v oo }v k vp/v µ }v (} ' v Ç vo}p^ ] dv](}o€¦ · installation & operating...

Installation & Operating Instructions forGenesys® Analog Series Manifolds

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

IN595900AV • 02/2017 of 28

Models NPCU & TMCU Model TMLU



IN595900AV • 02/2017 of 28

ContentsFeatures & Benefits 3

Introduction 4

General Instructions 4

InstallationControl Cabinet 5Headers 5Plumbing 6Electrical 8Headers, Pigtails & Cylinders 10

Start Up & Testing Procedures 12

Model TML Emergency Reserve 13

Cylinder Replacement & Handling 14

Line Delivery Pressure Adjustment 14

Replacement Parts 15

Trouble Shooting Guide 17

General Maintenance 18

Appendix A Technical Specifications 19

Appendix B Models NPC & TMC Piping Schematic 20

Appendix C Model TML Piping Schematic 21

Appendix D Models NPC & TMC Wiring Schematic 22

Appendix E Model TML Wiring Schematic 23

Appendix F Model TMC Heater Wiring Schematic 24

Warranty 25

Technical Assistance 1-888-769-7979



IN595900AV • 02/2017 of 28

Features & Benefits• Fully automatic changeover • Novalvesorleverstoresetaftereachchangeover.

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

• 400 psig pressure differential rated solenoid valve

• Exclusive single solenoid pressure differential rated changeover on cylinder x cylinder models

• Circuit board triggers secondary use alarm

• Easy to service layout/design

• Circuit board incorporates LEDs • Easilyvisibleeveninpoorlightingconditions

• Analog gauges provided

• Built in DISS gas specific emergency feed port

• Built in emergency reserve bank ports

• Input power 120 VAC, 50 to 60 Hz • Singlepointconnection,evenforunitswithheaters

• Dual line pressure regulators available

• Make unit NFPA 99 compliant

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

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

• Optional part# PX-88-1075 single point vent kit available for NPCU models

• Optional part# PX-17-0169 and PX-17-0271 union assembly vent kits available for all models



IN595900AV • 02/2017 of 28

IntroductionPowerex manifolds are cleaned for use with oxygen. Eachsystem is tested forchangeover, triggeringof secondary inusealarm, leakage and flow. Each unit is designed and preparedfor the indicated gas service. Powerex manifolds are built inaccordance with the National Fire Protection Association andCompressedGasAssociationguidelines.

WarrantyAll Powerex manifolds are warranted against defects in material and workmanship for the period of one year from date ofpurchase. All circuit boards are warranted against defects inmaterial andworkmanship for the period of three years fromdateofpurchase.

General Instructions/Location & ShelterManifolds should be installed in accordance with guidelinesstatedbytheNationalFireProtectionAssociation,theCompressedGasAssociation,OSHA, andall applicable local codes. Centralsupplysystemsandcylindersshouldnotbeplacedinalocationwherethetemperaturewillexceed125°F(51.6°C)orfallbelow-20°F(-29°C).Amanifoldplacedinanopenlocationshouldbeprotectedagainstweatherconditions.Duringwinter,protectthemanifoldfromiceandsnow.Insummer,shadethemanifoldandcylindersfromcontinuousexposuretodirectsunlight.

Leaveallprotectivecoversinplaceuntiltheirremovalisrequiredfor installation. This precautionwill keepmoisture anddebrisfromthepipinginterior.

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. Oil and grease may react with explosive force when ignited while in contact with some gases – particularly oxygen and nitrous oxide.

• Cylinder and master valves should always be opened very slowly. Heat of recompression may ignite combustible materials creating an explosive force.

• Pigtails should never be kinked, twisted, or bent into a radius smaller than 3 inches. Mistreatment may cause the pigtail to burst.

• Do not apply heat. Oil and grease may react with explosive force when ignited 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 from its current position.

• 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.

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



IN595900AV • 02/2017 of 28

Control Cabinet Installation• Determineandmarktheverticalcenterlineforinstallationofthemanifoldcontrolcabinet.

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

•Mount the Zmounting bracket to the wall using fastenerssuitableforthetypeofwallconstruction.

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

• Remove themanifold cabinet and install female portion ofsuitablefastenersforlowercabinetmountingholes.

• Re-hangthemanifoldcabinetandinstallsuitablefastenersinthelowercabinetmountingholes.

*aff=abovefinishedfloor

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

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



IN595900AV • 02/2017 of 28

•Markthemountingholeandinstallfastenerssuitablefortypeofwallconstruction.

