Series AK M60
Crossover Manifold
INSTALLATION AND OPERATION
MANUAL
Part Number 00-15000012
Revision 1
Copyright © August 2008
Advanced Pressure Technology (“AP Tech”)
687 Technology Way
Napa, CA 94558
Phone: (707) 259-0102
FAX: (707) 259-0117
AK M60 Manual P/N 00-15000012 Rev 1
TABLE OF CONTENTS
DESCRIPTION.............................................................................................................................3
1.
2. SAFETY .......................................................................................................................................4
2.1. General Safety Information.......................................................................................................4
2.2. AK M60 Crossover Manifold Specific Safety Information......................................................4
3. TECHNICAL SPECIFICATIONS ...............................................................................................5
3.1. AK M60 Specifications.............................................................................................................5
3.2. AK M60 Facility Requirements................................................................................................5
4. INSTALLATION .........................................................................................................................6
4.1. General......................................................................................................................................6
4.2. AK M60 Installation .................................................................................................................6
4.3. Connect Gas Lines to M60........................................................................................................7
4.4. Relief Valve Installation ...........................................................................................................7
4.5. Purge and Vent Equipment.......................................................................................................8
4.6. Initial Leak Test........................................................................................................................8
5. OPERATION................................................................................................................................9
5.1. AK M60 Operation ...................................................................................................................9
6. TROUBLESHOOTING..............................................................................................................12
6.1. External leak ...........................................................................................................................12
6.2. Relief valve is opening and venting gas..................................................................................12
6.3. High delivery line pressure.....................................................................................................12
6.4. Low delivery line outlet pressure............................................................................................13
6.5. Both cylinders empty simultaneously.....................................................................................13
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AK M60 Manual P/N 00-15000012 Rev 1
1. DESCRIPTION
This installation and operation manual covers the series AK M60 crossover manifold. The AK M60
crossover manifold is used to maintain a continuous supply of source gas when the “in use” gas cylinder
is depleted, by automatically drawing gas from a standby cylinder. The AK M60 consists of a crossover
regulator and pressure gauges. The crossover regulator has a panel nut for mounting. The crossover
regulator consists of two regulators with separate inlets and a common outlet, machined into a single
body. Two pressure gauges are installed in the crossover regulator to indicate the inlet pressure from the
Source A and Source B gas cylinders. The crossover regulator has an outlet pressure gauge and an outlet
port. A relief valve is recommended to be installed to protect the low pressure side of the crossover
regulator from full cylinder pressure in the event of a seat failure. Custom configurations may vary
slightly from this standard design. Figure 1 shows the basic design.
Figure 1. AK M60 Crossover Manifold Front View
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AK M60 Manual P/N 00-15000012 Rev 1
2. SAFETY
The user is strongly recommended to carefully read this section covering general safety information
and to adhere to specific safety information located throughout this manual.
2.1. General Safety Information
All technicians that install, operate, or maintain this equipment should be trained in the use and hazards of
compressed gases. Technicians should also be familiar with the hazards associated with the particular gas
being delivered. These hazards can include high pressure, asphyxiation, toxicity, flammability,
corrosivity, etc. Material safety data sheets are available from gas suppliers that provide detailed
information on the hazards associated with a particular gas.
Appropriate personal protective equipment should be worn at all times as recommended by the material
safety data sheet for the particular gas and as required by safety practices at the installation site. This
equipment may include safety glasses, safety shield, rubber gloves, aprons, etc.
Never exceed the maximum working pressure of the equipment.
Equipment shall be installed in a manner that meets local, state, and federal regulations and safety
guidelines. General guidelines for compressed gases can be obtained from the Compressed Gas
Association (http://www.cganet.com/
Prior to disassembling manifold lines, the system may need to be purged using nitrogen or another gas to
remove any hazardous gases. The AK M60 system does not have built-in purging capability, which is the
responsibility of the user.
