Instruction Manual Simplex Manifolds THIS BOOKLET CONTAINS PROPRIETARY INFORMATION OF BEACONMEDÆS AND IS PROVIDED TO THE PURCHASER SOLELY FOR USE IN CONJUNCTION WITH SIMPLEX MANIFOLDS (SIM SERIES). Important These instructions are for experienced operators who know the general principles and safety precau- tions to be observed in handling compressed gases. If you are not certain you fully understand the safety precautions for handling gases, we urge you to obtain and read the Material Safety Data Sheet (MSDS) for each gas being used. Do not permit untrained persons to install, operate, or maintain these manifolds. Do not attempt to install or operate these manifolds until you have read and fully understand these instructions. If you do not fully understand these instructions, contact BeaconMedæs. Be sure this information reaches the operator. Your supplier has extra copies. Part No. 1
Transcript
Instruction Manual
Simplex ManifoldsTHIS BOOKLET CONTAINS PROPRIETARY INFORMATION OF BEACONMEDÆS AND IS PROVIDED TO THE PURCHASER SOLELY FOR USE IN CONJUNCTION WITH SIMPLEX MANIFOLDS (SIM SERIES).
Important
These instructions are for experienced operators who know the general principles and safety precau-tions to be observed in handling compressed gases. If you are not certain you fully understand the safety precautions for handling gases, we urge you to obtain and read the Material Safety Data Sheet (MSDS) for each gas being used.
Do not permit untrained persons to install, operate, or maintain these manifolds. Do not attempt to install or operate these manifolds until you have read and fully understand these instructions. If you do not fully understand these instructions, contact BeaconMedæs.
Be sure this information reaches the operator. Your supplier has extra copies.
Part No. 1
Instruction Manual
Simplex Manifolds1 - Safety PrecautionsProtect yourself and others. Read and understand the following instructions before attempting to use this equipment. Failure to understand and follow these instructions could result in serious personal injury and/or damage to equipment. Because of the many potential hazards associated with gases, read the Material Safety Data Sheet for each gas you will be using.
• Know and understand the physical and chemical properties of the gas being detected.
• Observe general precautions for the use of gases.
• Observe safety precautions for the gas being used.
• Read and follow precautions on cylinder labels.
• Never use these regulators with gases not compatible with the materials of construction. The use of gases not compatible with the materials of construction may cause damage to equipment or injury to personnel.
• Iftoxicorflammablegasesareusedwithcompressedgasequipment,emergencyequipmentapplicabletothegasesin use should be available in operating area.
• Many gases can cause asphyxiation by displacing oxygen in the atmosphere. Make certain the area where compressed gas equipment is operated is well ventilated. Provide a device to warn personnel of oxygen depletion in the work area.
• Donotreleasetoxicorflammablegasesinthevicinityofpersonnel.Usecompressedgasequipmentonlyinwellven-tilated areas. Vent gases to the outside atmosphere, and in an area away from personnel. Be sure that venting and disposal methods are in accordance with Federal, State, Provincial and local requirements. Locate and construct vent lines to prevent condensation or gas accumulation. Be sure the vent outlet cannot be obstructed by rain, snow, ice, insects, birds, etc. Do not inter-connect vent lines; if more than one vent is needed, use separate lines.
• Relief devices should be installed and properly vented in all gas handling systems to protect against compressed gas equipment failure and over-pressurization.
• Never connect this equipment to a supply source having a pressure greater than the maximum rated pressure. Refer totheProductSpecificationsformaximuminletpressures.
• Never permit oil, grease, or other combustible materials to come in contact with cylinders, compressed gas equip-ment, and connections. Oil and grease may react and ignite when in contact with some gases – particularly oxygen and nitrous oxide.
• Cylinder, header, and master valves should always be opened very s-l-o-w-l-y. Heat of recompression may ignite combustible materials.
• Flexible hoses should never be kinked, twisted, or bent into a radius smaller than 3 inches. Mistreatment may cause theflexiblehosestoburst.
