FHM2 Service Manual - Western Enterprises

FHM2 Service Manual - Western Enterprises
AUTOMATIC CHANGEOVER MANIFOLD
FHM2, FHM2HL, & FHM2HP SERIES
SERVICE MANUAL
LIN E PRESSU RE
IN SERVIC E
IN SERVIC E
SYSTEM N O RM A L
REA D Y FO R U SE
REA D Y FO R U SE
BA N K D EPLETED
BA N K D EPLETED
LEFT BA N K
RIG H T BA N K
FH M 2
FULLY AUTO M ATIC HEALTH C ARE G AS M AN IFO LD
W ESTERN IN N O VA TO R
875 BASSETT RO AD
W ESTLAKE,O H IO 44145
1-800-783-7890
WESTERN ENTERPRISES
PRINTED IN USA
B20353 ECN-13787 (0701)
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 FHM2, FHM2HL, and FHM2HP series
manifolds. This information is intended for use by technicians or personnel qualified to repair and service manifold equipment.
The information contained in this document, including performance specifications, is subject to change without notice.
WARRANTY
Western Enterprises makes no warranty of any kind with regard to the material in this manual. Including but not limited to
the implied warranties of merchantability and fitness for a particular purpose.
Refer to the Installation and Operation Instructions manual for warranty information.
i
B20353 ECN-13787 (0701)
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 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.
ABBREVIATIONS
C
CGA
FT-LBS
IN-LBS
N/C
N/O
NPT
Common
Compressed Gas Association
Foot-Pounds
Inch-Pounds
Normally Closed
Normally Open
National Pipe Taper
NFPA
OSHA
PSIG
SCFH
VAC
VDC
PCB
National Fire Protection Association
Occupational Safety & Health Administration
Pounds per Square Inch Gauge
Standard Cubic Feet per Hour
Voltage, Alternating Current
Voltage, Direct Current
Printed Circuit Board
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
B20353 ECN-13787 (0701)
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
Solenoid Bypass Check Valve .................................................................................................................2-7
Solenoid Valves........................................................................................................................................2-8
Pressure Switch .......................................................................................................................................2-8
Line Pressure Regulator ..........................................................................................................................2-9
Pressure Transducer................................................................................................................................2-9
3-1
SECTION 3
FIELD TESTING AND TROUBLESHOOTING
Performance Verification Procedure ........................................................................................................3-1
Troubleshooting........................................................................................................................................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 Case 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
Solenoid Valve Repair..............................................................................................................................4-9
Line Regulator Repair ............................................................................................................................4-12
PCB Replacement..................................................................................................................................4-14
Electrical Power-Up ...............................................................................................................................4-15
Transducer Replacement.......................................................................................................................4-18
iii
B20353 ECN-13787 (0701)
SECTION 5
MAINTENANCE AND REPAIR PARTS
5-1
Replacement Pigtails...............................................................................................................................5-1
Gauges.....................................................................................................................................................5-1
Regulators and Repair Kits ......................................................................................................................5-1
Valves and Valve Repair Kits...................................................................................................................5-2
Pressure Switches....................................................................................................................................5-2
Power Supply Replacement Parts............................................................................................................5-2
Transducers .............................................................................................................................................5-2
Printed Circuit Board ................................................................................................................................5-2
Solenoids..................................................................................................................................................5-2
Components and Miscellaneous Hardware – FHM2 & FHM2HP Series .................................................5-3
Components and Miscellaneous Hardware - FHM2HL Series.................................................................5-5
Left Primary Regulator Components........................................................................................................5-7
Right Primary Regulator Components......................................................................................................5-8
Check Valve Components........................................................................................................................5-9
Power Supply Components....................................................................................................................5-10
iv
B20353 ECN-13787 (0701)
This page intentionally left blank.
v
B20353 ECN-13787 (0701)
SECTION 1
INTRODUCTION & GENERAL INFORMATION
PRODUCT DESCRIPTION
The fully 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 “Service” supply and “Secondary” supply banks, automatically
switching to the “Secondary” supply when the “Service” 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.
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.
CAUTION:
• Remove all protective caps prior to assembly. The protective cap may ignite due to heat of recompression in
an oxygen system.
Overall Manifold Length
Manifold
Depth 10”
LIN E PRESSU RE
19”
IN SERVICE
IN SERVICE
SYSTEM N O RM AL
READY FO R U SE
READY FO R U SE
BA N K D EPLETED
BA N K D EPLETED
LEFT BA N K
RIG H T BA N K
FH M 2
FULLY AU TO M ATIC HEALTH C ARE G AS M AN IFO LD
W ESTERN IN N O V ATO R
875 BASSETT RO AD
W ESTLAKE,O HIO 44145
1-800-783-7890
16”
Example
FHM2-9-4
10”
Typ.
45”
Total number of cylinders
4
6
8
10
12
Overall manifold length
5’ - 11”
7’ - 7”
9’ - 3”
10” - 11”
12’ - 7”
Figure 1-1 Installation Dimensions
1-1
B20353 ECN-13787 (0701)
MANIFOLD SPECIFICATIONS
Flow Capability
Oxygen:
2200 SCFH at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure.
800 SCFH at 50 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure.
Nitrogen:
4650 SCFH at 160 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure.
400 SCFH at 160 psig delivery with a 5 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. 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:
2500 SCFH at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure.
650 SCFH at 50 psig with a 5 psi pressure drop and 2000 psig inlet pressure.
Helium:
2500 SCFH at 50 psig delivery with a 15 psi pressure drop and 2000 psig inlet pressure.
650 SCFH at 50 psig delivery with a 5 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. 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 status lights on the manifold. Under normal operation the manifold will draw a maximum of 1.5 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 primary regulator, preventing “freeze-up”. The heater operates at 115 VAC and draws
4 amperes.
Piping Connections
Header Inlets: Carbon Dioxide
Nitrous Oxide
Breathing Air
Oxygen
Helium
Nitrogen
Med Breathing Mix.
CGA 320
CGA 326
CGA 346
CGA 540
CGA 580
CGA 580
CGA 280
Power
Supply
Box
Relief Valve
Vent Line
Delivery Pipeline
Relief Valve
Outlet
Manifold Outlet: 1/2 NPT male pipe thread (located
on the top center of the cabinet).
Relief Valve:
115
VAC
Conduit
1/2 NPT male pipe thread (located
on the top left side of the cabinet).
Manifold
Control
Cabinet
LIN E PRESSU RE
IN SERVIC E
IN SERVIC E
SYSTEM N O RM A L
REA D Y FO R U SE
REA D Y FO R U SE
BA N K D EPLETED
BA N K D EPLETED
LEFT BAN K
RIG H T BAN K
FH M 2
FULLY AUTO M ATIC HEALTH C ARE G AS M AN IFO LD
W ESTERN IN N O VATO R
875 BASSETT RO AD
W ESTLAKE,O H IO 44145
1-800-783-7890
FIGURE 1-2 Connection Locations
1-2
B20353 ECN-13787 (0701)
ADJUSTMENT SPECIFICATIONS
MODEL
Primary
Regulator
Intermediate
Pressure
Relief Valve
Pressure
Switch
Line
Regulators
Line
Pressure
Relief Valve
FHM2
*195-205
300
120-125
50-55
75
FHM2HP
*295-305
450
220-225
**160-165
(v4.0.x and up)
250
**170-175
(v2.02)
FHM2HL
*235-245
300
120-125
50-55
75
Unit above are PSIG
* All testing must be done with full cylinders. Primary regulator set pressure will vary with changing inlet pressures.
**Software version is located on back of circuit board.
CAUTION:
• Resetting/adjusting manifold components with cylinders that are not full may cause the manifold to function
improperly.
1-3
B20353 ECN-13787 (0701)
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
Available from local source
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
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
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
B20353 ECN-13787 (0701)
SECTION 2
THEORY OF OPERATION
GENERAL INFORMATION
This section concentrates on the basic theory of operation of the components of the fully automatic changeover manifold.
The first part of this section is an operating summary and traces the flow of gas through the various components of the
manifold. The second part of this section explains in detail the operation of the individual components contained in the
manifold control section.
