbow for all other models RWS 6 9 1 4 NPT Plug Large O Ring RO 015E CGA 580 Nut Seat Holder amp Stem for CGA 580 CV Nipple HGM2 HGM2HL HGM2HP RWS 6 8 HGM2 9 Series RWS 6 3 Item included in repair kits Repair Kit 5 8 B20318 ECN 13116 0501 Western Enterprises Automatic Changeover Manifold HGM2 HGM2HL amp HGM2HP Series Repair Drawing Check Valve Components DESCRIPTION Poppet Spring Washer Cap Item included in repair kit Repair Kit for HGM2 HGM2HL HGM2HP Series RK 1041 5 9 B20318 ECN 13116 0501 Western Enterprises Automati
32. ance a Pu Qasa te 2 8 Intermediate Reg lator NU EMEN XX Pe SERE 2 9 Line Pressure Regulator h et erbe a tage aquya aqasha aa ayka etu onu 2 9 Pressure Transd cer sor est uestre nsu RE sd tet cin app Qupap ERR eire de 2 10 SECTION 3 FIELD TESTING AND TROUBLE SHOOTING 3 1 Performance Verification Procedure redr EE ETAN EE Qe AN 3 1 Trouble 3 4 SECTION 4 SERVICE PROCEDURES 4 1 GeneraliMaintenance uu uu ee Ae ee ee side 4 1 Salety PreCautlons eoi L S A ise da patur tee S 4 1 Cleaning Lubrication and Sealing 4 2 General Repair Procedures iecore enaa re d AR EIE tasacaiebedncnpeatence cee ELE SL eR TOTEM 4 3 How to Open the Manifold u uu ua u ear ERTE UIRE sa nnns nennen sau uay nh 4 3 Manifold Cabinet Case Removal u S ua EEE ANERE akupana 4 3 How to Deplete the Secondary Bank u u a a 4 3 How to Shut Down the Manifold uuu l u A SS Sana O S Suwa aa G ESPE Saa 4 3 Gauge Replacement uoi coti t etie Re ide m eer uie ced teda aseo ne eed ies 4 4 Primary Regulator Repa u uy u tac Mervin iss ek ais el ied Syed rev ate eee vidi 4 5 Pressure Switch Replacement t en pe Pen a e
33. block TRANSDUCER LINE PRESSURE Removal 1 Shutdown and open the manifold as explained in the How to shut down the Manifold and How to open the Manifold sections NOTE The manifold must be fully shut down in order to replace the line pressure transducer 2 Using a 7 8 open end wrench turn the high pressure transducer counter clockwise If gas is heard escaping stop rotating the transducer and wait for the trapped pressure to deplete 3 Clean any remnants of Teflon Tape from the port on the inlet block Replacement 1 Apply Teflon Tape to the 1 4 NPT thread on the new transducer 2 Using a 7 8 open end wrench thread the transducer into the inlet block 4 21 B20318 ECN 13116 0501 SECTION 5 MANIFOLD MAINTENANCE 4 REPAIR PARTS REPLACEMENT PIGTAILS 24 Stainless Steel Flexible Braid with Check Valves PFP 320CV 24 CGA 320 for Carbon Dioxide CO2 Service PFP 326CV 24 CGA 326 for Nitrous Oxide N20 Service WPR 63CV 24 CGA 540 for Oxygen O gt Service PFP 92CV 24 CGA 580 for Inert Gas Service except Helium PFP 346CV 24 CGA 346 for Breathing Air Service 24 Synthetic Fiber Braid Hose with Check Valve PFS 92CV 24 CGA 580 for Helium He Service for non medical service GAUGES 2 Diameter 1 4 NPT Back Port 3 3 100 psi Line gauge HGM2
34. bly 18 Gage Black Wire Cord Assembly Strain Relief Bushing Transformer Wire Sub Assy 6 Wire Connector WME 8 94 J O 01 P QO ND 5 12 B20318 ECN 13116 0501
35. c Changeover Manifold HGM2 HGM2HL amp HGM2HP Series Repair Drawing Intermediate Regulator Components A J 01 GQ N DESCRIPTION Regulator Body Seat Capsule Bonnet Label Pivot Bonnet Bushing Retainer Bonnet Bushing Slip Ring HGM2 amp HGM2HL 2 Diaphragm Assembly Delivery Spring HGM2 amp HGM2HL 2 Adjusting Screw 1 4 NPT Plug Label Anti Vibrator B Size Elbow 3 8 Tube Elbow PART WLR 1 1 WLR 1 10 ACCUL RWC 2 8 RWS 2 2P RWC 3 14 RWC 3 12 RWS 3 17 RWS 7 4 RWS 3 28 WLR 1 8 RWS 1 12 WLR 1 11 WLF 1 21 HPRL WLR 1 14A 253 WLF 3 6 B20318 ECN 13116 0501 Western Enterprises Automatic Changeover Manifold HGM2 HGM2HL 8 HGM2HP Series Repair Drawing Right amp Left Line Regulator Components EY DESCRIPTION Regulator Body Seat Capsule Bonnet Label Pivot Bonnet Bushing Retainer Bonnet Bushing RWC 3 12 Slip Ring HGM2 amp HGM2HL RWS 3 17 HGM2HP RWS 7 4 Diaphragm Assembly RWS 3 28 Delivery Spring HGM2 amp HGM2HL WLR 1 8 HGM2HP RWS 1 12 Adjusting Screw WLR 1 11 1 4 NPT Plug WLF 1 21 Label HPRL Anti Vibrator WLR 1 14A 1 4 NPT BLM 4HP KEY 1 2 3 4 5 6 7 8 5 11 B20318 ECN 13116 0501 Western Enterprises Automatic Changeover Manifold HGM2 HGM2HL amp HGM2HP Series Repair Drawing Power Supply Components SECTION A A SECTION B B A DESCRIPTION Box and Cover 115 to 24 VAC Transformer PCB Assem
36. check valve immediately downstream of the intermediate regulator to open The gas pressure from the intermediate regulator is pushing against the bottom of the check valve seat When both cylinder banks are full and the regulators properly adjusted the pressure on the downstream side of the valve is greater than the intermediate regulator pressure This pressure differential holds the valve closed Turning the adjusting screw of the intermediate regulator in clockwise will increase the inter mediate regulator pressure thereby increasing the pressure at which the valve will open Turning the adjusting screw out counterclockwise will decrease the intermediate regulator pressure thereby decreasing the pressure at which the valve will open As the gas pressure in the Service bank of cylinders drops below the setting of the primary regulator the gas pressure from the Service bank primary regulator will begin to fall When the Service pressure falls below the pressure of the intermediate regulator setting as noted in Section 1 the check valve will be pushed open and the secondary bank of cylinders will begin to supply the system LINE PRESSURE REGULATOR The line pressure regulator used in the manifold is a single stage four port adjustable regulator Refer to Figure 2 14 has one inlet port and three outlet ports The inlet port is piped to the outlet of the manifold control assembly One outlet port is piped to the outlet of the dual
