LC Service Manual - Western Enterprises
Contents
1. Cross Section 1 Tubing is routed from each inlet to the pressure gauge for that bank The inlets are connected via tubing to the four way valve A check valve is connected in line be LEFT BANK RIGHT BANK tween each inlet and the four way valve This check valve prevents the gas from flowing FIGURE 2 1 External Components backwards toward the inlets 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 for the left manifold inlet to the outlet tubing on the right and connects the tubing from the right manifold inlet to the tubing leading to the intermediate regulator When the valve knob is rotated clockwise to the right position the valve connects the tubing from the right manifold inlet to the outlet tubing on the right and connects the tubing from the left manifold inlet to the tubing leading to the intermediate regulator Thus by turning the four way valve knob the operator may determine which bank of containers is the Service supply and which bank is the Secondary supply 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 pressure piping The low pressure switch is connected to this four way valve port A check valve located immediately downstream of the press2. 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 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 down ward 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 diaphragm increases resulting in a higher delivery pressure from the outlet port of the regulator Adjusting Screw Bonnet Pressure Plate Bonnet Sprint na Pusher Post Button dl OUTLET PORT Piston Assembly Ei c Piston Spring Bottom Plug Strainer Screen FIGURE 2 11 Line Pressure Regulator B20115 ECN 14800 0911 This page intentionally left
3. 41 2 Outlet Nut amp Nipple WMS 3 12 24 24 V Bulb 85 WME 8 42 3 Line Regulator 25 Dual Light Label WME 8 54 LC amp LCMP series WMR 6 4 26 Case Wiring Harness WMS 1 14 LCHP series WMR 6 6 27 Regulator Adjusting Screw WMC 6 38 4 1 4 NPT Pipe Nipple WLF 1 17 28 Concave Screen 1134 5 Inlet Block Right Side WMS 3 14 29 3 16 Hex Nut WMC 6 11 6 Bypass Check Valve See page 5 30 3 16 Lock Washer WMC 6 2 7 1 8 Tube x 1 4 NPT Female WLF 3 4 31 3 16 24 x 1 3 4 Carriage Bolt WMC 6 10 8 1 8 x Tubing WLF 6 17A 32 3 8 16 Hex Nut WMC 6 6 9 3 8 Tube x 1 4 NPT WLF 3 5 33 Tee Mounting Bracket WMC 6 7 10 3 8 Tubing 4 way to Regulator WMS 3 10 34 Backplate Assembly WMS 3 13 11 Inlet Block Left Side WMS 3 1 35 1 2 Nominal U bolt WMC 6 13 12 3 8 CV Tubing Left Inlet WMS 3 8 36 Flat Screen 1134 1 13 Pressure Switch 37 Case WMC 8 9 All except Oxygen WME 4 4 38 Outer Gauge Plate WMC 8 2 Oxygen WMS 4 4C 39 310 1 Self tapping Screw WMC 6 39 14 1 8 x11 Tubing WLF 6 17 40 Inner Gauge Plate WMC 3 5 15 Intermediate Regulator 41 Screw Receptacle WMC 6 35 LC amp LCMP series WMS 3 3 42 3 8 Tubing Safety Coupling WMC 3 17 LCHP series WMS 3 20 43 3 8 Tubing Safety Nut WMS 3 18 16 Switch Wire Harness WMS 1 13 44 3 8 Tube Tee WLF 3 14 17 Reserve CV Tubing WMS 3 11 45 90 Adaptor 223 18 3 8 CV Tubing Right Inlet WMS 3 7 46 3 8 Tubing Safety Vent WMS 3 28 19 Four Way Valve WMS 3 2 Case Lead Seal WEM 1 27 20 Intermediate Piping WMS 3 4
4. 8 Sheet Metal Case Screw WMC 6 23 21 Service CV Tubing WMS 3 16 Power Supply Box 8570D 22 Dual Light Lens WME 8 40 Item Not Pictured 5 4 20115 14800 0911 Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD LC LCMP amp LCHP Series Repair Drawing Gauge Plate Components p Te L 1 J JL J 4 4 KEY DESCRIPTION PART 1 Cylinder Contents Gauge 400 psi WMG 3 4 2 Line Pressure Gauge LC Series 200 psi WMG 3 2 LCMP Series 200 pis WMG 3 2 LCHP Series Except Nitrogen 200 psi WMG 3 2 LCHP Series Nitrogen 400 psi WMG 3 4 3 Gauge Plate WMC 8 1 1 4 1 8 Tube x 1 4 NPT Female WLF 3 4 5 5 B20115 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD LC LCMP amp LCHP Series Check Valve Components KEY 1 2 3 4 DESCRIPTION Poppet Spring Washer Cap Item included in repair kit Repair Kit for LC amp LCHP Series PART WMV 1 5 WMV 1 6 WMV 1 7 WMV 1 8 RK 1041 5 6 B20115 ECN 14800 0911
5. Capability The flow capability of the manifold will depend upon conditions at the installation site demands of the delivery system and the number of containers in supply service Maximum capability is 750 SCHF at 50 psig delivery and 125 psig inlet pressure Maximum capability is 800 SCFH at 160 psig delivery and 250 psig inlet pressure Installing the manifold in a location which exposes it to ambient temperatures below those specified on page 1 1 is not recommended Argon 750 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 125 psig inlet pressure 500 SCHF maximum at 50 psig delivery with a 5 psi pressure drop and 125 psig inlet pressure Oxygen 750 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 125 psig inlet pressure 500 SCHF maximum at 50 psig delivery with a 5 psi pressure drop and 125 psig inlet pressure Nitrogen 800 SCFH maximum at 160 psig delivery and 15 psi inlet pressure and 250 psig inlet pressure Nitrous Oxide 750 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 125 psig inlet pressure 500 SCHF maximum at 50 psig delivery with a 5 psi pressure drop and 125 psig inlet pressure Carbon Dioxide 750 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 125 psig inlet pressure 500 SCHF maximum at 50 psig delivery with a 5 psi pressure drop and 125 psig inlet pressure Practical Continuous Gas Withdrawal Rates from Liquid Containers at 70 F Argon 375 SCFH max fro
6. blank 2 9 B20115 ECN 14800 0911 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 PERFORMANCE VERIFICATION PROCEDURE 1 10 11 12 13 Shut down the manifold and remove the control sec tion cover as explained in Section 4 Remove the cap from the pressure test fitting on the left side of the intermediate pressure piping Attach a 400 psi test gauge to the test fitting Reinstall the control knob on the shaft of the four way valve Rotate the control knob counterclockwise to make the left cylinder the Service supply and the right bank the Reserve supply 5 open the gas use valve on one left bank container 5 1 1 open the gas use valve on one right bank container Using a leak detect solution verify that there are no leaks present at the connections Close the gas use valves on the left and right bank containers Loosen the union connection to the main supply line to create a slight gas flow through the manifold Vent the system until all gas has been removed from the manifold Tighten the main supply line union S I o0 w l y open the gas valve on one left bank container Verify that the left side contents gauge i
7. 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 intermediate regulator pressure thereby increasing the pressure at which the valve will open Turning the adjust ing screw out counterclockwise will decrease the intermediate regulator pressure thereby decreasing the pres sure at which the valve will open 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 Reserve bank will begin to supply the system B20115 ECN 14800 0911 BYPASS CHECK VALVE ECONOMIZER The bypass check valve is simply a check valve with a sufficient amount of spring force to created the substantial differential pressure required to open the valve Refer to Figure 2 10 The bypass valve is connected between the Reserve side of the four way valve and the intermediate pressure piping The bypass valve is factory set to open at a 50 psi pressure differential The spring force combined with the force exerted on the downstream side of the valve seat from the Service side pressure create the differential pressure required on the Reserve side to open the valve For example
