Automatic Medical Gas Manifold Digital Dome Loaded Regulator

Automatic Medical Gas Manifold Digital Dome Loaded Regulator
Operating & Maintenance Manual
Automatic Medical Gas Manifold Digital
Dome Loaded Regulator NFPA v1.3
w w w . a m i c o . c o m
Contents
User Responsibility
4
Introduction5
Features5
Description of the Manifold
Shipment Details
The Manifold Enclosure
Header Bar Wall Support Bracket
Manifold Display Board
Description of Parts
Main Line Source Valve
Bank Regulator
Pressure Transducers
Check Valve
Line Regulator Ball Valve
Dual Line Regulator
Pressure Relief Valve
Pilot Regulator
Solenoid Valve
Front Panel Indicators
Power Supply
Digital Display Board
Line Sensor
Gas Service Identification
Header Bar Connections
Operating Alarm System
6
6
6
6
6
7-10
7
7
7
7
8
8
8
8
8
9
9
9
9
10
10
10
Display Functions
11
Installation12
Wall Mounting Instructions
13-14
Cylinder Bank Installation Instructions
15
Testing for Leakage
16-17
Initial Power-Up
18-19
Gas Flow Through the Manifold
20
Manifold Switchover
21
Performance Verification
22-23
Bank Regulator Pressure Adjustment
24
Bank Regulator Replacement
25
Line Regulator Pressure Adjustment
25
2
Amico Corporation
Line Regulator Replacement
Control Board Replacement
Cylinder Changing Procedures
Ordering Information
Control Cabinet Part List
Appendix A: Manifold Internal Layout
Appendix B: Piping Schematic Diagram
Appendix C: Wiring Schematic Heater Units
Appendix D: Electrical Wiring Diagram
Appendix E: Control Cabinet Wiring Diagram
Appendix F: Staggered Header Bar
Appendix G: Straight Header Bar Setup
Appendix H: Optional Header Bar Setup
Appendix: Standard Manifold Flow Rates
26
27
28
29-30
29-30
31
32
33
34
35
36
37
38
39
www.amico.com
3
User Responsibility
The information contained in this Operating and Maintenance Manual pertains only to the Amico Automatic Gas
Manifold. This product will perform in conformity with the descriptions contained in this manual when assembled,
operated, maintained and serviced in accordance with the installation instructions provided.
The manifold MUST be checked periodically. Parts that are broken, missing, worn, distorted or contaminated must be
replaced immediately. Should such repair or replacement become necessary, please contact Amico Corporation or their
distributors.
For installing CO₂ and N₂O manifolds outdoors, please refer to NFPA 99C:
“Central supply systems for nitrous oxide and carbon dioxide shall be prevented from reaching temperatures lower than the
recommendations of the central supply system’s manufacturer, but shall never be lower than -7°C (20°F) or greater than 54°C
(130°F).”
All manifolds should not be repaired or altered without prior written approval by Amico Corporation or its
distributors. Failure to comply will void all warranty on the manifold.
Statements in this manual preceded by the words WARNING, CAUTION, DANGER and NOTE are of special significance.
Please read these sections carefully.
WARNING: denotes steps which can prevent injury.
CAUTION: denotes steps which can prevent damage to equipment.
DANGER: denotes steps which can prevent electrical shock to equipment or prevent serious injury
and/or death.
4
Amico Corporation
Introduction
The Amico Automatic Gas Manifold is a one of a kind design that provides a reliable, uninterrupted supply of gas to a
hospital or other medical facility. The manifold utilizes multiple high-pressure cylinders divided into two equal banks.
One bank is designated as a “Primary” source of gas while the other bank stands in reserve as a “Secondary” source.
A display of LED’s on the front of the manifold indicates the status of the gas supply. Each bank has a green “In Use”,
yellow “Ready” and red “Empty” LED. When the primary bank of cylinders is depleted, the manifold will automatically
switch to the secondary bank of cylinders without interruption of gas flow to the facility. The red LED will illuminate
when a bank is depleted and two normally closed dry contacts for the Reserve In-Use Alarm will open. One or both sets
of contacts may be wired to an external alarm, remote buzzer and/or a building management system.
When replacement cylinders are attached to the depleted bank, the red LED goes out and the yellow LED illuminates
indicating that the bank has been automatically designated as the secondary supply. No other user interaction is
required. Both sets of dry contacts close to cancel any external alarm condition.
The power supply is connected to the top right hand corner of the manifold. Connections from the manifold to the
Amico Master Alarm must be made from terminals marked C/Signal to the appropriate terminals (Reserve In Use) on the
Master Alarm or a remote buzzer.
The enclosure for the manifold is NEMA-1 (general purpose applications only) and it is not recommended to be mounted
outdoors.
The manifold has a removable front cabinet. The pre-assembled circuit board is mounted directly to the back plate of
the manifold. This design will reduce installation time and eliminate the risk of improper installation, since each of the
components of the manifold are connected and tested at the factory.
The Amico Automatic Gas Manifold is designed in accordance with the National Fire Protection Association (NFPA 99).
FEATURES INCLUDE:
• Input power to the manifold is 110-240 VAC, 50-60Hz
• Incorporates six LED’s and the digital display is readable even in the poorest of lighting conditions
• Dual line pressure regulators
• Single vent access from line and operating relief valve
• Wall mounting bracket attached to manifold for easy installation
• Manifold complies with NFPA 99
www.amico.com
5
Description of the Manifold
SHIPMENT DETAILS
The manifold system may be shipped in more than one carton, depending on the number of cylinder connections. The
main carton contains the following items:
• Manifold control panel (with power supply assembly)
• Wall mounting bracket (attached to manifold control panel)
• 3/4" Source shut-off valve
• Installation, Operation and Service Manual
Additional cartons may contain the appropriate number of header bars and cylinder pigtail assemblies. Standard
header bar assemblies are configured so that cylinder inlets are on 11" centers. Cylinders may be placed in a double
row “Staggered” or single row “Straight” configuration. Cylinder inlets closest to the manifold control panel are intended
for cylinders placed directly beneath the manifold control panel. For gases other than oxygen and helium, 36" stainless
steel, flexible type pigtails are used. Oxygen and helium pigtails are rigid copper and are pre-bent to the approximate
shape for connection to the cylinders. The manifold is designed to be mounted directly to a wall.
