AC70035 Manual

Instruction Manual:
Dual Position
Boombox Fill Station
PO Box 1000 Sophia, WV 25921-1000

Tel: (304) 683-4595 Fax: (304) 683-3257
Emai: sales@americanairworks.com
www.americanairworks.com
Dual Position Boombox Manual

INTRODUCTION
This manual contains operating instructions and maintenance information for the AC70035T-90, containment fill
station, manufactured by American Airworks of Sophia, WV, USA.
All instructions in this manual should be observed and carried out to prevent damage and premature wear to the
equipment and the units served by it. If these operating instructions are not followed and/or changes are made
to the unit without prior written authorization, including the use of maintenance parts not supplied by American Airworks, any claims under warranty shall be void. Please contact our customer service department at the
numbers or website listed below should you need any further assistance. While every effort is made to ensure
the accuracy of the information contained in this manual, American Airworks will not, under any circumstances,
be held accountable for any inaccuracies or the consequences thereof.
American Airworks
P.O. Box 1000
Sophia, WV 25921
Phone: (304)683-4595
FAX: (304) 683-3257
Email: sales@americanairworks.com
Page
Table of Contents
SECTION 1: OPERATING AND SAFETY PRECAUTIONS

1.1: General Safety and Procedures

1.2: Safety Warnings
04
04
05
SECTION 2: GENERAL INFORMATION

2.1: Technical Data

2.2: Description

2.3: Fill Station Air Flow
06
06
06
06
SECTION 3: INSTALLATION

3.1: Unpacking and Handling

3.2: Installing the Fill Station
07
07
07-08
SECTION 4: OPERATION AND MAINTENANCE

4.1: Single Fill Class 2 Fill Containment Station

4.1.1: General

4.1.2: Operation

4.1.2.1: Loading an SCBA or SCUBA cylinder

4.1.2.2: Filling a cylinder directly from a compressor

4.1.2.3: Filling a cylinder from a cylinder storage bank

4.1.2.4: Removing an SCBA or SCUBA cylinder

4.2: Air Storage System

4.2.1: General

4.2.2: Storage Cylinder Technical Data

4.3: Maintenance

4.3.1: Pressure gauges

4.3.2: Safety valve (Fill Station)

4.3.3: Tube Connections

4.3.4: Pressure Hoses

4.3.5: Storage cylinders

4.3.6: Safety Valves (Air Storage)
09
09
09
09
09
09
09
10
10
10
10
11
11
11
11
11
11
11
SECTION 5: TABLES

5.1: Tightening Torque Values

5.2: Lubrication Chart
12
12
12
SECTION 6: REPLACEMENT PARTS
13
SECTION 7: COMPONENT DATA SHEETS
14-21
SECTION 8: TEST AND INSPECTION RECORD
22
SECTION 9: WARRANTY
23
Page
1. Operating and Safety Precautions

1.1 GENERAL SAFETY PROCEDURES
-- Read the operating manual before installing or operating the machine and follow appropriate handling, operation and maintenance procedures from the very beginning. The maintenance plan contains measures required
to keep the machine in good condition. Maintenance is simple, but must be executed regularly to achieve safe
operation, maximum efficiency and long service life.
-- Consult and follow all NFPA, OSHA, NEMA, DOT, ASME and local regulations, laws and codes covering the
installation and operation of this fill station and accessories before operating the unit.
-- The unit must be installed, operated, maintained and repaired only by authorized, trained and qualified personnel.
-- Do not operate this unit in excess of its rated capacity, pressure, temperature or otherwise than in accordance with the instructions contained in this manual. Operation of this unit in excess of the conditions set forth
in this manual will subject the unit to limits which it many not be designed to withstand.
-- If any of the provisions contained in this list (especially concerning safety) do not comply with local provisions
of law, the safer provision must be applied.
-- Limits (pressure valves, temperature valves, time settings, etc.) must be permanently marked.
-- Do not play with compressed air. Pressurized air can cause serious injuries or death.
-- The operator is responsible for keeping the machine in safe operating condition. If parts and accessories are
not considered to be reliable for safe operation, they must be replaced immediately.
-- Periodically check all safety devices, temperature and pressure gauges to make sure the system is operating
within proper limits.
-- Keep the operating manual available for the operators, and take care that operation and maintenance are
performed according to the instructions contained in this manual. Enter all operating data, executed maintenance measures, etc. in a log. Observe all relevant safety provisions.
-- Failure to follow any of these warnings may result in an accident causing personal injury, death or property
damage.
Page

1.2 SAFETY WARNINGS
-- The use of repair parts other than those included within the American Airworks approved parts list may create hazardous conditions over which American Airworks has no control. Such hazardous conditions can lead to
accidents that may be life threatening, cause substantial bodily injury and/or result in damage to the equipment. Therefore, American Airworks can bear no responsibility for equipment in which non-approved repair
parts are installed.
-- The use of plastic pipe or rubber hose in place of stainless steel tube, or failure to insure system compatibility
of flex joints and flexible hose can result in mechanical failure, property damage, and serious injury or death.
-- American Airworks has rupture-tested containment units, but test conditions and actual field operations can
be completely different. The following points should be considered in your operation of this equipment.
-- Do not fill a cylinder:
-- That does not have a current hydro-test certification date
-- That has obvious damage, such as dents, cuts, abrasions or deformation
-- That has been exposed to high temperature
-- That has been exposed to chemicals
-- That is otherwise not designed to be refilled with breathing air
Page
2. General Information
Technical data is subject to change without prior notice. Air storage cylinders are optional accessories.
2.1 TECHNICAL DATA
Fill Station Model Number
AC70035T-90
Medium
Air
Number of Fill Positions
Maximum Operating Pressure Standard 4500 psig

