INSTRUCTIONS for
F-2885-Q
October, 2000
M-4 ACETYLENE & FUEL GAS MANIFOLDS
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe
practices for oxy-fuel gas equipment, we urge you to read our booklet Precautions and Safe Practices for Welding, Cutting and
Heating Form 2035. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install
or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these
instructions, contact your supplier for further information.
The manifolds covered by these instructions are listed by Underwriters Laboratories only when using parts manufactured to
ESAB Welding & Cutting Products specifications on file with Underwriters Laboratories, Inc., and when they are used in the gas
service which they are designed and listed. The use of other parts that cause damage or failure to the equipment will void the
manufacturers warranty.
INTRODUCTION
The M-4 Acetylene Manifold is designed to supply acetylene and LP Gases (not HP methane H2 etc.) from cylinders to a distribution piping system. The basic manifold
is supplied with connections for 4 cylinders and be enlarged (within certain limits) by addition of extension assemblies to each side.
The M-4 Fuel Gas Manifold (P/N 20425) is designed for
75 psig output for use with any fuel gas except acetylene.
A. Capacity Limitations
1. The liquid seal flash arrestor and back pressure relief valve (H-2 hydraulic or H-2 FG) furnished as part
of the manifold assembly has a rating of 500 cfh.,
acetylene at 15 psig. Regardless of the number of
cylinders connected to the unit, the flow should not
be allowed to exceed to the unit, the flow should not
be allowed to exceed this rating by more than 10%
(excess flow will entrain liquid and cause seal to be
lost).
2. It has been commonly accepted throughout the industry that the maximum hourly rate of flow from an
acetylene cylinder should not exceed 1/7 of the capacity of the cylinder. It is not recommended to withdraw at this rate for an extended period since the
release of acetylene from solution cools the cylinder; thereby, reducing the rate of release of gas. If
this rate of flow is maintained, the manifold pressure will drop until the regulator is unable to pass
the required flow. This will give a false indication that
the manifold cylinders are empty when, in fact, there
is ample gas remaining.
3. It is recommended that continuous hourly flow be
limited to 5% of the capacity of the cylinders and
that intermittent draws (10 Min. or less with at least
equal off time to permit cylinders to warm up) be
limited to 14% of the cylinder capacity. Table 1 lists
the maximum recommended flows using WK
approx. 300 ft.3) and WTL (approx. 390 ft. 3) acetylene cylinders on the M-4.
NOTE: Maximum withdrawal gases decrease with de-
creasing temperature and decreasing quantity
of remaining gas.
Table I - Maximum Recommended Flow Capacity/Acetylene
Alternate Operation of Banks
Total WK Cylinders WTL Cylinders
No. of Cont. Intermit. Cont. Intermit
Cylinders* Flow (cfh) Flow (cfh) Flow (cfh) Flow (cfh
m3/hr m3/hr m3/hr m3/hr
4 60 (1.70) 170 (4.81) 80 (2.27) 220 (6.23)
6 90 (2.55) 250 (7.08) 120 (3.40) 330 (9.34)
8 120 (3.40) 340 (9.63) 160 (4.53) 440 (12.40)
10 150 (4.25) 420 (11.89) 200 (5.66) 550 (15.5)
12 180 (5.10) 500 (14.16) 240 (6.80) **
* The Table assumes that half of the cylinders listed are on stand-by and the
other half of the cylinders are in operation. The flow valves are doubled, if two
M-4 manifolds are connected in parallel.
** Exceeds recommended capacity of the manifold.
All manifolds installations should be protected
against mechanical injury and exposure to fire or
excessive heat, and must conform with the latest
National Fire Protection Association Standard No.
51.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
Table I - Maximum Recommended Flow Capacity/Propane
and Propylene
Alternate Operation of Banks
T ota l Propane, 100# Cyl. Propylene, 104# Cyl.
No. of Cont. Cont.
Cylinders* Flow, cfh Flow, cfh
4 130 (3.68) 220 (6.23)
6 195 (5.52) 330 (9.34)
8 260 (7.36) 440 (12.46)
10 325 (9.20) 550 (15.57)
12 390 (11.04) 660 (18.69)
3
(m
/hr) (m3/hr)
*100 lb propane cylinder at 1/2 full, max. withdrawal rate is 65 cfh
(1.84 m3/hr) at 70°F lower temperature will reduce withdrawal ca
pacity of cylinder.
104 lb. propylene cylinder at 1/2 full, max. withdrawal rate should not
exceed 110 cfh (3.11 m3/hr) at 70°F.
I. INST ALLA TION INSTRUCTIONS
A. Fasten the manifold-header support-brackets to
the wall (see Figures 1 & 2).
