BeaconMedaes HTM02-01 Instruction Manual

Operation and Maintenance Instructions
Emergency Reserve Manifold - ERM
HTM02-01
Part number 2005715
Revision 05
May 24, 2019

Atlas Copco Ltd. trading as Atlas Copco Medical
 Unit18NueldWay,Abingdon,Oxfordshire,UKOX141RL
 Personnelmustmakethemselvesfamiliarwiththecontentsofthismanualandthe
 functionoftheunitbeforeinstalling,operatingormaintaining.
Operation and Maintenance Manual
EmergencyReserveManifold
Thisunitispurchasedfrom:
Datepurchased:
Modelnumber:
Serialnumber:
Option(s)included:
Anyinformation,serviceorsparepartsrequestsshouldincludetheserialnumberandbe
directedto:
BeaconMedæs
TelfordCrescent,Staveley
DerbyshireS433PF
Telephone:+44(0)1246474242
Email:[email protected]
WebsiteContacts:www.beaconmedaes.com
BeaconMedæsreservestherighttomakechangesandimprovementstoupdateproducts
soldpreviouslywithoutnoticeorobligation.
Abbreviations
Abbreviation FullDescription Abbreviation FullDescription
BS BritishStandard kPa Kilopascals
BSP BritishStandardPipe Max Maximum
CO2 Carbondioxide Med Medical
°C Degree Celsius m Meter
ø Diameter mm Millimetres
ERM Emergencyreservemanifold Min Minimum
EN European Standards N2 Nitrogen
1st First N2O Nitrousoxide
HTM HealthTechnicalMemorandum NRV Non-returnvalve
ID Identication OD OutsideDiameter
“Inch O2 Oxygen
ISO InternationalStandardOrganisation % Percentage
Kg Kilograms 2nd Second

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Table of Contents
0. Safety Precautions
1. General Information
2. Installation
3. Commissioning
4. Principles of Operation
5. Maintenance Procedures
6. Component Replacement Procedures
7. Recommended Spares
Figures
1 - ERM General Arrangement
2 - Schematic Diagram
3 & 4 - Typical Installation
5 - Reserve Low Alarm Wiring
6 to 12 - Cylinder header extension
13 - Typical tailpipe and cylinder connection
14 - Relief Valve Inspection
15 - Manifold header Non-Return Valve Inspection
16 - Line Non-return Valve Replacement
17 - Sampling Outlet Replacement
18 - 2nd Stage Regulator Replacement
19 - 1st Stage Regulator Replacement
20 - 2nd Stage Relief Valve Replacement
21 - 1st Stage Relief Valve Replacement
22 - Cylinder Bank Valve Replacement
23 - Cylinder Header Non-return Valve Replace-
ment
24 - Line Pressure Gauge Replacement
25 - Reserve Low Contact Gauge Alarm Wiring
Tables
1 - Relief Valve Set Points
2 - Cylinder Header Extension Kits
3 - Typical pressure settings
4 - Typical cylinder bank changeover pressure.
5 - Sampling Outlet Part Numbers
6 - 2nd Stage Regulator Part Numbers
7 - 2nd Stage Relief Valve Part Numbers
8 - Header Non-return Valve Part Numbers
9 - Line Pressure Gauge Part Numbers
10 - Content Pressure Gauge Part Numbers
11a - Accessories
11b - Spares scheduling

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Not applicable
0.6 Cleaning
The manifold should be wiped over with a damp
cloth frequently to remove any dust or foreign
substances
0.7 Safety Notice
Persons undertaking any installation and/or
maintenance must be fully trained in specialist
work of this nature.
The “PERMIT TO WORK” procedure must be
adhered to for all installations once commissioned.
The manifold is designed and built in accordance
with HTM 02-01 regulations and therefore should
be installed as such.
Oil, grease and jointing compounds must not be
used.
Do not attempt to prove the pressure relief valve,
under any circumstances, by altering the regulator.
Pressure relief valves must be removed and tested
o site by a registered test centre and a certicate
of conformity issued.
0. Safety Precautions
This section gives safety, storage and handling
information for the BeaconMedæs Emergency
Reserve Manifold only. Component parts lists and
descriptions are available on request.
Operators should have carefully read and become
familiar with the contents of this manual before
maintaining the Emergency Reserve Manifold.
Operators are expected to use common sense
safety precautions, good workmanship practices
and follow any related local safety regulations.
0.1 Identication of symbols
The following symbols apply to this product and
are used in these instructions and on the product
in question. The meanings of these symbols are as
specied below: -
Read instructions
Ambient temperature range
Ambient humidity range
Ambient pressure range
Date of manufacture
Do not dispose of in general waste
0.2 Environmental Transport and Storage
Conditions
All products are separately packaged and stored in
controlled conditions.
0.3 Environmental Operating Conditions
Adverse environmental conditions and harsh
abrasives or chemicals may cause damage to the
unit.
0.4 Environmental Protection
Discard the unit and/or components in any
standard refuse facility. The unit does not contain
and hazardous substances.
0.5 Electromagnetic Interference

