HBAC2 Service Manual - Western Enterprises

HBAC2 Service Manual - Western Enterprises
SERVICE MANUAL
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2, HBAC2HP & HBAC2HL SERIES
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Western Enterprises
Printed in U.S.A.
B20193 ECN-11612 (0112)
SAFETY
Statements in this manual preceded by the following safety signal words are of special significance. Definitions
of 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 may mean 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 HBAC2, HBAC2HL and
HBAC2HP 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 Operating Instructions manual for warranty information.
i
B20193 ECN-11612 (0112)
CAUTION
• Failure to follow the following instructions can result in personal injury or property damage:
•
Never permit oil, grease, or other combustible materials to come in contact with cylinders,
manifold, and connections. Oil and grease may react with explosive force when ignited
while 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 5 inches. Mistreatment may cause the pigtail to burst.
•
Do not apply heat. Some materials may react and ignite 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 not 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
OSHA ___
PSIG ____
SCFH ___
VAC_____
VDC_____
PCB_____
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
B20193 ECN-11612 (0112)
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...............................................................................................1-3
SECTION 2
THEORY OF OPERATION
2-1
General Information ..................................................................................................................................2-1
Manifold Operation....................................................................................................................................2-1
Primary Regulators ...................................................................................................................................2-9
Check Valves ..........................................................................................................................................2-10
Low Pressure Switches...........................................................................................................................2-10
Line Pressure Regulator .........................................................................................................................2-11
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 Shutdown the Manifold .................................................................................................................4-3
Manifold Cabinet Cover Removal .............................................................................................................4-3
Gauge Replacement .................................................................................................................................4-4
Intermediate Primary Regulator Replacement ..........................................................................................4-5
Change-over Primary Regulator Replacement .........................................................................................4-6
Pressure Switch Replacement ..................................................................................................................4-8
Check Valve Repair ..................................................................................................................................4-9
Line Regulator Repair .............................................................................................................................4-10
Light Socket Replacement ......................................................................................................................4-12
Indicator Lamp Replacement ..................................................................................................................4-12
iii
B20193 ECN-11612 (0112)
SECTION 5
MAINTENANCE AND REPAIR PARTS
5-1
Replacement Pigtails ................................................................................................................................5-1
Regulators ................................................................................................................................................5-1
Panel Mount Gauges ................................................................................................................................5-2
Valves and Check Valves .........................................................................................................................5-2
Indicator Lamp Replacement Parts...........................................................................................................5-2
Pressure Switches ....................................................................................................................................5-2
Power Supply Replacement Parts ............................................................................................................5-2
Remote Alarms .........................................................................................................................................5-2
SECTION 5
MAINTENANCE AND REPAIR PARTS (Repair Drawings)
5-3
Components and Miscellaneous Hardware - HBAC2 Series Fuel Gas Manifolds ....................................5-3
Components and Miscellaneous Hardware - HBAC2 & HBAC2HP Series except Fuel Gas ...................5-6
Components and Miscellaneous Hardware - HBAC2HL Series ...............................................................5-8
Inlet Block Components - HBAC2 & HBAC2HP Series ..........................................................................5-10
Inlet Block Components - HBAC2 Series, Fuel Gas ...............................................................................5-11
Inlet Block Components - HBAC2HL Series ...........................................................................................5-12
Intermediate Block Components .............................................................................................................5-13
Gauge Plate Components.......................................................................................................................5-14
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B20193 ECN-11612 (0112)
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B20193 ECN-11612 (0112)
SECTION 1
INTRODUCTION & GENERAL INFORMATION
PRODUCT DESCRIPTION
The automatic changeover manifold is designed to provide a reliable uninterrupted supply of gas to a gas pipeline system in a laboratory installation.
The manifold has an equal number of cylinders in its “Service” supply and “Reserve” supply banks, automatically
switching to the “Reserve” supply when the “Service” supply becomes depleted. When the manifold changes to “Reserve” supply, it sends a signal to the 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 other gases should not be placed in a location where the temperature will exceed 120°F (49°C) or fall
below 0°F (-18°C). A manifold placed in an open location should be protected against weather conditions, including direct contact with rain, snow, and heavy moisture. 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: 12"
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10"
10"
typ.
21"
50"
Note: All dimensions are approximate
Total number of cylinders
Overall manifold length
Acetylene manifold length
4
3’ - 11"
4’ - 5"
6
5’ - 7"
6’ - 7"
8
7’ - 3"
8’ - 9"
10
8’ - 11"
10" - 11"
12
10’ - 7"
13’ - 1"
Floor
Figure 1-1
1-1
B20193 ECN-11612 (0112)
MANIFOLD SPECIFICATIONS
Flow Capability
Oxygen:
250 SCFH maximum at 80 psig delivery with a 12 psi pressure drop and 2000 psig inlet pressure.
30 SCFH maximum at 80 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure.
Nitrogen:
250 SCFH maximum at 80 psig delivery with a 12 psi pressure drop and 2000 psig inlet pressure.
30 SCFH maximum at 80 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure.
Nitrous Oxide &
Carbon Dioxide:
The flow capability of a Nitrous Oxide or Carbon Dioxide cylinder manifold will depend upon
conditions at the installation site, demands of the delivery system and the number of cylinders
in service. Maximum capability is 35 SCFH at 80 psig delivery and 750 psig inlet pressure.
Higher flow rates up to 250 SCFH can be obtained using the HBAC2HL series manifolds. The
HBAC2HL manifold includes an internal heater. Installing a Nitrous Oxide or Carbon Dioxide
manifold in a location which exposes it to ambient temperatures below 20°F (-7°C) is not
recommended.
Air, Argon:
250 SCFH maximum at 80 psig delivery with a 12 psi pressure drop and 2000 psig inlet pressure.
30 SCFH maximum at 80 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure.
Helium &
Hydrogen:
250 SCFH maximum at 80 psig delivery with a 12 psi pressure drop and 2000 psig inlet pressure.
30 SCFH maximum at 80 psig delivery with a 5 psi pressure drop and 2000 psig inlet pressure.
Acetylene:
75 SCFH maximum at 15 psig delivery with a 5 psi pressure drop and 200 psig inlet pressure.
Power Source Requirements
A 115 VAC to 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).
HBAC2HL series 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.
Delivery
Pipline
Piping Connections
Header Inlets:
Acetylene
Carbon Dioxide
Nitrous Oxide
Air
Hydrogen
Oxygen
Argon
Helium
Nitrogen
CGA 300 or 510
CGA 320
CGA 326
CGA 346
CGA 350
CGA 540
CGA 580
CGA 580
CGA 580
Relief
Valve
Piping
Power Supply
Box
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115 VAC
Conduit
Manifold Outlet:
1/4 tube compression fitting (located on
the left side on top of the cabinet)
Relief Valve:
1/2 NPT female pipe thread (located on
the right side on top of the cabinet)
1-2
Manifold
Control
Settting
FIGURE 1-2 Connection Location
B20193 ECN-11612 (0112)
ADJUSTMENT SPECIFICATIONS
Primary
Change-Over
Regulator
Gas
Low Side
Setting
Primary
Intermediate
Regulator
Pressure
Switches
Pressure
Relief
Valve
Line
Regulator
High Side
Setting
HBAC2
120-125 200 min.
170-175**
205-215
300
75-80
HBAC2HL
120-125 200 min.
170-175**
205-215
300
75-80
HBAC2 Acetylene
50-55
85-90**
120-125*
N/A
10-15
270-275**
305-315
450
150-170
HBAC2HP
110 max.
220-225 300 max
Unit of measure: all units are in psig
N/A = Not Applicable
* Part of the optional fuel gas alarm kit.
** This is the approximate setting. This setting should be the midpoint of the changeover regulator settings ±5 psig.
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
3/32", 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
Liquid leak detector
Available from Western Enterprises
Part number LT-100
Teflon® tape
Available from Western Enterprises
Part number MTT-1 or MTT-2
Krytox Lubricant
Available from Miller Stevenson Chemical Co., Inc.
Teflon is a registered trademark of E. I. du Pont de Nemours & Co. (Inc.).
1-3
B20193 ECN-11612 (0112)
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1-4
B20193 ECN-11612 (0112)
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 service and
one reserve 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 bank” indicator
lights, cylinder pressure gauges, line pressure gauge, and intermediate safety relief valve. Supply banks consist of
a header with 24" stainless steel inner core flexible pigtails with check valves, individual header check valves, 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 2-4. Figures 2-5, 2-6, 2-7 and 2-8 show the piping schematics. Figure 2-9 is the
schematic diagram of the electrical system of the manifold. Figure 2-10 is the heater schematic.
Pressure Gauges
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Cabinet Lights
RIGHT BANK
LEFT BANK
Master
Valves
Check
Valves
FIGURE 2-1 External Components
The cylinder bank that supplies the piping system is known as the “Service” supply while the cylinder bank on standby is referred to as the "Reserve" 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 flows into the manifold control and to the pressure switches located on the left and right inlet blocks. In manifolds incorporating a heater (Nitrous Oxide and Carbon Dioxide HBAC2HL systems) the gas flows through the
heater and then through check valves. On all other manifolds the gas flows directly to the check valves. 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.