37. ck valve and tubing assembly from the control section Disassembly 1 Secure the check valve in a vise or similar holding fixture Using a 1 1 8 hex wrench rotate the valve cap counter clockwise and remove Remove the seal washer from the valve cap Pull the spring from the valve body Using a small needle nose pliers or tweezers grasp the valve poppet and remove it from the valve body Clean the interior of the valve body with isopropyl alcohol or 1 1 1 trichloroethylene solvent CAUTION Do not stand directly in font of the valve 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 Blow out the check valve body with oil free Air or Nitrogen to remove all foreign material and dry all surfaces 4 8 B20318 ECN 13116 0501 Reassembly 1 Insert a new valve poppet into the valve body 2 Insert the spring into the valve body 3 Position the new seal washer in the groove of the valve body 4 Place the valve cap over the spring and push the cap towards the body until the threads engage Rotate the clockwise and tighten securely Replacement 1 Position the check valve and tube assembly in the control section with the check valve flow arrow pointing towards the intermediate block 2 Connect the compression fittings to the four way valve and intermediate block using an 11 16 open end wrench and tighten
38. diate Relief Valve 6 High Pressure Check Valve 7 Four way Valve 8 Pressure Switch 9 Intermediate Check Valve 10 Left Inlet Block 11 Intermediate Regulator 12 Primary Regulator 13 Intermediate Test Gauge 14 Right Inlet Block 15 High Pressure Transducer 16 Low Pressure Transducer 17 Intermediate Pressure Relief Connection 18 Intermediate Block 19 Line Pressure Relief Valve 20 Relief Outlet Connection FIGURE 2 2 Internal Components HGM2 amp HGM2HP 2 2 B20318 ECN 13116 0501 LEGEND 1 Outlet Adaptor 2 Line Pressure Gauge 3 Ball Valves 4 Line Regulators 5 Intermediate Relief Valve 6 High Pressure Check Valve 7 Four way Valve 8 Pressure Switch 9 Intermediate Check Valve 10 Left Inlet Block 11 Intermediate Regulator 12 Primary Regulator 13 Heater Unit 14 Right Inlet Block 15 High Pressure Transducer 16 Low Pressure Transducer 17 Intermediate Test Gauge 18 Intermediate Pressure Relief Connection 19 Intermediate Block 20 Line Pressure Relief Valve 21 Relief Outlet Connection Note Carbon Dioxide an Nitrous Oxide units ordered without a heater do not include item 13 FIGURE 2 3 Internal Components HGM2HL 2 3 B20318 ECN 13116 0501 Pressure Gauge Ball Valve Line Regulators Check Valve Intermediate Regulator Intermediate Relief Valve Check Valve Pressure Transducer Left Primary Regulator Ball Valve Line R
39. e components Reassembly 1 Reverse order of disassembly 4 3 B20318 ECN 13116 0501 HOW TO DEPLETE THE SECONDARY BANK 1 Open the manifold as explained in the How to open the manifold section 2 3 4 5 CAUTION The compression fitting on the secondary bank primary regulator should be used to deplete pressure from Rotate the knob to make the bank that is going to be service the secondary bank Close the cylinder on the secondary bank Mark the compression fitting at the outlet of the primary regulator per the instructions on page 4 2 Crack open the compression fitting and allow the reserve bank to deplete the reserve bank If a different fitting is used there may be pressure trapped in the secondary bank 6 Once pressure has been depleted retighten the fitting per the instructions on page 4 2 HOW TO SHUTDOWN THE MANIFOLD 1 off the piping system isolation valve if present If an isolation valve is not present the entire buildings gas piping system will be reduced to atmospheric pressure 2 Open the manifold as explained in the How to open the manifold section WARNING e Do not shutdown the manifold until all personnel have been advised of the intended service and patients requiring medical gas are being supplied from portable supplies 3 Turn off right and left supply bank cylinder valves 4 Open the bleeder valve to vent residual gas from the system 5 Clo
40. e setting for the intermediate regulator listed in the Adjustment Specification chart in Section 1 e lfthe gauge stabilizes at a pressure higher than the chart specification turn the adjusting screw on the intermediate regulator counterclockwise to decrease the gauge reading e fthe gauge stabilizes at a pressure lower than the chart specification turn the adjusting screw on the intermediate regulator clockwise to increase the gauge reading 6 Close the bleeder valve 7 Pressurize the service bank 8 Simulate the changeover sequence from both sides and observe the intermediate gauge to verify proper setting 4 12 B20318 ECN 13116 0501 LINE REGULATOR REPAIR NOTE Removal and Replacement procedures are to be followed only if the line regulator assembly 15 10 be scrapped All service may be performed to the line regulator without removing it from the manifold Open the valves isolating the bypass line regulator and close the valves isolating the regulator being serviced Removal 1 Using 7 8 and 1 wrenches disconnect the union connections on both sides of the line regulator 2 Remove the regulator from the dual line assembly Disassembly 1 Remove the intermediate regulator following the instructions above 2 Rotate the adjusting screw of the regulator counter clockwise with a flat blade screwdriver and remove 3 Remove the bonnet by holding the body hex with a wrench to stabilize the assembly and using a
