Beacon HP x HP - The Medical Gas
Contents
1. h WHITE 3 EMPTY RED ep RED D EMPTY MV A y G READY d YELLOW CONTROL BOARD WHITE YELLOW D READY gt RED LA n o O O IN USE oreen File O Su EH ereen IN USE ja EE lt 41D i OME LEFT BANK Selga Sas FRONT PANEL LIGHTS 2710 i Sei RIGHT BANK Fag LR FRONT PANEL LIGHTS 50 Ste r VIOLET ag Ss 7 Beg VIOLET PRESSURE SWITCH o o PRESSURE SWITCH BLUE BLUE LEFT SECONDARY SUPPLY SWITCHES BLACK RIGHT SECONDARY SUPPLY BROWN PIN 7 Back RED PIN 3 H GREEN ON 2 M L BLUE PIN 1 WHITE PIN 6 ji BLACK PIN2. Installation Operation and Service Manual Lifeline Medical Systems High Pressure Fully Automatic Manifold e O GQ BescoMmnas Oro ata O mur OXYGEN a 5 Aro oot 999 o e Nu O OT a I eee HP x HP High Pressure x High Pressure Models Y BEACONMEDAS Part No 6 847700 00 Rev G00 Pg 1 Introduction Table of Contents INTRODUCTION Abbreviations nata 2 Definition of StatemMentS eeeemsesnen 3 Product Desenpllon cs aaa aia 3 INSTALLATION PreCauUtiONS ssssssssrssrrsrrenrsnrssrer nanna rann rr rn rn rna 4 Manifold System Components 4 Wall Mounting Instructions 5 Floor Mounting Instructions 10 Main Outlet and Relief Valve Connection 13 Power Supply Installation 14 Remote Alarm Connection 15 Pigtail Installation Cylinder Connection 16 Initial Power Up and Operational Testing 19 Leak Tesi mt daa 22 OPERATION Precautions err a enter OROAR 23 Manifold Specifications oooococc 24 Manifold Components 25 Gas Flow
3. G00 Intermediate Relief Valve The intermediate relief valve protects the components between the bank regulators and the line regulators in the event of an overpressure condition caused by bank regulator failure The outlet of the relief valve is piped to a common relief valve port on top of the manifold Line Regulator Isolation Valve Quarter turn ball valves are provided upstream and downstream of each line regulator These valves allow for removal and servicing of one line regulator while other is in use All four isolation valves are normally in open position Line Regulator A single stage diaphragm type regulator used to reduce manifold s intermediate pressure to normal hospital line pressure Two line regulators are provided per NFPA 99 requirements to allow for isolation and service of one while other is in use Line Relief Valve A relief valve to prevent over pressurization of the hospital piping system by failure of a line regulator Outlet of relief valve is piped to a common relief valve port on top of manifold Dome Regulator A single stage diaphragm type relieving regulator used to limit amount of pressure provided to domes of bank regulator Used only on nitrogen manifolds and manifolds with 100 PSI delivery pressures Solenoid Valve A 24 VDC solenoid assembly used to direct dome bias pressure to one of the bank regulators As dome bias pressure is directed to one of bank regulator dome of other bank regulator
4. by others Reposition assembly over holes and install mounting hardware by others Tighten all mounting bolts Attach 12 inch channel to top of one vertical channel as shown in Figure 9 Detail D 12 inch channel is used to mount power supply and may be located on either side of manifold control panel Use flat plate four each 3 8 bolts flat washers and channel nuts Unlike other hardware shown in Figure 9 3 8 bolts will pass through elongated holes in back of channel and will be secured with channel nuts inside Tighten all four bolts 9 Hang manifold control panel on mounting bracket Top two control panel mounting bolts will slide into the slots of bracket Bottom of control panel should be angled away from bracket until top two bolts have been inserted as shown in Figure 3 Bottom of manifold control panel can then be positioned toward bracket so 3 8 mounting stud passes through lower hole in mounting bracket Install and tighten 3 8 nut removed in step 2 A CAUTION Do not use thread sealant on header or pigtail connections 10 For manifolds with more than three cylinders per bank additional shipping cartons contain extension headers and header wall brackets Depending on the number of cylinders header extensions are configured with two or three cylinder inlets Large manifold systems may also include combinations and multiples of each type of header extension Remove large union nut and plug
5. in Figure 19 Lightly tighten two hinge screws Close service valve Using control board switches cycle manifold from bank to bank to vent residual dome bias pressure Ww N NOTE Some early production manifolds that incorporate a dome regulator do not have a dome bias shut off valve To shut off dome bias pressure on these units set dome regulator to its minimum setting NOTE By closing service valve if equipped manifold s outlet pressure gauge is also isolated Cycling manifold to vent residual dome bias pressure will also vent pressure shown on manifold s outlet pressure gauge Actual outlet pressure supplied by manifold is not affected by following procedure 4 Using 1 4 Allen wrench remove pipe plug from dome of bank regulator s to be adjusted 5 Shut off all cylinders on both banks of manifold 6 Open vent valve to vent all pressure from manifold 7 Close vent valve and slowly open one cylinder on side of manifold that needs adjustment For example if right bank regulator needs adjustment open one cylinder on right side of manifold 8 Slightly open vent valve to create a small flow of gas through manifold 9 Using 1 4 Allen wrench set bank regulator to the value specified in Table 1 Intermediate Pressure Ready Bank 10 Close vent valve and cylinder 11 If other bank regulator also needs to be adjusted repeat steps 6 through 10 12 Apply Teflon tape and reinstall pipe
6. 1 BOLT Ne to support one 2 2 EB A cylinder or 3 cylinder header segment on each 66 CHANNEL side of the x 2 manifold K Part No 6 847700 00 Rev G00 Figure 8 Installation Floor Mounting Instructions cont 1 Remove manifold control panel from shipping carton and place face down on foam packaging insert Mounting bracket is shipped attached to back of manifold control panel Remove lower 3 8 mounting nut as shown in Figure 1 Pull bottom of bracket away from manifold control panel and slide bracket off two upper control panel mounting bolts Only bracket will be needed at this time Set manifold control panel aside for installation later NOTE Return control panel to shipping carton if necessary to protect it and keep it clean Attach post base to one end of each 80 inch channel as shown in Figure 9 Detail A Use two each 3 8 bolts flat washers and channel nuts per base Tighten all four bolts Stand each channel base side by side Attach manifold mounting bracket to both bases as shown in Figure 9 Detail C Use four each 3 8 bolts flat washers and channel nuts per base Top of bracket should be level and positioned 79 3 4 above floor Tighten all four bolts Position entire assembly in desired manifold mounting location Mark location of eight base mounting holes Move assembly aside and drill holes Minimum 3 8 diameter mounting bolts are recommended
7. 5 U D 6 POWER SUPPLY SOLENOID VALVE J BOTTOM CABINET z POWER SUPPLY Es 5 CONNECTOR i FREE 123456 O pa 99909 BLACK PIN 5 WHITE PIN 6 EGO AC INPUT POWER BLUE PIN 1 GREEN PIN 2 Figure 26 44 Part No 6 847700 00 Rev G00 Illustrated Parts List Control Panel Components Item Part No Description ltem Part No Description 1 6 231940 00 Control Board Assembly 15 6 611645 01 Nylon Tube 8 5 2 6 867268 GR Panel Mount LED Green 16 6 611645 01 Nylon Tube 25 3 6 867268 YW Panel Mount LED Yellow 17 6 290830 00 Wire Harness Assembly Control 4 6 867268 RD Panel Mount LED Red Cabinet 5 6 130117 00 Bank Pressure Gauge 3000 PSI ar 6 6 130115 00 Line Pressure Gauge 100 PSI Tubing sold p r foot 6 130116 00 Line Pressure Gauge 300 PSI 7 6 515601 00 Female Connector 1 8 Tube x 1 4 NPT 8 6 513011 00 Reducing Coupler 1 8 NPT x 1 4 NPT 9 6 515602 00 Male Connector 1 8 Tube x 1 8 NPT 10 6 355003 00 1 8 Copper Tube 11 6 611645 01 Nylon Tube 22 12 6 645025 00 Muffler 13 6 103805 00 Solenoid Valve gt Denotes connections to other illustrated 14 6 515600 00 Fitting 1 8 Tube x 10 32 UNF parts lists Part No 6 847700 00 Rev G00 45 Illustrated Parts List Bank Regulator Components e Ite Part No 18 6 355010 UB 19 6 515629 00 20 6 515605 00 21 6 120005 00 22 6 868006 00 6 868007 00 23 6 122010 00 6 122011 00 24 6 130118 00 25 6 230763 50 26 6 515631 00 27
8. Kit 3 4 Ball Valve not shown Tubing sold per foot Denotes connections to other illustrated parts lists 48 Part No 6 847700 00 Rev G00 Illustrated Parts List Relief Vent Components Ite 41 42 43 44 45 46 47 48 Part No Description 6 616590 00 Male Elbow 3 8 Tube x 3 8 NPT 6 616592 00 Union Tee 3 8 Tube 6 611645 03 3 8 Nylon Tube 8 5 6 611645 03 3 8 Nylon Tube 3 6 611645 03 3 8 Nylon Tube 6 6 616591 00 Union Elbow 3 8 Tube 6 611645 03 3 8 Nylon Tube 5 5 6 622611 00 O Ring Relief Valve Outlet Zero Clearance Fitting Tubing sold per foot 7 Denotes connections to other illustrated parts lists Part No 6 847700 00 Rev G00 gJ Illustrated Parts List Cabinet Cover Components A E Je A E e a a 2 2D S Pl PA aa ail ae a A Item Part No Description 49 6 838153 00 Manifold Cover Draw Latch includes item 51 50 6 616505 00 Front Cover Window El Part No 6 847700 00 Rev G00 Illustrated Parts List Cabinet Base Plate Components SS Item Part No Description 51 6 838153 00 Manifold Base Latch Includes item 49 Part No 6 847700 00 Rev G00 El Illustrated Parts List Header Components AT lt 4 RE SS WALK A a O Denotes connections to other illustrated parts lists Item Pa
