Air Liquide ALPHAGAZ OP 350 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 350
Manifolds
Steel /brass
Operating manual

2
Manifolds steel /brass
Content Page
1Preliminary notes – Warranty and liability 4
2 Usage 5
2.1 Function 5
2.2 Type of Gas 5
2.3 Devices for requiring acceptance plants 5
2.4 General conditions for operation, transport and storage 5
2.5 Connections 5
2.6 Intended use 5
2.7 Guidelines 6
3Safety instructions 7
3.1 The handling of gases 7
3.2 Gas-specific design 7
3.3 Duties of the operator 7
3.4 Duties of the personnel 7
3.5 General regulations and notes 7
3.6 The resistance of the materials 7
3.7 Purging – leakage of harmful gases and vapors 7
3.8 Dangers due to pressure energy 7
3.9 Special hazards due to leakage 7
3.10 Dangers due to electrical energy 8
3.11 Cleaning the gas appliances and disposal of residues 8
3.12 Notes on special types of gas 8
4 Marking 8
4.1 Name plate 8
4.2 CE marking 8
5Flow scheme 9
6 Installation 10
6.1 Assembly 10
7 Operation 11
7.1 Commissioning 11
7.2 Changeover and cylinder change 11
7.3 Decommissioning 11
8Operation of the gas shortage warning device 12
8.1 General operation of the gas shortage warning device 12
8.2 Notes on pressure transmitter or cylinder scale 12
9Instructions for operation and maintenance 13
9.1 Troubleshooting 13
9.2 Maintenance 14
9.3 Repairs 15
9.4 Disposal and recycling 15
10 Gas compatibility 16

3
SGA2 SA
SGA2 SA V
SGA2 SA.S
SGA2 SA.S V
SGA2 P
SGA2 P V
SGA2 P.S
SGA2 P.S V
SGA2 M
SGA2 M V
1
1
1712
12
1271
6
1
7
4
11
11
11
2
22
22
3
3
8
6
6
6
9
9
9
10
10
1. Purge Valve
2. Process Gas Valve
3. Regulator
4. Regulator
5. Connection pig tails / flexible hose
6. Back pressure manometer gauge
7. Pre pressure manometer gauge
8. Active side switch
9. Block valve right
10. Block valve left
11. Safety relief valve
12. Outlet process gas
(Use of orifice (according to type of gas))
55

4
These devices are precision instruments of the highest qual-
ity. Through the use of selected materials, high surface qual-
ity and tightness it’s possible to control pressure and flow of
pures gases with consistent accuracy.
All steps – from conception, through production to final in-
spection – are subject to the strict criteria of our quality as-
surance according to DIN EN ISO 9001.
Each complete system and its individual parts are tested for
function and tested with helium for leak tightness, thus guar-
anteeing the well-known quality.
The warranty period of this fitting supplied by AIR LIQUIDE is
one year, including spare parts and repair, excluding postage
and packing costs.
Excluded from the warranty are gaskets, these parts are sub-
ject to natural wear.
No warranty is given for the following reasons:
• unsuitable and improper use
• improperly carried out repairs
• installation of non-original spare parts
• failure to follow these operating instructions.
For further information please refer to the General
Terms and Conditions of AIR LIQUIDE.
According to the legislator, the operator is responsible for the
safety and health of his employees. He is obliged to prepare
a risk analysis of his company. He must also provide employ-
ees with the necessary work equipment to prevent hazards
from arising. In addition, must regularly monitor and docu-
ment the safety-related systems document this.
This operating manual is intended to help that a small part
of these requirements can be met.
Our pressure control panels comply with the actual rules of
regulation and are design according to the state of the art.
Our “General Terms and Conditions of Sale and Terms of
Delivery” apply. These are available to the operator at the
latest upon conclusion of the contract. Warranty and liability
claims for personal injury and property damage are excluded
if they are attributable to one or more of the following causes:
• Improper use of the equipment.
• Improper installation, commissioning, operation and main-
tenance of the pressure and maintenance of the equip-
ment.
• Operation of the pressure equipment with defective safety
devices or improperly installed or or non-functioning safe-
ty and protective devices.
• Failure to observe the instructions in the operating manual
regarding transport, storage, assembly, commissioning,
operation, maintenance and set-up of the pressure equip-
ment.
• Unauthorized structural modifications to the pressure
equipment.
• Unauthorized alteration of the cylinder connections for the
use of other types of gas, exceeding the permissible inlet
pressure permissible inlet pressures, the use of foreign or
non-original seals.
• Inadequate monitoring of equipment, screwed connections
and sealing parts that are subject to wear.
• Improperly performed repairs.
• Exceeding or falling below the temperature range specified
in the data sheet during operation or during storage.
• Catastrophic events due to the effects of foreign bodies
and higher force majeure.
1 Preliminary notes
Warranty and liability