THE MANIFOLD ENCLOSURE
The manifold enclosure contains a switch mode power supply that can handle voltage from 110-240 VAC with a builtin fuse and terminal block. The enclosure on this manifold is NEMA-1 (general purpose applications only). This cabinet
must not be mounted outdoors.
The manifold also has a latched door that is easy to remove. The pre-assembled circuit board is located at the center of
the enclosure with a hinge mounting bracket. This design reduces installation time and eliminates the risk of improper
installation, since all the components of the manifold are connected and tested at the factory.
HEADER BAR WALL SUPPORT BRACKET
The manifold can support, at maximum, a 5x5 staggered header bar. While the straight header
bar contains a wall support bracket on every second pipe in between each cylinder, a standard
staggered header bar has a wall support bracket in place after every 5 cylinders, unless additional
support is requested.
MANIFOLD DISPLAY BOARD
The LEDs on the front of the manifold indicate the status of the gas supply. The primary bank will indicate “In Use“, with
the green LED turned on, and the reserve/secondary indicating “Ready”, with the yellow LED turned on, or “Empty”, with
the red LED turned on depending on the status of the gas supply. When the primary bank of cylinders is depleted, the
manifold will automatically switch to the secondary bank of cylinders without interruption of gas flow to the facility.
The red LED will illuminate when a bank is depleted and two normally closed dry contacts will open. One or both sets of
contacts may be wired to an external alarm, remote buzzer and/or a building management system.
6
Amico Corporation
Description of Parts
When replacement cylinders are attached to the depleted bank, the red LED goes out and the yellow LED illuminates
indicating that the bank has been automatically designated as the secondary supply. No other user interaction is
required. Both sets of dry contacts close to cancel any external alarm condition.
MAIN LINE SOURCE VALVE
A 3/4" isolation valve with a locking handle, supplied with the manifold,
should be installed on top of the manifold connecting to the main supply
line.
BANK REGULATOR
A dome loaded, single stage, diaphragm type regulator is used to reduce
the pressure of incoming cylinder contents to a lower intermediate
pressure. A bank regulator (one for each bank of cylinders) has an
internal adjusting spring used to set a “base” pressure of approximately
100 psi (200 psi on Nitrogen and Instrument Air manifolds). The “dome”
(i.e. bonnet or bell) of the regulator is a pressure tight chamber. When
pressure is applied to the dome, the amount of force applied is added to
the force of the adjusting spring. For example, when 55 psi of pressure is
applied to the dome, then the 100 psi base pressure setting is raised to
approximately 155 psi.
PRESSURE TRANSDUCERS
The pressure transducer senses the bank pressure and transfers
information to the display board to indicate the “In Use”, “Reserve” and
“Empty” modes. There are two transducers in the manifold cabinet, one
for the left bank cylinder and one for the right bank cylinder.
CHECK VALVE
The check valve is located upstream of each bank regulator to prevent
back flow while servicing a bank regulator.
www.amico.com
7
Description of Parts
LINE REGULATOR BALL VALVE
Quarter-turn ball valves are located upstream and downstream of each line
regulator. These valves allow for removal and servicing of one line regulator while
the other is in use.
DUAL LINE REGULATOR
On every Amico Automatic Gas Manifold, the line regulator is capable of
maintaining a constant dynamic delivery of pressure at the maximum designated
flow rate of the system. For Oxygen, Nitrous Oxide, Medical Air, Carbon Dioxide
,Helium and Argon service, the line regulators are factory preset at 55 psi and for
Nitrogen and Instrument Air at 170 psi.
PRESSURE RELIEF VALVE
Pressure relief valves are installed downstream of all pressure regulators and are
set at no more than 50% above the setting of the pressure regulator. Relief valves
are capable of fully relieving the pressure at the set point. All pressure relief valves
in the manifold have piping connections to allow for connection of a vent line to
the outside of the facility.
PILOT REGULATOR
A single stage, diaphragm type, relieving regulator used to limit the amount of
pressure provided to the domes of the bank regulator. It is used only on Nitrogen
manifolds and manifolds with 100 psi delivery pressure.
SOLENOID VALVE
A 12 VDC solenoid assembly is used to direct dome bias pressure to one of the
bank regulators. As dome bias pressure is directed to one of the bank regulators,
dome pressure of the other bank regulator is vented through an exhaust in the
solenoid valve.
8
Amico Corporation
Description of Parts
FRONT PANEL INDICATORS
Six front panel indicators monitor the status of the manifold.
POWER SUPPLY
The power supply is a 110-240 VAC, 50-60 hz, which is mounted
on the top right hand side of the manifold and is provided with
a 1 amp fuse.
DIGITAL DISPLAY BOARD
An electronic circuit board that reads the tank and supply line
pressure and also controls the bank switchover. It monitors the
pressure with the help of the bank transducers and controls
the solenoid valve in order to initiate the bank switch or
changeover. The display boards illuminates the appropriate
front panel indicators and also provides dry contacts for the
activation of a remote buzzer or external master alarm. Power
to the control board is provided by the external power supply.
LINE SENSOR
The line pressure sensor senses the line pressure and relays the
pressure information to the digital display board.
DANGER: Electrical shock hazard. Ensure that the main power source is turned off during the connection
of the power supply.
www.amico.com
9
Description of Parts
GAS SERVICE IDENTIFICATION
Amico manifolds are clearly labeled for the intended gas use, indicating the appropriate gas with a label that is
attached on the cabinet door. There are two pipes extending from the top of the cabinet, one is for the main line
pressure and the other is the vent for the pressure relief valves, which is also labeled accordingly.
