Spectron BM50 Series User manual

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2 GES_BM+BE_50_1115.docx
Operating Manual
of the BM/BE series
Contents
Contents.....................................................................................................................2
1.Introduction...........................................................................................................3
1.1General............................................................................................................3
1.2Description of the high-pressure panels of the BM and BE series..................3
1.3Intended use....................................................................................................4
1.4Personnel requirements..................................................................................4
2.For your safety .....................................................................................................5
2.1Symbols used..................................................................................................5
2.2Essential safety information ............................................................................5
2.3Safety information ...........................................................................................6
3.Description ...........................................................................................................7
3.1Overview of the high-pressure panel...............................................................7
3.2Functional description .....................................................................................8
3.3Technical data .................................................................................................8
3.4Connection options..........................................................................................8
4.Operation..............................................................................................................9
4.1Labelling..........................................................................................................9
4.2Installing the high-pressure panel ...................................................................9
4.3Putting the high-pressure panel into operation for the first time....................10
4.4Changing the cylinder....................................................................................11
4.5Taking the equipment out of operation..........................................................12
5.Problems ............................................................................................................12
6.Maintenance, cleaning and repairs.....................................................................13
6.1Regular maintenance work and visual inspections........................................13
6.2Regular cleaning ...........................................................................................13
6.3Repair information.........................................................................................13
6.4Returns..........................................................................................................13

GES_BM+BE_50_1115.docx 3
Operating Manual
of the BM/BE series
1. Introduction
1.1 General
Validity
This operating manual is valid for the high-pressure panels of the BM and BE series.
Manufacturer
Spectron Gas Control Systems GmbH
Fritz-Klatte-Straße 8
D-65933 Frankfurt
Germany
Phone: [phone]
Fax: [phone]
Email: [email protected]
Internet: www.spectron.de
Publication date
November 2015
Retention and completeness
This operating manual is a component of the BM- and BE-series high-pressure panels and must be
accessible to those with the relevant authorisation at all times.
Under no circumstances should chapters be removed from this operating manual. If the operating
manual is lost or if any chapters are missing –in particular the "For your safety" chapter – it or they must
be replaced without delay.
Copyright
This operating manual contains information that is protected by copyright.
It must not be photocopied, reproduced, translated or copied onto data carriers, either in full or in part,
without prior authorisation. All rights reserved.
Updates
No update service is provided for this operating manual by Spectron Gas Control Systems GmbH. Changes
can be made to this operating manual without the need to notify anyone about them.
1.2 Description of the high-pressure panels of the BM and BE series
Spectron high-pressure panels are available in BM and BE versions.
BM high-pressure panels are suitable for combustible gases, non-combustible gases and oxygen up to
a purity grade of 6.0. BE high-pressure panels are suitable, in addition, for use with corrosive gases.
In each series there are one-sided high-pressure panels (such as the BM50-1, as shown on the left of
the title page) and two-sided panels (such as the BM50-2, as shown on the right of the title page).
In the case of the two-sided version, the user can open and close the shut-off valves on each side
depending on which side is to supply the gas and which is to be the reserve side (manual switching panel).
All of the above high-pressure panels have a process gas valve and a waste gas valve on each side.
Contact pressure gauges, pressure transducers and pneumatically operated valves can also be configured
for each of the above versions.

