AGM2 Service Manual - Western Enterprises

AGM2 Service Manual - Western Enterprises
AUTOMATIC CHANGEOVER MANIFOLD
AGM2, AGM2HL, & AGM2HP SERIES
SERVICE MANUAL
AGM2
HEALTH CARE GAS MANIFOLD
SYSTEMNORMAL
REPLACE
DEPLETEDBANK
WESTERNINNOVATOR
875 BASSETT ROAD
WESTLAKE,OHIO44145
WESTERN ENTERPRISES
PRINTED IN USA
B20454 REL-0000 (0503)
SAFETY
Statements in this manual preceded by the following safety signal words are of special significance.
Definitions on the SAFETY signal words follow.
DANGER
Means a hazard that will cause death or serious injury if the warning is ignored.
WARNING
Means a hazard that could cause death or serious injury if the warning is ignored.
CAUTION
Means a hazard that may cause minor or moderate injury if the warning is ignored. It also
means a hazard that will only cause damage to property.
NOTE
Indicates points of particular interest for more efficient and convenient operation.
INTRODUCTION
This manual provides the information needed to service the Western Enterprises AGM2, AGM2HL, and AGM2HP series
manifolds. This information is intended for use by technicians or personnel qualified to repair and service manifold equipment.
The information contained in this document, including performance specifications, is subject to change without notice.
WARRANTY
Western Enterprises makes no warranty of any kind with regard to the material in this manual. Including but not limited to
the implied warranties of merchantability and fitness for a particular purpose.
Refer to the Installation and Operation Instruction manual for warranty information.
i
B20454 REL-0000 (0503)
CAUTION
• Failure to adhere to the following instructions may result in person injury or property damage:
• Never permit oil, grease, or other combustible materials to come in contact with cylinders, manifold, and
connections. Oil and grease may react and ignite when in contact with some gases-particularly oxygen
and nitrous oxide.
• Cylinder, header, and master valves should always be opened very s-l-o-w-l-y. Heat of recompression
may ignite combustible materials.
• Pigtails should never be kinked, twisted, or bent into a radius smaller than 3 inches. Mistreatment may
cause the pigtail to burst.
• Do not apply heat. Some materials may react while in contact with some gases-particularly
oxygen and nitrous oxide.
• Cylinders should always be secured individually with racks, chains, or straps. Unrestrained cylinders may
fall over and damage or break off the cylinder valve which may propel the cylinder with great force.
• Oxygen manifolds and cylinders should be grounded. Static discharges and lightning may ignite materials
in an oxygen atmosphere, creating a fire or explosive force.
• Welding should never be performed near nitrous oxide piping. Excessive heat may cause the gas to
dissociate, creating an explosive force.
• Do not use leak test solution that contains ammonia. Solutions containing ammonia may cause brass
tubing and fittings to crack.
ABBREVIATIONS
C
CGA
FT-LBS
IN-LBS
N/C
N/O
Common
Compressed Gas Association
Foot-Pounds
Inch-Pounds
Normally Closed
Normally Open
NPT
NFPA
OSHA
PSIG
SCFH
VAC
National Pipe Taper (Threading)
National Fire Protection Association
Occupational Safety & Health Administration
Pounds per Square Inch Gauge
Standard Cubic Feet per Hour
Voltage, Alternating Current
Western Enterprises shall not be liable for errors contained herein or incidental or consequential damages in connection
with providing this manual or the use of material in this manual.
ii
B20454 REL-0000 (0503)
TABLE OF CONTENTS
SECTION 1
INTRODUCTION
1-1
Product Description............................................................................................................................. 1-1
Installation Information ........................................................................................................................ 1-1
Manifold Specifications........................................................................................................................ 1-2
Adjustment Specifications ................................................................................................................... 1-3
Recommended Tools and Test Equipment .......................................................................................... 1-4
SECTION 2
THEORY OF OPERATION
2-1
General Information............................................................................................................................. 2-1
Manifold Operation.............................................................................................................................. 2-1
Primary Regulators.............................................................................................................................. 2-6
Check Valves...................................................................................................................................... 2-7
Four-Way Valve .................................................................................................................................. 2-7
Pressure Switches .............................................................................................................................. 2-8
Intermediate Regulator........................................................................................................................ 2-9
Line Pressure Regulator...................................................................................................................... 2-9
SECTION 3
FIELD TESTING AND TROUBLE-SHOOTING
3-1
Performance Verification Procedure .................................................................................................... 3-1
Trouble-shooting ................................................................................................................................. 3-4
SECTION 4
SERVICE PROCEDURES
4-1
General Maintenance.......................................................................................................................... 4-1
Safety Precautions .............................................................................................................................. 4-1
Cleaning, Lubrication, and Sealing ...................................................................................................... 4-2
General Repair Procedures................................................................................................................. 4-3
How to Open the Manifold ................................................................................................................... 4-3
Manifold Cabinet Cover Removal ........................................................................................................ 4-3
How to Deplete the Secondary Bank ................................................................................................... 4-4
How to Shut Down the Manifold........................................................................................................... 4-4
Gauge Replacement ........................................................................................................................... 4-4
Primary Regulator Repair.................................................................................................................... 4-5
Pressure Switch Replacement…………………………………………………………………………………..4-7
Check Valve Repair – Intermediate ..................................................................................................... 4-8
Check Valve Repair – Primary Regulator............................................................................................. 4-9
Four-Way Valve Replacement ........................................................................................................... 4-10
Intermediate Pressure Regulator Repair............................................................................................ 4-11
Line Regulator Repair ....................................................................................................................... 4-13
iii
B20454 REL-0000 (0503)
SECTION 5
MAINTENANCE AND REPAIR PARTS
5-1
Replacement Pigtails........................................................................................................................... 5-1
Pressure Gauges ................................................................................................................................ 5-1
Valves and Valve Repair Kits .............................................................................................................. 5-1
Pressure Switches .............................................................................................................................. 5-1
Power Supply Replacement Parts ....................................................................................................... 5-1
Indicator Lamp Replacement…………………………………………………………………………………… 5-1
Regulators and Repair Kits.................................................................................................................. 5-2
Relief Valves……………………………………………………………………………………………………....5-2
SECTION 5
MAINTENANCE AND REPAIR PARTS (Repair Drawing)
5-3
Components and Miscellaneous Hardware – AGM2 & AGM2HP Series .............................................. 5-3
Components and Miscellaneous Hardware - AGM2HL Series.............................................................. 5-5
Left Primary Regulator Components.................................................................................................... 5-7
Right Primary Regulator Components.................................................................................................. 5-8
Check Valve Components ................................................................................................................... 5-9
Intermediate Regulator Components ................................................................................................. 5-10
Right & Left Line Regulator Components........................................................................................... 5-11
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B20454 REL-0000 (0503)
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v
B20454 REL-0000 (0503)
SECTION 1
INTRODUCTION & GENERAL INFORMATION
PRODUCT DESCRIPTION
The automatic changeover manifold is designed to provide a reliable uninterrupted supply of gas to a hospital or clinic’s
medical gas pipeline system. It is designed to meet NFPA 99 type 1 facility requirements.
The manifold has an equal number of cylinders in its “Primary” supply and “Secondary” supply banks, automatically
switching to the “Secondary” supply when the “Primary” supply becomes depleted. When the manifold changes to
“Secondary” supply, it sends a signal to the hospital or clinic’s medical gas alarm system alerting the personnel of the
need for the exhausted bank of cylinders to be replaced with full cylinders. After new cylinders are in place and turned
on, no manual resetting of the manifold is necessary except for turning the control knob.
INSTALLATION INFORMATION
Manifolds should be installed in accordance with guidelines stated by the National Fire Protection Association, the Compressed Gas Association, OSHA, and all applicable local codes. The carbon dioxide and nitrous oxide manifolds should
not be placed in a location where the temperature will exceed 120°F (49°C) or fall below 20°F (-7°C). The manifolds for
all the other gases should not be placed in a location where the temperature will exceed 120°F (49°C) or fall below -20°
F (-29°C). A manifold placed in an open location should be protected against weather conditions. During winter, protect
the manifold from ice and snow. In summer, shade the manifold and cylinders from continuous exposure to direct rays
of the sun.
Leave all protective covers in place until their removal is required for installation. This precaution will keep moisture and
debris from the piping interior, avoiding operational problems.
Overall Manifold Length
Manifold
Depth 10”
19”
AGM2
HEALTH CARE GAS MANIFOLD
SYSTEM NORMAL
REPLACE
DEPLETEDBANK
WESTERN INNOVATOR
875 BASSETT
ROAD
WESTLAKE,
OHIO
44145
16”
Example
AGM2-9-4
10”
Typ.
42”
Total number of cylinders
4
6
8
10
12
Overall manifold length
5’ - 8”
(1.73 m)
7’ - 4”
(2.24 m)
9’ - 0”
(2.74 m)
10” - 8”
(3.25 m)
12’ - 4”
(3.76 m)
Figure 1-1 Installation Dimensions
1-1
B20454 REL-0000 (0503)
MANIFOLD SPECIFICATIONS
Flow Capability
Oxygen:
1200 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure.
500 SCFH maximum at 50 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure.
Nitrogen:
1200 SCFH maximum at 160 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure.
Nitrous Oxide: The flow capability of a Nitrous Oxide cylinder manifold will depend upon conditions at the installation
site, demands of the delivery system and the number of cylinders in supply service. Maximum capability
is 500 SCFH at 50 psig delivery and 750 psig inlet pressure. Installing a Nitrous Oxide manifold in a
location which exposes it to ambient temperatures below 20° F (-7° C) is not recommended.
Breathing Air:
1200 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure.
Helium:
1200 SCFH maximum at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure.
Carbon Dioxide:The flow capability of a Carbon Dioxide cylinder manifold will depend upon conditions at the installation
site, demands of the delivery system and the number of cylinders in supply service. Maximum capability
is 500 SCFH at 50 psig delivery and 750 psig inlet pressure. Installing a Carbon Dioxide manifold in a
location which exposes it to ambient temperatures below 20° F (-7° C) is not recommended.
Power Source Requirements
A 115 VAC / 24 VAC power supply is provided with the manifold to operate the alarm lights on the manifold. Under
normal operation the manifold will draw a maximum of 40 milliamperes (.040 amperes).
A five terminal remote alarm terminal strip is on the right side of the circuit board in the power supply box for remote
alarm interfacing. The top three terminals on this strip (N/C, N/O, and C) provide dry contacts for hookup to the hospital
or clinic’s medical gas alarm system. Contacts are rated up to 3 amps, 30 VDC or 2 amps 250 VAC.
Nitrous Oxide and Carbon Dioxide systems include a 500 SCFH capacity heater. The thermostatically controlled heater
warms the gas before entering the regulator, preventing “freeze-up”. The heater operates at 115 VAC and draws four
amperes.
Piping Connections
Header Inlets: Carbon Dioxide
Nitrous Oxide
Breathing Air
Oxygen
Helium
Nitrogen
CGA 320
CGA 326
CGA 346
CGA 540
CGA 580
CGA 580
Manifold Outlet: 1/2 NPT male pipe thread (located
on the top center of the cabinet).
