instruction manual - beacon - afam350b · • copper rigid pigtails • stainless steel rigid...

Instruction Manual AFAM350B

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THIS BOOKLET, WHICH CONTAINS PROPRIETARY INFORMATION OF BEACONMEDAES, IS PROVIDED TO THE PURCHASER SOLELY FOR USE IN CONJUNCTION WITH PRESSURE DIFFERENTIAL SWITCHOVER MANIFOLDS – LIQUID CYLINDERS – GASEOUS SERVICE (AFAM350B Series).

NORMAL

PRESSURE

LEFT

BANK

NORMAL

PRESSURE

RIGHT

BANK

Empty When

Not Lit

Empty When

Not Lit

LOW PRESSURE ALARM

SILENCE

ALARM BOX FORTWO CYL INDER BANKS

Important

These instructions are for experienced operators who know the general principles and safety precautions 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 BeaconMedaes.

Be sure this information reaches the operator. Your supplier has extra copies.


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1- General Safety Precautions Protect 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 used.

• 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 manifolds with gases not compatible with the materials of construction. The use of gases not compatible with the material of construction may cause damage to equipment or injury to personnel.

• Many gases can cause asphyxiation by displacing oxygen in the atmosphere. Make certain the area where these manifolds are operated is well ventilated. Provide a device to warn personnel of oxygen depletion in the work area.

• Use this equipment only in well ventilated 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 equipment failure and over- pressurization.

• Never connect this equipment to a supply source having a pressure greater than the maximum rated pressure. Refer to the Product Specifications for maximum inlet pressures.

• Never permit oil, grease, or other combustible materials to come in contact with cylinders, manifolds, 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 the flexible hoses to burst.

• Do not apply heat. Some materials may react and ignite while in contact with some gases – particularly oxygen and nitrous oxide.

• Cylinders should always be secured with racks, chains, or straps. Unrestrained cylinders may fall over and damage or break off the cylinder valve which may propel the cylinder with great force.

• Oxygen manifolds and cylinders should be grounded. Static discharges and lightning may ignite materials in an oxygen atmosphere, creating a fire or explosive force.

• Welding should not be performed near nitrous oxide piping. Excessive heat may cause the gas to dissociate, creating an explosive force.

• 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.


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2- Abbreviations C Common OSHA Occupational Safety & Health Administration

CGA Compressed Gas Association PSIG Pounds per Square Inch Gauge

FT-LBS Foot-Pounds SCFH Standard Cubic Feet per Hour

IN-LBS Inch-Pounds VAC Voltage, Alternating Current

N/C Normally Closed VDC Voltage, Direct Current

N/O Normally Open PCB Printed Circuit Board

NPT National Pipe Taper

3- Disclaimer BeaconMedaes 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 Statement The information contained in this instruction booklet has been compiled by BeaconMedaes, from what it believes are authoritative sources, and is offered solely as a convenience to its customers. While BeaconMedaes believes that this information is accurate and factual as of the date printed, the information, including design specifications, is subject to change without prior notice.

5- Introduction BeaconMedaes manifold systems are cleaned, tested and prepared for the indicated gas service and are built following National Fire

Protection Association and Compressed Gas Association guidelines. The manifold consists of a manifold box and two supply bank headers,

one service and one reserve supply, to provide an uninterrupted supply of gas for the specific gas application. The manifold box is designed

and built with features providing automatic switchover from the depleted “Service” supply bank to the “Reserve” supply. Pressure gauges,

optional alarm signal connections and lights show system status and alert the need to replace depleted cylinders. Features of the automatic

system include an adjustable line regulator, hoses with check valves, rigid wall-mounted headers and complete mounting hardware.


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6- Description BeaconMedaes AFAM350B Manifolds provide fully automatic system control. The manifold monitors cylinder bank pressure electronically,

controlling changeover and eliminating the need to manually reset levers or valves. Easy-to-read analog gauges show the line and individual

bank pressures. A series of lights for each bank indicates whether the bank is "in service", "ready for use", or "depleted".

The AFAM350B Series is designed for use with liquid cylinders (connected to the gas use valve of the liquid cylinder). It provides an

uninterrupted supply of gas as the primary bank of cylinders is depleted. At a preset pressure, the switchover unit automatically switches to

the reserve bank. AFAM350B Series manifolds operate on 115 VAC power, but will continue to function during a power failure.

Internal Economizer – The AFAM350B units are equipped with two (2) built-in economizers each set at 200 psig. The role of the economizer is to relieve the pressure of the reserve bank into the line regulator when the said pressure is above 200 psig. This is a by-pass circuit that helps saving some molecules prior to venting them through the thermal expansion relief valves.

