TYPE 4R TYPE 4R AUTOMATIC MANIFOLDAUTOMATIC ... · Manifold PCB LayoutManifold PCB Layout ... The...

Phoenix Pipeline Products Limited

Installation, Operation and Maintenance ManualInstallation, Operation and Maintenance ManualInstallation, Operation and Maintenance ManualInstallation, Operation and Maintenance Manual

Phoenix Pipeline Products Limited.

Unit 8, McKenzie Industrial Park, Tel No.: 44 (0) 161 428 7200

Bird Hall Lane, Fax No.: 44 (0) 161 428 7010

Stockport, Email: [email protected]

U.K., SK3 0SB www.p3-phoenix.com

TYPE 4R TYPE 4R TYPE 4R TYPE 4R AUTOMATIC MANIFOLDAUTOMATIC MANIFOLDAUTOMATIC MANIFOLDAUTOMATIC MANIFOLD CONTROL PANEL & HEADERSCONTROL PANEL & HEADERSCONTROL PANEL & HEADERSCONTROL PANEL & HEADERS

- 2 - Automatic Gas Manifold Rev 1



Contents PageContents PageContents PageContents Page

SectionSectionSectionSection PagePagePagePage

SafetySafetySafetySafety General 3

Product DescriptionProduct DescriptionProduct DescriptionProduct Description General 3 Automatic Control Panel 3 Manifold Headers 4

OperationOperationOperationOperation General 4 Service Pushbutton 4 Control Panel Layout 5 Control Panel Parts List 6 Pneumatic Operation 7 Pneumatic Schematic Diagram 8 Electrical Operation 9 Pressure Settings 10

InstallationInstallationInstallationInstallation General 11 Mechanical 11 Installation Drawing 12 Electrical 13 Simplified Electrical Connection Diagram 14

Connecting Connecting Connecting Connecting The ESM/ERMThe ESM/ERMThe ESM/ERMThe ESM/ERM General 15 Connecting a single pressure switch 15 Connecting two pressure switches 15

Manifold PCB LayoutManifold PCB LayoutManifold PCB LayoutManifold PCB Layout General 16 Client’s Wiring Diagram 17 User Adjustable Settings 18 User Adjustable Parameters 19 Position of Adjustable Potentiometers 21

TestingTestingTestingTesting and Commissioning and Commissioning and Commissioning and Commissioning General 22 Testing 22 Commissioning 23

MaintenanceMaintenanceMaintenanceMaintenance General 23 Preventative Maintenance 23

Spare PartsSpare PartsSpare PartsSpare Parts General 24




1.1.1.1. SafetySafetySafetySafety

1.1 General

This equipment should be installed, operated and maintained by personnel who are suitably trained, are fully conversant with HTM 02-01 and/or 2022 and are familiar with this product.

This equipment should be kept clean and be free from oil and grease at all times. Oil and grease will ignite spontaneously in the presence of oxygen. If you suspect that any equipment is contaminated, do not use it.

No attempt should be made to use or modify this equipment for use with a gas other than as identified.

This equipment should not be operated at pressures exceeding those stated in HTM 02-01 and/or 2022 and this manual.

Care should be taken when drawing conclusions about the contents of cylinders from their pressures. In the case of compressed gases, such as oxygen and medical air, the cylinder pressure represents the cylinder contents, for example, if the cylinder is half full, it will show half pressure. Liquefied gases, such as nitrous oxide continue to show full cylinder pressure whilst there is liquid in the cylinder. It should not be assumed that a cylinder of nitrous oxide is full simply because the gauge shows full pressure.

2.2.2.2. Product DescriptionProduct DescriptionProduct DescriptionProduct Description

2.1 General

Automatic Gas Manifolds comprise a control panel, manifold headers & racks, tailpipes, pigtails, a line isolation valve, non-return valve and a pressure relief valve.

The manifold provides a continuous supply of gas from two banks of cylinders to the medical gas pipeline system by automatically changing from the duty bank to the standby bank as the duty bank has become depleted.

