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UltraDoser Injector System with AB1500 Controller

1. Tress to open the cur recipe A recipe program screen will appear Press the up e down arrows to highlight the speed range to be adjusted Up and Downs Arrows for speed range Page 35 of 46 Document 15905 040207 Press the ENTER button to make changes to the desired speed range DEFAULT a opens refresh View Close Download Save Save As Enter the desired dose duration in the pop up screen that appears Press enter to save the value Repeat this procedure for all speed ranges Press the SAVE AS button A pop up window will appear DEFAULT Open refresh Download Save de e Save As button Enter new unit name En recipe name Figure 19 Recipe Pop Up Window Press the EDIT button A pop up keyboard window will appear Enter the name of the recipe using this window Press ENTER to save this recipe Press the DOWNLOAD button to load into the PLC program A pop up window will appear and advise the user that the recipe to be downloaded is different than the current recipe L File UliraDoser with AB1500 controller Page 36 of 46 Document 15905 040207 DEFAULT Open refresh Close Boch Save Save As Download button Press YES to continue with the download process Changing Recipes From the Dispense Setup Screen press the RECIPE button When the recipe screen appears th
2. UltraDoser Injector System with AB1500 Controller USER MANUAL Cryotech International Inc 745 B Camden Avenue Campbell CA 95008 S CRYOTECH 408 371 3303 Phone INTERNATIONAL 408 371 3320 Fax www cryotechinternational com Table of Contents General NOMINA ouiiinisicanonia a Ee 3 SE ET EE 3 Principles of LN2 DOSING i 3 205 e eee2 ores haus Ass EEN EN taera bee aeee shes EES ENNEN 3 Unpacking the injector ET 4 Unpacking Checklist Aust epdnggdenged erte be apecepeeci ngs beds ee Edge Ed EE bees Ste resonates 4 Product Warranty s222ccs hecteceets Eed E EREN AEn APEE NETEP ETEA EENE TEATA bawed ceohenerecereies 5 lge E 6 System Components asruuioinoccuenaninoncncan ranas ER ENNEN il 8 System Installation iii di 11 ACCOSSONICS ii A A A A a 14 Electronic Controller egen been iii ii ii 16 Gel gel 16 Start Up Procedure EE 17 Controller Screens ceci laa aan ida 17 Ml DEE 17 SN e lut le A A hee 18 Access and Passworcdes eee eee e eee eet KERKE tensa ea ea eee KEKERE 20 lt OYSLOM O DEE 21 DISPENSE Clair edi 21 gt System EDEGEM ie 23 Maintenance and Factory Geiup 25 AMS ti A dia 25 Controller Setup and Operation 27 ES E Et Seat deele ENEE ep ENEE 27 Synchronizing the Dose with the Container 29 gt HRECIDOS ibid dave bier EEN ENEE sii AEN Ae 34 Dally ODGIAllONS uri n 38 EEN 39 s ROWING cache denge eet SE Oe Eed deg e
3. DETECT LO 400 time delay mS i Recipe os er Inactive Units English Figure 9 System Set Up Calibration screen irst step prior to incorporating LN2 into the system System Setup sets the default values for the liquid level and supply pressure of the injection system and allows for calibration of each The PLC has been programmed to input a raw number a calculated number based upon the initial readings of the liquid level and supply pressure transducers located within the controller Dispense Setup Screen Accessible only when logged on Provides a means to precisely setup the system for dosing properly 4 200 4 400 1300 LCI 2000 L_ File UliraDoser with AB1500 controller Page 21 of 46 Figure 10 Dispense Setup Screen Document 15905 040207 Dispense Setup Screen Buttons e Units The button in the upper right hand corner of the screen displays the unit of measurement that the controller uses to calculate correct dose location in speed compensated mode If the distance measurements made for the Sensor to Nozzle and Container CL to CL are in inches then this button should read English If the distances are measured in mm then this button should read Metric e Pulses per Container The controller will not accurately dose bottles if the Pulses per Container value is incorrect The controller will calcula
4. bebida a D E ec OC Terminal Blocks TBH ed O O Ob e o l l Indicator Light L1 l l l Jl oml D fd Bosa Grel 6 0 6 o J6 CIA A Sogo pogo PAT TT CARICIA A CS En Zi seas S y dad d AAJ ZS 2 207 Distribution Box TI CTT W EE d ffe d We VT EZ 3 ya DTH E 4 Service Valve 6 Bottle Detect pena A C In El k a LX THIET AIT I Dose Solenokt Valve al Car rm Sensor g VO Functions Analog linO Liquid Level lin 1 Supply Pressure Inputs 1 0 114 US 1 6 1 7 Encoder Speed Sensor Dose Timing Sensor Confirm Sensor Bottle Detect Sensor Dose Disable Switch Outputs on 0 2 0 3 0 4 0 5 Service Valve Dose Solenoid Valve Red Indicator Light Green Indicator Light Yellow Indicator Light 0 6 Low Pressure NC O 7 Liquid Empty NC 0 11 Dose Valve Fault NC
5. Eed Redu EN cet 39 Preventative gebuede cece ENER ENEE Eed EN endaaecgaiatenseddeatate bv ead 40 Trouble Shooting erdeelt dd Keser 41 SEIVICE Plinio da gu geg A3 Replacement Parts ze sgek ES KEEREEEENNENEERE EEN ER AEN SEENEN NEE eh G ER GEES 44 Sensor POSINONING EE Appendix A Two Sensor Three Sensor Two Sensor and Encoder Wiring Diagram viaccess dicccserieic swan ardid apnea iE KiE Appendix B L File UliraDoser with AB1500 controller Page 2 of 46 Document 15905 040207 GENERAL SECTION Safety Liquid nitrogen LN has three primary hazards 1 Extremely cold temperature 320 F 196C 2 Oxygen depletion 3 Potential of bursting sealed environments 1 When working around LNs use personal protective equipment such as cryogenic rated gloves a face shield and a chemical apron Any LN that comes in contact with skin may cause burns Non insulated LN pipe or fittings such as a tank connection will become extremely cold and can cause flesh to freeze upon contact 2 A release of LN into an enclosed environment will begin to displace the breathable air When using LN2 in an enclosed environment such as a small room where portable LN tanks are filled Cryotech recommends that an oxygen monitor be installed and proper room ventilation be provided 3 Due to LN s high expansion rate 700 parts GN to 1 part LN the possibility of a pressure burst exists If LN2 is trapped in a pipe between two closed va
6. The maximum temperature of the dosing head heater is 150 F The purpose of the dosing head heater is to prevent any frost or ice formation at the vent area It is critical that no frost or ice be allowed to build up at the vent area If ice develops it has the potential of entering the injector reservoir and causing a malfunction CryotechFlex Hose A vacuum insulated hose that provides a connection between the injector unit and the LN supply Inlet Filter A 10 micron stainless steel inlet filter is provided with each unit The filter is located inside the male bayonet on the CryotechFlex hose connection point Mounting Bracket Assembly Each UltraDoser is supplied with a mounting bracket assembly The assembly consists of the bracket attaching to the UltraDoser and two clamps These clamps are designed to fit on 1 1 2 stainless steel rod The bracket can be mounted in 3 positions Longest reach position the clamps are opposite the arm straight back and both sides perpendicular to the arm Dosing Head Pressure Gauge This gauge measures the pressure of the liquid nitrogen source Note that the source pressure should be between 10 22 psi i e dewar fed If the source pressure drops below 10 psi the source has most likely been depleted and should be replaced If the source pressure is greater than 22 psi IMMEDIATELY STOP THE FILLING OPERATION by shutting off the source valve i e the valve on the dewar The pressure of the sourc
7. actual production line Pressing the Dose Duration button will bring up the numeric keypad Figure 16 If the desired results cannot be obtained by changing the dose duration the injection system nozzle can be changed to allow either more or less flow Dispense setup Unts English Sensor to nozzle in 4 200 Container CL to CL in 4400 Continuous dose speed CPM Pulses per container Dispense duration mS 1883 System Delay mS Line speed CPM b D H DETECT LCI 400 time delay mS 20 Main Recipes kean LCI 2000 Press button to activate keypad Value can be changed using keypad L_ File UliraDoser with AB1500 controller Page 32 of 46 Document 15905 040207 Continuous Dosing Speed This is the speed in CPM the injection system changes from discrete dosing to continuous dosing Continuous dosing is a mode where the dosing valve is always open unless there are no containers present Pressing the System Delay button will bring up the numeric keypad Figure 16 Dispense setup Units English Sensor to nozzle mi 4200 Container CL to CL in 4400 Continuous dose speed CPM 1300 Pulses per container Dispense duration mS 28 1883 System Delay mS bad Line speed CPM 10 2 DETECT LCI 400 time delay mS 20 Recipe Main Recipes Inactive LCI 2000 Press button to activate keypad Value can be changed using keypad Enabling the System The Syste