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1
Figure 1 - ERM General Arrangement (2 x 1
Manifold as standard). Additional Cylinder
Header Extension kits available.
2
The Emergency Reserve Manifold consists of: -
1. 2 x High Pressure Isolation Valves (1 per
cylinder bank.
2. 2 x Cylinder Pressure Gauges with Contact
Alarms (for signalling reserve low alarm fault).
3. 1st Stage Pressure Regulator (c/w inlet lter).
4. 2nd Stage Pressure Regulator.
5. Gauge for Distribution System Pressure.
6. Integral Non-return Valve Assembly.
7. 1st Stage Pressure Relief Valve.
8. Line Pressure Relief Valve.
9. Lockable Isolation Valve.
10. Medical Gas Sampling Test point (GEM 10).
11. Test point Isolation Valve.
12. Pipeline connection point (22mm OD Copper
Tube)
13. Pressure Relief Exhaust Connection point
(28mm OD Copper Tube).
14. Termination Box For Remote Alarm.
15. 2 x Cylinder Manifold Header Block.
16. 2 x Gas Specic Non-return Valve.
17. Product Label C/W Instructions for Use.
18. 4 x Chain Hooks for Cylinder Restraint.
Note: Cylinder Tailpipes are also required but
should be ordered separately. Header extensions
are available but are also ordered separately.
1. General Information
1.1 Introduction
The BeaconMedæs Emergency Reserve Manifold
(ERM) is principally designed for use as a
secondary source of supply, for emergency use or
to permit servicing or repair.
The ERM supplies one of the following Medical
gases to a piped distribution system, Oxygen,
Nitrous Oxide, O2/N2O 50%: 50%, Medical Air,
Surgical Air, Nitrogen & Carbon Dioxide.
See gure 1 for general arrangement and gure 2
for the schematic diagram.
3
4
5
6
7
8
9 (Shown in Open Position)
10
11 (Shown in Closed Position)
12
13
14
15
16
17
18
(VALVE ‘B’)
(VALVE ‘1’) (VALVE ‘2’)
(VALVE ‘C’)

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Figure 2 - Schematic Diagram
Additional manifold headers can be connected to
the Emergency Reserve Manifold (ERM) to increase
its gas supply capacity.
The manifold is connected to the distribution
system downstream of the primary medical gas
supply system. The ERM can be isolated from the
distribution system by the lockable isolation valve
supplied. This valve should be left open during
normal operation, so the ERM will automatically
supply the pipeline with medical gas in the event
of the primary system failing to supply.
The line pressure regulator should be set slightly
lower than the primary supply pressure to prevent
the ERM from feeding the pipeline during normal
operation of the primary system.
1.2 1st Stage Pressure Regulator
For safe operation with regard to performance,
mechanical strength, resistance to ignition in pure
high pressure oxygen supply and cleanliness,
the unit fully conforms to BS EN ISO 10524-2. A
pressure relief valve connected to the regulator
protects the downstream pressure and is set a
2000 kPa (20 bar).
1.3 2nd Stage Pressure Regula-
tor
For safe operation with regard to performance,
mechanical strength and contamination the
unit fully conforms to BS EN ISO 10524-2, the
second stage pressure regulator is a manually
set diaphragm type and is used to set the system
pressure to suit typical nominal values for 4, 7 and
11 bar pipeline systems.
1.4 Line Pressure Relief Valve
The line pressure relief valves are preset to
the values shown in table 1 for the dierent
distribution pressures.
Table 1: Relief Valve Set Points
Relief Valve Set Point Nominal Distribution
Pressure
530 kPa (5.3 bar) 400 kPa (4 bar)
1100 kPa (11 bar) 700 kPa (7 bar)
1300 kPa (13 bar) 1100 kPa (11 bar)
The line pressure relief valve is tted between
the pressure regulator and the isolation valve
(just before the integrated non-return valve),
thus protecting the delivery system from over
pressurisation by discharging to atmosphere in the
event of regulator failure.
1.5 Header Extension For Addi-
tional Cylinders
The ERM is suppled as standard with cylinder
connections for a 2x1 manifold (1 cylinder per
bank).
The ERM can be upgraded from a 2x2 to 2x6
manifold using the extension kits referenced in
table 2.

