Cylinder filling

Essential Reading

Haffmans BV is not responsible for any damage caused by the owner’s failure to follow the instructions given in this
manual. Haffmans BV is not responsible for print or translation errors in this edition of the manual. The specifications
and design of this product are subject of change without notice. All rights reserved. No part of this publication may be
reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior
written permission of Haffmans BV.

Art. no. : Cylinder filling

Release date : 18 November 2013
Version : V01.01-01/09
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TABLE OF CONTENTS

1 TECHNICAL SPECIFICATIONS ......................................................................................... 7

2 INTRODUCTION ................................................................................................................. 9
2.1 GENERAL INFORMATION ................................................................................................. 9
2.2 INTENDED USE ............................................................................................................... 9
2.3 GUARANTEE CONDITIONS ............................................................................................... 9
2.4 CUSTOMER SERVICE ...................................................................................................... 9
3 SAFETY ............................................................................................................................ 11
4 GENERAL PRODUCT INFORMATION ............................................................................ 13
4.1 GENERAL DESCRIPTION ................................................................................................ 13
4.1.1 The pump unit ..................................................................................................... 13
4.1.2 The floor scale with filling connection .................................................................. 14
4.1.3 The scale display with controls ............................................................................ 14
5 TRANSPORT AND INSTALLATION ................................................................................ 15
5.1 TRANSPORT ................................................................................................................ 15
5.2 UNPACKING ................................................................................................................. 15
5.3 ASSEMBLY ................................................................................................................... 15
5.4 INSTALLATION .............................................................................................................. 16
5.5 INITIAL START-UP ......................................................................................................... 18
6 OPERATION ..................................................................................................................... 19
6.1 INSPECTION ................................................................................................................. 19
6.1.1 Check all cylinders prior to filling: ........................................................................ 19
6.1.2 Check the installation prior to filling: .................................................................... 20
6.2 OPERATION ................................................................................................................. 20
6.2.1 Filling of the cylinders .......................................................................................... 20
6.3 OPERATION PANEL ....................................................................................................... 21
7 MAINTENANCE AND CLEANING .................................................................................... 23
7.1 MAINTENANCE ............................................................................................................. 23
7.1.1 After 50 hours or 1 week of operation.................................................................. 23
7.1.2 After 500 hours of operation or half yearly ........................................................... 23
7.1.3 Yearly .................................................................................................................. 23
7.2 CLEANING ................................................................................................................... 23
8 TROUBLE SHOOTING AND REPAIR .............................................................................. 25
8.1 TROUBLE SHOOTING .................................................................................................... 25
8.2 REPAIR ....................................................................................................................... 25
9 STORAGE AND DEACTIVATION .................................................................................... 27
9.1 STORAGE .................................................................................................................... 27
9.2 DEACTIVATION ............................................................................................................. 27
10 ENVIRONMENT......................................................................................................... 29
10.1 ENVIRONMENTAL REQUIREMENTS .............................................................................. 29
10.2 AFTER DEACTIVATION ............................................................................................... 29

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1 TECHNICAL SPECIFICATIONS

General:
Make : Filltech GmbH
Serial Number(s) :
Year of Manufacture : 2013

Process conditions:
Filling range : 6 – 30 kg
Filling performance : 200 kg/h
Accuracy : +/- 50 g
Supply pressure : Min. 17 bar(g)
Max. 50 bar(g)
Working pressure : approx. 65 bar(g)
System pressure : Max. 110 Bar(g)

Energy:
Power supply : 400 VAC
50 Hz
Consumption : approx. 1.1 kW
Power control circuit : 24 VDC

Dimensions:
Dimensions floor scale : 710 x 510 x 2000 mm
(L x W x H)
Dimensions switch box : 400 x 300 x 1230 mm
(L x W x H)
Dim. pump-motor unit : 440 x 380 x 570 mm
(L x W x H)
Scale : : Floor scale with load cell
Dimension : 600 x 400 mm
Weighing range : 0 -150 kg

Connections:
Filling connection CO2 : Thread DIN477
Cylinder filling connection : Manual release

Display : Electronic Display L115, with external keyboard and

1 switch point.
Controls : Electronic scale with one switch point,
2 solenoid valves controlled via a scale.
Display division : 20 g up to 60 kg,
50 g from 60 kg to150 kg.
Safety installations : Mechanical safety valve, Emergency switch.