Ambient Temperature
32 to 105 F (0 to 40 C)
Approximate Weight
500 lbs.
2.2 DESCRIPTION
The AC70035T-90 is used in conjunction with an air-storage system and/or an air compressor to refill one SCBA
or SCUBA cylinder. The fill station is designed to offer some operator protection against resultant explosive
forces should a cylinder fail during the filling operation and at the same time, to contain resulting shrapnel.
The unit is capable of refilling both 2216 PSI and 4500 PSI SCBAs without the need to change fill adapters. By
changing the SCBA fill adapter to a SCUBA yoke, the unit can also fill any SCUBA cylinders up to 31 in length.
NOTE: If cascade storage system pressure is greater than the service pressure of the SCBA or SCUBA cylinder
being refilled, then a regulator must be used.
2.3 FILL STATION AIR-FLOW
High pressure breathing air is supplied to the unit from either an air compressor, or a DOT or ASME cascade
storage system. High pressure breathing air enters the containment through a bulkhead fitting on the back of
the unit. The safety interlock, located inside the cabinet controls the air flow. When the door is closed and the
locking bar is in the down and locked position, air is available to fill an SCBA or SCUBA cylinder when the fill
valve is opened. If the fill valve is opened with the door open, no air will be available to fill the cylinder.
After the air enters the bulkhead fitting, it flows to an air operated control valve. Control pressure for the air
operated valve flows through a step-down regulator and then to a micro-switch. When the micro-switch is activated, control pressure flows to the air operated control valve, opening it and allowing high pressure breathing
air to flow to the fill valve. When the fill valve is opened, high pressure breathing air flows through the fill hose
and CGA hand tight fitting to the cylinder being refilled. Air also travels to the fill gauge, allowing the operator
to monitor pressure in the cylinder as it increases.
NOTE: This unit is an NFPA class 2 containment system. It will not operate unless the door is closed and
locked.
Page
3. Installation
3.1 UNPACKING AND HANDLING
This fill station is packaged according to the requirements for shipping via the requested type of carrier service.
It is possible that the fill station could have been damaged during shipping. For this reason, we urge you to
thoroughly examine the unit for possible damage and report any such damage to the shipping company immediately. If the outer shipping box is damaged in any way, do not accept delivery of the unit until the box is
opened and the unit is inspected for damage. Care must be taken in unpacking the fill station. Serious damage
could result by not checking for clearance between the item to be unpacked and the packaging to be removed.
Handling of the unpacked fill station should be performed only by the methods that the lifting devices are capable of handling the weight of the unit (see section 2 for the weight of the fill station). Before lifting the unit,
secure all loose or swinging parts to keep them from moving. Stay clear of lifted load.
3.2 INSTALLING THE FILL STATION
For installation observe the following:
-- The floor must be capable of supporting the weight of the unit.
-- Position the unit so that it is level.
-- Fire truck application: the unit must be positioned to allow a 22W x 18D opening directly under the
containment unit. A 1/8 thick rubber membrane should be installed between the floor and containment to prevent road debris from getting in the truck or containment. Bracing secured to the truck frame must be available
to allow for 1/2 grade 8 bolts to hold the unit in place
-- Fire station application: bolt the unit to the floor, using four 1/2 x 6 cement anchors. In the event of
a cylinder failure, a substantial amount of energy will be released. Allow at least 12 behind the unit for any
released air to escape. This extra measure may help secure the fill station.
Page
Page
Overall Height: 38"

Approx. Weight: 500#
Truck Mounted Containment

Floor Mounting Bolt Pattern
Tol: + - 1/8"
1/2"
(4 places)
Blue line is actual footprint of base of cabinet
3/4"
Vent Opening
(cut hole in
floor this size)
Front of Containment
Allow at least 2" clearance for locking bar
22"
29-1/2"
Rear of Containment
Allow at least 12" clearance from wall
2"
18"
3.75"
3/4"
1"
22"
1"
Right side of unit

Allow at least 3" clearance
to operate the locking bar
4. Operation and Maintenance