The gas on the right bank flows from the check valve into the intermediate primary regulator while gas from the left
bank flows into the change-over primary regulator. Tubing is connected from the high pressure port on these regulators to the cylinder pressure gauges to sense the pressure of the gas in the cylinders.
2-1
B20193 ECN-11612 (0112)
Pressure is regulated in these primary regulators to the pressures noted in the adjustment specification chart in Section 1. The intermediate primary regulator is set midway between the maximum and minimum settings of the
change-over regulator. The position of the change-over regulator knob determines which bank is in service. When
the regulator knob is rotated clockwise (arrow pointing to the left) the change-over regulator setting is higher than
the intermediate regulator setting. Therefore, the left bank will be in "Service" and the right bank will be in "Reserve". When the regulator knob is rotated counterclockwise (arrow pointing to the right) the change-over regulator
setting is lower than the intermediate regulator setting. Therefore, the right bank will be in "Service" and the left
bank will be in "Reserve".
The intermediate regulator setting and the low pressure setting of the change-over regulator determines at which
pressure the manifold will switch from "Service" to "Reserve". Gas will flow through the regulator that has the highest setting. When the change over knob is turned clockwise (pointing left) the change-over regulator setting is
greater than the intermediate regulator setting. Therefore gas will flow from the left bank. When the gas pressure
on the left bank drops to the set pressure of the intermediate regulator, the right bank will start to flow. Conversely,
when the change-over regulator knob is rotated counterclockwise (pointing right) the intermediate regulator setting
is higher than the change-over regulator set pressure. Therefore gas will flow from the right bank. When the gas
pressure on the right bank drops to the set pressure of the change-over regulator, the left bank will start to flow.
(When rotating the control knob you are altering the pressure setting of the change-over regulator above and below
the intermediate regulator setting. If the knob is not rotated until it stops the manifold will not function correctly).
The outlet port of each of these regulators is connected via tubing to the intermediate block. The intermediate block
has six ports all connected to the same chamber. The gas pressure at all ports is the same as the pressure at the inlet to the block. Gas enters the lower right port of the intermediate block from the change-over regulator. The upper
right port of the block is connected to the intermediate pressure relief valve for all gases except acetylene. The port
on the right end of the intermediate block is plugged. The intermediate pressure gauge is connected to the left end
of the block. The lower left port is connected via tubing to the intermediate regulator. The left top port connects to
the inlet of the line pressure regulator.
The intermediate pressure relief valve prevents over-pressurization of the intermediate controls of the manifold
should the "Service" or "Reserve" primary regulator fail. The relief valve setting is noted in the adjustment specification chart in Section 1.
The line pressure regulator further reduces the pressure to the final pressure delivered to the gas piping system.
The regulator has one inlet port and three outlet ports. One outlet port is plugged. Tubing is connected from the
second port to the line pressure gauge to sense the pressure of the gas on the downstream side of the regulator.
The other port is the outlet and is located 180° from the inlet.
The gas flows from the line regulator outlet to the pipeline distribution system.
When both cylinder banks are full, the switches complete the electrical circuit to the green "system normal" light.
Cylinder pressures for each bank are indicated on the gauges on the manifold front cover. The "Service" supply is
indicated by the position of the control knob. The line pressure is indicated by the center gauge on the manifold
front cover.
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, and the check valve and the line regulator also falls.
When the "Service" side pressure falls below the set point of the 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 "Service" pressure falls to the set point of the intermediate regulator, gas will flow from the intermediate regulator (i.e. the "Reserve" supply begins to supply the system).
After replacing empty cylinders and opening the master valve and cylinder valves, the cylinder pressure will actuate
the pressure switch, the red "replace depleted cylinders" light will be extinguished 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 "Reserve" bank the "Service" supply and the newly installed cylinders will become the "Reserve" supply.
2-2
B20193 ECN-11612 (0112)
LEGEND
1 Outlet adaptor
6 Change-over primary regulator
2 Line regulator
7 Intermediate primary regulator
3 Intermediate pressure gauge
8 Right side inlet
4 Left side inlet
9 Right side inlet pressure switch
5 Left side inlet pressure switch
10 Intermediate relief valve
FIGURE 2-2 Internal Components - HBAC2
2-3
B20193 ECN-11612 (0112)
LEGEND
1 Outlet adaptor
7 Heater assembly
2 Line regulator
8 Intermediate primary regulator
3 Intermediate pressure gauge
9 Right side inlet
4 Left side inlet
10 Right side inlet pressure switch
5 Left side inlet pressure switch
11 Intermediate relief valve
6 Change-over primary regulator
FIGURE 2-3 Internal Components - HBACHL
2-4
B20193 ECN-11612 (0112)
LEGEND
1 Outlet adaptor
6 Change-over primary regulator
2 Line regulator
7 Intermediate primary regulator
3 Intermediate pressure gauge
8 Right side inlet
4 Left side inlet
9 Intermediate relief valve
5 Explosion proof pressure switch connection
(Acetylene manifolds do not incorporate
the relief valve)
FIGURE 2-4 Internal Components - HBAC (fuel gases)
2-5
B20193 ECN-11612 (0112)
To Pipeline
Distribution
System
Relief Valve
Line Pressure Gauge
Line Pressure Regulator
Intermediate
Pressure Gauge
Pre-set Pressure
Regulator
Change-over Pressure
Regulator
Left Cylinder Bank Pressure
Gauge
Right Cylinder Bank
Pressure Gauge
Line Pressure
Intermediate Pressure
Cylinder Pressure
Pressure Switch
Check Valves
Pressure Switch
FIGURE 2-5 Piping Schematic - HBAC2
To Pipeline
Distribution
System
Relief Valve
Line Pressure Gauge
Line Pressure
Regulator
Intermediate
Pressure Gauge
Change-over Pressure
Regulator
Pre-set Pressure
Regulator
Left Cylinder Bank Pressure
Gauge
Right Cylinder Bank
Pressure Gauge
Line Pressure
Intermediate Pressure
Cylinder Pressure
Pressure
Switch
Check
Valve
Heater Check
Valve
Pressure
Switch
FIGURE 2-6 Piping Schematic - HBAC2HL
2-6
B20193 ECN-11612 (0112)
To Pipeline
Distribution
System
Line Pressure Gauge
Line Pressure Regulator
Intermediate Pressure
Gauge
Pre-set Pressure
Regulator
Change-over Pressure
Regulator
Left Cylinder Bank Pressure
Gauge
Right Cylinder Bank
Pressure Gauge
Line Pressure
Intermediate Pressure
Cylinder Pressure
Pressure Switch
Check Valves
Pressure Switch
FIGURE 2-7 Piping Schematic - HBAC2 - Acetylene
To Pipeline
Distribution
System
Relief Valve
Line Pressure Gauge
Line Pressure Regulator
Intermediate
Pressure Gauge
Pre-set Pressure
Regulator
Change-over Pressure
Regulator
Left Cylinder Bank
Pressure Gauge
Right Cylinder Bank
Pressure Gauge
Line Pressure
Intermediate Pressure
Cylinder Pressure
Pressure Switch
Check Valves
Pressure Switch
FIGURE 2-8 Piping Schematic - HBAC2 - Hydrogen
2-7
B20193 ECN-11612 (0112)
FIGURE 2-9 Electrical Schematic (less heater)
FIGURE 2-10 Heater Electrical Schematic
2-8
B20193 ECN-11612 (0112)
PRIMARY REGULATOR (change-over and intermediate)
The primary regulator’s function is to reduce the cylinder pressure of the supply banks to a more usable regulated
pressure.
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 2-11 and 2-12. 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.
Nut
Adjusting
Screw
Bonnet
Spring
Adjusting
Screw
Bonnet
Spring
Diaphragm
Seat and
Nozzle
Low
Pressure
Chamber
Inlet
Port
Outlet
Port
Seat and
Nozzle
Inlet
Port
Diaphragm
Low
Pressure
Chamber
Outlet
Port
High Pressure
Chamber
High Pressure
Chamber
FIGURE 2-11 Primary Change-over Regulator
FIGURE 2-12 Primary Intermediate Regulator
2-9
B20193 ECN-11612 (0112)
CHECK VALVES
The check valves prevent gas from flowing backward from one bank to the opposite bank. See Figures 2-13 and 214.
Gas enters the check valve 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.
Spring
Seat
Spring
Seat
Flow
Figure 2-13 CGA 580 nipple check valve
Flow
Figure 2-14 Inline check valve
PRESSURE SWITCH
The pressure switch used to signal "Reserve in Use" is a diaphragm type with one common contact, one normally
closed contact, and one normally open contact. See Figures 2-15 and 2-16.
When the manifold is pressurized to the normal pressures, the diaphragm in the switch is pushed up. The diaphragm 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 diaphragm moves down, releasing the force
against the switch activator. The contacts of the switch then return to the normally open and normally closed positions.
The switch completes the electrical circuit to the indicators on the front of the control section and to the remote
alarm terminal strip in the power supply box.
