ALPHAGAZ ML - ML1 - CLSA1

User Manualwww.airliquide.com

EN

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 1

WarningTo preserve the quality of our product throughout its usage in the best safety conditions, please read this manual carefully and strictly follow the instructionsthat it contains. Non-compliance with these instructions or modification of the product may result in serious accidents or bodily injuries. AIR LIQUIDEshall not be held responsible in case of non approved usage of the product.Air Liquide reserves the right to make all necessary modifications to the specifications described hereafter without notice.

OP 206 ML-ML1-CLSA1 08/2013 v.1.0

ML1300-16-8

ML1300-10-50

ML200-200-30

CLSA1

EN

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 3

Contents

1. Domain of usage and Characteristics............................. 41.1 Functions..............................................................................................41.2 Technical characteristics....................................................................... 41.3 Gas compatibiliy table.......................................................................... 4

2. AIR LIQUIDE commitments............................................ 72.1 Conformity ...........................................................................................72.2 Cleaning .............................................................................................. 72.3 Inspections ..........................................................................................72.4 Warranty ..............................................................................................7

3. Assembly - Activation.................................................... 83.1 Safety................................................................................................... 83.2 Precautions before assembly................................................................83.3 Assembly..............................................................................................83.4 Options.................................................................................................93.5 Checking the tightness of connections................................................. 93.6 Activation............................................................................................10

4. Usage...........................................................................114.1 Use.....................................................................................................114.2 Cylinders or Bundles change .............................................................114.3 After use.............................................................................................11

5. Maintenance.................................................................125.1 Troubleshooting.................................................................................. 125.2 Maintenance....................................................................................... 135.3 Spare parts.........................................................................................14

OP 206 ML-ML1-CLSA1 08/2013 v.1.04

1. Domain of usage and Characteristics

1.1 Functions

The ML1 & CLSA1 gas manifolds are used to:

connect one or several cylinders or bundles topipe network,

reduce a high-pressure conditioned gas (200 or300 bar at 15C) in cylinder or bundle.

ModelConnection on

Cylinders / BundlesContinued

supply

Continuouslycylinderschange

Adjustableoutlet

pressure

Gas panel ML - ML1 1x1 1x2 no no yes

Automatic changeover with reset

CLSA 1 2x1 2x2 yes yes no

The operation of the CLSA1 automatic change-over with reset is based on the assembly of twoopposing pressure regulators connected to twogas sources and adjusted to obtain a slightlydifferent pressure between the pressure regulatorinto operation and pressure regulator in the reserve.Since these two reducers have a commonoutlet, only the regulator set to the higher

pressure delivers gas to flow. When the source inservice is nearing exhaustion, the pressure dropcauses the commissioning of the second regulatorautomatically.The technician operates to switch the lever towardsthe new source to restore full operating pressure(hence the term "automatic with reset "), and thento replace the empty cylinders or bundles.

1.2 Technical characteristics

Operating temperature : -20C to + 50C

Leakage rate (Int/Ext.) : < 10-7 mbar.l/s helium.

1.3 Gas compatibiliy table

The gas manifold are mainly designed for theimplementation of pure gases and mixtures withpurity < N50 thus ALPHAGAZ 1.

IMPERATIVE: check the gasescompatibility of this equipment byreferring to the "Gas CompatibilityTable".

Legend :Suitable up to a working pressure of XXXbar at 15C.Not suitable.

* 1,013 bar at 15C, according to ISO 2503P1 Inlet = 2(P2 Outlet) + 1 bar

EN

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 5

Par

amet

ers

Mai

n g

ases

:

Outlet pressure(bar)

Pressure of gasin reserve supply

(bar)

Nominal nitrogenflow rate*(Nm3/h)

Calibration of reliefvalve (Bar)