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Tabel 2 - Header extension kits
Modular Header Rack Assembly 2X1
Modular Header Rack Assembly 2X2
Modular Header Rack Assembly 2X3
Modular Header Rack Assembly 2X4
Modular Header Rack Assembly 2X5
Modular Header Rack Assembly 2X6
Gas Type 2x1 2x2 2x3 2x4 2x5 2x6
Oxygen 8102371280 8102371281 8102371282 8102371283 8102371284 8102371285
Nitrous
Oxide 8102371286 8102371287 8102371288 8102371289 8102371290 8102371291
Entonox
O2/N2O 8102371292 8102371293 8102371294 8102371295 8102371296 8102371297
Medical Air 8102371298 8102371299 8102371300 8102371301 8102371302 8102371303
Nitrogen 8102371304 8102371305 8102371306 8102371307 8102371308 8102371309
Carbon
Dioxide 8102371310 8102371311 8102371312 8102371313 8102371314 8102371315

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2. Installation
2.1 Installation procedure for
Panel.
CAUTION: Ensure no contaminates, oil
or grease come into contact with any of the gas
connection/internals.
2.1.1 Unpack and inspect all items for damage.
2.1.2 Check wall for suitability.
 CAUTION:Suppliedxingsareforuse
with solid masonry walls only. Alternative
xingtypesarenotsuppledwiththeunit.For
securing to alternative wall types, ensure that
1.6 Halogen Free Components
The ERM contains NO HALOGENATED polymers
located in the gas stream that may experience
pressurised oxygen in excess of 3000 kPa (30 Bar)
in normal operation or single fault condition, as
recommended for safe practise of the medical gas
pipeline system.
wall structure and selected fasteners are suitable
for supporting the 16 kg weight of the ERM.
2.1.3 Identify the centre position of the ERM on
the wall and mark.
2.1.4 Drill wall and t wall plugs. Screw the ERM
to the wall, checking that it is rmly attached. See
gure 3 & 4 for typical mounting heights.
2.1.5 Loosely connect the supplied ø22mm OD
stub pipe (Item 12, gure 1) to the main pipeline
isolation valve (Item 9, gure 1). Do not t the
O’ring seal till after brazing.
2.1.6 Braze the pipework using the uxless
brazing technique with nitrogen purge.
CAUTION: Ensure the brazed connection
point is isolated from any other pipeline source
of supply.
2.1.7 Undo the securing nuts on the stub pipes
and insert the ‘O’ ring supplied into the connection
grooves and tighten.
Figure 3 - Typical Installation For Use With ‘J’ &
‘G’ Type Cylinder

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2.1.8 The pipework should be secured to the
wall using munsen rings (not supplied). It would
be recommended to t the rst pipe support to
the supplied ø22mm OD stub pipe (Item 12, gure
1). The next support should typically be tted
within 2m of the rst.
2.1.9 The ø28mm exhaust line (Item 13, gure
1) shall be brazed using uxless brazing technique
with nitrogen purge.
 CAUTION:Theø28mmexhaustline(Item
13,gure1)needstobepipedawayfromthe
manifold room to a safe location to prevent
buildup of waste gas in an enclosed space in the
event of a regulator failure.
CAUTION: Do not reduce the diameter of
thepipeusedfortheexhaustline.
Note - ‘J’ type cylinders typically for Oxygen and Medi-
cal Air.‘G’ type cylinders typically for Nitrous Oxide
and N2O/O2 mix (Entonox).
 CAUTION:Suppliedxingsareforuse
with solid masonry type walls only. Typical ERM
weight is 16kg.
Note - ‘VF’ size cylinders typically used for CO2
Figure 4 - Typical Installation For use with ‘VF’
Type Cylinders
 CAUTION:Suppliedxingsareforuse
with solid masonry type walls only. Typical ERM
weight is 16kg.