4.1 SINGLE FILL CLASS 2 CONTAINMENT FILL STATION
4.1.1 General
Filling bottles is a tremendous responsibility. Delegate your most reliable personnel to this task. This system is
capable of generating pressures in excess of the normal bottle fill pressure. It is important not to overfill bottles.
Every bottle is stamped with a maximum pressure and the last inspection date. Be sure the regulator and safety
valves are properly set. Do not fill a bottle with an outdated inspection stamp. Visually inspect each bottle and
valve for signs of damage before filling. Do not fill any bottles that appear to be damaged. Consult ASME and
DOT regulations and SCBA manufacturers recommendations before filling any cylinder.
4.1.2 Operation
Filling from air storage is best suited for multiple bottle fillings. For cascade filling from air storage, open the
desired bank valve. Adjust the fill pressure with the fill pressure regulator to the desired pressure.
4.1.2.1 Loading an SCBA or SCUBA cylinder
Make sure the fill valve on the containment is closed. Unlatch the fill station door by pulling out on the retractable pin on the right side of the locking bar then lift the locking bar to the up position. Release the retractable
pin and move the bar until the pin springs into place in the upper hole. Pull the door open by means of the
provided handle. Place the cylinder to be filled into the drawer and connect the fill adapter to the cylinder valve.
Close the fill hose bleed valve and open the cylinder valve. Close drawer and latch the locking bar by pulling the
retractable pin and lowering the locking bar to the down position. The containment drawer comes with three
foam blocks placed in the bottom. These three blocks are to be used to position the cylinder being filled within
the drawer so that the cylinder valve is just below the top of the drawer.
NOTE: The class 2 containment fill station will not fill a cylinder unless the door is closed and locked.
4.1.2.2 Filling a cylinder directly from a compressor
Open the fill valve to fill the cylinder. Start the compressor, if it is not set to start automatically. Air will begin to
flow into the cylinder. The pressure indication on the fill pressure gauge will increase while the cylinder is filling.
Filling is completed when the fill pressure gauge stops moving and indicates the desired pressure.
4.1.2.3 Filling a cylinder from a cylinder storage bank
SCBA or SCUBA cylinders may be filled from a storage bank either by the cascade method or by the bulk method. More SCBAs may be refilled from a given volume of stored air by using the cascade fill method than by the
bulk fill method.
For the cascade method, open the cylinder valve on the #1 DOT or ASME storage cylinder. Open the fill valve on
the containment to begin filling the cylinder. Control the speed with which the cylinder fills by adjusting the fill
valve. If the pressures between the storage cylinder and the containment fill gauge equalize before the desired
fill pressure is reached, then close the #1 storage cylinder valve and open #2 storage cylinder valve. If the
pressure still does not reach the desired fill pressure, then repeat this procedure with each successive storage
cylinder in the bank until the desired pressure has been reached. When the desired pressure has been reached,
close all storage cylinder valves and the containment fill valve.
Page

For the bulk method, all DOT and ASME storage cylinder valves are opened and remain open. Open the fill valve
on the containment to begin filling the cylinder. Control the speed with which the SCBA cylinder fills by adjusting the fill valve. When the pressures in the storage cylinders and the containment fill gauge equalize, close the
containment fill valve.
NOTE: The bulk method is most effective when the DOT or ASME storage cylinder pressures far exceed the pressure rating of the SCBA or SCUBA cylinder being refilled (such as when DOT 6000 storage cylinders are being
used to refill 4500 psi SCBAs or when DOT 4500 storage cylinders are being used to refill 2216 psi SCBAs).
4.1.2.4 Removing an SCBA or SCUBA cylinder
Unlock the fill station door by moving the fill station locking bar back to the up position. Open the drawer. Close
the SCBA cylinder valve and open the fill hose bleed valve to vent the residual pressure. Remove the fill adapter
from the filled cylinder valve. Remove the filled cylinder from the drawer and store in a secure location.
NOTE: During the filling procedure, the bottles will warm up due to recompression. After removal, allow the cylinders to cool down and the pressure to drop. They may then be reconnected and topped off to their maximum
filling pressures.
NOTE: The adapter uses a unique o-ring sealed tip. Light finger tightening assures a complete bubble tight seal
to the cylinder valve, even when the valve seating area has been somewhat scratched or dented.
4.2 AIR STORAGE SYSTEM
4.2.1 General
An air storage system consists of two (or more) DOT or ASME storage cylinders with some or all of the following
items: line valves, safety pressure relief valves, CGA nuts and nipples, interconnecting tubing, pressure gauges,
check valves, cylinder protection devices, and/or mounting clamps and hardware. DOT cylinders are approved
by the Department of Transportation for portable usage. DOT systems are available at 4500 psi, 5000 psi, and
6000 psi. ASME vessels conform to the American Society of Mechanical Engineers codes for permanent installation. These vessels have working pressures of 5250 psig, with a safety factor of 4 to 1; and 6000 psig, with a
safety factor of 3 to 1. A safety valve is provided on each ASME vessel to protect against excess pressure. It is
preset at the factory and sealed. It should not be adjusted.
4.2.2 Storage Cylinder Technical Data
DOT 4500
DOT 5000
DOT 6000
ASME 6000
Material
Lightweight steel
alloy 4130
Lightweight steel
alloy 4130
Lightweight steel
alloy 4130
Cr-Mo steel SA 372,

Type V, Grade 5,
Class B
Volume
444 cf @ 4500 psi
480 cf @ 5000 psi
540 cf @ 6000 psi
490 cf @ 6000 psi
Working Pressure
4500 psi
5000 psi
6000 psi
6000 psi
Test Pressure
6750 psi
7500 psi
9000 psi
10,500 psi
Diameter
9-11/32
9-3/8
9-25/64
9-9/16
Height
54 w/valve
55 w/valve
56 w/valve
54 w/out valve
Weight
148 lbs.
166 lbs.
185 lbs.
400 lbs.
Valve
CGA 347
CGA 347
CGA 702
YVA3010
Finish
Zinc Chromate
primer
Zinc Chromate
primer
Zinc Chromate
primer
Zinc Chromate
primer
Page 10

