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1. L Bypass Valve Line Pressure Regulator NNNM __ _ Line Pressure Regulator Check Valve Check Valve Solenoid Valve Solenoid Valve Solenoid Bypass Valve Solenoid Bypass Valve Rig ht Intermediate r essure Gauge Left Intermediate Pressure Gauge Right Bank Pressure Gauge Left Bank Header i E r Right Bank Header Left Bank Pressure Gauge 34 High Pressure Switch 77 Ded High Pressure wite Left Prima Right Primary Left Side Right Side Pressure Regulator Relief Valve Relef Valve Pressure Regulator FIGURE 2 3 Piping Schematic 2 2 B20130 ECN 11673 0201 Pressure is reduced in the primary regulators to the pressures noted in the adjustment specification chart lo cated on page 1 3 Both primary regulators are factory preset to deliver the same pressure The primary regula tors have three outlet ports The first low pressure port is connected via tubing to a low pressure switch A re lief valve is connected to the second port The third port is the gas outlet port which is connected via tubing to the appropriate solenoid valve The gas flows from the primary regulators to the solenoid valves The solenoid valves are either open or closed depending on which side is in service and whether the Reserve cylinders have adequate pressure The sole noid valve o
2. Turn the three way bypass valve to feed the reserve line regulator The manifold does not have to be shut down Mark the compression fittings per instructions on page 4 2 Use a 11 16 open end wrench to loosen the nuts Carefully remove the line regulator from the mani QOMERESSION fold FIGURE 4 10 Line Regulator Assembly Disassembly 1 Place the regulator in a vise or similar holding fixture 2 Using an 11 16 open end wrench loosen the locknut on the regulator adjusting screw and back off the adjust ing screw until it turns freely and all compression is removed from the bonnet spring 3 Using a 1 1 2 hex wrench remove the backcap and conical spring from the regulator 4 Remove the gasket from the backcap and discard 5 Use a phillips head screwdriver to remove the six screws attaching the bonnet to the body Lift the bonnet off of the body and set aside the bonnet pivot bonnet spring and screws 6 The diaphragm assembly and the seat stem assembly are attached at each end of the stainless steel rod The stainless steel rod is threaded on both ends Using a 5 8 hex wrench to stabilize the diaphragm assembly reach under the regulator with a 1 4 open end wrench placing it over the wrench flats provided on the bottom of the seat assembly and loosen the seat assembly The seat can be unscrewed by hand after loosening Remove and discard the diaphragm and seat assemblies Reassembly 1 Setthe new diaphragm ass
3. WLF 6 63 3 8 Tubing Relief Tee Tee WLF 6 60 Pipe away adaptor WMV 8 7 Inlet Adaptor WMS 1 44 Mounting Block Assembly WMS 1 32 Check Valve Right Side 8584 3 8 Tubing Left Reg Sol WLF 6 65 High Pressure Switch 8413 Check Valve Left Side 8583 Primary Regulator 8534 1 8 x 12 Tubing WLF 6 18 Block 3 way tubing WLF 6 61 3 8 Tubing L Relief Tee WLF 6 64 5 6 Bypass kit not on all assemblies KEY DESCRIPTION PART 19 20 21 22 23 24 25 26 27 28 3 8 Tubing R Relief Tee WLF 6 62 Left Line Regulator Assy 8563 Three Way Valve WMV 2 54 Right Line Regulator Assy 8564 Outlet Block Assembly WMC 2 26 Outlet Nipple D 20 Outlet Hex Nut D 7 Outlet Adaptor D 34 Heater Assembly 8590 Line Relief Valve HQ2HL 4 Series WMV 8 75 HQ2HL 8 Series WMV 8 60 3 8 Tube x 1 2 NPT Male WLF 3 15 3 8 Tubing Line Relief Tee 8341 Line Reg Tee CV Assy 8582 3 8 Tubing Tee Bulkhead 8321 3 8 Tubing Tee Outlet WLF 3 18 Right Solenoid Valve Assem 8552R B20130 ECN 11673 0201 INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HQ2 and HQ2HP Series Repair Drawing Mounting Block Components FRONT VIEW BOTTOM VIEW DESCRIPTION PART Mounting Block 8112 1 4 Street Elbow BL 4HP Adaptor for Primary
4. S l o w l y open one cylinder valve on the left bank of cylinders The ohmmeter should register approximately zero 0 ohms resistance as soon as the cylinder pressure on the left side in creases above 500 psig 300 psig for HQ2HL manifolds Close the cylinder valve on the right bank of cylinders 3 3 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Open the bleed valve to create a slight flow of gas through the manifold while observ ing the cabinet system status lights As soon as the manifold status indicators change the ohmmeter should read infinite resistance Close the bleed valve S l o w l y open one cylinder valve on the right bank of cylinders The ohmmeter should register approximately zero 0 ohms resistance as soon as the cylinder pressure on the right side in creases above 500 psig 300 psig for HQ2HL manifolds Close the cylinder valve on the left bank of cylinders Open the bleed valve to create a slight flow of gas through the manifold while observ ing the cabinet system status lights As soon as the manifold status indicators change the ohmmeter should read infinite resistance Close the bleed valve Close the cylinder valve on the right bank of cylinders Open the bleed valve and vent all remaining gas from the manifold Verify that the ohm meter continues to read infinite resistance Observe the cabinet system status in
5. AUTOMATIC CHANGEOVER MANIFOLD HQ2 Series Check Valve Components DESCRIPTION Poppet Spring Washer Cap Item included in repair kit Repair Kit for HQ2 HQ2HL amp HQ2HP Series 5 13 PART WMV 1 5 WMV 1 6 WMV 1 7 WMV 1 8 RK 1041 B20130 ECN 11673 0201 INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HQ2 Series Repair Drawing Gauge Plate Components FRONT VIEW OQ X 2 DESCRIPTION 5 x 9 Plate 1 8 Tube x 1 4 NPT Female Line Pressure Gauge for HQ2 amp HQ2HL Series 100 psi for HQ2HP Series 400 psi Cylinder Contents Gauge for HQ2 amp HQ2HP Series 4000 psi for HQ2HL Series 2000 psi 5 14 B20130 ECN 11673 0201 INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HQ2 HQ2HL amp HQ2HP Series Power Supply Components Repair Drawing Without CSA Certification DESCRIPTION PART B Size Valve 205 3 8 Tube x 1 2 NPT Male WLF 3 15 Pipe Away Adaptor WMV 8 7 3 16 Dia x 1 4 Rivet WMC 6 16 Relief Valve HQ2 HQ2 9 and HQ2HL Series WMV 8 75 HQ2HP Series WMC 8 250 1 8 Tube x 1 8 NPT Male WLF 3 11 3 8 Tube x 1 4 NPT
6. Adjust pressure switch if necessary Red indicator light does not come on when one bank is empty and changeover occurs Light burned out Replace manifold controller PCB Red indicator light does not come on when one bank is empty Changeover does not occur Low pressure switch set to open at zero pressure Adjust pressure switch or return faulty unit for factory setting Green indicator light does not come on even though bank is in service Low pressure switch wiring disconnected Manifold controller PCB defective Check wiring connections Replace manifold controller PCB Yellow indicator light comes on even though one bank of cylinders is empty High pressure switch set to open at too low a pressure Adjust pressure switch or return faulty unit for factory setting Yellow indicator light is on when side should be in service Low pressure switch wiring disconnected Flow capacity too high forcing premature changeover 3 4 Check wiring connections Reduce flow demand B20130 ECN 11673 0201 SYMPTOM RESERVE IN USE SIGNAL Remote alarm signal stays in one mode constantly regardless of changeover status PROBABLE CAUSE Power supply wiring is incorrect Flow demand too high Power supply PCB defective REMEDY OR CHECK Check wiring connections on both power supply terminal strips Reduce flow demand Replace power supply PCB Remote alar
7. contin ued PROBABLE CAUSE Leakage at cylinder valve Gauge leaks Regulator leaks REMEDY OR CHECK Replace cylinder Reseal or replace Repair or replace Venting at relief valve Line regulator setting too high Overpressure due to creeping or faulty regulation by primary regu lator Overpressure due to creeping or faulty regulation by line regulator Regulator freeze up Nitrous oxide or carbon dioxide Heater failure Nitrous oxide or carbon dioxide Set delivery pressure to specifications Replace regulator seat and nozzle components Replace regulator seat and nozzle components Reduce the flow demand or increase the number of supply cyl inders Reduce the flow demand or in crease the number of supply cylin ders Gas leakage around regulator body or bonnet Loose bonnet Diaphragm leak on regulator Tighten bonnet Replace diaphragm Gas leakage around valve stem or packing nut on mas ter valve or header valve LOSS OF RESERVE BANK CONTENTS Both banks feeding Valve packing leaks Faulty valve Solenoid valve seat leak Faulty primary regulator Loss of electrical power Faulty primary regulator Faulty solenoid bypass check valve Tighten packing nut Repair or replace valve Replace solenoid valve Replace regulator seat and nozzle components Check electrical power supply Replace regulator seat and nozzle compon
8. 3 12 4000 psi 8534 Primary Regulator for HQ2 amp HQ2HL 20 CO2 Breathing Air He S N up to 20799 98594 A Primary Regulator for HQ2 Breathing Air He S N 20800 and greater 853 Primary Regulator for HQ2HL CO2 amp N20 S N 20800 and greater 8592 ui itenim Primary Regulator for HQ2HP N2 S N up to 20799 85324 iet Primary Regulator HQ2HP N2 S N 20800 and greater 8530A Primary Regulator for HQ2 9 HQ2 12 amp HQ2 13 S N up to 11348 8538 weal Primary Regulator for HQ2 9 HQ2 12 amp HQ2 13 S N greater than 11348 up to 20799 85384 Primary Regulator for HQ2 Oxygen S N 20800 and greater 9430 ehe Line Regulator HQ2HP All Gases Line Regulator HQ2 amp HQ2HL All Gases 1020 Repair Kit for 8534 amp 8532 N20 CO2 He Air N2 RK 1100 Repair Kit for 8430 amp 8431 All gases Shipped prior to 6 1 95 RK 1100M Repair Kit for 8430 amp 8431 All gases Shipped after 6 1 95 1023 Repair Kit for 8430A O2 and Medical Breathing Mixtures RK 1033 Repair Kit for 8538 RK 1037 Repair kit for 8534A 8534B and 8532A N20 CO Air He N2 1038 Repair kit for 8538A Oxygen Replacement regulator not available Use repair kit or request upgrade to latest version If up