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Figure 5 - Reserve Low Alarm Wiring
Left bank
contact gauge
(pre-wired) 1
2
2
1
3 4
3 4
Right bank
contact gauge
(pre-wired)
5 6
5 6
To primary supplies
“Reserve Low” alarm input
(Wired on sight)
2.2 “Reserve Low” alarm wiring.
2.2.1 Use a at bladed screw driver to pop the
terminal cover at the corners.
2.2.2 Wire the reserve low alarm as shown in
gure 5. (Left and right bank contact gauges are
pre-wired)
2.3 Installation procedure for
Modular Manifold Header.
CAUTION: Ensure that all the header rails
supplied are the correct gas type. The gas ID is
stampedontotheatsectionoftheNRVcaps.
2.3.1 Cylinder Header Extension Kits (upgrade
to 2x2 manifold). See gure 6 and 7.
2.3.1.1 Remove the 3/8” BSP blanking plug and
bonded seal from the end of the header block and
t 3/8” x 5/8” BSP tting (supplied with kit) com-
plete with O-ring seals for connection of the exten-
sion header.
2.3.1.2 Oer cylinder support rack up to the
header rail and secure using the M6 x 16 hex head
set screws and ange nut supplied with the exten-
sion kit.
2.3.1.3 Secure the previously tted 5/8” connector
to the extension header.
2.2.1.4 If no more header extensions are to be
tted, blank o the end of the header with the 3/8”
BSP plug and bonded seal that was removed in
step 2.3.1.1.
2.3.1.5 Mark and drill the optional extension
bracket wall mount if required. Fit the wall plug
and secure with the No. 10 pan head supplied with
the kit.
 CAUTION:Suppliedxingsareforuse
with solid masonry type walls only. Typical
extensionbracketis1.5kgperside.

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Figure 7 - Typical cylinder header extension
layout details (upgrade to 2 x 2), extension kits
from table 2.
Figure 6 - Cylinder header extension tting de-
tails (upgrade to 2 x 2) 3/8” x 5/8 BSP
C/W seals
3/8” BSP plug and
bonded seal
Header Extension
Wall mounting
holes x 4

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2.3.2 Additional Cylinder Header Extensions
(upgrade to 2 x 3 plus manifold). See gure 8 to
12.
CAUTION: Ensure that all the header rails
supplied are the correct gas type. The gas ID is
stampedontotheatsectionoftheNRVcaps.
2.3.2.1 Remove the 3/8” BSP blanking plug and
bonded seal from the end of the header block and
t 3/8” x 5/8” BSP tting (supplied with kit) com-
plete with O-ring seals for connection of the exten-
sion header.
2.3.2.2 Line up the header connection, mark
mounting hole positions and drill. Fit the wall plug
and secure with the No. 10 pan head supplied with
the kit.
2.3.2.3 Secure the previously tted 5/8” connector
to the extension header.
2.3.2.4 Repeat 2.3.2.1 & 2.3.2.3 for any additional
header extensions.
2.3.2.4 If no more header extensions are to be
tted, blank of the end of the header with the 3/8”
BSP plug and bonded seal that was removed in
step 2.3.2.1.
 CAUTION:Suppliedxingsareforuse
with solid masonry type walls only. Typical
extensionbracketis2.5kgperside.
Header Extension
3/8” x 5/8 BSP
C/W seals
3/8” BSP plug and
bonded seal
Figure 8 - Cylinder header extension tting
details (upgrade to 2 x 3 plus)
4 x wall mounting holes

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Figure 10 - Typical cylinder header extension layout details (upgrade to 2 x 4), extension kits from
table 3.
Figure 11 - Typical cylinder header extension layout details (upgrade to 2 x 5), extension kits from
table 3.

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Figure 12 - Typical cylinder header extension layout details (upgrade to 2 x 6), extension kits from
table 3.
NOTE - For additional cylinders continue to add the dimensions of the last header kit from either gure 9
or 10 for either single or double racks.
2.4 Cylinder Connection
CAUTION: Ensure that all the tailpipes
supplied are the correct gas type. The gas ID
is stamped onto the nut that connects to the
header non-return valve.
2.4.1 Connect the tailpipes to the non-return
valves on the header racks as shown in gure 13.
2.4.2 Refer to hospitals/site policy for safe
cylinder handling (See section 4.6 for typical
cylinder handling safety check list), move the
cylinders into place (see gures 3, 7, 9-12) ready
for connection to the tailpipes.
CAUTION: Only persons who have had
specictraininginthesafetyofmedicalgases,
manual handling techniques and cylinder
changing procedures should be allowed to
change cylinders on medical gas manifolds or
medical equipment.
2.4.3 Connect the cylinders to the pin indexed
clamp on the tail pipe, as shown in gure 13.
Ensure the bodok seal is in place at the opposite
side to the thumb screw on the pin index clamp
before connection.
NOTE - Pipe index tailpipes to BE EN ISO 21969 are
supplied as standard. Alternative connection types
are available on request.
2.4.4 See section 4.7 for cylinder operation
procedure
2.5 Installation check
2.5.1 Ensure that all tailpipes are connected to
the cylinders and manifolds on both sides and
that the restraint chains are secure around the
cylinders.
2.5.2 Isolate the panel from the pipeline using
isolation valve ‘B’ (shown in gure 1).
2.5.3 Ensure that the left-hand bank high-
pressure isolation Valve ‘1’ (Figure 1) is fully open
by turning anticlockwise, and the right-hand high-
pressure isolation valve ‘2’ (Figure 1) is fully closed
by turning clockwise.
2.5.4 Using 1 cylinder, slowly pressurise
the left-hand bank (see section 4.7 - Cylinder
operation). The left-hand contents gauge should
indicate full cylinder pressure. The distribution
system pressure gauge on the regulator (adjust
as necessary) should read typically as per table 4
(Section 4 - Principle of Operating).
CAUTION: It would be recommended to
set the ERM line pressure at least 0.2 bar below
the main supply source pressure at full design
owtoensuretheemergencymanifolddoes
not supply the pipeline during normal primary
source operation.
2.5.5 Check for leaks. Now ensure all left-hand
bank cylinders are closed.
2.5.6 Open valve ‘C’ and relieve the pressure
from within the ERM from the sampling outlet
then close valve ‘C’ (Item 10 & 11, Figure 1).

