Allied Chemetron 4000 Series Manual

4000 SERIES
AUTOMATIC SWITCHOVER
MANIFOLD
Operation & Maintenance Manual
Allied Healthcare Products, Inc.
1720 Sublette Avenue - St. Louis, MO 63110
Telephone: [phone] - Fax: [phone]
Catalog No. S188-354-001 Rev. B
MANIFOLDS ARE AVAILABLE FOR THE FOLLOWING GASES:
OXYGEN
CARBON DIOXIDE
NITROGEN
MEDICAL AIR
NITROUS OXIDE

Table of Contents
Subject
Page
Introduction
1
Key Elements
2
Manifold Operation
3-4
Factory Settings
3
Schematic Diagram
4
Flow Charts
5
Site Selection
6
Installation
7
Manifold Outline
8
Method Of Operation
10
Safety Features
11
Remote Alarm Wiring Diagram
13
Leak Test
14
Ordering Information
15
Repair Parts List
16
Trouble Shooting
17-18
Limited Warranty
Back Cover

WARNING
ALL PRESSURE ADJUSTMENTS SHALL BE MADE BY AUTHORIZED PERSONNEL ONLY.
INCORRECT PRESSURES CAN DISRUPT GAS DELIVERY TO LINE.
WARNING
THE MANIFOLD SYSTEM MUST BE LOCATED IN A WELL VENTILATED AREA. NITROUS OXIDE
CAN CAUSE UNCONSCIOUSNESS AND DEATH. OXYGEN AND N2O AND CAN GREATLY
INTENSIFY A SPARK OR FIRE. CARBON DIOXIDE AND NITROGEN
CAN CAUSE SUFFOCATION.
CAUTION
DO NOT APPLY HEAT TO DELIVERY LINE UNION WHILE IT IS CONNECTED TO THE
CONTROL UNIT. HEAT WILL HARM O-RINGS CAUSING LEAKS AND MALFUNCTIONS.
WARNING
DO NOT USE THREAD SEALANT ON ANY JOINT OR UNION. MOST SEALANTS CONTAIN
HYDROCARBONS THAT CAN BE IGNITED BY HIGH PRESSURE OXIDIZING GASES.
WARNING
KEEP HANDS AND ALL PARTS CLEAN AND FREE OF OIL, GREASE OR ANY HYDROCARBON
COMPOUND. HYDROCARBON COMPOUNDS CAN BE IGNITED BY OXIDIZING GASES.
CAUTION
DO NOT ATTEMPT TO RETROFIT THE CONTROL UNIT TO ACCOMMODATE OTHER
GASES THAT THE CONTROL UNIT WAS NOT DESIGNED FOR.
WARNING
EACH CONTROL UNIT IS DESIGNED FOR USE WITH A SPECIFIC GAS AS INDICATED ON THE
CONTROL UNIT. ANY ATTEMPTS TO ALTER ITS USE COULD RESULT IN SERIOUS
INJURIES & FAILURE OF THE CONTROL UNIT.
CAUTION
THE HEALTH CARE FACILITY MUST HAVE PROCEDURES IN PLACE TO INSURE
THAT DEPLETED CYLINDERS ARE REPLACED AS SOON AS POSSIBLE TO
ASSURE A FRESH BANK AWAITS THE NEXT BANK SHIFT.
WARNING
SUDDEN RELEASE OF HIGH PRESSURE GAS CAN CAUSE BODILY INJURY.
ALWAYS BLEED DOWN PRESSURE SLOWLY. ALWAYS WEAR SAFETY
GLASSES WHEN CHANGING CYLINDERS OR SERVICING UNIT.