MANIFOLDCONTROLLER

ALARM CABLE

GAS DELIVERY OUTLET1/2” F.NPT

PIPELINE PRESSURERELIEF VALVE1/2” F.NPT

Must be Piped to a Safe Location

STAINLESS STEEL HOSE (2)WITH CGA NUT & NIPPLE

HEADER BAR THERMALEXPANSION PRESSURE

RELIEF VALVE (2)

PIPELINE DELIVERYPRESSURE

ADJUSTMENT

MANIFOLDBOX


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7- Ordering Information

AFAM350B

GasArgonCarbon dioxideNitrogenOxygen

InscribeCGA 580CGA 320CGA 580CGA 540

No. of CylindersMust be an even number tohave the same quantity ofcylinders per side(2 cyl. each side = 4)

Inscribe

Hoses & Pigtails

All stainless steel hoseInscribe

SSH

Installation HardwareWall mount bracket

InscribeWM

OptionsOutside InstallationUltra High Purity Cleaning

Inscribe3RUHP

8- General InstructionsManifolds should be installed in accordance with guidelines stated by the National Fire Protection Association, the Compressed Gas

Association, OSHA, and all applicable local codes. Carbon dioxide and nitrous oxide manifolds should not be placed in a location where the

temperature will exceed 120°F (49°C) or fall below 20°F (-7°C). The manifolds for all other gases should not be placed in a location where

the temperature will exceed 120°F (49°C) or fall below –20°F (-29°C). A manifold placed in an open location should be protected against

weather conditions. During winter, protect the manifold from ice and snow. In summer, shade the manifold and cylinders from continuous

exposure to direct rays of the sun. The manifold should be located in a clean, well ventilated area which is free of oil and combustible

materials.

Leave all protective covers in place until their removal is required for installation. This precaution will keep moisture and debris from

the piping interior, avoiding operational problems.

All safety relief valves should be piped/vented to an outside location.


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9- SpecificationsGas Refer to Part Number Matrix

Maximum Inlet Pressure 350 psig

Flow Cv = 0.4; Note: Flow will be limited by internal vaporizer on the liquid cylinder. Operating Temperature -40

oF to 100

oF

Pressure Gauge Size 2-1/2” Dial

Inlet Connection Gas Specific CGA Connection (Refer to Part Number Matrix)

Outlet Connection ½” F.NPT

Audible and Visual Alarm Standard

Header ½” Nominal Pipe Size (0.840” Outside Pipe Diameter)

Power Requirement Alarm Box: 110 VAC, 1 Amp. (hard wired)

Flexible Hose Length Liquid Cylinders: 60 inches or 72 inches

10- Standard Factory Pressure SettingsInlet Pressure Gauge 0-400 psig (Standard)

0-600 psig (for High Pressure Liquid Cylinder Models)

Outlet Pressure Gauge 0-200 psig (Standard)

0-600 psig (for High Pressure Liquid Cylinder Models)

Outlet Pressure Range 30-100 psig (Standard)Switchover Pressure 125 psig (Approx.)

Economizer 200 psig

Alarm Set Point (Both Banks) 125 psig Decreasing (Approx.)

Pressure Relief Valve 150 psig

The above mentioned settings will vary depending upon which AFAM Series Fully Automatic Switchover manifold is purchased. The specific settings of each piece of purchased equipment are indicated on their

respective nametags.


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11- Dimensions

Manifold Depth7” Without Regulator Knob.

Wall Mounting Bracket is 2” Deep.

16”

14”

30”


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12- Standard & Custom Configurations

Name Tag

Each piece of equipment bears a nametag telling you important information about:

• Gas service

• Alarm set points

• Pressure settings

• Year of manufacture

• Model number

Flexible Hoses

Flexible hose/rigid pigtails selection is critical to get the best performance from your manifold. We offer five types of hoses:

• Thermoplastic Hoses

• Teflon Core Hoses

• Stainless Steel Hoses

• Copper Rigid Pigtails

• Stainless Steel Rigid Pigtails

For additional safety, stainless steel hoses are available with:

• Armor guard

As a standard feature, each hose has:

• A check valve in the CGA nipple

Finally, we offer three cylinder hose connections (all CGA / gas related)

• Standard CGA nut & nipple

• Quick connects (zip nuts)

• Hand tight nuts

13- Oxygen Service EquipmentAll oxygen service equipment made by BeaconMedaes is cleaned as per the requirements of CGA G-4.1-1996. The flexible hoses installed on oxygen service discharging stations are Teflon core, stainless steel over braid with brass end connections. Also available for oxygen service are copper rigid pigtails with brass end fittings.

CAUTION

Remove all protective caps prior to assembly. The protective cap may ignite due to heat of recompression in an oxygen system.


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14- Installation The AFAM350B Series Manifolds come standard with two header bars. The cylinders are connected to the header bars via hoses or rigid pigtails. The first step is to install the manifold box. The second step is to install the header bars. Unless otherwise specified, the hoses are factory installed to the header bars.

1. MANIFOLD BOXSecurely mount the mounting bracket to a wall or stand. The manifold box should be located such that the headers are at

approximately 64 inches from the floor.

FLOOR

64”


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2. Screw the mounting bracket to the supporting wall.

Wood Screws

Drywall Screws withSelf-Drilling DrywallAnchors

Self TappingMetal Screws

Recommended Screw Types(to be supplied by installer)

1/4” O are required

S CREW

SCREW

S CREW

S CREW

3. Align the manifold box with the mounting bracket. The two upper knurled nuts should easily slide into their corresponding slot onthe mounting bracket. Then the stud should swiftly insert itself into its corresponding hole located on the lower part of themounting bracket. Return the washer and the mounting nut to the threaded stud so that the control box is permanently mounted toits corresponding bracket.

KNU R

L ED NU T

THR E

ADED

ST U

D

K NUR L

ED NUT


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HEADER BARS

1. Align the headers to the union on each side of the manifold box. Using a level, mark the placement of the mounting brackets whilemaintaining a horizontal plane.