8. connected between the intermediate pressure piping and intermediate regulator allows gas from the Service supply to flow back towards the intermediate regulator A check valve is connected in line between the intermediate regulator outlet and the intermediate pressure piping This check valve allows servicing the interme diate regulator without having to shutdown the manifold The intermediate regulator setting determines at which pressure the manifold will switch from Service to Secondary Gas from the Secondary supply flows from the four way valve through the intermediate regulator towards the bottom of the check valve When the gas pressure on the top side of the valve falls to a predetermined pressure the valve opens and routes the gas from the Secondary supply into the intermediate pressure piping and then to the line pressure regulator The bypass check valve is connected between the intermediate pressure piping and the four way valve on the Secondary side thereby passing the intermediate regulator The bypass check valve is factory set at a 50 psi differential pressure and opens to allow the Secondary side to feed the line regulator whenever the Secondary pressure exceeds the Service pressure by more than 50 psi This feature permits the system to use Secondary gas in low flow or minimum use systems rather than allowing the gas to vent to atmosphere from the containers The line pressure
9. if the Service bank is set for an inlet of 125 psig to the system the differential pressure required to open the valve would be 125 50 175 psig The Reserve side would have to build up to a pressure exceeding 175 psig before the bypass side As soon as the Reserve pres sure drops below 175 psig the bypass valve closes If the Service side pressure was increased to 150 psig the pressure required on the Reserve side to open the valve would be 150 50 200 psig PSI Hl m A liii d UII MI Gas from Gas from Four way Valve Intermediate Pressure Piping FIGURE 2 10 Bypass Check Valve 2 7 B20115 ECN 14800 0911 LINE PRESSURE REGULATOR The line pressure regulator used in the manifold is a single stage two port adjustable regulator Refer to Figure 2 11 It has one inlet port and one outlet port The inlet port is piped to a port in the intermediate pressure piping One outlet port is piped to the outlet of the manifold for connection to the main pipeline Tubing connected to the outlet piping is routed to the delivery line pressure gauge 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
10. 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 WARNING This product contains chemicals including lead known to the state of California to cause cancer and birth defects or other reproductive harm Wash hands after handling B20115 ECN 14800 0911 CAUTION Failure to the follow the following instructions can result in person injury or property damage Never permit oil grease or other combustible materials to come in contact with cylinders manifold and con nections Oil and grease may react with explosive force when ignited while ignited 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 5 inches Mistreatment may cause the pigtail to burst Do not apply heat Oil and grease may react with explosive force when 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
11. may ignite materials in an oxygen atmosphere creating a fire or explosive force Welding should never be performed near nitrous oxide piping Excessive heat may cause the gas to dissociate creating an explosive force Carefully read and follow instructions Manifolds are designed fro gas withdrawal from cryogenic liquids Con tact of a cryogenic liquid or cold gas with skin or eyes may cause a freezing injury ABBREVIATIONS OSHA 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 National Pipe Tape 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 B20115 ECN 14800 0911 TABLE OF CONTENTS SECTION 1 INTRODUCTION 1 1 Product DESCriptlOn EE 1 1 installation Informatio M EE 1 1 Manifold Specifications EE 1 2 Adjustment SpecifICatiOris Pocta e deu ran Pede 1 3 Recommended Tools and Test Eoumpment 1 3 SECTION 2 THEORY OF OPERATION 2 1 Ee TN rie Tu Le EE 2 1 Ettel Keel Le EE 2 1 Check E 2 4 SEVA uU 2 4 low
12. old sealant from the threads in the intermediate pressure piping CAUTION e 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 5 Blow out the internal pipe threads with oil free Air or Nitrogen to remove all foreign material 6 Place the bypass check valve in a vice or similar holding fixture and use a 3 4 hex wrench to remove the compression fitting 7 Remove the old sealant from the 1 4 NPT female pipe thread on the compression fitting Replacement 1 Apply Teflon tape to both 1 4 NPT male pipe thread on the new bypass check valve and assemble to the intermediate pressure piping Normal flow is from the four way valve to the intermediate pressure piping The flow arrow should point towards intermediate pressure piping CAUTION Pay careful attention to the economizer check valve flow direction Improper connection would cause mal function of the system during normal operation CAUTION Use care when performing steps 2 4 Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 5 1 1 open the gas use valve on one container on the side the economizer check valve is on Assemble the compression fitting to the bypass check valve with a 3 4 hex wrench and tighten When retightening
13. 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 container 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 open the cylinder valve s l o w l y to allow the heat of compression to dissipate 6 Useonly cleaning agents sealants and lubricants as specified in this instruction 4 1 B20115 ECN 14800 0911 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 gastight seal Assembly and Disassembly of Compression Fittings 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 f
14. 2 Using an 11 16 open end wrench disconnect and remove the intermediate regulator to intermediate pressure piping check valve tubing assembly Mark the compression fittings per the instructions on page 4 2 Using an 11 16 open end wrench disconnect and remove the four way valve to the intermediate pressure piping tubing Mark the 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 pressure gauge Mark the compression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the four way valve to bypass check valve tubing from the bypass check valve Using two 1 1 2 open end wrenches disconnect the main supply line from the manifold at the union Using a small pipe wrench remove the union nipple from the outlet of the line regulator Using a 7 16 hex wrench remove the U bolt from the bracket Remove the intermediate pressure piping and line regulator assembly from the control section Secure the intermediate pressure piping in a vise or similar holding fixture To remove the regulator from the intermediate block grasp the bonnet of the regulator and rotate the regulator counterclockwise Disassembly 1 Secure the intermediate regulator in a vise or similar holding fixture The vise should grip the regulator on the body hex 2 Loosen the lock nut and rotate the adjusting screw of the regulator c
15. ACEMENT PARTS Round Style WME 8 72 Bulb Receptacle and Amber Lens WME 8 10 115 V Light Bulb Square Style WME 8 42 Light Bulb WME 8 44 Bulb Receptacle WME 8 40 Red Green Lens MK 1010 Dual Light Assembly Repair Kit PANEL MOUNT GAUGES 2 Diameter 1 4 NPT Back Port WMG 3 2 200 psi WMQG 3 14 300 psi WMGQG 3 4 400 psi WMQG 3 5 600 psi WMS 3 3 Intermediate Regulators for LC and LCMP series manifolds 6 4 Line Regulator for LC and LCMP series manifolds 5 3 20 Intermediate Regulator for LCHP series 6 6 Line Regulator for LCHP series 1070 Repair Kit for WMS 3 3 WMR 6 4 WMR 6 6 WMS 3 20 VALVES AND VALVE REPAIR KITS WMV 5 25 50 Bypass Check Valve Economizer Oxygen WMV 5 7 see Bypass Check Valve Economizer Argon Helium Nitrogen CO2 Nitrogen 1041 Repair Kit for Low Pressure Check Valve 5 3 2 Four Way Valve Assembly WMV 6 4 Pigtail Check Valve 5 1 B20115 ECN 14800 0911 PRESSURE SWITCHES WME AA Pressure Switch adjustable 0 300 psi Argon Helium Nitrogen CO2 and N2O 4 4 Pressure Switc
