ULTRADOSER FS150 USER MANUAL
Contents
1. 14 EV AIM AMON tune Suas ac 14 S tan pert 14 Mounting the UltraDoser 16 15 Installing the FS150 COLO NCD ducentes 16 oed ea he rc 18 Positioning the Dosing Head 20 cea seo se 18 Installing the Bottle Detect 19 Principles of Liquid Nitrogen LN enne enne nn nnne ness nane n rnnt eee nns 20 ES 150 ontroller JUTUSLHICTIESa uuu RU MR 21 DFA ON T UU TT T 21 NSS 22 FS150 Controller Set up 0 000000006 0000000000000 000 23 ISI Geers 24 Daun Opera POC SO E Od 25 Dura Cyl Dewar Ped System oir 25 EET ET OE D TORO 27 Nozzle Change Out PrOCeQ Ute EE 27 Noz E ee sU OE T 28 Purging with Gaseous Nitrogen 0100000000000000000000020000000 28 FR OI Te STR RTI ITE TT T 20 rois 555 Om 30 10 322. 9 5 Ibs 4 3kg 0 01 7 grams dose 5 of dose value ms 1000 ms in 1 ms intervals 24 VDC Stainless steel construction Built to food and beverage industry standards 59 L x 29 W x 21 H 1499mm x 737mm x 533mm 225 lbs 102kg with support stand 140 Ibs 64kg without support stand 100 240 VAC 50 60Hz 110 W Portable Dura Cyl dewar 22 psi 1 5 bar House System with Chart Phase Separator 100 psi 6 9 bar Maximum flow rate 15 gallons 56 liters per hour 60 to 100 psi 4 1 to 6 9 bar 10 SCFH gas per 100 bottles or containers per minute PN 20552241 Page 9 of 33 UltraDoser Body Dimensions Note Mounting bracket can be mounted at 90 intervals around the central axis of the UltraDoser body See pages 16 and 17 for additional information www chartdosers com PN 20552241 Page 10 of 33 UltraDoser FS150 Components Front View Controller Mounting Assembly CryotechFlex Hose Inlet Filter 5150 Conftroller _ Bayonet Connection UltraDoser Body GN2 Requlator Assembly Dosing Valve Assembly Dosing Head Dosing Head Heater _ Y Mounting Bracket Assembly 4 g UltraDoser Body The stainless steel vacuum insulated reservoir provides a working supply of LN for dosing operations from your liquid nitrogen supply FS150 Controller FS150 controller dictates the dosing operation of the system The operator inputs
3. Switch to the 1 position e The nozzle is frozen shut e Remove clean and re install the nozzle see page 22 e There is insufficient GN2 to the dosing head valve Check the level of GN at the source If the level is empty or low replace Condition The unit is dosing but missing bottles or containers Possible Causes e UltraDoser dosing head is not over the bottle or e Position UltraDoser dosing head over the bottle or container container e Bottle detect sensor is not in the correct spot e Adjust position of the bottle detect sensor e Dose Delay time on FS150 controller is incorrect e Adjust Dose Delay time on FS150 controller www chartdosers com PN 20552241 Page 31 of 33 PSI T D oz 24VDC 2 5A POWER SUPPLY 5 O55 Oe 6 D ume ertet N scs uc 1 63 en e puni tam imd HE L 9 8 XH tv 8j a iid gt zi ze 425 NE 288 525 zi un 2 Page 32 of 33 PN 20552241 www chartdosers com Warranty All sales of Liquid Nitrogen Dosing Systems LN Dosing Systems from Chart Inc Chart to the purchaser are subject to all applicable Chart standard terms and conditions in effect at the time of sale unless otherwise agreed in writing by an authorized representative of Chart In addition to the warranty stated in Chart s Standa
4. The UltraDoser unit must only be purged with gaseous nitrogen Chart recommends the UltraDoser unit be purged when not in use However this may not be practical for all operators At a minimum the UltraDoser unit should be purged to eliminate any water that may be inside the unit after installation and prior to startup The UltraDoser reservoir may also require purging when there is liquid nitrogen flowing out of the vent The UltraDoser reservoir must also be purged when the nozzle becomes frozen shut 1 Attach the CryotechFlex hose 2 female flare side to the house GN system or portable GN cylinder Note this step will require additional fittings such as 2 male flare fitting and compression fittings 2 Flow GN 20 psi 1 38 bar through the UltraDoser body for approximately ten 10 minutes before system star t up IMPORTANT When purging the UltraDoser unit it will vent heavily and there will be a steady stream of fog from the vent This fog will be cold to the touch if the internal temperature of the UltraDoser unit 1s still at or near LN temperatures 320 F 196 C Once the UltraDoser unit is at or near ambient temperature the will warm up www chartdosers com PN 20552241 Page 25 of 33 System Start Up 1 Remove the CryotechFlex hose from the outlet with a 7 8 open end wrench or adjustable crescent wrench 2 Insert the supplied 10 micron filter into the male bayonet on the suppl
