RECHARGE / FILL

MANUAL
FOR
Fike ProInert™
SOLENOID & SLAVE ACTUATION
PACKAGES

Manual P/N 06-321 Rev.N/C

FIKE CORPORATION RECHARGE (FILL) PROCEDURE

CONTENTS .........................................................................................................................................................1

1.0 GENERAL ..................................................................................................................................................2

1.1 Scope................................................................................................................................................2
1.2 Purpose ............................................................................................................................................2
1.3 Safety Precautions ...........................................................................................................................2

2.0 EQUIPMENT ..............................................................................................................................................3

2.1 Equipment Calibration ......................................................................................................................3

3.0 CONTAINER PREPARATION...................................................................................................................4

3.1 Test and Inspection ..........................................................................................................................4
3.2 Valve Reconditioning........................................................................................................................4
3.2.1 Solenoid Actuator Valve Reconditioning Procedure ...........................................................4
3.2.2 Slave Actuator Valve Reconditioning Procedure ................................................................4
3.2.3 Valve Installation Procedure................................................................................................5

4.0 CONTAINER FILLING ...............................................................................................................................5

4.1 Filling by weight ................................................................................................................................5
4.2 Filling by pressure ............................................................................................................................6

5.0 LEAK DETECTION....................................................................................................................................6

6.0 CONTAINER PRESSURE CHECK ...........................................................................................................6

APPENDIX A – PRESSURE/TEMPERATURE CHART .....................................................................................7

ProInert™ Actuator Recharge (Fill) Procedure Page 1 of 7

Manual P/N 06-321 April, 2004
FIKE CORPORATION RECHARGE (FILL) PROCEDURE

1.0 GENERAL
1.1 SCOPE
This section of the manual contains the minimum requirements and procedures for recharging of ProInert™
Solenoid and Slave Actuation Package containers. The information contained herein is prepared for the use
and guidance of Fike authorized Sales Outlets and shall be strictly adhered to so that the ProInert™ Solenoid
and Slave Actuation Packages will function properly throughout its life.
1.2 PURPOSE
After a system discharge, it is imperative that the ProInert™ Solenoid and Slave Actuation Packages be
recharged and returned to service as soon as possible (24 hours maximum) to ensure continued protection.
The Fike approved filling station can remove the Actuation Package from service, perform the recharge, and
return the Actuation Package to service in a relatively short period of time.
1.3 SAFETY PRECAUTIONS
An understanding of the physical properties of Nitrogen gas, and the safe and proper use of techniques for
handling high pressure compressed gases, will allow the safe recharge of the Fike ProInert™ Solenoid & Slave
Actuation Packages. Prior to handling Nitrogen gas, its Material Safety Data Sheet (MSDS), and the safety
precautions listed below shall be read and understood by all individuals handling the product.
WARNING: Containers associated with this procedure will be filled with a non-liquefiable gas under
high pressure. Safe handling procedures associated with pressurized containers must be observed
at all times.
CAUTION: Suitable pressure relief devices shall be incorporated into the charging system to
prevent accidental over pressurization of the system. In pipe sections where Nitrogen could become
trapped, suitable pressure relief devices shall be provided.
CAUTION: ProInert™ filling areas must be well ventilated at all times.
CAUTION: Safety glasses and gloves shall be worn at all times when handling high pressure
Nitrogen gas.
CAUTION: Before filling, all containers shall be inspected for evidence of weak or corroded areas
and the date of the last hydrotest or inspection. See Section 3.1 for testing details.

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April, 2004 Manual P/N 06-321
FIKE CORPORATION RECHARGE (FILL) PROCEDURE

2.0 EQUIPMENT
The following equipment is required for the proper filling of ProInert™ containers from bulk storage
containers:
Item 1: Bulk supplies of Gas - A bulk supply of Nitrogen gas. The purity of the gas is to be as detailed below:

Nitrogen

Purity ≥ 99.99%
Moisture < 10 x 10-6
Other (CO, NO, NO2, CO2, O2 etc) < 20 x 10-6

Item 2: Pump - A pump system compatible with Nitrogen that is capable of supplying the gas at a pressure
of 180 bar.
Item 3: Fittings, valves and hoses, as required - Each shall be suitable for a minimum working pressure of
400 bar.
Item 6: High quality thermometer – Thermometer shall be accurate to +/- 1.0°C, shall be located in the
ProInert™ filling area.
Item 7: Scale - A scale capable of accurately weighing to within +/- 1 g, with a total range greater than the
maximum charged container weight, approximately 10 kg.
Item 8: Pressure Gauges - pressure gauge 0-300 bar with an accuracy of 0.1% of full scale reading,
calibrated in 1 bar increments, or less, for the output/discharge side of the pump.
Item 9: Pressure vs. Temperature Chart - A pressure vs. temperature table detailing the relationship of
Nitrogen vs. Temperature. See Appendix A.