N/O
C
N/C
Diaphragm
FIGURE 2-15 Pressure Switch
FIGURE 2-16 Switch Schematic
2-10
B20193 ECN-11612 (0112)
LINE PRESSURE REGULATOR
The line pressure regulator used in the manifold is a single stage, four port adjustable regulator. Refer to Figure 217. It has one inlet port and three outlet ports. The inlet port is piped to an intermediate pressure port in the manifold block. One outlet port is piped to the outlet of the manifold for connection to the main pipeline. One port is connected to the delivery line pressure gauge and the other outlet port is 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 sub-assembly. 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.
LEGEND
1 Adjusting screw
2 Bonnet
3 Pivot
4 Adjusting spring
5 Diaphragm assembly
6 Body
7 Valve spring
8 Seat assembly
9 nozzle
FIGURE 2-17 Line Pressure Regulator
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B20193 ECN-11612 (0112)
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2-12
B20193 ECN-11612 (0112)
SECTION 3
FIELD TESTING & TROUBLE-SHOOTING
The manifold performance tests are used to verify the manifolds 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.
PERFORMANCE VERIFICATION PROCEDURE
1.
Remove the control section cover as explained in Section 4.
2.
Reinstall the control knob on the shaft of the
change-over primary regulator.
3.
Rotate the control knob counter clockwise to
make the left cylinder bank the "Reserve"
supply and the right bank the "Service"
supply.
4.
Open the master valves located on the cylinder headers prior to pressurizing the manifold.
5.
S-l-o-w-l-y open one cylinder valve on the left
bank of cylinders.
6.
S-l-o-w-l-y open one cylinder valve on the
right bank of cylinders.
7.
Using a leak detect solution, verify that there
are no leaks present.
8.
Close the cylinder valves on the left and right
banks of cylinders.
9.
Deplete the gas from the manifold. The gas
must be expelled through the exit of the
manifold. Do not attempt to bleed gas
from the control inlet or headers. This will
cause gas to be trapped in the manifold
by check valves.
10.
S-l-o-w-l-y open one cylinder valve on the
left bank of cylinders.
11.
Verify that the intermediate gauge indicates
the low pressure setting as shown in the
specification chart in Section 1 for the
change-over primary regulator.
12.
Observe the intermediate gauge for two minutes. Verify that the change-over primary
regulator does not exhibit "creep" or an increase in pressure.
13.
Verify that the left side cylinder contents
gauge indicates a minimum of 1500 psig
for Oxygen, Nitrogen, Air, or gas mixtures
systems. Nitrous Oxide and Carbon Dioxide systems should indicate a minimum of
600 psig.
14.
Verify that the line pressure gauge is indicating a minimum of 30 psig on all systems
except acetylene. Acetylene should indicate a minimum of 10 psig or a maximum
of 15 psig. Adjust to the proper line pressure if necessary.
15.
Create a slight flow of gas through the manifold.
16.
Observe the test gauge and verify the
change-over regulator setting under a flow
condition. Adjust the change-over primary
regulator as necessary to obtain the required pressure.
17.
Rotate the knob clockwise so the changeover regulator is at its maximum setting.
18.
Verify that the intermediate gauge indicates
the high pressure setting as shown in the
specification chart in Section 1 for the
change-over primary regulator.
19.
Turn off the left cylinder valve and allow all
gas to vent from the manifold. Once gas
has depleted close the outlet used to create the flow.
20.
Rotate the control knob to its fully counterclockwise position.
21.
S-l-o-w-l-y open one cylinder valve on the
right bank of cylinders.
22.
Verify that the intermediate gauge indicates
the pressure setting as shown in the specification chart in Section 1 for the intermediate primary regulator.
23.
Observe the intermediate gauge for two minutes. Verify that the intermediate primary
3-1
B20193 ECN-11612 (0112)
regulator does not exhibit "creep" or an increase in pressure.
24.
25.
26.
27.
Verify that the right side cylinder contents
gauge indicates a minimum of 1500 psig
for Oxygen, Nitrogen, Air, or gas mixtures
systems. Nitrous Oxide and Carbon Dioxide systems should indicate a minimum of
600 psig.
Verify that the line pressure gauge is indicating a minimum of 30 psig on all systems
except acetylene. Acetylene should indicate a pressure between 10 and 15 psig.
Adjust to the proper line pressure if necessary.
Create a slight flow of gas through the manifold.
Observe the test gauge and verify the intermediate regulator setting under a flow condition. Adjust the intermediate primary
regulator as necessary to obtain the required pressure.
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.
29.
Create a slight flow of gas through the manifold.
point of the change-over regulator (see
the specification chart in Section 1). Adjust the intermediate regulator as necessary to obtain the required pressure.
36.
S-l-o-w-l-y open one cylinder valve on the
right bank of cylinders.
37.
Verify that the intermediate gauge has returned to the set pressure of the intermediate primary regulator.
38.
Rotate the control knob clockwise to make
the left bank the service supply.
39.
Close the cylinder valve on the left bank of
cylinders.
40.
Observe the cylinder contents gauges: the
left cylinder bank gauge should begin to
drop; the right cylinder bank gauge should
remain constant.
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).
42.
Close the outlet used to create the flow.
43.
Verify that the intermediate regulator is functioning properly by observing the intermediate gauge for two minutes. The gauge
should indicate the same pressure at the
end of the two minute period.
30.
Verify that the line pressure regulator maintains a constant pressure by observing
the line pressure gauge.
31.
S-l-o-w-l-y open one cylinder valve on the
left bank of cylinders.
44.
S-l-o-w-l-y open one cylinder valve on the
left bank of cylinders.
32.
Observe the cylinder contents pressure
gauges to verify cylinder pressure.
45.
Verify that the test gauge has returned to the
set pressure of the change-over primary
regulator.
33.
Close the cylinder valve on the right bank of
cylinders.
46.
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) terminals on the pressure switch. The ohmmeter should register approximately zero
(0) ohms resistance when connected to
the switch. Adjust or replace the faulty
34.
Observe the cylinder contents gauges: the
right cylinder bank gauge should begin to
drop; the left cylinder bank gauge 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 low set
3-2
B20193 ECN-11612 (0112)
switch. See Section 4 for servicing the
pressure switch. Reconnect the ohmmeter to the black and brown wires.
47.
Close the cylinder valve on the left bank of
cylinders.
48.
Loosen the union connection to the main
supply line to create a slight flow of gas
through the manifold.
49.
Verify an ohmmeter reading of infinite resistance as soon as the test gauge pressure
drops to the value for the pressure switch
setting indicated in the specification chart
in Section 1.
61.
Reinstall the manifold section cover as explained in Section 4.
62.
Connect the electrical power source and supply electrical power to the manifold.
63.
Observe the cabinet system status indicators. Verify that the green indicator is off
and the red indicator is lit.
64.
S-l-o-w-l-y open one cylinder valve on the
left and right banks of cylinders.
65.
Observe the cabinet system status indicators. Verify that the green indicator is lit
and the red indicator is off.
50.
S-l-o-w-l-y open one cylinder valve on the
left bank of cylinders.
66.
Readjust the line regulator setting if it was
modified during cover installation.
51.
Verify that the ohmmeter returns to approximately zero (0) ohms resistance.
67.
Close the cylinder valve on the right bank of
cylinders.
52.
Rotate the control knob counterclockwise to
make the right bank of cylinders the service supply.
68.
Create a slight flow of gas through the manifold.
69.
53.
Close the cylinder valve on the right bank of
cylinders.
Verify that the red light illuminates and the
green light is extinguished when the manifold changes over from service to reserve
supply.
54.
Verify an ohmmeter reading of infinite resistance as soon as the test gauge pressure
drops to the value for the pressure switch
setting indicated in the specification chart
in Section 1.
70.
S-l-o-w-l-y open one cylinder valve on the
right bank of cylinders.
71.
Rotate the control knob clockwise to make
the left cylinder bank the service supply.
72.
Observe the cabinet system status indicators. Verify that the green indicator is lit
and the red indicator is off.
73.
Close the cylinder valve on the left bank of
cylinders.
74.
Verify that the red light illuminates and the
green light is extinguished when the manifold changes over from service to reserve
supply.
75.
Close the outlet used to create the flow.
76.
S-l-o-w-l-y open all cylinder valves on the
left and right banks of cylinders.
77.
Rotate the control knob to select the bank of
cylinders supplying the system before
service was performed.
55.
S-l-o-w-l-y open one cylinder valve on the
right bank of cylinders.
56.
Verify that the ohmmeter returns to approximately zero (0) ohms resistance.
57.
Close all cylinder valves and vent all remaining gas from the manifold.
58.
Remove the ohmmeter leads from the black
and brown wires.
59.
Close the outlet used to create the flow.
60.
Remove the control knob from the changeover regulator.
3-3
B20193 ECN-11612 (0112)
TROUBLE-SHOOTING
(Only qualified repair personnel should make repairs)
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
Power Input.
Check electrical power supply.
Bulb burned out.
Replace bulb or lamp assembly.
Internal wiring disconnected.
Check all wiring connections.
Red Indicator light is on but
both banks are full.
Master valve, header valves, or
cylinder valves on bank are
closed.