5. on many variables including the position of the dosing head the position of the capper the size of the dosing nozzle the temperature of the bottle or container contents fill levels and head space Therefore the time setting for each filling operation must be evaluated 1 Remove the display cover 2 Press and HOLD ESC until cursor _ appears and blinks the Duration mS value line image below DURATION 20 mS DOSE DELAY 190 mS www chartdosers com PN 20552241 Page 21 of 33 3 Press and HOLD A plus sign with appear highlighted and blink five digits will also appear 1mage below DURATION 00020 mS DOSE DELAY 190 mS Press the arrow key gt to highlight the desired digit Use the arrow key A or V to change the value Repeat steps 4 and 5 to change each desired digit value Press to set value Press ESC to return to the home page image on page 21 Milliseconds 1000 IMPORTANT Duration setting may be set for more than 1000 mS on the display but the maximum time the RE ON C UltraDoser dosing valve opens to dose is 1000 mS 1 second Dose Delay The Dose Delay is the time in milliseconds mS between the time the bottle detect sensor senses a bottle or container and the UltraDoser dosing valve opens to dose The closer the bottle detect sensor to the dosing head the shorter the delay time to dose IMPORTANT The UltraDoser unit dispense
6. supply pressure Note A dewar can be vented to reduce the pressure e The ventis obstructed Check the UltraDoser unit vent If the vent 1s obstructed clear the obstruction If the vent is obstructed with ice contact Chart s service team at 1 408 371 4932 Condition Liquid is coming out of the vent Possible Causes e The LN supply pressure is too high Lower LN supply pressure to 22 psi 1 5 bar or lower e Ice has developed inside the unit causing the e UltraDoser unit must be drained of liquid internal float valve to malfunction allowed to warm up over a minimum of 24 hours with a continuous purge of warm nitrogen gas Contact Chart s service team at 1 408 371 4932 for a detailed procedure Condition Liquid is coming out of the dosing head even though the valve is shut close Possible Causes The LN supply pressure is too high Reduce the LN supply pressure e The valve seat is contaminated ice or particles UltraDoser unit must be drained of LN2 The dosing valve assembly must be removed and cleaned Contact Chart s service team at 1 408 371 4932 for a detailed procedure www chartdosers com PN 20552241 Page 30 of 33 Condition No liquid from the dosing head Possible Causes Actions e There is insufficient liquid inside the UltraDoser e Open the valve counter clockwise direction on unit the Dura Cyl dewar The unit is disabled The FS150 controller is off
7. ULTRADOSER FS150 USER MANUAL m B as x I E N 1 Ve ECH Table of Contents E 3 vadit 3 08 1 RETO TO TESI 3 CAU 3 PO OIN TOI 3 SUI D 5 DUU NN 6 Recervine Your UltraDoser FS150 innsir Ka N ENEN EASTEN EEE ETR 9 Unpacking the UltraDoset 5 50 55 24 ttr eee raro eae epe eb bus oa 9 BRI w and EB PEN 9 Product SC Cll 9 ROQuiIre HOS ne 9 10 MTD OSE COON OS 5p 11 dw A 11 iX 13
8. W 33 www chartdosers com PN 20552241 Page 2 of 33 Introduction Thank you for your purchase of the Chart Inc Chart UltraDoser FS150 Liquid Nitrogen LN2 Dosing System Chart has designed and fabricated your system with attention to detail and utilizing the leading cryogenic technologies to ensure a high efficient and reliable system Please contact us with any questions or comments that you may have If after reading this manual you are not confident in carrying out any task please call Chart s service team at 1 408 371 4932 Service Chart s UltraDoser FS150 has been designed for years of safe and dependable operation In the event service is required please contact Chart at Chart Inc 161 Baypointe Parkway san Jose CA 95134 USA www chartdosers com 1 408 371 4932 Manufacturer The UltraDoser FS150 is designed and manufactured by Chart Inc 161 Baypointe Parkway San Jose CA 95134 USA www chartdosers com 1 800 371 3303 Design Modification DO NOT use this product in a manner not consistent with the instruction outlined in this manual NEVER alter the design or perform service that is not consistent with the instructions outlined in this manual without prior written approval of Chart Additional Copies Additional copies of this manual are available by contacting Chart Chart Inc 161 Baypo
9. art shall void this warranty This warranty does not extend to defects caused by the effects of normal wear and tear erosion corrosion fire or explosion Chart s sole and exclusive liability under this Warranty 1s to the original purchaser and shall not exceed the lesser of the cost of repair cost of replacement or refund of the net purchase price paid of the Dosing System by the original purchaser Chart is not liable for any other losses damages or costs of delays including incidental or consequential damages CHART SPECIFICALLY MAKES NO WARRANTIES OR GUARANTEES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE OTHER THAN OR WHICH EXTEND THOSE WARRANTIES EXPRESSED HEREIN The original purchaser shall indemnify defend and hold Chart harmless from any third party claims as a result of the use sale or lease of the Dosing System www chartdosers com PN 20552241 Page 33 of 33