Inerts, Nitrogen

CO2**

CO

Breathable air

Air

Oxygen

Nitrous oxide

Hydrogen

Acetylene

Propane

Propylene

Ethylene

Methane

Ammonia

Fo

r b

reat

hab

le o

xyg

en, c

orr

osi

ve g

ases

, oth

er g

ases

and

mix

ture

s : P

leas

e co

ntac

t A

IR L

IQU

IDE

.M

L -

ML1

Gas

pan

els

ML1

300

-16

-8

168

30

050

300

300

4430

0

ML1

300

-10

-50

1050

30

050

300

300

4430

0

ML

200-

200-

3020

030

20

050

200

200

4420

0

CLS

A1

Sem

i-au

tom

atic

cha

nge

ove

rsC

LSA

1 20

0-10

-10

10

1015

200

50

200

200

4420

0

CLS

A1

200-

10-

5010

5015

200

5020

020

044

200

CLS

A1

200-

20-

5020

50

25

200

5020

020

044

20

0

OP 206 ML-ML1-CLSA1 08/2013 v.1.06

Material in contact with gas :

CLSA1CLSA1

200-10-10CLSA1

200-10-50CLSA1

200-20-50

Valve block / Purge Regulators

Body Nickel Plated Brass Nickel Plated Brass

Seat PTFCE Brass

Valve / SpringBrass / PA

Brass / SS 301 Brass + PTFCE / SS

Diaphragm SS 304 Hastelloy

Piston

Filter Bronze Monel Bronze

Pressure gauge Copper Alloy Copper Alloy

Relief valve SS / NBR Brass / NBR

Seal EPDM / PA 6.6 EPDM / PA 6.6 / PTFCE

ML/ML1 ML1 300-16-8 ML1 300-10-50 ML 200-200-30

Valve block / Purge Regulators

BodyNickel Plated Brass Nickel Plated Brass

ChroniumPlated Brass

Seat PTFCE Brass

Valve / Spring Brass / PABrass / Bronze

BrassPTFCE / Bronze

Brass PTFCE

Diaphragm Hastelloy

Piston SS

Filter Bronze Monel Bronze

Pressure gauge Copper Alloy Copper Alloy

Relief valve Brass / NBR Brass / NBR Brass / NBR

Seal EPDM / PA 6.6 EPDM / PA 6.6

NBR / PTFCE /Copper

Seat diameter :

ModelsSeat diameter

(Equivalentdiameter in mm)

ModelsSeat diameter

(Equivalentdiameter in mm)

ML1 300-16-8 1,73 CLSA1 200-10-10 1,73

ML1 300-10-50 3,57 CLSA1 200-10-50 4,67

ML 200-200-30 1,73 CLSA1 200-20-50 4,67

EN

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 7

2. AIR LIQUIDE commitments

2.1 Conformity

AIR LIQUIDE certifies that the equipment ismanufactured, tested and controlled, in accordancewith the technical specifications described in thespecifications of AIR LIQUIDE.In addition to technical specifications, a degreasingprocess consistant with oxygen service is applied.It is the responsibility of the end user to ensurethat such equipment are installed and used inaccordance with the current regulations.

2.1.1 Directive 97/23/EC: Pressurisedequipment (PED)

AIR LIQUIDE equipment of DN < 25 (e.g. pressureregulators, valves, non return valves) satisfy torequirement of article 33 of 97/23/EC directiveand at the state of the art. Consequently, theseequipments shall not be "CE" marked as definedin article 15.By design, these equipment may integrate pressurerelief valves or burst disks. In this case, those onesshall neither be CE marked according to paragraph2 of annex II.In other case, pressure relief valves and burst disksshall be CE marked.

2.1.2 Directive 94/9/EC ATEX: Explosiveatmospheres

The ML, ML1 & CLSA1 gas manifolds do nothave their own source of ignition. Consequently,they are excluded from field of application of theATEX 94/9/CE directive and shall not be CEmarked.They can be used in zone 2, according to ATEX1999/92/EC pending on up to date regulations,rules, operating instruction and state of the art arefollowed during installation and use.Every installation including one of those equipmentsin ATEX zone shall comply to the ATEX directive andbe certified. Remark: It belongs to the end user todefine the ATEX zone.

2.2 Cleaning

Each equipment is subject to a grease removal anda high quality cleaning to preserve the purity of gasin the equipment as well as for use with oxygen incompatible equipment.A suitable packaging protects the equipmentagainst exterior pollutions during storage andtransport.Take care to avoid polluting the equipmentduring usage.

