type 4r automatic manifold automatic manifold automatic manifold

type 4r automatic manifold automatic manifold automatic manifold
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
TYPE 4R AUTOMATIC MANIFOLD
CONTROL PANEL & HEADERS
Phoenix Pipeline Products L imited.
Unit 8, McKenzie Industrial Park,
Bird Hall Lane,
Stockport,
U.K., SK3 0SB
Tel No.: 44 (0) 161 428 7200
Fax No.: 44 (0) 161 428 7010
Email: [email protected]
www.p3-phoenix.com
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
Contents Page
Section
Page
Safety
General
3
Product Description
General
Automatic Control Panel
Manifold Headers
3
3
4
Operation
General
Service Pushbutton
Control Panel Layout
Control Panel Parts List
Pneumatic Operation
Pneumatic Schematic Diagram
Electrical Operation
Pressure Settings
4
4
5
6
7
8
9
10
Installation
General
Mechanical
Installation Drawing
Electrical
Simplified Electrical Connection Diagram
11
11
12
13
14
Connecting The ESM/ERM
General
Connecting a single pressure switch
Connecting two pressure switches
15
15
15
Manifold PCB Layout
General
Client’s Wiring Diagram
User Adjustable Settings
User Adjustable Parameters
Position of Adjustable Potentiometers
16
17
18
19
21
Testing and Commissioning
General
Testing
Commissioning
22
22
23
Maintenance
General
Preventative Maintenance
23
23
Spare Parts
General
24
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Automatic Gas Manifold Rev 1
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
1.
Safety
1.1
General
This equipment should be installed, operated and maintained by personnel who are
suitably trained, are fully conversant with HTM 02-01 and/or 2022 and are familiar
with this product.
This equipment should be kept clean and be free from oil and grease at
all times. Oil and grease will ignite spontaneously in the presence of
oxygen. If you suspect that any equipment is contaminated, do not use
it.
No attempt should be made to use or modify this equipment for use with a gas other
than as identified.
This equipment should not be operated at pressures exceeding those stated in HTM
02-01 and/or 2022 and this manual.
Care should be taken when drawing conclusions about the contents of cylinders from
their pressures. In the case of compressed gases, such as oxygen and medical air, the
cylinder pressure represents the cylinder contents, for example, if the cylinder is half
full, it will show half pressure.
Liquefied gases, such as nitrous oxide continue to show full cylinder pressure whilst
there is liquid in the cylinder. It should not be assumed that a cylinder of nitrous
oxide is full simply because the gauge shows full pressure.
2.
Product Description
2.1
General
Automatic Gas Manifolds comprise a control panel, manifold headers & racks,
tailpipes, pigtails, a line isolation valve, non-return valve and a pressure relief valve.
The manifold provides a continuous supply of gas from two banks of cylinders to the
medical gas pipeline system by automatically changing from the duty bank to the
standby bank as the duty bank has become depleted.
Manifolds are available for oxygen, nitrous oxide, 50% oxygen/50% nitrous oxide
mixture, medical air and surgical air.
2.2
Automatic Control Panel
The Automatic control panel comprises four regulators, bank selection solenoid
valves, cylinder contents and pipeline pressure transducers, gauges and an integral
monitoring and status panel, all housed in a molded enclosure with transparent
cover.
The monitoring & status panel indicates the duty and standby bank of cylinders, and
there status. The panel also indicates the distribution pipeline.
The display incorporates an alarm status indicator and includes volt free contacts for
connection to the central alarm system and BMS, these alarms become open circuit on
fault.
An isolation and pressure relief valve assembly is provided with copper stub pipes for
on site copper to copper joints to the hospital distribution pipeline and vent pipeline.
Interconnect pipes are also included to connect the control panel to the header racks.
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Automatic Gas Manifold Rev 1
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
2.3
Manifold Headers
Manifold headers comprise high-pressure headers with gas specific tailpipe
connections, cylinder tailpipes, support racks and restraining chains for the cylinders.
