I guess for the record I should disclaim and state - Despite my comments in this thread - Retailers have specifically recommended that DIN sealing plugs should NOT be used on high F02 cylinders. See Twin manifold plugs
I got curious and looked around a bit ... DGX makes almost the exact same statement for their (equivalent? - same?) plug (DGX HP Sealing DIN Plug | Dive Gear Express®), but interestingly not on their push-button plug (DGX HP Sealing DIN Plug w/Pressure Release | Dive Gear Express®) - by intent or omission, I don't know, but the push button one is only listed as Nitrox ready.
- Of merit, DGX provides a much more thorough explanation of the issues of releasing pressure with a pressurized, plugged valve. Worth checking out. -
Serious question for others out there - Is this "standard" received wisdom, something from the manufacturer's lawyers as a CYA, or from the folks that deal with high FO2 as hands on experts.
I am dubious about the relative risk of the impact claim as both the burst plug and valve mechanism are also vulnerable to impacts and exposed to the gas at full pressure, all the time.
Obviously, it is much easier to keep the internals of the cylinder and valve clean, than the DIN socket and plug. So in that regard, yes, the risk is relatively higher, but also applies when a reg is on there and pressurized too.
As for the venting/friction the same sorts of mechanical processes are also present during cylinder filling with whipping/boosting and venting. Again, hopefully in a meticulously clean environment.
I think it really comes down the relative risk of being seriously O2 clean and plugged vs The risk O2 jetting out into a confined, potentially fuel rich environment.
Maybe I am very wrong in my thinking about the relative risks ...
Ok starting from the top...
A non-venting SS DIN plug used in a high fO2 environment is not a great idea. The plug actually damages the threads in the DIN fitting because there is a ****load of friction if there is pressure behind it - hence needing a big wrench to undo it. Is that risk more or less than venting an AL40 of O2 into your car? Hard to say, neither happens often enough to develop a risk profile.
The venting plug is not "o2 cleaned" and DGX doesn't want to vouch for those convoluted passages being "o2 safe" BUT they mostly mitigate the high pressure O2 locking the plug into the valve if the knob gets bumped. You may still need a wrench and light force to remove it because the oring gets wedged into the sealing surface. But no massive friction forces involved.
DIN fill whips are fully vented prior to removing, and the DIN fitting itself provides enough leverage to remove it (moreso than the plug) hence you never need a wrench to remove these unless that valve is really corroded.
The mass of O2 behind a DIN plug is quite small and there has never been a publicized DIN plug O2 fire. There have been fires from accidentally turning on O2 tanks abruptly. Also fires from trying to remove a valve from an O2 tank while pressurized. Make of that what you will.
PS the Delrin and plastic plugs are awful. Yes they have a vent hole "in theory". They can and have shattered when pressurized sending grenade like plastic fragments into a diver's hand more than once because the hole is too small or the material too weak or the pressure is too high or all of the above. Either use a SS plug (venting or not as you see fit) or don't use a plug at all.