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Installation & Operating Instructions forGenesys2 LL & PL Series Manifolds

Powerex • 150 Production Drive • Harrison, OH 45030 • USA(T) 1.888.769.7979 • (F) 513-367-3125 • www.powerexinc.com

IN594900AV • 02/2017 of 36

Model LL Model PL



IN594900AV • 02/2017 of 36

ContentsFeatures & Benefits 3

General Instructions 4

Introduction 4

Installation 5Mounting 5Plumbing Model LL 6Plumbing Model PL 8Electrical 9

Remote Alarm Wiring Model LL 10, 12

Remote Alarm Wiring Model PL 11, 12

Installation – Pigtails & Cylinders 13

Start Up & Checking Procedures Model LL 15

Start Up & Checking Procedures Model PL 17

Emergency Reserve Plumbing & Wiring Models LL & PL 18

Cylinder Replacement & Handling 19

Line Delivery Pressure Adjustment 19

Programming Adjustments 20

General Maintenance 21

Table of Error Codes 21

Table of Alarm Codes 22

Replacement Parts 23

Trouble Shooting Guide 25

Appendix A Glossary of Terms 27

Appendix B Technical Specifications 28

Appendix C Operational Pressure Specifications 29

Appendix D Wiring Diagram 30

Appendix E Wiring Diagram for Buzzer Kit 31

Warranty 32

Technical Assistance 1-888-769-7979



IN594900AV • 02/2017 of 36

Features & Benefits• Fully automatic changeover • Novalvesorleverstoresetaftereachchangeover.

• Compatible with Powerex T-Net medical gas monitoring system • Savestimeandimprovessafety.

• Economizer software • Ensuresemptyportablebulkvesselswillnotbeputback intoreserveandtheentireliquidcontentsofportablebulk vesselsisused.

• Economizer hardware • Allowsheadpressurefromsecondaryportablebulk vesselstobeused–insteadofvented.

• Field upgradeable design • Kitsallowunittobechangedfrom-i.e.cylindersto portablebulkorfromstandardflowtohighfloworfrom lowerdeliverypressuretohigherdeliverypressure.

• Circuit board triggers all required NFPA 99 alarms • Simplifyingwiringandreducingcost.

• Unit includes hi/low line pressure transducer • Eliminatingneedtopurchasehi/lowpressureswitch improvingalarmaccuracyandimprovingsafety(manifold willautomaticallyalarmifatransducergoesbad).

• Easy to service layout/design

• Microprocessor-based control panel • IncorporatesLED’sandilluminatedtextdisplayreadable eveninpoorlightingconditions.

• Electronic monitoring of circuits • Upto19error,alarmorinformationmessagesdisplayed foreaseofmaintenance.

• Accurate, long life pressure transducers for monitoring of line pressure and bank pressures

• Analog gauges also provided for use in event of power failure

• Pressures may be displayed in PSIG / kPa / BAR

• Built in DISS gas specific emergency feed ports

• Built in emergency reserve bank ports

• Input power 120 VAC, 50 to 60 Hz (120–240VAC,50to60Hzonallmodelswithoutheaters)

• Dual line pressure regulators on NFPA 99 models

• Gas specific header bar with integral check valves and cylinder pigtail assemblies

• Variety of header configurations available to meet the available space requirements of your installation

• Available in weatherproof cabinet for outdoor installation



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IntroductionPowerex manifolds are cleaned for use with oxygen. Eachsystemistestedforchangeover,triggeringofalarmsandleakage.Eachunitisdesignedandpreparedfortheindicatedgasservice.Powerex manifolds are built in accordance with the NationalFire Protection Association and Compressed Gas Associationguidelines.

WarrantyAllPowerexmanifoldsarewarrantedagainstdefectsinmaterialand workmanship for the period of one year from date ofpurchase. All circuit boards are warranted against defects inmaterial andworkmanship for the period of three years fromdateofpurchase.

General Instructions/Location & ShelterManifolds should be installed in accordance with guidelinesstatedbytheNationalFireProtectionAssociation,theCompressedGasAssociation,OSHA, andall applicable local codes. Centralsupplysystemsandcylindersshouldnotbeplacedinalocationwherethetemperaturewillexceed125°F(51.6°C)orfallbelow-20°F(-29°C).Amanifoldplacedinanopenlocationshouldbeprotectedagainstweatherconditions.Duringwinter,protectthemanifoldfromiceandsnow.Insummer,shadethemanifoldandcylindersfromcontinuousexposuretodirectsunlight.Theflowcapacityofnitrousoxideandcarbondioxidemanifoldsdependuponambienttemperatureandthenumberofcylindersonline.Contact your gas supplier to determine the vaporization rateofCarbonDioxideandNitrousOxidecylinders for theambienttemperatureclimateattheinstallationsite.

Leaveallprotectivecoversinplaceuntiltheirremovalisrequiredfor installation. This precautionwill keepmoisture anddebrisfromthepipinginterior.

CautionFailure to follow the following instructions can result inpersonalinjuryorpropertydamage:

• Neverpermitoil,grease,orothercombustiblematerials tocomeincontactwithcylinders,manifold,and connections.Oilandgreasemayreactwithexplosive forcewhenignitedwhileincontactwithsomegases– particularlyoxygenandnitrousoxide.• Cylinderandmastervalvesshouldalwaysbeopenedvery slowly.Heatofrecompressionmayignitecombustible materialscreatinganexplosiveforce.

• Pigtailsshouldneverbekinked,twisted,orbentintoa radiussmallerthan3inches.Mistreatmentmaycause thepigtailtoburst.

• Donotapplyheat.Oilandgreasemayreactwith explosiveforcewhenignitedwhileincontactwithsome gases–particularlyoxygenandnitrousoxide.

• Cylindersshouldalwaysbesecuredwithracks,chains,or straps.Unrestrainedcylindersmayfalloveranddamage orbreakoffthecylindervalvewhichmaypropelthe cylinderfromitscurrentposition.

• Oxygenmanifoldsandcylindersshouldbegrounded. Staticdischargesandlightningmayignitematerialsinan oxygenatmosphere,creatingafireorexplosiveforce.

• Weldingshouldnotbeperformednearnitrousoxide piping.Excessiveheatmaycausethegastodissociate, creatinganexplosiveforce.

• Removeallprotectivecapspriortoassembly.The protectivecapmayigniteduetoheatofrecompression inanoxygensystem.



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Control Cabinet Installation• Determineandmarktheverticalcenterlineforinstallationofthemanifoldcontrolcabinet.

• If you wish to place cylinders under themanifold cabinet,measure from thefloor to a point 79” in height above thefinished floor of this vertical line. Using a level, mark ahorizontallineatthispointextendingapproximately7”totheleftand7”totherightofcenter.ThislineindicatesthelocationforthebottomtwomountingboltsoftheZmountingbracket.MountingtheZbracket@79”aff*willresultinthebottomofthemanifoldcabinetbeing60”aff–allowingcylinderstobeplacedunderthemanifoldcabinet.Ifyoudonotwishtoplacecylindersunderthemanifoldcabinet,measurefromthefloortoapoint58½”affandfollowthesamestepsabove.

•Mount the Zmounting bracket to the wall using fastenerssuitableforthetypeofwallconstruction.

• TemporarilyhangthemanifoldcabinetontheZbracketjustinstalled, mating it with the Z bracket on the back of themanifoldcabinet.Markthelocationsofthetwolowercabinetmountingholesonthewall.

• Remove themanifold cabinet and install female portion ofsuitablefastenersforlowercabinetmountingholes.

• Re-hangthemanifoldcabinetandinstallsuitablefastenersinthelowercabinetmountingholes.

*aff=abovefinishedfloor

Header Installation• Attachtheheaderstotheuniononeachsideofthemanifoldcontrol cabinet. Using a level, mark the placement ofmountingbracketswhilekeepingtheheaderonahorizontalplane.

• Remove the U-bolt assemblies from the header mountingbrackets.Positionthebracketssothatthetopofthebracketis alignedwith the bottom of the headers and is centeredbetweenthecylinderconnections.Theendbracketshouldbeplacedasclosetothelastcylinderaspossibletoprovidethemostsupportandstability.



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•Markthemountingholeandinstallfastenerssuitablefortypeofwallconstruction.

• Fit the U-bolt over the header piping and tighten the twomountingnuts.