10. ater is 150 F 65 IMPORTANT Always perform nozzle change out procedures before introducing LN into the UltraDoser unit Failure to do so may cause the nozzle to unthread and fall out IMPORTANT If the nozzle does not loosen easily drain the UltraDoser unit through the SRV drain plug and warm up nozzle with a low voltage heat gun www chartdosers com PN 20552241 Page 27 of 33 Nozzle Cleaning Procedure Remove the nozzle from the UltraDoser See Nozzle Change Out Procedure above Clean the nozzle opening with a very thin wire and blow dry nitrogen through it Thoroughly dry the nozzle with dry nitrogen gas before re installing 1 2 3 IMPORTANT moisture left on the nozzle will immediately freeze up when the nozzle 1s re installed which may cause the nozzle to unthread and fall out Purging with Gaseous Nitrogen The UltraDoser unit must only be purged with gaseous nitrogen Chart recommends the UltraDoser unit be purged when not in use However this may not be practical for all operators At a minimum the UltraDoser unit should be purged to eliminate any water that may be inside the unit after installation and prior to startup The UltraDoser reservoir may also require purging when there is liquid nitrogen flowing out of the vent The UltraDoser reservoir must also be purged when the nozzle becomes frozen shut 1 Attach the CryotechFlex hose 2 female flare side to the hous
11. d in the proper locations www chartdosers com PN 20552241 Page 14 of 33 E Mounting the UltraDoser Unit Once the stand is installed mount the UltraDoser unit on the stand using the supplied mounting bracket www chartdosers com PN 20552241 Page 15 of 33 E Installing the FS150 Controller Mount the FS150 controller at a convenient location Brackets are supplied to mount the controller on the Chart prefabricated support stand or 1 2 diameter rod or round bar www chartdosers com PN 20552241 Page 16 of 33 The bottom of the FS150 controller is the electrical plug connection The left side of the FS150 controller is the electrical connection between the operating parts of the UltraDoser unit and the FS150 controller There are five connections Input Power J1 The FS150 controller power cable 6ft is connected to the FS150 controller at port J1 Heater J2 This is the connector marked J2 on the FS150 controller A green light on the cable connector indicates that power 1s being supplied to the heater either dosing head or vent Solenoid J3 This is the connector marked J3 on the FS150 controller A green light on the cable connector indicates that power 1s being supplied to the solenoid valve A yellow light will appear when the solenoid valve 1s activated Sensor J4 This is the connector marked J4 on the FS150 controller A green light on the cable connector indicates that power 1s being s
12. e inside the unit reaches 50 psi or greater the safety relief valve will vent excess pressure Under normal operating conditions the SRV should not vent Vent Heater The UltraDoser unit has a self regulating vent heater The maximum temperature of the vent heater is 150 F 65 C and prevents frost or ice formation at the vent area The heater is held in place by a set of o rings If needed the vent heater can be removed by slipping it off of the vent area www chartdosers com PN 20552241 Page 13 of 33 Installation Application Evaluation The UltraDoser FS150 can be used for both inerting and pressurization applications The application must be evaluated to determine the ideal location of the dosing head on the filling line Inerting Inerting is the process of removing oxygen O2 from a bottle or container by dosing a relatively large amount of LN in the bottle or container to inert The liquid dose quickly converts into eas displacing air and oxygen from the bottle or container The ideal location for the UltraDoser unit must allow for enough time between dosing and capping so that the liquid dose 15 converted into a gas Pressurization Pressurization occurs by dosing a relatively small amount of LN into a bottle or container The liquid dose quickly converts into gas and the bottle or container 1s then capped or sealed to capture the expanding gas The UltraDoser unit should be installed as close to the ca
13. e GN system or portable GN cylinder this step will require additional fittings such as gt male flare fitting and compression fittings 2 Flow GN 20 psi 1 38 bar through the UltraDoser body for approximately ten 10 minutes before system Start up IMPORTANT When purging the UltraDoser unit 1t will vent heavily and there will be a steady stream of from the vent This fog will be cold to the touch if the internal temperature of the UltraDoser unit is still at or near LN temperatures 320 F 196 C Once the UltraDoser unit 15 at or near ambient temperature the will warm up www chartdosers com PN 20552241 Page 28 of 33 Replacement Parts Refer to pages 12 and 14 for location of most replacement parts on the UltraDoser FS150 Part Description Part Number Injection Unit Spare Parts Kit Includes PNs 102 103 104 105 106C 362 and 535 0 040 Nozzle 102 www chartdosers com PN 20552241 Page 29 of 33 General Trouble Shooting Below are a few general trouble shooting guidelines If after reading this section the condition does not change or the condition is not covered in this section please contact Chart s service team at 1 408 371 4932 Condition The safety relief valve is venting e The pressure of the LN supply is greater than 50 e Check the pressure of the LN supply If the psi 3 44 bar supply pressure is greater than 50 psi 3 44 bar reduce the