Non return valves are incorporated in each tailpipe connector, this prevents a whole
bank of cylinders becoming depleted in the event of a cylinder being disconnected or
a tailpipe rupture.
Tailpipes are available with pin-index, bull nose or CGA cylinder connections.
3.
Operation
3.1
General
All cylinder valves connected to the manifold headers should be open. Gas is then
supplied from either bank of cylinders to the automatic control panel. Under normal
working conditions, gas is supplied to the hospital distribution pipeline from only
one bank at a time. When the cylinder contents falls below the changeover pressure,
the solenoid valve for the duty bank closes and the solenoid valve for the standby
bank opens ensuring continuity of the gas supply.
In the event of an electrical failure, both solenoid valves default to open and gas will
be supplied from the duty and standby banks simultaneously. Upon restoration of
the electrical supply, the control panel will supply gas from the bank of cylinders that
has the higher pressure.
Both solenoid valves will also open in the event of the distribution pipeline pressure
falling below normal limits.
All regulators and pressure sensors within the control panel are preset and should
require no further adjustment.
The monitoring & status panel incorporates a duty bank push button to enable
manual selection of the left or right hand cylinders as the duty bank.
The manifold is fully automatic in operation and requires no manual intervention,
other than the replacement of empty cylinders.
3.2
Service Pushbutton
The monitoring & status panel incorporates a push button to access the following
functions.
1. Manual selection of the left or right cylinder banks. Change the "Duty" bank by
pressing the push button for 1 to 2 seconds and then releasing. The "Duty" bank
will change on release.
2. Review the set pressures. Press and hold the push button for longer than 5
seconds. The display will flash and show the values of, Change Over Pressure,
High Line Pressure, and Low Line Pressure (Viewed Left to Right). Release the
push button once viewed.
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Automatic Gas Manifold Rev 1
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
3.2
Control Panel Layout
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Automatic Gas Manifold Rev 1
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
3.3
Control Panel Parts List
ID
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Description
Outlet Stub Pipe
Right Hand Bank Solenoid Valve
Override Pressure Switch
Line Pressure Transducer
Mains Power Supply
Line Pressure Gauge
Outlet Block
Left Hand Bank Solenoid Valve
Low Voltage Fuse Carrier
Earth Stud
2nd Stage Regulator Left Hand Bank
2nd Stage Regulator Right Hand Bank
Left Hand Bank Outlet Pressure Gauge
Right Hand Bank Outlet Pressure Gauge
Backplate
Monitoring & Status Panel
Left Hand Regulator Outlet Pipe
Right Hand Regulator Outlet Pipe
Left Hand Contents Pressure Gauge
Right Hand Contents Pressure Gauge
Left Hand Interstage Pressure Gauge
Right Hand Interstage Pressure Gauge
st
1 Stage Regulator
Regulator Mounting Block
Header Inlet Connector
Contents Pressure Transducer
Enclosure
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Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
Automatic Gas Manifold Rev 1
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
3.4
Pneumatic Operation
The gas from the left hand (LH) bank of cylinders is connected to the LH inlet of the
control panel. This is monitored by gauge G1, transducer PT1 and passes through
regulator R1, pressure gauge G3, regulator R3, pressure gauge G5 to the solenoid
valve S1. Similarly, the gas from the right hand (RH) bank of cylinders is connected to
the RH inlet of the control panel. This is monitored by gauge G2, transducer PT2 and
passes through regulator R2, pressure gauge G4, regulator R4, pressure gauge G6 to
the solenoid valve S2.
Pressure gauges G1 and G2 indicate the high pressure cylinder contents in the LH
and RH banks respectively. Pressure gauges G3 and G4 indicate the interstage
pressure from regulators R1 and R2 respectively. Pressure Gauges G5 and G6 monitor
nd
the final outlet pressure from the 2 stage regulators.
