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BI Service Manual - Western Enterprises

1. 5 13 Gauge Plate Components 5 14 Primary Regulator Components except Oxygen Manifolds sse 5 15 Oxygen Primary Regulator Components 5 16 Intermediate Regulator Assembly 5 17 Intermediate Regulator Assembly Western 2 4 1111 5 18 Line Regulator Assembly Victor 5 19 Line Regulator Assembly Westen 5 20 Four way Valve 5 21 Check Valve 5 22 Power Supply Components without CSA certification 5 23 Power Supply Components with CSA certification ssessssssssseseeee eene 5 24 iv B20113 ECN 14800 0911 SECTION 1 INTRODUCTION amp GENERAL INFORMATION PRODUCT DESCRIPTION The automatic changeover manifold is designed to provide a reliable uninterrupted supply of gas to a gas pipeline system in an industrial installation The manifold has an equal number of cylinders in its Service supply and Reserve supply banks automatically switching to the Reserve supply when the Service supply becomes depleted When the manifold changes to Reserve supply it sends a signal to the gas alarm syst
2. KEY DESCRIPTION gt 3 4 Poppet Spring Washer Cap PART WMV 1 5 WMV 1 6 WMV 1 7 WMV 1 8 Item included in repair kit Repair Kit for Bl BIHL amp BIHP Series RK 1041 5 22 B20113 ECN 14800 0911
3. amp S N lt 22220 WMS 8 12 Intermediate Regulator for series Acetylene and LPG 22220 RK 1040 Repair Kit for WMS 1 5 and WMS 8 12 Intermediate Regulators WLR 2 5 Intermediate Regulator for amp BIHL series Air Ar 0 H2 amp S N gt 22220 WLR 2 7 Intermediate Regulator for BIHP series Air Ar CO2 0 H2 O2 amp S N gt 22220 WLR 8 12 Intermediate Regulator for series Acetylene and LPG 22220 RK 1160 Repair Kit for WLR 2 5 amp WLR 2 7 Intermediate Regulators RK 1161 Repair Kit for WLR 8 12 Intermediate Regulators WMS 1 6 Line Regulator for BI amp BIHL series Air Ar CO 0 amp S N lt 22220 WLR 2 6 Line Regulator for BI amp BIHL series Air Ar CO2 0 He amp S N gt 22220 WMS 8 13 Line Regulator for Bl 1 amp BI 1A series manifolds S N 22220 WLR 8 3 Line Regulator for Bl 1 amp BI 1A series manifolds S N gt 22220 WMS 5 3 Line Regulator for BIHP series manifolds Air Ar CO 0 He H2 O2 amp S N lt 22220 WLR 5 3 Line Regulator for BIHP series manifolds Air Ar CO N2O He H2 O2 amp S N gt 22220 WMS 8 13 Line Regulator for BI 10 S N lt 14600
4. ee A 2 9 luc ee e E 2 9 Line Pressure Regulator 2 10 SECTION 3 FIELD TESTING AND TROUBLE SHOOTING 3 1 Performance Verification Procedure A 3 1 Trouble sliootlnig fei side ie e cn eere tee ceste doeet esee 3 4 SECTION 4 SERVICE PROCEDURES 4 1 General Maintenance n uta ta tea ee pma dta ra te Eee Rap aa 4 1 Safety PreGautiONS DR rH 4 1 Cleaning Lubrication and nnne nnne nnne 4 2 General Repair PDrocecures 4 3 How to Shutdown the Manttold esee enne enne ensis nennen nen 4 3 Manifold Cabinet Case 4 3 Gauge Replacement EE 4 4 Primary Regulator iid Eee te e e e E dier ip a Ea cd Deche 4 5 Low Pressure Switch Replacement 4 8 Check Valve 4 9 Four Way Valve Replacement AA 4 10 Intermediate Regulator Repair 4 11 ten taU et dite 4 13 Light Socket Replacement 0 0 0 4 16 Indicator Lamp Replacement 022 41 1 010000 4 16 ii B20113 ECN 14800 0911 SECTION 5
5. 3 4 Shutdown the manifold and remove cover as explained earlier in this section Label and disconnect the four connectors attached to the back of the light socket Using a small flat blade screwdriver pry off the two metal clips securing the light socket to the manifold cover Slide the defective socket out through the front of the manifold cover Replacement 1 The new light socket will have two sets of terminals labeled A and Insert the back of the new light socket through the rectangular opening in the front of the manifold cover approximately 3 4 with the terminal of the A set on the top Grasp the back of the light socket on the sides and pull the socket in until the front of the socket is flush with the front of the manifold cover Reattach the connectors to the terminal on the socket Reinstall the manifold cover and connect electrical power to the manifold Test for proper function by following the Performance Verification Procedure in Section 3 INDICATOR LAMP REPLACEMENT Removal 1 2 Remove indicator lens cover by pulling lens cover forward A small depression is molded into the top and bottom of the lens cover to facilitate removal A flat blade screwdriver can be wedged in the depression and twisted to pry the lens cover off Remove the faulty lamp by pulling the built in extractor The clear plastic tab marked lamp pull is the extractor Replacement 1 Insert the re
6. 7 Carefully guide the bonnet over the body of the regulator until the threads engage Rotate the bonnet clockwise and tighten Using a wrench to stabilize the body tighten the bonnet using 50 60 ft lbs of torque 8 Loosely install the adjusting screw in the bonnet Replacement 1 Secure the intermediate pressure piping in a vise or similar holding fixture 2 Remove all old sealant from the regulator inlet nipple Clean all interior surfaces with isopropyl alcohol or 1 1 1 trichloroethylene solvent CAUTION Do not stand directly in front of the body or ports when performing the next step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 3 Remove all old sealant from the intermediate block Blow out the intermediate block with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 4 Apply Teflon tape to the 1 4 NPT male pipe thread on the regulator inlet nipple Start the threads of the nipple into the intermediate block 5 Position the inlet of the regulator over the nipple and rotate the regulator clockwise to tighten the threads inlet of the regulator is stamped IN 6 Grasp the bonnet of the regulator and rotate the regulator clockwise until tight The bonnet of the regulator must be parallel to the test fitting on the left side of the intermediate pressure piping 7 Remove the intermediate block from th
7. 1 2 5 Shutdown the manifold and remove cover as explained earlier in this section Mark the compression fittings per the instructions on page 4 2 Disconnect the four tubing assemblies at the compression fittings to the four way valve and at the compression fittings at the other end of the tubing assem blies using an 11 16 open end wrench Remove the tubing assemblies from the control section the two pri mary regulator to four way valve tubing sections and the two check valve tubing assemblies Use a phillips screwdriver to remove the two screws that secure the four way valve to the support bracket and remove the four way valve assembly Secure the valve assembly in a vise or similar holding fixture and use a 5 8 open end wrench to remove the two inlet and two outlet adaptors from the valve for use on the replacement valve Remove the old sealant from the 1 4 NPT male pipe threads on the compression fittings Replacement 1 2 3 Apply Teflon tape to the 1 4 NPT male pipe threads on the compression fittings Secure the new four way valve in a vise Install the 1 4 NPT x 3 8 tube straight compression fittings in the ports on the four way valve using a 5 8 open end wrench Remove the valve port from the vise and position it behind the support bracket with the CYL 2 port on the left and the CYL 1 port on the right Reinstall the two screws through the bracket and into the two upper threaded holes of the valve Ti
8. 8 Loosely install the adjusting screw in the bonnet 9 Remove the regulator from the vise 4 11 20113 14800 0911 Replacement 1 Position the intermediate regulator in the control section with the inlet connecting to the tubing coming from the four way valve The inlet of the regulator is stamped IN 2 When retightening the fitting the procedure outlined on page 4 2 shall be followed Connect the compres sion fittings using an 11 16 open end wrench and tighten to effect a gastight seal Intermediate Regulator Adjustment 1 If not already done open the manifold as explained in this section remove the manifold cover attach test gauge to the left side of the intermediate pressure block Reinstall the four way valve knob and rotate to select one bank of cylinders as the supply bank 2 S o w l y open one cylinder on the supply bank selected 3 Verify the cylinder pressure gauge indicates the minimum inlet pressure of 1500 psig on Oxygen Air and Nitrogen systems or a minimum of 600 psig on Nitrous Oxide and Carbon Dioxide systems 4 Verify a test gauge pressure indicating the primary regulator setting per the Adjustment Specification chart in Section 1 Adjust the primary regulator pressure as necessary to obtain the required pressure setting 5 Rotate the control knob so that the arrow of the four way valve is pointing to the opposite bank of cylinders 6 Loosen the main supply union slightly to relieve pr
9. Verify that the left side cylinder contents gauge indicates a full cylinder Verify that the line pressure gauge is indicating a minimum of 30 psig on all systems except Nitrogen Nitrogen should indicate a minimum of 50 psig Adjust to the proper line pressure if necessary Loosen the union connection to the main supply line to create a slight flow of gas through the manifold Observe the test gauge and verify the primary regulator setting under a flow condition Adjust the left primary regulator as necessary to obtain the required pressure Turn off the left cylinder valve and allow all gas to vent from the manifold Tighten the main supply line union Rotate the control knob to its fully clockwise position 5 1 1 open one cylinder valve on the right bank of cylinders cylinder should be full B20113 ECN 14800 0911 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Complete steps 14 22 for the right primary regulator Tighten main supply union Verify that the line pressure regulator is functioning properly by observing the line pressure gauge for two minutes The gauge should indicate the same pressure at the end of the two minute period Loosen the union connection to the main supply line to create a constant pressure by observing the line pressure gauge Verify that the line pressure regulator maintains a constant pressure by observing the line pres
10. WMS 1 53 CGA 540 Spud Check Valve WMV 2 3 CGA 580 Header Valve WMV 2 32 CGA 590 Header Valve 5 2 20113 ECN 14800 0911 INDICATOR LAMP REPLACEMENT PARTS Round Style for heater WME 8 4 24 V Light Bulb WME 8 72 Bulb Receptacle amp Lens Square Style WME 8 42 Light Bulb WME 8 41 Bulb Receptacle WME 8 40 Red Green Lens MK 1010 Square Light Repair Kit PRESSURE SWITCHES WME 4 4 Open Frame Pressure Switch Air Ar CO2 H2 He No amp N20 WME 4 AC Open Frame Pressure Switch Oxygen WME 4 5 Explosion Proof Pressure Switch FGAK H WME 4 6 Explosion Proof Pressure Switch FGAK A and FGAK L WMS 3 20 Intermediate Regulator for CLC2HP series manifold WMR 6 4 Line Regulator for CLC2 series manifold WMR 6 6 Line Regulator for CLC2HP series manifold RK 1070 Repair Kit for WMS 3 3 WMR 6 4 WMR 6 6 and WMS 3 20 REMOTE ALARMS 24 VAC Service Visual 1 Gas BIA end Audio Visual 2 Gas BIA Audio Visual 1 Gas WMS 9 25C Optional 115 to 24 VAC Power Supply for above Remote Alarms 5 3 20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD amp Series Hydrogen
11. 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 10 Hold the bonnet upside down and place the pivot and bonnet spring in the bore provided The small diame ter of the pivot should enter the internal diameter of the spring 11 Place the washer in the large bonnet cavity beveled side up 12 Lay the slip ring on top of the washer 13 Insert the diaphragm sub assembly in the bonnet cavity The side marked UP should be against the slip ring 14 Carefully place the bonnet on the regulator body Rotate the bonnet clockwise and tighten to 85 95 ft Ibs torque Replacement 1 Secure the inlet block in a vise or similar holding fixture 2 Remove all old sealant from the regulator inlet nipple Clean all interior surfaces with isopropyl alcohol or 1 1 1 trichloroethylene solvent CAUTION Do not stand directly in front of the body or ports when performing the next step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 3 Remove all old sealant from the inlet block Blow out the inlet block with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 4 Apply Teflon tape to the 1 4 NPT male pipe threads on the regulator inlet nipple Start the threads of the nipple into the inlet block 4 6 B20113 ECN