Power
Supply
Box
115
VAC
Conduit
Relief Valve
Outlet
Delivery Pipeline
Manifold
Control
Cabinet
AGM2
HEALTH CARE GAS MANIFOLD
S
Y
S
T
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N
O
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A
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ED
PLAC
ENK
DEPLR
ETE
BA
Relief Valve:
1/2 NPT male pipe thread (located
on the top left side of the cabinet).
WES8T7
ERNA
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ISN
ATO
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TH
TV
RO
WEST5LB
AKE
,SO
IO
4A
4D
145
FIGURE 1-2 Connection Locations
1-2
B20454 REL-0000 (0503)
ADJUSTMENT SPECIFICATIONS
MODEL
Primary
Regulator
Intermediate
Pressure
Relief Valve
Pressure
Switch
Intermediate
Regulator
Line
Regulators
Line
Pressure
Relief Valve
AGM2
*195-205
300
135-140
120-125
50-55
75
AGM2HP
*295-305
450
235-240
220-225
160-165
250
AGM2HL
*235-245
300
135-140
120-125
50-55
75
Units above are PSIG
* All testing must be done with full cylinders. Primary regulator set pressure will vary with inlet pressures.
CAUTION:
• Resetting/adjusting manifold components with cylinders that are not full may cause the manifold to function
improperly.
1-3
B20454 REL-0000 (0503)
RECOMMENDED TOOLS AND TEST EQUIPMENT
Volt/Ohm meter
Available from local source
Isopropyl alcohol
Available from local source
Phillips screwdriver
Available from local source
Flat blade screwdriver
Available from local source
Needle nose pliers
Available from local source
Wire cutters
Available from local source
5/32" hex key wrench
Provided with manifold
5/8" hex socket wrench
Available from local source
13/16" hex socket wrench
Available from local source
Set of combination wrenches
1/4" thru 1", 1 1/8", 1 3/8", 1 1/2", and 1 3/4"
Available from local source
Fluorolube® S-30 lubricant
Manufactured by Occidental Chemical Corporation
Niagara Falls, New York
Krytox® 240 AC
Available from E.I. Du Ponte
Wilmington, Delaware
Liquid leak detector
Available from Western Enterprises
Part number LT-100
Teflon® tape
Available from Western Enterprises
Part number MTT-1 or MTT-2
Fluorolube is a registered trademark of Occidental Chemical Corporation.
Teflon is a registered trademark of E. I. du Pont de Nemours & Co. (Inc.).
Krytox® is a register trademark of E. I. du Ponte de Nemours & Co. (Inc.)
1-4
B20454 REL-0000 (0503)
SECTION 2
THEORY OF OPERATION
GENERAL INFORMATION
This section concentrates on the basic theory of operation of the components of the automatic changeover manifold.
The first part of this section is an operating summary and traces the flow of gas through the various components of the
manifold. The second part of this section explains in detail the operation of the individual components contained in the
manifold control section.
MANIFOLD OPERATION
The automatic changeover manifold consists of a manifold control and two supply bank headers, one primary and one
secondary supply, to provide an uninterrupted supply of gas for the specific gas application. The manifold control
includes the following components and features: green “system normal” and red “replace depleted cylinders” indicator
lights, cylinder pressure gauges, line pressure gauge, internal dual line assembly and line relief valve. Supply banks
consist of a header with 24" stainless steel flexible pigtails with check valves, (rigid copper pigtails for oxygen),
individual check valve bushings, master shut-off valves, and union connections for attachment to the control unit. The
main components of the manifold are shown in Figures 2-1 through 2-3. Figures 2-4 and 2-5 show the piping schematics. Figure 2-6 is the schematic diagram of the electrical system of the manifold. Figure 2-7 is the heater schematic.
The cylinder bank that supplies the piping system is known as the “Primary” supply while the cylinder bank on stand-by
is referred to as the “Secondary” supply. Gas flows from the cylinder through the pigtails, check valves, headers, and
shut-off valves into the left and right inlets of the control section.
Gas enters the manifold cabinet and enters the pressure gauge.
Gas then flows to the primary regulators on all
manifolds except those for Nitrous Oxide and
Carbon Dioxide service (Nitrous Oxide and
Carbon Dioxide systems include a 500 SCFH capacity heater).
The thermostatically controlled heater warms
the gas before entering the regulator, preventing
“freeze-up” and loss of pressure due to the extreme
low temperatures generated when these gases rapidly expand.
Gas then enters the inlet nipple on the primary regulator which
has an integral check valve. This check valve prevents gas from
one bank feeding out into the other bank.
Control Knob
Master Valve
Master
Valve
AGM2
HEALTH CARE GAS MANIFOLD
S
Y
E
T
M
N
O
R
M
A
L
R
D
E
A
P
LC
EPE
LTEDBANK
LEFT BANK
Header Check Valves
RIGHT BANK
W
EST
ER
N
VAA
TO
8
5
ASN
SIO
EIN
TTO
R4O
DR
WE
ST7
LAK
E,BO
H
4145
Control Section
Header Check Valves
FIGURE 2-1 External Components
From the check valve nipple gas flows to the primary regulator. Pressure is reduced in the primary regulators to the
pressures noted in the adjustment specification chart in Section 1. Both primary regulators are factory preset to deliver
the same pressure. Each primary regulator has two ports on the low pressure side. One port is connected to an intermediate relief valve on the relief block assembly and a pressure switch. The other port is the outlet port and is connected via tubing to the four-way valve.
The gas then flows from the primary regulators to the four-way valve. Tubing connects the left primary regulator to the
left port of the four-way valve and the right primary regulator to the right port of the four-way valve. The four-way valve
assembly has three positions. The center position is OFF. The OFF position is only used during shipment of the manifold. Tubing connects the top port on the back of the four-way valve to the intermediate block and the bottom port on
the back of the four-way valve through an intermediate regulator and check valve before it also goes to the intermediate
block. When the valve knob is rotated counterclockwise to the left position, the four-way valve connects the left primary
regulator directly to the intermediate block through the top rear port on the four-way valve. This direct connection
makes the left bank the “primary” supply. In this position the valve also connects the right primary regulator to the intermediate regulator and check valve through the bottom port on the four-way valve. This route through the intermediate
regulator defines the right bank as the “secondary” supply. Rotating the four-way valve clockwise to the right position
now channels the gas from the right primary regulator directly to the intermediate block and gas from the left primary
regulator through the intermediate regulator and check valve. This reverses the service of the cylinder banks by making
the right bank “primary” and the left bank “secondary.” The turn of the four-way valve allows the operator to select
which bank is the “primary” supply and “secondary” supply.
2-1
B20454 REL-0000 (0503)
LEGEND
1
1– Outlet Block (with “D” size Adaptor)
2
2– Line Pressure Gauge
3– Ball Valves
3
16
4– Line Regulators
17
5– Intermediate Relief Valve
6– High Pressure Check Valve
4
19
4
7– Four-way Valve
8– Pressure Switch
5
5
9– Intermediate Check Valve
13
18
10– Left Inlet Block
11– Intermediate Regulator
8
8
12– Primary Regulator
9
13– Intermediate Test Gauge
7
14– Right Inlet Block
15– High Pressure Gauge
12
12
16– Relief Outlet Connection
17– Relief Block Connection
(Part of relief block assembly
that includes relief valves #5 & # 19)
6
6
14
11
18– Intermediate Block
15
19– Line Pressure Relief Valve
10
FIGURE 2-2 Internal Components – AGM2 & AGM2HP
2-2
B20454 REL-0000 (0503)
LEGEND
1– Outlet Block (with “D” size Adaptor)
1
2– Line Pressure Gauge
19
3– Ball Valves
16
2
3
4– Line Regulators
5– Intermediate Relief Valve
17
6– High Pressure Check Valve
7– Four-way Valve
4
4
19
8– Pressure Switch
5
9– Intermediate Check Valve
5
18
13
10– Left Inlet Block
11– Intermediate Regulator
8
12– Primary Regulator
8
9
13– Intermediate Test Gauge
7
14– Right Inlet Block
15– High Pressure Gauge
16– Relief Outlet Connection
12
12
17– Intermediate Relief Block
Connection (part of relief block
assembly that includes
relief valves #5 & #19)
18– Intermediate Block
6
6
11
10
14
19– Line Pressure Relief Valve
20
15
15
20– Heater Unit*
*Note: Carbon Dioxide an Nitrous Oxide units ordered
without a heater do not include item 20.
FIGURE 2-3 Internal Components – AGM2HL
2-3
B20454 REL-0000 (0503)
To Pipeline
Distribution System
Line Relief Valve
Pressure Gauge
Bleeder Valve
Line Pressure
Intermediate
Pressure
Cylinder
Pressure
Line Regulator
Line Regulator
Ball Valves
Vent
Pressure
Check Valve
Intermediate Pressure Gauge
Intermediate Regulator
Four Way Valve
Intermediate Relief Valve
Intermediate Relief Valve
Pressure Switch
Pressure Switch
Check Valve
Right Bank Pressure Gauge
Left Bank Pressure Gauge
Right Bank Header
Left Bank Header
Left Primary
Regulator
Right Primary
Regulator
Figure 2-4
AGM2 AND AGM2HP SERIES MANIFOLD—PIPING SCHEMATIC
Line Relief Valve
To Pipeline
Distribution System
Bleeder Valve
Line Pressure Gauge
Line Pressure
Intermediate
Pressure
Cylinder
Pressure
Line Regulator
Line Regulator
Ball Valves
Vent
Pressure
Intermediate Pressure Gauge
Check Valve
Intermediate Regulator
Four Way Valve
Intermediate Relief Valve
Intermediate Relief Valve
Pressure Switch
Pressure Switch
Check Valve
Check Valve
Right Bank Pressure Gauge
Left Bank Pressure Gauge
Left Bank Header
Right Bank Header
Left Primary Regulator
Heater
Right Primary Regulator
FIGURE 2-5
AGM2HL SERIES MANIFOLD—PIPING SSCHEMATIC
2-4
B20454 REL-0000 (0503)
FIGURE 2-6 Electrical Schematic (less heater)
The gas from the “Primary” supply is routed through the four-way valve outlet on the back of the four-way valve to the
intermediate block assembly. The intermediate block has 5 ports all connected to the same chamber. The gas pressure
at all 5 ports is the same as the pressure at the inlet to the block. Gas enters the intermediate block from the “Primary”
supply through the tubing connected at the right side. The left port is connected via tubing with check valve from the intermediate regulator. The top port connects to the inlet of the dual line assembly. Attached to the center port is a gauge
which indicates intermediate pressure. The bottom port is plugged.
As the gas enters the dual line assembly it can flow to either line regulator. Under normal operation one line regulator will
be isolated by closed ball valves. This regulator would only be used if the other regulator failed. Gas flows through the
line regulator on the side with the open ball valves. The line pressure regulator further reduces the pressure to the final
pressure delivered to the medical gas piping system. The regulator has one inlet port and three outlet ports. Two outlet
ports are plugged. The outlet port is located 180° from the inlet. The line pressure is shown on the line pressure gauge
on the front of the cabinet.
Gas flows out of the line regulator and into the outlet block.
The outlet block has 5 ports. The bottom port is connected directly to the dual line assembly. The left port is connected
through tubing to the line relief valve in the relief block assembly. The center port is connected to a line pressure gauge.