1. If the wall is of masonry construction, use 3/8in. bolts or lag screws. Thread the bolts into
expansion shields placed in holes drilled in the
wall.
2. If the wall is hollow tile use bolts instead of lag
screws. Extend them all the way through the
wall and fasten them over a plate or toggle on
the opposite side.
3. In setting up a manifold or in adding extension
sections, it is important that the wall brackets
be located so that all sections of the manifold
header will be level and in true horizontal alignment. To prevent misalignment, in locating by
measurement from sloping floors or uneven wall
surfaces, one bracket should be installed and
the other leveled and aligned with it. The manifold header should be level irrespective of the
floor surface; any differences in elevation between the cylinder valve outlets and the cylinder connections on the header tees will be taken
up by the flexible cylinder leads. Use shims or
spacing blocks behind the brackets for correcting any horizontal misalignment to avoid straining the joints of the manifold header .
43" to floor
Fig. 1 - Support Bracket Installed on a Wall of Masonry
Construction
C. Att ach the regulator and outlet pipe to the
header.
1. Disconnect the outlet pipe assembly (includes
relief valve) from the inlet of the H-2 hydraulic
backpressure valve at the union tee.
2. Apply a single turn of T eflon tape to the 3/8 NPT
male threads on the outlet pipe assembly and
then assemble to the outlet connection of the
regulator. The 5" long pipe nipple on the outlet
pipe assembly should end up parallel to the inlet connection of the regulator.
3. Connect the regulator to the regulator connection on the header as illustrated in Fig. 3. Tighten
connection nut firmly with a wrench.
D. Install the hydraulic.
1. Place the hydraulic with its support brackets attached in the position it will occupy on the manifold and connect its inlet to the union tee of the
regulator outlet pipe.
2. Place a temporary support under the hydraulic
while it is in this position to support its weight.
3. Make sure the brackets are square with the axis
of the hydraulic and that the feet of both legs
are parallel to the surface of the wall. Mark the
position of the bolt on the wall.
4. Disconnect the hydraulic from the regulator outlet pipe and drill the holes for the bracket bolts
in or through the wall (see Section I-A-1).
5. Place the hydraulic with brackets attached in
position for connection to the regulator outlet
pipe. Bolt the support brackets to the wall using
shims if necessary to keep the hydraulic connection union in alignment. Then make up the
union connection joining the hydraulic inlet pipe
to the regulator outlet pipe.
2
MANIFOLD VALVE
13-1/2"
SUPPORT BRACKET
Fig. 2 - Header Installed on Support Brackets
REGULATOR INLET CONNECTION
MANIFOLD HEADER
EXTENSION PIPE
E. Attach the cylinder leads to the manifold valves.
F. Place the manifold valve keys on the valves.
G . Connect the service and the two vent pipes. Each
vent pipe must be run separately to a point outside
of the building. This piping must be good quality,
standard weight galvanized steel pipe with galvanized fittings; must be of the same size as the relief
valve vent outlet connections for their entire length,
must terminate not less than 12 feet above the
ground at a location remote from windows or openings into building, and as far as possible from flue
or chimneys. The ends must be fitted with return
bends or elbows opening downward, preferably
screened or otherwise protected from obstruction
by snow, ice, birds and insects, and must be located
at least 3 feet from combustible construction. The
vent pipes must be installed without traps, and are
not to be connected to each other or to any other
piping. It is recommended that a long screw or malleable iron union be installed in each vent pipe.
MANIFOLD VALVE
13-1/2"
SUPPORT BRACKET
J. If all connections have been made in accordance
with the instructions, all parts examined and found
to be in first-class condition for service, the manifolds is now to be tested and put into service, as
directed in the following section.
II. TO PUT THE MANIFOLD INTO SERVICE
A. Blow out the service line. Use compressed air or
nitrogen to clear it of all dirt, or welding scale. First
hammer the pipe vigorously at all welding joints to
loosen any scale adhering to the interior. Connect
the supply of compressed air or nitrogen to the entrance end of the service line at the manifold and
blow out each station drop separately starting at the
station farthest from the manifold. To do this effectively, cap all other outlets and attach a used gate
valve to the pipe end of the station concerned. Open
and close this valve repeatedly , alternately blowing
off and refilling the line until the compressed air or
nitrogen discharge is clear of dirt and dust particles.
B. Test all joints in the service line for leaks.
H. Attach the warning sign to the header with the
brackets provided (see Figure 3).
I. Multiple Manifolds. In setting up two or more mani-
folds in parallel it is necessary to remove the 3/4-in.
plug (Part No. 6030-2275) from the banded cross
(Part No. 6837-1275) on the outlet connection of
the hydraulic back pressure valves. Use appropriate size schedule 40 seamless steel pipe and fittings for the piping system. Each manifold should
be isolated by valves from the pipeline.
