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ULTRADOSER 1020 INJECTION SYSTEM USER MANUAL

DO722 OM - 04 VERSION 2

VBS International, Inc.


745-B Camden Avenue Campbell, CA 95008 www.vbsinternational.com (408) 371-3303 Fax (408) 371-3320

Table of Contents

ULTRADOSER 1020 PRODUCT SPECIFICATIONS ............................................................................................ 3 ULTRADOSER 1020 UTILITY REQUIREMENTS ................................................................................................. 3 UNPACKING THE ULTRADOSER 1020 ............................................................................................................... 5 PRINCIPLES OF LN2 DOSING.............................................................................................................................. 6 ULTRADOSER 1020 SYSTEM COMPONENTS ................................................................................................... 6 ULTRADOSER RESERVOIR ..................................................................................................................................... 6 ULTRADOSER 1020 DOSING ARM ...................................................................................................................... 6 ELECTRO-PNEUMATIC SOLENOID VALVE ................................................................................................................. 6 ACTUATOR ............................................................................................................................................................ 7 NOZZLE................................................................................................................................................................. 7 ULTRADOSER DOSING HEAD HEATER .................................................................................................................... 7 OPTICAL SENSOR .................................................................................................................................................. 7 VENT HEATER ....................................................................................................................................................... 7 DOSING HEAD PRESSURE GAUGE .......................................................................................................................... 7 GAS REGULATOR AND PRESSURE GAUGE .............................................................................................................. 8 SOURCE PRESSURE GAUGE................................................................................................................................... 8 INTERNAL GASEOUS NITROGEN PURGE .................................................................................................................. 8 ULTRADOSER DRAIN ............................................................................................................................................. 8 SAFETY RELIEF VALVE ........................................................................................................................................... 8 STAINLESS STEEL 10 MICRON FILTER .................................................................................................................... 8 VBSFLEX HOSE .............................................................................................................................................. 10 DISTRIBUTION BOX .............................................................................................................................................. 10 CONTROLLER ...................................................................................................................................................... 11 INSTALLATION AND SET-UP............................................................................................................................. 12 SUPPORT STAND LOCATION ................................................................................................................................. 12 POSITIONING THE DOSING HEAD AND SETTING THE DELAY AND TIME FUNCTIONS ................................................... 13 SHUT-DOWN PROCEDURE................................................................................................................................ 19 LONG TERM SHUT DOWN ..................................................................................................................................... 19 SHORT TERM SHUT DOWN (I.E. MOVING FROM ONE LOCATION TO THE OTHER) ........................................................ 19 REPLACEMENT PARTS...................................................................................................................................... 20 PREVENTIVE MAINTENANCE............................................................................................................................ 21 NOZZLE CHANGE PROCEDURE ............................................................................................................................. 21 ULTRADOSER 1020 TROUBLESHOOTING ...................................................................................................... 22

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UltraDoser 1020 Product Specifications


Dimensions Overall height: 30 (762 mm.) Hexagonal: 6 (197 mm.) 2.0 (51 mm) wide x 9.8 (249 mm) high UltraDoser - 32 pounds (20.5 kilograms) Controller 10.5 lbs (4.76 kg) Minimum 0.01 gram Maximum 20 grams/second +/- 5% of dose value Effective Minimum: 2 milliseconds (ms) Maximum: 500 milliseconds (ms) 4 cubic feet per hour of N2 plus dewar connection loss (varies from 0- 300 CFH) Essentially all stainless steel construction. Built to food and beverage industry standards. 90L x 32W x 22 H 225 lbs with stand 140 lbs without stand

Dosing Head: Total Weight w/electronics: Dosing Range:

Dosing Accuracy: Timing Range: Steady State Consumption: Materials: Crate Dimensions:

UltraDoser 1020 Utility Requirements


Electrical Supply: Internal Control Voltage and External Heaters: Liquid Nitrogen Source: Gaseous Nitrogen: 95-220 Volts AC

24 volts (heaters) 5 volts (internal control)

Maximum 22 psig for portable system, 100 psig for plant system 60 psig regulated Note: Gaseous nitrogen is recommended. Dry compressed air will also operate the actuator. However, the actuator will have a longer expected life span if gaseous nitrogen is used.