4 GES_BM+BE_50_1115.docx
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1. Introduction
1.3 Intended use
Intended use
The BM50-1 and BM50-2 high-pressure panels described are intended for use with non-corrosive gases up
to a purity grade of 6.0. The BE50-1 and BE50-2 high-pressure panels are suitable, in addition, for corrosive
gases up to a purity grade of 6.0. The permissible gases and pressure ranges are specified on the type
plate. High-pressure panels serve as shut-off panels (one-sided version) or manual switching panels
(two-sided version), in each case without the option of reducing pressure.
The pressure is introduced exclusively via the process gas valve. Appropriate measures must be taken to
prevent the introduction of pressure to the outlet via the pipe system.
High-pressure panels without electrical components (such as a contact pressure gauge or pressure
transducer) may be used in potentially explosive atmospheres, since they do not have a potential ignition
source of their own (ignition hazard evaluated in accordance with DIN EN 13463-1).
The danger of ignition has to be taken into account with high-pressure panels with electrical components.
It is imperative that this is evaluated on the basis of the documentation of the electrical components,
taking into consideration how they are incorporated into the system as a whole, in compliance with directive
2014/34/EU (ATEX 95) and 1999/92/EC (ATEX 137).
.
Foreseeable misuse
The following operating conditions are deemed to constitute misuse:
Operation with gases that are not specified on the type plate.
Use with gases in their liquid state.
Operation outside of the permissible technical limit values.
Failure to heed and comply with any applicable legal regulations and other provisions.
Failure to follow the instructions in this operating manual.
Failure to carry out inspection and maintenance work.
Failure to heed the information on the type plate and in the product data sheet.
Pressurisation in reverse. (against normal flow direction)
1.4 Personnel requirements
Definition of an authorised person
An authorised person is a person with a technical training who has received technical instruction about
the system as a whole and the associated hazards – gas cylinder – gas type – gas cylinder valve –
pressure regulator – and has successfully completed training in the supply of pressurised gases.
Tasks of the operating personnel
The operating personnel must identify problems or irregularities and – if possible and permissible –
resolve them.
Requirements to be met by the operating personnel
To be able to do their work, the operating personnel must meet the following requirements:
The operating personnel must have received instruction in the operation of the high-pressure panel from
an authorised person and must have read and understood this operating manual in its entirety.

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6 GES_BM+BE_50_1115.docx
Operating Manual
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2. For your safety
2.3 Safety information
Possible hazard Hazard-prevention measures
Risk of fatal injury!
If oxygen comes into contact with oil or grease,
there is a risk of fire due to a chemical reaction.
Keep all parts that come into contact with oxygen free
of oil and grease.
Risk of fatal injury!
Gas escaping into the ambient air can ignite; there is
a risk of fire and explosion.
Smoking and naked flames are strictly prohibited near
gas supply equipment.
Risk of fatal injury!
The high-pressure panel may be damaged by
unauthorised changes or alterations and may no
longer work as intended. There is a risk of the
system malfunctioning, catching fire or getting
damaged.
No changes or alterations may be made without
the written approval of the manufacturer's authorised
technical personnel.
Risk of fatal injury!
If high-pressure panels are used that are not suitable
for the relevant gas and pressure range, there is
a risk of a fire or explosion occurring as a result of
a chemical reaction.
The high-pressure panel must be suitable for
the relevant gas and the pressure ranges involved.
Only use for the gases indicated on the device.
If there are no gas types specified on
the high-pressure panel, you have to ask the
manufacturer which gases it can be used with.
On no account must the high-pressure panel be put
into operation without this information.
Risk of fatal injury!
The use of the pressure control panel with
components or accessories that are not rated for the
same pressure as the control panel itself can lead to
serious damage or bursting.
Components or accessories (fittings, pipes etc.)
connected to the pressure control panel must be rated
for the pressure given on the type plate of the
pressure control panel.
If the high-pressure panel is used outside
the specified ambient temperature range, there is
a risk of the system malfunctioning, catching fire or
getting damaged.
Do not use in ambient temperatures below -30 °C or
over +60 °C.
If the device is not handled properly and used as
intended, this may be dangerous for the user and
others and may damage it.
Use and handle the high-pressure panel only as
described in this operating manual.
If the connecting surfaces or gaskets of the fittings
are damaged or missing, there is a danger of gas
escaping in an uncontrolled manner.
Check the connecting surfaces for damage, and do
not install if the connecting surfaces are damaged or
gaskets are missing.

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Operating Manual
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3. Description
3.1 Overview of the high-pressure panel
Drawing of the high-pressure panel
BM50-1BM50-2
Elements of the high-pressure panel
Item Designation Function
1 Distributor block Connecting point for the pipe system.
2 Waste gas valve or purge
valve
Optionally pneumatic
Is opened to remove the waste gases or vent the process gas pipe.
3 Process gas valve
Optionally pneumatic Separates the high-pressure panel from the gas source.
Flow chart of gas supply with a high-pressure panel
Legend
Process gas valve with inlet filter
Waste gas or purge gas valve
Distributor block
Pigtail
Gas cylinder connection
Valve port - closed
Waste gas
Waste gas
Waste gas
Process gas
Process gas