2.3 Inspections

Each equipment is inspected and has undergonea leak test (with helium) before packing.

2.4 Warranty

The warranty period for equipment supplied by AIRLIQUIDE is one year, covering faulty material andworkmanship during manufacture. The warrantydoes not cover packing and return transport costs.Excluded from warranty: seals and relief valves.These components are subjected to a natural wear.Warranty is not valid on deterioration resulting fromincorrect or improper use, use of spare parts whichare not marked AIR LIQUIDE or from the nonerespect of this operating instruction.For more information, refer to the general salesconditions of AIR LIQUIDE.

OP 206 ML-ML1-CLSA1 08/2013 v.1.08

3. Assembly - Activation

3.1 Safety

First of all, read and respectIMPERATIVELY the safety instructionsdescribed in the document GeneralSafety Instructions delivered with theproduct.

3.2 Precautions before assembly

After opening the packaging, check that theequipment is not damaged and that the contentscorrespond to the delivery notes accompanying theequipment. During assembly, it is important to take extreme

care to ensure cleanliness and avoid pollution. To install the equipment, select a ventilated area,

protected from the effects of bad weather.

3.3 Assembly

3.3.1 Assembly of the gas manifold

Set the manifold (see drawing) The surface on which the manifold will be mounted,must be flat. Any deformation of the plate couldaffect the proper operation of the equipment. Depending of the case, mount and connect the

extension ramps (Options) Fix the racks (in case of cylinder use). Attach the panels "Cylinders/bundles change

procedure" and the "Safety precautions"corresponding to the gas used. They have to bevisible and in close range.

Mount the anti-flapping connectors. Warning!They must be imperatively mounted in a verticalposition. Unused ports must be sealed with blindplugs provided for that purpose.

Place the cylinders in their racks with their safetychains.

Connect the flexible hoses or pigtails as specifiedin their operating instructions.

Attach the safety cables. Use the holes for thatpurpose on the manifold. In case of bundles,attach the anchor cable to a solid anchor point.

In case of CLSA1 used with hydrogen or Helium,install at the outlet the calibrated orifice adaptedto the gas used and delivered with the equipment.

Connect the outlet of the manifold to the pipenetwork.

Install a shut-off valve between the manifold andthe pipeline:-At a distance equal to 20 x internal diameter of

the pipe when used with breathable air. CheckThe compatibility of the seals.

-EFP9 shut-off valve for oxygen (> 20 bar) andhydrogen use

If continuous supply is required, even during themaintenance, install back up cross downstreamthe manifold

If necessary, collect the purges and the reliefvalve (particularly for the combustible gases) andconnect them to exhaust pipes to secure theinstallation. Height > 2,5m.

In case of combustible gases, connect the manifoldto the ground and check the electrical continuitybetween the different components.

3.3.2 Assembly of a compression fitting

Check dimensions and respect materialcompatibility between connection and pipe :Connection and pipe must always be made from thesame material, example: Stainless steel connectionfor stainless steel pipe < Rockwell hardness B90(exception : brass connection with copper pipe).

EN

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 9

Connector pre-assembled by hand. After cutting, de-burring and blowing on the tube

(use preferably a tube cutter), pre assemble thenut and the ferrules, following the order and thedirection indicated in the figure.

Introduce the tube inside the connector up to thestop limit on the body.

Clamp the nut completely by hand. Complete the clamping using a wrench by turning

the nut at a 1 1/4 turn.

3.4 Options

To choose the appropriate option, pleaseconsult the AIR LIQUIDE "Product sheet" inmyCatalogue.

For the options assembly, refer to Assembly - Activation chapter of the operating instructions delivered with the options.

3.5 Checking the tightness ofconnections

Even though the different components of theequipment have been carefully checked in thefactory, it is nevertheless necessary to make averification of the sealing of the mounted assemblybefore commissioning .

-Close the outlet valve.-Verify that the HP shut-off valves (2) and the

purge valves (3) are closed.-Open and then close gradually all valves of

cylinders or bundles (1). The cylinder pressureis read on the high pressure gauges (5).

