Western Innovator LC Series User manual

INTRODUCTION
Western manifold systems are cleaned, tested and prepared for the indicated gas service and are built follow-
ing National Fire Protection Association and Compressed Gas Association guidelines. The manifold is specifi-
cally designed to regulate and monitor vaporized gas from liquid cylinders with contents pressures between
125 - 250 psig and to provide an uninterrupted supply of gas for the specific gas application. The control is de-
signed and built with features providing automatic changeover from the depleted “Service” supply bank to the
“Secondary” supply with no loss or drop in delivery pressure. Pressure gauges, alarm signal connections and
lights show system status and alert the need to replace depleted cylinders. An economizer control valve is con-
tained within the cabinet to utilize accumulated pressure from the "Secondary" bank preventing the exhausting
of useful product into the atmosphere. Features of the automatic systems include an integral adjustable line
regulator, 72" cryogenic flexible pigtails with check valves and complete mounting hardware.
WARRANTY
All Western manifolds are warranted against defects in materials and workmanship for the period of one year
from date of purchase. See back cover for details of limited warranty.
B20105 0012 ECN-11129
Installation and Operating Instructions For
AUTOMATIC CHANGEOVER MANIFOLD
LC and LCHP SERIES
CAUTION
Failure to follow the following instructions can result in personal injury or property damage:
•Never permit oil, grease, or other combustible materials to come in contact with cylinders, manifold, and
connections.Oiland greasemayreactandignitewhenincontactwithsomegases—particularly oxygenandnitrous
oxide.
•Cylindervalves shouldalways beopenedverys-l-o-w-l-y.Heatofrecompressionmayignitecombustiblematerials.
•Pigtails should never be kinked, twisted, or bent into a radius smaller than 5 inches. Mistreatment may cause the
pigtail to burst.
•Do not apply heat. Some materials may react and ignite when 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.
•Carefully read and follow installation and mounting instructions! Manifolds are designed for gas withdrawal from
cryogenic liquids. Contact of a cryogenic liquid or cold gas with skin or eyes may cause a freezing injury.
•Oxygen manifolds and cylinders should be grounded. Static discharges and lightning strikes may ignite materials
in an oxygen atmosphere, creating a fire or explosive force.
•Weldingshouldnotbe performednear nitrousoxidepiping. Excessiveheatmaycausethe gasto dissociate, creating
an explosive force.
—1—

TABLE OF CONTENTS
GENERAL INSTRUCTIONS ..............................................................................................................3
CONTROL SECTION INSTALLATION ..............................................................................................4
HEADER INSTALLATION ..................................................................................................................4
PLUMBING .........................................................................................................................................5
HEALTH CARE INSTALLATIONS .....................................................................................................5
ELECTRICAL......................................................................................................................................5
REMOTE ALARM HOOKUP ..............................................................................................................6
INSTALLING PIGTAILS AND ATTACHING CYLINDERS .................................................................7
START UP AND CHECKING PROCEDURES...................................................................................7
MANIFOLD OPERATION ...................................................................................................................8
CYLINDER REPLACEMENT & HANDLING .....................................................................................9
LINE DELIVERY PRESSURE ADJUSTMENT...................................................................................10
GENERAL MAINTENANCE ...............................................................................................................10
TROUBLE-SHOOTING ......................................................................................................................11
MANIFOLD MAINTENANCE & REPAIR PARTS ...............................................................................13
REPLACEMENT PIGTAILS .........................................................................................................13
INDICATOR LAMP REPLACEMENT PARTS .............................................................................13
PANEL MOUNT GAUGES...........................................................................................................13
REGULATORS AND REGULATOR REPAIR KITS.....................................................................13
VALVES AND VALVE REPAIR KITS ..........................................................................................13
PRESSURE SWITCH REPLACEMENT PARTS .........................................................................13
POWER SUPPLY REPLACEMENT PARTS ...............................................................................13
REMOTE ALARMS ......................................................................................................................13
WARRANTY .......................................................................................................................................14
—2—