The right port is connected to a shutoff valve for testing. The
top port is connected to the piping distribution system.
The pressure switches off each primary regulator monitor the
intermediate pressure on both banks. Both switches have the
same setting which is between the settings of the primary regulator and intermediate regulator. The switch settings are noted
in the adjustment specification chart in Section 1. Should the
intermediate pressure for either bank drop below this preset
level the switch will indicate an alarm condition that changeover
has, or is about to occur.
2-5
FIGURE 2-7 Heater Electrical Schematic
B20454 REL-0000 (0503)
The check valve between the intermediate regulator and intermediate block provides a seal barrier between the higher
pressure gas from the primary regulator and the lower pressure gas from the intermediate regulator. This barrier provided
by the check valve is the dividing point between the left and right bank. It also, under certain conditions, prevents backflow
through the intermediate regulator. When gas pressure from the depleted primary bank drops below the pressure setting
of the intermediate regulator the check valve opens and allows gas flow through the intermediate regulator from the secondary bank.
The relief block assembly is a common junction for all of the relief valves connected by tubing to their respective components. The relief valves prevent dangerous over pressurization of the manifold in the event that a regulator should fail.
The relief valve settings are noted in the adjustment specification chart in Section 1. For manifolds located inside, the outlet of the relief block assembly should be vented to the outside.
When both cylinder banks are full, the switches complete the electrical circuit to display the green “system normal” light.
Cylinder pressures for each bank are indicated on the gauges on the manifold front cover. The “Primary” supply is indicated by the position of the control knob. The intermediate pressure is indicated by the gauge located on the intermediate
block. The line pressure is indicated by the gauge located on the outlet block.
As the gas from the “Primary” supply is depleted, the gas pressure to the primary regulator will begin to fall.
Simultaneously, the pressure to the pressure switch, intermediate block, and the line regulator also falls. When the
“Primary” side pressure falls below the set point of the bank pressure switch, the red “replace depleted
cylinders” light comes on and the green “system normal” light is extinguished. Any remote alarms are activated at this time.
When the “Primary” pressure falls to the set point of the intermediate regulator, the check valve between the
regulator and the intermediate block is pushed open by pressure applied from the intermediate regulator. The “Secondary”
bank begins to supply the system.
After replacing empty cylinders and opening the cylinder valves the pressure switch will activate and extinguish the red
“replace depleted cylinders” light and the green “system normal” light will come on. The operator should then turn the control knob to the opposite cylinder bank. This will make the partially used “secondary” bank the “Primary” supply and
the newly installed cylinders will become the “Secondary” supply. The system incorporates a fail-safe configuration so that
the red light can only be extinguished when sufficient pressure is supplied from both banks.
PRIMARY REGULATORS
The primary regulator’s function is to reduce the cylinder pressure of the supply banks to a more usable regulated
pressure.
Adjusting Screw
Bonnet Spring
Low Pressure Chamber
Seat and Nozzle
High Pressure Chamber
INLET PORT
OUTLET PORT
FIGURE 2-8 Primary Regulator
2-6
B20454 REL-0000 (0503)
Gas enters the regulator through the inlet port and fills the high pressure chamber and the port to the cylinder
contents gauge with gas. See Figure 2-8. Gas in these areas is at the same pressure as the gas in the cylinders. The
gas is sealed in this chamber by the seat holder and stem being pushed against the nozzle seal by gas pressure and the
body spring. An o-ring seals between the nozzle and the regulator body.
The next area of the regulator is the low (regulated) pressure area of the regulator. This chamber is sealed from the high
pressure area by the seat/nozzle assembly and the o-ring around the nozzle and is isolated from the atmospheric pressure by the diaphragm sub-assembly forming a seal around the body of the regulator. The diaphragm is squeezed between the body of the regulator, a slip ring, washer, and the regulator bonnet as the bonnet is tightened down on the
body.
The third chamber of the regulator is open to atmospheric pressure. This chamber contains the regulator bonnet, adjusting screw, pivot, bonnet spring, washer, and the top side of the diaphragm sub-assembly.
As the adjusting screw is turned in against the pivot, the bonnet spring is compressed and puts a downward force on the
diaphragm sub-assembly. The bottom of the diaphragm sub-assembly is in direct contact with the seat holder and stem.
When the diaphragm is forced down by the spring, the stem is pushed away from the nozzle and gas can then flow from
the high pressure chamber to the low pressure chamber.
When the low pressure chamber fills with gas, the gas will push upward against the diaphragm sub-assembly. As the
pressure continues to build in the low pressure chamber, more upward force will be exerted against the diaphragm and
the diaphragm will push up against the bonnet spring compressing the bonnet spring. As the diaphragm is gradually
raised by the gas pressure, the seat and nozzle gradually come
closer together filling the low pressure chamber slowly
Spring
and eventually the upward pressure exerted by the gas
Cap
will be slightly greater than the downward pressure of the
Seat
bonnet spring and the seat nozzle will close. As gas is released
from the low pressure chamber, a proportional amount
Valve
Valve
of gas will be let into the low pressure area from the
outlet
inlet
high pressure chamber. As the adjusting screw is turned
in farther and the bonnet spring is compressed, the gas
pressure required to lift the diaphragm increases, resulting
in a higher delivery pressure from the outlet port of the regulator.
Gas from Intermediate
Regulator
Gas from Primary
Regulator
FIGURE 2-9 Check Valve
CHECK VALVE
The check valve keeps gas from the primary regulator from flowing backward, See Figure 2-9. Pressure from the primary
regulator must drop below the pressure setting of the intermediate regulator. Then gas enters the check valve from the
intermediate regulator and pushes the check valve seat assembly away from the sealing surface of the valve body. This
allows the gas to flow to the outlet port of the valve. When the gas flow stops, the spring of the check valve pushes the
valve seat down on the sealing surface preventing any gas flow backward through the valve.
FOUR-WAY VALVE
The four-way valve assembly is used to route the gas
from the primary regulators to either the intermediate
block or the intermediate regulator. The four-way valve
has two inlet ports on the back side of the valve and
two outlet ports located 180° apart on the sides of the
valve. See Figure 2-10.
Figure 2-11a shows the flow channels within the valve
when the right bank of cylinders is the “Primary”
bank and the left bank is the “Secondary”.
FIGURE 2-10 Four-Way Valve (Back View)
2-7
B20454 REL-0000 (0503)
FIGURE 2-11 Four Way Valve (Back View)
Gas is directed from inlet (CYL 1) to outlet (PRESS) and from inlet (CYL 2) to outlet (EXIT) only. The seals in the valve
prevent gas from traveling to the other ports. With the valve in the full right position, the gas from the right primary regulator is routed to the intermediate block and the gas from the left primary regulator is routed to the intermediate regulator.
Figure 2-11b shows the valve in the OFF position. The OFF position is only used during shipment of the manifold. Notice
that the internal porting of the valve shown as solid fill does not connect any of the inlet ports of the valve with the outlet
ports.
Figure 2-11c shows the flow channels within valve at the full left position to make the left bank of cylinders “Primary” and
the right bank “Secondary”.
The only function the four-way valve serves is to route the gas to the other components of the manifold.
PRESSURE SWITCHES
The pressure switches are used
to signal “Secondary in Use”. These
switches are piston type with one common contact, one
normally closed contact, and one normally open
contact. See Figures 2-12 and 2-13.
Switch
When the manifold is pressurized to normal
pressures, the piston in the switch is pushed up.
The piston pushes the activator of the switch up.
This action closes the normally open contact and
opens the normally closed contacts. As gas from
the cylinder banks is depleted, the piston moves down,
releasing the force against the switch activator.
The contacts of the switch then return to the normally
open and normally closed positions.
End View
Adjusting Screw
Pressure Port
Side View
FIGURE 2-12 Low Pressure Switch
N/C
The switches complete the electrical circuits to the
indicator on the front of the control section and to the
remote alarm interface board in the power supply box.
O
N/C
FIGURE 2-13 Switch Schematic
2-8
B20454 REL-0000 (0503)
INTERMEDIATE REGULATOR
The intermediate regulator controls the gas flow from the secondary bank of cylinders to the intermediate block. The intermediate regulator pressure setting is the pressure at which the manifold will switchover from “Primary” to “Secondary”
supply. The intermediate regulator has an inlet port connected to the four-way valve. The outlet port of the intermediate
regulator is connected via tubing to the intermediate block. A check valve is located immediately upstream of the regulator.
The regulator is comparable to the line regulator illustrated in Figure 2-14. The regulator seat is held shut by the gas
pressure from the “Primary” bank regulator not allowing the check valve immediately downstream of the intermediate
regulator to open. The gas pressure from the intermediate regulator is pushing against the bottom of the check valve
seat. When both cylinder banks are full and the regulators properly adjusted, the pressure on the downstream side of the
valve is greater than the intermediate regulator pressure. This pressure differential holds the valve closed. Turning the
adjusting screw of the intermediate regulator in (clockwise) will increase the intermediate regulator pressure thereby increasing the pressure at which the valve will open. Turning the adjusting screw out (counterclockwise) will decrease the
intermediate regulator pressure thereby decreasing the pressure at which the valve will open.
As the gas in the “Primary” bank of cylinders is depleted, the gas pressure from the primary regulator will begin to fall.
When the “Primary” pressure falls below the pressure setting of the intermediate regulator, the check valve is pushed
open and the “Secondary” bank of cylinders begins to supply the system.
LINE PRESSURE REGULATOR
The line pressure regulator used in the manifold is a single stage, four port adjustable regulator. Refer to Figure 2-14. It
has one inlet port and three outlet ports. The regulator inlet port is connected to the outlet of the intermediate block on
the manifold control assembly. One regulator outlet port is connected to the outlet block. The other two outlet ports are
plugged.
Gas enters the regulator through the inlet port and with the adjusting screw backed away from the spring, is sealed in the
high pressure chamber of the regulator by the seat and nozzle.
As the adjusting screw is turned in, it compresses the spring and puts a downward force on the diaphragm subassembly. When the diaphragm is forced down by the spring, it pushes on the stem of the seat assembly. The seat is
pushed away from the nozzle and gas can then flow from the high pressure chamber to the low pressure chamber.
When the low pressure chamber fills with gas, the gas will push upward against the diaphragm sub-assembly. As the
pressure continues to build in the low pressure chamber, more upward force will be exerted against the diaphragm and
the diaphragm will push up against the bonnet spring compressing the bonnet spring. As the diaphragm is gradually
raised by the gas pressure, the seat and nozzle gradually come closer together filling the low pressure chamber slowly
and eventually the upward pressure exerted by the gas will be slightly greater than the downward pressure of the bonnet
spring and the seat nozzle will close. As gas is released from the low pressure chamber, a proportional amount of gas
will be let into the low pressure area from the high pressure chamber. As the adjusting screw is turned in farther and the
bonnet spring is compressed, the gas pressure required to lift the diaphragm increases, resulting in a higher delivery
pressure from the outlet port of the regulator.