Plumbing – Model LL• The outlet of themanifold is located at the top center ofthe unit as shownhere. Theoutlet connection is 1/2NPTfemale. A sourcevalve1/2MNPTx¾ tubeextensionhasbeenprovidedwithallNFPA99compliantmodels(part#48-0023)andshouldbeinstalledinthemanifoldoutlet.Itmaybenecessarytoinstalla1/2NPT90°streetelbow(part#17-0300soldseparately)tomeettheconfinesoftheinstallationsite.

• Source valve part # 48-0023 (should be installed on themanifoldcabinetpriortomountingonthewall).

Recommended Vent Line and Emergency Reserve Plumbing

Emergencyreservelowpressuretransducer(14-3001-12)

Union(suppliedbycontractor)Linepressurereliefvalve(1/2Fnptoutletconnection)

The installing contractor will need toprovide fittings and type K coppersufficienttoinstalltheemergencyreserveandventlines.Asindicatedbythedottedlinesinthisdrawing.



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Plumbing – Model LL• In addition to connecting the left & right primary andsecondaryportablebulkvesselsupplybanks,theLLmodelsmust also have a high pressure reserve bank of cylindersconnectedtothecabinettobeincompliancewithNFPA99guidelines.

• ThemodelLLhasone½NPTfemalelinepressurereliefvalveconnection and two3/8NPT female intermediate pressurerelief valve connections. (This installation is typical –withthetwo intermediatereliefvent linesandthe linepressurereliefventlinebroughttogetherasacommonventlinethatexitsthefacilityeitherthruanexteriorwallortheroof).Seebottomofpage6.

• The intermediate block has a ½ npt plug which may beremoved to allow the emergency reserve to be piped inthrougheithertheleftortherightsideofthecabinet.Slotshavebeenprovidedonboth the leftand right sidesof thecontrolcabinettoallowforthehighpressurereservepiping.

• Emergency reserve in use pressure transducer (14-3002) –installedinfactorywhenorderedwithLLmanifold.

• CV-050Fcheckvalve(mustbeinstalledbetweenthemanifoldcabinet and downstream of the high pressure reserveregulator).

Emergencyreservelowpressuretransducer(14-3001-12)installedintoportonRWPreservemanifoldbyplumber.

Unions(suppliedbycontractor)

Emergencyreservelowpressuretransducer(14-3001-12)

HighpressurereservemanifoldMainlineoutletconnection



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Plumbing – Model PL• Inadditiontoconnectingtheleftprimaryportablebulkvesselsupplybank, thePLmodelsmustalsohaveahighpressurereserve bank of cylinders and a high pressure emergencyreservebankofcylindersconnectedtothecabinettobe incompliancewithNFPA99guidelines.

• Atransducer(part#14-3001-5)mustbeinstalled(byinstaller)into the port provided in the right / secondary manifoldheader.

• ThemodelPLhasone½NPTfemalelinepressurereliefvalveconnection and one ⅜ NPT female intermediate pressurereliefvalveconnections.(Thisinstallationistypical–withtheintermediatereliefventlineandthelinepressurereliefventlinebrought togetherasacommonvent line thatexits thefacilityeitherthruanexteriorwallortheroof).(Seedrawingatbottomofpage).

• The intermediate block has a ½ npt plug which may beremoved to allow the emergency reserve to be piped inthrougheithertheleftortherightsideofthecabinet.Slotshavebeenprovidedonboth the leftand right sidesof thecontrolcabinettoallowforthehighpressurereservepiping.

• Emergency reserve in use pressure transducer (14-3002) –installedinfactorywhenorderedwithPLmanifold.

• CV-050Fcheckvalve(mustbeinstalledbetweenthemanifoldcabinet and downstream of the high pressure reserveregulator).

Emergencyreservelowpressuretransducer(14-3001-12)installedintoportonRWPreservemanifoldbyplumber.

Emergencyreservemanifoldsupply

Primary/portablebulksupply Reserve/secondary

manifoldsupply

The installing contractor willneedtoprovidefittingsandtypeKcoppersufficienttoinstalltheemergency reserve and ventlines.Asindicatedbythedottedlinesinthisdrawing.



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Electrical• Useoneofthetwo½”conduitknock-outsprovidedlocatednearesttothetopleftcornerofthecabinettorouteconduittosupply120VACtothepowersupply.

Note: Separateconduitshouldbeusedforlowvoltagewires(useknockoutsprovidedontheleftsideofthebox).

120-240/1/50–60Hzmaybeusedwithallunits.Iftheunithasheaters,theheatersonlymaybewiredto120/1/50-60.Anadditionaltransformer(soldseparatelypart#35-3004)isrequiredtoconnectheatersto240VAC.

• Remove the power supply cover by loosening the screwlocatedat the topof the coverand then sliding thepowersupplycovertotherightuntilthescrewisinthecenterofthetear-dropshapedcutout.Next,pullthecoverforwarduntilitclearsthescrewheadandthefuse.Note:thebottomofthecoverinsertsintoaslotinthebackplate.Allowthecovertorestontheduallineregulatorassemblyplumbingjustbelowthepowersupply.

• Route wires of proper gauge (per local building coderequirement) through the power supply conduit, thru thegrommetonthepowersupplybracketandintotheterminalstrip.

• Connect the 120 VAC facility emergency power sourceelectricalwiringtotheterminalstripprovidedonthefrontofthepowersupplymountingbracket(perphotosright).

(N=neutral,L=load,FG=fieldground). Note:Thegroundmustbeasolidearthgroundwithlittleornoresistance.A“noisy”earthgroundmayaffectthedigitaldisplayofthemanifold.

Conduitknockoutsfor120VAC Conduitknockoutforlowvoltage alarm signals

Neutral

Load

FieldGround



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Wiring – Remote Alarms – Model LLCaution: Never connect or disconnect any electrical components with the power on. This may result in damage to components and is not covered under warranty.

•Wires for remote alarms should be brought into thecabinet thru conduit or shielded cables (check local coderequirements) thru the knockouts on the left side of thecabinetshownhere.

Note: Separate conduit should be used for high voltagewires–neverrun lowvoltagewires inthesameconduitashighvoltagewires.

• IfyouareinstallingamodelLLwithemergencyreservetherearefivealarmsignalsrequiredperNFPA99:

•HighLinePressure • LowLinePressure • SecondaryinUse • EmergencyReserveinUse • EmergencyReserveLow

The circuit board will trigger all five of these alarms (nopressureswitchesarerequired).Thelinepressuretransducermustbeinstalledoutsideofthecabinet–downstreamofthesourceormain linevalvewiththecablebeingwiredtothemanifoldcircuitboardtocomplywithNFPA99.Inthisphotothe line pressure transducer has been assembled into ourPSM-XX assembly and connected to the gaugeport on thedownstream(patientside)ofthesourcevalveandwiredtothemanifoldcircuitboard.

• Thelinepressuretransducermayalsobemountedinsidethecabinet (as shown here). In this arrangement, a high/lowpressureswitch(soldseparately)willberequiredtomeettheNFPA99recommendations.

Note: Thehi/lowpressureswitch(suppliedseparately)wouldbewired directly to themaster alarm panels – not to themanifoldcircuitboard.

• Remote alarmwires are connected to the circuit board atthe terminal gate labeledMB5. Signalwires andCommonwiresfor;LowLinePressure,HighLinePressure,SecondaryinUse,EmergencyReserveinUseandEmergencyReserveLowshouldbeconnectedtotheterminalsasindicated.

Note: Allremotealarmterminalsarenormallyclosedwhenthegaspressureisinthenormalrange.Thehi/lowsetpointspre-programmed into themanifold circuit board logic chipareasperthechartsonpage31.Ifdesired,thehighandlowlinepressurealarmsetpointsmaybeadjustedbyfollowingtheinstructionsonpage20.

Knockoutforlowvoltageremotealarmwiring

Linepressuretransducer



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Wiring – Remote Alarms – Model PLCaution: Never connect or disconnect any electrical components with the power on. This may result in damage to components and is not covered under warranty.

•Wires for remote alarms should be brought into thecabinet thru conduit or shielded cables (check local coderequirements) thru the knockouts on the left side of thecabinetshownhere.

Note: Separate conduit should be used for high voltagewires–neverrun lowvoltagewires inthesameconduitashighvoltagewires.