16. CMP Nitrogen 250 400 450 235 240 220 230 205 210 Unit of measure all units are in psig Differential pressure 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 source Needle nose pliers Available from local source Wire cutters Available from local source 1 8 hex key wrench Available from local source 3 4 hex socket wrench Available from local source 3 16 hex socket wrench Available from local source Set of combination wrenches Available from local source 1 4 thru 1 1 1 8 1 1 2 Liquid leak detector Available from Western Enterprises Part number LT 100 Teflon tape Available from Western Enterprises Part number MTT 1 or MTT 2 Teflon is a registered trademark of E du Pont de Nemours amp Co Inc 1 3 B20115 ECN 14800 0911 This page intentionally left blank B20115 ECN 14800 0911 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
17. Press re SWIIChes utei ie ex nue SONT ene AUREUS DXX 2 5 due Ee e E 2 6 Bypass Check Valve 0 2 6 binePressure Fegulator 5 tri iit Huan es deg aes 2 6 SECTION 3 FIELD TESTING AND TROUBLE SHOOTING 3 1 Performance Verification Procedure A 3 1 Troubl shoollng cu ote ELE tee ase te tas A aes va ch E evt gab cet EE P RE Eod 3 4 SECTION 4 SERVICE PROCEDURES 4 1 General Maintenance dE e an uat a tege 4 1 Safety Precautions e RN DT 4 1 Cleaning Lubrication and Gealimg 4 2 General Procedures 1000000 4 3 How to Shutdown the Manttold enne nnne nennen nsns n 4 3 Manifold Cabinet Cover Hemoval 2 4 3 Gatge Replacement ee ege ect a statt tal ok M ALS S LEAL AL 4 4 Low Pressure Switch Replacement 4 5 Gheck Valve Bepalt stat cce A alles ok dete ut dace Don n LACE 4 6 Bypass Check Valve 4 7 Four Way Valve Replacement 4 8 Intermediate Regulator Repair 4 9 tee W IEE TEE 4 11 Light Socket R
18. T B BULB 7 A BULB RED LENS GREEN LENS MANIFOLD dM BROWN He N O 4 N C TO RED 2 BLACK Og VE SUPPLY WHITE opp 2 VAC NOTE PRESSURE SWITCH REFLECTS UNPRESSURIZED MANIFOLD FIGURE 2 4 Electrical Schematic 113 VAG POWER SUPPLY BOX 115 24 VAC TRANSFORMER CIRCUIT BOARD P 24 VAC 24 VAC REMOTE ALARM INTERFACING TERMINAL STRIP LOCATED ON RIGHT SIDE OF THE PCB IN THE POWER SUPPLY BOX RELAY PROVIDES DRY CONTACTS AT POSITIONS 5 6 AND 7 The gas from the Service supply is depleted the gas pressure on the Service side will begin to fall Simulta neously the pressure to the pressure switch the downstream side of the check valve below the intermediate regulator and the line regulator also falls When the Service side pressure falls below the set point of the low pressure switch the red replace depleted cylinders light comes on and the green systems 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 is pushed open by the pressure applied from the intermediate regulator The Secondary supply begins to feed the system After replacing empty containers and opening the gas use valves the pressure will actuate the pressur
19. WESTERN AUTOMATIC CHANGEOVER MANIFOLD INNOVATOR GAS MANIFOLD SYSTEMS LC LCMP amp LCHP Series SERVICE MANUAL WESTERN ENTERPRISES PRINTED IN USA B20115 ECN 14800 0911 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 LC and LCHP 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 WARRANTY Western Enterprises makes no warranty of any kind with regard to the material in this
20. ant Observe the test gauge as the right 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 specifica tion chart n Section 1 Tighten the main supply line union 3 2 40 41 42 43 44 45 46 47 48 51 Verify that the intermediate regulator is functioning properly by observing the test gauge for two min utes The gauge should indicate the same pres sure at the end of the two minute period 5 1 1 open the gas use valve on one left bank container Verify that the test gauge has returned to the set pressure of the pressure building regulator on the container 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 normally open N O and common C terminals 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 pressure switch Reconnect the ohmmeter to the black and brown wires Close the gas use valve on one left bank con tainer Loosen the union connection to the main supply line to create a slight flow of gas th
21. automatic changeover manifold consists of a manifold control and two supply bank crosses one service and one reserve supply to provide an uninterrupted supply of gas for the specific gas application The manifold control includes the following components and features inlet safety relief valves green system nor mal and red replace depleted cylinders indicator lights inlet pressure gauges an economizer bypass check valve and line pressure gauge Supply banks consist of 72 flexible pigtails with CGA cylinder connections for hookup to container s gas use port and 1 4 NPT connections for attachments to the control unit cross The main components of the manifold are shown in Figures 2 1 and 2 2 Figures 2 3 shows the piping schematic and Figure 2 4 is the schematic diagram of the electrical system of the manifold The bank that supplies the piping system is known as the Service supply while the bank ressure Gauges on stand by is referred to as the Secondary Control Knob supply Gas flows from the containers through the pigtails and into the left and right Cabinet inlets of the control sections Lights NC RI m hgh EE A safety relief valve is connected to each t 17 B Ver Tes sl inlet to protect the manifold from over v pressurization The relief valve setting is ZF VH noted in the adjustment specification chart in Inlet
22. ce Set delivery pressure to specifications Replace containers Replace regulator seat and nozzle components Reduce the flow demand or increase the number of supply containers Add external heaters if necessary Gas leakage around regulator body or bonnet LOSS OF RESERVE BANK CONTENTS Both banks feeding Loose bonnet Intermediate regulator seat leak Intermediate regulator set to open at too high a pressure Faulty four way valve Flow demand too high Faulty economizer check valve 3 6 Tighten bonnet Repair or replace regulator Adjust intermediate regulator per specifications Replace four way valve Reduce flow demand Replace economizer check valve B20115 ECN 14800 0911 SYMPTOM LOSS OF RESERVE BANK CONTENTS continued Opposite bank feeding Premature changeover to reserve bank No changeover PIPELINE DISTRIBUTION Pipeline not at desired pressure Required gas flow not available PROBABLE CAUSE Faulty primary regulator and or intermediate regulator Faulty economizer check valve Flow demand too high Leaks in the manifold system Intermediate regulator set to open at too high a pressure Closed gas use valves Intermediate regulator defective Empty reserve bank cylinders Line regulator not set correctly Line regulator not set correctly Flow demand too high 3 7 REMEDY OR CHECK Replace intermediate regulator seat and