) and the European Industrial Gases Association (www.eiga.org).
2.2. AK M60 Crossover Manifold Specific Safety Information
An overpressure relief device should be installed in a tee off the outlet port (6:00 o’clock position) of the
crossover regulator. The outlet of the relief device should be connected to a scrubber system or directed
away from personnel as appropriate.
The AK M60 crossover manifold should be checked for leaks upon installation and inspected periodically
during use.
A shut off valve and check valve should be installed between both supply cylinders and the AK M60
crossover manifold inlet connections to prevent gas escaping from the cylinder in use when a cylinder is
being replaced.
Installation of purge and vent valves are recommended when used with hazardous gases and exposure to
the gas can result in a safety hazard to personnel. Purge equipment is the responsibility of the user.
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AK M60 Manual P/N 00-15000012 Rev 1
3. TECHNICAL SPECIFICATIONS
3.1. AK M60 Specifications
3.1.1. Physical
Dimensions are approximately 6-1/2 inch wide by 6-1/8 inch high by 8-1/2 inch deep
Weight is approximately 5 lbs.
Recommended to be panel mounted in 1-27/64 (1.42) inch diameter hole
3.1.2. Pressure and Flow
3500 psig maximum inlet pressure (can be limited by inlet gauge range)
250, 150, and 100 psig nominal outlet pressure options (specified when ordered)
75 slm nitrogen maximum flow at 200 psig minimum inlet pressure (higher flow rates may be
obtainable depending on inlet pressure and system components)
3.2. AK M60 Facility Requirements
The following is needed to install the AK M60 manifold at the users facility.
1/4 inch NPT adapters
Secure mounting of the AK M60 to prevent loosening of fittings during operation of the knob
The recommended method of mounting the AK M60 manifold is with the panel mount feature. The panel
mount feature requires a 1-27/64 (1.42) inch diameter hole in a .30 inch maximum thickness panel. The
rear bonnet of the regulator is placed through the panel and secured in place with a panel nut as shown in
Figure 2. Alternately, it is possible to design a custom bracket that could secure the AK M60 manifold to
a fixed object.
The following is recommended for proper operation of the equipment:
Check valve for installation between each supply cylinder and each AK M60 inlet port
Manual valve for installation between cylinder and check valve
Appropriate purge and vent system for hazardous gases
Relief valve for installation on outlet delivery line
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AK M60 Manual P/N 00-15000012 Rev 1
4. INSTALLATION
This section describes how to install the equipment at a user facility.
4.1. General
Use Teflon® pipe thread tape on NPT connections. When mating a 316 stainless steel pipe fitting to a 316
stainless steel AK M60 body, it is recommended that Teflon tape be applied to the first NPT thread to
prevent galling upon assembly. For brass fittings, do not apply thread tape to the first NPT thread to
reduce the chance of introducing pieces of thread tape into the system. Use care not to apply Teflon tape
such that loose tape will come free and enter the flow path.
AP Tech recommends the use of Teflon tape for NPT connections to reduce the chance of galling 316
stainless steel threads, to maintain oxygen compatibility, and to maintain system cleanliness. Other types
of sealants can be used, but may not provide the same results.
Do not drop or jar the switchover manifold because damage to internal parts and pressure gauges may
result.
Inspect the manifold after unpacking and before installation. If any damage is observed, contact factory
for repair.
4.2. AK M60 Installation
Select a location for the manifold that is sheltered from the environment and away from sources of heat or
sparks. The area should be protected from vehicles and moving mechanical equipment. The area must be
accessible for ease of cylinder replacement.
A panel or bracket with a 1-27/64 inch hole is recommended to secure the AK M60 crossover manifold
and prevent movement during operation. Refer to Figure 2 for mounting location.
