CHART Trifecta Pro Series User manual

Part Number 21486938 Rev. A
© 2019 Chart Inc.
Designed and Built by:
Chart Inc.
407 7th Street NW
New Prague, MN 56071 USA
[phone]
Product Manual
Trifecta
Pro Series

iii
Product Manual - Trifecta®Pro Series
Contents
Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Highlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Acronyms / Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Typical Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Flow Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Oxygen Enriched Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Nitrogen and Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Placement of Trifecta Pro Series Skid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Liquid Line Piping to Bulk Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Piping to Vaporizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bulk Tank Pressure Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Purge and Pre-Charge of the Trifecta XPro Series . . . . . . . . . . . . . . . . . . . . . . . . . 11
Check Trifecta Pro Series Cylinder Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hard Sets (Complete Parameter List) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HMI Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
MAIN Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HIGH/HIGH HIGH ALARM Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
ALERT Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ALARM Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ALARM & ALERT HISTORY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
RESET COUNTS Popup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
SETPOINT DATA ENTRY Popup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INFO Popup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SCREEN MENU NAVIGATION Popup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ACTIVE SETPOINT Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
TREND Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MANUAL CONTROL Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parameter Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Fill Setpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Pressure Build Setpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Bulk Critical Setpoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Operation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mode “0” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mode Switch “0” to “1” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mode “1” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mode Switch “1” to “2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

iv
Table of Contents Product Manual - Trifecta®Pro Series
Mode “2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mode Switch “2” to “3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assist Mode “3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Mode Switch “3” to “2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Mode Switch “3” to “0” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Alerts & Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Manually Operating the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Check Valve Leaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Non-Energizing Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Contaminants on Solenoid Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Moisture in Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Solenoid Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Leaking Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pressure and Liquid Level Transmitters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Ball Valve Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Rail Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Normal Activation of Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Frost Formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Data from Main Screen and Analog Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
HMI Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
MAIN Screen - Master/Slave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
SETPOINT DATA ENTRY - Master/Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ACTIVE SETPOINT - Master/Slave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Revision Log
Revision Level Date Description
A 09/17/2019 Manual Creation

1
Product Manual - Trifecta®Pro Series
General
The Trifecta Pro Series is the preferred solution for reliable
and continuous laser assist gases for delivery pressures up


liquid pressure by alternately feeding two liquid cylinders
equipped with innovative multi-function pressure building
vaporizers. The Trifecta solution utilizes a standard bulk



tanks.
Product Highlights
• System utilizes standard medium-pressure bulk tank to
lower investment and use existing assets
• 


• Cylinders switch by pressure instead of level to further
reduce product loss and protect against pressure decay
• Robust design features streamlined all stainless steel

electronic control system (PLC) for increased durability
and reliability.
• 
up and continuous operation.
• Frame assembly features a protective top cover in a
compact footprint with an elevated base for improved
ventilation.
• 
(500 & 600 MAWP) service
• Inconel and copper material used where required on high
pressure oxygen unit
Product Manual
The Trifecta Pro Series Product Manual is designed to be
used in conjunction with all Trifecta models provided by
Chart. If there are any questions regarding the operation of

1-800-400-4683.
This manual contains information regarding the safe

oxygen with this system. It should be thoroughly read and
understood by anyone that operates the equipment.
The safety requirements for operating the 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.
The Introduction section discusses the general features of the

In the Installation section information is available on the best

commissioning of the system.
For information on settings and operation of the system refer
to the Operations section.

sections of this manual should aid in answering common
questions about the system. Part numbers are also available
for ease of ordering through www.chartparts.com.
Preface

2
Preface Product Manual - Trifecta®Pro Series
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)
CGA Compressed Gas Association
MAOP Maximum Allowable Operating Pressure
MAWP Maximum Allowable Working Pressure
MPT Male Pipe Thread
NFPA National Fire Protection Association
PB Pressure Builder
PLC Programmable Logic Controller
PN Part Number
PSI Pounds per Square Inch
PSIG Pounds per Square Inch (Gauge)
SCFH Standard Cubic Feet Hour

3
Product Manual - Trifecta®Pro Series
General

Pro Series high-pressure gas supply system.
Chart works closely with our customers to ensure the total



highest performance at the lowest operating cost - all while

management.
Typical Layout
There are three main components to the "Trifecta" system:
• Medium Pressure Bulk Tank (Minimum 175 psig)
• Vaporizer(s)
• Trifecta Pro Series Skid
The Trifecta Pro Series has been designed for ease of
installation and operation. An ideal install has the Trifecta
Pro Series skid close to the liquid use valve on the bulk

vaporizer facing the sun ("heat of the day").
A typical layout is shown here:
Flow Capacity
The Trifecta Pro Series system is designed to supply high


to maintain supply pressure at or above the required pressure
setting. The unique design has self-contained diagnostics that

the Trifecta.
The Pro Series can supply liquid nitrogen and liquid argon in
maximum allowable working pressures from 500 to 600 psi.
It can supply liquid oxygen in maximum allowable working
pressures of 500 psi.
Service MAWP*
(psig)
MAOP*
(psig)
LIN
500 450
600 550
LAR
500 450
600 550
LOX 500 450
*MAWP = Maximum Allowable Working Pressure
MAOP = Maximum Allowable Operating Pressure
The system uses ambient vaporizers to maintain pressure

is dependent on the weather conditions. The best ambient

above the freezing point.
The Pro Series was developed and tested by Chart's New

Minnesota winter conditions for optimal performance in the

For example: the Trifecta X15 is rated to deliver liquid

similar to Minnesota. If the end user can tolerate lower


be set to higher pressures.
Note: 
for continuous duties in excess of 8-10
hours per day. Higher duty cycles require
auxiliary pressure build capacity and
properly sized process vaporizers.
Introduction

4
Introduction Product Manual - Trifecta®Pro Series

system to:
• Build pressure in the transfer tanks using gravity and
ambient coils.
–
building coils.
–
require de-icing of the pressure building system or the
addition of higher capacity vaporizers.
• 
the use point.
–The vaporizer must be sized for the geographical

–
coils will reduce the performance.
• 
prior to the primary tank emptying.
–


–Special care must be given in selection of the bulk
tank that supplies the Trifecta.
–The tanks heat leak performance is critical in
transferring cryogen in the liquid state to the Trifecta.
–Liquid use lines and valves out of the bulk tank must
be sized properly. Small restrictive liquid lines and

–The pressure building system of the bulk tank
needs to be sized to build tank sub-cool. The sub-
cool condition (pressure above the liquid saturation

the liquid state as it travels to the Trifecta.
–Liquid feed lines from the bulk tank to the Trifecta


losses. Take great care in laying out your Trifecta
system. Insulating the liquid feed line will reduce its

reduced losses.

5
Product Manual - Trifecta®Pro Series
General
All operators should have a full and complete understanding
of the content of this manual before operating the equipment
described. This manual is intended to describe the operation
of the equipment and not intended to supersede any site-


any non-insulated piping can get extremely cold and should
not be touched by exposed skin. If the system requires

up.



transmitters can monitor the system pressure and liquid
levels.

that the manual isolation valve to the bulk tank be closed.
Safety Summary
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

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 Oxygen and Inert Gases following this Safety Summary.
Periodic review of the Safety Summary is recommended.
Warning! In oxygen enriched atmospheres
ammable items burn
vigorously and could explode.
Warning! Do not permit smoking or open
ame in any area where oxygen
is stored, handled, or used.
Failure to comply with this
warning may result in serious
personal injury.
Excess accumulation of oxygen creates an oxygen-enriched

as an oxygen concentration above 23%). Certain items
considered non-combustible in air may burn rapidly in
such an environment. Keep all organic materials and other





Caution! Before removing any parts or
loosening ttings, empty the
cryogenic container of liquid
contents and release any vapor
pressure in a safe manner.

and may cause painful burns to personnel unless properly
protected. Personnel must wear protective gloves and eye

Failure to do so may result in personal injury due to the
extreme cold and pressure in the tank.
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

goggles or a face shield should be worn if liquid ejection
or splashing may occur or cold gas may issue forcefully

removed and long sleeves are recommended for arm

shed spilled liquid.
Warning! Use only replacement parts
that are compatible with liquid
oxygen and have been cleaned
for oxygen use.

previously used in a compressed air environment. And do not
use oxygen equipment for compressed air. Failure to comply
with these instructions may result in serious damage to the
container.
Safety

6
Safety Product Manual - Trifecta®Pro Series
Caution! Before locating oxygen
equipment, become familiar
with the relevant National Fire
Protection Association (NFPA)
standards for “Bulk Oxygen
Systems at Customer Sites,”
and with all local safety codes.
The NFPA standard (www.nfpa.org) covers general
principles recommended for installing bulk oxygen systems
on industrial and institutional consumer premises.
Caution! To prevent possible tip over, do
not leave tank standing upright
unless it is secured to its
foundation (bolted down).
Transporting and erection of the tank should be performed in
accordance with rigging instructions available from Chart.
Failure to comply with these instructions may result in
serious damage to the container.
Safety Bulletin
Portions of the following information is extracted from


cryogenics is available from the CGA at www.cganet.com.

to time subjected to assorted environmental conditions of
an unforeseen nature. This safety bulletin is intended to call
attention to the fact that whenever a cryogenic container
is involved in any incident whereby the container or its

followed. The same holds true whenever the integrity or
function of a container is suspected of abnormal operation.
Good safety practices dictate the contents of a damaged or
suspect container be carefully emptied as soon as possible.
Under no circumstances should a damaged container be left



Incidents which require that such practices be followed





safety practices must be followed.
In the event of known or suspected container vacuum
problems (even if an extraordinary circumstance such as

unit. Continued use of a cryogenic container that has a
vacuum problem can lead to embrittlement and cracking.

unit is exposed to inordinate stress conditions caused by an
internal liquid leak.


recommended that any damaged container be returned to

The remainder of this safety bulletin addresses those adverse
environments that may be encountered when a cryogenic
container has been severely damaged. These are oxygen

exposure to inert gases.
Oxygen Decient Atmospheres
Warning! Nitrogen and argon vapors in
air may dilute the concentration
of oxygen necessary to support
or sustain life. Exposure to
such an oxygen decient
atmosphere can lead to
unconsciousness and serious
injury, including death.
The normal oxygen content of air is approximately 21%.


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%

immediate with virtually no warning.
When the oxygen content of air is reduced to about 15



an individual breathing the air is mentally incapable of
diagnosing the situation because the onset of symptoms

errors in judgment and confusion can be masked by a state of

and well being.