Pressure Differential Automatic Manifold For LPG PDH1000 Series LPG Installation & Operations Instructions Precise Equipment Company 3822 Market St., STE 101 Denton, Texas Phone : 800.795.8388
Precise Equipment Company Installation Instructions for the PDH1000 Series LPG manifold system Caution: Read and understand installation instructions thoroughly prior to using this system. If you have any questions on the installation, contact Precise Equipment Company (1-800-795-8388) for assistance. Warning: It is important that when installing components of the manifold system that no oil or contaminants are exposed to any manifold parts. If parts have been contaminated during shipment, do not use and contact Precise Equipment Company (1-800-795-8388) for replacement. (MAXIMUM INLET PRESSURE 200 PSIG) Mounting: 1. Locate the desired center line for the manifold control cabinet, (Fig. 1) 2. Attach control cabinet to wall using the four (4) tabs on box. (Inlets to control cabinet to be 5 2 5 3 ) 3. Attach upper center section (pipeline & relief valve outlet) to the control cabinet (fig 1). (Use backup wrench on manifold female outlet) 4. Locate and attach header brackets to wall and attach header valve to cabinet swivel connection. 5. Attach cylinder-holding racks to wall. 6. Attach pigtail hoses to header. (Use Teflon tape on male ends, making sure tape does not overlap the end of the fitting) 7. To connect a Remote alarm (optional), see the wiring diagram fig 4. ½" NPTF gas delivery outlet Pipe away relief valve Master header valve Wall bracket PDH Series Cabinet Set/Reset Lever 5' Pigtail with CGA fitting Fig 1 Cylinder rack with chain Precise Equipment Company Installation Instructions for the Precise Equipment Company 3822 Market St., STE 101 Denton, Texas Phone : 800.795.8388
PDH1000 Series LPG manifold system Caution: Read and understand operations instructions thoroughly prior to using this system. If you have any questions on the operation, contact Precise Equipment Company (1-800-795-8388) for assistance. WARNING: The gas in the cylinders is at high pressure. It is important that when opening valves on the cylinder or on the manifold system that it is done slowly to allow the pressure to build within the system rather than slam (impinge) into any control part. Initial Start-up Procedure: Note: The cylinder bank selection lever can be either pointed in the right or left bank position. The position indicated when initializing the manifold pressure, will be the in use cylinder bank first. 1. Secure cylinders to rack with chain and S hooks 2. Inspect all cylinder connections for dirt, oil or other contamination. If any is found, clean or remove from service and replace. 3. Connect cylinders to manifold taking precautions not to kink the flexible pigtail. (Flexible pigtail has a minimum bend radius of 4 ) 4. Turn off master header valves. Fig 1 5. Rotate selection lever to either the left or right cylinder bank. (This indicates which supply side starts as the in-use bank) 6. Slightly open each cylinder valve slowly to let the system pressurize from the cylinder to the header. 7. Check for leaks at the hose and cylinder connection as well as the header connection with an approved leak detection solution. 8. Once the pigtail hoses and header have been pressurized, slowly open cylinder valves completely. 9. Slowly open header valve to pressurize control cabinet. Once system is pressurized, fully open master valve. 10. Using an approved leak test solution, check all connections for leaks. If leaks are found, relieve pressure, tighten and retest. Fig 2 Delivery Pressure Regulator Adjusting Screw Delivery Pressure Gauge Plugged Pressure Port DEL PSI Changeover regulator DO NOT ADJUST Optional Pressure Switch DEL PSI Intermediate Pressure Test Gauge Inlet Pressure Left Cylinder Bank INLET PSI INLET PSI Inlet Pressure Right Cylinder Bank Cyl. Bank Selection Lever Adjusting Delivery Pressure: (See fig 2 for regulator location)
Open the cabinet to access delivery regulator adjusting screw. With system flowing turn regulator-adjusting screw until desired pressure is achieved. (Clockwise will increase the delivery pressure and counter clockwise will decrease the delivery pressure). Depleted Cylinder Change out Procedure 1. Move the cylinder bank selector lever to opposite bank. 2. Close master valve on depleted bank header. 3. Close valve on depleted bank of cylinders. 4. Disconnect depleted cylinder pigtails and remove depleted cylinder from the manifold. 5. Repeat steps 1-9 in the initial start-up procedure section. Procedure to change manifold switch over pressure point: (See Fig 2) Note: Factory Settings: The switchover pressure is factory-preset (the point of cylinder pressure when the manifold will switch from the in-use cylinder bank to the reserve). The minimum switch over setting is 15-25 psi over the desired pipeline delivery pressure (To customize these settings, see "Changing switchover pressure settings from factory settings"). Factory Setting Cabinet Model: PDH1000Y Maximum Delivery Pressure: 40 Switchover preset: 50 Changing switchover pressure settings from factory settings (With optional pressure switch and remote alarm), also see Adjusting Pressure Switch section. The switch over point (pressure at which the manifold will start using gas from the reserve cylinders) must be set higher than the desired final pipeline delivery pressure. This ensures that the manifold maintains the desired delivery pressure when in the reserve in use mode. To Raise Set Point: 1. Adjust the system in a normal flow situation. 2. Reserve side must have adequate gas supply connected 3. Turn off the cylinder supply from the side the "Cylinder Selection lever is pointing. 4. Adjust "Intermediate Pressure regulator" adjustment screw clockwise. (Monitor the "Intermediate pressure test gauge" to ensure the pressure adjustment made to the "Intermediate Regulator is sufficient to maintain delivery pressure at desired flow rate). 5. Turn on the cylinder supply on the side the "Cylinder Bank Selection Knob" is pointing. To Lower Change over Set Point: 1. Adjust the system in a normal flow situation. 2. Reserve side must have adequate gas supply connected 3. Turn off the cylinder supply from the side the "Cylinder Selection lever is pointing. 4. Adjust the "Change over Pressure regulator" adjustment screw counter clockwise. (Monitor the Intermediate pressure test gauge " to ensure the pressure adjustment made to the "Change over Regulator is sufficient to maintain delivery pressure at desired flow rate). 5. Continue with steps 3 until the desired set pressure is obtained. 6. Turn on the cylinder supply on the side the "Cylinder Bank Selection Lever" is pointing.
Optional Pressure Switch Remote Kit: Pressure switch is activated on decreasing pressure. Switch should be set approximately 2-5 psig higher than the changeover pressure regulator setting. Settings listed below have been preset. If the switchover pressure has been modified from factory setting, the pressure switch requires adjustment. See Adjusting Pressure Switch. Factory Setting Cabinet Model: PDH1000 Pressure Switch: 55 Fig 3 Adjusting Pressure Switch Note: Adjustments require a slight flow condition. 1. Open both banks of cylinders and both left and right master valves. 2. Move bank selector lever to the right bank. (Declaring this in use or primary) 3. Close in use supply master valve 4. Adjust change over regulator to five (5) psig above final switchover setting. Lower pressure switch setting: 5. Adjust pressure switch until red LED goes on 6. Lower the change over regulator setting five (5) psig to the final setting. 7. Open right bank master valve. (Red LED goes off and green LED on), Close right bank master valve and verify red LED on Raising pressure switch setting: 1. Follow steps 1 through 4 2. Adjust pressure switch until green LED goes on 3. Adjust pressure switch until Red LED goes on 4. Lower the change over regulator setting five (5) psig to the final setting. 5. Open right bank master valve. (Red LED goes off and green LED on), Close right bank master valve and verify red LED on