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

Plumbing• Theoutletofthemanifoldislocatedatthetopcenteroftheunitasshownhere.Theoutletconnectionis½NPTfemale.A½NPTmaleunionshouldbeinstalledbetweentheoutletofthemanifoldcabinetandthepipelinesystem.ThisunionisavailableaspartofanaccessorykitfromPowerex(part#PX-88-1075).

• NPC models include a PX-48-0023 ball valve ½ M NPT x ¾ extensiontube.

• TheintermediatereliefvalvesontheNPCmodelhavebeenplumbedtogether.The88-1075SinglePointVentKitshouldbe installed between the intermediate relief valves andthe relief (vent) pipeline system(s) for all indoor medicalapplicationsinordertobecompliantwithNFPA99.

• The TMC models do not include the pre-plumbing of theintermediate relief valves. Thisplumbingwouldneed tobeaddedbeforethe88-1075kitcouldbeused.

• PlumbingforTMCmodelsshownatright.Ventlines,(providedbyplumber),shownindottedlines.

• PlumbingforTMLmodelsshownbelow.Ventlines,(providedbyplumber),shownindottedlines.

Line relief valve ½ F npt

Intermediatereliefconnectionsfrombothintermediatereliefvalves(locatedontheheaders)maybeconnectedtoacommonventlinewiththelinereliefvalve.

Highpressurereservemaybeplumbedintotheintermediatereliefvalvefromeithertherightorleftsideofthecabinet.

Line relief valve ½ F nptOutlet½ F npt

Intermediatereliefconnectionsfrombothprimaryregulatorsconnected to a common vent line withthelinereliefvalve.88-1075SinglePointVentkitshownasdottedlines.



IN595900AV • 02/2017 of 28

• In addition to connecting the left & right primary andsecondaryportablebulkvesselsupplybanks,theTMLmodelsmust also have a high pressure reserve bank of cylindersconnected to the cabinet, a check valve, an “EmergencyReserve inUse”andan“EmergencyReserveLow”pressureswitchtobeincompliancewithNFPA99guidelines.

• Slotshavebeenprovidedonboththeleftandrightsidesofthe control cabinet to allow for the high pressure reservepiping.

• A check valve (part # PX-CV-050F shown here) must beinstalled between the emergency reserve in use pressureswitchandthehighpressurereserveregulator.

• Part#PX-17-0169union(soldseparately)shownhere.

Emergency reserve in usepressureswitch(#PX-PS-2-150)

NFPA 99 compliant TML(shownwithoutventpiping) Emergency reserve

lowpressureswitch(#PX-PS-160-3200)

Highpressurereservemanifold(RWPseries)

Checkvalve(#PX-CV-050F)



IN595900AV • 02/2017 of 28

Electrical• Useoneofthetwo½”conduitknock-outsprovidedlocatednearesttothetopleftcornerofthecabinettorouteconduittosupply120VACtothepowersupply.

Note: Separateconduitshouldbeusedforlowvoltagewires(useknockoutsprovidedontheleftsideofthebox).

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

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

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

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

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

Conduit knockouts for 120 VAC Conduit knockout for low voltage alarm signals

Neutral

Load

FieldGround



IN595900AV • 02/2017 of 28

Caution: Never connect or disconnect any electrical components with the power on. This may result in damage to components and is not covered under warranty.

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

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

• IfyouareinstallingamodelNPC(cylinderxcylinder)cabinettomeetNFPA99therearethreealarmsignalsrequiredperNFPA99,HighLinePressure,LowLinePressureandReserveinUse.TheNPCcircuitboardwilltriggerthe“SecondaryinUse” alarm. Anoptional hi/lowpressure switchPart # PX-PS-1-80maybeinstalledinordertoreceivehigh&lowlinepressurealarmsignals.

Note:Thehi/lowpressureswitchwouldbewireddirectlytothemasteralarmpanels–nottothemanifoldcircuitboard.

• 3.Remotealarmwiresforthe“SecondaryinUse”alarmmaybeconnectedtoaterminalstrip locatedjusttotherightofthecircuitboard.Thewires(labeledA1&A2)connectingthisterminalstriptothecircuitareconnectedtodrycontactsonthecircuitboard.Novoltagehigherthan24VDCshouldbeconnectedtotheseterminals.