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Figure 13 - Typical tailpipe and cylinder connec-
tion
Bodok Seal
Typical
tailpipe with
pin index
clamp
Header non-return valve
Tailpipe to
non-return valve
connection
2.5.7 Repeat the 2.6.3 to 2.6.6 for the right-hand
cylinder bank.
2.5.8 Check the reserve low alarm is connected
as shown in gure 5.
2.5.9 The installation must now be purged
as per HTM 02-01 for UK installations, or as per
relevant standards if installed outside the UK.

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3. Commissioning
3.1 General
Commissioning of the ERM must be carried
out in full after initial installation. The object of
the commissioning procedure is to ensure that
all components are serviceable and that the
overall system is operable and set to the correct
distribution pipeline pressure. Suitably qualied
competent personnel who are familiar with this
manual must only undertake commissioning of the
ERM.
3.2 Preparation
3.2.1 Ensure that all tailpipes are connected to
the cylinders and manifolds on both sides and
that the restraint chains are secure around the
cylinders.
3.2.2 Ensure that the outlet pipe from the ERM is
connected to the distribution system of the same
gas service, downstream of the main supply unit
and isolation valve ‘A’ (shown in gure 2).
3.2.3 Ensure that the ERM isolation valve ‘B’
(shown in gure 1) is tted and in the closed
position.
3.2.4 Open all cylinder valves on the ERM.
3.2.5 Fully open the high-pressure isolation
valves 1 and 2 (shown in gure 1).
3.2.6 Check connections on the headers,
tailpipes, regulator and associated pipework for
leaks.
3.2.7 Fully close the right-hand high-pressure
isolation valve 2 (gure 1 & 2).
3.3 Pressure Checks
3.3.1 Ensure that full gas cylinder pressure is
shown on the cylinder contents gauges (Fitted to
valve 1 & 2, see gure 1).
3.3.2 With Valve ‘B’ closed and valve ‘C’ open,
exhaust a quick blast of gas from the sampling
outlet, close valve ‘C’. Check that the pressure on
the pipeline distribution pressure gauge is typically
as per table 4. Adjust as necessary.
Note...For reducing the pressure set point, ensure
valve ‘B’ is closed and sampling outlet isolation
valve ‘C’ is open. Gently bleed the gas from the
sampling outlet while making adjustments, as the
4. Principles of Operation
4.1 General
The ERM line pressure is set below the normal
operating range of the primary supply. While the
primary supply is functioning within it’s design
limits, the ERM will not feed gas into the pipeline.
If the primary supply fails, causing the pipeline
pressure to fall to the ERM’s set point it will
automatically start feeding gas to the pipeline.
Table 3: Typical pressure settings for HTM02-
01 primary and emergency medical gas
supply system, during normal pipeline system
operation.
Pressure (Bar)
Nominal System Design 4 7 11
Max. Static Pressure Primary
Supply
4.6 8.2 11.5
Min. Dynamic Pressure Primary
Supply
4.2 7.4 10.3
Max. Static Pressure ERM 4.0 7.2 10.0
Min. Dynamic Pressure ERM 3.5 6.5 9.0
Note - Table 4 shows typical examples. These
gures may dier depending on the hospital’s
pipeline management policy.
CAUTION: It would be recommended to
set the ERM line pressure at least 0.2 bar below
the main supply source pressure at full design
owtoensuretheemergencymanifolddoes
not supply the pipeline during normal primary
source operation.
The recommended setup of the ERM is to have the
left hand bank open and ready to come online and
the right hand bank closed.
In the event of the primary system failing to
supply (Awareness of the Primary supply failure is
typically from central alarm system) the ERM line
regulator (see gure 1) can be manually increased
to match the primary supply’s nominal values, so
that the full distribution pressure is restored.
regulators is a none relieving type. Always leave
valve ‘C’ closed when nished.
3.3.3 Check that the line pressure does not vary
outside of the requirements of the installation
(see table 4, Section 4 - Principle of Operating, for
typical values).
3.3.4 Complete the steps in section 4.2 -
Procedure to prime ERM, to bring the ERM online.