2-9
B20454 REL-0000 (0503)
1
2
3
4
5
6
8
7
12
9
11
10
LEGEND
1 – Adjusting Screw
2 – Bonnet Assembly
3 – Pivot
4 – Adjusting Spring
5 – Diaphragm Assembly
6 – Slip Ring
7 – O-ring
8 – Body
9 – Capsule
10 – Seat Assembly
11 – Filter
12 – Friction Damper
FIGURE 2-14 Line and Intermediate Pressure Regulator
2-10
B20454 REL-0000 (0503)
SECTION 3
FIELD TESTING & TROUBLE SHOOTING
The manifold performance tests are use to verify the manifold functional performance. When used in conjunction with
the trouble-shooting charts, the technician can verify proper performance or rapidly identify the probable source of the
problem.
NOTE:
• All testing should be done using full cylinders. Using partially empty cylinders may result in improperly set
components.
PERFORMANCE VERIFICATION PROCEDURE
1. Remove control knob from four-way valve.
Note position of knob before removal.
See Section 4: “How to open the manifold.”
13. Create a slight flow of gas through the bleeder valve.
The intermediate gauge should settle and remain
constant.
2.
Open cabinet door and reinstall the control knob on 14. Turn off the flow of gas through the manifold.
the shaft of the four-way valve. Align knob to same
position as before removal.
15. Verify that the intermediate gauge indicated the pressure as shown in the specification chart in Section 1
3. Connect the electrical power source to the
for the primary regulator.
manifold and verify that the red light is on.
16. Observe the intermediate gauge for two minutes.
4. Rotate the control knob counterclockwise to make the
Verify that the primary regulator does not exhibit
left cylinder bank the “Primary” supply and the right
“creep” which is a gradual increase in pressure.
the “Secondary” supply.
17. Verify that the left side cylinder contents gauge indi5. Open the master valves located on the cylinder
cates a minimum of 2000 psig for Oxygen, Nitrogen,
header prior to pressurizing the manifold.
or Air systems. Nitrous Oxide and Carbon Dioxide
systems should indicate a minimum of 700 psig. Ad6. S-l-o-w-l-y open one cylinder valve on the left bank
just to the proper line pressure if necessary.
of cylinders.
18. Verify the line pressure gauge is indicating a mini7. S-l-o-w-l-y open one cylinder valve on the right bank
mum of 50 psig on all systems except Nitrogen. Niof cylinders.
trogen should indicate a minimum of 160 psig. Adjust
to the proper line pressure if necessary.
8. Using a leak detect solution, verify that there are
no leaks present at the connections.
19. Open the bleeder valve to create a slight flow of
gas through the manifold.
9. Close the cylinder valves on the left and right banks
of cylinders.
20. Observe the intermediate gauge and verify the
primary regulator setting under a flow condition.
10. Uncap and open the bleeder valve to create a slight
Adjust the left primary regulator as necessary to
gas flow through the manifold. Vent the system until
obtain the required pressure.
all gas has been removed from the manifold.
21. Turn off the left cylinder valve and allow all gas to
11. Close the bleeder valve.
vent from the manifold.
12. S-l-o-w-l-y open one cylinder valve on the left bank
of cylinders.
22. Close the bleeder valve.
3-1
B20454 REL-0000 (0503)
23. Rotate the control knob to its fully
clockwise position.
38. Rotate the control knob counterclockwise to make the
left bank the “Primary” supply.
24. S-l-o-w-l-y open one cylinder valve on
the right bank of cylinders.
39. Close the cylinder valve on the left bank of cylinders.
40. Observe the cylinder contents gauges: the left bank
gauge pressure should begin to drop; the right cylinder bank pressure should remain constant.
25. Complete steps 13-21 for the right
primary regulator.
26. Close the bleeder valve.
41. Observe the intermediate gauge as the left side pressure continues to drop. As the cylinder pressure
drops on the left side, the intermediate area also
loses pressure. Verify that the pressure falls to the
set point of the intermediate regulator (see the specification chart in Section 1).
27. Pressurize the right bank by opening one
cylinder valve.
28. Verify that the line pressure regulator is
functioning properly by observing the line
pressure gauge for two minutes. The gauge
should indicate the same pressure at the end
of the two minute period.
42. S-l-o-w-l-y open one cylinder valve on the left bank of
cylinders.
29. Open the bleeder valve to create a slight
flow of gas through the manifold. This valve stays
open for the duration of this test (through step #43).
30. Verify that the line pressure regulator
maintains a constant pressure by
observing the line pressure gauge.
43. Verify that the intermediate gauge has returned to the
set pressure of the left primary regulator.
44. Close the bleeder valve. Both banks remain under
cylinder pressure.
45. Disconnect the case wiring harness from the fail- safe
wiring harness. The three leads for both harnesses
are joined together with flat blade connectors.
31. S-l-o-w-l-y open one cylinder valve on the
left bank of cylinders.
46. Connect an ohmmeter across the black and brown
wires of the fail-safe wiring harness (The ends are
female flat blade connectors). The ohmmeter normally reads approximately zero (0) ohms resistance.
If the ohmmeter does not indicate approximately zero
(0) ohms, then one or both switches are faulty. Connect the meter across the normally open (N/O) and
common (C) terminal on each
pressure switch. The ohmmeter should register
approximately zero (0) ohms resistance when
connected to each switch. Adjust or replace any
faulty switch. See Section 4 for servicing the pressure switches. Reconnect the ohmmeter to the
female flat blade connectors on the end of the black
and brown wires.
32. Observe the cylinder contents pressure
gauges to verify cylinder pressure.
33. Close the cylinder valve on the right bank
of cylinders.
34. Observe the cylinder contents gauges: the
right cylinder bank pressure should begin to
drop; the left cylinder bank reading should
remain constant
35. Observe the intermediate gauge as the
right side pressure continues to drop. As the
cylinder pressure drops on the right side, the
intermediate area also loses pressure. Verify
that the pressure falls to the set point of the
Intermediate regulator (see the specification
chart in Section 1).
47. Close the Cylinder valve on the left bank of cylinders.
48. Open the bleeder valve to create a slight flow of gas
through the manifold.
36. S-l-o-w-l-y open one cylinder valve on
the right bank of cylinders.
49. Verify an ohmmeter reading of infinite resistance as
soon as the intermediate gauge pressure drops to the
value for the pressure switch setting indicated in the
specification chart in Section 1.
37. Verify that the intermediate gauge has returned to
the set pressure of the right primary regulator.
50. Close the bleeder valve.
51. S-l-o-w-l-y open one cylinder valve on the left bank
of cylinders.
3-2
B20454 REL-0000 (0503)
52. Verify that the ohmmeter returns to
approximately zero (0) ohms resistance.
71. S-l-o-w-l-y open one cylinder valve on the right
bank of cylinders.
53. Rotate the control knob clockwise to make the
right cylinder bank the “Primary” supply.
72. Rotate the control knob counterclockwise to make
the left cylinder bank the “Primary” bank.
54. Close the cylinder valve on the right bank of
cylinders.
73. Observe the cabinet indicator light. Verify that the
green indicator is lit and the red indicator is off.
55. Open the bleeder valve to create a slight flow
of gas through the manifold.
74. Close the cylinder valve on the left bank of cylinders.
75. Open the bleeder valve to create a slight flow of gas
through the manifold.
56. Verify an ohmmeter reading of infinite resistance as
soon as the intermediate gauge pressure drops to
the value for the pressure switch settings indicated
in the specification chart in Section 1.
76. Verify that the red light illuminates and the green
light is extinguished when the manifold changes
over from “Primary” to “Secondary” supply.
57. Close the bleeder valve.
77. Close the bleeder valve and recap.
58. S-l-o-w-l-y open one cylinder valve on the right
bank of cylinders.
78. S-l-o-w-l-y open all remaining cylinder valves on
the left and right banks of cylinders.
59. Verify that the ohmmeter returns to approximately
zero (0) ohms resistance.
79. Rotate the control knob to select the bank that was
in service before maintenance was performed.
60. Close all cylinder valves and vent all remaining
gas from the manifold.
80. Remove the control knob from the four-way valve.
Note position of knob before removal.
61. Remove the ohmmeter leads from the
black and brown wires.
81. Close cabinet door and replace control knob on
four-way valve. Align knob to same position as before removal. See section 4: “How to open the
manifold”.
62. Close the bleeder valve.
63. Connect the fail-safe wire harness to the case
wiring harness. Be sure wire colors match.
64. Observe the cabinet indicator light.
Verify that the green indicator is off and the
red indicator is lit.
65. S-l-o-w-l-y open one cylinder valve on the
left and right banks of cylinders.
66. Observe the cabinet indicator light. Verify
that the green indicator is lit and the red
indicator is off.
67. Close the cylinder valve on the right bank
of cylinders
68. Open the bleeder valve to create a slight
flow of gas through the manifold.
69. Verify that the red light illuminates and the green
light is extinguished when the manifold changes over
from “Primary” to “Secondary” supply.
70. Close the bleeder valve.
3-3
B20454 REL-0000 (0503)
Trouble-Shooting
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
Venting at relief valve.
Over pressure due to creeping or
faulty regulation of primary regulator.
Replace regulator seat
and nozzle components.
Gas leakage around primary
valve body halves.
Pressure regulator body and bonnet.
Loose bonnet.
Tighten bonnet.
Diaphragm leak.
Replace diaphragm.
Body halves not joined tightly enough.
Tighten screws.
O-rings worn.
Replace valve.
Gas leakage through body wall.
Porosity holes developed in casing.
Replace valve.
Both banks feeding.
Four-way valve seats leaking.
Replace valve.
PRIMARY REGULATOR
FOUR-WAY VALVE
Gas leakage around joint
in valve body halves.
INTERMEDIATE PRESSURE REGULATOR
Gas leakage around regulator
body/bonnet.
Loose bonnet.
Tighten bonnet.
Required gas flow not available
after change-over occurs.
Intermediate regulator not set correctly.
Adjust intermediate
regulator per specifications.
Both banks feeding.
Intermediate regulator set at too high
a delivery pressure.
Adjust intermediate
regulator per specifications.
Total draw from equipment on manifold
is too high
Reduce the amount of
equipment so total draw
matches manifold flow
capacity.
Gas leakage around regulator
body/bonnet.
Loose bonnet.
Tighten bonnet.
Pipeline not at desired pressure.
Line regulator not set correctly.
Set delivery pressure per
specifications.
Required gas flow not available.
Line regulator not set correctly.
Set delivery pressure per
specifications.
Total draw from equipment on manifold
is too high
Reduce the amount of
equipment so total draw
matches manifold flow
capacity.
LINE PRESSURE REGULATOR
3-4
B20454 REL-0000 (0503)
Trouble-Shooting
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
ELECTRICAL SYSTEM
No indicator lights
on front panel come on when
power is hooked up.
No power to unit.
Check Electrical power
supply.
Red indicator light does not
come on when one bank is
empty and changeover occurs.
Change-over occurring at too high a
pressure.
Adjust intermediate regulator
setting per specification
One or both pressure switches may be
set to low a pressure.
Adjust pressure switch per
specifications.
Master valve, or
cylinder valves on bank are closed.
Slowly open valves.
All pigtails on one or both banks installed
in direction against flow of the check valve.
Check that all pigtails are
installed correctly (check
valve ends connect to
cylinders).
Control knob was rotated to select new
“service” side without changing empty
cylinders
Replace depleted cylinders.
