Western Innovator LC Series Bedienungsanleitung

INTRODUCTION

Western manifold systems are cleaned, tested and prepared for the indicated gas service and are built follow-

ing National Fire Protection Association and Compressed Gas Association guidelines. The manifold is specifi-

cally designed to regulate and monitor vaporized gas from liquid cylinders with contents pressures between

125 - 250 psig and to provide an uninterrupted supply of gas for the specific gas application. The control is de-

signed and built with features providing automatic changeover from the depleted “Service” supply bank to the

“Secondary” supply with no loss or drop in delivery pressure. Pressure gauges, alarm signal connections and

lights show system status and alert the need to replace depleted cylinders. An economizer control valve is con-

tained within the cabinet to utilize accumulated pressure from the "Secondary" bank preventing the exhausting

of useful product into the atmosphere. Features of the automatic systems include an integral adjustable line

regulator, 72" cryogenic flexible pigtails with check valves and complete mounting hardware.

WARRANTY

All Western manifolds are warranted against defects in materials and workmanship for the period of one year

from date of purchase. See back cover for details of limited warranty.

B20105 0012 ECN-11129

Installation and Operating Instructions For

AUTOMATIC CHANGEOVER MANIFOLD

LC and LCHP SERIES

CAUTION

Failure to follow the following instructions can result in personal injury or property damage:

•Never permit oil, grease, or other combustible materials to come in contact with cylinders, manifold, and

connections.Oiland greasemayreactandignitewhenincontactwithsomegases—particularly oxygenandnitrous

oxide.

•Cylindervalves shouldalways beopenedverys-l-o-w-l-y.Heatofrecompressionmayignitecombustiblematerials.

•Pigtails should never be kinked, twisted, or bent into a radius smaller than 5 inches. Mistreatment may cause the

pigtail to burst.

•Do not apply heat. Some materials may react and ignite when in contact with some gases — particularly oxygen

and nitrous oxide.

•Cylinders should always be secured with racks, chains, or straps. Unrestrained cylinders may fall over and damage

or break off the cylinder valve which may propel the cylinder with great force.

•Carefully read and follow installation and mounting instructions! Manifolds are designed for gas withdrawal from

cryogenic liquids. Contact of a cryogenic liquid or cold gas with skin or eyes may cause a freezing injury.

•Oxygen manifolds and cylinders should be grounded. Static discharges and lightning strikes may ignite materials

in an oxygen atmosphere, creating a fire or explosive force.

•Weldingshouldnotbe performednear nitrousoxidepiping. Excessiveheatmaycausethe gasto dissociate, creating

an explosive force.

—1—

TABLE OF CONTENTS

GENERAL INSTRUCTIONS ..............................................................................................................3

CONTROL SECTION INSTALLATION ..............................................................................................4

HEADER INSTALLATION ..................................................................................................................4

PLUMBING .........................................................................................................................................5

HEALTH CARE INSTALLATIONS .....................................................................................................5

ELECTRICAL......................................................................................................................................5

REMOTE ALARM HOOKUP ..............................................................................................................6

INSTALLING PIGTAILS AND ATTACHING CYLINDERS .................................................................7

START UP AND CHECKING PROCEDURES...................................................................................7

MANIFOLD OPERATION ...................................................................................................................8

CYLINDER REPLACEMENT & HANDLING .....................................................................................9

LINE DELIVERY PRESSURE ADJUSTMENT...................................................................................10

GENERAL MAINTENANCE ...............................................................................................................10

TROUBLE-SHOOTING ......................................................................................................................11

MANIFOLD MAINTENANCE & REPAIR PARTS ...............................................................................13

REPLACEMENT PIGTAILS .........................................................................................................13

INDICATOR LAMP REPLACEMENT PARTS .............................................................................13

PANEL MOUNT GAUGES...........................................................................................................13

REGULATORS AND REGULATOR REPAIR KITS.....................................................................13

VALVES AND VALVE REPAIR KITS ..........................................................................................13

PRESSURE SWITCH REPLACEMENT PARTS .........................................................................13

POWER SUPPLY REPLACEMENT PARTS ...............................................................................13

REMOTE ALARMS ......................................................................................................................13

WARRANTY .......................................................................................................................................14

—2—

GENERAL INSTRUCTIONS

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 manifold should not be placed in

a location where the temperature will exceed 120°F (49°C) or fall below 0°F (-17°C). A manifold placed in an

open location should be protected against weather conditions including rain and heavy moisture. During win-

ter, protect the manifold from ice and snow. In summer, shade the manifold and cylinders from continuous ex-

posure 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. The control indicator knob on

the manifold control section should be left in the "OFF" position until supply or test cylinders are connected.