MANIFOLD OPERATION
The automatic changeover manifold consists of a manifold control and two supply bank headers, one service and one
secondary supply, to provide an uninterrupted supply of gas for the specific gas application. The manifold control includes the following components and features: green “in service”, yellow “ready for use”, and red “bank depleted” indicator lights, digital readouts for both cylinder pressure and line pressure, internal intermediate and 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, 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 “Service” 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 shutoff valves into the left and right inlets of the control section.
Gas enters the manifold cabinet and enters a pressure transducer. The pressure transducer displays the bank pressure
on the front of the cabinet. The transducer also monitors bank pressure and signals all connected alarms when the system changes from the service to the secondary bank.
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.
Master Valve
LIN E PRESSU RE
IN SERVICE
IN SERVICE
SYSTEM N O RM AL
REA D Y FO R U SE
REA D Y FO R U SE
BAN K D EPLETED
BAN K D EPLETED
LEFT BA N K
LEFT BANK
RIG H T BA N K
FH M 2
RIGHT BANK
FULLY AU TO M ATIC H EALTH C ARE G AS M ANIFO LD
W ESTERN IN NO VATO R
875 BASSETT RO AD
W ESTLAK E,O H IO 44145
1-800-78 3-7890
Header Check Valves
FIGURE 2-1 External Components
Pressure is regulated 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. The primary regulators have two ports on the
low pressure side. One port is connected to the intermediate relief valve and intermediate pressure gauge. The other
port is the outlet port and is connected via fittings to the solenoid valves.
The gas flows from the primary regulators to the solenoid valves. The solenoid valves are either open or closed depending on which side is in “Service” and whether the “Reserve” cylinders have adequate pressure. The solenoid valve on the
side that is in “Service” will be open. The solenoid valve on the “Reserve” side will be closed if the cylinder pressure on
that side is above the pressure transducer setting. The “Service side is determined by whichever side of the manifold is
initially pressurized.
Gas on the “Reserve” side is stopped at this point by the closed solenoid valve. The gas from the “Service” side continues to flow, entering a check valve after leaving the solenoid valve. The check valve prevents the gas from flowing backward toward the solenoid valve when the reserve side is in use.
2-1
B20353 ECN-13787 (0701)
LEGEND
1
1– Outlet Adaptor
18
2– Line Pressure Gauge
3– Ball Valves
2
15
17
14
6
4– Line Regulators
5– Intermediate Relief Valve
4
6– Bleed Valve
4
3
8
7– Pressure Switch
8
8– Intermediate Check Valves
7
9– Left Inlet Block
12
16
10– Primary Regulator
11– Intermediate Test Gauge
12– Relief Block
21
13– High Pressure Transducer
19
19
14– Line Pressure Transducer
15– Intermediate Pressure
Relief Connection
11
10
10
5
5
16– Intermediate Block
17– Line Pressure Relief Valve
13
13
18– Relief Outlet Connection
19–Solenoid Bypass Check Valve
20
9
20– Right Inlet Block
21 – Solenoid Valves
FIGURE 2-2 Internal Components – FHM2 & FHM2HP
2-2
B20353 ECN-13787 (0701)
LEGEND
1
18
1– Outlet Adaptor
2– Line Pressure Gauge
15
3– Ball Valves
4– Line Regulators
17
2
6
14
4
4
5– Intermediate Relief Valve
3
6– Bleed Valve
8
8
7– Pressure Switch
8– Intermediate Check Valves
7
16
12
9– Left Inlet Block
10– Primary Regulator
11– Intermediate Test Gauge
12– Relief Block
21
19
19
13– High Pressure Transducer
14– Line Pressure Transducer
11
10
15– Intermediate Pressure
Relief Connection
10
5
16– Intermediate Block
13
13
17– Line Pressure Relief Valve
18– Relief Outlet Connection
19– Solenoid Bypass Check Valve
9
20– Right Inlet Block
20
22
21 – Solenoid Valves
22 – Heater Unit*
*Note: Carbon Dioxide an Nitrous Oxide units ordered without a heater do not include item 22.
FIGURE 2-3 Internal Components – FHM2HL
2-3
B20353 ECN-13787 (0701)
Line Pressure Transducer
Line Pressure Gauge
Bleeder Valve
Line Relief Valve
Ball Valve
Ball Valve
Line Regulator
Line Regulator
Pressure Switch
Check Valve
Check Valve
Solenoid Valve
Solenoid Valve
Bypass Solenoid
Check Valve
Bypass Solenoid
Check Valve
Intermediate Pressure Gauge
Intermediate Pressure Gauge
Intermediate Relief Valve
Intermediate Relief Valve
Left Primary Regulator
Right Primary Regulator
Pressure Transducer
Pressure Transducer
FIGURE 2-4 Piping Schematic – FHM2 & FHM2HP
Bleeder Valve
Line Pressure Transducer
Line Relief Valve
Line Pressure Gauge
Ball Valve
Ball Valve
Line Regulator
Line Regulator
Pressure Switch
Check Valve
Check Valve
Solenoid Valve
Solenoid Valve
Bypass Solenoid
Check Valve
Bypass Solenoid
Check Valve
Intermediate Pressure Gauge
Intermediate Pressure Gauge
Intermediate Relief Valve
Intermediate Relief Valve
Left Primary Regulator
Right Primary Regulator
Pressure Transducer
Pressure Transducer
Heater
FIGURE 2-5 Piping Schematic - FHM2HL
2-4
B20353 ECN-13787 (0701)
FIGURE 2-6 Electrical Schematic (less heater)
The gas from the open solenoid valve is routed through the check valve to the intermediate block assembly. The intermediate block has 4 ports all connected to the same chamber. The gas pressure at all 3 ports is the same as the pressure at the inlet to the block. Gas enters the intermediate block from the “Service” supply through the tubing connected
at either the right or left side, depending on which side is in service. The opposite side would then be the reserve side.
The top port connects to the inlet of the dual line assembly. The bottom port is connected to a pressure switch.
The pressure switch monitors the intermediate pressure. Should the intermediate pressure drop below a preset level the
switch will indicate an alarm condition that changeover has occurred. The switch provides a redundant feature to ensure
proper changeover and alarming has taken place. The intermediate pressure relief valves prevents over-pressurization
of the intermediate controls of the manifold should the primary regulators fail. The relief valve settings are noted in the
adjustment specification chart in Section 1.
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 pressure is reduced to the line pressure which is shown on the
line pressure gauge and on the digital display on the front of the cabinet. The line relief valve prevents overpressurization
should the line regulator fail. The relief valve settings are noted in the adjustment specifications chart in Section 1.
FIGURE 2-7 Heater Electrical Schematic
2-5
B20353 ECN-13787 (0701)
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 delivery outlet port is located
180° from the inlet.
Gas flows out of the line regulator and into the outlet block. The outlet block has 4 ports. A line relief valve is connected to
the right port. The center port is connected to a line pressure gauge and bleeder valve. The left port is connected to the
line pressure transducer, which displays the line pressure on the front of the cabinet. The top port is connected to the piping distribution system. The pressure relief valve outlet port should be routed to the outside of the building for manifolds
located indoors.
When both cylinder banks are full, the transducers and the switch complete the electrical circuit to display the green
“system normal” light of the primary bank, and a yellow “ready for use“ light for the secondary bank. Cylinder pressures for
each bank are indicated on the readouts on the manifold front cover. As stated, the “Service” supply is determined by
which bank is pressurized first. The intermediate pressure is indicated by the gauges located on the respective primary
regulator. The line pressure is indicated by the digital readout, as well as, the gauge located on the outlet block.
As the gas from the “Service” supply is depleted, the gas pressure to the “Service” primary regulator will begin to fall.
Simultaneously, the pressure to the pressure switch, intermediate block, and the line regulator also falls. When the
“Service” side pressure falls below the set point of the bank pressure transducer, the red “bank depleted” light comes on
and the green “in service” light is extinguished. Any remote alarms are activated at this time. When the “Service” pressure
falls to the set point of the pressure transducer, the solenoid valve opens and the secondary supply begins to supply the
system.
