Air Liquide ALPHAGAZ OP 150 User manual

R1-08/04/14
ALPHAGAZ logotype - cmyk
AIR LIQUIDE 62386
C 100
M 16
Y 0
K 27
C 0
M 20
Y 100
K 0
OP 150
Pressure reducers for cylinders
used with pure gases
User manual

2
Content Page
1 Use 4
1.1 Intended use 4
1.2 Unintended use 4
1.3 ATEX Directive 2014/34/EC 4
1.4 REACH regulation (EC) n°1907/2006 4
1.5 PED Directive 2014/68/EC: Pressurized equipment 5
1.6 FOOD regulation (EC) n°1935/2004 5
1.7 Cleaning 5
2Safety instructions 5
3Starting operation 6
4Stopping operation 8
5Operation and maintenance note 9
5.1 Troubleshooting 9
5.2 Maintenance 9
5.3 Disposal 10
6 Repairs 10
7Cylinder pressure regulators with flow meter gauge 10
8 Guarantee 10
9 Note 10
Appendix 1 Gas compatibility 11

3
1
1
1
3
3
3
4
4
4
7
8
8
6
6
6
5
5
5
2
2
2
8
7
7
DHP
DHPS
DIM
DLM
DLM-CO
HBD
HBD.S
HD
HDBS
HD-CO
HBS
HBSI
BSI-GLC 50
Hepal 12 FOOD
AHL

4
1 Use
1.1 Intended use
These cylinder pressure regulators are intended
for use with compressed gases released under
pressure, on pressurized gas cylinders up to 300
bar filling pressure (depending on technical de-
sign) as well as for under pressure liquified gases,
to reduce the corresponding cylinder pressure and
to keep the desired working pressure constant.
The pressure regulator must only be used for
gases for which they’ve been designed for. See
gas compatibility table in Appendix1.
1.2 Unintended use
• Pressure regulation valves must not be
used for liquids.
• Pressure regulators must not be operated
in ambient temperatures below -20 °C and
above 50 °C (see datasheet).
• Only use pressure reducers for the gases
intended for them. These can be found in the
gas compatibility table (see attachment1)
or in the corresponding product catalogue.
Description according to EN ISO 2503
1. Cylinder valve
2. Inlet connection
3. High pressure gauge
4. Low pressure gauge
(gauge l/min in pressure regulator with flow-
meter gauge)
5. Pressure adjustment screw
6. Shut-off valve
7. Outlet connection
(E.g.. hose nozzle with filling nut.
Not included in the package.)
8. Pressure relief valve
On the regulator
Date of production – Code
Manufacturer Code
1.3 ATEX Directive 2014/34/EC
The cylinder pressure regulators are not in the
scope defined in points a), b) et c) of the article of
the ATEX Directive ; consequently, they shall not
bear the CE marking.
The regulators are not capable of causing an ex-
plosion through their own potential sources of
ignition: thus, they can be installed in ATEX zone
1 or 2, provided that up to date regulations, rules
and operating instructions are observed accord-
ingly during installation and operation.
Reminder: it is the responsibility of the end user to
define the ATEX zone.
1.4 REACH regulation (EC)
n°1907/2006
The pressure reducers are made of brass parts,
essentially the body, which is a copper alloy with
a lead content between 1 % and 4 % w/w. As
requested by art. 33 of REACH Regulation
(Registration, Evaluation and Authorisation of
Chemicals) and with reference to current list of
SVHC (substances of very high concern) available
on ECHA website, we inform that lead may be pre-
sent in a concentration above 0,1 % in our prod-
ucts made of brass.
This operating manual is intended to ensure the
safe use of the pressure regulator for its intended
purpose. Reading and following instruction in the
operating manual contributes to prevent hazards,
reduce downtime and increase reliability and ser-
vice life of the devices.
THIS OPERATING MANUAL
MUST ALWAYS REMAIN
AVAILABLE WITHIN REACH.
For safety instructions see also Point 2: in case
of doubt the manufacturer or distributor should
be contacted.