Pressure switch wiring incorrect or
disconnected.
Check pressure switch
wiring.
One or both pressure switches may be
set at too high a pressure.
Adjust pressure switch per
specifications.
Primary regulator set at too low a
pressure.
Adjust primary regulator
delivery pressure per
specifications.
Green indicator light does not
come on even though both banks
are full.
(Red indicator light stays on
With both banks full).
OPERATIONAL
One or more cylinders remain full after
manifold indicates a depleted bank.
Some pigtails installed in direction
against the flow of the check valve.
Check that all pigtails are
installed correctly (check
valve ends connect to
cylinders).
3-5
B20454 REL-0000 (0503)
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3-6
B20454 REL-0000 (0503)
SECTION 4
SERVICE PROCEDURES
GENERAL MAINTENANCE
1. Main section
a) Daily - record line pressure.
b) Monthly
1) Check regulators, valves and compression fittings for external leakage.
2) Check valves for closure ability.
c) Annually
1) Check relief valve pressures.
2) Check primary regulator seats.
2. Manifold header
a) Daily - observe Nitrous Oxide and Carbon Dioxide systems for cylinder frosting or surface condensation.
Should excessive condensation or frosting occur it may be necessary to increase manifold capacity.
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 2 years
1) Replace all copper pigtails.
d)
Every 4 years
1) Replace all stainless flex pigtails
SAFETY PRECAUTIONS
WARNING
• Repairs to manifold high pressure regulators, valve connections and piping should be made only by
qualified personnel, improperly repaired or assembled parts could fly apart when pressurized causing
death or serious injury.
1. Examine all parts before repair. Note: Because manifold parts may be exposed to high pressure
Oxygen and Nitrous Oxide and the condition of the unrepaired parts is unknown, a repair-inspection
should be performed before exposing the parts to high pressure gas.
2. Keep manifold parts, tools and work surfaces free of oil, grease and dirt. These and other flammable
materials may ignite when exposed to high pressure Oxygen or Nitrous Oxide.
3. Use only proper repair tools and parts. Parts for Western manifolds are shown in this instruction. Special
tools are called out as needed.
4. Before connecting the cylinder to the manifold, momentarily open and close the cylinder valve to blow out
any dirt or debris.
5. After connecting the cylinder to the manifold, open the cylinder valve s-l-o-w-l-y to allow the heat of
compression to dissipate.
6. Use only cleaning agents, sealants, and lubricants as specified in this instruction.
4-1
B20454 REL-0000 (0503)
CLEANING, LUBRICATION, AND SEALING
Clean metal parts of the manifold with isopropyl alcohol or oxygen compatible cleaner, detergent or solvent prior to
assembly.
Dry thoroughly. Do not clean o-rings with solvent.
Teflon® Tape Application
Threaded pipe connections should be sealed with Teflon® tape.
Remove the old sealant from both male and female threads. Apply Teflon® tape to the male pipe thread. Approximately
1 1/2 turns of tape should be sufficient. Do not cover the first thread with tape. Assemble the fittings wrench tight to
effect a gastight seal.
NOTE:
• Incorrect re-assembly of fittings may initially seal, however they may start to leak over time.
Mark the fitting and nut prior to disassembly. Before re-tightening, make sure the assembly has been inserted into the
fitting until the ferrule seats in the fitting. Retighten the nut by hand. Torque the nut with the wrench until the marks line
up, which indicates that the fitting has been tightened to its original position. A noticeable increase in mechanical resistance will be felt indicating the ferrule is being resprung into sealing position. Then snug the nut 1/12 of a turn (1/2 of a
wrench flat) past the original position.
Leak Testing
There are four types of manifold piping connections: sealed (soldered), threaded (unions and elbows), compression
(tubing connections), and gasket (diaphragms and o-rings).
When a leak is suspected and cannot be easily located, a leak detector solution should be applied to all connections
(in the event of leaks at more than one connection). Be certain to wipe fittings dry after testing to prevent corrosion
(Western’s LT-100 leak detector dries clean and will not harm apparatus).
If a leak is detected at:
sealed connections, replace the assembly which is joined by the leaking connection.
threaded connections, union sealing surfaces may have burrs or nicks which may be polished out. Be certain to
clean parts before reassembly. If the surface will not seal, replace the union. Elbows and tees may be cleaned of
old sealant and resealed with Teflon® tape. Refer to cleaning, sealing, and lubricating instructions.
compression fittings, sealing surfaces of fittings or brass ferrules may be damaged and must be replaced. Refer to
the parts list for appropriate items or call Western Enterprises for parts information.
gasket seals, leaks may occur at seals made by gaskets such as diaphragms or o-rings. Gas may leak to
atmosphere or across the seal into the opposite pressure circuit. External leaks are evidenced by application of
leak detector while leaks across the seal are detected by faulty manifold function. When replacing seals, use care
not to damage sealing surfaces.
4-2
B20454 REL-0000 (0503)
GENERAL REPAIR PROCEDURES
Be sure all pressure and electrical power is removed from the system prior to initiating any repair procedures.
WARNING
• Do not shutdown the manifold until personnel have been advised of the intended service and all
patients requiring medical gas are being supplied from portable supplies. Patients still on the pipeline will
not receive gas.
Replace parts with all components in the repair kit.
HOW TO OPEN THE MANIFOLD
Disassembly
1. Using the 5/32 allen wrench provided with manifold, remove the knob.
NOTE:
• Prior to removing the knob, make note of the knob orientation. When re-attaching the knob it should be
oriented in the same position as when it was removed.
2. Turn the latch counter-clockwise and open the door.
3. The knob should be reattached with the door open to allow the four-way valve to be rotated.
Reassembly
1. Reverse order of disassembly.
MANIFOLD CABINET COVER REMOVAL
Disassembly
1. Open the manifold as explained in the “How to open the manifold” section.
NOTE:
• Prior to removing the knob, make note of the knob orientation. When re-attaching the knob it should be
oriented in the same position as when it was removed.
2. Disconnect wires from indicator light on cabinet door. Note how the wires are connected so that they may be
properly reattached later.
3. Using the appropriate screwdriver (or 1/4” hex wrench) remove the 4 screws (2 on each side) holding the cover
in place.
4. Carefully pull the cover straight out to clear the components.
Reassembly
1. Reverse order of disassembly
4-3
B20454 REL-0000 (0503)
HOW TO DEPLETE THE SECONDARY BANK (While primary bank remains operational)
1. Open the manifold as explained in the “How to open the manifold” section.
2. Rotate the knob to make the bank that is going to be serviced the “secondary” bank.
3. Close the cylinder valves on the “secondary” bank.
4. Mark the compression fitting at the outlet of the primary regulator per the instructions on page 4-2.
5. Crack open the compression fitting and allow the reserve bank to deplete.
CAUTION:
• The compression fitting on the secondary bank primary regulator should be used to deplete pressure from
the reserve bank. This fitting will release gas at an intermediate pressure. Use of another connection may
release gas at high pressure.
6. Once pressure has been depleted retighten the fitting per the instructions on page 4-2.
HOW TO SHUTDOWN THE MANIFOLD
1. Turn off the piping system isolation valve, if present. If an isolation valve is not present, the entire buildings gas
piping system will be reduced to atmospheric pressure.
2. Open the manifold as explained in the “How to open the manifold” section.
WARNING
• Do not shutdown the manifold until all personnel have been advised of the intended service and all
patients requiring medical gas are being supplied from portable supplies.
3. Turn off right and left supply bank cylinder valves.
4. Open the bleeder valve to vent residual gas from the system.
5. Close the bleeder valve once all gas has depleted.
6. Turn off power to manifold. Alarms may sound.
GAUGE REPLACEMENT
Removal
1. Shutdown the manifold and open the manifold as explained in the “How to open the manifold” and “How to shut
down the manifold” sections. Cylinder bank pressure gauges may be replaced without shutting down the manifold. See “How to deplete the secondary bank” section.
2. Using a 9/16 open end wrench remove the pressure gauge from the system. Use second 3/4” wrench to keep
attached fittings from rotating.
3. Remove old sealant from the 1/4 NPT female pipe threads.
Replacement
1. Apply Teflon® tape to the 1/4 NPT male pipe thread on the new gauge and reassemble in the reverse order of
the removal procedure.
2. Make sure gauge face is properly oriented through the opening in the door.
3. Close manifold per the “How to open the manifold” section.
4-4
B20454 REL-0000 (0503)
PRIMARY REGULATOR REPAIR
NOTE:
• Removal and Replacement procedures are to be followed only if the primary regulator assembly is to be
scrapped. All service may be performed to the primary regulator without removing it from the manifold.
Shutdown the manifold and open the manifold as explained in the “How to open the manifold” section.
NOTE:
• This item may be repaired/replaced without shutting down the manifold completely. To work on the
manifold while it is still in service follow the steps outlined in “How to deplete the secondary bank”.
Removal
1. Mark the compression fittings per the instructions on page 4-2. Using an 11/16" open end wrench, disconnect the
outlet tubing and relief tubing from the regulator at the compression fitting joints.
2. Using 11/16” and 5/8” open end wrenches, remove the pressure switch from the tee on the regulator. The connection
uses a “B” size swivel nut.
3. Using two 1 1/8” hex wrenches disconnect the regulator from the inlet block at the CGA union connection.
Disassembly
1. Remove the nut from the regulator by turning it counterclockwise using a 11/16” wrench.
2. Using a flat blade screwdriver, turn the adjusting screw counterclockwise until it turns freely and all compression
is removed from the bonnet spring.
3. Using a 1 3/8" hex wrench, rotate the bonnet counterclockwise and remove it along with the pivot, bonnet spring,
washer, slip ring, and diaphragm sub-assembly.
4. Using a 13/16" hex socket wrench, rotate the nozzle counterclockwise and remove it along with the seat holder
and stem, compensating spring, and the spring retainer.
5. Clean all interior surfaces of the regulator body with isopropyl alcohol or 1,1,1 trichloroethylene solvent.
CAUTION:
• Do not stand directly in front of the body or ports when performing the next step. Eye protection should
be worn to protect the service technician. Chips and debris may be propelled into unprotected eyes.
6. Blow out the regulator body and ports with oil free air or nitrogen to remove all Foreign materials and dry all
surfaces.
4-5
B20454 REL-0000 (0503)
Reassembly
1. Apply a thin coating of Fluorolube® S-30 lubricant to the o-rings.
CAUTION:
• See section 5 for a picture showing the proper assembly of the regulator.
2. Assemble small o-rings with the spring retainer. Push the smaller o-ring to the bottom of the bore it rests in.
3. Assemble the large o-ring with the nozzle.
4. Insert the new seat holder and stem into the nozzle.
5. Place the spring filter and Teflon gasket over the seat holder and stem.
6. Place the spring retainer on the compensating spring. The boss on the retainer will enter the internal diameter of the
spring.
7. Grasp the flats of the nozzle with one hand and carefully guide the seat/nozzle assembly into the body of the regulator until the threads are engaged. Rotate the nozzle clockwise and hand tighten.
8. Using the 13/16" hex socket and torque wrench, tighten the nozzle to approximately 5 ft-lbs. torque.
9. Lubricate the outer (regulator body to diaphragm) sealing surface of the regulator body with a small amount of
water. Do not allow water to enter the low pressure chamber of the regulator.