• IfyouareinstallingamodelLLwithemergencyreservetherearefivealarmsignalsrequiredperNFPA99:

•HighLinePressure • LowLinePressure • SecondaryinUse • EmergencyReserveinUse • EmergencyReserveLow

The circuit board will trigger all six of these alarms (nopressureswitchesarerequired).Thelinepressuretransducermustbeinstalledoutsideofthecabinet–downstreamofthesourceormain linevalvewiththecablebeingwiredtothemanifoldcircuitboardtocomplywithNFPA99.Inthisphotothe line pressure transducer has been assembled into ourPSM-XX assembly and connected to the gaugeport on thedownstream(patientside)ofthesourcevalveandwiredtothemanifoldcircuitboard.

• Thelinepressuretransducermayalsobemountedinsidethecabinet (as shown here). In this arrangement, a high/lowpressureswitch(soldseparately)willberequiredtomeettheNFPA99recommendations.

Note: Thehigh/lowpressureswitchwouldbewireddirectlyto the master alarm panels – not to the manifold circuitboard.

• Remote alarmwires are connected to the circuit board atthe terminal gate labeledMB5andMB4. Signalwires andCommonwires for; Low Line Pressure, High Line Pressure,SecondaryinUse,EmergencyReserveinUseandEmergencyReserve Low should be connected to the terminals asindicatedonMB5.TheSignal&CommonwiresforSecondary(right bank) Low should be connected to the terminals asindicatedonMB4.

Note: Allremotealarmterminalsarenormallyclosedwhenthegaspressureisinthenormalrange.Thehi/lowsetpointspre-programmed into themanifold circuit board logic chipareasperthechartsonpage31.Ifdesired,thehighandlowlinepressurealarmsetpointsmaybeadjustedbyfollowingtheinstructionsonpage20.

Linepressuretransducer

Knockoutforlowvoltageremotealarmwiring



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Wiring – Remote Alarms – Model PLCaution: Never connect or disconnect any electrical components with the power on. This may result in damage to components and is not covered under warranty.

• BOTH MODELS LL & PL–The14-3001-12emergencyreservelowtransducermustbewiredtothemanifoldcircuitboardat the MB-3 connection points labeled “High PressureEmergencyReservePressureSensor”.

• MODEL PL ONLY–The14-3001-5Secondary(rightbank)LowtransducermustbewiredtothemanifoldcircuitboardattheMB-2connectionpointslabeledRightBankPressureSensor.

14-3001-12wiringlocation

14-3001-12wiringlocation



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Installing Pigtails & Attaching Cylinders• This drawing above shows a completed installation. Notethecopperventtubingandtubingbetweentheemergencereserve manifold and control cabinet are installed and furnishedbytheinstaller.Theunionspart#’sare17-0169forthe line relief and 17-0271 for the intermediate vent relief(tworequiredformodelLLifinstalledindoors).

• ThecheckvalveoutletfittingsonthemanifoldheaderbarsareCGA(CompressedGasAssociation)gasspecificthreads.Eachofthesefittingshasanintegralcheckvalve.Makesurethe 3 digit CGA number stamped on the outer perimeterof thesefittingsmatches theCGAnumber stampedon thematingCGAfittingsonthepigtails.Attachthepigtailstothecheckvalveoutletfittingsonthemanifoldheaderbars.

• Connecttheotherendofthepigtailtothe“Use”valvematingfittingontheportablebulkvessel.Opentheusevalve(turncounter-clockwise to open). The pressure building valveor regulator should be turned on or opened for all vesselsconnectedtothemanifold(bothserviceandreservebanks).Allowapproximately1hourfortheportablebulkvessel(s)tobuildpressure.

• Checkallcylinderandpigtailconnectionsfor leaksusinganoxygensafe leak test solution (anybubbles formingaroundconnectionsindicateleakage).

• Verify that the pressure being supplied to the manifoldcabinet exceeds the minimum inlet pressure requirementsperthetableonpage31.

Intermediaterelieflinewithunionforleftbank,rightbank.Finallineventlinewithunion.Linereliefis½Fnpt,intermediatereliefis⅜Fnpt.

Commonventlinethrurooforoutsidewall.(¾recommended)

Emergencyreserveinlet

Unions

Portsfortwopigtails

Intermediate pressurereliefvalvex⅜Fnpt



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• ThecheckvalveoutletfittingsonthemanifoldheaderbarsareCGA(CompressedGasAssociation)gasspecificthreads.Eachofthesefittingshasanintegralcheckvalve.Makesurethe 3 digit CGA number stamped on the outer perimeterof thesefittingsmatches theCGAnumber stampedon thematingCGAfittingsonthepigtails.

• Connectthepigtailstothecheckvalveoutletsonthemanifoldheaders.

• Check themaster valves to be certain they are open (turncounter-clockwisetoopen).(Note:themastervalveshouldalwaysbeleftopen.Itistobeusedonlyintheeventofanemergency).

• SLOWLYopenallcylindervalvesuntilfullyopen(turncounter-clockwisetoopen).Checkallcylinderandpigtailconnectionsforleaksusinganoxygensafeleaktestsolution(anybubblesformingaroundconnectionsindicateleakage).

Note: Themanifoldhasbeentestedforleaksatthefactory,buttheinstallerMUSTcheckforleaksatallconnectionsmadeduringinstallation.

Master valve

Attachpigtailstoheadercheckvalve outlets using1⅛”openendwrench

Checkvalveoutletfittings



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Start Up & Checking Procedures – Model LLThemanifoldispre-programmed(perpage31)andtestedbeforeit is shipped. Youmay, however,wish tomodify some of theprogramming(seepage20).Theunithasbeendesignedtoallowsomeprogrammingtobesimplyandsafelyalteredinthefield.

• Start with all cylinders turned off and with zero pressuresuppliedtothemanifoldcabinet.Toconducttheinitialstart-uptestingofthemanifold,itissimplerandfasterifthecircuitboardisswitchedfromthestandard‘cyclingview’(thisisthemodeinwhichitisshipped)tothe‘globalview’.Todothis,thecovermustbe removed fromthecircuitboardand thetop#1dipswitchmustbeswitchedfromtheRUNmodetothePROGRAMmode.(Note:localalarmsarenotdisplayedwhenintheglobalviewmode).

• Turnonthe120VACtotheunit.ForbothmodelsLL&PLwithEmergencyReserveheadersutilizingthe14-3001-12,14-3002and 14-3001-5 (PL only) transducers, the display shouldilluminateshowingallzerosfortheLinePressure(LIN),LeftBankPressure(LEFT)andRightBankPressure(RIGHT). Theintermediate(INT)andemergencyreserve(EMER).(Note:IftheLLorPLhasbeeninstalledwithoutanEmergencyReserveor with an Emergency Reserve utilizing pressure switchesin place of transducers, the INT (intermediate) and EMER(emergency reserve) can both be made to read zeros if a35-3013emergencyreservejumperkitisinstalled.BoththeleftandrightbankGreen(InUse)andYellowLED’s (Ready)shouldbeextinguishedandtheRed(Empty)LED’sshouldbeilluminated.

• Verifythattheleftvesselhas130psigorhigherbyobservingthepressuregaugeonthevessel.SLOWLYopenonecylindervalveontheleftbank.Theleftbankpressuregauge(insidethe cabinet) and the text display (on the outside of thecabinet) shouldshowthe fullpressureof thecylinder. TheRed(Depleted)LEDfortheleftbankshouldhaveextinguishedleavingonlytheGreen(InUse)LEDilluminated.

• Verifythattherightvesselhas130psigorhigherbyobservingthepressuregaugeonthevessel.SLOWLYopenonecylindervalve on the right bank. The right bank pressure gauge(inside the cabinet) and the digital display (on the outsideofthecabinet)shouldshowthefullpressureofthecylinder.The Red (Depleted) LED for the right bank should havebeenextinguishedand theYellow (Ready) LED shouldhaveilluminated.

Programcontrolbuttons

Dipswitch#1Run/Program



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• Turn off all open left bank cylinder valves. Create a slightflow of gas in the delivery pipeline system. DISS demandvalves have been provided on the line regulators. MatingDISSfittingsmaybeusedtocreateaflowofgaswithinthemanifold cabinet. The left bank pressure text display andpressure gauge should fall and the control automaticallyswitches over to the right bank. Delivery pressure remainsconstant.TheleftbankRed(Empty)LEDwillilluminate.Thesecondarysupplyinusealarmshouldactivateonthemasteralarm(s).

• SLOWLY reopen the cylinders on the left bank. The leftbankpressuregaugeanddigitaldisplayshouldreturntofullpressure. The left bank yellow (Ready) LED will illuminatesimultaneouslytheleftbankred(Empty)willextinguish.Allremotesecondarysupplyinusealarmswillbecanceled.