Slowly open valves.
Red indicator light does not
come on when one bank is
empty and changeover
occurs.
Bulb burned out.
Replace bulb or lamp assembly.
Pressure switch wiring
disconnected.
Check connections.
Pressure switch set at too low a
pressure.
Adjust pressure switch or return
faulty unit for factory setting.
Green indicator light does not
come on but both banks are
full.
Bulb burned out.
Replace bulb or lamp assembly.
Pressure switch wiring
disconnected.
Check connections.
Green indicator light comes
on even though one bank of
cylinders is empty.
Pressure switch wiring
disconnected.
Check wiring connections.
Pressure switch set at too low a
pressure.
Adjust pressure switch or return
faulty unit for factory setting.
Remote alarm signal stays in
one mode constantly
regardless of changeover
status.
Power supply wiring is incorrect.
Check wiring connections on both
power supply terminal strips.
Flow demand too high.
Reduce flow demand.
Remote alarm signals are
opposite of manifold status.
Faulty connection to remote
alarm unit.
Check input from alarm unit to
terminal strip.
CABINET INDICATOR LIGHTS
No indicator lights on front
panel come on when power
is hooked up.
"RESERVE IN USE" SIGNAL
3-4
B20193 ECN-11612 (0112)
SYMPTOM
"ABNORMAL" LINE
PRESSURE SIGNAL
PROBABLE CAUSE
REMEDY OR CHECK
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.
Primary regulator setting too low.
Set delivery pressure to
specifications.
Faulty line pressure gauge.
Replace line pressure gauge.
Faulty alarm pressure switch.
Readjust or replace pressure
switch as necessary.
Low pressure alarm activated.
High pressure alarm
activated.
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.
Add an internal heater to convert
the manifold from a HBAC2 to a
HBAC2HL.
Faulty line pressure gauge.
Replace line pressure gauge.
Faulty alarm pressure switch.
Readjust or replace pressure
switch as necessary.
LOSS OF CYLINDER
CONTENTS
Audible or inaudible gas
leakage (unknown origin).
Leakage at manifold piping
connections.
Tighten, reseal or replace.
Leakage at manifold tubing
connections.
Tighten, reseal or replace.
Leakage in downstream piping
system.
Repair as necessary.
3-5
B20193 ECN-11612 (0112)
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
LOSS OF CYLINDER
CONTENTS (continued)
Leakage at cylinder valve.
Replace cylinder.
Gauge leaks.
Reseal or replace.
Audible or inaudible gas
leakage (unknown origin).
(continued)
Regulator leaks.
Repair or replace.
Venting at relief valve.
Line regulator setting too high.
Set delivery pressure to
specifications.
Overpressure due to creeping or
faulty regulation by primary
regulator.
Replace regulator seat and
nozzle components.
Overpressure due to creeping or
faulty regulation by line 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 on regulator.
Replace diaphragm.
Valve packing leaks.
Tighten packing nut.
Faulty valve.
Repair or replace valve.
Intermediate regulator seat leak.
Repair or replace regulator.
Intermediate regulator set to
open at too high a pressure.
Adjust intermediate regulator per
specifications.
Flow demand too high.
Reduce flow demand.
Faulty primary regulator and/or
intermediate regulator.
Replace regulator seat and
nozzle components.
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.
3-6
B20193 ECN-11612 (0112)
SYMPTOM
PROBABLE CAUSE
REMEDY OR CHECK
Flow demand too high.
Reduce flow demand.
Leaks in the manifold system.
Leak test, tighten, reseal or
replace fittings as necessary.
Intermediate regulator set to
open at too high a pressure.
Adjust intermediate regulator per
specifications.
Closed cylinder or shutoff valves.
Open valves.
LOSS OF RESERVE BANK
CONTENTS (continued)
Premature changeover to
reserve bank.
No changeover
Intermediate regulator defective.
Replace or repair regulator.
Empty reserve bank cylinders.
Replace cylinders.
PIPELINE DISTRIBUTION
Pipeline not at desired
pressure.
Line regulator not set correctly.
Readjust line pressure regulator.
Required gas flow not
available.
Line regulator not set correctly.
Readjust line pressure regulator.
Flow demand too high.
Consult factory.
3-7
B20193 ECN-11612 (0112)
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3-8
B20193 ECN-11612 (0112)
SECTION 4
SERVICE PROCEDURES
GENERAL MAINTENANCE
1. Main section
a) Daily - record line pressure.
b) Monthly
1) Check regulators, compression fittings and valves for external leakage.
2) Check valves for closure ability.
c) Annually
1) Check relief valve pressures.
2) Check 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 4 Years
1) Replace pigtails.
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.
SAFETY PRECAUTIONS
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 (except for hydrogen manifolds).
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
B20193 ECN-11612 (0112)
CLEANING, LUBRICATION, AND SEALING
Clean metal parts of the manifold with isopropyl alcohol or 1,1,1 Trichloroethylene solvent prior to assembly.
Dry thoroughly. Do not clean o-rings with this solvent (Freon TF is acceptable).
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 gas tight seal.
Assembly and Disassembly of Compression Fittings
NOTE
• Incorrect reassembly 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 a wrench until
the marks line up, which indicates that the fitting has been tightened to its original 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 tubing.
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
B20193 ECN-11612 (0112)
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 all personnel have been advised of the intended service and all
systems requiring industrial gas are being supplied from portable or alternate supplies.
Replace parts with all components in the repair kit.
HOW TO SHUTDOWN THE MANIFOLD
1. Turn off the piping system isolation valve, if present. If an isolation valve is not present, the entire gas
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 systems requiring industrial gas are being
supplied from portable or alternate supplies.
2. Turn off right and left supply bank cylinder valves.
3. Deplete gas from the system. The gas must be expelled through the exit of the manifold. Do not attempt to
bleed gas from the control inlet or headers. This will cause gas to be trapped in the manifold by check
valves.
4. Disconnect electrical power from the manifold at the main power source.
MANIFOLD CABINET COVER REMOVAL
Disassembly
1. Cut lead seal wire with wire cutters and remove.
2. Remove the control knob on the front of the cabinet. Peal back the service arrow label and remove screw
with a Phillips screwdriver.
3. Using a flat blade screwdriver or a 5/16" hex wrench, unscrew the four screws holding the gauge plate to the
cabinet. Remove the cover plate.
4. Unscrew the electrical connector at the bottom of the unit and unplug the cord.
5. Unscrew the three screws attaching the cover to the backplate using an appropriate screwdriver.
6. Carefully pull the cover straight out to clear internal components.
7. Locate and disconnect the three male/female wire terminals to detach the cover electrical wiring from the
pressure switch wiring.
8. Lift the cover completely off the backplate.
Reassembly
Reverse order of disassembly. Connect internal wiring by matching up color-coded wires.
4-3
B20193 ECN-11612 (0112)
GAUGE REPLACEMENT
Removal
CAUTION
• Be careful not to kink or damage the tubing connected to the gauges. Damaged tubing may burst when
pressurized
1. Shutdown the manifold and remove cover as explained earlier in this section.
2. Pull the mounting plate up so that it provides easy access to the gauge screws on the underside of the gauge
plate.
3. Mark the compression fittings per the instructions on page 4-2. Using a 7/16" open end wrench, disconnect
the tubing from the defective gauge. When re-tightening the fitting the procedure outlined on page 4-2 shall
be followed.
4. Using a 3/8" hex wrench, remove the two nuts holding the gauge brackets. Slide the gauge brackets off of
the screw posts.
5. Slide the gauge out through the front of the gauge plate.
6. Using a 3/4" hex wrench, remove the compression fitting from the gauge. Use a 9/16" open end wrench to
stabilize the gauge.
7. Remove the old sealant from the 1/4 NPT female pipe thread on the compression fitting.
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 front of the gauge plate.
3. If the gauge needle is not on zero, unscrew the gauge bezel and adjust the needle using a flat blade
screwdriver.
4-4
B20193 ECN-11612 (0112)
INTERMEDIATE PRIMARY REGULATOR REPLACEMENT
NOTE
• Removal and Replacement procedures are to be followed for repair or replacement. To ensure proper
torques and that nothing is damage the regulator should always be removed from the system.
Shutdown the manifold and remove cover as explained earlier in this section.
Removal
1. Mark the compression fittings on both ends of the tubing per the instructions on page 4-2. Using an 9/16"
open end wrench, disconnect the outlet tubing from the regulator at the compression fittings.
2. Mark the compression fittings per the instructions on page 4-2. Using a 7/16" open end wrench, disconnect
the gauge tubing from the regulator at the compression fitting.
3. Using two 1 1/8" hex wrenches disconnect the regulator from the inlet block at the union connection.
4. Remove the intermediate primary regulator from the control section and clamp the regulator assembly in a
vise.
Replacement
1. Position the regulator assembly in the control section and hand tighten the inlet nut and nipple. Do not
tighten completely until all other connections have been made.
2. When re-tightening the fitting the procedure outlined on page 4-2 shall be followed. Using a 7/16" open end
wrench, connect the gauge tubing to the 1/8" tube compression fitting located on the left side of the
regulator, 90° from the regulator inlet.