10. Hold the bonnet upside down and place the pivot and bonnet spring in the bore provided. The small diameter of the
pivot should enter the internal diameter of the spring.
11. Place the washer in the large bonnet cavity, beveled side up.
12. Lay the slip ring on top of the washer.
13. Insert the diaphragm sub-assembly in the bonnet cavity. The side marked “UP” should be against the slip ring.
14. Carefully place the bonnet on the regulator body. Rotate the bonnet clockwise and tighten to 85-95 ft-lbs. torque.
Replacement
1. Connect the inlet of the regulator to the CGA bushing located on the inlet block handtight.
2. Connect the outlet and relief tube compression fittings to the primary regulator finger tight.
3. Connect the pressure switch to the tee on the primary regulator finger tight.
4. Tighten the CGA connection on the regulator inlet using two 1 1/8 wrenches.
5. Using an 11/16” open end wrench, tighten the 3/8” outlet and relief tube compression fittings. When retighting the
compression fittings follow the procedure outlined on page 4-2.
6. Using 11/16” and 5/8” open end wrenches tighten pressure switch “B” size swivel nut to regulator tee.
4-6
B20454 REL-0000 (0503)
Adjustment
1. If not already done, open the manifold by following the “How to open the manifold: as explained earlier in this
section.
2. Remove the nut from the primary regulator.
3. Reinstall the control knob on the four-way valve in the same orientation as it was prior to removal. Rotate the knob to
select the side the regulator is to be adjusted is on.
4. If the bank is not pressurized, s-l-o-w-l-y open the cylinders on the side of the regulator to be adjusted.
5. Verify the cylinder pressure readout indicates a minimum pressure of 2000 psig on Oxygen, Air, and Nitrogen
systems or a minimum of 700 psig on Nitrous Oxide and Carbon Dioxide systems.
6. Create a slight flow of gas by cracking open the bleeder valve.
7. Using a flat blade screwdriver, turn the adjusting screw of the regulator while observing the intermediate gauge.
(rotating the set screw clockwise will increase the regulator setting, while rotating it counterclockwise will lower the
regulator setting). Set the regulator to the pressure indicated on the Adjustment Specification chart in Section 1.
8. Close the bleeder valve. The test gauge will go up slightly higher than the flowing adjusted pressure.
9. Verify that the regulator does not creep by observing the intermediate gauge for two minutes. The gauge must
indicate the same pressure at the end of the two minute period.
10. Install and tighten the nut on the primary regulator. Use the flat blade screwdriver to keep the adjusting screw from
turning while nut is tightened on the regulator.
PRESSURE SWITCH REPLACEMENT
Removal
1. Open and shutdown the manifold as explained in the “How to open the manifold” and “How to shut down the manifold” sections.
Note:
• This item may be repaired / replaced without shutting down the manifold completely. To work on the manifold
while it is still in service follow the steps outlined in “How to deplete the secondary bank”.
2.Using an 11/16" and 5/8" open end wrenches, remove the pressure switch from the regulator tee. The connection
is a CGA 022 swivel.
WARNING:
• Be sure power is off when making electrical connections. Current flowing though the wires may shock
the service technician, blow fuses, and/or damage test equipment.
3. Label the three wires attached to the switch. Loosen the slot head screws on the pressure switch using a flat blade
screwdriver and remove the wires.
Replacement
1. Using an 11/16" and a 5/8" open end wrench, Install the pressure switch on the primary regulator and tighten to
effect a gastight seal.
2. Complete the adjustment instructions below prior to installing the signal wires to the pressure switch.
4-7
B20454 REL-0000 (0503)
Adjustment
WARNING:
• Be sure power is off when making electrical connections. Current flowing though the wires may shock the
service technician, blow fuses, and/or damage test equipment.
1. Connect an ohmmeter to the normally closed and common electrical contacts on the switch. The ohmmeter should
register nearly zero resistance.
2. Begin pressurizing the bank manifold by opening one cylinder valve on the side of the manifold switch is on: At the
actuation pressure, the ohmmeter reading will jump from nearly zero resistance to infinite resistance.
3. Close the cylinder valve.
4. Open the bleeder valve slightly to relieve pressure from the manifold while observing the test gauge and ohmmeter to
determine switch setting: At actuation pressure, the ohmmeter reading should drop from infinite resistance
to nearly zero resistance.
Note: If switch adjustment is performed while manifold is in service then the steps outlined in “How to deplete the secondary bank “ must be used instead of opening the bleeder valve in step 4 above.
5. Close the bleeder valve.
6. The pressure switch knurled adjustment screw also has holes along with the knurling to accommodate a 5/64” Allen
wrench. The inserted Allen wrench provides leverage to make adjustment easier. Using an Allen wrench or flat blade
screwdriver, turn the knurled adjustment screw on the pressure switch clockwise to raise the set point or counterclockwise to lower the set point. The pressure switch should be set per the Adjustment Specification chart in Section 1.
7. Cycle between actuation and re-actuation signal and make adjustments as required to achieve the signal setting. The
setting should be made on descending pressure. Make adjustments in response to the reading obtained in step 4.
8. After the setting has been made, connect the signal wires to the appropriate contacts on the pressure switch.
CHECK VALVE REPAIR – INTERMEDIATE
Removal
1. Open and shutdown the manifold as explained in the “How to open the manifold“ and “How to shut down the manifold” sections.
2. Mark the compression fittings per the instructions on page 4-2. Disconnect the tubing at the compression fittings
from the four-way valve and the intermediate block using an 11/16" open end wrench.
3. Remove the check valve and tubing assembly from the control section.
Disassembly
1. Secure the check valve in a vise or similar holding fixture. Using a 1 1/8" hex wrench, rotate the valve cap counterclockwise and remove.
2. Remove the seal washer from the valve cap.
3. Pull the spring from the valve body.
4. Using a small needle nose pliers or tweezers, grasp the valve poppet and remove it from the valve body.
5. Clean the interior of the valve body with isopropyl alcohol or 1,1,1 trichloroethylene solvent.
CAUTION:
• Do not stand directly in font of the valve when performing the next step. Eye protection should be worn to
protect the service technician. Chips and/or debris may be propelled into unprotected eyes.
6. Blow out the check valve body with oil free Air or Nitrogen to remove all foreign material and dry all surfaces.
4-8
B20454 REL-0000 (0503)
Reassembly
1. Insert a new valve poppet into the valve body.
2. Insert the spring into the valve body.
3. Position the new seal washer in the groove of the valve body.
4. Place the valve cap over the spring and push the cap towards the body until the threads engage. Rotate the cap
clockwise and tighten securely.
Replacement
1. Position the check valve and tube assembly in the control section with the check valve flow arrow pointing towards
the intermediate block.
2. Connect the compression fittings to the four-way valve and intermediate block using an 11/16" open end wrench and
tighten to effect a gastight seal. When retightening the compression fitting follow the procedure outlined on page 4-2.
CHECK VALVE REPLACEMENT – PRIMARY REGULATOR
1. Remove the primary regulator from the manifold as described in the “Primary Regulator Repair” section.
2. Place the regulator in a vice or similar holding fixture.
3. Using an 11/16 open end wrench remove the check valve nipple from the regulator inlet port.
4. Remove any remaining pipe sealant from the regulator inlet port.
5. Teflon® tape the threads on the replacement check valve nipple.
6. Nut must be replaced on the check valve nipple before it is assembled onto the regulator. Using an 11/16 open end
wrench, tighten the check valve nipple into the regulator.
7. Install the regulator back in the manifold as described in the “Primary regulator repair” section.
4-9
B20454 REL-0000 (0503)
FOUR-WAY VALVE REPLACEMENT
NOTE: If valve comes with Fittings in place then skip #5 & #6 in Removal section and #1 thru #3 in the
Replacement section.
Removal
1. Open and shutdown the manifold as explained in the “How open the manifold” and “How to shut down the manifold”
sections.
2. Mark the compression fittings per the instructions on page 4-2. Disconnect the three tubing assemblies at the compression fittings to the four-way valve and loosen the compression fittings at the other end of the tubing assemblies
using an 11/16" open end wrench.
3. Using a 11/16 wrench to loosen and disconnect the union fitting on the bottom of the four-way valve.
4. Use a flat blade screwdriver to remove the two screws that secure the four-way valve to the support bracket and
remove the four-way valve assembly.
5. Secure the valve assembly in a vise or similar holding fixture and use a 5/8” open end wrench to remove the two
inlet and two outlet adpators from the valve for use on the replacement valve.
6. Remove the old sealant from the 1/4 NPT male pipe threads on the compression fittings.
Replacement
1. Apply Teflon® tape to the 1/4 NPT male pipe threads on the compression fittings.
2. Secure the new four-way valve in a vise.
3. Install the fittings in the same orientation as they were removed (see sections 5 for the proper valve assembly
configuration).
4. Remove the valve from the vise and position it behind the support bracket with the CYL 2 port on the left and the
CYL 1 port on the right.
5. Reinstall the two screws through the bracket and into the two top threaded holes of the valve. Tighten with a
flat blade screwdriver.
6. Reconnect the tubing to the new valve. When retightening the compression fittings follow the procedure outlined on
page 4-2.
7. Reconnect the intermediate regulator to the bottom port of the new valve.
8. Using the 11/16” open end wrench, tighten the compression fitting at the ends of the tubing assemblies to effect a
gastight seal. When retightening the compression fittings follow the procedure outlined on page 4-2.
4-10
B20454 REL-0000 (0503)
INTERMEDIATE PRESSURE REGULATOR REPAIR
Removal
1. Shutdown and open the manifold as explained in “How to open the Manifold” and “How to shutdown the Manifold”
sections.
NOTE:
• This item may be repaired/replaced without shutting down the manifold completely. To work on the manifold
while it is still in service follow the steps outlined in “How to Deplete the Secondary Bank” section.
2. Mark the compression fitting at the regulator outlet per the instructions on page 4-2. Disconnect the tubing at this
compression fitting using an 11/16" open end wrench.
3. Disconnect the union fitting between the intermediate regulator and the four-way valve.
4. Remove the intermediate regulator from the control section.
Disassembly
1. Remove the intermediate regulator following the instructions above.
2. Rotate the adjusting screw of the regulator counter clockwise with a flat blade screwdriver and remove.
3. Remove the bonnet by holding the body hex with a wrench to stabilize the assembly and using another wrench to
loosen the bonnet. The adjusting spring vibration dampener and pivot will come off with the bonnet.
4. Remove the diaphragm assembly and slip ring.
5. Using a 1" socket wrench, rotate the seat capsule counterclockwise and remove the seat capsule.
CAUTION:
• Do not stand directly in front of the body and ports when performing the next step. Eye protection should be
worn to protect the service technician. Chips and/or debris may be propelled into unprotected eyes.
6. Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces.
Re-assembly
1. Assemble the new seat capsule into the regulator body and torque to 20-25 ft-lbs.
2. Place the pivot on the bonnet spring and insert inside the inverted regulator bonnet.
3. Insert the vibration dampener between the spring and the bonnet.
4. Assemble the slip ring and diaphragm into the bonnet (diaphragm should be on top of the stack and end up against
the regulator body).
