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Thread: BOC 8500 Multi Stage, 2 Bar, CO2 Regulator Build

  1. #1
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    BOC 8500 Multi Stage, 2 Bar, CO2 Regulator Build

    This is my build thread which is a continuation from my Q&A thread found here: http://www.barrreport.com/showthread...-Solenoid-Help

    Firstly I'd like to say thank you to Left C for his great advice and for taking the time to answer lots of my questions!

    This thread is aimed mainly at any British/European aquarists out there as most of the excellent build threads have been written by Americans who not only have a far greater selection of dual stage regulators to choose from but also use a different standard of threads and connections than us Brits!

    In the UK any CO2 regulators suitable for our use will likely come with BSP connections.
    BSP (British Standard Pipe)
    BSPP (British Standard Pipe Parallel)
    BSPT (British Standard Pipe Tapered)

    We may encounter threads or fittings designated as G/Threads, e.g G1/8.
    G/ are imperial 'PARALLEL' fittings and are exactly the same standard as BSPP, which means a male threaded G1/8 fitting (for example) will perfectly fit a 1/8" BSPP female threaded fitting.
    Male G/BSPP can 'ONLY' be used with female G/BSPP!
    When connecting G/BSPP fittings together a leak free seal is formed when the fittings are screwed together and finally compress against a washer/gasket (dowty washer etc. which won't come supplied with the fitting).

    We may also encounter threads or fittings designated as R/Threads, e.g R1/8.
    R/ are imperial 'TAPERED' fittings and these are also the exact same standard as BSPT, which means a male threaded R1/8 fitting (for example) will perfectly fit a female threaded 1/8" BSPT fitting.
    Male R/ unlike male G/ can be used not only on female tapered threads but also on female parallel threads for 'LOW' pressure applications only (e.g. attaching a male R/BSPT fitting into a female G/BSPP solenoid valve port connection) as long as PTFE tape is used!
    With R/BSPT a leak free seal is achieved when the male/female tapered threads become tighter and tighter on themselves as a result of being screwed together (in conjunction with PTFE tape)!

    BSPP/G Threads have a parallel form in accordance with ISO 228, (which means ISO 228 and BSPP/G will fit together), Swageloks ISO/parallel fittings for example are ISO 228 which will fit our BSPP connections.
    BSPT/R Threads have a tapered form in accordance with ISO 1/7, (which means ISO 1/7 and BSPT/R will fit together), Swageloks ISO/tapered fittings for example are ISO 1/7 which will fit our BSPT connections.

    Americans generally use NPT on their regulator setups which are tapered fittings, NPT isn't compatible with R/BSPT and will 'NOT' fit our R/BSPT connections so don't bother attempting it, there are a few exceptions to this rule that 'CAN' fit together but for the connection sizes we use it's irrelevant anyway!

    Onto the Build:

    I decided to go with a 2 bar (30 psi) BOC 8500 regulator as it's readily available in the UK, dual stage, has an adjustable working pressure, has three O'Clock inlet and nine O'Clock outlet connections and uses UK Industry, standard connections.
    The inlet connection is BS 341 No 8, which is the same specification as DIN 477 No 6 that's used throughout Europe (a regulator with a BS 341 No 8 inlet connection will fit a CO2 cylinder with a DIN 477 No 6 connection or vice versa).
    It comes with a reducing 1/4" to 3/8" BSPT outlet that screws directly into the 1/4"/BSPT female thread on the regulator body (I received conflicting information from several sources regarding this thread type and had been previously advised that it was NPT, BSPT and BSPP, but I confirm it's definitely a BSPT thread connection!).



    IMAG0022.jpg

    IMAG0011.jpg

    IMAG0010.jpg

    IMAG0012.jpg

    IMAG0024.jpg


    I won't be receiving my fittings from Swagelok for some time so that part of the thread will be delayed for a while but I'll be updating for the Burkert solenoid part of the thread either today or tomorrow?
    Last edited by dava6711; 07-26-2012 at 10:19 PM.

  2. #2
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    I hope to see this thread continue. I'm sure there are a lot of our European sisters and brothers that would benefit from all your research. Plus, I look forward to learning, too!

