Aquila RE160 UNI User guide

ORIGINAL
Instruction manual for
Recovery unit RE160 UNI
By Aquila Triventek
Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. [phone] · [e-mail] · www.aquila-triventek.com
DIP
-
D
RY
I
CE
P
RODUCTION

2
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Table of contents
1 INTRODUCTION 4
1.1 What is dry Ice? 4
1.2 Recovery unit 4
2 SAFETY 4
2.1 Safety data for Carbon Dioxide (CO
2
) 4
2.2 Safety data for Recovery unit RE160 UNI 6
3 EQUIPMENT FOR OPERATION 7
3.1 Delivery 7
3.2 Delivered equipment 7
3.2.1 Identification of main components in Recovery unit RE160 UNI 8
3.3 Connection of the equipment 13
3.3.1 Power supply 13
3.3.2 Connecting the hoses 13
4 OPERATING LIMITATIONS 14
5 OPERATING THE EQUIPMENT 14
5.1 Operation panel 15
5.2 Pressure gauge panel 16
5.2.1 Normal gauge readings during operations 16
5.2.2 Liquid CO
2
detector and reservoir 16
5.2.3 Automation 17
5.2.4 Power supply and control protection system 17
5.2.5 Pressure protection system 17
5.2.6 Main menu structure 18
5.3 Starting up the RE160 19
5.3.1 Stopping the RE160 20
6 ALARM MESSAGES 21
- Emergency stop 21
- Phase sequence protection 21
- CO
2
compressor protection 21
- CO
2
fan protection 22
- Too much oil in filter 22
- Low oil level 22
- High temperature 1st stage 23
- High temperature 2nd stage 23
DIP
-
D
RY
I
CE
P
RODUCTION

3
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Table of contents
6 ALARM MESSAGES
- Cooling 23
- Cooling compressor protection 23
- Cooling internal protection 24
- Cooling fan protection 24
- Cooling low pressure 24
- Cooling high pressure 25
- Cooling compressor oil diff. switch 25
7 MAINTENANCE 26
7.1 Maintenance intervals 26
7.2 Oil filter 26
7.3 Inspection and refill of CO
2
compresor oil 27
7.4 CO
2
pressure and venting 30
7.5 Maintenance and inspection of refrigeration system 31
7.5.1 Insufficient refrigiration 31
7.5.2 Refrigerant condensation high pressure 31
7.5.3 Refrigerant evaporation low pressure 32
7.5.4 Insufficient heat transmission in the CO
2
condenser 32
8 CLEANING THE EQUIPMENT 33
9 STORAGE 33
10 RECOMMENDED SPARE PARTS LIST 34
11 TROUBLESHOOTING 37
12 TECHNICAL DATA 40
12.1 Proporties of carbon dioxide 41
12.2 Electrical charge 42
13 EC DECLARATION OF CONFORMITY 57
14 GUARANTEE 58
15 DELIVERY REPORT 59
DIP
-
D
RY
I
CE
P
RODUCTION

4
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Introduction
We are pleased that you have chosen the Recovery Unit RE160 UNI by Aquila Triventek A/S for your company. The re-
covery RE160 UNI is especially designed to be connected to multiple types/brands of pelletizers, and not only the Aquila
Triventek PE80 Pelletizer.
This technology is the subject of a Patent application No. 0408224.4.
To obtain long and trouble-free operation of the equipment we recommend reading this manual carefully. All new
operators of the equipment should also familiarize themselves with the content of this document.
1.1 What is Dry Ice?
Carbon dioxide is a chemical compound formed by combining one atom of carbon with two atoms of oxygen and is
expressed by the chemical symbol CO
2
. It can exist in three states: as gas, as liquid or as a solid.
Dry ice is frozen carbon dioxide (CO
2
). The unique property of carbon dioxide is that at normal, atmospheric pressure
and temperature, it changes state directly from solid to gas without going through a liquid phase.
This process, called sublimation, makes the ice ‘dry’ and is exploited both for blast cleaning and for cooling. Dry ice
is stable at (minus) -79 ºC, at atmospheric pressure. It expands up to 800 times by volume when it
sublimes, and this property is exploited in the blast cleaning application.
1.2 Recovery Unit
Normal dry ice production uses liquid CO
2
which when brought to normal atmospheric pressure, in e.g. a pelletizer
converts to one half snow and one half gas, called ‘revert’ gas. The snow is then compressed into dry-ice pellets.
But, by using the RE160 UNI Recovery Unit, the revert gas, which is usually lost into atmosphere, is collected and
recycled to make more pellets. This becomes a continuous process and will, as a result, reduce production costs by up
to 50%.
Safety
2.1 Safety data for carbon dioxide (CO2)
Hazards identification
Liquid carbon dioxide is stored in pressure vessels and must be handled according to the vessel manufacturers´ and the
carbon dioxide suppliers´ instructions.
1. Precautions must also be taken when mounting and dismounting the hose for liquid carbon dioxide. The liquid
may be under pressure and could spray into the surrounding area, forming dry ice and causing frostbite and eye
damage.
2. Be careful if a liquid CO
2
hose is blocked by dry ice. The pressure behind the dry ice blockage will rise due to evapo-
ration of liquid CO
2
. A powerful blast will occur when the blockage breaks. DO NOT dismount a hose if it is blocked,
or if it is suspected to be blocked by dry ice. Loosen the connection slightly so that gas can escape. Leave the hose
until the blockage is evaporated.
DIP
-
D
RY
I
CE
P
RODUCTION