Manifolds are available for oxygen, nitrous oxide, 50% oxygen/50% nitrous oxide mixture, medical air and surgical air.

2.2 Automatic Control Panel

The Automatic control panel comprises four regulators, bank selection solenoid valves, cylinder contents and pipeline pressure transducers, gauges and an integral monitoring and status panel, all housed in a molded enclosure with transparent cover.

The monitoring & status panel indicates the duty and standby bank of cylinders, and there status. The panel also indicates the distribution pipeline. The display incorporates an alarm status indicator and includes volt free contacts for connection to the central alarm system and BMS, these alarms become open circuit on fault.

An isolation and pressure relief valve assembly is provided with copper stub pipes for on site copper to copper joints to the hospital distribution pipeline and vent pipeline. Interconnect pipes are also included to connect the control panel to the header racks.




2.3 Manifold Headers

Manifold headers comprise high-pressure headers with gas specific tailpipe connections, cylinder tailpipes, support racks and restraining chains for the cylinders.

Non return valves are incorporated in each tailpipe connector, this prevents a whole bank of cylinders becoming depleted in the event of a cylinder being disconnected or a tailpipe rupture.

Tailpipes are available with pin-index, bull nose or CGA cylinder connections.

3.3.3.3. OperationOperationOperationOperation

3.1 General

All cylinder valves connected to the manifold headers should be open. Gas is then supplied from either bank of cylinders to the automatic control panel. Under normal working conditions, gas is supplied to the hospital distribution pipeline from only one bank at a time. When the cylinder contents falls below the changeover pressure, the solenoid valve for the duty bank closes and the solenoid valve for the standby bank opens ensuring continuity of the gas supply.

In the event of an electrical failure, both solenoid valves default to open and gas will be supplied from the duty and standby banks simultaneously. Upon restoration of the electrical supply, the control panel will supply gas from the bank of cylinders that has the higher pressure.

Both solenoid valves will also open in the event of the distribution pipeline pressure falling below normal limits.

All regulators and pressure sensors within the control panel are preset and should require no further adjustment.

The monitoring & status panel incorporates a duty bank push button to enable manual selection of the left or right hand cylinders as the duty bank.

The manifold is fully automatic in operation and requires no manual intervention, other than the replacement of empty cylinders.

3.2 Service Pushbutton

The monitoring & status panel incorporates a push button to access the following functions. 1. Manual selection of the left or right cylinder banks. Change the "Duty" bank by pressing the push button for 1 to 2 seconds and then releasing. The "Duty" bank will change on release.

2. Review the set pressures. Press and hold the push button for longer than 5 seconds. The display will flash and show the values of, Change Over Pressure, High Line Pressure, and Low Line Pressure (Viewed Left to Right). Release the push button once viewed.




3.2 Control Panel Layout




3.3 Control Panel Parts List

ID Description Qty

1 Outlet Stub Pipe 1

2 Right Hand Bank Solenoid Valve 1

3 Override Pressure Switch 1

4 Line Pressure Transducer 1

5 Mains Power Supply 1

6 Line Pressure Gauge 1

7 Outlet Block 1

8 Left Hand Bank Solenoid Valve 1

9 Low Voltage Fuse Carrier 1

10 Earth Stud 1

11 2nd Stage Regulator Left Hand Bank 1

12 2nd Stage Regulator Right Hand Bank 1

13 Left Hand Bank Outlet Pressure Gauge 1 14 Right Hand Bank Outlet Pressure Gauge 1 15 Backplate 1 16 Monitoring & Status Panel 1 17 Left Hand Regulator Outlet Pipe 1 18 Right Hand Regulator Outlet Pipe 1 19 Left Hand Contents Pressure Gauge 1 20 Right Hand Contents Pressure Gauge 1 21 Left Hand Interstage Pressure Gauge 1 22 Right Hand Interstage Pressure Gauge 1 23 1

