OPERATING MANUAL PCR Pneumatically Controlled Regulator

PCR Pneumatically Controlled Regulator
OPERATING MANUAL
Aviation Oxygen System Solutions by Mountain High
Table of Contents
PCR System Description
1
Basic PCR system operation
2
Basic PCR Components & Suggested Installation Layouts
3-5
Mechanical & Pneumatic Technical Information
6 on
Congratulations on choosing the Mountain High PCR (Pneumatically Controlled Regulator) system.
The PCR system is a completely integrated, pneumatic powered oxygen regulator, designed to provide you with unmatched control, safety, comfort, and convenience at an affordable price.
The design intent of the PCR is to allow it to be used with any off-the-shelf CGA-540 valve cylinder,
providing the ability to remove the cylinder for refilling purposes. If removing the cylinder is not convenient, a 4-sae high pressure access port ( photo B ) was provided on the back of the PCR to allow
for an installation of a remote fill port and/or a remote pressure gauge, thus providing you with a variety options for your installation application needs. (see pages 3,4,5 & 6 for diagram installation suggestions).
The PCR is not intended to be used as the main high pressure shut off, rather it is for giving the customer ease of use during flights and cylinder installation location options. The valve of the cylinder
should be turned off during times of aircraft storage as to mitigate any oxygen system drainage. It is
not necessary to close the cylinder valve during refueling, lunch stops, leg stretches, etc.
The 1/8" O.D. pneumatic lines that connect the remote ON/OFF toggle switch to the PCR are flow
restricted to a minute 1/64 liter-per-minute to prevent against the low pressure oxygen contributing to
a shut-off event emergency.
The PCR is intended to be use with any CGA-540 valve cylinder with a service pressure range of 500
psig. to 2400 psig. (nominal 1850 psig.). The functioning high pressure inlet range is 3,000 psig MAX.
Operating past this inlet pressure will not cause damage, rather it may cause the PCR to be forced
open, causing a "safety venting" through the low pressure outlet.
The 3-way control switch option must be ordered if the PCR system
will be used in a pressurized aircraft.
PCR Aviation Oxygen System Description
A standard PCR-4p system kit includes items the following items:
L
01
02
03
04
05
06
07
08
Qty
1
1
1
1
3
4
4
1
Description
PCR regulator kit with remote on/off switch & 25’ of pneumatic control lines.
AL-682 cylinder. Optionally upgradeable to KF or CFF cylinders.
‘Ω’ or ‘A’ style CMK for that cylinder (your choice, ‘Ω’ style shown).
6 mm. polyurethane tubing kit. (25’).
‘T’ & ‘Y’ union kits for the 6 mm. tubing.
CPC bulkhead style oxygen station outlet kits.
XCP Breathing stations & tote-bags with your choice of MH3 or MH4 flowmeters.
SCD and instruction inserts for all items in kit.
A product of customer requests, the new PCR is a completely selfcontained remote-controlled oxygen regulator. It connects directly
to any oxygen cylinder with a CGA-540 (USA) or optionally with
DIN-477 (European) valve. Flow of oxygen to the user is controlled
pneumatically through a set of color-coded pneumatic signal-lines
that run to a panel mounted on/off switch. The PCR can be ordered
in various phases from just the PCR regulator to complete PCR
multi-place built-in aviation oxygen systems.
Once your PCR system is plumbed, you can use any of our oxygen delivery systems including the EDS pulse-demand system and
operate them at the same time others are using MH3 or MH4
flowmeters. A maximum number of six (6) slef-sealing bulkhead
outlets can be mounted in many ways to suite your needs. You can
add EDS stations at any time.
EDS O2D2
Two-Place
Pulse-Demand
Oxygen unit
The intended use of the PCR is for use as an aviation oxygen system where a typical cylinder pressure range would be from 500 to
2,400 psig (nominally 1850 psig). The PCR is intended to be used
with any off-the-shelf CGA-540 valve cylinder at pressures up to
3,000 psig. The PCR provides a means to remotely control the
low pressure outlet circuit for convenience and safety sake.