5
Lead inclusion in the SVHC list in June 2018 does
not modify the use conditions described in operat-
ing instructions.
Lead will not be released to the surrounding envi-
ronment or the gas used during normal use. After
product end of life, the pressure reducers must be
scrapped by an authorized metal recycler.
1.5 PED Directive 2014/68/EC:
Pressurized equipment
The AIR LIQUIDE fittings with a nominal diameter
<25 mm (e. g. pressure regulators, valves, filters,
etc.) meet the requirements of Article4, Paragraph3
of the Directive 2014/68/EU and the provisions of
the article. Therefore these devices do not bear a
CE marking according to Article18 of this Directive.
1.6 FOOD regulation (EC)
n°1935/2004
The AL equipment enhancing the term “FOOD” in
their designation are specifically designed for use
with food gases used for food and beverage ap-
plications. They are compliant with Regulation EC
1935/2004 which requires that packaging and
articles intended to be in contact with foodstuffs
are to be manufactured in compliance with good
manufacturing practices and standard operating
procedures.
Thus, under normal or foreseeable conditions of
use, no transfer of contaminants, eg, metal ele-
ments, to food in quantities that could endanger
human health, modify food composition or dete-
riorate organoleptic characteristics is expected.
Nethertheless, the end-user must check the com-
pliance with an eventual national regulation.
Articles for food usage has a Food logo marking.
For traceability purposes, the batch number is
written on each article and AL can perform a batch
recall, as requested by its Quality.
1.7 Cleaning
Each equipment is subject to a grease removal
and a high quality cleaning to preserve the purity
of gas in the equipment as well as for use with
oxygen for compatible equipment.
A suitable packaging protects the equipment against
exterior pollutants during storage and transport.
Take care to avoid polluting the equipment during
installation.
2 Safety instructions
All indications labeled with this symbol are
considered as special safety instructions.
2.1 The pressure regulators conform to the rec-
ognized state of the art, as well as the
requirements of existing standards.
• No changes or alterations may be performed
without the manufacturer‘s permission.
2.2 No adapters should be installed between
the cylinder valve and the cylinder pressure
regulator.
Improper operation, or use for purposes
other than those intended can create haz-
ards for the user and other persons, as well
as damage to the pressure regulator.
In general, the regulations, standards and legal
guidelines of the country of use are applied. As fol-
lows the most important from the D-A-CH region.
2.3 Regulations that are applicable in Germany:
2.3.1 Accident prevention regulations /
DGUV rules
• 100-001 “Principles of prevention“
• 113-001 “Explosion prevention rules“
Name plate
• 100-500 “Operation of work equipment“
2.3.2 Laws, directives, technical regulations
Product safety law (ProdSG) with the
specific:
• Product safety directives (ProdSV), e.g.
Explosion protection directive (11. ProdSV)
or Pressure device directive (14. ProdSV)
5.Dimensional drawing
• Work safety directive with Appendix 1 – 3
• Work safety technical rules (TRBS)
• Hazardous materials technical rules
(TRGS)
• Plant safety technical rules (TRAS)
2.3.3 Bulletins, norms and guidelines
• Pressure equipment directive, 2014/68/EU
• Bulletin Use of compressed gas cylinders
(DVS 0212)
• Refer to the safety data sheets of each
specific gas type

