INSTALLATION INSTRUCTIONS FOR
VA-TRAN VT-300-8 SATELLITES
Va-Tran Systems satellites are installed as a part of an existing High Pressure Vapor/Liquid CO2 Distribution system. Only qualified and authorized personnel should perform any maintenance. The Vapor/Liquid Distribution system is at approximately 300psig. Pressures of this magnitude can be dangerous or deadly if not handled properly. Questions about safe working practices for high pressure gasses should be answered before beginning work on a pressure charged system. The Va-Tran Systems satellite will continue to be under pressure even if the valve to the primary pressure source is closed.
The Va-Tran Systems Satellite reservoirs contain refrigeration equipment and like all such equipment, may condense water from ambient air. Care should be taken to ensure that this equipment will not cause dripping on personnel or equipment sensitive to water.
The location of Va-Tran Systems satellite reservoirs should be elevated relative to the environmental chamber(s) and as close to the point of liquid CO2 delivery as reasonably possible. The liquid line from the CO2 satellite should slope downhill at all points to allow any bubbles generated in the liquid line to return to the Satellite Reservoir. For proper performance the downward slope of the liquid delivery line should be a minimum of 10% (A drop of 1 foot vertical for every 10 foot of horizontal run).
When positioning the satellite it is important to allow a minimum of 12" clearance between any wall and the ventilation screens on the sides of the unit. The airflow through these screens must never be blocked or the compressor may overheat and have a dramatically decreased lifetime. The location of the cabinet should allow for ease of access to both end panels and screens to allow for installation as well as periodic cleaning and maintenance.
2. Remove the shipping bolts securing the unit to the pallet.
3. Install satellite in the desired location allowing a minimum of 12" clearance between a wall and the screens for proper cooling and maintenance.
4. Remove valve end panel.
5. Peel back the cork tape insulation from the liquid outlet line (if present) to expose the flare nut and elbow.
6. Remove the 5/8" flare nut from the 5/8" male flare elbow. Satellites are shipped with some residual pressure in the reservoir, this pressure may be relieved by opening the vapor inlet valve before connecting the unit to the vapor supply. An open end wrench should be used to support the elbow from within the cabinet and a 1 -1/16" socket may be used on the nut. Use care as the liquid outlet line is easily bent and must run slightly downhill as positioned at the factory.
7. Connect your CO2 liquid line to the satellite "liquid out" line using the 5/8" flare nut provided with the flare bonnet.
Va-Tran Systems recommends using a VT-11 3/4" Ball Valve on the liquid outlet of all satellite reservoirs. The use of this valve allows service to be performed on the liquid line without draining the entire satellite reservoir of liquid CO2. These valves are constructed specially to prevent liquid CO2 from being trapped within the ball when the valve is closed. If another valve is used a dangerous situation may occur causing the valve body to rupture.
8. Connect the CO2 vapor line from your source to the satellite vapor input valve. The satellite vapor input connection is a #4 male flare fitting. If this fitting is to be removed, use a 3/4" open end wrench to hold valve nut inside the cabinet while unscrewing the flare fitting using a 9/16" box wrench. If this procedure is not followed the valve adapter will unscrew from the valve body.
9. Purge CO2 vapor input lines and allow the satellite to fill with 300psig CO2 vapor. Leak check all connections with soapy water or leak indicator fluid. This purging procedure eliminates any air and moisture in the vapor supply lines.
10. Install insulation around all exposed areas of the liquid output line and the liquid line connection.
Va-Tran Systems recommends using 2" O.D. closed cell rubber tubing insulation. This 5/8" I.D. X 11/16" wall tubing can be slit and glued using contact cement, then wrapped with 1/8" X 2" foam insulation tape.
Seal any gaps between the insulation and pan hole with silicone rubber caulking to ensure a water tight seal (note: if CO2 lines are not properly insulated they may frost and drip.) This insulation tubing is available from Va-Tran Systems in six foot lengths (Part Number VT-6F).
11. Reinstall valve end panel.
12. Connect power cord to a grounded AC outlet. Refer to label above power cord on cabinet for proper power requirements (Generally 115VAC, 60Hz, 11.8Amps, Single Phase). Note: Compressor failure can occur if voltage is not within factory specifications +/- 10%.
Unplug the unit before any maintenance operation. The condenser radiator and fan should be cleaned periodically to prevent compressor overheating. The condenser radiator is located near the compressor and has a fan drawing air through it. Cleaning is easily done by removing the screen covering the condenser and vacuuming the dust accumulation from the condenser. A soft brush or compressed air may be used to dislodge the accumulated dust.