The PCR regulator directly connects
(by hand) to the service/refill port of
any oxygen cylinder with the standard
CGA-540 (USA) or optionally DIN-477
(Euro) valve allowing the cylinder to be
easily removed for refilling or service.
An auxiliary port on the rear side of the
regulator body (not shown) is provided
for an optional remote oxygen fill station and presure gauge.
The PCR system is not intend to be the main turn-off for the high
pressure of the cylinder used. The PCR has a minute amount of
weepage under operating pressure, therefore, the main cylinder
valve must be turned off during times of storage to mitigate cylinder drainage.
The PCR operates by using a small fraction of the regulated out
let oxygen to pneumatically operate a control valve in the PCR
body. The 1/8" O.D. pneumatic lines that connect the PCR to the
on/off control switch are flow restricted so that the regulated lowpressure oxygen does not contribute to any safety hazard in the
event shut-off emergencies are required. In distressed situations,
the amount of oxygen that may flow from a complete line cut
would be about 1/64 liter per minute. This flow is many orders
lower than what will be spilled from a severed 1/16" high-pressure
remote gauge capillary line. Over-pressure relief of the PCR is
intrinsic of its design.
During times of over pressure by means of the regulator not limiting to the specified pressure, the pneumatically operated control
valve then acts as a pressure relief valve where the oxygen from
the cylinder will be safely vented through the over-pressure fitting
outlets of the installed system.
1
Basic PCR System Operation
Basic PCR system configuration
Special considerations with the on/off control
switch:
The PCR (Pnuematically Controlled Regulator)
has three (3) main parts:
1) The PCR unit with on/off control switch
2) The oxygen source (Tank / Cylinder).
3) Oxygen plumbing & outlets
1
B
ON
A
While the switch is in the ‘ON’ position a very small
fraction of oxygen pressure from the regulator is used
to hold the low-pressure valve open.
The control switch operates the low-pressure valve on
the PCR to allow oxygen to flow to the oxygen station
outlets it does not turn the high-pressure supply of
oxygen on & off. It is not intend to be the main turn-off
for the high pressure of the cylinder used. The PCR
has a minute amount of weepage under operating
pressure, therefore, the main cylinder valve must be
turned off during times of storage to mitigate cylinder
drainage.
OFF
The 3-way control switch
option must be ordered if the
PCR system will be used in a
pressurized aircraft.
2
B
A
3
1800
2200
1000
124
500
69
152
35
207 3000
PSI bar
MH
3 0 0
OXYGEN
SUPPLY
USE NO
2
OIL
Basic PCR Components & Suggested Installation Layouts
Optional remote gauge & fill station kit includes:
L Qty
01 1
02 1
02a 1
03 1
04 1
Description
MH-300 gauge with rear-mount bezel & fitting kit (for AL & KF cylinders)
25’ coil of 1/8” OD copper line tubing kit (Standard issue)
25’ coil of 1/16” OD stainless-steel ‘capillary-line’ tubing kit. (Optional upgrade)
Basic remote oxygen fill-station kit. Can be upgraded to the deluxe fill, (right).
SCD and instruction inserts for all items in this kit.
Optional
MH-300 Remote
pressure gauge
ON
Optional
Remote Fill
Stations
OFF
1800
1000
2200
124
500
69
152
35
207 3000
PSI bar
MH
3 0 0
OXYGEN
SUPPLY
USE NO
OIL
1800
2200
1000
124
500
69
152
35
207 3000
PSI bar
M
H
3 0 0
OXYGEN
SUPPLY
USE NO
OIL
3
Basic PCR Components & Suggested Installation Layouts
ON
B
A
The 3-way control switch
option must be ordered if the
PCR system will be used in a
pressurized aircraft.