• 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 regulators and cylinders should be grounded. Static discharges and lightning may ignite materials in an oxygenatmosphere,creatingafireorexplosiveforce.
• Welding should not be performed near nitrous oxide piping. Excessive heat may cause the gas to dissociate, creating an explosive force.
• Do not use leak test solution that contains ammonia. Solutions containing ammonia may cause brass tubing to crack.
• Always use oxygen compatible leak test solution on oxygen or nitrous oxide service equipment.2 Part No.
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C Common OSHA Occupational Safety & Health AdministrationCGA Compressed Gas Association PSIG Pounds per Square Inch GaugeFT-LBS Foot-Pounds SCFH Standard Cubic Feet per HourIN-LBS Inch-Pounds VAC Voltage, Alternating CurrentN/C Normally Closed VDC Voltage, Direct CurrentN/O Normally Open PCB Printed Circuit BoardNPT National Pipe Taper
3 - DisclaimerBeaconMedæs 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.4 - Manufacturer StatementThe information contained in this instruction booklet has been compiled by BeaconMedæs, from what it believes are authoritative sources, and is offered solely as a convenience to its customers. While BeaconMedæs believes that this informationisaccurateandfactualasofthedateprinted,theinformation,includingdesignspecifications,issubjecttochange without prior notice.
2 - Abbreviations
5 - Introduction
BeaconMedæs Simplex Manifolds are cleaned, tested and prepared for indicated gas service and are built following National Fire Protection Association and Compressed Gas Association guidelines. The Simplex Manifold consists of a header bar, hose(s) or rigid pigtail(s), optional isolation valves, optional vent valves, designed to provide a gas supply foraspecificgasapplication.Theoptionalalarmsignalconnectionsandlightsshowsystemstatusandalerttheneedtoreplace depleted cylinders.
Standard 10” CenterStandard 5” CenterVertical crossover 5” centerSpecial(Please Provide Details)
WMFS
10S5S5V
SPX
LR
ABLeave Blank
SIM3000
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Instruction Manual
Simplex Manifolds7 - DescriptionSimplexmanifoldsareusedtoconnectthreeormorecylinderstogetherforgreateron-linestoragecapacityorhigherflowrates. These single row manifolds are available with the regulator installed either to the right (Simplex Right) or to the left (Simplex Left). In general, simplex manifolds are used when interruption of gas supply is generally not a critical issue.
BeaconMedæs offers a remote alarm box as an option with all simplex manifolds. The alarm box is equipped with lights andanaudiblealarmtowarntheoperatorwhenthebankpressureislow.TheNema4pressureswitchisfieldadjustable.
Thesinglestage,highpurityandhighflowpressurereducingregulatorcomesstandardwithastainlesssteeldiaphragm.Should you require a different pressure reducing regulator, please call BeaconMedæs to discuss.
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NORMALPRESSURE
LOW PRESSURE ALARM
SILENCE
ALARM BOX FORONE CYLINDER BANK
Alarm Pressure Switch
Single Stage, High Purity, Pressure
Reducing Regulator
Gas Service Outlet(1/2” F.NPT)
Master Shut Off Valve (presented this way to
show properties)
OPTIONAL REMOTE ALARM BOX
Normal Pressure Green Light
Low Pressure Red Light
Buzzer
Silence Push Button
Power Transformer
Manifold Header Block
Capped for Future Use
Header Wall Bracket
Hose/Pigtail with CGA Nut & Nipple (check valve in nipple)
Figure 1 - Overview
Instruction Manual
Simplex Manifolds8 - Configurations
Simplex Right Manifold Simplex Left Manifold
Figure 2 - Configurations: Simplex Left and Simplex Right
9 - Dimensions
Figure 3 - Typical Dimensions of a 4-Cylinder Manifold, 10-Inch Center Header Blocks
14-1/2” 8” 8” 8” 2-1/2”
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10 - Safety Instructions
1. Handlethecylinderwithcare.Useachainorothersuitabledevicetosecurethecylinderstoapermanentfixture.Takecarewhenmoving/transportingcylinders.Totransportcylinders(exceptwhenmovedviacylindercarts),firstremovethe regulators and replace the valve cap. NEVER use any cylinder in anything other than an upright position.
