Cold Jet COMBI PCS 110 DUAL User manual

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COMBIPCS110DUAL
USERMANUAL
OriginalInstructions[English]24‐03‐22REV2.0

COMBI PCS 110 DUAL
User’s manual
Version: 1.0
Page: 1 of 30
Date: 24.04.2022
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Copyright©2021ColdJet,DK
Allrightsreserved.PrintedinDenmark.
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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COMBI PCS 110 DUAL
User’s manual
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Page: 2 of 30
Date: 24.04.2022
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Contents
INTRODUCTION..............................................................................................................................................5
GENERAL INFORMATION...............................................................................................................................5
SYSTEM DESCRIPTION..................................................................................................................................7
FunctionalDescription..................................................................................................................................7
ProductionDescription2A0388...................................................................................................................7
SYSTEM IDENTIFICATION.............................................................................................................................9
SupplierResponsiblefortheEquipment.....................................................................................................9
TECHNICAL DATA.........................................................................................................................................10
SAFETY REGULATIONS................................................................................................................................11
GeneralMeasures.......................................................................................................................................11
PersonnelQualifications.............................................................................................................................11
SecurityandRisk.........................................................................................................................................11
C02Safety....................................................................................................................................................11
ElectrostaticDischarge...............................................................................................................................12
SafetyLabels...............................................................................................................................................13
DangerofSuffocation.................................................................................................................................13
StaticElectricity...........................................................................................................................................14
DangerofCongelation................................................................................................................................14
WearProtectiveGloves..............................................................................................................................14
SAFETY OPERATION.....................................................................................................................................15
EmergencyStop..........................................................................................................................................15
MachineSafety...........................................................................................................................................15
LiquidCO2Leakage......................................................................................................................................15
StopProduction..........................................................................................................................................15
DailyCheckupBeforeStart‐up...................................................................................................................15
MACHINESTRUCTURE.....................................................................................................................................16
MACHINECONTROL........................................................................................................................................17
FrontPage...................................................................................................................................................17
StartUp.......................................................................................................................................................18
ChangeofUserLevel..................................................................................................................................19

COMBI PCS 110 DUAL
User’s manual
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ProcessValues.............................................................................................................................................21
HardwareStatus.........................................................................................................................................21
InformationPage........................................................................................................................................22
ManualModeControl................................................................................................................................23
LanguageSelection.....................................................................................................................................25
ExternalCommunication............................................................................................................................26
Shutdown....................................................................................................................................................26
DailyMaintenanve......................................................................................................................................26
TREMSOFWARRANTY....................................................................................................................................27
Notes.............................................................................................................................................................28
Contact Information................................................................................................................................29
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COMBI PCS 110 DUAL
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INTRODUCTION
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Thismanualshouldbekeptwiththemachineandbereadilyaccessibletomachineusers.Thismanual
containsinformationonthesafetyandoperation.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properlytrainedand
understandsthecontentsofthismanual
GENERAL INFORMATION
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TheCOMBIPCS110DUALfromColdJetpresentsarevolutionaryalternativetoexistingDryIceproducing
andblastingmachinesinthatitcombinesDryIceproductionandDryIceblastinginONEMACHINE.
TheCOMBIPCS110DUALProvidesanon‐stopsupplyofhigh‐densitypellets.Thesourceofrawmaterialfor
theproductionofpelletsisliquidcarbondioxideconservedatlowtemperatureinastoragetank.Theliquid
CO2flowsintothemachineinaregulatedmannerandistransformedintoCO2Snowwhichisthenpressed
throughanextruderplatebymeansofthehorizontalmovementofahydraulicallydrivenpiston.
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Theproduceddryiceisthenledintothetwobuffertanksandblastedwhenactivatedbythecontrol
system.TheCOMBIPSC110DUALhasaQuickstart‐upthatreducesdowntimeandlossofvaluableCO2.
Thisissecuredbyastart‐upsequencepurgingtheliquidlineandusingaspecialvalvetofillthechamber.
Themachinealsousesaheatexchangerforsub‐coolingtheliquidCO2.EnablingahigherutilizationCO2and
abetterliquidCO2ratio.
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COMBI PCS 110 DUAL
User’s manual
Version: 1.0
Page: 6 of 30
Date: 24.04.2022
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TheCOMBIPCS110DUALpartsareprotectedbyamoisture‐freeenclosure,whichalsoreducesthenoise
leveltoaminimumof75dB(a).Pleasenotethatthenoiselevel,wherethedryisblasted,canoverseta
noiselevelof100dB(a).Dependingonhowtheblastingfunctionisinstalledandused.
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ThecontrolsystemoftheCOMBIPCS110DUAL,isbasedontheBeckhoffIndustrialPLCandHMIsystem.
WHICHoffersmaximumoffunctionalityandauser‐friendlyinterface.Productionandblastingcanbe
startedbypressingonebutton.Justintimeproductionminimizeslaborandwasteduringproductionand
blasting.
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COMBI PCS 110 DUAL
User’s manual
Version: 1.0
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SYSTEM DESCRIPTION
TheoperatormanualcoverstheCOMBIPCS110DUAL.Themainpartsaredescribedinthemachine
structuresection.Operatinginstructionsforadd‐onscanbefoundinseparateinstructions,andarenot
includedinthismanual.
FunctionalDescription
ThemainfunctionoftheCOMBIPCS110DUAListoproducedryicepelletsfromliquidcarbondioxideand
dryiceblasting.
ThisisperformedbyasequenceofoperationsexecutedbytheBeckhoffPanelPC.TheMainstepsina
normalapplicationareasfollowsandrefertotheP&Idiagram2A0388,whichisavailabletroughthe
documentationpacketorColdJetCONNECT.
1. Startup.
2. Production.
3. Blasting.
4. Standby.
5. Emptying.
6. Shutdown.
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ProductionDescription2A0388
Ateverystart‐upthehydrauliccylinder=(G01‐G1‐MO1)forextruderpistonisextractedtoitsmax.position
toextrudetheCO2snowinthechamberincaseofanemergencystopormachineerror.
LiquidCO2isfedfromanexternalCO2tank(notpartofthisdescription–seesupplierinformation)through
aninsulatedpipetotheCOMBIPCS110DUAL.Itisrecommendedtouseagasseparatortoeliminate
gaseousCO2fromtheliquidCO2.
Whenthehydrauliccylinder=(G01‐G1‐MO1)forextruderpistonisretractedandhydrauliccylinder=(G01‐
G1‐MO2)fortheextruderplatechangestotheupposition–CO2invalve=(W01‐Q1)andinjectionvalve
=(G01‐Q1)willopenandpurgegaseousCO2throughthechamber,andthedegassingfiltersandvia
degassingpipestoCO2out.Whenthetemperature=(W01‐TT2)intheliquidCO2is‐14°C(6.8°F)the
injectionwillproceeduntilatimerisreached.Degassingvalve=(G01‐Q2)onextruderwillopentoreduce
chamberpressurebeforehydrauliccylinder=(G01‐G1‐M01)forextruderpistonwillextractuntilfast
forwardpressuresetpointisreachedandthehydrauliccylinderwillagainretract.Thiswillcontinueuntil
theplugthicknesssetpointisreached.Whentheplugthicknessisreachedthehydrauliccylinder(G01‐G1‐
M01)forextruderplatechangerwillmovetheextruderplateinitsdownpositionandproductionofdryice
cancommence.Atstartupmodethedryicecutter=(V1‐M1)startsupandthemotorisrunningcontinually
duringproduction.
InproductionmodetheCO2invalve=(W01‐Q1)andinjectionvalve=(G1‐Q01)willopenuntilatimeris
reached.Degassingvalve=(G01‐Q2)ontheextruderchamberwillopentoreducechamberpressure
hydrauliccylinder=(G01‐G1‐M01)forextruderpistonwillextractuntilplugsetpointisreachedandthe
hydrauliccylinderwillretractagain.Thiscyclewillcontinueuntiladifferentstepisselected.