2.1 EQUIPMENT CALIBRATION

A program shall be established by the Fike approved filling station to assure that testing and measuring
equipment used in the production and/or inspection process is kept clean, is maintained in good working
order, and in calibration. The following calibration frequencies shall be adhered to at minimum:
• Scales shall be calibrated at a minimum of once every twelve months.
• Pressure gauges shall be calibrated at a minimum of once every three months.
• Equipment shall be calibrated when it has been subjected to abuse, such as being dropped or
struck with an object, or its accuracy is questionable.
The sales outlet or an outside laboratory may perform calibration. In either case, it shall be by comparison with
a standard that is traceable to the applicable U.S. or foreign National Standard. The Fike approved filling
station, until the next succeeding certification, shall maintain certification of calibration.

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Manual P/N 06-321 April, 2004
FIKE CORPORATION RECHARGE (FILL) PROCEDURE

3.0 CONTAINER PREPARATION

3.1 TEST AND INSPECTION
ProInert™ Solenoid & Slave Actuator gas containers shall not be recharged without retest if more than 10
years have elapsed since the date of the last test and inspection.

3.2 VALVE RECONDITIONING

After a system discharge, the solenoid and slave actuator valves may require to be reconditioned before it
can be recharged with Nitrogen.
WARNING: ProInert™ actuator container contents are under high pressure. Never attempt to
recondition the container valve until the contents have been discharged and the pressure gauge reads 0
bar.
CAUTION: Care should be taken, when handling valve components, to avoid damage of any kind.

3.2.1 SOLENOID ACTUATOR VALVE RECONDITIONING PROCEDURE

The only part that requires to be changed prior to the refilling of discharged ProInert™ solenoid actuation
container assembly is the High pressure valve core (P/N 02-10685) within the manual actuation port of the
container valve. The Manual actuator also requires to be reset.

To recondition the valve, performing the following steps:

Step 1: Remove the manual actuator. If it has been operated, reset by pulling the strike knob upwards
and check that the piston is retracted in the body.
Step 2: Remove the high pressure valve core.
Step 3: Inert a new high pressure valve core and tighten to a torque of 0.2 to 0.34 Nm.
Step 4: Insert the manual actuator and secure in position with the fixings provided. Fit the safety pin and
safety seal as shown.
The container is now ready for filling.
If the valve is found to be faulty i.e. leaking, do not attempt to repair it. Remove valve from container and
replace with a new valve (P/N IG71-020), return to Fike the faulty valve for repair.

3.2.2 SLAVE ACTUATOR VALVE RECONDITIONING PROCEDURE

The only part that requires to be changed prior to the refilling of
discharged ProInert™ solenoid actuation container assembly is the
High pressure valve core (P/N 02-10685) within the actuation port
of the container valve. The pneumatic actuator also requires to be OPERATED
reset. POSITION

To recondition the valve, performing the following steps (refer to

Figure 2):
Step 1: Remove the pneumatic actuator. If it has been
operated, reset by depressing the latching ball into its 3.6
housing with the aid of a thin blade, this will retract the
actuation piston.
Step 2: Remove the high pressure valve core. RETRACTED
POSITION
Step 3: Inert a new high pressure valve core and tighten to a
torque of 0.2 to 0.34 Nm.
Step 4: Insert the pneumatic actuator and secure in position
with the fixings provided.
The container is now ready for filling.

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April, 2004 Manual P/N 06-321
FIKE CORPORATION RECHARGE (FILL) PROCEDURE

If the valve is found to be faulty i.e. leaking, do not attempt to repair it. Remove valve from container and
replace with a new valve (P/N IG71-022), return to Fike the faulty valve for repair.

3.2.3 VALVE INSTALLATION PROCEDURE

The procedure detailed below describes the steps necessary to install a new valve to a cylinder:
Step 1: Apply Teflon tape (no more than 3 turns) onto the male thread of the container.
Step 2: Apply Swagelok Swak or equivalent onto Teflon tape.
Step 3: Screw valve into container.

The container is now ready for filling.