Introduction
The dual line regulator 4000 Series Medical Gas Manifold has been cleaned, tested and prepared at the factory for the
specific gas indicated. The unit complies with the National Fire Protection Association (NFPA) standard 99 “Health
Care Facilities”. All critical connections are gas specific and are designed to eliminate supply gas errors.
This manual is supplied to give the health care facility personnel installation, operation and maintenance instructions.
Keep this manual with the manifold for convenient reference.
The dual line regulator/single vent 4000 Series Medical Gas Manifold will need right and left header bars and pigtails
that must be ordered separately. The installed system will automatically switch to the reserve bank when the primary
bank is depleted. When the depleted cylinders are replaced with full ones the system will automatically reset itself in
preparation for the next bank change. The primary side is the bank in use and the reserve side is the bank on
“Reserve”. This designation will automatically change from left to right and right to left as each bank is depleted and, in
turn, refitted with full gas cylinders.
The empty LED indicator will show a depleted bank by turning red. When the system is reset, by replacing the depleted
cylinders, the indicator will turn yellow. If the manifold is connected to the health care facility’s central alarm system that
will also indicate that the bank was depleted and, in turn, reset.
The only manual activity the 4000 Series Medical Gas Manifold requires is the changing of the depleted cylinders.
The 4000 Series Manifold is available in five standard models, each specifically designed for its gas service. The gas
standard services offered are: oxygen, nitrogen, nitrous oxide, medical air and carbon dioxide.
Manifolds may be obtained in these gas services as standard units. The manifold unit and header bar sections can be
ordered complete by calling your Allied Sales Representative. Header bar sections can also be obtained by ordering the
number and type needed to complete the manifold from the list on Page 15. NFPA requires at least the number of
cylinders for an average twenty-four (24) hour day’s supply per bank, with a minimum of two cylinders per bank.
There are two methods of mounting the 4000 Series Manifold; either floor or wall (standard) systems. With the wall
type, the manifold is attached to a wall bracket and cylinders stand next to the wall. The floor type may stand free, in
the center of a room, with the manifold supported on a stand. The customer is responsible for design and
manufacturing of the floor type stand.
Three pressure gauges on the front of the control cabinet indicate left bank, right bank and line pressures.
Primary pressure regulator heaters are included on nitrous oxide and carbon dioxide 4000 Series Manifolds.Regulator
frosting may cause pressure fluctuations.
WARNING
REGULATORS MAY FREEZE UP IF THEY ARE USED AT HIGH FLOW RATES OR IN LOW
TEMPERATURES WITHOUT A HEATER.
Definitions
Shall:
Is intended to indicate a requirement as stipulated by a standard or code.
Should:
Is intended to indicate a recommendation or a suggestion or an item of advice, but not required.
Note:
Is intended to indicate additional information that will be helpful.
Caution:
Is intended to indicate that there is a slight chance of bodily injury or property damage. There is also the possibility
of a manifold shutdown if the “Caution” is not heeded. This will be highlighted by an outline box.
Warning:
Is intended to indicate that there is a moderate chance of bodily injury, death or property damage. This will be
highlighted by an outline box.
1

Manifold Key Elements
2
RIGHT BANK
HIGH PRESSURE
REGULATOR
PNEUMATIC
SWITCHING
VALVE
LINE
PRESSURE
GAUGE
LINE
OUTLET
EXHAUST
VENT
BALL
VALVE
CHECK
VALVES(NOT
SHOWN)
RIGHT LINE
PRESSURE
REGULATOR
POWER
SUPPLY
LEFT BANK
HIGH
PRESSURE
GAUGE
RIGHT BANK
HIGH
PRESSURE
GAUGE
SOLENOID
VALVE LT.
BANK
SOLENOID
VALVE RT.
BANK
LEFT BANK HIGH
PRESSURE
REGULATOR
SERVICE LINE
PRESSURE
RELIEF
LEFT BANK
INLET
VALVE
RIGHT
BANK
INLET
VALVE
LEFT LINE
PRESSURE
REGULATOR
AC POWER
CONNECTION
PC BOARD
CHECK
VALVES(NOT
SHOWN)

Key Elements
1. A pressure control manifold that maintains constant pressure to the pipeline and enables smooth uninterrupted
switchover from the “in use” to the “reserve” cylinders.
2. A 115VAC 0.2 Amps / 230 VAC 0.1 Amps input, 5/15 VDC output power supply. Power supply includes dry
contacts for local and remote alarm connections.
3. Control panel indicator LED’s indicate the status of the left and right cylinder banks. The “In Service” is
indicated by the green LED while the reserve cylinder bank is indicated by the yellow “Reserve Ready” LED. A
red “Replace Empty Cylinders” LED indicates a depleted cylinder bank.
4. Individual pressure gauges allow monitoring of left and right cylinder bank pressure, and, pipeline delivery
pressure.
5. Master valves used to shut off gas in emergency situations, should normally be left open.
6. Physical properties of manifold:
Dimensions (In inches):
25” H x 16-5/8” W x 6 “ D
Weight:
60 LBS Without Header Bars
Factory Settings
.
Relief Valve Settings
Supply Line
75 PSI
All gases except nitrogen
Supply Line
225 PSI
Nitrogen
High pressure
regulators
325 PSI
All gases
Regulator Settings
High Pressure
Regulator
250 PSI
All gases except Nitrogen
275 PSI
Nitrogen
Low Pressure
Regulator
55 PSI
All gases except Nitrogen
180 PSI
Nitrogen
WARNING
ALL PRESSURE ADJUSTMENTS SHALL BE MADE BY AUTHORIZED PERSONNEL ONLY.
INCORRECT PRESSURES CAN DISRUPT GAS DELIVERY TO LINE.
3

