FLOTEC INC

7625 West New York Street

Indianapolis, IN 46214-4911

317-273-6960

(Fax) 317-273-6979

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Service Manual

F l o p a c

Regulator

M-Service Manual FP.doc (03-06-07) Eng.

  1. TOOLS, TEST EQUIPMENT AND SERVICE MATERIAL
  1. TOOLS
  2. TEST EQUIPMENT
  3. SERVICE MATERIALS
  1. SPECIFICATIONS
  1. THEORY OF OPERATION
  1. DEFINITION OF STATEMENTS
  1. PRODUCT CLASSIFICATION DATABASE
  1. INSTALLATION INSTRUCTIONS
  1. TORGUE SPECIFICATIONS
  1. TRANSFILLING PROCEDURE
  1. VENTING AND VACUUMING PROCEDURE
  2. TRANSFILLING OXYGEN PROCEDURE
  1. SERVICE AND REPAIR
  1. CLEANING, LUBRICATION AND SEALING

B. FLOPAC REGULATOR COMPONENTS:

  1. INLET CONNECTIONS
  1. REMOVABLE CGA 540 OR SPECIFIC GASES CHECK VALVE
  2. TESTINGCGA 540 OR SPECIFIC GASES CHECK VALVE
  3. SERVICECGA 540 OR SPECIFIC GASES CHECK VALVE
  4. ASSEMBLYCGA 540 OR SPECIFIC GASES CHECK VALVE
  5. INSTALLATION CGA 540 OR SPECIFIC GASES CHECK VALVE
  1. SHUT-OFF VALVE

a. REMOVEL

b. SERVICE

c. INSTALLATION SHUT-OFF VALVE

  1. DISS AUXILIARY OUTLETS
  1. REMOVAL
  2. SERVICE
  3. INSTALLATION
  1. INTERNAL CONTENTS GAUGE
  1. RESETTING

b. MAINTENANCE

  1. FLOWMETER
  1. REMOVAL
  2. SERVICE
  3. INSTALLATION

6. FLOPAC CONNECTOR

  1. REMOVAL
  2. SERVICE
  3. ASSEMBLY

7. BURST DISK

  1. REMOVAL
  2. SERVICE
  3. INSTALLATION

8. PISTON-MANIFOLD SET

  1. REMOVAL
  2. SERVICE
  3. INSTALLATION

9. HANDLE ASSEMBLY WITH FLANGE WASHER

a. REMOVAL

b. SERVICE

c. INSTALLATION HANDLE ASSEMBLY WITH FLANGE WASHER

  1. TESTING
  1. FLOPAC HIGH PRESSURE LEAK TEST PROCEDURE
  2. FLOPAC OUTLET PRESSURE/ FLOW CALIBRATION PROCEDURE
  1. REPLACEMENT PARTS LIST FOR FP-XX-XXX-XXXXX
  1. TROUBLESHOOTING GUIDE

XIII. DRAWINGS:

  1. FLOPAC PICTURE W/ ALL INTERNAL PARTS,

b. FLOPAC PICTURE IN POS. NO PRESSURE AND MODULATED FLOW, 05-02-06

c. FLOPAC REGULATOR WITH CYLINDER, , FPX-XXX-XX-XXXXX, REV “D”

d. ENGINEERING SPECIFICATION #FES04-016 REV. 4

  1. TOOLS, TEST EQUIPMENT AND SERVICE MATERIAL

A.TOOLS

Screwdriver - (1/4 in. (6 mm) flat blade

Screwdriver-No.2 Phillips

Notched Spanner Driver for screw size #10

Torque Wrench 0-150 in-lbs

Torque Wrench 0-50 Ft-lbs

Torque Wrench 0-70 Ft-lbs

Torque Wrench 0-150 Ft-lbs

Torque Screwdriver 0-12 in-lbs

Open end wrenches – 7/16 in, 9/16 in, 5/8 in, 11/16 in

Open end ½” drive 1 7/16” Crowfoot Wrench for torque Flopac connector

Open end 3/8” drive 9/16” Crowfoot Wrench for pre-set Flopac Handle

Adjustable Wrench-10 in (25) cm

Hex key Wrench-1/16”

Internal retaining ring pliers

Punch-1/8 in (3mm)

Standard paper clip
Hammer

C-Clamp-3 in (8cm)

Dental Pick (or similar pointed instrument)

Pins dia: .173, .174, .175- for check Swivel body hole and dia .281, .282, .283- for check Connector’s On-off

valve hole.