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2 INTRODUCTION
2.1 GENERAL INFORMATION
This manual is a guidebook for the cylinder filling unit (CFU)

Beside the standard installation there might be several options explained. Some of the options
written down in this manual may not be included in your delivered system.
The pictures used in this manual are examples and can differ from the system you received

2.2 INTENDED USE

The cylinder filling unit (CFU) is intended to pressurize liquid CO2 to approximately 65 bar(g)
and to fill cylinders.
Using the CFU other than filling cylinders with CO2 is not allowed.

2.3 GUARANTEE CONDITIONS

See: General Terms & Conditions.

2.4 CUSTOMER SERVICE

Haffmans BV provides comprehensive service opportunities for maintaining CO2 plants. In most
cases this maintenance is planned but exceptional cases an experienced Haffmans service
engineer can be on-site at your plant within a few days if required. For details on Haffmans BV
extensive service contracts, contact Haffmans BV

Utmost care is taken in designing, fabricating, commissioning and checking the CO2-plant with
the aim of reliability of systems and convenience for operators.
If you nevertheless encounter troubles operating the CO2 plant please contact Haffmans BV at
[email protected]

If spare parts are required please contact Haffmans BV at [email protected].

When contacting Haffmans BV always mention the project number and if available the tag
number of the specific item. These can be found in chapter ’03-Drawings P&ID’.

Haffmans BV
Marinus Dammeweg 30
5928 PW Venlo, The Netherlands

P.O. box 3150

NL-5902 RD, The Netherlands
T : (+31) 77-3232300
F : (+31) 77-3232323
E : [email protected]
I : www.haffmans.nl

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3 SAFETY
• Read the general safety issues regarding working with CO2 in the main manual.
• Safety issues especially for this part of the installation will be showed in the grey
framework.
Read them carefully and act as required.

Warning Wear protective gloves at all times when handling and filling
cylinders.

Warning
CO2 is asphyxiating and causes breathing troubles or even death.
The place(s) where the CFU is situated and where the cylinders
are handled or stored should be well ventilated.

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4 GENERAL PRODUCT INFORMATION

4.1 GENERAL DESCRIPTION

Fig. 4.1: P&ID Cylinder Filling Unit

The Cylinder filling unit (CFU) is designed for filling standing CO2 cylinders with holding
capacities between 6 kg and 30 kg. The bottles must be fitted with a valve on top.
The filling unit consists of the following main components:
4.1.1 The pump unit
It is necessary to use a tank for the CO2 supply. For a constant flow of the liquid, the carbon
dioxide is pumped between the liquid outlet and the gas outlet of the supply tank. During the
filling process, the filling connection is opened via solenoid valves and the return valve is
closed.

Fig. 4.2: The pump unit

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4.1.2 The floor scale with filling connection

The height of the filling connection is adjustable to the different heights of the CO2 cylinders.
The filling connection must be connected and released manually at the end of each filling.
The quantity of filling with liquid CO2 can be set on the scale display.

Fig. 4.3: Floor scale with filling connection

4.1.3 The scale display with controls

An electronic scale monitors the filling process. The filling process stops automatically when the
required filling weight is reached.
For this the scale display L115 is fitted with one switch point.

At the customers request the scale of the filling unit can be delivered with PTB-admittance* and
dealer calibration. In this case it is not necessary to make control weightings on a second scale.
Otherwise the filled bottles must be checked on a second scale.

* PTB: Physikalisch Technische Bundesanstalt

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5 TRANSPORT AND INSTALLATION

Note! Read this manual carefully before starting up the installation.

5.1 TRANSPORT
For lifting instruction please refer to chapter 05-Drawings General Assembly

Warning The CFU is heavy and due to its shape injuries can occur when
not handled carefully.

5.2 UNPACKING
Check if the delivery is complete and undamaged.

If the delivery is incomplete or damaged, please contact Haffmans BV immediately.

Take pictures of the damaged goods.
Always include in the correspondence (if available) the serial number, project number, invoice
number and pictures of the part in question.

5.3 ASSEMBLY
The erection and commissioning should only be carried out by an experienced and qualified
personnel.

Note! All the relevant manuals and / or instructions included

requirements should be closely monitored.