GENERAL INSTRUCTIONS
Manifolds should be installed in accordance with guidelines stated by the National Fire Protection Association,
the Compressed Gas Association, OSHA and all applicable local codes. The manifold should not be placed in
a location where the temperature will exceed 120°F (49°C) or fall below 0°F (-17°C). A manifold placed in an
open location should be protected against weather conditions including rain and heavy moisture. During win-
ter, protect the manifold from ice and snow. In summer, shade the manifold and cylinders from continuous ex-
posure 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. The control indicator knob on
the manifold control section should be left in the "OFF" position until supply or test cylinders are connected.
This precaution will keep moisture and debris from the piping interior, avoiding operational problems.
41"
13"
50"
10"
FIGURE 1
CAUTION:
•Remove all protective caps prior to assembly. The protective cap may ignite due to heat of recompres-
sion in an oxygen system.
—3—

CONTROL SECTION INSTALLATION
1. Determine and mark the vertical center line for installation of the manifold
control. (Figure 2)
2. Measure from the floor to a point 57" in height* of this vertical line. Using
a spirit level, mark a horizontal line at this point extending approximately
10" to the left and 10" to the right of center.
(* — Suggested manifold height. Wall mounting heights may vary from one
installation to another depending on available space, cylinder height,
etc.)
3. Remove the mounting bracket from the back of the manifold control by
removing the nut at the bottom of the bracket. Place the upper edge of
the “tee” mounting bracket on the marked horizontal line and centered
with the vertical line. Holding the bracket with the slotted extensions
away from the wall, mark the locations for three mounting bolts. (Figure
3)
4. Anchor the mounting bracket to the wall. Selection of mounting fasteners will
depend upon wall construction. (Figure 3)
5. Secure the manifold control in place by sliding the round retainers on the back
of the cabinet into the slots on the bracket. Replace the nut on the bolt
which protrudes from the case and tighten lightly. This bolt only stabilizes
the bottom of the unit and is not load-bearing. (Figure 4)
NOTE: If using a single bank LC manifold with high pressure reserve
cylinders as the right bank, the following modifications to the
manifold unit are necessary. (see figure 5)
1. Remove the right side inlet cross and adaptor using a 11/4" hex
wrench to stabilize the inlet block and a pipe wrench to grip the
adaptor.
2. Remove all debris from the inside of the inlet block. Apply teflon tape
or a suitable oxygen safe pipe thread sealant to the male pipe
thread on the straight adaptor provided with the
high pressure reserve manifold.
3. Install the adaptor in the inlet block using a 11/4"
hex wrench to stabilize the inlet block and a 13/8"
wrench to grip the adaptor.
4. Secure the manifold control in place as noted in
step 5 above.
5. Attach the header to the regulator union on the right side of the
manifold control. Using a spirit level, mark the placement of mounting brackets while keeping the header
on a horizontal plane.
6. Remove the U-bolt assemblies from the header mounting brackets. Position the brackets so that the top of
the bracket is aligned with the bottom of the headers and is centered between the cylinder connections.
The end bracket should be placed as close to the last cylinder as possible to provide the most support and
stability.
7. Mark the mounting hole and install fasteners suitable for the type of wall construction.
8. Fit the U-bolt over the header piping and tighten the two mounting nuts.
Center
Line
Spirit
Level
57"
Floor
Line
FIGURE 2
Mounting
Bracket
FIGURE 3
Retainers
Mounting
Bracket
Nut
Control
FIGURE 4
Adaptor
FIGURE 5
—4—

