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14347902_McDs_Carbo-Max_450-750_Manual
14347902_McDs_Carbo-Max_450-750_Manual
MANUFACTURED
FOR
McDONALD’S™
BY
Chart Inc.
407 7th Street N.W.
New Prague, MN 56071-1000
TELEPHONE: 952-758-4484
FAX: 952-758-8275
TABLE OF CONTENTS
WARRANTY Page 1
SAFETY PRECAUTIONS Page 3
GENERAL DESCRIPTION Page 5
OPERATION FACTS AND PROCEDURES Page 8
McDONALD’S BEVERAGE SYSTEM LAYOUT Page 9
CARBO-MAX 450 / 750 VESSEL SPECIFICATIONS Page 10
VESSEL PARTS IDENTIFICATION & FUNCTION Page 11
FILL BOX PARTS & HOSE IDENTIFICATION Page 14
TROUBLESHOOTING GUIDE Page 15
SERVICE AND PARTS Page 19
SYSTEM FLOW SCHEMATIC Page 20
1
Copyright: Chart Inc., January 2010
CHART SPECIFICALLY MAKES NO and Conditions of Sale. In the event of a conflict
WARRANTIES OR GUARANTEES, between Chart’s Terms and Conditions of Sale
EXPRESSED OR IMPLIED, INCLUDING THE and this Warranty Policy, this Warranty Policy
WARRANTIES OF MERCHANTABILITY OR shall control.
FITNESS FOR A PARTICULAR PURPOSE
OR USE, OR WARRANTIES ARISING FROM WARRANTY CLAIMS PROCEDURE
COURSE OF DEALING OR USAGE OF TRADE,
1. All warranty claims must be previously
WHICH ARE ALL EXPRESSLY DISCLAIMED,
authorized by: Chart Inc. Telephonic / electronic
OTHER THAN LIMITED WARRANTIES
approval may be obtained by contacting Chart’s
EXPRESSLY SPECIFIED HEREIN.
MVE Beverage Systems Technical / Customer
IN NO EVENT SHALL CHART BE Services at:
LIABLE FOR ANY SPECIAL, INDIRECT, • Telephone: 800-247-4446
INCIDENTAL OR CONSEQUENTIAL 800-253-1769
DAMAGES, INCLUDING BUT NOT (Toll free in U.S.)
LIMITED TO LOSS OF PROFITS, LOST
• Facsimile: 952-758-8275
OPPORTUNITY, LOSS OF USE OF
or by writing to:
THE EQUIPMENT, CO2 LOSS, COST
OF CAPITAL, COST OF SUBSTITUTE Chart Inc.
EQUIPMENT, DOWNTIME COSTS, COSTS MVE Beverage Systems
OF DELAYS NOR FOR ANY PENALTIES, Storage Systems Division
WHETHER ANY SUCH CLAIM FOR 407 Seventh Street N.W.
THE SAME IS BASED ON CONTRACT, New Prague, MN 56071-1000
WARRANTY, TORT, NEGLIGENCE, STRICT USA
LIABILITY OR OTHERWISE. CHART’S
2. Authorization must be obtained from Chart prior
LIABILITY FOR ANY SUCH CLAIMS
to shipping any Equipment to Chart facilities. In
WHETHER IN CONTRACT, WARRANTY,
order to process the return of a vessel its model and
NEGLIGENCE, TORT, STRICT LIABILITY,
serial number must be provided. If approved, a
OR OTHERWISE OR FOR ANY LOSS OR
Return Material Authorization (RMA) number
DAMAGE ARISING OUT OF, CONNECTED
will be provided. The RMA number must be
WITH, OR FROM ANY DESIGN, SALE,
prominently indicated on the packing slip and
INSTALLATION, OPERATION OR USE OF
any packaging that accompanies the goods being
THE EQUIPMENT OR PERFORMANCE
returned. The customer returning the goods is
OF ANY SERVICES RENDERED BY
responsible for all freight, proper packing, and
CHART, SHALL IN NO EVENT EXCEED
any damage incurred during shipment of the
THE PURCHASE PRICE PAID TO CHART
goods back to Chart.
BY PURCHASER FOR THE SPECIFIC
EQUIPMENT OR PART THEREOF OR
FOR THE SERVICES GIVING RISE TO
THE CLAIM. PURCHASER AGREES TO
DEFEND, INDEMNIFY AND HOLD CHART
HARMLESS FROM ANY THIRD PARTY
CLAIMS ARISING OUT OF THE USE, SALE,
OR LEASE OF THE EQUIPMENT.
This Warranty Policy is not intended to replace or
supersede the warranties, limitations, exclusive
remedy and disclaimers set forth in Chart’s Terms
2
Copyright: Chart Inc., January 2010
Safety Precautions
IMPORTANT SAFETY PRECAUTIONS CO2 is heavier than air and can collect in low areas
such as basements, stairwells, and confined spaces.