14. he dose 1s dispensed AFTER the bottle or container reaches the dosing head REDUCE the dose delay www chartdosers com PN 20552241 Page 23 of 33 Other Screens The FS150 controller has other screens that may be accessed but should not be modified Modification could void Chart warranty If the operator should access any screens other than the home page image on page 21 1 Use the arrow key lt or to return to the Date screen image below Operator may be required to press the arrow key lt or gt multiple times 2 Once at the Date screen press the arrow key A to return to the home page image on page 21 Su 00 00 2008 01 01 IMPORTANT From the date screen avoid using ESC or OK www chartdosers com PN 20552241 Page 24 of 33 Daily Operating Procedures The UltraDoser FS150 unit can be fed by either a portable Dura Cyl dewar or a house liquid nitrogen system Most UltraDoser FS150 installations will utilize portable Dura Cyl dewars Dura Cyl Dewar Fed System Typical Dura Cyl Dewar Installation Set Up IMPORTANT LN is 320 F 196 C Any water and or moisture can cause ice which will affect the performance of the UltraDoser FS150 system Providing a positive pressure of also known as purging to the UltraDoser unit before introducing LN into the body will eliminate many performance interruptions Purging with Gaseous Nitrogen
15. hout constraint If oxygen deficient atmosphere is suspected or known to exist 1 Use the buddy system Use more than one buddy if necessary to move a fellow worker in an emergency 2 Both the worker and buddy should be equipped with self contained or airline breathing equipment www chartdosers com PN 20552241 Page 6 of 33 Nitrogen Nitrogen an inert gas is a simple asphyxiant It will not support or sustain life and can produce immediate hazardous conditions through the displacement of oxygen Under high pressure these gases may produce unconsciousness even though an adequate oxygen supply sufficient for life 1s detect Nitrogen vapors in air dilute the concentration of oxygen necessary to support or sustain life Inhalation of high concentrations of this gas can cause anoxia resulting in dizziness nausea vomiting or unconsciousness and possibly death Individuals should be prohibited from entering areas where the oxygen content 1s below 19 unless equipped with a self contained breathing apparatus Unconsciousness and death may occur with virtually no warning if the oxygen concentration is below approximately 8 Contact with cold nitrogen gas or liquid can cause cryogenic extreme low temperature burns and freeze body tissue Persons suffering from lack of oxygen should be immediately moved to areas with normal atmospheres SELF CONTAINED BREATHING APPARATUS MAY BE REQUIRED TO PREVENT ASPHYXIATION OF RESCUE WORKERS Assisted
16. ied 10 foot CryotechFlex hose using a 1 8 allen wrench 3 Attach the CryotechFlex hose male bayonet side to the UltraDoser unit with the supplied bayonet clamp and gasket 4 Attach the CryotechFlex hose female flare fitting side to the 22psi LN Dura Cyl dewar 5 Open the liquid valve counter clockwise direction on the Dura Cyl dewar 6 Wait until the UltraDoser unit 1s filled with liquid nitrogen approximately 10 minutes 6 Place the switch on the FS150 controller to the 1 position This will turn the FS150 controller on 7 Adjust the dosing parameters See FS150 Controller Adjustments page 21 for additional information IMPORTANT When the UltraDoser unit 1s filling it will vent heavily and there will be a steady stream of fog from the vent Once the UltraDoser unit is filled there will be a wisp of fog coming from the vent If the UltraDoser unit overfills and liquid nitrogen starts dripping out the vent close the liquid valve on the Dura Cyl dewar and call Chart service at 1 408 371 4932 System Shut Down 1 Place the switch on the FS150 controller to the 0 position This will turn the FS150 controller off 2 Shut the liquid valve clockwise direction on the Dura Cyl dewar 3 If possible purge with GN until next use See Purging with Gaseous Nitrogen page 25 for additional information Dura Cyl Dewar 22psi Change Out Procedure The Dura Cyl dewar will need to be changed out fro
17. inte Parkway San Jose CA 95134 USA www chartdosers com 1 800 371 3303 No part of this document may be reproduced in any form or by any means without the prior written permission of Chart Inc Copyright 2011 Chart Inc www chartdosers com PN 20552241 Page 3 of 33 This manual is intended for use by Chart UltraDoser 150 customers It 1s important to read and understand the information in this manual before installing or operating the system This manual is provided by Chart to its customers as a courtesy and except as expressly provided in this manual CHART MAKES NO WARRANTIES EXPRESS OR IMPLIED REGARDING THE CONTENTS IN THIS MANUAL CHART ASSUMES NO REPONSIBILITY FOR ANY OUTCOMES AS A RESULT OF USING THIS MANUAL SAFETY FIRST Liquid nitrogen must be handled properly Without proper handling severe frost bite cryogenic burning oxygen deprivation and bursting of sealed bottles or containers can result During this process you may need Safety glasses with side shields and or protective face shield Insulated gloves for cryogenic service Symbols and statements used throughout this text and their meaning are as follows VN Text following this symbol needs extra attention IMPORTANT Text like this 15 extra information helpful to the situation CAUTION Text like this 1s information to help avoid personal injury and or property damage WARNING Text like this is information to help avoid serious personal inju