SPIRIT LEVEL

MANIFOLDBOX

HEADERBAR

2. Drill a hole in the supporting wall or stand. By using the proper screws (provided by installer), fasten the mounting bracket to thewall or stand.

Nut

Washer

Bracket

Header Pipe

U-Bolt

Wood Screws

Drywall Screws withSelf-Drilling DrywallAnchors

Self TappingMetal Screws

Recommended Screw Types(to be supplied by installer)

1/4” O are required


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3. The mechanical connection between the header bars and their respective inlets to the manifold box is union type.

TIGHTENBY HAND

HOLD

TIGHTENCLOCKWISE

Fig. A Fig. B

The connection between the header bars and their respective inlets to the manifold box are metal to metal connections. Although the header bars have been shipped separate from the manifold box, the two header-to-manifold-inlet connections have been made and tested at the factory.

Fig. A - The union nut must be very easy to tighten by hand. You should be able to make at least two turns before the nut stops. If the nut is grinding or is difficult to turn by hand. The header bar is probably not lined up properly or there are debris in the connection. Resolve the situation and re-make the connection.

Fig. B - Once you have tightened the union nut properly to its corresponding adaptor, using a pipe wrench tighten the union nut while using use a second pipe wrench to hold the fitting on the manifold side as shown on the schematic above.

TECHNICAL TIP – How to Repair a Leaky Union

The first thing to do when a union assembly is leaking is to de-pressurize the assembly, disassemble the joint, and, with a cleaned paper towel or rag, wipe out any debris that would be located between the tailpiece and the union. Then, remake that joint by tightening the connection first by hand and then using pipe wrenches. Re-pressurize the conduit and check for leaks with a soapy solution. Re-

tighten if necessary with no pressure. Never tighten a union assembly under pressure.


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15- PlumbingIn high purity piping installations, the quality of tubing and fittings are of paramount importance. Therefore, the piping installer should be familiar with and experienced in such critical applications. Hereunder is a list of important points to consider:

• Privilege stainless steel tubing over copper, and copper over soft tubing such as Teflon or nylon.

• Always verify material compatibility with the service gas.

• A good piping network is always protected against overpressure with a safety (pressure) relief valve.

• Always pipe the safety relief valves to a safe location.

• A valve (ball type or diaphragm type) should be installed near the AFAM Series outlet line regulator.

• The best type of valve you can install is the diaphragm valve. They have a much better external leak rate than ball valves.

• If you have to install a ball valve, select an instrument ball valve and avoid using medical ball valves.

PIPING THE PRESSURE RELIEF VALVES There are three (3) pressure relief valves on a AFAM350B manifold: one per header bar and one at the manifold outlet. These three pressure relief valves can be manifolded together to a common vent pipe. The following design and installation criteria shall be followed:

• The size of the piping connected directly to the pressure relief valve shall not be smaller than the size of the pressure relief valveitself. If we take the example below, the header bar PRV’s are ¼” M.NPT. The piping shall not be smaller than ¼” NPS. Similarly,the manifold outlet PRV is ½” F.NPT. The vent piping directly connected to this ½” F.NPT shall not be smaller than ½” NPS.

• The main vent pipe collecting the individual vent pipes shall not create back flow or back pressure. Therefore, it cannot be smallerthan the total surface area of all piping connected to it. In our example, we have two (2) 1/4” NPS pipes and one (1) ½” NPSconnected to the main vent pipe. The main vent pipe should not be smaller than ¾” NPS or should be preferably 1” NPS.

• 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.

• Vent pipe discharge outlets shall be far away from any building air intake louvers so that the vented gas does not return into thebuilding air supply.

• If the vent piping is brazed, only high temperature melting point brazing material shall be used (therefore soldering is prohibited).

• The piping material(s) shall be compatible with the gases being vented.

• IT IS EXTREMELY IMPORTANT TO INSTALL UNIONS WHEN PIPING THE PRESSURE RELIEF VALVES.


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PIPING THE MANIFOLD GAS SERVICE OUTLET The manifold outlet is ½” F.NPT. It consists of four (4) parts making a union: a union nut (swivel), a flange, a boss (aka tailpiece) and an o-ring. This connection has been pressure tested at the factory. The gas service piping can be connected directly to the manifold outlet as described below.

Step 1 Remove tailpiece and the o-ring from the outlet assembly

Step 2 Install the process pipe to the

tailpiece

Step 3 Install the o-ring in the grove of

the tailpiece

Step 4 Put the tailpiece to the face of the flange by making sure both align

perfectly. Make sure the o-ring stayed into the grove of the tailpiece.

Step 5 Tighten by hand the swivel nut and the tailpiece

until a complete stop

Step 6 Using two wrenches, tighten the nut for about 1/8-turn. If this connection leaks during the pressure test, break the connection to check if the o-ring is not broken. Re-tighten

and leak check again.


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Source Valve Installation - The AFAM350B does not come standard with an outlet valve (aka source valve). We strongly recommend installing a source valve directly to the manifold outlet. As mentioned previously in this manual, the best possible valve you can use as an outlet valve is a diaphragm valve. Should you decide to go with a ball valve, we recommend two (2) installation scenarios:

• GOOD: High purity ball valve connected directly to the manifold union

• BETTER: A TIK Series Tie–In Kit also connected directly to the manifold union.