• Repeatsteps5&6tosimulateanemptyrightbank.

• ThemodelLL,willalsodisplaypressuresfortheintermediatearea (INT) and the emergency reserve (EMER) and triggerthemasteralarmsignalfor“EmergencyReserveinUse”and“EmergencyReserveLow”.Toproperlyadjusttheemergencyreserveregulatortheprimaryandsecondarybanksmustbothbeshutoffandthecabinetpressuredrained.SLOWLYopenone cylinder on the emergency reserve bank and observetheEMERpressuredisplayandchecktomakesureitagreeswiththegaugeontheemergencyreserveregulator. Adjustthedeliverypressurefromtheemergencyreserveregulatorfollowingthetableonpage31(ifthisisa50psiglinepressureapplication this regulator should be set to 65psig). WhentestingtheEmergencyReserveinUseandEmergencyReserveLowmasteralarmspleasenote–thereisa15seconddelaydesigned into the manifold logic. The Emergency Reservein Use alarmwill be triggeredwhen the INT pressure fallsbelow 75 psig (50 psig line pressure application) for morethan15seconds.TheEmergencyReserveLowalarmwillbetriggeredwhentheEMERpressurefallsbelow1200psigformorethan15seconds. TesttheEmergencyReserve inUsealarmbyfirstpressurizingboththeprimary&secondaryandtheemergencyreservebanks,setDipswitch#1totheRUN/PROGRAMpositionandclosethevalvesonboththeprimary& secondary bank vessels, establish a gas flow thru themanifold.Aftertheprimarythensecondarybanksdepletetoempty,andtheintermediatepressurefallsbelow75psig(50psilinepressureapplicationmodels)theEmergencyReserveinUsealarmshouldbetriggeredaftera15seconddelay.

• After you are satisfied that the manifold is functioningproperlyandthatallmasteralarmsignalsarebeingtriggeredproperly. Themanifold circuit board should be returned tothe‘cyclingview’mode.ThisisachievedbymovingthedipswitchfromthePROGRAMtotheRUNposition.

Dipswitch#1settoRun/Program



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Start Up & Checking Procedures – Model PL• Turnoffallopenleftbankvesselvalves.Createaslightflowofgasin the delivery pipeline system. DISS demand valves havebeenprovidedonthelineregulators.MatingDISSfittingsmaybeusedtocreateaflowofgaswithinthemanifoldcabinet.Theleftbankpressuretextdisplayandpressuregaugeshouldfallandthecontrolautomaticallyswitchesovertotherightbank. Deliverypressureremainsconstant.TheleftbankRed(Empty)LEDwill illuminate.Thesecondarysupplyinusealarmshouldactivateonthemasteralarm(s).

•Withtheleftbankinared(Empty)conditionandtherightbankinagreen(InUse)condition,createaslightgasflowandcloseallof therightbankcylindervalves. Whentherightbankpressuredropsbelow1,200psigstopthegasflow.Afterapproximately15seconds,therightbanklowalarmwillbetriggered.

• SLOWLY reopen the vessel(s) on the left bank. The left bankpressuregaugeanddigitaldisplayshouldreturnto fullpressure.Theleftbankgreen(InUse)LEDwillilluminatesimultaneouslytheleftbankred(Empty)willextinguish.Allremotesecondarysupplyinusealarmswillbecanceled.

• Theunitwillalsodisplaypressuresfortheintermediatearea(INT)andtheemergencyreserve(EMER)andtriggerthemasteralarmsignal for “Emergency Reserve inUse” and “Emergency ReserveLow”. To properly adjust the emergency reserve regulator theprimaryandsecondarybanksmustbothbeshutoffandthecabinetpressure drained. SLOWLY open one cylinder on the emergencyreservebank andobserve theEMERpressuredisplay and checktomakesureitagreeswiththegaugeontheemergencyreserveregulator. Withaslight flowofgas,adjust thedeliverypressurefromtheemergencyreserveregulatorfollowingthetableonpage31(ifthisisa50psiglinepressureapplicationthisregulatorshouldbeset to65psig). When testing theEmergencyReserve inUseandEmergencyReserveLowmasteralarmspleasenote–thereisa15seconddelaydesignedintothemanifoldlogic.TheEmergencyReserveinUsealarmwillbetriggeredwhentheINTpressurefallsbelow75psig(50psiglinepressureapplications)formorethan15seconds.TheEmergencyReserveLowalarmwillbetriggeredwhentheEMERpressurefallsbelow1200psigformorethan15seconds.TesttheEmergencyReserveinUsealarmbyfirstpressurizingboththeprimary&secondaryandtheemergencyreservebanks,setDipswitch#1RUN/PROGRAMpositionandclose thevalvesonboththeprimary& secondarybank vessels, establish a gas flow thruthemanifold.Aftertheprimarythensecondarybanksdepletetoempty, and the intermediate pressure falls below75psig (50 psilinepressureapplicationmodels) theEmergencyReserve inUsealarmshouldbetriggeredaftera15seconddelay.

• After you are satisfied that themanifold is functioning properlyand that all master alarm signals are being triggered properly.The manifold circuit board should be returned to the ‘cyclingview’mode.This isachievedbymovingthedipswitchfromthePROGRAMtotheRUNposition.

Dipswitch#1settoRun/Program



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Emergency Reserve Plumbing and WiringThe manifold includes digital displays for the emergency reservebankpressureandtheintermediateareapressure.(RefertoappendixE–page31).

Remote master alarms will be triggered by the manifold for therequiredNFPA99alarms;

• Highlinepressure,

• Lowlinepressure,

• Secondaryinuse,

• Emergencyreserveinuseand

• Emergencyreservelowand

• Rightbank(secondary)low(onPLunitsonly)

Refer to theappendixEonpage31 for informationonsetting thedelivery(outlet)pressureoftheemergencyreserveregulatorandpre-programmedemergency reserve inuseandemergency reserve lowalarmsetpoints.

The emergency reserve low bank pressure transducer (part # PX-14-3001-12)shouldbeinstalledontheextraportontheRWPseriesmanifold.Thisportislocatedprior(upstream)tothemastervalveandtheregulator.

Note: if the PX-14-3001-12 and PX-14-3002 transducers are notused (and pressure switches are used instead or not used at allbecauseareservemanifoldisnotbeingused)the“ReserveAlarms”programmingoption(seepage20)mustbedisabledandthe35-3013highpressurereservejumperkitmustbeinstalledorelseerrorcodeswillbedisplayedbythecircuitboard.

The emergency reserve in use pressure transducer (part # PX-14-3002)will be pre-installedon the intermediateblock at the factory(whenorderedasaset).

Boththeemergencyreservelowbankpressuretransducerandtheemergencyreserveinusetransducermustbewiredtothemanifoldcircuit board as indicated by the labeling instruction (see page33). Remote master alarm signal and common wires must also beconnectedtothemanifoldcircuitboardas indicatedbythe labelinginstructionsonthebackofthecircuitboardcover.



IN594900AV • 02/2017 of 36

Cylinder Replacement & Handling• Closeallcylindervalvesonthedepletedbank.

• SLOWLYloosenandremovethepigtailconnectionfromthedepletedcylinders.

• Removedepletedcylindersandreplaceprotectivecaps.

• Placeandsecurefullcylindersintopositionusingchains,beltsorcylinderstands.

• Remove protective cylinder caps from full replacementcylinders.Withthevalveoutletpointedawayfromallpeopleinthearea,slowlyopeneachcylindervalveslightlyforasplitsecondtoblowoutanydirtorcontaminantsthatmayhavebecomelodgedintothecylindervalve.

• Connectpigtailstocylindervalvesandtightenwithwrench.

• SLOWLYturneachcylindervalveuntileachcylinderisfullyon.

• Leaktesttheconnectionsusinganoxygenapprovedleaktestsolution.

• Observe the following conditions: The red (Empty) LED isextinguishedand theyellow (Ready)LED is illuminatedandthesecondaryinusealarmiscancelled.

• The manifold supply bank is now replenished andautomaticallyplacedin“reserve”.

Line Delivery Pressure Adjustment• Leavethemanifoldinfulloperationalstatus.

• Createa flowcondition in thedeliverypipingsystem. DISSdemandvalveshavebeenprovidedonthelineregulatorsforthispurpose. MatingDISS fittingsmaybeusedtocreateaflowofgaswithinthemanifoldcabinet.