After replacing empty cylinders and opening the cylinder valves, the pressure transducer will extinguish, the red “bank depleted” light, and the yellow “ready for use” light will come on energizing the secondary bank solenoid valve. 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
B20353 ECN-13787 (0701)
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 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 compressed, the gas pressure required to lift the diaphragm increases,
resulting in a higher delivery pressure from the outlet port of the
regulator.
Cap
Spring
Seat
Washer
Gas from Solenoid Valve
Gas from Intermediate Block
FIGURE 2-9 Check Valve
CHECK VALVES
The check valves prevent gas from flowing backward, See Figure 2-9.
Gas enters the check valve from the solenoid valves 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.
SOLENOID BYPASS
The bypass is to provide gas to the outlet of the solenoid in case the outlet fitting leaks. The bypass will
ensure that the maximum pressure differential across
the solenoid is not exceeded.
Gas enters the inlet of the bypass check valve from the
solenoid inlet. Gas also enters the outlet of the bypass
from the outlet of the solenoid. During normal operation
the inlet and the outlet pressures are equal. The bypass check valve is set around 130 psig, (it takes 130
psig differential from the inlet to the outlet to open the
bypass check valve). The only time this check valve will
open is if the solenoid outlet fitting leaks. If the outlet
fitting leaks, the bypass check valve will open and permit gas to flow. This flow of gas will ensure that the
maximum allowable differential pressure of the solenoid
is not exceeded.
FIGURE 2-10 Solenoid Bypass Valve
2-7
B20353 ECN-13787 (0701)
SOLENOID VALVES
The solenoid valves are the heart of the manifold for maintaining the stand-by or reserve bank. The solenoid valves are
constructed of two basic functional units: a solenoid (electromagnet) with its core and a valve body containing one or
more orifices. See Figure 2-11. Flow through an orifice is stopped or allowed by the action of the core when the solenoid is energized or de-energized. The solenoid is mounted directly on the valve body. The core is enclosed and free to
move in a sealed tube providing a compact, packless assembly.
The valve has a pilot and bleed orifice and utilizes the line pressure for operation. When the solenoid is energized, the
pilot orifice is closed and full line pressure is applied to the top of the diaphragm through the bleed orifice, thereby providing a seating force for tight closure. When the solenoid is de-energized, the core opens the pilot orifice and relieves
pressure from the top of the valve diaphragm to the outlet side of the valve. This results in an unbalanced pressure
which causes the line pressure to lift the diaphragm off the main orifice, thereby opening the valve.
FIGURE 2-11
PRESSURE SWITCH
The pressure switch is used as a redundant safety
feature to signal “Secondary in Use”. The switch is a
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 the normal pressures, the piston in the switch is pushed up. The piston pushes the activator of the switch up.
End View
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.
Adjusting Screw
Pressure Port
Side View
FIGURE 2-12 Low Pressure Switch
The switch completes the electrical circuits to the indicators on the front of the control section and to the
remote alarm interface board in the power supply box.
FIGURE 2-13 Switch Schematic
2-8
B20353 ECN-13787 (0701)
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 inlet port is piped to the outlet of the manifold control assembly. One outlet
port is piped to the outlet of the dual line assembly for connection to the main pipeline. 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 compressed, the gas pressure required to lift the diaphragm increases, resulting in a higher delivery pressure from the outlet port of the regulator.
FIGURE 2-14 Line Regulator
PRESSURE TRANSDUCER
The pressure transducers vary their outlet voltage depending on the pressure being supplied. The voltage output is
monitored by the manifold PCB. The voltage is converted to a pressure reading which is displayed on the PCB.
The line pressure transducer is used only to display the delivery pressure of the manifold. The bank pressure transducers display inlet pressures, opens and closes the solenoid valves, and signals when changeover has occurred.
2-9
B20353 ECN-13787 (0701)
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2-10
B20353 ECN-13787 (0701)
SECTION 3
FIELD TESTING & TROUBLE SHOOTING
The manifold performance tests are used to verify the manifold functional performance. When used in conjunction with
the troubleshooting 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 full cylinders may result in improperly set
components.
PERFORMANCE VERIFICATION PROCEDURE
1. Open the manifold as explained in Section 4.
11. Create a slight flow of gas through the bleeder valve.
The left bank intermediate gauge should settle and
remain constant.
2. Connect the electrical power source to the
manifold and verify that the 2 red, 2 yellow, and 2
green lights are on and the 3 pressure displays are
12. Turn off the flow of gas through the manifold.
illuminated. (The manifold will go through a start up
sequence that lasts about 15 seconds when power is 13. Verify that the intermediate gauge indicated the pressupplied)
sure as shown in the specification chart in Section 1
for the primary regulator.
3. Open the master valves located on the cylinder
header prior to pressurizing the manifold.
14. Observe the test gauge for two minutes. Verify that
the primary regulator does not exhibit “creep” and/or
increase in pressure.
4. S-l-o-w-l-y open one cylinder valve on the left bank
of cylinders.
15. Verify that the left side cylinder contents gauge indicates a minimum of 2000 psig for Oxygen, Nitrogen,
5. S-l-o-w-l-y open cylinder valve on the right bank
Air, or gas mixtures. Nitrous Oxide and Carbon Dioxof cylinders.
ide systems should indicate a minimum of 750 psig.
Adjust to the proper line pressure if necessary.
6. Using a leak detect solution, verify that there are
no leaks present at the connections.
16. Verify the line pressure gauges is indicating a minimum of 50 psig on all system except Nitrogen. Nitro7. Close the cylinder valves on the left and right banks
gen should indicate a minimum of 160 psig. Adjust
of cylinders.
to the proper line pressure if necessary.
8. Open the bleeder valve to create a slight gas flow
17. Open the bleeder valve to create a slight flow of
through the manifold. Vent the system until all gas
gas through the manifold.
has been removed from the manifold.
9. Close the bleeder valve.
10. S-l-o-w-l-y open one cylinder valve on the left bank
of cylinders.
18. Observe the intermediate gauge and verify the
primary regulator setting under a flow condition.
Adjust the left primary regulator as necessary to
obtain the required pressure.
19. Turn off the left cylinder valve and allow all gas to
vent from the manifold.
20. Close the bleeder valve.
3-1
B20353 ECN-13787 (0701)
21. S-l-o-w-l-y open one cylinder valve on
the right bank of cylinders.
22. Complete steps 11-21 for the right
primary regulator.
23. Close the bleeder valve.
24. Pressurize the right bank by opening one
cylinder valve.
25. 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.
26. Open the bleeder valve to create a slight
flow of gas through the manifold.
35. Close the cylinder valve on the left bank of cylinders.
36. Observe the cylinder contents gauges: the left bank
gauge should begin to drop; the right cylinder bank
should remain constant.
37. Observe the intermediate gauge as the right 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 208 psig before
the opposite solenoid valve opens. (see specification
chart in Section 1)
38. S-l-o-w-l-y open one cylinder valve on the left bank of
cylinders.
39. Verify that the intermediate gauge has returned to the
set pressure of the primary regulator.
40. Close the bleeder valve.
27. Verify that the line pressure regulator
maintains a constant pressure by
observing the line pressure gauge.
28. S-l-o-w-l-y open one cylinder valve on the
left bank of cylinders.
29. Observe the cylinder contents pressure
gauges to verify cylinder pressure.
33. Close the cylinder valve on the right bank
of cylinders.
31. Observe the cylinder contents readouts: the
right cylinder bank pressure should begin to
drop; the left cylinder bank reading should
remain constant
32. Observe the right 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 208 psig before the opposite
solenoid valve opens. (see Specification Chart
in Section 1)
33. S-l-o-w-l-y open one cylinder valve on
the right bank of cylinders.
34. Verify that the intermediate gauge has returned to the
set pressure of the primary regulator.
41. Disconnect the 3 wires from the manifold wiring harness that leads to the intermediate pressure switch.
Note: Alarm will sound and red indicator lights will be
lit.
42. Connect an ohmmeter across the black and brown
wires of the wiring harness. The ohmmeter should
indicate approximately zero (0) ohms resistance. If
the ohmmeter does not indicate approximately zero
(0) ohms, connect the meter across the normally open
(N/O) and common (C) terminal on the pressure
switch. The ohmmeter should register approximately
zero (0) ohms resistance when connected to the
switch. Adjust or replace the faulty switch. (See Section 4 for servicing the pressure switches). Disconnect
the ohmmeter leads from the black and brown wires.