Note:Theremotealarmterminalsarenormallyclosedwhenthegaspressureisinthenormalrange.Thehi/lowsetpointspre-setinthemanifoldareasperthefollowingcharts:

Knockout for low voltage remote alarm wiring

Secondary in use “changeover”remotedrycontactconnections

Maximum Inlet Pressure Normal Delivery Press Line Relief Setting Secondary In Use Set Point

3,000 50 75 135leftbank/110rightbank



Maximum Inlet Pressure Normal Delivery Press Line Relief Setting Secondary In Use Set Point

400 50 75 60bothbanks

400 80 150 135bothbanks

400 170 250 190bothbanks

Pressure Settings for NPC & TMC Models(all pressures in psig)

Pressure Settings for TML Models(all pressures in psig)



IN595900AV • 02/2017 of 28

Installing Headers & Attaching CylindersNPC & TMC Models•Matchthegasserviceindicatedbythelabelsonthecontrolcabinet with the gas service indicated by the label on theheadersandtheCGAfittingsontheheaderandthepigtails.Itiscriticalthattheheaders,pigtailsandcontrolcabinetgasservice/CGAmatch.

CGA320=CO2CarbonDioxide CGA326=N2ONitrousOxide CGA346=MedicalAir CGA540=Oxygen CGA580=N2Nitrogen or Argon

• Usingtwo1½”wrenches,oneontheinletblock insidethecontrolcabinetandtheotherontheunionnut,tightentheheaderstothecontrolcabinet.

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

• Attachthepigtailstotheheadercheckvalveoutletsusingtwo11/8”openendwrenches.

• SLOWLY open all cylinder valves (turn counter-clockwise toopen). Check all cylinder and pigtail connections for leaksusinganoxygensafeleaktestsolution(anybubblesformingaroundconnectionsindicateleakage).

• Checkallcylinderandpigtailconnectionsfor leaksusinganoxygensafeleaktestsolution(anybubblesorfoamformingaroundconnectionsindicateleakage).

Master Valve

CGA#saremarkedhere



IN595900AV • 02/2017 of 28

Installing Pigtails & Attaching CylindersTML Models• AtypicalheaderforamodelTMLportablebulkvesselvaporwithdrawal manifold is shown here. CGA connections arestampedonboththeheaderfittingsandonthepigtailfittings.It is critical that thesefittingsmatch the gas serviceof thecontrolcabinet.

CGA320=CO2CarbonDioxide CGA326=N2ONitrousOxide CGA346=MedicalAir CGA540=Oxygen CGA580=N2Nitrogen or Argon

• ConnecttheendofthepigtailwiththeCGAfittingtothe“Use”valvemating fitting on the portable bulk vessel. Open theusevalve.Thepressurebuildingvalveorregulatorshouldbeturnedonoropenedforallvesselsconnectedtothemanifold(bothserviceandreservebanks).Allowapproximately1hourfortheportablebulkvessel(s)tobuildpressure.

• Checkallcylinderandpigtailconnectionsfor leaksusinganoxygensafeleaktestsolution(anybubblesorfoamformingaroundconnectionsindicateleakage).

• Verify that the pressure being supplied to the manifoldcabinetexceedstheminimuminletpressurerequirementsinthetablebelow.

CGAconnectionsforpigtailswithgastightcap,chain,andhookrings

Intermediate pressure relief valvex⅜Fnpt

Manifold Delivery Pressure

Minimum Inlet Pressure Relief Valve Setting on Vessel

50 150 235

80 150 235

170 250 350

Minimum Inlet Pressure Requirements for TML Manifold(all pressures in psig)



IN595900AV • 02/2017 of 28

Start Up & Testing Procedures• Turnon thepower to theunit. Both the left& right bankRed(Depleted)LED’sshouldbeilluminatedandtheleftandright bank Green (In Use) and Yellow LED’s (Ready) shouldbeextinguished.Ifthemanifoldiswiredtoaremotealarm(masteralarm)–theSecondaryinUsealarmwillbeactivated.

• SLOWLYopenonecylindervalveon the leftbank. The leftbankpressuregauge(insidethecabinet)shoulddisplaythefull pressure of the cylinder. The Red (Empty) LED for theleft bank should have extinguished and theGreen (InUse)LEDshouldbeilluminated.TherightbankRed(Empty)LEDshouldremain illuminatedand if themanifold iswiredtoaremotealarm(masteralarm)–theSecondary inUsealarmwillbeactivated.