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3. Description
3.2 Functional description
The main job of the high-pressure panels of the BM and BE series is to shut off the supply sources
(e.g. pressure vessels, gas cylinders, etc.) from the rest of the high-pressure pipe system, which is
connected to the distributor block. This can be equipped with a pressure gauge, contact pressure gauge or
pressure transducer to display the outlet pressure.
The gas flow can be interrupted or released by the high-pressure panel's process gas valve. In the case of
two-sided versions (e.g. BM50-2), the process gas valves can be used to switch the side from which
the connected pipe system is supplied. The process gas valve must be opened on this side. The other side
is the reserve side. The process gas valve on that side remains closed. Waste gas valves or purge valves
relieve the pressure in the gas supply installation.
Note
The high-pressure panels can be equipped with contact pressure gauges. These issue
a switching signal when a specific pressure limit is violated or, in the same way as pressure
transducers, supply a current that varies continuously with the pressure (4-20 mA).
The switching signal or variable electrical current can be processed by means of connected
control units, resulting, for example, in the issue of a gas shortage alarm.
When these contact pressure gauges or pressure transducers are used in areas where there is
a risk of fire or explosion, special measures have to be taken, as described in directive
2014/34/EU (ATEX 95) and 1999/92/EC (ATEX 137).
Another option is to equip the high-pressure panel with pneumatically operated valves.
These require a pneumatic control pressure of between a minimum of 6 bar and a maximum of 8
bar.
3.3 Technical data
Note
The technical data can be taken from the Spectron data sheet for the relevant product. If this is
not available, you can view and download it at www.spectron.de.
The maximum inlet and outlet pressures and the gas type are indicated on the type plate.
3.4 Connection options
Inlet pressure connector: 1/4" NPT female thread, generally equipped with a stainless steel
compression fitting for 6 mm pipes.
Outlet pressure connector: 1/4" NPT female thread.
Extension connector: 1/4" NPT female thread.



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Operating Manual
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4. Operation
4.1 Labelling
Labelling example
Hydrogen (H2)
BM50-1-300-H2
P1: 300 bar
Note
The gas type must be specified on the high-pressure panel. If the gas type is not specified on
the type plate, it must be done using the attached gas-type adhesive labels before the device is
put into operation for the first time.
Warning
Only the gas type for which the high-pressure panel was ordered may be specified on it.
4.2 Installing the high-pressure panel
Note
You can find instructions on how to install the high-pressure panel in the installation manual
MA_BM+BE.
You can view and download this at www.spectron.de.



10 GES_BM+BE_50_1115.docx
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4. Operation
4.3 Putting the high-pressure panel into operation for the first time
Important
Before putting the high-pressure panel into operation for the first time, it must be purged from
the process gas valve to the consumer. It is imperative to adhere to the direction of the gas flow
when doing this. You must not purge counter to the usual direction of flow (from the tapping point
to the high-pressure panel), since this can flush debris resulting from the installation work,
for example, back into the high-pressure panel.
The connecting thread and connecting surfaces of the gas cylinder valves and the sealing rings of
the manual connectors of the pigtails must be checked to ensure they are in perfect condition.
Pigtails with manual connectors are connected to gas cylinder valves without the need for a tool.
Pigtails with flat faces for tightening (generally for corrosive or toxic gases) are tightened with
a suitable spanner until they are gas-tight.
In general – but especially for filling the downstream installation the process gas valves must be
opened gradually ensuring that any (audible) vibration of the pressure regulator is avoided.
Always turn shut-off valves as far as the stop when opening or closing them.
Step Activity
1 Ensure that:
The gas type is specified on the high-pressure panel.
All protective caps have been removed.
The installation has been carried out properly.
The pigtails and other connecting points have been checked for leaks.
The shut-off valves are closed (the red marking is visible in the handwheel window).
2 Pressure purge the system:
Slowly open the gas cylinder valve(s).
Close the gas cylinder valve(s).
Open the waste gas valve on the left (or left and right in the case of two-sided high-pressure
panels) to relieve the pressure, and then close it again.
Repeat at least three times.
If the inlet pressure is low, the process has to be repeated more often.
3 Slowly open the gas cylinder valve(s).
4 Slowly open the process gas valve.
In the case of two-sided high-pressure panels, open the process gas valve on the side that is to go
into operation. The process gas valve on the reserve side remains closed.
5 Check the entire high-pressure panel and all detachable connections for leaks.
6 Gas can now be drawn.