23. d assemblies in the body of the regulator Use a 1 1 2 hex wrench to tighten the plug 4 9 B20115 ECN 14800 0911 6 Place the pusher post button on the piston post Set the gasket and the metal diaphragms in the body cavity and place the pressure plate spring and spring button on top of them Place the bonnet on top of the body matching up the mounting screw holes Inset the screws and attach the nuts to them Tighten opposite screws alternately using a 7 16 hex wrench Remove the regulator from the vise Replacement 1 Position the intermediate regulator in the control section with the inlet connecting to the tubing coming from the four way valve The inlet of the regulator is stamped INLET When retightening the fitting the procedure outlined on page 4 2 shall be followed Connect the compres sion 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 earlier in this section remove the manifold cover and attach a test gauge to the left side of the intermediate pressure piping Reinstall the four way valve knob and rotate to select one bank of cylinders as the supply bank 5 1 1 open one cylinder on the supply bank selected Verify the contents pressure gauge indicates the minimum inlet pressure per the Adjustment Specification chart in Section 1 Adjust the pressure building regulator pr
24. e 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 bank This will make the partially used Secondary bank the Service supply and the newly installed containers will become the Secondary supply CHECK VALVES The check valves prevent gas from flowing backward from the four way valve to the inlets See Figure 2 5 Gas enters the check valve from the inlet 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 seal ing surface preventing any gas flow backward through the valve 2 4 FIGURE 2 5 Check Valve B20115 ECN 14800 0911 FOUR WAY VALVE The four way valve assembly is used to route the gas to either the intermediate pressure piping or the intermedi ate regulator 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 Figure 2 6 Figure 2 7a shows the position of the valve ports when the right bank is the Service bank and the left bank is the Reserve 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
25. e 4 2 shall be followed Using a 7 16 open end wrench reconnect the line pressure gauge tubing to the line pressure gauge 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 over pressurize the piping which may cause damage to a downstream item 10 11 5 1 1 open the gas use valve one container on the system Verify the cylinder pressure gauge indicates the minimum inlet pressure per the Adjustment Specification Chart in Section 1 Adjust the pressure building regulator pressure as necessary to obtain the required pressure setting 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 Loosen the main supply union 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 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 gas use valve on the container Loose
26. ediate block from the vise and using the carriage bolt reinstall the intermediate pressure piping to the bracket on the backplate Assemble the nuts and strap to the U bolt Tighten loosely 8 Remove all old sealant from the union nipple Clean all interior surfaces with isopropyl alcohol or 1 1 1 trichloroethylene solvent 9 Apply Teflon tape to the 1 4 NPT male pipe thread on the union nipple Start the threads of the nipple into the outlet of the line regulator 4 12 B20115 ECN 14800 0911 10 11 12 13 14 15 16 Using a small pipe wrench install the union nipple to the outlet of the line regulator Using a 7 16 hex wrench reassemble the U bolt to the bracket When retightening the fitting the procedure outlined on page 4 2 shall be followed Using and 11 16 open end wrench reconnect the four way valve to intermediate block tubing When retightening the fitting the procedure outlined on page 4 2 shall be followed Using and 11 16 open end wrench reinstall the intermediate regulator to intermediate pressure piping check valve tubing assembly When retightening the fitting the procedure outlined on page 4 2 shall be followed Reconnect the four way valve to bypass check valve tubing to the bypass check valve with a 7 16 open end wrench Using two 1 1 2 open end wrenches reconnect the main supply line to the manifold at the union When retightening the fitting the procedure outlined on pag
27. ent 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 Adjust ment Specifications chart in Section 1 7 Cycle between actuation and reactuation signals 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 through the wire may shock the service technician 8 After setting has been made connect the signal wires to the appropriate contacts on the pressure switch 4 5 B20115 ECN 14800 0911 CHECK VALVE REPAIR Removal 1 2 3 Shutdown the manifold and remove cover as explained earlier this section Mark the compression fittings per the instructions on page 4 2 Disconnect the tubing at the compression fittings using and 11 16 open end wrench Remove the check 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 counterclockwise and remove 2 Remove the seal washer from the valve cap 3 Pull the spring from the valve body 4 Using a small needle nose pliers or tweezers grasp the valve poppet and remove it from the valve body 5 Clean the interior of the valve body with isop
28. eplacement 4 14 Indicator E ul el el Ee EE 4 14 B20115 ECN 14800 0911 SECTION 5 MAINTENANCE AND REPAIR PARTS 5 1 Replacement PigtallS 3 222 run LL LT CM rt 5 1 Indicator Lamp Replacement Parts iet sten de naa ERROR RAE 5 1 Paneb Mount Gauges tates eege esatta ee os EES 5 1 Regulators ands Repairs e RR Em 5 1 Valves and Valve Repair kt 5 1 Pressure Switches easiest Ee 5 1 Power Supply Replacement Parts 5 1 eet Ati ede eine Aten 5 1 SECTION 5 MAINTENANCE AND REPAIR PARTS Repair Drawings 5 2 Components and Miscellaneous Hardware 5 2 Gauge Plate Componert einen entere enn sns 5 4 ere tret ende ce Pa E vede DUI E Reds 5 5 B20115 ECN 14800 0911 This page intentionally left blank B20115 ECN 14800 0911 SECTION 1 INTRODUCTION amp GENERAL INFORMATION PRODUCT DESCRIPTION The automatic changeover manifold is designed to provide a reliable uninterrupted supply of gas to a gas pipeline system The manifold has an equal number of cylinders in its Service supply and Secondary supply banks automati cally switching to the Secondary supply when the Service supply becomes depleted When the manifold changes t
29. essure as necessary to obtain the required pressure setting Rotate the control knob so that the arrow of the four way valve is pointing to the opposite bank Loosen the main supply union slightly to relieve pressure from the manifold while observing the test gauge Allow the gas to vent until the test gauge stabilizes or indicates less than the setting for the intermediate regulator listed in the adjustment Specification chart in Section 1 e lf the gauge stabilizes at a pressure higher than the chart specification turn the adjusting screw on the intermediate regulator clockwise to increase the gauge reading e If the gauge stabilizes at a pressure lower than the chart specifications turn the adjusting screw the intermediate regulator counterclockwise to decrease the gauge reading Tighten the union connection to the main supply line Simulate the changeover sequence from both sides and observe the intermediate gauge to verify proper setting Tighten the lock nut after proper setting is achieved 4 10 B20115 ECN 14800 0911 LINE REGULATOR REPAIR NOTE Removal and Replacement procedures are to be followed only if the line regulator assembly is to be scrapped All service may be performed to the line regulator without removing it from the manifold Shutdown the manifold and remove cover as explained earlier in this section Removal 1 10 Mark the compression fittings per the instructions on page 4