The type of vessel described in this manual holds Avoid entry into areas where CO2 leaks or high
and dispenses carbon dioxide (CO2) gas under concentrations of CO2 are suspected. Enter those areas with
pressure. All persons using this equipment must caution only after they have been thoroughly ventilated.
read and understand the operation and safety
information contained in this manual and must Whenever the vessel is inside a building, that
be adequately trained to operate this equipment. vessel’s safety relief circuit must be connected
CO2 gas is a colorless, odorless, tasteless gas to an outdoor vent; typically in the fill box. The
fill box and/or vent must never be located in or
above any below-ground spaces or stairwells. The
vessel must not block emergency exits, aisles,
fire suppression equipment or utility boxes or
SUFFOCATION HAZARD.
accesses. CO2 lines or hoses must be located
away from traffic areas and heat sources and must
CARBON DIOXIDE GAS can cause be protected from potential causes of damage. All
SERIOUS INJURY OR DEATH. connections, lines, and components must be leak-
DO NOT BREATHE CARBON
free.
DIOXIDE GAS. This equipment should be installed and serviced
AVOID ENTERING canister only by professional personnel who are qualified
area if a leak is suspected. to work with CO2 and the mini-bulk liquid CO2
THOROUGHLY VENTILATE area. pressure vessels. They should be familiar with all
pertinent safety procedures.
FROSTBITE HAZARD.
CONTENTS ARE EXTREMELY
COLD and can cause FROSTBITE.
Vessel Plumbing
Plumbing components on the vessel perform
five functions:
• Liquid CO2 fill (valve)
• Gas supply (gas delivery regulators)
• Pressure maintenance (“Economizer” regulator) Contents
Measurement
• Safety (Vent/Relief valves) High Phase
• Pressure and contents measurement (gauges) Line
1. The Mc Donald’s Carbo-Max vessel’s normal 1. Check for the following unusual symptoms every
internal operating pressure (43) is between day before the start of operations and CO2 use:
140 psi and 165 psi. • CO2 leaks (See “Safety”)
2. Vessel pressure can be as high as 300 psi after • Pressure readings (43) & (46) & (48)
a delivery but returns to its normal operating • CO2 contents (22)
pressure after a day or two of normal CO2 use. • Abnormal frost or condensation
3. The carbonator gas supply pressure (45) is 2. Always use caution when working with
normally between 90 psi and 115 psi. CO2. Read and understand the “Safety”
section of this manual.
4. The syrup gas supply pressure (44) is
normally 65 psi. 3. The CO2 storage system does not require
adjustment under normal operating conditions.
5. Frost or condensation on the vessel is normal
during periods of CO2 use. 4. Check the vessel daily before using CO2.
See ‘operation fact’ number 10.
6. Frost or condensation on the vessel before the
start of daily CO2 use is a sign of a CO2 leak. 5. In an emergency the flow of CO2 from or
Have the leak fixed. through the Carbo-Max can be stopped by
closing the following valves:
7. The Carbo-Max 450 holds 453 lb of CO2 for a
• Valves 33b or 33c to stop the flow of gas to
use rate of approximately 70 to 100 lb per week.
the beverage or syrup system respectively;
The Carbo-Max 750 holds 771 lb of CO2 for less
33a and 33d to stop gas flow from the vessel.
frequent fills or a use rate of over 100 lb per week.
• Valve 30 to stop CO2 flow or leakage
8. The contents gauge (22) displays the amount of through the fill hose and/or the brass fill
liquid CO2 in the vessel. fitting in the outdoor fill box.
9. CO2 becomes dry ice below a pressure of 61 psi. • Valve 33a to stop CO2 flow through the
The shut-off circuit regulator (41) will close and “Economizer” circuit.
stop CO2 flow if the vessel pressure (43) reaches
6. For CO2 equipment issues, call your CO2
70 psi or less.
supplier or service specialist. Before calling
10. An isolation (shut-off) valve is open when its handle for service or trouble shooting assistance,
is parallel to the valve body and the line. The valve please have the following information at hand:
is closed when its handle is perpendicular to • Serial number of the vessel
the valve body and the line. During normal
• Description of the problem
use, all isolation valves on the Carbo-Max
vessel should be in the open position. • Readings from:
the vessel contents gauge (22),
11. See the trouble-shooting section for additional the vessel pressure gauge (43) and
information on potential vessel problems. the final line pressure gauges (46 & 48).
• Observations such as unusual frosting and/
or events related to the problem.