st Stage Regulator 2

24 Regulator Mounting Block 2 25 Header Inlet Connector 2 26 Contents Pressure Transducer 2 27 Enclosure 1




3.4 Pneumatic Operation

The gas from the left hand (LH) bank of cylinders is connected to the LH inlet of the control panel. This is monitored by gauge G1, transducer PT1 and passes through regulator R1, pressure gauge G3, regulator R3, pressure gauge G5 to the solenoid valve S1. Similarly, the gas from the right hand (RH) bank of cylinders is connected to the RH inlet of the control panel. This is monitored by gauge G2, transducer PT2 and passes through regulator R2, pressure gauge G4, regulator R4, pressure gauge G6 to the solenoid valve S2. Pressure gauges G1 and G2 indicate the high pressure cylinder contents in the LH and RH banks respectively. Pressure gauges G3 and G4 indicate the interstage pressure from regulators R1 and R2 respectively. Pressure Gauges G5 and G6 monitor the final outlet pressure from the 2

nd stage regulators.

With the LH bank selected as the duty bank, the solenoid valve S1 is de-energised and opens allowing gas to pass to the distribution pipeline. Solenoid valve S2 is energised and closed to prevent the RH from supplying gas. When the pressure in the LH bank falls below the changeover threshold, monitored by transducer PT1, the solenoid valve S1 is energised and closes, whilst the solenoid valve S2 is de-energised and opens thus effecting the changeover from the LH duty bank to the RH standby bank.

The empty cylinders on the LH bank should now be replaced with full cylinders, ready to continue the supply of gas when the RH bank is depleted.

When the pressure in the RH bank falls below the changeover threshold, monitored by transducer PT2, the solenoid valve S2 is energised and closes and solenoid valve S1 is de-energised and opens thus allowing the LH bank (now full) to continue with the gas supply. The empty cylinders on the RH bank should now be replaced with full cylinders. This sequence will continue.

Pressure gauge G7 indicates the distribution pipeline pressure, whilst transducer PT3 monitors the distribution pipeline pressure for high or low pressure faults. Pressure switch P1 will de-energise both solenoid valves S1 and S2 in the event of the distribution pipeline pressure falling below normal limits allowing both banks to feed the system simultaneously.




3.5 Pneumatic Schematic Diagram




3.6 Electrical Operation

The control panel requires a 100V-240V AC, 50/60Hz, single-phase supply.

The monitoring & status panel incorporates three sections:-

1. The Auto Manifold Indicator Unit

2. Emergency Reserve Manifold Unit

3. Alarm Signal Status Unit

The Auto Manifold Indicator Unit

(a) For each bank, a green LED indicator (RUNNING) illuminates to indicate which bank is currently running.

(b) For each bank, a yellow LED indicator (LOW PRESSURE) illuminates to indicate that a bank of cylinders is empty and changeover to the standby bank has occurred.

(c) For each bank, a yellow LED indicator (EMPTY) illuminates to indicate that the bank that is running has fallen below the changeover threshold, and that the standby bank has not been replenished.

(d) A red LED indicator (HIGH PRESSURE) illuminates to indicate when the distribution pipeline pressure has risen above the pressure sensor setting.

(a) A red LED indicator (LOW PRESSURE) illuminates to indicate when the distribution pipeline pressure has fallen below the pressure sensor setting.

The Emergency Reserve Manifold Indicator Unit

(a) A yellow LED indicator (LEFT HAND BANK LOW) which illuminates to indicate when the left hand bank of Emergency Reserve Cylinders is 50% or less.

(b) A yellow LED indicator (RIGHT HAND BANK LOW) which illuminates to indicate when the right hand bank of Emergency Reserve Cylinders is 50% or less.

(e) If the ESM/ERM is set to operate with a single bank of cylinders both indicators will operate in parallel.

The Alarm Signal Status Unit

(b) A green LED indicator (POWER ON) illuminates to indicate that the power to the manifold is on.