• SLOWLYopenonecylindervalveontherightbank.Therightbankpressuregauge(insidethecabinet)shoulddisplaythefull pressure of the cylinder. The Red (Empty) LED for therightbankshouldhaveextinguishedandtheYellow(Ready)LED should have illuminated. If themanifold iswired to aremotealarm(masteralarm)–theSecondary inUsealarmwillnotbeactivated.

• Turnoffallopenleftbankcylindervalves.Createaslightflowofgasinthedeliverypipelinesystem.Theleftbankpressuregaugeshouldfallandthecontrolautomaticallyswitchesovertotherightbank.Deliverypressureremainsconstant. TheleftbankRed(Empty)LEDwillilluminate.TheSecondaryinUsealarmshouldactivateontheremoteormasteralarm(s).

• SLOWLYreopenthecylindersontheleftbank.Theleftbankpressuregaugeshouldreturntofullpressure.Theleftbankyellow (Ready) LEDwill illuminate. Simultaneously the leftbankred(Empty)willextinguish.AllremoteSecondaryinUsealarmswillbecanceled.Repeatsteps2–4substitutingrightforlefttosimulateachangeoverfromtherightbanktotheleftbank.



IN595900AV • 02/2017 of 28

Model TML – Emergency Reserve Pressure Settings & Alarm Set Points• NFPA99requiresfivealarmsforportablebulkmanifoldsystemswithhighpressurereserve;highlinepressure,lowlinepressure,secondaryinuse,emergencyreserveinuseandemergencyreservelow.

• Thehighandlowlinepressurealarmsaregeneratedbyapressureswitchwhichismountedonthedownstreamsideofthesourcevalve.NFPA99alsorequiresagaugeandaDISSunionassemblyonthedownstreamsideofthesourcevalve.Thisassembly(high/lowswitch,gaugeandDISSunionisavailableasanassembly.Thepart#’sareasfollows:

Gas Service Part #

Oxygen(O2) PX-PST-24

Medical Air PX-PST-16

NitrousOxide(N2) PX-PST-04

CarbonDioxide(CO2) PX-PST-08

Nitrogen(N2) PX-PSX-12

• Theemergencyreservelowbankpressureswitch(part#PX-PS-160-3200)shouldbeinstalledontheextraportontheRWPseriesmanifold.Thisportislocatedprior(upstream)tothemastervalveandtheregulator.

• Theemergencyreserveinusepressureswitch(part#PX-PS-2-150)shouldbeinstalledoncoppertubing(providedbyplumbingcontractor)after(downstream)thecheckvalve(part#PX-CV-050F).

• Refertothechartbelowforinformationonsettingthedelivery(outlet)pressureoftheemergencyreserveregulatorandemergencyreserveinuseandemergencyreservelowpressureswitches.

Manifold Delivery PressureRecommended Emergency Reserve Regulator Delivery

Pressure Setting

Recommended Emergency Reserve in Use alarm set

point

Pre-set* Emergency Reserve Low alarm set point

50 psig 65 psig 75 psig 1200 psig



*Emergencyreservelowpressureswitch(#PX-PS-160-3200)isshippedpre-setatapproximately1,200psig.Ifdesired,thisswitchmaybere-setinthefieldatadifferentpressuresetting.

Emergency reserve in usepressureswitch(#PX-PS-2-150)

NFPA 99 compliant TML(shownwithoutventpiping) Emergency reserve

lowpressureswitch(#PX-PS-160-3200)

Highpressurereservemanifold(RWPseries)

Checkvalve(#PX-CV-050F)



IN595900AV • 02/2017 of 28

Cylinder Replacement & Handling• Closeallcylindervalvesonthedepletedbank.

• SLOWLYloosenandremovethepigtailconnectionfromthedepletedcylinders.

• Removedepletedcylindersandreplaceprotectivecaps.

• Placeandsecurefullcylindersintopositionusingchains,beltsorcylinderstands.

• Remove protective cylinder caps from full replacement cylinders.Withthevalveoutletpointedawayfromallpeopleinthearea,slowlyopeneachcylindervalveslightlytoblowoutanydirtorcontaminantsthatmayhavebecomelodgedinthecylindervalve.

• Connectpigtailstocylindervalvesandtightenwithwrench.

• SLOWLYturneachcylindervalveuntileachcylinderisfullyon.

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

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

Line Delivery Pressure Adjustment• Leavethemanifoldinfulloperationalstatus.