5. Assemble the bonnet to the regulator while the regulator is inverted and torque to 40-50 ft-lbs.
4-11
B20454 REL-0000 (0503)
Replacement
1.
Position the intermediate regulator in the control section and attach the union fitting to the back of the four-way
valve finger tight.
2.
Connect the compression nut from the check valve assembly to the intermediate regulator fitting and tighten with a
11/16” open-end wrench to make a gas tight seal.
3.
Tighten union connection between intermediate regulator and four-way valve using 11/16” and 5/8” open-end
wrenches.
Adjustment
1.
If not already done, open the manifold as explained in the “How to open the Manifold” section. Reinstall the fourway valve knob and rotate to select one bank of cylinders as the supply bank.
2.
S-l-o-w-l-y open the cylinder valves on the secondary supply bank.
3.
Close the cylinder valves on the primary bank.
4.
Open the bleeder valve slightly to relieve pressure from the manifold while observing the intermediate gauge.
5.
Allow the gas to vent until the intermediate gauge stabilizes or indicates less than the setting for the intermediate
regulator listed in the Adjustment Specification chart in Section 1.
•
If the gauge stabilizes at a pressure higher than the chart specification, turn the adjusting screw on the
intermediate regulator counterclockwise (out) to decrease the gauge reading.
•
If the gauge stabilizes at a pressure lower than the chart specification, turn the adjusting screw on the
intermediate regulator clockwise (in) to increase the gauge reading.
6.
Close the bleeder valve.
7.
Pressurize the service bank.
8.
Simulate the changeover sequence from both sides and observe the intermediate gauge to verify proper setting.
4-12
B20454 REL-0000 (0503)
LINE REGULATOR REPAIR
NOTE:
• Removal and Replacement procedures are to be followed only if the line regulator assembly is to be
scrapped. All service may be performed to the line regulator without removing it from the manifold.
Open the valves isolating the bypass line regulator and close the valves isolating the regulator being serviced.
Removal
1. Using 1" and 1 1/4 " wrenches, disconnect the union connections on both sides of the line regulator.
2. Remove the regulator from the dual line assembly.
Disassembly
1. Remove regulator following the instructions above.
2. Use a 11/16” wrench to loosen retaining nut. Rotate the adjusting screw of the regulator counter clockwise (out) with
a 5/8” socket/wrench and remove.
3. Remove the bonnet by holding the body hex with a wrench to stabilize the assembly and using another wrench to
loosen the bonnet. The adjusting spring, vibration dampener, and pivot will come off with the bonnet.
4. Remove the diaphragm assembly and slip ring.
5. Using a 1" socket wrench, rotate the seat capsule counterclockwise and remove the seat capsule.
CAUTION:
• Do not stand directly in front of the body and ports when performing the next step. Eye protection should
be worn to protect the service technician. Chips and/or debris may be propelled into unprotected eyes.
6. Blow out the regulator body and ports with oil free air or nitrogen to remove all Foreign materials and dry all surfaces.
4-13
B20454 REL-0000 (0503)
Reassembly
1.
Assemble the new seat capsule into the regulator body and torque to 20-25 ft-lbs.
2.
Place the pivot on the bonnet spring and insert inside the inverted regulator bonnet.
3.
Insert the vibration dampener between the spring and the bonnet.
4.
Assemble the slip ring and diaphragm into the bonnet (diaphragm should be on top of the stack and end up
against the regulator body).
5.
Assemble the bonnet to the regulator while the regulator is inverted and torque to 40-50 ft-lbs.
Replacement
1.
Teflon® tape and assemble the union fittings from the regulator that were removed into the new regulator.
2.
Insert the regulator into the dual line assembly.
3.
Using 1" and 1 1/4 " open end wrenches, tighten the union fittings.
4.
Open the ball valves supplying the new regulator and leak check the union connections.
5.
Close the ball valves isolating the other regulator for future service.
Adjustment
1.
Open the manifold as described in the “How to open the Manifold” section.
2.
S-l-o-w-l-y open the ball valves that were isolating the regulator.
3.
Close the ball valves isolating the regulator that is not being adjusted.
4.
Verify the cylinder pressure gauge indicates a minimum pressure of 2000 psig on Oxygen, Air, and Nitrogen systems or a minimum of 700 psig on Nitrous Oxide and Carbon Dioxide systems.
5. Open the bleeder valve to create a slight flow of gas through the manifold.
6.
Using a flat blade screwdriver, turn the adjusting screw of the regulator in while observing the line pressure gauge.
Set the regulator to the desired pressure.
7.
Readjust the regulator to the proper specifications if necessary. Use Adjustment Specification chart in Section 1.
8.
Close the bleeder valve. The line pressure gauge will go up slightly higher than the flowing adjusted pressure.
9.
Verify that the regulator does not creep by observing the line pressure gauge for two minutes. The gauge must indicate the same pressure at the end of the two minute period.
4-14
B20454 REL-0000 (0503)
SECTION 5
MANIFOLD MAINTENANCE & REPAIR PARTS
REPLACEMENT PIGTAILS
24” Stainless Steel Flexible Braid with Check Valves ,
36” Pigtails for staggered systems have part numbers that end with “-36”.
PFP-320CV-24……………………………………………CGA 320 for Carbon Dioxide (CO2) Service
PFP-326CV-24……………………………………………CGA 326 for Nitrous Oxide (N2O) Service
WPR-63CVV………………………………………………CGA 540 for Oxygen (O2) Service
PFP-92CV-24……………………………………………..CGA 580 for Nitrogen (N2) Service
PFP-346CV-24……………………………………………CGA 346 for Compressed Air
24” Synthetic Fiber Braid Hose with Check Valve
PFS-92CV-24…………………………………………...CGA 580 for Helium (He) Service (for non medical service).
PRESSURE GAUGES – 2” Diameter, 1/4” NPT Back Port
WMG-3-3…………..100 psi…..Line gauge AGM2, AGM2HL
WMG-3-4…………..400 psi…..Line gauge AGM2HP
WMG-3-4…………..400 psi…..Intermediate gauge
WMG-3-8………….2000psi.....Cylinder pressure gauge AGM2-4, AGM2-8, AGM2HL
WMG-3-12………...4000psi….Cylinder pressure gauge AGM2-2,5,7,9, AGM2HP
VALVES AND VALVE REPAIR KITS
WMS-1-53……………...CGA 540 Check Valve Bushing
WMV-2-16………………Master Valve
WMS-13-53……………..Four way valve assembly
RK-1085………………...Repair kit for WMV-2-16
RK-1041………………...Repair kit for low pressure check valves
WMS-1-59……...CGA 326 Check Valve
WMS-1-62……...CGA 346 Check Valve
WMS-1-54……...CGA 580 Check Valve
WMS-1-65……...CGA 320 Check Valve
Bushing
Bushing
Bushing
Bushing
PRESSURE SWITCHES
WME-4-4………………..Pressure Switch (all gases except Oxygen & Compressed Air)
WME-4-4C……………...Pressure Switch (Oxygen& Compressed Air)
POWER SUPPLY REPLACEMENT PARTS
8570D…………………...Power Supply Assembly (transformer, PCB, case, and cable)
WME-8-1………………..Power Supply PCB (includes dry contacts for remote alarms)
9103002………………...2.5 Amp fuse for in line fuse holder.
INDICATOR LAMP REPLACEMENT
Square Style
WMS-1-136…………….Dual indicator light assembly.
MK-1011………………..Replacement bulb kit.
5-1
B20454 REL-0000 (0503)
MANIFOLD MAINTENANCE & REPAIR PARTS
AGM2 SERIES REGULATORS AND REGULATOR REPAIR KITS
AGM2 Series Primary Regulators
WMS-13-68..............Left Primary Regulator for AGM2 (Oxygen & Air)
WMS-13-73..............Right Primary Regulator for AGM2 (Oxygen & Air)
WMS-13-69..............Left Primary Regulator for AGM2 (N2, He )
WMS-13-74..............Right Primary Regulator for AGM2 ( N2, He)
WMS-13-72..............Left Primary Regulator for AGM2, AGM2HL & AGM2HP (CO2 & N2O )
WMS-13-77..............Right Primary Regulator for AGM2, AGM2HL & AGM2HP (CO2 & N2O)
WMS-13-70..............Left Primary Regulator for AGM2HP (N2, He)
WMS-13-75..............Right Primary Regulator for AGM2HP (N2, He)
WMS-13-71………….Left Primary Regulator for AGM2HP (Oxygen & Air)
WMS-13-76………….Right Primary Regulator for AGM2HP (Oxygen & Air)
RK-1037...................Repair Kit for WMS-13-69, WMS-13-70, WMS-13-72, WMS-13-74, WMS-13-75 & WMS-13-77
Primary Regulators
RK1038....................Repair Kit for WMS-13-68 and WMS-13-71, WMS-13-73, and WMS-13-76 Primary Regulators
(Oxygen & Air)
AGM2 Series Line Regulators
WLR-13-60L.............Left Line Regulator for AGM2 & AGM2HL (Air, He, CO2, N2O, O2, N2)
WLR-13-60R............Right Line Regulator for AGM2 & AGM2HL (Air, He, CO2, N2O, O2, N2)
WLR-13-200L...........Left Line Regulator for AGM2HP (Air, He, CO2, N2O, O2, N2)
WLR-13-200R..........Right Line Regulator for AGM2HP (Air, He, CO2, N2O, O2, N2)
RK-1160...................Repair Kit for WLR-13-200R (L)
RK-1161……………..Repair Kit for WLR-13-60R (L)
AGM2 Series Intermediate Regulators
WLR-15-125.............Intermediate Regulator for AGM2 & AGM2HL (Air, He, CO2, N2O, O2, N2)
WLR-15-225.............Intermediate Regulator for AGM2HP (Air, He, CO2, N2O, O2, N2)
RK-1160...................Repair Kit for WLR-15-125 and WLR-15-225
RELIEF VALVES
WMV-4C-75………...AGM2 & AGM2HL Line Relief Valve
WMV-4C-250……….AGM2HP Line Relief Valve
WMV-4C-300……….AGM2 & AGM2HL Intermediate Relief Valve
WMV-4C-450……….AGM2HP Intermediate Relief Valve
WMV-4-7…………….Pipe-Away Adaptor
5-2
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2 & AGM2HP Series
Repair Drawing
Components & Miscellaneous Hardware
19
2
1
25
26
24
23
17
22
27
16
18
6
4
8
15
8
5
7
9
10
13
3
11
21
12
20
14
* Not Shown
KEY # DESCRIPTION
PART #
KEY #
1
Outlet Nut
D-7
17
2
Outlet Nipple
D-20
3
Intermediate Regulator
See Page 5-2
4
4 way to Intermediate Tube
WMS-13-58
18
5
CV Assembly
WMS-13-48
19
6
Relief Tubing, Left Prim. Reg. WMS-13-54
7
Four Way Valve Assembly
WMS-13-53
8
Pressure Switch
20
AGM2 & AGM2HP(other gases) WMS-13-66
AGM2-9 & AGM2HP (O2/air)
WMS-13-67
9
Left Primary Regulator
See Page 5-2
21
10
Right Primary Regulator
See Page 5-2
22
11
Left Inlet Block
WMS-13-4
*
12
Right Inlet Block
WMS-13-3
23
13
Left Primary to 4-way Tube
WMS-13-56
24
14
Right Primary to 4-way Tube
WMS-13-57
25
15
Relief Tubing, Right Prim. Reg. WMS-13-55
26
16
Left Line Regulator Assembly
27
AGM2
WLR-13-60L
AGM2HP
WLR-13-200L
5-3
20
21
DESCRIPTION
Right Line Regulator Assembly
AGM2
AGM2HP
Intermediate Gauge
Line Pressure Gauge
AGM2
AGM2HP
AGM2HL Inlet Pressure Gauge
AGM2 (CO2 &N2O)
AGM2 & AGM2HP (other gases)
Inlet Union
Ball Valve
Ball Valve O Ring
Relief Union
Relief Tubing, Line Regulator
Backplate Assembly
Bleeder Valve
Relief Block Assembly
AGM2
AGM2HP
PART #
WLR-13-60R
WLR-13-200R
WMG-3-4
WMG-3-3
WMG-3-4
WMG-3-8
WMG-3-12
WMS-1-40
WMV-5-12
RO-016E
WLF-3-12
WMS-13-60
WMS-13-61
203
WMS-13-49
WMS-13-50
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2 & AGM2HP Series
Repair Drawing
Components & Miscellaneous Hardware
29
32
30
30
AGM2
28
HEALTH CARE GAS MANIFOLD
SYSTEM NORMAL
REPLACE
DEPLETED BANK
WESTERN
875 BA
WESTLAKE
OVATOR
T ROAD
IO 44145
30
30
31
32
32
KEY # DESCRIPTION
PART #
28
Case
WMC-2-70A
29
Outlet Union
D-34
30
#8 Sht. Metal Case Screw
WMC-6-23
31
Control Knob
WMV-5-3A
32
Lens Cover
MGL-71-1
* Case Wiring Harness
WMS-13-62
* Switch Wiring Harness
WMS-13-63
* Power Supply Box
8570D
* Item not pictured
5-4
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2HL Series
Repair Drawing
Components & Miscellaneous Hardware
2
23
19
1
25
24
26
17
22
27
16
18
6
8
4
8
15
5
7
9
13
14
10
3
11
12
20
20
21
21
28
KEY #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DESCRIPTION
Outlet Nut
Outlet Nipple
Intermediate Regulator
4 way to Intermediate Tube
CV Assembly
Relief Tubing, Left Prim. Reg.