OFF
1800
1000
2200
124
500
69
152
35
207
PSI bar
3000
MH
3 0 0
OXYGEN
SUPPLY
USE NO OIL
1 6
1 4
2 0
1 8
2 2
ALTITUDE
2 4
1 2
1 0
5
2 8
A34-2ip
B
A
PILOT STATION MUST BE FREE-FLOW TYPE OUTLET
ALL OTHERS MUST HAVE CHECK VALVES
B
A
HP
IN
1800
124
69
LP
IN
LP
OUT
2200
1000
500
152
35
207
PSI bar
3000
MH
3 0 0
OXYGEN
SUPPLY
USE NO OIL
4
OFF
Place the A34 between the outlet of
the PCR and station outlets to regulate
the flow to all stations with cannulas
and facemasks.
PILOT STATION MUST BE FREE-FLOW TYPE OUTLET
ALL OTHERS MUST HAVE CHECK VALVES
2 6
X 1 0 0 0
MH
The PCR regulator
compliments the A34!
ON
B
A
Basic PCR Components & Suggested Installation Layouts
The use of an optional pulse oximeter (see below) may be
used to determine optimum settings in unique situations
such as with persons who are elderly and/or are known to
have respiratory issues.
The PCR regulator
system can be used with
virtually any
oxygen cylinder with a
CGA-540 valve.
Use the EDS O2D1 or O2D2,
MH3 or MH4 with the
PCR regulator system.
FlightStat
by NONIN
CheckMate by SPO
MH-3 With
Oxymizer
MH-4 With
Facemask
5
Cannulas and Face Masks
Cannula
Oxymizer Cannula
Standard Avator type cannulas are
compatable with the MH-4 flowmwter
and aare specifically selected to
operate with the standard flow protocol of 1 liter per minute per 10,000 ft.
to operate with the PCR system.
They complement the physiological
needs of a person for flight operations from sea level to the edge of
class-A airspace, 18,000 ft. The
Aviator cannulas are silicone molded
with a 1 meter length of high quality
PVC tubing and fitting. They fit to the
face with a set of over-the-ear feed
tubes to accommodate almost any
face. Beards and mustaches will not compromise the delivery
properties of cannulas in general. However, even the slightest
amount of nasal congestion
can. Therefore, it is advisable Standard
that a face mask be used in
tip
the event of such problem.
The Oxymizer cannula is specifically calibrated to operate with
the MH-3 flowmeter and is compatable wit the PCR system.
In most
Flared
cases the
tip
standardtip cannula suits
the
needs of most people, while the flare-tip type
may be needed to fit a large person or one
that has large nasal openings. Standard-tip
cannulas are issued by default unless otherwise stated at time of purchase.
Cannulas are a personal device and should not be shared
between persons. In addition, it is the only item in the system that should be replaced frequently, because even with
the best cleaning efforts, bacteria and such can contaminate cannulas and pose a health risk.
Head-Set Boom Mounted Cannula
Our optionally available
MH E-Z-Flow
Boom Cannula is a
head-set mountable
cannula system that
can be used with the
PCR system.
Face masks
should be on
board in the
event someone should
develop nasal
congestion
where a nasal
c a n n u l a
would
fall
short in performance.
Alps Face Mask (with or without microphone)
Oxygen admission port with
swivel quick
disconnect
fitting
Oxygen feedtube to
distributor
unit
Voice port
or optional
Microphone
Ambient air
admission
port
Expiratory
valve
port
The Alps face mask is compatable with the MH-4 flowmeter to
complement the physiological needs of a person for flight operations from sea level through pressure altitudes up to 25,000 ft.
They have a four-point detachable clip system with two independently adjustable straps to accommodate almost any face. Beards
and mustaches will compromise the sealing properties of face
masks in general. These face masks can be cleaned with mild
detergents and water.
The Alps face masks have a
voice-port so vocal communication
is possible without mask removal.
The microphone of a head-set can
be placed close to the voice-port
Alps
and used with satisfactory results.
microphone
The Alps face mask can be
ordered with an optional noise canceling electret-condenser microphone & cord set compatible with
most com & audio systems in place of the voice port. Please specify during ordering.
The Alps face mask comes in three sizes: medium, small and
large. In most cases the medium and small fit most women, while
the medium and large fit most men. The medium size face mask
is issued by default unless otherwise stated at time of purchase.
