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Instrument Air 

A BeaconMedæs Continuing Education Publication 

A company within the Atlas Copco Group 

®

Notes 

Notes on Using this Pamphlet: 

This pamphlet is presented to assist an engineer or medical facility contemplating the installation of an Instrument Air 

system as countenanced under the NFPA 99 Healthcare Facilities standard, 2005 version. 

Users are cautioned that this pamphlet is intended to be used in conjuction with the standard, which should be 

obtained from: 

National Fire Protection Association 

1 Batterymarch Park 

Quincy, MA 02269-9101 

Phone 1-800-344-3555 

Internet www.NFPA.org 

Users are cautioned to read the pamphlet and the standard carefully, and are encouraged to use the information 

herein as suited to the conditions of their project, where such modification does not conflict with applicable local 

standards. 

This pamphlet only encompasses the requirements of the NFPA 99 through the 2005 version. Please contact 

BeaconMedaes to ensure you are using the most recent version of this pamphlet. 

Any opinions expressed and/or interpretations given or implied are the sole responsibility of BeaconMedaes, and 

should not be relied upon without reference to the NFPA 99 standard and Local Authorities Having Jurisdiction. 

This edition August 2006 

No Previous Editions 

Comments on this booklet or on any aspect of medical gases are welcome and encouraged. Please send to mallen@ 

beaconmedaes.com 

This Pamphlet in both print and electronic versions is Copyright 2006 BeaconMedæs. All Rights are Reserved, and 

no reproduction may be made of the whole or any part without permission in writing. Distribution of the Electronic 

version is permitted only where the whole is transmitted without alteration, including this notice. 

Instrument Air Page

Table of Contents 

Pneumatic power and medicine ………………….… 2 

The purpose and the history of Medical Support gases. 

Why Change ……………………………………….… 3 

Why consider instrument air in lieu of Nitrogen? 

Dollars and Cents …………………………….…… 4 

How to estimate the economics of an instrument air 

system. 

NFPA Rules for Instrument Air …………………….… 4 

What is an instrument air system and what are the 

requirements as found in the standard. 

Design and installation …………………………….… 8 

Design issues with instrument air pipelines. 

Change of Use …………………………………….… 11 

Converting nitrogen pipelines to run instrument air. 

Abstract 

The paper reviews the background of the most recent 

addition to NFPA’s piped gas systems and discusses 

when the use of Instrument Air might be appropriate. 

Also reviewed are the rules for the application. Design 

guidance is provided to allow a system to be sized and 

implemented. 

Pneumatic power and Medicine 

Medical facilities are very familiar with compressed air. A 

typical facility uses any number of individual air systems 

for power and control. These are as diverse as the laundry 

compressor for running the washers and dryers, a sterilizer 

compressor for the autoclaves and decontamination systems 

in central sterile supply and the HVAC compressor for the 

pneumatic controls in the air conditioning system. 

Given how familiar hospitals are with compressed air, it 

seems odd that most North American hospitals of any size 

supply nitrogen into the operating rooms to run surgical 

tools - a task easily within the capabilities of an appropriate 

compressed air system. 

Compressed air systems require only occasional 

maintenance, the air is of course free, and there is no 

management required. By comparison, the nitrogen 

system is an unending hassle. The nitrogen is in cylinders 

or containers which must be purchased, inventoried, and 

changed. Since hustling the cylinders or containers is labor 

intensive, there is always an overhead in costs and labor 

associated with its use. 

Although the nitrogen system could be used for many 

purposes per the NFPA standard, the nitrogen gas is 

relatively expensive so it is not wise to use it for all the 

applications for which it might otherwise be appropriate. 

This leaves a quandary when the facility wants pneumatic 

power in places like the morgue or central sterile supply. 

Often the unsatisfactory solution is to install separate local 

systems, which is expensive and increases the maintenance 

burden. 

Compressed air was in fact the original choice when gas 

- powered tools first came into the operating room, and 

only in North America was compressed air supplanted by 

Nitrogen. The reason for this decision is obscured by time, 

but most likely derives from difficulties with the quality of 

the air available at the time. Piped air was typically wet, 

often oily and sometimes dirty, none of which is good 

for high speed turbine tools. Nitrogen was the driest, 

cleanest gas they could easily substitute, so it became 

the gas of choice. Over time, primarily through received 

knowledge, it acquired the patina of a de facto standard. 

In fact, Nitrogen for tools has never been required by any 

Page Instrument Air

published standard. Nevertheless, Engineers continue even 

today to design, and facilities continue to install, nitrogen 

systems for the driving of surgical tools. 

In most of the world, compressed air never left the O.R. In 

the United Kingdom for instance, it is common to install 

a “7 bar” or “13 bar” surgical air system specifically for 

driving tools alongside the “4 bar” medical air for treating 

patients. 

There is a vestigial holdover from the use of compressed 

air for surgical tools in use in North America even today. 

Surgical tool hoses are still often fitted with a quick 

connect fitting on the end called a “Schræder” connector 

- originally manufactured by the Schræder Automotive 

Division, and used in garages to run their air-powered 

tools (the historic origin of our elegant surgical tools is not 

medical, but industrial). 

Oddly, although the pipelines changed from air to nitrogen, 

Schraeder never did make the change. Even today the 

version of that connector in most common use is stamped 

“Air” - Schræder itself never made a nitrogen-specific 

connector, and only very recently have their successor 

companies created one. 

Although Nitrogen systems have become the general 

standard, there have always been a small number of North 

American facilities willing to question this. These facilities 

have installed air systems to drive tools, following their own 

instincts in light of an absence of guidance in the NFPA 

or CSA standards. The trend has accelerated somewhat 

in the last decade, and in the 2002 edition NFPA for the 

first time included guidance on these systems. Although 

that might make it seem to be something new, in truth it is 

actually a return to something very old. 

When the Instrument Air system first appeared in the 2002 

NFPA 99, there was no Instrument Air terminal unit, and 

thus no outlets, controls or hoses were available. This 

was a problem which prevented many facilities from 

seriously looking at the Instrument Air option. In 2005, 

the Compressed Gas Association resolved this with the 

assignment of the CGA 2080 connection to Instrument Air. 

The only remaining hurdle therefore is the lack of design 

guidance, which this publication should help address. 

Why Change? 

There are two reasons to consider an Instrument Air system, 

and it is important to note that neither is specifically 

medical. In fact, from the medical standpoint, there is very 

little to choose between Instrument Air and nitrogen. Both 

will drive the tools, both (as contemplated by NFPA 99) 

have similar dryness, cleanliness, and operating pressures. 

Except for the costs involved, there is no reason a facility 

could not simply continue to use nitrogen. 

So the most compelling reason to consider an Instrument 

Air system over a Nitrogen system is dollars and cents. 

The cost of operating a nitrogen system can be surprisingly 

high, depending on the amount of nitrogen used. Nitrogen 

sources imply three particular costs: 

1. The cost of the gas itself. 

2. The cost of the demurrage (rental of the cylinders). 

3. The management cost, including the labor involved in 

hustling the cylinders from the dock to the manifold, 

attaching and detaching them, and moving the 

empties back to the dock, plus the management 

involved in keeping track of cylinder inventories and 

reordering). 

While it is possible to reduce these costs in many cases by 

using cryogenic liquid in place of gas cylinders, the costs 

are never completely eliminated, and the installation of 

a large cryogenic source system may be problematic in 

other ways. 

Generally speaking, an Instrument Air system is going to 

be more expensive to purchase than a similar capacity 

manifold or bulk liquid system. However, the Instrument 

Air itself is less costly on a volume to volume basis, so 

the Instrument Air system will pay for itself over time. 

Exactly when the crossover will occur will vary. In some 

cases, the crossover may be so far out that an Instrument 

Air system would be a questionable investment. In other 

cases the payback is so quick that Instrument Air would be 

worth retrofitting even where a nitrogen system is already 

in place. In the next chapter entitled “Dollars and Cents”, 

we give some guidance on how to calculate the crossover 

point for your facility. 

The other reason for considering Instrument Air is the 

variety of applications for which it can be used. NFPA has 

continuously sought to keep medical gas systems separate 

from all other systems and to ensure that the medical gases 

are not compromised by use for other purposes. NFPA 99 

2005 5.1.3.4.2 states “Central supply systems for oxygen, 

medical air, nitrous oxide, carbon dioxide and all other 

patient medical gases shall not be piped to, or used 

for, any purpose except patient care application”. The 

practical effect of this prohibition is found in the Annex 

A.5.1.3.4.2 “Prohibited uses of medical gases include 

fueling torches, blowing down or drying any equipment 

such as lab equipment endoscopy or scopes, or any other 

purposes. Also prohibited is using the oxygen or medical 

air to raise, lower or otherwise operate booms or other 

devices…”. 

Certain of these prohibitions are controversial, but 

the difficulty they cause can be illustrated. Consider 

endosurgical areas or central sterile supply. Here, a gas 

source is desirable to blow out or dry instruments during 


cleaning and sterilization. Medical Air cannot be used 

for this purpose, so the only acceptable alternative has 

been to install nitrogen. Aside from the cost of nitrogen, 

this use implies releasing quantities of Nitrogen into the 

room. Although Nitrogen is itself non-toxic, the release 

of too much nitrogen will dilute or displace the oxygen in 

the air and can cause asphyxiation. Nitrogen is therefore 

not ideal for use in workspace applications such as this, 

whereas Instrument Air is very suitable. 