9. No 6 847700 00 Rev G00 Ay WARNING All pigtail assemblies are shipped in sealed bags and are cleaned as if for oxygen use Manifold header connections are clean and capped Do not unpackage or remove any cap until ready to install During installation use care to maintain cleanliness Ay WARNING e Do not repeatedly bend sharply bend or twist copper pigtails as damage to tubing may occur e Do not bend flexible pigtails into a radius smaller than 3 e Always secure cylinders with racks straps or chains Unrestrained cylinders may fall over and damage or break off cylinder valve A CAUTION Do not use thread sealant on header or pigtail connections A CAUTION Prior to connecting pigtail to cylinder slightly open and close each cylinder valve to blow out dirt and debris NOTE Both ends of flexible pigtails are the same Either end may be connected to manifold header Rigid copper pigtails on oxygen and helium manifolds are pre formed and must be connected as shown in Figure 12 Installation Pigtail Installation Cylinder Connection Cont 24 Pigtail 24 Pigtails Figure 11 Part No 6 847700 00 Rev G00 Installation Pigtail I
10. Through The Manifold 30 Manifold Switch OVvel ccccsccsscseeesrees 31 TESTING AND ADJUSTMENTS Performance Verification eemreersrens 32 Bank Regulator Pressure Adjustment 34 Line Regulator Pressure Adjustment 36 Pressure Switch Adjustment 37 SERVICE PROCEDURES PrecautiONS caricias 38 Routine Maintenance 38 Techniques For Leak Tight Connections 39 Pressure Switch Replacement 40 Bank Regulator Replacement 41 Line Regulator Replacement 42 Control Board Replacement 43 Wiring DiaQraMsssnrsrssrsrrsrsrsrrsrrnrserrern narr n nn rann 44 A Part No 6 847700 00 Rev G00 ILLUSTRATED PARTS LISTS Control Panel COMPONENtS i rerrenn 45 Bank Regulator Componenkts 46 Line Regulator Component 0 0 08 47 Outlet Dome Regulator Components 48 Relief Vent Component eeeeeee 49 Cabinet Cover Component eee 50 Cabinet Base Plate Components 51 Header Components mexica 52 A ate ine a 54 Replacement Pigtail O Rings Washers 54 Manifold Stand Sais a 54 Manifold Accessories 54 Power Supply Component es0en 55 WARRANTY a dei 56 This manual provides information related to the installation and operation of the Lifeline High Pressure ma
11. bank red Empty light goes out Left bank yellow Ready light illuminates e Right bank green In Use light illuminates e Left bank cylinder contents gauge reads e Right bank cylinder contents gauge reads cylinder pressure cylinder pressure e If connected to a master alarm panel 6 Slowly open one cylinder on left side of 3 4 Source Shut Off Vave fan Vent Valve Line Regulator Isolation Valves Line Regulator Isolation Valve 2 E OM BracosMeoes K O OXYGEN o o O O Power Supply Master Valve o Connector Figure 14 20 Part No 6 847700 00 Rev G00 Installation Initial Power Up and Operational Testing Cont Secondary Supply alarm is not activated 8 Close right bank cylinder Slightly open vent valve Figure 14 Verify the following e Right bank cylinder contents gauge drops slowly e As right cylinder contents gauge is nearly depleted manifol
12. channel as shown in Figure 9 Detail B Use two each 3 8 bolts flat washers and channel nuts Tighten all bolts 13 Align header stand with two control panel vertical stands centering the header bracket between two pigtail connections Mark locations of all four base mounting holes Move header stand aside and drill holes Minimum 3 8 diameter mounting bolts are recommended by others 14 Reposition header stand over holes and install mounting hardware by others Tighten all mounting bolts 15 Assemble u bolt and bracket hardware as shown in Figure 6 Tighten u bolt nuts 16 Additional header extensions may be attached end to end if required 17 Install large nut and plug removed in step 10 on end of last header extension Tighten large nut Main Outlet and Relief Valve Connection Manifold s main outlet and relief valve outlet are supplied with zero clearance o ring sealed unions Main outlet connection is 3 4 FNPT and relief valve is 1 2 FNPT A 3 4 source shut off valve is also supplied with manifold control panel Inlet side of source shut off valve is 3 4 MNPT for connection directly to main outlet union Outlet side is a 3 4 nominal copper A plugged 1 8 FNPT port is provided on outlet side of valve and may be removed to aid in purging A CAUTION Close 3 4 source shut off valve to prevent debris from falling into manifold during brazing procedure A CAUTION To prevent damage to internal
13. is vented through solenoid valve Operation Manifold Components Cont Front Panel Indicators Six front panel indicators monitor the status of the manifold The indicators are 24 VDC LED Light Emitting Diode type Control Board An electronic circuit board that controls manifold switchover The control board monitors the pressure switches and controls the solenoid valve in order to initiate manifold switchover The control board illuminates the appropriate front panel indicators and also provides dry contacts for activation of the external master alarms Power to the control board is provided by the external power supply Power Supply Not Shown An external NEMA 3R rated enclosure contains a 120 VAC to 24 VAC transformer The 24 VAC is routed to the manifold control board via a detachable six conductor cable and connector An in line 0 25 amp slow blow fuse is provided in 120 VAC power line Terminal blocks inside power supply allow for connection of AC input power and master alarm panel normally closed dry contact outputs Refer to Figure 10 for power supply wiring NOTE Some components not shown for clarity Control Board Solenoid Valve Front Panel Indicators Left Bank Pressure Gaug Line Pressure Gauge Right Bank Pressure Gauge Figure 15 Part No 6 847700 00 Rev G00 Operation Manifold Components Cont NOTE Some components not shown for clarity Service Valve Dom
14. no event shall BeaconMedees be liable for damages in excess of the value of the defective product nor shall BeaconMedees be liable for any direct special or consequential damages loss of profit of any kind or for loss of use of the products LifeLine Medical Air Systems LifeLine Bare Compressors Compressor Head valves Compressor Rings and Bearings Standard Warranty Periods From Shipment 30 months 36 months 24 months 30 months 12 000 operating hours or 4 years 8 000 operating hours or 3 years From Startup Limitation Bare Compressor as below Normal consumables warranted as below LifeLine Desiccant Dryer Systems 30 months 24 months The 441 Valve in all LifeLine dryers is warranted for 10 Ten Years LifeLine Lubricated Vane Vacuum 30 months 24 months LifeLine Oilless Vane Vacuum 30 months 24 months Vane Life varies with horsepower Vane Replacement may be required within this interval Refer to manual for detail LifeLine Liquid Ring Vacuum 30 months 24 months LifeLine Dynamic Vacuum 30 months 24 months Lifeline Claw standard lubricant 30 months 24 months Lifeline Claw 02 Assured 30 months 24 months Pipeline products 30 months 24 months Part No 6 847700 00 Rev G00 Pg 56 Y BEACONMEDAS 2007 BeaconMedees All rights reserved For technical support or to place an order call 1 888 4 MEDGAS 1 888 463 3427 Fax 866 635 3296 www beaconmedaes com Corporate Headquarters BeaconMe
15. or screens when removing and reinstalling pressure switch 8 Apply Teflon tape to threads of new switch and install into bank regulator body Tighten switch so switch adjustment opening is facing outward 9 Route switch wires and attach them to appropriate control board terminals Secure wires with cable ties 40 Part No 6 847700 00 Rev G00 10 Loosen front panel hinge screws and return front panel to upright position Reinstall two front panel screws and tighten hinge screws 11 Tighten compression nut on back of front panel bank pressure gauge 12 S l o w l y open each cylinder on side of manifold where pressure switch was replaced 13 Reconnect power supply connector to bottom of manifold cabinet 14 Verify new switch is set correctly by performing appropriate steps of Performance Verification procedure Service Procedures Bank Regulator Replacement Following procedure describes process of replacing bank regulator If necessary bank regulator replacement can be performed while manifold is in service However this should only be done by qualified technicians experienced in servicing medical equipment Internal repair of bank regulator is not recommended 1 Remove two front panel screws A Figure 18 Loosen two hinge screws B Figure 18 Fold front panel down to service position as shown in Figure 19 Lightly tighten two hinge screws 2 Close all cylinders on side of manifold where bank regulator w
16. or placed in service by an authorized representative of BeaconMedees which includes the completion and forwarding to BeaconMedees of an appropriate start up checklist 2 certified in accordance with NFPA 99 most recent edition by a properly qualified verification agency and 3 maintained in strict accordance with Operation and Maintenance instructions provided with the product Warranty claims will be honored only after examination by BeaconMedes and only when such examination shall disclose to BeaconMedees reasonable satisfaction that such equipment has not been damaged in shipment or installation improperly installed operated outside of any published operating limits including but not limited to temperature pressure humidity or ventilation improperly or inadequately maintained field modified in any way improperly repaired or in any other way improperly applied or used All claims against this warranty require prompt notification within the warranty period of any seeming defect Failure to promptly notify BeaconMedees of the seeming defect will invalidate all warranties This warranty excludes damage or defect caused by shipping acts of God fire war labor difficulties action of government or other cause beyond the reasonable control of BeaconMedees This warranty is given in lieu of all other warranties expressed or implied including implied warranties of fitness for a particular purpose and merchantability In