Outlet (Source) Valve Installation

HIGH PURITY VALVE(Sold Separately)

UNION

MANIFOLD OUTLET1/2” F.NPT

B 2000v SeriesHigh Purity Ball valve

TO PROCESS

t ik SeriesHigh Purity Tie-In Kit

HIGH PURITYTIE-IN-KIT

TO PROCESS

UNION

MANIFOLD OUTLET1/2” F.NPT

GOOD BEST


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16- Electrical Installation

Control Module – There are two (2) types of connections that need to be made to the control module: 24 VAC power supply and the remote alarm connections (if required). The signal cable linking the control module to the manifold is factory installed.

Signal Cable: The signal cable length between the control module and the manifold box is about 4-ft long. Should you require a longer cable, please contact BeaconMedaes for options and availability.

24 VAC Power Supply: The control module requires 24 VAC to operate. The power consumption is maximum 6 Amp. at 24 VAC. The power transformer is supplied with your manifold but it is separate from the manifold itself. It has to be field installed. This power transformer must be installed inside a building (NEMA 1 rated). The terminals where the 24 VAC wires go are shown on the diagram “Control Module Wiring” on the next page. The hardware required - wires, conduits and related accessories - to connect the power transformer to the control module are to be supplied by others.

Remote Alarm Connection: The remote alarm signal (to a master alarm box for example) is a dry contact. This normally open relay will close when either bank is empty (i.e. when a switchover has occurred). The terminals where the remote alarm connection has to be made are indicated on the diagram “Control Module Wiring”. The wire size has to be determined by the installer.

EXTERNAL VIEW(Front)

REMOTE ALARM CABLE LOCATION(Performed in the filed)DRILL HOLE INTO BOTTOMPORTION OF THE ENCLOSURE(Hole size is according to connector)

POWER TRANSFORMER CABLE LOCATION(Performed in the filed)

DRILL HOLE INTO BOTTOMPORTION OF THE ENCLOSURE

(Hole size is according to connector)

EXTERNAL VIEW(Bottom)

1-1/2”1-1/2”

IN USE

LEFTBANK

IN USE

RIGHTBANK

Empty WhenNot Lit

Empty When

Not Lit

LOW PRESSURE ALARM

SILENCE

FULLY AUTOMATIC SWITCHOVERCONTROL MODULE

NORMALPRESSURE(READY)

NORMALPRESSURE(READY)

Warning – Do not go too far when drilling through the alarm box enclosure. The terminal strip is located about an inch from the enclosure wall. It is preferable to open the enclosure before drilling to make sure you don’t hit anything while drilling.


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PRIMARY

Voltage Input: 120 VACFrequency: 60 HZ

Phase: 1

SECONDARY

Output Voltage: 24 VACOutput Power: 150 VA

POWER TRANSFORMERManufacturer: MARCUS

Model: MC150BInstalled separately from the AFAM Controller Box

H1 X2

H2 X1

120 VACHardware &Installationby Electrician

Ground provided by electrician as per

applicable electrical code

Electrical Source120 VAC

according to applicableelectrical code

AFAM CONTROLLER

Alarm Module(by others)

AFAM ControllerEnclosure Limit

24 VACHardware &Installation

by Electrician

Hardware &Installation

by Electrician

24 VAC

24 VAC

WIRE 6

WIRE 5

WIRE 4

WIRE 3

WIRE 2

SIGNAL

SIGNAL

SQUARE ONE - FULLY AUTOMATIC SWITCHOVER MANIFOLD RELAY BOARD

TERMINALS FOR REMOTE ALARM Dry Contact

Normally Open 30 Amperes

Type:Position:Capacity:

Control Module Wiring


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17- Possible ConfigurationsThe goal of this section is not to explain how a liquid cylinder works but to give you enough information as to how to take full advantage of your AFAM350B manifold. But first, please find hereunder some basic information as to how a liquid cylinder works.

EXTERNAL COMPONENTS OF A TYPICAL LIQUID CYLINDER LIQUID CYLINDER FLOW DIAGRAM

1. Gas Use Valve Used for gas withdrawal

2. Liquid Valve Used for cryogenic liquid withdrawal operations

3. Pressure Control Valve Used to isolate (on/off) the pressure control regulator

4. Vent Valve Used to vent pressure

5. Pressure Control Manifold Used to automatically maintain pressure

6. Pressure Gauge Indicates cylinder pressure

7.* Combination Regulator MCR Used to automatically maintain pressure

8. Pressure Relief Valve Used to limit pressure in the liquid cylinder

9. Liquid Level Gauge Used to approximate the liquid contents of the liquid cylinder

* Economizer Depending upon the liquid cylinder model, 7 is a combination of a pressure build regulator and an economizer.

WHAT’S IMPORTANT TO KNOW Internal Vaporizer The internal vaporizer can convert cryogenic liquid to gas up to 350 SCF over a period of 60 minutes. For

carbon dioxide, this vaporizing capacity is 100 SCF. If you overshoot the internal vaporizer capacity, cryogenic liquid will come out of the gas use valve (instead of gas).

Gas Use Valve The gas vaporized by the internal vaporizer comes out from the gas use valve.

Pressure Control Valve The end user must open valve 3 to allow the liquid cylinder to properly regulate its internal pressure.