Applications for Instrument Air are discussed in NFPA 

99 5.1.3.8.2.1: “Instrument Air shall be permitted to be 

used for any medical support purpose (e.g. to operate 

tools, air driven booms, pendants or similar applications) 

and (if appropriate to the procedures) to be used in 

laboratories.” 

Whereas Medical Air is and Nitrogen may be prohibited 

from or undesirable in certain applications, Instrument Air 

may be used for any of them. 

The simple conclusion is that Instrument Air offers a very 

worthwhile design option. It is not for every facility, 

because in some it will not offer benefits sufficient to justify 

the additional up-front costs. But in our studies to date, we 

are surprised how often and at how low a nitrogen usage we 

can justify these systems purely on the money saved. Our 

experience suggests it is an option every facility (including 

facilities already using nitrogen) should at least examine. 

A 

Dollars and Cents 

A decision to use an Instrument Air system will hinge on 

the payback for most facilities. This can be calculated with 

reasonable accuracy if a few questions can be answered. 

Clearly, a facility which has some history with an existing 

nitrogen system will be at an advantage when collecting 

many of these answers, but even while a project is only in 

planning one can make a satisfactory estimate. Detail 4 

is a listing of the data required. Once you have obtained 

this data, your BeaconMedaes Sales Consultant has a pre 

configured spreadsheet which they can use to help you 

calculate the relative costs and system payback. 

NFPA Rules for Instrument Air 

The requirements for Instrument Air sources are found in 

the NFPA 99 under 5.1.3.8, and a few other requirements 

are found throughout the document. 

Instrument Air and nitrogen under the standard are meant 

to be opposite sides of the same coin. Indeed, a simple 

guiding principle for working with these systems is that if 

in doubt, do what you would have done for Nitrogen, and 

you will probably have done the right thing. 

The one place where an Instrument Air system is unique 

is in the design of the source. Instrument Air source 

equipment is unique in it’s form, permitted options and 

operating requirements. An overall view of the components 

of an Instrument Air source under NFPA 99 are shown in 

Detail 5 & 6. 

Detail 4 

Calculating Comparitive Costs for Nitrogen vs. Instrument Air 

Number of cylinders or containers used per Month 

(if you are evaluating a facility which is not yet in operation, see Detail 12) # 

B Cost of each cylinder $ 

C Cost of each Container (if used) $ 

D Cost of cylinder rental (demurrage) per month $ 

E Cost of container rental (demurrage) per month $ 

F 

G 

Labor rate / Hour for the person changing the cylinders or containers 

(include benefits and overhead costs if appropriate) $ 

Estimated time required to complete a standard cylinder or container 

change to ONE side of the manifold, including time to travel to and from the 

manifold location. (If your estimate is in minutes, ÷60 for hours) Hours 

H Labor cost per change $ 

I 

J 

Number of cylinders or containers on ONE side of the manifold. 

(if you are evaluating a facility which is not yet in operation, see Detail X) # 

Other known costs (delivery charges, supplier labor charges, manifold 

maintenance or repair, etc.) Ensure these charges are per month. 

(if you only know overall charges per year, ÷12 for monthly average) $ 

K Cost of Power per kWh ¢ 

L Years for amortization of capital yrs. 

Page Instrument Air

Primary Supply Secondary Supply 

Quality Control Monitoring 

Cylinder 

Header 

(manifold) 

200 psi+ 

Compressor(s) 

Cylinder 

Header 

200 psi+ 

Compressor(s) 

• Medical Air in Cylinders, 

purchased per USP. 

• Oil Separation 

• Dryer for -40° 

• Filtration to 0.01µ 

• Charcoal Odor/Taste Removal 

Detail 5 : Instrument Air Source System configurations (Per NFPA 99 ) 

The particular aspects unique to Instrument Air can be 

summarized: 

1. Compressor Type: A compressor used for Instrument Air 

may be of any type which can produce a pressure greater 

than 200 psig. Instrument Air compressors do not have 

to be oilless or oilfree (unlike compressors for Medical 

Air) but may include lubricated types. This is because 

the high pressure required makes lubrication inescapable, 

and since Instrument Air is not breathed by the patient or 

mixed with oxygen, any oil (should it enter the system) is 

less hazardous. 

The extraordinary pressure requirement comes from the 

need to ensure that the system can emulate the traditional 

nitrogen system, which may operate as high as 185 psig. 

185 psig is the pressure at which the Instrument Air pipeline 

system is designed to operate. Clearly, a compressor with 

a top pressure of 175 psig will not be able to achieve this 

requirement. 

2. Specific Filtration and Purification: Although a 

lubricated compressor is permitted, oil is not permitted in 

the system. Instrument Air sources must have coalescing 

filters to remove liquid oil and activated carbon absorbers 

to eliminate vapor and gaseous oil. A particulate filter is 

also required with a nominal pore size of 0.01µ. 

3. Dry to -40°: Recall that a major reason for the historic 

• Medical Air in Cylinders, 

purchased per USP. 

• Reserve Supply in Use 

• Reserve Low 

• Pressure Low 

• Pressure High 

• Oil indicators on Filter. 

• Dew point Monitoring, 

alarm at -30°C (-22°F) 

• Lag Alarm 

transition to nitrogen was wet air. In applications like 

tool drive, the dryness of the air is particularly significant, 

as the rapid expansion of air in the tools can produce 

adiabatic cooling which can condense moisture where it 

would otherwise never appear. Therefore, unlike medical 

air, Instrument Air must be dried to a nominal -40° dew 

point. This will necessitate desiccant dryers in virtually 

all cases. 

This combination of filters and dryers is intended to produce 

air which will comply with or exceed the specifications 

of the Instrument Society of America standard S-7.0.01 

Quality Standard for Instrument Air. 

4. A secondary or backup system. Unlike other medical gas 

systems, failure of an Instrument Air system is unlikely to be 

fatal. Nevertheless, the system is critical to any number of 

procedures, and if the procedure was suddenly terminated 

the patient(s) could be at risk. Thus a backup, just like any 

other medical gas system, is required. 

Unlike other systems however, the requirement for that 

backup is much less stringent. Uniquely, an Instrument Air 

compressor may include a redundant compressor(s) (similar 

to that required for Medical air) or it may be seconded by 

a bank of cylinders sufficient for one hour’s operation (a 

hybrid configuration). 

The allowance for a cylinder secondary offers a much less 


Elements of an Instrument Air Source 

After NFPA 99 2002 Figure A-5.1.3.8 

Detail 6 : Instrument Air Source Systems (Per NFPA 99 A.5.1.3.8 ) 

Filter with Change Indicator 

Pressure Regulator 

Automatic 

Trap & Drain 

Demand Check 

Pressure 

Indicator 

Outlet 

Isolation 

Valve(s) 

Dew Point 

Monitor 

Demand 

Check 

Check Valve 

Pressure 

Relief 

Valve 

Inlet 

Isolation 

Valve(s) 

Dryer(s) 

D.P. 

Ball Valve 

Automatic 

Trap & Drain 

Aftercoolers 

Legend 

Inlet 

Isolation 

Valve(s) 

Outlet 

Isolation 

Valve(s) 

Source 

Valve 

Inlet 

Isolation 

means 

(valve shown) 

Compressor 

Isolation 

Valve 

Source 

Valve 

Demand 

Check 

Relief 

Valve 

Page Instrument Air 

Aftercooler/ 

air dryer 

Monitoring 

Pressure 

Indicator 

System 

Pressure 

Switch/Sensor 

Check 

Valve 

Air 

Treatment 

& Control 

Receiver 

Relief 

Valve 

Compressor(s) 

Intake(s) 

Reserve 

Source 

Filter 

Outlet 

Isolation 

Valve or Check 

Manual 

Drain 

Inlet 

Isolation 

Valves 

Automatic 

Drain 

Sight 

Glass 

ASME 

Cylinder Reserve 

Header 

5.1.3.4.8 

Charcoal 

Adsorbers 

Regulator 

Change 

Indicators 

Guage 

Pressure 

Relief Valve

expensive option for installing smaller systems, and yet 

does not greatly reduce the operational safety of the system 

overall if properly alarmed. 

Where this cylinder secondary is applied, there is a 

special allowance in the standard for placing the cylinder 

header with the Instrument Air compressor itself. This 

is an exception to the general rule that cylinders are not 

permitted to be in the same room with compressors or 

pumps. It applies only to the active header used to back 

up an Instrument Air compressor. There is no exception for 

loose cylinders, even if those are intended for the Instrument 

Air system, so these must be stored in an appropriate room 

just like all other medical gas cylinders. 

Although Instrument Air systems are clearly intended to be 

compressor driven (otherwise the operating economies will 

be lost) it is possible to use a standard medical gas style 

manifold to source an Instrument Air system as well. 

5. The distribution system for Instrument Air will typically 

be similar to that for Nitrogen, but given it’s many potential 

uses, it may also be significantly more complex. The actual 

design will of course depend on the facility’s convenience 

and preferences. Some options are illustrated in Details 

8-10. 

