CHART CryoDoser FleX User manual

Part Number 15960 Rev. A
© 2017 Chart Inc.
Designed and Built by:
Chart Inc.
46441 Landing Parkway
Fremont, CA 94538 USA
[phone]
Product Manual
CryoDoser FleX™
Liquid Nitrogen Dosing System

iii
Product Manual - CryoDoser FleX™LN2Dosing System
Contents
Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Key Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Acronyms / Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oxygen Decient Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Application Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Support Stand and Base Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Mounting the Dosing Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Mounting the Control and Interface Boxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Top Tube Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Electro-Mechanical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installing the Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Positioning the Dosing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Installing the Container Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Installing the Timing Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Installing the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing the FleX Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Completed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Daily Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dura-Cyl® Liquid Cylinder Fed System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Dura-Cyl Cylinder Change Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Bulk Tank (House Fed) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Purging with Gaseous Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
System Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Best Practices for Superb Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Minimize the entry of moisture into the dosing system . . . . . . . . . . . . . . . . . . . . . . 15
Nozzle use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How much LN2is needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Activating Insta-Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Nozzle Change Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Nozzle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Purging with Gaseous Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

iv
Table of Contents Product Manual - CryoDoser FleX™LN2Dosing System
Revision Log
Revision Level Date Description
A 08/30/2017 Original
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CryoDoser FleX Technical Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
CryoDoser FleX Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Standard Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Optional Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Common Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Sensor Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Craft Custom Control Box Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Craft Custom Interface Box Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1
Product Manual - CryoDoser FleX™LN2Dosing System
General
The CryoDoser FleX™LN2 Dosing System is the rst doser
with the ability to serve every dosing application within one
unit. Chart Inc. has designed a brand new dosing system that
can be used from the slowest production lines to the fastest.
The CryoDoser FleX line features two distinct controller
systems but keeps the look and feel of each very similar. The
Craft Custom system includes the capability of changing
dose duration and dose delays for up to ten containers. The
Pack Premier system is capable of speeds in excess of 2000
cpm with superb accuracy.
With two premium controller options, more standard
functions than any other doser offered before, and a brand
new all-around design, the CryoDoser FleX system is ready
to change the market.
Features
• Compact Size - enables installation in limited spaces
• Discrete Dosing - Craft Custom (750 cpm) and Pack
Premier (2000+ cpm)
• SoftDose™ Compatible - Chart’s proven technology for
hot ll, powder and granular applications.
• MicroDose™ Standard - the Pack Premier has a controller
function that allows dosing pressure adjustments
• RemoteDose™ Standard* - monitor, troubleshoot and
make adjustments while connected to your VPN**
• ExacTrack™ - with the new EDS (Electric Dosing
System), supreme accuracy is achieved. Proportionally
control the amount the actuator opens and make dosing
duration changes in increments of 0.1 ms.
• Warranty - four (4) year vacuum warranty; highest in the
industry; one (1) year controller warranty
*Results achieved at Chart laboratory conditions.
**Access to the internal network is necessary for this function.
Key Benets
• Lightweight PET - reduce the weight of PET for cost and
environmental savings
• Glass to PET Transition - eliminate glass safety hazards
and weight of containers
• Container Rigidity - maintain container shape even with
lighter weight containers
• Eliminate Paneling - increase the internal pressure to
offset paneling issues
• Oxygen Reduction - create an inert environment to
preserve product freshness
• Extend Shelf Life - minimize oxygen levels
• Ease of Labeling - consistent container rigidity creates an
efcient labeling process
• Reduce Nitrogen Consumption - measurable and
repeatable liquid doses
• Maximize Warehouse Storage Space - increasing product
stackability utilizes less square footage
• Stabilize Organic Products - extend shelf life without
preservatives
Product Manual
This manual is designed to be used in conjunction with the
CryoDoser FleX Liquid Nitrogen Dosing System provided
by Chart. Chart makes no warranties, express or implied,
regarding the content in this manual. Chart assumes no
responsibility for any outcomes as a result of using this
manual. If after reading this manual you are not condent in
carrying out any task, please contact Chart’s service team at
1-408-371-4932.
The safety requirements for operating the CryoDoser FleX
system and handling or transporting extremely cold liquid
products are shown in the Safety section. Use this safety
section as a “Safety Checklist” each time the equipment is
being used.
In the Installation section there are illustrations for proper
connections.
The Controller Adjustments and Daily Operations Section
will give information on getting the system up and running
smoothly.
The remaining sections provide information on Service,
Troubleshooting, Specications and the Warranty provided
by Chart.
Preface

