Sharing 2 Page Reference Sheet For Operating A Common CO2 Tank Beverage Carbonator w/Soda Gun

[jimtmcdaniels]

Hi, 

Just wanted to share here for whoever might find it helpful (Can alter it to fit your set up), a 2 page sheet made for operating/handling CO2 tanks for fizzy beverages.

The problem was there was no condensed easy to short read literature for staff & management to refer to and learn for operating, safety, trouble shoot and what to do in an emergency release with our CO2 system. 

SO after scouring the internet and bringing ALL the pertinent info in and then greatly condensing it, without cutting anything needed out.

We got a 2 page list. We printed it, laminated it and displayed it.

Wanted to share it below for anyone looking for something similar.  Also At the end, some labels we printed and added to some of the equipment.

Thanks Take care

 

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Soda Syrup, Water & CO2 Cylinders(aka “Tanks”) - Important Info

Syrup Bag-In-Box(“BIB”) Replacement (Syrup is empty/running clear):

1. Reach into the hose-connected-box opening & feel the syrup bag. 2. If it’s not totally empty: Enlarge the box opening so to hang the bag out. So that all the remaining syrup portion is outside & above the hose. The remaining syrup will flow again.  3. Otherwise if/once the bag is empty: Find & select the oldest new box of the same syrup (hose is also flavor labeled).

4. Follow the box instructions, hand tear cardboard perforation. Avoid puncturing the bag with your nails. 5. Pull the bag neck out & secure it in place.  6. Remove & discard the bag’s seal-cap. 7. Unscrew the hose’s colored knob from the old bag. 8. Screw the knob fully onto the new box. 9. If available: record on a change out/re-order log-sheet. 10. Discard the old bag in box (recycle the cardboard). 11. Trigger the soda gun until the new syrup comes out.

When a syrup bag runs empty, CO2 tank consumption increases greatly - syrup pump exhaust puffs, rapidly-sucking: If a new box is not available Or a pump is broken: quick disconnect(Pull Red-release tab) & pull out that pump’s CO2 white-supply-line. It auto seals.

Syrup hose knob’s color coding & fitment vary: Red=Coke Brand, Green=Pepsi Brand, Maroon=Dr Pepper, Yellow=non-diet, Red=diet(artificial Sweetener), Blue or White=Sometimes Caffeine Free, Orange or Green, etc=Specialty/Energy/Juices. Black=Sweetened sodas, Grey=QCD pop-out-style connectors for non-Coke/Pepsi products.

Individual Syrup & Water Flow Cut-Off Valves:

Soda Gun - when a button is not shutting off: Manually turn off that liquid’s supply hose, by turning its yellow knob, found on the soda gun hose’s wall-mounted-manifold. Order repair.

Water/to Carbonator Supply, Main Shut Off Valve location: Under NE Bar Sink upstairs.

 

CO2 Tanks & related equipment should Only be handled & operated by authorized & properly trained personnel. Wear appropriate PPE: gloves, safety goggles & protective clothing.

 

Tank Replacement?(Soda water is flat): If the line(carbonator) gauge reads above 100 psi, check: the carbonator’s AC power plug & if the Soda water is not cold, ice chest needs filling.  Otherwise verify tank gauge is also reading low, proceed to replace the depleted Tank:

Disconnecting the Old Tank Hose (keeping Tank Outlet pointed Away from you):

1. Turn Tank’s top-knob-valve-off(CW). 2. Using the supplied 7/8” wrench & finally your hand: Unscrew(CCW) & disconnect the hose’s female coupler-nut.  3. Remove the used sealing-washer (can be saved to repurpose. For a non-sealing ordinary-washer purpose).

Connecting A New-Full Tank: 1. Select one(dust-cover is unsealed). 2. Open cover, revealing a new sealing-washer to use in hose’s coupler-nut. 3. Very briefly-slightly open & close the Tank knob, blows out any foreign material. 4. Strongly hand screw(CW) the hose’s coupler-nut onto the tank(avoid cross threading). 5. Use the supplied wrench to turn the Nut further, approx. 1/4 - 3/4(“good & tight”). 6. Turn fully Open(CCW) the Tank Valve. If leaking/hissing, tighten the nut more. 7. Trigger the soda water gun until carbonated water comes out.

 

Checking for small CO2 gas leak(s) - 2 common methods:

▶︎ 1. Pause dispensing. With Tank connected to the hose, Tank Knob Open & Gauges stable: 2. Listen for any faint leaking sound(s). 3. Next: Close(CW) the Tank Knob. 4. Note All 3 gauges’ readings. 5. Any dropping, even subtly, indicates a leak. 6. To test for smaller leaks, write down readings & come back 5-30 min. later(overnight is best) to check for any changes.

▶︎ 1. Brush/Spray onto the Hose to Tank connection: a sudsy mixture of 1:10 (dish soap:water). Also anywhere the system might leak.  2. Expanding soap bubbles, indicates an active leak.

With no leaks, a 20 LB tank makes approx. 140 gal. Soda(using 23.5 gal. of box syrup @ 5:1).

3 Pressure Gauges @ manifold:

1. Line w/Adjustable(105 PSI=Ideal) Regulator (Carbonator/Fizzy Water Maker): Hoses(Connections, Disconnect Check Valves), Carbonator(Tank, Valves, Internal Water/CO2 Back-flow Check Valve), Soda Gun(Fittings/Handle button Valves).