(c) A green LED indictor (NORMAL) that illuminates to indicate that the manifold is operating correctly and that no faults exist.

(d) A yellow LED indicator (CHANGE CYLINDERS) which illuminates to indicate when the changeover from the duty to the standby bank has occurred.

(e) A yellow LED indicator (CHANGE CYLINDERS IMMEDIATELY) which illuminates to indicate when the bank that is running has fallen below the pressure sensor setting and the standby bank is empty.

(f) A red LED indicator (RESERVE LOW) which illuminates to indicate when the duty bank of the remote emergency reserve manifold (ESM/ERM) has fallen below the low pressure setting.

(g) A red LED indicator (PRESSURE FAULT) which illuminates to indicate when the

distribution pipeline pressure has risen or fallen beyond the respective pressure sensor settings.

(c) A red LED indicator (SYSTEM FAULT) which illuminates in the event of a cabling fault between the remote ESM/ERM and the Auto Manifold panel.

(d) A yellow LED indicator (RIGHT HAND BANK LOW) which illuminates to indicate when the right hand bank of Emergency Reserve Cylinders is empty.

- 10 - Automatic Gas Manifold Rev

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3.7 Pressure Settings

Component O2 N2O O2/N2O Medical Air

(400 kPa)

Surgical Air

(700 kPa)

Dental Air

1st Stage Regulators

(static) 8.0 bar 8.0 bar 8.0 bar 8.0 bar 10.0 bar 10.0 bar

2nd Stage Regulators

(static) 4.5 bar 4.5 bar 4.5 bar 4.5 bar 7.5 bar 6.0 bar

Changeover Pressure 12.0 bar 14.0 bar

12.0 bar 12.0 bar 12.0 bar 12.0 bar

Pressure Relief Valve 5.5 bar 5.5 bar 5.5 bar 5.5 bar 9.0 bar 7.5 bar

Pipeline Pressure, High 5.0 bar 5.0 bar 5.0 bar 5.0 bar 8.0 bar 7.2 bar

Pipeline Pressure, Low 3.7 bar 3.7 bar 3.7 bar 3.7 bar 6.5 bar 5.1 bar

Override Switch 3.0 bar 3.0 bar 3.0 bar 3.0 bar 6.0 bar 4.2 bar

These pressure settings are factory set, and should not normally require adjustment.


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4.4.4.4. IIIInstallationnstallationnstallationnstallation

4.1 General

The automatic control panel is supplied with all internal electrical connections pre-wired. The only external wiring required for the installation is the connection of the mains power supply, the connection of the ESM/ERM pressure switch(es) (if required) and the connection of the central alarm system and BMS wiring (if required).

All regulators and pressure sensors are preset and no further adjustment of these settings should be required.

4.2 Mechanical

(a) Secure the automatic control panel enclosure to the wall using suitable fixings at the height indicated in figure 4.3. Ensure that there is sufficient space either side of the control panel to install the manifold headers.

(b) Replace the backplate assembly and secure with the six retaining screws.

(c) Connect the AC supply to the mains fuse carrier.

(d) Secure the manifold headers at the height and position indicated in figure 4.3 using suitable fixings. Use the header connecting pipes to assist in the accurate alignment of the racks.

(e) Install the outlet stub pipe, pressure relief valve and isolation valve.

(f) Install the discharge pipeline from the pressure relief valve to a safe external location.

(g) Fit all tailpipes onto the manifold headers.

(h) Check and tighten all mechanical joints (Do Not Over tighten).

(i) Connect cylinders, pressurise the manifold and check for leaks. Make sure that the isolation valve is closed if the connection to the distribution pipeline has been made.

(j) Connect the mains power supply as shown on the diagram.


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4.3 Installation Drawing


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4.4 Electrical

1. Connect the incoming mains power supply to the terminals in the auto manifold enclosure. (Connections should be made in accordance with the electrical connections diagram figure 4.5 of this manual).

The mains power supply should be via an unswitched fused spur rated at 5 amps.

