Cold Jet Aero2 PCS 60 User manual

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Original Instructions [English]

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Copyright © 2022 Cold Jet, LLC
All rights reserved. Printed in the USA.
Due to continued product development this information may change without notice. The
information and intellectual property contained herein is confidential between Cold Jet and
the client and remains the exclusive property of Cold Jet. If you find any problems in the
documentation, please report them to us in writing. Cold Jet does not warrant that this
document is error-free.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in
any form or by any means, electronic, mechanical, photocopying, recording or otherwise
without the prior written permission of Cold Jet.
This manual reflects the product configuration as was current at the time of its writing. An
item’s display in this manual does not guarantee the item’s availability at any time in the future.
Images shown are for representation purposes only. Products may vary from the images
displayed. Cold Jet is not liable for typographical errors or changes to specifications presented.

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Contents
4
Introduction
6
Safety
8
Lock Out Tag Out
14
PCS Description
16
PCS 60 Data
17
PCS 60 Components
18
Applicators
20
Nozzles
22
Control Panel and HMI Screens
26
Operation
30
Compressed Air Supply
38
Advanced Settings
50
Cold Jet CONNECT
53
Inspection
57
Warranty
59
Technical Schematics
62
Contact Information
73

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System Identification
Locate the data plate for this machine and record the information provided in the spaces below. To view
documentation for your machine, scan the QR code:
ASSEMBLY No.
SERIAL No.
ELECTRICAL No.
AC VOLTS
PHASE
FREQUENCY
AMPS
MAX OPERATION PRESSURE
MOTOR KW
Mo./Yr.
SCCC
Supplier Responsible for the Equipment: Cold Jet, LLC
455 Wards Corner Road Phone: [phone]
Loveland, Ohio 45140 USA Website: www.coldjet.com

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Introduction
About This Manual
This manual should be kept with the machine and be readily accessible to machine operators and
maintenance personnel.
This manual contains information on the safety, transportation, operation, and maintenance of this
machine.
The graphics used in this manual may show machine details that may be different than the actual machine.
Components of the machine may have been removed for illustrative purposes or the continuing
improvement of the machine’s design may cause changes that are not included in this publication.
The owner of this machine is responsible for verifying the operator of this machine is trained and
understands the contents of this manual.
About The PCS 60
This machine combines patented technology in a lightweight and compact design that gives the operator
unparalleled control for dry ice cleaning and surface preparation.
The Advanced Air-Flow System reduces pressure loss as the air flows straight through the system which
also decreases sublimation and loss of the dry ice particles.
The Blast Pressure Control System can be regulated digitally from the 7” HMI color screen on the control
panel or certain applicators.
The Sure Flow System with Dynamic Agitation is designed to keep warm air, moisture, and debris out of the
hopper while keeping the dry ice flowing. The level of dry ice in the hopper can be monitored from the HMI
screen of the control panel or certain applicators.
The Advanced Direct Drive Feeding System is a two-stage feeding system that improves feed rate
consistency and maximizes dry ice particle integrity.
This machine includes a Particle Control SystemTM brand blast media resizer that allows the operator to
control the size of dry ice particles being blasted from 0.3 mm micro-particles to 3.0 mm pellets.
Environmental Impact
Dry ice is a safe, clean, and non-toxic medium approved by the EPA, USDA, and FDA. The dry ice used in
this machine is made from reclaimed CO2generated from other industrial processes.