9. 8 77 Red Lens 8243 16 Gage Wire 16 WME 8 57 Yellow Lens 8244 Screw Receptacle WMC 6 35 Green Lens 8245 3 16 32 X 3 Bolt EQ 106 6 32 Self Tapping Screw WMC 2 29 3 16 Lock Washer WMC 6 12 PCB Support 1 2 8240 3 16 32 Hex nut WMC 6 8 Outlet Block Spacer WLF 6 66 7 Heater Cord WME 8 33 Mounting Screw WMC 6 49 Wire Nut WME 8 58 3 8 16 x 3 Bolt 8170 Block Spacer 8151 tem not pictured 54 B20130 ECN 11673 0201 Western Enterprises Repair Drawing INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HQ2 amp HQ2HP Series Manifold Components KEY DESCRIPTION Gauge Plate Assembly for HQ2 amp HQ2 9 Series for HQ2HP Series Relief Piping Adaptor 3 8 Tube Bulkhead 3 8 Tube Tee Left Solenoid Valve Assem 3 8 Tubing Reg Right Sol 3 8 Tubing Relief Tee Tee 3 8 Tubing Tee Outlet Inlet Adaptor Mounting Block Assembly Check Valve Right Side 3 8 Tubing Reg Left Sol High Pressure Switch Check Valve Left Side Primary Regulator for HQ2 Series for HQ2HP Series for HQ2 9 oxygen Series 1 8 x 12 Tubing Block 3 way 3 8 tubing PART 8540 8541 WLF 3 12 WLF 3 13 WLF 3 14 8551L WLF 6 63 WLF 6 60 WLF 3 18 WMS 1 44 WMS 1 32 8584 WLF 6 65 8413 85
10. Breathing Air CGA 346 Oxygen CGA 540 apan Helium CGA 580 Box Nitrogen CGA 580 Manifold Medical Cabinet T 115 VAC Breathing Mixtures CGA 280 amp Conduit ry Manifold Outlet 1 2 NPT male pipe thread located at the middle on top of the cabinet Relief Valve 1 2 NPT male pipe thread located on the right side on top of the cabinet FIGURE 1 2 Connection Locations 1 2 B20130 ECN 11673 0201 High Primary Low Line Pressure Primary Regulator Pressure Line Regulator Switch Regulator Relief Valve Switch Regulator Relief Valve 475 525 195 205 300 360 125 130 50 55 75 475 525 295 305 400 500 230 235 170 175 250 275 325 225 235 300 360 125 130 50 55 15 Unit of measure all units are in psig Some outlet pressures will vary depending on the inlet pressure to the manifold All testing must done with full cylinders B20130 ECN 11673 0201 ADJUSTMENT SPECIFICATIONS RECOMMENDED TOOLS AND TEST EQUIPMENT Volt Ohm meter Isopropyl alcohol Phillips screwdriver Flat blade screwdriver Needle nose pliers 5 32 hex key wrench 13 16 hex socket wrench Set of combination wrenches 1 4 thru 1 1 1 8 1 3 8 1 1 2 and 1 3 4 Fluorolube S 30 lubricant Liquid leak detector Teflon tape Available from local source Available from local source Available from local source Available from local source Available from local source Av
11. LED 2 LED 5 4 x R2 1 YO RS 1 LEFT YELLOW RIGHT YELLOW j 0 VDC T VDC E R3 R6 a TRANSFORMER 115 VAC PRIMARY 24 VAC SECONDARY 4 ids LEFT RED B 1 RIGHT RED 115 VAC FIGURE 2 4 Electrical Schematic Non Pressurized 2 3 B20130 ECN 11673 0201 MANIFOLD OPERATION When both cylinder banks are full the switches all close causing the solenoid valve on the Reserve side to close and activating the system status lights The service side is determined by whichever side of the manifold is pressurized first The Service supply is indicated by the green in service light The Reserve supply is indi cated by the yellow ready for use light Changeover from the Service to Reserve side is accomplished when the Service side pressure falls below the set point of the low pressure switch When this pressure drops to the set point the low pressure switch is ac tuated causing the solenoid valve on the Reserve side to open The red replace depleted cylinders light on the Service side comes on The Reserve bank automatically begins to flow without any interruption in service line delivery pressure There are two indicators as to which bank should be changed the red replace depleted cylinders light and the cylinder bank pressure gauge After replacing empty cylinders and opening the master and cyl
12. Regulator B 71 Low Pressure Switch WME 4 4 Intermediate Gauge 400 psi G 15 400 1 8 Tube x 1 4 NPT Male WLF 3 8 3 8 Tube x 1 4 NPT Male WLF 3 5 3 8 Tube x 1 2 NPT Male WLF 3 15 1 8 NPT to 1 4 NPT Bushing BB 2 4HP 5 7 B20130 ECN 11673 0201 INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HQ2HL Series Western Enterprises Repair Drawing Mounting Block Components FRONT VIEW 2 BOTTOM VIEW DESCRIPTION PART Mounting Block 8113 1 8 Tube x 1 8 NPT Male BL 4HP Adaptor for Primary Regulator B 71 Low Pressure Switch WME 4 4 Intermediate Gauge 400 psi G 15 400 1 8 Tube x 1 4 NPT Male WLF 3 8 3 8 Tube x 1 4 NPT Male WLF 3 5 1 4 Tube x 1 8 NPT Male 90 WLF 3 3 3 8 Tube x 1 2 NPT Male WLF 3 15 1 8 NPT to 1 4 NPT Bushing BB 2 4HP gt HRW HN 5 8 B20130 ECN 11673 0201 Western Enterprises Repair Drawing VIEW B B INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HQ2 HQ2HL and HQ2HP Series and HQ2 9 Series S N greater than 11348 Primary Regulator Components VIEW C C KEY DESCRIPTION 1 Retainer O Ring 2 m 4 5 e Spring Retainer Backup Ring Small O Ring Seal Retainer Body Spring fo
13. Safety relief valves Automatic bank switching Each of the supply banks consist of a header 24 stainless steel flexible pigtails with integral check valves indi vidual header valves master shut off valves and union connections for attachment to the control unit The main components of the manifold are shown in Figures 2 1 and 2 2 Figure 2 3 shows the piping schematic and the various gas pressure areas Figure 2 4 is the schematic diagram of the electrical system of the manifold NOTE Manifolds without header valves are constructed utilizing a check valve outlet bushing The cylinder bank that supplies the piping system is known as the Service supply while the cylinder bank on stand by is referred to as the Reserve supply Gas flows from the cylinder through the SubHLY ZEE SERVE wink SUPPLY RESERVE BANK pigtails check valves headers and shut off valves T into the left and right inlets of the control section S A pressure switch port is located the inlet block for sensing cylinder pressure for verification of ade 1 quate cylinder pressure for stand by mode Gas MASTER VALVE flows through the inlet to the primary regulators on all manifolds except those for Nitrous Oxide and Carbon Dioxide service Nitrous Oxide and Carbon e EADER CHECK N Y HEADER CHECK Dioxide systems include a 500 SCFH capacity 2 xv PRESSSURE CABINATE LIGHTS heater The thermostatically controlled heat
14. Tee WLF 3 18 Outlet Block WMC 2 26 5 15 B20130 ECN 11673 0201
15. a hospital or clinic s medical gas pipeline system The manifold has an equal number of cylinders in its Service supply and Reserve supply banks automat ically switching to the Reserve supply when the Service supply becomes depleted When the manifold changes to Reserve supply it sends a signal to the hospital or clinic s medical gas alarm system alerting the personnel of the need for the exhausted bank of cylinders to be replaced with full cylinders After new cylinders are in place and turned on they are automatically placed in Reserve No manual resetting of the manifold is necessary INSTALLATION INFORMATION Manifolds should be installed in accordance with guidelines stated by the National Fire Protection Association the Compressed Gas Association OSHA and all applicable local codes The carbon dioxide and nitrous oxide manifolds should not be placed in a location where the temperature will exceed 120 F 49 C or fall below 20 F 7 C The manifolds for all the other gases should not be placed in a location where the temperature will ex ceed 120 F 49 C or fall below O F 18 C A manifold placed in an open location should be protected against weather conditions During winter protect the manifold from ice and snow In summer shade the manifold and cylinders from continuous exposure to direct rays of the sun Leave all protective covers in place until their removal is required for installation This precaution will k
16. 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 re quired to lift the diaphragm increases resulting in a higher delivery pressure from the outlet port of the regulator THREE WAY BALL VALVE The three way valve determines which line regulator will be in service see Figure 2 13 Rotating the knob 1 2 turn the changes the direction of gas flow and causes the bypass line regulator to become the service line regu lator Gas enters the three way valve through the inlet port The gas then enters the flow directional ball The direc tional flow of the gas is determined by the orientation of the valve handle The direction of gas flow can be changed by rotating the valve handle 1 2 turn FLOW DIRECTION CONTROL BALL OUTLET FIGURE 2 13 Three Way Ball Valve 2 8 B20130 ECN 11673 0201 FIELD TESTING amp TROUBLE SHOOTING SECTION 3 The manifold performance tests are used to verify the manifold functional performance When used in conjunc tion with the trouble shooting charts the technician can verify proper performance or rapidly identify the prob able source of the problem PERFORMANCE VERIFICATION PROCEDURE NOTE It may be necessary to pipe the bleed valve line outside to vent the system during testing The bleed valve is equipped with a CGA 022 RH connection 9 16
17. body 2 Insert the spring into the valve body 3 Position the new seal washer in the groove of the valve body 4 Place the valve cap over the spring and push the cap towards the body until the threads engage Rotate the 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 away from the solenoid valve 2 Connect the compression fittings to the solenoid valve and the mounting block following the instructions on page 4 2 using an 11 16 open end wrench and tighten to effect a gastight seal FIGURE 4 7 Intermediate Check Valve 4 9 B20130 ECN 11673 0201 PRIMARY REGULATOR REPAIR NOTE e Removal and Replacement procedures are to be followed only if the primary regulator assembly is to be scrapped All service may be performed to the primary regulator without removing it from the manifold Refer to Figures 4 8 and 4 9 Shutdown the manifold as explained earlier in this section Removal 1 Mark the compression fittings per instructions on page 4 2 Using an 11 16 open end wrench disconnect the outlet tubing and the relief valve tubing from the regulator at the compression fittings 2 Mark the compression fittings per instructions on page 4 2 Using a 7 16 open end wrench disconnect the gauge tubing and pressure switch tubing from the regulator at the compression fittings 3 Using two 1 1 8 open end