6
2.4 Regulations that are applicable in Austria:
• Employee protection law ASchG
• Work equipment directive (AM-VO) BGBL.
II. Nr. 164/2000 igF.
• General operating instructions for acetylene
welding and cutting equipment according
to § 26 para. 4 of the AM-VO.
2.5 Regulations that must be observed in
Switzerland:
• SR 832.20 Federal Act on Accident Insu-
rance (AIA)
Art. 82 The employer is obligated to take all
the necessary steps to prevent workplace
accidents and occupational diseases,
which, according to experience, are neces-
sary, can be applied according to the latest
technology and are appropriate for the re-
spective circumstances.
• SR 832.30 Ordinance on the Prevention of
Art.3
• SR 930.114 Ordinance on the Safety of
Pressure Equipment (Pressure Equipment
Regulation, DGV)
• SR 832.312.12 Ordinance on the Safety and
Health Protection of Workers in the Use of
Pressure Equipment (Use of Pressure
Equipment Ordinance, DGVV)
• PrSG = Bundesgesetz über die Produkte-
sicherheit SR 930.11
- Verordnung über die Produktesicherheit
PrSV SR 930.111
- Verordnung über die Sicherheit von Ma-
schinen SR 819.14
2.6 Safety instructions for toxic and corrosive
gases:
• Due to malfunctions or open safety devices,
harmful gases and vapors can may escape.
Ensure sufficient ventilation or exhaust ven-
tilation. In case of hazardous gases, take
special actions. In particular, connect the
outlets of the savety valve and purge valves
with fixed pipelines and dispose the sub-
stances in a safe and evironmentally com-
patible manner.
• When changing cylinders with toxic, flam-
mable or corrosive gases, appropriate per-
sonal protection measures must be taken.
The permissible values of the workplace
concentration must be observed.
• Operators must be made aware of the spe-
cial hazards of the gas and of possible per-
sonal and that other protective measures
are pointed out.
Toxic and corrosive gases:
- Risk of poisoning and chemical burns!
Flammable gases:
- Fire and explosion hazard!
Oxidizing gases:
- Strongly fire-promoting!
Inert gases:
- Risk of suffocation!
3 Starting operation
The sequence must be strictly
respected!
Explosion hazard! All parts such as tools
and hands that come into contact with
oxygen must be kept free from oil and
grease.
3.1 Before starting work, the instructions in this
operating manual must be read and fol-
lowed during the work!
3.2 Check if the pressure regulator is suitable
for the intended gas type and pressure (see
symbol Point 3).
3.3 Before using the pressurized equipment make
sure that no one can be injured or endan-
gered by starting up the the pressurized unit.
3.4 Check if the cylinder valve connector and
the seal are clean and undamaged. In case
of any damage, the pressure regulator must
not be connected.
Before connecting the regulator, briefly
open the cylinder valve once and close it
again to blow out any dirt particles that
may be present. Do not stand in front of the
outlet of the valve and make sure that there
is no danger from the escaping gas. Ensure
good ventilation. Do not blow out flamma-
ble, corrosive, toxic or irritant gases.
3.5 Connect the regulator with screw connec-
tion to the bottle valve (1) using a suitable
spanner or connection bracket (2) in a gas-
tight manner. For regulators with manual
connection (O-ring seal), this screw connec-
tion must be tightened by hand. No tools
must be used for manual connection. The

7
mounting position of the regulator must
always be vertical to the pressure gauges.
3.6 Mount a suitable compression fitting/hose
nozzle on the outlet of the regulators and
seal it using a suitable wrench.
3.7 Connect the hose nozzle to the outlet con-
nection (7) and to the consumer device.
Link the hoses and hose connections (hose
nozzles) according to the current standard.
Secure hoses with suitable hose clamps.
1. The clamped metal tubes must always be
softer than the material of the double fer-
rule fittings. For example, stainless steel
tubes must never be used with brass tube
fittings.
2. Support sleeves are always necessary for
soft or flexible tubes. They give the hose the
strength it needs for a leak-free seal.
3. Make sure that the tube is cut perpendicular
(a good quality tube cutter with a suitable
cutting edge is recommended) and de-
burred. There must be no chamfer at the
end of the pipe.
4. Insert the tube inside the connector up to
the stop limit on the body. Clamp the nut
completely by hand (Fig.1).
Clamp ring fitting
incl. seal
1
5. Hold the fitting body firmly and mark the
position of the union nut. Complete the
clamping using a wrench by turning the nut
a 1 1/4 turn (Fig.2). The connection is now
correctly mounted.
6. For screw connections up to 4 mm, only one
3/4 turn from the hand-tight position is per-
missible.
3.8 Instructions for reassembly
Connections can be loosened and retightened
several times while maintaining a reliable, leak-
free seal.
1. Before loosening the connection, mark the
position of the nut to the fitting body.
2. Push the pipe with pre-assembled clamping
rings into the body until the pre clamping
ring is firmly seated.
3. Tighten the union nut by hand. Then tighten
the union with the spanner until you reach
the old assembled state position. If you reach
this position, you will notice an increased
resistance when thightening. Then tighten
the union nut lightly with the open-ended
spanner. Smaller pipes require less tighten-
ing than large ones.
2