WARNING
ALL PRESSURE ADJUSTMENTS SHALL BE MADE BY AUTHORIZED PERSONNEL ONLY.
INCORRECT PRESSURES CAN DISRUPT GAS DELIVERY TO LINE.
Schematic Piping Diagram
Schematic Piping Diagram
4

Flow Charts –4000 Manifold
4000 SERIES MANIFOLD (ALL GASES EXCEPT NITROGEN)
OUTLET PRESSURE SET AT 55 PSI
Pressure - vs- Flow
30
35
40
45
50
55
15 20 25 30 35 40 45 50 55 60 65 70
Flow Rate (SCFM)
Outlet Pressure (PSI)
4000 SERIES MANIFOLD (NITROGEN)
OUTLET PRESSURE SET AT 180 PSI
Pressure - vs- Flow
30
80
130
180
230
15 20 25 30 35 40 45 50 55 60 65 70
Flow Rate (SCFM)
Outlet Pressure (PSI)
5

Site Selection
The proximity to the health care facility’s central piping system is the obvious, but not the only reason for choosing an
installation site. Ventilation, temperature extremes, etc. must also be considered. Refer to NFPA 99 for specific
location requirements.
The manifold system shall be installed in a well ventilated area. None of the gas specific manifolds are designed for a
flammable gas. Some of the gases will actively support combustion. The gases with high oxidizer content, such as
oxygen and nitrous oxide, shall never have grease, oil, or other combustibles come in contact with any part of the
system. Also, tools and hands shall be kept clean and free of oil or grease. Spontaneous combustion may occur.
There shall be no open flame in the manifold area. This includes matches, smoking material, pilot lights, etc. There
shall be no spark generating equipment in the manifold area. This includes motors, switches, etc.
Even a gas as apparently harmless as nitrogen must be installed in a well ventilated area. If the nitrogen gas were
allowed to build up to a point, in an unventilated area, where all the oxygen was pushed out, then a person entering this
area would run the risk of suffocation. Carbon dioxide is the primary waste gas the lungs try to exhale. The carbon
dioxide in the blood must be removed before oxygen can be absorbed. Carbon dioxide inhaled in the air inhibits the
lungs availability to remove carbon dioxide from the blood. As the carbon dioxide concentration increases so does
breathing difficulty. In the extreme case, a high concentration of carbon dioxide can cause the equivalent to suffocation
even with some oxygen present.
Nitrous oxide is an anesthetic gas. It can cause unconsciousness and even death.
WARNING
THE MANIFOLD SYSTEM MUST BE LOCATED IN A WELL VENTILATED AREA. NITROUS OXIDE CAN
CAUSE UNCONSCIOUSNESS AND DEATH. OXYGEN AND O2/CO2 < 7% CAN GREATLY INTENSIFY A
SPARK OR FIRE. CARBON DIOXIDE AND NITROGEN CAN CAUSE SUFFOCATION.
The health care facility’s central forced air heating and air conditioning system should never have a return duct
connected to the manifold area. The manifold area should always be vented to the outside away from any intake
ducts. Refer to NFPA 99.
The manifold is designed to operate in a temperature range between 40° and 130°F. Relative humidity should not
exceed 90%. If the humidity is high and the temperature is low, frost and/or ice could interfere with the performance of
the regulators.
Allied Healthcare Products, Inc. (Allied) includes a set of heaters as standard equipment with carbon dioxide and
nitrous oxide control units that will preheat gas from the cylinders minimizing the frost problem.
Since carbon dioxide and nitrous oxide are both liquid when in the compressed gas cylinder, the phase change (from
liquid to gas) cooling is added to the gas expansion cooling. Thus the frost will form much quicker with carbon dioxide
and nitrous oxide than with nitrogen, oxygen, and medical air. Under extreme conditions of high flow, the cylinders
could become chilled to the point where droplets of liquid would pass down stream and harm the manifold and other
health care equipment.
Site selection should also take into consideration the handling convenience of the manifold and access to the loading
docks. In the case of carbon dioxide and nitrous oxide the temperature shall not go below 65°F.
6