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Preface Product Manual - CryoDoser FleX™LN2Dosing System
Terms
Throughout this manual safety precautions will be designated
as follows:
Warning! Description of a condition that
can result in personal injury or
death.
Caution! Description of a condition that
can result in equipment or
component damage.
Note: A statement that contains information
that is important enough to emphasize or
repeat.
Acronyms / Abbreviations
The following acronyms / abbreviations are used throughout
this manual:
BAR Pressure (Metric)
CPM Containers Per Minute
GN2Gaseous Nitrogen
HMI Human Machine Interface
Kg Kilogram
LN2Liquid Nitrogen
mS Milliseconds
O2Oxygen
PET Polyethylene Terephthalate
PLC Programmable Logic Controller
PN Part Number
PNP Positive-Negative-Positive
PSI Pounds per Square Inch

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Product Manual - CryoDoser FleX™LN2Dosing System
General
Thank you for your purchase of Chart Inc.’s CryoDoser
FleX™ Liquid Nitrogen Dosing System. Chart has designed
and fabricated your system with attention to detail utilizing
the leading cryogenic technologies to ensure a highly
efcient and reliable system.
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 from Chart.
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, it is 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.
Warning! Your CryoDoser FleX system
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 decient
atmosphere and extremely high
pressures.
External valves and ttings 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 ttings.
Failure to do so may result in personal injury due to the
extreme cold and pressure in the system.
Warning! Accidental 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.
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.
Warning! Any conguration 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. A section not
protected by an over-pressure
relief valve will experience
extremely high pressures and
signicant safety concerns.
Warning! Over pressurization of
containers can occur while
using Chart’s CryoDoser FleX
doser potentially bursting
the containers. Proper
calibration of the CryoDoser
FleX system ensures optimum
nitrogen doses to avoid over
pressurization. Be sure to
remove any containers that
receive more than the proper
LN2doses before sealing.
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
shutdown and allowed to warm
up.
Safety

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Safety Product Manual - CryoDoser FleX™LN2Dosing System
Caution! Before removing parts or
loosening ttings, empty the
CryoDoser FleX system of liquid
and release any vapor pressure
in a safe manner.
Safety Bulletin
Portions of the following information are extracted from
Safety Bulletin SB-2 from the Compressed Gas Association,
Inc. at www.cganet.com. Additional information on oxygen,
nitrogen, and cryogenics is available in CGA Pamphlet
P-9. Write to the Compressed Gas Association, Inc., 1235
Jefferson Davis Highway, Arlington, VA 22202..
Oxygen Decient Atmospheres
Warning! Nitrogen vapors in air may dilute
the concentration of oxygen
necessary to support or sustain
life.
The normal oxygen content of air is approximately 21%.
Depletion of oxygen content in air, either by combustion
or by displacement with inert gas, is a potential hazard and
users should exercise suitable precautions.
One aspect of this possible hazard is the response 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 is reduced to approximately
15 to 16%, the ame 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 because 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 essentially helpless.
This can occur if the condition is reached by an immediate
change of environment, or through the gradual depletion of
oxygen.
Most individuals working in or around oxygen decient
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 the unconscious partner
unless equipped with a portable air supply. Best protection
is obtainable by equipping all individuals with a portable
supply of respirable air. Life lines are acceptable only if the
area is essentially free of obstructions and individuals can
assist one another without constraint.
If an oxygen decient 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.
Nitrogen
Nitrogen (an inert gas) is a simple asphyxiate. It will not
support or sustain life and can produce immediate hazardous
conditions through the displacement of oxygen. Under high
pressure this gas may produce unconsciousness even though
an adequate oxygen supply sufcient for life is present.
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 is 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 respiration and supplemental oxygen
should be given if the victim is not breathing. If cryogenic
liquid or cold boil-off gas contacts worker’s skin or eyes,
the affected tissue should be ooded or soaked with tepid
water (105-115ºF or 41-46ºC). DO NOT USE HOT WATER.
Cryogenic burns that result in blistering or deeper tissue
freezing should be examined promptly by a physician.