3. When re-tightening the fitting the procedure outlined on page 4-2 shall be followed. Using an 11/16" open
end wrench, connect the outlet tubing to the 3/8" tube compression fitting located on the top of the
regulator, 180° from the regulator inlet.
4
Tighten the inlet nut and nipple connection using two 1-1/8 open end wrenches.
Intermediate Primary Regulator Adjustment
1. If not already done, shutdown the manifold as explained earlier in this section, remove the manifold cover,
attach a test gauge to the left side of the intermediate pressure block, and remove the acorn nut from the
intermediate primary regulator.
2. S-l-o-w-l-y open one cylinder on the right bank.
3. Verify the cylinder pressure gauge indicates a minimum pressure of 1500 psig on Oxygen, Air, and Nitrogen
systems or a minimum of 600 psig on Nitrous Oxide and Carbon Dioxide systems.
4. Using a flat blade screwdriver, turn the adjusting screw of the regulator in while observing the test gauge.
Set the regulator to the pressure indicated on the Adjustment Specification chart in Section 1.
5. Create a slight flow of gas through the manifold.
6. Readjust the regulator to the proper specifications if necessary.
7. Close the valve used to create the flow. The test gauge will go up slightly higher than the flowing adjusted
pressure.
4-5
B20193 ECN-11612 (0112)
8. Verify that the regulator does not creep by observing the test gauge for two minutes. The gauge must
indicate the same pressure at the end of the two minute period.
9. Close the cylinder valve.
10. Create a flow of gas through the manifold and vent all remaining gas from the manifold.
11. Close the valve used to create the flow.
12. Install the acorn nut on the intermediate primary regulator.
CHANGE-OVER PRIMARY REGULATOR REPLACEMENT
NOTE
• Removal and Replacement procedures are to be followed for repair or replacement. To ensure proper
torques and that nothing is damage the regulator should always be removed from the system.
Shutdown the manifold and remove cover as explained earlier in this section.
Removal
1. Mark the compression fittings on both ends of the 1/4" tubing per the instructions on page 4-2. Using an
9/16" open end wrench, disconnect the outlet tubing from the regulator at the compression fittings.
2. Mark the compression fittings per the instructions on page 4-2. Using a 7/16" open end wrench, disconnect
the gauge tubing from the regulator at the compression fitting.
3. Mark the compression fittings on both ends of the 1/4" tubing per the instructions on page 4-2. Using an
9/16" open end wrench, disconnect the inlet tubing from the regulator at the compression fittings.
4. Using 5/32 Allen wrench remove the cap screw from the regulator set screw collar.
5. Using 3/32 Allen wrench loosen but do not remove the two remaining set screws in the collar. Remove the
collar from the regulator set screw
6. Using a flat head screw driver remove the two screws holding the stop bracket from the mounting bracket.
7. Remove the four screws holding the mounting bracket to backplate.
8. Remove the change-over primary regulator from the control section
9. Remove the two screws holding the brackets to the regulator.
10. Clamp the regulator assembly in a vise.
Replacement
1. Position the new regulator in a vise (the vice need not be tightened).
2. Position the brackets on the new regulator. The order of the brackets should remain the same. Tighten the
two screws to mount the brackets onto the regulator.
3. Mount the regulator onto the backplate using the 4 self tapping screws.
4. When re-tightening the fitting the procedure outlined on page 4-2 shall be followed. Using a 7/16" open end
wrench, connect the gauge tubing to the 1/8" tube compression fitting located in the front of the regulator,
90° from the regulator inlet.
4-6
B20193 ECN-11612 (0112)
5. When re-tightening the fitting the procedure outlined on page 4-2 shall be followed. Using an 11/16" open
end wrench, connect the outlet tubing to the 3/8" tube compression fitting located on the right side of the
regulator, 180° from the regulator inlet.
6. When re-tightening the fitting the procedure outlined on page 4-2 shall be followed. Using an 9/16" open end
wrench, connect the inlet tubing to the 1/4" tube compression fitting located on the left side of the regulator.
7. Connect the stop plate to the brackets using two screws.
8. Thread the set screw into the bonnet hand tight.
9. Place the collar onto the set screw.
10. Proceed to the adjustment section to set the regulator correctly.
Change-Over Primary Regulator Adjustment
1. If not already done, shutdown the manifold as explained earlier in this section and remove the manifold cover.
2. Reinstall the control knob on the regulator.
3. S-l-o-w-l-y open one cylinder on the left bank.
4. Verify the cylinder pressure gauge indicates a minimum pressure of 1500 psig on Oxygen, Air, and Nitrogen
systems or a minimum of 600 psig on Nitrous Oxide and Carbon Dioxide systems.
5. Turn the adjusting screw of the regulator in while observing the test gauge. Set the regulator to the pressure
high pressure setting indicated on the Adjustment Specification chart in Section 1.
6. Create a slight flow of gas through the manifold.
7. Readjust the regulator to the proper specifications if necessary.
8. Close the valve used to create the flow. The test gauge will go up slightly higher than the flowing adjusted
pressure.
9. Verify that the regulator does not creep by observing the test gauge for two minutes. The gauge must
indicate the same pressure at the end of the two minute period.
10. Tighten the cap screw into the collar using a 5/32 Allen wrench. The side of the cap screw should be
against the right side of the stop bracket. (Once tight the knob should not be able to rotate clockwise).
11. Tighten the two remaining set screws using the 3/32 Allen wrench.
12. Create a slight flow of gas.
13. Turn the knob counter clockwise until the cap screw hits the left side of the stop plate.
14. Close the valve used to create the flow
15. The pressure on the test gauge should indicate indicated the pressure listed in the Adjustment Specification
chart in Section 1.
16. Close the left cylinder valve.
17. Vent all remaining gas from the manifold.
18. Close the valve used to create the flow after the gas pressure has been exhausted from the manifold.
19. The label indicating service bank will need to be repositioned. See the "manifold cabinet cover removal" reassembly procedure.
4-7
B20193 ECN-11612 (0112)
PRESSURE SWITCH REPLACEMENT
Removal
1. Shutdown the manifold and remove cover as explained earlier in this section.
2. Label the three wires attached to the switch. Remove the wires by grasping and pulling the connector. Do
not attempt to pull the wire. This may pull the wire out of the connector.
3. Use a 1-1/2" open end wrench to remove the pressure switch.
Replacement
CAUTION
• Do not stand directly in front of the 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.
1. Remove all old sealant from thepipe fitting. Blow out the inlet block with oil free Air or Nitrogen to remove all
foreign materials and dry all surfaces.
2. Apply Teflon® tape to the 1/4 NPT male pipe threads on the fitting. Start the threads of the fitting into the
pressure switch. Using a 1-1/12" open end wrench to tighten to effect a gas tight seal.
3. Complete the adjustment instructions below prior to installing the signal wires to the pressure switch.
Pressure Switch Adjustment
1. Connect an ohmmeter to the normally closed and common electrical contacts on the switch. The ohmmeter
should register zero resistance.
2. Begin pressurizing the manifold by opening one cylinder valve on the side of the manifold the switch is on: At
the actuation pressure, the ohmmeter reading will jump from zero resistance to infinite resistance.
3. Close the cylinder valve after at least 500 psig has been reached.
4. Create a slight flow of gas out of 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.
5. Close the valve used to create the flow. The test gauge will go up slightly higher than the flowing adjusted
pressure.
6. Lift the adjustment cover on the pressure switch.
7
Using a flat blade screwdriver, turn 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 signals and make adjustments as required to achieve the signal
setting. The setting should be made on descending pressure. Make adjustments response to the reading
obtained in step 4.
WARNING
• Be sure power is off when electrical connections are made. Current flowing through the wires may shock
the service technician.
9. After the setting has been made, connect the signal wires to the appropriate contacts on the pressure switch.
4-8
B20193 ECN-11612 (0112)
CHECK VALVE REPLACEMENT (Right Side)
Removal
1. Shutdown the manifold and remove cover as explained earlier in this section.
2. Remove the intermediate regulator as explained earlier in this section.
3. Put the regulator in a vice.
4. Using an 11/16 open end wrench remove the check valve nipple from the regulator body.
Replacement
CAUTION
• Do not stand directly in front of the 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.
1. Remove all old sealant from the regulator. Blow out the regulator with oil free Air or Nitrogen to remove all
foreign materials and dry all surfaces.
2. Apply Teflon® tape to the 1/4 NPT male pipe threads on the check valve. Start the threads of the check
valve into the regulator. Using an 11/16" open end wrench to tighten to effect a gas tight seal.
3. Install the regulator into the manifold as explained earlier in this section..
CHECK VALVE REPLACEMENT (Left Side)
Removal
1. Shutdown the manifold and remove cover as explained earlier in this section.
2. Mark the compression fittings on both ends of the 1/4" tubing per the instructions on page 4-2. Using an
9/16" open end wrench, disconnect the inlet tubing from the regulator at the compression fittings.
3. Using a 3/4 open end wrench to stabilize the assembly while using a 9/16 open end wrench to remove the
compression fitting from the check valve.
