50 GPM Operation and Service Manual
Contents
1. La TOUCH EL i Key Labels DANG ER MEANING IF THE DANGER IS NOT AVOIDED IT WILL CAUSE DEATH OR SERIOUS INJURY MEANING IF PREVENTIVE MEASURE IS NOT TAKEN SERIOUS INJURY OR DEATH MAY OCCUR MEANING IF THE PRECAUTION IS NOT TAKEN MINOR OR MODERATE INJURY MAY OCCUR FULL FACE SHIELD CRYOGENIC THERMAL GLOVES CRYOGENIC SMOCK SOLID SHOES THAT WITHSTAND CRYOGENIC LIQUIDS 4 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Introduction Thank you for allowing JC Carter LLC to be a part of your business JC Carter offers many different products for LNG Come visit us on the web at http www jccarternozzles com For the safety of yourself and other people read this manual before using the products Notice the WARNING labels and observe recommended safety guidelines of this manual and or other authorities You should understand the requirements and agree to the safety guidelines of using the product Keep this manual as a reference guide This user manual explains how to install use and troubleshoot the LNG Nozzles This manual contains essential information regarding safety proper fueling and maintenance repa2. RNC EN 39 Cause eiiitedemt 39 IVE DRE PUR ri P 41 2 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter MODELS 50E701 1 2 3 REV H LNG FUELING OPERATOR MUST BE FULLY TRAINED IN THE SAFE OPERATION OF THIS PRODUCT IN ACCORDANCE WITH REGULATIONS DETERMINED BY AUTHORITIES HAVING JURISDICTION AND ALL SERVICE WORK MUST BE CARRIED OUT BY TRAINED TECHNICIANS IN ACCORDANCE WITH REGULATIONS DETERMINED BY AUTHORITIES HAVING JURISDICTION JC CARTER LLC PROVIDES THIS DATA AS A GUIDELINE ONLY COMPLIANCE WITH REGULATIONS AND REQUIREMENTS IS THE RESPONSIBILITY OF THOSE PERFORMING THE WORK DESCRIBED HEREIN READ THE LNG NOZZLE OPERATION AND SERVICE WA R G MANUAL FOLLOW ALL WARNING AND SAFETY INSTRUCTIONS FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY 3 JC Carter Cleveland 44143 e Costa Mesa 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N 1340 JC Carter i ing ir
3. a 20 CON OCIS ntur 20 Spring Energized Seal 1 5 21 Poppet Seal Disc Installation Replacement a r 23 F r Models 50E701 amp 1u u u 23 mala on p 0412 iu aus na 24 omite S SU o 28 e e 001210 PRETI 29 TROUBLESHOOTING REFERENCE GUIDE 53 229 02 23 09 50 Tuala 32 yejblc 33 Handles WiIll NOUE BaBe mmm 33 1 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter Nozze Wil NotEngapewith RECEPTI O nu E 33 CE EUD 34 Handles Will Not Disengage From The Receptacle rr 34 MING VSS TETTE 34 Flow Chart for Nozzle Leakage Problem Resolution 35 Ji U so PER remm 36 POPE SCO 489 37 COT C 38 D Poppet SPECIAL CASE OF LEAKAGE iie peti
4. Do operate nozzle if any leakage occurs THE OPERATOR MUST WEAR THE PROTECTIVE CLOTHING OUTLINED WA R N N IN THE WARNINGS AND FOLLOW THE SAFETY INSTRUCTIONS OF THIS MANUAL FAILURE TO DO SO MAY RESULT IN INJURY NEVER POINT THE NOZZLE DIRECTLY AT YOURSELF OR OTHERS AT ANY TIME 8 Cleveland 44143 Costa Mesa 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter PLE Rd ire ram n ee Leader LC lit Mazrle TECTA REV H Overview The quick disconnect single line nozzle is intended for use in NO VENT top fill LNG fuel systems A key feature of this nozzle is the independent shut off valve located in the flow path within the nozzle The operator mates the nozzle 50E701 to the receptacle by pushing it over the receptacle with handles pulled all the way back See Stage 1 By pushing two handles forward locking of the nozzle to the receptacle and opening of the internal valves is achieved See Stage 2 and fueling can be started When fueling is complete the operator returns the handles back to vent position See Stage 3 and waits to complete venting of the residual LNG Then the nozzle can be unlocked and de mated by pulling two handles all the way back See S