6. Outlets for Instrument Air must be non interchangeable 

with other medical gases. It is not appropriate to use 

medical air outlets or nitrogen outlets in an Instrument 

Air system, even if they are relabelled. NFPA has three 

requirements for any outlet: 

a. Each outlet for a specific gas must be provided with an 

outlet not interchangeable with any outlet for another 

gas. 

b. That when a single gas is operated at multiple pressures, 

the outlet for each pressure be non interchangeable 

with the outlet for another pressure. 

c. That when an outlet is operated at pressures greater 

than 80 psig, that the outlet be of the DISS (threaded) 

type, or include a pressure interlock to prevent the 

hose from flying out of the outlet when disengaged. 

These requirements taken together mean that the ideal 

Instrument Air outlet is the CGA DISS outlet, and this is 

the outlet BeaconMedæs recommends for all Instrument 

Air terminals, hoses and accessories. 

Detail 7.1 : A pipeline label for Instrument Air Source Type 

Instrument Air Page 

Reserve 

Low 

Reserve 

in Use 

2ndry Header 

Low 

Changeover 

Low 

Press 

High 

Press 

Source 

Cylinder x Cylinder manifold 

Cylinder x Cylinder x Cylinder Manifold 

System 

Fault 

2 ndry 

Header 

2 ndry 

Header 

High 

Water in 

High 

Water in 

Thermal 

Shut- 

Lag in 

Use 

Dew 

point 

Low 

Press or 

High 

Press or 

Low 

In Use 

Receiver 

Separator 

down 

High 

Vac 

Vac 

Instrument Air, Hybrid Note (2) Note (1) Note (1) Note (3) 

Instrument Air, duplex/multiplex compressor Note (2) Note (1) Note (1) Note (3) 

Note ( ) Recommended when the compressor is water cooled or a water cooled aftercooler is used. 

Note ( ) Recommended when appropriate for the compressor or pump. 

Note ( ) Single signal alternate to having each signal on the master. Must activate when any signal within the double lines in that row activates. 

Detail 7.2 : Instrument Air Source Alarms

7. Instrument Air has it’s own color coding and labelling 

(see Detail 7.1). The color for Instrument Air is a red ground 

with white lettering, and the abbreviation is “Instrument 

Air”. Standard pressure is 160-185 psig through the 

pipeline, and the nonstandard pressure rules will apply for 

Instrument Air systems operated at different pressures (see 

NFPA 99 5.1.5.15, 5.1.11.1, 5.1.11.2.2, 5.1.11.3.2). 

8. Alarm requirements for Instrument Air are similar in 

most respects to those for any medical gas system (local, 

master and area alarms are all required). However, the 

unique configurations permitted for the source do imply 

Instrument Air 

Source 

Dew Point 

Monitor 

D.C. 

Isolating Valve 

Pressure 

Indicator 

Line Pressure 

Regulators 

Isolation Valve 

Dew Point 

Monitor 

D.C. 


Pressure 

Indicator 

Line Pressure 

Regulators 


Source Valve 

High Pressure 

some specific alarm signals (see Detail 7.2). 

Design and Installation 

Instrument Air systems are designed in the same manner as 

any medical gas system (please refer to the BeaconMedæs 

Medical Gas Design Guide, Chapter 9 for Medical Support 

Gases for detailed instructions). 

The design of an Instrument Air system and the selection 

of the source requires knowing all the many applications 

which it is intended to serve. The first step in the design 

Pressure 

Relief 

Valves, 

Source Valve 

Low Pressure 

Detail 8 

A Dual Pressure Arrangement per NFPA 99 5.1.3.4.6 

°C 

°C 

Pressure 

Relief 

Valves, 

Line Pressure 

Indicator 

Line Pressure 

Alarm Switch/Sensor 

To High 

Pressure 

Terminals 

To Low 

Pressure 

Terminals 


D.C. 

D.C. 

Line Pressure 

Indicator 

D.C. 

D.C. 

Line Pressure 

Alarm Switch/Sensor

Instrument 


Source 

Future Valve 

Detail 9 

Local Pressure Control 

Remote, 

pressure controlled 

Outlet(s) 

Dew Point 

Monitor 

D.C. 


Pressure 

Indicator 


must be to determine what all the applications demand in 

terms of pressure and flow, and then to determine the size 

of compressor required. 

An Instrument Air system will fall into either (and in some 

cases both) of two types. Systems for use at high pressures 

(e.g. to substitute for Nitrogen) will be designed as would 

Nitrogen systems. Systems for exclusively lower pressure 

applications (e.g. for labs, central sterile supply, etc.) can 

be laid out like any other pressure gas system. 

If it is the desire of the facility to supply both high and 

°C 

Line Pressure 

Regulators 

IAir Control Panel 

Source Valve 

Pressure 

Relief 

Valves, 

High Pressure 

Line Pressure 

Indicator 

Line Pressure 


low pressure applications from the same source of supply, 

there are some considerations which will affect the design. 

NFPA 99 5.1.3.4.6 discourages the construction of what is 

termed a distributed pressure system in favor of two distinct 

pipeline systems divided at the source and separately 

provided with all the necessary controls (see Detail 8). 

Nevertheless, the language is sufficiently open, and the 

application sufficiently unique that some degree of local 

pressure control may be permissible. 

If local pressure control is desired, the design of the 

system would roughly follow the current practice in the 

Instrument Air Page 

D.C. 

Pressure controlled 

outlet on the 

Control Panel 

Area Alarm 

Switch/Sensor 

D.C. 

Zone Valve 

D.C. 

D.C. 

Service Valve

Secondary Regulator 

(Provide one for 

each device) 

To Device(s) 

Instrument 


Source 

Future Valve 

Detail 10 

Secondary Pressure Control 

Device Regulator 

(Fixed or 

adjustable output) 

Dew Point 

Monitor 

D.C. 

Adapter 

fitting 

Outlet 

°C 


Pressure 

Indicator 

Line Pressure 

Regulators 


Uncontrolled 

Outlet(s) 

Source Valve 

Pressure 

Relief 

Valves, 

High Pressure 

O.R. There, the pipeline delivers the maximum pressure 

to ensure the best possible flow rate, and Instrument Air 

control panels are placed where necessary for control of 

the pressure to the tools. Similar local pressure control can 

be provided for other devices (see Detail 9). 

A third option does exist but is rarely the preferred 

implementation. This is illustrated in Detail 10, and simply 

involves the piping of the Instrument Air to uniform outlets 

operated at the standard 185 psig, and then regulating each 

device with it’s own portable regulator fitted to the device 

or the permanent outlet. 

Line Pressure 

Indicator 

Line Pressure 


Page 0 Instrument Air 

D.C. 

Area Alarm 

Switch/Sensor 

D.C. 

Zone Valve 

D.C. 

D.C. 

Service Valve 

It is also possible to blend the elements of the systems 

shown in these three figures to create a hybrid system 

appropriate to the facility’s needs. 

If a multiple pressure system is contemplated, be sure 

to size each of the branches at the appropriate pressure. 

Only for the purpose of sizing the source should they be 

considered as one system. 

In the layout process, outlets are placed first. In O.R. 

settings where tool drive is required, a pressure control 

box is placed on a convenient wall, and includes one 

outlet. A second and occasionally a third outlet are placed 

in the closest possible proximity to the O.R. table. These

are often found on the ceiling columns or booms. These 

outlets may be “slaved” from the wall mounted control or 

they may employ a scaled down version of the control itself 

in the ceiling column or boom. Mounting the controller 

on the column or boom is generally superior when flow is 

considered, but less desirable from the viewpoint of staff 

access and ease of use. 

After outlets are placed, the actual piping can be run and 

pipe sizing determined. This aspect of design is covered 

in detail in Chapter 9 of the BeaconMedæs Design Guide 

for Medical Gases. 

Change of Use 

The economic benefits of Instrument Air can be surprising, 

and of course it is the facility which is already struggling 

with the costs of a nitrogen system who is likely to see 

them most clearly. NFPA does provide for a system to be 

converted from one gas to another in a process termed 

“Change of Use”. 

Change of Use requires that a system originally intended for 

one gas and therefore made non-interchangeable for that 

gas be converted so that it is equally non-interchangeable 

for the new gas. This means changing the source, changing 

the outlets, changing the demand checks on alarm 

components, relabelling and retesting as if the system 

was new. A conversion from nitrogen to Instrument Air 

is very feasible under these rules. Since the pipeline itself 

need not be disturbed, the cost of such a conversion is 

not excessive. 

Sizing and Selecting an Instrument Air Source 

Any Instrument Air source will consist of a primary source 

(usually a compressor) and a reserve source (a second 

compressor or a manifold header). Each element is sized 

separately and by it’s own rules. 

To size the primary compressor, there are two considerations: 

first, the compressor must be large enough to drive all the 

tools, and second we don’t want to make the compressor 

any larger than is absolutely necessary. This is particularly 

true since there is a very large diversity in Instrument Air 

usage and in fact the average Instrument Air compressor 

will not run very much. To express this another way, when 

the Instrument Air is needed, there must be enough of it, 

but it is only typically needed in short bursts, so the system 

may sit idle for long periods. 

