Component Inspection and Service Beverage Systems Technical Service Bulletin TSB-Y10-007 Date: July 2006 Subject: Inspection of CO 2 Pressure Control Circuits Products Affected: All Chart Beverage Systems CO 2 storage vessels manufactured between June 2003 and June 2006: Mite 200, Charger 300, Mizer 450 and Carbo-Max 750. Description: All MVE Beverage Systems CO 2 storage vessels are equipped with pressure control circuits that consist of a regulator, tubing and compression fittings plumbed together. Whether the pressure control circuit is for pressure build or pressure relief, depending on system design, its function is critical to efficient and reliable storage of CO 2 liquid and dispensing of CO 2 gas. This bulletin focuses on the inspection and service of all pressure control circuits. Chart recommends, according to Installation Manual P/N 10654631 and Compressed Gas Association (G-6.5 Section 8.1), that all CO 2 storage vessels be inspected and checked for leaks by a qualified service agent during installation and scheduled general service. (Please refer to the Preventive Maintenance Schedule on page 6 of this bulletin.) Pressure control circuits on Chart s bulk CO 2 storage systems manufactured between June 2003 and June 2006 are equipped with Parker Vibra-Lok compression type fittings as seen in Figures 1 and 2. On June 1, 2006 Chart began using conventional style compression fittings in pressure control circuits. All fittings should be routinely checked for leakage during installation and during regular subsequent maintenance inspections. The following pages of this bulletin discuss the service and installation of compression fittings. Caution: Never move a vessel or allow a vessel to be moved by grabbing any of its plumbing components! Figure 1: Pressure Builder Circuit Figure 2: Economizer Circuit
Component Inspection and Service TSB-Y10-007 Page 2 Vibra-Lok Fitting (The Vibra-Lok fitting has a different installation procedure compared to a conventional compression fitting.) Inspection: Ensure that the Vibra-Lok fittings are fully tightened to the stainless steel Pressure Builder or Economizer tubing so that the nut bottoms out against the fitting such that the nut contacts the body of the fitting as seen in Figure 2. Figure 2 If the nut is not contacting the body of the fitting, the fitting should be removed and reassembled. Check for leaks where the tubing enters the fitting and where the nut tightens against the body of the fitting as indicated in Figures 2, 3, and 4. If a leak is detected, the fitting should be removed and reassembled or replaced. Disassembly (if necessary): Close the isolation valves on both ends of the Pressure Builder or Economizer Circuit. (Figures 3 and 4 show one end of each circuit) While the valves are closed, turn the nut on the compression fitting counterclockwise slowly at first to allow relief of possible trapped pressure. Continue turning the nut and remove it and the tubing from the fitting. Check the condition of the fitting s threads and its rubber grommet seal. If either is worn or distorted, the fitting must be replaced. Figure 3: Pressure Builder valve and Vibra-Lok fitting (Carbo-Mite, Charger, Mizer) Figure 4: Economizer valve and Vibra-Lok fitting (Carbo-Max 750) Note: According to the manufacturer, all Vibra-Lok fittings can be reassembled repeatedly. New sleeves can easily be added to retain original fitting performance. To obtain new sleeves please call Chart Customer Service at 800-247-4446. Assembly: Place the nut and the rubber grommet onto the tube and fully insert the tube into the fitting as shown in Figure 5. The rubber grommet should seat 1/4" from the end of the tube. While making sure that the tubing stays fully inserted into the fitting, tighten the nut to the fitting. Note: The nut on a Vibra-Lok fitting must be tightened until it contacts the body of the fitting. Open the respective isolation valves and check for leaks on the tightened fittings. Figure 5
Component Inspection and Service TSB-Y10-007 Page 3 Compression Fitting Change Consistent with the goal to continuously improve the overall serviceability of its CO 2 storage vessels, Chart has made some simple fitting changes. On June 1, 2006, Chart began manufacturing its bulk CO 2 storage systems using double ferrule industrial style fittings, as shown in Figures 6 and 7, instead of Vibra-Lok fittings in Pressure Builder circuits of the Carbo-Mite, Charger, Mizer, and McDonald s style systems and in the Economizer circuit of the Carbo-Max 750 systems. Figure 6 Figure 7 Pressure Builder Circuit with double ferrule fittings Economizer Circuit with double ferrule fittings Note: The conventional compression style fitting has a different installation procedure than a Vibra-Lok style compression fitting. Verify the type of compression fitting that is being used before servicing or installing the fitting. In addition to fitting changes in the pressure control circuits, Chart has made a fitting change in the vent circuits on all new vessels. Single ferrule industrial style fittings as shown in Figure 8 are now being used in the vent circuits of CO 2 storage systems. Those fittings are replacing the Presto-Lok style fittings seen in Figure 9. Figure 8 Figure 9 Single Ferrule vent circuit fitting Presto-Lok vent circuit fitting
Component Inspection and Service TSB-Y10-007 Page 4 Conventional Compression Fitting Assembly and Installation Procedures Assembly: Ensure that the tube has been cut squarely and is free of burrs. Place the nut and ferrules over the tube as shown in the example on the right, then insert the tube into the fitting body as far as it will go. Note: The small, tapered end of the ferrules must be facing toward the fitting body, with the larger ferrule being closest to the fitting body. Tighten the nut by hand until it stops. Using a wrench, tighten the nut an additional 1 1/4 turns as shown in the diagram to the right. Note: Use two wrenches when tightening the nut onto the fitting body. Hold the fitting body with one wrench while tightening the nut with another wrench. Do not over tighten compression fittings! Over tightened fittings will result in either a cracked or sheared tube. Double check all compression fitting connections and ensure that they are tightened properly. Check for leaks.
Page 5 Component Inspection and Service TSB-Y10-007 Monitoring CO2 Concentration Chart bulk CO2 storage systems are designed for safe operation when properly installed, ventilated and maintained. Leaks inside of buildings or enclosed spaces, that result in an increased concentration of CO2, are a very serious safety hazard that can result in permanent injury or death. Refer to CGA Pamphlet G6.5 section 4.5 and page 1 of the Chart (vessel) user manual for specific warnings in this regard. CO2 gas monitors should be used in any indoor installation without natural ventilation and where leaks or a gas discharge can create a dangerous concentration of CO2. Chart s Basic CO2 Monitor System Components Warning Beacon Central unit Sensor Unit If you have concerns or questions relative to the procedures or component descriptions in this bulletin, please contact your Chart Technical Service Representative at 800-253-1769 or 952-758-4400. Thank you for depending on Chart for high product quality and service. component_inspection_y10-007_0706_drc
Component Inspection and Service TSB-Y10-007 Page 6 Beverage CO 2 Storage Systems Recommended Preventive Maintenance Schedule Component Initial Routine Annual 3 Years 6 Years 8 Years Fill Box Inspect Inspect Inspect - - - Fill Fitting Replace Replace Replace Fill Hose Assembly - - Replace Vent Line Labeling Inspect Inspect Inspect - - - Anchoring Inspect Inspect Inspect - - - Liquid Level Indicators - - Replace Pressure Indicators Fill Circuit Isolation Valve Replace Replace Replace Isolation Valves Pressure Control Regulator Line Regulators Shut-down Regulators Relief Devices Inspect Tubing Threaded Joints / Connectors Collection Ring / Purge Port Inspect Purge - - - Getter Port Inspect Inspect Inspect Activate Activate Activate component_inspection_y10-007_0706_drc