8. containers following dose AI L File UliraDoser with AB1500 controller Page 3 of 46 Document 415905 040207 Unpacking the Injector The injector will arrive in a specially designed shipping crate If it is planned to have a mobile injector system or if the unit is being leased the shipping crate should be stored for future use It is important that the crate be inspected before unpacking the injector All exterior parts of the crate should be free from dents and or other damage If shipping damage is noted it should be reported to the carrier immediately While unpacking the crate all contents should be inspected All pieces should be free from dents and or other damage If there is a discrepancy between the packing list and the contents in the shipping crate contact Cryotech immediately at 408 371 3303 Injector Unpacking Checklist 1 Injector reservoir arm unit with bracket 2 Controller 3 Speed sensor and speed sensor extension cable 4 Container sensor 5 12 Extension for distribution cable 6 Two 2 12 Polyurethane tubes labeled as tube 03 and tube 04 7 Two spare compression fittings 8 10 CryotechFlex hose for portable systems 9 Three dosing nozzles one installed two additional and one nozzle installation tool 10 Stainless steel support stand and other accessories if ordered File UliraDoser with AB1500 controller Page 4 of 46 Document 15905 040207 Warr
9. information After each has been entered the Enter Jl button must be pressed to acknowledge the user and or password Figure 7 Login Screen Figure 8 Alpha Numeric Keypad When first initiating the system it important to change administrative password The default user password is Administrative access All functionality and screens User ADMIN Password ADMIN It is important to keep a log of passwords to ensure continued access to the system If it is lost it cannot be restored without downloading a new program IMPORTANT CRYOTECH has established an administrative password This password will be used by CRYOTECH personnel if an inadvertent erasure of other passwords occurs L File UliraDoser with AB1500 controller Page 20 of 46 Document 15905 040207 System Setup Screen Accessible only when logged on modify these settings System setup Calibrate pressures liquid level Set by Cryotech Personnel before the system leaves the factory There should be no need to 25899 Liquid level Supply ae ET Current raw value 43003 Current raw value am aa 6395 Dee 75 0 25 PSI 50 97 25 0 5PSI 0 a 23 PSI 26265 The System Setup button on the main screen is the f Dispense setup Sensor to nozzle in Container CL to CL in Continuous dose speed CPM Pulses per container Dispense duration mS 1883 System Delay mS Line speed CPM
10. power is being made available to the vent heater Dosing Head Heater Cable Connection D 2 Labeled D 2 on the distribution block this connector provides 24VDC power to the dosing head heater A green light on the cable connector indicates that power is being made available to the dosing head heater Timing Container Sensor Cable Connection D 3 Labeled D 3 on the distribution block this connector provides 24VDC power to the timing container sensor and indicates sensor activity A green light on the cable connector indicates that power is being supplied to the sensor A yellow light will appear whenever a container and or a container pulse is detected Solenoid Valve Cable Connection D 4 Labeled D 4 on the distribution block this connector provides 24VDC power to the solenoid valve assembly A green light on the cable connector indicates that power is being supplied to the solenoid valve A yellow light will appear whenever the solenoid valve has been activated Confirm Sensor Cable Connection D 5 Labeled D 5 on the distribution block this connector provides 24VDC power to the confirm sensor assembly A green light on the cable connector indicates that power is being supplied to the confirm sensor A yellow light will appear whenever the pneumatic cylinder has lifted the valve stem A similar yellow indicator will also be illuminated on the sensor body This light mirrors the yellow light activity on the cable and confirms the liftin
11. to detect points gear tooth or the like If necessary replace sensor 6 Check the speed sensor is operating correctly and is sending a signal to the controller 7 All appears ok but the unit still does not dose 8 Is an encoder being used If not is the sensor override button on Set to on Condition The dosing valve fault error is displayed Possible Causes Actions 1 The dosing valve assembly is not moving 1 Check the pneumatic pressure There must be at least 60 PSI to have the dosing valve function correctly Condition The speed sensor fault error is displayed Possible Causes Actions 1 The speed sensor has been dislodged moved or has shifted out of position 1 Check speed sensor connections Readjust 2 The speed sensor has malfunctioned 2 Replace speed sensor L_ File UliraDoser with AB1500 controller Page 42 of 46 Document 15905 040207 CONTACTING CRYOTECH FOR SERVICE SECTION XI If you are experiencing a malfunction with the unit and cannot isolate the problem Cryotech technicians are available to provide phone support NOTE BEFORE CALLING CRYOTECH PLEASE ENSURE THE FOLLOWING QUESTIONS HAVE BEEN ANSWERED CRYOTECH PERSONNELCAN BETTER ASSIST WITH TROUBLE SHOOTING YOUR SYSTEM IF THESE QUESTIONS HAVE BEEN ANSWERED Question 1 What is the pressure reading of the LN supply 2 What is the LN level reading a 4 What color light if any is illuminat
12. value is set at the factory and does not normally require adjustment To determines if the correct value is set into the controller operate the production line at a rate of 100 CPM or less and verify the dose is entering the bottle just inside the leading edge of the opening The factory value may have to be changed up or down depending on several parameters including the gas pressure and the distance between the top of the container and the dosing nozzle If values less than 20ms or greater than 40ms are required to adjust the dose correctly there may be an error with either the Pulses per Container value or one of the two distance measurements made during setup Pressing the System Delay button will bring up the numeric keypad Figure 16 Dispense setup Units English Sensor to nozzle in 4 200 Container CL to CL in 4400 Continuous dose speed CPM Pulses per container Dispense duration mS 4883 System Delay mS Line speed CPM DETECT LCI 400 time delay mS Recipe inactive UC 2p00 oe Main Recipes Press button to activate keypad Value can be changed using keypad d Dose Duration This is the time in milliseconds the dosing valve is open Normal settings range from 15 to 40 ms on a production line that is running approximately 600 containers per minute The proper duration for each line and product depends on many different factors and can only be determined on the
13. 32 W x 22 H 2286 mm x 813mm x 559 mm 225 lbs with stand 102 kg 140 Ibs without stand 64 kg Utility Requirements Electrical Supply 100 240 VAC Input 150VA MAX 50 60HZ Liquid Nitrogen Maximum 22 psig for portable system 100 psig for plant Source system with phase separator Maximum flow rate 15 gallons per hour Gaseous Nitrogen or 60 to 100 psi 4 1 to 6 9 bar CDA 10 SCFH gas per 100 containers per minute L File UliraDoser with AB1500 controller Page 6 of 46 Document 15905 040207 Note Bracket can be mounted at 90 intervals around the central axis of the injection body m 1224 em pam E File UltraD th AB1500 7 Fig 1 UltraDoser injector body Page 7 of 46 Document 15905 040207 SYSTEM COMPONENTS SECTION lll LN Reservoir The stainless steel vacuum insulated reservoir provides a ready supply of LN2 for dosing operations Distribution Block This electrical connection block houses the connectors and wiring interface between the operating parts of the Injector unit and the controller There are five Eurofast connections on this distribution block labeled D1 D5 as described below The distribution block connects to the control box via a 36 cable assembly Vent Heater Cable Connection D 1 Labeled D 1 on the distribution block this connector provides 24VDC power to the vent heater A green light on the cable connector indicates that