6
7
A
B
C
D
SAE-4
AUX PORT-1
4
3
MAIN REG.
FIXED
PRESSURE OF
1 BAR (15 PSIG
@ 20 L/MIN
VALVE
CLOSED
MAIN
VALVE
D.E.
N.C.
PORT 'A'
PORT 'B'
PORT-C
PORT-B
AMB
3
S1
COM
A
06-12-05
B
PLM
PORT 'A': FEED TO CONTROL SWITCH (10-32)
N.C.
S2
N.O. (AMB)
B
S4
±0.010
±0.005
±0.002
ANGLES
± 0.5°
FRACTIONS
± 1/64
PLM
ENGINEER:
2
APPR:
05-19-04
PLM
DRAWN:
DATE
05-19-04
DATE
ISSUED:
INTERPRET GD&T PER ASME 14.5
0.X
0.XX
0.XXX
(FMT REV C)
63
UNLESS OTHERWISE SPECIFIED DIMS ARE IN INCHES.
TOLERANCES ARE:
S3
MAIN SUPPLY TO STATIONS
TO PORT-A ON PCR (RED/ORN)
TO PORT-B ON PCR (YEL)
SERVICE PORT TO CONTROL SWITCH (RED/ORN)
00
SIZE A
DWG. #:
1
SHEET 1 OF 3 DO NOT SCALE DRAWING
REV B
MOUNTAIN HIGH
E&S CO.
REDMOND, OR. USA
IN THIS DRAWING / DOCUMENT
PER MH DOC: ESR-001
[ KC ] NUMBER OF KEY CHARACTERISTICS
S6
ON
OFF
SCHEMATIC PCR
THIRD ANGLE
PROJECTION
S5
7.65 mm (3.014)
B
A
ADDED CORRECT PORT MARKINGS
CONTROL ORIFICE WILL BE IN FITTING
1
NOTES
REFLECTING SMALLER FORM-FACTOR
INITIAL RELEASE
REVISION HISTORY
SERVICE PORT, FROM CONTROL SWITCH (YEL)
FLOW CONTROL ORIFICE INTEGRATED INTO BODY OR FITTING
PORT-A
PLM
01-02-05
PLM
E . C . O . / APPR.
DATE
05-19-04
A
REV
2
PORT 'B': RETURN FROM CONTROL SWITCH (10-32)
PORT 'C': BSPP TO 6 MM ELBOW TUBE OUTLET FITTING
OPTIONAL REMOTE GAUE & FILL STATION: AUX HP-1 (SAE-4)
CGA-540 (DIN-477)
MAIN INLET PORT
TO CYLINDER
VALVE
OPEN
INLET PRESSURE: 0-207 BAR (0-3000 PSIG.)
OUTLET PRESSURE: 1 BAR ± .125 (~15 PSIG.)
MAX. OUTLET FLOW: 50 L / MIN @ ~1 BAR
PNEUMATICALLY
CONTROLLED
OXYGEN SUPPLY
REGULATOR
PCR
4
A
B
C
D
D
C
B
A
4
P CR
PNEUMATICALLY
CONTROLLED
OXYGEN SUPPLY
REGULATOR
VALVE
OPEN
INLET PRESSURE: 0-207 BAR (0-3000 PSIG.)
OUTLET PRESSURE: 1 BAR ± .125 (~15 PSIG.)
MAX. OUTLET FLOW: 50 L / MIN @ ~1 BAR
SAE-4
AUX PORT-1
PORT-A
AMB
PORT-B
OUTLET
3
3
PORT 'A'
PORT 'B'
PORT C
B
COM
PORT 'C' FROM THE
CONTROL SWITCH
MUST BE VENTED TO
AREA WHERE THE PCR
RESIDES IF IT RESIDES
OUTSIDE OF THE
PRESURIZED CABIN
N.C.
N.O.
01-05-07
03-21-07
MO-DA-YR
PLM
PLM
E . C . O. / APPR.