Uncrating
All parts should be kept in their crates until they are needed for assembly. Check the gas type of the components to be
sure they are the items ordered.
If damage is discovered during the uncrating and assembly process, contact the freight carrier and make a concealed
damage report within seven (7) days. Allied will assist the claims process as much as possible, but it is the
responsibility of the receiver to file any claims.
Minimum Equipment Needed
One Control Unit and a pair of corresponding cylinder header bars with pigtails is the minimum equipment needed to
have a functioning manifold system. NFPA 99 requires a minimum of two cylinders per bank. Always install a
balanced set of header bars for each manifold system, i.e. an equal number of cylinders per bank.
Adding header bars and gas cylinders to each bank will not increase the maximum flow rate of the system, but it will
increase the time between cylinder changes, i.e. double the number of cylinders (and header bars) and the time
between cylinder changes will be doubled.
Installation
The 4000 Series Manifold meets the provisions of the National Fire Protection Association (NFPA) standard.
Control Unit
The Control Cabinet is designed to be water resistant, but it is not waterproof. The Control Cabinet should be mounted
in a location protected from moisture. Suitable anchoring bolts and washers will be necessary for mounting (bolts are
not furnished with the unit, 7/16” diameter bolts are recommended). The Control Cabinet must be mounted to a sound
structure that is designed to handle the weight of the Control Cabinet. Keep the cabinet both horizontally and vertically
level. If necessary, shim behind the back side. Since the Manifold Cabinet cover can be removed from the wall
mounted main panel, the possibility of mixing up cabinets covers with different main panels exists. Both the main panel
and manifold cabinet cover are labeled with a gas specific label and should be matched and returned to it’s original
manifold.
Plumbing
Connect the delivery line union, located at the top center of the Control Unit, to the health care facility’s central piping
system. NFPA requires that a main shut off valve be installed between the manifold delivery line and the central piping
system.
Be sure that the right and left header bar valves are turned off. Later in these Installation Instructions you will be
advised when and how these valves should be used.
7

Manifold Outline
Approximate floor space needed to install manifold and cross header bar sets.
Cylinder
Overall Width
Cylinder
Overall Width
1 X 1
17 inches
9 X 9
73.5 inches
2 X 2
22 inches
10 X 10
94 inches
3 X 3
22 inches
11 X 11
94 inches
4 X 4
42.5 inches
12 X 12
114.5 inches
5 X 5
42.5 inches
13 X 13
114.5 inches
6 X 6
63 inches
14 X 14
125 inches
7 X 7
63 inches
15 X 15
125 inches
8 X 8
73.5 inches
8

CAUTION
DO NOT APPLY HEAT TO DELIVERY LINE UNION WHILE IT IS CONNECTED TO THE CONTROL UNIT.
HEAT WILL HARM O-RINGS, CAUSING LEAKS AND MALFUNCTIONS.
Check for proper venting to atmosphere as required by job specifications and/or NFPA 99, If the manifold is installed in
an enclosed area, the safety relief valves must be vented to the outside atmosphere. On top of the control unit (to the
right of the hospital supply line) a safety relief valve with a 1/4” NPT threaded fitting has been provided to attach a vent
pipe. Provisions must be made to install this pipe to the outside atmosphere.
Electrical
The Manifold 4000 comes with a power supply that can accommodate either 115 VAC, 0.2 Amps or 230 VAC, 0.1 Amps power
input. See Wiring Diagram on page 13. The circuit board will display the status of the pressure in both banks with 3 LED's per
bank.
To connect power to the unit, route the incoming power lines through the conduit to the power terminal block. Connect the Neutral
wire to the terminal connection labeled N, connect the Line wire to the terminal connection labeled L connection and the ground
wire to the terminal connection labeled G.
The Manifold board is equipped with 2 Alarm Switch Outputs. These switch outputs are normally closed. If one or both sides are
low, a red LED will turn on and the alarm out put will be set (open) indicating a switch alarm. To use the outputs in conjunction
with the Impact Alarm system, connect the Manifolds AO1 or AO2 to one of the Impact Alarm 10 switch signal module SI inputs
and the Manifolds corresponding Gin to the Impact Alarm's corresponding GO input.
The Manifold circuit board will also monitor the pressure in both banks to detect a Double Drain condition, where gas is flowing
from both banks. If this condition is detected, the alarm output will be set and the primary sides green LED will be on while the
secondary's green LED will flash off and on.
Initialization
When you power up the Manifold for the first time. First connect power to the system. Both red LED's should turn on. Pressurize
one side, this will be the primary side, it's green LED will then turn on. Pressurize the other side and then its yellow LED will turn
on this is the secondary side.
In the event of a power failure the manifold will continue to operate properly but there will be no LED indications and there will be
no Alarm Signal outputs. Once power is returned the circuit board will assume that there has not been a switch over, thus which
ever side was the primary before the power failure will remain the primary. The software will monitor the pressure on both sides
and if the secondary is dropping but not the primary it will switch to the correct primary.
Header Bars
Divide the total quantity of header bar sections into two groups, one for the left bank and the other for the right bank of
cylinders. There should be an equal number of cylinder inlets on each side of the manifold.
After the Manifold has been mounted, the header bars should be securely anchored to the wall (or Header Stand Kit)
and carefully aligned and leveled. The union on each side of the bottom of the Manifold provides for a gas specific
header bar connection. Proper alignment is necessary to assure a leak free installation. Support all header bars with
firmly anchored wall brackets (or Header Stand Kits).
Space the wall brackets (or Header Stand Kits) to conform to the side of the header bars. The first wall bracket (or
Header Stand Kit) on either side of the Manifold should be between the first two cylinder connections closest to the
Manifold. A wall bracket (or Header Stand Kit) should be placed every third cylinder connection thereafter. If the
manifold system purchased has two or less cylinder connections per side, no wall brackets (or Header Stand Kits) are
needed.
9