41. e supply Close the cylinder valve on the left bank of cylin ders Observe the cylinder contents gauges the left bank gauge should begin to drop the right cylinder bank should remain constant Observe the intermediate gauge as the right side pressure continues to drop As the cylinder pres sure 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 S l o w l y open one cylinder valve on the left bank of cylinders Verify that the intermediate gauge has returned to the set pressure of the primary regulator Close the bleeder valve Disconnect the 3 wires from the manifold wiring harness that leads to the intermediate pressure switch Connect an ohmmeter across the black and brown wires of the wiring harness The ohmmeter should indicate approximately zero 0 ohms resistance If the ohmmeter does not indicate approximately zero 0 ohms connect the meter across the nor mally open N O and common C terminal on the pressure switch The ohmmeter should register approximately zero 0 ohms resistance when connected to the switch Adjust or replace the faulty switch See Section 4 for servicing the pres sure switches Reconnect the ohmmeter to the black and brown wires Close the Cylinder valve on the left bank of cylin ders Open the bleeder valve to create a slight flow of gas through
42. ecome the Secondary supply The system incorporates a fail safe configuration so that the red light can only be extinguished when sufficient pressure is supplied from both banks PRIMARY REGULATORS The primary regulator s function is to reduce the cylinder pressure of the supply banks to a more usable regulated pressure Adjusting Screw WI N SS S Mi Lor lt X XS NN gt S A OQ Bonnet Spring eX SOL YQ N CN bs BNL 0629 9 pu Low Pressure Chamber CLI X 1444 D Seat and Nozzle 72 s lt NI EA XW E High Pressure Chamber SRY ll H INLET ENA EU n OUTLET PORT x SS FIGURE 2 8 Primary Regulator xi RSS 2 6 B20318 ECN 13116 0501 Gas enters the regulator through the inlet port and fills the high pressure chamber and the port to the cylinder contents gauge with gas See Figure 2 8 Gas in these areas is at the same pressure as the gas in the cylinders 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 oring around the nozzle and is isolated from the atmospheric pres sure by the diaphragm sub asse
43. egulator Check Valve Intermediate Regulator Intermediate Relief Valve Left Primary Regulator Check Valve Pressure Transducer Heater E N 2E DQ GF P lt F l F L Line Pressure Transducer Bleeder Valve Ball Valve Pressure Switch Intermediate Pressure Gauge Four Way Valve py Intermediate Relief Valve Check Valve Pressure Transducer Right Primary Regulator Line Relief Valve Ball Valve xcu D lt o al Line Regulator Pressure Switch D lt L2 Intermediate Pressure auge Four Way Valve Intermediate Relief Valve Right Primary Regulator Check Valve Pressure Transducer FIGURE 2 5 Piping Schematic HGM2HL 2 4 B20318 ECN 13116 0501 I RIGHT I BANK I TRANSDUCER OUTLET TRANSDUCER I P I EON Lo FIGURE 2 6 Electrical Schematic less heater The gas from the Service supply is routed through the four way valve outlet on the right of the four way valve to the intermediate block assembly The intermediate block has 4 ports all connected to the same chamber The gas pressure at all 3 ports is the same as the pressure at the inlet to the block Gas enters the intermediate block from the Service supply through the tubing connected at the bottom The left port is connected via tubing with check valve from the inter mediate regulator The top port con
44. er valves on bank are closed Wiring to pressure switch not correct Change over occurring at too high a pressure Control knob was rotated to select new service side without changing empty cylinders Pressure switch wiring incorrect or disconnected Pressure switch set at too high a pressure Primary regulator set at too low a pressure Pressure transducer wiring disconnected or faulty Pressure transducer faulty Dip switches set incorrectly Pressure transducer faulty Non volatile memory failure 3 5 REMEDY OR CHECK Check Electrical power supply Slowly open valves Check internal leads to the pressure switch Adjust intermediate regulator setting Replace depleted cylinders Check pressure switch wiring Adjust pressure switch Adjust primary regulator delivery pressure Check pressure transducer and controller board connections Replace transducer Check setting of the Dip switches Replace transducer Replace the controller board B20318 ECN 13116 0501 This page intentionally left blank 3 6 B20318 ECN 13116 0501 SECTION 4 SERVICE PROCEDURES GENERAL MAINTENANCE 1 Main section a b Daily record line pressure Monthly 1 Check regulators valves and compression fittings for external leakage 2 Check valves for closure ability Annually 1 Check relief valve pressures 2 Check primary regulator seats 2 Manifold header a
45. esents each open switch a 0 for closed Each digit of the displays will read 8 Each digit of the displays will be lit individually 2 The displays and status indicators will then be allowed to operate normally Software version located on back of PCB 4 18 B20318 ECN 13116 0501 UNITS OF MEASURE 1 The HGM2 manifold can be configured to display pressure in PSI KPA or BAR The manifold is shipped with PSI as the default unit of measure To switch the units proceed to step 2 If PSI units are desired no changes are necessary and step 2 may be skipped 2 To change the units perform the following steps e Remove power to the manifold switches are only read during power up Open the door of the manifold Locate the switches at the bottom edge of the PC Board on the door e For PSI set the switches as shown Models 2 Model HGM2HL Model HGM2HP ap H E Switch Position For KPa set the switches as shown Model HGM2HL Model HGM2HP Models HGM2 For BAR set the switches as shown Models HGM2 Model HGM2HL Model HGM2HP Close the cover and reconnect power to the manifold Verify that during power up the status of the switches are displayed on the digits of the right bank display and the right most digit of the left bank display as a series 1 s and 0 5 as follows 4 19 B20318 ECN 13116 0501 DIP SWITCH DISPLAY OPTION For PSI Models HGM2 Model