5
2.2 Type of Gas
Depending on the version of the manifold, for high purity
gases incl. 6.0. See gas compatibility table Chapter 10.
2.3 Devices for requiring acceptance
plants
Details of required test certificates or certificates for materi-
als, tightness, etc. must be known when the order is placed.
2.4 General conditions for operation,
transport and storage
Ambient temperatures: -20°C to 50°C
Transport and storage: -20°C to 55°C
Atmospheric conditions:
  rel.Humidity: 50 %at40°C
    90 %at20°C
Environment: ambient air free of unusual quantities of dust,
acids, corrosive gases or substances such as
smoke, steam, oil vapor, etc.
Note: Use of pressure control panels unprotected out-
doors will impair the quality of the gases and can en-
danger the functional safety.
Deviating conditions can be agreed between the manufac-
turer and user upon.
2.5 Connections
Input station:
More detailed information can be found in the corresponding
product data sheet.
Output Station:
More detailed information can be found in the corresponding
product data sheet.
Purge outlet:
More detailed information can be found in the corresponding
product data sheet.
2.6 Intended use
The pressure device is intended exclusively for the pressure
regulation of gaseous media from pressurized gas cylinders.
Any other use or use beyond this is considered to be not in
accordance with the intended use.
Intended use also includes
• observance of all instructions in the operating manual,
• observance of the inspection and maintenance work,
• observance of the type plate and the data sheet
2.1 Function
Pressure manifolds are used as central supply system for
technical and high-purity gases to supply one or more points
of use. The points of use are are supplied via a piping system
connected downstream the manifold.
Pressure control panels are available in various designs:
1. One-sided for connection of one or more cylinders.
These stations are used wherever a working process
can be interrupted due to a gas shortage or where the
gas consumption is so low that a cylinder change can
be calculated.
2. Manual changeover for connection of 2x1 or several
cylinders stored on two sides. The area of application
of this design is everywhere, where a process cannot be
interrupted due to a lack of gas, but a manual process
cannot be interrupted due to lack of gas, but a manual
changeoverispossible(e. g.duringnormalworking
hours).
3. Automatic changeover for connection of 2x1 or more
cylinders stored on two sides. If a working process runs
for a longer period of time and cannot be interrupted due
to lack of gas and a manual changeover is not possible
intermsoftime(e. g.outsideworkinghours,atnightor
at the weekend), then the use of these stations is re-
quired.
4. All pressure control panels can be supplied with pres-
sure transmitters. For flammable gases as Ex-version,
also for Ex-zone 1+2 applicable. The cylinder pressure
is measured in conjunction with a signal device which
indicates the level of ga in the cylinder. If the pressure
is below of a warning value, an alarm will be triggered.
5. Stations for oxygen, nitrous oxide and carbon dioxide
can be supplied with gas heaters.
6. If larger quantities of gas are required, it is of course
possible to luse cylinder bundles, which can be con-
nected via a high-pressure hose (please note the max.
flow rate of the station).
7. Pressure control panels can be extended as required by
retrofitting extension modules. The respective cylinder
pressure(max.200/300barat20 °C)isadjustedbythe
pressure regulator to the desired outlet pressure. The
exact parameters can be found from the data sheet or
product catalog.
8. A line shut-off valve should be installed in the pipeline
downstream of the battery pressure regulator. A protec-
tion against excess pressure of the main piping is man-
datory, here we recommend the installation of a suitable
safety valve. Options esspecially for the manifolds are
listed in the data sheet under “Options”.
2 Usage