1. Connect the station outlet valves and any branch
line or station hydraulics that are to be provided
on the service piping system. Cap the outlets of
the station valves and open these valves.
2. T emporarily disconnect the vent piping from the
relief valve outlets on the hydraulic back pressure valves and close these openings with pipe
plugs. If the system contains branch line hydraulics see that the line shut-off valves at the inlet
and outlet sides of these hydraulics are open.
Where the stations are equipped with hydrau-
3
13-1/2"
WARNING
SIGN
13-1/2"
13-1/2"
13-1/2"
MAINFOLD
VALVE
SOCKET
WRENCH
CYLINDER-
MANIFOLD
LEAD
DELIVERY
PRESSURE
GAUGE
R-5701
REGULATOR
RELIEF
VALVE
4"
4
MANIFOLD
SUPPORT
39 3/16"
4 WK OR WTL CYLINDERS, 5' - 6-3/8" APPROX.
6 WK OR WTL CYLINDERS, 7' - 9-1/4" APPROX.
8 WK OR WTL CYLINDERS, 10' - 1/8" APPROX.
10 WK OR WTL CYLINDERS, 12' -3" APPROX.
FLOOR
LINE
BRACKET
5"
HYDRAULIC
BACK-PRESSURE
VALVE
2' - 4-1/4"
APPROX.
WALL LINE
Fig. 3 - Single M-4 Acetylene Manifold Showing Dimensions and Principal Parts
Single M-4 Fuel Gas Manifold Showing Dimensions and Principal Parts
lics open the shutoff valve on the hydraulic inlet
pipe and cap the hydraulic service outlet.
3. Fill the piping to a pressure of 20 psig with compressed air or nitrogen. Test all pipe joints, and
all joints and outlets of valves and hydraulics for
leaks with leak test solution (Part No. 998771)
or a solution of soap and water. (Disregard any
leakage around the valve lifting stem of the relief valves as this results from the valve being in
an open position while its outlet is plugged.) If
any leakage is disclosed by this test, relieve the
pressure and remedy the leakage by rewelding
or remaking the defective joint.
4. Remove the pipe plugs previously installed in
the relief valve outlets and reconnect the vent
piping.
ing, close the station valves and relieve the pressure in the piping.
D. Fill the manifold hydraulic to the indicated liq-
uid - level with PRESTONE brand anti-freeze*.
E. Check the service line to make sure all station
valves are closed. Fill all branch line and station
hydraulics with PRESTONE brand anti-freeze*.
F. Close the service valve. Then close ALL mani-
fold valves.
G . Close the regulator by turning the pressure-adjust-
ing screw to the left (counterclockwise), until it spins
freely.
C. Check the pipe for leakage.
1. Fill the piping to a pressure of 20 psig. Close
the service valve through which it was introduced
and disconnect the compressed air or nitrogen
supply from the piping.
2. Close the inlet valves of the station hydraulics,
if used.
3. Close the shutoff valves on both sides of the
branch line hydraulics, if used.
4. Test the piping on each side of the hydraulic
separately . Allow the piping to st and under pressure at least five hours. Measure the pressure
of the compressed air or nitrogen in the piping
and the temperature of the atmosphere in the
vicinity of the piping at the end of the first hour
and again at the end of the test.
An increase in the temperature of the piping will
cause the pressure of the compressed air or
nitrogen in it to increase, and a decrease in temperature will cause it to decrease. The final pressure must be adjusted to correct for this temperature effect if the final temperature is more
than 5°F. different than the temperature at the
start of the test.
To make this correction adjustment, add 1 psig
to the final pressure for each 15°F decrease in
temperature or subtract 1 psig for 15° the temperature has increased.
H. Select a full acetylene cylinder; “crack” it (see
General Instructions, Sec. V-B.); and connect it to
the extreme left-hand cylinder lead. Slowly open
the cylinder valve one-half turn.
I. Remove the extreme right-hand cylinder lead
from the manifold valve and open this manifold
valve three turns.
J. Purge the header. Open slightly the manifold valve
to which the cylinder is connected. As soon as the
gas issuing from the right-hand manifold valve, which
is open, smells strongly of acetylene, close this valve,
and then close the cylinder valve and the manifold
valve on the left of the manifold. Reattach the righthand cylinder lead.
K. Purge the hydraulic back-pressure valve as fol-
lows:
1. Close the service valve.
2. Open the cylinder valve one-half turn.
3. Open the manifold valve to which the cylinder is
connected three turns.
4. Turn the regulator pressure-adjusting screw
handle to the right (clockwise) until the delivery
pressure gauge on the hydraulic outlet shows 5
psig.