The picture can be further complicated if the Instrument Air 

is being used for purposes in addition to driving surgical 

tools. Naturally, some of the other applications may 

place more steady demand on the system and change the 

diversity required. 

The first consideration in sizing is to ensure that the tools 

which are likely to be in simultaneous use are covered. 

These tools can be very demanding, with typical usages 

ranging from 225-425 lpm (8-15 scfm). At least this 

quantity of air must be available, so this is the minimum 

size for a system. 

More than one location will involve some degree of 

simultaneous use, and the calculation we recommend is 

that used by the HTM 2022 standard from the U.K., which 

allows for one tool at 100% and all remaining tools at 25%. 

The formula used is : 

350 + ((n-1) x 87.5) 

Where n is the number of locations using the system. 

Where 350 lpm is taken as the base load for a tool, and 

“n” is the number of locations piped with Instrument Air 

or the number of tools. 

If other applications are intended to use Instrument 

Air, they must be added to the tool demand based on a 

knowledge of the actual demand from that application. 

Some examples might include: operating pneumatic brakes 

for booms, which use negligible amounts of air and can 

be ignored as a capacity requirement; operating tools in 

the morgue, which might be treated like another tool-using 

location; operating a pneumatic O.R. table, which would 

have to be assessed based on a knowledge of the table 

itself; general lab uses, which might easily be greater than 

the use of air for tools when totalled. 

The sizing of the reserve is identical if a duplex compressor 

is used as the source configuration. If the source 

configuration is a compressor with a cylinder header as 

reserve (a hybrid configuration), then the secondary must 

contain one hour’s supply. This is most easily assessed 

by taking the total demand calculated for the primary 

source and multiplying it by 60 (minutes to hours), then 

dividing by 6,200 l (220 scfm) to determine the number of 

cylinders required in the secondary (Detail 12 allows you 

to determine this with minimal calculations). 

In the rare event that a manifold source will be used, this 

will be sized using a simple calculation of one cylinder 

for each ordinary O.R., and two for each O.R. intended 

for orthopedic or neurological surgery. Both sides of the 

manifold will be identically sized. If other applications 

are also going to be served form the manifold, they must 

be assessed individually. 

The selection of the Instrument Air source may be made 

from Detail 13, which also will link you to the necessary 

information for system dimensions. 

Conclusions and Cautions 

We believe that ultimately Instrument Air, especially when 


7.5 Hp. 

10 Hp. 

Duplex 

Source Ranges Instrument Air 

(Locations scale reflects Tool use only, HTM 2022 Sizing Method) 

(2) 7.5 Hp.* 

(3) 7.5 Hp. (3) 10 Hp. 

Triplex 

(2) 10 Hp.* 

5 7 11 16 

Compressor(s) 

Secondary Cylinder 

Counts 

14x14 7-14 

13x13 

6-13 

12x12 

6-12 

11x11 

5-11 

10x10 

5-10 

9x9 

8x8 

7x7 

4-9 

4-8 

3-7 

Cylinder 

Manifolds 

6x6 3-6 

5x5 2-5 

4x4 2-4 

3x3 1-3 

2x2 1-2 

1 10 20 

Quadruplex 

Hybrid Systems 

Source Type Legend 

Number of Locations piped with Instrument Air 


} 

Note: Larger I. Air 

systems are possible. 

Please contact 

BeaconMedæs for 

information. 

Notes: The ranges given for manifolds reflect a low (dark blue) and a high (white) 

estimate. The low estimate applies only if all locations are of the general O.R. type, 

the high estimate applies if all are of the specialty O.R. type. Factor your selection 

based on the proportion of each in the project. 

* Hybrid configurations marked with a “*” are systems with two compressors of this 

size as the primary source. They are not duplex systems in the usual meaning of one 

compressor in service, one on standby, but have two compressors available in the 

primary role with cylinders as the secondary. 

compared to Nitrogen, is a superior choice for any facility 

which needs high pressure gas for any reason. In the long 

run, the benefits are so compelling that we can anticipate 

nitrogen systems disappearing from the scene, entirely 

replaced by Instrument Air. 

However, that is some time in the future, and any facility 

built since at least the 1970’s probably has a nitrogen 

system already in place. Although the economics of 

Instrument Air are compelling, they are far more complex 

when a legacy system must also be considered. 

Instrument Air systems are more costly initially, but the 

gas is far less expensive per liter. This means that there 

is a payback for virtually any Instrument Air installation, 

whether new or a change of use. The question is the time 

Detail 12 : Instrument Air Source Selector 

frame for that payback. Naturally, the general rule will be 

the more gas used, the faster the payback. Small facilities 

using very little gas may find the payback too far in the 

future to justify the initial outlay, large facilities with heavy 

usage may find the savings grand enough to justify even 

a complicated change of use program. The only way to 

know is to do the math. 

We highly recommend that every medical gas design 

engineer add Instrument Air to their repertoire, and in 

future evaluate every facility as a potential candidate. They 

will find in most cases Instrument Air is a money saver for 

their client. 

Facilities who have to work to keep their nitrogen

systems from going empty should also look closely at the 

possibilities of performing a change of use conversion. 

They are likely to find the economics more favorable than 

they expected. 

That middle range of facilities whose nitrogen usage is 

a nuisance but not high enough to justify the costs of 

conversion will be the ones who will have to refuse change 

of use. Should they ever be fortunate enough to renovate 

their O.R. or build new, they will certainly find Instrument 

Air very attractive, but they may be best advised to leave 

Capacity 

@ 00 psig 

SCFM LPM 

Detail 13 

System Selection Table, Instrument Air Compressors 

Format HP 

NFPA Complete System 

Envelope Dimensions (inches) 

Cyl. 

Count Width Height Depth 

Information 

Sheet Page 

16.5 467 Duplex 1 7.5 NA 103.5 84.5 67 SSB-120-10 15 

24 679 Duplex 1 10 NA 103.5 84.5 67 SSB-120-10 15 

33 934 Triplex 1 7.5 NA 138 84.5 67 SSB-120-11 17 

48 1,359 Triplex 1 10 NA 138 84.5 67 SSB-120-11 17 

49.5 1,401 Quadruplex 1 7.5 NA 172.5 84.5 67 SSB-120-12 19 

72 2,038 Quadruplex 1 10 NA 172.5 84.5 67 SSB-120-12 19 

Hybrid Systems 

16.5 467 Simplex 2 7.5 5 89.5 85 67 SSB-120-10 21 

24 679 Simplex 2 10 7 89.5 85 67 SSB-120-10 21 

33 934 Duplex 2 7.5 

48 1,359 Duplex 2 10 

well enough alone in the interim. 

There are other possibilities for reducing the cost and labor 

involved with nitrogen which may be a half-way solution 

for such facilities. These involve conversion from cylinder 

(gaseous) sources to container (liquid) sources. While 

nitrogen will always be more expensive than compressed 

air, the reduction in cost can be significant, and the 

reduction in labor can be greater yet. More details on these 

systems can be obtained in the BeaconMedaes Applications 

Guide to Cryogenic Liquid Manifolds available through 

your BeaconMedaes representative. 

Call for information 

Notes 

. Capacites are shown as NFPA capacities with one compressor running and one in standby. Capacity shown is net 

system capacity, not simple compressor capacity (systems losses are already deducted). 

. Capacites are shown as NFPA capacities with compressor(s) running and cylinder header in standby. Capacity 

shown is net system capacity, not simple compressor(s) capacity (systems losses are already deducted). 


This product has been designed to meet U.S. NFPA 99, latest edition. 

Modifications made to meet current CSA Standards may result in changes to 

the product's weight and physical dimensions. Please contact BeaconMedæs at 

(704) 588-0854 or (704) 588-4949 (fax) for further information. 

Instrument Air Duplex Single Point Connection (SPC) Base Mount Systems 

(7½ - 10 HP) 

SPC (Single Point Connection) System Design 

The instrument air system shall be of a single point connection 

base mounted design consisting of two compressor modules 

with dryers, and a single control module with control panel, 

air receiver, filtration system and oil/water condensate 

separator. Each module has a maximum base width of 34.50" 

(88 cm), and be fully compliant with the latest edition of 

NFPA 99. The modules shall be assembled as one unit with 

single point connections for air discharge, electrical and 

condensate drain. 

Compressor/Dryer Module (Compressor, Drive, Motor, 

Piping, Dryer) 

The compressor shall be a high pressure "oil-lubricated" 

continuous duty rated type. The design shall be two staged, 

air-cooled, reciprocating type with corrosion resistant reed 

type valves with stainless steel reeds. Both oil scrapper ring 

and piston rings shall be made from long lasting special cast 

iron and designed for continuous duty operation. The 

crankshaft shall be constructed of forged steel and fully 

supported on both ends by heavy duty ball bearings and seals. 

The crankcase shall be constructed of gray cast iron. 