17. plug in dome of bank regulator s 13 Loosen front panel hinge screws and return front panel to its upright position Reinstall two front panel screws and tighten hinge screws 14 Slowly open all cylinders on both manifold banks 15 Open service valve or reset dome regulator to 40 45 PSI NOTE Dome regulator s red locking ring must be pulled out away from regulator body before adjustment knob can be turned After adjustment push locking ring inward to lock knob Since dome regulator is self relieving it is recommended dome regulator always be increased to desired pressure For example if dome regulator pressure is too high first lower pressure to approximately 30 PSI Then raise pressure to between 40 45 PSI E Part No 6 847700 00 Rev G00 Testing and Adjustments Figure 18 Some components not shown for clarity Switches Figure 19 Part No 6 847700 00 Rev G00 Testing and Adjustments Line Regulator Pressure Adjustment Following procedure describes process of setting line regulator pressure This procedure should only need to be performed if line regulator pressures were not within acceptable limits during Performance Verification procedure or after installation of a new line pressure regulator When shipped from factory inlet and outlet isolation valves to both line regulators are in open position Refer to Figure 16 for location of c
18. setting Counterclockwise rotation will lower switch setting Make small adjustments and retest as follows 8 Slowly open one cylinder on bank of manifold just tested 9 Using circuit board switches switch manifold back to bank just tested 10 Repeat steps 3 through 9 until pressure switch es have been set within acceptable limits 11 Slide pressure switch collar back to original position Adjustment Barrel ely SA sc S Figure 20 Collar Part No 6 847700 00 Rev G00 Precautions A WARNING Routine Maintenance Daily Tampering with gas specific connections shall be prohibited Do not alter remove or modify gas specific connections Keep all 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 Use only proper repair tools and parts Use only approved repair parts provided by BeaconMedees Do not use chemicals lubricants or sealants unless specified in these instructions Before connecting cylinder to manifold momentarily open and close cylinder valve to blow out dirt and debris After connecting cylinder to manifold open cylinder s l o w l y to allow heat of compression to dissipate Do not use flame or sniff test for leaks Do not apply heat to any part of manifold system Always secure cylinders with racks straps or chains Unrestrained cylinders may
19. 15 16 and 17 Master Valve Multi turn high pressure valves allow flow from cylinders to be shut off Master valves use metallic seating surfaces Both master valves should always be turned to fully open maximum counterclockwise position Bank Regulator A dome loaded single stage diaphragm type regulator Used to reduce incoming cylinder contents pressure to a lower intermediate pressure Bank regulator one for each bank of cylinders has an internal adjusting spring used to set a base pressure of approximately 70 PSI 210 PSI on nitrogen manifolds Dome i e bonnet or bell of regulator is a pressure tight chamber When pressure is applied to dome amount of force applied is added to force of adjusting spring For example when 55 PSI of pressure is applied to dome 70 PSI base pressure setting is raised to approximately 125 PSI Pressure Switch An adjustable single pole normally open pressure switch A pressure switch is connected to high pressure port of each bank regulator in order to monitor pressure in each bank of cylinders When adequate cylinder pressure is applied switch contacts are held closed When cylinder pressure drops to switch setting of 150 PSI 300 PSI for nitrogen manifolds switch contacts will open Check Valve Soft seal check valves are provided downstream of each bank regulator to allow service of upstream components while the other side of the manifold is in use 26 Part No 6 847700 00 Rev
20. 18 If there is a noticeable pressure change on either gauge perform leak testing described in the next section 21 Reinstall manifold control panel cover 22 Slowly open all cylinders on both banks of manifold 23 Open 3 4 source shut off valve Part No 6 847700 00 Rev G00 BJ Installation Leak Testing The following leak testing is recommended if a leak is observed during the previous Initial Power Up and Operational Testing procedure If a noticeable drop in either pressure gauge reading was not detected this leak testing is not required da wm N Release two latches on sides of manifold control panel cover one on each side Remove cover as shown in Figure 13 Close 3 4 source shut off valve Verify isolation valves on outlets of line regulators are open Slowly open one cylinder on left and right bank of manifold Close two internal isolation valves on inlets of line regulators Refer to Figure 12 for component location Close left and right side cylinders Record pressure readings of left and right bank cylinder contents gauges and line pressure gauge Wait 15 minutes Compare current readings of all three gauges to those recorded in step 6 10 A loss of pressure on line pressure gauge 1 x indicates a leak downstream of line regulator inlet isolation valves A loss of pressure on left or right cylinder contents gauges indicate a leak in components upstream of
21. 2 and O2 He CGA 280 CO2 02 and He O2 CGA 500 Wall Mount Cylinder Bracket not shown Single Double 90 Street Elbow 3 4 NPT not shown Note 90 Elbow used between zero clearance fitting and source valve to redirect direction due to low ceiling height 6804 2000 001 0204 6668 300 0204 6669 300 0204 6661 300 0204 6662 300 0204 6663 300 0204 6664 300 6 290641 01 6 290641 04 6 515725 00 Illustrated Parts List Power Supply Components Item Part No Description 67 6 231985 HP Power Supply Circuit Board 120 VAC 6 231984 HP Power Supply Circuit Board 240 VAC 68 6 865549 00 1 4 Amp Fuse 5 x 20 mm GMD 250mA 6 865542 00 1 8 Amp Fuse 5 x 20 mm GMD 125mA 69 6 865100 00 Strain Relief 70 6 290831 00 Wire Harness Assembly Power Supply Part No 6 847700 00 Rev G00 E BeaconMedes warrants the equipment it manufactures to be free of defect in materials or workmanship when installed and operated in accordance with instructions for the following periods All of the periods commence upon shipment or at start up whichever period terminates earlier This warranty covers all necessary parts and labor required for correction of the defect whether by any or all of repair replacement or credit which election shall be made by BeaconMedees at it s sole discretion This warranty requires the owner to ensure that the equipment is 1 started up
22. 6 136002 10 Oxygen CGA 540 6 136002 11 Nitrous Oxide CGA 326 6 136002 12 Medical Air CGA 346 6 136002 14 Nitrogen CGA 580 6 136002 16 Air International CGA 346 6 136002 18 Instrument Air CGA 346 6 136002 20 CO2 CGA 320 6 136002 21 CO2 02 CGA 500 6 136002 22 O2 CO2 CGA 280 6 136003 23 He O2 CGA 500 6 136003 24 O2 He CGA 280 6 136002 25 Helium CGA 580 6 136002 26 Argon CGA 580 O Denotes connections to other illustrated parts lists Lifeline Manifolds manufactured after October 2006 use check valves with 3 8 NPT connections on header segments Note hexagonal block sections where check spuds thread into header segments Replacement Check Valve Spud x 3 8 NPT Part numbers shown below Item Part No Description 60 Check Valve Spud x 3 8 NPT 6 511619 10 Oxygen CGA 540 6 511619 11 Nitrous Oxide CGA 326 6 511619 12 Medical Air Instrument Air CGA 346 6 511619 14 Nitrogen Argon or Helium CGA 580 6 511619 20 CO2 CGA 320 6 511619 21 CO2 02 or He O2 CGA 500 6 511619 22 O2 CO2 or O2 He CGA 280 Part No 6 847700 00 Rev G00 Illustrated Parts List Header Components Cont Ite Part No Description 61 Header Extension 6 136000 10 10 Length 6 136000 12 12 Length 6 136000 16 16 Length 62 Header Elbow 90 6 290657 01 3 3 4 Length 2 3 Part No Description 63 24 Flexible Pigtail Assembly 6 290811 24 Nitrous Oxide CGA 326 6 290812 24 Medical Air o
23. 6 230772 00 PA Cee Description Copper U Tube 5 8 OD Male Elbow 1 8 Tube x 1 4 NPT Male Connector 1 8 Tube x 1 4 NPT Master Valve Pressure Switch Preset at 150 PSI Pressure Switch Preset at 300 PSI Bank Regulator all gases except N20 8 CO2 Bank Regulator N20 amp CO2 only Bank Regulator Pressure Gauge 300 PSI Intermediate Relief Vale 350 PSI Male Elbow 5 8 Tube x 1 2 NPT Check Valve 1 2 NPT 46 Part No 6 847700 00 Rev G00 Denotes connections to other illustrated parts lists Illustrated Parts List Line Regulator Components Item Part No Description 28 6 622610 00 O Ring Line Regulator Ball Valve 29 6 230783 00 Ball Valve 1 2 NPT 30 6 122012 00 Line Regulator O Denotes connections to other illustrated parts lists Part No 6 847700 00 Rev G00 Illustrated Parts List Outlet Dome Regulator Components Item Part No Description C 31 6 515602 00 Male Connector 1 8 Tube x 1 8 NPT 32 6 130119 00 Dome Pressure Gauge 60 PSI 33 6 122013 00 Dome Pressure Regulator 34 6 515632 00 Male Elbow 1 8 Tube x 1 8 NPT 35 6 611645 01 1 8 Nylon Tube 5 5 36 6 230760 75 Line Relief Valve 75 PSI 6 230761 50 Line Relief Valve 150 PSI ps 6 230762 50 Line Relief Valve 250 PSI 37 6 515641 00 Male Run Tee 1 8 Tube x 1 8 NPT 38 6 230194 03 Ball Valve 1 8 NPT 39 6 622611 00 O Ring Main Outlet Zero Clearance Fitting 40 6 230784 00 3 4 Ball Valve 40a 6 290566 00 Repair