4. Using a 3/4 open end wrench remove the check valve from the inlet block.
Replacement
CAUTION
• Do not stand directly in front of the 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.
1. Remove all old sealant from the inlet block and the compression fitting. Blow out the inlet block and
compression fitting with oil free Air or Nitrogen to remove all foreign materials and dry all surfaces.
2. Apply Teflon® tape to the 1/4 NPT male pipe threads on the check valve. Start the threads of the check
valve into the inlet block. Using an 3/4" open end wrench to tighten to effect a gas tight seal.
3. Apply Teflon® tape to the 1/4 NPT male pipe threads on the compression fitting. Start the threads of the
compression fitting into the check valve. Using an 9/16" open end wrench to tighten to effect a gas tight
seal.
4. When re-tightening the fitting the procedure outlined on page 4-2 shall be followed. Using an 9/16" open end
wrench, connect the inlet tubing to the 1/4" tube compression fitting located on the left side of the regulator.
4-9
B20193 ECN-11612 (0112)
LINE REGULATOR REPLACEMENT
Shutdown the manifold and remove cover as explained earlier in this section.
Removal
1. Mark the 3/8 tube compression fittings, located on the intermediate block, per the instructions on page 4-2.
Using an 11/16" open end wrench, disconnect the compression nut.
2. Mark the 1/8 tube compression fittings per the instructions on page 4-2. Using a 7/16" open end wrench,
disconnect the line pressure gauge tubing from the line regulator.
3. Disconnect the intermediate pressure relief valve from the building’s vent line.
4. Disconnect the main supply line from the manifold at the 1/4 tube compression fitting.
5. Using a 3/4" hex wrench, remove the nipple from the outlet of the line regulator.
6. Using a 7/16" hex wrench, remove the U-bolt from the bracket.
7. Using a 3/8" hex wrench, remove the nut and washer from the carriage bolt holding the intermediate block to
the bracket and remove the bolt and the intermediate block.
8. Secure the intermediate block in a vise or similar holding fixture.
9. To remove the regulator from the intermediate block, grasp the bonnet of the regulator and rotate the
regulator counterclockwise.
Replacement
1. Secure the intermediate block in a vise or similar holding fixture.
2. Remove all old sealant from the regulator inlet nipple. Clean all interior surfaces with isopropyl alcohol or
1,1,1 Trichloroethylene solvent.
CAUTION
• Do not stand directly in front of the 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.
3. Remove all old sealant from the intermediate block. Blow out the intermediate block with oil free Air or
Nitrogen to remove all foreign materials and dry all surfaces.
4. Apply Teflon® tape to the 1/4 NPT male pipe threads on the regulator inlet nipple. Start the threads of the
nipple into the intermediate block.
5. Position the inlet of the regulator over the nipple and rotate the regulator clockwise to tighten the threads.
The inlet of the regulator is stamped IN.
6. Grasp the bonnet of the regulator and rotate the regulator clockwise until tight. The bonnet of the regulator
must be parallel to the test gauge on the left end of the intermediate block.
7. Remove the intermediate block from the vise and using the carriage bolt, reinstall the intermediate block to
the bracket on the backplate. Assemble the nut and washer to the carriage bolt. Tighten loosely.
8. Remove all old sealant from the union nipple. Clean all interior surfaces with isopropyl alcohol or 1,1,1
Trichloroethylene solvent.
4-10
B20193 ECN-11612 (0112)
9. Apply Teflon® tape to the 1/4 NPT male pipe threads on the nipple. Start the threads of the nipple into the
outlet of line regulator.
10. Using a 3/4" hex wrench, install the nipple to the outlet of the line regulator.
11. Using a 7/16" hex wrench, reassemble the U-bolt to the bracket.
12. When re-tightening the 3/8 tube fittings, the procedure outlined on page 4-2 shall be followed. Using an
11/16" open end wrench, reconnect the tubing.
13. When re-tightening the 1/8 tube fitting, the procedure outlined on page 4-2 shall be followed. Using an
7/16" open end wrench, reconnect the line pressure gauge tubing to the line regulator.
14. Reconnect the intermediate pressure relief valve to the building’s vent line.
15. Reconnect the main supply line to the manifold at the 1/4 compression fitting.
Line Regulator Adjustment
1. Reinstall the manifold cover as explained at the beginning of this section.
CAUTION
• Be sure to backout the adjusting screw on the line regulator prior to pressurizing the system. If the
adjusting screw position was changed it may overpressurize causing something to burst or rupture.
2. S-l-o-w-l-y open one cylinder on the system.
3. Verify the cylinder pressure gauge indicates a minimum pressure of 1500 psig on Oxygen, Air, and
Nitrogen systems or a minimum of 600 psig on Nitrous Oxide and Carbon Dioxide systems.
4. Turn the adjusting screw of the regulator in while observing the line pressure gauge. Set the regulator to
the desired pressure.
5. Create a slight flow of gas through the manifold.
6. Readjust the regulator to the proper specifications if necessary.
7. Tighten the union connection to the main supply line. The line pressure gauge will go up slightly higher than
the flowing adjusted pressure.
8. 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.
9. Close the cylinder valve.
10. Loosen the main supply line union and vent all remaining gas from the manifold.
11. Tighten the union connection to the main supply line after the gas pressure has been exhausted from the
manifold.
4-11
B20193 ECN-11612 (0112)
LIGHT SOCKET REPLACEMENT
Removal
1. Shutdown the manifold and remove cover as explained earlier in this section.
2. Label and disconnect the four connectors attached to the back of the light socket.
3. Using a small flat blade screwdriver, pry off the two metal clips securing the light socket to the manifold cover.
4. Slide the defective socket out through the front of the manifold cover.
Replacement
1. The new light socket will have two sets of terminals labeled "A" and "B". Insert the back of the new light
socket through the rectangular opening in the front of the manifold cover approximately 3/4" with the "+"
terminal of the "A" set on the top.
2. Grasp the back of the light socket on the sides and pull the socket in until the front of the socket is flush with
the front of the manifold cover.
3. Reattach the connectors to the terminals on the socket.
4. Reinstall the manifold cover and connect electrical power to the manifold. Test for proper function by
following the Performance Verification Procedure in Section 3.
INDICATOR LAMP REPLACEMENT
Removal
1. Remove indicator lens cover by pulling lens cover forward. A small depression is molded into the top and
bottom of the lens cover to facilitate removal. A flat blade screwdriver can be wedged in the depression
and twisted to pry the lens cover off.
2. Remove the faulty lamp by pulling the built-in extractor. The clear plastic tab marked lamp pull is the
extractor.
Replacement
1. Insert the replacement lamp and push on the lamp until it snaps into place.
CAUTION
• Too much force used to install the lamp could break the socket bezel and allow the socket to be pushed
completely through the front of the manifold cover.
2. Reinstall the indicator lens cover with the green lens above the red lens.
CAUTION
• Too much force used to install the lens cover could break the socket bezel and allow the socket to be
pushed completely through the front of the manifold cover.