COMBI PCS 110 DUAL
User’s manual
Version: 1.0
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Whenthemachinestartstoproducedryice,itwillbeginfillinguphoppertank=(C01‐C1)or=(C02‐C1)
dependingonwhichhopperisselectedintheprogram.Asadefault,hoppertank=C01‐C1willbefilledfirst.
Whensensor=(C01‐C1‐BL1)isactive,thehoppertank=(C01‐C1)isfull.Theblastingandemptyinghopper
symbolsonthecontroldisplaybecomevisibleandyoucannowactivate=(C01‐C1‐M1)forblastingor
emptyinghopper.Thehoppertankwillbeautomaticallyfilledagainwhensensor=(C01‐C1‐BL1)becomes
inactive.
Whensensor=(C02‐C1‐BL1)isactive,thehoppertank=(C02‐C1)isfull.Theblastingandemptyinghopper
symbolsonthecontroldisplaybecomevisibleandyoucannowactivate=(C02‐C1‐M1)forblastingor
emptyinghopper.Thehoppertankwillbeautomaticallyfilledagainwhensensor=(C02‐C1‐BL1)becomes
inactive.
TheshutdownsequenceensuresthatCOMBIPCSDUAL110isstoppedinaproperpositiontoempty
extruderchamberfromdryicesnowandavoidmoistureintheextruderchamber.Thehydrauliccylinder
=(G01‐Q3‐MO1)forextruderplatechangerwillmovetotheselectedpositionandthehydrauliccylinder
=(G01‐G1‐MO1)forextruderpistonwillextracttomax.positionandreturntoshutdownsetpointposition.
Thehydrauliccylinder=(G01‐Q3‐MO1)forextruderplatechangerisinmiddlepositionandallvalvesare
closed.
Undertheshutdownsequencethetwohoppertanksarealsoemptied.Thisoccurswhenthetwodiverter
valves=(C01‐Q1)and=(C02‐Q1)changespositionandwillblastthedryiceintotheCO2drainpipes.Thisis
anautomaticprocesswhichisactivatedwhenthemachineisshutdown.Theprocesswilldeactivate
automaticallyafteragiventime.
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COMBI PCS 110 DUAL
User’s manual
Version: 1.0
Page: 9 of 30
Date: 24.04.2022
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SYSTEM IDENTIFICATION
ThemachineisdoublemarkedwithEUandULapproval.