4.3 MAINTENANCE
4.3.1 Pressure gauges
Observe the pressure gauges daily. If the readings of any of the gauges seem to be incorrect, bleed off all system
pressure. Then, remove the gauge and check for wear and tear, accuracy and proper functioning by comparing
it to a precision test gauge or a dead weight tester. Replace all broken or damaged gauges immediately.
4.3.2 Safety valve (Fill Station)
Develop a regular program of visual inspection, looking for clogged drains and discharge pipe, dirt build up in
and around the valve seat and broken or missing parts. Do not paint, oil or otherwise cover any interior or working parts of any safety valve. They do not require any lubrication or protective coating to work properly. When
safety valves require repair, service adjustments or set pressure changes, work shall be accomplished by the
manufacturer or an approved technician.
4.3.3 Tube Connections - Never tighten fittings under pressure!
Pipe connections (swivel nuts): After all pressure has bee relieved, tighten just firmly enough so that leakage
is stopped (finger tight plus up to an additional turn as necessary). Please note that the compression type
coupling fittings are capable of exerting extreme force on the tubing and should not be tightened more than is
required to seal the joint. To improve the sealing of the pipe connections and to facilitate installation, the following should be observed:
-- Apply a thin layer of Never-Seez NSWT or equivalent on the outside of the ferrule during assembly; Lubricate
the threads of the connector with Never-Seez NSWT or a similar PFTE base lubricant to facilitate future disassembly.
4.3.4 Pressure Hoses
The hoses should be inspected periodically for wear and damage. If a hose is worn or damaged, remove and
replace it.
4.3.5 Storage cylinders
Every five (5) years, DOT cylinders must be hydro-tested. Check local and state regulations regarding testing
of ASME and/or DOT cylinders. Some states require an annual visual inspection. Hydro testing requirements
also differ from state to state.
4.3.6 Safety Valves (Air Storage)
Develop a regular program of visual inspection: looking for clogged drains and discharge pipe, dirt build-up
in and around the valve seat, and broken or missing parts. Do not paint, oil or otherwise cover any interior or
working parts of any safety valve. They do not require any lubrication or protective coating to work properly.
When ASME safety valves require repair, service adjustments or set pressure changes, work shall be accomplished by the manufacturer or holders of V, UV and /or VR stamps.
Page 11
5. Tables
5.1 TIGHTENING TORQUE VALUES
NOTE: Unless otherwise specified in text, the following tightening torque values apply. The indicated torque
values are valid for bolts in greased condition. Replace selfretaining nuts on reassembly.
Bolt or Screw
Thread
Maximum Torque
Hex and Allen Head
1/4 (M 6)
7 ft. lbs. (10 Nm)
Hex and Allen Head
5/16 (M 8)
18 ft. lbs. (25 Nm)
Hex and Allen Head
3/8 (M 10)
32 ft. lbs. (45 Nm)
Hex and Allen Head
1/2 (M 12)
53 ft. lbs. (75 Nm)
Hex and Allen Head
9/16 (M 14)
85 ft. lbs. (120 Nm)
Hex and Allen Head
5/8 (M 616)
141 ft. lbs. (200 Nm)
Pipe connections (swivel nuts): After all pressure has been relieved, tighten just firmly enough so that leakage
is stopped. (Finger tight plus up to an additional turn as necessary).
NOTE: Check for leakage of the complete system from time to time by brushing all fittings and couplings with
soapy water or spraying with leak test spray. Repair any leaks.
5.2 LUBRICATION CHART
If not stated elsewhere, use the following lubricants:
Usage
Lubricants
O-rings, rubber and plastic parts
Parker O Lube
Sealing rings
Parker O Lube
Bolts, nuts, studs, valve parts, copper

gaskets and tube connections (thread,
capnut and conpression rings)
Never-Seez NSWT, pipe Dope or teflon

taps
Ferrules of tube connections
Never-Seez NSWT
Page 12
6. Replacement Parts List

When placing an order for replacement parts, please provide the following information.
1. Unit model number and year delivered
2. Where purchased
3. Description
4. Quantity or amount required
Line
Desription
Quantity
Valve, Air operated, Control
Step-Down Regulator, 6000 to 120 PSI
Air Control Micro Switch, Upper
Air Control Micro Switch, Lower