6
2.7.5 FOOD regulation (EC) n°1935/2004
The AL equipment enhancing the term “FOOD” in their des-
ignation are specifically designed for use with food gases
used for food and beverage applications. 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,e. g.metalelements,tofoodin
quantities that could endanger human health, modify food
composition or deteriorate organoleptic characteristics is
expected.
Nethertheless, the end-user must check the compliance with
an eventual national regulation.
Articles for food usage has a Food logo marking. For trace-
ability purposes, the batch number is written on each article
and AL can perform a batch recall, as requested by its Quality.
2.7.6 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 installa-
tion.
2.7.7 Testing
Prior to packing, each valve is checked for function and for
tightness.
2.7 Guidelines
2.7.1 Conformity
AIR LIQUIDE certifies that these equipment are in conformity
with the technical specifications of AIR LIQUIDE, which have
been manufactured, tested and inspected accordingly. The
manifolds are suitable for use with oxygen, provided that the
valve is specified for this purpose in chapter 10.
Please observe the relevant national and international laws,
regulations, directives,standards, technical rules as well as
the regulations and bulletins of employers’ liability insurance
association.
2.7.2 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require
ments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.
2.7.3 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 ; con-
sequently, they shall not bear the CE marking.
The regulators are not capable of causing an explosion
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
accordingly during installation and operation. Reminder: it is
the responsibility of the end user to define the ATEX zone.
2.7.4 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presentinaconcentrationabove0,1 %inour
products made of brass.
Lead inclusion in the SVHC list in June 2018 does not modify
the use conditions described in operating instructions.
Lead will not be released to the surrounding environment or
the gas used during normal use. After product end of life, the
pressure reducers must be scrapped by an authorized metal
recycler.

7
3.5 General regulations and notes
The pressure control panels comply with the state of the art
and the recognized rules of technology. The devices have
been designed in accordance with the PED Article 4,
Paragraph 3, and are manufactured in accordance with good
engineering. Without the approval of the manufacturer no
modifications shall be made.
• Smokingorflames(e. g.candles)inthevicinityofyourgas
supply is strictly prohibited! Fire and explosion hazard!
• Donotuseinambienttemperaturesbelow 20 °Cand
above+ 50 °C,donotuseforgasesintheliquidphase.
• Use only for the marked pressures.
3.6 The resistance of the materials
The resistance of the materials is only ensured with dry gas
and dry flushed piping and fittings.Incorrect assembly, leak-
ing screw connections or improper purging can lead to a
limitation of the service life.
3.7 Purging – leakage of harmful gases
and vapors
When purging the system, care must be taken to ensure that
the gas can be discharged or disposal of the gas must be
ensured. This also applies to the outlet of the relief valve on
the pressure regulator.
When safety devices are open or in the event of a malfunction
harmful gases and vapors may escape. Ensure sufficient
ventilation or extraction.
3.8 Dangers due to pressure energy
Depressurize piping sections before starting repair work.
Check or even replace flexible hose at appropriate intervals,
even if no safety-relevant defects are apparent.
External influences such as high temperatures, heat radia-
tion, impact and the like, pressurized gas cylinders or pres-
surized system parts can become very hot or burst. Take
appropriate precautions and safety measures.
3.9 Special hazards due to leakage
Due to the use of very hazardous, hazardous or less hazard-
ous gases, leakages of equipment may result in danger to
life of the user.
Therefore, an operating instruction according to § 20
GefStoffV,anactualEUsafetydatasheetaccordingto§14
GefStoffV and a tremcard with instructions for the physician
in a suitable place.
Operators must be aware of the particular hazards of the gas
and of possible personal and other protective measures. be
pointed out.
3.1 The handling of gases
The handling of technical and high-purity gases, in particular
toxic (poisonous), flammable or fire-promoting gases, re-
quires expert knowledge, the observance of these operating
instructions and the existing regulations.
The training and regular safety instruction of the operating
personnel on how to handle this equipment, with toxic (poi-
sonous), flammable or fire-promoting gases and pressurized
gas containers is mandatory. In case of improper handling
and/or use of the equipment the equipment may result in
danger for the operating personnel and other persons as well
as damage to the system and the environment may occur.
These operating instructions must always be available to the
operating personnel at all times.
3.2 Gas-specific design
The manifold may only be used for the specified gas type
(see chapter 10). Alternating use for different gases and the
attachment of adapters to the cylinder connection is not per-
mitted. The selection of materials and gaskets is only related
to the respective specified gas type.
3.3 Duties of the operator
The operator is obligated to only allow persons to work on
the pressure device who
• are familiar with the basic regulations on work safety and
accident prevention and
• have permanent access to these regulations,
• have read and understood the safety chapter and the warn-
ing notes in this operating manual. These employees are
trained and instructed in order to be able to work on the
pressure control panels.
• The safety-conscious work of the personnel is checked at
regular intervals.
• The responsibilities of the personnel for assembly, com-
missioning and operating must be clearly defined.
• Personnel to be trained may only work on the pressure de-
vice under the supervision of an experienced supervisor.
• All safety and danger notices must always be kept in a
readable condition.
• The required personal protective gear must be provided by
the operator.
3.4 Duties of the personnel
All persons who are assigned to work on the pressure equip-
ment are obligated to read and understand the fundamental
safety and accident prevention regulations and to familiarize
themselves with the safety data sheet for the type of gas
used.
3 Safety instructions