24. Y light illuminates 25 Open two right side line regulator isolation valves 26 Close left and right side cylinders 27 Record pressure readings of left and right bank cylinder contents gauges 28 Verify after 15 minutes pressure gauge readings have not changed 29 Slowly open all cylinders on both banks of manifold 30 Using circuit board switches switch manifold to bank of cylinders with least pressure 31 Reinstall manifold control panel cover 32 Open 3 4 source shut off valve Part No 6 847700 00 Rev G00 ES Testing and Adjustments Bank Regulator Pressure Adjustment Following procedure describes process of setting bank regulator s base pressure This procedure should only need to be performed if bank regulator pressures were not within acceptable limits during performance verification procedure or after installation of a new bank pressure regulator Base pressure setting is a mechanical adjustment controlled by regulator s internal adjusting spring and is regulator s output pressure without any dome bias Recommended settings are listed in Table 1 under heading of Intermediate Pressure Ready Bank After base pressure has been set pressure will be increased by amount of dome bias pressure applied Refer to Figure 16 for location of components called out in this procedure 1 Remove two front panel screws A Figure 18 Loosen two hinge screws B Figure 18 Fold front panel down to service position as shown
25. arm wiring 120 VAC current draw will be less than 100 milliamperes Primary of 24 VAC transformer contains a 0 25 Amp time delay fuse Fuse type is 5 x 20 mm GMD 250mA 240 VAC models use 0 125 Amp time delay type 5 x 20 mm GMD 125mA 114 Part No 6 847700 00 Rev G00 Remote Alarm Connection Two sets of dry normally closed alarm contacts are available inside power supply assembly for connection to a remote alarm or building automation system Both sets of contacts are independent of each other and will be closed whenever manifold is powered and operating normally no alarm condition Each set of contacts will open if an alarm condition occurs manifold changeover or if power is removed from manifold Alarm contacts are rated for 2 A 30 VDC 0 6 A 110 VDC 0 6 A 125 VAC Refer to Figure 10 for power supply connections Installation Power Supply Wiring Two Sets of Dry Normally Closed Remote Alarm Contacts Alarm 1 Alarm 2 Connects to bottom of manifold control panel Bottom View x g Three 1 2 conduit knockouts for AC power input and alarm output field wiring Figure 10 Part No 6 847700 00 Rev G00 115 Installation Pigtail Installation Cylinder Connection All manifolds other than oxygen and helium utilize 24 length flexible stainless steel braided pigtails All cylinders on the right ban
26. ator If necessary line regulator replacement can be performed while manifold is in service However this should only be done by qualified technicians experienced in servicing medical equipment Internal repair of line regulator is not recommended NOTE Refer to Techniques For Leak Tight Fittings for recommendations concerning removal and reassembly of fittings 1 Close two isolation valves on inlet and outlet of line regulator to be replaced 2 Loosen union nuts on two closed isolation valves 3 Remove two line regulator bracket mounting nuts 4 Remove line regulator and bracket from manifold 5 Noting regulator bracket alignment remove regulator bracket from old regulator 6 Install regulator bracket on new regulator Align bracket as noted above NOTE Unused pressure ports in new line regulator body will be shipped with pipe plugs 7 Noting orientation of fittings remove fittings from old regulator 8 Install fittings on new regulator Verify correct orientation of fittings 9 Inspect o ring removed from each isolation valve union If damaged replace o ring 10 Insert o ring into each isolation valve and attach new regulator and bracket to manifold s base plate Hand tighten mounting nuts 11 Tighten two isolation valve union nuts 12 Tighten line regulator bracket mounting nuts Service Procedures Line Regulator Replacement Cont 13 Open line regulator isolation valves a
27. bias pressure Variations from the 55 PSI delivery pressure will affect the intermediate pressure reading Same as delivery pressure Parameter Intermediate Pressure Ready Bank Dome Bias Pressure Intermediate Pressure In Use Bank Intermediate Relief Valve Line Regulator Relief Valve Pressure Switch Setting on pressure drop Maximum Inlet Pressure Table 1 Part No 6 847700 00 Rev G00 23 Operation Manifold Specifications Cont Flow Characteristics at 150 psig Inlet with 55 psig Delivery Delivery Pressure psig Q py 10 0 r i r r r r r r r r r r r r 0 6 9 11 13 15 18 20 23 26 29 32 37 41 44 48 52 5 Delivery Flow scfm Flow Characteristics at 300 psig Inlet with 100 psig Delivery 110 100 90 80 3 2 70 2 3 60 n 2 a 50 gt o 2 5 40 a 30 20 10 0 T T T y y T T T T r r r r r r 0 8 10 12 14 16 18 20 24 28 32 37 43 50 59 67 74 76 Delivery Flow scfm En Part No 6 847700 00 Rev G00 Operation Manifold Specifications Cont Flow Characteristics at 300 psig Inlet with 180 psig Delivery 200 180 o S D o N Delivery Pressure psig amp 3 o o 0 y y y y y y y y y 0 16 24 34 44 53 63 76 90 102 110 Delivery Flow scfm Part No 6 847700 00 Rev G00 25 Manifold Components Refer to Figures
28. brand A Lok fittings are a type of compression fitting Mark nut and fitting prior to disassembly Before retightening make sure assembly has been inserted into fitting until ferrule seats in fitting Retighten nut by hand Torque nut with wrench until marks line up which indicates that fitting has been tightened to its original position A noticeable increase in mechanical resistance will be felt indicating ferrule is being resprung into sealing position Then tighten nut 1 12 of a turn 1 2 of a wrench flat past original position If tightening a fitting for first time make sure tube has been inserted completely into fitting and tighten nut by hand Wrench tighten nut an additional 1 1 4 turns Parker brand Prestolock fittings are used throughout manifold to attach each end of black nylon tubes To release tube from fitting press fitting s release button against body while pulling tube out If you experience difficulty open a Crescent wrench so that it just slides over outside of nylon tube Push side of Crescent wrench against fitting s release button while pulling out on tube Verify end of tube is cut square and free of burrs and debris Insert tube into fitting until it bottoms Pull on tubing to verify it is properly retained in fitting Q ring face seal fittings are used on main outlet and relief valve vent outlet unions and four line regulator isolation valve unions Leaks at these connections can be caused by damaged o ri
29. d changes over to left bank e After change over right bank green In Use light goes out and red Empty light illuminates e After change over left bank yellow Ready light goes out and the green In Use light illuminates 9 Close vent valve 10 Verify Line Pressure gauge reading is acceptable 11 Slowly open one cylinder on right side of manifold 12 Verify the following e Right bank red Empty light goes out e Right bank yellow Ready light illuminates e Right bank cylinder contents gauge reads cylinder pressure 13 Close left bank cylinder Slightly open vent valve Verify the following e Left bank cylinder contents gauge drops slowly e As left cylinder contents gauge is nearly depleted manifold changes over to right bank e After change over left bank green In Use light goes out and red Empty light illuminates e After change over right bank yellow Ready light goes out and green In Use light illuminates 14 Close vent valve 15 Slowly open one cylinder on left side of manifold 16 Verify the following Left bank red Empty light goes out e Left bank yellow Ready light illuminates Left bank cylinder contents gauge reads cylinder pressure 17 Close left and right side cylinders 18 Record pressure readings of left and right bank cylinder contents gauges 19 Wait 15 minutes 20 Compare current readings of left and right bank cylinder contents gauges to those recorded in step
30. daes 1800 Overview Dr Rock Hill SC 29730 Phone 803 817 5600 Fax 803 817 5750
31. e Regulator Line Regulator Isolation Valve Line Regulator Line Regulator Isolation Valve Check Valve Left Bank Regulator Pressure Switch Master Valve Figure 16 28 Part No 6 847700 00 Rev G00 1 8 27 NPT Port 3 4 Source Shut off Valve Relief Vent Outlet Line Relief Valve Vent Valve Line Regulator Isolation Valve Line Regulator Line Regulator Isolation Valve Check Valve Intermediate Relief Valve Right Bank Regulator Pressure Switch Master Valve oca Operation Manifold Components Cont Manifold Relief Valve Outlet Outlet Not used in manifolds ran l designed for 55 psi nominal Line Pressure delivery pressure l G gt ed Service Vent C l N lan lt Valve Valve 0 SKH DK T Dome l Regulator ji A E E M Line Relief Valve Valve Valve Line Line Regulator J Regulator Valve Valve Vent Vent pk al 5 Intermediate T Relief Valve Solenoid Valve Check Check Valve Valve Nn N N A NX Bank Bank Regulator Regulator Master Master Valve Valve Left Bank Right Bank Inlet Dx Eo up HP we X Inlet _ ix Gauge Gauge lt Pressure Pressure Switch Switch Manifold Cabinet Lifeline HP Manifold Piping Diagram Figure 17 Part No 6 847700 00 Rev G00 EJ Operation Gas Flow Through the Manifold Refe