PLUMBING
1. A 1/2" NPT male union is supplied with the control and
is located at the upper left side of the manifold control.
Connect this union to the pipeline system. Sweat joints
must be silver soldered. Use BAg series silver solder
(DO NOT USE SOFT SOLDER). Heat the entire joint
evenly. Apply enough heat favoring heavy sections, so
that solder flows freely around the joint leaving no pin
holes. (See National Fire Protection Association
Pamphlet No. 99). The union provided permits
removal of the manifold control for service. (Figure 6)
2. If the manifold is installed in a closed area, vent piping must be attached to the Inlet relief valves located on
the top right of the manifold control. The vent connection is 1/4 NPT male.
3. Installation of a shut-off valve to isolate the pipeline during service to the manifold is recommended.
HEALTH CARE INSTALLATIONS
1. Install LC system per plumbing
section.
2. Install the check valves, reserve
manifold, pressure switch and dual
line assembly per the schematic
showninfigure7.
ELECTRICAL
1. A 24 VAC power supply transformer
is furnished with the control unit.
Mount the box on the wall with the
bottom edge approximately at the
top of the control cabinet. The
attached control cable terminates in
a 4-way plug matching a receptacle
on the bottom of the control cabinet.
(Figure 6)
2. After mounting the power supply
box to the wall, plug the cable into
the control cabinet receptacle.
3. One hole on the underside of the
power supply box provides access
for conduit and connection of 115
VAC power to the black primary
leads. Remove 115 VAC power
prior to making connections. The
other hole on the underside of the
power supply transformer box
provides access for remote alarm
connections.
4. After completing the 115 VAC
connections, the power supply
should be complete and functional
and 115 VAC power can be
restored.
5. The manifold wiring schematic is shown in figure 8.
Power
Supply
Inlet Relief Valve Piping
Manifold
Control
cabinet
Isolation
Valve
115 VAC
Conduit
Delivery
Pipeline
FIGURE 6
WESTERN WME-4-14
"Reserve in Use" Switch
WESTERN
LC or LCHP
Series
WESTERN
CVF-8F or
CVF-12F
Check Valve
Pressure
Relief
Valve
WESTERN
WMS-1-20
WMS-1-22
DLA-4 OR
DLA-5
Dual Line
Assembly
WESTERN
CLA Series
Reserve
Manifold
Reserve Pressure
Regulator
Shutoff Valve
To Outside
of Building
WESTERN
WME-4-15
High/Low
Pressure Switch
Reserve
Low
Switch
FIGURE 7
FIGURE 8
—5—

REMOTE ALARM HOOKUP
A five terminal remote alarm terminal strip is on the right side of the circuit board in the power supply box for re-
mote alarm interfacing. The top three terminals on this strip (N/C, N/O, and C) provide dry contacts for remote
alarm hookup. Wiring diagrams for remote audio/visual alarms are included with the alarms. Listed below are
four different remote alarm configurations. Terminals identified as N/O and N/C have been marked in the un-
actuated state.
In some instances the power supply for the remote alarm is normally a part of the electrical contract
on proposed constructions and should exist in any furnished hospital. The following procedure
should be followed:
1. Two alarm signal wires
requiring dry contacts should
run to the manifold location.
2. Connect one signal wire to the
common (C) terminal and the
other signal wire to the
normally open (N/O) terminal
on the terminal strip on the
right side in the power supply
box. (Figure 9)
If the remote alarm is designed for 24 VAC operation then connect the alarm as follows:
(Also see WESTERN’S ALARM section below.)
1. Connect the ground wire from
the alarm to one 24 VAC
terminal on the right side of
the circuit board in the power
supply box. (Figure 10)
2. A jumper wire is connected
between the other 24 VAC
terminal and the common (C)
terminal.
3. Connect the "reserve in use" signal wire to the normally closed (N/C) terminal.
4. If a "system normal" signal is also employed, connect that signal wire to the normally open (N/O) terminal.
Alarm Signal Wire
N/O
C
N/C
24
VAC
Alarm Signal Wire
Note: Alarm function is initiated
on an open circuit
FIGURE 9
Alarm"ReserveinUse"
Signal Wire
Alarm "System Normal"
Signal Wire
Alarm Negative (-) Lead
(Ground Wire)
N/C
24
VAC
N/O
24
VAC
C
Note: Functions initiated on
a closed circuit
FIGURE 10
If the remote alarm is designed for voltages other than 24 VAC then connect the alarm as follows:
1. Connect the ground wire from
the alarm to the negative (-)
connection at the power
source. (Figure 11)
2. There should be NO
connections to the 24 VAC
terminals on the right side of
the circuit board.
3. Connect the positive (+)
connection from the power
source to the common (C) terminal on the circuit board.
4. Connect the "reserve in use" signal wire to the normally closed (N/C) terminal.
5. If a "system normal" signal is also employed, connect that signal wire to the normally open (N/O) terminal.
Alarm"ReserveinUse"
Signal Wire
Alarm "System Normal"
Signal Wire
Alarm Negative (-) Lead
(Ground Wire)
N/C
C
N/O
24
VAC POWER
SOURCE
(+) (-)
Note: Functions initiated on
a closed circuit
FIGURE 11
—6—