HEADER BAR CONNECTIONS
The gas-specific header bar should be attached to the Inlet block on either side of the manifold. The Inlet block is
provided with a sintered bronze filter and a “C” clip to secure it. The header should contain the proper gas connections
and all cylinder bar connections. The pigtail (hose) assemblies should comply with CGA standard B96, “Compressed
Gas Cylinder Valve Outlet and Inlet Connections.”
OPERATING ALARM SYSTEMS
The manifold control cabinet contains the required circuitry to send a dry contact signal to the alarm unit when a bank
is empty and changeover occurs. The normally closed internal circuitry is designed to alarm when there is an open
circuit. The depletion of a bank triggers a relay, which renders the alarm circuit open and initiates the alarm signal.
Line Relief Valve
Line Sensor
Solenoid Valve
Hinge Bracket
Digital Circuit Board Bracket
Digital Circuit Board
Cover Plate
10
Amico Corporation
Display Functions
1. Introduce power to the control cabinet.
2. Follow the Cylinder Changing procedure on the side of the cabinet to ensure that all cylinders and fittings are
secure and properly connected to the header bar.
3. Check the indicator LED for proper functioning.
4. The “In-use” bank will have a green LED turned on, and the reserve / secondary bank will indicate “Ready” with a
yellow LED turned on.
5. Close the cylinder valve on the primary bank and watch the indicator LED to ensure proper functioning. The
primary bank pressure should fall, while the secondary and line pressures stay constant.
6. When the primary pressure falls to approximately 120 psi for all gases (or 220 psi for Nitrogen and Instrument Air)
the bank switchover occurs. The line pressure will remain constant with the LED display indicating the bank
“In Use”.
7. With the Amico Automatic Gas Manifold wired up to the Amico Master Alarm, the changeover from “Primary” to
“Secondary” supply will cause an audible alarm buzzer and the appropriate indicator LED on the Master Alarm will
illuminate. This can also be achieved by using the switchover test button located on the back of the control board.
www.amico.com
11
Installation
PRECAUTIONS
•
Tampering with gas specific connections shall be prohibited. Do not alter, remove or modify gas specific
connections.
•
Keep all manifold parts, tools and work surfaces free of oil, grease and dirt. These and other flammable materials
may ignite when exposed to high pressure oxygen or nitrous oxide.
•
Do not use chemicals, lubricants or sealants unless specified in these instructions.
•
Before connecting cylinder to manifold, momentarily open and close cylinder valve to blow out dirt and debris.
•
After connecting cylinder to manifold, open cylinder valve S-L-O-W-L-Y to allow heat of compression to dissipate.
•
Do not use flame or “sniff” tests for leaks.
•
Do not apply heat to any part of the manifold system.
•
Always secure high-pressure cylinders with racks, straps or chains. Unrestrained cylinders may fall over and damage or break off cylinder valve.
•
Do not repeatedly bend, sharply bend or twist copper pigtails as damage to tubing may occur.
•
After the manifold wall bracket has been mounted, one person alone should not attempt to lift and hang the
manifold cabinet.
•
Do not put the manifold into operation until verified by a qualified person as per NFPA 99 or other local standards.
12
Amico Corporation
Wall Mounting Instructions
1. Remove manifold control panel from the shipping carton. If the manifold will be placed on a flat surface in the
upright position, do not remove the foam packaging material or the manifold may tip over. Only remove the foam
packaging material when ready to hang the manifold on the mounting bracket (in step 4).
2. Using the back support bracket as a template, place on the flat wall and align the top of the bracket with the
level horizontal line. The vertical center line of the bracket will be the vertical center line of the installed manifold.
The support bracket should be mounted 61-1/2” [1,562.1 mm] from the finished floor to the bottom hole of the
bracket as shown in Figure 1.
3. Mark locations of mounting holes. Remove the bracket and drill mounting holes. Attach the bracket to the wall
with appropriate anchors (supplied by others). 3/8” [9.525 mm] diameter anchors are recommended.
Figure 1
Locate bracket per
horizontal line
Mark Location
of holes
61 1/2"
[1,562.1mm]
To Floor
www.amico.com
13
Wall Mounting Instructions
4. Hang the manifold control panel on the mounting bracket. The top two
control panel mounting bolts will slide into slots of the bracket. The bottom
of the manifold control panel should be angled away from the bracket until
the top two bolts have been inserted as shown in Figure 2.
Figure 2
NOTE:
A bracket mounting height of 61-1/2" [1,562.1 mm] from the finished floor to the
bottom hole on the support bracket allows for adequate clearance beneath the
manifold when utilizing standard “H” size or slightly taller cylinders.
5. The bottom of the control panel can then be positioned so that the holes
at the bottom of the panel align with the holes in the hanging bracket.
Use 3/8” [9.525 mm] bolts to secure the cabinet to the bracket as shown in
Figure 3.
Figure 3
WARNING: Do not attempt to lift manifold alone. Two people are
recommended in order to hang the manifold onto the wall mounting
bracket.
CAUTION: Do not use thread sealant on header or pigtail connections.
CAUTION: Each header segment must be supported by a header
bracket before additional header segments are added.
14
Amico Corporation
Cylinder Bank Installation Instructions
CAUTION: This section contains important information necessary for proper installation of the cylinder
banks. Read it carefully before installing cylinder banks.
•
Position the wall brackets, if required, to support the header bars and bolt in place.
•
Connect the two high pressure inlet valve/header bar assemblies to the inlet blocks on either side of the cabinet.
•
Secure the header bar assembly by tightening the union nuts onto the inlet blocks. The manifold can support a maximum 5x5 staggered header bar. The straight header bar contains a wall support bracket on every second
pipe in between each cylinder, for the staggered orientation a support bracket is installed after every 4-5 cylinders,
unless additional support is required.
•
Remove the plug and chain assembly on each of the outlet connections on the cylinder extension bar. Attach the cylinder pigtails to the header bar connection, while ensuring the check valves are operating in the proper
direction.