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Unpacking the UltraDoser 1020


The UltraDoser 1020 unit will arrive in a specially designed shipping crate. If you are planning on moving the unit from one location to another or if you are leasing the unit, it is in your best interest to store the crate for future use. It is important that you inspect your crate before unpacking the UltraDoser 1020. All exterior parts of the crate should be free from dents and/or other damage. If you do note shipping damage, you should report it to the carrier immediately. While unpacking the crate, you should inspect all contents. All pieces should be free from dents and/or other damage. If any pieces are missing please call VBS immediately at 408-371-3303. UltraDoser 1020 Unpacking Checklist: This is a typical kit of individual ordered items. Refer to the purchase order. 1. 2. 3. 4. 5. 6. UltraDoser 1020 reservoir with bracket Controller (Electronics box) with brackets Cables and power cord Sensor 10 VBSFlex hose (for portable systems) Three dosing nozzles one installed, two additional and one nozzle installation tool 7. Stainless steel support stand and other accessories (if ordered)

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Principles of LN2 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. The UltraDoser from VBS International guarantees that a precise, accurate dose of LN2 is delivered. The UltraDoser 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. VBS has a unique internal design that ensures the continual availability of fresh, pure liquid at the dosing head. Constant Pressure Constant pressure at the dosing head is critical requirement for reproducible dose size. The LCI 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 units electronics. Dose duration is measured in milliseconds. The following production conditions must be controlled to ensure consistent dosing results: 1. 2. 3. 4. Fill levels must be consistent. Fill temperatures must be consistent. Capping techniques must be consistent. Product should not be spilled or splashed out of containers following dose.

ULTRADOSER 1020 System Components LCI Reservoir


The stainless steel vacuum insulated reservoir provides a ready supply of LN2 for dosing operations.

UltraDoser 1020 Dosing Arm


The integral, vacuum insulated dosing arm allows the liquid nitrogen to flow from the reservoir to the dosing head.

Electro-Pneumatic Solenoid Valve


The electro-pneumatic solenoid valve receives a signal from the optical sensor each time a container is detected. The solenoid valve then controls the flow of gaseous nitrogen/air to the actuator. The solenoid valve is fitted with a 1/4 O.D. push lock connection for gaseous nitrogen or clean, dry air. The gas source should be regulated to 60 psi.

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Actuator
The actuator is a spring loaded pneumatic cylinder with a valve stem attached to the cylinder piston. The position of the piston determines the state of the dosing valve.

Nozzle
A 0.040 nozzle has been installed in your UltraDoser 1020. A 0.050 and a 0.060 nozzle are shipped with the unit. Other size nozzles are available from VBS for specialized applications.

UltraDoser Dosing Head Heater


Each UltraDoser unit has a self-regulating dosing head heater. The maximum temperature of the dosing head heater is 150F. 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 nozzles 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 eliminates the chance of moisture in the ambient atmosphere from contaminating the dosing head. The dosing head assembly is held in place by a set of O-rings. If needed, the dosing head assembly can be removed by simply slipping the heater off of the dosing head.

Optical Sensor
The UltraDoser uses a retro-reflective sensor to detect the presence of a container. When a container is detected, a signal is sent to the electro-pneumatic solenoid valve. Numerous other commercially available sensors can be used with the UltraDoser 1020.

Vent Heater
The UltraDoser 1020 is continually venting cold nitrogen gas. To prevent any ice formation on the vent, a self-regulating heater is installed on the vent outlet. The heater will not get hotter than 150F. While the heater is warm enough to prevent ice formation, it is not hot enough to burn the skin.

Dosing Head Pressure Gauge


The dosing head pressure gauge measures the head pressure of the liquid nitrogen in the reservoir and acts as a liquid level indicator. This is a relative pressure and it may vary slightly depending on the location of the dosing arm (the pressure gauge sensor is actually in the dosing arm). The pressure gauge should read between 0.4 0.5 psi when the reservoir is full.