12. 10 WMS 1 128 WMS 1 8 WMS 1 127 WMS 1 4 WMS 1 16 See page 5 1 WMS 1 18 WMS 1 1 WLF 6 17 WMS 1 9 WMS 1 7 WME 4 4C WME 4 4 WLF 1 17 WLF 1 10 23 24 25 26 27 28 29 30 31 32 33 34 35 3110 1 Self tapping screw Outer Gauge Plate Case Screw Receptacle Inner Gauge Plate BI Series BIHP Series Backplate Assembly Tee Mounting Bracket 3 8 16 Hex Nut 3 6 24 x 1 3 4 Carriage Bolt 1 2 Nominal U Bolt 3 16 Lock Washer 3 16 Hex Nut Case Wiring Harness Dual Light Lens Dual Light Base 24 V Bulb 85 Dual Light Label D Size Nipple D Size Adaptor x 3 4 NPT Switch Wiring Harness Case Lead Seal 8 Sheet Metal Case Screw Power Supply Box Item not pictured PART 8 WMC 6 39 WMC 8 2 WMC 8 9 WMC 6 35 WMS 1 12 WMS 5 4 WMS 1 2 WMC 6 7 WMC 6 6 WMC 6 10 WMC 6 13 WMC 6 12 WMC 6 11 WMS 1 14 WME 8 40 WME 8 41 WME 8 42 WME 8 54 D 20 D 32 WMS 1 13 WEM 1 27 WMC 6 23 8570D 5 8 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BIHL Series Components amp Miscellaneous Hardware d 2 71 J _ JN gi y zi p m N L DE Lex H A M r e WS d VM T I 5 9 20113 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BIHL Series Components amp Miscellan
13. 3 8 Tubing Left Regulator 1 BI 6 10 amp BIHP 6 Primary Regulator Inlet Mount Nipple Inlet Block 1 8 x 11 Tubing 1 BI 6 10 amp BIHP 6 PART D 35 D 8 WLF 5 4 See Page 5 2 WMS 8 6 WMS 1 66 WMS 5 5 See page 5 1 WMS 8 5 WMS 1 10 WMS 8 5 WMS 1 128 WMS 1 130 WMS 1 8 WMS 1 129 WMS 1 127 WMS 1 4 WMS 8 9 WMS 1 16 See Page 5 1 WMS 1 18 WMS 4 1 WLF 6 19 WLF 6 17 KEY DESCRIPTION 15 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3 8 Tubing Right Regulator BI 1 BI 6 10 amp BIHP 6 3 8 CV Tubing 4 way to Int BI 1 BI 6 10 amp BIHP 6 1 4 NPT Pipe Nipple 1 6 10 BIHP 6 10 1 Self tapping screw Outer Gauge Plate Case BI 1 10 BI 6 amp BIHP 6 Screw Receptacle Inner Gauge Plate 1 6 10 6 Backplate Assembly Tee Mounting Bracket 3 8 16 Hex Nut 3 16 24 x 1 3 4 Carriage Bolt 1 2 Nominal U bolt 3 16 Lock Washer 3 16 Hex Nut D Size Nipple D Size Adaptor x 3 4 NPT Case Lead Seal 8 Sheet Metal Case Screw Item not Pictured Piping layout for BI 6 and BIHP 6 is shown on page 5 4 Piping layout for Bl 1 and 10 is shown on page 5 5 PART WMS 8 4 WMS 1 9 WMS 8 2 WMS 1 7 WLF 1 17 WLF 1 10 WMC 6 39 WMC 8 2 WMC 8 6 WMC 8 6S WMC 6 35 WMS 8 7 WMS 1 12 WMS 8 11 WMS 5 4 WMS 1 2 WMC 6 7 WMC 6 6 WMC 6 10 WMC 6 13 WMC 6 12 WMC 6 11 D 20 D 33 WEM
14. Cord Switch Wiring Harness Case Lead Seal 8 Sheet Metal Case Screw Wire Nut Power Supply Box Item not pictured PART WMC 6 35 WMS 2 3 WMS 1 2 WMC 6 7 WMC 6 6 WMC 6 10 WMC 6 13 WMC 6 12 WMC 6 11 WMS 1 14 WME 8 42 WME 8 54 WME 8 41 WME 8 40 WME 8 57 WME 8 27 WME 8 72 WME 8 10 D 20 D 32 WME 8 34 WME 8 33 WMS 1 13 WEM 1 27 WMC 6 23 WME 8 58 8570D 5 10 B20113 ECN 14800 0911 Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD BI amp BIHP Series Repair Drawing Inlet Block Components Left Side Inlet Right Side Inlet KEY DESCRIPTION PART 8 1 High Pressure Mounting Block WMC 2 20 2 17 11 1 2 NPSM x 1 2 Adaptor WMS 1 40 5 11 B20113 ECN 14800 0911 Western Enterprises AUTOMATIC CHANGEOVER MANIFOLD BIHL Series Repair Drawing Inlet Block Components A V T dl PED T V DESCRIPTION PART High Pressure Mounting Block Left Side Inlet WMC 2 22 Right Side Inlet WMC 2 23 1 11 1 2 NPSM x 1 2 NPT Adaptor WMS 1 40 1 4 Tube x 1 8 Male 90 WLF 3 3 1 8 NPT Street Elbow BL 2HP 5 12 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD Bl BIHL amp BIHP Series Intermediate Block Components Fuel Gas Manifolds 1 amp 10 Series KEY 12 13 Hydrogen Manifolds 6 Series All Others DESCRIPTION PART CGA 022 Nut
15. MAINTENANCE AND REPAIR PARTS 5 1 Replacement Pigtalls 2 beet isole td 5 1 Primary Regulators and Kits cies ciii iiiter etu dedo HRS ded Ed 5 1 Power Supply Replacement 5 2 Intermediate Regulators and Repair Kits 5 2 Line Regulators and Repair 5 2 Panel 5 2 Valves and Valve Repair Kits ee ed ee dee n b nenne 5 2 Indicator Lamp Replacement Parts 5 3 Pressure SWITCHES 2 e ether Pe ROI Ye lu 5 3 Remote Alarms see ea i et me ei 5 3 SECTION 5 MAINTENANCE AND REPAIR PARTS Repair Drawings 5 4 Components and Miscellaneous Hardware amp BIHP Series 5 4 Components and Miscellaneous Hardware amp BIHP Series Fuel 5 5 Components and Miscellaneous Hardware amp BIHP Series except Fuel 5 7 Components and Miscellaneous Hardware BIHL 5 9 Inlet Block Components amp BIHP 5 11 Inlet Block Components BIHL Gees 5 12 Intermediate Block
16. Manifolds Components amp Miscellaneous Hardware e F 1 4 If e Ke RE Refer to part numbers on page 5 6 P 7 m E ADENA JE T x 7 22 S Ne J X f SCH p aS Nf ROTTEN SN bw RT E PN NOS 22 5 4 20113 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BI amp BIHP Series Fuel Gas Manifolds Components amp Miscellaneous Hardware a j d 1i e 76 LE t O 22 D op ey gt d ju jt TL a P Lf eu TV A A Qa Su MJ Lei 22 Hefer to part numbers on page 5 6 5 5 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD amp BIHP Series Fuel Gas Manifolds Components amp Miscellaneous Hardware KEY DESCRIPTION ak c 11 12 13 14 Outlet Adaptor Outlet Nut Outlet Nipple Line Regulator Intermediate Block 1 10 6 6 Intermediate Regulator Intermediate CV Tubing S N 2220 1 6 10 6 SN gt 22220 1 6 10 amp BIHP 6 Reserve CV Tubing SN 22220 1 BI 6 10 amp BIHP 6 S N 22220 1 BI 6 10 amp BIHP Four Way Valve
17. REMEDY OR CHECK Tighten reseal or replace Tighten reseal or replace Repair as necessary Replace cylinder Reseal or replace Repair or replace Set delivery pressure to specifications Replace regulator seat and nozzle components Replace regulator seat and nozzle components Reduce the flow demand or increase the number of supply cylinders Reduce the flow demand or increase the number of supply cylinders Gas leakage around regulator body or bonnet Gas leakage around valve stem or packing nut on master valve or header valves Loose bonnet Diaphragm leak on regulator Valve packing leaks Faulty valve Tighten bonnet Replace diaphragm Tighten bonnet Replace diaphragm LOSS OF RESERVE BANK CONTENTS Both banks feeding Intermediate regulator seat leak Intermediate regulator set to open at too high a pressure Faulty four way valve Flow demand too high 3 6 Repair or replace regulator Adjust intermediate regulator per specifications Replace four way valve Reduce flow demand 20113 ECN 14800 0911 SYMPTOM LOSS OF RESERVE BANK CONTENTS continued Opposite bank feeding Premature changeover to reserve bank No changeover PIPELINE DISTRIBUTION Pipeline not at desired pressure Required gas flow not available PROBABLE CAUSE Faulty primary regulator and or intermediate regulator Flow demand too high Leaks in
18. WMS 8 14 Line Regulator for Bl 10 S N between 14600 and 22220 WLR 8 14 Line Regulator for 10 S N gt 22220 RK 1050 Repair Kit for WMS 1 6 Line Regulator for manifolds with serial 4199 RK 1051 Repair Kit for WMS 1 6 and WMS 8 13 Line Regulators Serial numbers between 4199 and 22220 RK 1040 Repair Kit for WMS 5 3 Line Regulator RK 1160 Repair Kit for WLR 2 6 Line Regulator RK 1161 Repair Kit for WLR 5 3 WLR 8 13 and WLR 8 14 Line Regulators PANEL MOUNT GAUGES 2 Diameter 1 4 NPT Back Port WMG 3 7 30 psi WMQG 3 5 600 psi WMG 3 3 100 psi WMG 3 2 200 psi WMG 3 4 400 psi WMG 3 14 300 psi WMG 3 8 2000 psi WMG 3 12 4000 psi VALVES AND VALVE REPAIR KITS RK 1044 Repair Kit for Low Pressure Check Valve WMS 1 4 Four Way Valve WMV 2 16 Master Valve RK 1083 Repair Kit for WMV 2 16 430A RK 1085 Repair Kit for WMV 2 16 430B amp C WMV 2 31 CGA 300 Header Valve WMV 2 7 CGA 320 Header Valve WMV 2 14 CGA 326 Header Valve WMV 2 4 CGA 346 Header Valve WMV 2 19 CGA 350 Header Valve WMV 3 30 CGA 510 Header Valve
19. When the gas pressure on the top side of the valve falls to predetermined pressure the valve opens and routes the gas from the Reserve supply into the intermediate block and then to the line pressure regulator The line pressure regulator further reduces the pressure to the final pressure delivered to the gas piping system The regulator has one inlet port and three outlet ports One outlet port is plugged Tubing is connected from the second port to the line pressure gauge to sense the pressure of the gas on the downstream side of the regulator The other port is the outlet and is located 180 from the inlet The gas flows from the line regulator outlet to the pipeline distribution system When both cylinder banks are full the switch completes the electrical circuit to the green system normal light Cylinder pressures for each bank are indicated on the gauges on the manifold front cover The Service supply is indicated by the position of the control knob The line pressure is indicated by the center gauge on the manifold front cover As the gas from the Service supply is depleted the gas pressure to the Service primary regulator will begin to fall Simultaneously the pressure to the pressure switch the downstream side of the check valve below the inter mediate regulator and the line regulator also falls When the Service side pressure falls below the set point of the low pressure switch the red replace depleted cylinders ligh
20. amp Plug WLF 5 8 CGA 022 x 1 8 M24 40 Intermediate Pressure Block 6 amp 10 series WMC 2 25 All others WMC 2 18 3 8 Tube x 1 4 NPT WLF 3 5 1 2 NPT Nipple 3 WLF 1 15 1 2 NPT Coupler Bl 1 10 use 1 2 Pipe PC 8HP other BIHL amp BIHP BF 8HP Safety Relief Valve NOT APPLICABLE for BI 1 10 manifolds BI amp BIHL series 375 psig WMV 8 375 BIHP and 9 series 450 psig WMV 8 450 Pipe Away Adaptor WMV 8 7 1 8 NPT Plug P 2HP 1 8 NPT x 1 4 NPT Adaptor NOT APPLICABLE for 1 BI 6 10 amp BIHP 6 All others BIHL amp BIHP Series BB 2 4HP 1 2 NPT Elbow or Tee 1 and 10 Series use Elbow BL 8HP BI 6 Series use Tee WHF 4 7 1 2 NPT Plug P 8HP 1 4 NPT Plug P AHP 5 13 B20113 ECN 14800 0911 Western Enterprises ACCU TROL AUTOMATIC CHANGEOVER MANIFOLD BIHL amp BIHP Series Repair Drawing Gauge Plate Components Front View Y Bottom View 4m VE iw KEY DESCRIPTION PART 1 Gauge Plate WMC 8 1 1 2 1 8 Tube x 1 4 NPT Female WLF 3 4 3 Cylinder Contents Gauge BI 1 10 400 psi WMG 3 4 BI amp BIHP series 4000 psi WMG 3 12 BIHL series 2000 psi WMG 3 8 4 Line Pressure Gauge BI 1 30 psi WMG 3 7 BI 10 100 psi WMG 3 3 BI amp BIHL series 200 psi WMG 3 2 BIHP series 400 psi WMG 3 4 5 14 B20113 ECN 14800 0911 AUTOMATIC CHANGEOVER MANIFOLD BI BIHL BIHP
21. from the regulator body Some regulators use a seat capsule This capsule is part of the nozzle assembly that was removed in step 4 Remove the gasket from the regulator body with a pair of tweezers not required on capsule style regulators Clean all interior surfaces of the regulator body with isopropyl alcohol or 1 1 1 trichloroethylene solvent B20113 ECN 14800 0911 CAUTION Do not stand directly in front of the body or ports when performing the next step Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 8 Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces Reassembly 1 Install the compensating spring gland and friction washer on the stem not required on capsule style 2 Position the stem assembly in the body of the regulator not required on capsule style 3 Install the nozzle over the stem and rotate clockwise to engage the threads Use the appropriate socket wrench and tighten securely Tighten the capsule of capsule style regulators 4 Hole 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 5 the slip ring in the large bonnet cavity 6 Insert the diaphragm sub assembly in the bonnet cavity Make sure backup plate and nut face the spring
22. heat of compression to dissipate Use only cleaning agents sealants and lubricants as specified in this instruction 4 1 B20113 ECN 14800 0911 CLEANING LUBRICATION AND SEALING Clean metal parts of the manifold with isopropyl alcohol or 1 1 1 trichloroethylene solvent prior to assembly Dry thoroughly Do not clean o rings with this solvent Freon TF is acceptable Teflon Tape Application Threaded pipe connections should be sealed with tape Remove the old sealant from both male and female threads Apply Teflon amp tape to the male pipe thread Approximately 1 1 2 turns of tape should be sufficient Do not cover the first thread with tape Assemble the fittings wrench tight to effect a gastight seal Assembly and Disassembly of Compression Fittings Mark the fitting and nut prior to disassembly Before re tightening make sure the assembly has been inserted into the fitting until the ferrule seats in the fitting Retighten the nut by hand Torque the nut with the wrench until the marks line up which indicates that the fitting has been tightened to its original position Then snug the nut 1 12 of a turn 1 2 of a wrench flat past the original position NOTE e Incorrect re assembly of fittings may initially seal however leakage may occur over time Leak Testing There are four types of manifold piping connections sealed soldered threaded unions and elbows compres sion tubing connections a