18. for operation When the solenoid is ener gized the pilot orifice is closed and full line pressure is applied to the top of the diaphragm through the bleed orifice thereby providing a seating force for tight closure When the solenoid is de energized the core opens the pilot orifice and relieves pressure from the top of the valve diaphragm to the outlet side of the valve This re sults in an unbalanced pressure which causes the line pressure to lift the diaphragm off the main orifice thereby opening the valve i HOUSING SOLENOID COIL PILOT ORIFICE S MOVABLE CORE DIAPHRAGM NI IS BLEED aS SN ORIFICE OUTLE m FIGURE 2 9 Solenoid Valve 2 6 B20130 ECN 11673 0201 CHECK VALVES The check valves prevent gas from flowing backward from the intermediate pressure area to the solenoid valve and primary regulator See Figure 2 10 Gas enters the check valve from the solenoid valve and pushes the check valve seat assembly away from the sealing surface of the valve body This allows the gas to flow to the outlet port of the valve When the gas flow stops the spring of the check valve pushes the v
19. open the manifold cover and remove the acorn nut from the primary regulator S l o w l y open one cylinder on the side of the regulator to be adjusted Verify the cylinder pressure gauge indicates a minimum pressure of 1400 psig on Oxygen Air and Nitrogen systems or a minimum of 600 psig on Nitrous Oxide and Carbon Dioxide systems Using a flat blade screwdriver held sideways turn the adjusting screw of the regulator in while observing the intermediate pressure gauge Set the regulator to the pressure indicated on the Adjustment Specification chart in Section 1 Open the bleed valve so as to create a slight flow of gas through the manifold Re adjust the regulator to the proper specifications if necessary 4 13 B20130 ECN 11673 0201 10 Close the bleed valve The intermediate pressure gauge will go up slightly higher than the flowing adjusted pressure Verify that the regulator does not creep by observing the intermediate pressure gauge for two minutes The gauge must indicate the same pressure at the end of the two minute period Close the cylinder valve Open the bleed valve to remove residual gas from the manifold 4 14 B20130 ECN 11673 0201 11 Close the bleed valve after the gas pressure has been 12 Install the lock nut on the primary regulator LINE REGULATOR REPAIR Refer to Figures 4 10 and 4 11 Removal 1 exhausted from the manifold OUTLET MOUNTING A BLOCK
20. the bleed valve to vent residual gas Residual gas Loro S Cover Screw could also be vented by loosening the manifold Location outlet connection to the supply main i A 4 Close the bleed valve Tighten the manifold outlet connection if gas was vented by that method H j Cover Screw 5 Disconnect electrical power from the manifold at Location the main power source CABINET WITH COVER OPEN Just removing the power will not shut the manifold down FIGURE 4 1 Cabinet Manifold 4 3 B20130 ECN 11673 0201 HIGH PRESSURE SWITCH REPLACEMENT Refer to Figure 4 2 An l NEC CONNECTION Removal 1 1 TERMINALS KEHN 1 Shutdown the manifold as explained earlier ADJUSTMENT SLEEVE 2 Disconnect the wiring from the pressure switch 3 Using a 1 1 4 open end wrench remove the pressure switch from the inlet block TM TRANSDUCER 4 Remove old sealant from the pipe fitting UNIT Replacement 1 4 NPT PRESSURE PORT 1 Apply Teflon tape to the 1 4 NPT male pipe thread of the pressure switch inlet fitting FIGURE 4 2 High Pressure Switch 4 Using a 1 1 4 open end wrench install the pressure switch into the inlet block 6 Complete the adjustment instructions below prior to installing the signal wires to the pressure switch Pressure Switch Adjustment CAUTION e Adjusting nut will turn easily until it hits a stop Do not over torque over torquing
21. to the manifold B20130 ECN 11673 0201 This page intentionally left blank 3 8 B20130 ECN 11673 0201 SECTION 4 SERVICE PROCEDURES GENERAL MAINTENANCE 1 Main section a Daily record line pressure b Monthly 1 Check regulators valves and compression fittings for external leakage 2 Check valves for closure ability c Annually 1 check relief valve pressures 2 Check regulator seats 2 Manifold header a Daily observe Nitrous Oxide and Carbon Dioxide systems for cylinder frosting or surface condensation Should excessive condensation or frosting occur it may be necessary to increase the number of cylinders or add external heaters b Monthly 1 Inspect valves for proper closure 2 Check cylinder pigtails for cleanliness flexibility wear leakage and thread damage Replace damaged pigtails immediately 3 Inspect pigtail check valves for closure ability C Every 4 Years 1 Replace all 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 pressurized caus ing death or serious injury SAFETY PRECAUTIONS 1 Examine all parts before repair Note Because manifold parts may be exposed to high pressure Oxygen and Nitrous Oxide and the condition of the unrepaired parts is unknown a repair inspection should be performed before exposing the parts to high pressure
22. wrenches loosen the inlet nut from the mounting block adaptor Continue to un screw the nut by hand until the regulator can be removed from the manifold Disassembly 1 Remove the acorn nut from the regulator by turning it counterclockwise using a 3 4 hex wrench 2 Using a flat blade screwdriver held sideways turn the adjusting screw counterclockwise until it turns freely and all compression is removed from the bonnet spring 3 Using a 1 3 8 hex wrench rotate the bonnet counterclockwise and remove it along with the pivot bonnet spring washer slip ring and diaphragm sub assembly 4 Using a 13 16 hex socket wrench rotate the nozzle counterclockwise and remove it along with the seat holder and stem compensating spring and the spring retainer In oxygen manifolds these parts are contained in a cartridge valve assembly CAUTION e not stand directly in front of the valve when performing this step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unpro tected eyes 5 Clean all interior surfaces of the regulator body with isopropyl alcohol 6 Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces Reassembly 1 Apply thin coating of Fluorolube amp S 30 lubricant to the o rings Note steps 2 6 are not applicable to Oxygen regulator cartridge valve assemblies 2 Assemble small o rings wi
23. 130 ECN 11673 0201 45 46 47 48 49 50 51 52 53 54 Close the cylinder valve on the left bank of cylinders Open the bleed valve to create a slight flow of gas through the manifold while observ ing the cylinder contents gauges The left cylinder bank gauge should begin to drop in oxygen manifold units there will be a pressure rise before the pressure will drop the right cylinder bank gauge should remain constant Observe the intermediate pressure gauge as the left side pressure continues to drop As the cylinder pressure drops on the left side the intermediate area also loses pres sure Verify that the pressure falls to the set point of the low pressure switch on the left side see the specification chart in Sec tion 1 the right solenoid valve then opens and the left intermediate pressure should stay at the low pressure switch set point Close the bleed valve Observe the cabinet system status indica tors The green indicator on the right side should be lit signifying that the right bank of cylinders is in service The red indicator on the left side should be lit signifying that the left side of the manifold is not pressur ized Remove the cover from the power supply box and connect an ohmmeter across the normally open N O and common C ter minals on the right side of the circuit board terminals 6 and 7 respectively Verify an ohmmeter reading of infinite re sistance
24. 18UNF 2A right hand thread for utilization of a hose connection The hose can be installed after completing step 1 below 10 11 12 13 Open the manifold cover by removing the two screws in the right side corners The cover is hinged on the left side Open the master valves located on the cylin der headers prior to pressurizing the mani fold S l o w l y open one cylinder valve on the left bank of cylinders S l o w l y open one cylinder valve on the right bank of cylinders Using a leak detect solution verify that there are no leaks present at the connections Close the left and right cylinder valves Open the bleed valve in the manifold to vent the system until all gas has been removed from the manifold Close the bleed valve Connect the electrical power source and sup ply electrical power to the manifold Observe the cabinet system status indica tors Verify that both green indicators and both red indicators are lit S l o w l y open one cylinder valve on the left bank of cylinders Open the bleed valve so as to create a slight flow of gas through the manifold Close the bleed valve 3 1 14 15 16 17 18 19 20 21 22 23 Verify that the left intermediate gauge indi cates the pressure as shown in the specifi cation chart in Section 1 for the primary regulator pressure page 1 3 Adjust the left primary regulator as necessary to ob tain the required pre
25. 83 See page 5 1 See page 5 1 See page 5 1 WLF 6 18 WLF 6 61 5 5 Bypass kit not on all solenoid assemblies KEY DESCRIPTION 18 19 20 3 8 Tubing L Relief Tee 3 8 Tubing R Relief Tee Left Line Regulator Assy for HQ2HP Series for HQ2 Series Three Way Valve Right Line Regulator Assy for HQ2HP Series for HQ2 Series Outlet Block Outlet Nipple Outlet Hex Nut Outlet Adaptor Line Relief Valve for HQ2 amp HQ2 9 Series for HQHP Series Pipe Away Adaptor 3 8 Tube x 1 2 NPT Male 3 8 Tubing Line Relief Tee LineReg Tee CV assembly 3 8 Tubing Tee Bulkhead PART WLF 6 64 WLF 6 62 8561 8563 WMV 2 54 8562 8564 WMC 2 26 D 20 D 7 D 34 WMV 8 75 WMV 8 250 WMV 8 7 WLF 3 15 8341 8582 8321 Right Solenoid Valve Assem 8551R B20130 ECN 11673 0201 Western Enterprises Repair Drawing INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HQ2HL Series Manifold Components KEY DESCRIPTION PART Gauge Plate Assembly 8542 Relief Piping Adaptor WLF 3 12 3 8 Tube Bulkhead WLF 3 13 3 8 Tube Tee WLF 3 14 Left Solenoid Valve Assem 85521 3 8 Tubing Right Reg Sol
26. AUTOMATIC CHANGEOVER MANIFOLD WESTERN INNOVATOR HQ2 HQ2HL amp HQ2HP SERIES SERVICE MANUAL Western Enterprises Printed in USA B20130 ECN 11673 0201 SAFETY Statements in this manual preceded by the following safety signal words are of special significance Definitions of 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 ingored It also may mean a hazard that will only cause damage to property NOTE Indicates points of particular interest for more efficient and convenient operation INTRODUCTION This manual provides the information needed to service the Western Enterprises HQ2 HQ2HL and HQ2HP 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 subjected to change without notice WARRANTY Western Enterprises makes no warranty of any kind with regard to the material in this manual including but not limited to the implied warranties of merchantability and fitness for a particular purpose Refer to the Installation and Operating Instructions manual fo