-Verify that the value indicated on the highpressure gauge does not vary over a sufficientlylong period. Otherwise, there is leakage ona connection. Identify it by using a leakdetector such as the Mille Bulles from AIR

LIQUIDE. After locating the leakage, purge theinstallation, check the state of seals and of theseats of seals, and retighten the connectorsagain.

Always turn valves GRADUALLY.Never retighten a fitting under gaspressure.

In the same way, during the pressurization of theinstallation, check also the tightness of the outputconnections.

OP 206 ML-ML1-CLSA1 08/2013 v.1.010

3.6 Activation

Never use the purge valves to purgethe pipeline connected downstreamof the gas manifold (risk polluting theregulators).

3.6.1 1st stage: Flexible hoses purging.

Initial stage: Closed HP shut-off valves (2) and purge valves

(3). Closed low-pressure outlet shut-off valve.Purge all flexible hoses or pigtails, by at leastof 3 compressions-reductions cycles, ie: openthe cylinder/bundle valves (1) and close it beforereaching the pressure of the cylinder (high pressuregauge (5)), wait 1 minute, slowly open the purgevalve (3) and then close it before falling toatmospheric pressure.

3.6.2 2nd stage: function control

Initial stage: Closed cylinder/bundle valves, Closed HP shut-off valves (2) and purge valves (3) Closed low pressure outlet shut-off valve.Indicate the main gas source to use first by usingthe lever (4). (In case of CLSA1): On the right: lever downwards On the left: lever upwards Slowly open all cylinder/bundle valves (1). Slowly open the HP shut-off valves (2) on the mainsource.Note the outlet pressure of the low pressure gauge(6). Adjust the pressure with the handwheel (exceptCLSA1: not adjustable).

Slowly open the HP shut-off valve on the 2nd gassource (In case of CLSA1).Slowly open the outlet shut-off valve.Let the gas flow normally through the manifold andpurge all pipes.Limit the outlet flow during the filling of the pipenetwork to avoid vibrations. Respect the nominalflow.

If necessary, adjuste the outlet pressure (Except withCLSA1: non-adjustable).

3.6.3 3rd stage: verification of theautomatic switchover (In case of CLSA1only)

Close the cylinder/bundle valves of the main gassource in service, the high pressure gauge (5)decreases.When the HP pressure falls below 2 times theworking pressure, the source in reserve must entergradually in service. The LP pressure gauge (6)indicates the pressure of the gas source in reserve.Change the position of the lever, the initial outletpressure is now restored. The previous gas sourcein reserve becames the main gas source inservice.Repeat in reverse the operation, to check that theautomatic switchover works well in both directions.Remark: if during the switchover, the pressuredifference "deltaP" is too disturbing for the user, itis recommended to install one 2nd stage pressureregulator at the outlet.

3.6.4 4th stage: setting in flow

The tested equipment is now ready to use.Slowly open the shut-off valve at the outlet.In the case of the CLSA1, when the gas source inservice is empty, the switchover to the gas sourcein reserve will be automatic. It will be sufficient toswitch over the position of the lever so that the gassource initially in reserve will be in service, at therequired working pressure.Change the empty cylinders or bundles which willbe automatically in reserve.The gas source in service is indicated by the positionof the lever. The arrow on the lever indicates themain source.

Open always the cylinder (orbundle) valves slowly andgradually.

EN

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 11

4. Usage

4.1 Use

Adjust the outlet pressure according toyour need with the handwheel (ML1 gas panel only).

4.2 Cylinders or Bundles change

Identify the empty cylinders or bundles.

-1. Push the handle (4) (for semi-automatic gasmanifold only):-Downwards: if empty cylinders are on the

left.-Upwards : if empty cylinders are on the right.

Change of empty cylinders or bundles.

-2. Close the High Pressure shut off valve(2) (empty side) on the gas panel or on theconnection point (in case of use of more than2 bundels).

-3. Close the cylinder or bundle valves (1).-4. Slowly open the purge valve (3) and release

the pressure, then close the valve.The pressuregauge must indicate 0 bar.