F
Clean-In-Place
(CIP) Sanitize
B
System D
H
E Beverage Machine
(Carbonator)
C
Fill Line Connection 5/8” Male 450 Flare 5/8” Male 450 Flare
Evaporation Rate** 3.0 lb/day (1.4 kg/day) 2.5 lb/day (1.1 kg/day)
Max. Allowable Working Pressure (MAWP) 300 psig (20.7 bar g) 300 psig (20.7 bar g)
ASME Relief Setting 300 psig (20.7 bar g) 300 psig (20.7 bar g)
Additional. Relief Setting 450 psig (31.0 bar g) 450 psig (31.0 bar g)
Internal Vaporizer Coil Eight wraps for sustained high flow rate
84
21
80
81
65
64
55
22
26
33e 23
E F
53 52 61
63 25
33g
24
54 62
20 66
31 39
94 43
51 33f
32
55
33d 48
35
68
44
54 35
47
69
33a 41 33c
57 45 67 73
30
47 69
50 33b 74
42
70
49a 49 75
76
35 46
49b 71
72
95
5
77
4 12 13
2
64
1 65
11
13 76
6
2 64 7
12
65
76 80
10
77
10
7 1
6 9
2 81
No CO2 to carbonator or CO2 storage vessel is empty. 1. Switch to emergency CO2 gas cylinder.
syrup systems. 2. Call CO2 supplier for delivery.
OR
Isolation valves (33a, b, c, d) closed. Open valve or valves as needed.
Carbonated drinks are flat.
Vessel pressure (43) is low Check for leak in gas supply lines, beverage
(110 psi or less). system, vessel plumbing, vessel safety system
and/or fill box. (Frost should not be present on
vessel after extended periods of no CO2 use.)
Constant low Economizer regulator (39) set low or Call CO2 service agent.
vessel pressure. stuck open.
(gauge 43 below 140 psi)
CO2 leak from vessel plumbing, CO2 1. See “Safety.” Evacuate & ventilate the room.
fill box and/or vessel safety system 2. Call CO2 service agent.
Sure-Fill assembly leaking or Close Sure-Fill valve (33d); call CO2 service agent
malfunctioning.
Frost on vessel after CO2 leak from the beverage or syrup 1. See “Safety.” Evacuate & ventilate the room.
extended periods with system (rupture disc), plumbing, or 2. Call appropriate service agent.
no CO2 use (such as CO2 fill box.
in the morning before
store operations begin.)
Vessel pressure (43) constantly high. See section on vessel pressure too high.
CO2 leak from vessel plumbing, CO2 fill 1. See “Safety.” Evacuate & ventilate room.
box, gas lines, and/or beverage or syrup 2. Locate & correct leak if possible
use-point equipment. 3. Call appropriate service agent.
CO2 vessel will not fill. CO2 vessel is already full. None
Fill valve (30) is shut off or is faulty. Consult CO2 service agent / open fill valve
Sure-Fill™ valve is closed Consult CO2 service agent / open Sure Fill valve
Brass fill fitting in CO2 fill box and/or on 1. Consult with CO2 supplier or service agent.
truck’s delivery hose is faulty. 2. Have brass fill fitting(s) replaced if needed.
Hissing sounds or Normal for short periods of time from Observe leak, if it is not large and does not last
evidence of gas leak. some regulators and relief valves. long and occur frequently, no action is needed.
Final line / gas use Final line regulators (44) or (45) None
pressure gauges intentionally set lower by beverage
indicate less than service agent.
65 psi on the syrup
side and/or less Final line regulators (44) or (45) not Call CO2 service agent.
than 100 psi on the operating in proper pressure range.
carbonator side.
Final line pressure gauge (46 or 48) Call CO2 service agent.
damaged or faulty.
One or more of the causes listed in “no 1. See indication sections regarding “no CO2”,
CO2” or “flat drinks” problem section. “flat drinks” etc.
2. Call CO2 service agent.
Fill Box
Fill box door will Wrong key. 1. Verify correct key and retry.
not close, lock, or
2. Contact CO2 supplier for spare key.
open.
3. Order new key.
Brass fill fitting in Particle of ice or debris caught in fill 1. If driver is still on site, reconnect CO2 delivery hose
fill box leaking fitting poppet. and then disconnect.
or hissing.
2. If driver is not available, carefully press poppet with
dull instrument to re seat poppet.
3. If leak continues after line warms, close the fill
isolation valve (30) and call service agent.
Fitting is defective or sealing surface is Close the fill isolation valve (30) on the vessel and
worn due to normal wear. call service agent to replace fitting.
Threads on brass Normal wear. Fill fitting must be Contact CO2 service agent to replace fitting.
fill fitting are replaced.
worn or stripped.
Fill fitting cross threaded with the CO2 Contact CO2 service agent to replace fitting.
delivery hose coupler
Normal for short periods of time if vessel 1. NONE if for short period(s) of time
pressure is at or over 300 psi 2. If vessel pressure consistently over 300 psi,
see section on vessel pressure too high.
Fill fitting is not sealing properly. Call CO2 service agent to replace fitting.
Sure-Fill Isolation Valve Economizer Low Phase Line Vessel Pressure Economizer Regulator (42)
Isolation Valve (Gas Side) Isolation Valve Gauge (43)
Sure-Fill Regulator
Gas-Use
Isolation Valves
Liquid Dispense
Valve (plugged)
Syrup Gas
Regulator (44)
Vaporizer
Vaporizer Coil Isolation Valve