23. pressure from the Service bank not allowing the check valve immediately downstream of the intermediate regulator to open The gas pressure from the intermediate regulator is pushing against the bottom of the check valve seat When both banks are full and the regulators properly adjusted the pressure on the downstream side of the valve is greater than the intermediate regulator pressure FIGURE 2 12 Low Pressure Switch FIGURE 2 13 Switch Schematic 2 9 20113 ECN 14800 0911 This pressure differential holds the valve closed Turning the adjusting screw of the intermediate regulator in clockwise will increase the intermediate regulator pressure thereby increasing the pressure at which the valve will open Turning the adjusting screw out counterclockwise will decrease the intermediate regulator pressure thereby decreasing the pressure at which the valve will open As the gas pressure in the Service bank of cylinders drops below the setting of the primary regulator the gas pressure from the Service bank primary regulator will begin to fall When the Service pressure falls below the pressure of the intermediate regulator setting as noted in Section 1 the check valve will be pushed open and the Reserve bank cylinders will begin to supply the system LINE PRESSURE REGULATOR The line pressure regulator used in the manifold is a single stage four port adjustable regulator Refer to Figure 2 14 and Figure 2 15 It has one i
24. 1 27 WMC 6 23 5 6 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BI amp BIHP Series Except Fuel Gas Components amp Miscellaneous Hardware d M b gu e 3 canis SS en 7 IR WH H Y H 4 it d N 21 3 RS r1 Le Ey ti JO m 7 Sj be J f f da jr m FA I ul F1 N 7 H e i H 5 7 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BI amp BIHP Series Except Fuel Gas Components amp Miscellaneous Hardware KEY DESCRIPTION 10 11 12 13 14 15 16 17 Outlet Adaptor Outlet Nut Outlet Nipple Line Regulator Intermediate Block Series BIHP Series Intermediate Regulator Intermediate CV Tubing S N 22220 S N 22220 Reserve CV Tubing S N 22220 S N 22220 Four Way Valve 3 8 Tubing Left Regulator Primary Regulator Inlet Mount Nipple Inlet Block 1 8 x 11 Tubing 3 8 Tubing Right Regulator 3 8 CV Tubing 4 way to Int Pressure Switch Oxygen service All other gases 1 4 NPT Pipe Nipple BI Series BIHP Series PART D 34 D 7 WLF 5 4 KEY DESCRIPTION 19 20 21 See Page 5 2 22 WMS 1 11 WMS 5 2 See page 5 1 WMS 1
25. 14800 0911 Position the inlet of the regulator over the nipple and rotate the regulator clockwise to tighten the threads Grasp the bonnet of the regulator and rotate the regulator clockwise until tight The bonnet of the regulator must be perpendicular to the inlet block Remove the inlet block from the vise Position the inlet block assembly in the control section and install the carriage bolts lock washers and nuts Using a 3 8 hex wrench tighten securely Connect the inlet of the block to the union connection of the header using a 1 3 8 hex wrench and a 1 3 4 hex wrench When retightening the fitting the procedure outlined on page 4 2 shall be followed Using a 7 16 open end wrench connect the outlet tubing to the 1 8 tube compression fitting located on the right side of the regulator 90 from the regulator inlet When retightening the fitting the procedure outlined on page 4 2 shall be followed Using and 11 16 open end wrench connect the outlet tubing to the 3 8 tube compression fitting located on the left side of the regulator 90 from the regulator inlet Primary Regulator Adjustment 1 If not already done shutdown the manifold as explained earlier in this section remove the manifold cover attach a test gauge to the left side of the intermediate pressure block and remove the acorn nut from the primary regulator Reinstall the control knob on the four way valve and rotate the knob to select the side the regu
26. 2CV 24R CGA 580 for Inert Gas Service except Helium PF 93CV 24R CGA 590 for Industrial Air Service PF 83CVR 24RV CGA 350 for Argon Methane Mixture 24 Synthetic Fiber Braid Hose with Check Valve PFS 83CV 24R CGA 350 for Hydrogen Service PFS 92CV 24R CGA 580 for Helium He Service REGULATOR amp REGULATOR REPAIR KITS Primary Regulators WMS 1 117 Primary Regulator for Bl 1 1A Acetylene S N gt 14349 WMS 1 118 Primary Regulator for Bl 1 series Air Ar He amp S N gt 14349 WMS 1 119 Primary Regulator for 9 series Oxygen S N gt 14349 WMS 1 120 Primary Regulator for BIHL series CO2 amp N20 S N gt 14349 WMS 1 121 Primary Regulator for BIHP series Air Ar He amp S N gt 14349 WMS 1 122 Primary Regulator for BIHP 9 series Oxygen S N 14349 WMS 1 56 Primary Regulator for BI 9 Oxygen S N gt 11348 WMS 1 3 0 Primary Regulator for BI amp BIHL series Air Ar He amp amp S N lt 14349 5 1 24 Primary Regulator for Bl series Oxygen Manifolds S N 7969 WMS 1 31 Primary Regulator for Bl series Oxygen Manifolds Serial numbers between 7969 and 11348 5 8 1 Primary
27. BIHP Series Western Style Intermediate Regulator Components M Un 8 9 cene V SECTION KEY DESCRIPTION PART KEY DESCRIPTION PART 1 Regulator Body 4 ports WLR 1 1 11 Adjusting Screw RWS 3 2 2 Seat Capsule WLR 1 10 12 1 4 NPT plug WLF 1 21 3 Anti Vibrator WLR 1 14 13 Label HPRL 4 Pivot RWC 2 8P 14 1 4 NPT x 3 8 tube WLF 3 5 5 Bonnet RWS 2 2P 15 1 4 NPT x 3 8 tube elbow WLF 3 6 6 Bushing Retainer RWC 3 14 7 Bonnet Bushing RWC 3 12 Item Included in repair kits 8 Slip Ring RWS 3 17 9 Diaphragm Assembly Repair kit for WLR 2 5 RWS 3 28 WLR 2 5 RK 1160 WLR 2 7 amp WLR 8 12 RWS 3 16 WLR 2 7 amp WLR 8 12 RK 1161 10 Delivery Spring WLR 2 5 RWS 1 11 WLR 2 7 RWS 1 12 WLR 8 12 RWC 1 4 5 18 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BIHL BIHP Series Victor Style Line Regulator Components KEY DESCRIPTION PART 1 1 4 NPT Plug WLF 1 21 2 Line Regulator BI amp BIHL Series 0 125 psi WMR 1 15 BIHP Series 0 200 psi WMR 1 20 3 1 8 Tube x 1 4 NPT WLF 3 8 4 Preset Adjusting Screw BI amp BIHL Series WMS 6 36 BIHP Series WMC 6 37 n For 1 10 order replacement spring WMR 1 16 Repair Kits for Line Regulato
28. E SWITCH The low pressure switch is used to signal Reserve in Use is a piston type with one common contact one normally closed contact and one normally open contact See Figures 2 12 and 2 13 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 contacts As gas from the cylinder banks is depleted the piston moves down releasing the force against the switch activator The contacts of the switch then return to the normally open and normally closed positions The switch complete the electrical circuit to the indicators on the front of the control section and to the remote alarm terminal strip in the power supply box INTERMEDIATE REGULATOR The intermediate regulator controls the gas flow from the reserve bank of cylinders to the intermediate block The intermediate regulator pressure setting is the pressure at which the manifold will switchover from Service to Reserve supply The intermediate regulator has an inlet port connected via tubing to the four way valve The outlet port of the intermediate regulator is connected via tubing to the intermediate block Check valves are located immediately upstream and immediately downstream of the regulator The regulator is comparable to the line regulator illustrated in Figure 2 14 and 2 15 The regulator seat is held shut by the gas
29. INNOVATOR WESTERN AUTOMATIC CHANGEOVER MANIFOLD BIHL amp BIHP Series SERVICE MANUAL WESTERN ENTERPRISES PRINTED IN USA 20113 ECN 14800 0911 SAFETY Statements in this manual preceded by the following safety signal words are of special significance Definitions on the SAFETY signal words follow DANGER Means a hazard that will cause death or serious injury if the warning is ignored WARNING Means a hazard that could cause death or serious injury if the warning is ignored CAUTION Means a hazard that may cause minor or moderate injury if the warning is ignored It also means a hazard that will only cause damage to property NOTE Indicates points of particular interest for more efficient and convenient operation INTRODUCTION This manual provides the information needed to service the Western Enterprises BIHL and BIHP series manifolds This information is intended for use by technicians or personnel qualified to repair and service manifold equipment The information contained in this document including performance specifications is subject to change without notice WARRANTY Western Enterprises makes no warranty of any kind with regard to the material in this manual Including but not limited to the implied warranties of merchantability and fitness for a particular purpose Refer to the Installation and Operation Instructions manual for warranty informat
30. LD 9 Series S N between 7969 and 11348 Primary Regulator Components VOY Ee m E Nw ell A gt i x i I KEY DESCRIPTION PART 60 KEY DESCRIPTION PART 1 Regulator Bocy 4 ports RWS 1 5 13 Relief Valve RWC 3 5 EN Cartridge Assembly RWD 2 19 14 Concave Screen 1134 3 Diaphragm Assembly RWS 3 28 15 1 4 NPT x 1 8 CPI Elbow WLF 3 7 4 Slip Ring RWS 3 17 16 1 4 NPT x 3 8 CPI Elbow WLF 3 6 5 Washer RWS 3 26P 6 Bonnet Bushing RWS 1 12 7 Pivot RWC 2 8P Item Included in repair kits 8 Bushing Retainer RWC 4 14 9 Bushing 7 16 14F RWC 3 12 Repair kit for BI 9 10 High Pressure Bonnet RWS 2 3 Serial 5 lt 4000 RK 1011 11 Preset Screw 7 16 14M RWS 3 3 3999 lt Serial s lt 7969 RK 1021 12 Acorn Nut RWS 3 1 7969 lt Serial 5 lt 11348 RK 1023 5 16 20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BIHL BIHP Series Victor Style Intermediate Regulator Components KEY a A Go DESCRIPTION 1 4 NPT Plug Intermediate Regulator 0 200 psi 3 8 Tube x 1 4 NPT 3 8 Tube x 1 4 NPT 90 Present Adjusting Screw PART WLF 1 21 WMR 1 20 WLF 3 5 WLF 3 6 WMC 6 37 Repair Kit for Intermediate Regulator internal parts components not shown RK 1040 5 17 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BIHL
31. OCEDURES Be sure all pressure and electrical power is removed from the system prior to initiating any repair procedures WARNING Do not shutdown the manifold until personnel have been advised of the intended service and all systems requiring industrial gas are being supplied from portable or alternate supplies Systems still running on the manifold gas line will not receive gas Replace parts with all components in the repair kit HOW TO SHUT DOWN THE MANIFOLD 1 2 3 4 5 Turn off the piping system isolation valve if present If an isolation valve is not present the entire gas system will be reduced to atmospheric pressure WARNING Do not shutdown the manifold until all personnel have been advised of the intended service and all systems requiring industrial gas are being supplied from portable or alternate supplies Turn off right and left supply bank cylinder valves Loosen the manifold outlet connection to the supply main to vent residual gas from the system Tighten the manifold outlet connection Disconnect electrical power from the manifold at the main power source MANIFOLD CABINET COVER REMOVAL Disassembly 1 Cut lead seal wire with wire cutters and remove 2 Remove the control knob on the front of the cabinet using a 1 8 hex key wrench 3 Using a flat blade screwdriver or 5 16 hex wrench unscrew the four screws holding the gauge plate to the cabinet Remove the cover plate 4
32. ON e Remove all protector caps prior to assembly The protective cap may ignite due to heat of compression in an oxygen system Overall Manifold Length 10 P u 13 BOB gri STAs e 9 TEN 5 i B 36 T 10 typ 50 Total number of cylinders 4 6 8 10 12 Overall manifold Length 5 5 7 1 8 9 10 5 11 9 Acetylene manifold length 5 9 8 0 10 4 12 4 14 5 Note All dimensions are approximate Floor Figure 1 1 nstallation Dimensions 1 1 20113 14800 0911 MANIFOLD SPECIFICATIONS Flow Capability Oxygen 1200 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure 500 SCHF maximum at 50 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure Nitrogen 1200 SCFH maximum at 160 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure Nitrous Oxide The flow capability of Nitrous Oxide cylinder manifold will depend upon conditions at the Carbon Dioxide 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 without adding additional heaters Installing a Nitrous Oxide manifold in a location which exposes it to ambient temperatures below 20 F 7 is not recommended Air Argon 1200 SCFH maximum at 50 psig delivery and 15 psi inlet pressure and 2000 p