• Createaflowconditioninthedeliverypipingsystem.ADISSdemandvalvehasbeenprovidedontheoutletblock.MatingDISSfittingsmaybeusedtocreateaflowofgaswithinthemanifoldcabinet.

• The line pressure regulator(s) is located at the top of themanifold cabinet. Ball valves are providedonly onmodelswithduallineregulatorsontheinletandoutletsidesofeachregulatordeterminewhichregulatoris“online”andwhichis“offline”.Note:whentheballvalvehandleisperpendiculartothepipeline,theballvalveisclosed.

• Turn the T-bar handle clockwise to increase line pressureor counter-clockwise to decrease line pressure. Itmay benecessarytousea3/4”open-endwrench,loosenthelocknutontheadjustingscrew(onhighflowmodelsonly).

• Afteradjustment,retightenthelocknut(onhighflowmodelsonly)ontheadjustingscrewandclosethecabinetdoor.

DISSDemandValve

Line Regulator



IN595900AV • 02/2017 of 28

Item Part # Description

Primary Regulator & Repair Kits PX-68-0003R 0–300psigdelivery,3,000psiginlet,6port

PX-68-0003RK Rebuild kit for primary regulator 68-0003

Line Regulators & Repair Kits PX-68-0017R 5–125psigstandardflowlineregulator

PX-68-0017RK Rebuildkitfor5-125standardflowlineregulator68-0017

PX-68-0002R 5–125psighighflowlineregulator

PX-68-0002RK Rebuildkitfor5-125highflowlineregulator68-0002

PX-68-0001R 10–200psighighflowlineregulator

PX-68-0001RK Rebuildkitfor0–200highflowlineregulator68-0001

CircuitBoard PX-35-1007R UniversalNPC,TMC&TMLManifoldCircuitBoard

PressureSwitches(incontrolcabinet)

PX-14-2013 NPC,TMC&TMLLeftBankPressureSwitch

PX-14-2014 NPC,TMC&TMLRightBankPressureSwitch

PressureSwitches(outsidecabinet)

PX-PS-1-80 High/Lowlinepressureswitchrange1–80psigpreset@40/60

PX-PS-2-150 Emergencyreserveinuseswitchrange2–150psig

PX-PS-10-250L N2Lowlinepressureswitchrange10-250psigpreset@160onfall

PX-PS-10-250H N2Highlinepressureswitchrange10-250psigpreset@200onrise

PX-PS-160-3200 Emergencyreservelowswitchrange160–3200psigpreset@1200

PressureSwitch,Gauge,DISSAssemblies(includesaboveappropriatepressureswitch(switches2forN2)pre-assembledinaTeeorCrosswitha4”gauge&DISSunioncheckvalve