4-12
B20193 ECN-11612 (0112)
SECTION 5
MAINTENANCE & REPAIR PARTS
REPLACEMENT PIGTAILS
24" Stainless Steel Inner Core Flexible with Check Valve
HPF-16CVFA-24 .... CGA 300 with flash arrestor for Acetylene Service
HPF-320CV-24....... CGA 320 for Carbon Dioxide (CO2) Service
HPF-326CV-24....... CGA 326 for Nitrous Oxide (N2O) Service
HPF-346CV-24....... CGA 346 for Breathing Air (Air) Service
HPF-83CV-24......... CGA 350 for Hydrogen (H2) Service
HPF-15CVFA-24 .... CGA 510 with flash arrestor for Acetylene Service
HPF-63CV-24......... CGA 540 for Oxygen (O2) Service
HPF-92CV-24......... CGA 580 for Inert Gas Service (Argon, Helium, and Nitrogen)
REGULATORS & REGULATOR REPAIR KITS
Intermediate Primary Regulators
WMS-11-104 .......... Intermediate Primary Regulator for HBAC2 & HBAC2HL -series CO2, N2O (S/N > 21583)
WMS-11-120 .......... Intermediate Primary Regulator for HBAC2-series Oxygen, Air, H2, Ar, He, N2 (S/N > 21583)
WMS-11-105 .......... Intermediate Primary Regulator for HBAC2-series Acetylene (S/N > 21583)
WMS-11-120 .......... Intermediate Primary Regulator for HBAC2HP-series Oxygen, Air, H2, Ar, He, N2 (S/N > 21583)
WMS-11-122 .......... Intermediate Primary Regulator for HBAC2 & HBAC2HL-series CO2, N2O (S/N < 21584)
WMS-11-123 .......... Intermediate Primary Regulator for HBAC2-series Oxygen, Air, H2, Ar, He, N2 (S/N < 21584)
WMS-11-121 .......... Intermediate Primary Regulator for HBAC2-series Acetylene(S/N < 21584)
WMS-11-123 .......... Intermediate Primary Regulator for HBAC2HP-series Oxygen, Air, H2, Ar, He, N2 (S/N < 21584)
Change-Over Primary Regulators
WMS-11-119 .......... Change-over Primary Regulator for HBAC2-series Oxygen, Air, H2, Ar, He, N2 (S/N > 21583)
WMS-11-103 .......... Change-over Primary Regulator for HBAC2 & HBAC2HL -series CO2, N2O(S/N > 21583)
WMS-11-115 .......... Change-over Primary Regulator for HBAC2-series Acetylene(S/N > 21583)
WMS-11-119 .......... Change-over Primary Regulator for HBAC2HP-series Oxygen, Air, H2, Ar, He, N2 (S/N > 21583)
WMS-11-126 .......... Change-over Primary Regulator for HBAC2-series Oxygen, Air, H2, Ar, He, N2 (S/N < 21584)
WMS-11-125 .......... Change-over Primary Regulator for HBAC2 & HBAC2HL -series CO2, N2O(S/N < 21584)
WMS-11-124 .......... Change-over Primary Regulator for HBAC2-series Acetylene(S/N < 21584)
WMS-11-126 .......... Change-over Primary Regulator for HBAC2HP-series Oxygen, Air, H2, Ar, He, N2 (S/N < 21584)
Line Regulators
WMS-11-19 ............ Line Regulator for HBAC2 & HBAC2HL-series Acetylene and Liquefied Fuel Gas
WMS-11-20 ............ Line Regulator for HBAC2-series except Acetylene and Liquefied Fuel Gas manifolds
WMS-11-39 ............ Line Regulator for HBAC2HP-series manifolds
5-1
B20193 ECN-11612 (0112)
PANEL MOUNT GAUGES — 2" Diameter, 1/4" NPT Back Port
WMG-3-7 .......................................................... 30 psi
WMG-3-9 .......................................................... 60 psi
WMG-3-3 ........................................................ 100 psi
WMG-3-2 ........................................................ 200 psi
WMG-3-14 .................... 300 psi
WMG-3-4 ...................... 400 psi
WMG-3-8 ...................... 2000 psi
WMG-3-12 .................... 4000 psi
VALVES AND CHECK VALVES
WMV-2-56..............................................Master Valve
WMS-1-65.................. CGA 320 Header Check Valve
WMS-1-99.................. CGA 350 Header Check Valve
WMS-1-53.................. CGA 540 Header Check Valve
WMS-1-59 .................... CGA 326 Header Check Valve
WMS-1-62 .................... CGA 346 Header Check Valve
WMS-1-100 .................. CGA 510 Header Check Valve
WMS-1-54 .................... CGA 580 Header Check Valve
INDICATOR LAMP REPLACEMENT PARTS
Square Style
WME-8-42...................................................Light Bulb
WME-8-41.........................................Bulb Receptacle
WME-8-40........................................ Red/Green Lens
MK-1010 ..................................Heater light Repair Kit
PRESSURE SWITCHES
WME-4-28...............Pressure Switch Explosion Proof (adjustable 150-375 psi) HBAC2, HBAC2HL & HBAC2HP
WME-4-5.................Explosion Proof Pressure Switch (adjustable 30-300 psi) Acetylene
WME-4-29...............Bracket for WME-4-28 switch
POWER SUPPLY REPLACEMENT PARTS
WMS-11-31.............Power Supply Assembly (transformer, PCB with dry contacts, case, and cable)
WME-8-1.................Power Supply PCB for WMS-11-31 and WMS-11-36 (includes dry contacts for remote alarms)
REMOTE ALARMS — 24 VAC Service
BIA-1 .......................Visual - 1 Gas
BIA-2 .......................Audio/Visual - 2 Gases
BIA-3 .......................Audio/Visual - 1 Gas
WMS-11-36.............Optional 115 to 24 VAC Power Supply for above Remote Alarms
5-2
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2 & HBAC2HP Series — Hydrogen Manifolds
Repair Drawing
Components & Miscellaneous Hardware
See Page 5-5 for Part Numbers and Descriptions
5-3
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2 Series — Acetylene Manifolds
Repair Drawing
Components & Miscellaneous Hardware
See Page 5-5 for Part Numbers and Descriptions
5-4
B20193 ECN-11612 (0112)
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2 & HBAC2HP Series
Hydrogen & Acetylene Manifolds
Components & Miscellaneous Hardware
Western Enterprises
Repair Drawing
KEY # DESCRIPTION
1
Outlet
HBAC2-1 Series Nut
HBAC2-6 Series Tube Fitting
HBAC2HP-6 Series Tube Fitting
2
Outlet
HBAC2-1 Series Nipple
KEY #
16
17
18
19
20
21
22
23
PART #
D-8
WLF-3-30
WLF-3-30
WLF-5-4
HBAC2-6 Series Tube Extender
WMS-11-24
HBAC2HP-6 Series Tube Extender
3
4
5
6
7
8
9
10
11
12
13
14
15
Line Regulator
for HBAC2-1 Series
WMS-11-19
for HBAC2-6 Series
WMS-11-20
for HBAC2HP-6 Series
WMS-11-39
Intermediate Block
for HBAC2-1 Series
WMS-11-48
for HBAC2-6 Series
WMS-11-49
for HBAC2HP Series
WMS-11-51
#10-32 Set Screw
WMC-6-58
Inlet Tube
WMS-11-45
Left Inlet
WMS-11-71
1/4" Tube Plug
WLF-3-32
1/8" Tube Bulkhead Fitting
WLF-3-33
1/8" Tubing
for HBAC2-1, 1A Series
WLF-6-19
for HBAC2-6 & HBAC2HP-6 Series
Intermediate Tubing
WMS-11-47
Right Inlet
WMS-11-29
Primary Int. Regulator
for HBAC2-1 Series
**
for HBAC2-6 Sereis
**
for HBAC2HP-6 Series
**
#10-32 Cap Screw
WMC-6-59
Change-over Regulator
for HBAC21 Series
**
for HBAC2-6 Series
**
for HBAC2HP-6 Series
**
DESCRIPTION
Stem Locking Nut
Change-over to Block Tube
1/4 NPT Adaptor
Control Knob
Control Knob Screw
#10-1" Self -tapping Screw
Outer Gauge Plate
Case
for HBAC2-1 Series
PART #
WMS-11-25
WMS-11-46
B-4HP
RWC-3-19
RWC-3-60
WMC-6-39
WMC-8-2
WMC-8-14
for HBAC2-6 & HBAC2HP-6 Series
24
25
26
27
28
29
30
31
32
*
*
Screw Receptacle
Inner Gauge Plate
for HBAC2-1 Series
for HBAC2-6 Series
for HBAC2HP-6 Series
Backplate Assembly
Tee Mounting Bracket
3/8-16 Hex Nut
3/16" Hex Nut
3/16" Lock Washer
1/2" Nominal U-bolt
3/16-24 x 1 3/4" Carr. Bolt
Case Lead Seal
#8 Sht. Metal Case Screw
WMC-6-35
WMS-8-7
WMS-1-12
WMS-5-4
WMS-11-28
WMC-6-7
WMC-6-6
WMC-6-11
WMC-6-12
WMC-6-13
WMC-6-10
WEM-1-27
WMC-6-23
* Item not pictured.
** See Maintenance & Repair Parts list on
page 5-1.
Piping Schematics for HBAC2-1, HBAC2-1A and HBAC2-6 are shown on page 2-7
5-5
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2 & HBAC2HP Series — Except Fuel Gas
Repair Drawing
Components & Miscellaneous Hardware
** See Maintenance & Repair Parts list
KEY #
1
2
3
4
5
6
7
8
DESCRIPTION
1/4" Tube Fitting
Outlet Extender
Line Regulator
for HBAC2 Series
for HBAC2HP Series
Intermediate Block
for HBAC2 Series
for HBAC2-4, -8 Series
for HBAC2HP Series
#10-32 Set Screw
Inlet Tube
Left Inlet
for HBAC2 Series
for HBAC2-4, -8 Series
for HBAC2HP Series
1/8" Tubing
KEY # DESCRIPTION
9
Intermediate Tubing
10
Primary Int. Regulator
for HBAC2 Series
for HBAC2-4, -8 Series
for HBAC2HP Series
11
Right Inlet
for HBAC2 Series
HBAC2-4,-8 Series
for HBAC2HP Series
12
#10-32 Cap Screw
13
Stem Locking Nut
14
Change-over Regulator
for HBAC2 Series
for HBAC2-4, -8 Series
for HBAC2HP Series
15
Change-over to Block Tube
16
1/4 NPT Adaptor
PART #
WLF-3-30
WMS-11-24
WMS-11-20
WMS-11-39
WMS-11-49
WMS-11-50
WMS-11-51
WMC-6-58
WMS-11-45
WMS-11-52
WMS-11-53
WMS-11-52
WLF-6-17
5-6
PART #
WMS-11-47
**
**
**
WMS-11-68
WMS-11-68
WMS-11-68
WMC-6-59
WMS-11-25
**
**
**
WMS-11-46
B-4HP
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2 & HBAC2HP Series — Except Fuel Gas
Repair Drawing
Components & Miscellaneous Hardware
KEY #
17
18
19
20
21
22
23
24
25
26
27
28
29
DESCRIPTION
Service Control Knob
#6-32 Flat Head Screw
#10-1 Washer head Screw
Outer Gauge Plate
Case
Screw Receptacle
Inner Gauge Plate
for HBAC2 Series
for HBAC2-4, -8 Series
for HBAC2HP Series
Backplate Assembly
Tee Mounting Bracket
3/8-16 Hex Nut
3/16-24 x 1 3/4" Carr. Bolt
1/2" Nominal U-bolt
3/16" Lock Washer
PART #
RWC-3-19
RWC-3-60
WMC-6-39
WMC-8-2
WMC-8-9
WMC-6-35
KEY #
30
31
32
33
34
35
*
*
*
WMS-1-12
WMS-2-3
WMS-5-4
WMS-11-1
WMC-6-7
WMC-6-6
WMC-6-10
WMC-6-13
WMC-6-12
DESCRIPTION
3/16" Hex Nut
Case Wiring Harness
Dual Light Lens
Dual Light Base
24 V Bulb (#85)
Dual Light Label
Case Lead Seal
#8 Sht. Metal Case Screw
Power Supply Box
PART #
WMC-6-11
WMS-11-72
WME-8-40
WME-8-41
WME-8-42
WME-8-54
WEM-1-27
WMC-6-23
WMS-11-31
* Item not pictured.