33. Regulator for series Acetylene and Liquefied Fuel Gas manifolds S N lt 14349 WMS 5 1 Primary Regulator for BIHP series manifolds S N lt 14349 RK 1010 Repair Kit for WMS 8 1 Primary Regulator and WMS 1 3 for manifolds with S N 3999 1020 Repair Kit for WMS 1 3 Primary Regulator S N gt 3999 and WMS 5 1 for BIHP series manifolds 1010 Repair Kit for WMS 1 24 Primary Regulator for Oxygen manifolds with S N lt 3999 1020 Repair Kit for WMS 1 24 Primary Regulator S N 3999 1023 Repair Kit for WMS 1 31 Primary Regulator S N lt 3999 1033 Repair Kit for WMS 1 56 Primary Regulator S N lt 11348 1036 Repair Kit for WMS 1 117 1037 Repair Kit for WMS 1 118 WMS 1 120 amp WMS 1 121 1038 Repair Kit for WMS 1 119 amp WMS 1 122 5 1 20113 ECN 14800 0911 POWER SUPPLY REPLACEMENT PARTS 8570D Power Supply Assembly transformers PCB with dry contacts case and cable WME 8 1 Power Supply PCB for WMS 9 3 includes dry contacts for remote alarms Intermediate Regulators WMS 1 5 Intermediate Regulator for BI BIHL amp BIHP series Air Ar CO 0 gt
34. Series and 9 Serial numbers greater than 11348 Western Enterprises Repair Drawing Primary Regulator Components This item not included with regulators shipped after serial number 14349 KEY DESCRIPTION PART 60 KEY DESCRIPTION PART 1 Acorn Nut RWS 3 1P 13 Seat Holder amp Stem 2 Preset Adjusting Screw RWS 3 3 BIHL BIHP RWS 6 8 3 Regulator Bonnet 9 RWS 6 3 1 10 RWS 2 2P 14 Body Spring BI BIHL RWS 2 3P BI 9 series RWS 1 17 4 Bonnet Bushing RWS 3 12 All others RWS 1 8 5 Bushing Retainer RWC 3 14 15 O ring 6 Pivot RWC 2 8P 1 10 RWS 3 13 7 Bonnet Spring BIHL RWS 3 47 1 10 RWS 1 11 16 Backup Ring RWS 5 7 BIHL amp BIHP RWS 1 13 17 Spring Retainer RWS 3 15 8 Washer 18 Small O ring NOT APPLICABLE for BI 1 10 10 RWS 3 11 For others BI BIHL BIHP RWS 3 26 BI BIHL BIHP RO 012E 9 Slip Ring RWS 3 17 19 Regulator Body RWS 1 3 10 Diaphragm Assembly 20 1 8 Tube x 1 4 90 WLF 3 7 1 10 RWS 3 16 21 Safety Relief Valve BIHL RWS 3 28 1 10 use pipe cap 11 Nozzle BHIL Series RWO 3 5 9 Series RWS 5 1 BIHP Series RWX X3 All others RWS 6 9 22 3 8 Tube x 1 4 NPT 90 WLF 3 6 12 Large O ring 23 Filter 1134 1 10 RWS 3 12 D Item included in repair kits BI BIHL RO 015E 5 15 20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFO
35. Unscrew the electrical connector at the bottom of the unit and unplug the cord 5 Unscrew the three screws attaching the cover to the backplate using a phillips screwdriver NOTE e may be necessary to turn the adjusting screw on the line regulator all the way so as to allow the cover to slide past the adjusting screw 6 Carefully pull the cover straight out to clear internal components 7 Locate and disconnect the three male female wire terminals to detach the cover electrical wiring from the pressure switch wiring 8 Lift the cover completely off the backplate 9 Back out the adjusting screw on the line regulator if it was readjusted to remove the cover Reassembly Reverse order of disassembly Connect internal wiring by matching up color coded wires 4 3 B20113 ECN 14800 0911 GAUGE CAUTION Be careful not to kink or damage the tubing connected to the gauges Damaged tubing may burst when pressurized Removal 1 Shutdown the manifold and remove cover as explained earlier in this section 2 Pullthe mounting plate up so that it provides easy access to the gauge screws on the underside of the gauge plate 3 Mark the compression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the tubing from the defective gauge When retightening the fitting procedures outlined on page 4 2 shall be followed 4 Using a 3 8 hex wrench remove the two sc
36. as rotated to select new Service side without changing empty cylinders Pressure switch wiring disconnected Pressure switch set at too low a pressure 3 4 REMEDY OR CHECK Check electrical power supply Replace bulb or lamp assembly Check all wiring connections Slowly open valves Adjust pressure switch or return faulty unit for factory setting Set primary regulator delivery pressure to specifications Replace depleted cylinders Replace bulb or lamp assembly Check connections Adjust pressure switch or return faulty unit for factory setting Set intermediate regulator delivery pressure to specifications Replace bulb or lamp assembly Check connections Adjust pressure switch or return faulty unit for factory setting Replace depleted containers Check wiring connections Adjust pressure switch or return faulty unit for factory setting 20113 ECN 14800 0911 SYMPTOM RESERVE IN USE SIGNAL Remote alarm signal stays in one mode constantly regardless of change over status Remote alarm signals are opposite of manifold status ABNORMAL LINE PRESSURE SIGNAL Low pressure alarm activated High pressure alarm activated PROBABLE CAUSE Power supply wiring is incorrect Flow demand too high Faulty connection to remote alarm unit Line pressure regulator improperly adjusted Closed master valves headers valves or cylinder valves Empty cylinders Primar
37. cover as explained at the beginning of this section CAUTION Be sure to backout the adjusting screw on the line regulator prior to pressurizing the system If the adjusting screw position was changed it may over pressurize the system causing something to burst or rupture 10 11 5 open one cylinder on the system Verify the cylinder pressure gauge indicated the minimum pressure of 1500 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 turn the adjusting screw of the regulator in while observing the line pressure gauge Set the regulator to the desired pressure Loosen the main supply union to create a slight flow of gas through the manifold Readjust the regulator to the proper specifications if necessary Tighten the union connection to the main supply line The line pressure gauge will go up slightly higher than the flowing adjusted pressure Verify that the regulator does not creep by observing the line pressure gauge for two minutes The gauge must indicate the same pressure at the end of the two minute period Close the cylinder valve Loosen the main supply line union and vent all remaining gas from the manifold Tighten the union connection to the main supply line after the gas pressure has been exhausted from the manifold 4 15 B20113 ECN 14800 0911 LIGHT SOCKET REPLACEMENT Removal 1 2
38. d excessive condensation or frosting occur it may be necessary to increase manifold capacity b Monthly 1 Inspect valves for proper closure 2 Check cylinder pigtails for cleanliness flexibility wear leakage and thread damage Replaced damaged pigtails immediately 3 Inspect pigtail check valves for closure ability C Every 4 years 1 Replace pigtails WARNING Repairs to manifold high pressure regulators valve connections and piping should be made only by qualified personnel improperly repaired or assembled parts could fly apart when pressurizing causing death or serious injury SAFETY PRECAUTIONS 1 Examine all parts before repair Note Because manifold parts may be exposed to Oxygen and Nitrous Oxide and the condition of the unrepaired parts is unknown a repair inspection should be performed before exposing the parts to high pressure gas 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 Use only proper repair tools and parts Parts for Western manifolds are shown in this instruction Special tools are called out as needed Before connecting the container to the manifold momentarily open and close the cylinder valve to blow out any dirt or debris except for Hydrogen manifolds After connecting the cylinder to the manifold open the cylinder valve s I o w l y to allow the
39. d on the left and right bank headers 1 2 20113 ECN 14800 0911 ADJUSTMENT SPECIFICATIONS Primary Primary Low Intermediate Intermediate Line Regulator Regulator Pressure Regulator Pressure Regulator Model Relief Valve Switch Relief Valve S N 14349 195 205 400 145 150 130 135 250 95 100 S N gt 14349 195 205 400 145 150 130 135 375 95 100 4 or BI 8 195 205 145 150 130 135 S N 14349 4 or 8 245 255 145 150 130 135 S N 14349 BIHP S N 14349 295 305 235 240 220 225 170 175 BIHP S N 14349 295 305 235 240 220 225 170 175 BIHL S N 14349 195 205 145 150 130 135 BIHL S N 14349 245 255 145 150 130 135 1 amp BI 1A 10 Unit of measures all units psig N A Not Applicable regulator setting should be made with full cylinders Regulator set pressures may vary from the listed values if partially filled cylinders are used for testing 1 3 20113 14800 0911 RECOMMENDED TOOLS AND TEST EQUIPMENT Volt Ohm meter Isopropyl alcohol Phillips screwdriver Flat blade screwdriver Needle nose pliers Wire cutters 1 8 hex key wrench 5 8 hex socket wrench 3 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 Flourolube 5 30 lubricant Liquid leak detector Teflon tape Available from local source Available from local source Available from local source Available from local
40. d pressure exerted by the gas will be slightly greater than the downward pressure of the bonnet spring and the seat nozzle will close As gas is released from the low pressure chamber a proportional amount of gas will be let into the low pressure area from the high pressure chamber As the adjusting screw is turned in farther and the bonnet spring compressed the gas pressure required to lift the diaphragm increases resulting in a higher delivery pressure from the outlet port of the regulator Figure 2 8 Primary Regulator 2 7 20113 ECN 14800 0911 FOUR WAY VALVE The four way valve assembly is used to route the gas from the primary regulators to either the intermediate block or the intermediate regulator The four way valve has two inlet ports on the back side of the valve and two outlet ports located 180 apart on the sides of the valve Figure 2 9 Figure 2 10a shows the position of the valve ports when the right bank of cylinders is the Service bank and the left bank is the Reserve Gas is directed from inlet port 1 to outlet port CYL1 and from inlet port 2 to outlet port CYL2 only The seals in the valve prevent gas from trav eling to the other ports With the valve in this position the gas from the right primary regulator routed to the interme diate block and the gas from the left primary regulator is routed to the intermediate regulator Figure 2 10b shows the valve in the OFF position The OFF position is only used durin
41. e chamber a proportional amount of gas will be let into the low pressure area from the high pres sure chamber As the adjusting screw is turned in farther and the bonnet spring compressed the gas pressure required to lift the diaphragm increases resulting in a higher delivery pressure from the outlet port of the regula tor 2 10 B20113 ECN 14800 0911 Figure 2 14 Line Pressure Regulator Victor LEGEND Adjusting Screw Bonnet Assembly Pivot Adjusting Screw Diaphragm Assembly Slip Ring O ring Body Valve Spring Seat Assembly Filter Screen Nozzle O ring Friction Damper LEGEND Adjusting Screw Bonnet Assembly Pivot Adjusting Screw Diaphragm Assembly Slip Ring O ring Body ON Oo Om FW a Seat Capsule Friction Damper Figure 2 15 Line Pressure Regulator Western 2 11 B20113 ECN 14800 0911 FIELD TESTING amp TROUBLE SHOOTING SECTION 3 The manifold performance tests are use to verify the manifold functional performance When used in conjunction with the trouble shooting charts the technician can verify proper performance or rapidly identify the probable source of the problem PERFORMANCE VERIFICATION PROCEDURE 1 10 11 12 Shut down the manifold and remove the control section cover as explained in Section 4 Remove the cap from the pressure test fitting on the left side of the intermediate bloc