Internal Pressure If you have two (2) liquid cylinders manifolded together and each liquid cylinder is isolated by a check valve (which is the case for most manifolds). Both liquid cylinders will have different pressure and, therefore, they will not empty equally.


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SETUP NO. 1 – ONE LIQUID CYLINDER PER SIDE IS CONNECTED DIRECTLY TO THE MANIFOLD

RIGHT BANKLEFT BANK

DEL IVERY

GAS MANIFOLD SYSTEMS

OUTLET PRESSURE

PRESSUREPRESSURE

PRESSURE

ADJUSTMENT

Connect Hoseto “Gas Use” Valveof Liquid Cylinder

350 SCFHMax.

350 SCFHMax.

GAS

GAS


• It is the most common way of connecting liquid cylinders to the manifold.

• The maximum flow is limited by the vaporizing capacity of the internal vaporizer of the liquid cylinder (350 SCFH in this case).

• The total storage capacity of this set up is one liquid cylinder per side.

SETUP NO. 2 – TWO OR MORE LIQUID CYLINDERS PER SIDE ARE CONNECTED DIRECTLY TO THE MANIFOLD (NO PRESSURE

EQUALIZER HOSES)


OUTLET PRESSUREPRESSUREPRE SS URE

ADJUSTMENT

350 SCFHMax.

GAS

RIGHT BANKLEFT BANK

DEL IVERY


PRESSURE

350 SCFHMax.

GAS

GAS

GAS


• It is a very common setup.

• Even if there are several liquid cylinders connected to the manifold. The maximum flow is still limited by the vaporizing capacity ofeach internal vaporizer of the liquid cylinder (350 SCFH in this case). It is extremely unlikely to have two liquid cylindersconnected together at the exact same pressure and we can only assume that only one liquid cylinder will empty at a time.

• The total storage capacity of this set up is equal to the amount of liquid cylinders X their net content.


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SETUP NO. 3 – TWO OR MORE LIQUID CYLINDERS PER SIDE ARE CONNECTED DIRECTLY TO THE MANIFOLD WITH VENT KIT

WITHOUT VENT KITS

The GAS USE valve of each

liquid cylinders are connected

to their respective manifold

header bars.

Without the Vent Kits, the liquid

cylinders are all at different

pressures. The liquid cylinder

having the highest pressure of

each header bar is feeding the

manifold. In this example, the

priority bank selector is pointing

to the right. Therefore, only the

153 PSI liquid cylinder is

feeding the manifold.

WITH VENT KITS

The VENT valve of each

liquid cylinder is connected to a

Vent Kit (2 liquid cylinders

per side). Because both liquid

cylinder headspaces are

connected together via the

Vent Kit, both liquid cylinder of

each side are now at the same

pressure (the highest

headspace pressure).

Both liquid cylinders of the

same bank have now the same

pressure. Therefore, both

liquid cylinders are feeding the

manifold at the same time.

Once again, in our example,

the right bank is the priority

bank.

1111

2 2 2 21111

3 3

135 PSIStand-By

147 PSIPriority

112 PSIStand-By

153 PSIPriority

147 PSI 147 PSI 153 PSI 153 PSI

Without Vent Kits

With Vent Kits

1

3

2

GAS USE

VALVE

VENTVALVE

• This setup should be used where an increased flow is required even for a short period of time.

• By connecting both gaseous headspaces together with a hose, both liquid cylinders have equal pressure (hence pressureequalizer hose). Because both liquid cylinders have the same pressure, both liquid cylinders are dispensing gas at the same time.Therefore, the maximum flow is equal to the internal vaporizer capacity of each liquid cylinder (in our example 350 SCFHvaporizing capacity X 2 liquid cylinders = 750 SCFH total).

• The total storage capacity of this set up is equal to the amount of liquid cylinders X their net content.


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SETUP NO. 4 – ONE OR MORE LIQUID CYLINDERS PER SIDE ARE CONNECTED TO EXTERNAL VAPORIZERS

RIGHT BANKLEFT BANK

DELIVERY


OUTLET PRESSUREPRESSUREPRESSURE

PRESSURE

ADJUSTMENT

The flow is nowlimited by the

vaporizer capacity

The flow is nowlimited by the

vaporizer capacity

GAS

GAS

CRYOGENICLIQUID

CRYOGENICLIQUID

Connect Hoseto “Liquid Use” Valveof Liquid Cylinder

Connect Hoseto “Liquid Use” Valveof Liquid Cylinder

EXTERNALVAPORIZERS

• This setup should be used where maximum flow is required even for a short period of time.

• In this example, we assume that external vaporizers have a vaporizing capacity of 1500 SCFH.

• Cryogenic liquids convert to their gaseous state at a ratio of at least 750:1. That means 1 cu.ft. of liquid nitrogen equals to 750cu.ft. at normal temperature and pressure.

• With this setup, the flow is either limited by the external vaporizer capacity or by the maximum flow capacity of the manifold itself.

• The pressure of each bank is controlled by the pressure build regulator of each liquid cylinder.

• The storage capacity is limited by the number of liquid cylinders connected to each bank (side).

CAUTION:

Care should be exercised when bending flexible hoses to connect them to cylinders.