WARNING
DO NOT USE THREAD SEALANT ON ANY JOINT OR UNION. MOST SEALANTS CONTAIN
HYDROCARBONS THAT CAN BE IGNITED BY HIGH PRESSURE OXIDIZING GASES.
Connect the header bar assembly to the master header valve fitting on the Control Unit. Use one wrench on the
Manifold inlet connection and another on the header gas specific nut. Hold the Manifold inlet connection steady and
tighten the header nut. This will prevent any twisting of internal components of the Manifold. Twisting of internal
components may cause leaks.
Check the alignment and level of the Manifold and header brackets. If there is an alignment problem loosen all the
header bar mounting hardware. Adjust as needed and tighten.
Cylinder Pigtails
Allied offers two styles of flexible pigtails: coiled copper (oxygen and nitrous oxide) and braided stainless steel (nitrous
oxide and all other gases). Refer to the Optional Equipment Section or contact your Allied Sales Representative. The
braided pigtail offers greater ease of handling the gas cylinders. Both styles of pigtails have built-in check valves. The
pigtail end that has the check valve is denoted by stamping on one of the flats of the CGA gas specific nut and/or a
label indicating direction of flow. The direction of flow is from the cylinder to the header bar. NFPA 99 requires copper
pigtails for Oxygen service.
Note: When installing the pigtails to the header bars be sure to note the flow direction of the pigtail.
Cylinders
Before pressuring the header bars, make sure all pigtails are properly connected. Remove the protective cylinder caps
from the cylinders and store in a safe place for later use. Place and secure the cylinders in position. Connect each
pigtail to a cylinder and tighten with a wrench.
For additional information regarding the handling of gas cylinders, refer to the Compressed Gas Association (CGA)
Pamphlet P-2, Section 4.1 for General Rules, Section 4.2 for Moving Cylinders and 4.3 for Storing Cylinders.
WARNING
KEEP HANDS AND ALL PARTS CLEAN AND FREE OF OIL, GREASE OR ANY HYDROCARBON
COMPOUND. HYDROCARBON COMPOUNDS CAN BE IGNITED BY OXIDIZING GASES.
Method of Operation
The 4000 Series Manifold delivers a regulated gas pressure through a wide range of flow rates to the health care
facilities central gas piping system. The source of the gas is two banks of high pressure cylinders (usually H size).
When a bank is depleted, the 4000 Series Manifold will automatically switch to the fresh bank delivering an
uninterrupted gas supply to the health care facility. Change over shall be performed by a pneumatic valve contained in
the manifold. In the event of an electrical power failure, no interruption of gas flow will occur. The manifold should not
require any manual resetting or adjustments except for the replacement of depleted cylinders.
Under normal operating conditions, the gas will leave the high pressure cylinders through the pigtails into the header
bars. The pigtails have one way valves (check valves) to allow the replacement of depleted cylinders without gas
pressure back flow into the remaining depleted cylinders on the bank. In the event a safety relief device on an
individual cylinder should activate or a pigtail should leak excessively, the local check valve will also prevent loss of gas
from the rest of the cylinders on that bank.
The gas flows through the header bar to the Manifold. A manually operated shut off valve is installed downstream of
each header bar. There are two of these valves located outside the Manifold, one on the right and one on the left side.
These valves are normally left fully open to allow unrestricted flow of gas from the two cylinder banks. In case of an
emergency, they can be closed to isolate one or both banks.
10

