ALPHAGAZ ML - ML1 - CLSA1

User Manual
www.airliquide.com

To preserve the quality of our product throughout its usage in the best safety conditions, please read this manual carefully and strictly follow the instructions
that it contains. Non-compliance with these instructions or modification of the product may result in serious accidents or bodily injuries. AIR LIQUIDE
shall 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

EN

Warning

ML1
300-16-8

ML1
300-10-50

ML
200-200-30

CLSA1

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

EN

Contents
1. Domain of usage and Characteristics............................. 4
1.1 Functions..............................................................................................4
1.2 Technical characteristics....................................................................... 4
1.3 Gas compatibiliy table.......................................................................... 4

2. AIR LIQUIDE commitments............................................ 7

2.1
2.2
2.3
2.4

Conformity ...........................................................................................7
Cleaning .............................................................................................. 7
Inspections .......................................................................................... 7
Warranty ..............................................................................................7

3. Assembly - Activation.................................................... 8
3.1
3.2
3.3
3.4
3.5
3.6

Safety................................................................................................... 8
Precautions before assembly................................................................8
Assembly.............................................................................................. 8
Options.................................................................................................9
Checking the tightness of connections................................................. 9
Activation............................................................................................10

4. Usage...........................................................................11
4.1 Use.....................................................................................................11
4.2 Cylinders or Bundles change .............................................................11
4.3 After use.............................................................................................11

5. Maintenance................................................................. 12
5.1 Troubleshooting.................................................................................. 12
5.2 Maintenance....................................................................................... 13
5.3 Spare parts.........................................................................................14

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

1. Domain of usage and Characteristics

1.1 Functions
The ML1 & CLSA1 gas manifolds are used to:

Model

Connection on
Cylinders / Bundles

Continued
supply

Continuously Adjustable
cylinders
outlet
change
pressure

Gas panel

ML - ML1

1x1

1x2

no

no

yes

Automatic change
over with reset

CLSA 1

2x1

2x2

yes

yes

no

The operation of the CLSA1 automatic changeover with reset is based on the assembly of two
opposing pressure regulators connected to two
gas sources and adjusted to obtain a slightly
different pressure between the pressure regulator
into operation and pressure regulator in the reserve.
Since these two reducers have a common
outlet, only the regulator set to the higher

1.2 Technical characteristics

Operating temperature : -20C to + 50C
-7
Leakage rate (Int/Ext.) : < 10 mbar.l/s helium.

1.3 Gas compatibiliy table

The gas manifold are mainly designed for the
implementation of pure gases and mixtures with
purity < N50 thus ALPHAGAZ 1.

connect one or several cylinders or bundles to

pipe network,
reduce a high-pressure conditioned gas (200 or
300 bar at 15C) in cylinder or bundle.

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

pressure delivers gas to flow. When the source in

service is nearing exhaustion, the pressure drop
causes the commissioning of the second regulator
automatically.
The technician operates to switch the lever towards
the new source to restore full operating pressure
(hence the term "automatic with reset "), and then
to replace the empty cylinders or bundles.

IMPERATIVE: check the gases

compatibility of this equipment by
referring to the "Gas Compatibility
Table".
Legend :
Suitable up to a working pressure of XXX
bar at 15C.
Not suitable.
* 1,013 bar at 15C, according to ISO 2503
P1 Inlet = 2(P2 Outlet) + 1 bar

Parameters

Main gases :

Nitrous oxide
Hydrogen

Oxygen

Breathable air
Air

CO

CO2**

Inerts, Nitrogen

Calibration of relief
valve (Bar)

Nominal nitrogen
3
flow rate*(Nm /h)

Pressure of gas
in reserve supply
(bar)

Outlet pressure(bar)

For breathable oxygen, corrosive gases, other gases and mixtures : Please contact AIR LIQUIDE.
ML - ML1 Gas panels
300
50
300 300 44 300
ML1 300-16-8
16
8
300
50
300 300 44 300
ML1 300-10-50
10
50
200
50
200 200 44 200
ML 200-200-30
200
30
CLSA1 Semi-automatic change overs
200
50
200 200 44 200
CLSA1 200-10-10
10
10
15
200
50
200 200 44 200
CLSA1 200-10-50
10
50
15
200
50
200 200 44 200
CLSA1 200-20-50
20
50
25

EN

Ammonia
Methane
Ethylene

Propylene
Propane

Acetylene

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

Material in contact with gas :