2. Connect the ESM/ERM pressure switch(es) using an E.O.L monitor (Connections should be made in accordance with the client’s wiring diagram figure 6.2 of this manual).

3. Connect the alarm terminal to the central alarm system. Refer to figure 6.2 for details of each alarm conditions position on the 8-way connector.

4. Connect the alarm conditions to the building management system (BMS) by connecting to BMS terminals on the PCB. Refer to figure 4.5 for details of each alarm conditions position on the 8-way connector.

5. Check that the DIP switches are set correctly. (Refer to Section 6.3 for DIP switch

settings).


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4.5 Simplified Electrical Connection Diagram


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5. Connecting The ESM/ERM


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5.1 General The Auto manifold control panel can monitor an ESM (HTM 2022) with one pressure switch, or an ERM (HTM 02) with two pressure switches. As standard the manifold PCB is set for the use of one pressure switch (HTM 2022) linked out with 3K3 resistors.

5.2 To connect a single Pressure Switch (HTM2022)

1. Turn off the power to the manifold PCB

2. Identify the ESM/ERM terminal block (Block 3) on the manifold PCB, 3.1,3.2 (Left Hand Bank, 3.3, 3.4 (Right Hand Bank) (See manifold PCB layout section 6 of this manual).

3. Remove either 3K3 resistor

4. Connect these terminals to P3 end of line monitor/Pressure Switch

5. Check that DIP switch 3 is set to the ‘ON’ position (Refer to user adjustable settings section 6.3 of this manual).

6. Turn on power to manifold PCB 5.3 To connect two Pressure Switches (HTM 02)

1. Turn off the power to the manifold PCB

2. Identify the ESM/ERM terminal block (Block 3) on the manifold PCB, 3.1,3.2 (Left Hand Bank, 3.3, 3.4 (Right Hand Bank) (See manifold PCB layout section 6 of this manual).

3. Remove both 3K3 resistors

4. Connect terminals 3.1,3.2 to the left bank end of line monitor/Pressure Switch (please check client’s wiring diagram section 6.2 of this manual).

5. Connect terminals 3.3,3.4 to the right bank end of line monitor/Pressure Switch (please check client’s wiring diagram section 6.2 of this manual).

6. Check that DIP switch 3 is set to the ‘OFF’ position (Refer to user adjustable settings section 6.3 of this manual).

7. Turn on power to manifold PCB Note:

End of line monitors MUST be P3 to ensure electronic compatibility.


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6. Manifold PCB Layout 6.1 General

VIEW FROM FRONT WITH FASCIA FOLDED FORWARDS

18V Supply

DIP Switch

BMS Bank Running Open = Running

Position of RTX1 Channel Switch (If Fitted)

Adjustable Low Pressure Alarm

Adjustable Change Over Pressure Alarm

Adjustable High Pressure Alarm

Service Push Button

ESM/ERM

BMS

Alarm

Encoded Alarm Type RTX 1 (Optional)


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Medical Gas Alarm

BMS

ALARM

On

12

34

56

View Of Underside of PCB

(Component Side)

with fascia folded forw

ards

Change Cyls

Change Cyls Imm

Reserve Low

Pressure Fault

2

Wiring By Client

78

6.2 Client’s Wiring Diagram


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6.3 User Adjustable Settings The manifold PCB includes a DIP switch, this allows the user to adjust certain Parameters. The table below shows settings that can be adjusted by the user. It is not necessary to disconnect the power to the auto manifold before changing any of the following settings, therefore care should be taken when adjusting the DIP switches. DIP switches 1 and 2 control the line pressure and the changeover pressure as shown below:- DIP Switch 1 DIP Switch 2 Setting

Off Off 4 Line Pressure, Low 3.7, high 5.0, 12 Bar Changeover Off On 4 Line Pressure, , Low 3.7, high 5.0, 14 Bar Changeover On Off 7 Line Pressure, Low 6.5, high 8.0, 12 Bar Changeover On On User adjusted settings

DIP switches 3 and 4 control the end of line monitor and the method of monitoring:- DIP Switch 3 DIP Switch 4 Setting

Off Off 2No. end of line monitors monitored with transducers Off On 2No. end of line monitors monitored with pressure switches On Off 1No. end of line monitor monitored with a transducer On On 1No. end of line monitor monitored with a pressure switch

Once the DIP switches have been set to the desired settings, test that the auto manifold operates correctly.