  3. #3
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    I plan to add more today Matt.

  4. #4
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    Thank you for the terrific UK thread information, dava6711. I am so glad that this is written up.

    I will look forward to your build!

  5. #5
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    Burkert 6011 Solenoid

    The Burkert 6011 solenoid valve was the obvious choice for my build based on the recommendations from this forum. The Burkert 6011 solenoid valves sold in the UK aren't as easily attached onto our regulators as their U.S counterparts are! The 6011's available in the U.S come with 'NPT' port connections whereas the models available in the UK generally come with 'PARALLEL' G1/8 port connections. In order to attach the solenoid valve to our regulator assembly we need to utilise 1/8", male, parallel/NPT combination fittings such as Swagelok's B-2-HN-2RS (Hex Nipple, 1/8 in. Male NPT x 1/8 in.) which is NPT one end and G/BSPP/ISO 228 on the other. This kind of fitting 'MUST' be used in conjunction with a Swagelok CU-2-RP-2 washer/gasket (or similar gasket/dowty washer) as a leak free seal is created when the Swagelok washer/gasket becomes compressed between the G1/8 port connection of the solenoid valve and the 'shoulder' on the parallel side of the Swagelok hex nipple. Again a leak free seal is created by using the correct type of washer/gasket and 'NOT' the result of twisting male and females threads tighter and tighter together! Failure to use the appropriate Swagelok CU-2-RP-2 (or equivalent dowty washer) washer/gasket may result in CO2 leaks!

    When ordering you'll need to ensure you select the following options:-
    Orifice: 2.0mm
    Port Connections: G1/8
    230v/50Hz

    My particular model came supplied with Viton (FKM) seals as standard, Buna N (NBR) seals may be available by special request (which are the better choice of the two) as well as NPT connections but a 4-6 week wait will likely ensue (it's definitely worth the wait if you're patient enough as you won't need to purchase as many brass/stainless steel fittings to complete your build which will save you money)


    One part of the build where we actually have it easier than the Americans is wiring the solenoid valve, if you check out Matt F's excellent 'Wiring a Burkert 6011 Solenoid Valve' thread here: http://www.barrreport.com/showthread...-6011-solenoid you'll see it's a fairly lengthy process whereas ours is really, really simple!

    Complete package contents
    WP_000030.jpg

    Contents of DIN plug bag
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    WP_000031.jpg

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    Attached Images Attached Images
    Last edited by dava6711; 07-25-2012 at 10:46 AM.

  6. #6
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    DIN plug close up
    WP_000035.jpg

    Cap removed
    WP_000036.jpg

    Terminal block removed
    WP_000041.jpg
    Attached Images Attached Images
    Last edited by dava6711; 05-03-2012 at 05:43 PM.

  7. #7
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    A power cable and plug aren't supplied as standard with the solenoid valve so I severed and re-used the power cable from an old/faulty Aqua Medic pump.

    The wires from my old Aqua Medic power cable have been stripped and prepared for attaching
    WP_000045.jpg

    Power cable threaded through, note order of DIN components: cord pressure screw, steel washer, additional crush washer and main DIN body
    WP_000046.jpg

    The appropriate wires are now connencted into the correct terminals on the terminal block. It's wired in the exact same fashion as a standard UK plug (as pictured: live top left, neutral top right and earth bottom center)
    WP_000047.jpg
    Last edited by dava6711; 07-26-2012 at 11:43 AM.

  8. #8
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    Then carefully pull the wire and attached terminal block assembly through so it's seated properly inside the DIN main body
    WP_000048.jpg

    Replace cap
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    Then place the rubber gasket between DIN and solenoid
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    WP_000051.jpg
    Last edited by dava6711; 07-24-2012 at 04:35 PM.

  9. #9
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    Finally mate the DIN and solenoid together and secure using the supplied screw
    WP_000056.jpg

    WP_000057.jpg

    Finished product
    WP_000058.jpg
    Last edited by dava6711; 07-24-2012 at 04:22 PM.

  10. #10
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    Just wanted to bump this thread to the top. Important info!
    dava6711, what's the latest?

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