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18- Theory of Operation

SS

PSPSHeader Bar Inlet - 1-11-1/2” RH(One per Side)

Inlet Pressure Gauge(One per Side)

PrimaryRegulator

(One per Side)

SwitchoverPressureSwitchEconomizer (2)

Normally Open Solenoid Valve(One per Side)

Check Valve(One per Side)

Line (Delivery)Pressure Regulator

Line (Delivery)Pressure Gauge

Pipeline PressureRelief Valve

Gas Delivery Outlet(1/2” F.NPT)

MANIFOLD OPERATION The automatic switchover manifold consists of a manifold box, a control module and two supply bank headers, one service and one reserve supply, to provide an uninterrupted supply of gas for the specific gas application.

The manifold control unit includes the following components and features: green “In Service”, yellow “Ready for Use”, and red “Bank Depleted” indicator lights, analog cylinder pressure gauges, analog line pressure gauge, internal line regulators, internal pressure relief valves, normally open solenoid valves, intermediate pressure relief valves, and a line pressure relief valve. Each supply bank consists of a header bar with flexible hoses and cylinder connections.

After initial power-up and with both banks empty, the red light will be illuminated. The bank that is pressurized first will be considered the “in service” bank. The cylinder bank that supplies the piping system is known as the “Service” supply (as indicated by the green “in Service“ light), while the cylinder bank on stand-by is referred to as the “Secondary” supply (as indicated by the yellow “ready for use” light). On the service bank, the gas flows into the manifold control unit inlet to the bank pressure switch, then into the primary regulator before heading to a solenoid valve followed by a check valve and the final line regulator. Delivery pressure is controlled by one line regulator and is adjustable (See Delivery Line Adjustment Section). The gas exits the line regulator and proceeds past the pressure gauge and into the delivery piping.

The gas on the secondary bank flows into the manifold cabinet to the bank pressure switch. The gas then flows through the other primary regulator. The gas is then stopped by a solenoid valve. Since this is the secondary bank, the valve is closed, preventing the secondary bank from flowing. Switchover from the “Service” to “Secondary” side is accomplished when the service pressure drops below a predetermined point (this changeover pressure is determined by the pressure switch). The control module then signals the secondary bank solenoid to open, allowing it to start to flow without any interruption in line delivery pressure. There are three definite indicators as to which bank should be changed; (1) the red “Bank Depleted” light, (2) the cylinder bank pressure readout (gauge) and (3) both the green light and the yellow light of the depleted side are extinguished.


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After replacing empty cylinders, open the cylinder valves. The control module will read this pressure and automatically place the fresh bank of cylinders into reserve (stand by/ready for use) mode, making it the secondary bank. The yellow light will come on indicating that the new bank is ready for use, and the red “Bank Depleted” light will be extinguished. Replacing the empty cylinders is all that is required to reset the manifold.

To insure proper operation, observe the following guidelines: 1. Carefully follow all instructions.2. Establish proper flow direction of check valves.3. Make sure cylinder valves are fully open.4. Replace depleted cylinders as soon as practical after the red “Bank Depleted” light comes on.

Manifoldnot energized

Left Bank:Right Bank:

In UseStand By


Stand ByIn Use


In UseEmpty


EmptyIn Use


EmptyEmpty

CONTROL MODULE MESSAGE CENTER


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What happens when a cylinder bank is depleted?

The switchover process explained

a) Red Light Comes On: The red light will come on regardless of which side is depleted. The depleted side’s green and yellowlights will NOT be illuminated.

b) Buzzer Sounds: The buzzer is energized when a cylinder bank is depleted. The silence pushbutton will kill the buzzer but the redlight remains energized and the dry contact (alarm signal) remains actuated until the depleted bank is replaced with full cylinders.

c) Alarm Signal is Energized: That means the dry contact switches from an open position to a closed position. The alarm signal

indicates that a switchover occurred from the bank in use to the bank in stand-by. This signal remains energized until the bank isreplenished. NOTE: If both banks are allowed to deplete, the signal will remain energized until BOTH banks are replenished.

d) Solenoid Valves: The solenoid valve of the depleted bank is energized (don’t forget the solenoid valves are normally openvalves). Hence, the solenoid of the bank in service is not energized. In fact, this is how the switchover process occursbetween the two cylinder banks.

ABOUT THE ECONOMIZER

The AFAM350B comes standard with two built-in economizer circuits.

BENEFIT The economizer’s purpose is to minimize product loss on the reserve bank. When the liquid cylinder on the reserve bank reaches 200 PSI. The economizer opens and the gas bypasses the primary regulators and feeds directly the line regulator until the pressure drops below 200

PSI.

IT COULD BE MISLEADING End users sometimes notice that both banks are depleting at the same time thinking. That’s because the economizer uses the “reserve”

bank as much “in use” bank. This is a clear indication that your gas consumption is too low to be fed by liquid cylinders.

NOISE Both economizers are set to open at 200 PSI. When the economizer throttles around 200 PSI, the enonomizer may make some noise. This

is a normal but temporary situation. The noise will stop as soon as the pressure of the reserve liquid cylinder drops under 200 PSI.


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19- Leak Testing & Purging

HEADERS 1. Connect the cylinders to the flexible hoses with the CGA nut/nipple end connections provided.

CAUTION:

Flexible hoses containing check valves can be pressurized with system pressure only up to the check valve seat. The threaded joints on the flexible hose, including the CGA connection, will not be pressurized with the

process gas.

