Summary of Contents for CHART Orca MicroBulk CO2 Series
- Page 1 Product Manual Orca MicroBulk Delivery System ™ Series Designed and Built by: Chart Inc. 407 7th Street NW New Prague, MN 56071 USA (800) 400-4683 Part Number 21235568 Rev. D © 2018 Chart Inc.
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Page 3: Table Of Contents
Product Manual - Orca Series MicroBulk Delivery System ™ Contents Revision Log Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 General Product Highlights Product Manual... - Page 4 Table of Contents Product Manual - Orca Series MicroBulk Delivery System ™ Receiving Tank Commission: Bulk Hose Hydraulic Power Supply Methods to Stop Pump Primary Trailer Operating Instructions Start Delivery End Delivery Methods to Stop Pump Maintenance Components & Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Plumbing Cabinet - Roadside Plumbing Cabinet - Top Center Plumbing Cabinet - Bottom Center...
- Page 5 Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Chart Standard Warranty...
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Page 6: Revision Log
Table of Contents Product Manual - Orca Series MicroBulk Delivery System ™ Revision Log Revision Level Date Description 2/21/2018 Original 3/8/2018 Added parts and specs update 6/18/2018 Specs change, added preventive maintenance log 10/15/2018 Inclusion of Trailer components... -
Page 7: Preface
If there are any questions with minimal pump cooling or product loss under normal regarding the operation of the tank, contact Chart’s Technical conditions Fill termination with Sure-Fill eliminates lost Service division at 1-800-400-4683 product associated with overfilling. -
Page 8: Terms
Preface Product Manual - Orca Series MicroBulk Delivery System ™ Terms Acronyms / Abbreviations Throughout this manual safety precautions will be designated The following acronyms / abbreviations are used throughout as follows: this manual: ASME American Society of Mechanical Engineers Warning! Description of a condition that can result in personal injury or Metric Unit of Pressure... -
Page 9: Safety
Technical Service Representative at Chart Inc 1-800-400-4683 before proceeding with the operation or repair of the vessel Warning! Do NOT use open flame in or Compatibility and Cleaning around the plumbing cabinet. -
Page 10: Oxygen Deficient Atmospheres
Best protection Chart for repair and re-certification. is obtainable by equipping all individuals with a portable supply of respirable air Life lines are acceptable only if the... -
Page 11: Nitrogen, Argon & Carbon Dioxide
Product Manual - Orca Series MicroBulk Delivery System Safety ™ Compatibility involves both combustibility and ease of Nitrogen and argon vapors in air dilute the concentration ignition Materials that burn in air may burn violently in pure of oxygen necessary to support or sustain life Inhalation oxygen at normal pressure, and explosively in pressurized of high concentrations of these gases can cause anoxia, oxygen In addition, many materials that do not burn in... -
Page 12: Safety - Co 2 Specific
Safety Product Manual - Orca Series MicroBulk Delivery System ™ Safety — CO Specific General Warning! Accidental contact of liquid or solid CO with the skin or eyes The Orca CO Series Tank consists of an inner pressure may cause a freezing injury vessel encased within an outer carbon steel vacuum shell similar to a burn. - Page 13 Product Manual - Orca Series MicroBulk Delivery System Safety ™...
- Page 14 Safety Product Manual - Orca Series MicroBulk Delivery System ™...