Maximum heat dissipation shall be achieved through cast iron 

cylinders with external cooling vanes. Cylinder sleeves are not 

required. Both low and high pressure pistons are made from 

cast aluminum with chrome-moly piston pins. Second stage 

cylinder head shall be equipped with a wired shutdown switch 

for high discharge air temperature. The connecting rod shall 

be of a one-piece design. The compressor shall be v-belt 

driven through a combination flywheel/sheave and steel motor 

sheave with tapered bushing and protected by an OSHA 

approved totally enclosed belt guard. A sliding motor 

mounting base that is fully adjustable through twin adjusting 

screws shall achieve belt tensioning. The motor shall be a 

NEMA rated, open drip proof, 1800 RPM, with 1.15 service 

factor suitable for 208 or 230/460V electrical service. Each 

compressor shall have its own inlet air filter mounted on the 

first stage compressor heads. Discharge air from the first 

stage compressor cylinder passes through an air-cooled 

intercooler prior to entering the second stage. The second 

stage discharge air then passes through an air-cooled 

aftercooler designed for a maximum approach temperature of 

12° F complete with moisture separator and zero loss 

automatic drain valve prior to entering the dryer. The 

compressor discharge line shall include a flex connector, 

safety relief valve, isolation valve, and check valve. The 

discharge air piping shall be of ASTM B-819 copper tubing, 

brass, and/or stainless steel. The discharge flex connector shall 

be braided 304 stainless steel, brass, or bronze. Each 

compressor has its own dedicated dryer. Each dryer is 

individually sized for peak calculated demand and capable of 

producing a -40° F (-40° C) pressure dew point. Dryer purge 

only occurs when it’s respective compressor is running. 

Upstream of the dryer will be a separator with a zero loss 

drain valve followed by a 0.01 micron coalescing filter. Both 

filters shall have element change indicators. 

SPECIFICATION 

BeaconMedæs � P. O. Box 7064 Charlotte, N. C. 28241 � Phone: (704) 588-0854 Fax: (704) 588-4949 

SSB-120-10 

Page 1 of 2 

10/01/06 

Isolation System 

Each compressor and motor assembly shall be fully isolated 

from the main compressor module base by means of a four 

point, heavy duty, spring isolation system for a minimum of 

95% isolation efficiency. Where required by local or state 

regulation, optional seismically restrained isolators can be 

provided at an additional cost. Each main compressor module 

base frame shall not exceed 34.50" in width. 

Control Module with Air Receiver/Filter/Regulator 

System 

The control module shall include a NEMA 12, U.L. labeled 

control system, duplexed final line filters, regulators, oil 

indicators, and a condensate oil/water separator and dew point 

monitor. All of the above shall be factory piped and wired in 

accordance with NFPA 99 and include valving to allow 

complete air receiver bypass and an air sampling port. The 

vertical air receiver shall be ASME Coded, National Board 

Certified, galvanized, rated for a minimum 250 PSIG design 

pressure and includes a liquid level gauge glass, safety relief 

valve, manual drain valve, and automatic solenoid drain valve. 

Control System 

The control system shall have an HMI touch screen control, 

automatic lead/lag sequencing with circuit breaker disconnects 

for each motor with external operators, full voltage motor 

starters, overload protection, 24V control circuit and hand-offauto 

selector switch for each compressor. Automatic 

alternation of both compressors based on first-on/first-off 

principle with provisions for simultaneous operation if 

required. Automatic activation of reserve unit, if required, will 

activate an audible alarm as well as a visual alarm on the 

HMI. The HMI displays service due, run hours for each 

compressor, system status, operating pressure, dew point and 

high discharge air temperature shutdown. A complete alarm 

and service history is available on the HMI. 

Dew Point Transmitter 

The control module shall incorporate a dew point transmitter 

that is mounted, pre-piped, wired to the control panel and 

displayed on the HMI touch screen. The transmitter probe 

shall be 316L SS with sintered stainless steel filter and thin 

film polymer sensor. The system accuracy shall be ± 2° C. 

Dew point alarm shall be factory set at -22° F (-30° C) per 

NFPA 99 with remote alarm contacts in the control panel. 

Statement of Warranty 

BeaconMedæs warrants all Instrument Air Systems, to be free 

of defects in material and workmanship under normal use for 

a period not to exceed thirty (30) months from date of 

shipment, or twenty four (24) months from date of start-up. 

DUPLEX 7.5-10 

BASE MOUNT 

Page

Page 

Complete 

System 

Model No. 

HP 





Instrument Air System Specifications 1 

System Capacity 2 System FLA 

200 psig 

System 3 

BTU/HR 

Receiver 4 

(Gallons) 

Noise 5 

Level 


SSB-120-10 


10/01/06 

208V 230V 460V 

HPA-7D-D200 7½ 16.5 17,062 200* 76 46 41 20 

HPA-10D-D200 10 24 23,014 200* 79 60 52 26 

Notes: 1 Normal operating conditions at a maximum ambient of 105° F. Consult factory for higher ambient conditions. 

2 All capacities are shown as NFPA system capacities (reserve compressor on standby) and are shown in Inlet Cubic 

Feet per Minute (ICFM). System losses subtracted from pump capacity. 

3 All system BTU/HR is shown with reserve compressor on standby. 

4 * Indicates standard receiver 

5 All noise levels are shown in dB(A) and reflect one pump running.





Instrument Air Triplex Single Point Connection (SPC) Base Mount Systems 

(7½ - 10 HP) 



base mounted design consisting of three compressor modules 





















































SPECIFICATION 


SSB-120-11 


10/01/06 










System 

















alternation of all compressors based on first-on/first-off 



activate an audible alarm as well as a visual alarm on the 


















TRIPLEX 7.5-10 

BASE MOUNT 

Page

Page 

Complete 

System 

Model No. 

HP 







200 psig 

System 3 

BTU/HR 

Receiver 4 

(Gallons) 

Noise 5 

Level 


SSB-120-11 


10/01/06 

208V 230V 460V 

HPA-7T-D200 7½ 33 34,124 200* 76 69 60 30 

HPA-10T-D200 10 48 46,028 200* 79 90 78 39 











Instrument Air Quadruplex Single Point Connection (SPC) Base Mount Systems 

(7½ - 10 HP) 



base mounted design consisting of four compressor modules 





















































SPECIFICATION 


SSB-120-12 


10/01/06 










System 

















alternation of all compressors based on first-on/first-off 



activate an audible alarms as well as a visual alarm on the 


















QUAD 7.5-10 

BASE MOUNT 

Page

Page 0 

Complete 

System 

Model No. 

HP 







200 psig 

System 3 

BTU/HR 

Receiver 4 

(Gallons) 

Noise 5 

Level 


SSB-120-12 


10/01/06 

208V 230V 460V 

HPA-7Q-D200 7½ 49.5 51,186 200* 76 92 80 40 

HPA-10Q-D200 10 72 69,042 200* 79 119 104 52 











Instrument Air Simplex Single Point Connection (SPC) Base Mount Systems 

with Cylinder Air Back-up Header (7½ - 10 HP) 



base mounted design consisting of one compressor module 

with dryer, and a single control module with control panel, air 

receiver, filtration system, oil/water condensate separator and 

backup cylinder header for cylinder air. Each module has a 

maximum base width of 34.50" (88 cm), and be fully 

compliant with the latest edition of NFPA 99. The modules 

shall be assembled as one unit with single point connections 

for air discharge, electrical and condensate drain. 






type valves with stainless steel reeds. Both oil scraper ring and 

piston rings shall be made from long lasting special cast iron 

and designed for continuous duty operation. The crankshaft 

shall be constructed of forged steel and fully supported on 

both ends by heavy duty ball bearings and seals. The 

crankcase shall be constructed of gray cast iron. Maximum 

heat dissipation shall be achieved through cast iron cylinders 

with external cooling vanes. Cylinder sleeves are not required. 

Both low and high pressure pistons are made from cast 

aluminum with chrome-moly piston pins. Second stage 























be braided 304 stainless steel, brass, or bronze. The dryer is 



only occurs when the compressor is running. Upstream of the 

dryer will be a separator with a zero loss drain valve followed 

by a 0.01 micron coalescing filter. Both filters shall have 

element change indicators. 


The compressor and motor assembly shall be fully isolated 





provided at an additional cost. 

SPECIFICATION 


SSB-120-13 


10/01/06 


System 



indicators, condensate oil/water separator, dew point monitor 

and an air sample port, backup cylinder header and cylinder 

restraint system. All of the above shall be factory piped and 

wired in accordance with NFPA 99. The vertical air receiver 

shall be ASME Coded, National Board Certified, galvanized, 

rated for a minimum 250 PSIG design pressure and includes a 

liquid level gauge glass, safety relief valve, manual drain 

valve, and automatic solenoid drain valve. 

Backup Air Cylinder Header 

A high-pressure header shall be provided to accommodate 

multiple air cylinders with staggered cylinder connections on 

5" centers. The header shall be designed for inlet pressures up 

to 3000 psig and shall be provided with a flexible pigtail with 

check valve for each cylinder connection. Pigtail connections 

shall be CGAV-1 #346 cylinder connections. A pressure 

regulator (field adjustable; 40 to 300 psig) shall be provided 

on the backup header to regulate the cylinder pressure. The 

regulator shall utilize high-pressure brass unions at the inlet 

and outlet connections for attachment to the header assembly 

and supply line. The simplex header shall be provided with a 

backup low pressure switch and a low flow adapter. The 

header shall be provided with a high-pressure master shut-off 

valve to isolate the header from the system, during service and 

repairs, without affecting the remainder of the system. The 

header shall be factory piped to the inlet side of the duplexed 

final line filters. 