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When the ERM is in operation there is provision for
an alarm output to warn when the running bank
contents is typically below half. The ERM contents
gauge should then be locally monitored. The Bank
valves can be used to cycle the left and right banks
allowing for empty cylinders to be changed while
keeping continues supply to the pipeline.
CAUTION: The following procedures
4.2 to 4.7 are only typical guides, where there
areconictswiththehospital’semergency
procedure,thehospital’spolicieswilltake
precedence.
4.2 Procedure to prime ERM.
4.2.1 The following procedure must be carried
out once the commissioning (section 3) is complete
and the system is ready to be put into use.
4.2.2 Ensure the high-pressure isolation valve
on the left-hand bank is fully open, the right-hand
bank isolation valve is closed, and all cylinder
valves on both banks are fully closed. Correct as
required, see section 4.7 Cylinder Operation.
4.2.4 Ensure the connecting pipeline is ready for
use. Slowly open the line valve ‘B’ (Item 9, gure
1).
4.3 Procedure when mains sup-
ply fails.
4.3.1 The following steps relate to gure 1 & 2,
and detail how to operate the ERM in the event of
the main supply system failing to supply gas at the
correct distribution pressure.
4.3.2 Ensure the ERM line valve ‘B’ is open. Close
main supply line valve (Shown as valve ‘A’ in gure
2).
4.3.3 Ensure that one of the high-pressure
bank isolation valve is fully open, the other bank
isolation valve is closed, and all cylinder valves on
both banks are fully closed. Correct as required.
4.3.4 The pressure regulator will be set below
the nominal distribution system pressure. This
should now be increased to the full distribution
pressure by increasing the line regulator setting,
until the correct distribution pressure can be
obtained.
4.3.5 Once the ERM is in operation there is
provision for an alarm output to warn when the
running bank contents is typically below half.
The ERM contents gauge should then be locally
monitored for cycling the cylinder banks for
continuous supply (see section 4.4 for bank cycling
procedure).
4.4 Procedure to cycle banks &
changing cylinders.
4.4.1 Refer to hospitals/site policy for safe
cylinder handling (See section 4.6 for typical
cylinder handling safety check list) when moving
the cylinders into place ready for connection to the
tailpipes.
4.4.2 When the running bank pressure falls to
the pressure for changing cylinder (for typical
changeover pressures see table 5). Slowly open the
standby bank isolation valve (see gure 1). With
the standby bank now operating as the running
bank, close the high pressure isolation valve and
cylinder valves for the empty cylinder bank.
Table 4: Typical cylinder bank changeover
pressure.
Nominal Supply
pressure
Typical Cylinder changeover
4 Bar 15 Bar (50 Bar Cyl. and Below)
4 Bar 20 Bar (137 Bar Cyl. and above)
7 Bar 30 Bar
11 Bar 30 Bar
Note - Values in table 5 are only for reference
as a typical guide, refer to hospital emergency
procedure policy.
4.4.3 For the empty cylinder/s disconnect the
tailpipe from the cylinder (see gure 13) by either
undoing the handwheel or unscrewing the nut
at the cylinder end, depending on the cylinder
connection type.
4.4.4 Replace the empty cylinder/s and reconnect
the tailpipes. Slowly open the cylinder valves (see
section 4.7 - Cylinder operation.
4.4.5 Repeat this section each time the running
bank drops to the changeover pressure until the
main supply is fully operational.
4.5 Procedure to reinstate main
supply.
4.5.1 The following steps detail how to reinstate
the mains supply once it has been returned to
normal operation.
4.5.2 Slowly open valve ‘A’ (See gure 2).
4.5.3 Complete the steps in section 3, followed by
4.2