5
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Solid
Contact with product may cause cold burns or frostbite due to the low temperature at (minus) -
79 ºC. (-110 F).
Solid dry ice sublimates into gas. This can cause pressure to build up in e.g. a container which is not suitably vented.
First aid measures
If contact with eyes: immediately flush eyes thoroughly with water for at least 15
minutes. In case of frostbite, spray with tepid water for at least 15 minutes. Apply a sterile
dressing. Obtain medical assistance.
Inhalation of sublimated CO
2
(gas)
CO
2
is heavier than air and may accumulate to hazardous levels in an unventilated enclosed area such as a small room,
tank, silo or pit. Always ensure adequate natural or mechanical ventilation or breathing apparatus in any hazardous area
such as a tank, silo or pit.
CO
2
is odourless therefore use always a CO
2
detector in working areas.
Low concentrations of CO
2
cause increased respiration and headache.
In high concentrations carbon dioxide gas can cause asphyxiation by displacing the oxygen required for breathing.
Symptoms may include loss of mobility or consciousness. Injured may not be aware of asphyxiation.
First aid measures
Remove Injured to uncontaminated area, the rescuer should wear breathing apparatus e.g. an emergency breathing air
bottle and mask to ensure that he/she does not also fall victim to asphyxiation. Keep Injured warm and rested. Call a
doctor. Apply artificial respiration if breathing has stopped.
Exposure controls / personal protection
Exposure limit: 5000ppm
The normal concentration of CO
2
in the atmosphere is 300ppm.
Personal protection: Protect eyes, face and skin from contact with solid product. Protect skin, especially hands,
from cold by wearing insulated gloves.
Training
The hazard of asphyxiation can be overlooked and must be stressed during operator training. Before using dry ice in
any new process or experiment, a thorough material compatibility and safety study should be carried out.
Ensure all national / local regulations are observed. The European Industrial Gas Association (EIGA), see www.eiga.org/,
provides useful background material and guides to good practice.
DIP
-
D
RY
I
CE
P
RODUCTION

6
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
2.2 Safety data forRecovery Unit RE160 UNI
Always use the following safety precautions:
Breathing apparatus
Where sufficient ventilation, either naturally or by mechanical means,
can- not be provided then a suitable supply of breathing air should be
arranged.
It is also recommended that an emergency breathing air bottle and mask be
provided in the vicinity of any carbon dioxide operations. The emergency
apparatus is for use by the rescuer in case of any incapacitation of a person
in an area where carbon dioxide has accumulated and could cause asphyxia-
tion to the rescuer.
System under pressure
Become aware that some part of the system is under pressure during
operation. Do not disconnect hoses when pressurized.
Inhalation of vaporized CO
2
In insufficiently ventilated rooms, an increased concentration of CO2
might lead to breathing difficulties as well as to suffocation. Always
ensure a sup- ply of fresh air in enclosed rooms. A CO
2
detector should be
used to confirm safe conditions. Where necessary, use a breathing mask
with suitable fresh air supply.
As CO
2
gas is heavier than air, please be aware of CO
2
build-up in lower working areas.
DIP
-
D
RY
I
CE
P
RODUCTION