• Openthemanifoldcabinetdoorandlocatethelinepressureregulators. Ballvalvesontheinletandoutletsidesofeachregulatordeterminewhichregulatoris“online”andwhichis“offline”.Note:whentheballvalvehandleisperpendicularto thepipeline, theball valve is closed. One line regulatorshouldbevalvedclosedandtheothervalvedopen.Thelineregulators on-line and off-line should be alternated everyothermonthtoensureeachisexcercised.

• Turn the T – bar handle clockwise to increase pressure orcounter-clockwisetodecreasepressure.Itmaybenecessarytousea3/4”open-endwrench, loosen the locknuton theadjustingscrew(onhighflowmodelsonly).

• After adjustment, retighten the locknut on the adjustingscrewandclosethecabinetdoor.

T-barhandle

DISSDemandValves

Ballvalves

Ballvalves

Line regulators



IN594900AV • 02/2017 of 36

Programming AdjustmentsThemanifoldispre-programmedandtestedbeforeitisshipped.Youmay, however,wish tomodify some of the programming.Theunithasbeendesignedtoallowsomeprogrammingtobesimplyandsafelyalteredinthefield.Theaspectsoftheprogramwhichmaybealteredinclude:

Lowlinepressuresetpoint

Highlinepressuesetpoint

Unitsofmeasure(psig,barorkPa)

Calibratelinesensor

Displayscrolltime(seconds)

Applicationlogic(thisshouldonlybechangediftheunitisbeingconvertedtoanewapplication–inconferencewithafactorytechnician)

• To make any programming change, the cover must beremoved from the circuit board and the top #1 dip switchmust be switched from the RUN mode to the PROGRAMmode.

• Oncethe#1dipswitchhasbeenchangedfromtheRUNmodetothePROGRAMmode,thedisplayshouldlooklikethis

•Whileviewing thedisplayon the frontof thecabinetdoor,usetheNEXTorPREVIOUSbuttonstotogglethruthemenuchoices. When you find the item you wish to reprogram,use the UP or DOWN buttons to display the new settingdesiredand thenuse theENTERbutton tosavechanges totheprogramming.Note–iftheENTERbuttonisnotpressedforeachandeverychange,thatprogrammingchangewillnotbesaved.ThedisplaywilldisplaythewordSAVEDwhenyouhavesuccessfullysavedaprogrammingchange.

• Return thedip switch to theRUNposition and replace thecircuitboardcoverwhenyouarefinishedmakingchangestotheprogramming.

Programcontrolbuttons

Dipswitch#1Run/Program

Displaysshowingcommonpre-programmedalarmsetpoints



IN594900AV • 02/2017 of 36

General Maintenance

Code Displayed Message Displayed Explanation

Error 01 Leftbanksensoroutofrange Thisconditionisactivatedwhentheleftsensor’srawreadingsareateitherextreme.Canbecausedbyadisconnected,wiredincorrectly,bad,orover-pressurizedsensor.

Error 02 Rightbanksensoroutofrange Thisconditionisactivatedwhentherightsensor’srawreadingsareateitherextreme.Canbecausedbyadisconnected,wiredincorrectly,bad,orover-pressurizedsensor.

Error 03 Intermediatepressureoutofrange Thisconditionisactivatedwhentheintermediatesensor’srawreadingsareateitherextreme.Canbecausedbyadisconnected,wiredincorrectly,bad,orover-pressurizedsensor.

Error 04 Emergencyreserveoutofrange Thisconditionisactivatedwhentheemergencysensor’srawreadingsareateitherextreme.Canbecausedbyadisconnected,wiredincorrectly,bad,orover-pressurizedsensor.

Error 07 Intermediatepressurehigh Messageisdisplayedwhenevertheintermediatepressureexceeds500psi.

Error 08 Emergencyreservepressurehigh Messageisdisplayedwheneverthehighpressureemergencyreservebankpressureexceeds3,000psi.

Error 09 Line sensor noise detected Messageisdisplayedifagasboarddetectsnoiseinthesignalfromit’sdigital sensor

Error 10 Linesensorfailedtorespond Messageisdisplayedifalinesensorisnotresponding.

Error 11 Line sensor is disconnected Messageisdisplayedwheneveralinesensorisdisconnected.

Error 12 Secondarysupplyleakdetected Messageisdisplayedwhenaleakisdetectedinthesecondarybank.

Error 13 Emergencyreserveleakdetected Messageisdisplayedwhenaleakisdetectedintheemergencyreservebank.

Error 14 Gastypemismatch Thiserrorcodeistriggeredbyamismatchingastypebetweenthelinesensoranduserselectedgastypeinsetupofthemanifoldcircuitboard.

Error Codes, Alarm Codes, & Information Codes

Interval Control Cabinet Headers & Pigtails

Daily Recordlineandbankpressures Observenitrousoxideandcarbondioxidesystemsforcylinderfrostingorsurfacecondensation.Shouldexcessivecondensationorfrostingoccuritmaybenecessarytoincreasemanifoldcapacity.

Monthly Checkregulators,compressionfittingsandvalvesforexternalleakage.Checkvalvesforclosureability.Alternatelineregulatorinuse(ifdual).

Inspectvalvesforproperclosure.Checkpigtailsforcleanliness,flexibility,wear,leakage,kinked,pinchedortwistedandthreaddamage.Replacedamagedpigtailsimmediately.Inspectheadercheckvalveoutletsforclosureability.

Annually Checkreliefvalvepressures.Checkregulatorseats.Tightenregulatorbonnets1to2degrees(outof360).

Every4years Replaceallpigtails

Every10years Rebuildorreplace:allregulators,PX-17-4003intermediatecheckvalves,PX-48-1008&PX-48-1009solenoidvalves,andDISSdemandcheckvalves.

Rebuildorreplacemastervalves.Replaceallcheckvalveoutlets.



IN594900AV • 02/2017 of 36

Code Displayed Message Displayed Explanation

Alarm 01 Linepressurelow Messageisdisplayedandlowlinepressurerelayactivatedwheneverthelinepressureisbelowtheprogrammedlowlinepressurealarmsetpoint.

Alarm 02 Linepressurehigh Messageisdisplayedandhighlinerelayactivatedwheneverthelinepressureisabovetheprogrammedhighlinepressurealarmsetpoint(highlinepressurealarmistriggered).

Alarm 03 Secondarysupplyinuse Messageisdisplayedandsecondaryinuserelayactivatedwhenthemanifoldhasswitchedovertothesecondarybank.Clearswhentankisreplaced.

Alarm 04 Emergencyreserveinuse Messageisdisplayedandemergencyinuserelayactivatedwhenevertheintermediatepressureisbelowtheprogrammedemergencyinusepressurealarmsetpoint.(LLmodelsonly).

Alarm 05 Emergencyreservepressurelow Messageisdisplayedandemergencylowrelayactivatedwhenevertheemergencypressureisbelowtheprogrammedemergencyreservelowpressurealarmsetpoint.(LLmodelsonly).

Alarm 06 Rightbank/Secondarylow Messageisdisplayedandlowlinepressurerelayactivatedwhenevertherightbankpressureisbelow1,200psigfactorypre-setorpressuresetpointasre-programmedinthefield.(PLmodelsonly)

Info 01 Economizerinuse Messageisdisplayedwheneverthereadybankpressureexceedstheservicebankpressureby50psigormore.Thelogiccomparestheserviceandreadybankpressuresonceasecond.(LLmodelsonly).

XX% Remains (emergencyreserveonly-exceptforN2O&CO2services).Itcalculatesanddisplaysthepercentofgasremainingintheemergencyreservebank.

Definitions and clarificationsAlarm Code – AlarmconditionsperNFPA99CandZ7396.1guidelines.

Error Code – Messagesthatprovidediagnosticinformationtoassistinresolvingsystemproblems.

Information Codes – Messagesthatprovideinformationregardingtheoperationofthesystem.