(for 90 degreedrawer option only)
Panel Mounted Valve
CGA 347 Hand Tight Adapter
CGA347 Hand Tight Nipple o-ring
Male x Female Bleed Valve
Relief Valve, 150#
10
Fill Hose, 54, 1/4 MNPT
11
Door Handle, 10
12
2-1/2 CBM 10,000 psi Dry Gauge
13
1/2-13 SS Retractable Pin
14
Double Base (for Station mount installations)
15
Drawer Scuff Guards
16
1/4 Vinyl Edge Trim
17
1/4 Nylon Control Tubing
18
1 Flange Bearing
19
.097 x 2.875 SS Pin
20
1/8 x 20.5 x 22 Rubber Bottom Vent Seal
21
Bulkhead Fitting, 1/4 Female NPT x 1/4 Tube
22
Bulkhead Fitting, 1/4 Female NPT, Long
23
Elbow, 1/4 Male NPT
24
Elbow, 1/4 Female NPT
25
Nipple, 1/4 Male NPT
26
Nipple 1/8 Male NPT (90 drawer option only)
27
Coupler, 1/4 Female NPT
28
Coupler, 1/8 Female NPT (90 drawer option only)
29
Connector, 1/4 Male NPT x 1/8 Tube
30
Connector, 1/4 Male NPT x 1/4 Tube
31
Tee, 1/4 Male NPT
32
Tee, 1/4 Female NPT
33
Run Tee, 1/4 Female NPT x 1/4 Male NPT run
34
Elbow, Push Lock, 1/8 NPT x 1/4 Tube
35
Straight, Push Lock, 1/4 NPT x 1/4Tube
Page 13
7. Component Data Sheets
Gauge
Line
Page 14
Micro Switch
Port 1
Fill Line
Micro Switch
Port 2
Fill Line
Breathing Air
Supply
Gauge
Line
Dual Containment Control System with relief

OPERATION AND MAINTENANCE
The Model 816 valve is an open or shut valve for air or gas lines up to 6000 PSI. In the normal position with no
control pressure applied the valve is shut. Providing control pressure to the upper control port opens the valve.
One typical application is to open a cylinder charging line only when a protective door is shut. A one inch thread
section is provided permitting a variety of ways to mount the valve. The 816-3 valve is similar to the older
816-1 valve except the -3 valve uses a larger control piston permitting the use of lower control pressure. The
valve, when used with an inexpensive low pressure solenoid, can be used in place of expensive high pressure
solenoids. The 816-3V is a 3 way valve. When control pressure is released the downstream pressure is vented
off. Similar valves with larger flow coefficients are available in our 1094 series valve.
TECHNICAL SPECIFICATIONS
Maximum Pressure
Inlet
Differential
Outlet
6000 PSI
6000 PSI
6000 PSI
Ports
Inlet
Outlet
1/4 MNPT
1/4 FMPT
Flow Coefficient (Cv)
.05 (.07 orifice)
Materials
Body
Internals
Seals
816-3 Actuating Pressure
45 @ 5000 PSI in/ out. 25 @ 5000 PSI in/ 0 PSI out
Maximum Allowable
Actuating Pressure
816-3
816-3V
Anodized Aluminum
Brass and Stainless
Vriton & KEL-F
1200 PSI
1200 PSI
INSTALLATION
Use pipe thread sealant Teflon tape on inlet and outlet threads. Do not over torque. Moderate torque applied
with a 6 or 8 inch wrench is ample. Use ample Teflon tape - 3 or 4 turns not 1 or 2 turns on pipe threads. The
inlet is the male thread and outlet is the female thread at the side of the valve. The one inch thread at the bottom of the valve can be used to mount the valve through a one inch hole in a panel or mounting plate provided
by the user. Actuating pressure for the valve can be any non-corrosive gas or liquid at any pressure between
the minimum and maximum given above under specifications. Pressure must be relieved for the valve to shut.
If an electric solenoid is used, use the three way type to relieve control pressure. The regulator is NOT shipped
oxygen clean and should NOT be used for oxygen service as provided. Consult the factory for details on oxygen
service.
MAINTENANCE & REPAIR
CAUTION As with any regulator or valve, particulates or moisture can plug or freeze the internal filter or valve
seat. This c an occur when upstream dryers are not changed or remain unused for long periods allowing corrosion materials to accumulate. In critical applications where it is important not to lose flow, a larger particulate
filter should be used upstream. Also an orifice such as the Aqua model 796 should be used downstream. This
reduces the tendency to freeze when moisture is present. Consult factory for details. The user should establish
time intervals for changing the valve cartridge, filter and upstream dryers based on experience and service conditions. Back-up systems should be used in very critical applications since field maintenance is hard to insure.
The poppet cartridge 832 is a factory assembled item and should be replaced if required and not disassembled
unless absolutely necessary. Spare cartridges areavailable at a nominal cost and should be kept on hand if rapid
repairs are required. Under severe conditions repacking of seals items 12, 14, and 15 with Cristo-Lube per the
drawing may periodically be required. IN ALL CASES THE UNIT CAN BE RETURNED TO THE FACTORY OR DEALER
FOR REPAIR UNDER WARRANTY OR AT A NOMINAL CHARGE. Maintenance or repairs can be done by qualified
personnel in a clean environment by following the drawings and parts lists herein.
Page 15

Assembly and Disassembly
Assembly and disassembly can be done using the following
drawings and parts list.
Control Air 1/4" FNPT
Parts List
Item
Qty.
Description
Poppet Cartridge Assy
Body
15
Cap
Stem (816-3 only)
Stem, Vented (816-3V only)
Cylinder
Piston
Plug
13
2-130 Viton 90 Seal
11
1 x 14, Jam Nut, Plt Stl
10
2-018 Viton, 90 Duro Seal
11
12
13
Spring (816-3 only)
Mount
Nut
14
2-124 Viton 90
15
2-122 Viton 75
cut through item 15 (note 3)
16
Repair Kit - includes items