The gas flows through the manually operated shut off valve into the primary regulator. This regulator reduces the high
cylinder pressure to an intermediate pressure. The intermediate pressure gas flows through the pneumatic valve to the
line regulator for its final (line) pressure reduction for use in the health care facility. Two line pressure regulators are
installed in parallel and each is capable of maintaining a constant dynamic delivery pressure at the maximum designed
flow rate of the system. Only one line regulator is in service at any given time and the other is held in reserve. The
reserve regulator can be serviced if necessary.
We recommend that the line regulators alternate actively supplying pressure to the piping system on a monthly basis.
This means that each line regulator will have one month of active service followed by one month of rest.
Pressure relief valves are installed down stream of all pressure regulators and are set at no more than 50% above the
setting of the pressure regulator located immediately upstream. All the pressure relief valves are capable of fully
relieving the pressure at the set point. All pressure relief valves are piped together to allow for the installation of a
single vent line leading outside.
The pneumatic valve is the key “automatic” mechanism in the 4000 Series Manifold. It is the bank switching control
that assures the uninterrupted flow of gas at an unfluctuating delivery pressure. When the operating bank pressure
falls to a predetermined level, the pneumatic valve automatically switches to the fresh (reserve) cylinder bank.
CAUTION
ALL PRESSURE ADJUSTMENTS SHALL BE MADE BY AUTHORIZED PERSONNEL ONLY.
INCORRECT PRESSURES CAN AFFECT CYLINDER BANK SWITCHING AND RESETTING
WHICH CAN DISRUPT GAS DELIVERY.
The 4000 Series Manifold control cabinet has two means of providing continuous status information on the system.
First, pressure gauges to indicate the bank pressures and the delivery pressure. Second, six (6) indicator LED’s: two
(2) green that indicate cylinder in use, two (2) yellow for Reserve Ready and two (2) red that indicate that a bank is now
depleted.
Bank Change-Over Indicators
The six (6) indicators are controlled by sensing the bank pressure. Replacing the depleted cylinders resets the system,
changing the indicator from red to green. At the same time the yellow LED will change to green when going from
“Reserve” to “in Service”.
Alarm Systems
Allied Healthcare Products, carries a complete line of alarm systems which can be used in conjunction with the 4000
Series Manifold, to provide the required visual and audible signals, when bank switching occurs.
For remote alarm electrical connection, use Electrical Wiring Diagram shown on page 13. The 4000 Manifold System,
when used in conjunction with these alarm systems, complies with CSA Z305.1-M1984. However, since these alarm
systems are external to the manifold, they are not dealt with in detail in this manual.
Safety Features
Each 4000 Series Manifold is clearly labeled for the only gas it is designed to deliver. A large nameplate is affixed to
the cabinet. The system is gas specific from the Manifold to the cylinder end of the pigtails.
11

Function Identification
The bank LED’s and pressure gauges on the cabinet face are clearly marked to explain their function.
The 4000 Series Manifold header bars are designed to assure that only cylinders containing the proper gas can be
connected to them. All header bar connections and pigtails comply with CGA Standards.
CAUTION
DO NOT ATTEMPT TO RETROFIT THE CONTROL UNIT TO ACCOMMODATE OTHER GASES THAT THE CONTROL
UNIT WAS NOT DESIGNED FOR.
WARNING
EACH CONTROL UNIT IS DESIGNED FOR USE WITH A SPECIFIC GAS AS INDICATED ON THE
CONTROL UNIT. ANY ATTEMPTS TO ALTER ITS USE COULD RESULT IN SERIOUS INJURIES
AND FAILURE OF THE CONTROL UNIT.
CAUTION
THE HEALTH CARE FACILITY MUST HAVE PROCEDURES IN PLACE TO INSURE THAT DEPLETED
CYLINDERS ARE REPLACED AS SOON AS POSSIBLE TO ASSURE A FRESH BANK AWAITS THE
NEXT BANK SHIFT.
WARNING
SUDDEN RELEASE OF HIGH PRESSURE GAS CAN CAUSE BODILY INJURY. OPEN VALVES SLOWLY.
ALWAYS BLEED DOWN PRESSURE SLOWLY. ALWAYS WEAR SAFETY GLASSES WHEN CHANGING
CYLINDERS OR SERVICING UNIT.
12

Wiring Diagram
TO RIGHT BANK
SOLENOID VALVE
2 #18 GA TO 2ND MASTER ALARM PANEL "RESERVE IN USE" ALARM
2 #18 GA TO MASTER ALARM PANEL "RESERVE IN USE" ALARM
TRANSDUCER
BLACK-LINE
RED
LEFT BANK
TRANSDUCER USE ONLY
FOR FUTURE
RIGHT BANK
AO2
OUTPUTS
LBS
RBS
OPS
AO1 GIN1
LEDS
GIN2
POWER SUPPLY
GREEN-GROUND
WHITE-NEUTRAL
LBV
DC POWER
FROM
YELLOW
LEDS
LEDS
GREEN
RBV
SOLENOID VALVE
TO LEFT BANK
TERMINAL
BLOCK
POWER
SUPPLY
MANIFOLD PC BOARD
115V AC-0.2A
50/60 HZ
AC POWER CONNECTION
230V AC-0.1A
13