30. from traveling to the other ports With the valve in this position the gas from the right inlet is routed to the intermediate pressure piping and the gas from the left inlet is routed to the intermedi ate regulator Figure 2 7b shows the valve in the OFF position The OFF position is only used during shipment of the mani fold 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 7c shows the position of the valve ports when the left bank is the Service bank and the right bank is the Reserve FIGURE 2 6 Four Way Valve The only function the four way valve serves is to route the gas to the other components of the manifold CYL 1 OUTLET INLET PORT 1 d cJ 4 X SS INLET PORT 2 INLET PORT 1 CYL 2 OUTLET CYL FIGURE A N CYL 1 OUTLET INLET PORT 1 CYL 1 OUTLET O 7 INLET PORT 2 n i E 7 INLET PORT 2 2 OUTLET CYL 2 OUTLET FIGURE B FIGURE C FIGURE 2 7 Four Way Valve 2 5 Figure 2 7 Heater Electrical Schematic B20115 ECN 14800 0911 LOW PRESSURE SWITCH The low pressure switch is used to signal Reserve in Use is a piston type with one common contact one normally closed contact and one normally open contact See Figures 2 8 and 2 9 When the manifold is pressurized to the normal pressures the piston in the switch is p
31. h adjustable 0 300 psi Oxygen WME 4 9 General Purpose Pressure Switch adjustable 100 1000 psi WME 4 10 General Purpose Pressure Switch adjustable 200 3000 psi WME 4 13 High Low Pressure Switch adjustable 0 300 psi WME 4 14 General Purpose Pressure Switch adjustable 20 200 psi WME 4 15 High Low Pressure Switch adjustable 0 100 psi POWER SUPPLY REPLACEMENT PARTS 8570 Power Supply Assembly transformer PCB with dry contacts case and cables 8 1 Power Supply PCB for 85700 includes dry contacts for remote alarms REMOTE ALARMS 24 VAC Service 1 Visual 1 Gas 2 Audio Visual 2 Gases EI eminus Audio Visual 1 Gas WMS 9 25C Optional 115 to 24 VAC Power Supply for above Remote Alarms 5 2 B20115 ECN 14800 0911 Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD LC LCMP amp LCHP Series Repair Drawing Components amp Miscellaneous Hardware 5 3 B20115 ECN 14800 0911 Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD LC LCMP amp LCHP Series Repair Drawing Components amp Miscellaneous Hardware KEY DESCRIPTION PART KEY DESCRIPTION PART 1 Outlet Adaptor D 34 23 Dual Light Base WME 8
32. h wire cutters and remove 2 Remove the control knob on the front of the cabinet using a 1 8 hex key wrench 3 Using a flat blade screwdriver or 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 a phillips screwdriver 6 Carefully pull the cover straight out to clear internal components NOTE e t may be necessary to turn the adjusting screw on the line regulator all the way in so as to allow the cover to slide past the adjusting screw 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 9 Back out the adjusting screw on the line regulator if it was readjusted to remove the cover Reassembly Reverse order of disassembly Connect internal wiring by matching up color coded wires 4 3 B20115 ECN 14800 0911 GAUGE REPLACMENT CAUTION careful not to kink or damage the tubing connected to the gauges Damaged tubing may burst when pressurized Removal 1 Shut down 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 c
33. he manifold changes over from service to reserve supply Tighten the main supply line union and test for leaks using a leak detect solution S l o w l y open all gas use valves on the left and right bank containers Rotate the control knob to select the bank supplying the system before service was performed System is now ready for use B20115 ECN 14800 0911 TROUBLESHOOTING only qualified personnel should make repairs SYMPTOM CABINET INDICATOR LIGHTS No indicator lights on front panel come on when power is hooked up Red indicator light is 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 but both banks are full Green indicator light comes on even though one bank of cylinders is empty PROBABLE CAUSE Power input Bulb burned out Internal wiring disconnected Gas use valves on bank are Closed Pressure switch set at too high a pressures Pressure building regulator s set too low Control knob was rotated to select new Service side without changing empty containers Bulb burned out Pressure switch wiring disconnected Pressure switch set at too low a pressure Intermediate regulator setting too high Bulb burned out Pressure switch wiring disconnected Pressure switch set at too high a pressure Control knob was rotated to select new Service side withou
34. he 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 B20115 ECN 14800 0911 GENERAL REPAIR PROCEDURES Be sure all pressure and electrical power is removed from the system prior to initiating any repair procedures WARNING systems requiring industrial gas are being supplied from portable or alternate supplies Patients still on the pipeline will not receive gas Do not shutdown the manifold until personnel have been advised of the intended service and all Replace parts with all components in the repair kit HOW TO SHUT DOWN THE MANIFOLD 1 2 3 4 5 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 Turn off right and left supply bank cylinder valves Loosen the manifold outlet connection to the supply main to vent residual gas from the system Tighten the manifold outlet connection Disconnect electrical power from the manifold at the main power source MANIFOLD CABINET COVER REMOVAL Disassembly 1 Cut lead seal wire wit
35. isassembly 1 Secure the intermediate regulator in a vise or similar holding fixture The vise should grip the regulator on the body hex 2 Loosing the lock nut and rotate the adjusting screw of the regulator counterclockwise until free of the spring tension 3 Remove six assembly screws and nuts using 7 16 wrenches and remove the bonnet spring button spring and pressure plate 4 Remove the metal diaphragm and the gasket 5 Lift the pusher post button off of the piston post 6 Using a1 1 2 hex wrench loosen the hexagon bottom plug and carefully unscrew by hand NOTE e The bottom plug is under slight tension because of the piston spring 7 Remove the plug piston spring and strainer screen 8 Unscrew and remove the hexagon cylinder using a 3 4 hex socket wrench to prevent distortion 9 Clean all interior surfaces of the regulator body with isopropyl alcohol or 1 1 1 trichloroethane 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 10 Blow out the regulator body and parts with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces Reassembly 1 2 Install the cylinder using a 3 4 hex socket wrench to prevent distortion Position the piston spring piston and spring retainer on the plug an
36. itting 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 NOTE e Incorrect assembly of fittings may initially seal however leakage may occur over time Leak Testing There are four types of manifold piping connections sealed soldered threaded unions and elbows compres sion 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 connec tions 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 t
37. m the first container 185 SCFH from each additional container Carbon Dioxide 110 SCFH max per container Nitrogen 375 SCFH max from the first container 185 SCFH from each additional container Nitrous Oxide 80 SCFH max per container Oxygen 375 SCFH max from the first container 185 SCFH from each additional container 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 Delivery Piping Connections Pipeling Reli Header Inlets Carbon Dioxide CGA 320 PE Nitrous Oxide CGA 326 Control od Oxygen CGA 540 Cabinet ETE Argon CGA 580 Nitrogen CGA 580 Manifold Outlet 1 2 NPT male pipe thread located on the left side on top of the cabinet Relief Valve 1 2 NPT or 3 4 NPT male pipe thread located on the left and right bank headers FIGURE 1 2 Connection Locations 1 2 B20115 ECN 14800 0911 ADJUSTMENT SPECIFICATIONS Minimum Inlet Low Intermediate Intermediate Line Cylinder Pressure Pressure Regulator Pressure Regulator Gas Pressure Relief Valve Switch Relief Valve LC Series 125 400 450 105 110 90 95 50 60 75 80 LCMP 160 400 450 140 145 130 135 50 60 120 125 LCMP 250 400 450 205 210 190 195 150 155 except Nitrogen L