The duplex mounted and wired control system shall be NEMA 

12 and U.L. labeled. The control system shall have an HMI 

touch screen control, automatic lead/lag sequencing with 

circuit breaker disconnects for each motor with external 

operators, full voltage motor starters, overload protection, 24V 

control circuit and hand-off-auto selector switch for each 

compressor. Automatic alternation of both compressors based 

on first-on/first-off principle with provisions for simultaneous 

operation if required. Automatic activation of reserve unit, if 

required, will activate an audible alarm as well as a visual 

alarm on the HMI. The HMI displays service due, run hours, 

system status, operating pressure, dew point and high 

discharge air temperature shutdown. A complete alarm and 

service history is available on the HMI. 














SIMLEX 7.5-10 

BASE MOUNT

Page 

Complete 

System 

Model No. 

HP 

System 

Capacity 2 

200 psig 






System 3 

BTU/HR 

Receiver 4 

(Gallons) 

Noise 

Level 5 

No. of 

Cylinders 6 


SSB-120-13 


10/01/06 

System FLA 

208V 230V 460V 

HPA-7S-D200 7½ 16.5 17,062 200* 76 5 23 20 10 

HPA-10S-D200 10 24 23,014 200* 79 7 30 26 13 






5 All noise levels are shown in dB(A) and reflect one pump running. 

6 Number of air cylinders for 1-hour of backup. All cylinders are supplied by others.

DISS Medical Gas Wall Outlet 

The DISS Medical Gas wall outlets shall be gas specific for 

the services indicated and accept only corresponding DISS 

nuts and nipples. The outlets shall be UL listed, CSA certified, 

and be fully compliant with the latest edition of NFPA 99. All 

outlets shall be 100% tested for flow, leaks and connector 

attachment. The outlets shall be cleaned for oxygen service 

prior to shipping. The outlets shall be made in the U.S.A. A 

die cast, light gray, epoxy powder coated trim plate can be 

provided to trim each wall outlet and to fill the space between 

adjacent outlets. The trim plate shall allow latch valves to be 

individually removed for servicing. 

Outlet Design 

A complete medical gas outlet shall consist of a gas-specific 

rough-in assembly for installation before the wall is finished 

and a matching gas-specific latch-valve assembly and cover 

plate for installation after the wall is finished. 

Rough-in Assembly 

The rough-in assembly shall be of modular design and include 

a gas-specific 16-gauge steel mounting plate designed to 

permit on-site ganging of multiple outlets, in any order, on 5" 

centerline spacing. A machined brass outlet block shall be 

permanently attached to the mounting bracket to permit the 

1/2" OD (3/8" nominal),type-K copper inlet tube to swivel 

360° for attachment to the piping system. Gas service 

Series B 

DISS 

(U.S.) 

Series B Recessed Medical Gas Wall Outlet 

DISS Key Style 

SPECIFICATION 

SSB-840-03 


2/01/2006 

identification shall be affixed to the inlet tube and the face of 

the mounting plate. A secondary valve shall be installed in 

the outlet block of the rough-in assembly for both pressure 

testing and preventing gas flow (except vacuum and WAGD) 

when the latch-valve assembly is removed for service. A 3/8" 

high metal flange around the outlet opening shall provide a 

plaster barrier. A temporary cover shall be provided to keep 

debris out of the outlet during installation. The rough-in 

assembly shall contain a double seal to prevent gas leakage 

between the rough-in and latch-valve assemblies after the wall 

is finished. A single o-ring seal shall not be acceptable. 

Latch Valve Assembly 

The latch-valve assembly shall include an o-ring seal primary 

valve, be gas specific for the labeled service, and accept only 

corresponding hose and apparatus with DISS nut and nipple 

adapters. The latch-valve assembly shall be indexed to the 

corresponding rough-in assembly to avoid accidental 

cross-connection and shall telescope up to 3/4" to allow for 

variation in finished wall thickness from 1/2" up to 1-1/4". A 

metal cover plate insert with permanent, color-coded marking 

of service identification shall be included as part of the 

latch-valve assembly. 

Item Concealed Wall Outlet 

Gas Service Color Code Complete Assembly Rough-in Assembly Latch-Valve Assembly 

Series B 

DISS 

(International) 

O2 White � 6-121100-00 � 6-233110-00 � 6-230910-00 

N2O Blue � 6-121101-00 � 6-233111-00 � 6-230911-00 

AIR Yellow � 6-121102-00 � 6-233112-00 � 6-230912-00 

VAC White � 6-121103-00 � 6-233113-00 � 6-230913-00 

N2 Black � 6-121104-00 � 6-233114-00 � 6-230914-00 

Instrument Air Red � 6-121108-00 � 6-233118-00 � 6-230916-00 

WAGD Purple � 6-121109-00 � 6-233119-00 � 6-230919-00 

CO2 Gray � 6-121110-00 � 6-233120-00 � 6-230920-00 

CO2-O2 (CO2 >7%) Gray/Green � 6-121111-00 � 6-233121-00 � 6-230921-00 

O2 -CO2 (CO2 80%) Brown/Green � 6-121113-00 � 6-233123-00 � 6-230923-00 

O2 -He (He < 80%) Green/Brown � 6-121114-00 � 6-233124-00 � 6-230924-00 


N2O Blue � 6-121101-00 � 6-233111-00 � 6-230911-00 

AIR Black/White � 6-151012-00 � 6-233116-00 � 6-230917-00 

VAC Yellow � 6-151013-00 � 6-233117-00 � 6-230918-00 

N2 Black � 6-121104-00 � 6-233114-00 � 6-230914-00 

Instrument Air Red � 6-121108-00 � 6-233118-00 � 6-230916-00 

WAGD Purple � 6-121109-00 � 6-233119-00 � 6-230919-00 

CO2 Gray � 6-121110-00 � 6-233120-00 � 6-230920-00 

Miscellaneous Slide* � 6-120978-00 

Blank, Gas � 6-120979-00 

Duplex Electrical Receptacle (Gray) � 6-120972-00 

Trim Plate (5") � 6-325161-00 

*Good design practice should include a slide for each vacuum outlet. 

BeaconMedæs � 14408 W. 105 th Street Lenexa, KS 66215 � Phone: (913) 894-6058 Fax: (913) 894-6088 

SERIES B DISS 

WALL OUTLET

Series B DISS Wall Assembly 

Page 

DISS Outlet 

Optional Assemblies 

SSB-840-03 


2/01/2006 

BeaconMedæs � 14408 W. 105 th Street Lenexa, KS 66215 � Phone: (913) 894-6058 Fax: (913) 894-6088

Series B Console and Modular Headwall Medical Gas Outlet 

DISS Key Style 

DISS Medical Gas Outlet 

The DISS Medical Gas outlets for consoles and modular walls 

shall be gas specific for the services indicated and accept only 

corresponding DISS nuts and nipples. The outlets shall be UL 

listed, CSA certified, and be fully compliant with the latest 

edition of NFPA 99. All outlets shall be 100% tested for flow, 

leaks and connector attachment. The outlets shall be cleaned 

for oxygen service prior to shipping. The outlets shall be made 

in the U.S.A. A die cast, light gray, epoxy powder coated or 

plastic trim plate (optional) can be provided to trim each outlet 

assembly. 

Outlet Design 

A complete medical gas outlet shall consist of a gas-specific 

rough-in assembly and a matching gas-specific latch-valve 

assembly. 

Rough-in Assembly 

The rough-in assembly shall be of modular design and include 

a gas-specific 16-gauge steel mounting plate designed to 

permit on-site installation. A machined brass outlet block shall 

be permanently attached to the mounting bracket to permit the 

1/2" OD (3/8" nominal), type-K copper inlet tube to swivel 

360° for attachment to the piping system. 

Series B 

DISS 

(U.S.) 

SPECIFICATION 

Item Standard Console 

Series B 

DISS 

(International) 

Miscellaneous 

SSB-840-04 


2/01/06 

Gas service identification shall be affixed to the inlet tube and 

the face of the mounting plate. A secondary valve shall be 

installed in the outlet block of the rough-in assembly for both 

pressure testing and preventing gas flow (except vacuum and 

WAGD) when the latch-valve assembly is removed for 

service. The rough-in assembly shall contain a double seal to 

prevent gas leakage between the rough-in and latch-valve 

assemblies after the wall is finished. A single o-ring seal shall 

not be acceptable. 

Latch Valve Assembly 

The latch-valve assembly shall include an o-ring seal primary 

valve and shall be indexed to the corresponding gas service 

rough-in assembly to avoid accidental cross-connection. Latch 

valves shall telescope up to 3/4" to allow for variation in wall 

thickness. A metal cover plate insert with permanent 

color-coded gas service identification shall be included as part 

of the latch valve assembly. 