The above diagram shows the manifold set up as a 4BarG system with a changeover pressure of 12BarG (Air), and the use of one pressure switch for the ESM.

Please Note:- Switches 6, 7 and 8 are not used.


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6.4 User Adjustable Parameters

It is possible for the user to create alternative pressure settings on the Auto manifold PCB.

The user can adjust the following three parameters:-

• Changeover pressure, adjustable between 2.0 and 22.0 bar,

• High pressure alarm, adjustable between 2.0 and 15.9 bar

• Low pressure alarm adjustable between 2.0 and 15.9 bar.

To Adjust The Pressure Settings 1. To enter "Edit" mode set DIP switch 5 to the "On" position.

2. Check the three digital displays are flashing (Flashing Indicates "Edit" mode).

3. In this mode the "Left Bank" display now indicates the changeover pressure for both cylinder banks.

4. In this mode the "Pipeline" display now indicates the High Pressure Alarm.

5. In this mode the "Right Bank" display now indicates the Low Pressure Alarm.

6. Identify the adjustment potentiometers on the PCB (See Page 21 Figure 3). 7. Adjust the potentiometers to create the desired pressure settings. 8. Set DIP switch 5 to the "Off" position to exit "Edit" mode. 9. Set both DIP switches 1 and 2 to the "On" position to apply the settings. 10. Press and hold the "Service push button" for longer than 5 seconds, to display and

confirm the applied operational settings. 11. Release "Service push button" once viewed, to return the display to operational

information.

Note:- 1. Until the new settings have been applied (Step 9), the control panel will continue to

operate using the previously selected pressure settings.

2. In "Edit" mode the displays DO NOTDO NOTDO NOTDO NOT show current operational information.

3. The low pressure alarm must be set lower than the high pressure alarm otherwise the display will read error (ERR).


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Power On

Normal

Change Cylinders

Change Cylinders Immediately

Reserve Low

Pressure Fault

System Fault

Left Bank

Low Pressure

Running

Empty

Running

Low Pressure

Empty

High Pressure

Low Pressure

Auto Manifold Indicator UnitAlarm Signal Status Unit

Left Hand

Bank Low

Right Hand

Bank Low

Emergency Reserve Manifold

E R M

Change OverPressure

High LinePressure Alarm

Low LinePressure Alarm

Pipeline Right Bank

Power On

Normal

Change Cylinders

Change Cylinders Immediately

Reserve Low

Pressure Fault

System Fault

Left Bank Right Bank

Low Pressure

Running

Empty

Running

Low Pressure

Empty

High Pressure

Low Pressure

Auto Manifold Indicator UnitAlarm Signal Status Unit

Pipeline

Left Hand

Bank Low

Right Hand

Bank Low

Emergency Reserve Manifold

E R M

Adjusting The Pressure Settings Continued In the example above the user has set the change over pressure to 15Bar, the High Line pressure alarm to 5.2Bar, and the Low Line Pressure Alarm to 2.0Bar.

In the example above the left cylinder bank pressure is 100Bar, the right cylinder bank pressure is 125Bar, and the Line Pressure is 4.4Bar.

Figure 1 Edit Mode

Figure 2 Operating Mode

DIP Switch 5 in the "On"

Position (Edit Mode Only)

DIP Switch 5 in the "Off"

Position

Displays Flashing


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6.5 Position Of Adjustable Potentiometers

Change Over

Pressure

High Pressure Alarm

Low Pressure Alarm

Adjust the potentiometers to adjust the alarm pressures

Figure 3 View From Underside Of Auto Manifold

Service Push Button


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7.7.7.7. TestingTestingTestingTesting & Commissioning & Commissioning & Commissioning & Commissioning

7.1 General

Prior to testing the manifold installation, please check the following.