32. e protects components between bank and line regulators in the event of a bank regulator seat failure Dual line regulator assembly consists of two E Part No 6 847700 00 Rev G00 line regulators plumbed in parallel with upstream and downstream isolation 1 4 turn ball valves Output of both line regulators tee together and exit at manifold s main outlet A line relief valve and line pressure gauge are connected to manifold s main outlet Outlet pressure is routed to a dome regulator reducing pressure to 40 PSI at solenoid valve Solenoid valve switches 40 PSI dome bias pressure to one of the bank regulators When one bank regulator is supplied bias pressure the other bank regulator s dome is vented to atmosphere An electronic circuit board controls solenoid valve based upon input from right and left pressure switches Solenoid valve directs bias pressure to bank designated as primary Manifolds designed for 55 PSI nominal output pressure do not incorporate a dome regulator Full line pressure 55 PSI is routed directly to solenoid valve and is used as dome bias Manifold Switch Over I After electrical power has been applied to manifold side pressurized first is designated primary or In Use bank In order to simplify the following explanation we will arbitrarily select right side of manifold as primary bank Green In Use light on right side is illuminated Yellow Ready light is illuminated on left secondary bank S
33. ed only by base pressure 70 PSI All flow is supplied by left bank of cylinders until pressure in left bank drops to left pressure switch setting 150 PSI Left pressure switch then opens causing switchover to right side in same fashion as previously described In the event of a power failure unpowered solenoid valve will direct dome bias pressure to left bank regulator A switchover alarm will be activated on master alarm panels All flow will be supplied by left bank of cylinders until depleted Right bank of cylinders will then automatically begin to supply flow Part No 6 847700 00 Rev G00 El Testing and Adjustments Performance Verification Use following test steps to verify manifold s functional performance Remove manifold cover Before beginning test verify following Both left and right side master valves are turned to full counterclockwise open position Cylinders are attached to both sides of manifold and left and right bank pressure gauges indicate at least 1800 PSI at least 600 PSI for Nitrous Oxide or Carbon Dioxide e Power is applied to manifold e N WARNING If necessary most service adjustment and testing can be performed while manifold is in service However this should only be done by qualified technicians experienced in servicing medical equipment Servicing and testing manifold while not in use with 3 4 source shut off valve closed is preferred Following test proc
34. edure assumes manifold is not in service 8 If manifold is equipped with a dome regulator verify dome regulator s gauge reads 40 45 PSI If manifold does not have a dome regulator proceed to next step NOTE The dome regulator s red locking ring must be pulled out away from the regulator body before adjustment knob can be turned After adjustment push locking ring inward to lock knob Since dome regulator is self relieving it is recommended that dome regulator always be increased to the desired pressure For example if dome regulator pressure is too high first lower pressure to approximately 30 PSI Then raise pressure to between 40 45 PSI 3 If manifold is not in use close 3 4 source shut off valve 4 Verify two right side line regulator isolation valves are open and two left side line regulator isolation valves are closed 5 Asa starting point for this procedure set manifold so right bank is in use If right bank green light is illuminated proceed to next step If left bank green light is illuminated manually switch manifold to right side by pressing left switch on control board 6 Verify only right bank green IN USE and left bank yellow READY lights are illuminated 7 If manifold is connected to a master alarm panel verify manifold switchover alarm is not activated El Part No 6 847700 00 Rev G00 9 Slightly open vent valve to create a small flow of gas through manifold 10 Ve
35. er valve e Do not repeatedly bend sharply bend or twist copper pigtails as damage to tubing may occur e Do not bend flexible pigtails into a radius smaller than 3 e Service to be performed by qualified medical equipment technician NOTE In order to ensure proper manifold switchover operation do not set delivery line pressure less than 40 PSI Manifold Specifications All Lifeline Manifold systems are designed in accordance with the current revision of NFPA 99 There are three categories of Lifeline manifolds depending upon the delivery pressure The following gas types are available for each delivery pressure 55 PSI Delivery Pressure e Oxygen e Nitrous Oxide e Medical Air e Carbon Dioxide e Helium e Carbon Dioxide Oxygen CO2 over 7 e Oxygen Carbon Dioxide CO2 not over 7 e Helium Oxygen Helium over 80 e Oxygen Helium Helium not over 80 e Argon 100 PSI Delivery Pressure e Oxygen e Medical Air e Carbon Dioxide 180 PSI Delivery Pressure e Nitrogen Instrument Air Refer to Table 1 for the manifold s specifications Delivery Line Pressure see NOTE above 55 PSI 100 PSI 180 PSI 70 PSI 210 PSI 210 PSI 55 PSI 40 PSI 40 PSI 125 10 PSI 1250 10 PSI 250 10 PSI 350 PSI 350 PSI 350 PSI 75 PSI 150 PSI 250 PSI 150 5 PSI 300 10 PSI 300 10 PSI 3000 PSI 3000 PSI 3000 PSI The intermediate pressure value of the In Use bank is dependent upon the dome
36. fall over and damage or break off cylinder valve Do not repeatedly bend sharply bend or twist copper pigtails as damage to tubing may occur Do not bend flexible pigtails into a radius smaller than 3 E Part No 6 847700 00 Rev G00 Visually inspect manifold for normal operation Record front panel indicator status e g left bank IN USE right bank READY Record left and right bank pressure gauge readings Record line pressure gauge reading At Cylinder Replacement Visually inspect each pigtail for cleanliness and damage Do not use and immediately replace dirty or damaged pigtails Check for leaks at cylinder to pigtail connection using oxygen compatible leak detector solution Annually Verify manifold operation using Performance Verification procedure Every 3 5 Years Replace pigtails Techniques For Leak Tight Connections Lifeline manifold utilizes four different types of connection between internal components e Threaded pipe fittings e Parker brand A Lok fittings e Parker brand Prestolock fittings e O ring face seal fittings Threaded pipe fittings should be sealed with Teflon tape Remove old Teflon tape from both male and female threads Use care so all fragments are removed from threads and interior of fittings Apply Teflon tape to male pipe threads Approximately 2 to 3 turns should be sufficient Do not cover first thread with tape Assemble fittings and tighten Parker
37. from left and right manifold inlets Attach appropriate header extension to manifold control panel Position cylinder inlet connections of each header extension so they are pointing out away from wall and tighten header extension Figure 4 Part No 6 847700 00 Rev G00 11 Installation Floor Mounting Instructions cont A CAUTION 11 Each header extension is shipped with a Each header segment must be supported by a header bracket Each header bracket should header bracket before additional header be attached to a manifold header stand segments are added Assemble each header stand by attaching a post base to one end of 66 inch channel as shown in Figure 9 Detail A MANIFOLD CONTROL AND HEADER STAND KIT ASSEMBLY MN YA SSS SS SSS SSS SS SS SS SS SS SSSSSSSSSSS 0 a 0 E o R TU k 0 7 ScccccccccccscccoccccccsccccstscssYAR e 0 CE 0 NV Figure 9 112 Part No 6 847700 00 Rev G00 Installation Floor Mounting Instructions cont Use two each 3 8 bolts flat washers and channel nuts Tighten all bolts 12 Set header stand in a vertical position roughly in alignment with two vertical control panel stands Position header bracket against channel and on bottom side of header as shown in Figure 6 Attach bracket to
38. ide Verify right bank red light goes out and right bank yellow READY light illuminates 17 Close two right side line regulator isolation valves and open two left side line regulator isolation valves 18 Slightly open vent valve to create a small flow of gas through manifold 19 Verify pressure gauge reading intermediate pressure in use bank on left side bank regulator is as indicated in Table 1 If pressure is not correct refer to Bank Regulator Pressure Adjustment procedure 20 Verify front panel line pressure gauge reading is same as in step 11 If pressure is not correct refer to Line Regulator Pressure Adjustment procedure 21 Close vent valve Watch pressure gauge readings of left side bank regulator and front panel line pressure gauge for at least five minutes Readings may be slightly higher without vent flow Verify readings do not continue to increase 22 Close all cylinders on left side of manifold Open vent valve slightly so front panel left bank high pressure gauge drops slowly Verify manifold switches to right bank when left bank high pressure gauge drops to value indicated in Table 1 If pressure value is not correct left pressure switch needs adjustment Refer to Pressure Switch Adjustment procedure 23 Close vent valve Verify only right bank green IN USE and left bank red EMPTY lights illuminate 24 Slowly open one cylinder on left side Verify left bank red light goes out and left bank yellow READ
39. igure 3 Bottom of control panel can then be positioned toward bracket so 3 8 mounting stud passes through PE lower hole in mounting bracket Install and tighten 3 8 nut removed in step 2 HEADER A CAUTION ASSEMBLY Do not use thread sealant on header or pigtail connections 7 For manifolds with more than three cylinders per bank additional shipping cartons contain extension headers and header wall brackets Depending on the number of cylinders header extensions are configured with two or three cylinder inlets Large manifold systems may also include combinations and multiples of each type of header extension Remove large union nut and plug from left and right manifold inlets Attach appropriate header extension to manifold control panel Position cylinder inlet connections of each header extension so they are pointing out away from the wall and tighten header extension Figure 4 A CAUTION Each header segment must be supported by a header bracket before additional header segments are added 8 Part No 6 847700 00 Rev G00 Installation Wall Mounting Instructions cont 8 Each header extension is shipped with a 9 Assemble u bolt and bracket hardware as header bracket Position bracket against wall shown Tighten u bolt nuts and on bottom side of header as shown in 10 Additional header extensions may be attached Figure 6 Attach bracket to wall using end to end if required appropriate a