-5. Disconnect the flexible hoses or the pigtailsfrom the cylinders or the bundles.

-6. Replace the empty cylinders or bundles andsafely store.

-7. Verify the cleanliness of the cylinders' orbundles' valve outlet.

-8. Connect the flexible hoses or the pigtailsafter change the seals. Do not forget toremount the Safety cable.

-9. Slowly open the cylinder or bundel valves(1) and close them again before to reach themaximum pressure.

-10. Wait about 1 minute..-11. Slowly open the purge valve (3) and

close it again before to reach the atmosphericpressure.

-12. Start twice this cycle from point (9) to (11).(4 to 6 times in case of pure gases).

-13. Slowly open the cylinder or bundel valves(1) at least 2 turns.

-14. Slowly open the High Pressure shut offvalve (2).

Do not allow a flexible hoses to rub against theground or a wall.Fix the chain holding the cylinders in the racks. Inthe case of bundles, make sure that they are onhorizontal surface.All flexible hoses or pigtails must be connectedand safety cables hooked up before opening thecylinders or bundles.In case of combustible gases, make sure that thebundles are connected to the ground, before toconnect them to the gas manifold.* Different positions according to models

4.3 After use

Close all of shut-off valves and cylinder (or bundle)valves.

Open the purge valves, purge the installation andthe flexible hoses (or pigtails). The gauges shallindicate "0".

Close the purge valves again. Dismantle and store carefully the flexible hoses

or the pigtails. Store safely from dust and ofmoisture.

Screw the blind plugs on the "High Pressure" inletports.

OP 206 ML-ML1-CLSA1 08/2013 v.1.012

5. Maintenance

5.1 Troubleshooting

FAULT CAUSE REMEDYImpossible assembly of theconnections

Verify the compatibility with gases,inlet and outlet

Impossible assembly

Dammaged connection Change the connectionCross section passage limited bya valve.

Open the valve

Insufficient filled or empty cylinder Change the cylinderNot operating valve Change the cylinderUnder-dimensioned equipment Contact AIR LIQUIDE

Insufficient output of gas

Equipment in output notoperational

Change the equipment

Occasional over consumption Replace by an equipment with alower output

Leakage check out the gas tightness

The gas source in reserve drainswithout being used (Change overonly)

Leakage at the main valve of theregulator

Replace the main valve* or theregulator,

At the same pressure and outputentry, the outlet pressure is notthe same which side you areusing

Disturb regulators Adjust the regulators

Leakage at the flap of theregulator

Replace the regulatorGas comes out of the relief valve

defect relief valve Replace the relief valveToo low working pressure Close the cylinder valve.

Increase the temperature of theequipment above 0C

Frosting

The used gas is argon (Ar),carbon dioxide (CO2) or nitrousoxide (N2O)

Mount an heater at the inlet

The outlet pressure decreases Output flow too high

Respect the regulator flow. Limitthe flow by using a valve or acalibrated orifice.

Vibrations

Presence of a valve with rapidopening on the outlet pipe.

Limit the flow by using a valve or acalibrated orifice.

EN

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 13

5.2 Maintenance

Even though the equipment is reliable, it mustbe checked periodically. Since this task requiressome precautions, it must be done exclusively by aqualified technician.

The periodicity of this verification dependsessentially on the usage of the equipment (intensive,moderate, occasional). It can be performed annuallyby AIR LIQUIDE under a maintenance contract(SERVIGAZ).The period will in no case exceed 5years.

Legend Periodically Once a yearEvery

3 years

We suggest the use of the following table toensure an optimum usage of your equipment

V : to verify

C : to change Leakage

Operation

condition of threads

Sealing of closure

Fastening

Appearance

Setting

Safety

Cleanliness

Labelling

Seal

Setting

Filter

Electrical continuity

Flexible hoses / Pigtails V V V V V V C V CSafety cable V V CRacks V VChain V V

Cylinder/Manifoldconnection

Fittings / Filters V V V CSupport plate V V V V VHP Valves V V VRegulators V V V V V VLP Valves V V VRelief valves V V C

Manifold

Pressure Gauges V V V

2nd Stage reducer V V V C V CMonitoring system V V V Others

Pipe network V V V V V V C V

In case of operating accident (insufficient output,leakage, opening of the relief valve or accidentaldamage) : Contact AIR LIQUIDE.