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Operating Manual
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4. Operation
4.4 Changing the cylinder
Important
Each time you change the cylinder, check that the gasket is in perfect condition and replace it
if necessary.
Note
Each time you change the cylinder, ambient air gets into the connecting parts of the system.
To prevent the gas and the entire system from being contaminated, the connection must be purged
before gas is drawn from the cylinder again. In the case of non-toxic, non-corrosive gases, this can
be done by means of multiple pressure purges with own gas. In the case of corrosive or toxic
gases or gases that are hazardous in some other way, purging must be carried out with foreign
gas. The flushing device required for this has the designation BE55-SP. It may have to
be retrofitted.
Step Activity
1 Close the process gas valve.
In the case of two-sided high-pressure panels, slowly open the gas cylinder valve and the process
gas valve of the reserve side so that the reserve side can take over the supply function.
2 Close the gas cylinder valve of the emptied gas cylinder.
3 To relieve the pressure completely, open the waste gas valve of the side on which the cylinder is
to be changed.
Close the waste gas valve again.
Loosen the pigtail connection to the gas cylinder valve, replace the gas cylinder, and connect
the pigtail to the new gas cylinder in accordance with the regulations.
Check the cylinder connection and all of the connections you loosened for leakage again.
4 Pressure purge the system:
Slowly open the gas cylinder valve.
Close the gas cylinder valve.
Open the waste gas valve of the side on which the cylinder is to be changed
– this relieves the pressure.
Close the waste gas valve again.
Repeat at least three times.
If the inlet pressure is low, the process has to be repeated more often.
5 Slowly open the gas cylinder valve.
6 Slowly open the process gas valve.
In the case of two-sided high-pressure panels, keep the process gas valve closed. Do not open it
until the supply side has to be changed again.



12 GES_BM+BE_50_1115.docx
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4. Operation
4.5 Taking the equipment out of operation
Taking out of operation or interrupting operation for a short period
When interrupting operation for a short period, all you need to do is close the process gas valve.
The red marking in the handwheel window indicates immediately that the valve is closed.
Taking out of operation or interrupting operation for a longer period
Step Activity
1 Close all valves.
To do this, turn until you can see the red marking in the handwheel window.
2 Open the waste gas valves.
3 Any gas in the system flows out of the waste gas pipe.
4 Close the waste gas valves.
5 The pressure in the high-pressure panel itself must be released by allowing the gas to flow away
via the consumer.
It is not possible to check that the pressure in the high-pressure panel has been
completely relieved unless the distributor block has a pressure gauge.
If it has been used with corrosive or toxic gases, the entire high-pressure panel must be
purged with inert gas.
5. Problems
Problem/cause Remedy
There is a leak.
This indicates a defect in one of
the high-pressure panel's components.
Close all valves immediately.
Have the high-pressure panel checked immediately by
the manufacturer or an authorised specialist company.


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Operating Manual
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6. Maintenance, cleaning and repairs
6.1 Regular maintenance work and visual inspections
Regular maintenance work
To ensure the high-pressure panel remains in perfect working order and a constantly high level of
operational safety and reliability is maintained, it should be checked by a specialist once a year.
Regular visual inspections
Visual inspection of all
parts for Interval
Damage
Correct functioning
Leaks
Integrity/stability
Corrosion
Regular inspections at intervals of 12 months and each time the device is put
into operation make an important contribution to the cost-effectiveness and
preservation of the value of the fittings.
Note
If you find defects during the visual inspection, do not put the high-pressure panel into operation.
Have the high-pressure panel checked immediately by the manufacturer or an authorised
specialist company.
6.2 Regular cleaning
Warning
Detergents or disinfectants can corrode and ruin gaskets inside the fittings. Do not use detergents
or disinfectants.
If the high-pressure panel gets very dirty, this can interfere with operation. If it becomes
necessary to clean the high-pressure panel, use only a damp, lint-free cloth.
6.3 Repair information
Important
Repairs may only be carried out by specialist personnel in authorised repair workshops.
After repairs, the entire high-pressure panel must be checked in accordance with the original
Spectron inspection instructions.
Safe and reliable operation can only be guaranteed if original spare parts are used.
Note
The manufacturer accepts no liability for damage resulting from unauthorised repairs or
modifications carried out by the user or third parties without the express written approval of
the manufacturer.
6.4 Returns
If the high-pressure panel is returned to the manufacturer for testing, maintenance or repair, and it has been
in contact with corrosive and toxic gases, it is imperative that it is purged with inert gas.



Spectron Gas Control Systems GmbH
Fritz-Klatte-Straße 8
D-65933 Frankfurt
Germany
Phone: [phone]
Fax: [phone]
Email: [email protected]
Internet: www.spectron.de