2. Use the process gas to leak test the headers.

3. Isolate the manifold box by closing both the left and right bank cylinder valves.

4. Stand to the side of the manifold box and s-l-o-w-l-y open the gas cylinder valves from the left side of the control box. Repeat the

same procedure for the right side of the manifold.

5. With cylinders connected, but with the cylinder valves closed, leak test all connections with either a soap solution or a gas leakdetector such as Snoop®. Repair any leaks with NO pressure in the headers.

6. Purge both the right and left side headers by opening the pipeline valve for five seconds.

7. Vent the system to atmospheric pressure if the system will not be put in to service for a while.

MANIFOLD BOX The manifold box has been factory tested and is believed to be leak free. Nevertheless, it is preferable to verify that the manifold box remains leak free before putting it into service.

1. With the left bank gauge pressurized by the service gas, energize the manifold. The left bank green LED should be lit.

2. Make sure the source valve (valve at the outlet of the manifold) is closed.

3. The delivery gauge should read some pressure. If not, adjust to the desired pipeline pressure by turning the regulator knob clockwise to increase or counter clock wise to decrease.

4. Shut off all cylinder valves.

5. Note the pressure of all gauges and let it sit for three hours. Any pressure decrease on any gauge would indicate a leak. Check for leaks and make repairs with NO pressure in the system.

6. Repeat steps 1-5 for the right bank.


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20- Start Up and Checking Procedures

1. S-L-O-W-L-Y open one cylinder valve on the right bank (turn counter-clockwise to open). The right bank pressure gauge should show the full pressure of the right bank of cylinders and the green light should be illuminated.

2. S-L-O-W-L-Y open one cylinder valve on the left bank. The left bank pressure gauge will show the full pressure of the left bank of cylinders. The yellow “Ready for Use” light comes on, extinguishing the red “Depleted Bank” light, on the left side.

3. Create a slight flow of gas by opening the line (source) valve. Close the right cylinder valve to simulate a depleting right bank. Observe the following: • The right bank pressure slowly falls and the manifold control automatically switches over to the left bank.• Delivery pressure remains constant.• Green “In Service” light is extinguished (left bank).• Red “Depleted Bank” light illuminates.• Any remote alarms should be activated at this time.• The left bank green “In Service” light comes on, extinguishing the yellow “Ready for Use” light.

4. S-L-O-W-L-Y reopen the right cylinder valve. Observe the following: • Right bank pressure returns to full pressure.• Yellow “Ready for Use” light illuminates.• Red “Depleted Bank” light is extinguished.• Any remote alarms should be canceled.

5. Repeat procedures 3 & 4 simulating an empty left bank.

21- Cylinder Replacement

1. Shut off all valves on the depleted liquid cylinder(s).

2. S-L-O-W-L-Y loosen and remove the flexible hose connections from the depleted liquid cylinder(s).

3. Remove the depleted liquid cylinder(s).

4. With the valve outlet pointed away from you or anyone else, slowly open each liquid cylinder “gas use” valve slightly to blow outany dirt or contaminants which may have become lodged in the liquid cylinder valve.

5. Place and, if necessary or required, secure the full liquid cylinder(s) into position using chains, belts, or cylinder stands as required.

6. Connect the flexible hose(s) to the liquid cylinder “gas use” valve(s) and tighten with a wrench. DO NOT OVERTIGHTEN.

7. S-L-O-W-L-Y turn each liquid cylinder “gas use” valve until each cylinder is fully open.

8. The manifold is equipped with an alarm box, observe the following conditions:

• The red ”Low Pressure” light turns off, and the yellow “Ready” light turns on.

9. The manifold supply bank is now replenished.

22- Line Pressure Adjustment The delivery line pressure (top and center pressure gauge) can be increased by turning the line regulator knob, located in the middle of the control panel, clockwise, or decreased by turning the line regulator knob counterclockwise. To decrease the pipeline pressure, the operator must create a flow downstream of the line regulator.


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23- General Maintenance

CAUTION: Do not use leak test solution that contains ammonia. Solutions containing ammonia may cause brass tubing to crack.

1. Main control sectiona) On a daily basis, maintain a record of the line pressureb) On a monthly basis:

1) Check regulators and valves for external leakage.2) Check valves for closure ability

c) On an annual basis:1) Check relief valve pressures2) Check regulator seats

2. Manifold headera) On a daily basis, observe nitrous oxide and carbon dioxide systems for cylinder frosting and surface condensation. Should

excessive condensation or frosting occur it may be necessary to increase the manifold capacity.b) On a monthly basis:

1) Inspect valves for proper closure.2) Check cylinder flexible hoses for cleanliness, flexibility, wear, leakage, and thread damage. Replace damaged flexible

hoses immediately.3) Inspect flexible hoses check valves for closure ability.

c) Every 4 years

1) Replace all flexible hoses

24- Shutdown

WARNING: Hazardous gases must be discharged into a safety vent. Be sure to use a venting procedure that is environmentally acceptable and complies with Federal, State, Provincial and local requirements.

1. Close all cylinder valves.2. Vent the system pressure to 0 psig. If a hazardous gas is used, purge the entire system with clean, dry nitrogen gas. Continue

purging until the hazardous gas level in the system is below the TLV for the gas.3. Close all system valves by turning the knobs fully clockwise.4. On the AFAM Series, close the line regulator by turning the knob counterclockwise until it reaches the stop.