With the LH bank selected as the duty bank, the solenoid valve S1 is de-energised
and opens allowing gas to pass to the distribution pipeline. Solenoid valve S2 is
energised and closed to prevent the RH from supplying gas. When the pressure in the
LH bank falls below the changeover threshold, monitored by transducer PT1, the
solenoid valve S1 is energised and closes, whilst the solenoid valve S2 is de-energised
and opens thus effecting the changeover from the LH duty bank to the RH standby
bank.
The empty cylinders on the LH bank should now be replaced with full cylinders, ready
to continue the supply of gas when the RH bank is depleted.
When the pressure in the RH bank falls below the changeover threshold, monitored
by transducer PT2, the solenoid valve S2 is energised and closes and solenoid valve
S1 is de-energised and opens thus allowing the LH bank (now full) to continue with
the gas supply. The empty cylinders on the RH bank should now be replaced with full
cylinders. This sequence will continue.
Pressure gauge G7 indicates the distribution pipeline pressure, whilst transducer PT3
monitors the distribution pipeline pressure for high or low pressure faults. Pressure
switch P1 will de-energise both solenoid valves S1 and S2 in the event of the
distribution pipeline pressure falling below normal limits allowing both banks to
feed the system simultaneously.
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Automatic Gas Manifold Rev 1
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
3.5
Pneumatic Schematic Diagram
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Automatic Gas Manifold Rev 1
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
3.6
Electrical Operation
The control panel requires a 100V-240V AC, 50/60Hz, single-phase supply.
The monitoring & status panel incorporates three sections:1. The Auto Manifold Indicator Unit
2. Emergency Reserve Manifold Unit
3. Alarm Signal Status Unit
The Auto Manifold Indicator Unit
(a) For each bank, a green LED indicator (RUNNING) illuminates to indicate which
bank is currently running.
(b) For each bank, a yellow LED indicator (LOW PRESSURE) illuminates to indicate
that a bank of cylinders is empty and changeover to the standby bank has
occurred.
(c) For each bank, a yellow LED indicator (EMPTY) illuminates to indicate that the
bank that is running has fallen below the changeover threshold, and that the
standby bank has not been replenished.
(d) A red LED indicator (HIGH PRESSURE) illuminates to indicate when the
distribution pipeline pressure has risen above the pressure sensor setting.
(a) A red LED indicator (LOW PRESSURE) illuminates to indicate when the
distribution pipeline pressure has fallen below the pressure sensor setting.
The Emergency Reserve Manifold Indicator Unit
(a) A yellow LED indicator (LEFT HAND BANK LOW) which illuminates to indicate
when the left hand bank of Emergency Reserve Cylinders is 50% or less.
(b) A yellow LED indicator (RIGHT HAND BANK LOW) which illuminates to indicate
when the right hand bank of Emergency Reserve Cylinders is 50% or less.
(e) If the ESM/ERM is set to operate with a single bank of cylinders both indicators
will operate in parallel.
The Alarm Signal Status Unit
(b) A green LED indicator (POWER ON) illuminates to indicate that the power to the
manifold is on.
(c) A green LED indictor (NORMAL) that illuminates to indicate that the manifold is
operating correctly and that no faults exist.
(d) A yellow LED indicator (CHANGE CYLINDERS) which illuminates to indicate when
the changeover from the duty to the standby bank has occurred.
(e) A yellow LED indicator (CHANGE CYLINDERS IMMEDIATELY) which illuminates to
indicate when the bank that is running has fallen below the pressure sensor
setting and the standby bank is empty.
(f) A red LED indicator (RESERVE LOW) which illuminates to indicate when the duty
bank of the remote emergency reserve manifold (ESM/ERM) has fallen below the
low pressure setting.
(g) A red LED indicator (PRESSURE FAULT) which illuminates to indicate when the
distribution pipeline pressure has risen or fallen beyond the respective pressure
sensor settings.