5
Product Manual - CryoDoser FleX™LN2Dosing System
Receiving
The CryoDoser FleX™ system will arrive in a specially
designed shipping crate. If the system is intended to be
moved from one location to another, storing the crate for
future use is ideal.
Upon arrival of the CryoDoser FleX system, it is advised to
immediately inspect for any signs of damage. If any damage
occurred in shipping, claims must be led with the shipping
carrier immediately prior to unpacking.
Unpacking
All contents should be carefully inspected while unpacking
the unit. Things to check for upon arrival include:
• Dents in the CryoDoser FleX unit
• Male and female bayonets should be protected
• Proper number of bayonet clamps/anges and o-rings
(one set for every female bayonet)
• Any other components that were dened to ship loose
If there are any pieces listed on the packing slip and/or
materials list not in the shipping crate, please contact Chart
immediately at 1-800-371-3303.
Caution! When removing the CryoDoser
FleX unit from the crate, gently
set it on the ground. DO NOT
drop the CryoDoser FleX unit!
When transporting the unit
through the facility be sure to
carry with care. Take care not
to run into walls or drag the
CryoDoser FleX unit on the
ground.
If not installed immediately, the CryoDoser FleX system
should be stored in a location that is out of the way of
frequent trafc and will prevent dirt, water, or other debris
from getting inside the system. Chart recommends storing
the system in the crate when not in service.
Installation
Application Evaluation
The CryoDoser FleX system 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 lling line.
• Inerting - Inerting is the process of removing oxygen
(O2) from a container by dosing a relatively large amount
of LN2 in the container to inert. The liquid dose quickly
converts into gas displacing air and oxygen from the
container. The ideal location for the CryoDoser FleX unit
must allow for enough time between dosing and capping
so that the liquid dose is converted into a gas.
• Pressurization - Pressurization occurs by dosing a
relatively small amount of LN2 into a container. The
liquid dose quickly converts into gas and the container is
then capped or sealed to capture the expanding gas. The
CryoDoser FleX unit should be installed as close to the
capper as possible.
Support Stand and Base Location
Installation
Image 1

6
Installation Product Manual - CryoDoser FleX™LN2Dosing System
The CryoDoser FleX unit is supplied with a mounting
bracket assembly. The assembly consists of the bracket
attaching to the CryoDoser FleX body and two clamps
designed to t on a 1½” stainless steel rod. Chart can supply
a prefabricated stand (and stand base) 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 a 1½” diameter
rod or round bar will make installation of the CryoDoser
FleX system simpler. The instructions below will assume
installation of Chart’s prefabricated support stand (Image 2).
1. The CryoDoser FleX unit can be
installed on either side of a production
line. Select the side that best suits the
workplace.
2. Place the base on a level surface and
position the bottom half of the stand
aligning the holes in the stand to those
on the base.
3. Measure 27-1/2” (when a long arm
is used or 20-1/2” when a short arm
is used) back from the dosing head
location. This is the distance from the
center of the support stand to the farthest
point on the dosing head.
4. Mark the location of the stand and install
the four 5/8” bolts included with the
support stand in the proper location.
Mounting the Dosing Body
Image 3 depicts the dosing body
with various parts not included
for clarity. The dosing body will
come completely assembled on
the bracket. Loosen the 8 bolts
on the black Delrin blocks to
ensure they will slip over the
1-1/2” round bar. It is benecial
if two people perform this task,
one to hold the body in the
approximately position and the
other to tighten the bolts.
Note: Do not remove the bolts completely. Doing
so could cause the bracket to separate
from the clamps.
Mounting the Control and Interface Boxes
Secure the Control Box and the Interface Box on to the top
section of the stand.
Note: The Control box is mounted to the two
Delrin “arms”.
The Interface box slips over the top of the round bar. Loosen
the clamps of each to allow for mounting.
Top Tube Connections
The inlet and pressure tubes will generally come already
secured to the dosing body. Color and/or labeling may be
used to identify each connection. Push the end of each
corresponding tube to the location marked or shown on the
Interface box.
Image 2
Image 3
Image 4
Image 5