CLSA1
200-10-10

CLSA1

Body
Seat
Valve / Spring

CLSA1
200-10-50

CLSA1
200-20-50

Valve block / Purge

Regulators

Nickel Plated Brass

Nickel Plated Brass

Brass / PA

PTFCE

Brass

Brass / SS 301

Brass + PTFCE / SS

Diaphragm

SS 304

Hastelloy

Piston
Filter

Bronze

Pressure gauge

Monel
Copper Alloy

Relief valve
Seal

Bronze

Copper Alloy
SS / NBR

Brass / NBR

EPDM / PA 6.6
ML/ML1

EPDM / PA 6.6 / PTFCE

ML1 300-16-8

ML1 300-10-50

Valve block / Purge

Body

Nickel Plated Brass

PTFCE
Brass / PA

Chronium
Plated Brass

Nickel Plated Brass

Seat
Valve / Spring

ML 200-200-30

Regulators

Brass

Brass / Bronze

Brass
PTFCE / Bronze

Brass PTFCE

Diaphragm

Hastelloy

Piston

SS

Filter

Bronze

Pressure gauge

Monel

Copper Alloy

Relief valve
Seal

Bronze
Copper Alloy

Brass / NBR
EPDM / PA 6.6

Brass / NBR

EPDM / PA 6.6

Brass / NBR
NBR / PTFCE /
Copper

Seat diameter :
Models

Seat diameter
(Equivalent
diameter in mm)

Models

Seat diameter
(Equivalent
diameter 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

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

EN

2. AIR LIQUIDE commitments

2.1 Conformity

2.2 Cleaning

AIR LIQUIDE certifies that the equipment is

manufactured, tested and controlled, in accordance
with the technical specifications described in the
specifications of AIR LIQUIDE.
In addition to technical specifications, a degreasing
process consistant with oxygen service is applied.
It is the responsibility of the end user to ensure
that such equipment are installed and used in
accordance with the current regulations.

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 in
compatible equipment.
A suitable packaging protects the equipment
against exterior pollutions during storage and
transport.
Take care to avoid polluting the equipment
during usage.

2.1.1 Directive 97/23/EC: Pressurised

equipment (PED)

2.3 Inspections

AIR LIQUIDE equipment of DN < 25 (e.g. pressure

regulators, valves, non return valves) satisfy to
requirement of article 33 of 97/23/EC directive
and at the state of the art. Consequently, these
equipments shall not be "CE" marked as defined
in article 15.
By design, these equipment may integrate pressure
relief valves or burst disks. In this case, those ones
shall neither be CE marked according to paragraph
2 of annex II.
In other case, pressure relief valves and burst disks
shall be CE marked.

2.1.2 Directive 94/9/EC ATEX: Explosive

atmospheres
The ML, ML1 & CLSA1 gas manifolds do not
have their own source of ignition. Consequently,
they are excluded from field of application of the
ATEX 94/9/CE directive and shall not be CE
marked.
They can be used in zone 2, according to ATEX
1999/92/EC pending on up to date regulations,
rules, operating instruction and state of the art are
followed during installation and use.
Every installation including one of those equipments
in ATEX zone shall comply to the ATEX directive and
be certified. Remark: It belongs to the end user to
define the ATEX zone.

Each equipment is inspected and has undergone

a leak test (with helium) before packing.

2.4 Warranty
The warranty period for equipment supplied by AIR
LIQUIDE is one year, covering faulty material and
workmanship during manufacture. The warranty
does 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 from
incorrect or improper use, use of spare parts which
are not marked AIR LIQUIDE or from the none
respect of this operating instruction.
For more information, refer to the general sales
conditions of AIR LIQUIDE.

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

3. Assembly - Activation
3.1 Safety
First of all, read and respect
IMPERATIVELY the safety instructions
described in the document General
Safety Instructions delivered with the
product.

3.2 Precautions before assembly

After opening the packaging, check that the
equipment is not damaged and that the contents
correspond to the delivery notes accompanying the
equipment.
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 could
affect 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 be
visible and in close range.
Mount the anti-flapping connectors. Warning!
They must be imperatively mounted in a vertical
position. Unused ports must be sealed with blind
plugs provided for that purpose.
Place the cylinders in their racks with their safety
chains.
Connect the flexible hoses or pigtails as specified
in their operating instructions.

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

Attach the safety cables. Use the holes for that

purpose 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 adapted
to the gas used and delivered with the equipment.
Connect the outlet of the manifold to the pipe
network.
Install a shut-off valve between the manifold and
the pipeline:
-At a distance equal to 20 x internal diameter of
the pipe when used with breathable air. Check
The compatibility of the seals.
-EFP9 shut-off valve for oxygen (> 20 bar) and
hydrogen use
If continuous supply is required, even during the
maintenance, install back up cross downstream
the manifold
If necessary, collect the purges and the relief
valve (particularly for the combustible gases) and
connect them to exhaust pipes to secure the
installation. Height > 2,5m.
In case of combustible gases, connect the manifold
to the ground and check the electrical continuity
between the different components.