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General Safety Guidelines
This machine is designed to comply with international design standards and the European Machinery
Directives. Therefore, using the machine does not pose a risk to the operator when the instructions in this
manual are followed. However, certain precautions must be followed during its use. To understand all the
necessary precautions, the machine operator must read the entire manual before operating or performing
maintenance on the machine.
Operation should only be performed by trained personnel. Below are some basic safety guidelines:
a. Follow local governing codes to ensure a minimum standard of safety.
b. Wear protective gloves, eye protection, and hearing protection.
c. Operate the machine in a well-ventilated work area.
d. Follow the prescribed Inspection schedule (see “Inspection” on page 57).
e. Start up and shut down the machine according to the instructions in this manual.
f. Do not operate a machine that is damaged or in disrepair.
g. Do not store objects on top of machine.
CO2Safety
WARNING Ensure adequate ventilation when operating this equipment to
prevent the build-up of carbon dioxide gas. If used indoors or other confined space,
a CO2 detector should be used to monitor for excessive unsafe levels of CO2 gas
and provide a suitable warning. The legal exposure limit by OSHA is a 0.5% average
over an 8-hour workday.
This machine uses dry ice (CO2in solid form). The temperature of dry ice is -109°F (-78.9°C). Avoid coming
into direct contact with dry ice as it may cause severe tissue damage. Study the material safety data sheet
(MSDS) of dry ice (CO2) supplied with the delivery of dry ice and follow all the recommendations and
guidelines listed therein.
Operate the blaster in a well-ventilated work area with continuous CO2-level monitoring. The effects of CO2
are entirely independent of the effects of oxygen deficiency. Therefore, CO2concentrations at 3-5% causes
headaches, fast breathing, and discomfort while higher concentrations may cause unconsciousness,
suffocation, or respiratory arrest. The legal exposure limit set by OSHA is a 0.5% average over an 8-hour
workday and the acute (15 minute) exposure limit is 3.0%.
Always use a CO2monitoring/alarm system when working with machinery that emits CO2in a confined
room/space.
Safety

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Electrostatic Discharge
WARNING Dry ice blasting may create electrostatic discharges which may harm
personnel. Ensure that the surfaces being cleaned are properly grounded with the
supplied grounding cable. This machine is fitted with effective electrostatic
dischargers to prevent injury or damage. It is recommended to avoid operating the
machine near explosive or flammable material. Also, use a polymer shovel when
handling dry ice to eliminate any electrostatic discharge.
Electrical Grounding
WARNING To prevent electrical shock, the machine must be properly grounded
using outlets and power cords that have a ground lug. The machine must be
plugged into a properly grounded outlet. If there is no ground connection, DO NOT
USE.

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Safety Labels
The symbols used on the machine were developed by the International Organization for Standardization
(ISO) and are defined below. These symbols may include yellow warning triangles, blue mandatory action
circles, or red prohibited action circles. ***Replace any safety labels or warning signs if they become damaged,
missing, or illegible.
Symbol Definition
Attention
Cold Temperature Warning
Pressurized Material Ejection Hazards
Electrical Hazard
Asphyxiation Warning
Wear protective gloves
Wear hearing protection
Wear eye protection
Read operator and maintenance manual
Do not operate without Safeguard Grate/guard in place
No foreign objects allowed inside machine
CO2is in use

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Safety Labels cont.
Protective Earth/Ground
Frame/Chassis Ground Terminal
Cautions and Warnings
Please review the following cautions and warnings before operating or performing maintenance on
the machine.
CAUTION Read the instructions before using the machine. Only qualified personnel should operate
the PCS 60.
WARNING Ensure adequate ventilation when operating this equipment to prevent the build-up of
carbon dioxide gas. If used indoors or other confined space, a CO2 detector should be used to monitor for
excessive unsafe levels of CO2 gas and provide a suitable warning. The legal exposure limit by OSHA is a
0.5% average over an 8-hour workday and the acute (15 minute) exposure limit is 3.0%.
WARNING Ensure that expended dry ice pellet emissions are not in the vicinity of air ducts that could
allow CO2 to enter another space.
WARNING Due to the nature of dry ice, and atmospheric conditions, use caution when operating,
storing, and cleaning the machine as condensate can build up and leave moisture on the ground near the
machine and blast hose. It is recommended to wear appropriate non-slip work shoes and it is necessary to
wipe up and dry any condensate from the work area that could cause a slip hazard.
WARNING This machine has been designed for use with 3mm dry ice pellets recommended by Cold
Jet. The use of other cleaning agents or chemicals may adversely affect the safety of the machine.
WARNING High pressure blast streams can be dangerous if subject to misuse. The blast stream must
never be directed at persons, live electrical equipment, or the machine itself.
WARNING Do not use the machine within range of persons unless they wear the required personal
protective equipment (PPE).
WARNING Do not direct the blast stream of air or air and dry ice against yourself or others.