7
InstallationProduct Manual - CryoDoser FleX™LN2Dosing System
Electro-Mechanical Connections
The bottom of the Control and Interface boxes are provided
with connectors and ttings for communication, power, and
gaseous nitrogen feed. Depending on system conguration,
not all connectors will be utilized.
A. USB Port Connector - Use this port with a USB
memory stick to load any future software changes/
upgrades.
B. 24 VDC Out Connector - DC power from the Control
box to Interface box. Connect the DC power cable.
C. Pronet Connector - Industrial Ethernet. Connect
the Green Ethernet cable to the Ethernet port of the
Interface Box.
D. Ethernet Connector - Used only when external
communication is to be used.
E. User Interface Connector - High end applications
when I/O signals will be exchanged between the dosing
system and lling lines.
F. AC Power Connector - Connect the AC power cord to
a 110VAC Outlet.
A. 24VDC IN Connector - Connect DC cable from the
control box to this connector.
B. Pronet Connector - Connect the green Ethernet cable
from the control box to this connector.
C. Line Speed Connector - For systems that will be using
either an encoder or speed sensor, connect the encoder
or speed sensor cable to this connector.
D. Timing Connector - All systems will use this connector
to detect a container or container pocket (all Craft
Custom users, connect the container sensor cable to this
connector).
E. Container Detect Connector - For Pack Premier users,
connect the container detect cable to this connector.
F. Actuator Connector - Connect either the EDS or
EASE actuator cable to this connector.
G. Vent Heater Connector - The short heater cable
connects to this connector.
H. Head Heater Connector - The longer heater cable
connects to this connector.
I. Gas Supply Fitting - Main gas inlet. Connect the black
polytube.
J. Purge Fitting - Connect the polytube to the tting on
the actuator.
Installing the Nozzle
Three nozzles are supplied with the CryoDoser FleX system
(0.040 inch, 0.050 inch, and 0.060 inch). Custom sizes may
be ordered from Chart.
1. Remove the dosing head heater.
Image 6
Image 7
Image 8

8
Installation Product Manual - CryoDoser FleX™LN2Dosing System
2. Select a nozzle.
3. Insert the nozzle into the nozzle tool, threads out (see
Image 9).
4. Thread the nozzle into the dosing head area in a
clockwise direction (Image 10 & 11). Do not over
torque.
5. Re-apply the dosing head heater.
Caution! Never use any sharp or pointed
object such as an ice-pick,
screwdriver, torch or similar
device on the dosing head
(Image 10). 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.
Image 9
Image 10
Image 11

9
InstallationProduct Manual - CryoDoser FleX™LN2Dosing System
Positioning the Dosing Head
The dosing head should be directly over the container
opening. The dosing head is typically installed 1/2” - 3/4”
above the container opening. The CryoDoser FleX unit
must be manually adjusted to accommodate different sized
containers running on the same production line.
Installing the Container Detect Sensor
The container detect sensor must be a PNP type sensor and
is used to detect if containers are present on the line. Chart
provides a container detect sensor with the CryoDoser FleX
system (Image 13). Ideal sensor placement is about four
to six pockets from the dosing head. If the sensor does not
detect a container for the user dened number of seconds,
the CryoDoser FleX unit will stop dosing. See the Inputs/
Outputs and Container Sensor sections for additional
information.
The diagram below shows three different ways of positioning
the sensor.
Installing the Timing Sensor
The timing sensor is installed to identify container location
and must be installed for the CryoDoser FleX system to
operate properly. Chart provides a PNP 12mm inductive
proximity sensor with the CryoDoser FleX system. Ideal
sensor placement must provide a one-to-one signal.
Image 15
Image 12
0.75in. (19mm)
Image 13
Image 14