5. Open the relief valve on the hydraulic outlet by
lifting the relief valve operating lever — then,
after a minute, close the relief valve.
If the final pressure, after making this adjustment, is more than 1 psig lower than the pressure at the start of the test, check the pipe and
all joints, valves and outlets for leaks using lea
test solution or a solution of soap and water. All
leaks must be located and repaired before the
manifold system is placed in service. Af ter test-
* Use concentrated or undiluted PRESTONE brand anti-freeze unless the hy-
draulic may be exposed to temperatures below 5°F. Where anti-freeze protection at lower temperatures must be provided, use a water solution of
PRESTONE (anti-freeze as directed in the booklet “Cold Weather Care of
Acetylene Generating and Distributing Equipment,” Form 3088.
5
L. T est the manifold for leaks. Allow the delivery pres-
sure to build up to 15 psig. Close the manifold valve
to which the cylinder is connected and then close
the cylinder valve. Test all joints and connections
for leaks with leak test solution or a solution of soap
and water.
NOTE: This test must be made with full cylinder
pressure in the manifold header and a pressure of 15 psig in the hydraulic. After closing the manifold valve to which the cylinder
is connected, watch the cylinder-pressure
gauge on the regulator and the deliverypressure gauge on the outlet of the hydraulic. If these gauges show any appreciable
drop in pressure, locate the leakage causing it, relieve the pressure in the manifold
through the relief valve on the hydraulic
outlet and repair the leakage. Then refill the
manifold to test pressure and test the repair and all other joints or connections.
M. Purge the service line.
1. Attach full cylinders, after “cracking” (see Sect.
V-B), to all the other cylinder leads on the manifold. Open the cylinder valves on the right-hand
side of the manifold one and one-half turns.
Open the corresponding manifold valves three
turns.
2. Open the service valve slowly .
3. At the far end of each branch of the system,
connect torches equipped with cutting nozzles
or welding heads to one or more stations
equipped with either regulators or hydraulic
back-pressure valves.
4. Open the station valves and the torch acetylene
valves and light the torches as soon as the issuing gas will burn. The flames will gradually
increase in size and depth of color, (becoming
a deeper yellow) as the acetylene concentration increases.
5. After the character or appearance of the flames
remains constant for at least ten minutes, close
the torch valves and the station valves.
N. Close all manifold valves. Close the cylinder
valves. Release the regulator pressure-adjusting screw — turn it to the left (counterclockwise)
until it turns freely .
III. OPERA TING PRECAUTIONS
1 Keep all flames, sparks, and lights away from
the acetylene manifold and acetylene cylinders.
Do NOT permit smoking in the vicinity of the
acetylene manifold. NEVER use an open flame
to test for leaks.
2. Do not attempt to operate the acetylene manifold with any cylinders other than type WK or
WTL acetylene cylinder or other approved acetylene cylinders of equivalent size and capacity.
Under no circumstances should a cylinder containing any fuel gas other than acetylene be connected to the acetylene manifold.
3. Do NOT operate the M-4 acetylene manifold without flash arresters in the cylinder leads. In case
a cylinder lead becomes clogged, or subjected
to any damaging force, the flash arrester or the
entire lead should be replaced. Never attempt
to make any repair to a cylinder lead or to the
manifold valves or header. Never attempt to repair a flash arrester that has been clogged.
4. The relief valves on the inlet and on the outlet of
the hydraulic are to vent at no more than 20 psig
pressure for acetylene and 125 psig pressure for
fuel gas and should be kept in good working
order by lifting the operating levers of both relief valves each time that the hydraulic liquid
level is checked. Always relieve the pressure in
the hydraulic through the relief valve mounted
on its outlet before opening the relief valve on
the inlet of the hydraulic.
5. Acetylene and fuel gas piping systems must be
kept absolutely gas-tight. If an odor of acetylene
or fuel gas is noticed, open the windows to provide ventilation and then test for leaks with OxyT ec leak test solution or a solution of soap and
water. The manifold should be shut down and
the necessary repairs made to the system before regular operation is resumed.
6. Acetylene manifolds must be installed and operated in accordance with latest NFP A St andard
No. 51.
IV . OPERA TING INSTRUCTIONS
Continuous service, without interruption for replacing
cylinders after they have become exhausted, can be
obtained by operating the two sides of the manifold alternately . This is accomplished by operating one side at
a time and replacing the exhausted cylinders from the
other side before those on the operating side are exhausted. However, if the acetylene consuming operations are of intermittent occurrence, both sides of the
manifold can be operated simultaneously. Thus all of
cylinders on the manifold will supply the consumption
load. Tis method of operation is an advantage in that it
6
extends the serviceability of the manifold by doubling its
delivery capacity rate, or where increased capacity is
not a factor, by decreasing its discharge rate per cylinder.