43. Close the Cylinder valve on the left bank of cylinders.
44. Open the bleeder valve to create a slight flow of gas
through the manifold.
45. 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.
46. S-l-o-w-l-y open one cylinder valve on the left bank of
cylinders.
3-2
B20353 ECN-13787 (0701)
47. Verify that the ohmmeter returns to
approximately zero (0) ohms resistance.
57. Verify that the red light illuminates and the yellow light
on the secondary bank changes to green when the
manifold changes over from service to secondary
supply.
48. Remove the ohmmeter leads from the black
and brown wires.
58. S-l-o-w-l-y open one cylinder valve on the depleted
bank of cylinders.
49. Connect the switch wires to the manifold
wiring harness.
59. Observe the cabinet system status indicators. Verify
that the green and yellow indicators are lit and the red
indicators are off.
50. Close all cylinder valves and vent all remaining
gas from the manifold.
51. Close the bleeder valve.
60. Close the cylinder valve on the service bank of cylinders.
52. Observe the cabinet status indicators.
Verify that both the green indicators and
both the red indicators are illuminated.
61. Verify that the red light illuminates and the yellow light
is extinguished when the manifold changes over from
service to secondary supply.
53. S-l-o-w-l-y open the cylinder valve on the
left and right banks of cylinders.
62. Close the bleeder valve and test for leaks using a leak
detect solution.
54. Observe the cabinet status indicator. Verify
that the green and yellow indicators are lit and
both red indicators are off .
63. S-l-o-w-l-y open all cylinder valves on the left and
right banks of cylinders.
55. Close the cylinder valve on the service bank
of cylinders.
64. Reinstall the manifold section cover as explained in
Section 4.
56. Open the bleeder valve to create a slight
flow of gas through the manifold.
3-3
B20353 ECN-13787 (0701)
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.
Loose bonnet
Tighten bonnet.
Pressure regulator body and bonnet
Diaphragm leak.
Replace diaphragm.
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.
Flow capacity too high.
Reduce flow capacity.
Solenoid faulty.
Replace solenoid.
Power not reaching the solenoid.
Check all wiring connections.
Power not reaching the solenoid.
Check all wiring connections.
PCB not driving solenoid.
Component failure on PCB.
PRIMARY REGULATOR
LINE PRESSURE REGULATOR
SOLENOID VALVES
Gas leakage through a
close solenoid.
Solenoid not actuating
properly (not “clicking”
during power-up - v4.0.x
and up).
Replace PCB.
PCB configured for HGM2.
Check DIP switch settings.
Solenoid faulty.
Replace solenoid.
3-4
B20353 ECN-13787 (0701)
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
Electrical System
No indicator lights or displays
on front panel come on when
power is hooked up.
Power Input.
Check electrical power supply.
Red indicator light(s) on but
both banks are full.
Master valve, header valves, or
cylinder valves on bank are closed.
Slowly open valves.
Wiring to pressure transducer
not correct.
Check internal leads to the
pressure transducer.
Red indicator light does not come
on when one bank is empty and
changeover occurs.
Change-over occurring at too high a
pressure.
Check transducers and pressure
switch setting.
Green indicator light does not
come on even though both banks
are full.
New “service” side set without
changing empty cylinders.
Replace depleted cylinders.
Pressure transducer wiring incorrect
or disconnected.
Check pressure transducer wiring.
Pressure transducer reading
too high a pressure.
Replace pressure transducer.
Display reads “0” even when
pressure is present.
Pressure transducer wiring
disconnected or faulty.
Check pressure transducer
and controller board connections.
Display incorrect.
Pressure transducer faulty.
Dip switches set incorrectly.
Replace transducer
Check setting of the Dip switches.
One or both of the red indicators
are blinking.
Pressure transducer faulty.
Non-volatile memory failure
Replace transducer
Replace the controller board.
No display on the green indicator
flashing.
Input out of range during calibration
routine.
Adjust the line and primary
regulators prior to calibration.
3-5
B20353 ECN-13787 (0701)
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
“RESERVE IN USE” SIGNAL
Remote alarm signal stays in
one mode constantly
regardless of changeover
status.
Remote alarm signals are
opposite of manifold status.
Power supply wiring is incorrect.
Check wiring connection on
both power supply terminal strips.
Flow demand too high.
Reduce flow demand.
Power supply PCB defective.
Replace power supply PCB.
Faulty connection to remote
alarm unit.
Check input from alarm unit to
terminal strip.
“ABNORMAL” LINE PRESSURE SIGNAL
Low pressure alarm activated.
High pressure alarm activated.
Line pressure regulator
improperly adjusted
Readjust line pressure regulator.
Closed master valves, header
valves, or cylinder valves.
Slowly open valves.
Empty cylinders.
Replace with full cylinders.
Line regulator setting too high.
Readjust line pressure regulator.
Regulator freeze-up.
(Nitrous Oxide or Carbon Dioxide)
Reduce the flow demand or
increase the number of supply
cylinders.
Faulty pressure transducer.
Replace pressure transducer.
Faulty PCB.
Replace PCB.
Leakage at manifold piping
connections.
Tighten, reseal or replace.
Leakage in downstream piping
connections.
Tighten, reseal or replace.
Leakage at manifold tubing
system.
Repair as necessary.
LOSS OF CYLINDER CONTENTS
Audible or inaudible gas leakage
(origin unknown).
3-6
B20353 ECN-13787 (0701)
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
Leakage at cylinder valve.
Replace cylinder valve.
Gauge leaks.
Reseal or replace.
Regulator leaks.
Repair or replace.
Line regulator setting too high.
Set delivery pressure to
specification.
Overpressure due to creeping or
faulty regulation by primary regulator.
Replace regulator seat and nozzle
components.
Regulator freeze-up.
(Nitrous oxide or Carbon Dioxide)
Reduce the flow demand or
increase the number of supply
cylinders.
Heater failure.
(Nitrous oxide or Carbon Dioxide)
Reduce the flow demand or
increase the number of supply
cylinders.
Loose bonnet.
Tighten bonnet.
Diaphragm leak.
Replace diaphragm.
Valve packing leaks.
Tighten packing nut.
Faulty valve.
Repair or replace valve.
Solenoid valve seat leak.
Replace solenoid valve.
Faulty primary regulator.
Replace regulator seat and nozzle
components.
Loss of electrical power.
Check electrical power supply.
Faulty primary regulator.
Replace regulator seat and nozzle
components.
Faulty solenoid bypass check
valve.
Replace solenoid bypass.
Solenoid valve wiring incorrect.
Swap wiring from one solenoid
valve to the other.
LOSS OF CYLINDER
CONTENTS (continued)
Audible or inaudible gas leakage
(unknown origin). (continued)
Venting at relief valve.
Gas leakage around regulator
body or bonnet.
Gas leakage around valve
stem or packing nut on master
valve or header valve.
LOSS OF RESERVE BANK
CONTENTS.
Both banks feeding.
Opposite bank feeding.
3-7
B20353 ECN-13787 (0701)
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
Premature changeover to
reserve bank.
Flow demand too high.
Readjust line pressure regulator.
Faulty Transducer
Replace Transducer.
Faulty PCB.
Replace PCB.
Pipeline not at desired pressure.
Line regulator not set correctly.
Adjust line regulator.
Required gas flow not available.
Line regulator not set correctly.
Adjust line regulator.
Flow demand too high.
Consult factory.
Leakage at outlet fitting of the
solenoid that will not open.
1. Remove power from the system.
2. Close valves on the cylinders.
3. Deplete gas from the headers by
cracking open a fitting.
4. Tighten solenoid outlet fitting.
5. Open the cylinder valves.
6. Reconnect power to the manifold.
Primary regulator set pressure
150 psig higher than the change
over pressure.
1. Remove power from the system.
2. Close valves on the cylinders
3. Deplete gas from the headers by
cracking open a fitting.
4. Reset the primary regulator.
5. Open the cylinder valves.
6. Reconnect power to the manifold.
PIPELINE DISTRIBUTION
MANIFOLD LOCKS UP OR
WON’T FLOW
Reserve bank won’t flow, or
the manifold locks up and
neither bank will flow.