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Page 15: Introduction
Product Manual - Orca Series MicroBulk Delivery System ™ Introduction Theory of Operation Liquid density, temperature, and equilibrium pressure change with the saturation condition of the liquid Saturation can also be described as an energy state Liquid molecules at a Although the Orca CO Series system can have pressure or pump delivery options, all units have the same general... -
Page 16: Vaporization
Introduction Product Manual - Orca Series MicroBulk Delivery System ™ Vaporization Depressurization Flash Losses Changing liquid into vapor by warming the liquid for the Dropping the vapor space pressure below the saturation purpose of subcooling or for gas use The Orca CO Series pressure of the liquid causing the liquid to boil During delivery system uses a pressure building coil inside of a... -
Page 17: Operations
Product Manual - Orca Series MicroBulk Delivery System ™ Operations Modes of Operation Note: Cryogenic ball valves have a flow direction; the higher pressure must Orca CO — First Use — 11 always be on the inlet side of the ball valve. If there is significantly higher Fill Orca CO from Bulk Tank Pump — 11 pressure on the outlet side, product WILL leak past the ball valve. -
Page 18: Fill Orca Co 2 From Bulk Tank Pump
Operations Product Manual - Orca Series MicroBulk Delivery System ™ II. Fill Orca CO from Bulk Tank Pump III. Fill Orca CO from Onboard Pump Remove hoses from storage tubes, set in place and open In order to minimize pump cavitation and surging: cabinet doors a The liquid level in the supply tank must be above the Connect supply tank vapor balance hose to Vapor... -
Page 19: Filling Levels - Mc-338
Product Manual - Orca Series MicroBulk Delivery System Operations ™ vapor balance and Orca CO Vapor Balance Close Fill Line Drain (V-9) and Vapor Balance Line (V-44) valves Drain (V-45) valves — If Orca CO is higher pressure than supply tank: Warning! Fast depressurization of liquid can cause dry ice to form, a Open supply tank vapor balance and Orca CO... -
Page 20: Pressure Build: Operation
Operations Product Manual - Orca Series MicroBulk Delivery System ™ V. Pressure Build: Operation a. The timer can be set to turn on the heater at a specific time each day of the week This normally won’t be needed but can be used After the heater has been on for appropriate time, the Pressure Build Coil (PBC-1) has built sufficient heat Press center button on timer to start heater Heater will... -
Page 21: Pressure Delivery: Hose Reel
Product Manual - Orca Series MicroBulk Delivery System Operations ™ ii The lower the liquid level, the lower the rate of i Use the PB Force Feed (V-16) valve with low pressure build liquid levels when the PB Liquid (V-28) valve cannot build pressure and throttle as necessary iii At low liquid levels (less than 1/4 full), the pressure build rate will be diminished and stop... - Page 22 13 Close Pressure Dispense (V-4) and Pressure Build Liquid (V-28) valves d Open Delivery Hose (V-46) valve 14 On Chart printer-equipped models: 7 Press START on Flowcom Slowly open Dispense (V-41) valve to start delivery. Monitor flow rate to not exceed a Open printer box, press RELEASE to insert paper into maximum flow rate allowed.
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Page 23: Pump Delivery: Bulk Hose
Product Manual - Orca Series MicroBulk Delivery System Operations ™ Note: To fully empty Orca CO , dump the truck Note: Some customers do not allow vapor air bags or park so the back of the Orca balancing. is lower than the front. a Slowly open vapor balance on the lower pressure tank first. VII. Pump Delivery: Bulk Hose Note: Cryogenic ball valves have a flow direction; the higher pressure must Start Pressure Build Heater with adequate time before always be on the inlet side of the ball delivery... - Page 24 Operations Product Manual - Orca Series MicroBulk Delivery System ™ b Orca CO tank pressure may decrease over time b If pump discharge pressure is less than 50 psig higher if the pressure build rate cannot keep up with the than CO Orca tank —...
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Page 25: Receiving Tank Commission: Hose Reel
Open and close Vapor Balance Line air bags or park so the back of the Orca Drain (V-45) valve to depressurize is lower than the front. 22 On Chart printer-equipped models a Open printer box, press RELEASE to insert paper into VIII. Receiving Tank Commission: printer, press FORWARD to lock paper in... -
Page 26: Hydraulic Power Supply
Operations Product Manual - Orca Series MicroBulk Delivery System ™ Disconnect Bulk Transfer Hose from Vapor Balance Note: Label in cab should determine the max (DC-5) engine speed. Refer to “VII . Pump Delivery” for delivery Note: Many OEM trucks have different ways instructions to achieve operating speed. Confirm provided instructions meet OEM truck recommendations and can be easily Hydraulic Power Supply understood by all operators. -
Page 27: Trailer Operating Instructions
Product Manual - Orca Series MicroBulk Delivery System Operations ™ Trailer Operating Instructions The heater internal fan will start, followed by the furnace lighting Note: If the heater shuts off or fails to start, Start Delivery verify battery voltage is greater than 11.5 volts. Check diesel fuel, hydraulic oil and engine oil levels Periodically check engine coolant level Open the plumbing cabinet doors and follow the Modes of Operation instructions as previously explained a If pressure build heater fails to work or if pink liquid... - Page 28 Operations Product Manual - Orca Series MicroBulk Delivery System ™...