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25- Troubleshooting

SYMPTOM PROBABLE CAUSE REMEDY OR CHECK

LOSS OF CYLINDER CONTENTS

Audible or inaudible gas leakage (unknown origin)

Leakage at manifold piping connection Tighten, reseal or replace

Leakage in downstream piping system Repair as necessary

Leakage at cylinder valve Replace cylinder

Gauge leaks Reseal or replace

Regulator leaks Repair or replace

Venting at relief valves Line regulator setting too high Set delivery pressure to specifications

Overpressure due to creeping or faulty regulation by primary regulator

Replace regulator seat and nozzle components

Cylinder pressure is too high Put on new cylinders with adequate pressure setting

Overpressure due to creeping or faulty regulation by line regulator

Replace regulator seat and nozzle components

Regulator freeze-up Reduce the flow demand or increase the number of supply cylinders. Tighten bonnet

Gas leakage around regulator body or bonnet

Loose bonnet Tighten bonnet

Diaphragm leak on regulator Replace regulator

Gas leakage around valve stem on isolation valve

Bonnet is leaking Tighten packing nut

Faulty valve Repair or replace valve


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SYMPTOM PROBABLE CAUSE REMEDY OR CHECK

LOSS OF RESERVE BANK CONTENTS

Both banks feeding Fixed-pressure regulator seat leak

Replace regulator

Fixed-pressure regulator set to open at too high a pressure

Adjust intermediate regulator per

specifications

Flow demand too high Reduce flow demand

Opposite bank feeding Faulty primary regulator and/or fixed-pressure regulator

Replace regulator

Flow demand too high Reduce flow demand

Liquid cylinder pressure is too low Adjust pressure build-up regulator Premature switchover to reserve bank

Pressure switch is set too high or too low Re-adjust pressure switch settings

Pressure switches are no longer adjusted properly

Re-adjust pressure switches

Defective Electronics Replace control module No switchover

Primary regulators are defective Replace or re-adjust primary regulators

PIPELINE DISTRIBUTION

Pipeline not at desired pressure Line regulator not set correctly Readjust line pressure regulator

Required gas flow not available Line regulator not set correctly Flow demand too high

Readjust line pressure regulator Consult factory

SOLENOID VALVES

Gas leakage through a closed solenoid valve

Solenoid faulty Replace solenoid valve

Solenoid valve not closing Solenoid faulty Replace solenoid valve

Electrical connection Verify wiring to solenoid valve


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26- Repairs If the manifold or any part of the switchover leaks or malfunctions, take it out of service immediately. Repairs should be made only by BeaconMedaes with the special tools, test equipment and trained personnel required to make a safe repair. Tampering with switchover manifolds voids the warranty. Please contact BeaconMedaes to arrange for any necessary repairs.

Repairs to switchover manifolds done after the initial warranty period has expired are chargeable to the customer. Upon receipt at the

factory, the switchover manifolds will be inspected and you will be contacted with a repair cost estimate. No item will be repaired until

approval is received. There will be an evaluation charge assessed for equipment not repaired. All repairs should be arranged through your

BeaconMedaes supplier.

NOTE: All equipment being returned must be purged of all hazardous materials using a clean, dry inert gas (e.g. Dry Nitrogen) prior to

return.

27- Warning Our equipment is primarily intended for use in compressed gas systems. BeaconMedaes products are designed 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. BEACONMEDAES expressly warns against the sale to, or use of our products by, anyone other than professionally trained personnel. Do not use this equipment where pressures and temperatures can exceed those listed under « Specifications ». 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:

• Pressure relief devices adequately piped to a safe location;

• Gas detection devices connected to a proper warning audible and visual alarm;

• Automatic shutoff valves and/or manual shutoff valves with an emergency stop push button;

• Self-contained breathing apparatus;

• Pipeline purge system with inert gas;

• Fire extinguishers and/or automatic sprinklers. 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 BeaconMedaes. BeaconMedaes’s 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.

28- Design Changes In line with our commitment to continuous improvement, BeaconMedaes reserves the right to make design modifications or discontinue manufacture of any equipment without prior notice.


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Trademarks used in our instruction manual include:

Buna-N, Delrin, Kalrez, Teflon, Tefzel. Vespel, Viton and Viton-A are trademarks of E.I. DuPont de Nemours & Company Monel is a trademark of Inco Alloys International, Inc. Kynar is a trademark of Atochem North America, Inc. Snoop is a trademark of Nupro Company Swagelok is a trademark of Crawford Fitting Company Hastelloy is a trademark of Union Carbide Corporation VCR is a trademark of Cajon Company

BeaconMedaes 1800 Overview Drive Rock Hill, SC 29730 Tel.: 888.4MEDGAS (463.3427) www.beaconmedaes.com

BeaconMedaes Printed in U.S.A. Decemberl 2014

Instruction Manual: IM-AFAM350B-4441

LIMITED WARRANTY

WARRANTY: The Seller expressly warrants that the products manufactured by it

will be free from defects in material, workmanship 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 MERCHANTABILITY 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, operated, maintained, modified and/or repaired by an organization other than the seller. Adjustment for products not 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.

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