3-8
B20353 ECN-13787 (0701)
SECTION 4
SERVICE PROCEDURES
GENERAL MAINTENANCE
1. Main section
a) Daily
1) 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
1) 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.
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 pressurizing 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
B20353 ECN-13787 (0701)
CLEANING, LUBRICATION, AND SEALING
Clean metal parts of the manifold with isopropyl alcohol or oxygen compatible media prior to assembly. Dry thoroughly.
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.
Assembly and Disassembly of Compression Fittings
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. Tighten the nut with an appropriate 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.
(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 part numbers.
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
B20353 ECN-13787 (0701)
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.
Note: When servicing a manifold component with a repair kit, use all components supplied with the kit.
HOW TO OPEN THE MANIFOLD
Door Open
1. Turn the latch counter-clockwise and open the door.
Door Closed
1. Close door and rotate knob clockwise until secure.
MANIFOLD CABINET COVER REMOVAL
Disassembly
1. Open the manifold as explained in the “How to open the manifold” section.
2. Disconnect the two wire harness terminal blocks from the manifold PCB.
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
B20353 ECN-13787 (0701)
HOW TO DEPLETE THE SECONDARY BANK
1. Open the manifold as explained in the “How to open the manifold” section.
2. Close the cylinder on the “secondary” bank.
3. Mark the compression fitting at the outlet of the primary regulator per compression fitting instructions on page 4-2.
4. 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. If a different fitting is used, there may be pressure trapped in the secondary bank.
5. 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.
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.
2. Open the manifold as explained in the “How to open the manifold” section.
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.
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
2. Using a 9/16 open end wrench remove the subject pressure gauge from the system.
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.
3. Re-assemble the case per the “How to shut down the manifold” and “How to open the manifold” sections.
4-4
B20353 ECN-13787 (0701)
PRIMARY REGULATOR REPAIR
NOTE:
• Removal and Replacement procedures are to be followed only if the primary regulator assembly is to be discarded. All service may be performed to the primary regulator without removing it from the manifold, as long
as the regulator is properly supported.
•
Shutdown the manifold and open the manifold as explained in the “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”.
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 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 3/4" hex 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 oxygen compatible media.
6. Blow out the regulator body and ports with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces.
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 of debris may be propelled into unprotected eyes.
4-5
B20353 ECN-13787 (0701)
Reassembly
1. Apply a thin coating of Krytox® lubricant or oxygen compatible equivalent to the o-rings.
NOTE:
• 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 compression fitting to the primary regulator finger tight.
3. Tighten the CGA connection on the regulator inlet using two 1 1/8 wrenches.
4. Using an 11/16” open end wrench, connect the outlet and relief tubing to the 3/8” tube compression fittings. When
retighting the compression fittings, follow the procedure outlined on page 4-2.
4-6
B20353 ECN-13787 (0701)
PRIMARY REGULATOR 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. If the bank is not pressurized, s-l-o-w-l-y open the cylinders on the side of the regulator to be adjusted.
4. Verify the cylinder pressure readout indicates a minimum pressure of 2000 psig for Oxygen, Air, and Nitrogen systems or a minimum of 700 psig on Nitrous Oxide and Carbon Dioxide systems.
5. Create a slight flow of gas by cracking open the bleeder valve.
6. Using a flat blade screwdriver, turn the adjusting screw of the regulator while observing the test 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.
7. Close the bleeder valve. The test gauge will go up slightly higher than the flowing adjusted pressure.
8. 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.
9. Install the nut on the primary 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.
2. 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.
3. Using an open end wrench, remove the pressure switch from the intermediate block.
• CAUTION:
The alarm will trigger upon disconnecting the wires.
Replacement
1. Apply Teflon® tape to the male threads, making sure not to cover the first thread.
2. Using an open end wrench; install the pressure switch on the intermediate block and tighten to effect a gastight seal.
3. Complete the adjustment instructions below prior to installing the signal wires to the pressure switch.
Pressure Switch Adjustment
1. Mark and disconnect the three wires from the pressure switch.
2. Connect an ohmmeter to the normally closed and common electrical contacts on the switch. The ohmmeter should
register zero resistance.
3. Begin pressurizing the service bank manifold by opening one cylinder valve on the service side of the manifold.
At the actuation pressure, the ohmmeter reading will jump from zero resistance to infinite resistance.
4. Close the cylinder valve.
5. 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 zero
resistance.
4-7
B20353 ECN-13787 (0701)
6. Close the bleeder valve.
7. Using a allen wrench, 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.
8. 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.
WARNING:
• Be sure power is off when electrical connections are made. Current flowing though the wires may shock
the service technician, or damage the Ohmmeter or pressure switch.
9. 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 solenoid 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 oxygen compatible media.
CAUTION:
• Do not stand directly in front 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
B20353 ECN-13787 (0701)
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 to 35 ft-lbs. torque.
Replacement
1. Position the check valve and tube assembly in the control section with the check valve flow arrow pointing towards
the back of the manifold.
2. Connect the compression fittings to the solenoid 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.
SOLENOID VALVE REPAIR
Refer to Figure 4-8
CAUTION:
• Solenoid valve may be hot when energized.
Disassembly
1. Shutdown the manifold as explained earlier in this section.
2. Disconnect the electrical wires at the wire nut attachment points.
CAUTION:
• When metal retaining clip disengages, it could spring upwards.
3. Remove the retaining cap or clip, spacer, nameplate, and cover.
4. Slip entire solenoid enclosure off the solenoid base sub-assembly.
5. Unscrew the solenoid base sub-assembly and remove the core, plugnut, gasket, plugnut assembly, and solenoid
base gasket.
6. Remove the four valve bonnet screws, valve bonnet, disc holder sub-assembly, disc holder spring, diaphragm/spring
sub-assembly, and body gasket.
NOTE:
• Should diaphragm/spring sub-assembly become disassembled, be sure to replace the diaphragm/spring
support with the lip facing upward towards the valve bonnet.
4-9
B20353 ECN-13787 (0701)
Reassembly
1
Reassemble in reverse order of disassembly paying careful attention to exploded views provided for identification
and placement of parts (see Figure 4-8).
2. Replace body gasket and diaphragm/spring sub-assembly. Locate bleed hole in diaphragm/spring sub-assembly
approximately 45° from valve outlet. Replace the disc holder spring and disc holder sub-assembly.
3. Replace valve bonnet and bonnet screws, sliding valve under mounting bracket and lining up screw mounting holes.
Torque bonnet screw in a crisscross manner to 110 ± 10 in-lbs.
4. Install solenoid base gasket, plugnut assembly and plugnut gasket. Position core, small end up, on plugnut assembly.
5. Replace solenoid base sub-assembly and torque 117 ± 25 in-lbs.
WARNING:
• Be sure power is off when electrical connections are made. Current flowing through the wires my shock the
service technician.
6. Replace solenoid enclosure and retaining cap or clip.
7. Connect the wires to the appropriate wires coming from the manifold controller PCB.
8. After maintenance, restore power to the system and operate the valve several times to be sure of proper opening
and closing.
4-10
B20353 ECN-13787 (0701)
Retaining Clip
Washer
Solenoid Valve
Spring Washer
*Diaphragm Return Spring
*Plunger Tube Assembly
*Plunger Tube
Assembly Gasket
Torque plunger tube assembly
to 117± 25 inch-pounds.
Hand tighten all cover screws (4)
first. Torque cover screws in a
crisscross manner to 110± 10 inch
pounds.
Cover
Assemble tab over “out” port.
*Diaphragm Assembly
*Body Gasket
Body
* Parts included in
rebuild kit
FIGURE 4-8 Parker Solenoid Valve
4-11
B20353 ECN-13787 (0701)
LINE REGULATOR REPAIR
Refer to Figure 4-9
Removal
1. Turn the two ball valves to feed the reserve line regulator and close the two ball valves to isolate the service regulator. The manifold does not have to be shut down.
2. Using 7/8” and 1” wrenches, disconnect the union connections on both sides of the regulator.
3. Carefully remove the line regulator from the manifold.
Disassembly
1. Place the regulator in a vise or similar holding fixture.
2. Using an 11/16” open end wrench, loosen the locknut on the regulator adjusting screw and back off the adjusting
screw until it turns freely and all compression is removed from the bonnet spring.