B.TEST EQUIPMENT

Test Flowmeter FL-110, flow 0-100 ml/min, with an accuracy of + or – 2% if reading @ 70 degrees F (21 degrees C) and 14.7 psi (101 kPa)

Test Flowmeter FL-111, flow 0-626 cc/min

Mass Flowmeter FMA 1812, flow 0-500 ml/min

Mass Flowmeter BW509003, flow 0-10 lpm

Mass Flowmeter Omega # FMA1842, flow 0-100 lpm

Test Flowmeter Omega FL-1448C, flow 0-60 lpm

Test pressure gauge with a range of 0-100 psi (0-690 kPa) and accuracy in according to ASME 40.1-1998, Grade “B”, permissible error (+/-% of span):

- lower ¼ of scale (0-25 psig) = +/- 3%;

- middle ½ of scale (25-75 psig) = +/-2%;

- upper ¼ of scale (75-100 psig) = +/- 3%.

Vacuum gauge with a range 0-30 in Hg vac.

Leak detector – Nupro “Snoop” or equivalent (oxygen compatible)

C.SERVICE MATERIALS

Krytox 240 AC Fluorinated Grease (DuPont)

Teflon tape – ¼ in (6mm)

Isopropyl alcohol

Cloth – lint free

Oxygen tubing – ¼ in (6mm) I.D.

Screw – 6-32 UNC

Service Instructions:

810-6554-061 Rev “E” – for Oxygen

810-6554-081 Rev “D”- for Heliox (80%% He & 20% Oxy.)

810-6571-071 Rev”A” – for Medical Air

  1. SPECIFICATIONS

Flotec Flopac Regulators are small, lightweight devices that are available in a variety of configurations to meet the various requirements for medical gas delivery. Flotec Flopac Regulators can be equipped with a 12 position, detented flow control valve or a variety of designated inlet flow connectors. Units are also available with single or dual high flow DISS outlets. Every Flopac Regulator design has an internal safety burst disk to prevent over-pressurization of the Flopac Regulator. Both small cylinder and large cylinder inlet connections are available on all regulators. The following instructions provide information to assist qualified personnel in the service and repair of Flotec Flopac Regulators. It is recommended that the repair technician read this service and repairs instructions thoroughly before servicing Flotec Flopac Regulators.

Storage Temperature: -40 degrees F to 140 degrees F

Operating Temperature: -20 degrees F to 150 degrees F

Materials: Brass, Bronze, Anodized Aluminum, Stainless Steel,Teflon, Viton, Neoprene, Silicone.

Filtration: 30 micronSintered Cooper-Nickel Low Pressure filter

SupplyPressureRange: 250 to 3000 psi

Operating Pressure: 50 psi (17, 20, 24, 30, 40, 58, 70, 90, 110 PSI available upon request)

Relief Valve Pressure: 75 PSI or 95 PSI (for operating pressure 50 and 70 psi).

Inlet Connections: Any CGA inlet connection is available for specific gases and most International applications are available upon request. Any CGA inlet connector must include a special Check Valve for venting- vacuuming and

transfilling Flopac cylinder.

Dimensions: Variable depending on type and style specified, as usual it is approximately 6.4” (and 5.3” after install into cylinder). Handle has clearance 2.0”-2.3” above Flopac FM knob.

Flopac Regulator options:

FP1- Integral Shut Off Valve w/ Knurled Knob, Halo Handle Welded

FP3- Integral Shut Off Valve w/ Knurled Knob, Bent Handle

FP4- Integral Shut Off Valve w/ Knurled Knob, Halo Handle

FP5- Integral Shut Off Valve w/ Knurled Knob, Bent Handle, CGA 280 (Heliox)

FP6- Integral Shut Off Valve w/ Knurled Knob, Halo Handle, CGA 346 (Medical Air)

FP7- Integral Shut Off Valve w/ Knurled Knob, Halo Handle, ½-14 NGT (for steel cylinder)

FP8- Integral Shut Off Valve w/ Knurled Knob, Halo Handle Welded, ½-14 NGT (for steel cylinder)

FP9- Integral Shut Off Valve w/ Knurled Knob, Halo Handle Welded, External 1.4”, 3000 psi Gauge

FPA- Integral Shut Off Valve w/ Knurled Knob, Halo Handle Welded, ½-14 NGT,External 1.4”, 3000 psi Gauge

FPP- Integral Shut Off Valve w/ Knurled Knob, No Handle

Weight: Variable depending on type and style specified, but no more than 2.0 lbs w/out handle and approximately 2.5 lbs

with handle and protect s.s. ring.

