FasTest G346 BH Series User manual

FasTest, Inc. 1646 Terrace Drive Roseville, MN 55113 Support: [phone] Fax: [phone] www.fastestinc.com
Bail Handle Compressed Gas Connectors
INTRODUCTION TO FASTEST
Table of Contents
FasTest is a dedicated manufacturer of advanced connection
tools for pressure and vacuum testing applications. Our
connection tools are easy, safe, and reliable and can dramatically
lower your operating costs and increase operational throughput.
FasTest customers have switched from inefcient plugging
or sealing methods for their testing or lling needs. Our
connectors are used in the compressed gas, manufacturing,
calibration, processing with refrigerant and medical industries,
as well as major automotive manufacturers and leading
appliance companies internationally.
Our connection products and extensive experience since 1985
will help you specify the right connector for your application.
At FasTest, we regularly modify standard products to t your
specic application and testing requirements.
FasTest Connection Tools Offer:
• A unique and proprietary pressure-assisted gripping
and sealing technology that increases gripping
pressure as the pressure increases, virtually
eliminating accidental removal under pressure
• A oating split collet design that eliminates operator
adjustment
• Dynamic Seals that minimize seal stress to increase
seal life, reliability and sealing pressure
• Seals that provide a wide range of options to meet
your application demands
• Minimal maintenance, easy seal replacement, long life
and ergonomically friendly designs
We thank you for deciding to use FasTest series gas
connectors. The following pages include operating and
maintenance instructions. Read these instructions carefully
and follow them before using any gas connectors.
The information corresponds with product knowledge at the
time of printing. Failure to observe these instructions may
result in loss of warranty.
FasTest connectors may be used for a variety of applications.
However, the customer should check with FasTest to see
whether the connector is appropriate for their application.
Why Choose FasTest? ...
Thank You ...
Application Guidelines . . . . . . . . . . . . . . . . . . .1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Operation (Connect & Disconnect) . . . . . . .3-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Standard Replacement Parts List . . . . . . . . . .9
Troubleshooting . . . . . . . . . . . . . . . . . . . .10-11
Warranty . . . . . . . . . . . . . . . . . . . . .Back Cover

Bail Handle Compressed Gas Connectors
FasTest, Inc. 1646 Terrace Drive Roseville, MN 55113 Support: [phone] Fax: [phone] www.fastestinc.com 1
APPLICATION GUIDELINES
zFasTest gas series connectors are designed to connect to specic CGA gas valves
zDo not connect to a damaged cylinder valve
zContact FasTest if the product is damaged, or if you have inquiries on the proper function of the connector
zDo not use the connector until clarication is sought
zConnectors may only be dismantled by FasTest or trained personnel
zDo not use excessive force when connecting. See Operating Instructions outlined in this manual
zFilling gas cylinders is potentially dangerous. Appropriate safety measures must be taken. FasTest is not liable or
injuries to persons or property arising from incorrect use
zConnectors for respiratory air/oxygen must be kept free from oil and grease
zConnectors without an operating loop require additional security by means of safety wire, safety cage, etc
zWhen using a quick connector with lling hose, please ensure that the cylinders to be lled are secure

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Bail Handle Compressed Gas Connectors
INSTALLATION
Step 1
Protect the connector from damage and dirt by keeping it in the original packaging until you are ready to use it.
Step 2
Check that the connector part number and delivery notes (if applicable) comply with the application.
Step 3
Connect the hose securely and leak-tight to inlet B (Figure 1). Tighten to a max torque of 15 ft-lbs.
A higher torque can result in damage causing leaks when the system is pressurized.
Ensure that the connectors cannot be damaged when loading and removing the cylinder.
Step 4
Review total function:
• Check leak-tight seal
• Check if collets open and close properly by actuating
the connector several times
• Check if connector marking complies with the
application
• The FasTest connector is ready to operate
Note
Avoid lateral forces like short connecting hoses because
this could cause leakage.
Figure 1. Torque to maximum 15 ft-lb
!
CAUTION: Do not over tighten.
Over tightening could break
connector and cause injury to operator.