A. Alternate operation of the two sides of the mani-
fold for continuous service.
1. Select one side of the manifold as the operating side. See that the valves of the cylinders
attached to the other side, the reverse side of
the manifold, are closed.
2. Open the cylinder valves on all cylinders attached to the operating side one and one-half
turns — no more.
3. Open the manifold valves on the operating side
to which these cylinders are connected three
turns.
4. Turn the regulator pressure-adjusting screw to
the right (clockwise) a few turns. Open the service valve slowly. Turn the pressure-adjusting
screw to the right (clockwise) slowly until the
delivery pressure gauge indicates the desired
line pressure. The system is now ready for service use. As soon as usage at stations on the
piping system develops a normal working load
flow through the regulator, readjust the regulator to compensate for the drop in delivery pressure occasioned by the flow load.
5. When the cylinders are exhausted, close all of
the manifold valves on the operating side of the
manifold and then close the valves of all the
cylinders connected to them. Near cylinder-exhaustion is evidenced by a low cylinder-pressure reading on the gauge of the regulator together with a continuous gradual lowering of the
line pressure as shown by the gauge on the
outlet of the hydraulic.
6. Put the reserve bank of cylinders into service
immediately . First open the valves of all the cylinders on this side of the manifold and then open
the manifold valves to which these cylinders are
connected.
7. Disconnect the exhausted cylinders from the
other bank and connect full cylinders from the
other bank and connect full cylinders, after they
have been “cracked,” in their place. This should
be done before the cylinders of the bank now in
operation are more than half exhausted.
8. When the bank of cylinders in operation is exhausted, repeat the cycle of operations described in preceding steps 5, 6, and 7.
9. Check the liquid level of the hydraulic as often
as necessary to maintain a sufficient quantity of
liquid for satisfactory operation of the hydraulic.
(See Section V-F). The liquid level should be
checked during off hours — preferably in the
morning before putting the manifold into operation. T o check the liquid level, first close the regulator by turning the pressure-adjusting screw to
the left until it turns freely; then close the service valve. Lift the operating lever of the relief
valve. Remove the liquid level plug. Af ter checking the liquid level plug, open the service valve,
and turn the regulator pressure-adjusting screw
to the right (clockwise) until the delivery pressure gauge indicates the desired delivery pressure.
B. Simultaneous operation of both sides of the
manifold for intermittent service.
1. Connect full cylinders to all of the manifold
valves.
2. Open the cylinder valves on all of the cylinders
one and one-half turns — no more.
3. Open all of the manifold valves three turns.
4. Place the manifold in operation as described in
Sect. IV-A-4.
5. When the cylinders are nearly exhausted, notify all operators using acetylene equipment that
service will be temporarily discontinued. Close
all manifold valves on the manifold and then
close valves or all cylinders connected to them.
Near cylinder-exhaustion is evidenced by a low
reading of the cylinder pressure gauge on the
regulator and by a continuous gradual decrease
in the line pressure as shown by the gauge on
the outlet of the hydraulic.
6. Disconnect all of the exhausted cylinders. Connect full cylinders, after “cracking,” in their place.
7. Repeat steps 2 and 3. Then notify all operators
of acetylene equipment that the system is ready
for service.
8. Check the liquid level of the hydraulic as often
as necessary to maintain a sufficient quantity of
liquid for satisfactory operation of the hydraulic.
(See Section V-F.)
C. To take the manifold out of service. When the
manifold is to be out of service for extended length
of time (such as overnight, week-ends, or longer
non-operating periods) adjust the manifold as follows:
1. Close all manifold valves and then close the
valves of all cylinders connected to the manifold.
2. Lift the operating lever of the relief valve
mounted on the outlet of the hydraulic momentarily . (Leaving the pressure in the manifold will
7
prevent its “breathing” in air if the temperature
of the manifold should become lower.)
3. Close the service valve.
4. Leave the pressure-adjusting screw in the position to which it was adjusted so that it will support the diaphragm against the thrust of the pressure in the regulator.
V . GENERAL INSTRUCTIONS
A. To adjust the delivery pressure. The delivery (or
line) pressure may be adjusted to any pressure up
to 15 psig.
tion; never “crack” the valve any wider
nor leave it open any longer than is necessary to clear the valve of dust or dirt.
C. Before opening cylinder valves, make sure that
the manifold valves to which the cylinders are connected are closed. After the cylinder valves have
been opened one and one-half turns, open the manifold valve three turns.
D. When disconnecting cylinders, always make sure
the manifold valves to which the cylinders are connected are closed first. Then close the cylinder
valves.