Leak Test
In order to determine whether any leaks exist between header bar sections or at the central pipe system connection,
the system must be pressurized. Either oil-free dry air or oil-free dry nitrogen may be used for new installations. In the
case of either a medical air or nitrogen 4000 Series Manifold, the actual service gas may be used to perform the leak
tests. In the case of oxygen, nitrous oxide or carbon dioxide 4000 Series Manifolds, the actual service gases are not
suitable for leak testing due to their inherent dangerous properties.
The following steps should be followed to leak test the 4000 Manifold:
1. Shut off the flow at the outlet of the pressure control cabinet.
2. Shut off all cylinders supplying pressure to the supply headers.
3. Monitor pressure on the three gauges on the pressure control cabinet.
4. If any of the gauges drop in pressure, a leak is occurring.
5. Leaks may be detected audibly, or an approved leak detector solution may be used.
6. If a leak detector solution is used to detect leaks inside the pressure control cabinet, use caution to ensure the
solution does not get into electrical components.
7. If leaks are detected, bleed all pressure from the manifold before repairing the leak.
8. Leaking joints utilizing metal-to-metal seals should be disassembled and examined. If dents, scratches, or other
damage to the seals are the cause of the leak, the damaged components should be replaced and the manifold
connection properly reassembled.
9. Leaking joints utilizing pipe threads should have the threaded component removed, the old tape removed, and
new Teflon tape applied to the threads. The component should then be re-installed, the manifold re-pressurized,
and then re-tested for leaks.
10. Leaking joints utilizing o-ring seals should be disassembled and the o-ring examined. If the o-ring is cut, dented,
or otherwise damaged, the o-ring should be replaced, the joint reassembled, the manifold re-pressurized, and the
joint retested for leaks.
11. All leaking components must be repaired or replaced.
All joints must be pressure tested again using the above procedures.
When there are no leaks, bleed the system and remove the test cylinders, pigtails and gas adapters. The system is
now ready to accept cylinders of the proper gas and service the health care facility needs.
If gas conversion adapters were used to test the manifold system, it is important that the gas conversion adapters and
the nitrogen or medical air pigtails be removed from the area. Every precaution must be taken to prevent hazardous
gas mixing by accidentally using these test adapters. Each manifold shall be tested for proper gas supply prior to
system use.
14

Ordering Information
The 4000 Series Manifold has two (2) outlet (line) regulators and one (3) safety relief vent. The 4000 Series Manifold
will shift banks automatically and will automatically reset when the depleted cylinders are replaced.
MAIFOLDS:
Catalog Numbers
System
Gas
86-71-2100
Control Unit Only
Oxygen
86-73-2100
Control Unit Only
Nitrous Oxide
86-74-2100
Control Unit Only
Medical Air
86-75-2100
Control Unit Only
Carbon Dioxide
86-76-2100
Control Unit Only
Nitrogen
A complete system must have one Control Unit and one pigtail per cylinder and one header bar inlet per cylinder.
Header bars must be used in pairs to assure a balanced system, i.e. right and left banks with an equal number of
cylinders. For your convenience, we have balanced sets of header bars available see Table below.
HEADER BARS:
NUMBER OF
CYLINDERS
OXYGEN:
COPPER
PIGTAIL
NITROUS
OXIDE:
COPPER
PIGTAIL
NITROUS
OXIDE:
FLEX
PIGTAIL
MEDICAL
AIR:
FLEX
PIGTAIL
CARBON
DIOXIDE:
FLEX
PIGTAIL
NITROGEN:
FLEX
PIGTAIL
1X1
86-71-0102
86-72-0102
86-73-0102
86-74-0102
86-75-0102
86-76-0102
2X2
86-71-0104
86-72-0104
86-73-0104
86-74-0104
86-75-0104
86-76-0104
3X3
86-71-0106
86-72-0106
86-73-0106
86-74-0106
86-75-0106
86-76-0106
4X4
86-71-0108
86-72-0108
86-73-0108
86-74-0108
86-75-0108
86-76-0108
5X5
86-71-0110
86-72-0110
86-73-0110
86-74-0110
86-75-0110
86-76-0110
6X6
86-71-0112
86-72-0112
86-73-0112
86-74-0112
86-75-0112
86-76-0112
7X7
86-71-0114
86-72-0114
86-73-0114
86-74-0114
86-75-0114
86-76-0114
ELBOW ASSEMBLIES
Allows header bars to negotiate corners when space is not sufficient for complete manifold to be mounted to wall.
Elbow measure: 3” X 4”
Catalog Numbers:
86-51-1007
O2
86-53-1007
N2O
86-54-1007
Medical Air
86-55-1007
CO2
86-56-1007
N2
15