46. gure 2 6 is the schematic diagram of the electrical system of the manifold Figure 2 7 is the heater schematic 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 Secondary 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 enters the manifold cabinet and enters a pressure transducer The pressure transducer displays the bank pressure on the front of the cabinet The transducer also monitors bank pressure and signals and connected alarms when the system changes from the service to the secondary bank Control Knob Gas then flows to the primary regulators on all manifolds except those for Nitrous Oxide and Carbon Dioxide service Nitrous Oxide and Carbon Dioxide systems include a 500 SCFH capacity heater 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 Master Valve The inlet nipple on the primary regulator has an integral check valve This check valve prevents gas from one bank from feeding out the other bank FIGURE 2 1 External Components Pressure is regulated in the primary regulators to the pressures noted in the adjustment specification chart in Section 1 Bot
47. h primary regulators are factory preset to deliver the same pressure The primary regulators have two ports on the low pressure side One port is connected to the intermediate relief valve The other port is the outlet port and is connected via tubing to the four way valve The gas flows from the primary regulators to the four way valve The four way valve assembly has three positions The center position is OFF The OFF position is only used during shipment of the manifold When the valve knob is rotated counterclockwise to the left position the valve connects the tubing from the left primary regulator to the outlet tubing on the right of the 4 way valve and connects the tubing from the right primary regulator to the intermediate regulator on the left side of the 4 way valve The secondary supply is the bank that feeds through the intermediate regulator When the valve knob is rotated clockwise to the right position the valve connects the tubing from the right primary regulator to the outlet tubing on the right side of the 4way valve and connects the tubing from the left primary regulator to the intermedi ate regulator on the left side of the 4way valve Thus by turning the four way valve knob the operator may determine which bank of cylinders is the Service supply and which bank is the Secondary supply 2 1 B20318 ECN 13116 0501 LEGEND 1 Outlet Adaptor 2 Line Pressure Gauge 3 Ball Valves 4 Line Regulators 5 Interme
48. h the manifold Verify that the intermediate gauge indicated the pres sure as shown in the specification chart in Section 1 for the primary regulator Observe the test gauge for two minutes Verify that the primary regulator does not exhibit creep and or increase in pressure Verify that the left side cylinder contents gauge indi cates a minimum of 2000 psig for Oxygen Nitrogen Air or gas mixtures Nitrous Oxide and Carbon Diox ide systems should indicate a minimum of 160 psig Adjust to the proper line pressure if necessary Verify the line pressure gauge is indicating a mini mum of 50 psig on all system except Nitrogen Nitro gen should indicate a minimum of 160 psig Adjust to the proper line pressure if necessary Open the bleeder valve to create a slight flow of gas through the manifold Observe the intermediate gauge and verify the primary regulator setting under a flow condition Adjust the left primary regulator as necessary to obtain the required pressure Turn off the left cylinder valve and allow all gas to vent from the manifold Close the bleeder valve B20318 ECN 13116 0501 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Rotate the control knob to its fully clockwise position S l o w l y open one cylinder valve on the right bank of cylinders Complete steps 13 21 for the right primary regulator Close the bleeder valve Pressurize
49. ification chart in section 1 Close the bleeder valve 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 pressure at the end of the two minute period 10 Install the nut on the primary regulator PRESSURE SWITCH REPLACEMENT Removal Li Open and shutdown the manifold as explained in the How to open the manifold and How to shut down the mani fold sections Using an 11 16 and 5 8 open end wrenches remove the pressure switch from the intermediate block Label the three wires attached to the switch Loosen the slot head screws on the pressure switch using a flat blade screwdriver and remove the wires Replacement 1 2 Using an 11 16 and a 5 8 open end wrench Install the pressure switch on the primary regulator and tighten to effect a gastight seal 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 Begin pressurizing the service bank manifold by opening one cylinder valve on the side of the manifold switch is on At the actuation pressure the ohmmeter reading will jump from zero resistance to infinite resistance Close the cylinder valve