FIGURE 12 Western’s Remote Alarm
INSTALLING PIGTAILS AND ATTACHING CYLINDERS
1. Establish flow direction of check valves in pigtails.
2. Connect pigtails to the manifold inlet tee with direction of check valve flow from cylinder to manifold end of
pigtail.
3. Attach full cylinders to the pigtail connections as explained in “Cylinder Replacement & Handling” on page 9.
4. S-L-O-W-L-Y turn all cylinders on fully (turn counter-clockwise to open). Check all cylinder and pigtail
connections for leaks using Western leak detector LT-100 or an oxygen safe solution. (Any bubbles
around connections indicate leakage.)
5. Turn power on to the 24 V power supply transformer box. The red “Replace Depleted Bank” light on the
control cabinet should be activated.
START UP AND CHECKING PROCEDURES
1. Turn the control indicator knob fully to the right. S-L-O-W-L-Y open the right cylinder valve (turn
counter-clockwise to open). The right bank pressure gauge should show the full pressure of the right bank
of cylinders. The green “System Normal” light comes on, extinguishing the red “Replace Depleted Bank”
light.
2. S-L-O-W-L-Y open the left cylinder valve fully. The left bank pressure gauge will show the full pressure of
the left bank of cylinders.
WESTERN’S ALARM
1. Connect one 24 VAC lead from the alarm to one 24 VAC terminal on the right side of the circuit
board in the power supply box. (Figure 12)
2. Connect the other 24 VAC lead from the alarm to the other 24 VAC terminal.
3. A jumper wire is connected between one 24 VAC terminal and the common (C) terminal.
4. Connect the alarm signal wire to the normally open (N/O) terminal.
Signal Wires
Note: Alarm function is initiated on an open circuit
Remote
Alarm
PCB
Power
Supply
PCB
N/C
C
N/O
24 VAC
24
VAC 12 GAS
—7—

3. Create a slight flow of gas in the delivery pipeline system. Close the right master valve to simulate a
depleting right bank. Observe the following:
•The right bank gauge pressure slowly falls and the control automatically switches over to the left
bank.
•Delivery pressure remains constant.
•Green “System Normal” light is extinguished.
•Red “Replace Depleted Bank” light comes on.
•Any remote alarms should be activated at this time.
4. S-L-O-W-L-Y reopen the right cylinder valve. Observe the following:
•Right bank pressure gauge returns to full pressure.
•Green “System Normal” light comes on.
•Red “Replace Depleted Bank” light is extinguished.
•Any remote alarms should be canceled.
5. Turn the control indicator knob fully to the left and repeat procedures 3 and 4 to simulate an empty left
bank.
MANIFOLD OPERATION
The manifold control includes the following components and features: green “System Normal”, and red
“Replace Depleted Bank” indicator lights, cylinder pressure gauges, line pressure gauges, Inlet relief
valves, supply bank control indicator knob, and automatic bank switching. Supply banks consist of a tee
with 72" cryogenic flexible pigtails with check valves.
The cylinder bank that supplies the piping system is known as the “Service” supply, while the cylinders on
stand-by are referred to as the “Secondary” supply. Gas flows through the manifold control directly
through the line regulator. Delivery pressure is controlled by the line regulator and is adjustable via the ac-
cess hole in the upper left hand side of the cabinet. (See Delivery Line Adjustment — page 10).
Changeover from the "Service" to "Secondary" side is accomplished by a pressure differential between the
inlet and intermediate regulator. As cylinder contents are depleting, pressure passing through the mani-
fold will drop. When this pressure drops to the set pressure of the intermediate regulator, a pressure
switch is actuated causing the green “System Normal” light to go out and a red “Replace Depleted Bank”
light to come on. The “secondary” bank will automatically begin to flow without any interruption in service
line delivery pressure.
There are two definite indicators as to which bank should be changed; (1) the arrow on the control indica-
tor knob in conjunction with the red “Replace Depleted Bank” light and (2) the cylinder bank pressure
gauge.
After replacing empty cylinders, open cylinder valves. Because the cylinder pressure will actuate the pres-
sure switch, the red “Replace Depleted Bank” light will be extinguished and the knob indicator must be
turned to it’s opposite position to indicate the new supply bank now in service. Moving the indicator knob
to it’s new position after replacement of an empty bank is the only action that must be taken to reset the
manifold. The indicator knob must always be in the extreme right or left position.
—8—