2. Use“goodhousekeeping”inallworkareas.Keepsparksandflameawayfromcombustibles.Prepareyourworkareaprior to welding or cutting.
3. Do NOT use oil or grease on any equipment. The equipment does NOT require lubrication. Oil or grease is easily ignited and burns violently with oxygen.
4. “Crack” the cylinder valve before installing the regulator by opening the valve slightly and then closing it. This will clear the valve of dust or dirt which may be carried to the regulator and cause damage or an accident. Do NOT direct the dischargeofflowinggasatanypersonorflammablematerial.
5. Besurethatallconnectionsaretight,butDON’Tforceaconnection.NEVERtestforleakswithaflame.Useasoapywater solution to check for leaks.
6. Use the recommended pressure settings. Improper pressures are wasteful. Extreme pressure build-up in regulators is a warning sign that they need to be repaired.
7. Do NOT work with damaged or leaking equipment. Use soapy water when checking for leaks. Do NOT use frayed or damaged hose.
8. Handle the equipment with care. Its continued good service and your safety depend upon it.9. Keep the work area well ventilated. Flammable materials burn violently in an oxygen atmosphere. Flames and glowing
materials, including tobacco smoking, MUST be avoided.10. When working with acetylene, NEVER use at pressures over 15 psig (pounds per square inch gauge).11. DONOTFORCEconnectorsandthreads.Allconnections/threadsaregasspecificandareONLYintendedforuse
withthespecifiedgasservice.
11 - Installation
Height-Theheaderbarshouldbeinstalledsothatthemiddleofthemountingblockisat64”fromthefloor.Aspiritlevelshould be used to align the mounting panel horizontally.
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Spirit Level
FLOOR
64”
Figure 4 - Suggested Installation Height
Instruction Manual
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Wall Brackets – We supply one wall bracket per mounting block (i.e. per cylinder). The wall bracket locations are subject to change based upon the type of wall. The wall brackets can be installed anywhere if the wall is made of bricks, concrete and blocks or wood reinforced dry walls. For standard dry walls, we recommend to install the wall brackets where the studs are located.
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Figure 5 – Preferred Locations of Wall Brackets
Suggested Locations for the Wall Brackets
U-Bolt
Header PipeBracketWasher
Nut
Figure 6 – Wall Brackets Anchoring Details
Recommended Screw Types(to be supplied by installer)
CAUTION:Care should be exercised when bending flexible hoses to connect them to cylinders.
DO NOT KINK HOSE.
14 - Leak Testing the Simplex Manifold
An internal leak may be detected as follows:1. Close the regulator by turning the adjusting key counter-clockwise.2. Close the cylinder valve.3. Close the regulator outlet valve.4. Drain the downstream line.5. The low pressure gauge should indicate zero.6. The cylinder or high pressure gauge should indicate zero.7. Open the cylinder valve and the master shut-off valve.8. The inlet gauge of the regulator should read full cylinder pressure. If it does not, it may be damaged. Attempt to locate and correct the cause of the damage and/or replace the gauge.9.Byusingasoapysolutionoracommercialleakdetectionsolution,sprayallfittingsandseekforbubbles.Formationofbubblesorfoamindicatesaleak.Closecylindervalve,ventgastoasafelocationandtightenanyleakyfittingsorcorrectthecauseoftheleakand/orreplacethedefectivefitting.10. Repeat steps 1 though 9 until the system is leak free.
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15 - Pressure Reducing Regulator Operation
The pressure reducing regulator is ordered separately from this equipment. Please refer to the pressure reducing regula-tor instruction manual for details.
16 - Alarm Box Operation & Installation
When the SIM Series equipment is ordered with the alarm box option, the alarm box operation and instruction manual is delivered separately from the present instruction manual.