(c) A red LED indicator (SYSTEM FAULT) which illuminates in the event of a cabling
fault between the remote ESM/ERM and the Auto Manifold panel.
(d) A yellow LED indicator (RIGHT HAND BANK LOW) which illuminates to indicate
when the right hand bank of Emergency Reserve Cylinders is empty.
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Automatic Gas Manifold Rev 1
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
3.7
Pressure Settings
O2
N2O
O2/N2O
Medical
Air
(400 kPa)
Surgical
Air
(700 kPa)
Dental
Air
8.0 bar
8.0 bar
8.0 bar
8.0 bar
10.0 bar
10.0 bar
4.5 bar
4.5 bar
4.5 bar
4.5 bar
7.5 bar
6.0 bar
Changeover Pressure
12.0 bar
14.0
bar
12.0 bar
12.0 bar
12.0 bar
12.0 bar
Pressure Relief Valve
5.5 bar
5.5 bar
5.5 bar
5.5 bar
9.0 bar
7.5 bar
Pipeline Pressure, High
5.0 bar
5.0 bar
5.0 bar
5.0 bar
8.0 bar
7.2 bar
Pipeline Pressure, Low
3.7 bar
3.7 bar
3.7 bar
3.7 bar
6.5 bar
5.1 bar
Override Switch
3.0 bar
3.0 bar
3.0 bar
3.0 bar
6.0 bar
4.2 bar
Component
1st Stage Regulators
(static)
2nd Stage Regulators
(static)
These pressure settings are factory set, and should not normally require adjustment.
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
4.
Installation
4.1
General
The automatic control panel is supplied with all internal electrical connections prewired. The only external wiring required for the installation is the connection of the
mains power supply, the connection of the ESM/ERM pressure switch(es) (if required)
and the connection of the central alarm system and BMS wiring (if required).
All regulators and pressure sensors are preset and no further adjustment of these
settings should be required.
4.2
Mechanical
(a) Secure the automatic control panel enclosure to the wall using suitable fixings at
the height indicated in figure 4.3. Ensure that there is sufficient space either side
of the control panel to install the manifold headers.
(b) Replace the backplate assembly and secure with the six retaining screws.
(c) Connect the AC supply to the mains fuse carrier.
(d) Secure the manifold headers at the height and position indicated in figure 4.3
using suitable fixings. Use the header connecting pipes to assist in the accurate
alignment of the racks.
(e) Install the outlet stub pipe, pressure relief valve and isolation valve.
(f) Install the discharge pipeline from the pressure relief valve to a safe external
location.
(g) Fit all tailpipes onto the manifold headers.
(h) Check and tighten all mechanical joints (Do Not Over tighten).
(i) Connect cylinders, pressurise the manifold and check for leaks. Make sure that
the isolation valve is closed if the connection to the distribution pipeline has been
made.
(j) Connect the mains power supply as shown on the diagram.
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
4.3
Installation Drawing
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
4.4
Electrical
1.
Connect the incoming mains power supply to the terminals in the auto manifold
enclosure. (Connections should be made in accordance with the electrical
connections diagram figure 4.5 of this manual).
The mains power supply should be via an unswitched fused spur rated at 5 amps.
2. Connect the ESM/ERM pressure switch(es) using an E.O.L monitor (Connections
should be made in accordance with the client’s wiring diagram figure 6.2 of this
manual).
3. Connect the alarm terminal to the central alarm system. Refer to figure 6.2 for
details of each alarm conditions position on the 8-way connector.
4. Connect the alarm conditions to the building management system (BMS) by
connecting to BMS terminals on the PCB. Refer to figure 4.5 for details of each
alarm conditions position on the 8-way connector.
5. Check that the DIP switches are set correctly. (Refer to Section 6.3 for DIP switch
settings).
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
4.5
Simplified Electrical Connection Diagram
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
5.