10
Installation Product Manual - CryoDoser FleX™LN2Dosing System
The speed sensor is installed to detect lling line speed and
must be installed for the CryoDoser FleX system to operate
properly. Chart provides an additional PNP 12mm inductive
proximity sensor that may be used with the CryoDoser FleX
system.
Installing the Encoder
For high speed lines where extreme accuracy is required
an encoder (Image 16) must be installed to increase the
resolution of the speed output for better performance of the
CryoDoser FleX at higher line speeds. The encoder provided
by Chart comes from the factory preset to 500 pulses per
revolution.
Note: Only one channel is used to provide
necessary pulses for the CryoDoser FleX
system. For correct encoder functionality,
shielded cabling must be used. The
encoder should be grounded, either thru
the mounting bracket or separate ground
wire.
Encoder Pin No. Function Wire Color
1 Not Used N/A
2 Not Used N/A
3 Not Used N/A
4 CH B Output Pink
5 Not Used N/A
6 Not Used N/A
7 Return (-24Vdc) Blue
8 Supply Voltage (+24Vdc) Red
Shield
The encoder location should be accessible for installation
and maintenance. The location may be a spindle to spindle
connection where the encoder spindle may be integrated with
the ller/capper spindle.
Encoder Mounting Information
Ensure encoder is properly mounted and securely afxed so
it will perform at its optimum capability. Follow the drawing
below and mount with suitable hardware. Grounding is
achieved by proper mounting of the encoder case. Ensure
good electrical contact is made from the mounting anges to
an earthed bracket or other grounded mounting means.
Image 16
Image 17 - Encoder Cable Connections
Image 18

11
InstallationProduct Manual - CryoDoser FleX™LN2Dosing System
Installing the FleX Controller
Locate the ideal location for the FleX controller. Brackets are
supplied to mount the controller on the Chart prefabricated
support stand or 1-1/2” diameter rod or round bar. If Chart’s
prefabricated brackets are not utilized, the controller’s
mounting tabs can be utilized.
The following images show both Pack Premier and Craft
Custom controllers for reference.
Image 19
• On/Off Switch - Main power switch for the FleX
controller
• Dose Disable Button - Manual dose enable/disable button
to disable dosing
• Light Tower Status - The indicator light provides a visual
display of the operating status of the CryoDoser FleX
system
• Green - Normal operation
• Amber (solid) - Warning condition; see “Alarms” section
for additional information
• Red - Fault condition; see “Alarms” section for additional
information
• For more detailed information pertaining to the
controllers please reference the Pack Premier Controller
or Craft Custom Controller Quick Start Guides.
Completed Assembly
When fully assembled, the CryoDoser FleX will generally
take the form shown here.
Image 20
Image 21

13
Product Manual - CryoDoser FleX™LN2Dosing System
The CryoDoser FleX system can be fed by either a portable
Dura-Cyl® Liquid Cylinder or a bulk tank (house fed) liquid
nitrogen system.
Dura-Cyl®Liquid Cylinder Fed
System
Note: LN2is -320°F (-196°C). Any water and/
or moisture can cause ice which will affect
the performance of the CryoDoser FleX
system. Providing a positive pressure
Daily Operating Procedures
Dura-Cyl Cylinder Change Out Procedure
The Dura-Cyl cylinder will need to be changed out from
time to time. The operator should visually check the gauges
on the Dura-Cyl cylinder to monitor the internal liquid
level. When the gauges read low levels, it must be swapped
with a full Dura-Cyl cylinder. Chart recommends a cylinder
pressure of 60 psi and above.
1. Close the liquid valve (clockwise direction) on the
Dura-Cyl cylinder.
2. Disconnect the C-Flex hose from the Dura-Cyl cylinder
using a 7/8” open end wrench or adjustable crescent
wrench.
3. Connect the C-Flex hose to the liquid outlet on the full
Dura-Cyl cylinder using a 7/8” open end wrench or
adjustable crescent wrench.
Note: The CryoDoser FleX unit will continue to
dose properly until the liquid level inside
the CryoDoser FleX unit runs low. This
feature gives the operator a reasonable
window in which to change out the
Dura-Cyl cylinder without disrupting the
production operation.
of GN2(also known as purging) to the
CryoDoser FleX unit before introducing
LN2into the body will eliminate many
performance interruptions.
Image 22

14
Daily Operating Procedures Product Manual - CryoDoser FleX™LN2Dosing System
Bulk Tank (House Fed) System
Note: LN2is -320°F (-196°C). Any water and/
or moisture can cause ice which will affect
the performance of the CryoDoser FleX
system. Providing a positive pressure
of GN2(also known as purging) to the
CryoDoser FleX unit before introducing
LN2into the body will eliminate many
performance interruptions.
Image 23
Purging with Gaseous Nitrogen
Purging is the process of introducing nitrogen gas into the
CryoDoser FleX body to minimize and/or eliminate ice
that may have formed within the system. Ice may form
whenever there is an introduction of a liquid substance into
the CryoDoser FleX body. This may be because of product
splashing, steam from CIP, or just an intake of moisture from
the environment.
Freeze-ups may result in delays - some extreme if the ice
within the body has occurred deep inside the vessel.
With the CryoDoser FleX system, Chart has taken steps to
ensure freeze-ups are minimized. Each system is provided
with integral purging capabilities including an option to
provide heated gas. Heating the gas accelerates the removal
of ice so as to bring the down time to a minimum.
For additional information about purging please refer to the
Controller Quick Start Guide.
Caution! When purging the CryoDoser
FleX 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
CryoDoser FleX unit is still at or
near LN2temperatures (-320°F;
-196°C). Once the CryoDoser
FleX unit is at or near ambient
temperature, the “fog” will warm
up.
System Start Up
There are two primary methods for delivering liquid nitrogen
to the CryoDoser FleX system; phase separator through a
Y-pattern valve and Chart Dura-Cyl® Liquid Cylinder or
similar dewar through a Chart exible “123” hose.
If the CryoDoser FleX system is being fed liquid nitrogen
via a phase separator, ensure the phase separator has been

15
Daily Operating ProceduresProduct Manual - CryoDoser FleX™LN2Dosing System
properly set up prior to set up of the CryoDoser FleX.
Refer to the Phase Separator Product Manual for specic
instructions.
If the CryoDoser FleX system is being fed liquid nitrogen
from the Chart Dura-Cyl cylinder, ensure the connection
hose to the CryoDoser FleX has been properly connected
including the installation of a safety relief device as part
of the hose installation, that the stainless steel lter has
been installed in the end of the hose bayonet, and that the
bayonet connection to the CryoDoser FleX has been properly
installed and secured.
Manually open (counter clockwise) the blue handle valve on
the Dura-Cyl liquid cylinder.
Refer to the CryoDoser FleX Controller Quick Start Guide
for additional information.
System Shut Down
1. Manually close (clockwise) the Y-Pattern valve (blue
handle).
2. Manually open (clockwise) the ball valve (yellow
handle) on the Purge Kit.
Note: The supply pressure reading on the FleX
controller may read 12 ± psi due to the
added GN2pressure.
Also, refer to the phase separator product manual for
instructions regarding shutting down of the phase separator if
applicable.
If your CryoDoser FleX system is being fed off of a Chart
Dura-Cyl liquid cylinder close (clockwise) the valve of the
cylinder.
Best Practices for Superb Operation
Minimize the entry of moisture into the
dosing system
1. Moisture turns into ice when subjected to cryogenic
temperatures. Ice causes blockages and can lead to
tremendous down time. Moisture can inadvertently
enter the dosing system in various ways including
splashing product, system cleaning, or from the
environment. It is extremely important to be aware of
this and prevent moisture from entering or accumulating
in the dosing system.
2. How can moisture be prevented from entering the
dosing system?
a. When not in use, or being cleaned, cap the vent and
the dosing head area.
b. If the system will not be used for a short period
of time it is helpful to keep some liquid in the
dosing body to provide positive pressure at the vent
preventing moisture from creeping in.
Nozzle use
Standard nozzles are single opening devices with diameters
ranging from 0.020” to 0.110” in 0.005” increments. In
addition to these devices, Chart provides a range of specialty
nozzles in our “Soft Dose” packages. These nozzles include:
Ventilator, Regar, Diverging, Converging, Angle and Hot
Chute.
• Where to use - There is no set standard that identies
a specic nozzle for a product. Each product, product
line, and requirement will lead towards dening the
type of nozzle(s) used. In general, standard single
opening nozzles are used in the vast majority of
liquids; such as water, teas, coffees and beers. They
are also used with dry goods such as peanuts and
almonds. The same nozzles can be used for both
pressurization or inerting (oxygen reduction).
• Soft dose nozzles may also be used for pressurization
or inerting. The use of these nozzles may provide
added benets such as less spray for products that
can tend to be ejected from their container if a single
hole nozzle is used. Powder or granulated products
such as ground spices, ground coffee, teas, or even
baby formula are examples of susceptible products.
• Soft dose nozzles such as the “Regar” nozzle have a
shower head spray pattern that can be used to diffuse
slightly to minimize product ejection. In addition,
this particular nozzle has a wide spray pattern
making it suitable for larger opening containers.
• The Hot Chute is a unique soft dose product.
This device utilizes a standard nozzle but also
incorporates a set of heating elements and nose
extension allowing access to some locations where a
standard dosing head may not be able to reach into a
small space. The added heating elements diffuse the
nitrogen stream causing it to become more of a mist
which also minimizes product expulsion.
Sensors
The Chart dosing systems typically utilize three sensors for
high speed operation. Lower speed lines or manual operated
lines can operate on just one sensor.

16
Daily Operating Procedures Product Manual - CryoDoser FleX™LN2Dosing System
1. Sensors provided for Chart dosing systems are as
follows:
Timing
Container detect
Encoder
• Timing - typically an inductive proximity device.
This sensor will provide a pulse identifying a start
time where a container has been detected until it
reaches the dosing head. This sensor is suitable
for detecting on any metal object such as a gear
tooth or shaft collar bolt. This sensor is typically a
barrel type and comes in three different diameters:
13mm, 18mm and 30mm. Sensing distances are
approximately as follows:
13mm dia. = 2mm (0.08 in.)
18mm dia. = 4mm (0.2 in.)
30mm dia. = 7-8mm (0.3 in.)
• Container detect - Typically a photo-electric device.
This sensor will provide a signal identifying an
approaching container. It is capable of detecting
virtually any type of object that is placed within its
sensing distance, therefore good for cans, bottles,
pouches of all shapes, sizes and colors. The sensing
distance may vary based upon the manufacturer
of the sensor but it typically has a range of
approximately 4 inches (10cm).
The sensor is typically a barrel type and is provided
in an 18mm diameter.
The sensor is typically placed at or near the dosing
head. It also serves the purpose of nozzle cooling
when placed at some short distance in front of the
dosing head. This feature can be very important
when the ller tends to sit idle with no containers
passing for short periods of time.
As the system sits without dosing, the dosing head
heats up which results in the next dose (or couple
of doses) being slightly warmer and therefore more
gaseous. This will result in lower pressure in the rst
few containers.
• Encoder - this device does provide an input to the
control box but unlike the other two sensing devices
that provide one pulse each time it is triggered,
this device provides hundreds or even thousands of
pulses. The device can be programmed to output up
to the maximum capability of the device (65,000
pulses per shaft revolution). Considering the standard
pulses necessary for high speed dosing is about 500
pulses per container, this encoder is capable of many
more than needed to perform optimally.
How much LN2is needed?
Identifying the right amount of liquid can be challenging.
Some trial and error is commonplace. However, there are
a couple of ways to minimize the number of trial and error
situations.
1. Use the largest nozzle and lower the dose duration. It
is much easier to punch a button rather than removing
a nozzle so the fewer number of times a nozzle is to be
removed, the better. Start with a larger nozzle size than
you think is necessary and run a shorter dose duration
than what is probably needed. Test to see what the
pressure or oxygen level is and increase the duration
until a desirable result is achieved.
2. Use a continuous stream as a starting point. Targeting
a small opening can also be challenging. However,
if a continuous stream is used initially it can then be
reasoned that the nozzle size is correct. The second
half of this test is to then “shorten” the stream. In other
words target the stream to start and stop within the
opening.
3. Semi-continuous stream - a trick to use when
targeting is more difcult due to erratic conveyor
movement, environment issues, poor sensing or sensor
susceptibility is to start and stop the stream before and
after each container. Set the dose early (starting just
before the container gets under the dosing head) and
end it just after the container has passed.
4. How do you know if you’re hitting the target? Two
simple techniques:
• Look for the “smoke” out of the container
• Feel test
Is the smoke good enough? Depending on your
specication and/or requirement more or less nitrogen
may be needed. Once smoke is seen, a measurement is
taken (pressure or oxygen levels). That measurement can
then be used to determine whether more or less nitrogen
is needed. Increase the dose duration. If the pressure
goes up, the initial target was fairly accurate. If it stays
the same, then the initial target was a bit late and the
added dose duration just placed nitrogen into the space
after the container has passed. In this case move the
targeting sensor so it triggers sooner.
What about oxygen content? This will require an oxygen
meter or tester. Oxygen measurements can be even
trickier.