1. T o increase the delivery pressure, turn the regulator pressure-adjusting screw to the right (clockwise).
2. T o decrease the deliver pressure, turn the regulator pressure-adjusting screw to the left (counterclockwise).
Pressures preferably should be adjusted when there
is some flow through the regulator. Minor adjustments of the line pressure can be made when the
system is supplying torch equipment in operation.
Do not make any extensive change of pressure when
the manifold is in operation without first notifying all
persons operating acetylene equipment. Operators
should be prepared for the change and ready to
adjust their equipment for use of the new pressure.
To restore service to a service piping system from
which all or most of the acetylene pressure has been
discharged, turn the regulator pressure-adjusting
screw to the right slowly. When the desired pressure is indicated by the line pressure gauge on the
outlet of the hydraulic, the acetylene equipment can
be placed in service. Then readjust the regulator as
required as soon as the torches are lighted and a
normal service load is established.
E. Before connecting cylinders to the acetylene
manifold, always test the pressure of each cylinder
by attaching an acetylene regulator with its pressureadjusting screw in the released position to the cylinder valve. If the two sides of the manifold are operated alternately , do not connect cylinders which vary
more than 50 psig in pressure to the same side of
the manifold. If both sides of the manifold are to be
operated simultaneously do not connect such cylinders to either side.
F . Keep a sufficient quantify of liquid in the hydrau-
lic. The evaporation rate of concentrated (undiluted)
PRESTONE brand anti-freeze for temperatures at
which hydraulic back-pressure valves operate is
extremely slow. Consequently , if the hydraulic is initially filled with concentrated PRESTONE brand antifreeze, a check of the liquid level once every two
weeks is sufficient providing that no unusual operating condition, such as an abnormal surge of flow
that might have entrained and carried some of the
liquid out of the hydraulic, has occurred. However, if
a water solution of PRESTONE brand anti-freeze is
used it will be necessary to check the liquid level at
least twice a week to replenish the water which has
been absorbed by the dry acetylene.
To reduce the pressure when there is no acetylene
equipment in operation, lift the operating lever of the
relief valve on the outlet of the hydraulic until the
line pressure is reduced to a value slightly lower than
wanted. Then increase the pressure to that desired.
B. “Cracking” a cylinder clears the valve of dust or
dirt. To “crack” an acetylene cylinder, stand to one
side of the cylinder outlet and open the valve very
slightly (not more than 1/4 turn) for an instant and
then close the valve immediately .
CAUTION: Never “crack” a cylinder near an open
flame or other possible source of igni-
G. After shutting down the manifold, or after clos-
ing the service valve, always make sure all station
valves on the service line are closed before turning
acetylene or fuel gas back into the service line.
H. When exhausted or partially exhausted acetylene
or fuel gas cylinders are connected to one side of
the manifold, and if full or nearly full cylinders are
connected to the other side, always be doubly sure
that the manifold valves and the cylinder valves
on the exhausted or partially exhausted cylinders are closed. This will prevent the possibility of
acetylene from the full cylinders passing by the check
valves in the cylinder leads and going to the ex-
8
hausted cylinders. It is for this reason that all the
cylinders on one side of the manifold should be
changed at the same time.
VI. INSTRUCTIONS FOR PURGING THE MANI-
FOLD OUT OF SERVICE
A. Purge the manifold assembly as follows:
1. Notify all operators using acetylene equipment
that service will be temporarily discontinued.
2. Close the service valve.
3. Close all manifold valves and then close the
valves of all cylinders connected to the manifold.
4. Disconnect all cylinders connected to the manifold.
5. Lift the operating lever of the relief valve
mounted on the outlet of the hydraulic until the
pressure is reduced to zero psig.
6. Remove the 1/2" NPT cap on one end of the
manifold and connect a cylinder of nitrogen or
compressed air with a regulator to this point
using appropriate fittings.
7. Lift the operating lever of the relief valve
mounted on the outlet of the hydraulic and bleed
nitrogen or compressed air through the manifold and hydraulic back pressure valve for approximately ten minutes.
8. Remove the pipe cap on the opposite end of
the manifold and bleed nitrogen or compressed
air through the manifold until there is no odor of
acetylene present.
VII.INSTRUCTIONS FOR ADDING EXTENSIONS
A. To accommodate additional cylinders, (refer to
T able 1 for limit ation) extensions may be added
to the original manifold as follows:
1. Purge the manifold in accordance with Sect. VI
(Instructions for Purging the Manifold Out of
Service).
2. Apply T eflon tape or plastic pipe joint compound
to the male threads on the original manifold.
3. Assemble the extensions with couplings into the
original manifold. Hold the end of the original
manifold with a wrench to prevent it from turning. Assemble and tighten the extensions, making sure the manifold valves are left in the upright position. (If the wall clearance prevents
turning the extensions, remove the extension
manifold valves, assemble the extensions, and
replace the manifold valves in their original position using T eflon tape or plastic pipe joint compound.)