17 - Principle of Operation
Isolation ValvesThe SIM Series Simplex Manifolds are designed to operate with all cylinders open at all times. As an option, the manifold can be ordered with an isolation valve installed between each hose/pigtail and the header bar. These valves are used to isolate each cylinder individually. The isolation valve allows you to turn on or off the supply of gas from its cylinder. When turned off, the valve will allow you to replace a hose/pigtail.
Vent ValvesVent valves are designed to evacuate any process gas or any contaminants out of the equipment. Each vent valve has to be piped to a safe location. To evacuate contaminants out of the equipment, the vent valve should be opened for about one second at a time, 3-4 times, right after a cylinder replacement. For better performance, the regulator must be turned off.
Alarm BoxThe alarm box is equipped with a green light, a red light, a buzzer and a silence button. The green light indicates that the cylinder pressure is high enough to continue to operate the equipment. The red light indicates a depleted cylinder and the need to replace the empty cylinder by a full cylinder. Each time a red light is turned on, the buzzer is also energized. The silence button kills the buzzer but does not turn off the red light.
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Simplex Manifolds18 - Pressure Switch Field Calibration - Brass Pressure SwitchesTools NeededFlathead screwdriver with 3/16” or 1/4” wide blade
Figure 8 - Pressure Switch Adjustment
FACTORY SEALEDLEADWIRES 20 ± 1” LG.
1/2 NPT (ALUMINUM)
CAUTION LABEL
ADJUSTMENT ACCESS COVER, SLIDE UP TO OPEN
SLOTTED ADJUSTMENT SCREW, TURN IN TO RAISE SET POINT
NOTE:The Hi-Low Pressure Switch Assemblies DO NOT come factory calibrated as a standard feature.
2. With power disconnected, slide cover toward electrical terminations while twisting it to over-come friction.
3. Connect power to terminals or leads.
4. Insert screwdriver into adjustment slot and turn left (clockwise) to increase setting or right (counterclock-wise) to de-creasesetting.(seefigureabove)
For setting on RISE, apply desired pressure and turn adjustment left (clockwise) until switch actuates (circuit across N.O. and COM terminals closes).
For setting on FALL, apply pressure equal to normal system operating pressure. Reduce source pressure to setpoint val-ue. Turn adjustment right (counter clockwise) until switch actuates (circuit across N.C. and COM terminals closes).
19 - Maintenance Instructions1. When not in use, close the cylinder valve.2. Inspectandtesttheequipmentatleastevery6monthsafteritsfirstuse.3. Onlyqualifiedrepairmenshouldservice,testandcleantheequipment.4. Theflexiblehoseshouldbereplacedeverytwoyears.5. ONLYusethreadsealantsthatarecompatiblewiththegasservicespecified.
Instruction Manual
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21 - PlumbingInhighpuritypipinginstallations,qualityoftubingandfittingsareofparamountimportance.Therefore,thepipinginstallershould be familiar with and experienced in such critical applications. Hereunder is a list of important points to consider:Where possible• PrivilegestainlesssteeltubingovercopperandcopperoversofttubingsuchasTeflonornylon.• Always verify material compatibility with the service gas.• A good piping network is always protected against overpressure with a safety (pressure) relief valve (vented to a safe
location).• A valve (ball type or diaphragm type) should be installed near the regulator.• Privilege welded or brazed joints over threaded or compression joints.
CAUTION:Remove all protective caps prior to assembly.
The protective cap may ignite due to the heat of recompression in an oxygen system.
Figure 9 - Plumbing Details
FLANGEHAND-TIGHT ONLY(Do not over tighten
with wrench)
TAIL PIECEGas Service Outlet
½” F.NPT (Provided)
O-Ring(Provided)
TeflonTape(By Others)
End UserPipeline
Note to InstallerAfteryourfirstpressuretest,iftheflange/tailpieceassemblyisleaking,youmaywanttotighten1/32ofaturnusingpipewrenches.Ifthe assembly is still leaking, the O-ring is probably broken. Please replace the O-ring with the provided spare O-ring.