27. F 3 8 2 Diaphragm Assembly RWS 3 26 10 Inlet Nut 92 3 Slip Ring RWS 3 17 11 Inlet Nipple 15 8 Washer RWS 3 28 12 1 8 Tube x 1 4 NPT 90 WLF 3 7 Bonnet Spring RWS 1 12 13 1 4 NPT Elbow M x F BL 4 4LP Pivot RWC 2 8P 14 3 8 Tube x 1 4 NPT 90 WLF 3 6 Adjusting Screw RWS 3 3 15 Safety Relief Valve 8533 Acorn Nut RWS 3 1 16 Relief Valve Adaptor 8131 Item included in repair kits Repair Kit for HQ2 9 Series RK 1023 5 10 B20130 ECN 11673 0201 Western Enterprises Repair Drawing OUTLET INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HQ2 HQ2HL amp HQ2HP Series Right Line Regulator Components DESCRIPTION Line Regulator for HQ2HP Series for HQ2 amp HQ2HL Series 3 8 Tube x 1 2 NPT Elbow 3 8 Tube End x 1 2 NPT Adapter Repair Kit for Line Regulator Internal Parts Components not shown 5 11 RK 1100 B20130 ECN 11673 0201 Western Enterprises Repair Drawing INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HQ2 HQ2HL amp HQ2HP Series Left Line Regulator Components OUTLET DESCRIPTION Line Regulator for HQ2HP Series for HQ2 amp HQ2HL Series 3 8 Tube x 1 2 NPT Elbow 3 8 Tube End x 1 2 NPT Adapter Repair Kit for Line Regulator Internal Parts Components not shown 5 12 RK 1100 B20130 ECN 11673 0201 Western Enterprises Repair Drawing INNOVATOR
28. ailable from local source Available from local source Available from local source Manufactured by Occidental Chemical Corporation Niagara Falls New York Available from Western Enterprises Part number LT 100 Available from Western Enterprises Part number MTT 1 or MTT 2 Fluorolube is a registered trademark of Occidental Chemical Corporation Teflon is a registered trademark of E I du Pont de Nemours amp Co Inc 14 B20130 ECN 11673 0201 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 compo nents of the manifold The second part of this section explains in detail the operation of the individual compo nents contained in the manifold control section GAS FLOW THROUGH THE MANIFOLD The automatic changeover manifold consists of a manifold control unit and two supply bank headers The two supply banks alternate between service and reserve to provide an uninterrupted supply of gas The manifold control includes the following components and features Green in service indicator light for each cylinder bank Yellow ready for use indicator light for each cylinder bank Red replace depleted cylinders indicator light for each cylinder bank Cylinder bank pressure gauges Line pressure gauge
29. alve seat down on the sealing surface preventing any gas FIGURE 2 10 Check Valve flow backward through the valve SOLENOID BYPASS The bypass is to provide gas to the outlet of the solenoid in case the outlet fitting leaks The bypass will ensure that the maximum pressure differential across the solenoid is not exceeded Gas enters the inlet of the bypass check valve from the solenoid inlet Gas also enters the outlet of the bypass from the outlet of the sole noid During normal operation the inlet and the outlet pressures are equal The bypass check valve is set around 130 psig it takes 130 psig differential from the inlet to the outlet to open the bypass check valve The only time this check valve will open is if the solenoid outlet fitting leaks If the outlet fitting leaks the bypass check valve will open and permit gas to flow This flow of gas will ensure that the maximum allowable differential pressure of the solenoid is not exceeded FIGURE 2 11 Solenoid Bypass Valve LINE PRESSURE REGULATORS The line pressure regulator used in the manifold is a single stage four port adjustable regulator The regulator utilizes a tied diaphragm valve seat design to achieve maximum flow rates Refer to Figure 2 12 It has one inlet port and three outlet ports The inlet port is piped to an intermediate pressure port in the manifold block One outlet port is piped to the outlet of the manifold for connection to the mai
30. bleed valve is connected to one outlet port which is only used during field service to set the regulators and switches Tubing is connected from the second outlet port to the line pressure gauge to sense the pressure of the gas on the downstream side of the line regulator A line pressure relief valve is also located on the outlet block This relief valve is connected via tubing to the primary regulator relief valves The tubing is routed from these relief valves to the outside of the control unit for piping to the outside of the building for manifolds located indoors The gas flows from the outlet block to the pipeline distribution system TS L 7 MOV 2 MOV 1 TS 145 I REMOTE ALARM INTERFACING ERMINAL STRIP S SOLENOID SOLENOID TOCATED ON RIGHT SIDE VALVE Ens 48 TS 1 46 8 VALVE F RIGHT THE PCB IN THE POWER SUPPLY BOX REMOTE ALARM SIGNAL LEFT HIGH RELAY PROVIDES DRY CONTACTS PRESSURE SWITCH RIGHT HIGH PRESSURE SWITCH AT POSITIONS 5 6 AND 7 _ NO 1 N C 24 VAG TS TS 1416 5 _ 14 TS 1 13 C 50 60 7 8 E 0 Bw TS 1 11 TS 1 49 152 010 al Ad N C 000 LEFT 10 RIGHT L PRESSURE SWITCH PRESSURE SWITCH REMOTE ALARM SIGNAL AC LED 4 LED 1 a Yo R4 R1 RICHT GREEN Q LEFT CREEN
31. bre Hn i d 2 5 Low Pressure Switches 05 ot eu d b alt a e a 2 6 SOLENOID Valves 31 le n d bt t a bus ta t ben ug RN ei a aH 2 6 CHECK VAlVeS I 2 7 hine Pressure REUN itil th tin pe RE HER gd debe Hn Pee pH Hd d n ae eat 2 7 Three Way Ball Valve 4 2 ate a ete eite ute udete te gie deut etr utei dtu fotu 2 8 SECTION 3 FIELD TESTING AND TROUBLE SHOOTING 3 1 Performance Verification Procedure sssssssssssssssssssseseeeeeeeene nennen nnne nnne nennen nnns 3 1 TROUDIE SHOOUMG EI Mm 3 4 SECTION 4 SERVICE PROCEDURES 4 1 IC Iz BETREUER 4 1 Safety Precautlons debis mbi edis mnia bi eed 4 1 Cleaning Lubrication and Sealing ssssssssssssssssssssssssseseeeenne nnne 4 2 General Repair Procedures enne nnne enne tn nnr nets eterni nrnr tn 4 3 How to Shutdown the Manifold esses nennen nennt nnne nnne nentes 4 3 High Pressure Switch Replacement ccccseceeeceeseeeeeeeeeeeeeeeeaeeeeesaeeeaeesaeeeeesaeesaeesaeeeaeesaeesaeeseeseaeeseeeatesas 4 4 Low Pressure Switch 4 5 Manifold Controller Printed Circuit Board Replacement sssssssssssseeeeenennee nnns 4 6 Gauge Replacement asea rrna aa ee dnbie e e 4 7 So
32. dating the regu lators to the latest configuration both regulators and solenoid bypass check valves P N WMV 5 15 for Air CO2 N20 He and P N WMS 1 134 for oxygen must be replaced 5 1 B20130 ECN 11673 0201 VALVES AND VALVE REPAIR KITS 942 3 2 tacta Solenoid Valve for all HQ2 and HQ2HP Breathing Air He N2 O2 9422 iicet Solenoid Valve for all HQ2HL N20 and CO2 manifolds 5 1 53 540 Spud Check Valve 5 1 64 280 Spud Check Valve WMV 2 7 CGA 320 Header Valve WMV 2 4 CGA 346 Header Valve 2 14 326 Header Valve WMV 2 3 580 Header Valve 2 54 Three Way Bypass Valve WMV 2 16 Master Valve WMV 5 15 Solenoid Bypass Check Valve RK 1085 Repair Kit for WMV 2 16 PRESSURE SWITCHES 9413 sete High Pressure Switch for all series 4 4 Low Pressure Switch adjustable 0 300 psi 4 4 Low Pressure Switch Oxygen POWER SUPPLY REPLACEMENT PARTS Manifold Controller PCB 85700 Power Supply Assembly transformer case and cable WME 8 1 Power Supply includes contacts
33. dica tors Both green indicators and both red in dicators should be lit Close the bleed valve Remove the hose con nection used to vent gas to the outside if applicable Close the manifold cover using the two screws in the corners on the right side of the cover to secure it Remove the ohmmeter leads from the con nections in the power supply box and rein stall the box cover B20130 ECN 11673 0201 TROUBLE SHOOTING SYMPTOM CABINET INDICATOR LIGHTS No indicator lights on front panel come on when power is hooked up PROBABLE CAUSE Power Input Internal wiring disconnected Manifold controller PCB defective Only qualified repair personnel should make repairs REMEDY OR CHECK Check electrical power supply Check all wiring connections Replace manifold controller PCB Red Indicator light is on but both banks are full Note Full cylinder pressure is considered to be pressure above the high pressure Switch setting see page 1 3 Master valve header valves or cylinder valves on bank are closed Low pressure switch set to open above the primary regulator set ting Primary regulator setting below the low pressure switch setting Bank pressure below high pressure switch setting Slowly open valves Adjust pressure switch or return faulty unit for factory setting Set primary regulator delivery pressure to specifications Replace cylinders if below switch factory setting
34. eep mois ture and debris from the piping interior avoiding operational problems Overall Manifold Length 1 1 2typ 17 Note All dimensions are approximate Total number of cylinders 4 6 8 Overall manifold length FIGURE 1 1 Installation Dimensions 1 1 B20130 ECN 11673 0201 MANIFOLD SPECIFICATIONS Flow Capability Oxygen 2000 SCFH maximum at 50 psig delivery and 2000 psig inlet pressure Nitrogen 3000 SCFH maximum at 160 psig delivery and 2000 psig inlet pressure Nitrous Oxide flow capability of a Nitrous Oxide cylinder manifold will depend upon conditions at the installation site demands of the delivery system and the number of cylinders in supply service Maximum capability is 500 SCFH at 50 psig delivery and 750 psig inlet pressure Installing a Nitrous Oxide manifold in a location which exposes it to ambient temperatures below 20 F 7 C is not recommended Higher flows are obtainable by adding additional cylinders or heaters Please call Western for Technical Information Breathing Air 2000 SCFH maximum at 50 psig delivery and 2000 psig inlet pressure Helium 2000 SCFH maximum at 50 psig delivery and 2000 psig inlet pressure Carbon Dioxide The flow capability of a Carbon Dioxide cylinder ma