18. l contact of liquid gases with skin or eyes may cause a freezing injury similar to a burn Handle liquid so that it will not splash or spill Protect your eyes and cover skin where the possibility of contact with liquid cold pipes and equipment or cold gas exists Safety goggles or a face shield should be worn if liquid ejection or splashing may occur or cold gas may exit forcefully from equipment Clean insulated gloves that can be easily removed and long sleeves are recommended for arm and hand protection Cuff less trousers should be worn over the shoes to shed spilled liquid Safety Bulletin Portions of the following information are extracted from Safety Bulletin SB 2 from the Compressed Gas Association Inc CGA For the full text of Safety Bulletin SB 2 and for more information about oxygen atmospheres refer to Safety Bulletin SB 2 from the Compressed Gas Association Inc CGA at http www cganet com Additional information on nitrogen and liquid cylinders is available in CGA Pamphlet P 9 Write to the Compressed Gas Association Inc 1235 Jefferson Davis Highway Arlington VA 22202 or visit their website at http www cganet com Oxygen Deficient Atmospheres The normal oxygen content of air is approximately 21 Depletion of oxygen content in air either by combustion or by displacement with inert gas 1s a potential hazard Users should exercise suitable precautions One aspect of this possible hazard is the respo
19. m time to time The operator should visually check the gauges on the Dura Cyl dewar to monitor the internal liquid level When the gauges read low levels it must be swapped with a full Dura Dyl dewar 1 Shut the liquid valve counter clockwise direction on the Dura Cyl dewar 2 Disconnect the CryotechFlex hose from the Dura Cul dewar using a 7 8 open end wrench or adjustable crescent wrench 3 Connect the CryotechFlex hose to the liquid outlet on the full Dura Cyl dewar using a 7 8 open end wrench or adjustable crescent wrench IMPORTANT The UltraDoser FS150 will continue to dose properly until the liquid level inside the UltraDoser unit runs low This feature gives the operator a reasonable window in which to change out the Dura Cyl dewar without disrupting the production operation www chartdosers com PN 20552241 Page 26 of 33 Service and Maintenance Nozzle Change Out Procedure Remove the dosing head heater Insert the nozzle tool into the nozzle area until the tool connects with the nozzle image 1 Remove the nozzle with the driver in a counter clockwise direction Remove Once the nozzle is removed place the new nozzle or cleaned nozzle into the nozzle tool and insert in a clockwise direction image 2 oo Image 2 Image 1 CAUTION The dosing head heater may still be in operation Do not expose skin to prolonged contact with the dosing head heater The maximum temperature of the dosing head he
20. nse of humans when exposed to an atmosphere containing only 8 to 12 oxygen In this environment unconsciousness can be immediate with virtually no warning When the oxygen content of air 1s reduced to approximately 15 or 16 the flame of ordinary combustible materials including those commonly used as fuel for heat or light may be extinguished Somewhat below this concentration an individual breathing the air is mentally incapable of diagnosing the situation The onset of symptoms such as sleepiness fatigue lassitude loss of coordination errors in judgment and confusion can be masked by a state of euphoria leaving the victim with a false sense of security and well being Human exposure to atmosphere containing 12 or less oxygen leads to rapid unconsciousness Unconsciousness can occur so rapidly that the user is rendered helpless This can occur if the condition is reached by immediate change of environment or through the gradual depletion of oxygen Most individuals working in or around oxygen deficient atmospheres rely on the buddy system for protection obviously the buddy is equally susceptible to asphyxiation if he or she enters the area to assist an unconscious partner unless equipped with a portable air supply Best protection is obtainable by equipping all individuals with a portable supply of respiratory air Lifelines are acceptable only if the area 1s essentially free of obstructions and individuals can assist one another wit
21. nts that were defined to ship loose If there are any pieces listed on the Pack Slip and or Materials List not in the shipping crate please contact Chart immediately at 1 800 371 3303 CAUTION When removing the UltraDoser unit from the crate gently set 1t on the ground Do not drop the UltraDoser unit When transporting the UltraDoser unit through the facility be sure to carry with care Take care not to run into walls or drag the UltraDoser unit on the ground Prior to installation the UltraDoser FS150 should be stored in a location that will prevent dirt water or other debris from getting inside the system Similarly it should be stored in a place that 1s generally out of the way of frequent traffic to reduce the risk of damage Chart recommends storing the system in the crate when not in service www chartdosers com PN 20552241 Page 8 of 33 Overview and Utilities Product Specifications UltraDoser Body Dimensions UltraDoser Dosing Head Total Weight w electronics Dosing Range Dosing Accuracy Timing Range Control Voltage Materials Crate Dimensions Utility Requirements Electrical Supply Liquid Nitrogen Gaseous Nitrogen www chartdosers com Reservoir height 18 457mm Hexagonal 6 197mm Arm reach 12 or 18 305mm or 457mm from stand dependent on mounting bracket location 2 W x 9 5 H 51mm x 241mm UltraDoser 32 Ibs 14 5kg FS150 Controller