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Gas Regulator and Pressure Gauge


The regulator controls the pressure of the gas flowing to the actuator. The regulator is preset to 60 psi. If necessary, on-site adjustments may be made. Ideally, gaseous nitrogen should be used in this application. However, compressed dry air is an acceptable alternative.

Source Pressure Gauge


This gauge measures the pressure of the liquid nitrogen source. Note that the source pressure should always be between 10-22 psi. 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 source must be lowered to 22psi before the fill operation can occur. Filling at a pressure higher than 22 psi can damage the equipment and/or cause liquid nitrogen to come out vent.

Internal Gaseous Nitrogen Purge


It is important to continually flush the dosing head with gaseous nitrogen. This purge prevents moisture in the air from coming into contact with the dosing head. The purge is a self-regulating device that is supplied by the internal LN2 reservoir. The internal LN2 reservoir must contain LN2 for the internal gaseous purge to operate.

UltraDoser Drain
This drain allows one to quickly empty the LN2 reservoir. Typically this may be done to shut down the system for service. The drain plug is a safety relief valve to protect the UltraDoser.

Safety Relief Valve


A safety relief valve (SRV) relieves excess pressure in a system. Typically, a SRV is installed between two valves. If both valves are shut simultaneously, trapped liquid will quickly turn to gas building up excessive pressure. It is highly recommended to install a std. dewar SRV (Part# 0614) when the UltraDoser is connected to a dewar. This will protect the transfer hose (VBSFlex Hose) between the internal float mechanism (which acts as a valve) and the dewar/source valve. In the highly unlikely event that both valves were shut, the dewar SRV would start relieving pressure at 50 psi.

Stainless Steel 10 Micron Filter


Installed at the LN2 inlet, the stainless steel filter prevents foreign particles from entering the UltraDoser 1020 system.

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Distribution Box

Clamps Mounting Bracket

Fill Level Port Drain Plug LN2 Inlet Pressure

Blind port

Note: Bracket can be mounted at 90 intervals around the central axis of the injection body.

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Mounting Bracket Assembly


Each UltraDoser unit 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.

VBSFlex Hose
A 10 VBSFlex stainless steel, vacuum insulated hose is provided. This hose connects the UltraDoser 1020 to the dewar or LN2 source.

Distribution Box
This box houses the connections between the operating parts of the LCI unit and the controller. There are five cables with indicator lights on this distribution box. Vent Heater Cable This is the first cable. A green light on the cable connector indicates that power is being supplied to the vent heater. Dosing Head Heater Cable This is the second cable. A green light on the cable connector indicates that power is being supplied to the dosing head heater cable. Bottle Sensor Cable This is the third cable. A green light on the cable connector indicates that power is being supplied to the sensor. A yellow light will appear whenever a container is detected. Valve Cable This is the fourth cable. 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. Valve Confirm Cable This is the fifth cable. A green light on the cable connector indicates that power is being supplied to the valve confirm assembly. A yellow light indicates that the valve has opened. The distribution box also has a 32 cable to connect to the UltraDoser controller. Extension cables are available.

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Controller
The controller houses the electronics of the UltraDoser 1020 in a moisture tight box. The controller has several important components: 1. Emergency off switch - This switch simply needs to be pushed and the electric supply for the entire UltraDoser 1020 unit will be shut down. The EMO switch is located on the bottom of the controller. 2. Sensor Delay - The sensor delay is located on the front of the controller. One can easily access the sensor delay by opening the controller box. The setting is the delay between the time a container is detected and the time a dose is given. The closer the sensor is to the dosing head, the shorter the time delay. The sensor delay can be set from 0 seconds to 0.2 seconds. A word of caution - if the sensor is far from the dosing head and the time delay is consequently large, be sure to do a trial run at line speed. The electro-pneumatic solenoid valve does not record signals from the sensor while it is dosing or in a delay mode from the previous signal. During the initial set up, one should verify that all containers are receiving a dose. 3. Dose Duration - The dose duration (effectively the dose amount) is measured in milliseconds. The maximum dose duration is 500 milliseconds. The operator can easily adjust the dose duration by turning the control knob on the side of control box. The actual dose duration is displayed on the front panel. 4. Distribution Box Cable - The cable connector connects the two heaters, the solenoid, the confirm sensor and the bottle sensors from the distribution box to the controller. 5. Electrical Cord - A yellow electrical cord is provided with the UltraDoser 1020 unit. One end of the electrical cord connects to the controller. The other end of the electrical cord plugs into a standard electrical outlet. The plug contains an integral fuse. 6. Enable Switch - The on/off switch must be turned to the on position in order for the solenoid and sensor to operate. 7. Display Panel 1. LED dosing duration display ( 0 - 500 milliseconds) 2. Sensor delay control knob ( 0 -0.2 seconds) 3. 24 VDC indicator light (red) - is illuminated when there is power to heaters 4. 5 VDC indicator light (red) - is illuminated when the internal circuit board is receiving power 5. Enable indicator light (green) - is illuminated when there is power to the solenoid and sensor components. Enable light is controlled by on/off switch. 6. Sensor indicator light (green) - is illuminated when a container is detected 7. Delay indicator light (yellow) - is illuminated when the delay function is activated and the valve stem has moved to the open position.
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8. Valve indicator light (yellow) - is illuminated when an electrical signal is sent to the solenoid valve. 9. Valve confirm indicator light (yellow) is illuminated when the actuator has been activated.

