Backcountry	  Access	   1	  Cylinder	  Refill	  Procedure	  BCA DEALER CYLINDER	  REFILL	  PROCEDURE 	  1.0 General	  Information	  This	  procedure	  outlines	  the	  process	  by	  which	  authorized	  BCA	  refill	  centers	  should	  complete	  a	   refill	   on	   an	   empty	   BCA	   compressed	   air	   float	   cylinder	   (“cylinder”).	   The	   refill	   equipment	  utilized	   should	   meet	   BCA	   minimum	   requirements	   as	   outlined	   below	   to	   ensure	   a	   quality	  refill	  is	  performed.	  
2.0 Minimum	  Requirements	  1. The	  air	  utilized	  to	  fill	  BCA	  cylinders	  MUST	  be	  dry	  breathable	  compressed	  air.
2. The	  refill	  equipment	  MUST	  be	  capable	  of	  filling	  to	  a	  pressure	  of	  3300	  psi.
3. A	   pressure	   gauge	   separate	   from	   the	   cylinder	   gauge	   must	   be	   used	   for	   refill
equipment.
4. The	  secondary	  pressure	  gauge	  MUST	  have	  an	  accuracy	  of	  a	  least	  ±	  50	  psi	  across	  theoperating	  range	  or	  be	  Grade	  2A	  or	  higher.	  We	  recommend	  purchasing	  the	  BCA	  RefillCenter	  Kit,	  which	  includes	  an	  approved	  secondary	  gauge.
5. The	  fill	  rate	  should	  be	  slow	  enough	  to	  keep	  the	  cylinder	  from	  becoming	  hot	  to	  thetouch.
6. The	  fill	  station	  MUST	  have	  a	  bleed	  port	  that	  allows	  the	  pressure	  to	  bleed	  fast	  enoughthat	  the	  cylinder	  check	  valve	  closes	  and	  no	  pressure	  drop	  is	  observed.
7. A	  clean	  work	  place	  MUST	  be	  available	  for	  resetting	  and	  re-­‐greasing	  the	  cylinder	  O-­‐rings.
3.0 Cylinder	  Components	  Fig	  2:	  Hex	  screws	  and	  valve	  stem	  housing	  for	  1.0	  and	  2.0	  Float	  cylinders	  Backcountry	  Access	   2	  Cylinder	  Refill	  Procedure	  Fig	  1:	  Cylinder	  head	  assembly	  for	  1.0	  and	  2.0	  Float	  cylinders	  1. Fill	  port
2. Valve	  stem	  housing
3. Hex	  screws
4. Trigger	  pin	  connection
5. Trigger	  pin	  housing	  connection
6. Quick	  connect	  coupler
7. Cylinder	  pressure	  gauge
Cylinder	  Inspection	  NOTE:	   Proceed	   with	   refill	   if	   cylinder	   resembles	   O	   photos.	   	   Refill	   cylinder	   but	   advise	  customer	   to	   contact	   BCA	   warranty	   department	   if	   cylinder	   resembles	   O	   photo.	   Reject	   for	  warranty	  and	  contact	  BCA	  warranty	  department	  if	  cylinder	  resembles	  X 	  photo	  (see	  the	  link	  below).	  	  1. Record	   the	   following	   on	   the	   Release	   of	   Liability,	   Waiver	   of	   Claims,	   Assumption	   ofRisk	  and	  Indemnity	  Agreement	  (“BCA	  Release”)	  before	  refilling	  a	  cylinder:a. Serial	   number	   or	   manufacture	   date	   code,	   depending	   on	   the	   date	   it	   wasmanufactured.
• For	  1.0:	  cylinder	  head	  serial	  number	  located	  on	  the	  back	  of	  the	  cylinder
head	  as	  shown	  in	  Figure	  3	  or	  cylinder	  head	  four	  digit	  manufacture	  datecode	  (xx-­‐xx)	  located	  on	  the	  cylinder	  head,	  as	  shown	  in	  Figure	  4.
• For	   2.0:	   cylinder	   head	   manufacture	   date	   code	   (xx-­‐xx)	   located	   on	   thecylinder	  head,	  as	  shown	  in	  Figure	  4.
b. Shop,	  technician	  name,	  and	  date.

