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CHART ULTRADOSER 2K, User Manua, Page: 1 / 66

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ULTRADOSER 2K 

USER MANUAL 

 

 

 

 

Summary of Contents for ULTRADOSER 2K

Page 1: ...ULTRADOSER 2K USER MANUAL...

Page 2: ...alling the Bottle Detect Sensor 19 Installing the Timing Sensor 19 Installing the Encoder 20 Installing the 2K Controller 22 2K Controller Adjustments 24 Home Screen 24 About 25 Languages 26 Setup 27...

Page 3: ...Appendix B 2KA Allen Bradley Controller Wiring Diagram 65 Appendix C 2KS Siemens Controller Wiring Diagram 66...

Page 4: ...rt Inc 161 Baypointe Parkway San Jose CA 95134 USA www chartdosers com 1 408 371 4932 Manufacturer The UltraDoser 2K is designed and manufactured by Chart Inc 161 Baypointe Parkway San Jose CA 95134 U...

Page 5: ...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...

Page 6: ...be touched by exposed skin If the system requires maintenance it should be shutdown and allowed to warm up Strict compliance with proper safety and handling practices is necessary when using a cryoge...

Page 7: ...containing only 8 to 12 oxygen In this environment unconsciousness can be immediate with virtually no warning When the oxygen content of air is reduced to approximately 15 or 16 the flame of ordinary...

Page 8: ...elf 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...

Page 9: ...ude Dents in the UltraDoser unit Male and female bayonets should be protected Proper number of bayonet clamps flanges and o rings one set for every female bayonet Any other components that were define...

Page 10: ...ight Timing Range 5 5 1000 milliseconds in 0 1 millisecond intervals Control Voltage 24 VDC Materials Stainless steel construction Built to food and beverage industry standards Crate Dimensions 58 L x...

Page 11: ...UltraDoser Body Dimensions Shown with Standard Head...

Page 12: ...Shown with EP Head...

Page 13: ...et attaching to the UltraDoser unit and two clamps These clamps are designed to fit on Chart s support stand or 1 1 2 stainless steel rod Dosing Head The dosing head delivers the dose of LN2 Dosing Va...

Page 14: ...he 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 Optional Components C Flex Hose A vacuum insulated hose that provides a conn...

Page 15: ...cket assembly The assembly consists of the bracket attaching to the UltraDoser body and two clamps designed to fit on 1 stainless steel rod Chart can supply a prefabricated stand to accommodate the mo...

Page 16: ...Mounting the UltraDoser Unit Once the stand is installed mount the UltraDoser unit on the stand using the supplied mounting bracket...

Page 17: ...container sensor and indicates sensor activity A green light on the cable connector indicates that power is being supplied to the sensor A yellow light will flash when a container is detected Dose So...

Page 18: ...ices 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...

Page 19: ...the UltraDoser unit will stop dosing See Inputs Outputs Bottle Sensor on page 41 for additional information See Appendix A Sensor Positioning on page 63 for additional information Installing the Timin...

Page 20: ...ry preset to 500 pulses per container See Appendix A Sensor Positioning on page 63 for additional information Encoder Installation IMPORTANT Only one channel is used to provide necessary pulse for the...

Page 21: ...os must be provided to ensure optimum dosing results Encoder Mounting Information Ensure encoder is properly mounted and securely affixed so it will perform at its optimum capability Follow the drawin...

Page 22: ...troller Dose Disable Push Button Manual dose disable push button to disable dosing Light Tower Status The indicator light provides a visual display of the operating status of the UltraDoser 2K Green N...

Page 23: ...to the 2K controller at Tube 04 Encoder J5 An encoder must be used to provide approximately 500 24v pulses per container A PNP 12mm proximity speed sensor is provided as a back up to provide the 2K c...

Page 24: ...n buttons on the bottom of the screen Home Screen overview and meanings Dose Mode This is the Dose Delay Mode either Fixed or Auto Dose Delay mS The Dose Delay should be a steady number proportionally...

Page 25: ...On the Home screen pressing the Chart logo will show the About screen Chart s contact information as well as the 2K controller s PLC and HMI version and default IP address will be available on this s...

Page 26: ...age USA English Mexico Spanish Brazil Portuguese UK English Spain Spanish Portugal Portuguese China Simplified Chinese Poland Polish Italy Italian IMPORTANT Selecting a language automatically determin...

Page 27: ...p navigation button will prompt two sub navigation buttons System Settings and Calibration Access to these screens will require log in with user ID and password See Access and Passwords on page 27 for...

Page 28: ...K controller has been programmed to a default user and password as described below User A Password A IMPORTANT Once logged in any and all user information is changeable Care must be taken when enterin...

Page 29: ...e field Dosing Head Actuations Displays the total number of actuations and the batch number of actuations Total will show the life of the system while batch can be reset Banner Alarm Hide or show alar...

Page 30: ...elay and the dose duration will remain unchanged IMPORTANT Proper set up of the Calibration screen is essential to the successful operation of the UltraDoser 2K system If after reading this section yo...

Page 31: ...e Delay Calibration Point Low Distance Delay mm Jog the filler until timing sensor is activated distribution block D 3 cable yellow light Measure the distance from the center of the dosing head to the...

Page 32: ...image below for additional information in determining this value 2 Enter the Continuous Dosing Speed CPM This is the maximum speed at which the UltraDoser 2K will dose in discrete pulse mode If the li...