(a) All components have been installed, and are tightened.

(b) The mains power supply has been installed and power is available.

(c) The isolation valves on the automatic manifold and ESM are closed.

(d) Full cylinders have been fitted to all tailpipes.

7.2 Testing Leak Testing

(a) Slowly open all cylinders on each bank and allow the system to pressurise.

(b) Check all tailpipes and header interconnecting pipes for leaks.

(c) Slowly open all cylinders on the ESM/ERM (if available) and check for leaks.

(d) Depressurise the Auto manifold and ESM/ERM. Function Test

(e) Apply mains power to the panel, Note, on power up the display board undertakes a sequential lamp test, the POWER ON indicator will then illuminate. Open one cylinder on the LH bank first, the LH bank RUNNING indicator will illuminate. Open one cylinder on the RH bank, the NORMAL indicator will illuminate.

(f) Close the cylinders on both banks. Create a flow between the control panel and the distribution pipeline and very slowly depressurise the system. Monitor the LED display on the left hand bank as the pressure drops.

(g) At changeover pressure (refer to the settings in table 2.5), the LH bank RUNNING indicator will extinguish and the EMPTY indicator will illuminate. The RH bank RUNNING indicator simultaneously illuminates as the control panel changes to run from the RH bank. The NORMAL indicator on the alarm signal status unit will extinguish and the CHANGE CYLINDERS will illuminate.

(h) Open the cylinder again on the LH bank. The CHANGE CYLINDERS indicator will extinguish and the NORMAL indicator will illuminate. The LH bank EMPTY indicator will extinguish, now close the cylinder.

(i) The system should be running on the RH bank. Create a leak again and slowly depressurise the system.

(j) At changeover pressure, the RH bank RUNNING indicator will extinguish and the EMPTY indicator will illuminate. The LH bank RUNNING indicator will illuminate. The NORMAL indicator will extinguish and the CHANGE CYLINDERS indicator will illuminate. Monitor the LED display on the left hand bank as the pressure drops.

(k) Continue to depressurise the LH bank, at changeover pressure the LH bank LOW PRESSURE and CHANGE CYLINDERS IMMEDIATELY indicators will illuminate.

(l) As the system is further depressurised the pipeline LOW PRESSURE, and PRESSURE FAULT indicators will illuminate.

(m) Open the cylinder on the ESM/ERM (if available), and close the cylinder at 70 BarG. Open the isolation valve on the ESM/ERM. Continue to depressurise the system. At the setting of the ESM/ERM pressure switch, the RESERVE LOW indicator, and ERM BANK LOW indicator will illuminate.

(n) Continue to depressurise the system. When the pressure falls to the setting of the low pressure, the LOW PRESSURE indicator on the manifold indicator unit will


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illuminate and the PRESSURE FAULT indicator on the alarm signal status unit will illuminate.

(o) Close all flows and isolation valves and re-pressurise the system. All alarm signal indicators will extinguish and the NORMAL indicators will illuminate.

(p) Check all alarm system outputs using a continuity tester or multimeter. All outputs are normally closed and as each alarm condition occurs, the respective contact opens circuit (to recreate alarm conditions repeat steps e through to o). Please refer to the client’s connection diagram section 6.2, to refer to the alarm terminals.

7.3 Commissioning

Demonstrate the manifold installation to the client by repeating the above-mentioned test procedure.

It is essential to confirm that a central alarm system is operating and indicating correctly at the same time.

The manifold must not be used until all testing & commissioning procedures for the pipeline system as detailed in HTM 02-01, or 2022 have been satisfactorily completed and accepted.