WARNING: To avoid contamination with particles or other potentially hazardous materials, keep pigtails
in plastic wrapping until such time as connection to the gas cylinder is planned.
•
When the medical gas piping system has been tested in accordance with NFPA 99, the manifold can then be
connected to it.
•
The outlet pipes leading from the Amico control cabinet should be connected to their respective pipeline system
connections. The connection to the relief valves should be made with a union (supplied by others) to facilitate
change, if required.
•
An appropriate sealing compound that is suitable for the gas being transmitted shall be used for threaded
connections.
WARNING: If downstream joints near the cabinet outlet are to be silver brazed, special attention must be
given not to overheat the copper tubing, since this may alter the sealing compound used in the threaded
joints leading from the control cabinet.
www.amico.com
15
Testing for Leakage
The following instructions apply for performing a leak test on the joints made during assembly and connection of the
Amico manifold.
The connections inside the Amico control cabinet have been inspected at the manufacturing plant and DO NOT require
leak testing. In order to determine whether any leaks exist between cylinder header bar sections or at the pipeline
connections, the systems must be pressurized using either oil-free dry air or oil-free dry nitrogen.
In the case of Medical Oxygen, Nitrous Oxide, or Carbon Dioxide Amico Manifolds, the actual service gases ARE NOT
suitable for leak testing due to their inherent dangerous properties. Leak testing must be performed using either oil-free
dry air or oil-free dry nitrogen. In the case of either Medical Air or a Nitrogen Amico manifold, the actual service gas may
be used to perform the leak tests as follows:
1. Connect a cylinder of the manifold service gas to each side of the header bar using the proper cylinder connection
hose assemblies (pigtails) supplied.
2. Make sure all other outlets are capped with the plug and chain assemblies supplied.
3. Make sure that the high pressure inlet valves of each bank are fully OPEN.
4. S-L-O-W-L-Y open the two cylinder valves on each side of the cabinet, one at a time, to pressurize the header bar
and pipeline.
5. All outlets from the pipeline, downstream of the manifold, should be closed and thus there should be no flow from the manifold.
6. Check for leaks at all cylinder extension joints and at the joints where the pipes are connected to the pipeline,
using a commercial leak detector which is compatible with oxygen.
7. If any leaks are found, the system must be depressurized by bleeding through a convenient pipeline outlet and
the faulty connections must be repaired.
8. The header bar connections may be tightened one more turn to maintain the horizontal location of the cylinder
adapters or a further application of an oxygen service threaded sealant may be required.
9. If the brazed pipeline connections leak they must be removed, cleaned and then re-brazed following the proper
technique. All repaired joints must be pressure tested as above.
16
Amico Corporation
Testing for Leakage
PRECAUTIONS
The Amico Automatic Gas Manifolds are designed in accordance with the current revision of NFPA 99.
There are three categories of Amico manifolds depending upon the delivery pressure. The following gas types are
available for each delivery pressure:
55 psi Delivery Pressure
• Oxygen, Nitrous Oxide, Medical Air, Carbon Dioxide, Helium, Argon
100 psi Delivery Pressure
• Oxygen, Medical Air, Carbon Dioxide
170 psi Delivery Pressure
• Nitrogen, Instrument Air
Delivery (Line) Pressure - (see above)
55 psi
100 psi
170 psi
Intermediate Pressure - Ready Bank
100 psi
200 psi
200 psi
Dome Bias Pressure
55 psi**
50 psi
50 psi
150 ± 10 psi*
250 ± 10 psi
250 ± 10 psi
Intermediate Relief Valve
350 psi
350 psi
350 psi
Line Regulator Relief Valve
75 psi
150 psi
225 psi
3000 psi
3000 psi
3000 psi
Intermediate Pressure - In Use Bank
Maximum Inlet Pressure
* The intermediate pressure valve of the “In Use” bank is dependent upon the dome bias pressure. Variations from the 55
psi delivery pressure will affect the intermediate pressure reading.
** Same as delivery pressure.
www.amico.com
17
Initial Power-Up
1. Release the two latches on either side of the manifold control panel and remove the cover.
2. Verify the following:
• Both master valves located on both header bars are turned fully counter clockwise (open)
• All four line regulator isolation valves are open (handles horizontal)
• Power supply has been connected
• Both red “Empty” indicators on the front of the manifold are illuminated
• If connected to a master alarm panel, “Secondary Supply” alarm is activated
3. Close 3/4” source shut-off valve.
4. Slowly open one cylinder on the right side of the manifold.
5. Verify the following:
• Right bank red “Empty” LED goes out
• Right bank green “In Use” LED illuminates
• Right bank cylinder contents gauge reads cylinder pressure
6. Slowly open one cylinder on the left side of the manifold.
7. Verify the following:
• Left bank red “Empty” LED goes out
• Left bank yellow “Ready” LED illuminates
• Left bank cylinder contents gauge reads cylinder pressure
• If connected to a master alarm panel, “Secondary Supply” alarm is not activated
8. Close right bank cylinder. Slightly depress bleed valve located on the side of the regulator. Verify the following:
• Right bank cylinder contents gauge drops slowly
• As the right cylinder contents gauge is nearly depleted, the manifold changes over to the left bank
• After changeover, the right bank green “In Use” LED goes out and the red “Empty” LED illuminates
• After changeover, the left bank yellow “Ready” LED goes out and the green “In Use” LED illuminates
9. Verify the line pressure gauge reading is acceptable.
10. Slowly open one cylinder on the right side of the manifold.
18
Amico Corporation
Initial Power-Up
11. Verify the following:
• Right bank red “Empty” LED goes out
• Right bank yellow “Ready” LED illuminates
• Right bank cylinder contents gauge reads cylinder pressure
12. Close the left bank cylinder. Depress the valve located on the side of the line regulator. Verify the following:
• Left bank cylinder contents gauge drops slowly
• As left cylinder contents gauge is nearly depleted, the manifold changes over to the right bank
• After changeover, the left bank green “In Use” LED goes out and red “Empty” LED illuminates
• After changeover, the right bank yellow “Ready” LED goes out and green “In Use” LED illuminates
13. Slowly open one cylinder on the left side of the manifold.
14. Verify the following:
• Left bank red “Empty” LED goes out
• Left bank yellow “Ready” LED illuminates
• Left bank cylinder contents gauge reads cylinder pressure
• If connected to a master alarm panel, “Secondary Supply” alarm is not activated
15. Close the left and right side cylinders.
16. Record the pressure readings of the left and right bank cylinder contents gauges.
17. Wait 15 minutes.
18. Compare current readings of the left and right bank cylinder contents gauges to those recorded in step 16.
If there is a noticeable pressure change on either gauge, perform leak testing described in Leak Testing on
page 17.