7
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Equipment for operation
3.1 Delivery
Transport
After the Recovery Unit RE160 UNI has been delivered, it must be checked for damage which may have occurred during
transport. If necessary, the transport company must be informed to register the damage. Check that all parts described
on the delivery note have been delivered.
3.2 Delivered equipment
The Recovery Unit RE160 UNI by Aquila Triventek consists of the following items:
Recovery Unit RE160 with build in condensing unit
One complete connection hose pack and nessesary check valves as described in
your written order confirmation.
Revert gas buffer/receiver tank if ordered.
The Recovery Unit RE160 UNI and the equipment must be handled carefully to avoid shock damage to
mechanical and electrical components.
DIP
-
D
RY
I
CE
P
RODUCTION

8
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
2
1
3.2.1 Identification of main components in recovery unit
1:
Second stage CO
2
compressor
(item no. 22400000)
2 :
First stage CO
2
Compressor
(item no. 22400004)
DIP
-
D
RY
I
CE
P
RODUCTION

9
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
4
3
2
1
1:
CO
2
Gas cooler
(item no.
36359584)
2:
St.1 motor 7,5kW 50/60Hz
(item no. 22103010)
3:
4:
St.2 motor 4kW 50/60Hz
Complete refrigiation unit condenser Bitzer
(item no.
22103008)
DIP
-
D
RY
I
CE
P
RODUCTION

10
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
1
2
1:
CO
2
Gas cooler
(item no. 36359584)
2:
Check valve NRV16
(item no. 34739502)
DIP
-
D
RY
I
CE
P
RODUCTION

11
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Components for 3*220V; 60Hz
1:
Main switch
2: Motor protection 4,7A
3: Motor protection 39A
4: Motor protection 27A
5: Motor protection 40A
6: Motor protection 7,8A
7: Transformer 240V/24V
8: Separation transformer
9:
Contactor DILM50
10: Contactor DILM40
11: Contactor DILM7-01
12: Contactor DILM32-01
13: Contactor DILM32-01
14: Contactor DILM7-01
15:
Main PLC
16: EPROM for PLC
17: Slave module PLC
18: Relays 24V DC
19: Relays 230V AV
20: PT1000 to 4-20mA converter
21: EKC315A controller
22: Transformer 230V/24V
23: Phase monitoring relay
8
7
6
5
4
3
2
1
9
10
11
12
13
14
23
22
21
20
19
18
17
16
15
DIP
-
D
RY
I
CE
P
RODUCTION

12
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Components for 3*400V; 50Hz
Main switch
Motor protection 4,7A
Motor protection 0,75A
Motor protection 18A
Motor protection 15A
Motor protection 31A
Motor protection 2,5A
8: Motor protection 2,5A
9: Motor protection 5A
10: Motor protection 0,75A
11: Transformer 240V/24V
12:
Softstarter 25A
13: Softstarter 15A
14: Contactor DILM7-01
15: Contactor DILM17-10
With auxiliary contact module 4NO
16: Contactor DILM17-10
17- 21: Contactor DILM7-01
22: Main PLC
23: EPROM for PLC
24: Slave module PLC
25: Relays 24V DC
26: Relays 230V AV
27: PT1000 to 4-20mA converter
28: EKC315A controller
29: Transformer 230V/24V
30: Phase monitoring relay
1
2
3
4
5
6
7
8
9
10 11
1:
2:
3:
4:
5:
6:
7:
12
13 14 15 16 17 18 19 20 21
30
29
28
27
26
25
24
23
22
DIP
-
D
RY
I
CE
P
RODUCTION

13
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
7
6
5
4
3
2
1
3.3 Connection of the equipment
3.3.1 Power supply
The RE80 is delivered with a 63Amp cable without plug. The plug has to be mounted locally to fit local socket-
design.
Take of the side cover and pull the cable with box out under the frame and connect to your own power supply.
Remember to turn of the main switch before applying power to the unit.
3.3.2 Connecting the hoses (RE160 + PE80 pelletiser)
The connectors are different for each hose and will only fit into the right connections at the Recovery Unit, and at the
Pelletizer.
Always ensure that the hoses are arranged as straight as possible i.e. with easy radius bends and avoiding kinks which
may increase pressure drop, or even stop flow.
Connection table:
1:
3/8” BSP
Pressure equalisation from pelletizer (only for PE80 pelletizer)
2:
1/2” BSP
Liquid CO2to pelletizer
3:
1/2” BSP
Liquid CO
2
from tank (only with PE80 pelletizer)
4:
1 ½” cam male
CO
2
revert gas from pelletizer
5:
1 ½””cam male
Buffer tank
6:
Pressure relief
7: Main electrical power supply cable
DIP
-
D
RY
I
CE
P
RODUCTION