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4.6 Typical Cylinder Handling
Checklist
CAUTION: Only persons who have had
specictraininginthesafetyofmedicalgases,
manual handling techniques and cylinder
changing procedures should be allowed to
change cylinders on medical gas manifolds or
medical equipment.
• Safety shoes should be worn at all times. When
moving larger cylinders, wear heavy protective
gloves (preferably textile or leather). Keep all
items clean and grease/oil free.
• Do not smoke or use naked lights.
• When handling smaller cylinders, the use of
protective gloves may be inconvenient. Extra
care should be taken to avoid injury and to
make sure that hands are free from oil or
grease BEFORE the cylinders are handled.
• Do not knock cylinders against each other or
other solid objects.
• Do not drop or drag the cylinders.
• Do not use cylinders as rollers or wheel
chocks.
• Do not lift any cylinder by its valve or cap
• Use appropriate trolley for larger cylinders.
4.7 Cylinder Operation
CAUTION: Undue force should not be
used to open or close cylinder valves, or to attach
connectors to cylinders.
CAUTION: ALL cylinder valves should be
opened gently. TAPPING the operating key GENTLY
with a soft-faced (copper) mallet is acceptable but
undue force should not be used. If it is obvious
that injury or damage could arise from trying
to open a sticking valve, the cylinder should be
removed from service and returned to the supplier
as a faulty cylinder.
CAUTION: Opening cylinder valves SLOWLY
will prevent a sudden rise in pressure in the
system. It is at this time when there will be most
stress on components and when most explosions
will occur due to adiabatic compression of any oil
or grease that may be present.
4.7.1 The cylinder valve should be FULLY opened
(slowly, anticlockwise) using the appropriate
cylinder key or handwheel where tted and then
turned clockwise a quarter turn.
CAUTION: If there is any leakage of gas
the cylinder should be removed from service and
returned as faulty. DO NOT attempt to tighten
gland nuts etc, as this may cause damage to the
valve.
4.7.2 To close the valve, turn the spindle or
handwheel clockwise. Hand pressure only should
be used to close the valve.
5. Maintenance Procedures
A competent person who is conversant with
the maintenance of high-pressure medical gas
installations and any special national conditions,
which may apply, must carry out all maintenance.
Preventative maintenance contracts are available
from BEACONMEDÆS for installations within the
U.K., overseas distributors will be able to supply
similar contracts in other areas.
WARNING: OBTAIN A WORK PERMIT
(OR EQUIVALENT FOR OVERSEAS) BEFORE
COMMENCING ANY WORK ON A MEDICAL GAS
INSTALLATION.
5.1 Daily Inspection
5.1.1 Check visual indicators for correct function
and damage.
5.1.2 If the ERM is observed to be in operation
on its “emergency reserve” bank, replacements
for empty cylinders should be made available
immediately.
5.1.3 Check manifold pressure gauges for
abnormal conditions.
5.1.4 Check ERM for unusual noises or
vibrations.
5.2 Weekly
5.2.1 Check that all cylinders are properly
secured and that batch labels are correct and in
date.
5.3 Quarterly
5.3.1 Ensure that:
(a) when the duty (primary) manifold is
running the reserve (secondary) manifold cylinders
are full;

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5.3.5 Close one cylinder valve and disconnect
the tailpipe at the cylinder end (see gure
15). Listen for a leak from the tailpipe. A minor
leak is permissible and likely but an obvious major
leak denotes failure of the manifold non-return
valve (NRV). If the latter happens, do not totally
detach the tailpipe but instead retighten it and test
other tailpipes in the same way. Any failed NRV’s
can be replaced (see section 6.8) after all cylinder
valves have been closed and the system has been
depressurised. Repeat this test when the new
NRV’s have been tted (See gure 15 and section
4.7 - Cylinder Operation).
Figure 14 - Relief Valve Inspection
Flat face
connector
with O-ring
seal & swivel
nut
1st stage relief valve
2nd stage relief valve
Figure 15 - Manifold header Non-Return Valve
Inspection.
Tailpipe to
cylinder
connection
Typical Cylinder
Valve
Bodok Seal
(b) all system pressures are normal;
(c) all alarms are showing “green” normal
lamps;
(d) the automatic manifold main isolating
valve is open; and
(e) the manifold is supplying the hospital.
5.3.2 Close the isolating valve on the ERM slowly
and conrm that there is no eect on the line
pressure to the hospital.
5.3.3 Open all cylinder and header high-pressure
isolating valves.
5.3.4 Check that the ERM safety valves are
not passing, by disconnecting their downstream
exhaust coupling and inspecting for a gas leak and
check the condition of the seals (See gure 14).
Replace the valve or seals as necessary. Reconnect
the exhaust pipework, ensure the O-ring seals
correctly in place.
5.3.6 Ensure the line valve ‘B’ is closed and one
cylinder and bank valve on 1 side of the ERM is
open (see gure 1). Open Valve ‘C’ and probe
the sampling outlet to produce a steady ow and
check the pressure on the line gauge does not dip
by more than 10%. If possible attach a owmeter
to the sampling outlet and pipe away to a safe
location while performing this test. Close valve ‘C’
when nished.
 CAUTION:Foranaestheticandoxygen
manifolds ensure that the manifold room is well
ventilated and no potential ignition sources are
present while running this test. Run this test
forasshortatimeaspossible.Oxygencanbe
absorbed into clothing etc., so once the test is
complete it would be recommended to spend at
least20minutesoutdoorstoensuretheoxygen
has released. During this time stay away from
nakedame,donotsmokeetc.Donotperform
this test unless the risks can be kept within an
acceptable level.
5.3.7 Check the static pressure of the regulator
(should be typically as per table 4 in section 4).
Observe this pressure for typically 10-20 minutes
to ensure that there is no regulator creepage.
Excessive creepage will necessitate replacement
(see section 6.3) and a repeat of this test.
5.3.8 To test the “reserve low” contact gauge,
open one cylinder/header isolating valve until the
cylinder content gauge indicates full pressure, and
then close the valve.