5. 12 JC Carter Cleveland 44143 e Costa Mesa CA 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter Global Leader in Cryogenic Mazzle Technology REV H MAINTENANCE SERVICE 13 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED Carter MANUAL P N 1340 REV H Please note that JC Carter recommends the following maintenance schedule be followed to ensure trouble free operation and maximum life Failure to follow the schedule may result in less than optimal performance or reduced operating life Daily Nozzle Maintenance At the start of each fueling day Check to be sure no pressure is present in the nozzle e Clean out the mating end of the nozzle with dry clean compressed air or nitrogen Each Fueling Before and after each fueling e Clean out the cup of the receptacle with dry clean compressed air or nitrogen e Clean out the mating end of the nozzle Suggested Maintenance Seals Seals will eventually become inoperative due to wear climate dust humidity and operational conditions The environm
6. e Insure good quality of LNG supply 38 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 J6 Carter Global Leader in Cryogenic Morrie Technology D Poppet SPECIAL CASE OF LEAKAGE REV H Sometimes leakage can occur due to the poppet not closing off LNG supply Visual appearance of the escaping LNG could range from a mist to full exposure of gases this depends on the rate of pressure and the position of the poppet NOTE THIS TYPE OF LEAK 15 NOT DUE TO FAULTY SEALS SEAL REPLACEMENT WILL NOT RECTIFY THE PROBLEM AND IS NOT REQUIRED Cause Of Malfunction Over time ice and other contaminants from the LNG system can accumulate in these areas As the result of connection and refueling water can condense around the poppet and the poppet then freezes in place when fueling LNG AREAS OF ICE AND CONTAMINANT ACCUMULATION 39 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED JC Carter MANUAL P N 1340 REV H Preventive Actions e LNG system shoul
7. for sealing at low pressure at high pressure the system pressure augments the spring force to provide an even tighter seal iis Possible Causes Of Reduction In Seal Performance e Contaminants the LNG system not removed during installation Water condensation inside of the system which forms into ice crystals and when flow is passing over the seal scratches and abrades the sealing edge e Solid contaminants brought from LNG supply bulk delivery Quality of LNG Preventive Actions To Increase Seal Life Do not leave connecting lines and nozzle open to atmosphere when removed from dispenser e Periodic maintenance of the nozzle e Ensure good quality of LNG supply Seal Replacement JC Carter recommends the poppet seal disc should be replaced when leakage is noted Due to different climate dust humidity and operational conditions the life of the poppet seal disc will vary For disassembly and reassembly of the seal disc for 50E701 amp 1 see page 23 and 50E701 2 amp 3 see page 28 16 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Norrie Technology INSTALLATION SERVICE REPAIRS 17 JC Carter Cleveland OH 44143 Costa Mesa C
8. 01340 JC Carter REV H Global Leader in Cryogenic Norrie Technology e Place Boss Seal inside threaded port with widest part of the seal at the top NOTE Seal must be handled with care to avoid damaging the seal coating e Use appropriate wrenches to tighten the adaptor e Tighten the adaptor to the nozzle between 100 and 120 ft lb NOTE Do not over tighten IF OVER TIGHTENING HAPPENS BETWEEN THE ADAPTOR AND NOZZLE POSSIBLE GALLING CAN OCCUR WHICH MAY REQUIRE SHROUD REPLACEMENT JC CARTER IS NOT LIABLE FOR DAMAGE THAT MAY OCCUR AS A RESULT OF FAILURE TO FOLLOW INSTRUCTIONS INTENDED FOR THIS ASSEMBLY JC CARTER LLC IS NOT RESPONSIBLE FOR DUE NEGLIGENCE OF THIS ACTION OR ANY OTHER ACTION RESULTING AND OR PERTAINING TO ASSEMBLY PRODUCT S WARRANTY MAY BE NULL AND VOID SEE WARRANTY FOR MORE DETAIL e Pressure test connection with nitrogen at 250 PSI after nozzle is connected to the hose Do not put nozzle into service if any connections are found to be leaking 19 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED Carter MANUAL P N C01340 REV H Global Leader in Cryogenic Mazzle Technology Nozzle With Installation Kit B91546 3 Installation Components Installation Of Noz