This precaution will keep moisture and debris from the piping interior, avoiding operational problems.

41"

13"

50"

10"

FIGURE 1

CAUTION:

•Remove all protective caps prior to assembly. The protective cap may ignite due to heat of recompres-

sion in an oxygen system.

—3—

CONTROL SECTION INSTALLATION

1. Determine and mark the vertical center line for installation of the manifold

control. (Figure 2)

2. Measure from the floor to a point 57" in height* of this vertical line. Using

a spirit level, mark a horizontal line at this point extending approximately

10" to the left and 10" to the right of center.

(* — Suggested manifold height. Wall mounting heights may vary from one

installation to another depending on available space, cylinder height,

etc.)

3. Remove the mounting bracket from the back of the manifold control by

removing the nut at the bottom of the bracket. Place the upper edge of

the “tee” mounting bracket on the marked horizontal line and centered

with the vertical line. Holding the bracket with the slotted extensions

away from the wall, mark the locations for three mounting bolts. (Figure

4. Anchor the mounting bracket to the wall. Selection of mounting fasteners will

depend upon wall construction. (Figure 3)

5. Secure the manifold control in place by sliding the round retainers on the back

of the cabinet into the slots on the bracket. Replace the nut on the bolt

which protrudes from the case and tighten lightly. This bolt only stabilizes

the bottom of the unit and is not load-bearing. (Figure 4)

NOTE: If using a single bank LC manifold with high pressure reserve

cylinders as the right bank, the following modifications to the

manifold unit are necessary. (see figure 5)

1. Remove the right side inlet cross and adaptor using a 11/4" hex

wrench to stabilize the inlet block and a pipe wrench to grip the

adaptor.

2. Remove all debris from the inside of the inlet block. Apply teflon tape

or a suitable oxygen safe pipe thread sealant to the male pipe

thread on the straight adaptor provided with the

high pressure reserve manifold.

3. Install the adaptor in the inlet block using a 11/4"

hex wrench to stabilize the inlet block and a 13/8"

wrench to grip the adaptor.

4. Secure the manifold control in place as noted in

step 5 above.

5. Attach the header to the regulator union on the right side of the

manifold control. Using a spirit level, mark the placement of mounting brackets while keeping the header

on a horizontal plane.

6. Remove the U-bolt assemblies from the header mounting brackets. Position the brackets so that the top of

the bracket is aligned with the bottom of the headers and is centered between the cylinder connections.

The end bracket should be placed as close to the last cylinder as possible to provide the most support and

stability.

7. Mark the mounting hole and install fasteners suitable for the type of wall construction.

8. Fit the U-bolt over the header piping and tighten the two mounting nuts.

Center

Line

Spirit

Level

57"

Floor

Line

FIGURE 2

Mounting

Bracket

FIGURE 3

Retainers

Mounting

Bracket

Nut

Control

FIGURE 4

Adaptor

FIGURE 5

—4—

PLUMBING

1. A 1/2" NPT male union is supplied with the control and

is located at the upper left side of the manifold control.

Connect this union to the pipeline system. Sweat joints

must be silver soldered. Use BAg series silver solder

(DO NOT USE SOFT SOLDER). Heat the entire joint

evenly. Apply enough heat favoring heavy sections, so

that solder flows freely around the joint leaving no pin

holes. (See National Fire Protection Association

Pamphlet No. 99). The union provided permits

removal of the manifold control for service. (Figure 6)

2. If the manifold is installed in a closed area, vent piping must be attached to the Inlet relief valves located on

the top right of the manifold control. The vent connection is 1/4 NPT male.