Bail Handle Compressed Gas Connectors
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Step 2
When making a connection:
• Ensure that the connector is in the fully open position
and in direct contact with the front of the valve before
moving the actuator
• Align the connector to the thread to prevent damage
to the front seal from sharp edges of the valve
• Place the connector onto/into the valve until it stops.
DO NOT USE FORCE!
• Rotate the bail to engage the connector. Do
not actuate the loop with excessive force. If the
connection is made correctly, it will connect with
relative ease
• Ensure that the actuating loop has traveled to a
position below parallel to the connector body. Check
to make sure the collets are fully engaged.
(See good vs. bad connection photos, pages 4-5)
Figure 2. CGA 346, CGA 540 Figure 3. CGA 580, CGA 590
OPERATION
Step 1
At the start of each shift
• Check all connectors for main seal condition
• Check for smooth operation of the actuating loop before the rst ll
Collet Collet
Main Seal Main Seal
Sleeve
Sleeve
Bail
Handle
Bail
Handle
Incoming Line
Termination
Incoming Line
Termination
Figure 4a - 4b. Correct CGA 346/540 alignment and connection
Figure 4c - 4d. Align CGA 580/590 connector tight and
square against valve with no visible gap to avoid damage to
the sealing surface

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Bail Handle Compressed Gas Connectors
OPERATION
Step 3
Connecting to the Cylinder/Good Connections
Correct Handle Positioning
580 RPV Pin Retraction
Figure 5a. Note how the pin
is extended
Figure 6a. Demonstrates
good connection to CGA
346 or CGA 540
Figure 6b. Use minimal
force on bail
Figure 7a. Demonstrates
good connection to CGA 580
or CGA 590
Figure 7b. Use minimal
force on bail and handle
Figure 5b. Push down Figure 5c. Rotate 90° Figure 5d. Retracted
Figure 8a. Correct positioning: handle rests at a
downward angle to connector body
Note
Pin retraction is shown using FasTest tool G580RPVPT.
Retraction may also be done using standard pliers

Bail Handle Compressed Gas Connectors
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Incorrect Handle Positioning
Step 4
Connect. The safety pin protrudes out (engages) at
a pressure of approximately 150 psig, depending on
connector age, cleanliness and lubrication.
Step 5
Disconnect. Disconnect only when the connector is
depressurized and the safety pin retracts.
DO NOT ATTEMPT TO DISCONNECT ACTUATOR
STYLE CONNECTORS WHILE UNDER SYSTEM
PRESSURE. (See Safety Pin care in Maintenance
section of this manual).
OPERATION
Figure 9. Safety pin extends
to stop sleeve travel and
accidental disconnection
Figure 8b. Incorrect positioning: handle is parallel or at an
upward angle relative to the connector body
Figure 10. Safety pin
retracts when connector is
depressurized
Figure 6c. Misaligned
CGA 346/540
Figure 7c. Misaligned
CGA 580/590
Figure 6d. Exposed threads
CGA 346/540
Figure 7d. Exposed threads
CGA 580/590
Incorrect Connections
!
WARNING: Improper thread connection
can result in injury or death.