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Page 29: Components & Systems
Product Manual - Orca Series MicroBulk Delivery System ™ Components & Systems Roadside Center Curbside This is the view of the Orca CO Series delivery system cabinet This section will discuss in detail the plumbing cabinet components and systems... -
Page 30: Plumbing Cabinet - Roadside
Components & Systems Product Manual - Orca Series MicroBulk Delivery System ™ Plumbing Cabinet - Roadside Item Description AI-1 Anti-Tow Valve TRAN-1 Hose Reel Flex Hose HR-1 Hose Reel TRAN-2 Delivery Flex Hose to Hose Reel Fill-Gun Assembly DC-3 Connection, Hose Reel Inlet V-47 Valve, Delivery Flex Hose... -
Page 31: Plumbing Cabinet - Top Center
Pressure Indicator, Inner Vessel LI-1 Level Indicator, Inner Vessel DP-1 Transmitter, DP Meter Low DP-2 Transmitter, DP Meter High SW-1 Switch, Pump Start Flow Meter, Delivery PI-3 Pressure Indicator, Inner Vessel Liquid Level Gauge Chart Size Range 7,800 11,000 13,200 10.5 21,000... -
Page 32: Plumbing Cabinet - Bottom Center
Components & Systems Product Manual - Orca Series MicroBulk Delivery System ™ Plumbing Cabinet - Bottom Center Item Description Valve, Pump Inlet/Fill CV-2 Check Valve, PB Inlet V-28 Valve, PB Liquid V-41 Valve, Dispense DC-2 Connection, Dispense RV-6 Relief Valve, Dispense Valve, Dispense Line Drain DC-1 Connection, Fill Line... -
Page 33: Plumbing Cabinet - Curb Side
Product Manual - Orca Series MicroBulk Delivery System Components & Systems ™ Plumbing Cabinet - Curb Side Item Description Valve, Bypass Pump RV-11 Relief Valve, Pump Discharge RTD-1 Resistance Temperature Device MTR-1 Motor CPL-1 Coupler, Motor to Pump Motor High Pressure Side Motor Low Pressure Side Motor Case Drain... -
Page 34: Plumbing Cabinet - Other Piping
Components & Systems Product Manual - Orca Series MicroBulk Delivery System ™ Plumbing Cabinet - Other Piping Item Description V-13 Valve, Vapor Balance/PB Isolation PBC-1 Pressure Building Coil RV-5 Relief Valve, Pressure Build CV-5 Check Valve, Bypass RV-1A Safety Valve, Inner 350 psig RV-1B Safety Valve, Inner 375 psig V-15... -
Page 35: Anti-Tow Valve
Product Manual - Orca Series MicroBulk Delivery System Components & Systems ™ Anti-Tow Valve Metering System The metering system provides an accurate and calibrated means for measuring the amount of product dispensed from the Orca tank to the customer. The system is made up of five components: the Meter Section, two Differential Pressure Transmitters, Resistance Temperature Device and the Flowcom... -
Page 36: Rtd - Resistance Temperature Device
Note: If programming assistance is required, refer to Flowcom manual or contact a Flowcom meter system in a 4-20 milliamp signal technical service representative at Chart Inc. at 1.800.400.4683. RTD - Resistance Temperature Device Note: See the Flowcom manuals for preference The resistance temperature device (RTD) is located upstream of... -
Page 37: Work Lights
Product Manual - Orca Series MicroBulk Delivery System Components & Systems ™ Work Lights Dash Controls - Truck Three LED work lights are located on the back of the Orca Programmable timer Button (A) turns on and off the pressure The dome light in the cabinet has a switch (A) that powers build heater Arrow Buttons (B) and (C) adjust heater on all three The dome light also acts as a junction box for 12-... -
Page 38: Hydraulic System - Truck