1, 4, 10, 11, 12, 13, 14, & 15
17
Vent Seat (816-3V only)
18
2-009 Viton 90 Seal (816-3V only)
14
5
12
4
Outlet
3
Poppet
Cartridge
10
Inlet
Air Operated Valve

Model 816-3
Control Port 1/4" MNPT

5
NOTES
1. Use Cristo-Lube MCG 121 or 111 or equivalent grease
on O-rings. Fully pack 12, 14 & 15.
2. Technical bulletin - 818
3. Cut through one side of O ring item 15 to insure it acts
only as an expander and not as a seal.
18
17
Poppet
Cartridge
Mount
Nut
Inlet
Page 16
Air Operated Valve, 3 way

Model 816-3V

General
The AC60033 is a small, economical piston type spring loading regulator. It is suitable for either gas or
liquid service. The regulator is self venting. Venting occurs when outlet pressure rises 20 to 60% above set
pressure.
SPECIFICATIONS
Maximum Inlet Pressure
6000 PSI (40 MPa)
Outlet Pressure
200 -1000 PSI (-1)

100-300 PSI (-2)
40-120 PSI (-3)
50-100 PSI (-4)
10-100 PSI (-5)
Flow Coefficient (Cv)
0.03
(equivalent to 0.040 orifice)
Rise of Outlet Pressure/

Rise of Inlet Pressure
8 PSI/1000 PSI
Materials
body and cap - aluminum

internals - brass, alum
seals - delrin, Buna N Viton
Fittings
1/4 FNPT inlet

l/4FNPT outlet
Size
1.0 hex x 3.5 lg
Installation
The regulator can be mounted in line in a tubing or pipe run. Use a suitable pipe thread sealant such as teflon
tape on the 1/4 inlet and 1/4 outlet connections. The 1/4 thread at the bottom (in item 1) is the inlet. Connect
the inlet to the source gas such as a high pressure storage tank. The outlet is capable of being adjusted from
0 to 1000 PSI or lower pressure ranges depending on the spring used. (See drawing notes) AN OUTLET GUAGE
AND RELIEF VALVE SET SLIGHTLY HIGHER THAN THE DESIRED OUTLET PRESSURE SHOULD BE CONNECTED
TO THE OUTLET. IF THE INLET PRESSURE CAN EXCEED 6000 PSI A RELIEF VALVE SHOULD ALSO BE INSTALLED
AT THE INLET TO PREVENT EXCEEDING 6000 PSI. Avoid overtorquing pipe threads. Normal torque with a 6 or
8 inch wrench is ample. Use ample teflon tape - 3 or 4 turns, not 1 or 2.. The regulator is NOT shipped oxygen
clean and should NOT be used for oxygen service as provided. Consult the factory for details.
Operation
Outlet pressure can be adjusted by turning the body item 1 into or out of the cap item 3. Once desired pressure is obtained lock nut item 2 can be tightened against the cap 3 to prevent further movement. The regulator
should not be set under pressure. It is intended primarily for applications where one outlet pressure is used.
Maintenance & Repair
CAUTION - As with any regulator or valve, particulates or moisture can plug or freeze the internal filter or
valve seat.This can occur when upstream dryers are not changed or remain unused for long periods allowing
corossion materials to accumulate. In critical applications where it is important not to lose flow, a larger particulate filter should be used upstream. Also an orifice should be used downstream. This reduces the tendency
to freeze when moisture is present. Consult factory for details. The user should establish time intervals for
changing the valve cartridge, filter and upstream dryers based on experience and service conditions. No representation is made herein as to time intervals as each use is unique. Back-up systems should be used in very
critical applications since field maintenance is hard to insure. IN ALL CASES THE UNIT CAN BE RETURNED TO
THE FACTORY OR DEALER FOR REPAIR UNDER WARRANTY IF APPLICABLE OR AT A NOMINAL CHARGE. Maintenance or repairs should only be done by qualified personnel in a clean environment by following the drawings
and parts lists herein.
Page 17

ASSEMBLY & DISASSEMBLY
PARTS LIST
Inlet 1/4 NPT
ITEM
QTY.
DESCRIPTION
Body
Lock Nut
Cap
Reataining Nut
Seat
Poppet
Guide
Piston
Relief Plate
10
2-113 70N
11
Spring
Spring
Spring
Spring
Spring
3
16
4
15
300-1000 PSI
100-300 PSI note 3
40-120 PSI note 3
50-100 PSI note 3
10-100 PSI note 3
12
Seal 2-017 90V
13
Seal 2-012 70N
14
Seal 2-009 90V
15
Seal 2-009 90V
16
Filter
17
14
12
6
13
12
REPAIR KIT - includes items 5,

6, 7, 12, 14(2ea), 15, 16, 17,
18
NOTES
1. Technical bulletin - 1250. test - 1249
11
2. Use Dow silicone grease 111 or equivalent on seals and

threads. Except on seals 12 and 15 use Cristolub 121 or
equivilent
3. Maximum allowable inlet pressure is limited at lower
outlet pressures as follows:
OUTLET PRESSURE MAX. INLET PRESSURE
150 PSI and up 6000 PSI
10
4. ASSEMBLY
a. Clean all part and insure there are no visible chips or
particulates.
b. Inspect seat 6 under 10X magnification at sealing edge.
c. Assemble parts as shown on drawing
5. Outlet pressure ranges are:
11247-1 200-1000 PSI
1247-2 100-300 PSI
1247-3 40-120 PSI
1247-4 50-100 PSI
1247-5 10-100 PSI
Page 18
Outlet 1/4 NPT