42. e vise and using the carriage bolt reinstall the intermediate block to the bracket on the backplate Assemble the nuts and washer to the carriage bolt Tighten loosely 4 14 B20113 ECN 14800 0911 10 11 12 13 14 15 16 Remove all old sealant from the union nipple Clean all interior surfaces with isopropyl alcohol or 1 1 1 trichloroethylene solvent Apply Teflon amp tape to the 1 4 NPT male pipe thread on the union nipple Start the threads of the nipple into the outlet of the line regulator Using a small pipe wrench install the union nipple to the outlet of the line regulator Using a 7 16 hex wrench reassemble the U bolt to the bracket When retightening the fitting the procedure outlined on page 4 2 shall be followed Using and 11 16 open end wrench reconnect the four way valve to intermediate block tubing When retightening the fitting the procedure outlined on page 4 2 shall be followed Using and 11 16 open end wrench reinstall the intermediate regulator to intermediate block tubing assembly Reconnect the intermediate pressure relief valve to the building s vent line Using two 1 1 2 open end wrenches reconnect the main supply line to the manifold at the union When retightening the fitting the procedure outlined on page 4 2 shall be followed Using a 7 16 open end wrench reconnect the line pressure gauge tubing to the line regulator Line Regulator Adjustment 1 Reinstall the manifold
43. eating an explosive force e Do not leak test solution that contains ammonia Solutions containing ammonia may cause the tubing to crack ABBREVIATIONS C Common OSHA Occupational Safety amp Health Administration CGA Compressed Gas Association PSIG Pounds per Square Inch Gauge FT LBS Foot Pounds SCFH Standard Cubic Feet per Hour IN LBS Inch Pounds VAC Voltage Alternating Current N C Normally Closed VDC Voltage Direct Current N O Normally Open PCB Printed Circuit Board NPT National Pipe Tape Western Enterprises shall not be liable for errors contained herein or incidental or consequential damages in connection with providing this manual or the use of material in this manual 20113 ECN 14800 0911 5 SECTION 1 INTRODUCTION 1 1 Product DESCriPtlOn PEE 1 1 Installation Information cede 1 1 Manifold Eeer e le 1 2 1 3 Recommended Tools and Test Equipment eene nene enne 1 4 SECTION 2 THEORY OF OPERATION 2 1 General Information e ca pr 2 1 Manifold Ope ratio EE 2 1 Primary ee ETC 2 7 FOUI Way 2 8 Check ValV8S IR 2 9 LOWsPIESSULE SWITCMOS
44. em if installed alerting the personnel of the need for the exhausted bank of cylinders to be replaced with full cylinders After new cylinders are in place and turned on no manual resetting of the manifold is necessary except for turning the control knob INSTALLATION INFORMATION Manifolds should be installed in accordance with guidelines stated by the National Fire Protection Association the Compressed Gas Association OSHA and all applicable local codes The Carbon Dioxide and Nitrous Oxide manifolds should not be placed a location where the temperature will exceed 120 F 49 C or fall below 20 F 7 C The manifold for all other gases should not be placed in a location where the temperature will exceed 120 F 49 C or fall below 20 F 29 C A manifold placed in an open location should be protected against adverse weather conditions including rain and heavy moisture During winter protect the manifold from ice and snow In summer shade the manifold and cylinders from continuous exposure to direct rays of the sun The manifold should be located in a clean well ventilated area which is free of oil and combustible materials Leave all protective covers in place until their removal is required for installation This precaution will keep moisture and debris from the piping interior avoiding operational problems safety relief valves including those on flash arrestor Bl acetylene systems shall be piped outside CAUTI
45. ench and a 1 3 4 hex wrench disconnect the header from the inlet block to the mani fold at the union connection 4 Using a 3 8 hex wrench remove the hex nuts and lock washers from the two carriage bolts holding the inlet block to the backplate 5 Using a soft face hammer tap gently on the end of the carriage bolts to loosen them Reach behind the backplate and pull the bolts out with one hand while holding the regulator and inlet block with the other 6 Remove the inlet block and primary regulator from the control section and clamp the block assembly in a vise 7 Toremove the regulator from the inlet block grasp the bonnet of the regulator and rotate the regulator counterclockwise 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 turn the adjusting screw counterclockwise until it turns freely and all com pression is removed from the bonnet spring 3 Using a 1 3 8 hex wrench rotate the bonnet counterclockwise and remove it along with the pivot bonnet spring washer slip ring and diaphragm sub assembly 4 Using a 13 16 hex socket wrench rotate the nozzle counterclockwise and remove it along with the seat holder and stem compensating spring and the spring retainer 5 Clean all interior surfaces of the regulator body with isopropyl alcohol or 1 1 1 trichloroethylene solvent CAUTION e Do not stand directly in front
46. eous Hardware KEY DESCRIPTION NOOO gt 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Outlet Adaptor Outlet Nut Outlet Nipple Line Regulator Intermediate Block Intermediate Regulator Intermediate CV Tubing S N 22220 S N 22220 Reserve CV Tubing S N 22220 S N 22220 Four Way Valve 3 8 Tubing Left Regulator Primary Regulator Inlet Mount Nipple Inlet Block Left Side 1 8 x 11 Tubing 115 VAC Heater Inlet Block Right Side 3 8 Tubing Right Regulator 3 8 CV tubing 4 way to Tin Pressure Switch 1 4 NPT Pipe Nipple 310 1 Self Tapping Screw Outer Gauge Plate Case PART D 34 D 7 WLF 5 4 See Page 5 2 WMS 1 11 See page 5 1 WMS 1 10 WMS 1 128 WMS 1 8 WMS 1 127 WMS 1 4 WMS 1 16 See page 5 1 WMS 1 18 WMS 2 2 WLF 6 17 WMS 11 42 WMS 2 1 WMS 1 9 WMS 1 7 WME 4 4 WLF 1 17 WMC 6 39 WMC 8 2 WMC 8 9 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 KEY DESCRIPTION Screw Receptacle Inner Gauge Plate Backplate Assembly Tee Mounting Bracket 3 8 16 Hex Nut 3 6 24 x 1 3 4 Carriage Bolt 1 2 Nominal U Bolt 3 16 Lock Washer 3 16 Hex Nut Case Wiring Harness 24 V Bulb 85 Dual Light Label Dual Light Base Dual Light Lens 16 Gage Wire 16 Female Wire Terminal Light Receptacle amp Lens 115 V Bulb D Size Nipple D Size Adaptor x 3 4 NPT Strain Relief Bushing 7 Header
47. essure from the manifold while observing the test gauge 7 Allow the gas to vent until the test gauge stabilizes or indicates less than the setting for the intermediate regulator listed in the adjustment Specification chart in Section 1 e lf the gauge stabilizes at a pressure higher than the chart specification turn the adjusting screw on the intermediate regulator clockwise to increase the gauge reading e If the gauge stabilizes at a pressure lower than the chart specifications turn the adjusting screw the intermediate regulator counterclockwise to decrease the gauge reading 8 Tighten the union connection to the main supply line 9 Simulate the changeover sequence from both sides and observe the intermediate gauge to verify proper setting 4 12 20113 14800 0911 LINE REGULATOR REPAIR NOTE Removal and Replacement procedures are to be followed only if the line regulator assembly is to be scrapped All service may be performed to the line regulator without removing it from the manifold Shutdown the manifold and remove cover as explained earlier in this section Removal 1 9 10 Mark the compression fittings per the instructions on page 4 2 Using an 11 16 open end wrench disconnect and remove the intermediate regulator to intermediate block tubing assembly Mark the compression fittings per the instructions on page 4 2 Using an 11 16 open end wrench disconnect and remove the four
48. g shipment of the mani fold Notice that the internal porting of the valve shown as dashed lines does not connect any of the inlet ports of the valve with the outlet ports Figure 2 10c shows the position of the valve ports when the left bank is the Service bank and the right bank is the Reserve INLET PORT 1 CYL 1 OUTLET CYL 2 OUTLET INLET PORT 2 FIGURE 2 9 Four Way Valve CYL 1 OUTLET INLET PORT 1 L MA P EU 7 e lt 7 Jn A 7 INLET PORT 2 INLET PORT 1 CYL 2 OUTLET FIGURE A CYL 1 OUTLET S INLET PORT 2 CYL 2 OUTLET FIGURE B CYL 1 OUTLET Si INLET PORT 1 E 7 zu _ s 2 INLET PORT 2 CYL 2 OUTLET FIGURE C FIGURE 2 10 Four Way Valve The only function the four way valve serves is to route the gas to the other components of the manifold 2 8 20113 ECN 14800 0911 CHECK VALVES The check valves prevent gas from flowing backward from the four way valve to the inlets See Figure 2 11 Gas enters the check valve from the four way 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 7 When the gas flow stops the spring of the check d valve pushes the valve seat down on the sealing surface preventing any gas flow backward through the valve FIGURE 2 11 Check Valve LOW PRESSUR
49. ghten with a phillips screwdriver Reconnect the inlet tubing assemblies to the new valve Reconnect the check valve tubing assemblies to the new valve Note the flow direction arrow on the check valves must point towards the four way valve When retightening the fitting the procedure outline on page 4 2 shall be followed Using an 11 16 open end wrench tighten the compression fittings at the ends of the tubing assemblies to effect a gastight seal 4 10 B20113 ECN 14800 0911 INTERMEDIATE PRESSURE REGULATOR REPAIR Removal 1 2 3 Shutdown the manifold and remove cover as explained earlier in this section Mark the compression fittings per the instructions on page 4 2 Disconnect the tubing at the compression fitting to the four way valve and the intermediate block using an 11 16 open end wrench Remove the intermediate regulator from the control section Disassembly 1 Secure the intermediate regulator in a vise or similar holding fixture The vise should grip the regulator on the body hex 2 Rotate the adjusting screw of the regulator counterclockwise and remove 3 Remove the bonnet by holding the body hex with a wrench to stabilize the assembly and using another wrench to loosen the bonnet The adjusting spring and pivot will come off with the bonnet 4 Remove the diaphragm assembly and slip ring 5 Using a 5 8 socket wrench rotate the nozzle counterclockwise and remove the nozzle 6 G
50. green light is extinguished when the manifold changes over from service to reserve supply Tighten the main supply line union and test for leaks using a leak detect solution S l o w l y open all cylinder valves on the left and right bank of cylinders Rotate the control knob to select the bank of cylin ders supplying the system before service was performed B20113 ECN 14800 0911 TROUBLESHOOTING only qualified personnel should make repairs SYMPTOM CABINET INDICATOR LIGHTS No indicator lights on front panel come on when power is hooked up Red indicator light is on but both banks are full Red indicator light does not come on when one bank is empty and changeover occurs Green indicator light does not come on but both banks are full Green indicator light comes on even though one bank of cylinders is empty PROBABLE CAUSE Power input Bulb burned out Internal wiring disconnected Master valve header valves or cylinder valves on bank are closed Pressure switch set at too high a pressures Service primary regulator setting too low Control knob was rotated to select new Service side without changing empty containers Bulb burned out Pressure switch wiring disconnected Pressure switch set at too low a pressure Intermediate regulator setting too high Bulb burned out Pressure switch wiring disconnected Pressure switch set at too a high pressure Control knob w
51. ing Schematic BI amp BIHP To Pipeline Distribution System Line Pressure Gauge Line Pressure Regulator Intermediate Relief Valve Check Valve Low Pressure Switch Intermediate Regulator Check Valve Four Way Valve Check Valve Not on all models 35 Regulator Relief Valve Regulator Relief Valve Right Primary Regulator Left Primary Regulator Left High Pressure vy Right High Pressure Gauge Gauge Le 7 Line Pressure Intermediate Pressure Cylinder Pressure Heater Figure 2 5 Piping Schematic BIHL 2 4 B20113 ECN 14800 0911 FIGURE 2 6 Electrical Schematic less heater The gas from the Service supply is routed through the four way valve outlet on the right of the four way valve to the intermediate block assembly A check valve is connected in line between the four way valve outlet and the intermediate block This check valve prevents the gas from flowing backwards toward the four way valve The intermediate block has seven ports all connected to the same chamber The gas pressure at all ports is the same as the pressure at the inlet to the block Gas enters the intermediate block from the Service supply through the tubing connected at the top center right The upper right port of the block is connected to the intermediate pressure relief valve The port on the right end of the intermediate block is plugged The low pressure switch is connected to the lower right port The lower left port