Indicators: Cylinder Contents, Pressure Medical Gas Flow Rate

Power take off Outlet Connections: none, 1 or 2 of any combination of the following: DISS check valve, plugged 1/8” FNPT ports.

Flowmeter Outlet Connection: DISS fitting or Hose Barb

III.THEORY OF OPERATION

The Flotec Flopac Regulator is a single stage piston-type regulator. When it is initially attached to a high-pressure gas cylinder, the internal components are in the position shown in enclosed drawings. When the Flopac “On-Off valve” is closed, the spring exerts force against the piston assembly and pushes the piston assembly away from the regulator seat.

When the Flopac “On-Off valve” is opened, high-pressure medical gas (approximately 2000-2200 psi for a full cylinder) passes through special flow- hole into the Flopac connector and flows through the seat. The gas then flows through the shaft of the piston and exits to the regulated output cavity.

The gas continues to flow into this area until the cavity builds enough pressure to overcome the force of the spring, which occurs at 50 psi. The piston assembly then moves toward the seat and the seal blocks the flow path and prevents the pressure from rising above 50psi. This all occurs in a fraction of a second. When gas is let out of the output cavity through the flow-controlling device, the pressure in the cavity drops. The spring then pushes the piston assembly away from the seat to allow the oxygen or specific gases to restore the pressure to 50 psi and deliver the flow through the flow-controlling device at the prescribed rate. This too happens in a fraction of a second.

In the unlikely event that the Flopac Regulator does not regulate properly and should the internal pressure rise above ( 75 psi or 95 PSI) the relief valve will unseat and safely release gas through the vent holes in the side of the swivel body.

NOTE The Flotec Flopac Regulator adjustable flow regulator is shown in enclosed drawings. The internal Flopac Regulator components are common to all Flotec Ingage™ Regulators and Pressure Reducers.

IV.DEFINITION OF STATEMENTS

Statements in this manual proceeded by the following words are of special significance.

WARNING means there is the possibility of injury or death to you or others.

CAUTION means there is the possibility of damage to the unit or other property.

NOTE indicates points of particular interest for more efficient and convenient operation.

Always disassemble, inspect, clean and repair regulator components in accordance with these instructions. Be aware of all the potential hazards associated with handling and using high-pressure gas equipment. Also, be aware that the possibility of fire exists when the combination of a combustible material, a source of ignition and oxygen is present (Called the Fire Triangle).

WARNING Replacement of parts on high-pressure Flopac regulators should be made only by qualified personnel familiar with their operation. Do no remove or install parts with the Flopac regulator installed on a cylinder. Always verify that oxygen or specific gases in cylinder is empty before disconnecting the regulator from the cylinder. Use only the proper repair tools and parts. Always wear eye protection when servicing high-pressure regulators.

WARNING Contaminants or hydrocarbons may, in the presence of an ignition source and oxygen or specific gases may combine and burn violently. Never permit oil, grease or other combustible substances to come in contact with oxygen cylinders, regulator parts or repair tools. Provide a clean; oil free surface on which to place disassembled regulator parts.

WARNING Always open high-pressure Flopac “Shut-Off valve” SLOWLY. This should always be done in order to allow the heat of gas compression to dissipate. Always verify that oxygen or specific gases in cylinder is exactly empty before disconnecting the regulator from the cylinder.Check it! Open Flopac “Shut-off valve”, briefly rotate Flopac flow selector knob to max rate position while verifying flow is existing from outlet port. Gently depress DISS-1240 Check-Valve (if equipped) to re-ensure all remaining regulator internal residual pressure has been evacuated.

WARNING Do not obstruct the vent holes in the swivel body of the Flopac Regulator. These holes must be open to atmosphere for proper regulator operation.