3. Installation of a shut-off valve to isolate the pipeline during service to the manifold is recommended.

HEALTH CARE INSTALLATIONS

1. Install LC system per plumbing

section.

2. Install the check valves, reserve

manifold, pressure switch and dual

line assembly per the schematic

showninfigure7.

ELECTRICAL

1. A 24 VAC power supply transformer

is furnished with the control unit.

Mount the box on the wall with the

bottom edge approximately at the

top of the control cabinet. The

attached control cable terminates in

a 4-way plug matching a receptacle

on the bottom of the control cabinet.

(Figure 6)

2. After mounting the power supply

box to the wall, plug the cable into

the control cabinet receptacle.

3. One hole on the underside of the

power supply box provides access

for conduit and connection of 115

VAC power to the black primary

leads. Remove 115 VAC power

prior to making connections. The

other hole on the underside of the

power supply transformer box

provides access for remote alarm

connections.

4. After completing the 115 VAC

connections, the power supply

should be complete and functional

and 115 VAC power can be

restored.

5. The manifold wiring schematic is shown in figure 8.

Power

Supply

Inlet Relief Valve Piping

Manifold

Control

cabinet

Isolation

Valve

115 VAC

Conduit

Delivery

Pipeline

FIGURE 6

WESTERN WME-4-14

"Reserve in Use" Switch

WESTERN

LC or LCHP

Series

WESTERN

CVF-8F or

CVF-12F

Check Valve

Pressure

Relief

Valve

WESTERN

WMS-1-20

WMS-1-22

DLA-4 OR

DLA-5

Dual Line

Assembly

WESTERN

CLA Series

Reserve

Manifold

Reserve Pressure

Regulator

Shutoff Valve

To Outside

of Building

WESTERN

WME-4-15

High/Low

Pressure Switch

Reserve

Low

Switch

FIGURE 7

FIGURE 8

—5—

REMOTE ALARM HOOKUP

A five terminal remote alarm terminal strip is on the right side of the circuit board in the power supply box for re-

mote alarm interfacing. The top three terminals on this strip (N/C, N/O, and C) provide dry contacts for remote

alarm hookup. Wiring diagrams for remote audio/visual alarms are included with the alarms. Listed below are

four different remote alarm configurations. Terminals identified as N/O and N/C have been marked in the un-

actuated state.

In some instances the power supply for the remote alarm is normally a part of the electrical contract

on proposed constructions and should exist in any furnished hospital. The following procedure

should be followed:

1. Two alarm signal wires

requiring dry contacts should

run to the manifold location.

2. Connect one signal wire to the

common (C) terminal and the

other signal wire to the

normally open (N/O) terminal

on the terminal strip on the

right side in the power supply

box. (Figure 9)

If the remote alarm is designed for 24 VAC operation then connect the alarm as follows:

(Also see WESTERN’S ALARM section below.)

1. Connect the ground wire from

the alarm to one 24 VAC

terminal on the right side of

the circuit board in the power

supply box. (Figure 10)

2. A jumper wire is connected

between the other 24 VAC

terminal and the common (C)

terminal.

3. Connect the "reserve in use" signal wire to the normally closed (N/C) terminal.

4. If a "system normal" signal is also employed, connect that signal wire to the normally open (N/O) terminal.

Alarm Signal Wire

N/O

N/C

VAC

Alarm Signal Wire

Note: Alarm function is initiated

on an open circuit

FIGURE 9

Alarm"ReserveinUse"

Signal Wire

Alarm "System Normal"

Signal Wire

Alarm Negative (-) Lead

(Ground Wire)

N/C

VAC

N/O

VAC

Note: Functions initiated on

a closed circuit

FIGURE 10

If the remote alarm is designed for voltages other than 24 VAC then connect the alarm as follows:

1. Connect the ground wire from

the alarm to the negative (-)

connection at the power

source. (Figure 11)

2. There should be NO

connections to the 24 VAC

terminals on the right side of

the circuit board.

3. Connect the positive (+)

connection from the power

source to the common (C) terminal on the circuit board.

