CHART Orca MicroBulk CO2 Series, Product Manual

Page 1: ...Part Number 21235568 Rev D 2018 Chart Inc Designed and Built by Chart Inc 407 7th Street NW New Prague MN 56071 USA 800 400 4683 Product Manual Orca MicroBulk Delivery System CO2 Series...

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Page 3: ...Cryogenic 9 Cryogenic Temperatures 9 States of Matter 9 Saturation 9 Equilibrium 9 Saturation Pressure 9 Subcool 9 Two Phase Liquid 9 Cavitation 9 Vaporization 10 Vapor Pressure 10 Condensation 10 Con...

Page 4: ...30 Flowcom Flow Meter System 30 Cabinet Power Truck 30 Work Lights 31 Dash Controls Truck 31 Hydraulic System Truck 32 Motor and CO2 Pump Rotation Direction 32 Grease Fitting Locations 33 Pressure Bui...

Page 5: ...um Integrity Check as required 44 Preventive Maintenance Log 41 Specifications 47 Piping Schematic 48 Nomenclature 49 Truck Electrical System Diagram 50 Trailer Electrical System 51 Truck Hydraulic Sy...

Page 6: ...2 Series MicroBulk Delivery System Revision Log Revision Level Date Description A 2 21 2018 Original B 3 8 2018 Added parts and specs update C 6 18 2018 Specs change added preventive maintenance log D...

Page 7: ...ing parts for minimal maintenance Vessel designed with robust inner support system for rugged road conditions Stainless steel plumbing with stainless steel and brass valves for long service life and r...

Page 8: ...Pressure CGA Compressed Gas Association CO2 Carbon Dioxide DOT Department of Transportation NER Normal Evaporation Rate GAWR Gross Axle Weight Rating GPM Gallons Per Minute GVWR Gross Vehicle Weight...

Page 9: ...cold and tank pressure Accidental contact of liquid gases to skin or eyes may cause a freezing injury similar to a burn Warning If cryogenic liquid or cold boil off gas contacts a worker s skin or eye...

Page 10: ...s 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 atmosp...

Page 11: ...ases may produce narcosis even though an adequate oxygen supply sufficient for life is present Nitrogen and argon vapors in air dilute the concentration of oxygen necessary to support or sustain life...

Page 12: ...ly 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 r...

Page 13: ...Safety 7 Product Manual Orca CO2 Series MicroBulk Delivery System...

Page 14: ...8 Safety Product Manual Orca CO2 Series MicroBulk Delivery System...

Page 15: ...saturation condition of the liquid Saturation can also be described as an energy state Liquid molecules at a higher energy state warmer take up more space which is often referred to as liquid growth...

Page 16: ...h Losses Dropping the vapor space pressure below the saturation pressure of the liquid causing the liquid to boil During the venting of the tank below the saturation pressure of the liquid the liquid...

Page 17: ...higher pressure on the outlet side product WILL leak past the ball valve 6 Open Vapor Vent V 5 and vent tank under 5 psig Close Vapor Vent 7 Open Bottom Fill V 17 and pressurize to 250 psig 8 Remove...

Page 18: ...Balance DC 5 and Line DC 1 connections 13 Close cabinet doors and stow hoses Replace all dust caps III Fill Orca CO2 from Onboard Pump 1 In order to minimize pump cavitation and surging a The liquid...

Page 19: ...in V 9 and Vapor Balance Line Drain V 45 valves to drain and release all pressure Close Fill Line Drain V 9 and Vapor Balance Line Drain V 45 valves Warning Fast depressurization of liquid CO2 can cau...

Page 20: ...runs on high until coolant temperature reaches 176 F 80 C ii Cycles to low mode until coolant drops to 167 F 75 C iii This repeats until coolant reaches 185 F 85 C at which heater shuts off iv Heater...

Page 21: ...tling the PB Liquid V 28 valve at high liquid levels will delay the time the coil takes to over run Throttling may have effects on PB rate and should be analyzed in each delivery scenario where needed...

Page 22: ...k as necessary c Once the issue is addressed open the closed Dispense V 41 valve There will be no delay in Totalizer now as the hose volume is already accounted for d Do not exceed 100 flow rate on Fl...

Page 23: ...etering 5 Open Pump Inlet Fill V 1 valve 6 Power on Flowcom and select DELIVERY mode This also powers on the printer 7A If vapor balancing Connect 1 0 vapor balance hose to Vapor Balance Connection DC...