Page 33: ...rom the dosing head in milliseconds Recipes Creating a Recipe 1 From the Recipes screen press Transfer Upload from PLC to upload the dosing parameters from the Calibration screen The Recipe Parameters...

Page 34: ...ue IMPORTANT The Recipes Name value will be used to identify recipes on the Home screen 4 Press Save This name will appear on the Home screen when the recipe is Download ed to the PLC as opposed to th...

Page 35: ...e has been activated The Recipes Name Value should appear on the Home screen IMPORTANT If any changes are made to the Calibration settings of an activated recipe the recipe will become deactivated and...

Page 36: ...ons Maintenance Modes Graphs and Inputs Outputs Access to these screens will require log in with user ID and password See Access and Passwords on page 27 for additional information Maintenance Modes F...

Page 37: ...to air moisture may have accumulated which could result in ice formation causing a blockage in the system Purging by sending gaseous nitrogen will dry out the system IMPORTANT Press and HOLD Enable Q...

Page 38: ...every few seconds with current CPM data The graph shows the CPM timing of the last 250 containers The important characteristic to watch is the consistency of the data There should not be large spikes...

Page 39: ...yellow bar graph is the Dosing Delay time b Dosing Duration mS The green bar graph is the Dosing Duration or the time the LN2 valve is actuated c Realtime The graph updates in realtime showing continu...

Page 40: ...een light to normal operation b Red Light press the Force On toggle pushbutton to turn the red light on Press the Force Off toggle pushbutton to turn the red light off The force action is enabled when...

Page 41: ...shbutton the raw reading will become the Offset Level d 100 Calibrate Push this pushbutton when calibrating at the 100 Liquid Level e Current Level The blue box indicates the current liquid level f Fo...

Page 42: ...pressure offset c Final Inlet Pressure The blue box indicates the current inlet pressure d Forced Inlet Pressure You can force an inlet pressure by typing a value in the yellow input box and pressing...

Page 43: ...or or the Bypass Enabled Disabled pushbutton b Bypass Enabled Disabled Pushbutton Provides the ability to override the bottle detect sensor Ideal if the bottle detect sensor goes bad the doser will st...

Page 44: ...igital input This is the status of the one per bottle sensor c Valve Confirm digital input This is the status of the LN2 valve actuator sensor d Bottle Detect digital input This is the status of the b...

Page 45: ...they are currently active and are retentively displayed on the Alarm History screen IMPORTANT Alarm conditions do not stop liquid nitrogen dosing IMPORTANT Alarm conditions are shown on the Alarms sc...

Page 46: ...int Level 2 Alarms These sensor alarms require checking sensors if persistent These alarms trigger a solid red light FAULT 20 Speed Sensor Pulses not seen on input 0 Check the wiring to input 0 24VDC...

Page 47: ...he red mushroom pushbutton on the front of the Doser control panel is pushed FAULT 51 Remote Disable on The remote Doser disable is active FAULT 53 Bottle Sensor Pulses seen too fast Check the encoder...

Page 48: ...rogen system Dura Cyl Dewar Fed System IMPORTANT LN2 is 320 F 196 C Any water and or moisture can cause ice which will affect the performance of the UltraDoser 2K system Providing a positive pressure...

Page 49: ...emperature of the UltraDoser unit is still at or near LN2 temperatures 320 F 196 C Once the UltraDoser unit is at or near ambient temperature the fog will warm up System Start Up 1 Place the On Off sw...

Page 50: ...he 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 Cyl dewar 1 Shut the liquid valve clockwise direction on the Du...

Page 51: ...ice which will affect the performance of the UltraDoser 2K system Providing a positive pressure of GN2 also known as purging to the UltraDoser unit before introducing LN2 into the body will eliminate...

Page 52: ...to eliminate performance interruptions A dedicated GN2 source is required to purge the UltraDoser unit Chart recommends a dedicated GN2 source from the facility 1 Manually close clockwise the Y Patter...

Page 53: ...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 Y Pattern valve and call Chart service at 1 408 371...

Page 54: ...ead heater is 150 F 65 C IMPORTANT Always perform nozzle change out procedures before introducing LN2 into the UltraDoser unit Failure to do so may cause the nozzle to unthread and fall out IMPORTANT...

Page 55: ...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 nitr...

Page 56: ...P Head 323 11 Confirm Sensor Cable 1 5mt D 5 for Std Head 1201 12 Confirm Sensor Cable 1 5mt D 5 for EP Head 323 13 75 Micron 1 8 M x F Snubber 160 14 SRV 50 psi 211 15 Distribution Block Cable 5mt 57...

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Page 61: ...n Liquid is coming out of the vent Possible Causes Actions The LN2 supply pressure is too high Lower LN2 supply pressure to 22 psi 1 5 bar or lower Ice has developed inside the unit causing the intern...

Page 62: ...ect points gear tooth or the like If necessary replace sensor The speed sensor encoder is not functioning Check the speed sensor encoder is operating correctly and is sending a signal to the 2K contro...

Page 63: ...shall inspect the returned LN2 Dosing System and if said LN2 Dosing System is found defective shall at Chart s option as purchaser s sole and exclusive remedy either i repair or replace such LN2 Dosi...

Page 64: ...Appendix A Sensor Positioning...

Page 65: ...Appendix B 2KA Allen Bradley Controller Wiring Diagram...

Page 66: ...Appendix C 2KS Siemens Controller Wiring Diagram...

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