35. embly on the body with the spring retainer facing up 2 Insert the new stem seat assembly through the backcap port and screw into the diaphragm assembly by hand Stabilize the diaphragm assembly using one hand and snug up the seat stem assembly with the other hand using a 1 4 open end wrench Do not over tighten 3 Place the new gasket in the backcap groove 4 Place the conical spring large end first into the backcap cavity 5 Carefully line up the spring small end so that it slides over the wrench flats on the seat stem assembly and screw the backcap into position Tighten with a 1 1 2 hex wrench 4 15 B20130 ECN 11673 0201 N Q 10 11 Line up the diaphragm holes with the screw holes in the body Set the bonnet spring in the retainer on the diaphragm assembly Set the pivot on top of the spring pointed end down Set the bonnet carefully over the spring and pivot and line up the screw holes in the bonnet with the screw holes in the body Insert the six screws in the screw holes and tighten by hand Use a phillips head screwdriver and tighten the Screws in a crisscross manner Remove the regulator from the vice Replacement 1 Install the regulator in the manifold 2 Tighten the inlet and outlet union connections per the instructions on page 4 2 Use a 11 16 open end wrench to snug up the connections per instructions on page 4 2 3 Leak test all of the line regulator connections and the c
36. ents Replace solenoid bypass 3 6 B20130 ECN 11673 0201 SYMPTOM LOSS OF RESERVE BANK CONTENTS continued Opposite bank feeding PROBABLE CAUSE Solenoid valve wiring incorrect REMEDY OR CHECK Swap wiring from one solenoid valve to the other Reduce flow demand Set delivery pressure per specifica tions Premature changeover to re serve bank PIPELINE DISTRIBUTION Pipeline not at desired pressure Flow demand too high Primary regulator setting too low Line regulator not set correctly Readjust line pressure regulator Readjust line pressure regulator Consult factory Required gas flow not available MANIFOLD LOCKS UP OR WON T FLOW Reserve bank won t flow or the manifold locks up and nei ther bank will flow Line regulator not set correctly Flow demand too high Leakage at outlet fitting of the so lenoid that will not open Primary regulator set pressure 150 psig higher than the change over pressure 3 7 1 Remove power from the system 2 Close valves on the cylinders 3 Deplete gas from the headers by cracking open a fitting 4 Tighten solenoid outlet fitting 5 Open the cylinder valves 6 Reconnect power to the manifold 1 Remove power from the system 2 Close valves on the cylinders 3 Deplete gas from the headers by cracking open a fitting 4 Reset the primary regulator 5 Open the cylinder valves 6 Reconnect power
37. er b N warms the gas before entering the regulator pre E i ii i B venting freeze up and loss of pressure due to the N i extreme low temperatures generated when these MASTER VALVE gases rapidly expand An amber light on the con LEFT BANK RIGHT BANK trol indicates when the heater circuit is on Tubing is connected from the primary regulator high pres sure port to the cylinder pressure gauges to sense the supply pressure of the gas in the cylinders FIGURE 2 1 External Components 2 1 B20130 ECN 11673 0201 To pipeline distribution Vent to LEGEND system Cabinet outside of building High Pressure Switch Primary Regulator Relief Valve Low Pressure Switch Inter Press Gauge Solenoid Valve Check Valve Line Regulator Bleed Valve Line Relief Valve Bypass Valve 12 Solenoid Bypass Installed in systems after July 1 1994 FIGURE 2 2 Internal Components 5 To Pipeline Vent to Outside Line Pressure Line Distribution System of Building Intermediate Pressure Pressure Line Relief Valve Cylinder Pressure Gauge Relief Vent Line Line Bleed Valve Check Valve Check Valve
38. for remote alarms REMOTE ALARMS 24 VAC Service BIAST tennis aee Visual 1 Gas BIA 2 hende Audio Visual 2 Gases pe ute Audio Visual 1 Gas 5 2 B20130 ECN 11673 0201 Western Enterprises Repair Drawing KEY DESCRIPTION Outlet Grommet Inlet Grommet Plug Wire Clip Printed Circuit Board PCB Cover Red Lens Yellow Lens Green Lens 6 32 Self Tapping Screw PCB Support 1 2 Outlet Block Spacer 5 3 INNOVATOR AUTOMATIC CHANGEOVER MANIFOLD HQ2 amp HQ2HP Series Miscellaneous Hardware KEY DESCRIPTION 13 Mounting Screw 14 3 8 16 x 3 Bolt 15 Block Spacer 16 3 8 Lock Washer 17 3 8 16 Hex Nut 18 Wiring Harness 19 Screw Receptacle 20 3 16 32 X 3 Bolt 21 3 16 Lock Washer 22 3 16 32 Hex nut Wire Nut tem not pictured PART WMC 6 49 8170 8151 8171 WMC 6 6 8571 WMC 6 35 EQ 106 WMC 6 12 WMC 6 8 WME 8 58 B20130 ECN 11673 0201 INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HQ2HL Series Repair Drawing Miscellaneous Hardware KEY DESCRIPTION PART DESCRIPTION PART Outlet Grommet 8281 3 8 Lock Washer 8171 Inlet Grommet 8280 3 8 16 Hex Nut WMC 6 6 Strain Relief Bushing WME 8 34 Wiring Harness 8571 Wire Clip 8242 115 Volt Bulb WME 8 10 Printed Circuit Board 8450 Indicator Receptacle amp Lens WME 8 72 PCB Cover 8246 Wire Terminal WME
39. forced down by the spring the stem is pushed away from the nozzle and gas can then flow from the high pressure chamber to the low pressure chamber When the low pressure chamber fills with gas the gas will push upward against the diaphragm sub assembly As the pressure continues to build in the low pressure chamber more upward force will be exerted against the diaphragm and the diaphragm will push up against the bonnet spring compressing the bonnet spring As the diaphragm is gradually raised by the gas pressure the seat and nozzle gradually come closer together filling the low pressure chamber slowly and eventually the upward pressure exerted by the gas will be slightly greater than the downward pressure of the bonnet spring and the seat nozzle will close As gas is released from the 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 re quired to lift the diaphragm increases resulting in a higher delivery pressure from the outlet port of the regulator LOCK NUT _ ADJUSTING se SCREW mE DIAPHRAGM BONNET SPRING SEAT AND NOZZLE LOW PRESSURE CHAMBER INLET PORT H OUTLET PORT HIGH PRESSURE CHAMBER FIGURE 2 7 Primary Regulator 2 5 B20130 ECN 11673 0201 LOW PRESSURE SWITCHES The low p
40. g Hex Nut Screw Post Gauge Screw FIGURE 4 6 Gauge Plate Assembly 4 7 B20130 ECN 11673 0201 SOLENOID VALVE REPLACEMENT NOTE e It may be desirable to remove the gauge plate brackets prior to disassembly for easier access to the solenoid valve It is not necessary to remove the valve from the system for repairs To remove the gauge plate brackets use a flat blade screwdriver to remove the 4 screws holding the gauges in place The gauge plate brackets can now be removed by removing the eight mounting screws with a phillips head screwdriver Removal 1 Shutdown the manifold as explained earlier in this section 2 Disconnect the electrical wires at the wire nut attachment points 3 Mark the compression fittings per instructions on page 4 2 disconnect the tubing at the compression fittings using an 11 16 open end wrench 4 Remove the solenoid assembly from the control section Remove the four valve bonnet screws valve bonnet disc holder sub assembly disc holder spring dia phragm spring sub assembly and body gasket It may be necessary to bend body assembly and tubing to clear mounting bracket to ease removal of some parts Replacement 1 Position the solenoid assembly with the inlet end connected to the primary regulator outlet tubing NOTE e Should diaphragm spring sub assembly become disassembled be sure to replace the dia phragm spring support with the lip facing upward towards the valve bo
41. g gasket seals leaks may occur at seals made by gaskets such as diaphragms or o rings Gas may leak to atmosphere or across the seal into the opposite pressure circuit External leaks are evidenced by application of leak detector while leaks across the seal are detected by faulty manifold function When replacing seals use care not to damage sealing surfaces 4 2 B20130 ECN 11673 0201 GENERAL REPAIR PROCEDURES Be sure all pressure and electrical power is removed from the system prior to initiating any repair procedures WARNING e Do not shutdown the manifold until all personnel have been advised of the intended service and all pa tients requiring medical gas are being supplied from portable supplies Patients still on the manifold pipe line will not receive gas Replace parts with all components in the repair kit HOW TO SHUTDOWN THE MANIFOLD 1 Turn off the piping system isolation valve if present If an isolation valve is not present the entire building s gas system will be reduced to atmospheric pressure WARNING Do not shut down the manifold until all personnel have been advised of the intended service and all patients Bleed Valve requiring medical gas are being supplied from portable supplies Manifold Outlet Union 2 Turn off right and left supply bank cylinder valves to Supply Main N p 3 Open the manifold cover by removing the two mn screws in the corners on the right side and open dl Has c
42. gas 2 Keep manifold parts tools and work surfaces free of oil grease and dirt These and other flammable materials may ignite when exposed to high pressure Oxygen or Nitrous Oxide 3 Useonly proper repair tools and parts Parts for Western manifolds are shown in this instruction Special tools are called out as needed 4 Before connecting the cylinder to the manifold momentarily open and close the cylinder valve to blow out any dirt or debris 5 After connecting the cylinder to the manifold open the cylinder valve s l o w l y to allow the heat of compres sion to dissipate 6 Useonly cleaning agents sealants and lubricants as specified in this instruction 4 1 B20130 ECN 11673 0201 CLEANING LUBRICATION AND SEALING Clean metal parts of the manifold with isopropyl alcohol prior to assembly Dry thoroughly Do not clean o rings with this solvent Freon TF is acceptable Teflon amp 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 Ap proximately 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 retightening make sure the assembly has been inserted into the fitting until the ferrule seats in
43. he tubing connected to the gauges Damaged tubing may burst when pressurized 3 Pull the mounting plate up so that it provides easy access to the gauge screws on the underside of the gauge plate 4 Mark the compression fittings per instructions on page 4 2 Using 7 16 open end wrench disconnect the tubing from the defective gauge When re tightening the fitting the procedure outlined on page 4 2 shall be followed 5 Using a 3 8 hex wrench remove the two screws holding the gauge brackets Slide the gauge brackets off of the screw posts 6 Slide the gauge out through the front of the gauge plate 7 Using a 3 4 hex wrench remove the compression fitting from the gauge Use a 9 16 open end wrench to stabilize the gauge 8 Remove the old sealant from the 1 4 NPT female pipe thread on the compression fitting Replacement 1 Apply Teflon tape to the 1 4 NPT male pipe 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 Ifthe gauge needle is not on zero unscrew the gauge bezel and adjust the needle using a flat blade screwdriver 4 install the mounting screws to secure the gauge plate to the gauge brackets Front View Gauge Plate Brackets gt Mounting Screws UT T T Tu Bottom View Gauge Brackets Compression Fittin
