1. Introduction
This manual provides essential instructions for the safe and effective use of your Flame King Refillable 1LB Propane Cylinder Tank with Refill Kit (Model: YSN1LBKT). This kit offers a reusable, DOT-compliant solution for refilling 1LB propane cylinders from a standard 20LB propane tank, reducing waste and offering a convenient alternative to disposable tanks. Please read all instructions and safety warnings carefully before use.
Figure 1: Flame King 1LB Propane Cylinder Refill Kit components.
2. Safety Information
Your safety is paramount. Adhere to all warnings and instructions to prevent injury or property damage.
- DOT Compliance: Flame King refillable propane tanks are the only 1LB tanks certified by the DOT as legally and lawfully refillable and transportable. It is not safe or legal to refill and transport disposable 1LB tanks.
- Outdoor Use Only: Always refill propane cylinders outdoors in a well-ventilated area, away from any ignition sources, open flames, sparks, or heat.
- Overfilling is Hazardous: Do not allow your LP-gas container to be overfilled. Stop filling when liquid appears at the fixed liquid level gauge. Bleed off excess propane in a safe area.
- Proper Storage: Never store or place a propane cylinder in an area of excessive heat (120 degrees F or higher) or near a stove, fireplace, or other heat source. The heat builds up pressure inside the cylinder, which may cause the pressure relief valve to release propane.
- Personal Protective Equipment: Always wear appropriate personal protective equipment, such as gloves and eye protection, when handling propane and refilling cylinders.
- Refill Stand Warning: The refill stand is designed to hold a 20LB tank upside down. Do not stand or sit on the fixture. The side with the warning label should face the ground.
3. Setup
3.1 Assemble the Refill Stand
- Cross the two stand legs (U-shaped metal bars) to form an 'X' shape.
- Insert the flathead bolts through the holes where the legs intersect.
- Secure the bolts with washers and wingnuts, tightening them firmly.
- Place the green stand base on top of the assembled legs, aligning the four screw holes on the base with the corresponding holes on the stand legs.
- Insert the remaining four flathead bolts through the base and legs, securing them with washers and wingnuts. Ensure the side of the base with the warning label faces the ground.
Figure 2: Assembly of the refill stand.
3.2 Prepare the 20LB Propane Tank
- Place the assembled refill stand on a stable, flat surface outdoors.
- Carefully invert your 20LB propane tank and place it securely into the refill stand. Ensure the tank's valve is easily accessible.
- Connect the refill adapter device to the 20LB propane tank's valve. Hand-tighten the connection firmly to prevent leaks.
Figure 3: 20LB propane tank inverted on the refill stand with adapter.
3.3 Prepare the 1LB Refillable Cylinder
- Ensure the 1LB refillable cylinder is empty and cool. For best results, chill the 1LB cylinder in a freezer for 15-30 minutes before refilling.
- Remove the black cap from the 1LB cylinder.
Figure 4: Flame King 1LB refillable propane cylinder.
4. Operating Instructions (Refilling Process)
Follow these steps carefully to refill your 1LB propane cylinder:
- Connect the 1LB refillable cylinder to the CGA600 connection on the refill adapter. Ensure the connection is hand-tightened securely.
- Insert the provided 2mm (5/64") Allen key into the bleeder screw hole on the 1LB cylinder's valve. Turn the Allen key counter-clockwise a small amount to open the bleeder screw. This allows air to escape during filling.
- Slowly open the valve on the 20LB propane tank. You should hear propane flowing into the 1LB cylinder.
- Observe the bleeder screw. When liquid propane starts to mist or spray from the bleeder screw, the 1LB cylinder has reached its safe fill level (approximately 80% capacity).
- Immediately close the bleeder screw by turning the Allen key clockwise.
- Close the valve on the 20LB propane tank.
- Disconnect the 1LB refillable cylinder from the adapter. A small amount of residual propane may escape; this is normal.
- Apply soapy water to the valve area of the refilled 1LB cylinder to check for any leaks. If bubbles appear, tighten the valve or replace the cylinder if necessary.
- Replace the black protective cap on the 1LB cylinder.
Figure 5: Connecting the 1LB cylinder to the refill adapter.
Figure 6: Detailed view of the refill adapter.
Official Refilling Instruction Video
Video 1: Official Flame King instructions for refilling 1LB propane cylinders.
Detailed Refilling Guide Video
Video 2: Comprehensive guide on how to refill 16.4 oz camping fuel cylinders with a 20 lb. propane tank.
5. Maintenance
Regular maintenance ensures the longevity and safe operation of your Flame King Refillable 1LB Propane Cylinder and Refill Kit.
- Inspection: Before each use, visually inspect the 1LB cylinder, refill adapter, and 20LB tank for any signs of damage, corrosion, dents, or leaks. Do not use damaged equipment.
- Cleaning: Keep all components clean and free from dirt, debris, and moisture. Use a damp cloth to wipe surfaces.
- Storage: Store the 1LB cylinders and refill kit in a cool, dry, well-ventilated area, away from direct sunlight, heat sources, and ignition sources. Always store cylinders with their protective caps securely in place.
- Valve Care: Ensure the cylinder valves are always closed tightly when not in use or during transport.
6. Troubleshooting
If you encounter issues during the refilling process, consider the following:
- Cylinder Not Filling Completely:
- Ensure the 20LB tank is inverted correctly on the stand.
- Make sure the 1LB cylinder is sufficiently chilled (e.g., in a freezer for 15-30 minutes) to create a temperature differential.
- Verify the bleeder screw on the 1LB cylinder is open during filling.
- Ensure the 20LB tank has sufficient propane.
- Propane Leakage:
- Check all connections (20LB tank to adapter, 1LB cylinder to adapter) for tightness. Hand-tighten only.
- Apply soapy water to all connections and the cylinder valve. If bubbles appear, tighten the connection or replace any faulty components.
- Ensure the 1LB cylinder's valve is fully closed after filling.
- Difficulty Connecting Adapter:
- Ensure threads are clean and free of debris.
- Align connections carefully to avoid cross-threading.
7. Specifications
| Feature | Specification |
|---|---|
| Brand | Flame King |
| Model Number | YSN1LBKT |
| Item Weight | 1 Pounds (empty cylinder) |
| Product Dimensions | 14 x 5 x 14.5 inches (overall kit packaging) |
| Fuel Type | Propane |
| Special Feature | Portable, Refillable, DOT Compliant |
| Construction Material | High-Grade Steel (cylinder), Brass (adapter) |
| Valve Type | UL1769 listed valve |
| Connection Type | CGA600 |
8. Warranty and Support
For warranty information, technical support, or any questions regarding your Flame King Refillable 1LB Propane Cylinder Tank with Refill Kit, please contact Flame King customer service directly. Refer to the product packaging or the official Flame King website for the most current contact details and warranty terms.