To insure proper operation, observe
the following guidelines:
1. Carefully follow all instructions.
2. Establish proper flow direction of
check valves.
3. Be sure cylinder valves are fully
opened.
4. Replace depleted cylinders as soon
as practical after the red "replace
depleted cylinders" light comes
on.
CYLINDER REPLACEMENT &
HANDLING
1. Shut off all cylinder valves on depleted cylinder bank.
2. S-L-O-W-L-Y loosen and remove the pigtail connection from the depleted cylinders.
3. Remove depleted cylinders and replace protective caps.
4. Remove protective cylinder caps from full replacement cylinders. With the valve outlet pointed away
from you or anyone else, slowly open each cylinder valve slightly to blow out any dirt or contaminants
which may have become lodged into the cylinder valve.
5. Place and secure full cylinders into position using chains, belts, or cylinder stands.
6. Connect pigtails to cylinder valves and tighten with wrench.
7. S-L-O-W-L-Y turn each cylinder valve until each cylinder is fully on. Check all cylinder and pigtail
connections for leaks using Western leak detector LT-100 or an oxygen safe solution (any bubbles
around connections indicate leakage).
NOTE: All cylinders shall have their pressure building regulators set at the same pressure.
8. Observe the following conditions:
A red “Replace Depleted Bank” light goes out, and the green “Service Normal” light comes on.
9. Turn the control indicator knob fully to the opposite supply bank to indicate the service bank.
To Pipeline
Distribution
System
Line Pressure
Gauge
Line Pressure
Regulator
Test Gauge
Port
Low Pressure
Switch
Four Way
Valve
Left Bank
Pressure
Gauge
Left Bank
Relief Valve
Line Pressure
Cylinder
Pressure
Relief Valve
Outlet
Check Valve
Bypass Valve
Intermediate
Regulator
Right Bank
Pressure
Gauge
Right Bank
Relief Valve
Check Valve
Check Valve
FIGURE 12
—9—

LINE DELIVERY PRESSURE ADJUSTMENT
The delivery line pressure (center gauge) has been factory set. If adjustment is required, carefully proceed ac-
cording to the following instructions.
1. Leave the manifold in full operational status.
2. Create a flow condition in the delivery pipeline system.
3. Locate the line pressure adjustment access hole on the left side of the manifold control.
4. Adjustment: Using a flat blade screwdriver, turn clockwise to “increase” pressure, turn counterclockwise to
“decrease” pressure.
5. Line pressure settings: Minimum / Maximum
LC Models: 40 psig 85 psig
LCHP Models: 40 psig 180 psig
LCHP-7 Models: 40 psig 210 psig
GENERAL MAINTENANCE
1. Main section
a) Daily - record line pressure.
b) Monthly
1) Check regulators and valves for external leakage.
2) Check line and intermediate regulators for ’creep’. Repair or replace as necessary.
3) Check valves for closure ability.
c) Annually - check relief valve pressures.
2. Manifold header
a) Daily - observe nitrous oxide and carbon dioxide systems for cylinder frosting or surface condensation.
Should excessive condensation or frosting occur it may be necessary to increase the number of supply
cylinders.
b) Monthly
1) Inspect valves for proper closure.
2) Check cylinder pigtails for cleanliness, flexibility, wear, leakage, and thread damage. Replace damaged
pigtails immediately.
3) Inspect pigtail check valves for closure ability.
c) Every 4 Years
1) Replace all pigtails
—10—