3.3.2 Assembly of a compression fitting

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

EN

Connector pre-assembled by hand.

After cutting, de-burring and blowing on the tube
(use preferably a tube cutter), pre assemble the
nut and the ferrules, following the order and the
direction indicated in the figure.
Introduce the tube inside the connector up to the
stop 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, please
consult the AIR LIQUIDE "Product sheet" in
myCatalogue.
For the options assembly, refer to Assembly - Activation
chapter of the operating instructions delivered with the options.

3.5 Checking the tightness of

connections
Even though the different components of the
equipment have been carefully checked in the
factory, it is nevertheless necessary to make a
verification of the sealing of the mounted assembly
before 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 pressure
is read on the high pressure gauges (5).
-Verify that the value indicated on the high
pressure gauge does not vary over a sufficiently
long period. Otherwise, there is leakage on
a connection. Identify it by using a leak
detector such as the Mille Bulles from AIR

LIQUIDE. After locating the leakage, purge the

installation, check the state of seals and of the
seats of seals, and retighten the connectors
again.

Always turn valves GRADUALLY.

Never retighten a fitting under gas
pressure.
In the same way, during the pressurization of the
installation, check also the tightness of the output
connections.

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

3.6 Activation
Never use the purge valves to purge
the pipeline connected downstream
of the gas manifold (risk polluting the
regulators).
st

3.6.1 1 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 least
of 3 compressions-reductions cycles, ie: open
the cylinder/bundle valves (1) and close it before
reaching the pressure of the cylinder (high pressure
gauge (5)), wait 1 minute, slowly open the purge
valve (3) and then close it before falling to
atmospheric pressure.
nd

3.6.2 2 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 using
the 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 main
source.
Note the outlet pressure of the low pressure gauge
(6). Adjust the pressure with the handwheel (except
CLSA1: not adjustable).
nd
Slowly open the HP shut-off valve on the 2 gas
source (In case of CLSA1).
Slowly open the outlet shut-off valve.
Let the gas flow normally through the manifold and
purge all pipes.
Limit the outlet flow during the filling of the pipe
network to avoid vibrations. Respect the nominal
flow.

10

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

If necessary, adjuste the outlet pressure (Except with

CLSA1: non-adjustable).
rd

3.6.3 3 stage: verification of

the
automatic switchover (In case of CLSA1
only)
Close the cylinder/bundle valves of the main gas
source in service, the high pressure gauge (5)
decreases.
When the HP pressure falls below 2 times the
working pressure, the source in reserve must enter
gradually in service. The LP pressure gauge (6)
indicates the pressure of the gas source in reserve.
Change the position of the lever, the initial outlet
pressure is now restored. The previous gas source
in reserve becames the main gas source in
service.
Repeat in reverse the operation, to check that the
automatic switchover works well in both directions.
Remark: if during the switchover, the pressure
difference "deltaP" is too disturbing for the user, it
is recommended to install one 2nd stage pressure
regulator at the outlet.
th

3.6.4 4 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 in
service is empty, the switchover to the gas source
in reserve will be automatic. It will be sufficient to
switch over the position of the lever so that the gas
source initially in reserve will be in service, at the
required working pressure.
Change the empty cylinders or bundles which will
be automatically in reserve.
The gas source in service is indicated by the position
of the lever. The arrow on the lever indicates the
main source.

Open always the cylinder (or

bundle)
valves
slowly
and
gradually.

EN

4. Usage
4.1 Use
Adjust the outlet pressure according to
your 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 gas
manifold 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 the
connection point (in case of use of more than
2 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 pressure
gauge must indicate 0 bar.
-5. Disconnect the flexible hoses or the pigtails
from the cylinders or the bundles.
-6. Replace the empty cylinders or bundles and
safely store.
-7. Verify the cleanliness of the cylinders' or
bundles' valve outlet.
-8. Connect the flexible hoses or the pigtails
after change the seals. Do not forget to
remount the Safety cable.
-9. Slowly open the cylinder or bundel valves
(1) and close them again before to reach the
maximum pressure.
-10. Wait about 1 minute..
-11. Slowly open the purge valve (3) and
close it again before to reach the atmospheric
pressure.
-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 off
valve (2).
Do not allow a flexible hoses to rub against the
ground or a wall.
Fix the chain holding the cylinders in the racks. In
the case of bundles, make sure that they are on
horizontal surface.
All flexible hoses or pigtails must be connected
and safety cables hooked up before opening the
cylinders or bundles.
In case of combustible gases, make sure that the
bundles are connected to the ground, before to
connect 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 and
the flexible hoses (or pigtails). The gauges shall
indicate "0".
Close the purge valves again.
Dismantle and store carefully the flexible hoses
or the pigtails. Store safely from dust and of
moisture.
Screw the blind plugs on the "High Pressure" inlet
ports.