Installation and Set-Up


Support Stand Location
The UltraDoser can be installed on either side of a production line. Select the side that best suits your workplace. Measure 29-1/2 directly back from the dosing location. Then measure an additional 5-1/2 to the right/left or beyond the original 29-1/2 measurement. These three installation locations result in the dosing arm being located in the same position. Since the dosing arm is flexible, it can be adjusted as needed. The installation location to either the left or right of the original 29-1/2 measurement is preferred. These two positions allow for greater flexibility when changing the line over to a new bottle size. Mark the location of the stand and install four (4) 5/8 bolts in the proper locations. 1. Mount the UltraDoser reservoir on the support stand. 2. Note that the provided black clamps are matched pairs. 3. The control box and regulator are designed to be affixed to the UltraDoser 1020 stand. If this is not convenient, the control box and regulator can be moved to an alternate location. If the control box/regulator assembly is to be moved, the pneumatic supply hoses and main cable may need to be lengthened. All lines are color coded. Custom cable lengths can be ordered from VBS. 4. Install the dosing head on the filling line. For your convenience, VBS has installed a mounting bracket on the LCI arm. 5. Plug the yellow electric cord into the electric supply. The two heaters will automatically turn on. Turn the enable switch to the off position. The enable switch controls power to the sensor and solenoid valve. It is helpful to disable these components until later in the set up procedure. 6. Install the optical sensor so that it is before the dosing head and will see the approaching container. 7. Ensure that the distribution box cable from the modular junction box is connected to the controller. 8. Make sure that the emergency off switch is deactivated. This is done by simply rotating the switch in a clockwise direction.

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9. Turn on the enable switch. Confirm that the electronics are functioning properly by monitoring the display lights on the controller panel. The 24vdc, 5vdc, and enable lights should be illuminated. Set the dose value to 30 milliseconds. 10. Connect the male bayonet end of the hose to the female bayonet inlet at the top of the UltraDoser 1020 reservoir. Make sure that the white gasket is in place between the two flanges before the bayonet clamp is fastened. 11. Connect the other end of the hose to the liquid valve of the low pressure (i.e. 22 psi) LN2 supply dewar. NOTE: You must use a low pressure source of LN2. If you mistakenly ordered a high pressure dewar, you must bring the pressure down to 22 psi or lower. This can be done by opening the vent valve on the dewar. NOTE: It is highly recommended to install a dewar SRV (Part# 0614) between the dewar and the transfer hose! 12. Once the hose is connected and the dewar is at the proper pressure, open the liquid valve of the dewar. Liquid nitrogen will begin to fill the UltraDoser 1020 reservoir. You will notice cold gas being expelled through the vent at the bottom of the UltraDoser 1020 reservoir. The source gauge on the UltraDoser 1020 unit will measure the pressure of the source. If the pressure is higher than 22 psi, immediately stop the filling operation by turning off the valve at the dewar (source). Reduce the source pressure to 22 psi before allowing the filling operation to occur. It will take about 10-15 minutes for the UltraDoser 1020 reservoir to fill. You can monitor this filling operation by watching the head pressure reservoir gauge. The gauge will rise to approximately psi and remain at that level indicating a full status. 13. Connect the gaseous nitrogen or air supply to the regulator. You will need 1/4 OD tubing for this connection. Note: It is important to have a regulated gaseous nitrogen or air supply to the solenoid valve. This gas supply is used to open/close the actuator. Fluctuation in the gas supply could cause inconsistent dosing. 14. Wave your hand or manually pass a container in front of the sensor. A dose of LN2 should be dispensed from the dosing head. Safety Note: When a small amount of liquid nitrogen is dispensed, some of the liquid will immediately turn into gas. This gas layer actually insulates the liquid (you may notice that the liquid dances on a surface). The layer of insulating gas also protects your skin from freezing. A small amount of liquid nitrogen on your skin is generally not harmful. however, caution must be exercised to prevent large amounts of liquid nitrogen from coming into contact with your skin or clothing. Refer to the MSDS for additional health and safety information about liquid nitrogen.