14. L_ File UliraDoser with AB1500 controller Page 14 of 46 Document 415905 040207 Wire color refers to the conductors of the shielded communication cable Programming the encoder The DC25F S1FPRGMCS is a programmable device allowing the user to set the number of pulses per encoder revolution For more specific information instructions log on to the AMC website at http Awww amci com documents asp VALVE HEAD ASSEMBLY SECTION VI Electro pneumatic Actuated Valve The Injector may be provided with either a standard valve assembly or an Electro pneumatic actuated dosing valve assembly The valve is driven by a pneumatic cylinder Gas pressure to the cylinder is controlled by a 24 volt solenoid valve L_ File UliraDoser with AB1500 controller Page 15 of 46 Document 15905 040207 CONTROLLER SECTION VII The electrical control box controller is used to provide electrical power for the system take input signals from sensors and provide output signals to the injector to activate the dosing valve The Cryotech Model 2830 Injection Controller is a Rockwell based system utilizing a ML1500 PLC Power Supply and HMI Touch Screen manufactured by Rockwell Corporation The controller PLC has been wired to support PNP type sensors The Controller incorporates speed compensation enabling customers to vary line speeds and still maintain accurate bottle can dosing while in discrete dose mode Components Fi
15. T gt 260 CABLE ASSEMBLY CSUPPLIED W UNIT DOSING UNIT FILLER nn 3 CUSTOMER C 2779 12mm ULTRASONIC OR BRACKET y 336 12mm ULTRASONIC TIMING CONTAINER SENSOR 2329 SENSOR CABLE 12 0 THREE SENSOR lt SUPPLIED W UNIT gt 329 SENSOR CABLE lt 12 0 lt CUSTOMER OPTION DOSING UNIT 260 CABLE ASSEMBLY SUPPLIED W UNIT gt 2807 12mm INDUCTIVE PROXIMITY lt TIMING SENSOR CUSTOMER OPTION gt 2807 12mm INDUCTIVE PROXIMITY SPEED SENSOR SUPPLIED W UNIT gt FILLER 2329 SENSOR CABLE 12 0 2202 SENSOR CABLE lt 6 0 gt CUSTOMER OPTION 2779 l2mm ULTRASONIC SENSOR BRACKET y 336 12mm ULTRASONIC CONTAINER PRESENT SENSOR 2058 ENCODER CABLE lt 20 0 CUSTOMER OPTION 329 SENSOR CABLE 12 0 gt CUSTOMER OPTION DOSING UNIT 2054 ENCODER SPEED SENSOR CUSTOMER OPTION gt 260 CABLE ASSEMBLY lt SUPPLIED W UNIT gt 2807 12mm INDUCTIVE PROXIMITY TIMING SENSOR SUPPLIED W UNIT gt FILLER MAY USE 2329 SENSOR CABLE 12 0 IF NEEDED lt SUPPLIED W UNIT gt Y CUSTOMER OPTION 2779 12mm ULTRASONIC SENSOR BRACKET y 336 12mm ULTRASONIC CONTAINER PRESENT SENSOR L_ File UliraDoser with AB1500 controller Page 45 of 46 Document 415905 040207 Appendix B Wiring Diagram AB1500 CONTROLLER WIRING DIAGRAM ee A E VAG VAC VAC KH V u e us COM VOCO WDC1 WDC2 03 nr rn mew Serial Cable SE
16. activate keypad that allows this value to be changed L_ File UliraDoser with AB1500 controller Page 29 of 46 Document 15905 040207 CONTAINER CENTERLINE TO CONTAINER CENTERLINE DISTANCE MEASURED ON CONTAINER TRAVEL ARC Enter measured value by pressing Container CL to CL button A numeric keypad will pop up Figure 16 Enter value and press Enter Figure 16 Numeric Keypad L File UliraDoser with AB1500 controller Page 30 of 46 Document 15905 040207 Timing Sensor The timing sensor synchronizes the dose and the container It is important that the correct value be entered into the controller This parameter is determined by determining the distance from the center of the dose to the edge of the container opening when the timing sensor initially detects the bottle or capper clock signal Dispense setup Unts English Sensor to nozzle in 4200 Container CL to CL in 4400 Continuous dose speed CPM 1300 Pulses per container Dispense duration mS 20 System Delay ms 40 Main Recipes active TO CENTER OF STAR WHEEL S CENTERLINE OF DOSING HEAD ON LCI INJECTOR _ E Figure 17 Sensor to Nozzle Measurement Enter measured value by pressing Sensor to nozzle button A numeric keypad will pop up Figure 16 L_ File UliraDoser with AB1500 controller Page 31 of 46 Document 15905 040207 System Delay This
17. alve to liquid allowed to warm up over a minimum malfunction of 24 hours with a continuous purge of warm nitrogen gas at 5 25 psig introduced at the vent opening The supply connection must be open to allow the gas to flow freely through the entire system Condition Liquid is being dispensed out of the dosing head even though the main valve is shut close Possible Causes Actions 1 The LN supply pressure is too high 1 Reduce the supply pressure 2 The valve seat is contaminated ice or 2 Drain LN remove valve clean valve particles seat 3 Air supply to the solenoid is reversed 3 Reverse the LN lines that supply and vent to the solenoid L_ File UliraDoser with AB1500 controller Page 41 of 46 Document 15905 040207 Condition No liquid is being dispensed from the dosing head Possible Causes Actions 1 There is insufficient liquid inside the Injector unit 2 The system is in disable mode 4 The nozzle is frozen shut 5 The container sensor is not detecting a container 6 The speed sensor is not functioning 1 Check the level of LN If the level is empty or low open the supply valve 2a Pull out dose disable switch 2b Proceed to System Functions screen and press enable to enter enable mode 4a Remove clean and reinstall the nozzle Note A purge may be necessary to remove a frozen nozzle 5 Check sensor connections Ensure the sensor is correctly positioned
18. anty Cryotech International Cryotech International warrants that each of its products will be free from defects in material and workmanship in the normal service for which the product was manufactured for a period of one year from the date of shipment to the original purchaser The following products carry an additional two years of warranty StatiFlex and DynaFlex vacuum insulated piping To make a claim under this warranty the purchaser must 1 give Cryotech written notice within ten 10 days after the discovery of a claimed defect 2 immediately discontinue the use of the product and 3 return such product freight prepaid to the location specified by Cryotech for evaluation to validate the warranty claim If the claimed defect is confirmed by Cryotech s inspection Cryotech will at its option and as the purchaser s sole remedy repair or replace such product or any component part thereof or refund the original purchase price This warranty is voided by alterations or by repairs of others Cryotech shall not be liable under this warranty or otherwise for defects or accidents caused by the purchaser s negligence abuse misuse or modifications to the product or for failures due to corrosion fire heat or the effects of normal wear Proper installation by the purchaser of normal maintenance parts supplied by Cryotech shall not constitute modifications to the product Any related components or other equipment manufactured by others which may
19. as just been drained 6 Once the procedure is complete replace the tubes to the Bimba and remove the cap from the vent 7 Install the drain plug into the injector body 8 Turn on the LN supply N gt Maintenance Preventative Cryotech recommends the following preventive maintenance schedule 1 Filter Cleaning Cryotech recommends that the filter be cleaned only as necessary Note that the filter must be thoroughly dried with GN before it is re installed L_ File UliraDoser with AB1500 controller Page 40 of 46 Document 15905 040207 TROUBLE SHOOTING SECTION X The Injector has many built in trouble shooting features The following describes some trouble shooting tips Condition The safety relief valve is going off venting Actions o Possible Causes 1 The pressure of the LN supply is 1 Check the pressure of the LN supply If greater than 50 psi the supply pressure is greater than 50 psi reduce the supply pressure Note A dewar can be vented to reduce the pressure 2 The vent is obstructed 2 Check the Injector vent If the vent is obstructed clear the obstruction If the vent is obstructed with ice contact Cryotech Condition Liquid is being dispensed out of the vent Possible Causes 1 The LN supply pressure is too high 1 Lower supply pressure to 22 psig or lower 2 Ice has developed inside the unit 2 Entire Injector unit must be drained of causing the internal float v