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Bail Handle Compressed Gas Connectors
Main Seal
The main O-ring seal must be replaced at least every 1000 cycles. FasTest recommends a daily visual
inspection of the sealing O-ring, located at the tip of the lling nozzle. Inspect for tears or cracks in the
O-ring surface. Replace O-ring if tears or cracks are visible or veried. Some applications require more
frequent seal changes.
MAINTENANCE
Good Maintenance Practices
• CGA standards for medical oxygen lling, CGA 870 and CGA 346/540 series connectors may require
periodic lubrication. Use Krytox or approved equivalent only.
• Maintain accurate and complete product maintenance records.
• In addition to these suggested maintenance guidelines, your companies overall safety and maintenance
requirements should be applied to FasTest gas connector products.
• It is recommended that gas connector products involved in high-volume lling be returned to FasTest for
a complete product inspection and required maintenance every 5 years.
• Adhering to a consistent product maintenance program will minimize product returns for inspection as
well as required maintenance costs.
• Minimize the use of soap solutions sprayed directly onto connector. These types of solutions cause
a build-up that can hamper proper connector operation. Also, avoid contacting connector with any
petroleum base chemicals that can cause product contamination.
• DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE AS STATED IN BOTH PRODUCT
LITERATURE AND ON ALL INDIVIDUAL CONNECTOR PRODUCTS SOLD BY FASTEST.
Connector Maintenance
The following maintenance guidelines apply to all FasTest gas connector products. Additional guidelines that
apply only to a specic CGA standard connector are noted.
• A daily, weekly and periodic inspection of the connector by a competent person is recommended.
Inspection should include wear of swivel joints, damage to the body, leak-tightness, ease of operation,
sufcient lubrication, wear, dirt accumulation and damage. (See Maintenance Checklist)
• If upon inspection a problem is noted, refer to the Troubleshooting Guide at the end of this manual.
DO NOT DISMANTLE THE CONNECTOR.
• The manufacturer (FasTest) should refurbish connectors after 50,000 ll cycles.
• You may use only original FasTest spare parts that are designed for the application and are subject to
strict quality control. See Warranty.
Figure 11. An example of a
good O-ring main seal
Figure 12. An example of a
bad O-ring main seal

Bail Handle Compressed Gas Connectors
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Bail Handles
FasTest recommends a periodic inspection and tightening
of the actuator handles on applicable CGA standards. If
screws are loose, tighten to 8-10 ft-lb.
Do not over tighten screws.
A drop of Loctite 242 on the threads of the screw is
appropriate.
Safety Pins
Safety pin operation must be inspected daily. With
actuator handle connectors, the safety pin will protrude
out during the lling cycle at approximately 150-psig. The
safety pin retracts back into the connector body upon
completion of the ll/vent cycle. The actuator handle will
ip back easily when the connector is depressurized and
the safety pin retracts. Failure to wait may cause damage
to the safety pin.
If the safety pin does not function properly, the pin
assembly may require cleaning and lubrication. Or, if bent,
the safety pin will require total replacement. Attempting to
disconnect the connector while pressurized contributes to
the bending of the safety pin.
DO NOT ATTEMPT TO DISCONNECT ACTUATOR
STYLE CONNECTORS WHILE UNDER PRESSURE.
MAINTENANCE
Figure 13. Tighten with a torque wrench
Figure 14b. Straight handles, side view
Figure 15. Example
of a bad or damaged
safety pin. When the
pin is bent it will not
retract. There is a
noticeable indentation
on the sleeve from
contact with pin. The
handle is also bent
from forcing actuation
while the pin is
protruding out
Figure 14a. Inspect bail handles for straight position

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Bail Handle Compressed Gas Connectors
MAINTENANCE
Maintenance Checklist
Daily
Inspect for Leak-tight seal
• The main seal must be replaced more frequently depending on wear. Dismantling of the
connector for this purpose is not required. It is recommended that an O-ring pick be used for
removal to avoid damage to the groove
• Clean groove if required and insert new O-ring
Inspect for correct function.
• Does the safety pin properly protrude and lock the connector under pressure?
• Does the safety pin move backwards when the system is depressurized?
Weekly
Inspect for correct function
• Inspect the correct engagement of the collets
• Check the connector’s collet thread with gauge
• Check for any bent or missing components
Periodic
• Inspect that all threaded components are tight and properly torqued
• Check for any bent or missing components
• Check for proper actuation of handle, collets and all moving components
• Check for leaks