V. PRODUCT CLASSIFICATION DATABASE

FDA 21 Classification

Device- Regulator, Pressure, Gas Cylinder

Device Description- Pressure regulator

Medical Specialty Anesthesiology

Product Code CAN

Regulation Number FDA #868.2700

Device Class 1

GMP Exempt? No

510(k) Exempt? Yes

European Commision Meddev 2.4/1 Rev 8 Part 2 Rule 11 – Active devices to administer, remove medicines and

other substances to or from body, or Directive 93/42/EEC – Class 2B– Pressure regulator for medical gases.

Health Canada CAN/CSA-Z305 87M- Medical Devices Regulations Classification Rules for Medical devices, Part 1,

Rule 9- Active devices to administer or withdraw energy to or from the body- Class 2 – Medical Pressure regulator.

VI. INSTALLATION INSTRUCTIONS

See Install Instructions provided with each Flopac Regulator of the Flotec Engineering Specification #FES04-016 Rev 4.

  1. TORQUE SPECIFICATIONS

See Engineering Torque Specifications for different modifications of the Flopac Regulators FES04-016 Rev “4”.

VIII. TRANSFILLING PROCEDURE

  1. VENTING AND VACUUMING PROCEDURE

See Flopac Transfilling procedure Instruction, part A.of the Flotec Engineering Specification #FES04-016 Rev 4.

  1. TRANSFILLING OXYGEN PROCEDURE

See Flopac Transfilling procedure Instruction, part B.of the Flotec Engineering Specification #FES04-016 Rev 4.

  1. SERVICE AND REPAIR

NOTE Always perform the Flopac Regulator test procedures in this manual before placing a repaired Flopac Regulator back in service.

NOTE Refer to the Parts List and Parts Illustration for identification of parts referenced with bold numbers.

  1. CLEANING, LUBRICATION AND SEALING

Clean metal parts of the Flopac Regulator with isopropyl alcohol and thoroughly blow dry with dry, oil free compressed gas. Use a mild solution of soap and water to clean plastic parts. Use a clean lint free cloth with isopropyl alcohol to clean internal parts, being certain to remove any residual fibers.

O-ring seals that have been cleaned or are new replacements should be lubricated with a film of KRYTOX 240AC Fluorinated Grease.

Whenever pipe threaded (NPT) connections must be disassembled, reseal the threads with Teflon tape. When applying teflon tape remove old sealant from the male and female threads and wrap the male threads with Teflon tape in a clockwise direction, starting 1 to 2 threads back from the end.

  1. FLOPAC REGULATOR COMPONENTS:
  1. INLET CONNECTIONS

a.REMOVABLE CGA 540 (003-3000-452) OR SPECIFIC GASES CHECK VALVE (003-3000-453; -454)

  1. Using “1” socket wrench remove the Flopac CGA 540 or specific gases Check valve Assembly from

Flopac Connector 9/16-18 UNF-2A female port.

b. TESTING CGA 540 (003-3000-452) OR SPECIFIC GASES CHECK VALVE (003-3000-453 or

003-3000-454)

1. Testing Check valve for leaking on the Special Flopac Test station for 2000 psi Oxygen. Repeat this

test 2-3 times by pressurizing and de- pressurizing of the Check valve Assy.

c. SERVICE

1. Using 5/32” and 9/64” T-handle Hex Tool remove Flopac Check valve Nut and Retainer.

2. Remove Flopac Check valve poppet w/urethane O- ring and spring.

3. Check all Flopac CGA-540 or specific gases Check valve components,especially straight THD

O-ring, threads of the body, poppet, retainer. Clean all Check valve components with isopropyl alcohol

and thoroughly blow dry.

4. Inspect the CGA-540 or specific gages Check valve urethane O- ring for cuts and wear.

Replace as necessary with new square cut ring.

5. Where possible, blow out the CGA-540 or specific gases Check Valve body chamber using clean, dry

compressed air or Nitrogen to remove any foreign particles.

d.ASSEMBLY CGA 540 OR SPECIFIC GASES CHECK VALVE.

  1. Install poppet w/urethane O- ring into body.
  2. Using special plate, screw s.s. nut and poppet w/urethane O- ring.
  3. Install spring on the poppet and screw retainer into body.
  4. Install urethane O-ring to special groove of 9/16-18 THD.

e.INSTALLATION CGA 540 OR SPECIFIC GASES CHECK VALVE.

1.Using 1” socket and torque wrench , tighten Flopac CGA-540 or specific gases Check valve

Assyto 37 ft. lbs (50 N.m).