52. ion WARNING This product contains chemicals including lead known to the state of California to cause cancer and birth defects or other reproductive harm Wash hands after handling B20113 ECN 14800 0911 CAUTION e Failure to adhere to the following instructions may result in person injury or property damage e Never permit oil grease or other combustible materials to come in contact with cylinders manifold and connections Oil and grease may react with explosive and ignite when ignited when in contact with some gases particularly oxygen and nitrous oxide e Cylinder header and master valves should always be opened very s l o w l y Heat of recompres sion may ignite combustible materials e Pigtails should never be kinked twisted or bent into a radius smaller than 3 inches Mistreatment may cause the pigtail to burst e Do not apply heat Some materials may react and ignite while in contact with some gases particu larly oxygen and nitrous oxide e Cylinders should always be secured with racks chains or straps Unrestrained cylinders may fall over and damage or break off the cylinder valve which may propel the cylinder with great force Oxygen manifolds and cylinders should be grounded Static discharges and lightning may ignite materials in an oxygen atmosphere creating a fire or explosive force e Welding should never be performed near nitrous oxide piping Excessive heat may cause the gas to dissociate cr
53. is connected via tubing to the inter mediate regulator The left port has an adaptor for a test gauge used during manifold testing The left top port connects the inlet of the line pressure regulator The intermediate pressure relief valve prevents over pressurization of the intermediate controls of the manifold should the Service primary regulator fail The relief valve setting is noted in the adjust ment specification chart in Section 1 The tubing connected between the intermediate block and intermediate regulator allows gas from the Service supply to flow back toward in interme diate regulator A check valve is connected in line between the intermediate regulator outlet and the intermediate block This check valve allows servic ing the intermediate regulator without having to shutdown the manifold The intermediate regulator setting determines at which pressure the manifold will switch from Service to Reserve A check valve is connected in line between the four way valve outlet and the intermediate regulator This check valve prevents the gas from flowing backwards towards the four way valve 2 5 AMBER LIGHT NOT ON ALL MODELS HEATER AMBER LIGHT TO 120 VAC THERMOSTATS HEATER Figure 2 7 Heater Electrical Schematic 20113 ECN 14800 0911 Gas from the Reserve supply flows from the four way valve through the check valve and the intermediate regula tor towards the bottom of the second check valve
54. k Attach a 400 psi test gauge to the test fitting Reinstall the control knob on the shaft of the four way valve Rotate the control knob counterclockwise to make the left cylinder the Service supply and the right bank the Reserve supply Open the master valves located on the cylinder headers prior to pressurizing the manifold 5 open one cylinder valve on the left bank of cylinders 5 1 1 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 cylinder valves on the left and right banks Loosen the union connection to the main supply line to create a slight gas flow through the manifold Vent the system until all gas has been removed from the manifold Tighten the union connection to the main supply line S l o w l y open one cylinder valve on the left bank cylinders cylinder should be full 3 1 14 15 17 18 19 20 21 23 24 25 Create slight flow of gas through the manifold outlet or test port The test gauge should settle and remain constant Turn off the flow of gas through the manifold Verify that the test gauge indicates the pressure shown in the specification chart in Section 1 for the primary regulator Observe the test gauge for two minutes Very that the primary regulator does not exhibit creep or an increase in pressure
55. lator to be adjusted is on S I o w l y open one cylinder on the side of the regulator to be adjusted Verify the cylinder pressure gauge indicated the minimum pressure of 1500 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 turn the adjusting screw of the regulator in while observing the test gauge Set the regulator to the pressure indicated on the Adjustment Specification chart Section1 Loosen the main supply union to create a slight flow of gas through the manifold Readjust the regulator to the proper specifications if necessary Tighten the union connection to the main supply line The line pressure gauge will go up slightly higher than the flowing adjusted pressure Verify that the regulator does not creep by observing the test gauge for two minutes The gauge must indicate the same pressure at the end of the two minute period Close the cylinder valve Loosen the main supply line union and vent all remaining gas from the manifold Tighten the union connection to the main supply line after the gas pressure has been exhausted from the manifold Install the acorn nut on the primary regulator 4 7 20113 ECN 14800 0911 LOW PESSURE SWITCH REPLACEMENT Removal 1 Shutdown the manifold and remove cover as explained earlier in the section 2 Label the three wires attached to the switch Loosen the slot head screws on the p
56. nd gasket diaphragms and o rings When 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 Do NOT use solution con taining ammonia on Acetylene manifolds The ammonia may cause stress cracks in the brass tubing If a leak is detected at sealed connections replace the assembly which is joined by the leaking connection threaded connections union sealing surfaces may have burrs or nicks which may be polished out Be certain to clean parts before reassembly If the surface will not seal replace the union Elbows and tees may be cleaned of old sealant and resealed with Teflon tape Refer to cleaning sealing and lubricating instructions compression fittings sealing surfaces of fittings or brass ferrules may be damaged and must be replaced Refer to the parts list for appropriate tubing gasket seals leaks may occur at seals made by gaskets such as diaphragms or o rings Gas may leak to atmosphere or across the seal into the opposite pressure circuit External leaks are evidenced by application of leak detector while leaks across the seal are detected by faulty manifold function When replacing seals use care not to damage sealing surfaces B20113 ECN 14800 0911 GENERAL REPAIR PR
57. ne to create a slight gas flow through the manifold and allow all gas to vent from the manifold Remove the control knob from the four way valve Reinstall the manifold section cover as explained in Section 4 69 70 71 72 73 74 75 77 78 79 80 82 83 84 3 3 Connect the electrical power source and supply electric power to the manifold Observe the cabinet system status indicators Verify that the green indicator is shut off and the red indicator is lit 5 1 1 open one cylinder valve on one left and right bank of cylinders Observe the cabinet system status indicators Verify that the green indicator is lit and the red indicator is off Readjust the line regulator setting if it was modified during cover installation Close the cylinder valve on the right bank of cylinders Loosen the main supply union to create a slight flow of gas through the manifold Verify that the red light illuminates and the green light is extinguished when the manifold changes over from service to reserve supply S l o w l y open one cylinder valve on one right bank of cylinders Rotate the control knob counterclockwise to make the left bank the service supply Observe the cabinet system status indicators Verify that the green indicator is lit and the red indicator is off Close the cylinder valve on the left bank of cylin ders Verify that the red light illuminates and the
58. nlet port and three outlet port The inlet port is piped to an intermediate pres sure port in the manifold block One outlet port is piped to the outlet of the manifold for connection to the main pipeline One port is connected to the delivery line pressure gauge and the other port is plugged Gas enters the regulator through the inlet port and with the adjusting screw backed away from the spring is sealed in the high pressure chamber of the regulator by the seat and nozzle As the adjusting screw is turned in it compresses the spring and puts a downward force on the diaphragm sub assembly When the diaphragm is forced down by the spring it pushes on the stem of the seat assembly The seat is pushed away from the nozzle and gas can then flow from the high pressure chamber to the low pressure chamber When the low pressure chamber fils 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 pressur
59. of the body ports when performing the next steps Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 6 Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces 4 5 B20113 ECN 14800 0911 Reassembly 1 Apply a thin coating of Flourolube amp S 30 lubricant to the o rings Note steps 2 6 are not applicable to Oxygen regulator cartridge valve assemblies manifold S N 7969 through 11348 2 Assemble small o rings with 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 6 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 Not all assemblies use an o ring in this area 7 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 8 Using the 13 16 hex socket and torque wrench tighten the nozzle to approximately 5 ft lbs torque 9 Lubricate the outer
60. placement lamp and push on the lamp until it snaps into place NOTE Too much force used to install the lamp could break the socket bezel and allow the socket to be pushed completely through the front of the manifold cover 2 Reinstall the indicator lens cover with the green lens above the red lens NOTE Too much force used to install the lamp could break the socket bezel and allow the socket to be pushed completely through the front of the manifold cover B20113 ECN 14800 0911 SECTION 5 MANIFOLD MAINTENANCE amp REPAIR PARTS NOTE e Western manifold systems are designed and tested for optimal performance and adherence to safety specifications We recommend the use of Western replacement components to maintain the standards of performance and the safety of the product REPLACEMENT PIGTAILS 24 Stainless Steel Flexible Braid with Check Valves PF 16CVFA 24R CGA 300 with flash arrestor for Acetylene Service PF 320CV 24R CGA 320 for Carbon Dioxide CO Service PF 326CV 24R CGA 326 for Nitrous Oxide N2O Service PF 346CV 24R CGA 346 for Breathing Air Service PF 83CV 24R CGA 350 except Hydrogen Service PF 15CVFA 24R CGA 510 with flash arrestor for Acetylene Service PF 15CV 24R CGA 510 with Liquid Fuel Gas Service PF 63CV 24 CGA 540 for Oxygen Oz Service PF 9
61. pply union slightly to relieve pressure from the manifold while observing the test gauge and ohmmeter to determine switch setting At the actuation pressure the ohmmeter reading will jump from infinite resistance to zero resistance 5 Tighten the union connection to the main supply line 6 Using a flat blade screwdriver turn the knurl 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 Adjust ment Specifications chart in Section 1 7 Cycle between actuation and reactuation signals and make adjustments as required to achieve the signal setting The setting should be made on descending pressure Make adjustments in response to the reading obtained in step 4 WARNING e sure power is off when electrical connections are made Current flowing through the wire may shock the service technician 8 After setting has been made connect the signal wires to the appropriate contacts on the pressure switch 4 8 B20113 ECN 14800 0911 CHECK VALVE REPAIR Removal 1 2 3 Shutdown the manifold and remove cover as explained earlier this section Mark the compression fittings per the instructions on page 4 2 Disconnect the tubing at the compression fittings using and 11 16 open end wrench Remove the check valve and tubing assembly from the control section Disassembly 1 Secure the check valve in a vise o