8
3.9 Adjusting the pressure
Before releasing the gas into the system, check
the following:
1. Correct version of the cylinder pressure
regulator
2. All indicators at zero
3. Pressure fully turned off on the pressure
adjustment screw (5) (anticlockwise)
4. Re-adjustment valves are closed.
Then close the shut-off valve (6) and release pres-
sure and pressure regulator by unscrewing the
pressure adjustment screw (5). Open the cylinder
valve slowly, the high-pressure gauge (3) indicates
the cylinder pressure. Open the shut-off valve (6)
and slightly open the corresponding shut-off valve
of the consumer device. Then screw down the
pressure adjustment screw (5) to set the desired
outlet pressure (operating pressure) and check it
on the low pressure gauge (4). Correct the pres-
sure setting if the pressure dips.
Perform leak test. Never use leaking or defec-
tive devices. Never point an open flame to
leaking device. Never tighten leaking screw
connections which are under pressure.
4 Stopping operation
• For short shutdown periods: close the shut-
off valve on the pressure regulator.
• For longer shutdown periods: Close the cylin-
der valve, release pressure, pressure regulator
has zero pressure, loosen pressure adjust-
ment screw (5). Close the shut-off valves on
the pressure regulator and the consumer de-
vice. Never tighten or loosen screw connec-
tors while they are under pressure!

9
5 Operation and
maintenance note
5.1 Troubleshooting
Default Cause Remedy
Mounting impossible Connections cannot be mount Verify the compatibility of
gases, inlet and outlet
Damaged connections Replace the regulator
Insufficient flow rate
Cross section of passage limited by a valve Open the valve
Insufficiently filled or empty cylinder Change the cylinder
Valve not operating Change the cylinder
Under-dimensional equipment Contact Air Liquide
Downstream device not operational Change the device
Gas leak Tightness default
Close the cylinder valve
and replace the safety valve.
Gas comes out of the
relief valve
Leakage at the poppet
or damaged relief valve
Rise of the outlet
pressure Leakage at the poppet
Unstable outlet
pressure or frosting
Working temperature too low
Close the cylinder valve.
Bring back the equipment
temperature above 0 °C.
Gas used is (Ar), carbon dioxide (CO2)
or nitrous oxide (N2O). Use a heater at the inlet.
Flow rate to high
Respect the max. flow rate
of the regulator.
Limit the flow by a valve
or a calibrated orifice.
Vibrations
Flow rate to high Limit the flow by a valve
or a calibrated orifice.
Presence of valve with quick opening
on the downstream pipe
5.2 Maintenance
Always protect the pressure regulator from dam-
age (visual inspection at regular intervals).
The factory settings of the connection
seals must not be changed.
Ensure that the connector seals, sealing surfaces
and gauges are in perfect condition.
If a fault occurs, for example if the outlet
pressure rises when output = 0, if there are
leaks into the atmosphere, the gauges are
defective, or when the safety valve is acti-
vated, shut off the pressure regulator, close
the cylinder valve immediately.
Air Liquide recommends annual periodic inspec-
tions of the pressure regulator by competent, au-
thorized personnel. The frequency of this test
depends mainly on the use of the device (inten-
sive, moderate, occasional).
Faults that occur can have many causes.
For your own safety, avoid tampering or
making repairs on your own.