Figure 2. AK M60 Crossover Manifold Panel Mounting Detail
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AK M60 Manual P/N 00-15000012 Rev 1
4.3. Connect Gas Lines to M60
Refer to Figure 3 for a schematic of the recommended installation that shows the relative location of the
AK M60 crossover manifold and other components. AP Tech recommends both a check valve and
manual valve are used to isolate each gas cylinder from the AK M60 crossover manifold. It is possible to
isolate the AK M60 manifold from each gas cylinder using only either a check valve or a manual valve.
The Source A high pressure inlet ports are labeled with “HP-A” marked into the body. Arrows are used
next to the HP-A to point toward the high pressure gauge port and the high pressure inlet port. The
Source B high pressure inlet ports are similarly labeled with “HP-B” and arrows.
The low pressure outlet ports are labeled with “LP” marked into the body near the port. Arrows are used
next to the LP to point toward the low pressure port (both the outlet pressure gauge port and outlet port).
Position a gas cylinder on each side of the AK M60 manifold. Secure cylinders in place using an
appropriate restraint system.
Equipment can be supplied with various types of fittings and connections. The standard connections are
1/4 inch female NPT. Inspect the system to determine if the connection is NPT, tube compression, or
other.
Install a check valve into port labeled “HP-A” on AK M60 manifold. Flow arrow on check valve should
be pointing into the AK M60 manifold inlet port. Install a manual shut off valve onto check valve.
Install a check valve into port labeled “HP-B” on AK M60 manifold. Flow arrow on check valve should
be pointing into the AK M60 manifold inlet port. Install a manual shut off valve onto check valve.
Connect a “pigtail” (bent piece of tubing with loops for flexibility and to reduce stress on connections) or
flexible braided hose from the outlet of the left cylinder valve to the manual valve on the AK M60
manifold regulator inlet port labeled “HP-A”.
Connect a “pigtail” (bent piece of tubing with loops for flexibility and to reduce stress on connections) or
flexible braided hose from the outlet of the right cylinder valve to the manual valve on the AK M60
manifold regulator inlet port labeled “HP-B”.
Install appropriate fitting into AK M60 manifold 1/4 inch NPT female outlet port. Install delivery line to
point of use using tubing or piping. A tee should be placed on the delivery line close to the AK M60
manifold for installation of a relief valve.
4.4. Relief Valve Installation
Install a relief valve on one leg of tee installed as part of the delivery line. The relief valve should be set
above the AK M60 crossover regulator pressure settings. See Table 1 for recommended nominal relief
valve set pressures. If necessary due to gas properties, route the relief valve outlet line to an appropriate
scrubber or exhaust system. Otherwise, direct the relief valve outlet away from personnel.
AK M60 Model Nominal Crossover
Regulator Outlet Range
Relief Valve
Set Pressure
AK M6010 85-115 psig 150 psig
AK M6015 135-165 psig 200 psig
AK M6025 225-275 psig 325 psig
Table 1. Crossover Relief Valve Nominal Set Pressures
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AK M60 Manual P/N 00-15000012 Rev 1
4.5. Purge and Vent Equipment
If required due to gas properties (such as for hazardous gases), install purge and vent valves to enable the
operator to remove hazardous gases from the lines using an inert purge gas before connecting and
disconnecting gas cylinders.
4.6. Initial Leak Test
Note: Depending on the application, the user may opt for skipping the initial leak test and connect the
process gas cylinders. A leak test should be performed as described in 5.1.2 as part of the initial
pressurization.
Connect a nitrogen (or other appropriate inert gas) cylinder with a pressure regulator to the pigtail lines
connected to the AK M60 manifold Source A and Source B inlet ports using appropriate adapter fittings.
Regulate the pressure to less than the manifold maximum inlet pressure and no more than 90% of the inlet
gauge maximum range.
Pressurize the manifold with nitrogen and then isolate the supply gas cylinder.
Check all lines for leaks by listening for audible leakage and applying soap solution to NPT connections.
Monitor the pressure gauges on the AK M60 manifold for a pressure drop that would indicate a leak.