3. Using a 1-1/2” hex wrench, remove the backcap and conical spring from the regulator.
4. Remove the gasket from the backcap and discard.
5. Use a phillips head screwdriver to remove the six screws attaching the bonnet to the body. Lift the bonnet off of the
body and set aside the bonnet, pivot, bonnet spring, and screws.
6. The diaphragm assembly and the seat/stem assembly are attached at each end of the stainless steel rod. The
stainless steel rod is threaded on both ends. Using a 5/8” hex wrench to stabilize the diaphragm assembly, reach
under the regulator with a 1/4” open end wrench, placing it over the wrench flats provided on the bottom of the seat
assembly, and loosen the seat assembly. The seat can be unscrewed by hand after loosening. Remove and discard
the diaphragm and seat assemblies.
Reassembly
1.
Set the new diaphragm assembly on the body with the spring retainer facing up.
2.
Insert the new stem/seat assembly through the backup port and screw into the diaphragm assembly by hand.
Stabilize the diaphragm assembly using one hand and snug up the seat/stem assembly with the other hand using
a 1/4” open wrench. Do not over tighten.
3.
Place the new gasket in the backcap groove.
4.
Place the conical spring, large end first, into the backcap cavity.
5.
Carefully line up the spring small end so that it slides over the wrench flats on the seat/stem assembly and screw
the backcap into position. Tighten with a 1-1/2” hex wrench.
6.
Line up the diaphragm holes with the screw holes in the body.
7.
Set the bonnet spring in the retainer on the diaphragm assembly.
4-12
B20353 ECN-13787 (0701)
8.
Set the pivot on top of the spring, pointed end down.
9.
Set the bonnet carefully over the spring and pivot and line up the screw holes in the bonnet with the screw holes in
the body.
10. Insert the screws in the screw holes and tighten by hand. Use a phillips head screwdriver and tighten the screws in
a crisscross manner.
11
Remove the regulator from the vice.
Replacement
1.
Install the regulator in the manifold, following the removal procedure in reverse order.
2.
Leak test all of the line regulator connections and the connections on the check valve.
Locknut
Adjusting
Screw
Bonnet
Pivot
Bonnet
Spring
Diaphragm
Assembly
Spring
Retainer
Bonnet
Screw
Body
Stainless Steel Rod
(Stem)
Conical
Spring
Gasket
Seat/Stem Assembly
Backcap
FIGURE 4-9 Line Regulator
4-13
B20353 ECN-13787 (0701)
PCB Replacement
Removal
1. Open the manifold as explained in the “How to open the Manifold” section.
2. Remove power by disconnecting the cable from the power supply.
3. Remove the 4 hex nuts holding the PCB cover in place.
4. Remove the 2 wire clips from the PCB.
5. Pop the PCB off the door.
Replacement
1. Align the PCB on the standoffs and carefully press into place.
2. Install the two wire clips to the PCB.
3. Install the PCB cover and tighten the 4 hex nuts.
4. Reconnect power.
4-14
B20353 ECN-13787 (0701)
ELECTRICAL POWER-UP
Software version 4.0.x and higher*:
1. When power is applied to the manifold, the displays will cycle through a power-up sequence before displaying pressure. This process takes approximately 12 seconds.
• All six status indication lights will be lit.
• A solenoid test will be performed on each bank. The left green
status light will turn off and on, followed by the right green status Switches
light. A noticeable “click” can be heard from each solenoid valve.
• The state of the DIP switches will be shown on the right bank display
and right most digits of the left bank display. A “1” represents each
open switch; a “0” for closed.
• The status lights will extinguish in the order: green, yellow, red for
each bank.
• Each digit of the displays will read “8”.
• A pressure switch status test will be conducted. If the red and green
status lights are on, the pressure switch is in an open state (no inlet
pressure, wired incorrectly, broken connection). Otherwise, no status lights will be on.
• Each digit of the display will be lit individually.
2. The displays and status indicators will then be allowed to operate normally.
Software version 2.02*:
1. When power is applied to the manifold, the displays will first cycle through a power-up sequence before displaying
pressure. This process takes approximately 16 seconds.
• All six status indication lights will be lit.
• The lights will turn off sequentially.
• The status of the DIP switches will be shown on the digits of the right bank display and the right most digits of the
left bank display. A “1” represents each open switch; a “0” for closed.
• Each digit of the displays will read “8”.
• Each digit of the displays will be lit individually.
2. The displays and status indicators will then be allowed to operate normally.
* Software version located on back of PCB
4-15
B20353 ECN-13787 (0701)
UNITS OF MEASURE
1. The FHM2 manifold can be configured to display pressure in PSI, KPa or BAR. The manifold is shipped with PSI
as the default unit of measure. To switch the units, proceed to step 2. If PSI units are desired, no changes are
necessary and step 2 may be skipped.
2. To change the units, perform the following steps:
• Remove power to the manifold (switches are only read during power-up).
• Open the door of the manifold.
• Locate the DIP switches at the bottom edge of the PC Board on the door.
• For PSI set the switches as shown:
Model FHM2
Model FHM2HL
Model FHM2HP:
(Switch Position)
• For KPa set the switches as show:
Model FHM2
• For BAR set the switches as shown:
Model FHM2
Model FHM2HL
Model FHM2HP:
Model FHM2HL
Model FHM2HP:
• Close the cover and reconnect power to the manifold.
• Verify that during power-up the status of the switches are displayed on the digits of the right bank display and
the right most digit of the left bank display as a series of “1”s and “0”s as follows:
4-16
B20353 ECN-13787 (0701)
DIP SWITCH/DISPLAY OPTION
• For PSI:
Model FHM2
Left Display
11
Right Display
01110
• For KPA;
Model FHM2
Left Display
01
Right Display
01110
Model FHM2
00
Left Display
11
Right Display
01010
Left Display
01
Right Display
01010
01110
Left Display
00
11
Right Display
00110
Left Display
01
Right Display
00110
Model FHM2HP:
Model FHM2HL
Right Display
Left Display
Model FHM2HP:
Model FHM2HL
• For BAR:
Left Display
Model FHM2HP:
Model FHM2HL
Right Display
01010
Left Display
00
Right Display
00110
4-17
B20353 ECN-13787 (0701)
TRANSDUCERS – HIGH PRESSURE
Removal
1. Shutdown and open the manifold as explained in the “How to shut down the Manifold” and “How to open the
Manifold” sections.
NOTE:
• This item may be replaced without shutting down the manifold completely. To work on the manifold while it is still
in service follow the steps in “How to open the Manifold” and “How to deplete the Service Bank” sections.
2. Using a 7/8” open end wrench turn the high pressure transducer counter-clockwise. If gas is heard escaping, stop
rotating the transducer and wait for the trapped pressure to deplete.
3. Clean any remnant of Teflon® tape from the port on the inlet block.
Replacement
1. Apply Teflon® tape to the 1/4 NPT thread on the new transducer, leaving the first thread exposed.
2. Using a 7/8” open end wrench thread the transducer into the inlet block.
TRANSDUCER – LINE PRESSURE
Removal
1. Shutdown and open the manifold as explained in the “How to shut down the Manifold” and “How to open the Manifold” sections.
NOTE:
• The manifold must be fully shut down in order to replace the line pressure transducer.
2. Using a 7/8” open end wrench turn the high pressure transducer counter-clockwise. If gas is heard escaping, stop
rotating the transducer and wait for the trapped pressure to deplete.
3. Clean any remnants of Teflon® tape from the port on the inlet block.
Replacement
1. Apply Teflon® tape to the 1/4 NPT thread on the new transducer, leaving the first thread exposed.
2. Using a 7/8” open end wrench thread the transducer into the inlet block.
4-18
B20353 ECN-13787 (0701)
This page intentionally left blank
4-19
B20353 ECN-13787 (0701)
SECTION 5
MANIFOLD MAINTENANCE & REPAIR PARTS
REPLACEMENT PIGTAILS
24” Stainless Steel Flexible Braid with Check Valves
PFP-320CV-24 ...............CGA 320 for Carbon Dioxide (CO2) Service
PFP-326CV-24 ...............CGA 326 for Nitrous Oxide (N2O) Service
WPR-63CV-24 ................CGA 540 for Oxygen (O2) Service
PFP-92CV-24 .................CGA 580 for Inert Gas Service (N2) except Helium
PFP-346CV-24 ...............CGA 346 for Breathing Air (Air) Service
24” Synthetic Fiber Braid Hose with Check Valve
PFS-92CV-24 .................CGA 580 for Helium (He) Service (for non medical service).