Bail Handle Compressed Gas Connectors
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STANDARD FIELD REPLACEMENT PARTS
Gas connector standard replacement components listed in
this section are immediately available for eld replacement.
Additional eld replacement components such as bail
handles are also available by consulting FasTest. Remaining
components are not offered for eld replacement as they
typically require special tools and handling precautions
during assembly.
Due to the high pressure of compressed gas lling, as well as
the Oxygen cleaning requirements of specic CGA standards,
FasTest requires you to return gas connector products for
maintenance and repair. Specic CGA standards require
Oxygen cleaning before being returned to eld service.
Please contact FasTest, Inc. for additional information.
Connectors Part Numbers Material Description
G346 .. BH SG346-*
SG346E-*
Viton
EPDM
Replacement main seals
Replacement main seals
G540 .. BRP SG540-*
SG540E-*
Viton
EPDM
Replacement main seals
Replacement main seals
G540 .. BRP - Stainless G540-BRPP1
G540-BRPN1
Stainless steel
Stainless steel
Replacement pins (5/pkg)
Replacement pin and nut pin
G540 .. BRP - Monel G540-BRPPM1
G540-BRPNM1
Monel
Monel
Replacement pins (5/pkg)
Replacement pin and nut pin
G580 .. BH SG580-*
SG580E-*
Viton
EPDM
Replacement main seals
Replacement main seals
G580 .. RPV SG580RPV-*
SG580ERPV-*
Viton
EPDM
Replacement main seals
Replacement main seals
G540 .. BRP
G580 .. BRP
G540-BRPPT1
G580-BRPPT1 Stainless steel
Retraction tool / pin nut tool
Retraction tool / pin nut tool
G590 .. BH SG580-*
SG580E-*
Viton
EPDM
Replacement main seals
Replacement main seals
All bail handles styles GBHB2530 Stainless steel Replacement bolts (5/pkg)
*Replacement seals available in quantites of 100, 250 and 500. Example: SG540-100 = 100 seals

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Bail Handle Compressed Gas Connectors
TROUBLESHOOTING
Problem Recognized By Probable Cause Recommended Action
Gas leakage at
connection of
connector to valve
Continual sound of
escaping gas
Damaged or worn connector
sealing O-ring or damaged
cylinder valve
Visual inspection of connector
O-ring. Replace as required.
Recommended O-ring replacement
every 1000 lling cycles
Gas leakage at
initiation of lling
cycle, leakage
decreasing as
pressure increases
Sound of escaping gas (a) Improper connection
(b) Side load to lling connector
due to rigid supply line
(a) Terminate lling cycle and
repeat connection
(b) Replace supply line with swivel
and/or exible pigtail
Gas leakage
increases as
pressure increases
Sound of escaping gas
Blow off
Valve threads damaged
Seat area of valve scored or
damaged
Terminate lling cycle and replace
damaged or worn valve
Safety pin does not
activate during
lling cycle
Safety pin at rear of
connector not extended
outward from connector
body
(a) Damaged or bent pin
(b) Lack of lubrication and/or dirt
contamination
(a) Field replacement of actuator
pin assembly
(b) Remove safety pin assembly,
clean and lubricate with
approved lubricant
Safety pin does
not retract upon
completion of
lling cycle
Unable to remove
connector
(a) Damaged or bent pin
(b) Lack of lubrication and/or dirt
contamination
(c) System under pressure
(a) Field replacement of actuator
pin assembly
(b) Remove safety pin assembly,
clean and lubricate with
approved lubricant
(c) Vent or exhaust system of gas
before attempting disconnection
Actuator handle
loose
Excessive handle
movement from
side-to-side when
connected to valve
Loose or missing actuator
handle screws
Replace missing screw or remove
existing screw. Apply thread lock to
screw threads. Reinsert and tighten
to 8-10 ft-lbs.
Do not over tighten screw
Inability to fully
engage actuator
handle
Visually inspect
connection with valve to
determine if connector
threads are exposed
Short connection to cylinder
valve
Disconnect and reconnect to
valve with connector fully seated
into valve
Gas Connector CGA standards 346, 540, 580 and 580 RPV series. Gas connector products should be visibly inspected
on a routine basis to ensure efcient product performance. Refer to the Maintenance Checklist on page 8.