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5.4 INSTALLATION
Make the following connections between the different parts of the cylinder filling unit and the
storage tank (all according drawings to be found in chapter ’05-Drawings General Assembly'):
• Liquid CO2 suction line to pump
• Liquid CO2 return line to the storage tank
• Mount the weight platform in a concrete setting (Fig. 5.1)
• Connect the metallic hoses from the pump to the filling connection. (Fig 5.2)

Fig. 5.1: Overview of the weight platform installation

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Fig. 5.2: The filling unit connections installation

• Connect all electrical items from the refrigerant according the electrical drawings to be
found the appendix of this manual.
• Ensure that the CO2 pump crankcase contains the correct quantity and grade of oil (see
Chapter 7: Maintenance).

Note! Take care that the pipe material is in accordance with the
engineering diagram.
The distance between pump and tank must be as short as
possible.
For a good construction, the suction line should have a slope
towards the pump of at least 2.5% and may not rise in between.
All piping and valves must be insulated before start up.

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5.5 INITIAL START-UP

• Check that the valves on the storage tank, to and from the pump, are open and purge
softly the suction line until liquid CO2 is present.
• Switch on the electric panel the pump and the scale (I/O switch). Check that the rotation
of the pump is in the right direction.
• Check in the return line if liquid CO2 is present. This can be done by shortly opening the
drain valve.
• Let the system operating on return flow for at least 10 minutes to cool the whole system.
• When the system is cold it is ready for use. Read the Chapter 6: Operation for filling the
cylinders.

The panel and scale normally stays switched “ON” even when the unit is not in operation.

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6 OPERATION

Note! Prior to performing the daily operations to the system, the

installation needs to be checked to guarantee optimal reliability
and safety.

The panel and scale normally are switched “ON” even when the unit is not in operation.
When the installation is not switched “ON” check the installation thoroughly using the Chapter
5: Installation and Initial startup as a guide line.

6.1 INSPECTION
6.1.1 Check all cylinders prior to filling:

Warning Wear protective gloves at all times when handling and filling
cylinders.

Note! Segregate filled cylinders from empty cylinders and keep rejected
cylinders far away from ‘clean’ cylinders at all times.

1. Visually inspect all cylinders for fitness.

2. Check cylinder markings. Mark and reject any cylinder not for use with carbon dioxide.
3. Check last hydraulic test date stamp. Mark and reject any cylinders not currently within
the inspection period.
4. Check the operation of the cylinder valve.
5. Check cylinders for corrosion, damage or other faults.
6. Cylinders should be checked for odours. This can be checked by pointing the cylinder
valve outlet away from personnel, opening the valve and blow-off a small amount of
residual gasses. Reject any cylinder where there is an odour indicating contamination.

Warning CO2 is asphyxiating and causes breathing troubles or even death.

Opening valves of cylinders for odour check or blowing off
residual gasses must take place at well ventilated places,
preferably outside. When checking for odours wave with your
hand some CO2 to your face and exchange this with longer
periods of breathtaking.

7. Cylinders with residual pressure should be checked for odours and if there is any doubt
of contamination with other (odourless) gasses, the cylinder must be marked and
rejected.
8. If there is any possibility of liquid contamination in the cylinder it should be inverted and
allowed to drain. Mark and reject if contaminated.
9. If frosting occurs on the cylinder during blowing off residuals, allow this to thaw
completely before re-filling.
10. Ensure that the cylinder is completely empty before starting filling operation.

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6.1.2 Check the installation prior to filling:

1. Check the level of the crankcase lubricating oil.
2. Check the installation for leakages.

Note! The platform must be empty during the starting procedure!

3. The scale must show “0” when the platform is empty. If the display does not show “0”
press the “Zero” button.
4. Control weighing: Put control weight on the platform. The display must show the same
weight as the control weight.

6.2 OPERATION
6.2.1 Filling of the cylinders
1. Place cylinder to be filled on the weighing-scale and adjust the height of the filling
connection.
2. Connect filling connection to the cylinder and open the valve of the cylinder.
3. Program the desired filling weight.

Warning Do not overfill the cylinder, program the correct filling weight of
the chosen cylinder.

4. Use only the external keyboard to set the set point. Only one set point can be stored in
the memory of the L115 display.

Setting of the set point:

• Open memory – press “1” and “Fill”
• Type in the weight
• Confirm input with “Enter”
• Close memory (end) with “Fill”

Warning It is dangerous to overfill cylinders. Local regulations for the

filling and the filling limits of the cylinders must be adhered at all
times.