20. be sold with Cryotech products are not covered by this warranty but would carry any applicable original equipment manufacturer s warranty This warranty is in lieu of any other warranties express or implied including any implied warranty of merchantability or fitness for a particular purpose The remedies set forth herein are exclusive Cryotech shall not be liable for any consequential special or incidental damages resulting from the delivery use or failure of the product or from any other cause whatsoever By accepting delivery of the product sold hereunder the purchaser acknowledges that this limitation of remedies is reasonable and enforceable In no event shall Cryotech s liability exceed the value of the product sold L_ File UliraDoser with AB1500 controller Page 5 of 46 Document 15905 040207 SPECIFICATIONS SECTION II Product Specifications Dimensions Reservoir height 29 737 mm Hexagonal 6 152 mm Arm reach 12 805 mm Dosing Head 2 0 51 mm wide x 9 229 mm high Total Weight UltraDoser Injector 32 pounds 14 5 kg w electronics Controller 22 5 pounds 10 2 kg Dosing Range Minimum 0 5 grams second Maximum 12 grams second Dosing Accuracy 5 of dose value Timing Range Effective Minimum 15 milliseconds Maximum 1000 milliseconds Control Voltage 24 VDC Materials Stainless steel construction Built to food and beverage industry standards Crate Dimensions 90 L x
21. d factory setup Service count R tc t 000 095 621 a Save Defaults Restore Defaults Main Administrative i Figure 13 Maintenance screen IMPORTANT This screen is used on initialization by CRYOTECH Personnel Modification of values using this screen could disrupt dosing Do not use unless properly trained by CRYOTECH Personnel The Restore Defaults button loads the values set by the factory into the minimum and maximum values for the liquid level and supply pressure The current values will be replaced Alarm Screen Indicates alarm conditions that should be examined but may not necessarily require immediate attention Date A 3 41 55 PM 2 12 2007 ABCDE FGHIJK LMNOPQ RS Ack All Close Figure14 Alarm Screen L File UliraDoser with AB1500 controller Page 25 of 46 Document 15905 040207 Note Alarm conditions do not stop nitrogen dosing An alarm is denoted in the light tower by a flashing red light and is also indicated in the alarm screen figure 14 Example A flashing red light is noted When calling up the alarm screen the fault is indicated as a liquid level low The system continues to run and dosing well but the light continues to flash red After a couple of minutes the light changes back to green indicating all is well and the liquid level low fault disappears from the alarms screen The system was just alerting the user of a low level before the feed system began
22. e default is highlighted Press the UP and DOWN buttons to highlight the desired recipe Press ENTER button to select the desired recipe Press the DOWNLOAD button to load into the PLC program A pop up window will appear and advise the user that the recipe to be downloaded is different than the current recipe e Press YES to continue with the download process IMPORTANT A recipe is not available to be used by the controller until it has been downloaded to the PLC After the recipe has been saved it can then be downloaded with the download button Viewing the Current Recipe e From the Dispense Setup Screen press the RECIPE button e When the recipe screen appears the default is highlighted e Press the VIEW button to open the recipe graph ressing the CLOSE button Recipe graph The recipe graph can be closed b RT 100 200 300 400 500 600 700 800 900 ala ola o o o o alo 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 Close Figure 20 Recipe Graph Page 37 of 46 Document 1590 5 040207 1 2 1 2 DAILY OPERATION PROCEDURES SECTION VIII System Start Up If the system is Dewar fed open the liquid valve on the Dewar Wait until the injector reservoir is filled with liquid nitrogen approximately 10 minutes When the injector is filling it will vent heavily and there will be a steady stream of fog steam from the vent Once the injector is filled the
23. e must be 22psi before the fill operation can occur Filling at a pressure higher than 22psi can damage the equipment and or cause liquid nitrogen to spill from the injector vent Controller The injector controller is a state of the art device incorporating a programmable logic controller PLC providing precise timing and distribution of control signals to the Cryotech injector L_ File UliraDoser with AB1500 controller Page 10 of 46 Document 15905 040207 SYSTEM INSTALLATION SECTION IV Application Evaluation The Cryotech injection system is used for both inerting and pressurization applications The application must be evaluated to determine the ideal location of the dosing head on the filling line Inerting Inerting is the process of displacing oxygen air within a container to increase product shelf life To inert a container a relatively large dose of LN gt is introduced into the container The dose evaporates displacing air and oxygen from the container The container is then sealed so that minimal oxygen air is allowed to re enter the container The ideal location must allow for enough time between dosing and capping sealing so that the liquid dose may have time to be converted into a gas Pressurization Pressurization is the process of introducing liquid nitrogen into a container sealing the container and allowing the liquid nitrogen to warm and change into its gas form while the container is capped Seal
24. ed on the 5 1 Vent heater connectors on the distribution box 2 Dosing head heater 3 Sensor 4 Valve 5 Valve confirm shunt 5 Wave an object in front of the container timing 5a Y N sensor a Does the sensor cable connector flash yellow 5b Y N b Does the valve sensor flash yellow 7 What if any error messages are displayed on the main screen of the Injector controller a Red 8 What color is the indicator light on top of the b Green Injector controller c Yellow 9 What was the last item changed on the Injector system 10 When was the liquid nitrogen supply last changed SERVICE PARTS SECTION XIV Name Description Cryotech Part Number Comments Transducer 0 5PSI 2208 Liquid Level Transducer 0 25 PSI 2209 Supply Pressure L_ File UliraDoser with AB1500 controller Page 43 of 46 Document 15905 040207 REPLACEMENT PARTS SECTION XV 102 104 103 362 363 106 141 275 140 ETA 108 109 211 105 315 Me A AA Distribution Block with 36 Cable 207 209 210 143 146 Switch Shaft 2820 09 2820 08 410 2820 05 1201 2806 2805 1200 Miscellaneous 123 119 135 103 L_ File UliraDoser with AB1500 controller Page 44 of 46 Document 15905 040207 Appendix A Sensor Positioning TWO SENSOR 2329 SENSOR CABLE 12 D SUPPLIED W UNIT gt 2807 12mm INDUCTIVE PROXIMITY SPEED SENSOR CSUPPLIED W UNI
25. ero supply pressure and liquid level Press Save as Min for both supply pressure and Liquid level Also note the 0 25 PSI and 0 5 PSI buttons These buttons correspond to the type of LN2 delivery system being used If operating from a Dewar the scale 0 25 PSI is to be used Pressing this button will change the bar graph accordingly The 0 5 PSI will do likewise if the delivery system is a phase separator The introduction of LN2 into the system will cause the raw values for liquid level and supply pressure to rise When the system has stabilized indicating full levels the Save as Max buttons are pressed setting both the maximum liquid levels and supply pressure and will be shown in the appropriate graphs The numbers corresponding to PSI and of liquid level will be shown in the fields adjacent to the graphs The minimum and maximum values can be set manually by pressing the min or max values and manually entering the new value L File UliraDoser with AB1500 controller Page 27 of 46 Document 15905 040207 System Mode The controller has two modes of automatic operation LCI 2000 and LCI 400 The LCI 2000 mode is a speed compensated mode that calculates where the bottle is for all line soeeds and adjusts the dose delay accordingly The LCI 400 mode has a fixed delay where a container is detected and controller always waits a fixed number of milliseconds before it doses This mode should only be used for ver