50. ing located on the inlet block handtight Connect the compression fitting to the primary regulator finger tight Tighten the CGA connection on the regulator inlet using two 1 1 8 wrenches Using an 11 16 open end wrench connect the outlet and relief tubing to the 3 8 tube compression fittings When retighting the compression fittings follow the procedure outlined on page 4 2 4 6 B20318 ECN 13116 0501 Primary Regulator Adjustment 1 If not already done open the manifold by following the How to open the manifold as explained earlier in this section Remove the nut from the primary regulator Reinstall the control knob on the four way valve in the same orientation as it was prior to removal Rotate the knob to select the side the regulator is to be adjusted is on If the bank is not pressurized s l o w l y open the cylinders on the side of the regulator to be adjusted Verify the cylinder pressure readout indicates a minimum pressure of 2000 psig on Oxygen Air and Nitrogen systems or a minimum of 700 psig on Nitrous Oxide and Carbon Dioxide systems Create a slight slow of gas by cracking open the bleeder valve Using a flat blade screwdriver turn the adjusting screw of the regulator while observing the test gauge rotating the set screw clockwise will increase the regulator setting while rotating it counterclockwise will lower the regulator setting Set the regulator to the pressure indicated on the Adjustment Spec
51. ized to the normal pressures the piston in the switch is pushed up The piston 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 piston moves down releasing the force against the switch activator The contacts of the switch then return to the normally open and normally closed positions The switch completes the electrical circuits to the indicators on the front of the control section and to the remote alarm interface board in the power supply box 2 8 Adjusting Screw Pressure Port End View Side View FIGURE 2 12 Low Pressure Switch gt C N C _ FIGURE 2 13 Switch Schematic B20318 ECN 13116 0501 INTERMEDIATE REGULATOR The intermediate regulator controls the gas flow from the secondary bank of cylinders to the intermediate block The in termediate regulator pressure setting is the pressure at which the manifold will switchover from Service to Secondary supply The intermediate regulator has an inlet port connected to the four way valve The outlet port of the intermediate regulator is connected via tubing to the intermediate block A check valve is located immediately upstream of the regula tor The regulator is comparable to the line regulator illustrated in Figure 2 14 The regulator seat is held shut by the gas pressure from the Service bank regulator not allowing the
52. ly Bleeder Valve Line Relief Valve Inlet Union PART WLR 13 60R WMG 3 4 WMG 3 3 WME 9 1A WME 9 3A WMV 5 12 RO 016E WLF 3 12 WMS 13 21 WMS 13 24 203 WMV 4C 75 WMS 1 40 B20318 ECN 13116 0501 Western Enterprises Repair Drawing KEY DESCRIPTION 29 Case 30 Outlet Union 31 8 Sht Metal Case Screw Case Wiring Harness Switch Wiring Harness Power Supply Box Manifold PCB 5 6 Automatic Changeover Manifold HGM2 amp HGM2HL Series Components amp Miscellaneous Hardware PART WMC 2 56A D 34 WMC 6 23 WMS 13 25 WMS 1 13 WME 13 23 WME 8 84 Item not pictured B20318 ECN 13116 0501 Western Enterprises Repair Drawing KEY DESCRIPTION Nut Preset Adjusting Screw Regulator Bonnet Bonnet Bushing Bushing Retainer Pivot Bonnet Spring Washer Slip Ring Diaphragm Assembly Nozzle for HGM2 9 Series for all other models Large O Ring Seat Holder amp Stem for HGM2 HGM2HL HGM2HP HGMe 9 Series PART WMC 6 90 RWS 3 3 RWS 2 3P RWC 3 12 RWC 3 14 RWC 2 8P RWS 1 12 RWS 3 26 RWS 3 17 RWS 3 28 RWS 5 1 RWS 6 9 RO 015E RWS 6 8 RWS 6 3 Automatic Changeover Manifold HGM2 HGM2HL amp HGM2HP Series Left Regulator Components DESCRIPTION Valve Spring for HGM2 9 Series for all others Teflon Ring Filter Spring Retainer Regulator Body Pipe Away Adaptor Relief Valve HGM2 HGM2HL HGM2HP 1 4 NPT Plug 90 Elbow CGA 580 Nut CGA 580 C
53. mbly forming a seal around the body of the regulator The diaphragm is squeezed be tween 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 adjust ing 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 high 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 diaphragm and the diaphragm will push up against the bonnet spring compressing_the bonnet spring As the diaphragm 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
54. nects to the inlet of the dual line assembly Attached to the center port is a gauge which indicates intermediate pressure The right port is connected to a pressure switch The pressure switch monitors the intermediate pressure Should the intermediate pressure drop below a preset level the switch will indicate an alarm condition that changeover has occurred The switch provides a redundant feature to ensure proper changeover alarming has taken place As the gas enters the dual line assembly it can flow to either line regulator Under normal operation one line regulator will be isolated by closed ball valves This regulator would only be used if the other regulator failed Gas flows through the line regulator on the side with the open ball valves The pressure is reduced to the line pressure which is shown on the line pressure gauge and on the digital display on the front of the cabinet The line relief valve prevents overpressurization should the line regulator fail The relief valve settings are noted in the adjustment specifications chart in section 1 The intermediate pressure relief valves prevents over pressurization of the intermediate controls of the manifold should of the primary regulators fail relief valve settings are noted in the adjustment specification chart in Section 1 The tubing connected between the intermediate block and the intermediate regulator allows gas from the Service supply to flow back toward