38. minute period Loosing the union connection to the main supply line to create a slight flow of gas through the manifold B20115 ECN 14800 0911 27 28 29 30 31 32 33 34 35 36 37 38 39 Verify that the line pressure regulator maintains a constant pressure by observing the line pressure gauge 5 open the gas use valve on one left bank container Observe the contents pressure gauges to verify inlet pressures Close the gas use valve on the right bank con tainer Observe the contents gauges the right bank gauge should begin to drop the left bank gauge should remain constant Observe the test gauge as the right side pressure continues to drop As the inlet 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 specifica tion chart in Section 1 Adjust the intermediate regulator as necessary to obtain the required pres sure 5 open the gas use valve on one right bank container Verify that the test gauge has returned to the set pressure of the pressure building regulator on the container Rotate the control knob counterclockwise to make the left bank the service supply Close the gas use valve on the left bank container Observe the contents gauges the left bank gauge should begin to drop the right bank gauge should remain const
39. mpression fitting in the inlet ports on the four way valve using 5 8 open end wrench Install the adaptor fittings in the outlet ports on the four way valve using an 11 16 open end wrench The bypass check valve tubing must be connected to the CYL 2 port and the pressure switch must be connected to the CYL 1 Remove the valve from the vise and position it behind the support bracket with the CYL 2 port on the left and the CYL 1 port on the right Reinstall the two screws through the bracket and into the two upper threaded holes of the valve Tighten with a phillips screwdriver Reconnect the check valve tubing assemblies to the new valve Note the flow direction arrow on the check valves must point towards the four way valve Reconnect the two outlet tubing sections to the new valve When retightening the fitting the procedure outline on page 4 2 shall be followed Using an 11 16 open end wrench tighten the compression fittings at the ends of the tubing assemblies to effect a gastight seal 4 8 B20115 ECN 14800 0911 INTERMEDIATE PRESSURE REGULATOR REPAIR Removal 1 2 3 Shutdown the manifold and remove cover as explained earlier in this section Mark the compression fittings per the instructions on page 4 2 Disconnect the tubing at the compression fitting to the four way valve and the intermediate pressure piping using an 11 16 open end wrench Remove the intermediate regulator from the control section D
40. n 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 13 B20115 ECN 14800 0911 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 A and B Insert the back of the new light socket through the rectangular opening in the front 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 terminal on the socket 4 Reinstall the manifold cover and connect electrical power to the manifold Test for proper function by follow ing 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 rem
41. ndicates a minimum inlet pressure as specified in the chart in Section 1 Adjust the pressure building regulator on the container as necessary to obtain the required pressure 3 1 14 15 16 17 18 19 20 21 22 23 24 25 26 Verify that the line pressure gauge is indicating a minimum of 50 psig on all systems except Nitrogen Nitrogen should indicate a minimum of 160 psig Adjust to the proper line pressure if necessary Loosen the union connection to the main supply line to create a slight flow of gas through the manifold Observe the test gauge and verify the pressure building regulator setting under a flow condition Adjust the pressure building regulator a necessary to obtain the required pressure Turn off the gas use valve and allow all gas to vent from the manifold Tighten the union connection to the main supply line Repeat steps 12 18 for the other containers on the left bank Rotate the control knob to its fully clockwise position 5 1 1 open the gas valve on one right bank container Complete steps 13 18 for the pressure building regu lator on the container Repeat steps 21 and 22 for the other containers on the right bank Tighten the main supply union if not already done 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
42. nozzle components Replace economizer check valve Reduce flow demand Leak test tighten reseal or replace fittings as necessary Adjust intermediate regulator per specifications Open valves Replace or repair regulator Replace cylinders Readjust line pressure regulator Readjust line pressure regulator Consult factory B20115 ECN 14800 0911 This page intentionally left blank 3 8 B20115 ECN 14800 0911 SECTION 4 SERVICE PROCEDURES GENERAL MAINTENANCE 1 Daily record line pressure 2 Monthly a Check regulators and valves for external leakage b Check valves for closure ability c Check pigtails for cleanliness flexibility wear leakage and thread damage Replace damaged pigtails immediately 3 Annually check relief valve pressures 4 Every 4 years a Replace pigtails WARNING e 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 SAFETY PRECAUTIONS 1 Examine all parts before repair Note Because manifold parts may be exposed to Oxygen and Nitrous Oxide and the condition of the unrepaired parts is unknown a repair inspection should be performed 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
43. o Secondary supply it sends a signal to the gas alarm system alerting the personnel of the need for the exhausted containers to be replaced with full containers 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 manifolds 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 direct rain snow and heavy moisture During winter protect the manifold from ice and snow In summer shade the manifold and cylinders from con tinuous 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 CAUTION e Remove all protective caps prior to assembly The protective cap may ignite due to heat of recompression in oxygen systems 50 Floor Figure 1 1 Installation Dimensions 1 1 B20115 ECN 14800 0911 MANIFOLD SPECIFICATIONS Flow
44. ompression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the tubing from the defective gauge 4 Using a 3 8 hex wrench remove the two screws holding the gauge brackets Slide the gauge brackets off of the screw post 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 Using a 9 16 open end wrench to stabilize the gauge 7 Remove 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 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 B20115 ECN 14800 0911 LOW PESSURE SWITCH REPLACEMENT Removal 1 2 Shutdown the manifold and remove cover as explained earlier in the section 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 Use a 5 8 open end wrench to stabilize the adaptor and use a 7 8 open end wrench to remove the pres sure switch Replacement CAUTION Do not stand directly in front of the body or ports when performing the next step Eye protection