Connecting The ESM/ERM
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
5.1
General
The Auto manifold control panel can monitor an ESM (HTM 2022) with one pressure
switch, or an ERM (HTM 02) with two pressure switches.
As standard the manifold PCB is set for the use of one pressure switch (HTM 2022) linked
out with 3K3 resistors.
5.2
To connect a single Pressure Switch (HTM2022)
1. Turn off the power to the manifold PCB
2. Identify the ESM/ERM terminal block (Block 3) on the manifold PCB, 3.1,3.2 (Left
Hand Bank, 3.3, 3.4 (Right Hand Bank) (See manifold PCB layout section 6 of this
manual).
3. Remove either 3K3 resistor
4. Connect these terminals to P3 end of line monitor/Pressure Switch
5. Check that DIP switch 3 is set to the ‘ON’ position (Refer to user adjustable settings
section 6.3 of this manual).
6. Turn on power to manifold PCB
5.3
To connect two Pressure Switches (HTM 02)
1. Turn off the power to the manifold PCB
2. Identify the ESM/ERM terminal block (Block 3) on the manifold PCB, 3.1,3.2 (Left
Hand Bank, 3.3, 3.4 (Right Hand Bank) (See manifold PCB layout section 6 of this
manual).
3. Remove both 3K3 resistors
4. Connect terminals 3.1,3.2 to the left bank end of line monitor/Pressure Switch
(please check client’s wiring diagram section 6.2 of this manual).
5. Connect terminals 3.3,3.4 to the right bank end of line monitor/Pressure Switch
(please check client’s wiring diagram section 6.2 of this manual).
6. Check that DIP switch 3 is set to the ‘OFF’ position (Refer to user adjustable settings
section 6.3 of this manual).
7. Turn on power to manifold PCB
Note:
End of line monitors MUST be P3 to ensure electronic compatibility.
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
6.
Manifold PCB Layout
6.1
General
ESM/ERM
Encoded Alarm Type RTX 1 (Optional)
BMS
BMS Bank
Running
Open = Running
Alarm
VIEW FROM FRONT WITH FASCIA FOLDED FORWARDS
18V Supply
Position of
RTX1
Channel Switch
(If Fitted)
Adjustable Low
Pressure Alarm
Adjustable High
Pressure Alarm
Adjustable
Change Over
Pressure Alarm
Service
Push Button
DIP Switch
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
Medical Gas Alarm
2
View Of Underside of PCB
(Component Side)
with fascia folded forwards
Change Cyls
Change Cyls Imm
Reserve Low
Pressure Fault
BMS
ALARM
On
1
2
3
4
5
6
7
8
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Wiring By Client
6.2 Client’s Wiring Diagram
Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
6.3 User Adjustable Settings
The manifold PCB includes a DIP switch, this allows the user to adjust certain Parameters.
The table below shows settings that can be adjusted by the user.
It is not necessary to disconnect the power to the auto manifold before changing any of the
following settings, therefore care should be taken when adjusting the DIP switches.
DIP switches 1 and 2 control the line pressure and the changeover pressure as shown
below:DIP Switch 1
Off
Off
On
On
DIP Switch 2
Off
On
Off
On
Setting
4 Line Pressure, Low 3.7, high 5.0, 12 Bar Changeover
4 Line Pressure, , Low 3.7, high 5.0, 14 Bar Changeover
7 Line Pressure, Low 6.5, high 8.0, 12 Bar Changeover
User adjusted settings
DIP switches 3 and 4 control the end of line monitor and the method of monitoring:DIP Switch 3
Off
Off
On
On
DIP Switch 4
Off
On
Off
On
Setting
2No. end of line monitors monitored with transducers
2No. end of line monitors monitored with pressure switches
1No. end of line monitor monitored with a transducer
1No. end of line monitor monitored with a pressure switch
Once the DIP switches have been set to the desired settings, test that the auto manifold
operates correctly.