4. Connect the "reserve in use" signal wire to the normally closed (N/C) terminal.

5. If a "system normal" signal is also employed, connect that signal wire to the normally open (N/O) terminal.

Alarm"ReserveinUse"

Signal Wire

Alarm "System Normal"

Signal Wire

Alarm Negative (-) Lead

(Ground Wire)

N/C

N/O

VAC POWER

SOURCE

(+) (-)

Note: Functions initiated on

a closed circuit

FIGURE 11

—6—

FIGURE 12 Western’s Remote Alarm

INSTALLING PIGTAILS AND ATTACHING CYLINDERS

1. Establish flow direction of check valves in pigtails.

2. Connect pigtails to the manifold inlet tee with direction of check valve flow from cylinder to manifold end of

pigtail.

3. Attach full cylinders to the pigtail connections as explained in “Cylinder Replacement & Handling” on page 9.

4. S-L-O-W-L-Y turn all cylinders on fully (turn counter-clockwise to open). Check all cylinder and pigtail

connections for leaks using Western leak detector LT-100 or an oxygen safe solution. (Any bubbles

around connections indicate leakage.)

5. Turn power on to the 24 V power supply transformer box. The red “Replace Depleted Bank” light on the

control cabinet should be activated.

START UP AND CHECKING PROCEDURES

1. Turn the control indicator knob fully to the right. S-L-O-W-L-Y open the right cylinder valve (turn

counter-clockwise to open). The right bank pressure gauge should show the full pressure of the right bank

of cylinders. The green “System Normal” light comes on, extinguishing the red “Replace Depleted Bank”

light.

2. S-L-O-W-L-Y open the left cylinder valve fully. The left bank pressure gauge will show the full pressure of

the left bank of cylinders.

WESTERN’S ALARM

1. Connect one 24 VAC lead from the alarm to one 24 VAC terminal on the right side of the circuit

board in the power supply box. (Figure 12)

2. Connect the other 24 VAC lead from the alarm to the other 24 VAC terminal.

3. A jumper wire is connected between one 24 VAC terminal and the common (C) terminal.

4. Connect the alarm signal wire to the normally open (N/O) terminal.

Signal Wires

Note: Alarm function is initiated on an open circuit

Remote

Alarm

PCB

Power

Supply

PCB

N/C

N/O

24 VAC

VAC 12

GAS

—7—

3. Create a slight flow of gas in the delivery pipeline system. Close the right master valve to simulate a

depleting right bank. Observe the following:

•The right bank gauge pressure slowly falls and the control automatically switches over to the left

bank.

•Delivery pressure remains constant.

•Green “System Normal” light is extinguished.

•Red “Replace Depleted Bank” light comes on.

•Any remote alarms should be activated at this time.

4. S-L-O-W-L-Y reopen the right cylinder valve. Observe the following:

•Right bank pressure gauge returns to full pressure.

•Green “System Normal” light comes on.

•Red “Replace Depleted Bank” light is extinguished.

•Any remote alarms should be canceled.

5. Turn the control indicator knob fully to the left and repeat procedures 3 and 4 to simulate an empty left

bank.

MANIFOLD OPERATION

The manifold control includes the following components and features: green “System Normal”, and red

“Replace Depleted Bank” indicator lights, cylinder pressure gauges, line pressure gauges, Inlet relief

valves, supply bank control indicator knob, and automatic bank switching. Supply banks consist of a tee

with 72" cryogenic flexible pigtails with check valves.

The cylinder bank that supplies the piping system is known as the “Service” supply, while the cylinders on

stand-by are referred to as the “Secondary” supply. Gas flows through the manifold control directly

through the line regulator. Delivery pressure is controlled by the line regulator and is adjustable via the ac-

cess hole in the upper left hand side of the cabinet. (See Delivery Line Adjustment — page 10).

Changeover from the "Service" to "Secondary" side is accomplished by a pressure differential between the

inlet and intermediate regulator. As cylinder contents are depleting, pressure passing through the mani-

fold will drop. When this pressure drops to the set pressure of the intermediate regulator, a pressure

switch is actuated causing the green “System Normal” light to go out and a red “Replace Depleted Bank”

light to come on. The “secondary” bank will automatically begin to flow without any interruption in service

line delivery pressure.