Components & Systems Product Manual - Orca Series MicroBulk Delivery System ™ Hydraulic System - Truck Hydraulic System cont. Power Take-Off (A) is connected to hydraulic pump (B). The hydraulic electrical junction box (F) contains a fuse Ensure reservoir (C) is filled to proper height (D). Filter (E) and relays for powering solenoid block (G) and the cooling is located in the reservoir fan When the cabinet switch (SW-1) is in the up position,... -
Page 39: Grease Fitting Locations
Product Manual - Orca Series MicroBulk Delivery System Components & Systems ™ Grease Fitting Locations Pressure Build Heater and Safety Equipment PB Heater (A) is located on the frame behind the fuel tank Safety cones (B) may be located anywhere on the truck frame. Wheel chocks (C) and safety flares (D) are in the tool box (E), which may be located anywhere on the frame The optional fire extinguisher (F) is located curb side at the cabinet. -
Page 40: Trailer System Components
Components & Systems Product Manual - Orca Series MicroBulk Delivery System ™ Trailer System Components Top Deck Engine and Battery Hydraulic Reservoir/ Diesel Fuel Tank Battery supplies power Cooler/Filter to the engine, cabinet and Supply to engine and pressure build heater Same as on truck system pressure build heater Access Panel... -
Page 41: Control Panel
Product Manual - Orca Series MicroBulk Delivery System Components & Systems ™ Control Panel Engine Throttle Engine Control Panel Control with Key Switch Pressure Build Heater Switch Roadside Frame Rail Cones Tool Box (Triangles, wheel chocks) Pressure Build Heater... - Page 42 Components & Systems Product Manual - Orca Series MicroBulk Delivery System ™...
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Page 43: Troubleshooting
Product Manual - Orca Series MicroBulk Delivery System ™ Troubleshooting Use the following troubleshooting table as a guideline to diagnose your Orca system should problems develop This table cannot replace the knowledge that an experienced operator or cryogenic technician has, and should be considered as a guide only. -
Page 44: Overview Of Operation Error Codes
Troubleshooting Product Manual - Orca Series MicroBulk Delivery System ™ Overview of Operation Error Codes Symptom Possible Cause Remedy Flowcom Flow Meter System Breaker tripped in 12 volt control circuit. Check breaker in fuseblock in truck. ® does not power up. Flowcom Flow Meter System 12V supply voltage low. - Page 45 Spray soap solution on build pressure at a joints to test for leaks. Repair leaks if possible sufficient rate otherwise call Chart for assistance. Tank is contaminated with moisture or CO byproducts. Contaminants such as water will freeze in...
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Page 46: Error Codes & Warnings
Troubleshooting Product Manual - Orca Series MicroBulk Delivery System ™ Error Codes & Warnings During the switch-on phase, the Flowcom Flow Meter System checks the important system functions and ® the data integrity. The differentiation is made between errors and warnings. Warnings and errors that can be addressed can be confirmed. -
Page 47: Overview Of Warnings
Product Manual - Orca Series MicroBulk Delivery System Troubleshooting ™ Error Cause Task E032 Meter System serial numbers have not Configure device. See also section 6 “Parameters/Settings.” been entered yet. The calibration seal does not need to be broken. Checksum error identified when reading the corresponding settings. - Page 48 Troubleshooting Product Manual - Orca Series MicroBulk Delivery System ™...