PX-PST-04 N2O

PX-PST-08 CO2

PX-PSX-12 N2

PX-PST-16 Medical Air

PX-PST-24 Oxygen

DISSDemandCheckUnionAssemblies

PX-PS-04 NitrousOxide¼Mnptdemandvalvex1/8Mnptnipple

PX-PS-08 CO2¼Mnptdemandvalvex1/8Mnptnipple

PX-PS-12 N2¼Mnptdemandvalvex1/8Mnptnipple

PX-PS-16 MedicalAir¼Mnptdemandvalvex1/8Mnptnipple

PX-PS-24 Oxygen¼Mnptdemandvalvex1/8Mnptnipple

Solenoid Valves PX-48-1007R Used on TMC models for all gas services

PX-48-1008R UsedonTMLmodelsforallgasservices-leftside

PX-48-1009R UsedonTMLmodelsforallgasservices-rightside

Power Supply PX-35-2013R 110VAC/24&5VDC

Gauges(insidecabinet) PX-14-1018 0–4,000psig1½”x1/8Mnptcenterback

PX-14-1016 0–400psig2”x¼Mnptbottomport

PX-14-1017 0–400psig1½”x1/8Mnptcenterback



Gauges(outsidecabinet) PX-ZV300-5 0–100psig4”x¼Mnptbottomport

PX-ZV300-6 0–300psig4”x¼Mnptbottomport

Relief Valves PX-RV-22-075 75 psig x ½ M npt inlet

PX-RV-22-150 150 psig x ½ M npt inlet

PX-RV-22-250 250 psig x ½ M npt inlet

PX-RV-11-400 400psigx¼Mnptinlet

Replacement Parts & Accessories



IN595900AV • 02/2017 of 28

Item Part # Description

IntermediateCheckValve PX-17-4003R ½Mnptx½ODtubecompression

Pigtails for cylinders PX-20-1001 24”singlelooprigidcopperO2–CGA540

PX-20-0001 24”FlexiblestainlessbraidedO2-CGA540

PX-20-1002 24”singlelooprigidcopperN2O–CGA326

PX-20-0002 24”FlexiblestainlessbraidedN2O-CGA326

PX-20-0003 24”FlexiblestainlessbraidedCO2–CGA320

PX-20-0004 24”FlexiblestainlessbraidedAIR–CGA346

PX-20-0005 24”FlexiblestainlessbraidedN2orAr–CGA580

Pigtails for portable bulk vessels PX-20-2001 72”Flexiblewithcheckvalve–O2–CGA540

PX-20-2002 72”Flexiblewithcheckvalve–N2orAr–CGA580

PX-20-2003 72”Flexiblewithcheckvalve–CO2–CGA320

PX-20-2004 72”Flexiblewithcheckvalve–N2O–CGA326

Union PX-17-0169 ½”Mnptx½”Mnpt3pieceunion

WallBrackets PX-WB-1 Singlecylinderwallbracketwithchain

PX-WB-2 Dualcylinderwallbracketwithchain

Source Valve PX-48-0023 Ballvalve-1/2MNPTx3/4tubeextension

Replacement Parts & Accessories (Continued)



IN595900AV • 02/2017 of 28

Symptom Probable Cause Remedy or Check

Cabinet Indicator Lights

Noindicatorlightsonfrontpanelilluminatewhenpowerisconnected.

Power input Checkelectricalpowersupply

Blownfuse Checkfusesonpowersupply

Internal wiring disconnected Checkallwiringconnections

Redindicatorlightsareonbutbothbanksarefull

Master valve or cylinder valves on bank are closed

OpenvalvesSLOWLY

Pigtailsareinstalledwithcheckvalvesinwrongdirection

Closecylindersandre-installpigtailsinproperflowdirection

Bankpressureisnotsufficientforlogicboardtoplaceitin“InUse”or“Ready”status

Replacecylinderswithfullcylinders.Or,ifusingportablebulkvessels,open pressure building valve on vessel or replace portable bulk vessel withhigherdeliverypressureportablebulkvessel

Primary regulators are out of adjustment

Adjustprimaryregulators–permanual

Circuitboarddefective Replace circuit board

Loss of Cylinder Contents

Audible or inaudible gas leakage (originunknown)

Leakage at manifold piping connections

Tighten,resealorreplace

Leakagethrumanifoldsolenoidvent / relief

Replace solenoid valve

Regulatorwithbadseat Rebuild or replace regulator

Leaking gauge Replace gauge

Ventingatreliefvalve Regulatorsettoohigh Setdeliverypressureperspecifications

Overpressureduetofailedregulator seat

Rebuild or replace regulator

Regulatorfreeze-up(N2OorCO2)/heaterfailure

Repairheateroraddheaterandconsideraddingadditionalcylinders

Leftbankwillnotbeplacedintoready(Red/Emptystatusstaysilluminated)whenbankpressureis full

Leftprimaryregulatorisoutofadjustment–settoolow

Adjustleftprimaryregulator–permanual

Rightbankwillnotbeplacedintoready(Red/Emptystatusstaysilluminated)whenbankpressureis full

Rightprimaryregulatorisoutofadjustment–settoolow

Adjustrightprimaryregulator–permanual

Bothbanksfeeding Leakingheader/pigtailconnection Tightenfittingorre-tapewithOxygensafeTeflontape(ifnptfitting)andtighten.

Leakingintermediatecheckvalve Replacecheckvalve

Leaking solenoid valve Replace solenoid valve

ModelNPC&TMC–primaryregulator(s)outofadjustment

Setdeliverypressuretospecificationsperchartonpage20

ModelTML–inletpressuretocontrol cabinet is too low

Verifythatminimuminletpressurerequirementsaremet

ModelTML–portablebulkventing Gasusagenothighenoughtojustifyportablebulkreserve

Troubleshooting GuideNOTE: Troubleshootingandrepairsshouldbedonebyqualifiedpersonnelonly.