55. nges to Secondary supply it sends a signal to the hospital or clinic s medical 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 Com pressed 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 the other gases should not be placed in a location where the temperature will exceed 120 F 49 C or fall below 20 F 29 C A manifold placed in an open location should be protected against weather conditions 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 required for installation This precaution will keep moisture and debris from the piping interior avoiding operational problems Overall Manifold Length LI Depth 10 foul Example HGM2 9 4 Figure 1 1 Installation Dimensions 1 1 B20318 ECN 13116 0501 MANIFOLD SPECIFIC
56. nother wrench to loosen the bonnet The adjusting spring vibration dampaner and pivot will come off with the bonnet 4 Remove the diaphragm assembly and slip ring CAUTION Do not stand directly in front of the body and 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 5 Using a 1 socket wrench rotate the seat capsule counterclockwise and remove the seat capsule 6 Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 4 13 B20318 ECN 13116 0501 Reassembly 1 2 3 4 5 Assemble the new seat capsule into the regulator body and torque to 20 25 ft Ibs Place the pivot on the bonnet spring and insert inside the regulator bonnet Insert the vibration dampaner between the spring and the bonnet Assemble the slip ring diaphragm onto the slip ring diaphragm should be against the regulator body Assemble the bonnet to the regulator while the regulator is inverted and torque to 40 50 ft Ibs Replacement 1 2 Assemble the union fitting from the regulator that were removed into the new regulator Insert the regulator into the dual line assembly Using 7 8 and 1 open end wrenches tighten the union fittings Open the ball valve supplying the regulator and leak check the union connections Close the ball valves isolating the
57. our way valve assembly Secure the valve assembly in a vise or similar holding fixture and use a 5 8 open end wrench to remove the two inlet and two outlet adpators from the valve for use on the replacement valve Remove the old sealant from the 1 4 NPT male pipe threads on the compression fittings Replacement 1 2 3 Apply Teflon tape to the 1 4 NPT male pipe threads on the compression fittings Secure the new four way valve in a vise Install the fittings in the same orientation as they were removed see sections 5 for the proper valve assembly con figuration Remove the valve from the vise and position it behind the support bracket with the CYL 2port on the left and the CYL 1 port on the right Reinstall the two screws through the bracket and into the two bottom threaded holes of the valve Tighten with a phillips screwdriver Reconnect the tubing to the new valve When retightening the compression fittings follow the procedure outlined on page 42 Reconnect the intermediate regulator to the left port of the new valve Using the 11 16 open end wrench tighten the compression fitting at the ends of the tubing assemblies to effect a gastight seal When retightening the compression fittings follow the procedure outlined on page 4 2 4 10 B20318 ECN 13116 0501 INTERMEDIATE PRESSURE REGULATOR REPAIR Removal 1 Shutdown and open the manifold as explained in How to open the Manifold and How to shutdown
58. re required to lift the diaphragm increases resulting in a higher delivery pressure from the outlet port of the regulator 2 9 B20318 ECN 13116 0501 E LEGEND A iy 1 Adjusting Screw Gain Ni 7 a E lt lt Z 4 Adjusting Spring lt z 2 5 Diaphragm Assembly A VA e UL v N VY Swe Wea 8 Body LALN 9 Capsule 10 Seat Assembly 11 Filter Screen 12 Friction Damper SIRIA A 2 SS SQV KRIS R L2 2 FIGURE 2 14 Line and Intermediate Pressure Regulator PRESSURE TRANSDUCER The pressure transducers vary their outlet voltage depending on the pressure being supplied The voltage output is monitored by the manifold PCB The voltage is converted to a pressure reading which is displayed on the PCB The line pressure transducer is used only to display the delivery pressure of the manifold The bank pressure transducers display inlet pressures and signal when changeover has occurred 2 10 B20318 ECN 13116 0501 FIELD TESTING amp TROUBLE SHOOTING SECTION 3 The manifold performance tests are use to verify the manifold functional performance When used in conjunction with the trouble shooting charts the technician can verify proper performance or rapidly identify the probable source of the problem NOTE e All testing should be done using full cylinders Using par
59. regulator for future service Line Regulator Adjustment Open the manifold as described in the How to open the Manifold section S l o w l y open the ball valves that were isolating the regulator Close the ball valves isolating the regulator that is not being adjusted Verify the cylinder pressure gauge indicates a minimum pressure of 2000 psig on Oxygen Air and Nitrogen sys tems or a minimum of 700 psig on Nitrous Oxide and Carbon Dioxide systems Open the bleeder valve to create a slight flow of gas Using a flat blade screwdriver turn the adjusting screw of the regulator in while observing the line pressure gauge Set the regulator to the desired pressure Open the bleeder valve to 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 lowing adjusted pressure Verify that the regulator does not creep by observing the line pressure gauge for two minutes The gauge must indi cate the same pressure at the end of the two minute period 4 14 B20318 ECN 13116 0501 PCB Replacement Removal 1 2 3 4 5 Open the manifold as explained in the How to open the Manifold section Remove power by disconnecting the cable from the power supply Remove the 4 hex nuts holding the PCB cover in place Remove the 2 wire clips from the PCB