Error Codes, Alarm Codes, & Information Codes



IN594900AV • 02/2017 of 36

Item Part # Description

LineRegulators&RepairKits PX-68-0004R Lineregulatorstandardflow5-125psig

PX-68-0004RK Standardflowlineregulatorrepair/rebuildkit

PX-68-0002R Lineregulatorhighflow5-125psig

PX-68-0002RK Highflowlineregulatorrepair/rebuildkit5-125psig

PX-68-0001R Lineregulatorhighflow10-200psig

PX-68-0001RK Highflowlineregulatorrepair/rebuildkit10-250psig

CircuitBoard PX-35-1004R LL/PLseriesPLCboardwithsingletextdisplay

PowerSupply PX-35-2013R Powersupply

Transducers/Sensors PX-14-3001-12R 0-2,500psigtransducerwith12’cableforemergencyreservelow(bothLLandPLmodels)

PX-14-3001-5R 0-2,500psigtransducerwith15’cableforrightbanklow(PLmodelsonly)

PX-14-3002 0–500psigtransducerwith3’cableforleftorrightbanksandemergencyreserve in use

PX-14-3024 0-250psigtransducerwith1.5’cableN2

PX-14-3025 0-100psigtransducerwith1.5’cableOxygen

PX-14-3028 0-100psigtransducerwith1.5’cableMedAir

PX-14-3027 0-100psigtransducerwith1.5’cableN2O

PX-14-3028 0-100psigtransducerwith1.5’cableCO2

Solenoid Valves PX-48-1008R LeftsolenoidvalveforLL/PLseries

PX-48-1009R RightSolenoidvalveforLL/PLseries

CheckValve PX-17-4003R Intermediatecheckvalve1/2nptmalex1/2ODtube

Tubes&CompressionFittings PX-17-4012 CompressionSleeve1/2ODtube-glassfilledTeflon

PX-17-4005 CompressionNutfor17-4012

PX-Q1100-1 1/2ODcoppertubex7"

PX-17-4013 CompressionSleeve3/8ODtube-glassfilledTeflon

PX-17-4024 CompressionNutfor17-4013

Gauges PX-14-1018 0-4,000psig11/2"x1/8mnptcenterbackgauge

PX-14-1016 0-400psig2"x1/4mnptbottomportgauge

PX-14-1017 0-400psig11/2"x1/8mnptcenterbackgauge



Relief Valves PX-RV-22-075 75psigx½Mnptinletwithpipeawayadaptor

PX-RV-22-150 150psigx½Mnptinletwithpipeawayadaptor

PX-RV-22-250 250psigx½Mnptinletwithpipeawayadaptor

PX-RV-11-400 400psigx¼Mnptinletwithpipeawayadaptor

Pigtails PX-20-1001 36”(pre-bend)singlelooprigidcopperO2(w/ocheck)–CGA540

PX-20-1002 36”singlelooprigidcopperN2O–CGA326

PX-20-0002 24”FlexiblestainlessbraidedN2O-CGA326withcapturedfittings

PX-20-0003 24”FlexiblestainlessbraidedCO2–CGA320withcapturedfittings

PX-20-0004 24”FlexiblestainlessbraidedAIR–CGA346withcapturedfittings

PX-20-0005 24”FlexiblestainlessbraidedN2–CGA580withcapturedfittings

Replacement Parts & Accessories



IN594900AV • 02/2017 of 36

Item Part # Description

Union PX-17-0169 Union3piece½”Mnptx½”Mnpt1”11½NPS

Master Valve PX-17-0256 MasterValve1/2"Fnptx1/2Fnpt

MasterValveRepairKit PX-GMV-1001RK Mastervalverebuildkit

Heaterelement PX-35-2001 CeramicHeater

Accessory PX-35-3012 Manifoldbuzzerkit

PigtailsforRWP&RSPModels PX-20-1001 24”singlelooprigidcopperO2–CGA540

PX-20-0001 24”FlexiblestainlessbraidedO2-CGA540

PX-20-1002 24”singlelooprigidcopperN2O–CGA326

PX-20-0002 24”FlexiblestainlessbraidedN2O-CGA326

PX-20-0003 24”FlexiblestainlessbraidedCO2–CGA320

PX-20-0004 24”FlexiblestainlessbraidedAIR–CGA346

PX-20-0005 24”FlexiblestainlessbraidedInert–CGA580

PigtailsforLL,TML&PLModels PX-20-2001 72”Flexible–O2–CGA540

PX-20-2002 72”Flexible–N2,Ar,He–CGA580

PX-20-2003 72”Flexible–CO2–CGA320

PX-20-2004 72”Flexible–N2O–CGA326

Union for Line Vent PX-17-0169 Union3piece½”Mnptx½”Mnpt1¼-14UNS

Union for Intermediate Vent PX-17-0271(2required)

Union3piece3/8”Mnptx½”Mnpt1¼-14UNS

Master Valve PX-17-0256 MasterValve1/2”Fnptx1/2Fnpt

MasterValveRepairKit PX-GMV-1001RK Mastervalverebuildkit

PX-35-3013 HighPressureReserveJumperKit

Heaterelement PX-35-2001 CeramicHeater

Accessory PX-35-3012 Manifoldbuzzerkit

Replacement Parts & Accessories (Continued)



IN594900AV • 02/2017 of 36

Component Symptom Probable Cause Remedy or Check

Circuitboard Noindicatorlightsonfrontpanelilluminatewhenpowerisconnected.

Wiringconnection. Checkwiringconnections.

Powerinputoutofrange Checkelectricalpowersupplyoutputvoltages.

Badcircuitboard Replacepowersupplyorcircuitboard.

Redindicatorlightsareonbutbothbanksarefull

Mastervalveorcylindervalvesonbankareclosed.

OpenvalvesSLOWLY

Pigtailsareinstalledwithcheckvalvesinwrongdirection

Closecylindersandre-installpigtailsinproperflowdirection

Bankpressureisnotsufficientforlogicboardtoplaceitin“InUse”or“Ready”status(seeappendixEminimuminletpressurespage27)

Replacecylinderswithfullcylinders.Or,ifusingportablebulkvessels,openpressurebuildingvalveonvesselorreplaceportablebulkvesselwithhigherdeliverypressureportablebulkvessel

Errorcode(s)beingdisplayed

Loose or disconnected or brokenwire,mis-connectedwire,abadtransducer,acalibrationproblemoranover-pressuresituation.

Checkwiresforgoodandcorrectlocationconnectiontocircuitboard(SeeERRORCODESpg15)

Ifallwiresareconnectedproperlyandlocatedproperly–itmaybenecessarytoreplaceatransducer.

Entiremanifold Lossofcylindercontents Leakageinmanifoldcabinet,headersorpigtails.

Locateleakusingoxygencompatibleleaktestsolution,tighten,resealorreplaceleakingfitting(s)orpigtails.

Leakagethrumanifoldsolenoidvent / relief

Replacesolenoidvalve

Leakagearoundregulatorbonnet

Tightenregulatorbonnet

Regulatorwithbadseat Rebuildorreplaceregulator

Leakinggauge Replacegauge

Regulatorsettoohigh Setdeliverypressureperspecifications(seepage27)

Overpressureduetofailedregulator seat

Rebuildorreplaceregulator

Regulatorfreeze-up(N2OorCO2)/heaterfailure

Flowrateexceedsmanifolddesigncapacityorcylinderwithdrawlcapacity–addcylinders.

Repairheateroraddheaterandconsideraddingadditionalcylinders

Troubleshooting GuideNOTE: Troubleshootingandrepairsshouldbedonebyqualifiedpersonnelonly.



IN594900AV • 02/2017 of 36

Component Symptom Probable Cause Remedy or Check

Lossofcylindercontents Bothbanksfeeding Leakingheader/pigtailconnection

Tightenfittingorre-tapewithOxygensafeTeflontape(ifnptfitting)andtighten.

Leakingintermediatecheckvalve

Replacecheckvalve

Leakingsolenoidvalve Replacesolenoidvalve

Inletpressuretocontrolcabinetistoolow

Verifythatminimuminletpressurerequirementsaremetperchartonpage31

Portablebulkvesselisventing Gasusageisnotsufficienttojustifyportablebulkreserve

Gasflowingthrutheeconomizercircuit

Thisisnormalwhenthereservebankpressureis50psiggreaterthantheservicebankpressure–nocorrectionneededtomanifoldcontrolcabinet.Mayconsiderreducingthenumberofliquidvesselsoneachbankifthereservebankismorethan35%depletedatthetimeitisplacedinservice.

Ifgasisflowingthrutheeconomizerwhenthereservebankpressureisnot50psiggreaterthantheservicebankpressure–theeconomizercheckvalveneedstobereplaced.

Manifoldisunabletosupportrequiredflow(N2OorCO2units)

Increasemanifoldflowcapacity(callfactoryforassistance)

System Changeoveroccurs,secondaryinusealarmistriggeredandthenclearsplacingemptyornearemptybankintoreserve

Manifoldisunabletosupportrequiredflow(N2OorCO2units)

Increasemanifoldflowcapacity(callfactoryforassistance)

Increasebanksize

Ifusingtwoormoreportablebulkvesselsperbankcurrently,connectpigtail(s)(nocheckvalve)fromventtoventofallvesselsonthesamebankandopentheventvalves.Thiswillequalizetheheadpressuresandutilizethecombinedvaporizationcapacity–notjustthevaporizationcapacityofthevesselwiththehighestdeliverysetpoint.