If any leaks are found, then disassemble, repair, and retest.
Disconnect the nitrogen cylinder.
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AK M60 Manual P/N 00-15000012 Rev 1
5. OPERATION
This section describes operation of the AK M60 crossover manifold.
Figure 3. AK M60 Installation Schematic
5.1. AK M60 Operation
5.1.1. General Principle of Operation
The knob for the crossover regulator has an “IN SERVICE” label with an arrow. When the knob is turned
so that the arrow points toward the Source B (right) cylinder (approximately the 4:30 o’clock position
with the outlet pressure gauge at 12:00 o’clock position), then the Source B (right) cylinder is the primary
gas supply and the Source A (left) cylinder is the standby gas supply. This knob position is shown in
Figure 1. When the knob is turned so that the arrow points toward the Source A (left) cylinder
(approximately the 7:30 o’clock position), then the Source A (left) cylinder is the primary gas supply and
the Source B (right) cylinder is the standby gas supply.
The crossover regulator is comprised of a fixed outlet pressure regulator and an adjustable (limited range)
outlet pressure regulator. The Source A (left) cylinder supplies the fixed outlet pressure regulator. The
Source B (right) cylinder supplies the adjustable outlet pressure regulator. The adjustable outlet pressure
regulator has the “source selection outlet” knob with the “IN SERVICE” label and arrow. This regulator
can be rotated only 270 degrees to adjust the Source B outlet pressure slightly above or slightly below the
Source A fixed outlet pressure. It is this slight change in Source B outlet pressure that selects which
cylinder is supplying gas and which cylinder is on standby. When the cylinder supplying gas is depleted,
then it is time to replace that cylinder using the protocol in Section 5.1.3 or 5.1.4 as appropriate.
5.1.2. Initial Pressurization with Process Gas
Confirm that an initial leak test has been performed and all leaks repaired.
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AK M60 Manual P/N 00-15000012 Rev 1
Close all system valves.
Rotate source selection knob on AK M60 crossover regulator clockwise until internal stop is contacted.
The knob will rotate approximately 270 degrees. The “IN SERVICE” label arrow on the knob should be
pointing toward the Source B (right) cylinder (approximately the 4:30 o’clock position).
Open Source B cylinder valve and manual valve between Source B (right) cylinder and AK M60
crossover manifold. Pressure on Source B (right) gauge should indicate the cylinder pressure.
Open Source A cylinder valve and manual valve between Source A (left) cylinder and AK M60 crossover
manifold. Pressure on Source A (left) gauge should indicate the cylinder pressure.
Check all system connections for leaks. This can be done with soap solution on each connection, by
listening for an audible hissing sound, using an appropriate gas detector, or a pressure decay test that
monitors system pressure gauges.
5.1.3. Source B (right) Cylinder Depleted
Confirm that Source B (right) cylinder is depleted by reading the pressure gauge. The exact pressure will
depend on the specific AK M60 model. The approximate pressure when the Source B cylinder is depleted
is given in Table 2.
Rotate source selection knob on AK M60 crossover manifold counterclockwise until internal stop is
contacted. The knob will rotate approximately 270 degrees. The “IN SERVICE” label arrow on the knob
should be pointing toward the Source A (left) cylinder (approximately the 7:30 o’clock position).
Close Source B (right) cylinder valve and manual valve between Source B (right) cylinder and AK M60
crossover manifold. If required, operate equipment to purge line from cylinder to manifold.
Disconnect depleted Source B cylinder and connect full cylinder.
Open Source B (right) cylinder valve and manual valve between Source B (right) cylinder and AK M60
crossover manifold. Pressure on Source B (right) gauge should indicate the full cylinder pressure.