9. 27 JC Carter Cleveland 44143 e Costa Mesa 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Leader in Cryogenic Nozzle Technology For Models 50E701 2 amp 3 P N 212535 Seal Disc P N 212536 o Body P N 93239 o Socket Head Cap Screw P N NAS1351C3 10 o Flat Washer P N AN960 C10L Anti seize Compound Swagelok Silver P N 93222 Another viable option if seal disc needs to be replaced is a new poppet assembly P N 93243 Tools Required o Adjustable Torque Screwdriver o 1 4 Square drive 5 32 hex size 4 7 16 long o Retaining Ring Pliers Note Use of functionally equivalent tools is permissible 28 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter Global Leader in Cryogenic Mazzle Technology REV H Installation Replacement e Remove Union See Nozzle Hose installation Pg 18 e Locate retaining ring P N B78698 125 e With Retaining Ring Pliers carefully remove Internal Retaining Ring NOTE E
10. 373 1 e Turn nozzle upside down With your finger push the poppet assembly down e Poppet Assembly P N 212538 is removed e f Phillips screw is installed as shown use Phillips screwdriver to remove it Otherwise use 5 32 hex Allen wrench 25 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Norrie Technology e Put the Flat Washer P N AN960 C10L on the screw P N NAS1351C3 8 insert it into the Poppet Body P N 212537 hole and install the Seal Disc P N 212536 e Apply Anti seize compound as shown Set the Torque Screwdriver to 42 in lb per manufacturer instructions 26 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Norrie Technology e Hold the Poppet Assembly in a bench vise and torque the screw to 42 in Ib P e Clean off excess Anti Seize Compound from the Poppet Assembly and reinstall back into the nozzle
11. A 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter Global Leader in Cryogenic Norrie Technology Nozzle Installation REV H OPEN NOZZLE PACKAGE ONLY IN A DRY PROTECTED AREA DO NOT ALLOW WATER OR OTHER CONTAMINANTS TO ENTER THE INTERNAL MECHANISM OF THE COUPLING Nozzle With Installation Kit B91546 1 Installation Components e Stainless Steel Adapter Union P N C01578 016 e Boss Seal P N B91668 016 T 001 e PTFE O Ring alternate to Boss Seal P N 93238 916 Anti seize compound Swagelok Silver Goop P N 93222 e Two wrenches are required to tighten the union a 1 5 8 and 1 3 4 wrench to hold the nozzle Installation Of Nozzle Hose Union Do not use pipe sealant or Teflon tape e Install union to nozzle before connecting to the hose e Place nozzle on flat surface with connection end facing upward e Apply anti seize compound on the inner threads of the nozzle Be sure there is no anti seize compound on the sealing surface 18 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C
12. Compound from the Poppet Assembly and reinstall in the nozzle 3 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 USA www jccarternozzles com MANUAL P N C01340 REV H THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Norrie Technology TROUBLESHOOTING REFERENCE GUIDE 32 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Follow all safety requirements when operating the nozzle LNG supply needs to be properly filtered and instructions for proper storage of the nozzle must be followed Do not leave nozzle on the ground Following these steps will help ensure water will not collect inside the nozzle and then refreeze forming ice crystals and causing the poppet to lock up SYMPTOM No LNG e Make sure supply of LNG is turned on Make sure nozzle is connected to receptacle and engaged e Check with station or facility Handles Will Not Engage e Make sure nozzle is seated on receptacle e Make sure no objects are in between nozzle and receptacle when en