Bail Handle Compressed Gas Connectors
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Problem Recognized By Probable Cause Recommended Action
Connector’s thread
collets not expanding
properly during initial
hook-up to cylinder valve
Visual inspection of
connection joint
Short connection of connector
to valve
Visual inspection of valve.
Replace if damaged or worn.
Disconnect and reconnect
connector to valve. Be sure
actuator handle sleeve is fully
engaged. If problem is unresolved,
contact FasTest
Loose connection Connector is loose
despite proper
connection
Worn or damaged threads of
cylinder valve
Replace cylinder valve.
Damage, deformation
or distortion to connector
body, sleeve, and collet
threads. Possible internal
leakage
Visual inspection of
connector
Difcult operation of
connector
Improper operation Remove connector from lling
operation immediately!
Return to FasTest to determine
probable cause
Inability to connect to,
or a leakage with 540
and 580 RPV style
connectors and Residual
Pressure Valves
Inability to fully
actuate connector
actuator handle and/
or outer sleeve
(a) Bent actuator pin
(b) Damaged actuator piston
(a) Replace actuator pin
(b) Return to FasTest for repair
Inability to connect or
leakage of RPV version
connector to non RPV
cylinder valves
Inability to fully
actuate and/or gas
leakage at initial lling
(c) Actuator pin not retracted (c) Retract/remove actuator pin
according to specic connector
operation instructions
TROUBLESHOOTING

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12
Bail Handle Compressed Gas Connectors
NOTES

Bail Handle Compressed Gas Connectors
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NOTES

FasTest, Inc. 1646 Terrace Drive Roseville, MN 55113 Support: [phone] Fax: [phone] www.fastestinc.com
WP075 Rev D 04/14PDF - 4/7/14
FasTest, Inc. warrants its products against defects in workmanship and materials for 12 months from the date of sale by FasTest, Inc. or its authorized
distributor. This warranty is void if the product is misused, tampered with or used in a manner that is contrary to FasTest, Inc.’s written recommendations
and/or instructions. FasTest, Inc. does not warrant the suitability of the product for any particular application. Determining product application suitability
is solely the customer’s responsibility. FasTest, Inc. is not liable for consequential or other damages including, but not limited to, loss, damage, personal
injury, or any other expense directly or indirectly arising from the use of or inability to use its products either separately or in combination with other
products. ALL OTHER WARRANTIES EXPRESS OR IMPLIED, WHETHER ORAL, WRITTEN OR IN ANY OTHER FORM, INCLUDING BUT NOT
LIMITED TO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY EXCLUDED.
The sole and exclusive remedy under this warranty is limited to replacement of the product or an account credit in the amount of the original selling
price, at the option of FasTest, Inc. All allegedly defective products must be returned prepaid transportation to FasTest, Inc., together with information
describing the product’s performance, unless disposition in the eld is authorized in writing by FasTest, Inc.
WARNING: High pressure is potentially dangerous. Do not use Gas Filling connectors without rst reading and following the operating instructions
included with the product. Additional copies of all gas product instructions may be obtained from FasTest, Inc.
INTENDED USE/ MODIFICATION WARNING: FasTest gas connector products are ONLY intended for use with a specic CGA standard. FasTest
assumes no product liability if modications are made to the product. If modications are made, the product warranty becomes null and void.
Non-Warranty Claims: FasTest gas connector products which are no longer covered by the original warranty period are subject to a at rate charge
for required product repairs. Flat rate charges will vary depending on CGA standard. Non-warranty connectors, returned to FasTest for repairs, are
subject to inspection to determine feasibility of repair.
Contact FasTest, Inc. directly for non-warranty repair and maintenance requests.
Warranty
Specications in this brochure are subject to change without notice. FasTest also reserves the right to make modications and makes no guarantee of
the accuracy of the information contained herein.
© 2014 FasTest Inc. All rights reserved. No part of this publication may be reproduced without written permission.
Certications: FasTest Inc. is ISO 9001: 2008 certied.
Notications and Copyright