44. inder valves the cylinder pressure will actuate the high pressure switch the red replace depleted cylinders light will be extinguished and the yellow ready for use light will come on There are no levers or knobs to reposition after replacement of an empty bank HIGH PRESSURE SWITCHES The high pressure switches used in the manifold are diaphragm piston type with one pressure port for sensing gas pressure as shown in Figure 2 5 The switches have three electrical contacts common normally closed and normally open See Figure 2 6 For proper manifold operation signal wires are be connected to the com mon and normally closed terminals When the manifold is pressurized to the normal pressures the piston in the switch is pushed up The piston pushes the activator of the switch up This action closes the normally open contact and opens the normally closed contact As the 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 7 SWITCH TERMINALS Sud USTMENT SLEEVE SWITCH SCHEMATIC N O CO mewspucER C UNIT NAR A FIGURE 2 6 Switch Schematic FIGURE 2 5 High Pressure Switch PRESSURE PORT 2 4 B20130 ECN 11673 0201 PRIMARY REGULATORS The primary
45. ion pressure the ohmmeter reading should drop from infinite resistance to zero resistance Close the bleed valve 6 Using a flat blade screwdriver turn the knurled adjustment screw on the pressure switch clockwise to raise the set point or counterclockwise to lower the set point The pressure switch should be set per the Adjustment Specification chart in Section 1 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 wires may shock the service technician 8 After the setting has been made connect the signal wires to the common C and normally closed N C contacts on the pressure switch 4 5 B20130 ECN 11673 0201 MANIFOLD CONTROLLER PRINTED CIRCUIT BOARD REPLACEMENT Refer to Figures 4 4 and 4 5 Removal PCB SUPPORT CAP BASE 1 Shutdown the manifold as explained earlier in this section 2 Disconnect the plug from the top of the circuit board by grasping the plug on each end with one hand and stabilizing the circuit board with the other Work the plug back and forth side to side slightly while pulling up until it releases 3 Press the locking feature of one circuit board sup port and pull the circuit board away from the mani fold cover sligh
46. lenoid Valve Replacement cccccceseceeeeeeeeeaeeeeeeeeeeeeeeaaeeseaeceeaeeeecaaeesaeeseaeeseaeessaeeseeaeeseaeeneeseaeeesaeessiseess 4 8 Intermediate Pressure Check Valve Repair cccccceeecceceeeeeeeeeeeeeeeeaeececeaeeceaeeseaeeseaeeecaeeseaneetaaeeseeessaeessaees 4 9 Primary Regulator entia pan reet eredi i edd dre dates 4 10 Eine Regulator Sepalt dh len han ean ea et dt canes emet ates ee ee 4 15 B20130 ECN 11673 0201 SECTION 5 MAINTENANCE AND REPAIR PARTS 5 1 Replacement ATS 5 1 Indicator Lamp and Replacement Parts 5 1 Panel Mount Gauges endrerit eben ade ava ERE eg 5 1 Regulators and Repair Kits nete tee b Head ba ead a e RA need 5 1 Valves and Valve Repair Kits cccccccccceeceeeceeeeeeeseeeeeneeceneecaeeecaceesaaeesaeeecaeeecaeeesaceesaeeseaaeeeeeseaeeeeaseesiaeeesaees 5 2 Pressure Switches eee tete er die Ha terne licent A reti e etae eA teram dade 5 2 Power Supply Replacement Parts sssssssssssssssssssseeeee nennen nnne tenerte nnne tr entrent nnns 5 2 Remote Alarms s emet eee eee edite btt etti etr 5 2 SECTION 5 MAINTENANCE AND REPAIR PARTS Repair Drawings 5 3 Miscellaneous Hardwa
47. m signals are opposite of manifold status ABNORMAL LINE PRESSURE SIGNAL Low pressure alarm activated Faulty connection to remote alarm unit Line pressure regulator improperly adjusted Closed master valves header valves or cylinder valves Empty cylinders Primary regulator setting too low Faulty line pressure gauge Faulty alarm pressure switch Check input from alarm unit to terminal strip Readjust line pressure regulator Slowly open valves Replace with full cylinders Set delivery pressure to specifications Replace line pressure gauge Readjust or replace pressure Switch as necessary High pressure alarm activated LOSS OF CYLINDER CONTENTS Audible or inaudible gas leak age unknown origin Line regulator setting too high Regulator freeze up Nitrous oxide or carbon dioxide Faulty line pressure gauge Faulty alarm pressure switch Leakage at manifold piping connections Leakage at manifold tubing connections Leakage in downstream piping system Readjust line pressure regulator Reduce the flow demand or increase the number of supply cyl inders Replace line pressure gauge Readjust or replace pressure Switch as necessary Tighten reseal or replace Tighten reseal or replace Repair as necessary 3 5 B20130 ECN 11673 0201 SYMPTOM LOSS OF CYLINDER CONTENTS continued Audible or inaudible gas leak age unknown origin
48. may cause damage damaged switch may burst or fly apart when pressurized 1 The plastic housing is rotated to adjust the pressure switch 2 Connect an ohmmeter to the normally closed and common electrical contacts on the switch The ohmmeter should register zero resistance 3 Begin pressurizing the manifold by opening one cylinder valve on the side of the manifold the switch is on 4 Observe the cylinder pressure gauge and the ohmmeter to determine switch setting At the actuation pressure the ohmmeter reading should jump from zero resistance to infinite resistance 5 Cycle between actuation and reactuation signals and make adjustment to the nut as required to achieve the signal setting per the Adjustment Specifications chart in Section 1 The actuation pressure setting should be made on increasing pressure only The reacutation point will be slightly lower than the acuation point WARNING e sure power is off when electrical connections are made Current flowing through the wires may shock the service technician 6 Afterthe setting has been made connect the signal wires to the common C and normally closed N C contacts on the pressure switch 4 4 B20130 ECN 11673 0201 ADJUSTING SCREW LOW PRESSURE SWITCH REPLACEMENT SWITCH PRESSURE PORT Refer to figure 4 3 a Removal O 1 Shutdown the manifold as explained earlier in this section END VIEW SIDE VIEW 2 Loosen the slot head screw
49. n pipeline One port is connected to the delivery line pressure gauge and the other outlet port is connected to a bleed valve for use in field adjust ment 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 FIGURE 2 12 Line Regulator 2 7 B20130 ECN 11673 0201 As the adjusting screw is turned in it compresses the spring and puts a downward force on the diaphragm sub assembly The bottom of the diaphragm sub assembly is connected to the seat holder When the diaphragm is forced down by the spring the stem is pushed away from the nozzle and gas can then flow from the high pres sure chamber to the low pressure chamber When the low pressure chamber fills with gas the gas will push upward against the diaphragm sub assembly As the pressure continues to build in the low pressure chamber more upward force will be exerted against the diaphragm and the diaphragm will push up against the bonnet spring compressing the bonnet spring As the diaphragm is gradually raised by the gas pressure the seat and nozzle gradually come closer together filling the low pressure chamber slowly and eventually the upward pressure exerted by the gas will be slightly greater than the downward pressure of the bonnet spring and the seat nozzle will close As gas is released from the low pressure chamber a proportional
50. n the side that is in service will be open The solenoid valve on the Reserve side will be closed if the cylinder pressure on that side is above the high pressure switch setting listed in Chart 1 page 1 3 The Service side is determined by whichever side of the manifold is initially pressurized Gas on the Reserve side is stopped at this point by the closed solenoid valve The gas from the Service side continues to flow entering a check valve after leaving the solenoid valve The check valve prevents the gas from flowing backwards towards the solenoid valve when the reserve side is in use The gas flows from the check valve into a three way bypass valve This three way valve toggles the gas be tween the supply circuit and a bypass circuit The supply circuit and the bypass circuit are identical The by pass circuit allows the supply line regulator to be removed without interrupting the gas supply The gas flows from the three way valve to the inlet of the line regulator The line pressure regulator further re duces the pressure to the final pressure delivered to the medical gas piping system The regulator has one inlet port and three outlet ports Two of the three outlet ports are not used and are plugged Gas flows through the third outlet port into a check valve This check valve keeps gas from back flowing into the line regulator when the bypass circuit is being used The gas flows from the check valve into the outlet block assembly A
51. nifold will depend upon conditions at the installation site demands of the delivery system and the number of cylinders in supply service Maximum capability is 500 SCFH at 50 psig delivery and 750 psig inlet pressure Installing a Carbon Dioxide manifold in a location which exposes it to ambient temperatures below 20 F 7 C is not recommended Higher flows are obtainable by adding additional cylinders or heaters Please call Western for Technical Information Power Source Requirements 115 VAC to 24 VAC power supply is provided with the manifold to operate the solenoid valves and alarm lights on the manifold Under normal operation the manifold will draw a maximum of 1 5 amperes A five terminal remote alarm terminal strip is on the right side of the circuit board in the power supply box for re mote alarm interfacing The top three terminals on this strip N C N O and C provide dry contacts for hookup to the hospital or clinic s medical gas alarm system Contacts are rated up to 3 amps 30 VDC or 2 amps 250 VAC Nitrous Oxide and Carbon Dioxide systems include a 500 SCFH capacity heater The thermostatically control led heater warms the gas before entering the regulator preventing freeze up An amber light on the control in dicates when the heater circuit is on The heater operates at 115 VAC and draws approximately four amperes Piping Connections Header Inlets Carbon Dioxide CGA 320 Nitrous Oxide CGA 326