26. g of the valve stem Bayonet Connection This bayonet connection allows the CryotechFlex hose to connect to the injector unit Bayonets are vacuum insulated and provide a warm frost free connection File UliraDoser with AB1500 controller Page 8 of 46 Document 15905 040207 Dosing Head The dosing head is the injector component that delivers the dose of LN Dosing Valve Assembly The dosing valve assembly consists of a solenoid an air cylinder and a stem This assembly allows a dose of liquid nitrogen be made available in specific quantities as dictated by the operator Valve Confirm Assembly The valve confirm assembly is attached to the pneumatic cylinder The assembly consists of an electromagnetic sensor and related cabling The sensor confirms that the valve stem was lifted thereby providing a dose of LN Dosing Head Heater The injector unit has a self regulating dosing head heater The maximum temperature of the dosing head heater is 150 F The purpose of the dosing head heater is to prevent any frost or ice formation at the dosing head area The dosing head heater has a built in splashguard to minimize the dosing nozzle s exposure to splashed product The dosing head heater is filled with gaseous nitrogen from the built in gaseous nitrogen purge Hence gaseous nitrogen is always flowing out of the dosing head heater This positive pressure greatly minimizes the chance of moisture in the ambient at
27. gure 3 Controller front view Light Tower The indicator light provides a visual display of the operating status of the controller Green Unit is in normal operation Solid Amber Unit is in disable mode Flashing Amber Unit is in Quick Service mode Flashing Red Unit is indicating a fault condition but still operational See Alarms for additional information Eile UliraDoser with AB150C controller Page 16 of 46 Document 415905 040207 Start Up Procedure Step 1 Remove the yellow power cable from its shipping packaging and connect to the ac input connector located on the bottom of the controller Connect the I O cable from the distribution block of the injector to the I O connector on the bottom of the controller Step 2 Turn unit on Controller Screens Upon power up the controller will go through a self check which will result in the solenoid activating for 5 pulses The controller will then complete the boot up sequence and display the Main screen Main Screen Default screen The system will display the Main screen as the default screen From this screen the operator can navigate to other screens and functions Wg CRYOTECH Software tr PLE PA TERNATIONAL version 4 00 4 00 1 4 2007 12 01 02 PM LCI2000 Recipe Inactive Administrati Line Speed CPM 1200 delas Dose duration ms 20 System Dispense i Setup Setup High System Funct
28. he 11 2 stand post are available from Cryotech International L_ File UltraDoser with AB1500 controller Page 11 of 46 Document 15905 040207 Controller Cable Connection Port J 2 The controller I O input output cable a component of the distribution block is connected to the controller at port J 2 For remote locations of the Controller extension cables of 12 and 25 feet are available Refer to spare parts list Speed Sensor Connector J 5 If the controller has an option for speed compensation it will require a sensor when operating in Speed Compensated mode The sensor provides the controller with pulses that are used to calculate the line speed This sensor is only required when the unit is in Speed Compensated mode Sensors must be PNP for Siemens The injector uses a 30 mm inductive proximity sensor to detect the speed of the line The speed sensor should be connected to the controller at J 5 Aux connector J 7 Customers have the option of purchasing a Container Detect Sensor When used with a 3 sensor system distribution block output D 3 is used solely for the timing sensor The container detect function is now transferred to this input and is strictly for the container detect This input is also NPN PNP specific The correct sensor must be used Pressure Tap Outlets There are two pressure taps on the UltraDoser One pressure tap allows the controller to monitor the supply pressure The other pressure
29. ing the container while the liquid expands Causes an increase in pressure within the container To pressurize a container a relatively small dose of LN2 is introduced into the container immediately before the container is capped or sealed Space Availability Once the ideal dosing location has been determined the operator must confirm that there is sufficient space to install the dosing head A 2 x 9 area is needed for the dosing head Support Stand Location 1 The injector can be installed on either side of a production line Select the side that best suits the workplace The injector can be mounted in the mounting bracket such that the 112 round stand bracket is located on either side perpendicular to the arm or straight back opposite to the arm A distance of 18 2 is measured directly back from the dosing location This is the installation location of the stand If the injector arm is more or less perpendicular to the container travel the fine distance adjustment can be made by turning the Injection left or right on the stand The location of the stand is then marked and four 4 5 8 bolts are installed in the proper locations Mounting the Injector Unit Once the stand is installed the injector unit can then be mounted on the stand using the factory supplied equipment clamps Installing the Injector Controller The controller should be mounted at a convenient location Optional brackets to mount the controller on t
30. ions Hormal Maintenance Alarms Low Liquid Supply level pressure Figure 4 Main Screen Main Screen Buttons Administrative Provides access to administrative screen to log on and configure terminal System Setup Takes user to SET UP screen used to calibrate pressure and liquid levels NOTE This button is only seen if there is an administrator logged into the system Dispense Setup Takes user to screen used to input parameters for dosing including nozzle to dosing head distance container centerline to centerline distance continuous dose speed and pulses per container NOTE This button is only seen if there is an administrator logged into the system System Functions Screen provides controls to enable disable dosing activate self test quick service and auto manual modes Alarms Screen shows alarm conditions L_ File UliraDoser with AB1500 controller Page 17 of 46 Document 15905 040207 e Maintenance Used on initial calibration to save the system fill pressure and liquid level parameters and retrieve them should the need arise to go back to initial parameters NOTE This button is only seen if there is an administrator logged into the system Screen Graphs e The Main screen is provided with two graphs to provide a status of the system liquid level and supply pressure The levels are set in the System Set Up screen Levels that are too low or too high generate a
31. is using recipes The recipe method allows the storage of unique dose durations for every 100CPM in line speed This feature can be used if the line runs products that require different amounts of nitrogen The controller can store multiple recipes for different size containers or product lines Figure 18 shows the recipe screen with a dose duration of 40ms Dose durations for all speed ranges can either be equal or vary with each speed range Dose durations are set by the user by pressing to the right of the speed range Recipes are stored in the Stored Recipe Display area Open refresh NN eae N NN Download Save Save As Figure 18 Recipe Screen Close L File UliraDoser with AB1500 controller Page 34 of 46 Document 15905 040207 Creating a recipe The following steps are required to create a recipe From the Dispense Setup Screen press the RECIPE button Dispense setup Unts English Sensor to nozzle in 4 200 Container CL to CL in 4 400 Continuous dose speed CPM 1300 Pulses per container Dispense duration mS 20 System Delay mS MON Line speed CPM 10 DETECT LCI 400 time delay mS 20 Main Recipes Recipe 112000 Inactive Press button to access recipe screen When the recipe screen appears the default is highlighted Press the OPEN REFRESH button DEFAULT A opens PP ES Se 2 CPM 40 300 399 CPM_ 40 40D BOE IZ
32. lves or in a sealed vessel then the LN inside will expand and build up pressure This expansion may result in a rupture of the pipe or vessel To prevent this a pressure relief valve must be installed wherever there is a potential to trap liquid Principles of LN Dosing To ensure consistent dosing results an accurate dose must be delivered to each container AND each container must be processed in the same manner Injection systems from Cryotech International guarantee that a precise accurate dose of LN is delivered The injection series meets the following fundamental dosing conditions Pure Liquid at the Dosing Head Pure liquid i e liquid with no gas pockets must be instantaneously available at the dosing head Cryotech has a unique internal design that ensures the continual availability of pure liquid at the dosing head Constant Pressure Constant pressure at the dosing head is critical requirement for reproducible dose size The unit has a float valve that is monitored by the controller During operation the pressure at the dosing head remains constant Dose Duration The dose duration is tightly controlled by the unit s electronics Dose duration is measured in milliseconds The following production conditions must be controlled to ensure consistent dosing results Fill levels must be consistent Fill temperatures must be consistent Capping techniques must be consistent Product may not be spilled or splashed out of
