CHART ULTRADOSER 500S User manual

ULTRADOSER®500S
LN2Dosing System
USER MANUAL

www.chartdosers.com PN 15920 Page 2 of 43
Table of Contents
Introduction.............................................................................................................................................................................3
 Service ...................................................................................................................................3
 Manufacturer..........................................................................................................................3
 Design Modification ..............................................................................................................3
 Additional Copies ..................................................................................................................3
Safety ......................................................................................................................................................................................5
 Safety Bulletin .......................................................................................................................6
Receiving Your UltraDoser®500S LN2Dosing System ........................................................................................................8
 Unpacking the UltraDoser 500S System .....................................................................................................................8
UltraDoser®500S LN2Dosing System Overview and Utilities..............................................................................................9
 Product Specifications ...........................................................................................................9
 Utility Requirements..............................................................................................................9
UltraDoser®LN2Dosing System Body Dimensions ............................................................................................................10
UltraDoser®500S LN2Dosing System Components............................................................................................................11
 Standard Components (Front View)....................................................................................11
Valve Confirm Assembly..................................................................................................................11
 Standard Components (Back View).....................................................................................13
 Optional Components ..........................................................................................................13
Principles of Liquid Nitrogen (LN2) Dosing.........................................................................................................................14
Installation.............................................................................................................................................................................15
 Application Evaluation ........................................................................................................15
 Support Stand Location........................................................................................................15
 Mounting the UltraDoser®LN2Dosing System Unit ..........................................................16
 Connecting the Distribution Block ......................................................................................17
 Installing the Nozzle............................................................................................................18
 Positioning the Dosing Head ...............................................................................................18
 Installing the Container Sensor............................................................................................19
 Installing the Speed Sensor (optional).................................................................................19
 Installing the 500S Controller..............................................................................................20
500S Controller Adjustments................................................................................................................................................22
 Home Screen........................................................................................................................23
 Alarm Screen .......................................................................................................................24
 Fixed Delay Mode (FXDD).................................................................................................25
 500S Controller Set-up Verification....................................................................................27
 Speed Compensated Mode (SCMP) ....................................................................................28
 500S Controller Set-up Verification....................................................................................33
 System Information Screen..................................................................................................33
 Advanced Settings (System Response Time) ......................................................................34
Daily Operating Procedures..................................................................................................................................................35
 Dura-Cyl Liquid Cylinder Fed System................................................................................35
UltraDoser®LN2Dosing System Service and Maintenance.................................................................................................37
 Nozzle Change Out Procedure.............................................................................................37
 Nozzle Cleaning Procedure..................................................................................................39
 Purging the UltraDoser®LN2Dosing System with Gaseous Nitrogen................................39
UltraDoser®500S LN2Dosing System Replacement Parts..................................................................................................39
General Troubleshooting ......................................................................................................................................................40
500S Controller Wiring Diagram..........................................................................................................................................42
Warranty ...............................................................................................................................................................................44

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I
In nt tr ro od du uc ct ti io on n
Thank you for your purchase of the Chart Inc. (Chart) UltraDoser®500S LN2Dosing System. Chart has
designed and fabricated your system with attention to detail and utilizing the leading cryogenic technologies to
ensure a high efficient and reliable system.
Please contact us with any questions or comments that you may have. If after reading this manual you are not
confident in carrying out any task, please call Chart’s service team at +1 408.371.4932.
 Service
Chart’s UltraDoser 500S Dosing System has been designed for years of safe and dependable operation. In the
event service is required, please contact Chart at:
Chart Inc.
46441 Landing Parkway
Fremont, CA 94538 USA
www.chartdosers.com
+1 408.371.4932
 Manufacturer
The UltraDoser 500S Dosing System is designed and manufactured by:
Chart Inc.
46441 Landing Parkway
Fremont, CA 94538 USA
www.chartdosers.com
+1 800.371.3303
 Design Modification
DO NOT use this product in a manner not consistent with the instruction outlined in this manual.
NEVER alter the design, or perform service that is not consistent with the instructions outlined in this manual
without prior written approval of Chart.
 Additional Copies
Additional copies of this manual are available by contacting Chart:
Chart Inc.
46441 Landing Parkway
Fremont, CA 94538 USA
www.chartdosers.com
+1 800.371.3303
No part of this document may be reproduced in any form or by any means without the prior written permission
of Chart Inc. Copyright 2015
Chart Inc.

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This manual is intended for use by Chart UltraDoser®500S LN2Dosing System customers. It is important to
read and understand the information in this manual before installing or operating the system. This manual is
provided by Chart to its customers as a courtesy and, except as expressly provided in this manual, CHART
MAKES NO WARRANTIES, EXPRESS OR IMPLIED, REGARDING THE CONTENTS IN THIS
MANUAL. CHART ASSUMES NO REPONSIBILITY FOR ANY OUTCOMES AS A RESULT OF
USING THIS MANUAL.
SAFETY FIRST!
Liquid nitrogen must be handled properly. Without proper handling, severe frost bite, cryogenic burning,
oxygen deprivation, and bursting of sealed bottles (or containers) can result.
During this process, you may need:
Safety glasses with side shields and/or protective face shield
Insulated gloves for cryogenic service
Symbols and statements used throughout this text and their meaning are as follows:
Text following this symbol needs extra attention.
IMPORTANT: Text like this is extra information helpful to the situation
CAUTION: Text like this is information to help avoid personal injury and/or property damage.
WARNING! Text like this is information to help avoid serious personal injury or death and/or
property damage.

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S
Sa af fe et ty y
WARNING! Your UltraDoser®500S LN2Dosing 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 deficient atmosphere
and extremely high pressures.
WARNING! Any configuration which allows a trapped volume of cryogenic liquid or cold gas must
be protected by a pressure relief valve. As the cold liquid/gas gains heat, the contents will expand and
increase in pressure. A section not protected by an over-pressure relief valve will experience extremely
high pressures and significant safety concerns.
WARNING! Over pressurization of bottles (or containers) can occur while using Chart’s UltraDoser
500S system potentially bursting the bottles (or containers). Proper calibration of the UltraDoser 500S
ensures optimum nitrogen doses to avoid over pressurization. Be sure to remove any bottles (or
containers) that receive more than its proper LN2doses before sealing.
WARNING! If you are at all unsure of how to safely work on this system, STOP and contact Chart
immediately at +1 408.371.4932.
CAUTION: As with any cryogenic system, it should be observed that any non-insulated piping can get
extremely cold and should not be touched by exposed skin. If the system requires maintenance, it should be
shutdown and allowed to warm up.
Strict compliance with proper safety and handling practices is necessary when using a cryogenic system.
We recommend that all our customers re-emphasize safety and safe handling practices to all their employees
and customers. While every possible safety feature has been designed into the system and safe operations are
anticipated, 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! Nitrogen vapors in air may dilute the concentration of oxygen necessary to support or
sustain life.
Exposure to such an oxygen deficient atmosphere can lead to unconsciousness and serious injury, including
death.
CAUTION: Before removing parts or loosening fittings, empty the UltraDoser 500S system of liquid and
release any vapor pressure in a safe manner.
External valves and fittings can become extremely cold and may cause painful burns to personnel unless
properly protected. Personnel must wear protective gloves and eye protection whenever removing parts or
loosening fittings. Failure to do so may result in personal injury due to the extreme cold and pressure in the
system.

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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.
 Safety Bulletin
Portions of the following information are extracted from Safety Bulletin SB-2 from the Compressed Gas
Association, Inc. (CGA). For the full text of Safety Bulletin SB-2 and for more information about oxygen
atmospheres, refer to Safety Bulletin SB-2 from the Compressed Gas Association, Inc. (CGA) at
www.cganet.com. Additional information on nitrogen and liquid cylinders is available in CGA Pamphlet P-9.
Write to the Compressed Gas Association, Inc., 1235 Jefferson Davis Highway, Arlington, VA 22202 or visit
their website at www.cganet.com.
Oxygen Deficient Atmospheres
The normal oxygen content of air is approximately 21%. Depletion of oxygen content in air, either by
combustion or by displacement with inert gas, is a potential hazard. 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 or 16%, the flame of ordinary combustible
materials, including those commonly used as fuel for heat or light, may be extinguished. Somewhat below this
concentration, an individual breathing the air is mentally incapable of diagnosing the situation. The onset of
symptoms such as sleepiness, fatigue, lassitude, loss of coordination, errors in judgment and confusion can be
masked by a state of "euphoria," leaving the victim with a false sense of security and well being.
Human exposure to atmosphere containing 12% or less oxygen leads to rapid unconsciousness.
Unconsciousness can occur so rapidly that the user is rendered helpless. This can occur if the condition is
reached by immediate change of environment, or through the gradual depletion of oxygen.
Most individuals working in or around oxygen deficient atmospheres rely on the "buddy system" for protection
- obviously, the "buddy" is equally susceptible to asphyxiation if he or she enters the area to assist an
unconscious partner unless equipped with a portable air supply. Best protection is obtainable by equipping all
individuals with a portable supply of respiratory air. Lifelines are acceptable only if the area is essentially free
of obstructions and individuals can assist one another without constraint.
If oxygen deficient atmosphere is suspected or known to exist:
1. Use the "buddy system." Use more than one "buddy" if necessary to move a fellow worker in an
emergency.
2. Both the worker and "buddy" should be equipped with self-contained or airline breathing equipment.

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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 these gases may produce
unconsciousness even though an adequate oxygen supply, sufficient for life, is detected.
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 a worker's skin or eyes, the affected tissues should be
promptly flooded or soaked with tepid water (105-115oF; 41-46oC). DO NOT USE HOT WATER. Cryogenic
burns, which result in blistering or deeper tissue freezing, should be examined promptly by a physician.

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R
Re ec ce ei iv vi in ng g Y Yo ou ur r U Ul lt tr ra aD Do os se er r®
®
5 50 00 0S S L LN N2
2
D Do os si in ng g S Sy ys st te em m
The UltraDoser 500S system is designed for variable speed filling lines up to 500 bottles (or containers) per
minute. If set up properly, the UltraDoser 500S system will accommodate for any changes in line speed up to
500 bottlers (or containers).
 Unpacking the UltraDoser 500S System
The UltraDoser 500S system will arrive in a specially designed shipping crate. If the unit is intended to be
moved from one location to another, storing the crate for future use is ideal.
Upon arrival of the UltraDoser 500S system, it is advised to immediately inspect for any signs of damage. If
any damage occurred in shipping, claims must be filed with the shipping carrier immediately prior to unpacking
the UltraDoser 500S system.
While unpacking the crate, all contents should be carefully inspected. Things to check for upon arrival include:
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 defined to ship loose
If there are any pieces listed on the Pack Slip and/or Materials List not in the shipping crate please contact
Chart immediately at +1 800.371.3303.
CAUTION: When removing the UltraDoser unit from the crate, gently set it on the ground. Do not drop the
UltraDoser unit! When transporting the UltraDoser unit through the facility, be sure to carry with care. Take
care not to run into walls or drag the UltraDoser unit on the ground.
Prior to installation the UltraDoser 500S system should be stored in a location that will prevent dirt, water or
other debris from getting inside the system. Similarly, it should be stored in a place that is generally out of the
way of frequent traffic to reduce the risk of damage. Chart recommends storing the system in the crate when
not in service.

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U
Ul lt tr ra aD Do os se er r®
®
5 50 00 0S S L LN N2
2
D Do os si in ng g S Sy ys st te em m O Ov ve er rv vi ie ew w a an nd d U Ut ti il li it ti ie es s
 Product Specifications
UltraDoser Body Dimensions: Reservoir height: 18” (457mm)
Hexagonal: 6” (197mm)
Arm reach : 12” or 18” (305mm or 457mm) from stand dependent on
mounting bracket location
UltraDoser Dosing Head: 2”W x 9.5”H (51mm x 241mm)
Total Weight (w/electronics):
UltraDoser: 32 lbs (14.5kg)
500S Controller: 10.5 lbs (4.8kg)
Dosing Range: 0.01 – 14 grams/dose
Dosing Accuracy: +/- 5% of dose value
Timing Range: 15 ms – 1000 ms (in 1 ms intervals)
Control Voltage: 24 VDC
Materials: Stainless steel construction
Built to food and beverage industry standards
Crate Dimensions: 59”L x 29”W x 21”H (1499mm x 737mm x 533mm)
225 lbs (102kg) with support stand
140 lbs (64kg) without support stand
 Utility Requirements
Electrical Supply: 100-240 VAC 50-60Hz 110 W
Liquid Nitrogen: Portable Dura-Cyl®Liquid Cylinder – 22 psi (1.5 bar)
House System (with Chart Phase Separator) – 100 psi (6.9 bar)
Maximum flow rate 15 gallons (56 liters) per hour
Gaseous Nitrogen: 60 to 100 psi (4.1 to 6.9 bar)
10 SCFH gas per 100 bottles (or containers) per minute

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U
Ul lt tr ra aD Do os se er r®
®
L LN N2
2
D Do os si in ng g S Sy ys st te em m B Bo od dy y D Di im me en ns si io on ns s
Note: Mounting bracket can be mounted
at 90° intervals around the central axis
of the UltraDoser body. See page 16
for additional information.
*Shown with Standard Head