13. E SLIDE NOZZLE ONTO RECEPTACLE n DO NOT FORCE NOZZLE ONTO RECEPTACLE When the nozzle is located on the receptacle push handles toward the vehicle to complete the connection and start flow PUSH HANDLES PUSH HAND m LES i RECEPTACLE TOWARD RECEPTACLE 11 Cleveland 44143 e Costa Mesa 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N 1340 JC Carter REV H Global Leader in Cryogenic Nozzle Technology e When fueling cycle is completed slowly pull the nozzle handles towards the operator until vent position is reached Do not move handles past vent position until venting from the nozzle receptacle interface is completed W A R N IF VENTING CONTINUES RECONNECT THE NOZZLE AND REPORT INCIDENT ALLOW TRAPPED GASES TO VENT COMPLETELY PULL HANDLES UNTIL THE PLATE STOPS AT RETAINING RING 29 e When venting is completed pull handles fully towards the operator to remove the nozzle from receptacle COMPLETEN TOREMOVENOIE PULL HANDLES BACK cy y ci COMPLETELY TO REMOVE NOZZLE After removal clean nozzle and receptacle surfaces with compressed air e Replace nozzle in the nozzle holder e Replace the receptacle protective cap
14. JC CARTER LLC 50 GPM LNG NOZZLE OPERATION AND SERVICE MANUAL MODELS 50E701 1 2 3 MANUAL P N C01340 JC Carter Table of Contents Kev Pabels uuu unn u unun uuu uama u u CI maa s s 4 lili Ci i u u uuu u uu kausai asas 5 JC Carter Model 50E701 Nozzle Features amp Specifications 6 OPERATING INSIRUCIIDNS uuu luu 7 sj PISCIS 8 VO UIO M 9 F PO cro LE RN 10 MAINTENANCE SERVICE 13 Daily Nozzle iiis DB e uuu u EDO 14 sed Fe 14 Suggested IV ait A Br u u uu A 14 0 14 Safe I LCN To C 15 POPPEL T mU A 16 INSTALLATION SERVICE REPAIRS XX PAR NES ER VORPFSKRS Ea TR RSEN CES IN FUE UV ERE RN DE EE SU DE 17 Lil pu 18 Nozzle With Installation Kit B91546 1 18 Nozzle With Installation Kit B91546 3
15. LE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Flow Chart for Nozzle Leakage Problem Resolution Coupled Is the nozzle leaking while Y ized coupled or uncoupled in ue Shroud Seal Uncoupled Is the leakage a constant Ops Replace disk seal in stream or a few drops per U Poppet Assembly minute Constant Stream Poppet stuck Need new JCC nozzle technology 35 JC Carter Cleveland 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Norrie Technology A Energized Seal WHEN THE SPRING ENERGIZED SEAL IS WORN OR DAMAGED THE LEAKAGE CAN BE DETECTED ONLY WHEN NOZZLE IS COUPLED TO THE RECEPTACLE AND PRESSURIZED Signs Of Leakage e Forceful streams of gas are escaping around the end of the nozzle near the receptacle e LNG is dripping around front part of the nozzle Possible Causes Of Reduction In Seal Performance ice buildup in the spring coils e Abrasive dirt deposits on the sealing surfaces e Ice buildup on the sealing surfaces e Sharp edges on the receptacle vent holes can damage sealing surface Preventive Actions To Increase Seal Life e Clean seal before and after
16. XERCISE CAUTION INTERNAL PARTS ARE SPRING LOADED e Remove Tube Spacer P N B84399 1 e Remove Spring Seat P N B84383 1 29 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Leader in Cryogenic Nozzle Technology e Remove Compression Spring P N B84373 1 e Turn nozzle upside down With your finger push the poppet assembly down e Poppet Assembly P N 93243 is removed e Hold nosepiece in bench vise and use 5 32 hex Allen wrench to remove screw 30 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED JC Carter Global Leader in Cryogenic Nozzle Technology e Put the Flat Washer P N AN960 C10L on the Screw P N NAS1351C3 10 insert it into the Poppet Body P N 93239 hole and install the Seal Disc P N 212536 e Apply Anti seize compound as shown Set the Torque Screwdriver to 42 in lb per manufacturer instructions e Install the Poppet Assembly in the bench vise and torque the screw to 42 in lb e Clean off excess Anti Seize
17. d be free of any contaminants debris or water e During maintenance keep cold equipment isolated from ambient air e When this type of event happens remove the nozzle from the dispenser and clean and dry the internals of the nozzle 40 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED Carter MANUAL P N C01340 REV H NEED REPAIR Contact your local authorized repair service center for e Service amp Maintenance e Warranty service e Purchasing products parts and accessories e Product information To find an Authorized JC Carter Parts and Repair Service Center please visit us at WWW JCCARTERNOZZLES COM 4 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED
18. ent and operating conditions will determine the safe service life of the seals Periodic inspections and following practices described in this manual may prolong service life of the seal It is recommended by JC Carter to change seals when leakage is noted per instructions outlined in this manual 14 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter Global Leader an Cryogenic Mazzle Technology REV H Sealing surface against nozzle shroud Seal Maintenance Spring Energized Seal P N B78705 6 Overview When the seal is seated in the gland the spring is under compression LNG system pressure ealing surface against receptacle inlet applying force on the gland sealing surfaces creating a tight barrier to prevent gas or fluids from leaking The spring also provides resiliency to compensate for seal wear gland misalignment or eccentricity While spring force provides adequate force for sealing at low pressure at high pressure the system pressure augments the spring force to provide an even tighter seal Possible Causes Of Reduction In Seal Performance ice buildup in the spring coils e Abrasive dirt deposits on the sealing surfaces Ice buildup on the sealing surface
19. every use with dry compressed air or nitrogen Do insert nozzle into receptacle if ice accumulation is noted on internal receptacle surface or on the nozzle outlet area Defrost ice with dry compressed air or nitrogen If heated dry compressed air is available it will reduce the defrosting time e Check inlet of the receptacle before engaging the nozzle If dirt is noted wipe it clean with a soft lint free cloth 36 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter Leader in Cryogenic Nozzle Technology B Poppet Seal Disc REV H ee moss Shroud sealing surface 1 1 M b L LNG system a pressure ETE AREA TO LOOK FOR SIGNS OF LEAKAGE Poppet Seal Disc WHEN THE POPPET SEAL DISC IS WORN OR DAMAGED THE LEAKAGE CAN BE DETECTED ONLY WHEN NOZZLE IS DECOUPLED FROM THE RECEPTACLE AND PRESSURIZED Signs Of Leakage e Forceful streams of gas are escaping around the poppet nosepiece Small amount of liquid gas spraying out of the nozzle outlet Possible Causes Of Reduction In Seal Performance Contaminants in the LNG system not removed during installation Water condensation inside of the LNG system
20. gaging e Unit may have been damaged DO NOT USE Contact station distributor facility Nozzle Will Not Engage with Receptacle e Make sure nozzle is seated on receptacle e Make sure no objects are in between nozzle and receptacle when engaging e Unit may have been damaged DO NOT USE Contact station distributor facility DO NOT FORCE NOZZLE ONTO RECEPTACLE 33 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED JC Carter MANUAL P N 1340 Ice Buildup This can happen when refueling the unique design of the JC Carter nozzle accounts for this e May need to engage and disengage the nozzle handles a few times if ice buildup is heavy e Remove ice buildup with dry air Handles Will Not Disengage From The Receptacle STOP TURN OFF THE SUPPLY TO THE LNG e See ice buildup e Unit might have been damaged DO NOT USE Contact station distributor facility LNG Is Leaking STOP TURN OFF THE SUPPLY TO THE LNG Energized Seal Pg 36 Poppet Seal Disc Pg 37 Union Connection Pg 38 Poppet Pg 39 34 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHO
21. ir with a troubleshooting help guide included 5 Cleveland OH 44143 Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED JC Carter MANUAL P N C01340 REV H JC Carter Model 50 7 01 Nozzle Features amp Specifications FEATURES e Safe secure positive shut off preventing unintended discharge before during and after delivery Self cleaning diametric sealing prevents liquid leakage while fueling e Unique ICE BREAKER feature allows removal of nozzle from the receptacle under most weather conditions e Durable design protects against damage in the field e Unique design offers industry leading flow rates with minimal pressure drop e Minimal discharge upon disconnection e Designed to be compliant with ISO 16924 and ISO 12617 e Compliant with ASME B31 3 SPECIFICATION e Fluid compatibility e Nominal flow e Max Working Pressure e Burst pressure Cv e Spillage on de mating e Leakage during fueling e Operating temperature e Storage temperature e Dimensions Length Width including operating handles Weight Process connection with adapter 6 LNG LN2 Methane 50 GPM at 15 PSI differential 500 PSI 3 48 MPa 2000 PSI 13 79 MPa 9 less than 1cc N
22. one 320 F to 185 F 195 56 C to 85 C 60 F to 120 F 51 1 C to 48 89 C 14 74 370 84 mm 6 167 64 mm 12 165 5 44 kg 1 JIC 37 Flare fitting CAUTION FAILURE TO ADHERE TO THE SPECIFICATION MAY RESULT IN INJURY JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Morrie Technology OPERATING INSTRUCTIONS 7 JC Carter Cleveland 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED JC Carter MANUAL P N C01340 REV H Safety Precautions e Always wear protective clothing as required by authorities having jurisdiction FULL FACE SHIELD CRYOGENIC SMOCK CRYOGENIC THERMAL GLOVES SOLID SHOES THAT WITHSTAND CRYOGENIC LIQUIDS e Follow all regulations as specified by authorities having jurisdiction Read the Operation Service Manual completely before operating e Keep area of operation clear of all persons other than operator Use this nozzle only as described in this manual Do not operate nozzle if it is damaged
23. ound Swagelok Silver P N 93222 Another viable option if seal disc needs to be replaced is a new poppet assembly P N 212538 with sleeve poppet P N B91415 1 Tools Required o Adjustable Torque Screwdriver o 1 4 Square drive 5 32 hex size 4 7 16 long o Retaining Ring Pliers Note Use of functionally equivalent tools is permissible 23 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter Global Leader in Cryogenic Mazzle Technology Installation Replacement REV H e Remove Union See Nozzle Hose installation Pg 18 e Locate Internal Retaining Ring P N B78698 125 e With Retaining Ring Pliers carefully remove retaining ring NOTE EXERCISE CAUTION INTERNAL PARTS ARE SPRING LOADED e Remove Tube Spacer P N B84399 1 e Remove Spring Seat P N B84383 1 24 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Leader in Cryogenic Nozzle Technology e Remove Compression Spring P N B84
24. p e Remove Retaining ring B91877SS 112 using Retaining Ring Pliers e Remove Brass Seal Retainer B84398 1 21 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter iia ini manani Werre DG DES MI Late HI arzne ECN ur REV H e Remove used Spring Energized Seal B78705 6 e Carefully install new Spring Energized Seal B78705 6 Note Pay attention to direction of seal opening it must be face up see picture e Reverse order to reassemble 22 JC Carter Cleveland OH 44143 Costa Mesa CA 92627 USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter Global Leader in Cryogenic Nozzle Technology REV H Poppet Seal Disc Installation Replacement When disassembling and reassembling the seal disc the following components are required For Models 50E701 amp 1 P N 212535 Seal Disc P N 212536 o Body P N 212537 o Sleeve Poppet P N B91415 1 o Socket Head Cap Screw P N NAS1351C3 8 o Flat Washer P N AN960 C10L o Anti seize Comp
25. s e Sharp edges on the vent holes in the receptacle can damage sealing surface Preventive Actions To Increase Seal Life e Clean seal before and after every use with dry compressed air or nitrogen Do insert nozzle into receptacle if ice accumulation is present on internal receptacle surfaces or on the nozzle outlet area Defrost ice with dry compressed air or nitrogen If heated dry compressed air is accessible it will reduce the defrosting time e Check inlet of the receptacle before engaging the nozzle If dirt is noted wipe it clean with a soft lint free cloth Seal Replacement P N B78705 6 JC Carter recommends the spring energized seal should be replaced when leakage is noted Due to different climate dust humidity and operational conditions the life of the spring energized seal will vary 15 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Leader in Cryogenic Nozzle Technology Poppet Seal Disc P N 212536 Overview The shroud sealing the surface is finished to provide a RA tight leak free seal when edge of the disc seal is compressed by means of the spring and the system pressure While spring force provides adequate force LNG system pressure