Gas Service Color Code Complete Assembly* Latch-Valve Assembly Rough-in Assembly 


N2O Blue N/A � 6-230911-00 � 6-233011-00 

AIR Yellow � 6-121052-00 � 6-230912-00 � 6-233012-00 

VAC White � 6-121053-00 � 6-230913-00 � 6-233013-00 

Inst Air Red N/A � 6-230916-00 � 6-233018-00 

WAGD Purple N/A � 6-230919-00 � 6-233019-00 

N2 CO2 Black 

Gray 


N/A 

N/A 

� 

� 

6-230914-00 

6-230920-00 

� 

� 

6-233014-00 

6-233020-00 

O2 White N/A � 6-230910-00 � 6-233010-00 

AIR Black/White N/A � 6-230917-00 � 6-233016-00 

VAC Yellow N/A � 6-230918-00 � 6-233017-00 

Slide � 6-135012-00 

Blank, Gas � 6-415169-00 

*Complete assembly consists of a rough-in assembly and latch-valve assembly. Optional trim plate must be ordered separately. 

SERIES B DISS 

CONSOLES 

Page

Page 

Series B DISS Console Assembly 

Optional assemblies shown with optional 5” trim plate 

SSB-840-04 


2/01/06 


Gas Control Panels 

HORIZONTAL 

CONTROL 

PANEL 

VERTICAL 

CONTROL 

PANEL 

BeaconMedæs � 14408 105 th Street Lenexa, KS 66215 � Phone: (913) 894-6058 Fax: (913) 894-6088 

SSB-850-01 


2/01/06 

Page

Page

Fittings and Components 

All BeaconMedaes DISS valves, bodies, nuts and nipples are 

manufactured to comply with the latest edition of CGA V-5, 

Diameter Index Safety System (Non-interchangeable low 

pressure connections for medical gas applications) 

Gas Specific DISS Valve or DISS Body 

DISS BODY: When the DISS nut and nipple are disconnected 

gas will continue to flow. 

DISS VALVE: Contains a valve mechanism and begins to flow 

gas when the DISS nut and nipple are connected and stops flow 

when the DISS nut and nipple are disconnected. 

DISS valves and valve bodies are available with 1/4 -18 NPT 

male threads, 1/8 -27 NPT male threads or barbed ends for 

installation in hose assemblies 

HOSE ASSEMBLIES 

To order hose assemblies: 

Hose Assemblies, Valves, Fittings, and Components 

SPECIFICATIONS AND ORDERING INFORMATION 

SSB-890-01 


8/1/06 

Gas Specific DISS Nipples 

The gas specific DISS nipple mates with the gas specific DISS 

valve or valve body. They are supplied with O-rings where 

required and are available with 1/4 -18 NPT male threads, 

1/8 -27 NPT male threads or barbed ends for installation in 

hose assemblies 

DISS Nut 

The DISS nut is used to secure the DISS nipple to the valve or 

valve body. Often times the DISS nut may be used on several 

different gases. The valve or body and the nipple are the 

components to make the system gas specific. 

For assistance in determining the components you may require, 

please call 1-888-4MEDGAS to speak with one of our 

specialists. 

1. Select the fitting for each end of the hose assembly-one from (A) and one from (C) using the matrix shown. 

2. Choose the appropriate part number according to the gas service required (B). 

3. Replace the XX with a two-digit number from the chart (D). This two-digit number corresponds with the length of the hose required. 

Example: A hose assembly for oxygen that is five feet long and uses a Geometric valve on one end and a Diameter-Index Safety System 

(DISS) nut and nipple on the other end would carry a part number of 6-139103-05 

NOTE: 

Maximum length is thirty feet. Unless otherwise specified, all assemblies utilize 1/4” ID hose. 


HOSE 

ASSEMBLIES 

Page

HOSE ASSEMBLIES 

A B 

Schrader quick-connect 

D 

DISS nut and nipple 

Page 0 

Geometric valve 

Pin Index valve 

Latch Key valve 

DISS male valve 


SPECIFICATIONS AND ORDERING INFORMATION (continued) 

C 

N2 6-132184-XX 

DISS nut and nipple Geometric adapter 

SSB-890-01 


8/1/06 

Latch Key adapter Pin Index adapter 

O2 6-132106-XX 6-132026-XX 6-132500-XX 

N2O 6-132107-XX 6-132027-XX 6-132501-XX 

AIR 6-132110-XX 6-132028-XX 6-132502-XX 

VAC 6-132111-XX 6-132029-XX 6-123503-XX 

N2 6-132112-XX 

CO2 6-132118-XX 

WAGD 6-132364-XX 6-132401-XX 6-132504-XX 

O2 6-139103-XX 6-139012-XX 

N2O 6-139105-XX 6-139013-XX 

AIR 6-139109-XX 6-139014-XX 

VAC 6-139108-XX 6-139015-XX 

VAC 5/16” ID 6-139500-XX 6-139501-XX 

WAGD 6-139366-XX 6-139340-XX 

O2 6-139380-XX 6-139391-XX 

N2O 6-139381-XX 6-139392-XX 

AIR 6-139382-XX 6-139393-XX 

VAC 6-139383-XX 6-139394-XX 

VAC 5/16” ID 6-139502-XX 6-139503-XX 

WAGD 6-139384-XX 6-139395-XX 

O2 6-139370-XX 6-139396-XX 

N2O 6-139371-XX 6-139397-XX 

AIR 6-139372-XX 6-139398-XX 

VAC 6-139373-XX 6-139399-XX 

VAC 5/16” ID 6-139504-XX 6-139505-XX 

WAGD 6-139374-XX 6-139400-XX 

O2 6-139140-XX 6-139016-XX 

N2O 6-139141-XX 6-139017-XX 

AIR 6-139142-XX 6-139018-XX 

VAC 6-139143-XX 6-139019-XX 

VAC 5/16” ID 6-139506-XX 6-139507-XX 

N2 6-139144-XX 

WAGD 6-139149-XX 6-139390-XX 

CO2 6-139385-XX 

Refer to the table below for overall length of hose assembly. Use the numbers in the XX column to denote hose length. 

XX HOSE LENGTH 1 (ft) XX HOSE LENGTH 1 (ft) XX HOSE LENGTH 2 (in) NOTE 

01 1 09 9 31 32” 

1 

XX numbers 01 through 30 represent hose length 

02 2 10 10 32 38” 

in feet. 

03 

04 

3 

4 

11 

12 

11 

12 

33 

34 

44” 

50” 

DOES NOT INCLUDE END FITTINGS. 

2 

XX numbers 31 through 36 represent special 

05 

06 

5 

6 

15 

22 

15 

22 

35 

36 

56” 

68” 

application sizes (ceiling drop hoses) in inches. 

INCLUDES END FITTINGS. 

08 8 30 30 


HOSE 

ASSEMBLIES



SSB-890-01 


8/1/06 

VALVES 

The check valves below operate smoothly and are available with U.S. or international color coding. Gas-specific components are 

permanently indexed to prevent accidental incorrect assembly. 

NOTE: Unless otherwise specified, hose barb check valves are for 1/4” ID hose 

Geometric DISS Valve Pin Index Latch Key 

HOSE BARB CONNECTION 

Gas Geometric DISS Pin Index Latch Key 

Oxygen 6-121200-10 6-121201-10 6-121202-10 6-121203-10 

Nitrous Oxide 6-121200-11 6-121201-11 6-121202-11 6-121203-11 

Air 6-121200-12 6-121201-12 6-121202-12 6-121203-12 

Vacuum 6-121200-13 6-121201-13 6-121202-13 6-121203-13 

Vacuum 5/16” ID hose 6-121200-53 6-121201-53 6-121202-53 6-121203-53 

Nitrogen 6-121201-14 

Instrument Air 6-121201-18 

WAGD 6-121200-19 6-121201-19 6-121202-19 6-121203-19 

Carbon Dioxide 6-121201-20 

INTERNATIONAL COLOR CODING 

Oxygen 6-121200-15 6-121201-15 6-121202-15 6-121203-15 


Vacuum 6-121200-17 6-121201-17 6-121202-17 6-121203-17 

Vacuum 5/16” ID hose 6-121200-57 6-121201-57 6-121202-57 6-121203-57 


1/4 - 18 NPT CONNECTION 


Oxygen 6-121210-10 6-121211-10 6-121212-10 6-121213-10 

Nitrous Oxide 6-121210-11 6-121211-11 6-121212-11 6-121213-11 


Vacuum 6-121210-13 6-121211-13 6-121212-13 6-121213-13 

Nitrogen 6-121211-14 

Instrument Air 6-121211-18 

WAGD 6-121210-19 6-121211-19 6-121212-19 6-121213-19 

Carbon Dioxide, CO 2-O 2 6-121211-20 

O2-CO2 6-121211-22 

Helium, He-O2 6-121211-23 

O2-He 6-121211-24 

INTERNATIONAL COLOR CODING 

Oxygen 6-121210-10 6-121211-10 6-121212-15 6-121213-15 


Vacuum 6-121210-17 6-121211-13 6-121212-17 6-121213-17 


HOSE 

ASSEMBLIES 

Page

VALVES (continued) 