GAUGES – 2” Diameter, 1/4” NPT Back Port
WMG-3-3 ........................100 psi…..Line gauge FHM2, FHM2HL
WMG-3-4 ........................400 psi…..Line gauge FHM2HP
G-15-400W .....................400 psi…..Intermediate Gauge
REGULATORS
Primary Regulators
WMS-14-27.....................Right Primary Regulator for FHM2 – Air, He, N2
WMS-14-9.......................Right Primary Regulator for FHM2 – Oxygen and Medical Mixture
WMS-14-29.....................Right Primary Regulator for FHM2HL – CO2 & N2O
WMS-14-31.....................Right Primary Regulator for FHM2HP – Air, He, N2
WMS-14-26.....................Left Primary Regulator for FHM2 – Air, He, N2
WMS-14-8.......................Left Primary Regulator for FHM2 – Oxygen and Medical Mixture
WMS-14-28.....................Left Primary Regulator for FHM2HL – CO2 & N2O
WMS-14-30.....................Left Primary Regulator for FHM2HP – Air, He, N2
Line and Intermediate Regulators
WLR-14-50R...................Right Line Regulator for FHM2 & FHM2HL – series manifolds
WLR-14-200R.................Right Line Regulator for FHM2HP – series manifolds
WLR-14-50L ...................Left Line Regulator for FHM2 & FHM2HL – series manifolds
WLR-14-200L .................Left Line Regulator for FHM2HP – series manifolds
REGULATOR REPAIR KITS
Primary Regulator Kits
RK-1037..........................Repair Kits for WMS-14-26(L & R), WMS-14-27 (L & R), WMS-14-28 (L & R), WMS-14-29 (L & R)
WMS-14-30 (L & R), WMS-14-31 (L & R) Primary Regulators
RK-1038..........................Repair Kits for WMS-14-9 (L & R), WMS-14-8 (L & R) Primary Regulators
5-1
B20353 ECN-13787 (0701)
REGULATOR REPAIRS KITS (continued)
Line & Intermediate Regulator Kits
RK-1100M…………..Repair Kit for all line regulators
VALVES AND VALVE REPAIR KITS
WMS-1-65 ................CGA 320 Check Valve Bushing
WMS-1-59 ................CGA 326 Check Valve Bushing
WMS-1-62 ................CGA 346 Check Valve Bushing
WMS-1-53 ................CGA 540 Check Valve Bushing
WMS-1-54 ................CGA 580 Check Valve Bushing
WMS-1-64 ............... CGA 280 Check Valve Bushing
WMV-2-16 ................Master Valve
RK-1041 ...................Repair Kit for Low Pressure Check Valve
RK-1085 ...................Repair Kit for WMV-2-16
PRESSURE SWITCHES
WME-4-4 ..................All Gases except Oxygen
WME-4-4C............... For Oxygen Manifolds
POWER SUPPLY REPLACEMENT PARTS
WMS-13-23 ..............Power Supply Assembly (transformer, PCB with dry contacts, case, and cable)
WME-8-85 ................Power Supply PCB for WMS-13-23 (includes dry contact for remote alarms)
TRANSDUCERS
WME-9-1A................Inlet Transducer
WME-9-2A................Line Transducer for FHM2HP
WME-9-3A................Line Transducer for FHM2 & FHM2HL
MANIFOLD PCB
WME-8-98A..............Manifold PCB for FHM2
WME-8-98B…………Manifold PCB for FHM2HL
WME-8-98C………...Manifold PCB for FHM2HP
SOLENOIDS
8423 .........................Solenoid Valve for oxygen, nitrogen, and air systems
8422 .........................Solenoid Valve for CO2 and N2O systems
WMV-5-15 ................Solenoid Bypass Check Valve
FHM2 SERIES PRINTED CIRCUIT BOARDS-CALIBRATED
WME-8-98A..............PCB-Calibrated for FHM2 (Air, He, N2, O2)
WME-8-98B..............PCB-Calibrated for FHM2HL (CO2 & N2O)
WME-8-98C..............PCB-Calibrated for FHM2HP (Air, He, N2, O2)
5-2
B20353 ECN-13787 (0701)
Western Enterprises
Automatic Changeover Manifold
FHM2 & FHM2HP Series
Repair Drawing
Components & Miscellaneous Hardware
19
20
17 31
32 18
24
29
28
13
27
11
12
7
5
15
10
9
6
8
21
14
22
26
4
3
16
25
30
30
2
1
* Not Shown
23
KEY # DESCRIPTION
PART #
KEY # DESCRIPTION
1
Right Inlet Block Assembly
WMS-13-3
2
Left Inlet Block Assembly
WMS-13-4
FHM2
WME-9-3A
3
Right Primary Assembly
WMS-14-31
FHM2HP
WME-9-2A
4
Left Primary Assembly
WMS-14-30
18
Exit Block Assembly
WMS-14-38
5
Right Side Check Valve Assembly
WMS-14-20R
19
Bulkhead Connector
WLF-3-49
6
Right Primary CV to CV Block Tube WMS-14-15
20
Relief Tube Adaptor
WLF-3-12
7
Left Side Check Valve Assembly
WMS-14-20L
21
Left Solenoid Valve Assembly
WMS-14-6
8
Left Primary CV to CV Block Tube
WMS-14-16
22
Right Solenoid Valve Assembly
WMS-14-7
9
Pressure Switch
23
Hole Plug
WME-8-97
24
Line Pressure Gauge
FHM2, FHM2HL, FHM2HP
WME-4-4
17
PART #
Line Transducer
Oxygen
WME-4-4C
FHM2
WMG-3-3
10
Center Block Assembly
WMS-14-2
FHM2HP
WMG-3-4
11
Left Line Regulator Assembly
12
25
Inlet Transducer
WME-9-1A
FHM2
WLR-14-50L
26
Intermediate Gauge
G-15-400W
FHM2HP
WLR-14-200L
27
Ball Valve
WMV-5-13
Ball Valve O-Ring
RO-303E
203
Right Line Regulator Assembly
*
FHM2
WLR-14-50R
28
Bleeder Valve
FHM2HP
WLR-14-200R
29
Line Relief Valve
13
Bulkhead to RV Block Tube
WMS-14-18
14
Relief Block Assembly
WMS-14-1
15
Line RV to RV Block Tube
WMS-14-17
30
16
Backplate Assembly
WMS-14-24
5-3
FHM2
WMV-4C-75
FHM2HP
WMV-4C-250
Inlet Union
WMS-1-40
31
Nipple
D-20
32
Nut
D-7
B20353 ECN-13787 (0701)
Western Enterprises
Automatic Changeover Manifold
FHM2 & FHM2HL Series
Repair Drawing
Components & Miscellaneous Hardware
34
33
35
35
LIN E PRESSU RE
IN SERVIC E
IN SERVIC E
SYSTEM N O RM A L
REA D Y FO R U SE
REA D Y FO R U SE
BA N K D EPLETED
BA N K D EPLETED
LEFT BA N K
RIG H T BA N K
FH M 2
FULLY AUTO M ATIC HEALTH C ARE G AS M AN IFO LD
W ESTERN IN N O VA TO R
875 BASSETT RO AD
W ESTLAKE,O HIO 44145
1-800-783-7890
35