AK M80 Model Source B Depletion
Pressure, psig
AK M6010 100
AK M6015 150
AK M6025 250
Table 2. Approximate Source B Cylinder Depletion Pressure
5.1.4. Source A (left) Cylinder Depleted
Confirm that Source A (left) cylinder is depleted by reading the pressure gauge. The exact pressure will
depend on the specific AK M60 model. The approximate pressure when the Source A cylinder is depleted
is given in Table 3.
Rotate AK M60 crossover manifold “selection” knob clockwise until internal stop is contacted. The knob
will rotate approximately 270 degrees. The “IN SERVICE” label arrow on the knob should be pointing at
approximately 4:30 o’clock position toward the Source B (right) cylinder.
Close Source A (left) cylinder valve and manual valve between Source A (left) cylinder and AK M60
crossover manifold. If required, operate equipment to purge line from cylinder to manifold.
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AK M60 Manual P/N 00-15000012 Rev 1
Disconnect depleted Source A cylinder and connect full cylinder.
Open Source A (left) cylinder valve and manual valve between Source A (left) cylinder and AK M60
crossover manifold. Pressure on Source A (left) gauge should indicate the full cylinder pressure.
AK M60 Model Source A Depletion
Pressure, psig
AK M6010 85
AK M6015 135
AK M6025 225
Table 3. Approximate Source A Cylinder Depletion Pressure
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AK M60 Manual P/N 00-15000012 Rev 1
6. TROUBLESHOOTING
The most common problem conditions and possible causes/corrections are described below. Please
contact the factory for assistance with other problem conditions or to discuss a specific problem in more
detail.
6.1. External leak
Possible causes:
Connection not assembled properly with Teflon tape.
Connection not tightened properly.
Correction:
Inspect equipment to determine source of the leak. Repair leak by disassembling the connection,
inspecting parts, and reassembling using good shop practice.
If the leak is from the bonnet of the regulator, then AP Tech recommends that the AK M60 manifold
be sent back to the factory for repair. However, a field repair kit is available.
6.2. Relief valve is opening and venting gas
Possible causes:
Relief valve opens below set pressure.
High delivery pressure (see section 6.3).
Correction:
Verify relief valve is opening below set pressure by checking pressure on outlet gauge. If gauge
reading is within range listed in Table 1, then remove and bench test relief valve. Replace relief valve
if defective.
6.3. High delivery line pressure
Possible causes:
Other gas source from point of use is pressurizing delivery line.
Seat leak or high creep on AK M60 crossover regulator.
Correction:
Check to see if a different gas source can be pressurizing the line.
If another gas source is not the cause of the high delivery line pressure, then it is likely the AK M60
crossover regulator has a seat leak or high creep and AP Tech recommends that the AK M60
manifold be sent back to the factory for repair. However, a field repair kit is available.
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AK M60 Manual P/N 00-15000012 Rev 1
6.4. Low delivery line outlet pressure
Possible causes:
Flow restriction.
High flow at point of use
Correction:
Shut off the supply to the point of use and see if the line outlet pressure returns to normal setting. If
outlet pressure returns to normal, then high flow or a flow restriction is the likely cause. Check the
flow requirement at the point of use.
6.5. Both cylinders empty simultaneously
Possible causes:
External leak on high pressure connection from standby cylinder to AK M60 crossover manifold.
Vent valve leaking past seat (if installed).
High flow at point of use.
Seat leak on crossover regulator supplied by standby gas cylinder.
Correction:
Check for external leaks especially on the high pressure line from the standby cylinder to the
AK M60 crossover manifold.
If there is a vent valve on the line from the gas cylin der to the AK M60 crossover manifold, check to
see if the vent valve is leaking across the seat.
Verify the flow demand is below the manifold rating. In general, high flow will empty the “IN
SERVICE” cylinder faster than the standby gas cylinder.
Momentarily shut off the cylinder valve on the standby gas cylinder. If the pressure on the standby
gas cylinder pressure gauge drops, then high flow demand or a seat leak on the regulator supplied by
the standby gas cylinder is the probably cause.
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