Troubleshooting Guide (Continued)



IN594900AV • 02/2017 of 36

AC Alternating Current Anelectriccurrentthatreversesdirectionorpolarity atregularintervals.

Alarm Code

AlarmconditionsperNFPA99Cguidelines.

BAR Bar

Ameasurementoftheforceinacompressedgassystem.

1BAR=14.7psig(1atmosphere)

Check Valve

Avalvewhichoperatesmechanicallyandautomaticallytostopareverseflowofgas.

DC Direct Current

Anelectriccurrentthatflowsinonedirection.The currentcanbesteadyorpulse.

Economizer Circuit

Amechanicalpipingcircuitwhichallowsbuiltupreservegastobeusedinlowvolumeratherthanallowingthegastoventtoatmosphere.

Information Code

Messagesthatprovideinformationregardingtheoperationofthesystem.

KPa Kilopascals Ameasurementoftheforceinacompressedgas system. 1kPa=.14PSI

LED Light Emitting Diode Asemiconductordiodethatconvertsappliedvoltage tolight.

NFPA National Fire Protection Association TheNationalFireProtectionAssociationisan associationengagedinstandardsdevelopment.

NO Normally Open Anelectricalcircuitinwhichtheswitchisnormally open.Nocurrentflowsthroughthecircuitinnormal operation.Onlywhentheswitchisclosedistheflow ofcurrentstarted.

Anormallyopensolenoidvalveisonedesignedsothatitisopenwhenthereisnopowertothesolenoidandclosedwhenitisenergized.

NC Normally Closed Anelectricalcircuitinwhichtheswitchisnormally closed.Currentflowsthroughthecircuitinnormal operation.Onlywhentheswitchisopenedisthe flowofcurrentstopped.

PSI Pounds per Square Inch Ameasurementoftheforceinacompressedgas system. 1PSI=6.9kPa

Solenoid ValveAvalvethatisopenedorclosedelectromagnetically.

TransducerAdevicethatconvertspressureintoanelectricalsignal.

Transient SignalAnintermittentandbriefsignalthatquicklycorrectsandreturnsthealarmtoanormaloperatingmodebeforemonitoringpersonnelcansilencethealarm

V VoltageVoltageiselectricalpressureorforce.Onevoltisequaltothedifferenceofelectricalpotentialbetweentwopointsonaconductingwirecarryingaconstantcurrentofoneamperewhenthepowerdissipatedbetweenthepointsisonewatt.

Appendix A

Glossary of Terms



IN594900AV • 02/2017 of 36

Appendix B

Technical SpecificationsMaximum Inlet Pressure: EmergencyReserve(bothLL&PLModels) 3000psig

Rightbank(secondary)modelPLonly 3,000psig

CabinetmodelsLL&PL: 400psig

Operating Ambient Temperature range:-20F(-29C)to125F(54.4C)

Storage Temperature:-20F(-29C)to185F(85C)

AC Input:120voltsAC-50-60Hz

Input Fuse: 5ampinputAClinefuseprotectstheinputwiringtopowersupply

Power Consumption: 45W(0.4ampsusing120VAC)maximumwithoutheaters

245W(2.1ampsusing120VAC)maximumwithheaters

Full Load Amps: .375withoutheaters 2.10withheaters

Pressure Measurement Accuracy: 0-100PSIGtransducer+/-1%offullscale–LinePressure–Oxygen,NitrousOxide,MedicalAir,CarbonDioxide

0-250PSIGtransducer+/-1%offullscale–LinePressure–Nitrogen

0500PSIGtransducer+/-2%offullscale–Bank&IntermediatePressuresmodelLLonly

0–2,500PSIGtransducer+/-2%offullscale–BankPressuresmodelCC,EmergencyReserveBankPressuremodelLL

Solenoid Valve: 24VDC–NormallyOpen(Valveopenswhende-energized)

DimensionsControl Cabinet: Dimensionsexcludinginlet&outletfittings 153/8”Wx25”Hx9¼”D

Dimensionsincludinginlet&outletfittings 17¼”Wx27”Hx9¼”D

Line PressureTransducers: Housingdimensions:1.25”Diameterx3.75”Lengthincludinginletfittings

WeatherproofControl Cabinet: Dimensionsexcludinginlet&outletfittings 17¼”W(cabinet)18¾:W(door)x263/4”Hx11”D

Dimensionsincludinginlet&outletfittings 20¼”Wx29”Hx11”D



IN594900AV • 02/2017 of 36

Appendix C

Operational Pressure SpecificationsMinimum inlet pressure requirements for LL Manifold

Manifold delivery pressure Minimum inlet pressure Relief valve setting on vessel

50 135 235

80 135 235

170 250 350

Minimum inlet pressure requirements for PL Manifold

Manifold Delivery Pressure Minimum Inlet PressureLeft Bank

Regulator SettingRight Bank

Minimum Bank PressureRight Bank

50 135 150 1,200(factorypre-setrightbanklowpressurealarm)



Line Pressure Alarm Pressure Settings for LL Models

Normal Delivery Press Line Relief Setting High Line Press Set Point Low Line Press Set Point Secondary In Use Set Point

50 75 60 40 95bothbanks

80 150 96 64 95bothbanks

170 250 200 140 190bothbanks

Line Pressure Alarm Pressure Settings for PL Models

Normal Delivery Press Line Relief Setting High Line Press Set Point Low Line Press Set Point Secondary In Use Set Point

50 75 60 40 95bothbanks

80 150 96 64 95bothbanks

170 250 200 140 190bothbanks

Alarm Pressure Settings for LL & PL Models Emergency Reserve In Use & Emergency Reserve Low

Manifold Delivery PressureRecommended Emergency Reserve Regulator Delivery

Pressure Setting

Pre-programmed Emergency Reserve In Use Alarm Set Point

Pre-programmed Emergency Reserve Low Alarm Set Point

50 65 75 1200

80 70 80 1200

190 170 180 1200



IN594900AV • 02/2017 of 36

Appendix D

Wiring Diagram



IN594900AV • 02/2017 of 36

Appendix E

Wiring Diagram for Buzzer KitBuzzerKitPart#PX-35-3012



IN594900AV • 02/2017 of 36

Powerex Limited WarrantyWarranty and Remedies. (a) Standard Period of Warranty – Parts and Labor. PowerexwarrantsandrepresentsallProductsshallbefreefromDefectsforthefirsttwelve(12)monthsfromthedateofshipmentbyPowerex.Duringsuchwarrantyperiod,PowerexshallbefullyliableforallDefectsintheProducts(the“ProductDefects”),i.e.,allcostsofrepairorreplacement,whichmayinclude“inandout”charges,solongastheProductsarelocatedintheUnitedStatesorCanada,andtheProductsarereasonablylocatedandaccessiblebyservicepersonnelforremoval.“Inandout”chargesincludethecostsofremovingaProductfrombuyer’sequipmentforrepairorreplacement.

(b) Additional Period of Warranty – Parts Only (No Labor). In addition to theabove,Powerexwarrants theproductsdescribedhereintobefreefromdefects inmaterialandworkmanshipfor forty-eight (48)monthsfromendofStandardPeriodofWarrantywiththeexceptionofanycomponentswhicharerecommendedtobereplacedinlessthansixtymonthsinourInstallation/Operationmanuals.WithinsaidperiodPowerexwillrepairorreplaceanypartorcomponentwhichisproventobedefectiveineithermaterialorworkmanship.Thiswarrantycoverspartsonly.Laborisnotincluded.Thiswarrantyisvalidonlywhentheproducthasbeenproperlyinstalledaccording toPowerex specifications,used in anormalmannerand servicedaccording to factory recommendations. Thiswarrantydoesnotcover failuresduetodamagewhichoccurs inshipmentor failureswhichresult fromaccidents,misuse,abuse,neglect,mishandling,alteration,misapplicationordamageduetoactsofnature.