IN595900AV • 02/2017 of 28

Symptom Probable Cause Remedy or Check

Bothbanksfeeding(continued) ModelTML–gasflowingthrueconomizercircuit

Thisisnormalwhenreservebankpressureis50psiggreaterthanservicebankpressure–nocorrectionneededtomanifoldcontrolcabinet.Mayconsiderreducingsizeofbanksifreservebankismorethan35%depletedattimeitisplacedinservice“InUse”

Ifgasisflowingthrueconomizerwhenthereservebankpressureisnot50psiggreaterthanservicebankpressure–theeconomizercheckvalveneedstobereplaced.

Changeoveroccurs,reserveinusealarmistriggeredandthenclears

Manifold is unable to support requiredflow

Increasemanifoldflowcapacity(callfactoryforassistance)

ModelTML–portablebulkvessel(s)areunabletosupportrequiredflow

Increasebanksize.

If using two or more portable bulk vessels per bank currently, connect pigtail(s)(nocheckvalve)fromventtoventofallvesselsonthesamebankandopentheventvalves.Thiswillequalizetheheadpressureofthevesselsandutilizethecombinedvaporizationcapacity–notjustthecapacityofthevesselwiththehighestdeliverypressuresetpoint.

Troubleshooting Guide (Continued)NOTE: Troubleshootingandrepairsshouldbedonebyqualifiedpersonnelonly.

General Maintenance

Interval Control Cabinet Headers & Pigtails

Daily Record line and bank pressures Observenitrousoxideandcarbondioxidesystemsforcylinderfrostingorsurfacecondensation.Shouldexcessivecondensationorfrostingoccuritmaybenecessarytoincreasemanifoldcapacity.

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

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

Annually CheckreliefvalvepressuresCheckregulatorseats.

Checkpigtailsforcleanliness,flexibility,wear,leakage,kinked,pinchedortwistedandthreaddamage.Replacedamagedorwornpigtailsimmediately.

Tightenregulatorbonnetsapproximately1to2degrees(outof360).

Every 4 years Replace all pigtails

Every 10 years Rebuildorreplace:allregulators,PX-17-4003intermediatecheckvalves,PX-48-1007solenoidvalve,andDISSdemandcheckvalves.

Rebuildorreplacemastervalves.Replaceallcheckvalveoutlets.



IN595900AV • 02/2017 of 28

Appendix A

Manifold SpecificationsMinimum Inlet Pressure: ModelNPC&TMC: 3000psig

ModelTML: 400psig

Operating Ambient Temperature range: ModelNPC&TMC: 0°F(-18°C)to130°F(54.4°C)allgasesexceptN20&CO2

20°F(-7°C)to130°F(54.4°C)N2O&CO2

ModelTML: -20°F(-29°C)to130°F(54.4°C)

Storage Temperature:-20°C(-4°F)to+85°C(185°F)

AC Input:120voltsAC–50-60Hz

Input Fuse: 5ampinputAClinefuseprotectstheinputwiringtopowersupply

Power Consumption: 45W(0.4ampsusing120VAC)maximumwithoutheaters

50W(2.1ampsusing120VAC)maximumwithheaters

Pressure Measurement Accuracy: Allgaugesare3/2/3design.Theyare±3%offullscaleinthefirstandlast1/3oftheirrange. Theyare±2%offullscaleinthemiddle1/3rdoftheirrange.

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

Control Cabinet Dimensions: Dimensionsexcludinginlet&outletfittings

15¾”Wx24¾”Hx9¼”D

Dimensionsincludinginlet&outletfittings

17¼”Wx27”Hx9¼”D

Primary Regulator Settings (NPC & TMC Models)

NOTE: Allsettingsdonewith2,200psigcylinderpressureandwithslightgasflowthruthemanifold.Primaryregulatoroutletpressurewillvarywithvaryinginletpressures.(Theoutletpressurewillriseasthecylinderpressuredecreasesasmuchas40–50psig).Allpressuresshowninpsig.

Normal Delivery Pressure (factory delivery pressure) Left Primary Regulator Set Point Right Primary Regulator Set Point

50 160 120

80 260 220

170 260 220



IN595900AV • 02/2017 of 28

Appendix B

NPC & TMC Piping Schematic

120VACconnectionterminals,fuses and power supply

(transformer)

Possible line pressure regulator(iforderedwith

duallineregulators)

Checkvalve

Pressureswitch(seepage9forproper

settings)

Rightbankprimaryregulator(seepage18for

propersettings)

Rightbankprimaryregulator outlet pressure gauge

Inlet block

Inlet pressure gauge

Checkvalve

Intermediate block

Line pressure regulatorSeepage14forsetting

instructions

DISSdemandvalve–maybe used to bleed line

pressure during service and as an emergency feed port

forthefacility

Line pressure relief valve ½ F npt(notvisibleinthisphoto-outsidecabinet)