There are two definite indicators as to which bank should be changed; (1) the arrow on the control indica-

tor knob in conjunction with the red “Replace Depleted Bank” light and (2) the cylinder bank pressure

gauge.

After replacing empty cylinders, open cylinder valves. Because the cylinder pressure will actuate the pres-

sure switch, the red “Replace Depleted Bank” light will be extinguished and the knob indicator must be

turned to it’s opposite position to indicate the new supply bank now in service. Moving the indicator knob

to it’s new position after replacement of an empty bank is the only action that must be taken to reset the

manifold. The indicator knob must always be in the extreme right or left position.

—8—

To insure proper operation, observe

the following guidelines:

1. Carefully follow all instructions.

2. Establish proper flow direction of

check valves.

3. Be sure cylinder valves are fully

opened.

4. Replace depleted cylinders as soon

as practical after the red "replace

depleted cylinders" light comes

on.

CYLINDER REPLACEMENT &

HANDLING

1. Shut off all cylinder valves on depleted cylinder bank.

2. S-L-O-W-L-Y loosen and remove the pigtail connection from the depleted cylinders.

3. Remove depleted cylinders and replace protective caps.

4. Remove protective cylinder caps from full replacement cylinders. With the valve outlet pointed away

from you or anyone else, slowly open each cylinder valve slightly to blow out any dirt or contaminants

which may have become lodged into the cylinder valve.

5. Place and secure full cylinders into position using chains, belts, or cylinder stands.

6. Connect pigtails to cylinder valves and tighten with wrench.

7. S-L-O-W-L-Y turn each cylinder valve until each cylinder is fully on. Check all cylinder and pigtail

connections for leaks using Western leak detector LT-100 or an oxygen safe solution (any bubbles

around connections indicate leakage).

NOTE: All cylinders shall have their pressure building regulators set at the same pressure.

8. Observe the following conditions:

A red “Replace Depleted Bank” light goes out, and the green “Service Normal” light comes on.

9. Turn the control indicator knob fully to the opposite supply bank to indicate the service bank.

To Pipeline

Distribution

System

Line Pressure

Gauge

Line Pressure

Regulator

Test Gauge

Port

Low Pressure

Switch

Four Way

Valve

Left Bank

Pressure

Gauge

Left Bank

Relief Valve

Line Pressure

Cylinder

Pressure

Relief Valve

Outlet

Check Valve

Bypass Valve

Intermediate

Regulator

Right Bank

Pressure

Gauge

Right Bank

Relief Valve

Check Valve

FIGURE 12

—9—

LINE DELIVERY PRESSURE ADJUSTMENT

The delivery line pressure (center gauge) has been factory set. If adjustment is required, carefully proceed ac-

cording to the following instructions.

1. Leave the manifold in full operational status.

2. Create a flow condition in the delivery pipeline system.

3. Locate the line pressure adjustment access hole on the left side of the manifold control.

4. Adjustment: Using a flat blade screwdriver, turn clockwise to “increase” pressure, turn counterclockwise to

“decrease” pressure.

5. Line pressure settings: Minimum / Maximum

LC Models: 40 psig 85 psig

LCHP Models: 40 psig 180 psig

LCHP-7 Models: 40 psig 210 psig

GENERAL MAINTENANCE

1. Main section

a) Daily - record line pressure.

b) Monthly

1) Check regulators and valves for external leakage.

2) Check line and intermediate regulators for ’creep’. Repair or replace as necessary.

3) Check valves for closure ability.

c) Annually - check relief valve pressures.

2. Manifold header

a) Daily - observe nitrous oxide and carbon dioxide systems for cylinder frosting or surface condensation.

Should excessive condensation or frosting occur it may be necessary to increase the number of supply

cylinders.

b) Monthly

1) Inspect valves for proper closure.

2) Check cylinder pigtails for cleanliness, flexibility, wear, leakage, and thread damage. Replace damaged

pigtails immediately.

3) Inspect pigtail check valves for closure ability.

c) Every 4 Years

1) Replace all pigtails

—10—

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