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