62. r internal parts components not shown BI amp BIHL Serial 5 up to 4199 RK 1050 BI amp BIHL Series Serial s gt 4199 RK 1051 BIHP Series RK 1040 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BIHL BIHP Series Western Style Line Regulator Components Q EE 2 KEY DESCRIPTION PART KEY DESCRIPTION PART 1 Regulator Body 4 ports WLR 1 1 11 Adjusting Screw WLR 1 11 2 Seat Capsule WLR 1 10 12 1 4 NPT plug WLF 1 21 3 Anti Vibrator WLR 1 14 13 Label HPRL 4 Pivot RWC 2 8P 14 1 4 NPT x 1 8 tube WLF 3 8 5 Bonnet RWS 2 2P 6 Bushing Retainer RWC 3 14 7 Bonnet Bushing RWC 3 12 Item Included in repair kits 8 Slip Ring RWS 3 17 9 Diaphragm Assembly Repair kit for WLR 2 6 RWS 3 28 WLR 2 6 RK 1160 WLR 5 3 amp WLR 8 13 RWS 3 16 WLR 5 3 amp WLR 8 13 RK 1161 WLR 8 14 RWS 3 16 WLR 8 14 RK 1161 10 Delivery Spring WLR 2 6 WLR 1 8 WLR 5 3 RWS 1 12 WLR 8 13 RWC 1 14 WLR 8 14 RWC 1 14 5 20 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BIHL BIHP Series Four Way Valve Components Y KEY DESCRIPTION PART 8 1 Four Way Valve WMV 5 3 2 3 8 Tube x 1 4 NPT WLF 3 5 5 21 B20113 ECN 14800 0911 Western Enterprises Repair Drawing AUTOMATIC CHANGEOVER MANIFOLD BIHL BIHP Series Check Valve Components
63. r is sealed from the high pressure area by the seat nozzle assembly and the o ring around the nozzle and is isolated from the atmospheric pressure by the diaphragm sub assembly forming a seal around the body of the regulator The diaphragm is squeezed between the body of the regulator a slip ring washer and the regulator bonnet as the bonnet is tightened down on the bogy The third chamber of the regulator is open to atmospheric pressure This chamber contains the regulator bonnet adjusting screw pivot bonnet spring washer and the top side of the diaphragm sub assembly As the adjusting screw is turned in against the pivot the bonnet spring is compressed an puts a downward force on the diaphragm sub assembly The bottom of the diaphragm sub assembly is in direct contact with the seat holder and stem When the diaphragm is forced down by the spring the stem is pushed away from the nozzle and gas can then flow from the high pressure chamber to the low pressure chamber When the low pressure chamber fills with gas the gas will push upward against the diaphragm sub assembly As the pressure continues to build in the low pressure chamber more upward force will be exerted against the diaphragm and the diaphragm will push up against the bonnet spring compressing the bonnet spring As the diaphragm is gradually raised by the gas pressure the seat and nozzle gradually come closer together filling the low pressure chamber slowly and eventually the upwar
64. r reading of infinite resistance as soon as the test gauge pressure drops to the value for the pressure switch setting indicated in the Specification chart Section 1 5 1 1 open one cylinder valve on the left bank of cylinders B20113 ECN 14800 0911 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 Verify that the ohmmeter returns to approximately zero 0 ohms resistance Rotate the control knob clockwise to make the right bank of cylinders the service supply Close the cylinder valve on the right bank of cylinders Verify an ohmmeter reading of infinite resistance as soon as the test gauge pressure drops to the value for the pressure switch setting indicated in the Specification chart in Section 1 S lo w l y open one cylinder valve on one right bank of cylinders Verify that the ohmmeter returns to approximately zero 0 ohms resistance Close all cylinder valves and vent all remaining gas from the manifold Remove the ohmmeter leads from the black and brown wires Remove the test gauge from the test fitting and reinstall the test cap Tighten the main supply line union 5 1 1 open one cylinder valve on one right bank of cylinders Using a leak test solution verify that there are no leaks present at the test cap fitting Close the cylinder valve on the right bank of cylinders Loosen the union connection to the main supply li
65. r similar holding fixture Using a 1 1 8 hex wrench rotate the valve cap counterclockwise and remove 2 Remove the seal washer from the valve cap 3 Pull the spring from the valve body 4 Using a small needle nose pliers or tweezers grasp the valve poppet and remove it from the valve body 5 Clean the interior of the valve body with isopropyl alcohol or 1 1 1 trichloroethylene solvent CAUTION Do not stand directly in front of the body or ports when performing the next step Eye protection should be worn to protect the service technician Chips and debris may be propelled into unprotected eyes 6 Blow out the check valve body with oil free nitrogen to remove all foreign material and dry all surfaces Reassembly 1 Insert a new valve poppet into the valve body 2 Insert the spring into the valve body 3 Position a new seal washer in the groove of the valve body 4 Place the valve cap over the spring and push the cap towards the body until the threads engage Rotate cap clockwise and tighten securely Replacement 1 Position the check valve and tube assembly in the control section with the check valve flow arrow pointing towards the intermediate block When retightening the fitting the procedure outlined on page 4 2 shall be followed Connect the compres sion fittings using an 11 16 open end wrench and tighten to effect a gastight seal 4 9 B20113 ECN 14800 0911 FOUR WAY VALVE REPLACEMENT Removal
66. rasp the stem of the seat and pull the seat compensating spring gland and friction washer from the regu lator body 7 Remove the gasket from the regulator body with a pair of tweezers 8 Clean all interior surfaces of the regulator body with isopropyl alcohol or 1 1 1 trichloroethylene solvent CAUTION e Do not stand directly in front of the body or ports when performing the next steps Eye protection should be worn to protect the service technician Chips and or debris may be propelled into unprotected eyes 9 Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces Reassembly 1 Install the compensating spring gland and friction washer on the stem 2 Position the stem assembly in the body of the regulator 3 Install the nozzle over the stem and rotate clockwise to engage the threads Use a 5 8 socket wrench and tighten securely 4 Hold the bonnet upside down and place the pivot and bonnet spring in the bore provided The small diame ter of the pivot should enter the internal diameter of the spring 5 Lay the slip ring in the large bonnet cavity 6 Insert the diaphragm sub assembly in the bonnet cavity Make sure backup plate and nut face the spring 7 Carefully guide the bonnet over the body of the regulator until the threads engage Rotate the bonnet clock wise and tighten Using a wrench to stabilize the body tighten the bonnet using 50 60 ft Ib of torque
67. relief valve Supply banks consist of 24 stainless steel flexible pigtails with check valves individual 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 through 2 3 Figures 2 4 and 2 5 show the piping schematic Figure 2 6 is the schematic diagram of the electrical system of the manifold Figure 2 7 is the heater schematic The cylinder bank that supplies the piping system is known as the Service supply while the cylinder bank on stand by is referred to as the Reserve supply Gas flows from the cylinder through the pigtails check valves headers and shut off valves into the left and right inlets of the control section Gas flows through the manifold control to the primary regulators on all manifolds except those for Nitrous Oxide and Carbon Control Knob Dioxide service Nitrous Oxide and Carbon Dioxide systems include 500 SCFH pce capacity heater thermostatically q controlled heater warms the gas before en tering the regulator preventing freeze up LEFT BANK a RIGHT BANK and loss of pressure due to the extreme low temperatures generated when these gases rapidly expand Some systems include an amber light which indicates there is power to the heater Tubing is connected from the high pressure port on the primary regulators Master Valves Feader Valves or Check Valves to the cylinder pressure gauges to sen
68. ressure switch using a flat blade screwdriver and remove the wires 3 Use a 5 8 open end wrench to stabilize the adaptor between the pressure switch and the intermediate block and use a 7 8 open end wrench to remove the pressure switch Replacement CAUTION e Do not stand directly in front of the body or ports when performing the next step Eye protection should be worn to protect the service technician Chips and debris may be propelled into unprotected eyes 1 Remove old sealant from the intermediate block adaptor Blow out the intermediate block with oil free Air or Nitrogen to remove all foreign material and dry all surfaces 2 Apply Teflon tape to the 1 8 NPT male pipe threads on the pressure switch Start the threads of the pressure switch into the street tee adaptor Use a 5 8 open end wrench to stabilize the adaptor while using a 7 8 open end wrench to tighten to effect a gastight seal 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 on the side of the manifold the switch is on At the actuation pressure the ohmmeter reading will jump from zero resistance to infinite resistance 3 Close the cylinder valve 4 Loosen the main su
69. rews holding the gauge brackets Slide the gauge brackets off of the screw post 5 Slide the gauge out through the front of the gauge plate 6 Using a 3 4 hex wrench remove the compression fitting from the gauge Using a 9 16 open end wrench to stabilize the gauge 7 Remove old sealant from the 1 4 NPT female pipe thread on the compression fitting Replacement 1 Apply Teflon tape to the 1 4 NPT male pipe thread on the new gauge and reassemble in the reverse order of the removal procedure 2 Make sure gauge face is properly oriented through the front of the gauge plate 3 If the gauge needle is not on zero unscrew the gauge bezel and adjust the needle using a flat blade screwdriver 4 4 20113 ECN 14800 0911 PRIMARY REGULATOR REPAIR NOTE Removal and Replacement Procedures are to be followed only in the primary regulator assembly is to be scrapped All service be performed to the primary regulator without removing it from the manifold Shutdown the manifold and remove cover as explained earlier in this section Removal 1 Mark the compression fittings per the instructions on page 4 2 Using a 11 16 open end wrench discon nect the outlet tubing from the regulator at the compression fitting 2 Mark the compression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the gauge tubing from the regulator at the compression fitting 3 Using a 1 3 8 hex wr
70. s without header valves are constructed utilizing a check valve outlet bushing on B20113 ECN 14800 0911 LEGEND 1 Outlet Adaptor 8 Manifold Inlet 2 Line Regulator 9 High Pressure Gauge Tubing 3 Intermediate Block 10 Line Pressure Gauge Tubing 4 Check Valve 11 Low Pressure Switch 5 Intermediate Regulator 12 Intermediate Relief Valve 6 Four Way Valve 13 Primary Regulator Relief Valve 7 Primary Regulator 14 Test Port FIGURE 2 2 Internal Components BI amp BIHP 2 2 20113 14800 0911 LEGEND 1 Outlet Adaptor 8 Manifold Inlet 2 Line Regulator 9 High Pressure Gauge Tubing 3 Intermediate Block 10 Line Pressure Gauge Tubing 4 Check Valve 11 Low Pressure Switch 5 Intermediate Regulator 12 Intermediate Relief Valve 6 Four Way Valve 13 Primary Regulator Relief Valve 7 Primary Regulator 14 Test Port 15 Heater FIGURE 2 3 nternal Components BIHL 23 B20113 ECN 14800 0911 To Pipeline Line Pressure Gauge Distribution System Line Pressure Regulator Intermediate Relief Valve Check Valve Low Pressure Switch Intermediate Regulator Check Valve Four Way Valve Check Valve Not on all model x Regulator Relief Valve Regulator Relief Valve Right High Pressure Gauge Left High Pressure Gauge Line Pressure Intermediate Pressure Oylinder Pressure Left Primary Regulator Right Primary Regulator Figure 2 4 Pip