Serial	  Number	  Figure	  3:	  O	  –	  serial	  number	  and	  brass	  burst	  disc	  Manufacture	  Date	  Code	  Figure	  4:	  O	  –	  manufacture	  	  Figure	  5:	  O No	  burst	  disc	  	  date	  code	  and	  brass	  burst	  disc	  2. Inspect	  the	  following:Backcountry	  Access	   3	  Cylinder	  Refill	  Procedure	  a. Complete	  a	  visual	  inspection	  of	  the	  cylinder	  and	  cylinder	  head	  for	  damage	  anddents.
b. Confirm	  the	  quick	  connect	  coupler	  has	  an	  O-­‐ring	  and	  retaining	  clip	  installed.	   SeeFigure	  7.
c. Inspect	   the	   trigger	   pin	   threads	   for	   damage	   and	   ensure	   the	   pin	   is	   not	   bent.	   SeeFigures	  8	  and	  9.
d. Confirm	  the	  cylinder	  head	  has	  a	  burst	  disc.	  See	  Figures	  3	  and	  4.

Figure	  7:	  O	  Retaining	  clip	  Figure	  8:	  O Straight	  trigger	  pin

Figure	  9:	  X Bent	  trigger	  pin	  and	  bad	  gauge	  e. If	  any	  damage	  as	  described	  above	  is	  observed	  or	  component	  parts	  are	  missing,the	   cylinder	   should	   not	   be	   refilled,	   and	   the	   customer	   should	   be	   instructed	   tocontact	  BCA	  to	  arrange	  for	  a	  replacement.
http://backcountryaccess.com/services/warranty/
4.0 Cylinder	  Refill	  WARNING:	  Before	  refilling	  or	  working	  on	  a	   cylinder,	  ensure	  there	  is	  no	  pressure	  left	  in	  the	  system.	   If	   the	   pressure	   gauge	   does	   not	   read	   zero,	   then	   connect	   the	   cylinder	   to	   the	   Float	  airbag,	   deploy	   the	   system,	   and	   re-­‐check	   the	   pressure	   to	   make	   sure	   it	   is	   zero.	   Releasing	  compressed	  air	  from	  the	  cylinder	  without	  the	  Float	  airbag	  connected	  could	  cause	  injury.	  
NOTE:	   The	   refilling	   equipment	   should	   meet	   the	   BCA	   minimum	   requirements	   set	   forth	   in	  Section	  2.0.	  
NOTE:	  The	  refill	  center	  must	  maintain	  the	  cylinder	  O-­‐rings	  according	  to	  sections	  4.1	  and	  4.2	  or	  verify	  that	  the	  customer	  has	  done	  so.	  
Please	  visit	  our	  Float	  Resources	  page	  to	  see	  our	  video	  on	  cylinder	  maintenance:	  www.backcountryaccess.com/services/float-­‐resources	  	  4.1 Cleaning	  the	  Head-­‐to-­‐Cylinder	  O-­‐ring	  NOTE:	   This	   procedure	   is	   only	   to	   be	   performed	   if	   the	   customer	   has	   removed	   the	  cylinder	  head	  from	  the	  cylinder	  or	  if	  the	  cylinder	  is	  experiencing	  a	  slow	  leak.	  
NOTE:	  	  For	  a	  cleaning	  supply	  list	  see	  Appendix	  A	  found	  on	  page	  7.	  
1. Unscrew	  the	  cylinder	  head	  from	  the	  cylinder.	  See	  Figure	  10.
2. Remove	   the	   head-­‐to-­‐cylinder	   O-­‐ring	   with	   a	   toothpick	   or	   dental	   pick.	   SeeFigure	  11.

Backcountry	  Access	   4	  Cylinder	  Refill	  Procedure	  	  3. Inspect	   and	   clean	   the	   threads	   on	   the	   cylinder	   head	   and	   cylinder	   with	  rubbing	  alcohol	  and	  a	  lint-­‐free	  cloth	  or	  Q-­‐tip.	  Allow	  components	  to	  dry.	  	  4. Apply	  a	  small	  amount	  of	  Dow	  Corning	  high	  vacuum	  grease	  around	  the	  O-­‐ring	  and	  place	  it	  in	  the	  O-­‐ring	  groove	  on	  the	  cylinder.	  See	  Figure	  12.	  