2
A
REV
A
N.C.
PLM
05-01-07
REVISION HISTORY
C
1
NOTES
N.O.
7.65 mm (3.014)
COM
00
OFF
MOUNTAIN HIGH
E&S CO.
REDMOND, OR. USA
IN THIS DRAWING / DOCUMENT
PER MH DOC: ESR-001
[ KC ] NUMBER OF KEY CHARACTERISTICS
A
DWG. #:
SIZE
1
SHEET 1 OF 1
DO NOT SCALEDRAWING
REV A
SCHEMATIC PCR PRESSURIZED APP
THIRD ANGLE
PROJECTION
ON
INITIAL RELEASE
CORRECTED CALL-OUTS FOR CONTROL SWITCH
B
CONTROL ORIFICE WILL BE IN FITTING
PORT 'A': FEED TO CONTROL SWITCH (10-32)
MAIN SUPPLY TO STATIONS
PORT 'B': RETURN FROM CONTROL SWITCH (10-32)
A
C
ORIG:
05-01-07
05-01-07
PLM
DATE
PLM
ENG:
NAME
2
APPR:
DRWN:
PRESSURIZED
ON
APPLICATIO
SERVICE PORT, FROM CONTROL SWITCH (YEL)
SERVICE PORT TO CONTROL SWITCH (RED/ORN)
FLOW CONTROL ORIFICE INTEGRATED INTO BODY OR FITTING
MAIN OUTLET BSPP TO 6 MM ELBOW TUBE OUTLET FITTING
OPTIONAL REMOTE GAUE & FILL STATION: AUX HP-1 (SAE-4)
N.C.
D.E.
MAIN
VALVE
MAIN SUPPLY TO STATIONS
VALVE
CLOSED
MAIN REG.
FIXED
PRESSURE OF
1 BAR (15 PSIG
@ 20 L/MIN
CGA-540 (DIN-477)
MAIN INLET PORT
TO CYLINDER
4
D
C
B
A
8
9
A
B
C
D
SAE-4
AUX PORT-1
4
CGA-540 (DIN-477)
MAIN INLET PORT
TO CYLINDER
MAIN
VALVE
D.E.
N.C.
OUTLET
PORT-B
AMB
PORT-A
MAIN SUPPLY TO STATIONS
A PORT: NC
MAIN REG.
FIXED
PRESSURE OF
1 BAR (15 PSIG
@ 20 L/MIN
PCR
PORT A:
NC
PORT B:
COM
4
C PORT: NO
3
SWITCH
'A'
S1
PORT B: COM
SWITCH
'A'
B PORT: COM
3
04-11-07
-
S2
S4
04-11-07
04-11-07
MO-DA-YR
PLM
PLM
NAME
ENG:
APPR:
2
04-11-07
PLM
DRWN:
S5
00
MOUNTAIN HIGH
E&S CO.
REDMOND, OR. USA
IN THIS DRAWING / DOCUMENT
PER MH DOC: ESR-001
[ KC ] NUMBER OF KEY CHARACTERISTICS
S6
PORT C: N.O. (AMB)
PORT A: N.C.
OFF
ON
SIZE
A
DWG. #:
1
SHEET 1 OF 1
DO NOT SCALE DRAWING
REV -
SCHEMATIC FOR PCR DUAL-SEAT
THIRD ANGLE
PROJECTION
PORT B: COM
NOTES
1
PORT C:
NO
(AMB VENT)
SWITCH
'B'
SWITCH
'B'
B
A
INITIAL RELEASE
REVISIONHISTORY
DUAL-SEAT
APPLICATIO
ON
S3
PLM
E . C . O . / APPR.
ORIG:
PORT C: N.O.
PORT A: N.C.
A PORT: NC
B PORT: COM
MO-DA-YR
REV
2
A
B
C
D
625 SE Salmon Ave. Redmond, OR. 97756-8696 U S A
800-468-8185 World Voice: 541-923-4100 World Fax: 541-923-4141 www.mhoxygen.com
PCR-001-00
rev 2