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

11

5. Maintenance
5.1 Troubleshooting
FAULT
Impossible assembly

Insufficient output of gas

The gas source in reserve drains

without being used (Change over
only)

At the same pressure and output

entry, the outlet pressure is not
the same which side you are
using
Gas comes out of the relief valve

CAUSE
Impossible assembly of the
connections
Dammaged connection
Cross section passage limited by
a valve.
Insufficient filled or empty cylinder
Not operating valve
Under-dimensioned equipment
Equipment in output not
operational
Occasional over consumption
Leakage
Leakage at the main valve of the
regulator
Disturb regulators

Frosting

Leakage at the flap of the

regulator
defect relief valve
Too low working pressure

The outlet pressure decreases

The used gas is argon (Ar),

carbon dioxide (CO2) or nitrous
oxide (N2O)
Output flow too high

Vibrations
Presence of a valve with rapid
opening on the outlet pipe.

12

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

REMEDY
Verify the compatibility with gases,
inlet and outlet
Change the connection
Open the valve
Change the cylinder
Change the cylinder
Contact AIR LIQUIDE
Change the equipment
Replace by an equipment with a
lower output
check out the gas tightness
Replace the main valve* or the
regulator,
Adjust the regulators

Replace the regulator

Replace the relief valve
Close the cylinder valve.
Increase the temperature of the
equipment above 0C
Mount an heater at the inlet

Respect the regulator flow. Limit

the flow by using a valve or a
calibrated orifice.
Limit the flow by using a valve or a
calibrated orifice.

Even though the equipment is reliable, it must

be checked periodically. Since this task requires
some precautions, it must be done exclusively by a
qualified technician.

Legend

Periodically

Every
3 years

Filter

Electrical continuity

Seal

V V C

C
C

V V

Fittings / Filters

Support plate

V V

HP Valves

V V

Regulators

V V

LP Valves

V V

Relief valves

Pressure Gauges

V V

V V

Stage reducer

Setting

Others

Labelling

V V

nd

Safety

Racks

Cleanliness

Setting

V V

Safety cable

Chain

Manifold

Fastening

Appearance

Sealing of closure

Cylinder/Manifold
connection

Leakage

Flexible hoses / Pigtails

Operation

V : to verify
C : to change

condition of threads

We suggest the use of the following table to

ensure an optimum usage of your equipment

Once a year

EN

The periodicity of this verification depends

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

5.2 Maintenance

Monitoring system

V V

Pipe network

V
V

V V

C
V

V
C
C V C
V

V V

V V

C V

In case of operating accident (insufficient output,

leakage, opening of the relief valve or accidental
damage) :
Contact AIR LIQUIDE.

Use only original parts and do not modify the

equipment,
Never dismantle any of the equipments
components.

Defective reassembly may cause

bursting, malfunctioning and/or an

increasing output pressure, which is

dangerous for your safety.

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

13

5.3 Spare parts

Inlet
Outlet
pressure pressure
gauge (5) gauge (6)

Manifold
Designation

Relief
valve (7)

Regulator
(8)

Shutoff/purge
valves
block (9)

Code

ML1 300-16-8

151821

ML1 300-10-50

16004

ML 200-200-30

15337

15969

CLSA1 200-10-10

15209

16003

CLSA1 200-10-50

15228

CLSA1 200-20-50

15247

15970

152809

18554

18544

15653
17076

15481
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

14

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

EN

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
Code

Change over

Orifice
mm

Helium He

Code

Orifice
mm

Hydrogen H2

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.1.0

15

1. Drawings
1.1 Dimensions
ML - ML1
L: 135 mm
H: 115 mm
P: 112 mm
Weight: 7-7,5 Kg

CLSA1

L: 530 mm
H: 115 mm
P: 112 mm
Weight: 12,5 Kg

16

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

FR

1.2 CLSA1

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

17

1.3 ML-ML1

18

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

Contact:
AIR LIQUIDE
European Platform and Services
Tour Kupka C
92039 Paris La Dfense Cedex, France
www.airliquide.com

www.ai rl i qu i de.co m
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-minded
people working at 500 facilities, each one committed to inventiveness in moving our customers businesses forward. This means always being
ready 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-CLSA1 08/2013 v.1.0 AIR LIQUIDE, G Boulay

We are present in more than 80 countries.