(c) General. PowerexwarrantseachPowerexbrandedPipelineAccessory(collectively“Products”,individuallyeacha“Product”)tobe free fromdefects inmaterialandworkmanship (“Defects”)at thedateofshipment.EXCEPTASSETFORTHBELOW,NOOTHERWARRANTY,WHETHER EXPRESSOR IMPLIED, INCLUDINGANYWARRANTYOFMERCHANTABILITYOR FITNESS FOR A PARTICULARPURPOSE,SHALLEXISTINCONNECTIONWITHTHESALEORUSEOFSUCHPRODUCTS.TOTHEEXTENTPERMITTEDBYLAW,ANYANDALLIMPLIEDWARRANTIESAREEXCLUDED.AllwarrantyclaimsmustbemadeinwritinganddeliveredtoPowerexinaccordancewiththeproceduressetforthonitswebsite(www.powerexinc.com),orsuchclaimshallbebarred.Upontimelyreceiptofawarrantyclaim,PowerexshallinspecttheProductclaimedtohaveaDefect,andPowerexshallreplaceanyProductwhichitdeterminestohavehadaDefect;provided,however,thatPowerexmayelect,uponreturnoftheProduct,torefundtobuyeranypartofthepurchasepriceofsuchProductspaidtoPowerex.FreightforreturningProductstoPowerexforinspectionorforshippingwarrantypartsshallbepaidbybuyerwherepermittedbyapplicablelaw.Powerexisnotresponsibleforanyimportfees,taxes,duties,licensesorotherfeesimposedbyanygovernmentalauthorityupontheproduction,sale,shipmentand/oruseofProductscoveredhereunder.ThewarrantiesandremedieshereinarethesoleandexclusiveremedyforanybreachofwarrantyorforanyotherclaimbasedonanyDefect,ornon-performanceoftheProducts,whetherbaseduponcontract,warrantyornegligence.

(d) Coverage. ThewarrantyprovidedhereinappliestoPowerexpipelineproductsonly.

(e) Exceptions. Notwithstandinganythingtothecontraryherein,PowerexshallhavenowarrantyobligationswithrespecttoProducts:

(i)ThathavenotbeeninstalledinaccordancewithPowerex’swrittenspecificationsandinstructions;

(ii)ThathavenotbeenmaintainedinaccordancewithPowerex’swritteninstructions;

(iii) ThathavebeenmateriallymodifiedwithoutthepriorwrittenapprovalofPowerex;or

(iv)Thatexperiencefailuresresultingfromoperation,eitherintentionalorotherwise,inexcessofratedcapacitiesorinanotherwiseimpropermanner.

Thewarranty provided herein shall not apply to: (i) any defects arising from corrosion, abrasion, use of insoluble lubricants, ornegligentattendancetoorfaultyoperationoftheProducts;(ii)ordinarywearandtearoftheProducts;or(iii) defects arising from abnormalconditionsoftemperature,dirtorcorrosivematter;(iv)anyOEMcomponentwhichisshippedbyPowerexwiththeoriginalmanufacturer’swarranty,whichshallbethesoleapplicablewarrantyforsuchcomponent.

Limitation of Liability. NOTWITHSTANDINGANYTHINGTOTHECONTRARYHEREIN,TOTHEEXTENTALLOWABLEUNDERAPPLICABLELAW,UNDERNOCIRCUMSTANCESSHALLPOWEREXBELIABLEFORANY INCIDENTAL,CONSEQUENTAL,PUNITIVE,SPECULATIVEORINDIRECTLOSSESORDAMAGESWHATSOEVERARISINGOUTOFORINANYWAYRELATEDTOANYOFTHEPRODUCTSORGOODSSOLDORAGREEDTOBESOLDBYPOWEREXTOBUYER. TOTHEEXTENTALLOWABLEUNDERAPPLICABLELAW,POWEREX’SLIABILITY INALLEVENTSISLIMITEDTO,ANDSHALLNOTEXCEED,THEPURCHASEPRICEPAID.Intheeventofbreachofanywarrantyhereunder,Powerex’ssoleandexclusiveliabilityshallbeatitsoptioneithertorepairortoreplaceanydefectiveproduct,ortoacceptreturn,transportationprepaid,of suchproductand refund thepurchaseprice; ineithercaseprovided thatwrittennoticeof suchdefectisgiventoPowerexwithintwelve(12)monthsfromdateofshipmenttoBuyer,thattheproductisfoundbyPowerextohavebeendefectiveatthetimeofsuchshipment,thattheproducthasbeeninstalledand/oroperatedinaccordancewithPowerex’sinstructions,

Buyer’s purchase order is subject to the following conditions of sale:



IN594900AV • 02/2017 of 36

thatnorepairs,alterationsorreplacementshavebeenmadebyotherswithoutPowerex’swrittenapproval,andthatBuyernotifiesPowerexinwritingwithinfifteen(15)daysafterthedefectbecomesapparentandpromptlyfurnishesfullparticularsinconnectiontherewith;andprovidedfurtherthatinnoeventshalltheaggregateliabilityofPowerexinconnectionwithbreachofanywarrantyorwarrantiesexceedthepurchasepricepaidfortheproductpurchasedhereunder.Powerexmay,atitsoption,requirethereturnofanyproduct,transportationanddutiesprepaid,toestablishanyclaimofdefectmadebyBuyer.Unlessotherwiseagreedinwriting(a) Powerexwillnotacceptandshallhavenoresponsibilityforproductsreturnedwithoutitspriorwrittenconsent,and(b)Powerexwillnotassumeanyexpenseorliabilityforrepairstoproductsmadeoutsideofitsplantbythirdparties.IntheeventPowerexelectstoreplaceadefectiveproduct,costsofinstallation,labor,service,andallothercoststoreplacetheproductshallbetheresponsibilityofBuyer.

Powerexshallnot,exceptassetforthabove,beotherwiseliabletoBuyerortoanypersonwhoshallpurchasefromBuyer,oruse,anyproductssuppliedhereunderfordamagesofanykind,including,butnotlimitedto,indirect,specialorconsequentialdamagesorlossofproductionoflossofprofitsresultingfromanycausewhatsoever,including,butnotlimitedto,anydelay,act,errororomissionofPowerex.Supplier’srepairorreplacementofanyProductshallnotextendtheperiodofanywarrantyofanyProduct.

Warranty Disclaimer.PowerexhasmadeadiligentefforttoillustrateanddescribetheProductsinitsliterature,includingitsPriceBook,accurately;however,suchillustrationsanddescriptionsareforthesolepurposeofidentification,anddonotexpressorimplyawarrantythattheProductsaremerchantable,orfitforaparticularpurpose,orthattheProductswillnecessarilyconformtotheillustrationsordescriptions.

Product Suitability.Manyjurisdictionshavecodesandregulationsgoverningsales,construction,installation,and/oruseofProductsforcertainpurposes,whichmayvaryfromthoseinneighboringareas.WhilePowerexattemptstoassurethatitsProductscomplywithsuchcodes,itcannotguaranteecompliance,andcannotberesponsibleforhowtheproductisinstalledorused.BeforepurchaseanduseofaProduct,pleasereviewtheProductapplications,andnationalandlocalcodesandregulations,andbesurethattheProduct,installation,andusewillcomplywiththem.

Claims.Anynon-warrantyclaimspertainingtotheProductsmustbefiledwithPowerexwithin(6)monthsoftheinvoicedate,ortheywillnotbehonored.Prices,discounts,andtermsaresubjecttochangewithoutnoticeorasstipulatedinspecificProductquotations.Powerexshallnotbeliableforanydelayorfailurearisingoutofactsofthepublicenemy,fire,flood,oranydisaster,labortrouble,riotordisorder,delayinthesupplyofmaterialsoranyothercause,whethersimilarordissimilar,beyondthecontrolofCompany.Allshipmentsarecarefullyinspectedandcountedbeforeleavingthefactory.PleaseinspectcarefullyanyreceiptofProductsnotinganydiscrepancyordamageonthecarrier’sfreightbillatthetimeofdelivery.Discrepanciesordamagewhichobviouslyoccurredintransitarethecarrier’sresponsibilityandrelatedclaimsshouldbemadepromptlydirectlytothecarrier.ReturnedProductswillnotbeacceptedwithoutpriorwrittenauthorizationbyPowerexanddeductionsfrominvoicesforshortageordamageclaimswillnotbeallowed.UNLESS OTHERWISE AGREED TO IN WRITING, THE TERMS AND CONDITIONS CONTAINED IN THIS LIMITED WARRANTY WILL CONTROL IN ANY TRANSACTION WITH POWEREX.Anydifferentorconflictingtermsasmayappearonanyorderformnoworlatersubmittedbythebuyerwillnotcontrol.AllordersaresubjecttoacceptancebyPowerex.



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