14
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
Operating limitations
RE160 UNI
•For a standard configuration machine, the surrounding working temperature should be between -25°C
and 40°C. (-13°F - 104°F)
•The machine should never be stored in an ambient temperature exceeding 50ºC. (122°F)
• When choosing a location for the Recovery Unit RE160 UNI, the room must be dry, clean and well ventilated.
•Make certain that the Recovery Unit RE160 UNI is placed on a horizontal plane with a maximum slope of 2°C
• It is not recommended to locate the Recovery in dusty and/or dirty surroundings. The CO
2
gas cooling coil fins can
be covered with dirt the performance of the Recovery will be reduced.
• The perforated covers at the left side of the unit (looking from the electrical box) are for the air intake for the CO2
gas cooler and for the condensing unit. Exhaust of hot air is on the right side of the unit (cover with fans). The air
intake side must have at least 2m of free space to any walls. The exhaust side must have at least 5m of free space. In
any case a proper air circulation has to be ensured, meaning that the hot air must not circulate back to the air intake
side.
Condensing system
•The min./max. ambient temperatures for the Condensing unit is -25°C to 40 °C (-13°F to 104°F) at normal air
humidity.
•The unit should never be stored in an ambient temperature exceeding 50 °C
• The unit must be protected against direct sun and rain
•Air flow through the condenser coil is approx. 7300m³/h and requires a well-ventilated room or facility. If the
airflow is restricted the cooling capacity will decrease as above (2% per 1°C).
•The foundation must be solid and as level as possible. Max. slope 2 °C.
• The unit is only designed to operate with R452A refrigerant. Any other refrigerant can damage the compressor and
influence the capacity.
Operatingtheequipment
Use the Recovery Unit RE160 only for the designed purpose and follow the guidelines described in this manual.
DIP
-
D
RY
I
CE
P
RODUCTION

15
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
5.1 Operation panel
The operation panel at the front of the RE160 UNI includes the following functions:
Buttons:
1: Display
2: Manual start button
3: Manual stop button
4: Emergency stop button
DIP
-
D
RY
I
CE
P
RODUCTION

16
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
5.2 Pressure gauge panel (from left)
1. CO2 Gas pressure from pelletiser
2. CO2 Gas pressure
Pressure after 1st stage compression
3. CO2 Gas high pressure
Pressure after 2nd stage compression
5.2.1 Normal gauge readings during operations
These are the readings you would expect to see after the Recovery has cooled down and commenced stable operation
(after 10-15 minutes)
Refrigeration Condensing Pressure: Between 13 and 22 bar.
Refrigeration Evaporation Pressure: Between 1 and 2 bar.
CO2 Gas Pressure from Pelletizer: Between 0,1and 0,8
bar.
Pressure after 1st stage compression: Between 4 and 5 bar.
CO2 High Pressure: Between 16 and 20 bar.
5.2.2 Liquid CO2 detector and reservoir
The liquefied CO2 flows to a small reservoir containing a level sensor. The level sensor gives a signal to the
control system when liquid CO2 is detected and a yellow light shows. The green light indicates that the level detector is
electrically supplied.
Function:
Green light = Power on
Yellow light = Liquid CO2
Red light = Error
DIP
-
D
RY
I
CE
P
RODUCTION