5-7
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2HL Series
Repair Drawing
Components & Miscellaneous Hardware
** See Maintenance & Repair Parts list
KEY #
1
2
3
4
5
6
7
8
9
DESCRIPTION
1/8" Tube Fitting
Outlet Extender
Line Regulator
Intermediate Block
#10-32 Set Screw
Inlet Tube
Left Inlet
Heater
1/8" Tubing
PART #
WLF-3-30
WMS-11-24
WMS-11-20
WMS-11-50
WMC-6-58
WMS-11-45
WMS-11-54
WMS-11-42
WLF-6-17
KEY #
10
11
12
13
14
15
16
17
5-8
DESCRIPTION
Intermediate Tubing
Primary Int. Regulator
Right Inlet
#10-32 Cap Screw
Stem Locking Nut
Change-over Regulator
Change-over to Block Tube
1/4 NPT Adaptor
PART #
WMS-11-47
**
WMS-11-69
WMC-6-59
WMS-11-25
**
WMS-11-7
B-4HP
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2HL Series
Repair Drawing
Components & Miscellaneous Hardware
KEY #
18
19
20
21
22
23
24
25
26
27
28
29
DESCRIPTION
Control Knob
Control Knob Screw
Gauge Plate Screw
Outer Gauge Plate
Case
Screw Receptacle
Inner Gauge Plate
Backplate Assembly
Tee Mounting Bracket
3/8-16 Hex Nut
3/16-24 x 1 3/4" Carr. Bolt
1/2" Nominal U-bolt
KEY #
30
31
32
33
34
35
36
37
38
*
*
*
*
PART #
RWC-3-19
RWC-3-60
WMC-6-39
WMC-8-2
WMC-8-9
WMC-6-35
WMS-2-3
WMS-11-1
WMC-6-7
WMC-6-6
WMC-6-10
WMC-6-1
DESCRIPTION
3/16" Lock Washer
3/16" Hex Nut
Strain Relief Bushing
7’ Heater Cord
Case Wiring Harness
Dual Light Lens
Dual Light Base
Dual Light Bulb
Dual Light Label
Case Lead Seal
#8 Sht. Metal Case Screw
Wire Nut
Power Supply Box
PART #
WMC-6-12
WMC-6-11
WME-8-34
WME-8-33
WMS-11-72
WME-8-40
WME-8-41
WME-8-42
WME-8-54
WEM-1-27
WMC-6-23
WME-8-58
WMS-11-31
* Item not pictured.
5-9
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2 and HBAC2HP Series
Repair Drawing
Inlet Block Components
KEY #
1
2
3
4
DESCRIPTION
CGA 580 Nipple
CGA 580 Nut
Inlet Block
Pressure Switch
For HBAC2 Series
For HBAC2HP Series
5
Check Valve
For HBAC2-4 & HBAC2-8 Series
For all others
6
1/4 Tube Connection
7
1/4 x 1/8 NPT Adaptor
Not shown: Female Wire Connector
PART #
15-8SF10
92
WMC-2-34
Left Side Inlet
WME-4-28
WME-4-28
CVM-4F
CVM-4FV
WLF-3-30SS
B-4-2HP
WME-8-11
KEY #
1
2
3
4
DESCRIPTION
CGA 580 Nipple
CGA 580 Nut
Inlet Block
Pressure Switch
For HBAC2 Series
For HBAC2HP Series
5
CGA 580 Adaptor
6
1/8 NPT Elbow
7
1/4 x 1/8 NPT Adaptor
Not shown: Female Wire Connector
PART #
15-8SF10
92
WMC-2-37
WME-4-28
WME-4-28
B-70
BSL-2HP
B-4-2HP
WME-8-11
Right Side Inlet
5-10
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2-1, -1A and -6 Series
Repair Drawing
Inlet Block Components
Left Side Inlet
KEY #
1
2
3
4
5
6
DESCRIPTION
CGA 580 Nipple
CGA 580 Nut
Inlet Block
1/8 Tube Connection
Check Valve
1/4 Tube Connection
PART #
15-8SF10
92
WMC-2-34
WLF-3-11
CVM-4FV
WLF-3-30SS
DESCRIPTION
CGA 580 Nipple
CGA 580 Nut
Inlet Block
1/8 Tube Compression Fitting
CGA 580 Adaptor
PART #
15-8SF10
92
WMC-2-34
WLF-3-11
B-70
Right Side Inlet
KEY #
1
2
3
4
5
5-11
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2HL Series
Repair Drawing
Inlet Block Components
KEY # DESCRIPTION
1
CGA 580 Nipple
2
CGA 580 Nut
3
Inlet Block
4
Pressure Switch
5
1/4 Tube Fitting
6
Check Valve
7
1/4 Tube Fitting
8
1/8 x 1/4 NPT Adaptor
9
1/8 NPT Street Elbow
Not shown: Female Wire Connector
PART #
15-8SF10
92
WMC-2-33
WME-4-28
WLF-3-30SS
CVM-4F
WLF-3-3
B-4-2HP
BL-2HP
WME-8-11
Left Side Inlet
KEY # DESCRIPTION
1
CGA 580 Nipple
2
CGA 580 Nut
3
Inlet Block
4
Pressure Switch
5
CGA 580 Adaptor
6
1/4 Tube Connection
7
1/8 NPT Street Tee
8
1/8 NPT Eblow
9
1/8 x 1/4 NPT Adaptor
Not show: Female Wire Connector
PART #
15-8SF10
92
WMC-2-38
WME-4-28
B-70
WLF-3-3
BL-2HP
BSL-2HP
B-4-2HP
WME-8-11
Right Side Inlet
5-12
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2, HBAC2HL, & HBAC2HP Series
Repair Drawing
Intermediate Block Components
KEY #
1
2
3
4
5
6
7
8
9
DESCRIPTION
400 PSI Gauge
1/8 NPT Bushing
Intermediate Block
1/2 NPT Pipe Fitting
1/2 NPT Coupler
Safety Relief Valve
for HBAC2HL Series (300 psig)
for HBAC2HP Series (450 psig)
for HBAC2 Series (300 psig)
Pipe-away Adaptor
1/8 NPT Plug
3/8" Tube x 1/4 NPT
PART #
G-15-400W
BA-2HP
WMC-2-36
WLF-1-15
BF-8HP
WMV-8C-300
WMV-8V-450
WMV-8V-300
WMV-8-7
P-2HP
WLF-3-30SS
DESCRIPTION
400 PSI Gauge
1/8 NPT Bushing
Intermediate Block
1/2 NPT Pipe Fitting
HBAC2-1 Series 1/2 NPT Plug
1/8 NPT Plug
3/8" Tube x 1/4 NPT
PART #
G-15-400W
BA-2HP
WMC-2-36
WLF-1-15
PC-8HP
P-2HP
WLF-3-30SS
HBAC2-1 and -1A Series
KEY #
1
2
3
4
5
6
7
5-13
B20193 ECN-11612 (0112)
Western Enterprises
INNOVATOR
AUTOMATIC CHANGEOVER MANIFOLD
HBAC2, HBAC2HL, & HBAC2HP Series
Repair Drawing
Gauge Plate Components
KEY #
1
2
3
4
DESCRIPTION
Cylinder Contents Gauge
for HBAC2-1 (400 psi)
for other HBAC2 & HBAC2HP Series (4000 psi)
for HBAC2HL and HBAC2-4, -8 Series (2000 psi)
Line Pressure Gauge
for HBAC2-1,-1A (30 psi)
for other HBAC2 & HBAC2HL Series (200 psi)
for HBAC2HP Series (400 psi)
Gauge Plate
1/8" Tube x 1/4 NPT Female
5-14
PART #
WMG-3-4
WMG-3-12
WMG-3-8
WMG-3-7
WMG-3-2
WMG-3-4
WMC-8-11
WLF-3-4
B20193 ECN-11612 (0112)
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