22. pper as possible support Stand Location The UltraDoser unit is supplied with a mounting bracket assembly The assembly consists of the bracket attaching to the UltraDoser body and two clamps designed to fit on stainless steel rod Chart can supply a prefabricated stand to accommodate the mounting bracket assembly This stand can be utilized in almost all installations If the Chart stand cannot be used in your installation fabricating one with 15 diameter rod or round bar will make installation of the UltraDoser FS150 simpler The following instructions will assume installation of Chart s prefabricated support stand Figure 4 34 00 24 00 24 00 24 00 g 18 00 12 23 P 5 78 12 23 a 1223 578 Figure 1 Figure 2 Figure 3 Figure 4 1 The UltraDoser unit can be installed on either side of a production line Select the side that best suits the workplace The mounting bracket assembly is installed straight back opposite to the arm from the factory However the UltraDoser body can be mounted in the mounting bracket such that the support stand 1s located on either side perpendicular to the arm Figure 1 3 2 Measure the appropriate distance depending on the UltraDoser configuration This 1s the location for the installation of the support stand 3 Mark the location of the stand and install the four 4 5 8 bolts included with the support stan
23. rd Terms and Conditions of Sale Chart warrants to the original purchaser of Chart manufactured LN Dosing Systems that for one 1 year after the date of shipment to the original purchaser said Chart manufactured LN Dosing System will maintain all vacuum and performance standards for said LN Dosing System as published by Chart on the date of invoice Purchaser agrees that as a pre condition to any Chart warranty obligation hereunder purchaser shall fully inspect the LN Dosing System immediately upon delivery to purchaser and shall give Chart written notice of any claim or purported defect within ten 10 days after receipt of the LN Dosing System As a further pre condition to any Chart warranty obligation hereunder purchaser shall return said purportedly defective LN Dosing System freight prepaid to the plant of the manufacturer within thirty 30 days after receipt of the LIN Dosing System Chart shall inspect the returned LN Dosing System and if said LN Dosing System is found defective shall at Chart s option as purchaser s sole and exclusive remedy either 1 repair or replace such LN Dosing System or any defective component or part thereof which proves to be defective or 11 refund the net purchase price paid by the original purchaser Alterations or repairs by others or operation of such LN Dosing System in a manner inconsistent with Chart accepted practices and all operating instructions unless preauthorized in writing by Ch
24. re designed to fit on Chart s support stand or 1 1 2 stainless steel rod The bracket can be mounted in 3 positions See page 16 for additional information Dosing Head Heater The UltraDoser unit has a self regulating dosing head heater The maximum temperature of the dosing head heater is 150 F 65 C and prevents frost or ice formation at the dosing head area The heater is held in place by a set of o rings If needed the dosing head heater can be removed by slipping it off of the dosing head The dosing head heater has a built in splash guard to minimize the dosing nozzle s exposure to splashed product or LN Dosing Head The dosing head delivers the dose of 1 Dosing Valve Assembly The dosing valve assembly contains the solenoid coil the electromagnetic core with the valve stem the return spring and the sealed valve housing Dosing Nozzle not shown The size of the dosing nozzle directly affects the amount of LN dosed 0 040 ID 0 050 ID and a 0 060 ID nozzles ship loose with the LN Dosing System Custom sizes may be ordered from Chart www chartdosers com PN 20552241 Page 12 of 33 Back View SRV Drain Plug Vent Heater SRV Drain Plug 50psi SRV drain plug are located on the back of the UltraDoser unit When removed this allows the LN to drain from the UltraDoser body The 50psi safety relief valve SRV is provided to protect the unit against over pressurization If the pressur
25. respiration and supplemental oxygen should be given if the victim 15 not breathing If cryogenic liquid or cold boil off gas contacts a worker s skin or eyes the affected tissues should be promptly flooded or soaked with tepid water 105 115 F 41 46 DO NOT USE HOT WATER Cryogenic burns which result in blistering or deeper tissue freezing should be examined promptly by a physician www chartdosers com PN 20552241 Page 7 of 33 Receiving Your UltraDoser FS150 The UltraDoser FS150 is designed for steady speed filling lines up to 150 bottles or containers per minute It does not compensate for changes in line speed Any changes to the line speed may require changes to the dose settings Unpacking the UltraDoser FS150 The UltraDoser FS150 will arrive in a specially designed shipping crate If the unit 16 intended to be moved from one location to another storing the crate for future use 15 ideal Upon arrival of the UltraDoser FS150 it is advised to immediately inspect for any signs of damage If any damage occurred in shipping claims must be filed with the shipping carrier immediately prior to unpacking the UltraDoser FS150 While unpacking the crate all contents should be carefully inspected Things to check for upon arrival include v Dents in the UltraDoser unit v Male and female bayonets should be protected V Proper number of bayonet clamps flanges and o rings one set for every female bayonet v Any other compone