Repair Parts List
Catalog No.
Description
Gas
Qty. Per Kit
86-90-3041
High Pressure Relief Valve
All
1
86-90-3042
Line Pressure Relief Valve
Nitrous Oxide, Carbon Dioxide, Medical Air & Oxygen
1
86-90-3043
Line Pressure Relief Valve
Nitrogen
1
86-90-3001
High Pressure Hand Valve
Oxygen
1
86-90-3002
High Pressure Hand Valve
Nitrous Oxide
1
86-90-3003
High Pressure Hand Valve
Medical Air
1
86-90-3004
High Pressure Hand Valve
Carbon Dioxide
1
86-90-3005
High Pressure Hand Valve
Nitrogen
1
86-90-3044
0-5000 PSI Back Mount Gauge
All
1
86-90-3045
0-100 PSI Back Mount Gauge
All Except Nitrogen
1
86-90-3046
0-300 PSI Back Mount Gauge
Nitrogen
1
86-90-3047
0-600 PSI Back Mount Gauge
All
1
86-90-3048
Solenoid
All
1
86-90-3014
High Pressure Regulator
All
1
86-90-3027
Line Pressure Regulator
All Except Nitrogen
1
86-90-3029
Line Pressure Regulator
Nitrogen
1
86-90-3049
Check Valve Complete
All
1
86-90-3026
3-Way Ball Valve Complete
All
1
86-90-3050
Diaphragm
All
1
86-90-3051
PCB, Electronic Circuit Board
All
1
86-90-3052
Power supply
All
1
86-90-3053
On/Off switch
All
1
86-90-3054
Fuse Holder
All
1
86-90-3055
Fuse, 3 Amp
All
1
86-90-3057
Wire Harness, Power Supply
All
1
86-90-3058
0-3000 PSI, Pressure Transducer
All
1
86-90-3059
Thermostat
Nitrous Oxide, Carbon Dioxide
1
86-90-3060
Heater Assy. w/ extra spade connector
Nitrous Oxide, Carbon Dioxide
1
86-90-3061
Heater Assy. w/o extra spade connector
Nitrous Oxide, Carbon Dioxide
1
86-90-3028
Line pressure regulator repair Kit
All
1
86-90-3018
High pressure regulator repair Kit
All
1
16

Trouble Shooting
This section is intended to serve as a general guide for identifying the potential functional problems which could occur
in the operation of the manifold.
Only some minor checks and repairs are recommended to be made in the field.
Components removed from the manifold system for maintenance must be serviced, repaired and tested by properly
qualified medical service personnel only. Original manufacturer’s parts, as supplied by Allied, must be used in the
maintenance of manifolds.
Trouble
Probable Cause
Remedy or Check
0-5000 PSI Gauge not showing
pressure
Empty gas cylinders
Replace empty tanks
Inlet valve closed
Open inlet valve
Gauge failure
Replace faulty gauge
Continuous flow of gas through vent
line exhaust. (Note: under normal
operation when the cylinders are
replaced and bank is brought back on
line a very small burp of gas will be
vented outside)
Faulty High pressure relief valve
Replace high pressure relief vale
Faulty Line pressure relief valve
Replace line pressure relief valve
Faulty Solenoid
Replace Solenoid
Pressure dropping simultaneously
through both cylinder banks (Note, an
alarm will be indicated by both green
LEDs being lit, one flashing and one
on continuously)
Pneumatic membrane seal not
seated. Gas flowing through both
sides of membrane.
The green LED which stays on
continuously indicates the primary side.
The blinking green LED is the reserve
side. Close the reserve bank inlet valve
and wait approximately 30 minutes until
the membrane seal is made. Then open
the reserve side inlet valve. The yellow
LED, on the reserve side should turn on
indicating normal manifold operation.
Diaphragm failure in Pneumatic
switch
Replace Diaphragm
Solenoid Failure
Replace Solenoid
Check valve Failure
Replace check valve
LED’s don’t light
On/Off switch turned Off
Turn switch to on position
Fuse failure
Replace fuse
Loose wire connection
Tighten wire connection
No power in.
Measure power in to be 115 VAC
Power supply failure
Measure power supply output to be
15VDC
PCB failure
Replace PCB
17