33. m is enable from the System Function Screen The enable button allows the system to operate when containers are detected The Disable button prevents the system from dosing Upon powering the system up the unit automatically defaults into Disabled mode The user must press the Enable button and the unit must indicate a change from Disabled to Enabled Actual dosing starts once line has been started System Functions Self test Activate Quick service reng Sestao ococtwatea Dispense Open valve Override Main OFF Press to Enable System L_ File UliraDoser with AB1500 controller Page 33 of 46 Document 15905 040207 Recipes The two buttons at the bottom of the Dispense Setup Screen activate the recipes and allow the user to create the recipes Most applications do not require Recipes The Recipe Inactive wording should be visible for most operating conditions Dispense setup Units English Sensor to nozzle in 4200 Container CL to CL in 4 400 Continuous dose speed CPM 1300 E Pulses per container Dispense duration mS 1883 System Delay mS Line speed CPM DETECT LCI 400 time delay mS Recipe Inactive LCI 2000 Main Recipes Pressing Button will toggle recipes on and off When the injector is in the LCI 2000 mode there are two methods of operation Normal operation is without recipes A second method of operation
34. mosphere from contaminating the dosing head The dosing head heater assembly is held in place by a set of O rings If needed the heater assembly can be removed by twisting the heater off of the dosing head Dosing Nozzle s The injector system utilizes nozzles to deliver specific quantities of LN2 The size of the dosing nozzle directly impacts the amount of LN dosed Each unit is supplied with a 0 040 ID installed and spares of 0 050 ID and a 0 060 ID nozzle Additional sizes custom may be ordered from Cryotech The maximum dosing orifice is 0 125 ID GN Purge Pathway Internal to the injector unit is a gaseous nitrogen purge pathway This pathway allows a small amount of liquid nitrogen to exit the reservoir area Once in the purge pathway the liquid warms and turns into a gas This gas is used for the dosing head purge Drain Plug A drain plug is located on the GN purge pathway When removed this drain allows the LN to drain from the Injector reservoir SRV The safety relief valve SRV is set to 50 psi It protects the hose against over pressurization If the pressure inside the unit is 50 psi or greater the safety relief valve will vent excess pressure Under normal operating conditions the SRV should not vent File UltraDoser with AB1500 controller Page 9 of 46 Document 15905 040207 Vent Heater Each injector unit has a self regulating 26 watt maximum dosing vent heater
35. n alarm and a flashing red light Display items e Line Speed Shows the speed of the production line Dose Duration Display Amount of time dosing valve is open milliseconds e LCI 2000 LCI 400 There are two modes of operation The LCI 2000 mode is the speed compensated mode The LCI 400 mode is not speed compensated e Recipe Inactive Recipe Active Shows if a Recipe is active or inactive Does not appear when in LCI 400 mode e Software Versions PLC and HMI Administrative Screen Provides access to special functions Administrative Log on Currently logged on ADMIN Log off Password Configure terminal Set time Main Figure 5 Administrative screen Administrative Screen Buttons Log On Brings up log on screen Enter User Name and Password Log Off Logs user off Only visible after logon Password Allows logged on user to change its password Only visible after logon Main Takes user to the main screen Configure Terminal Allows access to terminal for a variety of functions such as touch screen calibration and file management File UliraDoser with AB1500 controller Page 18 of 46 Document 15905 040207 e Set Time Communicates with the PLC to set the correct date and time Date Time is set at the CRYOTECH factory and should not require modification However if necessary to change the date or time see
36. nter to container detection is approximately 3 4 the distance between containers For example If the centerline distance between two containers is 4 7 in 120mm then the timing sensor is approximately 3 5 in from the center of the dosing head The sensor used must be a PNP type sensor for the Siemens based system The injector is commonly supplied with a 12mm ultrasonic sensor When D 3 is used solely as a timing sensor it is positioned away from the containers on a remote gear typically that provides 1to1 pulses per container The gear is moved until the sensor detects the gear At this point the measurement of container to dosing head must be made as accurately as possible L_ File UliraDoser with AB1500 controller Page 13 of 46 Document 15905 040207 ACCESSORIES SECTION V Mounting Bracket Assembly Each injector unit is supplied with a mounting bracket assembly The assembly consists of the bracket attaching to the injector with two clamps These clamps are designed to fit on 1 1 2 stainless steel rod The bracket can be mounted in 3 positions Longest reach position the clamps are opposite the arm straight back and both sides perpendicular to the arm Positioning the Dosing Head The dosing head must be directly over the container opening The dosing head is installed so that is approximately 1 2 3 4 above the container opening It may however be installed up to 3 above the container opening If
37. oller will calculate Pulses per Container by pressing the DETECT button on the Dispense Setup screen Always check to see that the Line Speed indicator is reading the actual line speed This can be done by counting the number of containers that are processed in one minute and comparing the count to the value displayed on the screen It is critical that the Pulses per Container be detected Dispense setup Units English Sensor to nozzle in 4 200 Container CLto CL in 4400 Continuous dose speed CPM 1300 Dispense duration mS 20 System Delay mS Line speed CPM 10 DETECT LCI 400 time delay mS 20 Pulses per container 1883 Recipe Inactive Main Recipes LCI 2000 Press to calculate the Pulses per Container function Synchronizing the Dose with the Container Container to Container Distance The distance from one container to the next container must be accurately measured This distance should be measured at the centerline of the containers Multiple measurements should be made on different bottles to verify this distance Dispense setup units English Sensor to nozzle in 4 200 Container CL to CL in 4400 f 3 Continuous dose speed CPM 1300 gt a Pulses per container Dispense duration mS i 28 4883 System Delay mS U 40 Line speed CPM 10 DETECT LCI 400 time delay mS 20 Main Recipes Recipe Lo 2000 Inactive Press to
38. only be used for very slow lines 100 CPM or less or when the encoder speed sensor fails Normal operation will be in the LCI 2000 mode System Functions Screen The System Functions screen serves as the location for activation of the system once all the parameters have been set Buttons are shown in figure 12 and describes as follows System Functions System Disabled Self test Deactivated Quick service Deactivated Dispense Bottle Sensor Override Override OFF Closed Figure 12 System Functions Screen L_ File UliraDoser with AB1500 controller Page 23 of 46 Document 15905 040207 System Function Buttons System The enable button allows the system to operate when containers are detected The Disable button prevents the system from dosing Upon powering the system up the unit automatically defaults into Disabled mode The user must press the Enable button and the unit must indicate a change from Disabled to Enabled Actual dosing starts once line has been started Self Test Used to test the firing of the dosing solenoid Pressing self test activates the solenoid for 5 pulses Self Test can only be activated when the unit is in Disabled mode Quick Service The quick service button engages a solenoid which routes gaseous nitrogen GN2 through the body to the dosing head This is typically used for purging the system to ensure a clean pathway fo