8
4.1 Name plate
A name plate with following information is located on the
base plate of the manifold:
Manufacturer, date of manufacture, type designation, ap-
proved prepressure pressure (P1), unit-specific backpressure
or mean closing pressure (P2), maximum flow rate and part
number.
The serial number is printed as a device-specific identifier on
a separate label in barcode 128 and in plain text.
4.2 CE marking
Since the station has been designed according to “good en-
gineeringpractice”inaccordancewithArticle4,Para.3,the
station must not be CE marked. The marking of the manu-
facturer is affixed to the nameplate.
3.10 Dangers due to electrical energy
Work on electrical components, display and control units
(e. g.ALMS)mayonlybecarriedoutbyaqualifiedelectrician.
Check the electrical equipment of the plant regularly. Loose
connections and damaged cables must be immediately re-
paired or replaced.
The control cabinet or the electrical assemblies must always
be locked at all times. Access is only permitted to authorized
personnel with a key or tool.
If it is necessary to work on live parts, a second person must
be called to switch off the main switch if necessary.
3.11 Cleaning the gas appliances and
disposal of residues
Used equipment or equipment which is going through a main-
tenance check must be purged with inert gas (nitrogen, ar-
gon). Take care of solid gas residues in an appropriate man-
ner. In particular, do not contaminate with oily rags or lubri-
cants. Do not clean with solvents.
3.12 Notes on special types of gas
All parts that come into contact with oxygen must be kept
free of oil and grease. Only use lubricants with special oxygen
approval.
4 Marking

9
5 Flow scheme
SGA2 P
SGA2 P V
SGA2 P.S
SGA2 P.S V
SGA2 SA
SGA2 SA V
SGA2 SA.S
SGA2 SA.S V
SGA2 M
SGA2 M V

10
6.1.6 Check connection threads and connection surfaces
of the cylinder valves and the gaskets for proper con-
ditionandfit(seeFig.8.10 / 8.11).MountFlexible
hoses / pigtailswithhandconnection(Oringseal)
without tools on the cylinder valve. Before connecting
theflexiblehose / pigtail,brieflyopenthecylinder
valve once and then close it again, to blow out any dirt
particles that may be present. Do not stand in front of
the outlet opening of the of the valve (7) and make
sure that no danger arises from the escaping gas.
Good ventilation must be provided. Do not blow out
flammable, corrosive, toxic and irritant gases.
6.1.7 At the outlet of the pressure regulator (12), the orifice
plate included in the scope of delivery or optionally
supplied must be inserted or mounted, depending on
the type of gas.
Adapt the outlet to the pipeline by using a compres-
sion fitting. Shortly after the outlet of the pressure
regulator (12), a main line shut-off valve and, if neces-
sary, a safety valve should be installed in the pipeline.
6.1.8 When toxic or flammable gases are used, safe dis-
charge of the purge gas must be ensured. The exhaust
gas pipes must be connected to the outlet connection
of the blow-off valve on the pressure regulator (3 or 8)
and to the purging valves (1) by using compression
fittings.
6.1.9 After successful installation, the system must be purged
with dry inert gas of suitable quality (e.g. nitrogen). All
detachable connections must be leak tight. The tight-
ness test must be certified and checked repeatedly at
regular intervals.
6.1 Assembly
6.1.1 Assembly may only be carried out by persons who are
trained, experienced in the field of application (gas
installations) and have been instructed in safety tech-
nology. The trainings and instructions must be carried
out in regular intervals.
6.1.2 The pressure manifolds shall be supplied pre-assem-
bled as far as possible. Check scope of delivery in
accordance with the datasheet. Check on the basis of
the type plate whether the station is suitable for the
intended use (pressure, gas type, material).
6.1.3 Determine the dimensions of the drill holes according
to the data sheet and fasten the base plate with ap-
propriate screws.
6.1.4 The Cylinder brackets must be fixed on a Wall or similar.
The support must be sufficient to prevent the Cylinder
from falling down. When doing this the outer edges of
the base plate should be vertical and approx. 3/4 of
thecylinderheight(foracylinderheightof1500 mm,
thisisapprox.1100 mm)ashorizontalorientation.
6.1.5 Hose lines / spiral tubes (5) via adapter / check valve
or check valve with filter (antiflapping). First screw the
adapter / check valve into the station inlet first.
The tool must only be applied to the narrow hexagonal.
Then mount the hose line / spiral pipe on the check valve
while holding it against the fitting body with a second wrench.
6 Installation
O-Ring O-Ring
Abb. 8.10 300 bar Abb. 8.11 200 bar