4.0 CONTAINER FILLING

ProInert™ Solenoid and Slave Actuation Package is to be filled to a pressure of 160 bar at a temperature of
15°C.

The following is a step-by-step procedure, suggested by Fike Corporation, for the filling of ProInert™ Solenoid
and Slave Actuation Package containers. See Appendix A, for the pressure vs. temperature chart.
NOTE: Containers and valves to be recharged must be reconditioned in accordance with Section
3.0 of this manual.

CAUTION: Suitable precautions such as wearing of protective equipment such as safety glasses and
gloves to be taken.
CAUTION: The maximum fill pressure shall not exceed beyond 200 bar at a temperature of 50°C.
CAUTION: Filling gases at high pressure causes the container temperature to rise. Care is to be
taken not to exceed a container temperature of 50°C during the filling process.
CAUTION: Do not leave container unattended while filling.

There are two methods available for filling the containers with Nitrogen gas, either by pressure of by weight.
The preferred method is to fill by weight as this is more accurate and is not temperature dependant.

Detailed below are the steps necessary to prepare the container valve assembly for filling:

Step 1: Connect filling hose to valve outlet port (Valve outlet is ¼” SAE male thread).
The container is now ready for filling.

4.1 FILLING BY WEIGHT

Detailed below are the steps necessary to fill the container valve assembly:
Step 1: Place container assembly on the weighing scales and tare the weight.
Step 2: Fill via the outlet with 78 ± 0.5 grams of nitrogen gas. Verify by ensuring that the final
pressure is 160 bar at 15°C. If required refer to the pressure vs. temperature chart in
Appendix A.
Step 3: Allow the assembly to stabilize for 1 minute and then vent the filling hose.
Step 4: Vent filling hose and check that there is no flow from the valve outlet.
Step 5: Remove filling hose and screw on the recoil cap on discharge outlet.
Step 6: Proceed to Leak checking (Section 5).
Step 7: Check container pressure (Section 6).

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Manual P/N 06-321 April, 2004
FIKE CORPORATION RECHARGE (FILL) PROCEDURE

4.2 FILLING BY PRESSURE

Detailed below are the steps necessary to fill the container valve assembly:
Step 1: Fill via the outlet with nitrogen to 160 ± 3 bar. Ensure that the fill rate is slow such that the
temperature of the container does not rise above 15°C. Should the temperature go above
15°C, then wait for the container to cool down and top up the pressure to 160 bar. Verify by
ensuring that the final pressure is 160 ± 3 bar at 15°C. If required refer to the pressure vs.
temperature chart in Appendix A.
Step 2: Allow the assembly to stabilize for 1 minute after completion of filling and then vent the filling
hose.
Step 3: Vent filling hose and check that there is no flow from the valve outlet.
Step 4: Remove filling hose and screw on the recoil cap on discharge outlet.
Step 5: Proceed to Leak checking (Section 5).
Step 6: Check container pressure (Section 6).

5.0 LEAK DETECTION

After the container has been filled, it must be carefully checked for leaks. All potential leak points on each
container (pay particular attention to the valve recoil cap vent holes) must be carefully inspected with a leak
detection solution e.g. SwageLok Snoop or equivalent. No leaks are to be accepted.
Containers that have NO indication of leakage are acceptable for shipment and system use.
Record container acceptance date, any comments or remarks, and the inspector’s initials in the fill station
logbook.
Containers with leaks shall be emptied, inspected, and repaired or rebuilt.

6.0 CONTAINER PRESSURE CHECK

Upon completion of leak testing check container pressure is within the limits as detailed in the pressure vs.
temperature chart in Appendix A to ensure correct fills. The container fill pressure shall be within ±3 bar of the
nominal fill pressure at 15°C.

Page 6 of 7 ProInert™ Actuator Recharge (Fill) Procedure

April, 2004 Manual P/N 06-321
FIKE CORPORATION RECHARGE (FILL) PROCEDURE

APPENDIX A – PRESSURE/TEMPERATURE CHART Based on fill at @ 15ºC

Pressure Vs. Temperature Curve

ProInert Actuator

190

180

170
Pressure (bar)

160

150

140

130

120
-20 -10 0 10 20 30 40 50
Temperature (°C)

ProInert™ Actuator Recharge (Fill) Procedure Page 7 of 7

Manual P/N 06-321 April, 2004
 704 South 10th Street
P.O. Box 610
Blue Springs, Missouri 64013 U.S.A.
(816) 229-3405
Fax: (816) 229-4615
http://www.fike.com