5. Screw	  the	  cylinder	  head	  back	  onto	  the	  cylinder	  until	  hand	  tight.	  	  	  Figure	  10	   	  	  	  	  	  Figure	  11	  	  	  	  	  	  	  Figure	  12	  WARNING:	   Do	  not	  utilize	  tools	  or	  excessive	  force	  to	  tighten	  the	  cylinder	  head	  onto	  the	  cylinder;	  this	  may	  damage	  the	  cylinder	  head	  assembly.	  	  4.2 Resetting	  the	  Valve	  Stem	  O-­‐ring	  	  1. Unscrew	  the	  hex	  screws	  on	  the	  trigger	  housing	  with	  a	  5/32”	  Allen	  wrench.	  
See	  Figure	  13.	  
2. Pull	  the	  trigger	  pin	  out	  with	  your	  fingers	  and	  then	  slowly	  remove	  the	  trigger	  housing	  from	  around	  the	  valve	  stem.	  	  See	  Figure	  14.	  
3. Pull	  the	  valve	  stem	  out	  of	  the	  cylinder	  head	  with	  your	  fingers.	  See	  Figure	  15.	  
4. Use	  a	  dental	  pick	  or	  toothpick	  to	  remove	  the	  valve	  stem	  O-­‐ring.	  Use	  care	  to	  avoid	  scratching	  the	  valve	  stem	  and	  O-­‐ring	  groove.	  See	  Figures	  16	  and	  17.	  	  	  Figure	  13:	  Hex	  screws	  	  	  	  	  	  	  Figure	  14:	  Pull	  trigger	  pin	  right	  and	  remove	  housing	  	  simultaneously.	  	  	  	  	  	  	  Figure	  15:	  Pull	  valve	  stem	  up	  to	  	  remove.	  Push	  down	  firmly	  to	  reinstall.	  	  NOTE:	  As	  a	  result	  of	  discharging	  the	  cylinder,	  the	  valve	  stem	  O-­‐ring	  is	  likely	  to	  be	  displaced	  from	  its	  groove,	  as	  shown	  in	  Figure	  16.	  	  5. Remove	   the	   old	   valve	   stem	   O-­‐ring.	   See	   Figures	   16	   and	   17.	   Apply	   Dow	  Corning	   high	   vacuum	   grease	   to	   a	   new	   valve	   stem	   O-­‐ring	   and	   install	   in	   the	  valve	   stem	   groove.	   See	   Figure	   18.	   Place	   the	   valve	   stem	   back	   inside	   the	  cylinder	  head.	  See	  Figure	  15.	  Backcountry	  Access	   5	  Cylinder	  Refill	  Procedure	  	  	  	  Figure	  16:	  Valve	  stem	  O-­‐ring	  	   	  	  Figure	  17:	  O-­‐ring	  removal	  	  	  Figure	  18:	  Reset	  O-­‐ring	  	  NOTE:	  Ensure	  the	  installed	  valve	  stem	  O-­‐ring	  is	  free	  of	  contamination.	  	  6. Reinstall	  the	  trigger	  housing	  by	  pulling	  out	  the	  trigger	  pin	  and	  placing	  it	  over	  the	  valve	  stem.	  See	  Figure	  14.	  	  7. Install	  the	  hex	  screws	  on	  the	  trigger	  housing	  and	  tighten	  with	  a	  5/32”	  Allen	  wrench	  until	  hand	  tight.	  Make	  sure	  the	  valve	  stem	  is	  flush	  with	  the	  top	  of	  the	  housing.	  See	  Figures	  19	  and	  20.	  	  	  Figure	  19:	  O Flush	  valve	  stem	   	  	  Figure	  20: X	  	  Improperly	  installed	  valve	  stem	  	  4.3 Filling	  the	  Cylinder	  	  Note:	  Do	  not	  refill	  using	  any	  gas	  other	  than	  dry	  breathable	  compressed	  air.	  	  1. Connect	  fill	  port	  on	  the	  cylinder	  to	  the	  fill	  station	  and	  begin	  filling	  slowly.	  See	  Figure	  21.	  	  	  Figure	  21:	  Pull	  back	  on	  the	  quick	  connect	  coupler	  to	  connect	  to	  and	  disconnect	  from	  the	  fill	  station.	  	  2. Always	  use	  a	  secondary	  pressure	  gauge	  for	  filling	  cylinders	  to	  the	  required	  pressure.	  If	  using	  a	  regulator,	  set	  the	  pressure	  to	  2700	  psi	  for	  the	  1.0	  Float	  system	  or	  3000	  psi	  for	  the	  2.0	  Float	  system.	  Allow	  the	  cylinder	  pressure	  to	  Backcountry	  Access	   6	  Cylinder	  Refill	  Procedure	  	  3.