Page 24: ...discharge when pump is started causing Pump Discharge Relief RV 11 to relieve i Bypass V 7 valve is factory set to 70 psid The pump discharge pressure will be 70 psig greater than the vessel pressure...

Page 25: ...net doors and stow hoses Replace all dust caps 29 Disengage engine speed control and disengage PTO 30 Keep pressure build heater running or turn off as necessary Note This procedure can also be used f...

Page 26: ...by all operators Note Damage may occur to PTO system or transmission if proper PTO engagement is not followed It is highly recommended to develop instructions and place a label on the dash 2 Set speed...

Page 27: ...he engine must be run at high idle to keep battery charged Note Battery state of charge can be monitored in the Flowcom Inputs Outputs screen Vs_Main_In c The pressure build heater water pump will sta...

Page 28: ...22 Operations Product Manual Orca CO2 Series MicroBulk Delivery System...

Page 29: ...O2 Series MicroBulk Delivery System This is the view of the Orca CO2 Series delivery system cabinet This section will discuss in detail the plumbing cabinet components and systems Components Systems R...

Page 30: ...very System Plumbing Cabinet Roadside Item Tag Description A AI 1 Anti Tow Valve B TRAN 1 Hose Reel Flex Hose C HR 1 Hose Reel D TRAN 2 Delivery Flex Hose to Hose Reel E Fill Gun Assembly F DC 3 Conne...

Page 31: ...ure Indicator Pump Discharge D V 32 Valve Liquid Phase Isolation E PI 1 Pressure Indicator Inner Vessel F LI 1 Level Indicator Inner Vessel G DP 1 Transmitter DP Meter Low H DP 2 Transmitter DP Meter...

Page 32: ...e PB Liquid D V 41 Valve Dispense E DC 2 Connection Dispense F RV 6 Relief Valve Dispense G V 8 Valve Dispense Line Drain H DC 1 Connection Fill Line I RV 10 Relief Valve Fill J V 9 Valve Fill Line Dr...

Page 33: ...mbing Cabinet Curb Side Item Tag Description A V 7 Valve Bypass B P 1 Pump C RV 11 Relief Valve Pump Discharge D RTD 1 Resistance Temperature Device E MTR 1 Motor F CPL 1 Coupler Motor to Pump G Motor...

Page 34: ...Vapor Balance PB Isolation B PBC 1 Pressure Building Coil C RV 5 Relief Valve Pressure Build D CV 5 Check Valve Bypass E RV 1A Safety Valve Inner 350 psig F RV 1B Safety Valve Inner 375 psig G V 15 V...

Page 35: ...a tank to the customer The system is made up of five components the Meter Section two Differential Pressure Transmitters Resistance Temperature Device and the Flowcom Flow Meter System Meter Section T...

Page 36: ...ding cabinet power The 10 amp breaker protects the circuit These are Rosemount Pre Set Differential Pressure Transmitters used on the Orca system They are connected to the meter section and the Flowco...

Page 37: ...re build heater Arrow Buttons B and C adjust heater on time with key in OFF or ACC positions If the truck is equipped with two heaters one for truck engine and one for pressure build a second timer or...

Page 38: ...ays for powering solenoid block G and the cooling fan When the cabinet switch SW 1 is in the up position recirculating flow is redirected to the motor MTR 1 in the cabinet to power the CO2 pump Pl 1 B...

Page 39: ...PB Heater A is located on the frame behind the fuel tank Safety cones B may be located anywhere on the truck frame Wheel chocks C and safety flares D are in the tool box E which may be located anywhe...

Page 40: ...Deck Hydraulic Reservoir Cooler Filter Same as on truck system Engine and Battery Battery supplies power to the engine cabinet and pressure build heater Access Panel In order to check coolant and add...

Page 41: ...anual Orca CO2 Series MicroBulk Delivery System Control Panel Engine Throttle Control Engine Control Panel with Key Switch Pressure Build Heater Switch Roadside Frame Rail Tool Box Triangles wheel cho...

Page 42: ...36 Components Systems Product Manual Orca CO2 Series MicroBulk Delivery System...

Page 43: ...nspect wires from connector to control panel for break cuts etc Repair if necessary Turn to ACC or ON Unstable flow of product Depletion of subcool Vessel transmitter fault Manual valves closed Liquid...