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Page 49: Preventive Maintenance
Proper and immediate action to correct any damage or malfunction is advised Note: If loud grinding noise is observed, contact Chart for proper diagnosis. Persons making repairs to piping, valves, and gauges must be familiar with cleanliness requirements for components used... -
Page 50: Every Three Months Preventive Maintenance
Preventive Maintenance Product Manual - Orca Series MicroBulk Delivery System ™ Every Three Months Preventive Yearly Preventive Maintenance Maintenance Ensure proper service in all programmable settings Drain the air tank(s) every year before the winter months Electrical Connection Inspection (12v) Perform a DOT inspection Check voltage at the batteries Test anti-tow system... -
Page 51: Preventive Maintenance Log
Product Manual - Orca Series MicroBulk Delivery System Preventive Maintenance ™ Preventive Maintenance Log Date Preventive Maintenance Performed Notes... - Page 52 Preventive Maintenance Product Manual - Orca Series MicroBulk Delivery System ™ Date Preventive Maintenance Performed Notes...
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Page 53: Specifications
Product Manual - Orca Series MicroBulk Delivery System ™ Specifications Model 3.8 Ton 5.5 Ton 6.5 Ton 10.5 Ton 13 Ton Type Truck Trailer Real Axle Single Tandem Over 33,000# FET Design Code DOT MC-338 Flow Meter Type Flowcom® Flow Meter System Pressure Build Type ThermaFired or ThermaFired XL... -
Page 54: Piping Schematic
Specifications Product Manual - Orca Series MicroBulk Delivery System ™ Piping Schematic... -
Page 55: Nomenclature
Product Manual - Orca Series MicroBulk Delivery System Specifications ™ Nomenclature... -
Page 56: Truck Electrical System Diagram
Specifications Product Manual - Orca Series MicroBulk Delivery System ™ Truck Electrical System Diagram TRUCK ELECTRICAL SYSTEM IGNITION 14 GA RD 18 GA OR TRUCK CAB KEY SWITCHED OPEN TO ACC OR ON PORT 12 GA RD 12 GA WT ROAD SIDE FRAME TRUCK RAIL NEAR CAB... -
Page 57: Trailer Electrical System
Product Manual - Orca Series MicroBulk Delivery System Specifications ™ Trailer Electrical System TRAILER ELECTRICAL SYSTEM ROAD SIDE FRAME RAIL UNDER DECK ROAD SIDE TOP DECK AUXILIARY CONTROL CHARGING BATTERY PANEL FROM HEATER TRAILER SWITCH HARNESS ENGINE CONTROL DISCONNECT ENGINE HYDRAULIC MANUAL POWER... -
Page 58: Truck Hydraulic System
Specifications Product Manual - Orca Series MicroBulk Delivery System ™ TRUCK HYDRAULIC SYSTEM Truck Hydraulic System WITH PUMP ELECTRICAL TRANSMISSION 18 GA VT (Dash Switch BEHIND CAB CURB SIDE FRAME RAIL Starts PTO, PTO sends out TEMPERATURE 12 GA BK +12v on 18 GA SWITCH wire) -
Page 59: Trailer Hydraulic System
Product Manual - Orca Series MicroBulk Delivery System Specifications ™ Trailer Hydraulic System TRAILER HYDRAULIC SYSTEM HYDRAULIC POWER UNIT INSIDE SHROUD HYDRAULIC POWER UNIT OUTSIDE SHROUD DIESEL TEMPERATURE ENGINE 12 GA BK SWITCH HYDRAULIC COOLER HYDRAULIC RESERVIOR PUMP SUCTION HIGH PRESSURE FILTER CASE DRAIN... -
Page 60: Pressure Build Heater Electrical Diagrams
Specifications Product Manual - Orca Series MicroBulk Delivery System ™ PRESSURE BUILD HEATER ELECTRICAL SYSTEMS Note: This is the basic wiring per the heater manufacturer. Integration with the truck Pessure Build Heater Electrical wiring will vary but should follow these concepts for proper heater operation. 5 KILOWATT INTERNAL FUEL PUMP Key On 7-DAY TIMER CONTROLLER... -
Page 61: Warranty Statement
If warranty Chart Inc. will pass on all warranties offered to us by our repair is required, the Orca CO Series unit will be repaired... - Page 62 Product Manual - Orca Series MicroBulk Delivery System ™...