4. Close all manifold valves.
5. Fasten the manifold-header support brackets to
the wall in accordance with Sect. I (Installation
Instructions) A and B.
B. Clean the Manifold Extensions as Follows:
1. With the pipe cap removed from each end of
the manifold, use compressed air or nitrogen to
blow the manifold clear of all dirt and scale.
2. Replace the pipe cap on each end after applying Teflon tape or plastic joint compound on the
male pipe threads.
C. Purge the Manifold for Service
1. Attach the new cylinder leads to the manifold
valves except for the extreme right hand valve.
2. Place the manifold valve keys on the valves.
3. Select a full acetylene cylinder, “crack it” (see
General Instructions, Sect. V-B) and connect it
to the extreme left hand cylinder lead. Slowly
open the cylinder valve one-half turn.
4. Open the extreme right hand valve three turns.
5. Close the regulator by turning the pressure-adjusting screw to the left (counterclockwise) until
it turns freely .
6. Open slightly the manifold valve to which the
cylinder is connected. As soon as the gas issuing from the right-hand manifold valve, which is
open, smells strongly of acetylene, close this
valve and then close the cylinder valve and the
manifold valve to which the cylinder is connected.
7. Attach the new lead on the right-hand manifold
valve.
8. Open the cylinder valve one-half turn.
9. Open the manifold valve to which the cylinder is
connected, three turns.
10. Turn the regulator pressure-adjusting screw
handle to the right (clockwise) until the delivery
pressure gauge on the hydraulic outlet shows 5
psig.
11. Open the relief valve on the hydraulic outlet by
lifting the relief valve operating lever - then, after one minute, close the relief valve.
12. Test the manifold for leaks. Allow the delivery
pressure to build up to 12 psig. Close the manifold valve to which the cylinder is connected and
then close the cylinder valve. Test all joints and
connections for leaks with leak test solution or
a solution of soap and water.
9
NOTE: This test must be made with full cylinder
pressure in the manifold header and a pressure of 15 psig in the hydraulic. After closing the manifold valve to which the cylinder
is connected watch the cylinder-pressure
gauge on the regulator and the deliverypressure gauge on the regulator and the
delivery-pressure gauge on the outlet of the
hydraulic. If these gauges show any appreciable drop in pressure, locate the leakage
causing it, relieve the pressure in the manifold through the relief valve on the hydraulic outlet and repair the leakage. Then refill
the manifold to test pressure and test the
repair and all other joints or connections.
13. Attach full cylinders, after “cracking” (see Sect.
IV-B.) to all the other cylinder leads on the manifold.
14. The manifold may now be returned to service in
accordance with Sect. III, Operating Instructions.
RV -28 Relief Valve and R-5700 Series Regulators
The RV -28 relief valve (1 1P63) shown in Figure 5 is covered in Form 9373 packed with the M-4 Manifold. If parts
information is needed for the R-5701/R-5702 regulator,
request Form 12-524.
ACCESSORY
Manifold Extensions
Extension Part No.
Single-Cylinder, R.H. .......................................04B81
Single-Cylinder, L.H.........................................04B82
Two-Cylinder , R.H........................................... 28R36
Two-Cylinder , L.H. .......................................... 28R37
Three-Cylinder, R.H........................................ 28R26
Three-Cylinder, L. H. ...................................... 28R27
Each extension assembly is equipped with a manifold
valve (12P85 - see View “A”, Fig. 5) per cylinder and a
1/2-in. NPT coupling (6822-5996). Each extension
assembly is supplied with the following per cylinder:
Lead Assembly..........................................13B72
V alve Key ................................................ 505L00