Page 



SSB-890-01 


8/1/06 


1/8 - 27 NPT CONNECTION 


Oxygen 6-121208-10 

Nitrous Oxide 6-121208-11 

Air 6-121208-12 

Nitrogen 6-121208-14 

DISS FITTINGS 

DISS NIPPLES WITH O-RINGS TO MALE PIPE THREAD 

PART NUMBER DESCRIPTION 

NUT NIPPLE 

6-825000-00 6-510016-00 Nipple, oxygen with o-ring to 1/8 -27 NPT male 

6-511511-00 6-511605-00 Nipple, nitrous oxide with o-ring to 1/4 -18 NPT male 

6-511511-00 6-511604-00 Nipple, air nipple with o-ring to 1/4 -18 NPT male 

6-511511-00 6-512070-01 Nipple, vacuum with o-ring to 1/4 -18 NPT male 

6-511511-00 6-511603-00 Nipple, nitrogen with o-ring to 1/4 -18 NPT male 

6-511518-00 6-511620-00 Nipple, instrument air with o-ring to 1/4 -18 NPT male 

6-511510-00 6-510079-00 Nipple, WAGD with o-ring to 1/8 -27 NPT male 

6-511511-00 6-511612-00 Nipple, carbon dioxide, CO2-O2 mixture with o-ring to 1/4 -18 NPT male 

6-511511-00 6-511614-00 Nipple, O2-CO2 mixture with o-ring to 1/4 -18 NPT male 

6-511511-00 6-511616-00 Nipple, helium, He-O 2 mixture with o-ring to 1/4 -18 NPT male 

6-511511-00 6-511617-00 Nipple, O 2-He with o-ring to 1/4 -18 NPT male 

DISS NUT AND NIPPLE ASSEMBLIES WITH O-RINGS TO 1/8 -27 NPT MALE THREADS 


6-121209-10 Assembly, oxygen nut and nipple with o-ring to 1/8 -27 NPT 

6-121209-11 Assembly, nitrous oxide nut and nipple with o-ring to 1/8 -27 NPT 

6-121209-12 Assembly, air nut and nipple with o-ring to 1/8 -27 NPT 

6-121209-13 Assembly, vacuum nut and nipple with o-ring to 1/8 -27 NPT 

6-121209-14 Assembly, nitrogen nut and nipple with o-ring to 1/8 -27 NPT 

6-121209-19 Assembly, WAGD nut and nipple with o-ring to 1/8 -27 NPT 

6-121209-20 Assembly, carbon dioxide nut and nipple with o-ring to 1/8 -27 NPT 


HOSE 

ASSEMBLIES

QUICK-CONNECT FITTINGS 



SSB-890-01 


8/1/06 

GEOMETRIC QUICK-CONNECT ADAPTERS WITH PIPE THREADS 


6-512013-00 Adapter, oxygen, 1-3/4” long, with 1/4 –18 NPT male thread 

6-512001-00 Adapter, nitrous oxide, with 1/4 –18 NPT male thread 

6-210636-00 Adapter, air, 1-3/4” long, non-swivel, with 1/4 –18 NPT male thread 

6-512003-00 Adapter, vacuum, with 1/4 –18 NPT male thread 

6-512092-00 Adapter, oxygen, with 1/8 –27 NPT male thread 


6-512542-00 Adapter, oxygen, 2-15/16” long, with 1/4 –18 NPT male thread 

6-230338-00 Adapter, air, 2-15/16” long, with 1/4 –18 NPT male thread 

6-230348-00 Adapter, WAGD, 2-15/16” long, with 1/4 –18 NPT male thread 

GEOMETRIC QUICK-CONNECT ADAPTER WITH DISS THREAD 

6-512019-00 Adapter, oxygen, with 9/16 –18 DISS male thread 

PIN INDEX QUICK-CONNECT ADAPTERS 


6-230624-00 Adapter, oxygen, International, with 1/4 –18 NPT male thread 

6-230627-00 Adapter, air, with 1/4 –18 NPT male thread 





LATCH KEY QUICK-CONNECT ADAPTERS 

6-231030-00 Adapter, oxygen, round striker, with 1/4 –18 NPT male thread 

6-231032-00 Adapter, air, rectangular striker, with 1/4 –18 NPT male thread 

6-231034-00 Adapter, vacuum, rectangular striker, with 1/4 –18 NPT male thread 

DISS BODY ADAPTERS 



6-511554-00 Adapter, nitrogen, with 1/4 –18 NPT male thread 


6-520395-00 Adapter, nitrous oxide, with 1/4 –18 NPT male thread 


6-515606-00 Adapter, WAGD, with 1/4 –18 NPT male thread 

6-511558-00 Adapter, instrument air with 1/4-18 NPT male thread 

6-520288-00 Adapter, CO 2 and CO 2-O 2 mixtures with 1/4 -18 NPT male threads 


Page

Page 



HOSE BARB ADAPTERS, HOSE RETRACTORS, BULK HOSES, AND FERRULES 

SSB-890-01 


8/1/06 

Geometric DISS Pin Index Latch Key 

HOSE BARB ADAPTERS FOR 1/4” ID HOSE 

Gas 

Geometric 

With Ferrule 

Geometric 

DISS 

Nipple w/O-ring Nut 

Pin Index Latch Key 

Oxygen 6-210221-00 6-512007-00 6-512076-00 6-825000-00 6-231016-00 6-232114-00 

Nitrous Oxide 6-210220-00 6-512018-00 6-511611-00 6-511511-00 6-232129-00 6-232115-00 

Air 6-210222-00 6-230339-00 6-511609-00 6-511511-00 6-231018-00 6-232116-00 

Vacuum 6-210223-00 6-512009-00 6-512077-00 6-511511-00 6-231017-00 6-232117-00 

Nitrogen 6-511610-00 6-511511-00 

Instrument Air 6-511621-00 6-511518-00 

WAGD 6-230350-00 6-511515-00 6-511510-00 6-232139-00 6-232118-00 

Carbon Dioxide 6-511607-00 6-511511-00 

HOSE BARB ADAPTERS FOR 5/16” ID HOSE 

Gas Geometric 

DISS 

Nipple w/O-ring Nut 

Vacuum 6-512115-00 6-134157-00 6-511511-00 

WAGD 6-230349-00 6-511606-00 6-511510-00 

Heavy Duty, Double Retractor for 

all Pressure and Vacuum Service 

HOSE RETRACTOR 

6-132002-00 

BULK HOSE 1/4” ID (Length sold per foot) 

Gas Service Color Code Part Number 

Oxygen Green 6-611044-02 

Nitrous Oxide Blue 6-611044-01 

Air Yellow 6-611044-03 

Vacuum White 6-611044-04 

WAGD Purple 6-611044-05 

Nitrogen Black 6-611044-00 

All Others Black 6-611044-00 

5/16” ID 

Vacuum White 6-656010-06 

FERRULES 

For 1/4” ID Hose (pressure) 6-355021-00 

For 5/16” ID Hose (vacuum) 6-405000-00 

Ferrule Hand Crimping Tool 6-995508-00 

Fittings and Components 

Unless otherwise indicated, the fittings and 

components listed in this catalog are designed for low 

pressure medical gas systems where pressure does not 

exceed 200 psig. In addition to fittings and 

components that utilize geometric shape indexing and 

DISS connections, a complete offering of general 

purpose fittings is also available. 

Caution: 

Common threads, crimp or slip-fit connections 

permit the assembly of components which may 

permit the cross-indexing of services, unanticipated 

performance, poor flow, and excessive pressure 

drops. The user is cautioned to consider such 

factors when using these components. 

BeaconMedæs fittings and components are medicalgrade 

fittings, carefully machined to precise 

dimensions, and offer outstanding durability. 


FITTINGS AND COUPLINGS 



HOSE/TUBING FITTINGS 

SSB-890-01 


8/1/06 

6-512012-00 Connector, hose barb for 1/4” ID hose, to 1/4 –18 NPT female thread 

6-512506-00 Connector, hose barb for 5/16” ID hose, to 1/4 –18 NPT female thread 

6-512508-00 Connector, hose barb for 5/16” ID hose, to 1/4 –18 NPT male thread 

6-515002-00 Connector, hose barb for 1/4” ID hose, to 1/4 –18 NPT male thread 

DISS BODY WITH HOSE BARB 

6-520174-00 Adapter, oxygen, for 1/4” ID hose 

6-525300-53 Adapter, vacuum, large bore, for 5/16” ID hose 

6-525298-00 Adapter, nitrous oxide, for 1/4” ID hose 

6-525299-00 Adapter, air, for 1/4” ID hose 

6-525300-00 Adapter, vacuum, for 1/4” ID hose 

6-525302-00 Adapter, nitrogen, for 1/4” ID hose 

6-525303-00 Adapter, WAGD, for 1/4” ID hose 

6-525301-00 Adapter, carbon dioxide, for 1/4” ID hose 

COUPLINGS AND BUSHINGS 

6-835020-00 Coupling, 1/4 –18 NPT female each end 

6-513011-00 Coupling, 1/4 –18 NPT female to 1/8 –27 NPT female 

6-513003-00 Coupling, 1/4 –18 NPT male thread x 1/8 -27 NPT male thread 

6-835000-00 Bushing, 1/4 –18 NPT male to 1/8 –27 NPT female 

6-835001-00 Coupling, 1/4 –18 NPT female thread x 1/8 -27 NPT male 


HOSE 

ASSEMBLIES 

Page

Page

A company within the Atlas Copco Group 

13325 Carowinds Blvd • Charlotte, NC 28273 • Phone 1 888 4 MED GAS • Fax 704 588 4949 

www.beaconmedaes.com 

Page 

®

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