40. ill be replaced 3 Vent pressure from bank that was shut off in step 2 by slightly loosening the compression nut on back of front panel bank pressure gauge NOTE Replacement bank regulator is supplied with inlet nut and tailpiece All other fittings pressure gauge and pressure switch must be removed from old regulator and reused A CAUTION Bank regulator high pressure parts incorporate filter material between inner and outer wire screens Take care not to dislodge filter or screens when removing and reinstalling pressure switch NOTE Pressure switch may be removed from bank regulator body without disconnecting pressure switch wires from control board Carefully unscrew pressure switch and allow wires to twist Removal of switch typically requires 4 5 revolutions When reinstalling switch twist wires 4 5 revolutions in a counterclockwise direction so when tightened wires will return to approximate original position NOTE Refer to Techniques For Leak Tight Fittings for recommendations concerning removal and reassembly of fittings 4 Remove 5 8 OD copper tube from outlet of bank regulator NOTE Check valves downstream of line regulators will prevent back flow Check valves are intended to prevent gross leaks during service and may not be bubble tight 5 Remove pressure switch from bank regulator body 6 Remove 1 8 copper tube between bank regulator elbow fitt
41. ing and front panel bank pressure gauge 7 Loosen large union nut on inlet of bank regulator 8 Remove nylon tube from regulator dome 9 Remove two bank regulator bracket mounting nuts 10 Remove regulator and bracket from manifold 11 Remove pressure gauge and remaining fittings from old regulator 12 Noting regulator bracket alignment remove regulator bracket from old regulator 13 Install regulator bracket on new regulator Align bracket as noted above 14 Using Teflon tape reinstall pressure gauge and fittings into new regulator body NOTE Some pressure ports in new regulator body will be shipped with pipe plugs Remove plugs where applicable 15 Attach new regulator and bracket to manifold s base plate Hand tighten mounting nuts Part No 6 847700 00 Rev G00 g Service Procedures Bank Regulator Replacement Cont 16 Tighten large nut on inlet of new bank regulator 17 Install 5 8 OD copper tube 18 Tighten regulator bracket mounting nuts 19 Install pressure switch Remember to pre twist pressure switch wires 20 Install 1 8 copper tube between regulator fitting and front panel bank pressure gauge 21 Reinstall nylon tube 22 Slowly open cylinders and set bank regulator s output pressure as described in Bank Regulator Pressure Adjustment procedure 142 Part No 6 847700 00 Rev G00 Line Regulator Replacement Following procedure describes process of replacing line regul
42. k of the manifold even those placed directly beneath should be positioned so that the cylinder outlets face right All cylinders on the left bank of the manifold even those placed directly beneath should be positioned so that the cylinder outlets face left Figure 11 illustrates a typical 5 x 5 manifold system utilizing 24 length flexible pigtails Oxygen and helium manifolds are supplied with pre formed rigid copper pigtails All cylinders on the right bank of the manifold even those placed directly beneath should be positioned so that the cylinder outlets face right All cylinders on the left bank of the manifold even those placed directly beneath should be positioned so that the cylinder outlets face left Figure 12 illustrates a typical 5 x 5 oxygen or helium manifold utilizing pre formed rigid copper pigtails 1 Remove plastic shipping caps from manifold header pigtail connections 2 Connect one end of pigtail assembly to header connection Coiled end of rigid copper pigtails attaches to header connection 3 Position gas cylinders as shown in Figures 11 and 12 Secure each cylinder to wall or floor stand with chains or straps 4 Connect pigtails to each cylinder Rigid copper pigtails used on oxygen and helium manifolds are pre formed to approximate required shape Lower end of rigid copper pigtails must be bent 90 toward cylinder outlets 5 Tighten all pigtail connections firmly Do not over tighten 16 Part
43. l grease and dirt These control panel and other flammable materials may ignite Power supply assembly when exposed to high pressure oxygen or 3 4 source shut off valve nitrous oxide Installation Operation and Service Manual e Do not use chemicals lubricants or sealants unless specified in these instructions Additional cartons contain appropriate number of header extensions and cylinder pigtail assemblies As a standard header assemblies are configured so cylinder inlets are on 5 inch centers Cylinders must be placed in a double row staggered e Before connecting cylinder to manifold momentarily open and close cylinder valve to blow out dirt and debris e After connecting cylinder to manifold open configuration Cylinder inlets closest to manifold cylinder valve s l o w l y to allow heat of control panel are intended for cylinders placed compression to dissipate directly beneath manifold control panel Pigtails for gases other than oxygen and helium are 24 length stainless steel flexible type Oxygen and Do not apply heat to any part of the manifold helium pigtails are rigid copper and are pre bent to system approximate shape for connection to cylinders Manifold is designed to be mounted directly to a wall but may be freestanding floor mounted with addition of a manifold control panel floor mount kit and an appropriate number of header floor mount kits ordered separately Do not use flame or sniff test
44. line regulator inlet isolation valves Locate leak by applying a small amount of an oxygen compatible leak detector solution while manifold is under pressure Formation of bubbles indicates a leak Since manifold is factory leak tested suspect those items first that were added during installation process For example main outlet union fitting for leaks downstream of line regulator isolation valves and header connection points for leaks upstream of line regulator isolation valves A Part No 6 847700 00 Rev G00 12 Eliminate leaks by tightening or replacing connections or tubing Retest and verify all leaks have been eliminated 13 Open line regulator isolation valves 14 Reinstall manifold control panel cover 15 Slowly open all cylinders on both banks of manifold 16 Open 3 4 source shut off valve A CAUTION Avoid getting leak detector solution onto electrical components Wipe off excess leak detector solution after testing A WARNING e Tampering with gas specific connections shall be prohibited Do not alter remove or modify gas specific connections e Before connecting cylinder to manifold momentarily open and close cylinder valve to blow out dirt and debris e After connecting cylinder to manifold open cylinder valve s l o w y to allow heat of compression to dissipate e Always secure cylinders with racks straps or chains Unrestrained cylinders may fall over and damage or break off cylind
45. nchors by others 3 8 diameter 11 Install large nut and plug removed in step 7 on anchors are recommended end of last header extension Tighten large nut HEADER ASSEMBLY U BOLT HEADER BRACKET ANCHORS NOT PROVIDED 3 8 DIA ANCHORS RECOMMENDED FLANGE NUTS Figure 6 Part No 6 847700 00 Rev G00 EH Installation Floor Mounting Instructions For floor mounting the manifold control panel Verify contents of stand kits Figures 7 and 8 and headers a manifold control panel stand kit and an appropriate number of manifold header stand kits should have been ordered separately O de STAND KIT MANIFOLD CONTROL PANEL manifold control P N 6 1 35000 KT panel stand kit contains 12 CHANNEL all items Xx 1 needed to aoe mount the 7 se FLAT WASHER control J x 12 panel Ce 16 x 1 BOLT Si Depending x 12 a on the oe nas Nd so s 1 4 20 CHANNEL NU x 1 S2 k Pa number of e SA header ot BASE 14 20 BOLT x 2 x 2 segments one or more header 80 CHANNEL stand kits x 2 are required A header STAND KIT MANIFOLD HEADER stand is required P N 6 135001 KT for each header POST BASE el segment An 02 ARK a a Pon 8 8 16 CHANNEL NUT x 12 Figure 7 Each header stand kit contains 4 3 8 16 CHANNEL NUT two vertical ae e x 8 3 8 FLAT WASHER stands and all s Xx 8 necessary items 3 8 16 x
46. nd set line regulator s output pressure as described in Line Regulator Pressure Adjustment procedure Control Board Replacement Following procedure describes process of replacing manifold s electronic control circuit board If necessary control board replacement can be performed while manifold is in service However this should only be done by qualified technicians experienced in servicing medical equipment Repair of the control board is not recommended 1 Remove two front panel screws A Figure 18 Loosen two hinge screws B Figure 18 Fold front panel down to service position as shown in Figure 19 Lightly tighten two hinge screws 2 Disconnect power supply connector from bottom of manifold cabinet 3 Using small blade screwdriver remove each wire from control board terminals 4 Remove four control board screws Note orientation of old control board and remove from manifold 5 Install new control board and secure with four screws 6 Connect each wire to appropriate terminal Refer to wiring diagram Figure 21 for wire locations 7 Loosen front panel hinge screws and return front panel to upright position Reinstall two front panel screws and tighten hinge screws 8 Reconnect power supply connector to bottom of manifold cabinet 9 Verify correct operation of new control board by performing Performance Verification Part No 6 847700 00 Rev G00 43 Wiring Diagram Service Procedures WHITE