26. tage 1 STAGE 1 CONNECTED READY TO FILL STAGE 2 STAGE 3 IMPORTANT SAFETY STOP JC Carter Cleveland OH 44143 Costa Mesa CA 92627 USA WWW jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter CL hai d gardar ir freeman Di Leger AT L TH Jm un REV H Fueling Procedure FAILURE TO CLEAN NOZZLE AND RECEPTACLE PRIOR TO OR AFTER FUELING IS HAZARDOUS e Connect grounding cable to vehicle e Remove receptacle protective cap Thoroughly clean nozzle and receptacle connections with compressed air Ensure that no dirt or ice is visible on either the nozzle or receptacle CLEAN WITH DRY AIR 10 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Norrie Technology e With nozzle handles completely retracted toward the operator allowing the locking latches to open slide the nozzle onto the receptacle until housing is squarely stopped by the receptacle flange SLIDE NOZZLE ONTO RECEPTACLE SLID
27. which forms into ice crystals and when flow passes over the seal thereby scratching and abrading the sealing edge e Solid contaminants within the LNG bulk delivery supply Quality of LNG Preventive Actions To Increase Seal Life leave connecting lines and nozzle orifices open to atmosphere when removed e Periodic maintenance and cleaning of the nozzle e Insure good quality of LNG supply 37 Cleveland 44143 e Costa Mesa 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Mazzle Technology C Union Connection BOSS SEAL Signs Of Leakage e Forceful streams of gas are escaping around the union connection e Small amount of liquid gas is spraying out of the nozzle connection and or hose connection Possible Causes Of The Union Connection Failure Wrong connection size for union and hose e Abrasive dirt deposits on the sealing surfaces e Ice buildup on the sealing surfaces e Seals are damaged e Connection of union to nozzle may be loose or seated incorrectly e Connection of hose to union may be loose or seated incorrectly Preventive Actions use pipe sealant or Teflon tape e Periodic maintenance and inspection of the union
28. zle Hose Union Do not use pipe sealant or Teflon tape Brass Adapter Union P N 93242 016 Boss Seal P N B91668 016 T 001 PTFE O Ring Alternate to Boss Seal P N 93238 916 Two wrenches are required to tighten the union a 1 5 8 and 1 3 4 wrench to hold the nozzle Install union to nozzle before connecting to the hose Place nozzle on flat surface with connection end facing upward Use appropriate wrenches to tighten the adaptor Tighten the adaptor to the nozzle between 100 and 120 ft lb NOTE Do not over tighten Pressure test connection with nitrogen at 250 PSI after nozzle is connected to the hose Do not put nozzle into service if any connections are found to be leaking 20 JC Carter Cleveland OH 44143 e Costa Mesa CA 92627 e USA www jccarternozzles com THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF JC CARTER LLC ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION OF JC CARTER LLC IS PROHIBITED MANUAL P N C01340 JC Carter REV H Global Leader in Cryogenic Nozze Technology Spring Energized Seal Installation Replacement Installation Components e Kit Seal Replacement P N B91548 1 content o Seal Spring Energized P N B78705 6 o Retainer Seal P N B84398 1 o Ring Retainer P N 93223 112 e Tools required o Retaining Ring Pliers Installation Replacement e Push the nozzle handles all the way up and put nozzle on a flat surface with nose piece facing u
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