5. Start the filling by pushing the ‘Start’-button. The return valve will close and the filling
valve will open.
6. As soon as the desired weight (set point) is reached the return valve opens and the
filling valve will close.
7. Close the valve of the cylinder.
8. Depressurize filling connection, by slowly unscrewing (vent hole will release the
pressure).
9. Disconnect filling connection and fit cylinder valve cap.

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6.3 OPERATION PANEL

Functional description of the buttons.

Button: Function:
CE : erases last input
Zero : set scale to zero
Fill : opens witch point menu
Enter : confirms input-data
Start : starts filling process

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7 MAINTENANCE AND CLEANING

7.1 MAINTENANCE
7.1.1 After 50 hours or 1 week of operation
• Check the level of lubricating oil.
• Check pump for leakages.
• Check the correct tension and wear of the V-belts.
• Check and clean the inlet strainer of the pump.
• Check the insulation for damage or signs of vapor barrier breakdown.

7.1.2 After 500 hours of operation or half yearly

• Drain the crankcase and refill with synthetic SAE 0 W 40 grade oil.
• Check the correct tension and wear of the V-belts.

7.1.3 Yearly
• Drain the crankcase and refill with synthetic SAE 0 W 40 grade oil.
• Check the correct tension and wear of the V-belts.
• Check the valves, valve seat and spring for wear and replace them if necessary.
• Inspect the pump discharge and suction valve for signs of wear and renew if necessary.
• Check the crankshaft bearings and connecting guide pin for excessive play and renew if
necessary.
• Tighten all studs, nuts and cap screws and check all gaskets and connections for
leakage.
• Check and clean the inlet strainer of the pump.
• Check the pump for bearing noise and replace the bearings if necessary.
• Check all piping for leakages
• Check the installation for corrosion
• Check the insulation for damage or signs of vapor barrier breakdown.

7.2 CLEANING
Marked and rejected cylinders which were contaminated with odors, other gasses or liquids
must be cleaned.
Gasses can be cleaned by purging the cylinder. This means filling the cylinder for about 5% with
clean CO2 and depressurizing them to free air. This is done several times until no contamination
is detected anymore.
Liquids and other contamination must be cleaned by depressurizing the cylinder, removing the
valve and cleaning the cylinder inside with high pressure steam cleaners.
According to local regulations a new hydraulic or pressure test may be needed.

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8 TROUBLE SHOOTING AND REPAIR

8.1 TROUBLE SHOOTING
Failure Possible cause Which action is needed
CFU no pressure build-up. The bypass valve does not Disassemble and clean the
close. valve.
The pump valves leak. Clean or replace the valves.
(polluted)
Gas in the pump. Degas the lines before
starting the pump.
CFU fills the bottles too The bypass valve does not Disassemble and clean the
slowly. close 100%. valve.
CFU does not pump any The line is filled with CO2 Degas the line before filling.
liquid. gas.
Too much gas in suction line Insulation is ineffective, repair
is needed
CFU scales give an incorrect The scales are not level. Check the ground calibration.
reading The weighing facility is Clean the weighing unit.
polluted.
The scales have been Check the calibration.
incorrectly calibrated.
CFU filling does not stop The switch-off point has been Check the settings.
automatically set incorrectly.
The set weight has been Check the Tara weight.
input incorrectly.

8.2 REPAIR
There are no repair issues.

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9 STORAGE AND DEACTIVATION

9.1 STORAGE
All parts must be stored in a dry environment with temperatures above 0°C.
Check that equipment can not be filled with water.

9.2 DEACTIVATION
When deactivating the cylinder filling unit act regarding following guidelines:

Note It is presumed that no cylinder filling unit is connected when

using following guidelines

1. Close the liquid inlet valve and secure this with a lock.
2. Close the gas balance valve on the pump and secure this with a lock
3. Switch off the road tanker pump on the switch panel and lock the switch.
4. Remove the fuses of the pump.
5. Empty the content of the piping by opening the drain valves.

Warning Liquid CO2 is very cold and causes burns. Use gloves which
protect against cold liquids when draining systems or e.g.
handling liquid leakages.

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10 ENVIRONMENT
10.1 ENVIRONMENTAL REQUIREMENTS
There are no special environmental requirements for this cylinder filling unit.

10.2 AFTER DEACTIVATION

After deactivation the following material will be released:
• Iron
• aluminum cladding
• insulation foam

Separate these materials and dispose them environmentally friendly and according local
regulations.

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