47. ngs or scratches nicks in brass fittings where o rings contact Replace either o ring or fitting as necessary to correct leak Lubrication of o ring is not required Part No 6 847700 00 Rev G00 E Service Procedures Pressure Switch Replacement Following procedure describes process of replacing pressure switch If necessary pressure switch replacement can be performed while manifold is in service However this should only be done by qualified technicians experienced in servicing medical equipment _ Remove two front panel screws A Figure 18 Loosen two hinge screws B Figure 18 Fold front panel down to service position as shown in Figure 19 Lightly tighten two hinge screws Disconnect power supply connector from bottom of manifold cabinet 3 Close all cylinders on side of manifold where pressure switch will be replaced 4 Vent pressure from bank that was shut off in step 3 by slightly loosening compression nut on back of front panel bank pressure gauge 5 Using small blade screwdriver remove violet and blue pressure switch wires from control board terminals Note location of each wire 6 Cut cable ties and remove pressure switch wires from manifold s harness 7 Verify all pressure has been vented Remove old pressure switch from bank regulator body N A CAUTION Bank regulator high pressure parts incorporate filter material between inner and outer wire screens Take care not to dislodge filter
48. nifold manufactured by BeaconMedees Service information contained in this manual is intended for use by technicians or personnel qualified to repair and service medical equipment Abbreviations C Common CGA Compressed Gas Association FNPT Female National Pipe Thread MNPT Male National Pipe Thread N C Normally Closed N O Normally Open PSIG Pounds Per Square Inch Gauge SCFM Standard Cubic Feet Per Minute VAC Voltage Alternating Current VDC Voltage Direct Current Introduction Definition of Statements wired to an external alarm or a building management system Statements in this manual preceded by following words are of special significance When replacement cylinders are attached to A WARNING Means there is a possibility depleted bank red lamp goes out and yellow of injury or death to yourself or others lamp illuminates indicating bank has been A CAUTION Means there is a poss biiy ai automatically designated as secondary supply damage to unit or other property No other user interaction is required Both sets of dry contacts close to cancel any external NOTE Indicates points of particular interest sl nncohditior for more efficient and convenient operation An external power supply converts 120 VAC to 24 VAC to power manifold Power supply is connected to bottom of manifold control panel via a 48 cable Two sets of dry normally closed alarm contacts can be accessed inside external power supply so unde
49. nstallation Cylinder Connection Cont Coiled ends of rigid copper pigtails attach to header connections Lower ends of rigid copper pigtails must be bent 90 toward cylinder outlets Figure 12 18 Part No 6 847700 00 Rev G00 Installation Initial Power Up and Operational Testing 1 Release two latches on sides of manifold e Power supply cable has been attached to the control panel cover one on each side connector on bottom of manifold Remove cover as shown in Figure 13 Both red Empty indicators on front of manifold 2 Verify the following Refer to Figure 14 for are illuminated component location e If connected to a master alarm panel e Both master valves are turned fully Secondary Supply alarm is activated counterclockwise open 3 Close 3 4 source shut off valve e All four line regulator isolation valves are open handles horizontal Figure 13 Part No 6 847700 00 Rev G00 19 Installation Initial Power Up and Operational Testing Cont 4 Slowly open one cylinder on right side of manifold manifold 7 Verify the following 5 Verify the following Left bank red Empty light goes out e Right
50. o ring do not apply heat to relief valve union Braze male sweat adapter to relief piping prior to attaching to union Part No 6 847700 00 Rev G00 13 Installation Power Supply Installation A separate power supply assembly is provided with manifold control panel Power supply assembly should be mounted to wall on either right or left side of manifold control panel with top of power supply roughly in alignment with top of manifold control panel 1 4 diameter mounting holes are provided in back of power supply box wall mounting hardware by others If floor mounting manifold control panel mount power supply assembly to 12 inch channel as shown in Figure 9 Detail E Use two each 1 4 bolts and channel nuts per base Tighten all bolts Power supply shall be connected to a building installed circuit breaker Circuit breaker shall be marked as disconnecting means for manifold It is recommended that circuit breaker be in close proximity to manifold power supply Power supply assembly houses a 24 VAC transformer and terminal blocks for AC input power and remote alarm connection A 48 long cable connects power supply to a six pin connector on bottom of manifold control panel NOTE All wiring shall be protected from physical damage by raceways or conduit in accordance with NFPA 70 National Electric Code Holes for 1 2 conduit are located on bottom of power supply box for 120 VAC power and remote al
51. olenoid valve directs dome bias pressure to bank regulator on right side If we use a 55 PSI oxygen manifold as an example output of right bank pressure regulator is approximately 125 PSI 70 PSI base pressure 55 PSI bias pressure Output of left bank regulator is 70 PSI base pressure only no bias pressure Since bank regulator on right side has highest pressure all flow is supplied by right bank of cylinders As cylinder pressure on right side depletes pressure falls to pressure switch setting 150 PSI Right side pressure switch opens signaling circuit board to switch solenoid valve Solenoid valve vents dome bias pressure from right bank regulator and directs bias pressure to left bank regulator Green light on right side goes out and red Empty light illuminates Yellow light on left side goes out and green In Use light illuminates Circuit board alarm contacts open in order to activate master alarm panel switchover alarm All flow is supplied by left bank of cylinders When cylinders on right side are replaced and pressure is restored right pressure switch closes and signals circuit board Circuit board will in turn cancel remote switchover alarm turn off right side red light and illuminate right side yellow Ready light Since left bank regulator has dome bias pressure applied its output pressure is boosted to approximately 125 PSI Right bank regulator has no dome bias pressure and its output pressure is controll
52. omponents called out in this procedure NOTE If inlet and outlet isolation valves for both line regulators are open manifold s outlet pressure gauge will indicate pressure of line regulator with highest setting Verify setting of each regulator individually as described in following procedure 1 Open two right side line regulator isolation valves and close two left side line regulator isolation valves 2 Slightly open vent valve to create a small flow of gas through manifold 3 Using 6mm Allen wrench turn right line regulator adjusting screw for an appropriate front panel output pressure gauge reading Note reading for later use Refer to Table 1 delivery pressure for factory settings 4 Open two left side line regulator isolation valves and close two right side line regulator isolation valves 5 Using 6mm Allen wrench turn left line regulator adjusting screw for same outlet pressure gauge reading noted in step 3 6 Close vent valve 7 Open two right side line regulator isolation valves E Part No 6 847700 00 Rev G00 Testing and Adjustments Pressure Switch Adjustment Following procedure describes process of setting pressure switches This procedure should only need to be performed if manifold switchover pressures were not within acceptable limits during Performance Verification procedure Recommended settings are listed in Table 1 Pressure switch is a normally open type that closes when press
53. r Instrument Air CGA 346 6 290814 24 Nitrogen or Argon CGA 580 6 290820 24 CO2 CGA 320 64 36 Flexible Pigtail Assembly 6 290811 36 Nitrous Oxide CGA 326 6 290812 36 Medical Air or Instrument Air CGA 346 6 290814 36 Nitrogen or Argon CGA 580 6 290820 36 CO2 CGA 320 65 6 290810 00 Rigid Copper Pigtail Oxygen CGA 540 6 290822 00 Rigid Copper Pigtail O2 CO2 or O2 He CGA 280 66 6 290821 00 Rigid Copper Pigtail CO2 02 or He O2 CGA 500 6 290825 00 Rigid Copper Pigtail Helium CGA 580 Replacement Pigtail O Rings Washers Manifold Accessories Item Item Part No Description Replacement O rings Pkg of 10 not shown Oxygen CGA 540 02 C02 and O2 He CGA 280 Nitrous Oxide CGA 326 CO2 O2 and He O2 CGA 500 Helium Nitrogen or Argon CGA 580 6 622615 PG Air and Instrument Air CGA 346 Replacement Washers Pkg of 10 not shown 6 621600 PG Carbon Dioxide CGA 320 Manifold Stand Kits Item Part No Description 6 622612 PG 6 622613 PG 6 622614 PG 6 135000 KT Control Panel Stand Kit shown on Pg 10 6 135001 KT Header Stand Kit shown on Pg 10 54 Part No 6 847700 00 Rev G00 g Y Part No Description Nut amp Blind Gland for Header Check not shown Oxygen CGA 540 Nitrous Oxide CGA 326 Helium Nitrogen or Argon CGA 580 Air and Instrument Air CGA 346 Carbon Dioxide CGA 320 02 C0