52. nnet 2 Connect the compression fittings using an 11 16 open end wrench and tighten to effect gas tight seal When retightening the compression fitting follow the procedure outlined on page 4 2 4 8 B20130 ECN 11673 0201 INTERMEDIATE PRESSURE CHECK VALVE REPAIR Refer to Figure 4 7 Removal 1 Shutdown the manifold as explained earlier in this section 2 Mark the compression fittings per instructions on page 4 2 Disconnect the tubing at the compression fittings to the solenoid valve and the mounting block using an 11 16 open end wrench 3 Remove the check valve and tubing assembly from the control section Disassembly 1 Secure the check valve in a vice 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 Pullthe 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 isopropyl alcohol or 1 1 1 trichloroethane solvent CAUTION e not stand directly in front of the valve when performing the next step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 6 Blow out the check valve body with oil free Air or Nitrogen to remove all foreign material and dry all surfaces Reassembly 1 Insert a new valve poppet into the valve
53. onnections on the check valve SPRING RSS TI aan CENA ANA FIGURE 4 11 Line Regulator 4 16 B20130 ECN 11673 0201 SECTION 5 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 stand ards of performance and the safety of the product REPLACEMENT PIGTAILS 24 Stainless Steel Flexible Braid with Check Valves PF 320CV 24R CGA 320 for Carbon Dioxide CO2 Service PF 326CV 24R CGA 326 for Nitrous Oxide N2O Service PF 346CV 24R CGA 346 for Breathing Air Air Service PF 63CV 24 CGA 540 for Oxygen O2 Service PF 92CV 24R CGA 580 for Nitrogen N2 Service PF 280CV 24 CGA 280 for Medical Mixtures 24 Synthetic Fiber Braid Hose with Check Valve PFS 92CV 24R CGA 580 for Helium He Service INDICATOR LAMP REPLACEMENT PARTS for Nitrous Oxide or Carbon Dioxide Heater 8 5 Bulb Receptacle WME 8 8 Amber Lens WME 8 10 115 V Light Bulb PANEL MOUNT GAUGES 2 Diameter 1 4 NPT Back Port 3 3 100 psi 3 4 400 psi WMG 3 8 2000 psi WMG
54. per Hour FT LBS Foot Pounds VAC Voltage Alternating Current IN LBS Inch Pounds VDC Voltage Direct Current N C Normally Closed PCB Printed Circuit Board N O Normally Open NPT National Pipe Taper Western Enterprises shall not be liable for errors contained herein or incidental or consequential damages in connection with providing this manual or the use of material in this manual ii B20130 ECN 11673 0201 TABLE OF CONTENTS SECTION 1 INTRODUCTION 1 1 Product B ordeo 1 1 Installation Information sse enne nennen _ nennen 1 1 Manifold Specifications cccccccccceeecceeeceeeeeeceeeseeececeeceaeeceaeeccaeeecaceesaaeeseaeeccaeescaeeecaceeseaeesereceaeeseaeessiseeeaseeeans 1 2 Adjustment Specifications aissius tice cnet ne eee etn e tu etn ane ta ante 1 4 Recommended Tools and Test Equipment nennen nennen nnns 1 4 SECTION 2 THEORY OF OPERATION 2 1 General Information oe n ete e tb atti d i ion Boe 2 1 Gas Flow Through thie Marifold e e Oe E a e PR IR e OL n HER 2 1 Manifold Operations ts nii d e tt e e b t a e aa gate ea a ad de oae 2 4 High Pressure SWIECIIGS x rete ete P eH HR dH bei HORE e MEL LE t et de e dee dt 2 4 Primary Begulators 1 edere Le P m iH d HR HL gb e ete
55. r HQ2 9 Series for all others Seat Stem Assembly for HQ2 amp HQ2HP Series for HQ2HL Series for HQ2 9 Series Filter Gasket Large O Ring Nozzle for HQ2 9 Series for all others Diaphragm Assembly Slip Ring PART RO 012E RWS 3 15 RWS 5 7 RWS 3 47 RWS 6 4 RWS 1 17 RWS 1 8 RWS 3 6 RWS 3 6 RWS 6 3 S 5 RWS 3 70 RO 015E RWS 5 1 RWS 3 18 RWS 3 26 RWS 3 17 5 9 KEY DESCRIPTION PART 14 Washer RWS 3 28 15 Bonnet Spring RWS 7 54 16 Pivot RWC 2 8P 17 Adjusting Screw RWS 3 3 18 Lock Nut WMC 6 90 19 1 8 Tube x 1 4 NPT 90 WLF 3 7 20 1 4 NPT Elbow M x F BL 4 4LP 21 3 8 Tube x 1 4 NPT 90 WLF 3 6 22 1 8 Tube x 1 4 NPT Male WLF 3 8 23 Inlet Nut 92 24 Inlet Nipple 15 8 25 Safety Relief Valve for HQ2 amp HQ2HL Series 8531 for HQ2HP Series 8533 26 Relief Valve Adaptor 8131 tems included in repair kits See page 5 1 Item 1 part no RO 012E not included with Manifolds after serial number 20799 B20130 ECN 11673 0201 INNOVATOR Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD HQ2 9 Series S N up to 11348 Repair Drawing Primary Regulator Components c H 12 PORT a Xo o nues INLET OUTLET t D VIEW 1 1 9 KEY DESCRIPTION PART KEY DESCRIPTION PART 1 Cartridge Assembly RWD 2 19 9 1 8 Tube x 1 4 NPT Male WL
56. r contents gauge indicates a minimum of 1400 psig for Oxygen Nitrogen Air or gas mixtures systems Nitrous Oxide and Carbon Diox ide systems should indicate a minimum of 600 psig Verify that the line pressure gauge is indicat ing a minimum of 50 psig on all systems except Nitrogen Nitrogen should indicate a minimum of 160 psig Adjust to the proper line pressure if necessary Verify that the line pressure regulator is func tioning properly by observing the line pres sure gauge for two minutes The gauge should indicate the same pressure at the end of the two minute period Open the bleed valve to create a slight flow of gas through the manifold Verify that the line pressure regulator main tains a constant pressure by observing the line pressure gauge Close the bleed valve Verify the cabinet system status indicators The green indicator on the right side should be lit signifying that the right bank of cylinders is in service The red indicator on the left side should be lit signifying that the left side of the manifold has not been pressurized S l o w l y open one cylinder valve on the left bank of cylinders Observe the cylinder contents pressure gauges to verify cylinder pressure 3 2 35 36 37 38 39 40 41 42 43 44 Observe the cabinet system status indica tors The red indicator on the left side should have been extinguished and the yellow ready for use indicato
57. r should be lit Close the cylinder valve on the right bank of cylinders Open the bleed valve to create a slight flow of gas through the manifold while observ ing the cylinder contents gauges The right cylinder bank gauge should begin to drop in oxygen manifold units there will be a pressure rise before the pressure will drop the left cylinder bank gauge should remain constant Observe the intermediate pressure gauge as the right side pressure continues to drop As the cylinder pressure drops on the right side the intermediate area also loses pres sure Verify that the pressure falls to the set point of the low pressure switch on the right side see the specification chart in Section 1 the left solenoid valve then opens and the right intermediate pressure should stay at the low pressure switch set point Close the bleed valve Observe the cabinet system status indica tors The green indicator on the left side should be lit signifying that the left bank of cylinders is in service The red indicator on the right side should be lit signifying that the right side of the manifold is not pressurized S l o w l y open one cylinder valve on the right bank of cylinders Observe the cylinder contents pressure gauges to verify cylinder pressure Observe the cabinet system status indica tors The red indicator on the right side should have been extinguished and the yellow ready for use indicator should be lit B20
58. r warranty information i B20130 ECN 11673 0201 CAUTION e Failure to follow the following instructions can result in personal injury or property damage Never permit oil grease or other combustible materials to come in contact with cylinders manifold and connections Oil and grease may react and ignite while in contact with some gases particu larly oxygen and nitrous oxide Cylinder header and master valves should always be opened very s l o w l y Heat of recompres sion 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 Some materials may react and ignite while in contact with some gases particu larly 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 lighting may ignite mate rials in an oxygen atmosphere creating a fire or explosive force Welding should not be performed near nitrous oxide piping Excessive heat may cause the gas to dissociate creating an explosive force ABBREVIATIONS OSHA J Occupational Safety amp Health Association C Common PSIG Pounds per Square Inch Gauge CGA Compressed Gas Association SCFH Standard Cubic Feet
59. re HQ2 amp HQ2HP Series 5 3 Miscellaneous Hardware HQ2HL Series sssssssssssssssssssseeeeeee eene 5 4 Manifold Components HQ2 amp HQ2HP Series sss nennen 5 5 Manifold Components HQ2HL Series enne entrent 5 6 Mounting Block Components HQ2 amp HQ2HP Series rennen 5 7 Mounting Block Components HQ2HL Series sssssssssssssssseeeeeeeneee nennen rennen nnns 5 8 Primary Regulator Components HQ2 HQ2HP and HQ2HL 5 9 Primary Regulator Components HQ2 9 oxygen ssssssssseeeeneenen nennen ennemi 5 10 Right Line Regulator Assembly ette iride cte diede dt da i do dedere d iade 5 11 Left Line Regulator Assembly iieri ette itin dette A 5 12 Check Valve Components nece diee evan diee a ede Le va c e donee ue uad 5 13 Gauge Plate 2 cut da eoe dinde 5 14 Power Supply Components 2 oie uL Ree use Ug Tuc e dece a Een ud 5 15 iv B20130 ECN 11673 0201 This page intentionally left blank v B20130 ECN 11673 0201 SECTION 1 INTRODUCTION amp GENERAL INFORMATION PRODUCT DESCRIPTION The automatic changeover manifold is designed to provide a reliable uninterrupted supply of gas to
60. regulator s function is to reduce the cylinder pressure of the supply banks to a more usable pres sure Gas enters the regulator through the inlet port and fills the high pressure chamber and the port to the cylinder contents gauge with gas See Figure 2 7 Gas in these areas is at the same pressure as the gas in the cylin ders The gas is sealed in this chamber by the seat holder and stem being pushed against the nozzle seal by gas pressure and the body spring An o ring seals between the nozzle and the regulator body The next area of the regulator is the low regulated pressure area of the regulator This chamber is sealed from the high pressure area by the seat nozzle assembly and the o ring around the nozzle and is isolated from the at mospheric pressure by the diaphragm sub assembly forming a seal around the body of the regulator The dia phragm is squeezed between the body of the regulator a slip ring washer and the regulator bonnet as the bon net is tightened down on the body The third chamber of the regulator is open to atmospheric pressure This chamber contains the regulator bon net adjusting screw pivot bonnet spring washer and the top side of the diaphragm sub assembly As the adjusting screw is turned in against the pivot the bonnet spring is compressed and puts a downward force on the diaphragm sub assembly The bottom of the diaphragm sub assembly is in direct contact with the seat holder and stem When the diaphragm is