Positioning the Dosing Head and Setting the Delay and Time Functions
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1. Position the unit so that the dosing head is centered over the container. The dosing head should be only 1/2 - 3/4 above the container. 2. Adjust the optical sensor (part 1422: Complete Sensor Bracket for UltraDoser) so that it is in a convenient location before the dosing head. This is an option and if you ordered it with your unit, it will be attached to the front of the dosing head. 3. Turn the conveyor belt on. 4. Set the delay to zero. 5. Send a container down the line. Note if the dose is dispensed before, in, or after the container. If the dose is dispensed before the container reaches the dosing head, increase the time delay until the dose is dispensed into the container. If the dose is dispensed after the container reaches the dosing head, reduce the delay time (if possible) or reposition the optical sensor further away from the dosing head. HELPFUL HINT: To verify that the dose is being dispensed into the container, fill the container with water and look for the tell-tale steam from the dose of LN2 on the water. REMINDER: The UltraDoser 1020 is designed for steady speed filling lines. It does not compensate for changes in line speed. Therefore, you should initialize the system at the line speed you intend to use. If you change the line speed substantially, you should verify the delay setting. 6. Setting the time function - The time setting controls the amount of time (in milliseconds) that the dosing valve is open. The amount of LN2 that is trapped inside a container depends on many variables including the position of the dosing head, the position of the capper, the size of the dosing nozzle, the temperature of the container contents, fill levels and head space. Therefore, the time setting for each filling operation must be evaluated. Your UltraDoser 1020 unit has been fitted with a general purpose 0.040 nozzle. Start with a moderate time of 30 milliseconds and work up or down from this setting until the desired pressure or inerting effect is attained.

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STEP ONE INSTALL STAND

18.12

1A. Measure 18.12 back from dosing location (as shown). 5/8 Nuts and bolts provided by VBS.

1B. Attach stand to base. (tool required: 15/16 wrench) 5/8 Nuts are welded to the stand base. 5/8 Bolts provided by VBS.

STEP TWO MOUNT UltraDoser BODY ON STAND (tool required: 3/16 Allen wrench)

STEP THREE MOUNT UltraDoser CONTROLLER ON STAND (tool required: 3/16 Allen wrench)

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STEP FOUR CONNECT DISTRIBUTION CABLE Connect the black distribution cable as shown. (no tool required)

STEP FIVE CONNECT POWER CABLE 5A. Connect female fitting to UltraDoser 1020 Controller. 5B. Plug power cable into a standard electrical outlet.

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STEP SIX CONNECT COLOR CODED PNEUMATIC TUBES (push lock connectors provided) These tubes connect from the UltraDoser body to the controller. 6A. Clear tube Connection from supply pressure tap to gauge 6B. Green tube Connection from Liquid level 6A. Black tube Pneumatic supply to dosing stem

STEP SEVEN CONNECT THE VBSFLEX HOSE TO THE UNIT 7A. Top Fill Unit Bayonet Connection

7B. Connect the 1/2 JIC fitting to a low pressure dewar.