54. r normal conditions all ae external wiring will be connected to power Product Description supply not manifold control panel Lifeline automatic changeover manifold is Lifeline manifold is designed in accordance designed to provide a reliable uninterrupted with National Fire Protection Association NFPA supply of gas to a hospital or other medical 99 facility Manifold utilizes multiple high pressure cylinders divided into two equal banks One bank is designated as Primary source of gas while other bank stands in reserve as Secondary source Lights on front of manifold indicate status of gas supply Each bank has a green IN USE yellow READY and red EMPTY lamp When primary bank of cylinders is depleted manifold will automatically switch to secondary bank of cylinders without interruption of gas flow to facility Red lamp on depleted bank will illuminate and two normally closed dry contacts will open One or both sets of contacts may be Part No 6 847700 00 Rev G00 EH Installation Manifold System Components A WARNING Manifold system may be shipped in more than e Tampering with gas specific connections shall one carton depending on number of cylinder be prohibited Do not alter remove or modify connections Main carton contains following gas specific connections items e Manifold control panel e Keep all manifold parts tools and work Wall mounting bracket attached to manifold surfaces free of oi
55. r to Figure 17 High pressure gas is provided to left and right manifold bank inlets via cylinders pigtails and header assemblies Flow of high pressure gas through left and right side of manifold is exactly the same each passing through a master valve and then directly to a bank regulator Cylinder pressure is also applied to a normally open pressure switch closes when pressure is applied and a front panel high pressure gauge Bank regulators reduce incoming cylinder pressures to an intermediate pressure Bank regulators are referred to as a dome loaded type of regulator These regulators have an internal adjusting spring manually set at a specific pressure similar to other diaphragm type pressure regulators In addition to internal adjusting spring bias pressure may be applied to dome of regulator adjusting spring side of diaphragm thus boosting pressure above what is manually set by adjusting spring This output pressure boost will be approximately equal to amount of bias pressure For example if a bank regulator is manually adjusted to 70 PSI via internal adjusting spring and a dome bias pressure of 55 PSI is applied output pressure will increase to approximately 125 PSI 70 55 When bias pressure is removed output pressure setting will return to 70 PSI Outputs of both left and right bank regulators pass through check valves and connect together upstream of a dual line regulator assembly An intermediate relief valv
56. re to be used Figure 1 Part No 6 847700 00 Rev G00 O Installation Wall Mounting Instructions cont 4 Place bracket flat against wall as shown in bracket and drill mounting holes Attach Figure 2 and align top of bracket with level bracket to wall with appropriate anchors by horizontal line Vertical center line of bracket others 3 8 diameter anchors are will be vertical center line of installed manifold recommended Mounting top of bracket at 79 3 4 height will A WARNING net a 61 height from center of header to finished floor 5 Mark locations of mounting holes Remove Do not attempt to lift manifold alone Two people are recommended in order to hang manifold onto wall mounting bracket LOCATE BRACKET d PER LEVEL A HORIZONTAL LINE y y ae __ BS MARK LOCATIONS OF MOUNTING HOLES 5 PL 79 3 4 b TO FLOOR Figure 2 g Part No 6 847700 00 Rev G00 Installation Wall Mounting Instructions cont Figure 3 Part No 6 847700 00 Rev G00 Installation Wall Mounting Instructions cont 6 Hang manifold control panel on mounting bracket Top two control panel mounting bolts will slide into slots of bracket Bottom of manifold control panel should be angled away from bracket until top two bolts have been inserted as shown in F
57. rify pressure gauge reading intermediate pressure in use bank on right side bank regulator is as indicated in Table 1 If pressure is not correct refer to Bank Regulator Pressure Adjustment procedure 11 Verify front panel line pressure gauge reading is as indicated in Table 1 delivery pressure If pressure is not correct refer to Line Regulator Pressure Adjustment procedure Note reading for later use NOTE Line pressure values listed in Table 1 are nominal factory settings Actual customer settings may vary 12 Close vent valve Watch pressure gauge readings of right side bank regulator and front panel line pressure gauge for at least five minutes Readings may be slightly higher without vent flow Verify readings do not continue to increase Testing and Adjustments Performance Verification Continued 13 Close all cylinders on right side of manifold Open vent valve slightly so front panel right bank high pressure gauge drops slowly Verify manifold switches to left bank when right bank high pressure gauge drops to value indicated in Table 1 If pressure value is not correct right pressure switch needs adjustment Refer to Pressure Switch Adjustment procedure 14 Close vent valve Verify only left bank green IN USE and right bank red EMPTY lights illuminate 15 If manifold is connected to a master alarm panel verify manifold switchover alarm is activated 16 Slowly open one cylinder on right s
58. rt No 52 6 515708 00 53 6 425564 KT 54 6 515724 00 6 511615 10 6 511615 11 6 511615 12 6 511615 14 6 511615 20 6 511615 21 6 511615 22 56 6 515700 00 Description Union Bushing 1 11 1 2 NPT x 1 2 NPT Header Wall Bracket includes hardware 90 Street Elbow 1 2 NPT Check Valve Spud x 1 2 NPT Oxygen CGA 540 Nitrous Oxide CGA 326 Medical Air Instrument Air CGA 346 Nitrogen Argon or Helium CGA 580 CO2 CGA 320 CO2 02 or He O2 CGA 500 02 C02 or 02 He CGA 280 Plug 1 2 NPT El Part No 6 847700 00 Rev G00 Pe e MMENDED Illustrated Parts List Header Components Lifeline Manifolds manufactured prior to October 2006 used check valves with 1 2 NPT connections on header segments Note square block sections where check spuds thread into header segments Replacement Check Valve Spud x 1 2 NPT 58 Part numbers shown on page 52 Item Part No Description 57 3 Cylinder Header Segment 6 136003 10 Oxygen CGA 540 6 136003 11 Nitrous Oxide CGA 326 6 136003 12 Medical Air CGA 346 6 136003 14 Nitrogen CGA 580 6 136003 16 Air International CGA 346 6 136003 18 Instrument Air CGA 346 6 136003 20 CO2 CGA 320 6 136003 21 CO2 02 CGA 500 6 136003 22 O2 CO2 CGA 280 6 136003 23 He O2 CGA 500 6 136003 24 O2 He CGA 280 6 136003 25 Helium CGA 580 6 136003 26 Argon CGA 580 58 6 515763 00 Header Plug and Nut Assembly 59 2 Cylinder Header Segment
59. s for leaks e Always secure high pressure cylinders with racks straps or chains Unrestrained cylinders may fall over and damage or break off cylinder valve e Do not repeatedly bend sharply bend or twist copper pigtails as damage to tubing may occur e Do not bend flexible pigtails into a radius smaller than 3 e After manifold wall bracket has been mounted one person alone should not attempt to lift and hang the manifold cabinet e Do not put manifold into operation until verified by a qualified person per NFPA 99 or other local standard EN Part No 6 847700 00 Rev G00 Installation Wall Mounting Instructions 1 Remove manifold control panel from shipping carton and place face down on foam packaging insert 2 Mounting bracket is shipped attached to back of manifold control panel Remove lower 3 8 mounting nut as shown in Figure 1 Pull bottom of bracket away from manifold control panel and slide bracket off two upper control panel mounting bolts Mounting Bracket Manifold Control Panel 3 Mark wall 79 3 4 from finished floor in location where manifold will be mounted Convert mark to level horizontal line approximately 8 long NOTE A bracket mounting height of 79 3 4 allows for adequate clearance beneath manifold when utilizing standard H size cylinders 55 tall overall Bracket mounting height should be increased proportionally if taller cylinders a
60. ure in excess of switch setting is applied When cylinder pressure is applied to both banks of manifold both pressure switches are closed When cylinder pressure of IN USE bank drops to switch setting manifold will switch to opposite cylinder bank Switches should always be adjusted as pressure decreases If pressure switch can not be set switch must be replaced Pressure switches are not repairable Refer to Figure 16 for location of components called out in this procedure 1 Verify at least one cylinder is open on each bank of manifold 2 Using circuit board switches switch manifold to bank whose pressure switch is to be adjusted For example if pressure switch on right side is to be adjusted press left circuit board switch so green IN USE light on right bank is illuminated Close cylinders on IN USE bank 4 Slightly open vent valve to create a small flow of gas through manifold Front panel cylinder contents gauge for IN USE bank should begin to drop Adjust vent valve so gauge drops very slowly 5 Note gauge reading when manifold switchover takes place Recommended settings are listed in Table 1 6 Close vent valve w 7 If switch adjustment is necessary slide collar of switch toward wires to access internal adjustment barrel Insert tip of small screwdriver into adjustment barrel and rotate barrel Figure 20 NOTE When viewing switch from wire end rotating barrel clockwise will raise switch
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