Inlinewithourcommitmenttocontinuousimprovement,BeaconMedæsreservestherighttomakedesignmodificationsor discontinue manufacture of any equipment without prior notice.
22 - Warning
Our equipment is primarily intended for use in compressed gas systems. BeaconMedæs products are de-signed for use by persons technically trained in the proper use and safe handling of gas delivery systems. Due to the high pressure and hazardous gases employed in these processes, misapplication could result in injury or death. BeaconMedæs expressly warns against the sale to, or use of our products by, anyone other than pro-fessionally trained personnel. Do not use this equipment where pressures and temperatures can exceed those listedunderthe«Specifications»section.Through misuse, age, or malfunction, components used with inert, combustible, corrosive, toxic, or oxidizing gases can fail in various modes. The system designer is warned to consider the failure modes of all component parts used with the above mentioned gases and to provide adequate safeguards to prevent personal injury or damage to equipment in the event of such failure modes. Adequate safeguards can be, but are not limited to: •Pressurereliefdevicesadequatelypipedtoasafelocation; •Gasdetectiondevicesconnectedtoaproperwarningaudibleandvisualalarm; •Automaticshutoffvalvesand/ormanualshutoffvalveswithanemergencystoppushbutton; •Self-containedbreathingapparatus; •Pipelinepurgesystemwithinertgas; •Fireextinguishersand/orautomaticsprinklers.System designers must provide a warning to end users in the systems instructional manual if protection against a failure mode cannot be adequately provided for. It should be recognized that warnings are valid for any equipment, regardless of manufacturer, and are not restricted to equipment manufactured by BeaconMedæs. BeaconMedæs’ reputation for equipment quality performance is well established. We feel we have the additional obligation to provide information or warnings to customers to assist them in applying our equipment in a reasonable and safe manner.
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Trademarks used in our instruction manual include:Buna-N,Delrin,Kalrez,Teflon,Tefzel,Vespel,VitonandViton-A are trademarks of E.I. DuPont de Nemours & CompanyMonel is a trademark of Inco Alloys International, Inc.Kynar is a trademark of Atochem North America, Inc.Snoop is a trademark of Nupro CompanySwagelok is a trademark of Crawford Fitting CompanyHastelloy is a trademark of Union Carbide CorporationVCR is a trademark of Cajon Company
BeaconMedæs1800 Overview DriveRock Hill, SC 29730 USATel.: 888.4MEDGAS (463.3427)www.beaconmedæs.com
Printed in U.S.A.July 2014
Instruction Manual: BM-SIM-2300
25 - Warranty
The Seller expressly warrants that the products manufactured by it will be free from defects in material, work-manship and title at the date of shipment. This warranty is exclusive and is IN LIEU OF ALL IMPLIED OR STATUTORY WARRANTIES (INCLUDING WITHOUT LIMITATION, WARRANTIES AS TO MERCHANTABILI-TY OR FITNESS FOR A PARTICULAR PURPOSE, OR ARISING FROM COURSE OF DEALING OF USAGE OR TRADE) or any other express or implied warranties or representations. All claims under this warranty must be made in writing and delivered to the seller prior to the expiration of 1 year from the date of shipment from the factory, or be barred. Upon receipt of a timely claim, the seller shall inspect the item or items claimed to be defective, and seller shall, at its option, modify, repair, or replace free of charge, any item or items which the seller determines to have been defective at the time of shipment from the factory, excluding normal wear and tear. Inspection must be performed at the seller’s plant and in such event, freight for returning items to the plant shall be paid by Buyer. Seller shall have no responsibility if such item has been improperly stored, installed, op-erated,maintained,modifiedand/orrepairedbyanorganizationotherthantheseller.Adjustmentforproductsnot manufactured by Seller shall be made to the extent of any warranty of the manufacturer or supplier thereof. The foregoing shall be the Seller’s sole and exclusive liability and buyer’s sole and exclusive remedy for any breach of warranty or for any other claim based on any defect in, or non-performance of, the products whether based on breach of contract or in tort, including negligence or strict liability.