“T”-wrench .............................................. 903L00
(2) Support Bracket ............................... 4785L00
Stove Bolt & Nut................................. 6623-0314
(2) Lag Screw.....................................6121-2146
10
R-5701 REGULAT OR - 639628
** R-5702 REGULAT OR - 639628
WARNING SIGN - 06S09
(See page 10)
GAUGE - 999441
HANGER - 4929L00
(3) NIPPLE - 6720-1175
# GASKET - 04B62
# (8) SCREW - 6134-1415
# (8) NUT - 6330-0136
ELBOW - 6824-3995
NIPPLE - 6730-0548
ELBOW - 6824-1587
NIPPLE - 6730-0548
UNION - 6522-5100
UNION - 6524-5050
GAUGE-999437
999434**
PIPE ASSEM. - 2028745
(2) CAP - 6823-1996
(8) SCREW - 6121-2146
4) VALVE ASSEM. - 12P85
(See View “A”)
GLAND - 5562L00
PACKING
5390L00
WASHER
5561L00
PLUG - 6030-2275
ELBOW - 6834-2284
PLUG - 6070-2175
VIEW “A”
VALVE STEM
5387L00
NUT 5386K00
FRONT VIEW
(4) CYL. LEAD ASSEM. - 13B72
includes
ARRESTER - 11R94
(4) WRENCH - 903L00
ELBOW 6834-3284
(4) SCREW - 6121-2146
CROSS - 6837-1275
RV-28 RELIEF VALVE 11P63 (See pg. 10)
(4) VALVE KEY - 505L00
NIPPLE - 6722-0550
(4) BOLT & NUT 6623-0314
(8) BRACKET - 4785L00
BUSHING - 6820-7280
# RV-28 RELIEF VALVE - 11P63
** 125 PSI RELIEF VALVE 22X56
(See pages 9 & 10)
** Parts used on Fuel Gas Manifold
# Parts included with H-2
Hyd. Back-Pressure Valve - 04B13
FIG. 5 - M4 OXWELD Acetylene Manifold
M-4 OXWELD Fuel Gas Manifold
BUSHING - 6830-8276
NIPPLE - 6730-1275
(2) NIPPLE - 6830-6275
# TEE - 6836-1275
# NIPPLE - 6730-6275
# ELBOW - 6834-3284
UNION TEE- 6524-8251
# VALVE - 03R19
# PLUG - 6030-2998
SIDE VIEW
4-Cylinder - 04B40 (Illustrated)
6-Cylinder - 04B85 (04B40 supplied with extensions 04B81 & 04B82)
8-Cylinder - 14P41 (04B40 supplied with extensions 28R36 & 28R37)
10-Cylinder - 14P40 (04B40 supplied with extensions 28R26 & 28R27)
11
HARDW ARE
Part No. Description
6030-2275 3/4-in. Square Head Galvanized Pipe Plug
6030-2998 1/2-in. Square Head Galvanized Pipe Plug
6070-2175 1/2-in. Square Head Brass (Nickel Plated) Pipe Plug
6121-2146 3/8-in. x 2-in. Square Head Lag Screw
6134-1415 3/8-in. - 16 x 1-in. Hex Head Steel Cap Screw, Cad. Plated
6330-0136 3/8-in. - 16 Hex Steel Nut
6522-5100 1/2-in. Union Sch. 80
6524-5050 1/2-in. Union Sch. 40
6524-8251 3/4-in. Female Union Tee
6623-0314 3/8-in. x 2-in. Round Head Stove Bolt with Nut
6623-0146 3/8-in. x 1-3/4-in. Round Head Stove Bolt with Nut
6720-1175 1/2-in. Close Nipple Sch. 80
6722-0550 1/2-in. x 5-3/8-in. Sch. 40 Seamless Steel Pipe Nipple
6730-0548 1/2-in. x 2-1/2 Lg. Nipple Sch. 40
6730-0550 1/2-in. x 5 Lg, Nipple /Sch., 49
67301275 3/4-in. x Wrought Steel Pipe Close Nipple
6730-6275 3/4-in. x 2-in. Wrought Steel (Galv.) Pipe Short Nipple
6810-0176 1/2-in. x 3/8-in. Bushing
6820-3199 1/2-in. x 1/4-in. Bushing
6820-7280 3/4-in. x 1/2-in. Reducing Flush Bushing
6822-5996 1/2-in. Pipe Coupling
6823-1996 1/2-in. Pipe Cap
6824-1587 1/2-in. x 90 Elbow
6824-3995 1/2-in. x 90 Steel Elbow
6826-0650 1/2-in. x 1/2 x 1/2 Tee Sch. 80
6830-8276 3/4-in. x 1/2--in. Outside Hex Cast Iron (Galv.) Pipe Bushing
6834-2284 3/4-in. Malleable Iron (Galv.) Elbow
6834-3284 3/4-in. Street Elbow
6836-1275 3/4-in. Malleable Iron Banded Tee
6837-1275 3/4-in. Malleable Iron (Galv.) Banded Cross
LITERATURE CHANGES
The P edition was printed to cover the following changes:
1. Capacity table revised to include operations from WTL cylinders and the recommended maximum withdrawal
rates for continuous and intermittent operations.
2. Manifold pipe assembly (2028745) and the optional extensions are equipped with welded-on-fittings which replace a series of pipes and tees.
3. Piping assembly was revised between the R-66MFD regulators and the H-2 hydraulic.
The Q edition (10/92) covers the addition of manifolds for fuel gases other than acetylene. All manifolds are now
listed by U.L.
F-2885-Q 10/2000 Printed In U.S.A.
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