8.8.8.8. MaintenanceMaintenanceMaintenanceMaintenance

8.1 General

Maintenance of the manifold should be restricted to periodic checking and adjustment and if necessary the replacement of faulty components. It should be noted that although many of the components appear to be standard items, they have been selected and treated to ensure compatibility with the gases carried and the pressures involved.

8.2 Preventative Maintenance

Regular inspections and maintenance of the manifold will prolong its life and reduce the possibility of sudden, inconvenient component failures.

Automatic Manifolds should be subjected to regular inspection and testing as detailed below.

• Monthly;

(a) Visually inspect the manifold for signs of damage. (b) Check all mechanical joints for leaks. (c) Check that changeover from the duty bank to the standby bank is operating

correctly. (d) Check that the duty bank changeover switch operates correctly.

• Annually;

(a) Visually inspect the manifold system for signs of damage. (b) Check that one bank of cylinders on the ESM/ERM is open ready for use. (c) Check all mechanical joints for leaks. (d) Test the manifold system as detailed in section 7.2 to confirm correct

operation. (e) Observe that all indicators are working correctly.

All maintenance should be carried out with the knowledge of the “Authorised person” and in accordance with the Permit-to-Work system.


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9.9.9.9. Spare PartsSpare PartsSpare PartsSpare Parts

When ordering spare parts, quote the batch number of the equipment and a description of the component required.

ItemItemItemItem DescriptionDescriptionDescriptionDescription Part NumberPart NumberPart NumberPart Number

1 Tailpipe, O2, Pin-index 1-40800-01

2 Tailpipe, O2, Bull-nose 1-40801-01

3 Tailpipe, O2, CGA 540 1-40806-01

4 Tailpipe, N2O, BS 341 No.13 1-40802-02

5 Tailpipe, N2O, CGA 326 1-40807-02

6 Tailpipe, 50% O2/50% N2O, Pin-index 1-40803-03

7 Tailpipe, Medical Air, Pin-index 1-40804-04

8 Tailpipe, Medical Air, Bull-nose 1-40805-04

9 Tailpipe, Medical Air, CGA 346 1-40808-04

10 Pressure Relief Valve, 5.5 Bar 1-46000-09

11 Pressure Relief Valve, 9.0 Bar 1-46001-09

12 Regulator Assembly, 8 Bar 1-46034-09

14 Regulator Assembly, 10 Bar 1-46035-09

15 Regulator Assembly, 8 Bar (N2O) 1-46036-09

16 Contents Pressure Transducer, 0-250 Bar 1-46102-09

17 Contents Pressure Gauge, 0 – 400 Bar 1-46007-09

18 Contents Pressure Gauge, 0 – 160 Bar 1-46008-02

19 Outlet Pressure Gauge, 0 – 6 Bar 1-46009-09

20 Outlet Pressure Gauge, 0 – 16 Bar 1-46010-09

21 Bodok Seal for pin-index tailpipes 1-46011-09

22 O-ring for bull-nose tailpipes 1-46012-09

23 Solenoid Valve 1-46013-09


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ItemItemItemItem DescriptionDescriptionDescriptionDescription Part NumberPart NumberPart NumberPart Number

24 Pipeline Pressure Transducer, 0-16 Bar 1-46101-09

25 Override Switch, 3.0 Bar 1-46018-09



28 Line Pressure Gauge, 0-10 Bar 1-46020-09

29 Automatic Manifold PCB TR1 1-46100-09

30 Manifold Header Link Pipe c/w o-rings 1-46023-09

31 Header O-ring Service Kit (per cylinder) 1-46027-09

32 Auto Control Panel Seal Service Kit 1-46028-09

33 Tailpipe, Medical Air, CGA 540 1-40810-04

34 2nd Stage Regulator Assembly 4.5 Bar 1-46037-09



Due to our policy of continuous product improvement, Phoenix Pipeline Products Ltd. reserve the right to alter dimensions and/or

specification without notice although every effort will be made to advise of any such modifications. Certain aspects of P³ Ltd. designs are

protected.


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