Outlet–½Fnpt(notvisibleinthisphoto–outsidecabinet)Line pressure gauge

Intermediate pressure relief valves(behindcircuitboardonbottomportofprimaryregulators

Solenoid valve

Pressureswitch(seepage9forproper

settings)

Leftbankprimaryregulator(seepage18for

propersettings)

Leftbankprimaryregulator outlet pressure gauge

Inlet pressure block




IN595900AV • 02/2017 of 28

Appendix C

TML Piping Schematic

120VACconnectionterminals,fuses and power supply

(transformer)

Possible line pressure regulator(iforderedwith

duallineregulators)

Checkvalve

Intermediate block

Line pressure regulatorSeepage14forsetting

instructions

DISSdemandvalve–maybe used to bleed line

pressure during service and as an emergency feed port

forthefacility

Line pressure relief valve ½ F npt(notvisibleinthisphoto-outsidecabinet)

Outlet–½Fnpt(notvisibleinthisphoto–outsidecabinet)Line pressure gauge

Circuit board

Solenoid valve


Highpressureswitch

Lowpressureswitch

EconomizercircuitCheckvalve

Solenoid valve


Highpressureswitch

Lowpressureswitch

Economizercircuit



IN595900AV • 02/2017 of 28

Appendix D

NPC & TMC Wiring Schematic



IN595900AV • 02/2017 of 28

Appendix E

TML Wiring Schematic



IN595900AV • 02/2017 of 28

Appendix F

TMC Heater Wiring Schematic



IN595900AV • 02/2017 of 28

Powerex Limited WarrantyWarranty and Remedies. (a) Standard Period of Warranty – Parts and Labor. PowerexwarrantsandrepresentsallProductsshallbefreefromDefectsforthefirsttwenty-four(24)monthsfromthedateofshipmentbyPowerex.Duringsuchwarrantyperiod,PowerexshallbefullyliableforallDefectsintheProducts(the“ProductDefects”),i.e.,allcostsofrepairorreplacement,whichmayinclude“inandout”charges,solongastheProductsarelocatedintheUnitedStatesorCanada,andtheProductsarereasonablylocatedandaccessiblebyservicepersonnelforremoval.“Inandout”chargesincludethecostsofremovingaProductfrombuyer’sequipmentforrepairorreplacement.

(b) Additional Period of Warranty – Parts Only (No Labor). Inadditiontotheabove,Powerexwarrantstheproductsdescribedhereintobefreefromdefectsinmaterialandworkmanshipforsixty(60)monthsfromendofStandardPeriodofWarrantywiththeexceptionofanycomponentswhicharerecommendedtobereplacedinlessthansixtymonthsinourInstallation/Operationmanuals.WithinsaidperiodPowerexwillrepairorreplaceanypartorcomponentwhichisproventobedefectiveineithermaterialorworkmanship.Thiswarrantycoverspartsonly.Laborisnotincluded.ThiswarrantyisvalidonlywhentheproducthasbeenproperlyinstalledaccordingtoPowerex specifications,used in anormalmannerand servicedaccording to factory recommendations. Thiswarrantydoesnotcoverfailuresduetodamagewhichoccursinshipmentorfailureswhichresultfromaccidents,misuse,abuse,neglect,mishandling,alteration,misapplicationordamageduetoactsofnature.

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

(d) Coverage. ThewarrantyprovidedhereinappliestoPowerexpipelineproductsonly.

(e) Exceptions. Notwithstandinganythingtothecontraryherein,PowerexshallhavenowarrantyobligationswithrespecttoProducts:

(i)ThathavenotbeeninstalledinaccordancewithPowerex’swrittenspecificationsandinstructions;

(ii)ThathavenotbeenmaintainedinaccordancewithPowerex’swritteninstructions;

(iii) ThathavebeenmateriallymodifiedwithoutthepriorwrittenapprovalofPowerex;or

(iv)Thatexperiencefailuresresultingfromoperation,eitherintentionalorotherwise,inexcessofratedcapacitiesorinanotherwiseimpropermanner.

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

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

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



IN595900AV • 02/2017 of 28

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

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

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

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

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



IN595900AV • 02/2017 of 28

Notes

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

v oo }v k vp/v µ }v (} ' v Ç vo}p^ ] dv](}o€¦ · installation & operating...

Documents