39. providing more LN2 The following faults will trigger an alarm condition Speed sensor fault Dose valve fault Dose valve stuck open Supply Pressure high Supply Pressure low Liquid level high Liquid level empty Dose Disable depressed L_ File UliraDoser with AB1500 controller Page 26 of 46 Document 15905 040207 Controller Set Up amp Operation The following is set by Cryotech Personnel before the system leaves the factory There should be no need to modify these settings This information is included for reference or if the system has been taken down for maintenance and has been non operational for an extended period of time The System Setup button on the main screen is the first step prior to incorporating LN2 into the system System Setup sets the default values for the liquid level and supply pressure of the injection system and allows for calibration of each The PLC has been programmed to input a raw number a calculated number based upon the initial readings of the liquid level and supply pressure transducers located within the control box see figure 2 An example of these raw numbers is shown System setup Calibrate pressures liquid level Liquid level Supply ee Current raw value 13003 Current raw value 25899 8071 13411 6395 26265 mE IC 0 25 PSI 50 97 23 PSI 25 0 5 PSI 0 L With no LN2 in either the LCI or in the supply line the raw values depict the z
40. r liquid to flow If a system has been left off for some time or exposed to air moisture may have accumulated which could result in ice formation causing a blockage in the system Purging by sending gaseous nitrogen will dry out the system Dispense The dispense function allows the user to manually open and hold open the dosing valve when the unit is in the disabled mode The valve is opened by pressing and holding the Open Valve button The button may be held indefinitely holding open the dosing head valve or pulsed by pressing and releasing the button Bottle Sensor Override The bottle sensor Override button allows the system to run even when there is no bottle sensor present The Override must be activated if either the bottle sensor is malfunctioning or the timing sensor is being used for both timing and container present Pushing button will toggle Override When operating in a three sensor mode speed encoder timing container present the override button should indicate Override OFF If the system is configured in the two sensor mode speed encoder container the override button should indicate Override ON L_ File UliraDoser with AB1500 controller Page 24 of 46 Document 15905 040207 Maintenance and Factory Setup Screen Used on initial calibration to save the system fill pressure and liquid level parameters and retrieve them should the need arise to go back to initial parameters Maintenance an
41. r the controller indicates that the supply pressure is low Note The Injector will continue to dose properly until the liquid level inside the LN gt reservoir runs low This feature gives the operator a reasonable window in which to change out the Dewar without disrupting the production operation To change out the Dewar 1 Close the liquid valve on the Dewar 2 Disconnect the hose from the Dewar using a 5 8 wrench 3 Ifa full Dewar is available immediately connect the Cryotech Flex hose to the liquid outlet on the full Dewar 4 Ifa full Dewar is not readily available plug the 1 2 JIC end of the CryotechFlex hose so that moisture is not introduced into the Injector L_ File UliraDoser with AB1500 controller Page 39 of 46 Document 15905 040207 Purging with Gaseous Nitrogen Procedure General Purging is the introduction of warm gaseous nitrogen into the system Any moisture in the system will form ice when subjected to liquid nitrogen temperatures Warm nitrogen gas serves to defrost the system melt the ice and force out moisture As part of routine maintenance or if necessary due to a frozen injector a purge should be performed The injector must only be purged with gaseous nitrogen Warming the nitrogen gas will accelerate the purging process The optimum nitrogen pressure is dependent upon the application time and equipment available In general a low approx 5psi pressure feed overnight is desi
42. rable If time is of the essence a 40 50psi feed could be used For specific recommendations contact Cryotech Service Cryotech recommends that after installation and prior to startup the injector should be purged to eliminate any moisture that may be inside the unit The injector may also require purging when there is liquid nitrogen flowing out the vent or when the nozzle becomes frozen shut These two conditions require the injector be purged using the following procedure Remove or disable the LN source Drain the injection unit via drain on the bottom of the body Introduce warm GN into the fill hose to the top of the injector Allow GN to flow into the injector until ambient gas is being vented out the vent This may take several hours if the injector has just been drained 4 To purge the dosing head nozzle area ensure the gas used to open the solenoid valve is off Plug the vent opening so the GN is diverted to the dosing head Remove and reverse the tubes to the solenoid valve In other words switch the bottom to the top and the top to the bottom Doing so will actuate the Bimba actuator keeping it open once the gas is turned back on Turn on the gas to the solenoid valve Open the GN dewar valve so gas is running through the injector and to the dosing heater area 5 Continue to run OGN to the dosing head until ambient gas is being vented out the dosing head nozzle area Again this may take several hours if the injector h
43. re will be only a wisp of fog coming from the vent If the injector overfills and liquid nitrogen starts dripping out the vent close the liquid valve on the dewar and call Cryotech service Do not operate the unit Ensure the DOSE DISABLE switch on the controller is illuminated pushed in This will prevent the injector from dosing until the operator is ready Turn the controller ON by rotating the Off On switch mechanism to the On position The front panel will show the DISPLAY screen if the controller is functioning correctly Adjust the dosing parameters See Set Up Section of this manual for details Ensure the DOSE DISABLE switch on the controller is not illuminated pulled out This will allow the unit to begin dosing System Shut Down Place the DOSE DISABLE switch on the controller in the illuminated pushed in position This will stop the machine from dosing nitrogen If the system is Dewar fed shut the liquid valve on the Dewar If the hose is disconnected from the Dewar the hose termination must be capped to prevent moisture intrusion Rotate the Off On switch to the Off position if the injector will be shut down for over 8 hours or if work will be done on the injector If the injector is being shut down for a short time less than 8 hours it is not necessary to turn the unit off It is desirable to have the heaters on during short production breaks to minimize freeze up of the dosing head or ven
44. t area L_ File UliraDoser with AB1500 controller Page 38 of 46 Document 15905 040207 MAINTENANCE SECTION IX Maintenance Routine Nozzle Change Procedure To change a nozzle 1 If using a standard nozzle the system is comes complete with a nozzle tool 4 mm hex nut driver Insert the nozzle removal tool into the nozzle area until the tool connects with the nozzle The optional SoftDose nozzles require different removal tools A hex head socket set will work in this application CAUTION The dosing head heater is still in operation Do not expose skin to prolonged contact with the dosing head heater 2 Remove the nozzle by rotating the driver in a counter clock wise direction Note If the nozzle does not loosen easily drain the Injector and warm up nozzle with a low power heat gun Do not expose the nozzle area to direct heat for extended periods of time as internal seals may be adversely affected 3 Once the nozzle is removed place the new nozzle or cleaned nozzle into the hex driver and insert in the Injector Nozzle Cleaning Procedure 1 Remove the nozzle from the Injector 2 Clean the nozzle opening with a very thin wire and blow dry air through it 3 Thoroughly dry the nozzle with dry nitrogen gas before re installing the nozzle NOTE Any moisture left on the nozzle will immediately freeze up when the nozzle is re installed Dewar Change Out Procedure The Dewar should be changed out wheneve