60. rials and dry all surfaces Re assembly 1 Assemble the new seat capsule into the regulator body and torque to 20 25 ft lbs 2 Place the pivot on the bonnet spring and insert inside the regulator bonnet 3 Insert the vibration dampaner between the spring and the bonnet 4 Assemble the slip ring diaphragm onto the slip ring diaphragm should be against the regulator body 5 Assemble the bonnet to the regulator while the regulator is inverted and torque to 40 50 ft Ibs 4 11 B20318 ECN 13116 0501 Replacement 1 Position the intermediate regulator in the control section with the inlet connecting to the four way valve The inlet of the four way valve The inlet of the regulator is stamped INLET 2 When retightening the fitting the procedure outlined on page 42 shall be followed Connect the compression fittings using an 11 16 open end wrench and tighten to effect a gastight seal Intermediate Regulator Adjustment 1 If not already done open the manifold as explained in the How to open the Manifold section Reinstall the four way valve knob and rotate to select one bank of cylinders as the supply bank 2 S l o w I y open the cylinder valves on the secondary supply bank 3 Close the cylinder valves on the service bank 4 Open the bleeder slightly to relieve pressure from the manifold while observing the intermediate gauge 5 Allow the gas to vent until the intermediate gauge stabilizes or indicates less than th
61. s a check valve It also allows gas from the Secondary supply to flow from the four way valve through he intermediate regulator up to the check valve When the gas pressure on the service side of the check valve falls to SSE S SSE SSE the intermediate regulator set pressure the check valve opens and routes the gas from the Secondary supply into the intermediate block and then to the line pressure regulator FIGURE 2 7 Heater Electrical Schematic 2 5 B20318 ECN 13116 0501 The line pressure regulator further reduces the pressure to the final pressure delivered to the medical gas piping system The regulator has one inlet port and three outlet ports Two outlet ports are plugged The outlet port is located 180 from the inlet Gas flows out of the line regulator and into the outlet block The outlet block has 4 ports A line relief valve is connected to the right port The center port is connected to a line pressure gauge The left port is connected to the line pressure trans ducer which displays the line pressure on the front of the cabinet The top port is connected to the piping distribution system The pressure relief valve outlet port should be routed to the outside of the building for manifolds located indoors When both cylinder banks full the transducers and the switch complete the electrical circuit to display the green system normal light Cylinder pressures for each bank are indicated on the readouts
62. se the bleeder valve once all gas has depleted GAUGE REPLACEMENT Removal 1 Shutdown the manifold and open the manifold as explained in the How to open the manifold and How to shut down the manifold sections 2 Using a 9 16 open end wrench remove the pressure gauge from the system 3 Remove old sealant from the 1 4 NPT female pipe threads Replacement 1 Apply Teflon tape to the 1 4 NPT male pipe 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 Re assemble the case per the How to shut down the manifold and How to open the manifold sections 4 4 B20318 ECN 13116 0501 PRIMARY REGULATOR REPAIR NOTE e Removal and Replacement procedures are to be followed only if the primary regulator assembly is to be scrapped All service may be performed to the primary regulator without removing it from the manifold Shutdown the manifold and open the manifold as explained in the How to open the manifold section NOTE e This item may be repaired replaced without shutting down the manifold completely To work on the manifold while it is still in service follow the steps outlined in How to deplete the secondary bank Removal 1 Mark the compression fittings per the instructions on page 42 Using an 11 16 open end wrench disconnect the outlet tubing and relief tubing from the reg
63. tially empty cylinders may result in improperly set components PERFORMANCE VERIFICATION PROCEDURE 1 Open the manifold as explained in Section 4 2 Reinstall the control knob on the shaft of the four way valve Connect the electrical power source to the manifold and verify that the 2 red lights are on and the 3 pressure displays are illuminated The mani fold will go through a start up sequence that lasts about 15 seconds when power is supplied Rotate the control knob counterclockwise to make the left cylinder bank the Service supply and the right the Secondary supply 5 Open the master valves located on the cylinder header prior to pressurizing the manifold 6 S o w l y open one cylinder valve on the left bank of cylinders 7 S o w l y open cylinder valve on the right bank of cylinders 8 Using a leak detect solution verify that there are no leaks present at the connections 9 Close the cylinder valves on the left and right banks of cylinders 10 Open the bleeder valve to create a slight gas flow through the manifold Vent the system until all gas has been removed from the manifold 11 Close the bleeder valve 12 S l o w l y open one cylinder valve on the left bank of cylinders 14 15 16 17 18 19 20 21 22 Create a slight flow of gas through the bleeder valve The intermediate gauge should settle and remain constant Turn off the flow of gas throug