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equalize	   to	   the	   required	   pressure	   (on	   the	   secondary	   gauge)	   for	   1	   minute.	  
You	   will	   notice	   the	   cylinder	   warms	   up	   as	   it	   fills:	   this	   is	   normal.	   Do	   not	  overheat.	  
Inspect	  the	  pressure	  gauge	  on	  the	  cylinder	  head	  and	  ensure	  it	  reads	  between	  2500-­‐2700	  psi	  (1.0	  cylinder)	  or	  2800–3000	  psi	  (2.0	  cylinder).	  	  Quickly	  bleed	  the	  air	  from	  the	  fill	  station	  while	  ensuring	  that	  the	  reading	  on	  the	   cylinder	   pressure	   gauge	   does	   not	   decrease.	   If	   the	   system	   is	   bled	   too	  slowly,	  the	  check	  valve	  will	  not	  close	  immediately,	  causing	  a	  loss	  in	  pressure.	  	  Remove	  cylinder	  by	  disconnecting	  the	  quick	  connect	  coupler.	  	  See	  Figure	  21.	  
Place	  cylinder	  inspection	  label	  on	  cylinder.	  See	  Figure	  22.	  
Allow	  cylinder	  to	  cool	  to	  room	  temperature	  (approximately	  20°C/68°F)	  and	  top	  off	  to	  required	  pressure	  if	  needed.	  	  Advise	  refill	  center	  customers	  that	  in	  14	  days,	  they	  should	  check	  the	  reading	  on	   the	   cylinder	   pressure	   gauge–at	   room	   temperature–and	   record	   it	   on	   the	  cylinder	   inspection	   label.	   See	   Figure	   22.	   If	   the	   pressure	   reading	   is	   more	   than	  100	   psi	   lower	   than	   the	   pressure	   recorded	   at	   the	   time	   of	   the	   refill,	   they	  should	  contact	  BCA.	  	  	  	  Figure	  22:	  Cylinder	  inspection	  label.	  	  9. In	   addition,	   always	   advise	   customers	   to	   check	   their	   cylinder	   pressure	   each	  time	   they	   are	   preparing	   to	   travel	   in	   the	   backcountry.	   	   Cylinder	   pressure	  should	  always	  be	  recorded	  at	  room	  temperature,	  as	  readings	  will	  be	  lower	  at	  cold	  temperatures.	  
10. Always	   have	   refill	   customers	   sign	   the	   BCA	   Release.	   This	   form	   must	   be	  completed,	  signed,	  and	  kept	  on	  file	  by	  the	  refill	  center.	  	  NOTE:	   It	  is	  not	  necessary	  to	  perform	  periodic	  hydrostatic	  testing	  on	  BCA	  cylinders.	  
Federal	   regulation,	   49	   CFR	   §	   180.209	   states	   “Any	   cylinder	   not	   exceeding	   2	   inches	  outside	   diameter	   and	   less	   than	   2	   feet	   in	   length	   is	   excepted	   for	   volumetric	   expansion	  test.”	  	  See	  49	  CFR	  §	  180.209	  	  	  	  	  	  	  	  	  	  	  	  	  Backcountry	  Access	   7	  Cylinder	  Refill	  Procedure	  	  Appendix	  A-­‐Cleaning	  Supply	  List	  	  	  1.	  Dow	  Corning	  high	  vacuum	  grease	  2.	  5/32”	  Allen	  wrench	  3.	  Head-­‐to-­‐cylinder	  O-­‐rings	  4.	  Valve	  stem	  O-­‐rings	  5.	  Toothpick	  6.	  Q-­‐tips	  7.	  Alcohol