10
5.3 Disposal and recycling
At the end of the equipment’s useful life or when
it is impossible to repair it, it is essential to respect
the local regulations for recycling / disposal of our
equipment. To prevent reuse, these products must
be unsuitable for use.
In accordance with EU Directive 2018/851 on
waste, the owner of the equipment ensures that
when recovery is not carried out in accordance
with article10, the waste will be subjected to safe
disposal operations that comply with the provisions
of article13 on the protection of human health and
the environment.
The licensee must take steps to promote high
quality recycling and, to this end, must establish
separate waste collections when technically, envi-
ronmentally and economically feasible and ade-
quate to meet the quality standards required by
the relevant recycling sectors.
6 Repairs
Repairs to the pressure regulators must
only be done by competent and trained per-
sonnel in authorized specialist workshops.
Only original spare parts must be used for
repairs.
6.1 If unauthorized repairs or changes are
made by the user or a third party without
permission from the manufacturer, respon-
sibility will no longer be assumed for the
consequences.
7 Cylinder pressure regula-
tors with flow meter
gauge
For these pressure regulators, points 1 to 7 in this
operating manual also apply. The flow quantity set
by the pressure adjustment screw (5) is indicated
on the flow meter gauge (4). In pressure regula-
tors with a flow meter gauge, a regulating office/
throttle (for pressure control) (9) is built in. Check
if a regulating office/ throttle (for pressure con-
trol) is already installed in your equipment. If yes
this must be removed because the mounting
holes are not adapted to the pressure regulator.
8 Guarantee
The standard warranty period is one year from the
date of delivery in accordance with the general
terms and conditions of Air Liquide. The standard
warranty period is only valid for goods that have
been used according to the operating manual and
generally applicable industry practices and stand-
ards.
9 Note
Please use the product only for the purpose that
Air Liquide intended and only if you are competent
in the application and follow the technical safety
guidelines or safety procedures. If there are any
doubts related to the use of the product, request
specific Air Liquide product information before-
hand or talk to an Air Liquide specialist.

11
Equipment Parameters Main gases
Number of
pressure stages
Max. flow rate
in Nm3/h
Adjustable
Back pressures
minimum
to maximum
in bar
Inert gases
Argon-CO2-
mixture
Carbon dioxide
Carbon
monoxide
Breathable air
Synth. air
Oxygen
Nitrous oxide
Hydrogen
Acetylen
Propane
Propylene
Ethylene
Methane
Ammonia
Chromed-brass HP Reducers AHL 1 25 1.0 - 16 200 200 50 200 200 44 200
Hepal 12 FOOD 1 25 1.0 - 16 200 200 50 200 200 HD 300 1 8 0.3 - 16 300 300 50 300 300 44 300 HD 300 CO 1 2 1.0 - 4 200 HBS; HBS.V 2 3.5 0.01 - 10 200 200 50 200 200 44 200 10 10 70 200 HDBS 2 5 0.1 - 10 300 300 50 300 300 44 300 DLM 300; DLM BA 1 100 0.5 - 50 300 300 50 200 300 44 300 DLM 200 CO 1 8 1.0 - 15 200 DLRS 1 12 0,1 - 15 200 200 50 200 200 44 DHP 200 1 30 20 - 200 200 200 200 44 DHPS 200 1 30 20 - 200 200 200 200 Stainless steel HP Reducers DIM 1 50 1.0 - 25 200 200 200 70 200 HD.S 1 5 0.2 - 8 200 200 200 70 200 HBD.S 2 5 0.2 - 8 200 200 200 70 200 HBSI 2 3.5 0.05 - 10 200 200 200 200 200 200 BSI-GLC 50 1 3.5 0.05 - 10 50
Appendix 1: Gas compatibility

A world leader in gases, technologies and services for Industry and
Health, Air Liquide is present in 78 countries with approximately 64,500
employees and serves more than 3.8 million customers and patients.
OP 150/A:01 from November 2022 · Subject to technical modifications, all data supplied without liability.
Contact
Air Liquide Deutschland GmbH
Fütingsweg 34
47805 Krefeld
Tel: [phone] - 4555
[email protected]
www.airliquide.de
Air Liquide Austria GmbH
Sendnergasse 30
2320 Schwechat
Tel: [phone]
[email protected]
www.airliquide.at
Carbagas AG
Hofgut
3073 Gümligen
Tel: [phone]
[email protected]
www.carbagas.ch
Air Liquide Romania SRL
Dinu Vintila street, no.11
Euro Tower building, 7th floor
Bucharest, District 2, 021101
Tel: [phone]/83/84
office.rom[email protected]
www.airliquide.ro
Air Liquide Polska Sp. z o.o
ul. Jasnogórska 9
31-358 Kraków
Tel: [phone]
[e-mail]
przemysl.air-liquide.pl
Air Liquide Bulgaria
Hofgut
1 Business Park Sofia Street Build. 7B
Floor 5
1766 Sofia
Tel: [phone]
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Resitpasa Mah. Eski Büyükdere Cad.
Park Plaza No:14 Kat:2 D:8
34398 Maslak
Sarıyer - Istanbul
Tel: [phone]
ww-[email protected]
tr.airliquide.com