A dewar SRV is recommended before the transfer hose!

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STEP EIGHT CONNECT PNEUMATIC SUPPLY Connect CDA (Compressed dry air) or GN2 @ 60-100 psi to the 1/4 FPT fitting

Note: Here we are using a 1/4 MPT x push lock elbow connector (not provided with unit)

STEP NINE FILL UNIT WITH LN2 9A. Turn on the LN2 source 9B. When full, the liquid level gauge will read approximately 0.45 psi

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Shut-Down Procedure Long Term Shut Down


1. Turn off the LN2 supply valve on the dewar. 2. Ideally the hose should remain connected to the LN2 source to prevent any moisture intrusion into the system. If you must disconnect the hose from the dewar, it is important to plug the end of the hose to prevent moisture intrusion into the system. 3. Leave the unit connected to the electrical source for at least 24 hours. It is critically important that the heaters and gaseous nitrogen purge be left on while the system slowly empties of liquid nitrogen.

Short Term Shut Down (i.e. moving from one location to the other)
1. Turn off the LN2 supply valve on the dewar. 2. Disconnect the VBSFlex hose from the dewar. 3. Loosen the clamps that hold the UltraDoser 1020 on the stand. 4. Remove the control panel from its location. 5. Taking care to prevent your skin from coming into direct contact with the cold gaseous nitrogen output, remove the unit from the stand. 6. Keeping the unit upright, move the unit to the new location. If the unit is put on its side, there is a chance that some liquid nitrogen will escape through the vent. Although this will not damage the UltraDoser 1020, the operator should take care not be come into contact with large amounts of liquid nitrogen. 7. Install the UltraDoser 1020 on the second stand. 8. Connect the VBSFlex hose to the LN2 supply dewar. If this can not be done immediately, plug the hose to prevent moisture intrusion. 9. Affix the control panel to a convenient location and reposition the dosing head.

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Replacement Parts
Part Description Dosing Arm/Head Parts Dosing Stem Assembly Dosing Stem o-ring 0.060 Dosing Nozzle 0.050 Dosing Nozzle 0.040 Dosing Nozzle Nozzle Tool 4mm Hex Nut Driver Optical sensor (general purpose retro-reflective sensor - Banner) Optical Sensor Assembly (sensor, cable and connector) Dosing Head Heater Assembly with Cable Solenoid Valve - 4 way-MOD Arm Support Bracket UltraDoser 1020 Reservoir Parts Inlet Filter Assembly Drain Plug Safety Relief Valve set to 50 psi Vent Heater Assembly with Cable Shaft collar UltraDoser 1020 Controller Parts Confirm Sensor Assembly Controller PC board/Display Panel Controller Extension Cable - 6 Controller Extension Cable - 12 Controller Extension Cable - 25 Controller 24 vdc Power Supply Distribution Box with 30 Cable Extension Cable (for use with Distribution Box) EMO Switch Enable Switch (on/off switch) Power Input Cable (wall plug included for US orders) Solenoid Valve Cable Assembly Confirm Sensor Cable (from distribution box) Confirm Sensor with Pico Fast Connector Miscellaneous 10 VBSFlex hose with Female bayonet (for use in bottom feed systems) 10 VBSFlex hose with Male bayonet (for use in bottom feed systems) Stainless steel support stand Gauge, 0-100 psi, 1-1/2 Gauge, 0-100 psi, 2 , back mount Gauge, 0-3 psi, 2-1/2 Complete Gauge Assembly PN-122 PN-123 PN-119 PN-135 PN-136 PN-134 PN-133 PN-205 PN-146 PN-143 PN-175 PN-175 PN-206 PN-138 PN-124 PN-208 PN-209 PN-210 PN-145 PN-207 PN-108 PN-109 PN-211 PN-105 PN-797 PN-141 PN-275 PN-102 PN-104 PN-103 PN-362 PN-363 PN-364 PN-106 PN-140 PN-107 Part Number