26. ry or death and or property damage www chartdosers com PN 20552241 Page 4 of 33 Safety WARNING Your UltraDoser FS150 may be fed by a vacuum insulated pipe system designed to contain pressurized ultra cold cryogenic liquids These systems should only be worked on by trained personnel to avoid serious injuries such as freezing oxygen deficient atmosphere and extremely high pressures WARNING Any configuration which allows a trapped volume of cryogenic liquid or cold gas must be protected by a pressure relief valve As the cold liquid gas gains heat the contents will expand and increase in pressure section not protected by an over pressure relief valve will experience extremely high pressures and significant safety concerns VN WARNING Over pressurization of bottles or containers can occur while using Chart s UltraDoser FS150 potentially bursting the bottles or containers Proper calibration of the UltraDoser FS150 ensures optimum nitrogen doses to avoid over pressurization Be sure to remove any bottles or containers that receive more than its proper LN doses before sealing wARNING If you are at all unsure of how to safely work on this system STOP and contact Chart immediately at 1 408 371 4932 CAUTION As with any cryogenic system it should be observed that any non insulated piping can get extremely cold and should not be touched by exposed skin If the system requires maintenance it should be shu
27. s liquid nitrogen defined by the user defined milliseconds REGARDLESS of line speed 1 Press and HOLD ESC until the cursor _ appears and blinks on the Duration mS value line 2 Press the arrow key to move the cursor _ to the Dose Delay mS value line image below DURATION 20 mS DOSE DELAY 190 mS www chartdosers com PN 20552241 Page 22 of 33 3 Press and HOLD A plus sign with be highlighted and blink five digits will also appear image below DURATION 20 mS DOSE DELAY 00190 mS 4 Press the arrow key to highlight the desired digit Operator may be required to press the arrow key gt multiple times to highlight the desired digit Use the arrow key A or V to change the value Repeat steps 4 and 5 to change each desired digit value Press to set value Press ESC to return to the home page image on page 21 Re attach the display cover Dose Delay Milliseconds 32699 IMPORTANT Dose Delay setting may be set for a maximum of 32699 mS 32 seconds which may be xd 2 led impractical for most installations FS150 Controller Set up Verification Send a bottle or container down the filling line Note if the dose 1s dispensed before in or after the bottle or container If the dose 1s dispensed BEFORE the bottle or container reaches the dosing head INCREASE the dose delay until the dose 1s dispensed into the bottle or container If t
28. t be controlled to ensure consistent dosing results 1 Product bottle or container fill levels must be consistent 2 Product bottle or container fill temperatures must be consistent 3 Capping techniques must be consistent 4 Product may not be spilled or splashed out of bottles or containers following dose IMPORTANT Enough time must be allowed for specific dosing operations When using the UltraDoser FS150 for inerting purposes removal of oxygen time must be allowed between dosing and complete capping of the bottle or container See Inerting page 14 for additional information www chartdosers com PN 20552241 Page 20 of 33 FS150 Controller Adjustments The FS150 controller is designed to dose at a fixed speed only The only adjustments are Duration of Dose and Dose Delay IMPORTANT There are additional screens accessible on the FS150 controller but should not be modified Modification to certain screens may void Chart warranty See Other Screens page 24 for additional information IMPORTANT The FS150 controller allows approximately 20 seconds to make adjustments to the Duration and Dose Delay features before returning to the home screen image below DURATION 20 mS DOSE DELAY 190 mS Duration of Dose The Duration of Dose is the time in milliseconds mS that the UltraDoser dosing valve opens to dose The amount of LN that is trapped inside a bottle or container depends