Please Note:Switches 6, 7 and 8
are not used.
The above diagram shows the manifold set up as a 4BarG system with a changeover
pressure of 12BarG (Air), and the use of one pressure switch for the ESM.
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Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
6.4 User Adjustable Parameters
It is possible for the user to create alternative pressure settings on the Auto manifold PCB.
The user can adjust the following three parameters:• Changeover pressure, adjustable between 2.0 and 22.0 bar,
• High pressure alarm, adjustable between 2.0 and 15.9 bar
• Low pressure alarm adjustable between 2.0 and 15.9 bar.
To Adjust The Pressure Settings
1.
To enter "Edit" mode set DIP switch 5 to the "On" position.
2.
Check the three digital displays are flashing (Flashing Indicates "Edit" mode).
3.
In this mode the "Left Bank" display now indicates the changeover pressure for both
cylinder banks.
4.
In this mode the "Pipeline" display now indicates the High Pressure Alarm.
5.
In this mode the "Right Bank" display now indicates the Low Pressure Alarm.
6.
Identify the adjustment potentiometers on the PCB (See Page 21 Figure 3).
7.
Adjust the potentiometers to create the desired pressure settings.
8.
Set DIP switch 5 to the "Off" position to exit "Edit" mode.
9.
Set both DIP switches 1 and 2 to the "On" position to apply the settings.
10. Press and hold the "Service push button" for longer than 5 seconds, to display and
confirm the applied operational settings.
11. Release "Service push button" once viewed, to return the display to operational
information.
Note:1.
Until the new settings have been applied (Step 9), the control panel will continue to
operate using the previously selected pressure settings.
2.
In "Edit" mode the displays DO NOT show current operational information.
3.
The low pressure alarm must be set lower than the high pressure alarm otherwise the
display will read error (ERR).
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
Adjusting The Pressure Settings Continued
Change Over
High Line
Pressure Pressure Alarm
Low Line
Pressure Alarm
Auto Manifold Indicator Unit
Left Bank
Pipeline
Right Bank
Power On
Displays Flashing
Running
DIP Switch 5 in the
"On"
Position
(Edit Mode Only)
Alarm Signal Status Unit
Running
Normal
Low Pressure
High Pressure
Low Pressure
Change Cylinders
Empty
Low Pressure
Empty
Change Cylinders Immediately
Reserve Low
Emergency Reserve Manifold
ERM
Left Hand
Bank Low
Pressure Fault
Right Hand
Bank Low
System Fault
Figure 1 Edit Mode
In the example above the user has set the change over pressure to 15Bar, the High Line
pressure alarm to 5.2Bar, and the Low Line Pressure Alarm to 2.0Bar.
Auto Manifold Indicator Unit
Left Bank
Pipeline
Right Bank
Alarm Signal Status Unit
Power On
Running
DIP Switch 5 in the
"Off"
Position
Running
Normal
Low Pressure
High Pressure
Low Pressure
Change Cylinders
Empty
Low Pressure
Empty
Change Cylinders Immediately
Reserve Low
Emergency Reserve Manifold
ERM
Left Hand
Bank Low
Pressure Fault
Right Hand
Bank Low
System Fault
Figure 2 Operating Mode
In the example above the left cylinder bank pressure is 100Bar, the right cylinder bank
pressure is 125Bar, and the Line Pressure is 4.4Bar.
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Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
6.5 Position Of Adjustable Potentiometers
Figure 3 View From Underside Of Auto Manifold
Adjust the
potentiometers to
adjust the alarm
pressures
Service
Push
Button
Change
Over
Pressure
High
Pressure
Alarm
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Low
Pressure
Alarm
Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
7.
Testing & Commissioning
7.1
General
Prior to testing the manifold installation, please check the following.
(a) All components have been installed, and are tightened.
(b) The mains power supply has been installed and power is available.