35
KEY # DESCRIPTION
PART #
33
Case
WMC-2-59A
34
Outlet Union
D-34
35
# 8 Sheet Metal Screw
WMC-6-23
*
Case Wiring Harness
WMS-13-51
*
Switch Wiring Harness
WMS-1-13
*
Power Supply Box
WMS-13-23
*
Manifold PCB
WME-8-98
* Item Not Pictured
5-4
B20353 ECN-13787 (0701)
Western Enterprises
Automatic Changeover Manifold
FHM2HL Series
Repair Drawing
Components & Miscellaneous Hardware
20
32
31
18
17
19
24
29
13
28
27
11
12
7
5
15
10
9
8
14
22
21
4
6
3
26
16
25
30
30
2
1
33
23
KEY # DESCRIPTION
PART #
KEY # DESCRIPTION
PART #
1
Right Inlet Block Assembly
WMS-13-3
18
Exit Block Assembly
WMS-14-38
2
Left Inlet Block Assembly
WMS-13-4
19
Bulkhead Connector
WLF-3-49
3
Right Primary Assembly
WMS-14-31
20
Relief Tube Adaptor
WLF-3-12
4
Left Primary Assembly
WMS-14-30
21
Left Solenoid Valve Assembly
WMS-14-12
5
Right Side Check Valve Assembly
WMS-14-20R
22
Right Solenoid Valve Assembly
WMS-14-13
6
Right Primary CV to CV Block Tube WMS-14-15
23
Hole Plug
WME-8-97
7
Left Side Check Valve Assembly
WMS-14-20L
24
Line Pressure Gauge
WMG-3-3
8
Left Primary CV to CV Block Tube
WMS-14-16
25
Inlet Transducer
WME-9-1A
9
Pressure Switch
WME-4-4
26
Intermediate Gauge
G-15-400W
10
Center Block Assembly
WMS-14-2
27
Ball Valve
WMV-5-13
11
Left Line Regulator Assembly
WLR-14-50L
*
Ball Valve O-Ring
RO-303E
12
Right Line Regulator Assembly
WLR-14-50R
28
Bleeder Valve
203
13
Bulkhead to RV Block Tube
WMS-14-18
29
Line Relief Valve
WMV-4C-75
14
Relief Block Assembly
WMS-14-1
30
Inlet Union
WMS-1-40
15
Line RV to RV Block Tube
WMS-14-17
31
Nipple
D-20
16
Backplate Assembly
WMS-14-24
32
Nut
D-7
17
Line Transducer
WME-9-3A
33
Heater
WMS-13-37
5-5
B20353 ECN-13787 (0701)
Western Enterprises
Automatic Changeover Manifold
FHM2 & FHM2HL Series
Repair Drawing
Components & Miscellaneous Hardware
34
35
36
36
LIN E PRESSU RE
IN SERVIC E
IN SERVIC E
SYSTEM N O RM AL
READ Y FO R U SE
READ Y FO R U SE
BA N K D EPLETED
BA N K D EPLETED
LEFT BA N K
RIG H T BA N K
FH M 2
FULLY AUTO M ATIC H EALTH C ARE G AS M AN IFO LD
W ESTERN IN N O VA TO R
875 BASSETT RO AD
W ESTLAKE,O HIO 44145
1-800-783-7890
36
36
KEY # DESCRIPTION
PART #
34
Case
WMC-2-59A
35
Outlet Union
D-34
36
# 8 Sheet Metal Screw
WMC-6-23
*
Case Wiring Harness
WMS-13-51
*
Switch Wiring Harness
WMS-1-13
*
Power Supply Box
WMS-13-23
*
Manifold PCB
WME-8-98
* Item Not Pictured
5-6
B20353 ECN-13787 (0701)
Western Enterprises
Automatic Changeover Manifold
FHM2, FHM2HL, & FHM2HP Series
Repair Drawing
Left Regulator Components
KEY # DESCRIPTION
PART #
KEY # DESCRIPTION
PART #
1
Nut
WMC-6-90
15*
Teflon Ring
RWS-3-47
2
Preset Adjusting Screw
RWS-3-3
16*
Filter
S-5
3
Regulator Bonnet
RWS-2-3P
17*
Spring Retainer
RWS-3-81
4
Bonnet Bushing
RWC-3-12
18
Regulator Body
RWS-1-3
5
Bushing Retainer
RWC-3-14
19
Pipe Away Adaptor
WMV-4-7
6
Pivot
RWC-2-8P
20
Relief Valve
7
Bonnet Spring
RWS-1-12
8*
Washer
RWS-3-26
9*
Slip Ring
RWS-3-17
21
10*
Diaphragm Assembly
RWS-3-28
11*
Nozzle
FHM2, FHM2HL
WMV-4C-300
FHM2HP
WMV-4C-450
1/4 NPT Plug
P-4HP
22
90º Elbow 3/8 Tube
WLF-3-6
WLR-14-200L
23
CGA 580 Nut
92
for FHM2-9 Series
RWS-5-1
24
CGA 580 Nipple
15-8
for all other models
RWS-6-9
25
Bushing 1/8 x 1/4
BB-2-4HP
12*
Large O-Ring
RO-015E
26
Elbow
BL-4HP
13*
Seat Holder and Stem for
27
Tee
BST-4LP
28
1/4 x 1/4 Adaptor
BA-4LP
14*
FHM2, FHM2HL, FHM2HP
RWS-6-8
FHM2-9 Series
RWS-6-3
Valve Spring
*
for FHM2-9 Series
RWS-6-5
for all other models
RWS-1-8
Item included in repair kits
5-7
B20353 ECN-13787 (0701)
Western Enterprises
Automatic Changeover Manifold
FHM2, FHM2HL, & FHM2HP Series
Repair Drawing
Right Regulator Components
KEY # DESCRIPTION
PART #
KEY # DESCRIPTION
PART #
1
Nut
WMC-6-90
15*
Teflon Ring
RWS-3-47
2
Preset Adjusting Screw
RWS-3-3
16*
Filter
S-5
3
Regulator Bonnet
RWS-2-3P
17*
Spring Retainer
RWS-3-81
4
Bonnet Bushing
RWC-3-12
18
Regulator Body
RWS-1-3
5
Bushing Retainer
RWC-3-14
19
Pipe Away Adaptor
WMV-4-7
6
Pivot
RWC-2-8P
20
Relief Valve
7
Bonnet Spring
RWS-1-12
FHM2, FHM2HL
WMV-4C-300
8*
Washer
RWS-3-26
FHM2HP
WMV-4C-450
9*
Slip Ring
RWS-3-17
21
1/4 NPT Plug
P-4HP
10*
Diaphragm Assembly
RWS-3-28
22
90º Elbow 3/8 Tube
WLF-3-6
11*
Nozzle
WLR-14-200L
23
CGA 580 Nut
92
for FHM2-9 Series
RWS-5-1
24
CGA 580 Nipple
15-8
for all other models
RWS-6-9
25
Bushing 1/8 x 1/4
BB-2-4HP
12*
Large O-Ring
RO-015E
26
Elbow
BL-4HP
13*
Seat Holder and Stem for
27
Tee
BST-4LP
28
1/4 x 1/4 Adaptor
BA-4LP
14*
FHM2, FHM2HL, FHM2HP
RWS-6-8
FHM2-9 Series
RWS-6-3
Valve Spring
*
for FHM2-9 Series
RWS-6-5
for all other models
RWS-1-8
Item included in repair kits
5-8
B20353 ECN-13787 (0701)
Western Enterprises
Automatic Changeover Manifold
FHM2, FHM2HL, & FHM2HP Series
Repair Drawing
Check Valve Components
KEY # DESCRIPTION
PART #
1*
Poppet
WMV-1-5
2*
Spring
WMV-1-6
3*
Washer
WMV-1-7
4*
Cap
WMV-1-8
Repair Kit for FHM2, FHM2HL
RK-1041
FHM2HP series
* All items included in repair kit.
5-9
B20353 ECN-13787 (0701)
Western Enterprises
Automatic Changeover Manifold
FHM2, FHM2HL, & FHM2HP Series
Repair Drawing
Power Supply Components
KEY # DESCRIPTION
PART #
1
Box and Cover
WME-7-6
2
115 to 24 VAC Transformer
8440
3
PCB Assembly
WME-8-85
4
18 Gauge Black Wire
WME-8-96A
5
Cord Assembly
WMS-13-40
6
Strain Relief Bushing
WMC-6-42
7
Transformer Wire Sub-Assy
WMS-13-41
8
6 Wire Connector
WME-8-94
5-10
B20353 ECN-13787 (0701)
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