2. SHUT-OFF VALVE

a. REMOVAL

1. Using Notched Spanner Driver (For screw size #10) unscrew Stem nut.

2. Remove Knurled Knob with Lock washer.

3. Using 11/16” socket wrench unscrew Bonnet w/Stem assy from Flopac Connector.

4. Unscrew Stem Assy from Bonnet.

b. SERVICE

1. Check all Shut-Off valve components. Check internal and external Bonnet thread.

2. Check Stem 3/8-24 UNF-2A and 10-24 UNC-2A threads.

3. Inspect Back-up ring and O-ring for cuts and wear. Check Nylon seal for wear. Replace as necessary

with new O-ring, Back-up ring and Nylon seal.

4. Clean all Shut-Off valve components with isopropyl alcohol and thoroughly blow dry. O-ring and

Back-up rings should be lubricated with a film of KRYTOX 240 AC Fluorinated Grease.

c. INSTALLATION SHUT-OFF VALVE

1. Screw Stem Assy with Bonnet by hand

2. Using 11/16” socket and torque wrench, tighten Bonnet w/Stem Assy to Flopac Connector to

25-30 ft.lbs (34-40.5 N.m)

3. Install Knurled Knob to Stem square in pos. “OFF” when Shut-Off valve is closed.

4. Install Lockwasher

5. Using Notched Spanner Driver, screw Stem nut, torque to 5 ft.lbs (6.8N.m).

3. DISS AUXILIARY OUTLETS

  1. REMOVAL
  1. Using a 5/8” open end wrench, remove the DISS auxiliary outlet from the Flopac Regulator
  2. Remove old sealant from the male and female threads. CAUTION Hold the Flopac Regulator with the DISS auxiliary outlet ports down so that any particulate matter will fall out of the port.
  1. SERVICE
  1. Disassemble the DISS auxiliary outlet by depressing the check valve plunger until the opposite end containing the o-ring clears the body. Remove the 0-ring to gain access to the plunger and spring.
  2. Inspect the components for wear or damage and replace as necessary. Reassemble in reverse order.
  1. INSTALLATION
  1. Reseal the male threads on the DISS auxiliary outlet with Teflon tape.
  2. Thread the outlet into the regulator body and tighten 30 in.lbs (3.5 N.m).

4. INTERNAL CONTENTS GAUGE

a. RESETTING

1. Insert Pocket Scriber with ¼” Handle dia.intoSwivel body special slot .38x.05 and turn Gauge

body until gauge aligns with (-0-) PSI.

  1. MAINTENANCE

1. Keep internal contents gauge free of debris and contaminates.

2. Do not use oil or other lubricants with internal contents gauge.

WARNINGThe Flotec Flopac Regulator contains an internal contents gauge, which should only be removed or replaced by a trained Flotec Technician.

5. FLOWMETER

Before attempting to disassemble the flow control valve to resolve a flow related problem, perform the following procedures for back flushing the valve to remove any debris from the valve orifices. NOTE: The flow control valve must be removed from the regulator before back flushing.

  1. REMOVAL
  1. Using a vise with Holding Fixture, place swivel body with Flowmeter assy and turn the Flowmeter counter clockwise to loosen.
  1. SERVICE
  1. Backflush all 11 flow positions with a medical gas. Check the screw holding the rotor assembly onto the knob shaft for tightness. NOTE: Any other service work must be done by the manufacturer; there are no user serviceable parts in the flowmeter assembly. If the flowmeter needs to be returned to the manufacturer reassemble the flowmeter with the upper body before returning.
  2. CAUTION The flow control valve is manufactured to exacting tolerances and utilizes a number of extremely small orifices. To prevent improper valve operation due to contaminants, ensure hands, tools and worktable are clean when disassembling and servicing the flow control valve. There are no user serviceable parts in the flowmeter assembly
  3. Clean all flow control valve components with isopropyl alcohol and thoroughly blow dry.
  4. CAUTION Do not allow a lubricant film applied on the rotor face to accumulate in the rotor orifices.
  5. WARNING Do not interchange rotors and flow control valve bodies. Always assemble rotor with its original flow control valve body.
  6. Verify that the valve shaft rotates smoothly and stops at each detented position.
  1. INSTALLATION
  1. Replace the O-ring on the Flowmeter assembly as needed.

2. Using a vise with Holding Fixture, place swivel body with Flowmeter assy and turn the Flowmeter