(c) The isolation valves on the automatic manifold and ESM are closed.
(d) Full cylinders have been fitted to all tailpipes.
7.2
Testing
Leak Testing
(a) Slowly open all cylinders on each bank and allow the system to pressurise.
(b) Check all tailpipes and header interconnecting pipes for leaks.
(c) Slowly open all cylinders on the ESM/ERM (if available) and check for leaks.
(d) Depressurise the Auto manifold and ESM/ERM.
Function Test
(e) Apply mains power to the panel, Note, on power up the display board undertakes
a sequential lamp test, the POWER ON indicator will then illuminate. Open one
cylinder on the LH bank first, the LH bank RUNNING indicator will illuminate.
Open one cylinder on the RH bank, the NORMAL indicator will illuminate.
(f) Close the cylinders on both banks. Create a flow between the control panel and
the distribution pipeline and very slowly depressurise the system. Monitor the
LED display on the left hand bank as the pressure drops.
(g) At changeover pressure (refer to the settings in table 2.5), the LH bank RUNNING
indicator will extinguish and the EMPTY indicator will illuminate. The RH bank
RUNNING indicator simultaneously illuminates as the control panel changes to
run from the RH bank. The NORMAL indicator on the alarm signal status unit will
extinguish and the CHANGE CYLINDERS will illuminate.
(h) Open the cylinder again on the LH bank. The CHANGE CYLINDERS indicator will
extinguish and the NORMAL indicator will illuminate. The LH bank EMPTY
indicator will extinguish, now close the cylinder.
(i) The system should be running on the RH bank. Create a leak again and slowly
depressurise the system.
(j) At changeover pressure, the RH bank RUNNING indicator will extinguish and the
EMPTY indicator will illuminate. The LH bank RUNNING indicator will illuminate.
The NORMAL indicator will extinguish and the CHANGE CYLINDERS indicator will
illuminate. Monitor the LED display on the left hand bank as the pressure drops.
(k) Continue to depressurise the LH bank, at changeover pressure the LH bank LOW
PRESSURE and CHANGE CYLINDERS IMMEDIATELY indicators will illuminate.
(l) As the system is further depressurised the pipeline LOW PRESSURE, and
PRESSURE FAULT indicators will illuminate.
(m) Open the cylinder on the ESM/ERM (if available), and close the cylinder at 70
BarG. Open the isolation valve on the ESM/ERM. Continue to depressurise the
system. At the setting of the ESM/ERM pressure switch, the RESERVE LOW
indicator, and ERM BANK LOW indicator will illuminate.
(n) Continue to depressurise the system. When the pressure falls to the setting of the
low pressure, the LOW PRESSURE indicator on the manifold indicator unit will
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Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
illuminate and the PRESSURE FAULT indicator on the alarm signal status unit will
illuminate.
(o) Close all flows and isolation valves and re-pressurise the system. All alarm signal
indicators will extinguish and the NORMAL indicators will illuminate.
(p) Check all alarm system outputs using a continuity tester or multimeter. All
outputs are normally closed and as each alarm condition occurs, the respective
contact opens circuit (to recreate alarm conditions repeat steps e through to o).
Please refer to the client’s connection diagram section 6.2, to refer to the alarm
terminals.
7.3
Commissioning
Demonstrate the manifold installation to the client by repeating the abovementioned test procedure.
It is essential to confirm that a central alarm system is operating and indicating
correctly at the same time.
The manifold must not be used until all testing & commissioning procedures for the
pipeline system as detailed in HTM 02-01, or 2022 have been satisfactorily completed
and accepted.
8. Maintenance
8.1
General
Maintenance of the manifold should be restricted to periodic checking and
adjustment and if necessary the replacement of faulty components. It should be
noted that although many of the components appear to be standard items, they have
been selected and treated to ensure compatibility with the gases carried and the
pressures involved.