45. on connection to the main supply line to create a slight gas flow through the manifold 75 and allow all gas to vent from the manifold Remove the control knob from the four way valve 76 Reinstall the manifold section cover as explained in Section 4 77 Connect the electrical power source and supply electric power to the manifold 78 Observe the cabinet system status indicators Verify that the green indicator is shut off and the red indicator is lit 79 S l o w l y open the gas use valve on one left bank container and one right bank container 80 3 3 Observe the cabinet system status indicators Verify that the green indicator is lit and the red indicator is off Readjust the line regulator setting if it was modified during cover installation Close the gas use valve on the right bank container Loosen the main supply union 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 reserve supply 5 1 1 open the gas use valve on one right bank container Rotate the control knob counterclockwise to make the left bank the service supply Observe the cabinet system status indicators Verify that the green indicator is lit and the red indicator is 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 t
46. ounterclockwise until free of the spring tension 3 Remove six assembly screws and nuts using 7 16 wrenches and remove the bonnet spring button spring and pressure plate 4 Remove the metal diaphragms and the gasket 5 Lift the pusher post button off of the piston post 6 Using 1 1 2 hex wrench loosen the hexagon bottom plug and carefully unscrew by hand NOTE e The bottom plug is under slight tension because of the piston spring 7 Remove the plug piston piston spring and strainer screen 4 11 20115 14800 0911 8 Unscrew and remove the hexagon cylinder using a 3 4 hex socket wrench to prevent distortion 9 Clean all interior surfaces of the regulator body with isopropyl alcohol or 1 1 1 trichloroethane 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 or debris may be propelled into unprotected eyes 10 Blow out the regulator body ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces Reassembly 1 Install the cylinder using a 3 4 hex socket wrench to prevent distortion 2 Position the piston spring piston and spring retainer on the plug and assemble in the body of the regulator 3 Place the pusher post button on the piston post 4 Set the gasket and the metal diaphragms in the body cavity and place the pressure plate sp
47. oval 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 ex tractor Replacement 1 Insert the replacement lamp and push on the lamp until it snaps into place NOTE 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 NOTE 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 B20115 ECN 14800 0911 SECTION 5 MANIFOLD MAINTENANCE amp REPAIR PARTS NOTE e Western manifold systems are designed and tested for optimal performance and adherence to safety specifications We recommend the use of Western replacement components to maintain the standards of performance and the safety of the product REPLACEMENT PIGTAILS 72 Cryogenic Flexible Pigtails 2 5 CGA 320 for Carbon Dioxide CO Service WMH 2 6 CGA 326 for Nitrous Oxide N2O Service 2 7 CGA 540 for Breathing Oxygen Oz Service 2 8 CGA 580 for Inert Gas Service INDICATOR LAMP REPL
48. regulator further reduces the pressure to the final pressure delivered to the gas piping system The regulator has one inlet port and one outlet port Tubing is connected from the outlet piping to the line pres sure gauge to sense the pressure of the gas on the downstream side of the regulator The outlet port is located 180 from the inlet The gas flows from the line regulator outlet to the pipeline distribution system A line pressure relief valve is not provided but should be tapped into the line routed along with the inlet pressure relief valve to the outside of the building for manifolds located indoors When both banks are full the pressure switch completes the electrical circuit to the green light Pressures for each bank are indicated on the gauges on the manifold front cover The Service supply is indicated by the posi tion of the control knob The line pressure is indicated by the center gauge on the manifold front cover To Pipeline Line Pressure Gauge Distribution System Line Pressure Regulator Intermediate Relief Valve Check Valve Low Pressure Switch Intermediate Regulator Check Valve Four Way Valve Check Valve Not on all models Regulator Relief Valve Regulator Relief Valve Right High Pressure Gauge Left High Pressure Gauge Line Pressure Intermediate Pressure Cylinder Pressure Left Primary Regulator Right Primary Regulator FIGURE 2 3 Piping Schematic 2 3 B20115 ECN 14800 0911 MANIFOLD DUAL LIGH
49. ring and spring button on top of them 5 Place the bonnet o top of the body matching up the mounting screw holes Insert the screws and attach the nuts to them Tighten opposite screws alternately using a 7 16 hex wrench 6 Remove the regulator from the vise Replacement 1 Secure the intermediate pressure piping 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 trichloroethane solvent CAUTION e 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 or debris may be propelled into unprotected eyes 3 Remove all old sealant from the intermediate pressure piping Blow out the intermediate pressure piping with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 4 Apply Teflon tape to the 1 4 NPT male pipe thread on the regulator inlet nipple Start the threads of the nip ple into the intermediate pressure piping 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 INLET 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 fitting on the left side of the intermediate pressure piping 7 Remove the interm
50. ropyl alcohol or 1 1 1 trichloroethylene solvent CAUTION e 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 debris may be propelled into unprotected eyes 6 Blow out the check valve body with oil free nitrogen to remove all foreign material and dry all surfaces Reassembly 1 Insert a new valve poppet into the valve body 2 Insert the spring into the valve body 3 Position a 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 cap 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 outlet When retightening the fitting the procedure outlined on page 4 2 shall be followed Connect the compres sion fittings using an 11 16 open end wrench and tighten to effect a gastight seal 4 6 B20115 ECN 14800 0911 ECONOMIZER CHECK VALVE REPLACEMENT Removal 1 Shutdown the manifold and remove cover as explained earlier in this section 2 Mark the compression fittings per the instructions on page 4 2 Disconnect the tubing from the bypass check valve using a 7 16 open end wrench 3 Using a 9 16 open end wrench remove the economizer check valve from the intermediate pressure piping 4 Remove
51. rough the manifold Verify an ohmmeter reading of infinite resistance as soon as the test gauge pressure drops to the value for the pressure switch setting indicated in the Specification chart Section 1 5 1 1 open the gas use valve on one left bank container Verify that the ohmmeter returns to approximately zero 0 ohms resistance Rotate the control knob clockwise to make the right bank the service supply Close the gas use valve on the right bank con tainer Verify an ohmmeter reading of infinite resistance as soon as the test gauge pressure drops to the value for the pressure switch setting indicated in the Specification chart in Section 1 B20115 ECN 14800 0911 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 S lo w l y open the gas use valve on one right 67 bank container Verify that the ohmmeter returns to approximately zero 0 ohms resistance 68 Close all cylinder valves and vent all remaining gas from the manifold 69 Remove the ohmmeter leads from the black and 70 brown wires Remove the test gauge from the test fitting and 71 reinstall the test cap Tighten the main supply line union 72 5 open gas use valve on one right bank container 73 Using a leak test solution verify that there are no leaks present at the test cap fitting 74 Close the gas use valve on the right bank container Loosen the uni