29. tdown and allowed to warm up Strict compliance with proper safety and handling practices is necessary when using a cryogenic system We recommend that all our customers re emphasize safety and safe handling practices to all their employees and customers While every possible safety feature has been designed into the system and safe operations are anticipated 1t 1s essential that the user of the cryogenic system carefully read to fully understand all WARNINGS and CAUTION notes listed in this safety summary and enumerated below Also read the information provided in the Safety Bulletin for Inert Gases following this Safety Summary Periodic review of the Safety Summary is recommended VN WARNING N itrogen vapors in air may dilute the concentration of oxygen necessary to support or sustain life Exposure to such an oxygen deficient atmosphere can lead to unconsciousness and serious injury including death CAUTION Before removing parts or loosening fittings empty the UltraDoser FS150 of liquid and release any vapor pressure in a safe manner External valves and fittings can become extremely cold and may cause painful burns to personnel unless properly protected Personnel must wear protective gloves and eye protection whenever removing parts or loosening fittings Failure to do so may result in personal injury due to the extreme cold and pressure in the system www chartdosers com PN 20552241 Page 5 of 33 WARNING Accidenta
30. the Duration of dose and the Dose Delay settings When the bottle detect sensor detects a bottle or container the UltraDoser unit will dose for the set duration Duration after the Dose Delay wait The controller will automatically change to continuous dose if the Dose Delay 15 set less than 190 mS milliseconds Inlet Filter A 10 micron stainless steel inlet filter 15 provided The filter needs to be installed inside the male bayonet on the CryotechFlex hose www chartdosers com PN 20552241 Page 11 of 33 CryotechFlex Hose A vacuum insulated hose that provides a connection between the UltraDoser unit and the LN supply Controller Mounting Assembly The FS150 controller is supplied with a mounting assembly This assembly is designed to attach to the FS150 controller and fit on Chart s support stand or 1 1 2 stainless steel rod See page 17 for additional information Bayonet Connection The bayonet connection allows a completely vacuum insulated warm and frost free connection between the CryotechFlex hose and the UltraDoser unit GN Regulator Assembly Controls the pressure of the house GN DO NOT use air even if compressed dry air CDA to the dosing valve assembly The regulator 1s preset to 60 psi 4 bar Mounting Bracket Assembly The UltraDoser unit is supplied with a mounting bracket assembly The assembly consists of the bracket attaching to the UltraDoser unit and two clamps These clamps a
31. ttles or containers running on the same production line www chartdosers com PN 20552241 Page 18 of 33 E Installing the Bottle Detect Sensor The bottle detect sensor must be a PNP type sensor and must be installed for the UltraDoser FS150 to operate correctly The sensor must be mounted approximately 2 5 from the UltraDoser dosing head www chartdosers com PN 20552241 Page 19 of 33 Principles of Liquid Nitrogen LN Dosing To ensure consistent dosing results an accurate dose must be delivered to each bottle or container AND each bottle or container must be processed in the same manner Chart s UltraDoser FS150 guarantees that a precise accurate dose of LN is delivered The UltraDoser FS150 meets the following fundamental dosing conditions Pure Liquid at the Dosing Head Pure liquid i e liquid with no gas pockets must be instantaneously available at the dosing head Chart has a unique internal design that ensures the continual availability of pure liquid at the dosing head Constant Pressure Constant pressure at the dosing head is a critical requirement for reproducible dose size The unit utilizes a float valve that allows for a stable liquid level This allows the pressure at the dosing head to remain constant during operation Dose Duration The dose duration 15 tightly controlled by the FS150 controller s electronics Dose duration 1s measured in milliseconds IMPORTANT The following production conditions mus
32. upplied to the bottle detect sensor A yellow light will appear when the product bottle or container 1s detected Heater J5 This is the connector marked J5 on the FS150 controller A green light on the cable connector indicates that power 1s being supplied to the heater either dosing head or vent www chartdosers com PN 20552241 Page 17 of 33 E Installing the Nozzle Three nozzles are supplied with the UltraDoser FS150 0 040 0 050 and 0 060 Custom sizes may be ordered from Chart Remove the dosing head heater Select a nozzle Insert the nozzle into the nozzle tool threads out image 1 Thread the nozzle into the dosing head area in a clockwise direction 1mage 2 amp 3 Do not over torque Re apply the dosing head heater pO Meis Image 1 Image 2 Image 3 CAUTION Never use an ice pick screwdriver torch or similar devices on the dosing head image 2 The ribs of the internal bellows are a thin walled metal and the hole on the outer ring of the dosing head is a positive pressure port to help keep moisture out and ice from forming High heat and puncture holes will destroy the vacuum insulation and VOID WARRANTY E Positioning the Dosing Head The dosing head should be directly over the bottle or container opening The dosing head is typically installed 1 2 3 4 above the bottle or container opening The UltraDoser unit must be manually adjusted to accommodate different sized bo
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