8.2
Preventative Maintenance
Regular inspections and maintenance of the manifold will prolong its life and reduce
the possibility of sudden, inconvenient component failures.
Automatic Manifolds should be subjected to regular inspection and testing as
detailed below.
•
Monthly;
(a) Visually inspect the manifold for signs of damage.
(b) Check all mechanical joints for leaks.
(c) Check that changeover from the duty bank to the standby bank is operating
correctly.
(d) Check that the duty bank changeover switch operates correctly.
•
Annually;
(a)
(b)
(c)
(d)
Visually inspect the manifold system for signs of damage.
Check that one bank of cylinders on the ESM/ERM is open ready for use.
Check all mechanical joints for leaks.
Test the manifold system as detailed in section 7.2 to confirm correct
operation.
(e) Observe that all indicators are working correctly.
All maintenance should be carried out with the knowledge of the “Authorised
person” and in accordance with the Permit-to-Work system.
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
9. Spare Parts
When ordering spare parts, quote the batch number of the equipment and a
description of the component required.
Item
Description
Part Number
1
Tailpipe, O2, Pin-index
1-40800-01
2
Tailpipe, O2, Bull-nose
1-40801-01
3
Tailpipe, O2, CGA 540
1-40806-01
4
Tailpipe, N2O, BS 341 No.13
1-40802-02
5
Tailpipe, N2O, CGA 326
1-40807-02
6
Tailpipe, 50% O2/50% N2O, Pin-index
1-40803-03
7
Tailpipe, Medical Air, Pin-index
1-40804-04
8
Tailpipe, Medical Air, Bull-nose
1-40805-04
9
Tailpipe, Medical Air, CGA 346
1-40808-04
10
Pressure Relief Valve, 5.5 Bar
1-46000-09
11
Pressure Relief Valve, 9.0 Bar
1-46001-09
12
Regulator Assembly, 8 Bar
1-46034-09
14
Regulator Assembly, 10 Bar
1-46035-09
15
Regulator Assembly, 8 Bar (N2O)
1-46036-09
16
Contents Pressure Transducer, 0-250 Bar
1-46102-09
17
Contents Pressure Gauge, 0 – 400 Bar
1-46007-09
18
Contents Pressure Gauge, 0 – 160 Bar
1-46008-02
19
Outlet Pressure Gauge, 0 – 6 Bar
1-46009-09
20
Outlet Pressure Gauge, 0 – 16 Bar
1-46010-09
21
Bodok Seal for pin-index tailpipes
1-46011-09
22
O-ring for bull-nose tailpipes
1-46012-09
23
Solenoid Valve
1-46013-09
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
Item
Description
Part Number
24
Pipeline Pressure Transducer, 0-16 Bar
1-46101-09
25
Override Switch, 3.0 Bar
1-46018-09
26
Override Switch, 6.0 Bar
1-46019-09
27
Override Switch, 4.2 Bar
1-46040-09
28
Line Pressure Gauge, 0-10 Bar
1-46020-09
29
Automatic Manifold PCB TR1
1-46100-09
30
Manifold Header Link Pipe c/w o-rings
1-46023-09
31
Header O-ring Service Kit (per cylinder)
1-46027-09
32
Auto Control Panel Seal Service Kit
1-46028-09
33
Tailpipe, Medical Air, CGA 540
1-40810-04
34
2
nd
Stage Regulator Assembly 4.5 Bar
1-46037-09
2
nd
Stage Regulator Assembly 7.5 Bar
1-46038-09
2
nd
Stage Regulator Assembly 6.0 Bar
1-46039-09
35
36
Due to our policy of continuous product improvement, Phoenix Pipeline Products Ltd. reserve the right to alter dimensions and/or
specification without notice although every effort will be made to advise of any such modifications. Certain aspects of P³ Ltd. designs are
protected.
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Automatic Gas Manifold Rev
Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual
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Automatic Gas Manifold Rev
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