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Preventive Maintenance
VBS recommends the following preventive maintenance schedule. 1. Solenoid Replacement VBS recommends that the solenoid valve be replaced on an annual basis. 2. Dosing Stem Assembly VBS recommends that the dosing stem assembly be replaced every 5 million (500 x 10,000) doses. 3. Filter Cleaning VBS recommends that the filter be cleaned only as necessary. DO NOT USE WATER TO CLEAN THE INLET FILTER. Note that the filter must be thoroughly dried before it is reinstalled

Nozzle Change Procedure


Nozzles may need to be changed for cleaning/preventive maintenance procedures or when different dosing parameters are required. 1. Drain the LN2 out of the LCI reservoir by removing the drain plug from the underside of the UltraDoser 1020 unit. Note that when full, the UltraDoser 1020 reservoir will hold approximately 2 liters of LN2. Be prepared to drain 2 liters of LN2 into an appropriate container. 2. Once the reservoir is drained, immediately replace the LCI drain plug. Failure to do so will allow moisture intrusion into the LCI unit. Any resulting ice crystals may impair the performance of the LCI. 3. Drain the LN2 from the dosing arm by manually depressing the solenoid valve. Note that you must continue to depress the solenoid valve until the arm is completely drained of LN2. 4. Once the reservoir and arm are completely drained of LN2, allow the unit to warm. The warming process can be expedited with a heat gun. If you intend to use a heat gun, remove the LCI heater. 5. Once warm, remove the nozzle with the nozzle removal tool. 6. The nozzle is located inside the dosing head heater unit. 7. Install the new nozzle.

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UltraDoser 1020 Troubleshooting


Condition: 1. The UltraDoser 1020 does not deliver a dose of liquid nitrogen. Possible Causes 1. The unit is disconnected from the power source. 2. The emergency shut off switch has been activated. 3 .The key on the control box is turned to the off position. 4. The LN2 reservoir is empty. Action 1. Plug in the UltraDoser to the power source. 2. Deactivate the emergency shut off switch by rotating it counter-clockwise. 3. Turn the key to the on position.

4. Check the level of the LN2 reservoir by looking at the reservoir gauge. If the reservoir is empty, fill the reservoir by opening the valve on the LN2 source. 5. Check to make sure that the gas is on. Adjust the pressure of the gas to 60 psi. 6. First try all actions listed above. If the condition remains, and the valve confirm light is not illuminated when a container is moved in front of the sensor, the actuator may need to be replaced. To change the actuator, first drain the system of LN2 (refer to procedure in nozzle change section). Disconnect the pneumatic lines from the actuator. Unscrew/remove the actuator. Install the new actuator and reconnect the pneumatic lines.

5. The nitrogen gas or clean dry air is off or not at an adequate pressure.

6. Valve stem is stuck in closed position.

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Condition: 2. The dose of liquid nitrogen is missing the container. Possible Causes 1. The time delay function is improperly set. Action 1. Reset the time delay function. Refer to the installation section for additional information. 2. Center the dosing head over the center of the container. 3. Adjust the time delay function.

2. The dosing head is not centered over the container. 3. The line speed has been adjusted. Note that the UltraDoser 1020 does not have speed compensation. Therefore if you change the line speed, you must adjust the time delay.

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Condition: 3. The containers are over-pressurized or under-pressurized Possible Causes 1. Too much or too little liquid nitrogen is being dispensed into the container. Action 1. Reduce or increase the time setting on the UltraDoser 1020 controller.

Condition: 4. The UltraDoser 1020 reservoir does not fill with liquid nitrogen. Possible Causes 1. The valve to the liquid nitrogen dewar is closed. 2. The liquid nitrogen dewar is empty. Action 1. Open the valve.

2. Disconnect hose from existing dewar. Connect hose to a full dewar.

Condition: 5. Inconsistent pressures are being obtained. Possible Causes 1. Fill levels are inconsistent making the resultant head spaces inconsistent. 2. Fill temperatures are inconsistent creating varying vacuum conditions. Action 1. Adjust the filler so that constant fill levels are obtained.

2. Change process so that fill temperatures are consistent.

3. Inconsistent capping techniques. 3. Standardize the capping technique or automate the capping process. This is a problem especially when hand capping containers.

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UltraDoser 1020 Instruction Manual September 2004, Version 2 VBS International 408-371- 3303 Page 24 of 24