52. should be worn to protect the service technician Chips and debris may be propelled into unprotected eyes 3 Remove old sealant from the street tee adaptor Blow out the street tee adaptor with oil free Air or Nitrogen to remove all foreign material and dry all surfaces Apply Teflon tape to the 1 8 NPT male pipe threads on the pressure switch Start the threads of the pressure switch into the street tee adaptor Use a 5 8 open end wrench to stabilize the adaptor while using a 7 8 open end wrench to 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 2 Begin pressurizing the manifold by opening the gas use valve on one container 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 4 Loosen the main supply union slightly to relieve pressure from the manifold while observing the test gauge and ohmmeter to determine switch setting At the actuation pressure the ohmmeter reading will jump from infinite resistance to zero resistance 5 Tighten the union connection to the main supply line 6 Using a flat blade screwdriver turn the knurl adjustm
53. t changing empty cylinders Pressure switch wiring disconnected Pressure switch set at too low a pressure 3 4 REMEDY OR CHECK Check electrical power supply Replace bulb or lamp assembly Check all wiring connections Slowly open valves Adjust pressure switch or return faulty unit for factory setting Set pressure building regulator s Delivery pressure to specifications Replace depleted containers Replace bulb or lamp assembly Check connections Adjust pressure switch or return faulty unit for factory setting Set intermediate regulator delivery pressure to specifications Replace bulb or lamp assembly Check connections Adjust pressure switch or return faulty unit for factory setting Replace depleted containers Check wiring connections Adjust pressure switch or return faulty unit for factory setting B20115 ECN 14800 0911 SYMPTOM RESERVE IN USE SIGNAL Remote alarm signal stays in one mode constantly regardless of change over status Remote alarm signals are opposite of manifold status ABNORMAL LINE PRESSURE SIGNAL Low pressure alarm activated High pressure alarm activated PROBABLE CAUSE Power supply wiring is incorrect Flow demand too high Faulty connection to remote alarm unit Line pressure regulator improperly adjusted Closed gas use valves on containers Empty containers Pressure building regulator s set too low Fault
54. the fitting the procedure outline on page 4 2 shall be followed Using a 7 16 open end wrench reconnect the tubing to the compression fitting 4 7 B20115 ECN 14800 0911 FOUR WAY VALVE REPLACEMENT Removal 1 2 5 Shutdown the manifold and remove cover as explained earlier in this section Mark the compression fittings per the instructions on page 4 2 Disconnect the four tubing assemblies at the compression fittings to the four way valve and at the compression fittings at the other end of the tubing assem blies using an 11 16 open end wrench Remove the tubing assemblies from the control section the two inlet check valve tubing assemblies and the two four way valve outlet tubing sections Use a phillips screwdriver to remove the two screws that secure the four way valve to the support bracket and remove the four 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 an 11 16 open end to remove the two outlet adaptors from the valve for use on the replace ment valve Remove the old sealant from the 1 4 NPT male pipe threads on the compression fittings and adaptors Replacement 1 2 3 Apply Teflon tape to the 1 4 NPT male pipe threads on the compression fittings and adaptors Secure the new four way valve in a vise When retightening the fitting the procedure outlined on page 4 2 shall be followed Install the co
55. ure switch prevents reactuation of the pressure switch after changeover to the Secondary supply The intermediate pressure piping has five ports all connected to the same chamber The gas pressure at all ports is the same as the pressure at the inlet to the piping Gas enters the intermediate pressure piping from the Service supply through the tubing connected at the top right The lower right port is connected via tubing to the intermediate regulator The bypass check valve is connected to the lower left port and is connected via tubing to the secondary side on the four way valve The left port has an adaptor for a test gauge used during manifold testing The left top port connects to the inlet of the line pressure regulator Ed B20115 ECN 14800 0911 LEGEND 1 Outlet Adaptor 9 Bypass Inlet Relief Valve 19 Right Inlet Check Valve 2 Outlet Nut 10 Reserve Side Tubing 20 Four Way Valve 3 Outlet Nipple 11 Left Inlet 19 Intermediate Pressure Piping 4 Line Regulator 12 Left Inlet Check Valve 20 Service Side Check Valve 5 Line Pressure Gauge 13 Low Pressure Switch 21 Right Inlet Tubing 14 Inlet Gauges Tubing 22 Relief Valve Vent Tubing 6 Bypass Check Valve 15 Intermediate Regulator 23 Test Port 7 Left Inlet Relief Valve 16 Reserve Side Check 8 Bypass Check Valve Valve Tubing i FIGURE 2 2 Internal Components 2 2 B20115 ECN 14800 0911 The tubing
56. ushed 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 circuit to the indicators on the front of the control section and to the remote alarm interface terminal strip in the power supply box FIGURE 2 8 Low Pressure Switch FIGURE 2 9 Switch Schematic INTERMEDIATE REGULATOR The intermediate regulator controls the gas flow from the reserve bank to the intermediate pressure piping The intermediate regulator pressure setting is the pressure at which the manifold will switch over from Service to Reserve supply The intermediate regulator has an inlet port connected via tubing to the four way valve The outlet port of the intermediate regulator is connected via tubing to the intermediate pressure piping A Check valve is located immediately downstream of the regulator The regulator is comparable to the line regulator illustrated in Figure 2 11 The regulator seat is held shut by the gas pressure from the Service bank not allowing the check valve immediately downstream of the intermediate regulator to open The gas pressure from the intermediate regulator is pushing against the bottom of the
57. y line pressure gauge Faulty alarm pressure switch Line regulator setting too high Regulator freeze up Faulty line pressure gauge Faulty alarm pressure switch 3 5 REMEDY OR CHECK Check wiring connections on both power supply terminal strips Reduce flow demand Check input from alarm unit to terminal strip Readjust line pressure regulator Slowly open valves Replace with full containers Set delivery pressure to specifications Replace line pressure gauge Readjust or replace pressure switch as necessary Readjust line pressure regulator Reduce the flow demand or increase the number of supply cylinders Replace line pressure gauge Readjust or replace pressure switch as necessary B20115 ECN 14800 0911 SYMPTOM LOSS OF CYLINDER CONTENTS Audible or inaudible gas leakage unknown origin Venting at relief valve PROBABLE CAUSE Leakage at manifold piping connections Leakage at manifold tubing connections Leakage in downstream piping system Leakage at cylinder valve Gauge leaks Regulator leaks Line regulator setting too high Overpressure due to creeping or faulty regulation by pressure building regulator Overpressure due to creeping or faulty regulation by line regulator Regulator freeze up REMEDY OR CHECK Tighten reseal or replace Tighten reseal or replace Repair as necessary Replace cylinder Reseal or replace Repair or repla
Download Pdf Manuals
Related Search