64. to effect a gastight seal When retightening the compression fitting follow the procedure outlined on page 4 2 CHECK VALVE REPLACEMENT PRIMARY REGULATOR 1 Remove the primary regulator from the manifold as described in the Primary Regulator Repair section 2 Place the regulator in a vice or similar holding fixture 3 Using an 11 16 open end wrench remove the check valve nipple from the regulator inlet port 4 Remove any remaining pipe sealant from the regulator inlet port 5 Teflon tape the threads on the replacement check nipple 6 Using an 11 16 open end wrench tighten the check valve nipple into the regulator 7 Install the regulator back in the manifold as described in the Primary regulator repair section 4 9 B20318 ECN 13116 0501 FOUR WAY VALVE REPLACEMENT Removal 1 6 Open and shutdown the manifold as explained in the How open the manifold and How to shut down the manifold sections Mark the compression fittings per the instructions on 4 2 Disconnect the three tubing assemblies at the pression fittings to the four way valve and loosen the compression fittings at the other end of the tubing assemblies using an 11 16 open end wrench Using a 11 16 wrench to loosen and disconnect the union fitting on the left side of the four way valve Use a phillips screwdriver to remove the two screws that secure the four way valve to the support bracket and re move the f
65. to make the left cylinder bank the service bank Observe the cabinet system status indicators Verify that the green indicator is lit and the red indicators are off Close the cylinder valve on the left bank of cylin ders Verify that the red light illuminates and the green light is extinguished when the manifold changes over from service to secondary supply Close the bleeder valve and test for leaks using a leak detect solution 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 cylinder supply the system before service was performed Remove the control knob from the four way valve Reinstall the manifold section cover as explained in Section 4 B20318 ECN 13116 0501 Trouble Shooting SYMPTOM PRIMARY REGULATOR Venting at relief valve Gas leakage around primary valve body halves Pressure regulator body and bonnet FOUR WAY VALVE Gas leakage around joint In valve body halves Gas leakage through body wall Both banks feeding PROBABLE CAUSE Over pressure due to creeping or faulty regulation of primary regulator Loose bonnet Diaphragm leak Body halves not joined tightly enough O rings worn Porosity holes developed in casing Four way valve seats leaking INTERMEDIATE PRESSURE REGULATOR Gas leakage around regulator body bonnet Required gas flow not available after change over occurs Both
66. ulator at the compression fitting joints 2 Using two 1 1 8 hex wrenches disconnect the regulator from the inlet block at the CGA union connection Disassembly 1 Remove the nut from the regulator by turning it counterclockwise using a 3 4 hex wrench 2 Using a flat blade screwdriver turn the adjusting screw counterclockwise until it turns freely and all compression is removed from the bonnet spring 3 Using a 1 3 8 hex wrench rotate the bonnet counterclockwise and remove it along with the pivot bonnet spring washer slip ring and diaphragm sub assembly 4 Using a 13 16 hex socket wrench rotate the nozzle counterclockwise and remove it along with the seat holder and stem compensating spring and the spring retainer 5 Clean all interior surfaces of the regulator body with isopropyl alcohol or 1 1 1 trichloroethylene solvent 6 Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces CAUTION Do not stand directly in front of the body or ports when performing the next step Eye protection should be worn to protect the service technician Chips and debris may be propelled into unprotected eyes 4 5 B20318 ECN 13116 0501 Reassembly 1 Apply a thin coating of Fluorolube S 30 lubricant to the o rings CAUTION 10 11 12 13 14 See section 5 for a picture showing the proper assembly of the regulator Assemble small o
67. ur N C Normally Closed VAC Voltage Alternating Current N O Normally Open VDC Voltage Direct Current NPT National Pipe Taper PCB Printed Circuit Board 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 B20318 ECN 13116 0501 TABLE OF CONTENTS SECTION 1 INTRODUCTION 1 1 Product 1 1 Installation MOM a au ui eene odere t de eet rh Len pcr de tnde Eu RR eb PL TR LACE 1 1 Manifold SpecifiCatiOls suu ua Oe ENG ndi ERO RH EQUOS REN EAE cree ERE RS aasma 1 2 Adjustment Specifications 020996 erectae cse deg ccr ese cta doce Dey daa dunes ACA EX od aa 1 3 Recommended Tools and Test Equipment eene nnne eene 1 4 SECTION 2 THEORY OF OPERATION 2 1 General InfottriatiODn teg deduce sto ete a ee e tenu 2 1 Manifold Operatiot etel aya REED dd 2 1 Primary Regulators sic Um 2 6 Check Valves edie acer e Evi dee akin ol teehee ee s a 2 7 Four Way VaVe E AARAA ORRA RENAE AREA 2 7 Pressure SWITCH uuu Zn Qaya nee tees Ee haz su Re ek

HGM2 Service Manual - Western Enterprises

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