The fan on the condensing unit should be oiled every 3-6 months with 2-3 drops of SAE 30 oil. This can be done by removing the compressor end panel and the removing the dust plug at the rear of the fan motor. The dust plug must be replaced after each oiling or the lifetime of the fan will be shortened.
The compressor oil level should be maintained at or slightly above the center of the sightglass while operating. An abnormally low oil level may result in a loss of lubrication; while an excessively high oil level may result in oil slugging and possible damage to the compressor valves or excessive oil circulation. The oil level may very considerably on initial start-up if liquid refrigerant is present in the crankcase. The oil level should be checked with the compressor running after having reached a stabilized condition.
If a Va-Tran Systems reservoir must be emptied for service or transportation the safest and simplest method is to simply remove electrical power from the satellite. Be sure that a free path to the bulk tank exists (no closed valves on the vapor line between the satellite and bulk tank). This allows the liquid in the reservoir to boil back to the bulk tank. This process generally takes several hours depending upon the configuration of the CO2 distribution system. Check to ensure that all residual liquid CO2 has been removed from the tank by slightly cracking a connection in the liquid outlet line to see if dry ice is generated. If liquid CO2 is still present, the opening will "spit" dry ice as a white cloud.
NOTE: After the liquid has boiled back to the bulk tank, there will still be 300psig CO2 vapor in the satellite.
If it is necessary to drain the reservoir quickly, the method recommended by Va-Tran Systems is to remove electrical power and to attach an injection tube to the liquid outlet line. Open the output valve allowing the CO2 liquid be turned to dry ice and vapor in the injection tube. Leave the vapor input line connected and input valve open. Va-Tran Systems injection tubes have been specially designed for the conversion from liquid to solid to occur within these tubes.
A satellite can also be drained through the liquid outlet by continuous injection into the temperature chamber attached to it. Leave the vapor input line connected and input valve open. Simply leave the door on your chamber open and set the chamber to go cold.
CAUTION: Make sure there is a free path "downwind" from the satellite if it will be drained in this manner. This procedure can generate a cloud of high velocity CO2 several feet from the chamber or injection tube. Allow for adequate ventilation in the area in which this procedure will be done. CO2 will fall to the floor because it is heavier than air, however the hazard of an Oxygen depleted environment must be avoided. Carbon Dioxide is not a toxic gas, it will however displace Oxygen and can cause unconsciousness if breathed in a concentration exceeding 10%. Before the concentration reaches this level however a sharp odor or taste will be detected. The liquid from a VT 300-8 will occupy over 1,300 cubic feet as a vapor, so any area smaller than 13,000 cubic feet should not be used for this procedure without proper ventilation.
DO NOT SIMPLY OPEN EITHER THE INPUT OR OUTPUT VALVES DIRECTLY TO ATMOSPHERE. Opening the vapor line to the atmosphere will allow the pressure to be reduced in the tank to the point where all of the liquid will solidify and turn to dry ice. It can take over a week for the dry ice in the satellite to sublime (vaporize) and this will only occur if the valve continues to be left open. Leaving the valves to the satellite open will allow water vapor in the air to enter the tank and condense which will contaminate the entire CO2 system served by the satellite.
Opening the liquid line directly to atmosphere will allow dry ice to be formed in a number of possible places, such as in the valve or in any hose connected to the valve. This dry ice will form a plug and stop the flow. This can cause overpressure to occur or the plug may dislodge as the pressure rises allowing it to become a dangerous projectile.
ALWAYS DRAIN THE VA-TRAN SYSTEMS SATELLITE RESERVOIR FOLLOWING THE ABOVE INSTRUCTIONS. DO NOT PERFORM A SUBSTITUTE PROCEDURE NOT AUTHORIZED BY VA-TRAN SYSTEMS.
All Va-Tran Systems equipment has been designed with the safety of the user in mind. This equipment is protected against overpressure. Do not defeat or replace the factory installed safety devices with unapproved substitutes.
When the Va-Tran Systems satellite devices have liquid CO2 in the reservoir, do not close the Satellite vapor input valve. Overpressure may occur causing the overpressure device to rupture as designed.
Additional Relief Valves and Rupture Devices are available directly from Va-Tran Systems. Occasionally an overpressurization of a satellite reservoir will cause a rupture device to burst. Spare rupture disks should be readily available to allow for immediate replacement.
677 ANITA STREET, SUITE A, CHULA
VISTA, CALIFORNIA 91911
phone: 619/423-4555 toll free 800/379-4231 fax: 619/423-4604
Copyright 1998, Va-Tran Systems