45. tap allows the controller to monitor the dosing head pressure Blanked off Ports The controller has a two blanked off ports for future expansion Speed Sensor Quick Service Connection Connection Bottle Detect d ed Sensor Level E Supply 207 Distribution 7 ac Input Figure 2 Controller Connections L File UliraDoser with AB1500 controller Page 12 of 46 Document 15905 040207 Utility Connections Electric An electrical power cord 6 feet long is supplied with each unit The power cord is to the connected to the bottom of the Injector controller at connection point J 1 The injector will operate with a voltage potential between 100 240VAC 50 60Hz Liquid Nitrogen The Cryotech Flex hose is to be connected to the inlet of the injector The CryotechFlex hose male bayonet is provided with a 1 4 FPT on the tip A 10 micron filter is to be inserted into this FPT fitting The 1 2 JIC end of the CryotechFlex hose is then to be connected to the 1 2 male flare fitting on the low pressure 22psi LN2 dewar Gaseous Nitrogen A source of gaseous nitrogen must then be connected to the injector The pressure must be a minimum of 60 PSI and the volume is approximately 10 SCFH per 100 containers per minute Installing the Timing Sensor When input D 3 is used as a combination timing container sensor the sensor must be positioned to perform both functions The optimal distance from the dosing head ce
46. te Pulses per Container by pressing the DETECT button on the Dispense Setup screen e Sensor to nozzle Enter measured value by pressing Sensor to nozzle button A numeric keypad will pop up Figure 11 Enter value and press Enter Figure 11 Numeric Keypad e Container CL to CL The distance from one container to the next container must be accurately measured This distance should be measured at the centerline of the containers Multiple measurements should be made on different bottles to verify this distance Enter measured value by pressing Container CL to CL button A numeric keypad will pop up Figure 11 e System Delay This value is set at the factory and does not normally require adjustment To determines if the correct value is set into the controller operate the production line at a rate of 100 CPM or less and verify the dose is entering the bottle just inside the leading edge of the opening The factory value may have to be changed up or down depending on several parameters including the gas pressure L File UliraDoser with AB1500 controller Page 22 of 46 Document 15905 040207 and the distance between the top of the container and the dosing nozzle If values less than 20ms or greater than 40ms are required to adjust the dose correctly there may be an error with either the Pulses per Container value or one of the two distance measurements made during setup Pressing the S
47. the instructions below Set Date Time The panel gets its clock from the timer located within the PLC The PLC must first be told to keep time based upon an input from the panel Once complete the clock information is fed back to the panel and is maintained correctly within the PLC To set the correct date and time 1 Press the Set Time button This brings up the date time screen in Figure 6 Time Set display date M D Current D I 04 2007 New 01 142007 Write to PLC Set display time h m S Administrative 12 46 50 PM Main Figure 6 Initial date time screen 2 Press any of the time or date fields This action will bring up a keypad allowing for the insertion of time and date information 3 Once the correct date and time have been inserted press Write to PLC The system will now keep the correct date and time A delay of up to one minute may be experienced before the newly inserted date and time appear in the corresponding fields This is normal L_ File UliraDoser with AB1500 controller Page 19 of 46 Document 415905 040207 Access and Passwords The controller has been programmed with a user hierarchy When accessing certain screens buttons or fields a user will be required to log on and provide a password Figure 7 illustrates the log on screen Pressing the field area User provides the user with a alpha numeric keypad Figure 8 to enter the log on
48. there is a possibility of the product splashing out of the containers it is suggested to mount the dosing head at the maximum distance CryotechFlex Hose A vacuum insulated hose that provides a connection between the Injector unit and the LN supply Inlet Filter A 10 micron stainless steel inlet filter is provided with each unit The filter is located inside the male bayonet on the Cryotech Flex hose connection joint Encoder Information An encoder may be used with the injection system in lieu of a speed sensor An encoder provides additional pulses per container The additional pulses allow for greater speed resolution allowing the injection unit to dose more effectively specifically at higher line speeds The encoder is typically located on a known gear or star wheel matching the speed of the production line The following connection information is for an AMCI encoder p n DC25F S1FPRGMCS The mating connector is p n MS 16 Note Only one channel is used to provide necessary pulses for the injector system For correct encoder functionality shielded cabling must be used Type CM Communications Cable is a suitable option The encoder case should be grounded either thru its mounting bracket or separate ground wire Encoder Cable Connections Encoder Function Wire color Controller Pin No Pin No A CH A Output Green or Blue 4 D DC Output Red F DC Return Black 3 G Case Ground Shield Wire N C
49. y slow lines 100 CPM or less or when the encoder speed sensor fails Normal operation will be in the LCI 2000 mode Dispense setup Unts English Sensor to nozzle in 4200 Container CL to CL in 4 400 Continuous dose speed CPM 1300 Pulses per container Dispense duration mS 20 1883 System Delay mS 40 Line speed CPM 10 DETECT LCI 400 time delay mS 20 i Recipe Main Recipes tnective Lal 2000 Press to toggle LCI400 LCI2000 modes Units The button in the upper right hand corner of the screen displays the unit of measurement that the controller uses to calculate correct dose location in speed compensated mode lfthe distance measurements made for the Sensor to Nozzle and Container CL to CL are in inches then this button should read English If the distances are measured in mm then this button should read Metric Dispense setup Unts English Sensor to nozzle mi 4200 Container CL to CL in 4 400 Continuous dose speed CPM 1300 ises per container Dispense duration mS 20 4303 System Delay mi 40 Line speed CPM 10 DETECT LCI 400 time delay E 20 Main Recipes Recipe Lo 2900 Inactive Press to toggle Units L_ File UliraDoser with AB1500 controller Page 28 of 46 Document 15905 040207 Pulses per Container The controller will not accurately dose bottles if the Pulses per Container value is incorrect The contr
50. ystem Delay button will bring up the numeric keypad Figure 11 e Dose Duration This is the time in milliseconds the dosing valve is open Normal settings range from 15 to 40 ms on a production line that is running approximately 600 containers per minute The proper duration for each line and product depends on many different factors and can only be determined on the actual production line Pressing the Dose Duration button will bring up the numeric keypad Figure 11 e Continuous Dosing Speed This is the speed in CPM the injection system changes from discrete dosing to continuous dosing Continuous dosing is a mode where the dosing valve is always open unless there are no containers present Pressing the Continuous Dosing Speed button will bring up the numeric keypad Figure 11 e Recipe Buttons The two buttons at the bottom of the Dispense Setup Screen activate the recipes and allow the user to create the recipes Most applications do not require Recipes The Recipe Inactive wording should be visible for most operating conditions e System Mode The controller has two modes of automatic operation LCI 2000 and LCI 400 The LCI 2000 mode is a speed compensated mode that calculates where the bottle is for all line speeds and adjusts the dose delay accordingly The LCI 400 mode has a fixed delay where a container is detected and controller always waits a fixed number of milliseconds before it doses This mode should

UltraDoser Injector System with AB1500 Controller

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