61. ressure switches used to signal Reserve in Use are piston type with one common contact one nor mally closed contact and one normally open contact See Figures 2 6 and 2 8 When the manifold is pressurized to the normal pres sures the piston in the switch is pushed up The piston pushes the activator of the switch up This action closes the normally open contact and opens the normally closed contacts FIGURE 2 8 Low Pressure Switch As gas from the cylinder banks is depleted the piston moves down releasing the force against the switch acti vator The contacts of the switch then return to the normally open and normally closed positions The switches complete the electrical circuits to the indicators on the front of the control section and to the re mote alarm interface board in the power supply box SOLENOID VALVES The solenoid valves are the heart of the manifold for maintaining the stand by or reserve bank The solenoid valves are constructed of two basic functional units a solenoid electromagnet with its core and a valve body containing one or more orifices See Figure 2 9 Flow through an orifice is stopped or allowed by the action of the core when the solenoid is energized or de energized The solenoid is mounted directly on the valve body The core is enclosed and free to move in a sealed tube providing a compact packless assembly The valve has a pilot and bleed orifice and utilizes the line pressure
62. s on the pressure switch FIGURE 4 3 Low Pressure Switch using a flat blade screwdriver and remove the wires Using a 13 16 open end wrench remove the pressure switch from the mounting block Remove old sealant from the threads in the mounting block CAUTION e not stand directly in front of the valve when performing the next step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 5 Blow out the internal pipe threads with oil free Air or Nitrogen to remove all foreign material Replacement 1 Apply Teflon tape to the pipe threads on the new pressure switch 2 Install the pressure switch in the mounting block using a 13 16 open end wrench and tighten to effect a gas tight seal 3 Complete the adjustment instructions below prior to installing the signal wires to the pressure switch Pressure Switch Adjustment 1 Connect an ohmmeter to the normally closed and common electrical contacts on the switch The ohmmeter should register zero resistance 2 Begin pressurizing the manifold by opening one cylinder valve on the side of the manifold the switch is on At the actuation pressure the ohmmeter reading will jump from zero resistance to infinite resistance Close the cylinder valve 4 Open the bleed valve slightly to relieve pressure from the manifold while observing the intermediate pressure gauge and ohmmeter to determine switch setting At actuat
63. ssure Observe the intermediate gauge for two min utes Verify that the primary regulator does not exhibit creep or an increase in pres sure Verify that the left side cylinder contents gauge indicates a minimum of 1400 psig for Oxygen Nitrogen Air or gas mixtures Systems Nitrous Oxide and Carbon Diox ide systems should indicate a minimum of 600 psig Verify that the line pressure gauge is indicat ing a minimum of 50 psig on all systems except Nitrogen Nitrogen should indicate a minimum of 160 psig Adjust to the proper line pressure if necessary Open the bleed valve so as to create a slight flow of gas through the manifold Turn off the left cylinder valve and allow all gas to vent from the manifold Close the bleed valve S l o w l y open one cylinder valve on the right bank of cylinders Open the bleed valve so as to create a slight flow of gas through the manifold Close the bleed valve B20130 ECN 11673 0201 24 25 26 27 28 29 30 31 32 33 34 Verify that the right intermediate gauge indi cates the pressure as shown in the specifi cation chart in Section 1 for the primary regulator pressure page 1 3 Adjust the right primary regulator as necessary to ob tain the required pressure Observe the intermediate gauge for two min utes Verify that the primary regulator does not exhibit creep or an increase in pres sure Verify that the right side cylinde
64. t cavity beveled side up Lay the slip ring on top of the washer Insert the diaphragm sub assembly in the bonnet cavity The side marked UP should be against the slip ring Carefully place the bonnet on the regulator body Rotate the bonnet clockwise and tighten to 50 60 ft lbs torque Replacement 1 Connect the regulator inlet to the regulator port on the mounting block and assemble hand tight Orient the regulator so the bonnet is facing towards the ground with the manifold mounted on a wall Using two 1 1 8 open end wrenches tighten the inlet nut mounting block adaptor connection to effect a gas tight seal Using a 7 16 open end wrench connect the pressure switch tubing to the 1 8 tube compression fitting located 90 from the inlet of the regulator With the regulator installed and facing towards the ground it is the fitting on the left side Connect the gauge tubing to the other 1 8 tube compression fitting on the regulator per tightening instructions on page 4 2 Using an 11 16 open end wrench connect the outlet tubing to the 3 8 tube compression fitting located 180 from the inlet of the regulator per tightening instructions on page 4 2 Connect the relief valve tubing to the 3 8 tube compression fitting on the relief valve of the regulator per tightening instructions on page 4 2 Primary Regulator Adjustment 1 If not already done shutdown the manifold as explained earlier in this section
65. th the spring retainer Push the smaller o ring to the bottom of the bore it rests in 3 Assemble the large o ring with the nozzle 4 Insert the new seat holder and stem into the nozzle The silver colored end of the seat holder and stem must enter the nozzle first 5 Place the compensating spring over the seat holder and stem 4 10 B20130 ECN 11673 0201 VIEW A A Legend 1 Body 2 Retainer O ring 3 Spring Retainer 4 Teflon Back up O Ring 5 Small O ring 6 Seal Retainer 7 Valve Spring 8 Seat Stem Assembly 9 Filter 10 Gasket 11 Large O ring 12 Nozzle 13 Diaphragm 14 Slip Ring 15 Washer 16 Bonnet Spring 17 Pivot 18 Bonnet 19 Adjusting Screw 20 Locknut OUTLET 21 90 1 8 Tube Fitting 22 90 Elbow 23 90 3 8 Tube Fitting 24 1 8 Tube Fitting 25 Inlet Nut 26 Inlet Nipple 27 Relief Valve 28 3 8 Tube Fitting This O Ring is not used on manifolds with S N 20800 and greater Some regulators do not include this filter or gasket When installing a repair kit the filter and gas ket should be installed e FIGURE 4 8 Primary Regulator Except Oxygen S N up to 11348 4 11 B20130 ECN 11673 0201 Legend 1 Body 10 Acorn Nut 2 Cartridge Assembly 11 1 8 T
66. the fitting Retighten the nut by hand Torque the nut with a wrench until the marks line up which indicates that the fitting has been tightened to its original position A noticeable in crease in mechanical resistance will be felt indicating the ferrule is being resprung into sealing position Then snug the nut 1 12 of a turn 1 2 of a wrench flat past the original position Leak Testing 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 tubin
67. tly until the circuit board slides over the lock 4 Dothe same at the other three corners of the cir cuit board FIGURE 4 4 Printed Circuit Board 5 Slide the circuit board and cover completely off of the supports 6 Savethe circuit board cover for installation with the new circuit board Replacement LOCKING FEATURE we 1 Slide the new circuit board over the supports plug edge on top lights facing inside manifold cover 2 Carefully line up the circuit board lights with the cap E I E bases protruding through the manifold cover 3 Firmly press each corner of the circuit board until the support locking feature snaps over the board PCB 7 SUPPORT 4 Slide the circuit board cover over the circuit board SLIDE PCB OFF supports and press snugly at the corners OF SUPPORT m 5 Carefully insert the plug into the circuit board using CABINET one hand to stabilize the board and the other to push COVER the plug in place PCB 6 Close the cabinet cover 7 Connect electrical power to the manifold and test for proper function by following the Performance FIGURE 4 5 PCB Removal Verification procedure in Section 3 4 6 B20130 ECN 11673 0201 GAUGE REPLACEMENT Refer to Figure 4 6 Removal 1 Shutdown the manifold as explained earlier in this section 2 Use a flat blade screwdriver and remove the six gauge plate mounting screws CAUTION e Be careful not to kink or damage t
68. ube Fitting 3 Diaphragm 12 Inlet Nut 4 Slip Ring 13 Inlet Nipple 5 Washer 14 90 1 8 Tube Fitting 6 Bonnet Spring 15 90 Elbow 7 Pivot 16 90 3 8 Tube Fitting 8 Bonnet 17 Relief Valve 9 Adjusting Screw 18 3 8 Tube Fitting HP C PORT 22 p FIGURE 4 9 Primary Regulator Oxygen S N to 11348 4 12 B20130 ECN 11673 0201 10 11 12 13 14 Place the compensating spring retainer on the compensating spring The boss on the retainer will enter the internal diameter of the spring and the larger o ring will now be on top Grasp the flats of the nozzle with one hand and carefully guide the seat nozzle assembly into the body of the regulator until the threads are engaged Rotate the nozzle clockwise and hand tighten Using the 13 16 hex socket and torque wrench tighten the nozzle to approximately 5 ft lbs torque Lubricate the outer regulator body to diaphragm sealing surface of the regulator body with a small amount of water Do not allow water to enter the low pressure chamber of the regulator Hold the bonnet upside down and place the pivot and bonnet spring in the bore provided The small diameter of the pivot should enter the internal diameter of the spring Place the washer in the large bonne

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