19. Reinstall manifold control panel cover.
20. Slowly open all cylinders for both banks of the manifold.
21. Open 3/4" source shut-off valve.
www.amico.com
19
Gas Flow Through the Manifold
High pressure gas is provided to the left and right manifold bank inlets via cylinders, pigtails and header assemblies.
Flow of high pressure gas through the left and right side of manifold is exactly the same, each passing through a master
valve located on the header and then directly to a bank regulator.
Bank regulators reduce incoming cylinder pressures to an intermediate pressure. Bank regulators are referred to as a
"dome loaded" type of regulator. These regulators have an internal adjusting spring manually set at a specific pressure
similar to other diaphragm-type pressure regulators. In addition to internal adjusting spring, bias pressure may be applied
to the dome of the regulator (adjusting spring side of diaphragm) thus boosting pressure above what is manually set by
the adjusting spring. This output pressure boost will be approximately equal to the amount of bias pressure.
For example, if a bank regulator is manually adjusted to 100 psi via internal adjusting spring, and a dome bias pressure
of 55 psi is applied, the output pressure will increase to approximately 155 psi (100 + 55). When the bias pressure is
removed, the output pressure setting will return to 100 psi.
Outputs of both the left and right bank regulators pass through check valves and connect together upstream of the
dual line regulator assembly. An intermediate relief valve protects components between the bank and line regulators in
the event of a bank regulator seat failure.
The dual line regulator assembly consists of two line regulators plumbed in parallel with upstream and downstream
isolation 1/4" turn ball valves. Output of both the line regulators tee together and exit at the manifold’s main outlet. A
line relief valve along with a line pressure gauge is connected to the manifold’s main outlet.
Outlet pressure is then routed to a dome regulator reducing pressure to 55 psi at the solenoid switch. Solenoid switches
55 psi (dome bias pressure) to one of the bank regulators. When one bank regulator is supplied bias pressure, the other
bank’s dome regulator is vented to the atmosphere. An electronic circuit board controls the solenoid valve based upon
the input received from the right and left pressure transducer. The solenoid valve directs bias pressure to the bank
designated as primary.
Manifolds designed for 55 psi nominal output pressure do not incorporate a Pilot regulator. Full line pressure (55 psi) is
routed directly to the solenoid valve which is used as dome bias pressure.
20
Amico Corporation
Manifold Switchover
After electrical power has been applied to the manifold, the side pressurized first is designated primary or “In Use” bank.
In order to simplify the following explanation, we will arbitrarily select the right side of the manifold as primary bank.
The green “In Use” LED on the right side will be illuminated and the yellow “Ready” LED on the left (secondary) bank will
be illuminated.
The solenoid valve directs dome bias pressure to the bank regulator on the right side. If we use a 55 psi oxygen manifold
as an example, the output of the right bank pressure regulator is approximately 155 psi (100 psi base pressure + 55 psi
bias pressure). The output of the left bank regulator is approximately 100 psi (base pressure only, no bias pressure). Since
the bank regulator on right side has the highest pressure, all flow is supplied by the right bank of cylinders.
As the cylinder pressure on the right side depletes, the pressure transducer on that side signals to the circuit board
to switch the solenoid valve. The solenoid valve then vents the dome bias pressure from the right bank regulator and
directs the bias pressure to the left bank regulator. The green LED “In Use” on the right side goes out and the red “Empty”
LED illuminates, indicating a “Reserve In-Use” alarm with the yellow LED on left going off and the green LED being
illuminated.
When cylinders on the right side are replaced and pressure is restored, the right pressure transducer sends a signal to
the circuit board, which in turn cancels the remote switchover alarm and the red ”Empty” LED turns off and the yellow
“Ready” LED gets illuminated.
Since the left bank regulator has the dome bias pressure applied, its output pressure is boosted to approximately 155
psi. The right bank regulator has no dome bias pressure and its output pressure is controlled only by base pressure (100
psi). All flow is supplied by the left bank of cylinders until the pressure drops to approximately 120 psi, the pressure
transducer sends a signal to the circuit board, causing a switchover to the right side in same fashion as previously
described.
NOTE:
In the event of a power fluctuation or failure, a switchover alarm will be activated on the master alarm panels.
•
For the “In Use” bank, the solenoid valve will continue to direct dome bias pressure until the bank depletes before
the reserve takes over.
•
The solenoid will not prevent the flow from being supplied no matter which side is “In Use” and until the system is
fully depleted of gas.
www.amico.com
21
Performance Verification
Use following test steps to verify the manifold’s functional performance:
1. Remove manifold cover.
2. Before beginning the test, verify following:
• If the manifold is not in use, close the 3/4" source shut-off valve
• Verify that the two right side line regulator isolation valves are open and the two left side line regulator
isolation valves are closed
3. As a starting point for this procedure, set the manifold, so right bank is “In Use”. If the right bank green LED is
illuminated, proceed to the next step. If the left bank green LED is illuminated, manually switch the manifold to the
right side by pressing the left switch on control board.