Page 44: ...treme high flow rate Repair leak Use dispense valve to throttle Audible change in pump Liquid level low Worn components in pump Check liquid level gauge Delivery of product should not be attempted at...

Page 45: ...Carbon dioxide ice in tank If the pressure in the tank drops below 61 psi dry ice slush will form in the tank which will restrict liquid CO2 from entering the pressure building coil To liquefy solid...

Page 46: ...bration seal needs to be broken E004 User settings 1 of the meter system have not been entered yet Checksum error identified when reading the corresponding settings Configure device See also section 6...

Page 47: ...Check connection cable ribbon cable and or replace Expansion module E040 Battery Voltage lower than 1 82V Nominal value is 3 0V Replace battery Check date and time of internal clock and set if necessa...

Page 48: ...42 Troubleshooting Product Manual Orca CO2 Series MicroBulk Delivery System...

Page 49: ...or of a leak 3 If ice forms around valves ensure the valves are fully operational If not defrost with water 4 Check for loose hardware hydraulic oil leaks glycol system leaks and in general items out...

Page 50: ...th a MIL G 10924 C ball bearing grease rating of 50 F Follow maintenance procedures in pump manual Yearly Preventive Maintenance 1 Ensure proper service in all programmable settings 2 Drain the air ta...

Page 51: ...45 Preventive Maintenance Product Manual Orca CO2 Series MicroBulk Delivery System Date Preventive Maintenance Performed Notes Preventive Maintenance Log...

Page 52: ...46 Preventive Maintenance Product Manual Orca CO2 Series MicroBulk Delivery System Date Preventive Maintenance Performed Notes...

Page 53: ...Dispense Rate lb min kg min 500 227 Max Dispense Pres sure psig barg Pressure 350 24 1 Pump 400 27 6 Min and Max Dispense Rates are based on NTEP approval and dependant on many variables Orca pressure...

Page 54: ...48 Specifications Product Manual Orca CO2 Series MicroBulk Delivery System Piping Schematic...

Page 55: ...49 Specifications Product Manual Orca CO2 Series MicroBulk Delivery System Nomenclature...

Page 56: ...PEN PORT 10A 18 GA OR 75A 12 GA WT 12 GA BK 12 GA RD 12 GA RD 14 GA RD 10 GA RD TRUCK CAB ROAD SIDE FRAME RAIL NEAR CAB FROM TRUCK TAIL LIGHT WIRING WT BN WT BN WT BN RD WT WT BN WT BN BK BK RD WT RD...

Page 57: ...VS IN OUTSIDE CABINET PRINTER ENCLOSURE REAR OF TRAILER ROAD SIDE FRAME RAIL TRANSMITTER DP 2 HIGH TRANSMITTER DP 1 LOW 24V DC INSIDE CABINET PUMP START SWITCH SEE HEATER MANUAL HYDRAULIC SOLENOID VAL...

Page 58: ...TEMPERATURE SWITCH Pump Start Switch JUNCTION BOX BEHIND RESERVOIR CURB SIDE FRAME RAIL FAN 40A CABINET POWER 75 A TRUCK HYDRAULIC SYSTEM WITH PUMP ELECTRICAL SUCTION RECIRCULATION RETURN CASE DRAIN H...

Page 59: ...OTOR HYDRAULIC RESERVIOR FILTER COOLER TEMPERATURE SWITCH Pump Start Switch TRAILER HYDRAULIC SYSTEM SUCTION RECIRCULATION RETURN CASE DRAIN HIGH PRESSURE LOW PRESSURE INSIDE CABINET FAN HYDRAULIC POW...

Page 60: ...20A 5A A B C D E RD YL YL RD RD BN GN BN BN DASH TIMER CONNECTOR WIRE SIDE YL RD RD BN BN RD DASH TOGGLE SWITCH YL BU RD BN GN BIG CONNECTOR 4 10 7 1 11 12 8 9 5 6 3 2 DASH TIMER CONNECTOR WIRE SIDE...

Page 61: ...warrants all Orca CO2 Series units manufactured to be free from defects in material and workmanship for three years after shipment subject to the exclusions listed below and statements on the precedi...

Page 62: ...Product Manual Orca CO2 Series MicroBulk Delivery System...