Use only original parts and do not modify theequipment,

Never dismantle any of the equipmentscomponents.

Defective reassembly may causebursting, malfunctioning and/or an

increasing output pressure, which isdangerous for your safety.

OP 206 ML-ML1-CLSA1 08/2013 v.1.014

5.3 Spare parts

ManifoldInlet

pressuregauge (5)

Outletpressuregauge (6)

Reliefvalve (7)

Regulator(8)

Shut-off/purge

valvesblock (9)

Designation Code

ML1 300-16-8 16004 152809

ML1 300-10-50 151821

18554

ML 200-200-30 15337 15969 15653

CLSA1 200-10-10 15209 16003 15481

CLSA1 200-10-50 15228

17076

CLSA1 200-20-50 15247

15970

18544

16188

Spare part seals (package of ten):

Designation Code

O-Ring EPDM R6 PC851 for inlet port 16x1,336 SI 17129

Flat seal PTFCE (Kel-F) 14,5x10x2 for outlet port G3/8 AL 17141

Flat seal Alu/ARCAP for gauge M10x1 (Kit of seals, Alu:8,5x5x1, ARCAP:8,5x5x0,3) 17084

Flat seal PA 6.6 for gauge G1/4 151862

Flat seal annealed copper for intet fitting 16x1,336 SI 137203

EN

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 15

Other spare parts

Dsignation Code

Plug for orifice 16x1,336 SI in stainless steel 16597

Plug for orifice G 3/8 in stainless steel 16596

Plug for orifice M10x1 in stainless steel 16598

Fitting with non-flapping valve brass/EPDM + filter 16x1,336 SI M - M20x1,5 M 16413

Fitting with non-flapping valve brass/EPDM + filter 16x1,336 SI M - CF10MM 151804

Plastic cover for central 83401

Cylinder/Bundle Change Procedure Panel for CLSA/ML 152662

Multilingual stickers Change procedure for cylinders or bundles CLSA/ML 153663

Hazard panel Oxygen - Nitrous oxide 153687

Hazard panel Combustible Gases 155103

Hazard panel Inert Gases 153689

Choice of the calibrated orifice :

Nitrogen N2 Helium He Hydrogen H2Code Change over Orifice

mmCode

Orifice mm

Code Orifice mm

Code

15209 CLSA1 200-10-10 1,5 155748 0,9 155743 0,8 155742

15228 CLSA1 200-10-50 3,8 155761 2,3 155755 2,0 155752

15247 CLSA1 200-20-50 2,2 155754 1,3 155746 1,1 155745

OP 206 ML-ML1-CLSA1 08/2013 v.1.016

1. Drawings

1.1 Dimensions

ML - ML1

L: 135 mmH: 115 mmP: 112 mmWeight: 7-7,5 Kg

CLSA1

L: 530 mmH: 115 mmP: 112 mmWeight: 12,5 Kg

FR

OP 206 ML-ML1-CLSA1 08/2013 v.1.0 17

1.2 CLSA1

OP 206 ML-ML1-CLSA1 08/2013 v.1.018

1.3 ML-ML1

We are present in more than 80 countries.

Contact:AIR LIQUIDEEuropean Platform and ServicesTour Kupka C92039 Paris La Dfense Cedex, Francewww.airliquide.com

www.ai r l iqu ide.com

Air Liquide is the world leader in gases for industry, health and the environment, and is present in 80 countries serving over 2 million customers.Its Industrial Merchant Business Line plays a vital role in helping Air Liquide achieve its goals. We are a network of over 20,000 open-mindedpeople working at 500 facilities, each one committed to inventiveness in moving our customers businesses forward. This means always beingready to adapt, to understand, to recognise opportunities and to innovate, in order to drive long-term performance at every stage of your growth.

OP

206

ML-

ML1

-C

LSA

1 08

/201

3 v.

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IQU

IDE

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oula

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