71. se the pressure of the gas in the cylinders Pressure Gauges rec Hep 920 08 FIGURE 2 1 External Components Pressure is regulated in the primary regulators to the pressure noted in the adjustment specification chart in Section 1 Both primary regulators are factory preset to deliver the same pressure The primary regulators have two ports on the low pressure side A safety relief valve is connected to one port The other port is the outlet port and is connected via tubing to the four way valve The gas flows from the primary regulators to the four way valve The four way valve assembly has three positions The center position is OFF The OFF position is only used during shipment of the manifold When the valve knob is rotated counterclockwise to the left the valve connects the tubing from the left primary regulator to the outlet tubing on the right and connects the tubing from the right primary regulator to the tubing leading to the intermediate regulator When the valve knob is rotated clockwise to the right position the valve connects the tubing from the right primary regulator to the outlet tubing on the right and connects the tubing from the left primary regulator to the tubing leading to the intermediate regulator Thus by turning the four way valve knob the operator may determine which bank of cylinders is the Service supply and which bank is the Reserve supply Note Oxygen manifolds do not incorporate header valves Manifold
72. side the intermediate area also loses pressure Verify that the pressure falls to the set point of the intermediate regulator see specifica tion chart n Section 1 Tighten the main supply line union Verify that the intermediate regulator is functioning properly by observing the test gauge for two min utes The gauge should indicate the same pres sure at the end of the two minute period 5 open one cylinder valve on the left bank of cylinders Create a slight flow of gas through the manifold outlet or test port The test gauge should settle and remain constant Turn off the flow of gas through the manifold Verify that the test gauge has returned to the set pressure of the primary regulator Connect an ohmmeter across the black and brown wires of the wiring harness The ohmmeter should indicate approximately zero 0 ohms resistance If the ohmmeter does not indicate approximately zero 0 ohms connect the meter across the normally open N O and common C terminals on the pressure switch The ohmmeter should register approximately zero 0 ohms resistance when connected to the switch Adjust or replace the faulty switch See Section 4 for servicing the pressure switch Reconnect the ohmmeter to the black and brown wires Close the cylinder valve on the left bank of cylin ders Loosen the union connection to the main supply line to create a slight flow of gas through the manifold Verify an ohmmete
73. sig inlet pressure Helium 1200 SCFH maximum at 50 psig delivery and 15 psi inlet pressure and 2000 psig inlet pressure Hydrogen Acetylene 300 SCFH maximum at 15 psig delivery and 5 psi inlet pressure and 200 psig inlet pressure Liquid Fuel 400 SCFH maximum at 30 psig delivery and 7 psi inlet pressure and 100 psig inlet pressure Power Source Requirements A 115 VAC to 24 VAC power supply is provided with the manifold to operate the alarm lights on the manifold Under normal operation the manifold will draw a maximum of 40 milliamperes 040 amperes Nitrous Oxide and Carbon Dioxide systems include a 500 SCFH capacity heater The thermostatically controlled heater warms the gas before entering the regulator preventing freeze up An amber light on the control indicates when the heater circuit is on This heater light is not included on all BIHL units The heater operates at 115 VAC and draws approximately four amperes Piping Connections Ae Pipin Header Inlets Acetylene CGA 300 or 510 Ge B Du Carbon Dioxide CGA 320 amp Nitrous Oxide CGA 326 i Air CGA 346 Hydrogen CGA 350 E Liquid Fuel Gas CGA 510 MM 540 Te EE Argon CGA 580 gt Helium CGA 580 T Nitrogen CGA 580 Cabinet Argon Methane CGA 350 Manifold Outlet 1 2 NPT male pipe thread located on the left side on top of the cabinet FIGURE 1 2 Connection Locations Relief Valve 1 2 or 3 4 male pipe thread locate
74. source Available from local source Available from local source Available from local source Available from local source Available from local source Available from local source Manufactured by Occidental Chemical Corporation Niagara Falls New York Available from Western Enterprises Part number LT 100 Do not use leak test containing ammonia Available from Western Enterprises Part number MTT 1 or MTT 2 Flourolube is a registered trademark of Occidental Chemical Corporation Teflon is a registered trademark of E du Pont de Nemours amp Co Inc B20113 ECN 14800 0911 SECTION 2 THEORY OF OPERATION GENERAL INFORMATION This section concentrates on the basic theory of operation of the components of the automatic changeover manifold The first part of this section is an operating summary and traces the flow of gas through the various components of the manifold The second part of this section explains in detail the operation of the individual components contained in the manifold control section MANIFOLD OPERATION The automatic changeover manifold consists of a manifold control and two supply bank headers one service and one reserve supply to provide an uninterrupted supply of gas for the specific gas application The manifold control includes the following components and features green system normal and red replace depleted bank indicator lights cylinder pressure gauges line pressure gauge and intermediate
75. sure gauge 5 1 1 open one cylinder valve on the left bank of cylinders Observe the cylinder contents pressure gauges to verify cylinder pressure Close the cylinder valve on the right bank of cylinders Observe the cylinder contents gauges the right cylinder bank gauge should begin to drop the left cylinder bank gauge should remain constant Note test gauge may rise before dropping Observe the test gauge as the right side pressure continues to drop As the cylinder pressure drops on the right side the intermediate area also loses pressure Verify that the pressure falls to the set point of the intermediate regulator see specifica tion chart n Section 1 Adjust the intermediate regulator as necessary to obtain the required pres sure 5 1 1 open one cylinder valve on the right bank of cylinders Verify that the test gauge has returned to the set pressure of the primary regulator Rotate the control knob counterclockwise to make the left bank the service supply Close the cylinder on the left bank of cylinders Observe the cylinder contents gauges the left cylinder bank gauge should begin to drop the right cylinder bank gauge should remain constant Note test gauge may rise before falling 3 2 41 42 43 44 45 46 47 48 49 50 51 52 Observe the test gauge as the right side pressure continues to drop As the cylinder pressure drops on the left
76. t comes on and the green system normal light is extinguished Any remote alarms are activated at this time When the Service pressure falls to the set point of the intermediate regulator the check valve is pushed open by the pressure applied from intermediate regulator The Reserve supply begins to supply the system After replacing the empty cylinders and opening the master valve and cylinder valves the cylinder pressure will actuate the pressure switch the red replace depleted cylinders light will be extinguished and the green system normal light will come on The operator should then turn the control knob to the opposite cylinder bank This will make the partially used Reserve bank the Service supply and the newly installed cylinders will become the Reserve supply 2 6 20113 ECN 14800 0911 PRIMARY REGULATOR The primary regulator s function is to reduce the cylinder pressure of the supply banks to a more useable pressure Gas enters the regulator through the inlet port and fills the high pressure chamber and the port to the cylinder contents gauge with gas Figure 2 8 Gas in these areas is at the same pressure as the gas in the cylinders The gas is sealed in this camber 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 chambe
77. the manifold system Intermediate regulator set to open at too high a pressure Close cylinder or shutoff valves Intermediate regulator defective Empty reserve bank cylinders Line regulator not set correctly Line regulator not set correctly Flow demand too high 3 7 REMEDY OR CHECK Replace intermediate regulator seat and nozzle components Reduce flow demand Leak test tighten reseal or replace fittings as necessary Adjust intermediate regulator per specifications Open valves Replace or repair regulator Replace cylinders Readjust line pressure regulator Readjust line pressure regulator Consult factory B20113 ECN 14800 0911 This page intentionally left blank 3 8 20113 ECN 14800 0911 SECTION 4 SERVICE PROCEDURES NOTE 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 standard of performance and safety of the product GENERAL MAINTENANCE 1 Main section a Daily record line pressure b Monthly 1 Check regulators compression fittings and valves for external leakage 2 Check valves for closure ability c Annually 1 Check relief valve pressures 2 Check primary regulator seats 3 Manifold header a Daily observe Nitrous Oxide and Carbon Dioxide systems for cylinder frosting or surface condensation Shoul
78. way valve to the intermediate block tubing Mark the compression fittings per the instructions on page 4 2 Using a 7 16 open end wrench disconnect the line pressure gauge tubing from the line regulator Disconnect the intermediate pressure relief valve from the building s vent line Using two 1 1 2 open end wrenches disconnect the main supply line from the manifold at the union Using a small pipe wrench remove the union nipple from the outlet of the line regulator Using a 7 16 hex wrench remove the U bolt from the bracket Using a 3 8 hex wrench remove the nut and washer from the carriage bolt holding the intermediate block to the bracket and remove the bolt and the intermediate block Secure the intermediate block in a vise or similar holding fixture To remove the regulator from the intermediate block grasp the bonnet of the regulator and rotate the regula tor counterclockwise Disassembly 1 2 Rotate the adjusting screw of the regulator counterclockwise with a flat blade screwdriver and remove Remove the bonnet by holding the body hex with a wrench to stabilize the assembly and using another wrench to loosen the bonnet The adjusting spring and pivot will come off with the bonnet Remove the diaphragm assembly and slip ring Using the appropriate socket wrench rotate the nozzle counterclockwise and remove the nozzle Grasp the stem of the seat and pull the seat compensating spring gland and friction washer
79. y regulator setting too low Faulty line pressure gauge Faulty alarm pressure switch Line regulator setting too high Regulator freeze up Nitrous Oxide or Carbon Dioxide Faulty line pressure gauge Faulty alarm pressure switch 3 5 REMEDY OR CHECK Check wiring connections on both power supply terminal strips Reduce flow demand Check input from alarm unit to terminal strip Readjust line pressure regulator Slowly open valves Replace with full cylinders Set delivery pressure to specifications Replace line pressure gauge Readjust or replace pressure switch as necessary Readjust line pressure regulator Reduce the flow demand or increase the number of supply cylinders Replace line pressure gauge Readjust or replace pressure switch as necessary B20113 ECN 14800 0911 SYMPTOM LOSS OF CYLINDER CONTENTS Audible or inaudible gas leakage unknown origin Venting at relief valve PROBABLE CAUSE Leakage at manifold piping connections Leakage at manifold tubing connections Leakage in downstream piping system Leakage at cylinder valve Gauge leaks Regulator leaks Line regulator setting too high Overpressure due to creeping or faulty regulation by pressure building regulator Overpressure due to creeping or faulty regulation by line regulator Regulator freeze up Nitrous Oxide or Carbon Dioxide Heater Failure Nitrous Oxide or Carbon Dioxide

BI Service Manual - Western Enterprises

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