4. Verify that the right bank green LED “In Use” and the left bank yellow “Ready” lights are illuminated.
5. If the manifold is connected to a master alarm panel, verify the manifold switchover alarm is not activated.
6. If the manifold is equipped with a pilot regulator, verify the gauge on it reads 50 psi.
7. Verify gauge reading for the “In Use” right bank regulator. If the pressure is not correct, refer to the Bank Regulator
Pressure Adjustment procedure.
8. Verify the line pressure gauge reading. If the pressure is not correct, refer to the line regulator pressure adjustment
procedure. Note the reading for later use.
9. Watch the pressure gauge readings of the right side bank regulator and the line pressure gauge for at least five
minutes. Readings may be slightly higher without vent flow but verify the readings do not continue to increase.
10. Close all cylinders on the right side of the manifold. Use the bleed valve on the line regulator to slowly vent off
pressure until the right bank high pressure gauge drops. Verify that the manifold switches to left bank when the
right bank high pressure gauge drops below the specified setting of the bank regulator.
11. Verify only the left bank green LED “In Use” and the right bank red “Empty” LED illuminates.
12. If the manifold is connected to a master alarm panel, verify that the switchover alarm is activated.
13. Close the right side line regulator ball valves and open the left line regulator ball valves.
22
Amico Corporation
Performance Verification
14. Slightly depress the bleed valve on the left line regulator to create a small flow of gas through manifold.
15. Verify the pressure gauge reading on the bank “In Use” regulator to see if it is set up as per the specified
pressure setting. If the pressure is not correct, refer to the bank regulator pressure adjustment procedure.
16. Verify that the line pressure gauge reading is the same as in step 11. If the pressure is not correct, refer to the
Line Regulator Pressure Adjustment procedure.
17. Watch the pressure gauge readings on the left bank regulator and the supply line for at least five minutes to
ensure the readings do not continue to increase.
18. Close all cylinders on the left side of the manifold. Depress the bleed valve slightly so that the left bank high
pressure gauge drops slowly. Verify that the manifold switches to the right bank when the left bank high
pressure gauge drops below the specified setting of the bank regulator.
19. Verify only the right bank green “In Use” LED and the left bank red “Empty” illuminates.
20. Slowly open a cylinder on left side. Verify that the left bank red “Empty” LED goes out and the left bank
yellow “Ready” LED illuminates.
21. Open both the right side line regulator ball valves.
22. Close the left and right side cylinders.
23. Record the pressure readings of the left and right bank cylinder content gauges.
24. Verify after 15 minutes that the pressure reading on the gauges has remained the same.
25. Slowly open all cylinders on both banks of the manifold.
26. Using the switches on the circuit board, switch the manifold to the bank of cylinders with the least pressure.
27. Reinstall the manifold control panel cover.
28. Open the 3/4" source (line) shut-off valve.
www.amico.com
23
Bank Regulator Pressure Adjustment
This procedure should only be performed if the bank regulator pressures are not within acceptable limits during the
Performance Verification procedure or after installation of a new bank pressure regulator.
Base pressure setting is a mechanical adjustment controlled by the regulator’s internal adjusting spring and without
any dome bias pressure. Recommended settings are listed in the table on page 17 under the heading of Intermediate
Pressure - Ready Bank. After the base pressure has been set, the pressure will be increased by the amount of dome bias
pressure applied.
1. Shut off all cylinders on both banks of the manifold.
2. Close the main supply source valve.
3. Using the control board switches, cycle the manifold from bank to bank to vent residual dome bias pressure.
4. Remove nylon tube, then, using a 9/16" wrench, remove pipe (quick connect) adaptor from the dome of bank
regulator(s) to be adjusted.
5. Depress the bleed valves on both line regulators to relieve all pressure from the manifold.
6. Slowly open one cylinder on the side of the manifold that needs adjustment. For example, if the right bank
regulator needs adjustment, open one cylinder on the right side of manifold.
7. Slightly vent off the pressure from the bleed valve to create a small flow of gas through the manifold.
8. Using a 7/32" Allen wrench through the hole of the dome/bell, set the bank regulator to the specified setting:
Intermediate Pressure-Ready Bank.
9. Close cylinder valves.
10. If the other bank regulator also needs to be adjusted, repeat steps 6 through 10.
11. Apply Teflon tape, reinstall the pipe (quick connect) adaptor on dome of bank regulator and reinstall the nylon
tube.
12. Slowly open all cylinders on both manifold banks.
13. Open main supply source valve.
24
Amico Corporation
Bank Regulator Replacement
Should it be necessary to replace the bank regulator, it can be done while the manifold is in service. However, this should
only be done by qualified technicians experienced in servicing medical equipment.
1. Remove the two top screws at the base of the display board bracket and tilt back the display board assembly for
easy access to the union nuts that secure the bank regulator. (Follow the instructions on the label).
2. Close all cylinders on the side of the manifold where the bank regulator is to be replaced.
3. Ensure that the service bank is the reserve/secondary. If not, cycle the manifold from “In Use” to “Reserve” by using
the circuit board control switch to vent residual dome bias pressure.
4. Slowly break the 1-1/8" union(s) allowing gas to slowly vent out from both the inlet and outlet side of the bank
regulator.
5. Remove the nylon tube from the regulator dome.
6. Install the new bank regulator. This may require slight adjustment to the fittings on the regulator to align with the
secure fittings on the manifold.
7. Tighten the union nut on the inlet and outlet of the new bank regulator.
8. Reinstall the nylon tube.
9. Close the display board assembly and attach the bracket with the two screws.
10. Slowly open the cylinders and set the bank regulator’s output pressure as described in Bank Regulator Pressure
Adjustment procedure.
Line Regulator Pressure Adjustment
This procedure should be performed if the line regulator pressure is not within acceptable limits during the Performance
Verification procedure, or after installation of a new line regulator.
1. With both the bank regulators supplying pressure, open only one ball valve on the inlet and outlet of the line
regulator to be adjusted.
2. Slightly open/depress the bleed valve on the side of the regulator to create a small flow of gas though the
manifold.