17
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
5.2.3 Automation
The following operations and features are automated
5.2.4 Power supply and control protection system.
A voltage monitoring relay in the panel stops the recovery and lights up the electrical failure lamp on the panel. The relay
switches off if the voltage is too low, the phases order is wrong or a phase is missing.
5.2.5 Pressure protection system.
The recovery will only run if the revert gas hose from the pelletizer is pressurized (0.1-0,8 bar (1.45-8.7 Psi)).
The pressure is constantly measured in order to prevent air from entering the Recovery. When the pressure drops to 0,1
bar, the internal pressure relief is opened in order to keep the unit running (in case some small disturbance between the
pelletizer and Recovery takes place).
When the pressure drops down to 0,0 bar the CO2 compressors stop after 60 seconds. Message “CO2 INLET
LOW” shows
on the display. The refrigeration part in the unit keeps working for maximum 30 minutes. If the pressure will rise back
the unit will start automatically (immediately if the refrigeration part was still running or after few minutes if the whole
machine was stopped (see the starting and stopping sequence described page 18).
If the pressure rises above 0,8 bar, the AV304 valve is opened in order to drop the CO2 gas. When the pressure
keeps
rising and reaches 1,0 bar, second valve - AV302 – opens in order to lower the pressure.
DIP
-
D
RY
I
CE
P
RODUCTION

18
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
5.2.6 Main menu structure - RE160 UNI PLC
Main menu is as shown above.
1. Cooling pressures
2. CO2 pressures
3. CO2 temperatures 1st and 2nd stage.
4. Working hours counter
5. Time and date
6. Status on Recovery
7. Settings
8. Alarm log
9. I/O status
10. Home button.
DIP
-
D
RY
I
CE
P
RODUCTION
1
2
3
4
5
6
7
8
9
10

19
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
5.3 Starting up the Recovery Unit RE160
• Check equipment visually before starting to ensure that all hoses and cables are properly connected.
• Ensure that main power has been turned on for min. 4 hours. **
•If “STOP” status shows on the display push the white “ON” button – the status should change for “WAIT”
• As soon as pelletizer starts running and revert gas pressure exceeds 0,2bar, the start-up sequence is initiated
on the Recovery Unit. Some blow-off will occur until the Recovery has stabilized (ab 60 seconds). After that
time message “RUN” will show on the display.
The unit can be started manually by pressing the “ON” button or if not then it will start automatically
after 5 minutes. During production some minor intermediate blow-off can occur due to variations in production,
high surrounding temperatures or too big pelletizer capacity compared to the Recovery capacity.
** Caution
At start up after more than 3 hours stand still the power has to be turned on for min. 4 hours due to the crankshaft
heating in the Cooling unit of the RE160. Any attempt to start earlier will damage the compressor of the Cooling unit.
The unit needs to be powered up for 6 hours, if ambiente temperature is below 10 deg.
DIP
-
D
RY
I
CE
P
RODUCTION

20
Aquila Triventek A/S Industrivej 9 DK-5580 Noerre Aaby Tel. [phone] · [e-mail] · www.aquila-triventek.com
5.3.1 Stopping the Recovery Unit RE160 UNI
Stopping without depressurising the system.
The Recovery and pelletizer can be stopped at any time. It is not advisable to switch off the power or use the emer-
gency stop button without first emptying the Recovery of liquid CO2. The liquid CO2 will evaporate through
the safety valve. The purpose of the safety valve is to protect the Recovery and the surroundings against damage
caused by too high CO2 pressure. The safety valve is not supposed to be used regularly. If the power is switched on
the CO2 vapour will evacuate through the blow-off solenoid valve.
Note: The Recovery Unit, Pelletizer and the hoses are under pressure. DO NOT attempt to disconnect any hoses
before depressurising.
Depressurising the system before stopping.
1. Close liquid CO2 valve at vessel.
2. The pelletizer and CO2 part of the Recovery stops automatically after a short time from the moment when the
supply of liquid from the tank has been closed. After the pelletiser has stopped, it is advisable to turn also the
Recovery unit off by pressing the “OFF” button. The message “STOP”will show on the display. The
machine will not restart unless the “ON” button is depressed.
CAUTION : After manual shut –off (by pressing the OFF button) the unit will not restart automatically. The status
“STOP” will be displayed on the panel. If the “OFF” button will not be pressed, the Recovery will also shut
down automatically with “C02 INLET LOW” message on the display, but it is possible that the unit will try
to restart several times.
3. Now it is possible to disconnect the depressurised hoses.
Note: Some overpressure must be expected. Disconnect with caution.
Depressurising the system if there is a power failure.
1. Close liquid CO2 valve at vessel.
2. The automatic valve system of the PE80 will ensure that close-down and depressurisation will commence
correctly.
3. WAIT until the pressure has dropped (no more gas coming out).
4. Now it is possible to disconnect the depressurised hoses.
DIP
-
D
RY
I
CE
P
RODUCTION