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WARNING High pressure cleaners shall not be used by children or untrained personnel.
WARNING High pressure hoses, fittings and couplings are important for the safety of the machine.
Use only hoses, fittings, and couplings supplied by Cold Jet.
WARNING To ensure machine safety, use only original and replacement parts from Cold Jet.
WARNING The applicator and applicator hose contain electrical connections. Do not immerse in
water.
WARNING Only use Cold Jet applicators, nozzles, and hoses.
WARNING Do not use the machine if an electrical supply cord or important parts of the machine are
damaged or missing, e.g., safety devices, side panels, guards, high pressure hoses, applicator, hardware,
nuts and bolts, or screws.
WARNING Inadequate extension cords can be dangerous. If an extension cord is used, it shall be
suitable for the environment in which it is used. If used outdoors the connection must be kept dry and off
the ground. It is recommended that this is accomplished by means of a cord reel which keeps the socket
at least 2.4 inches (60 mm) above the ground. Ensure that the extension cord is properly sized for the
machine electrical requirements.
WARNING Always switch off the main disconnecting switch, or unplug the blaster power cord, bleed
any pressure, and disconnect the air supply when leaving the machine unattended or shutting down. Reel
the cord up to the machine and place a locking device over the plug of the unit when Lock Out Tag Out is
necessary.
WARNING Ensure all safety grates and machine covers are in place before operating the PCS 60.
WARNING Never insert a foreign object into the hopper of the machine for any reason without the
machine in Lock Out Tag Out (completely de-energized).
WARNING Dry ice blasting may create electrostatic discharges which may harm personnel. Ensure
that the surfaces being cleaned are properly grounded with the supplied grounding cable.

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Safety Label Locations

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Steps for conducting a Lockout Tagout or “LO/TO”
Throughout this manual, “Lockout Tagout” (LO/TO) will be referred to in instances when power must be
removed from the machine. There are (6) universally accepted basics to this procedure. They are listed
below but may not be limited to these (6) steps; each individual entity owning and/or operating a PCS 60
may have their own LO/TO procedures. Please refer to those procedures and decide which procedure will
provide the safest working conditions and environment.
Preparation: The first step to completing a proper lockout tagout is preparing the
equipment to be powered off:
Note: There are (2) energy sources that supply the PCS60: an electrical supply
and a compressed air supply. Both energy sources must be removed.
1. Shut Down: The machine’s power button is to be turned off.
2. Isolation: The electrical power supplying the machine must be turned off. The power cord
must be unplugged from the supply source. Leave power cord within visual distance of the
machine. The compressed air supplying the machine must be turned off and disconnected
from the machine.
3. Check for Stored Energy:At the applicator, press the “Air-Only” once, pull the trigger. No
activity should be present at the machine.
4. Isolation Verification: Does the machine have electric power or compressed air present?
The power button should have no luminescence presence; it should be off. The HMI display
should have no images present. At the applicator, press the “Air-Only” once, pull the trigger.
No activity should be present at the machine.
5. Verify the reason for using the LO/TO procedure has been solved. For example, if the
reason for initiating the LO/TO procedure was a screwdriver that fell into the hopper causing
the doser to stop, verify that the screwdriver has been removed. Once verified that the
problem is solved, in this case that the screwdriver has been removed, follow the
instructions to “Setting Up the PCS 60 System” on Page 41.
Emergency Stop
The Emergency Stop button is used if the PCS 60 must be shut down immediately. If any event
occurs that could cause harm to personnel or equipment, then use the Emergency Stop to shut
down the PCS 60. The Emergency Stop button is a push button. Once pushed, the button
becomes locked in the down position. The button must be rotated clockwise to reset. Once
rotated, the button will pop outward to its ready state. The display on the machine now turns to
a “Reset Screen.”
Note: When the PCS 60 is in idle, such as between cleaning cycles, the machine has full power to
all functions and motors.
Note: When the Emergency Stop has been activated, there is only power going to the control
board and safety relay. Nothing on the machine will operate until the emergency stop has been
reset.
CAUTION Do not use the emergency stop button to shut down the PCS 60
for anything other than an emergency.

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Reset Screen
The reset screen appears if the Emergency Stop Button has been depressed (activated) or if the
safety grate has been opened.
If an emergency has occurred in which the Emergency Stop button has been depressed
(activated), correct any issues that initially caused the emergency. When the issue(s) have
been corrected, reset the Emergency Stop button by following the instructions on Page 14.
If the Safety Grate has been opened, close it. Then, reset the Emergency Stop button by
following the instructions on Page 14.
Once the Emergency Stop Button has been reset or the Safety Grate has been properly
closed, press the rotary encoder dial as on the reset screen as shown below. This will cause
the machine to go through a calibration sequence that lasts about (15) seconds. It will then
return to its last mode of operation prior to shut down.
Reset Screen

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PCS 60 System Description
The PCS 60 may be supplied with the Performance Kit or the Precision Kit or both depending on what was
ordered with the purchase of the machine. An optional Advanced Applicator is available for purchase upon
request.
The standard applicator kits are as follows:
Performance Kit
•3/4 in or 1in Performance Applicator
•Performance nozzle
•Control cable
•Nozzle handle
•1in air supply hose 25 ft (7.62 meters)
•3/4 in or 1in hybrid-flex blast hose 20 ft (6.09 meters)
•Hose carrier
•Hose wrap
Precision Kit
•1/2 in Precision Applicator
•2 Precision nozzles
•Control cable
•1in air supply hose 25 ft (7.62 meters)
•1/2 in hybrid-flex blast hose 12 ft (3.66 meters)
•Hose carrier
•Hose wrap

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PCS 60 Data
Dimensions 38.75 x 18.98 x 45.03 in (984.33 x 482.21 x 1143.82 mm)
Weight 269 lb. (122 kg)
Blast Medium 3 mm dry ice pellets
Hopper Capacity 60 lb. (27 kg)
Power Requirement 110/220 VAC (50/60 Hz) = AMPS 4.5
Short Circuit Current Rating (SCCR) 10Ka
Air Supply Pressure 40- 145 psi (2.8-10 bar)
Air Flow 12-100 cfm at 80 psi (0.33-2.83 m3/min at 5.5 bar)
Air Flow Line ¾ in (19 mm) straight-through
Blast Pressure 20- 145 psi (1.4 - 10 bar)
Variable Feed Rate 0-4 lb/min (0 - 1.8 kg/min)
Blast Particle Size 3.0 mm to 0.3 mm (Variable Particle Size Controls)
Air Hose 1in (25.4 mm) Air Supply Hose
Blast Hose - ½ in (12.7 mm) Advanced combination material flex hose (low flow)
- ¾ in (19 mm) Advanced combination material flex hose (medium
flow)
- 1in (25.4 mm) Advanced combination material flex hose (standard)
-½ in (12.7 mm) Precision Applicator with on/off; air only; light control
-¾ in (19 mm) Performance Applicator with on/off; air only; light control
-¾ in (19 mm) Advanced Applicator with LED light control; mode air only or blast;
feed rate; air pressure; particle size
-1in (25.4 mm) Performance Applicator with on/off; air only; light control
Applicators - 1in (25.4 mm) Advanced Applicator with LED light control; air only or blast; feed rate;
air pressure; particle size
-1in (25.4 mm) Heavy Duty Applicator with on/off; air only; light control; blasting
pressure, and dry ice feed rate
Control/Display 7 in (17.7 cm) LCD screen with rotary encoder dial
Integration Automation/Integration capable with PLC Controlled system (Integration
upgrade is optional)
Communication IoT connectivity via a cellular service and Cold Jet Connect®
Noise Level Noise level 50 dB(A) up to 137 dB(A)
(See Maximum Sound Pressure Levels on page 70)
Guard interlock functions conform to EN ISO 13849-1:2015 Category 1 PLc
Emergency stop functions conform to EN ISO 13849-1:2015 Category 1 PLc
Safety Relay functions conform to EN ISO 13849-1:2015 Category 1 PLc
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Integration

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PCS 60 Components
The PCS 60:
Lid
Power Button
HMI Display
Emergency Stop Button
Rotary Encoder Dial
Power Cord Connection
Applicator Cord Connection
Blast Hose Connection
Ground Reel
Parking Brake
Hose Whip Check
Air Supply Connection

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PCS 60 Machine in its typical Set-Up format