3. Using the handle on the bonnet of the regulator, turn to adjust the pressure to the specified setting mentioned on
the cabinet door by observing the line gauge.
4. Repeat steps 1-3 to adjust the other line regulator.
5. After adjusting the pressure to the specified setting open all balls valves and ensure the supply line remains open.
www.amico.com
25
Line Regulator Replacement
If necessary, the line regulator replacement can be performed while the manifold is in service. However, this should only
be done by qualified technicians experienced in servicing medical equipment.
1. Close the two ball valves on the inlet and outlet of the line regulator to be replaced.
2. Loosen union nuts on the two closed isolation valves.
3. Vent pressure from the bank which was shut off in step 2 by depressing the bleed valve on the side of the
regulator.
4. Ensure the orientation of fittings (direction of gas flow) is the same on the replacement regulator. Install fittings on
the new regulator.
5. Inspect the O-ring removed from the ball valve union. If damaged, replace the O-ring.
6. Verify the correct orientation of fittings on the regulator, some slight adjustment may be required to align with the
ball valves without causing stress to the fittings.
7. Hand-tighten the two ball valve union nuts and then, with a wrench, lightly tighten to ensure that the fittings are
secure. NOTE: do not over-tighten unions, as it is an O-ring seal.
8. Open the ball valves and set the line regulator’s output pressure as described in the Line Regulator Pressure
Adjustment procedure.
26
Amico Corporation
Display Board Replacement
If necessary, the control board replacement can be performed while the manifold is in service. However, this should only
be done by qualified technicians experienced in servicing medical equipment.
1. Disconnect the power supply.
2. Loosen the two wingnuts on the side of the display board bracket and tilt the display board assembly back.
3. To further tilt back the display board assembly, remove the two bottom screws at the base of the board bracket
and tilt the complete assembly back.
4. Remove the screws located on the display board, detaching it from the front plate. Note the orientation of the old
display board and remove the wires one at a time and connect each wire to the appropriate terminal on the new
board.
5. Install the display board and fasten the screws to secure it. Turn the bracket to its original position and fasten the
wingnuts on the side of the board’s bracket and the two screws at the base of the bracket.
6. Reconnect the power supply to the manifold cabinet.
7. Check the correct operation of the display board by simulating a bank switchovers a few times.
www.amico.com
27
Cylinder Changing Procedures
1. Keep the main bank valve open throughout these procedures.
2. Close the cylinder valves on all empty cylinders.
3. Disconnect the pigtails from the cylinder valve outlets, using an appropriate wrench.
4. Place the protective caps over the cylinder valves of the empty cylinders and move them aside.
5. Remove the protective caps of the full cylinders. Visually inspect the cylinder valves for dust, grease or oil.
6. Using a clean (lint free) cloth, wipe each cylinder valve outlet clean. Do not use your fingers.
7. Standing to one side, “crack” each cylinder valve by briefly opening and closing to blow out any dust. Make sure
they are pointing away from you and other personnel.
8. Connect the pigtails to the cylinder valve outlets and tighten the nut with an appropriate wrench.
9. Very S-L-O-W-L-Y open the cylinder valve on the cylinder closest to the control cabinet. Watch the bank pressure
display on the front of the cabinet to make sure the pressure rises slowly to the full cylinder pressure reading. Wait
one full minute.
10. S-L-O-W-L-Y open the remaining cylinder valves one at a time.
WARNING: High pressure oxygen systems must be handled with CAUTION. Spontaneous combustion
may occur if oxygen comes into contact with grease or oil. Ensure that hands, gloves, clothing and tools
are kept clean and free of oil and grease. Be careful not to introduce dust or other contaminants into the
system when changing cylinders. Failure to comply with this procedure may be hazardous.
WARNING: Fire Hazard. DO NOT permit smoking or any other source of ignition in the area where the
manifold is located or near the relief valve vent outlet. Be certain that all connections are free of dirt,
grease and oil. These substances burn with great intensity in air enriched with oxygen or nitrous oxide
and some gas mixtures.
28
Amico Corporation
Ordering Information
DL = Dome Loaded (NFPA)
M4D-DL-HH(H)-L-XXX
Manifold Cabinet:
The Letter “L” Defines
the Language
D = Digital
HH
= High Pressure
The Letters “XXX” Define the
Type of Gas:
Oxygen
= OXY
U = English (NFPA)
Nitrogen = NIT
S = Spanish
Medical Air
= AIR
HHH = Heaters
Carbon Dioxide = CO2
Nitrous Oxide
Header-Bar Assembly:
= N2O
M2-HBYY-XXL-XXX
The Letters “YY” Define the Type of
Header-Bar Assembly:
The Letters “XX” Define the Number
of Cylinders:
TS = Straight c/w Stainless Pigtails
2 x 2 use 04
TC = Straight c/w Copper Pigtails
4 x 4 use 08
XS = Staggered c/w Stainless Pigtails
XC = Staggered c/w Copper Pigtails
Wall Bracket for Header-Bar Assembly: M-X-HB-WLBRKIT
CONTROL CABINET PARTS LIST
DESCRIPTION
MODEL NUMBER
Pressure transducer for Oxy, N₂O, Air, CO₂, & Nit
M2-X-MAN-07B
Line pressure regulator for all gases except Nitrogen (Left Side)
M2-X-MAN-42E-L
Line pressure regulator for all gases except Nitrogen (Right Side)
M2-X-MAN-42E-R
Line pressure regulator for Nitrogen (Left Side)
M2-X-MAN-42E-LN
Line pressure regulator for Nitrogen (Right Side)
M2-X-MAN-42E-RN
Operating pressure regulator for HD Manifolds (Left)
M3-X-MAN-18DL-L
Operating pressure regulator for HD Manifolds (Right)
M3-X-MAN-18DL-R
Repair kit line pressure regulator - HD
M2-REG700-RK
Repair kit operating pressure regulator
M3-REG250-RK-DL
www.amico.com
29
Ordering Information
Control Cabinet Parts List
DESCRIPTION
30
MODEL NUMBER
Intermediate check valve for all gases
M-X-MAN-33B
Operating pressure relief valve Nitrogen
M-X-IN-72W-350
Operating pressure relief valve Oxy, N₂O, Air & CO₂
M-X-IN-72W-350
Line pressure relief valve for Nitrogen
M-X-IN-72W-225
Line pressure relief valve for Oxy, N₂O, Air & CO₂
M-X-IN-72W-075
Plug & chain assembly - Air
M-X-HB-NUT-AIR
Plug & chain assembly - CO₂
M-X-HB-NUT-CO2
Plug & chain assembly - N₂O
M-X-HB-NUT-N2O
Plug & chain assembly - Nit
M-X-HB-NUT-NIT
Plug & chain assembly - Oxy
M-X-MAN-36
Copper pigtail c/w check valve - Air
M-X-HB-PTC-AIR
Copper pigtail c/w check valve - CO₂
M-X-HB-PTC-CO2
Copper pigtail c/w check valve - N₂O
M-X-HB-PTC-N2O
Copper pigtail c/w check valve - Nit
M-X-HB-PTC-NIT
Copper pigtail c/w check valve - Oxy
M-X-HB-PTC-OXY
Stainless pigtail c/w check valve - Air
M-X-HB-PTS-AIR
Stainless pigtail c/w check valve - CO₂
M-X-HB-PTS-CO2
Stainless pigtail c/w check valve - N₂O
M-X-HB-PTS-N2O
Stainless pigtail c/w check valve - Nit
M-X-HB-PTS-NIT
Extension wall support
M-X-HB-WLBRKIT
High pressure inlet valve
M-X-HB-HPVLV-A
ALERT-2.1 LED circuit board assembly
M4-LED-DLCB
Manifold power supply
M2-X-POWER
Solenoid valve
M3-X-MAN-SOLVLV
Sensor module for line pressure
A3P-SENS-U-GAS(AIR,OXY,ETC)
Amico Corporation
Appendix A
Manifold Internal Layout
www.amico.com
31
Appendix B
Piping Schematic Diagram
Item
1
2
3
4
5
6
7
8
9
TO
PIPELINE
DISTRIBUTION
SYSTEM
VENT TO
OUTSIDE
10
14
9
7
11
12
13
14
13
8
7
11
Description
Pig-Tail check valve
Cylinder valve
High pressure inlet valve
Pressure transducer
Operating pressure regulator
Check valve
Line pressure regulator
2 - Way valve
Sensor
Operating pressure relief valve
Bleed valve
Operating pressure gauge
Pilot regulator for nitrogen
Line pressure relief valve
CONTROL CABINET
10
6
6
4
LEFT HAND BANK
CYLINDER PRESSURE
3
HP
LB
12
6
12
4
HP
RB
3
1
LEFT
BANK
5
5
RIGHT
BANK
PIPING SCHEMATIC DIAGRAM
DUAL LINE REGULATORS (NFPA)
32
Amico Corporation
2
RIGHT HAND BANK
CYLINDER PRESSURE
Appendix C
Wiring Schematic Heater Units
Power Supply
Heater Cartridge
Wires
Heater Cartridge
(Inside Inlet Pressure Block)
Inlet Pressure
Block
Reset Switch
Reset Switch
Heater Cartridge
(Inside Inlet Pressure Block)
Inlet Pressure
Block
The heaters normally switch on when the temperature drops below 24°C or 75°F.  If the temperature exceeds 65-75°C
or 160-175°F, the Heater reset switch will trip and the heaters will automatically switch off. To reset the heaters, remove
the heater covers and press the red button on the reset switch to activate. When the heaters are “In Use” or switched on,
it will draw up to 3 amps of current. The heater cartridge is 200 watts (each side). Normally both sides do not switch on
together, it depends on the flow of gas or climate conditions.
www.amico.com
33
Appendix D
Electrical Wiring Diagram
Amico Medical Gas
Alarm Master Alarm
115 VAC
Supply
Voltage
Amico Gas
Manifold
Connect the NO loop to
the appropriate points.
C
NO
110 / 240 VAC Wiring
50 / 60 Hz
Current Draw: 1 Amp. Max.
External Power
Supply
34
Amico Corporation
Appendix E
Control Cabinet Wiring Diagram
www.amico.com
35
Appendix F
Staggered Header Bar
Inch
[mm]
GAS MANIFOLD
LEFT BANK
RIGHT BANK
IN USE
IN USE
READY
EMPTY
36
READY
TEST
EMPTY
No. of Cylinders
Overall Length
No. of Cylinders
Overall Length
2
42 [1067]
12
86 [2184]
4
42 [1067]
14
108 [2743]
6
64 [1626]
16
108 [2743]
8
64 [1626]
18
130 [3302]
10
86 [2184]
20
130 [3302]
Amico Corporation
Appendix G
Straight Header Bar Setup
Inch
[mm]
GAS MANIFOLD
LEFT BANK
RIGHT BANK
IN USE
IN USE
READY
EMPTY
READY
TEST
EMPTY
www.amico.com
37
Appendix H
Optional Header Bar Setup
Inch
[mm]
GAS MANIFOLD
LEFT BANK
RIGHT BANK
IN USE
IN USE
READY
EMPTY
38
Amico Corporation
READY
TEST
EMPTY
Appendix I
Standard Manifold Flow Rates
Amico Manifold Flow Capacity
www.amico.com
39
www.amico.com
Amico Corporation | www.amico.com
85 Fulton Way, Richmond Hill
Ontario, L4B 2N4, Canada
Toll Free Tel: 1.877.462.6426
Toll Free Fax: 1.866.440.4986
Tel: 905.764.0800
Fax: 905.764.0862
Email: [email protected]
APE-INSTAL-MAINT-DL-MANI-NFPA-DIGITAL 12.05.2016
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement