CHART Carbo-MAX 450 User manual

Part Number 20852765 Rev. E
© 2017 Chart Inc.
Designed and Built by:
Chart Inc.
1300 Airport Dr.
Ball Ground, GA 30107 USA
[phone]
Product Manual
Carbo-Max® Bulk CO2Storage Systems
450/600/750/1000

iii
Product Manual - Carbo-Max®Bulk CO2Systems
Contents
Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Acronyms / Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Equipment Safety and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CO2Monitoring Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
First Aid and Emergency Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Bulk CO2Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fill Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fill Hose and Vent Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Tank Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Site Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fill Box Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Storage Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fill Station (Wall Box) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Flush-Mount Fill Box (PN 9723139). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Surface-Mount Fill Box (PN 9722279). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Fill Hose Line Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Connect Lines to Fill Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Run Lines to Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CO2Storage Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Bolting a Tank (with 6” legs) to the Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connect Line to the CO2Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Connecting to the Beverage System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operation and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Filling the CO2Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General CO2Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Carbon Dioxide Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Operating the Bulk CO2System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Facts to Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Operation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fill Box Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

iv
Table of Contents Product Manual - Carbo-Max®Bulk CO2Systems
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parts Identication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Carbo-Max 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tank Parts: Carbo-Max 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Carbo-Max 450/600/750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tank Parts: Carbo-Max 450/600/750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
PED Carbo-Max Relief Conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PED Fill Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Fill Box Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Direct Fill Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Fill and Vent Hose Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Fill “Gun” Assembly CO2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Carbo-Max 1000 Flow Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Carbo-Max 450/600/750 Flow Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Carbo-Max 450/600 PED Flow Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Service and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Warranty Claims Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Revision Log
Revision Level Date Description
A 02/13/2015 Original
B 04/13/2017 Revise syrup table on page 14, change vacuum warranty to 7 years, add
Carbo-Max 600
C 07/14/2017 Update Specications section with PED information
D08/07/2017 Add 450 PED
E11/22/2017 Updated P/Ns on page 24.

1
Product Manual - Carbo-Max®Bulk CO2Systems
General
The Carbo-Max 600 High Flow, 750 High Flow and
Carbo-Max 1000 systems are innovative bulk CO2systems
that meet the demands of high volume customers. These
systems oer the capacity and ow rates necessary for high
volume users such as stadiums, brew pubs, cineplexs and
microbreweries.
Each Chart Carbo-Series tank is equipped with a proprietary
vacuum maintenance system to ensure optimized long-term
performance. Unique to the market, this feature oers greater
eciency over longer periods of time.
Product Advantages
• Stainless steel, double-walled, vacuum-insulated
container
• Proprietary vacuum regeneration system for on-site
maintenance
• Optional patented Sure-Fill™ System enables tank lling
with no manual venting
• Stable 6” unibody legs meet health department sanitation
requirements standard on Carbo-Max 600 & 750
• Lab Base available with the Carbo-Max 1000 model so it
can be moved with a pallet jack
• Safe, low operating pressure
• Easy-to-read gauges for CO2contents and tank pressure
• Ecient CO2liquid withdrawal system
• Fully automated system requiring no electricity
• Maximizes limited space with one system replacing all of
your high-pressure cylinders, using less than 3’ of oor
space
• Sized to match usage needs - available in a variety of
sizes to meet the unique demands of your business
Product Manual
The Carbo-Max Series Product Manual is designed to be
used in conjunction with Carbo Max 450, 600, 750 and 1000.
If there are any questions regarding the operation of the tank,
contact Chart’s Technical Service division at 1-800-247-
4446.
This manual contains information regarding the safe
operation and handling of CO2. It should be thoroughly read
and understood by anyone that operates the equipment.
The schematics, piping illustrations, and parts lists located in
the Specications section show a reference number for each
component used on the tank. The reference numbers may
refer to the same functional component between the various
models. The reference numbers will be used throughout
this manual to draw specic attention to a component while
describing its function, operation, or repair.
The safety requirements for operating the tank 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
tank and the theory of operation.
Determining locations of the storage tank and the ll box
are included in the Installation section. Part numbers are
provided for easy identication of ush-mount and surface-
mount ll boxes. This Installation section details the various
connections required for the system and concludes with
information on connecting to the beverage system.
The Operation and Troubleshooting section will help with
instructions on lling the storage tank, operating the system,
and general troubleshooting questions that may arise.
Preface

2
Preface Product Manual - Carbo-Max®Bulk CO2Systems
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:
ASME American Society of Mechanical Engineers
BAR Pressure (Metric)
CO2Carbon Dioxide
DOT Department of Transportation
DP Dierential Pressure
FDA Food and Drug Administration
FPT Female Pipe Thread
ID Inner Diameter
Kg Kilogram
MAWP Maximum Allowable Working Pressure
MPT Male Pipe Thread
N2Nitrogen
NPT National Pipe Thread
OD Outer Diameter
PB Pressure Builder
PED Pressure Equipment Directive
PN Part Number
PSI Pounds per Square Inch
PSIG Pounds per Square Inch (Gauge)

3
Product Manual - Carbo-Max®Bulk CO2Systems
General
The system described in this manual holds and dispenses
carbon dioxide (CO2) gas under pressure. All persons using
this equipment must read and understand the operation and
safety information contained in this manual and must be
adequately trained to operate this equipment.
Warning! Asphyxiation hazard. Carbon
dioxide gas can cause serious
injury or death. Do not breathe
CO2gas. Avoid entering tank
area if a leak is suspected and
thoroughly ventilate area.
Warning! Frostbite hazard. Contents are
extremely cold and can cause
frostbite. Do not touch liquid,
ice, or ice crystals on or near
tank. Stay away from escaping
gas.
Warning! CO2vapors 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.
CO2gas is a colorless, odorless, tasteless gas that displaces
oxygen and does not support life. The gas is dicult to
detect without the assistance of special equipment. Avoid
breathing or contacting CO2in gas, liquid or solid form.
Exposure to concentrations of less than 5% can cause
physical symptoms including unconsciousness, injuries or
death. Even low concentrations of CO2can cause:
• Dizziness, headaches, nausea or disorientation
• Increased respiration or heart rate
• Shortness of breath or rapid suocation
CO2is heavier than air and can collect in low areas such
as basements, stairwells, and conned spaces. Avoid entry
into areas where CO2leaks or high concentrations of CO2
are suspected. Enter those areas with caution only after they
have been thoroughly ventilated.
Whenever the tank is inside a building its safety relief circuit
must be connected to an outdoor vent typically in the ll box.
The ll box and/or vent must never be located in or above
any below-ground spaces or stairwells. The tank must not
block emergency exits, aisles, re suppression equipment
or utility boxes or accesses. CO2lines or hoses must be
located away from trac areas and heat sources and must be
protected from potential causes of damage. All connections,
lines, and components must be leak-free.
This equipment should be installed and serviced only by
professional agents who are qualied to work with CO2
and the mini-bulk liquid CO2storage tanks. They should be
familiar with all pertinent safety procedures.
Handle liquid so that it will not splash or spill. Protect your
eyes and cover skin where the possibility of contact with
liquid CO2, cold pipes and equipment, or cold gas exists.
Safety goggles or a face shield should be worn at all times
when connecting to ll connections, while lling the tank
and during disconnection from the ll connection. Clean,
insulated gloves that can be easily removed and long sleeves
are recommended for arm and hand protection. Cuess
trousers should be worn over the shoes to shed spilled liquid.
Equipment Safety and Handling
Note: A bulk CO2storage tank is an ASME coded
tank designed for permanent installation.
It is not designed to meet DOT regulations
and must not be transported when
containing liquid CO2. It must be shipped,
stored and used in a vertical position to
avoid structural damage. When loading a
tank onto or o of a truck, use a power lift
gate, crane, or an inclined ramp. Never
attempt to manually lift or slide a tank on
or o a truck bed.
CO2Monitoring Systems
The Analox 50™and Ax 50™Carbon Dioxide Analyzers
are precision instruments that provide continuous, accurate
monitoring of CO2levels to ensure a safe working
environment for your employees, suppliers and yourself.
Safety

4
Safety Product Manual - Carbo-Max®Bulk CO2Systems
A proven system with over 80,000 units installed worldwide.
The Chart/Analox 50 Monitoring System is comprised of
one detector (with visual and audible alarms) and one alarm
repeater for remote mounting. The Chart/Ax 50 Monitoring
System includes one detector, one alarm repeater and one
relay for additional notications.
For more information look for PN 13586611 on http://
literature.chart-ind.com.
First Aid and Emergency Action
If inhaled:
• Move to fresh air immediately
• If not breathing, give articial respiration
• If breathing is dicult, give oxygen
• Get immediate medical attention
In case of frostbite:
• End exposure immediately
• Do not rub or pour water on the aected area
• Get immediate medical attention
Rescue:
• Do not attempt a rescue in areas of high CO2
concentrations without proper self contained breathing
apparatus.
• Thoroughly ventilate areas of possible high CO2
concentration before entering.
In case of spills or leaks:
• Evacuate all personnel immediately from aected areas
• Thoroughly ventilate the area of the spill or leak before
entering
Personal Protective Equipment
(PPE)
The following personal protective equipment is
recommended when working around cryogenic liquid:
• Safety glasses with side shields to prevent cryogenic
liquid from splashing into the eyes
• Chemical / Liquid resistant gloves to prevent cryogenic
burns on exposed hands
• Long sleeve shirts to protect the arms
• Cuess trousers worn over closed shoes

5
Product Manual - Carbo-Max®Bulk CO2Systems
System Overview
The Bulk CO2Storage System is designed to provide safe,
convenient low pressure liquid storage and supply of carbon
dioxide gas for purposes including beverage carbonation,
beer dispensing, brewing, and pH control in swimming
pools. The system consists of three primary elements: the
CO2storage tank, a CO2 ll box (ll station), and connecting
ll hose and vent line.
Bulk CO2Storage Tank
The storage tank consists of an inner tank and an outer
tank, much like a giant Thermos®bottle. The space between
the two tanks contains a vacuum and additional insulating
material. The vacuum and insulation minimize the entry of
unwanted heat into the liquid CO2stored in the inner tank.
The tank construction includes an internal vaporizer (coil)
and external plumbing conguration that combines to
maintain adequate CO2gas supply rates. When CO2gas
is needed, liquid CO2is drawn from the inner tank and
converted to gas. An adjustable line regulator supplies gas
to the end use point at the desired pressure. The gas use or
"nal line" regulator is normally set between 90 and 115 psi.
In accordance with ASME standard, primary and secondary
relief valves protect the tank in the event of excessive
pressure. Excess pressure is vented safely to the outside.
Fill Station
The stainless steel ll station (box) is the second major
element of the bulk CO2storage system. The lockable
remote ll box is permanently mounted on an outside wall. It
contains a tting for lling the storage tank at any time of the
day without entering the store. The ll box is also equipped
with a vent connection through which CO2gas from the
storage tank's pressure relief or Sure-Fill™System circuits
can be released to a safe area outside. If a tank is located
indoors and is equipped with a direct ll tting, not using a
ll box located outside, the tank pressure relief circuit must
still be vented to the outside.
Fill Hose and Vent Line
The third major element of the stationary bulk CO2system
is comprised of a ll hose and vent line. These two lines join
the outdoor ll box with the CO2storage tank.
The ll hose, constructed with FDA approved food grade
materials, is a pressure rated line that connects the brass ll
tting in the ll box with the ll circuit on the tank. The hose
is available in standard lengths equipped with connector
ttings. Common standard ll hose lengths are 5, 10, 15, 25,
and 30 feet.
The vent line is as important as any component in the bulk
CO2system. It connects the safety relief valves and the Sure-
Fill system on the tank to either the outdoor ll box vent
xture or to an alternative outdoor vent tube.
Note: When used indoors a CO2storage tank
must always be connected with a vent line
to the outdoors (see Safety section).
Introduction

6
Introduction Product Manual - Carbo-Max®Bulk CO2Systems
Tank Plumbing
Plumbing components on the liquid CO2storage tank
perform ve functions (refer to illustrations on this page):
1. The ll tube allows liquid CO2to be transferred into the
tank during the delivery process.
2. The gas-use circuit dispenses CO2gas to the end use
system (shown in red).
3. The pressure control circuit (Economizer on Carbo-
Max HF tanks - shown in pink) maintains optimal
operating pressure and conserves gas for ecient
system performance. The Carbo-Max 1000 also has the
pressure building circuit from the Carbo-Mizer®Bulk
CO2System Series (shown in blue).
4. The relief/vent circuit allows excess pressure to safely
exit the tank and the building (shown in yellow). The
Sure-Fill™CO2Tank Filling System assembly is a
standard feature on both the Carbo-Max 450, 600, 750
and 1000.
5. Contents (shown in orange) and pressure gauges
monitor the status of the CO2inside the storage tank
(included in the economizer circuit shown in pink).
Carbo-Max 450, 600 & 750 Carbo-Max 1000

7
Product Manual - Carbo-Max®Bulk CO2Systems
Equipment Location
Site Survey
Prior to installation of the CO2system components, a site
survey should be performed to determine the best location
for placing the bulk CO2 tank and the ll station. As a matter
of safety, this would be a good time to determine the proper
location for a CO2monitor (CO2is 1-1/2 times heavier than
air and in the event of a leak is likely to collect in low-lying
and conned spaces). Bulk CO2tanks should be installed
outdoors in an unenclosed space whenever possible. Tanks
should not be installed on roofs, in basements, or below
grade. Tanks should have foundations or oors capable of
supporting the full weight of the tank plus product. Tanks
should not be installed near electrical panels, ventilation
intakes, stairwells or elevators.
A site survey form created by the installer should be used
to plan, understand, and approve the best location for the
equipment. The survey must be conducted with the store
owner or their designated representative and the system
installer. Any subsequent modications to the installation
should be noted on the form and signed by the store
representative and the installer.
Fill Box Location
The ll box location must be determined before locating
the CO2 tank. A ll box is typically mounted on a back
wall at a height of 3-1/2 to 4 feet. It should be located out
of the way of store customer operations if possible. It must
be located within a distance allowing easy delivery access
and considering the length of the ll hose from the delivery
truck. The ll box may be located in a drive-thru lane and the
ll hose may be driven over when it is pressurized during the
lling operation.
While determining the best location for the ll box always
check the inside wall of the proposed location to be sure
the box installation will not interfere with appliances in the
store and will not damage anything inside the wall such as
plumbing and electrical conduits. In some stores the ll line
between the ll box and the storage tank must be sleeved.
In those cases be sure to locate the box where it will allow
the inside sleeve to have adequate radius for the ll hose to
easily pass thru for installation and for future maintenance.
The sleeve must not interfere with store operations.
The ll box and/or vent must never be located in or above
any below-ground spaces or stairwells. The tank must not
block emergency exits, aisles, re suppression equipment
or utility boxes or accesses. CO2lines or hoses must be
located away from trac areas and heat sources and must be
protected from potential causes of damage. All connections,
lines, and components must be leak-free.
Storage Tank Location
Once the ll box location has been dened, the location
of the CO2storage tank can be determined. The primary
considerations for placing the storage tank are space and
distance from the ll box. The storage tank must be placed as
close to the ll box as possible to maximize lling eciency;
ideally within 25 feet. The distance from the storage tank to
the beverage machine or other use point is not critical.
The storage tank should not be installed in hallways. It
should be placed in locations out of the way of other xtures
such as electrical panels and sinks. Although the tank should
be in the most out-of-the-way location available, it must be
placed where it is accessible for service and in a manner that
allows its gauges to be read. Tanks installed outside near
trac should have protective bollards or guards installed.
Check local codes for specic requirements.
Note: To prevent damage to the tank’s plumbing
components the tank’s handling ring
must never be used as a hanging rack or
platform for storage.
Installation Equipment
Installation Tools and Supplies
Installation of the bulk CO2system requires certain tools
and installation materials. A supply of the following
materials and tools should be maintained for most simple
and economic installations though not all installations will
require them:
Warning! When using the following tools,
suitable eye and ear protection
must be worn. Failure to do so
could result in serious personal
injury.
Installation

8
Installation Product Manual - Carbo-Max®Bulk CO2Systems
Tools
• Electric Hammer Drill - for drilling holes and chiseling
brick. Accessories:
–3/4” x 21” Scaling Chisel
–3” Core Bit
–1” x 21” Masonry Bit
–1/4” x 13” Masonry Bit
–1/2” Masonry Bit
• 7-1/4” Builder’s Circular Saw - for scoring brick and
cutting wood exteriors. Accessories:
–Masonry Cut-O Wheel
–Combination Blade
• Reciprocating Saw - for cutting through wood walls.
Accessories:
–Metal Cutting Blades
–Wood Cutting Blades
• Electric Hand Drill - for drilling anchor holes.
Accessories:
–1/4” and 3/8” Masonry Bits
–Set of Twist Drills
–3” Hole Saw
• Oxyacetylene Torch - for cutting rebar in poured concrete
walls and oors.
Supplies
• Hand Truck with Strapping Attachment
• Torpedo Level
• Carpenter Square
• Extension Cord
• Oetiker Clamp Pliers
• Step Ladder
• Caulk Gun
• Assorted Hand Tools
• Flashlight
• Silicone Sealant (clear and white)
• 2” PVC Pipe and Elbows
• 1/4” Plastic Screw Anchors
• 1/4” x 1” Self-Tapping Screws
• 9” Cable Ties
• PVC Cement
• Duct Tape
• Teon Tape
• PVC Flanges
• Chalk or Other Marker
• Leak Check Solution
Hardware Chart PN
Clamps for 1/4” ID Tubing 3411321
1/4” Hose Barb Nipple 1611481
1/4” Female Flare Nut 1611471
1/4” Hose Barb x 1/4” Female Elbow 1611461
Flare Nut Connector 1111222
1/4” ID Beverage Tubing 2811416
Concrete Wedge Anchor
Hilti Kwik-Bolt® (3/8” x 3-3/8”)
or
Red Head True Bolt®
10559713
11557752
Note: Stainless steel ttings should be used.
Fill Station (Wall Box) Installation
Note: For ll-box diagrams and components
identication refer to the Specications
section of this manual
If possible, select a ll station location that will not interfere
with store / customer operations. A neat and clean installation
is important since the ll station is visible to the general
public.

9
InstallationProduct Manual - Carbo-Max®Bulk CO2Systems
Before marking the ll station location on the exterior wall,
check to be sure the ll box will not interfere with any
electrical, plumbing, or gas lines inside or outside the store.
Flush-Mount Fill Box (PN 9723139)
1. Using a pre-cut template or carpenter’s square and a
level, mark a 6-1/2” square on the exterior wall making
sure the marking is plumb. Match the ll box to the
outline on the wall to make sure the outline is correct.
2. Using a circular saw, make a 1/2” to 1” perimeter cut
along the inside of the outline. Use a masonry blade to
cut brick, concrete or block wall.
Caution! Do not attempt to remove
material from the wall without
rst making the perimeter cut.
Warning! To help prevent serious injury,
always wear goggles, gloves,
and a dust mask when making
perimeter cuts.
3. Use a hammer drill and 3/4” scaling chisel to remove
brick or concrete material within the perimeter of the
cut. Begin chiseling near the bottom of the perimeter
and work toward the top.
For easier separation of wall material from a poured
concrete wall, drill 3/4” holes about 3” deep around the
inside of the perimeter to perforate the material before
chiseling.
Warning! Be very careful when handling
the chisel. The chisel may have
a tendency to “jump” and could
cause personal injury or damage
to the surrounding wall.
4. Remove debris from the hole.
Note: Some concrete walls contain reinforcing
rods. Cut rebar with an oxyacetylene torch
if necessary.
5. Slide the box into the opening and make sure its ange
lies at against the wall surface.
6. While holding the box in position mark the four corner
mounting holes.
7. Drill the corner mounting holes about 1-1/2” deep using
a 1/4” drill bit or masonry bit as necessary. Insert plastic
screw anchors.
8. Drill a 3” ‘center hole’ in the back of the ll box
opening using a 3” core bit.
Caution! To prevent damage to the inside
wall surface, the center hole may
need to be drilled from inside
to outside. To accomplish this,
rst drill a 1/4” pilot hole through
from the outside; then drill the
3” hole from the inside using the
pilot hole as a guide.
9. Insert the box into position and fasten it using sheet
metal screws.
Surface-Mount Fill Box (PN 9722279)
When the use of a surface mounted box is preferred, it will
simply be mounted onto the outside surface of the store wall.
1. At the desired ll box location mark and drill the center
hole using a 3” bit.
2. Place the box in position so its ll and vent ttings are
within the 3” hole. Mark the four corner holes while
using a carpenter’s level to make sure the box is level.
3. Drill the four corner pilot holes. Use a 1/4” bit if
necessary for screw anchors. Insert the anchors.
4. Fasten the box in place using sheet metal screws.

10
Installation Product Manual - Carbo-Max®Bulk CO2Systems
Fill Hose Line Installation
Fill and vent lines will likely be routed dierently in each
store. By following basic recommendations, the lines should
be run properly and as easily and simply as possible.
Distance from the outside ll box to the CO2storage tank
should be as short as possible and typically varies from 1 to
30 running feet. Fill line distances of longer than 30 feet are
not recommended because longer ll hose length results in
reduced CO2 ll eciency.
Note: When installing the ll and vent lines
please be aware that they need to be
accessible for inspection and service. The
lines should be inspected at least once a
year for leaks, damage, or signs of wear.
They should be replaced every eight years.
Fill and vent lines are generally secured together with cable
ties about every 18 inches and attached to the wall using
conduit straps about every 2 or 3 feet along the run. The
lines should run either horizontally or vertically and as
inconspicuously as possible. Excess line should be coiled
and tied.
Running lines through a conduit sleeve is generally not
necessary. However, if the lines were to be exposed in a high
trac area, it may be best to run them through a sleeve to
ensure protection. Sleeve material generally used is 2” or 3”
PVC piping.
Connect Lines to Fill Box
1. Gain access to the back of the ll box by temporarily
removing the box from its mount.
Note: The ll tting is fastened to the ll box by
four lock nuts on threaded studs. The tting
can be easily removed for service or for
attaching the ll line.
2. Fasten the vent line simply by pushing the line onto the
barbed tting on the back of the ll box.
3. Fasten the are connector on the end of the ll hose to
the are connection end of the ll tting.
Note: In the event that a ll hose needs to
be attached at a right angle to the ll
box, a are tting 90° elbow (Chart PN
11388573) may be used to connect the ll
hose to the ll tting.
Run Lines to Tank Location
1. Feed the ll and vent lines through the wall (or PVC
wall ange if used) to the inside of the store.
2. Re-attach the ll box if necessary.
3. If sleeve material is not being used, route lines to the
tank location according to plan and attach them to the
wall with conduit straps about every 2 or 3 feet. Proceed
to CO2storage tank installation.
4. If a sleeve is being used, size and cut the sleeve material
to the proper length and with a bend radius toward the
wall ange. Bond sleeves to elbows with PVC glue only
if necessary. If the connections are not bonded they will
be easier to separate when future service is required.
If the connections are bonded the bend radius should
allow the ll hose to slide freely within the sleeve for
future maintenance and replacement.
Note: A ll hose should be replaced every eight
years.
5. Feed the ll and vent lines through the PVC sleeve
conduit and run the sleeve conduit to the CO2storage
tank.
6. Attach the PVC sleeve to the wall with conduit straps.
Proceed to CO2storage tank installation.
CO2Storage Tank Installation
The bulk CO2storage tank should be installed in compliance
with local code requirements as applicable. It should be
installed in an area having free owing air space and out of
the way of pedestrian trac. It should be located away from
chemical storage areas. The tank should be positioned so its
plumbing components are accessible for service and so its
gauges are facing “forward” and are readable.
Caution! The storage tank must be
vented to the outside to prevent
hazardous CO2concentrations
from developing if a pressure
relief valve should open.
Bolting a Tank (with 6” legs) to the Floor
1. Place the tank in its best position and mark three oor-
anchor holes through the holes in the bottom of the legs.
Move the tank.

11
InstallationProduct Manual - Carbo-Max®Bulk CO2Systems
2. Drill holes with a masonry bit having the same diameter
as the anchor. Make sure the hole depth exceeds the
minimum embedment of the anchor.
3. Assemble each anchor with a nut and washer so the top
of the nut is ush with the bolt. Drive each anchor into a
oor hole until the nut is against the surface of the oor.
Expand the anchor by tightening the nuts 3-5 turns until
rmly tight. Remove and save the nuts and washers.
4. Move the tank back into position being careful that the
hold in the bottom of each leg is over an anchor bolt.
Place a washer and nut onto each bolt and tighten.
5. The Carbo-Max 1000 has a at base with holes for
securing the tank. A lab base is also oered with bolt
holes included for ease while mounting.
Connect Line to the CO2Storage Tank
Bulk CO2storage tanks contain positive CO2gas pressure
when they are shipped. Before installing the lines onto the
tank, any residual pressure should be vented o by simply
opening the gas-use valve.
1. Connect the liquid ll hose to the inlet are tting on
the tank, then open the tank valve.
2. Squarely cut the vent tubing to the proper length and
attach the tubing to vent the circuit tting of the tank.
3. Connect the supply line tubing to the tank’s supply
regulator.
Note: Do not use copper tubing for CO2gas
supply.
For best results, the tank should be lled at this time to
ensure that the lines are properly purged before use with
the beverage system. This is also the best time to check the
system for leaks.
Connecting to the Beverage System
The gas-use line from the CO2storage tank to the beverage
equipment or other end use point(s) will probably be run
dierently in each location. The distance from the CO2tank
to the equipment is not critical and can be several hundred
feet.
Beverage tubing lines with 1/4” ID are generally adequate
for service up to 50 feet. For longer runs a larger ID tubing
may be desired to compensate for pressure drop. See the
chart on the next page for recommended gas line sizes for
various distances. For certain applications where several
‘stations’ are supplied by a single CO2source, a larger
diameter ‘header’ or ‘trunk’ line may be used while teeing
1/4” ‘drop’ lines to supply individual stations. By following
basic recommendations described in this section, CO2supply
lines can be run as easily and as eectively as possible.
1. Run the gas use line in a manner that is as
inconspicuous as possible.
2. The line should be attached along the run in horizontal
or vertical orientation; level and plumb wherever
possible to present a neat and careful installation. Never
leave loose line hanging.
3. Cut the line to proper length.
4. Secure connections to the CO2 storage tank’s nal line
(supply) regulator and to the drink system equipment
using appropriate ttings.
5. Open the gas-use isolation valve on the bulk CO2
storage tank and check the supply regulator gauge for
proper set pressure within the range of 90-115 psi while
gas is owing.
6. Perform a leak check with soap solution on all joints to
the drink system and correct as necessary.

12
Installation Product Manual - Carbo-Max®Bulk CO2Systems
Note: Beverage systems consist of a variety of
equipment functions. Each function may
require a dierent CO2pressure. The bulk
CO2 storage system supplies a pre-set
CO2 pressure of about 110 psi. Therefore,
secondary or ‘step-down’ regulators
should be used as necessary to meet the
requirements of system functions. Since
high pressure regulators normally used on
high pressure cylinders are constructed
to respond to very high inlet pressures,
they may not perform properly in the low
pressure bulk CO2system and their use is
not recommended.
Gas-Use Tubing Size / Distance Recommendations From a Single Supply Regulator
Tubing ID To 1 Carbonator To 2 Carbonators To 3-5 Carbonators To 6-8 Carbonators
1/4” 0’ - 50’ 0’ - 20’ -- --
3/8” 51’ - 250’ 21’ - 100’ 0’ - 20’ --
1/2” 251’ - 500’ 101’ - 500’ 21’ - 100’ 0’ - 50’
5/8” * or (2) 1/2” -- -- 101’ - 250’ 51’ - 100’
3/4” * or (3) 1/2” -- -- 251’ - 500’ 101’ - 250’
*Non-standard tubing

13
Product Manual - Carbo-Max®Bulk CO2Systems
Filling the CO2Storage Tank
First Fill
The rst ll of the tank cools the inner tank of the storage
system. Since the inner tank of a new CO2storage tank is
relatively ‘warm,’ its rst ll may take 20 to 30 minutes
and a larger than normal amount of CO2gas will be vented
during the ll. A higher-than-normal operating pressure can
be expected for several days after the rst ll.
1. Open the ll box door and inspect the threaded ll-
tting for debris and damage. Wipe the tting with a
clean dry cloth if necessary.
2. Inspect the delivery hose quick-connect and wipe the
tting if necessary.
3. Connect the delivery hose to the ll box ll tting.
If lling a tank equipped with the Sure-Fill™System
option proceed to step 7.
4. Open the liquid delivery valve to allow liquid CO2
to ow into the tank. CO2 will stop owing when the
tank’s pressure equals the pressure of the delivery
source. At this point the tank should be just over half
full.
5. Close the liquid delivery valve; then open the vent valve
on the delivery hose assembly to reduce pressure in the
tank. Drop the tank pressure to between 100 and 125 psi
(frost should be seen at the bottom of the tank). Close
the vent valve.
6. Repeat the liquid delivery and vent cycle as often as
necessary to get the tank contents to about 350 pounds
on the 450 pound model.
Note: The initial ll will take considerably longer
time than subsequent lls. If scheduling
permits, it can be a good idea to initially
ll the tank about halfway and then return
in a day or two to complete the ll.
7. When lling a tank equipped with the Sure-Fill vent
option, make sure the isolation valve in the Sure-Fill
relief circuit is open.
Operation and Troubleshooting
8. Open the liquid delivery valve to allow liquid CO2to
ow into the tank. The Sure-Fill vent valve will open
when the tank pressure reaches approximately 200 psi.
At that point a pressure relief venting noise will be
heard from the vent tting below the ll connection in
the ll box. Continue lling.
9. When the venting stops the tank is full. Disconnect the
ll hose from the ll station.
10. Using a leak check solution check all connections
and ttings on the tank and ll box for leaks. Tighten
connections if necessary.
General CO2Delivery
To minimize delivery expense, delivery frequency should be
scheduled to allow a 200-500 pound delivery; depending on
tank size. For most restaurants, this will be every 20-30 days.
Delivery routes are typically planned to minimize travel time
and “rush-hour” trac situations.
1. Delivery vehicle pressure must be maintained at 280-
300 psi for proper operation. Low delivery pressure can
cause 45-50 minute ll times.
2. A delivery pressure of 50 psi higher than the restaurant
storage tank pressure should be maintained during
lling. A low pressure dierential will cause long ll
times.
3. Maintain a delivery log for each account to help detect
irregularities in CO2consumption.
4. Adjust delivery program to longer intervals between
deliveries as consumption justies.
Carbon Dioxide Consumption
The amount of CO2that will be consumed in the variety of
restaurant applications is almost impossible to predict. While
primarily used for beverage carbonation, CO2is also used
for carbonating frozen drinks and for driving pumps and
automatic dispense systems.

14
Operation and Troubleshooting Product Manual - Carbo-Max®Bulk CO2Systems
A typical 16 oz. soft drink contains about 2.4 oz. of syrup
and water carbonated with 0.0112 lb. of CO2(approximately
1 lb. of CO2is required to carbonate one hundred 16
oz. drinks). The table below shows an estimate of CO2
consumption just for beverage carbonation based on a use
ratio of 0.6 lb. CO2per gallon of syrup.
Weekly Syrup
Usage (gallons)
Bag-In-Box
Containers
CO2Consumption for
Carbonation (lb.)
10 2 6
20 4 12
30 6 18
40 8 24
50 10 30
60 12 36
70 14 42
80 16 48
90 18 54
100 20 60
CO2is also used to ‘push’ beer from kegs. To push a ‘direct
draw’ beer dispense system, which dispenses directly from
the keg, only the fresh-keg (rack) pressure of 12 to 15 psi
needs to be maintained on the keg to pour the beer and
prevent excessive foaming caused by over-carbonation.
Note: To push beer greater distances in common
‘long draw’ dispense systems higher gas
pressures are required. However, to avoid
over-carbonation and excessive foaming,
that higher gas pressure must consist of a
calculated blend of CO2and N2. Blend gas
equipment is available for this purpose.
The following table shows the approximate amount of CO2
consumed to dispense beer.
15.5 Gallon Kegs CO2Consumption (lb.)
10 2.5
20 5.0
30 7.5
40 10.0
50 12.5
60 15.0
Operating the Bulk CO2System
The store operator should be familiar with basic elements of the system. The installer is responsible for explaining the CO2
system to the store operator upon completion of the bulk CO2system installation. The following table describes functional
elements of the system and is intended to assist with that explanation.
Component Function
CO2Contents Gauge Indicates the approximate amount of liquid CO2 inside the tank.
CO2 Tank Pressure Gauge Indicates tank pressure. Normal operation pressure is between 110 and
175 psi.
Tank pressure may be as high as 300 psi after a CO2delivery
Final Line (Supply) Regulator
Note: Actual regulator may not match style shown in
diagrams in this manual.
Controls pressure in supply line from tank to beverage equipment.
Final Line (Supply) Regulator Gauge Indicates supply pressure in the gas-use line. Final line (gas-use)
pressure is normally 90 - 115 psi.
Gas-Use Valve On / O󰀨 valve for gas supply.
Primary Relief Valve Prevents tank pressure from exceeding 300 psi.
Vent Hose Vents excess gas pressure to ll box outside.
Fill Hose Transports liquid CO2 from ll box to tank during ll.
Fill Box Connection point for liquid CO2 delivery and transfer line.
Filling Schedule Should be established with supplier based on CO2use (normally every
4-6 weeks).
Periodic Frost Frost indicates that liquid CO2is being converted to gas to meet a
demand. Frost near the bottom of the tank is normal during periods of
high or continuous use.
Continuous Frost Continuous presence of frost during non-business hours or in mornings
before business hours indicates a demand for CO2gas perhaps caused
by a leak in the beverage system.

15
Operation and TroubleshootingProduct Manual - Carbo-Max®Bulk CO2Systems
Facts to Know
1. A tank’s normal internal operating pressure is between
125 psi and 150 psi, which is sucient pressure to
supply the carbonator (typically 90 psi) and low enough
pressure to be lled directly.
2. Tank pressure can be as high as 300 psi after a delivery
but returns to its normal operating pressure after a day
or two of normal CO2use.
Note: Topping o small amounts of liquid
between normal delivery cycles will add
excessive heat to the cylinder keeping the
pressure high.
3. The gas supply pressure is normally between 90 psi and
120 psi.
4. Frost or condensation on the tank is normal during
periods of CO2use.
5. Frost or condensation on the tank before starting the
daily use of CO2is a sign of a CO2leak. Have the leak
xed.
6. A Carbo-Max 450 holds 477 lbs of CO2for a use rate of
50 to 300 lbs per week.
A Carbo-Max 600 holds 612 lbs of CO2for a use rate of
50 to 300 lbs per week.
A Carbo-Max 750 holds 771 lbs of CO2for a use rate of
50 to 300 lbs per week.
A Carbo-Max 1000 holds 1000 lbs of CO2for a use rate
of 70 to 400 lbs per week.
7. The contents gauge displays the approximate amount of
liquid CO2in the tank.
8. CO2becomes dry ice below a pressure of 61 psi. Stop
using CO2from the tank if its pressure reaches 70 psi or
less.
9. An isolation (shut-o) valve is open when its handle
is parallel to the valve body and the line. The valve is
closed when its handle is perpendicular to the valve
body and the line.
General Operation Notes
1. Always use caution when working with CO2. Read and
understand the Safety Section of this manual.
2. The Carbo-Max system does not require adjustment
under normal operating conditions.
3. In an emergency the ow of CO2from or through the
storage tank can be stopped by closing the red-handles
valves marked with the Emergency Shut-O labels.
4. For CO2equipment issues, call your CO2supplier
or service specialist. Before calling for service or
troubleshooting assistance, please have the following
information at hand:
• Serial number of the tank
• Description of the problem
• Readings from:
the tank contents gauge,
the tank pressure gauge, and
the nal line pressure gauge
• Observations such as unusual frosting and/or events
related to the problem
5. Every day before starting operations and CO2use check
for:
• CO2leaks (see Safety)
• Pressure readings
• CO2contents
• Abnormal frost or condensation
• Anything unusual

16
Operation and Troubleshooting Product Manual - Carbo-Max®Bulk CO2Systems
Troubleshooting
The following table is arranged in a Trouble/Probable Cause/Remedy format. The probable causes for specic problems
are listed in descending order of signicance. That is, check out the rst cause listed before proceeding to the next. Perform
all procedures in the order listed and exactly as stated (Refer to diagrams in the Specications section as required to locate
system components identied in the troubleshooting guide.) If you need further assistance please contact Chart’s service team
at 1-800-253-1769.
Trouble Probable Cause Remedy
No CO2to carbonator or
use-point system.
OR
Carbonated drinks are at.
CO2 storage tank is empty.
Switch to emergency CO2 gas cylinder.
Call CO2 supplier for delivery
Isolation valve to nal line regulator is
closed. Open valve or valves as required.
Tank pressure is low (110 psi or less).
Switch to emergency CO2 gas cylinder.
Stop CO2 withdrawal from bulk CO2 tank by
closing isolation valve.
If tank pressure fails to rebuild see section on low
tank pressure.
On Carbo-Max 1000 tanks, pressure
building regulator is not operating
properly; is set too low, plugged, or faulty
(closed).
Ensure that isolation valves are open (valve
handles should be parallel with the line).
Call CO2 service agent.
Pressure relief “Economizer” regulator
not operating properly; set too low or
stuck open.
Close supply pressure valve and switch to
emergency CO2 gas cylinder. If tank pressure
fails to rise within 24 hours see section below on
low tank pressure.
Unknown Call CO2 service agent.
Frost on the bottom, sides,
or top of the tank.
A normal condition during or following
CO2 use. None
Leak in beverage system and/or gas
supply lines or CO2 ll box.
See Safety section. Evacuate and ventilate.
Check for frost in the morning before CO2has
been used. If possible, locate and correct leak.
Call appropriate equipment service agent.
Frost on tank after extended
periods of no CO2use; such
as in the morning before
store operations begin.
Leak from the beverage system, CO2
tank’s plumbing, or ll box.
Bag-in-box pump running because B.I.B.
is empty.
See Safety section. Evacuate and ventilate the
room.
Locate and correct leak if possible.
Call appropriate service agent.
Constant low tank pressure
(Gauge below 125 psi for
PB on Max 1000 and 150
psi for Econ).
On Carbo-Max 1000 tanks PB regulator
set low or plugged. Call CO2 service agent for service.
PB shut-o󰀨 valve closed. Open valve by turning handle parallel to line.
Economizer regulator set too low or stuck
open. Call CO2 service agent.
CO2 leak from tank plumbing, CO2 ll box
and/or tank safety system.
See Safety section. Evacuate and ventilate the
room.
Call CO2 service agent.