2. BIB(Bag-In-Box) Pumps Adjustable(65 PSI=Ideal) Regulator: powered by CO2 gas exhaust “Puffs”. Hoses/Manifolds to Syrup Pumps, Pump Diaphragm.

3. Tank (CO2) fill. (If in the Red & Line gauge is below its 105 psi setting=replace the tank).

(Multiple gauges dropping indicates: a leak before the Adj. knob regulators Or multiple leaks).

Lifting Tanks: A common “20 LB size” Aluminum CO2 tank, weighs 25 LB empty(T.WT) & 45 LB when filled(w/20 LB of liquid CO2). Use proper lifting techniques, your legs, not your back. Use 2 people when needed. Never roll, drop or drag a tank, it can damage the tank/valve.

Tank(s) Limit connected-to-equipment:  > 99 LB CO2 requires an alarm system & more.

Securely fasten ALL tanks, grouped together in place: Install the Restraining Buckle Strap tightly around the tanks’ metal bodies @ 2/3 rds height. Assure they can not move/fall over.

Transporting: Use equipment, such as trolleys/carts. During transport, storage & use, securely fasten tanks & in an upright position.  Fastened: with approved chains/straps/racks, to prevent them from falling/rolling damage & personal injury. Upright: so that the CO2 liquid is in the bottom, while the rising gas is in the top-valve portion of the tank. So that the valve can dispense the proper metered gas, to the connected gas receiving equipment.

Also to discharge only gas firstly, during any incidental high-pressure safety-valve discharge.

Common Uses of CO2: Various applications including fire suppression & medical & industrial processes. Also the Beverage Industry, to carbonate cold-water for soft-drinks/beverages.

 

Physical & Chemical Properties: Carbon dioxide is naturally present in our atmosphere @ .04%. Is a colorless, odorless gas, heavier than air & is non-flammable. When stored in a high pressure(860+ psi) metal CO2 tank, it’s a concentrated, potent high-volume liquid.

Potential Hazards Associated with concentrated CO2:

Asphyxiation: High concentrations can displace oxygen in the air.This is particularly dangerous in confined/poorly ventilated spaces/basements. Direct contact with escaping CO2 from a high-pressure tank can cause severe frostbite, due to the extremely low temperature, liquid releases create, as it rapidly expands(1 LB into 8.74 cu ft), back into a natural state.

Vent/Explosion Tank Hazard: An over filled/pressurized or over heated(125+ F) CO2 tank is designed to safety vent, but it could rupture, especially if damaged.  A rupture can cause serious injuries/property damage & even turn the tank into a very dangerous projectile.

Corrosion: CO2, when combine with cold water, forms a weak carbonic acid.

Store CO2 tanks in a dry place, separate from: reactive materials, gases & heat sources.

Primary safety concern is gas leakage: Tanks are robust, compared to the associated soda equipment. A large/long term leak can fill a room, incapacitating/suffocating persons. Fatal if exposure is long/severe enough. Heavier than air, CO2 tends to accumulate in low-lying areas(basements/floor areas/under). Lingering for hours if not properly ventilated.

Signs of a Large Leak: A hissing sound/frost formation. The presence of a white fog, etc.    

 

Immediate Actions are Critical in the Event of an Uncontrolled/Large Leak:

CO2 Tank Shutoff: If safe to do so. Use appropriate PPE & protect skin from frostbite. Evacuate the Area: Move everyone from the affected area to a separate well-ventilated location/outside. Account for everyone/assure no-one is left behind/has fallen unconscious.
Ventilate: Open doors & windows. Use ventilation systems/fans to disperse the gas.

Exposure Symptoms (Mild to Severe): From headache, dizziness, rapid breathing, to confusion, nausea, short breath, chest pain, loss of consciousness(might require CPR).

First Aid: CO2 doesn’t stay in the body. But severe/prolonged exposure=body organs stress & brain fog. Avoid injuries from falling. Monitor breathing & provide aid to anyone who has been exposed. Especially if severe & to vulnerable infants/children, pregnant women, elderly & those with a preexisting medical condition. Symptoms usually disappear within a few hours.

Call 911: Their first aid/oxygen treatment can be critically beneficial & is generally a totally Free service. A person’s insurance is only billed, if they need & agree to be transported.

 

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Some Helpful Equipment Labels (Print, cut out, clear scotch/box tape on both sides to make water proof. Attach with double sided tape on the label backside and Clear Tape On top). :

When a syrup bag runs empty, CO2 tank consumption increases greatly(syrup pump exhaust puffs rapidly-sucking): If a new box is not available Or a pump is broken: quick disconnect(Pull Red-release tab) & pull out that pump’s CO2 white supply line. It auto seals. Insert hose to reinstall.

 

Syrup(“BIB”)Bag In Box PUMP-

Powered By CO2 Gas Line

 

Syrup IN Hose

-From a Syrup Box

 

Syrup OUT Hose

-To Soda Gun

 

CO2 Hose To Syrup Pumps-

Gas Powers The Pumps

 

Red-release tab-(Pull Tab To Disconnect.

If needed, use a small tool, to pull Red tab towards you)

 

 

Please place used CO2 sealing-washers here.

Generally Not CO2 reusable.

Great repurpose, for a non-sealing,

ordinary-washer purpose.

Thank you!

 

TAKE CARE