General
The AC50110-C is an economical, small, high pressure relief valve having excellent set pressure control over a
large pressure range to 6000 PSI. It stays bubble tight to within a few PSI of set pressure and reseats bubble
tight even after many vent cycles. Safety wire holes are provided for optional locking of set pressure adjustment.
SPECIFICATIONS
Set pressure
adj. 300 to 6000 PSI
Leakage
bubble tight
Max. flow (air)
100 SCFM at 3000 PSI

50 SCFM at 1500 PSI
Equivalent orifice
.078 inch dia.
Fluids
gas or liquid
Inlet
1/4 male NPT
Outlet
side vent
Size
7/8 hex by 2.1 long
Temperatures
-40F to 160F
Materials
bronze, anodized aluminum,

& Viton
INSTALLATION
Use pipe thread sealant Teflon tape on inlet and outlet threads. Avoid over torquing pipe thread. Normal
torque applied with a 6 or 8 inch long wrench is ample. Use ample Teflon tape - 3 or 4 turns, not 1 or 2 turns.
It is important to maintain piping internals free of particulates such as metal chips, dirt, weld slag, etc. If present these will tend to lodge in the relief valve when it opens causing damage to the seat and leakage. Since it
is difficult to keep piping completely clean during assembly it is advisable to blow high velocity air through the
system and out the relief valve port just prior to installing it. This normally cleans the system of particulates.
A high-pressure air tank can provide a strong flow for this cleaning operation. Suitable ear and eye protection
should be used when flowing high-pressure air. It is NOT advisable to install any type of filter before the relief
valve. A filter could become clogged disabling the safety function of the relief. The relief can be either set prior to
installing in the system or after. Set the relief above set pressure using the adjusting screw (item 6 in the drawing). Bring system pressure up to desired relief valve pressure then back off the adjusting screw until the relief
valve vents. Use the locking nut (item 7) to lock the position of the setscrew. Cycle pressure once or twice to
insure the relief opens at the desired pressure. Safety wire holes are provided in the body and adjusting screw.
The regulator is NOT shipped oxygen clean and should NOT be used for oxygen service as provided. Consult the
factory for details on oxygen service.
MAINTENANCE & REPAIR
Routine maintenance is generally not required. As mentioned above, the relief is sensitive to solid particles flowing through it. As with any relief valve, these particulates tend to lodge on the sealing surfaces or damage the
sealing surfaces as they pass through. The result is leakage after the valve reseats. In the event of leakage, the
valve can be repaired as follows. (Refer to the drawing on the opposite side of this sheet.) Remove adjusting
screw 6, spring 8, spring guide 5, and poppet 4. Inspect the sealing edge of the poppet 4 for scratches and seal
surface 9 for imbedded particles. A 5X or 10X magnifier is helpful for this inspection. In most cases the problem
will be imbedded particles in the seal. These can be removed with a Q-tip, or tooth pick. If this does not correct
the problem the seal 9 and possibly the poppet 4 will need to be replaced. To replace the seal 9, remove poppet
guide 3 using a large screwdriver. If a new seal is not available the old seal can be turned over and reinstalled.
This exposes a fresh sealing surface. The seal is a 90 durometer (extra hard) size 2-006 O ring. These are readily available. When installing the seal insure washer 6 is installed under the seal as shown. Insure the seal and
washer stay in place until the guide 4 is installed. Torque guide 4 about as tight as possible while holding the
relief valve body - i.e. without using a wrench on the body.
IN ALL CASES THE UNIT CAN BE RETURNED TO THE FACTORY OR DEALER FOR REPAIR UNDER WARRANTY OR
AT A NOMINAL CHARGE. Maintenance or repairs can be done by qualified personnel in a clean environment by
following the drawings and parts lists herein.
Page 19

AC50110-C - RELIEF VALVE
ASSEMBLY & DISASSEMBLY
PARTS LIST
ITEM
QTY
DESCRIPTION
body
washer
guide
poppet
spring guide
lock nut
pressure adj. screw
spring (6000 PSI max)
seat - 2-006 - 90duroViton
10
label
NOTES
1. Adjust using 5/16 Allen wrench
2. Inlet is 1/4 MNPT
8
5
3
2
9
1
Page 20
Note 2

2
Filler Valve with Bleed, No On-Off

Item
Description
Body
Bleed Screw Assembly
Yoke
Yoke Nut
Handwheel
1
11
Line Valve
Item
Description
Body
Plug & Seat
Gasket
Stem
Thin Teflon Ring
Thick Teflon Ring
Bonnet Nut
Spring
Stem Nut
10
Handwheel (short, round style)
11
Handwheel Cap
10
4
6
5
2
Page 21
8. Test and Inspection Record

Operational Checks:

1. Locking bar lowers into place without contacting door knobs.

2. Retractable pin locks into both positions on strike plate without difficulty.
3. Air flows into fill whip when valve is opened and stops when valve is closed.
4. Open drawer and check for air leaks.
5. Air flow stops when locking bar is opened.
6. Containment tested to 6000 psi.
7. Fill whip tested o 6000 psi.
8. Micro switch actuator pin inspected for clearence with drawer open.
9. Micro switch actuator pin, and retractable pin have locktite.
10. CD and extra copy of this checklist placed inside.
11. 504H Relief set at 4800 psi.
Visual

Checks:
1. No visible marks or scratches
2. Door aligns properly.
3. Bulkhead label and valve labels attached as appropriate.
4. Plastic sleeves installed on stop pins.
5. Teflon glides in place.
6. All screws and bolts are tight.
7. Foam spacers in each drawer (3 each).
8. Manual and extra copy of this checklist placed inside unit.
9. Plastic bag placed over hand-tight.
10. Foam and platic wrap around containment.
Page 22
9. Warranty
American Airworks warrants that new equipment manufactured and delivered by it will be free
from defects in material and workmanship for a period of 24 months from the date of first operation or 27 months from the date of shipment, whichever shall first occur. Repairs are warranted
to be free from defects in material and workmanship for a period of 90 days from the date of
shipment from our plant. Piston rings not installed by us and expendable material such as filter
cartridges are specifically excluded from this warranty. Electrical and electronic components are
warranted to be free from defects in material and workmanship for a period of 90 days from the
date of shipment from our plant. The purchaser shall be obligated to promptly report any failure
to conform to this warranty, in writing to American Airworks within said period, whereupon American Airworks shall, at its option, correct any such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. our factory, or to repay the purchase price, provided
the purchaser has stored, installed, and operated such equipment in accordance with good industry practices and has complied with specific recommendations of American Airworks. Accessories
or equipment furnished by American Airworks but manufactured by others, shall carry whatever
warranty the manufacturers have conveyed to American Airworks and which can be passed on to
the purchaser. American Airworks shall not be liable for repairs, replacements, or adjustments to
the equipment or any costs of labor performed by the purchaser or others without express written
approval from American Airworks. The effects of corrosion, erosion, and normal wear and tear are
specifically excluded. The effects of electrical over voltage, over current, power surge, improper
installation or maintenance, lightning strike or other weather related damage are specifically excluded. Performance warranties are limited to those specifically stated within American Airworks
proposal. Unless responsibility for meeting such performance warranties are limited to specified
shop or fields tests, the obligation of American Airworks shall be to correct in the manner and
for the period of time provided above. American Airworks MAKES NO OTHER WARRANTY
OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF
TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE HEREBY DISCLAIMED. Correction by American Airworks of nonconformity, in the
manner and for the period provided above, shall constitute fulfillment of all liabilities of American
Airworks for such nonconformity, whether based on contract, warranty, negligence, indemnity,
strict liability or otherwise with respect to or arising out of such equipment. The purchaser shall
not operate equipment, which is considered to be defective without first notifying American Airworks in writing of its intention to do so. Any such use of equipment will be at the purchasers
sole risk and liability.
Page 23

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Instruction Manual:

PO Box 1000 Sophia, WV 25921-1000

Dual Position Boombox Manual

Dual Position Boombox Manual

SECTION 2: GENERAL INFORMATION

SECTION 4: OPERATION AND MAINTENANCE

SECTION 6: REPLACEMENT PARTS

SECTION 7: COMPONENT DATA SHEETS

SECTION 8: TEST AND INSPECTION RECORD

Dual Position Boombox Manual

1. Operating and Safety Precautions

Dual Position Boombox Manual

Dual Position Boombox Manual

Number of Fill Positions

Maximum Operating Pressure Standard 4500 psig

Dual Position Boombox Manual

Overall Height: 38"

Truck Mounted Containment

Blue line is actual footprint of base of cabinet

Right side of unit

Dual Position Boombox Manual

Dual Position Boombox Manual

4. Operation and Maintenance

Dual Position Boombox Manual

Cr-Mo steel SA 372,

444 cf @ 4500 psi

480 cf @ 5000 psi

540 cf @ 6000 psi

490 cf @ 6000 psi

Dual Position Boombox Manual

Dual Position Boombox Manual

Hex and Allen Head

7 ft. lbs. (10 Nm)

Hex and Allen Head

18 ft. lbs. (25 Nm)

Hex and Allen Head

32 ft. lbs. (45 Nm)

Hex and Allen Head

53 ft. lbs. (75 Nm)

Hex and Allen Head

85 ft. lbs. (120 Nm)

Hex and Allen Head

141 ft. lbs. (200 Nm)

O-rings, rubber and plastic parts

Bolts, nuts, studs, valve parts, copper

Never-Seez NSWT, pipe Dope or teflon

Ferrules of tube connections

Dual Position Boombox Manual

6. Replacement Parts List

Valve, Air operated, Control

Step-Down Regulator, 6000 to 120 PSI

Air Control Micro Switch, Upper

Air Control Micro Switch, Lower

Panel Mounted Valve

CGA 347 Hand Tight Adapter

CGA347 Hand Tight Nipple o-ring

Male x Female Bleed Valve

Relief Valve, 150#

Fill Hose, 54, 1/4 MNPT

2-1/2 CBM 10,000 psi Dry Gauge