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6.0 Component Replacement
Procedures
WARNING: IT IS ESSENTIAL THAT ONLY
GENUINE BEACONMEDÆS SPARE PARTS ARE
FITTED DURING MAINTENANCE.
CAUTION: Ensure no contaminates, oil
or grease come into contact with any of the gas
connection/internals.
Preparation For Component Re-
placement
6.0.1 Ensure the main gas supply system is
functioning correctly and supplying the pipeline.
6.0.2 Close the ERM line isolation valve ‘B’ (See
gure 1). Close all the cylinder and open both
bank valves (see gure 1 and 2).
5.3.9 Open Valve ‘C’ and carefully bleed gas from
the sampling outlet.
5.3.10 Observe the falling pressure on the contact
gauge.
5.3.11 When the pressure falls to 14 bar for 100
bar scale, and 68 bar for the 315 scale gauges the
contact will provide an open signal, initiating a
“Reserve Low” alarm on the primary alarm system.
Should this not occur replace the contact gauge
(See section 6.10).
5.3.12 Repeat steps 5.3.8 to 5.3.11 for the
opposite contact gauge. Close valve ‘C’ when
nished.
5.3.13 Finally, tighten all joints, open all cylinder
valves and perform a leak test on all joints.
5.3.18 Perform the steps in section 4.2 -
Procedure to prime ERM.
5.3.19 The ERM is now ready for use.
5.4 5 Years
Replace the pressure safety valve for a new
certied relief valve, see sections 6.4 & 6.5.
5.5 As Required
Replace tailpipes, pressure safety valve, pressure
regulator, high-pressure isolation valve, isolation
valves, contact gauges, non-return valve etc. as
and when required (see section 6.0 to 6.10).
6.0.3 Open the sampling outlet valve ‘C’, and
probe the outlet to depressurise the system.
 CAUTION:Whenexhaustinganaesthetic
andoxygenmanifoldsensurethatthemanifold
room is well ventilated and no potential ignition
sources are present.
Note - If the cylinder contents gauges are not
rapidly dropping in pressure, stop draining the
system and check all cylinders are correctly
isolated.
6.1 Replace line non-return valve
(P/N: 2005778)
6.1.1 Complete steps in section 6.1 before
carrying out any component replacement on the
ERM.
6.1.2 Slowly turn the swivel nut of the top 1”
connection. If the you hear gas escaping do not
fully unscrew the joint until the system is fully
drained.
6.1.3 Fully disconnect all 4 joints as shown in
gure 16 and gently remove the unit by sliding it
towards you. Take care not to damage the seals.
6.1.4 Inspect the existing seals and replace if
required, see gure 16 for seal part numbers.
6.1.5 Taking care not to damage the O-ring seals
replace the new non-return valve as shown in
gure 16, and fasten the 4 at face joints.
6.1.6 Follow steps in section 6.11 bring the ERM
back online.
Figure 16 - Line Non-return Valve Replacement
3 x 1” at face
connections with swivel
nut and O-ring seal
(Seal P/N: 2000152)
1 x 1/2” at face
connection with swivel
nut and O-ring seal (Seal
P/N: 1823637)