Four Way Valve Assembly
Pressure Switch
Left Primary Regulator
Right Primary Regulator
Left Inlet Block
Right Inlet Block
Left Primary to 4 way Tube
Right Primary to 4 way Tube
Relief Tubing, Right Prim. Reg.
Left Line Regulator Assembly
PART #
D-7
D-20
See Page 5-2
WMS-13-58
WMS-13-48
WMS-13-54
WMS-13-53
WMS13-66
See Page 5-2
See Page 5-2
WMS-13-33
WMS-13-32
WMS-13-56
WMS-13-57
WMS-13-55
WMS-13-60L
KEY #
17
18
19
20
21
22
*
23
24
25
26
27
28
DESCRIPTION
Right Line Regulator Assembly
Intermediate Gauge
Line Pressure Gauge
Inlet Pressure Gauge
Inlet Union
Ball Valve
Ball Valve O Ring
Relief Union
Relief Tubing, Line Regulator
Backplate Assembly
Bleeder Valve
Relief Block Assembly
Heater
PART #
WLR-13-60R
WMG-3-4
WMG-3-3
WMG-3-8
WMS-1-40
WMV-5-12
RO-016E
WLF-3-12
WMS-13-60
WMS-13-61
203
WMS-13-49
WMS-13-37
* Not Shown
5-5
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2HL Series
Repair Drawing
Components & Miscellaneous Hardware
30
33
31
31
AGM2
29
HEALTH CARE GAS MANIFOLD
SYSTEMNORMAL
REPLACE
DEPLETEDBANK
WESTERN
875 BA
WESTLAKE
OVATOR
T ROAD
IO 44145
31
31
33
32
KEY # DESCRIPTION
29
Case
30
Outlet Union
31
# 8 Sht. Metal Case Screw
32
Control Knob
33
Lens Cover
* Case Wiring Harness
* Switch Wiring Harness
* Power Supply Box
33
PART #
WMC-2-70A
D-34
WMC-6-23
WMV-5-3A
MGL-71-1
WMS-13-62
WMS-13-63
8570D
* Item not pictured
5-6
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2, AGM2HL, & AGM2HP Series
Repair Drawing
Left Regulator Components
KEY # DESCRIPTION
1
Nut
2
Preset Adjusting Screw
3
Regulator Bonnet
4
Bonnet Bushing
5
Bushing Retainer
6
Pivot
7
Bonnet Spring
8*
Washer
9*
Slip Ring
10*
Diaphragm Assembly
11*
Nozzle
for AGM2 Models (oxygen)
AGM2 Models (other Gases)
12*
Large O-Ring
13*
Seat Holder & Stem for
AGM2 Models (oxygen)
AGM2 Models (other gases)
PART #
WMC-6-90
RWS-3-3
RWS-2-3P
RWC-3-12
RWC-3-14
RWC-2-8P
RWS-1-12
RWS-3-26
RWS-3-17
RWS-3-28
KEY # DESCRIPTION
PART #
14*
Valve Spring
AGM2 Models (oxygen)
RWS-6-5
AGM2 Models (other gases)
RWS-1-8
15*
Teflon Ring
RWS-3-70
16*
Filter
S-5
17*
Spring Retainer
RWS-3-81
18
Regulator Body
RWS-1-3
19
90° CGA 022 Elbow
253
20
NPT Street Tee
BST-4LP
21
1/4 NPT Plug
P-4HP
22
90° Tube Elbow
WLF-3-6
23
CGA 580 Nut
92
24
CGA 580 CV Nipple
15-8CV
25*
O-ring
RWS-3-47
26*
Back-up Ring
RWS-5-7
27*
Seal Retainer
RWS-6-4
*
Part of Repair Kit RK-1038 (OXYGEN)
and RK-1037 (other gases).
RWS-5-1
RWS-6-9
RO-015E
RWS-6-3
RWS-6-8
5-7
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2, AGM2HL, & AGM2HP Series
Repair Drawing
Right Regulator Components
KEY # DESCRIPTION
1
Nut
2
Preset Adjusting Screw
3
Regulator Bonnet
4
Bonnet Bushing
5
Bushing Retainer
6
Pivot
7
Bonnet Spring
8*
Washer
9*
Slip Ring
10*
Diaphragm Assembly
11*
Nozzle
AGM2 Models (oxygen)
AGM2 Models (other gases)
12*
Large O-Ring
13*
Seat Holder & Stem for
AGM2 Models (oxygen)
AGM2 Models (other gases)
PART #
WMC-6-90
RWS-3-3
RWS-2-3P
RWC-3-12
RWC-3-14
RWC-2-8P
RWS-1-12
RWS-3-26
RWS-3-17
RWS-3-28
KEY # DESCRIPTION
PART #
14*
Valve Spring
AGM2 Models (oxygen)
RWS-6-5
AGM2 Models (other gases)
RWS-1-8
15*
O-Ring
RWS-3-70
16*
Filter
S-5
17*
Spring Retainer
RWS-3-81
18
Regulator Body
RWS-1-3
19
90° CGA022 Elbow
253
20
NPT Street Tee
BST-4LP
21
90° Tube Elbow
WLF-3-6
22
1/4 NPT Plug
P-4HP
23
CGA 580 Nut
92
24
CGA 580 CV Nipple
15-8CV
25*
O-ring
RWS-3-47
26*
Back Up Ring
RWS-5-7
27*
Seal Retainer
RWS-6-4
28
Straight Tube Adaptor
WLF-3-5
*
Part of Repair Kit RK-1038 (oxygen)
and RK-1037 (other gases).
RWS-5-1
RWS-6-9
RO-015E
RWS-6-3
RWS-6-8
5-8
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2, AGM2HL, & AGM2HP Series
Repair Drawing
Check Valve Components
4
3
2
1
KEY #
1*
2*
3*
4
DESCRIPTION
Poppet
Spring
Washer
Cap
PART #
WMV-1-5
WMV-1-6
WMV-1-7
WMV-1-8
*Item included in repair kit RK-1041.
5-9
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2, AGM2HL, & AGM2HP Series
Repair Drawing
Intermediate Regulator Components
12
9
11
4
8
2
1
5
3
15
7
6
10
14
13
KEY #
1
2*
3
4
5
6
7
8*
9*
10
11
12
13
14
15
DESCRIPTION
Regulator Body
Seat Capsule
NPT Adaptor
Pivot
Bonnet
Bushing Retainer
Bonnet Bushing
Slip Ring
AGM2 & AGM2HL
AGM2HP
Diaphragm Assembly
Delivery Spring
AGM2 & AGM2HL
AGM2HP
Adjusting Screw
1/4 NPT Plug
Anti Vibrator
AGM2, AGM2HL
AGM2HP
“B” Size Elbow
3/8 Tube Elbow
* Part of Repair Kit RK-1160.
PART #
WLR-1-1
WLR-1-10
BA-4HP
RWC-2-8
RWS-2-2P
RWC-3-14
RWC-3-12
RWS-3-17*
RWS-7-4
RWS-3-28
WLR-1-8
RWS-1-12
WLR-1-11
WLF-1-21
WLR-1-14A
WLR-1-14
253
WLF-3-6
5-10
B20454 REL-0000 (0503)
Western Enterprises
Automatic Changeover Manifold
AGM2, AGM2HL, & AGM2HP Series
Repair Drawing
Right & Left Line Regulator Components
14
1
2
13
8
9
5
4
11
12
12
14
10
6
7
Note: Right side regulator shown above with Fittings installed. Open end of elbows (part 14) pointed in opposite
direction for left side regulator assembly.
KEY #
1
2*
3
4
5
6
7
8*
9*
10
11
12
13
14
DESCRIPTION
PART #
Regulator Body
WLR-1-1
Seat Capsule
WLR-1-10
Nut for AGM2 &AGM2HL Only (Not Shown)
WMC-6-90
Pivot
RWC-2-8
Bonnet
RWS-2-2P
Bushing Retainer
RWC-3-14
Bonnet Bushing
RWC-3-12
Slip Ring
AGM2 & AGM2HL
RWS-3-17*
AGM2HP
RWS-7-4
Diaphragm Assembly
AGM2 & AGM2HL
RWS-3-16
AGM2HP
RWS-3-28
Delivery Spring
AGM2 & AGM2HL
WLR-1-31
AGM2HP
RWS-1-12
Adjusting Screw
AGM2 & AGM2HL
WLR-2-4
AGM2HP
WLR-1-11
1/4 NPT Plug
WLF-1-21
Anti Vibrator
AGM2 & AGM2HL
WLR-1-14A
AGM2HP
WLR-1-14
1/4 NPT Male Elbow
BLM-4HP
* Part of Repair Kit RK-1161 (AGM2 & AMG2HL) and RK-1160 (AGM2HP).
5-11
B20454 REL-0000 (0503)
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