SupplierResponsiblefortheEquipment
ColdJetApS
Industrivej68
DK‐6740Bramming
Denmark
Phone:+4575561500
Homepage:www.coldjet.com
Email:[email protected]
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User’s manual
Version: 1.0
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TECHNICAL DATA
RatedOutputofDryIce:
kg/h:upto120
lbs/h:upto264,5
Dependingonnozzlecombination.
InletLiquidCO
2
Pressure:
Liquid CO2 Supply System COMBI PCS 110 DUAL
Supply Pressure (Min-Max) 13-18 bar (189-261 psi)
Supply Pressure Range +/- 1.0 bar (14.5 psi)
Supply Pressure (Recommended PBU Setting) 16,5 bar (240 psi)
LiquidCO
2
DrynessFraction:
Thewatercontentshouldnotexceed35ppmandshouldnotbelessthan5ppm–orequivalenttoadewpointtemperatureof‐
66°Cto‐51°C(‐86.8°Fto‐59.8°F).
NOTE:
TheliquidCO
2
supplymustbecompletelyfreeofoilandmusthaveaminimalpurityof99.9%.
LiquidCO
2
SupplyPipe:
Internaldia.20mm(0.8inch),verywellinsulatedwithaminimumnumberofbendsandfittings.
NOTE:Ifover20m(65.6feet)inlength,useaninternaldia.of25mm(1inch).
PowerSupply:
3x380‐480VAC+PE,50‐60Hz,
TN‐SEarthingsystem
Imax.32A
Air Supply:
Bar:min.5–max.10
Psi:min72‐145
RatedPower:
15kW/20Hp@3x400VAC

RatedAirConsumption:
Nm3/min:3‐11
Cfm:106‐388
Dependingonnozzlecombination.

MachineDimensions:
Length: 1800mm/71in
Width: 1200mm/47.3in
Height: 2100mm/82.7in
Height: 2200mm/82.7in(incl.ext.legsandpipes)
Weight:1380kg/3042lbs
Noiselevel:below75dB(a)

COMBI PCS 110 DUAL
User’s manual
Version: 1.0
Page: 11 of 30
Date: 24.04.2022
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
SAFETY REGULATIONS
GeneralMeasures
TheCOMBIPCS110DUALmanualcontainsinstructionsonstartingup,operatingandservicingthe
machine.Theoperatormustfollowtheinstructionsinthemanual.Moreover,itisimportantthatthe
ownermakessurethattheoperatorunderstandsthecontentsofthismanualandfollowsitsguidelinesand
safetyregulations.
PersonnelQualifications
Employeeswhoareinchargeofmounting,operation,serviceandmaintenancemustbeadequately
qualifiedtotakecareofsuchjobfunctions.

Iftheemployeesdonotpossesssufficientknowledge,theymustbeinstructedandtrainedproperly.If
necessary,thiscanbearrangedincooperationwiththemanufacturerofthemachine.

Theownerofthemachineshallmakesurethattheoperator,whoistoworkwiththeCOMBIPCS110
DUAL,fullyunderstandstheimportanceofcomplyingwiththeSAFETYREGULATIONSdescribedonthe
followingpagesaswellasthoseplacedonthemachine,andtheimportanceofcarefullystudyingthe
contentsofthemanualbeforestartingupthemachine.
SecurityandRisk
TheCOMBIPCS110DUALisdesignedsoastocomplywiththeECDeclarationofConformityforMachinery.
Therefore,usingthemachinedoesnotposearisktotheoperatorwhentheinstructionsinthismanualare
followedcarefully.

Installationmustbecarriedoutaccordingtotheinstruction”Unpackingandpreparationsbefore
installation”.

Themachinemayonlybeinstalledbyauthorizedpersonnel,thatiselectricianswithknowledgeofthe
CouncilDirectives73/23/EECandthe89/336/EECandthe89/336/EEC(orsimilardirectivesinotherparts
oftheworld).


C02Safety
Thismachineusesdryice(CO2insolidform).Thetemperatureofdryiceis‐78.9°C(‐109°F).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)providedbythesupplierand
followalltherecommendationsandguidelineslistedtherein.

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User’s manual
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

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,CO2
concentrations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setis3.0%.
AlwaysuseaCO2monitoring/alarmsystemwhenworkingwithmachinerythatemitsCO2ina
confinedroom/space.

ElectrostaticDischarge
Dryiceblastingmaycreateelectrostaticdischarges.Thismachineisfittedwitheffective
electrostaticdischargerstopreventinjuryordamage.Also,themachinemustbepluggedintoa
properlygroundedelectricaloutlet.
Itisrecommendedtoavoidoperatingthemachinenearexplosiveorflammablematerial.Also,useaplastic
scooperwhenhandlingdryicepelletstoeliminateanyelectrostaticdischarge.

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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warnings
triangles,bluemandatoryactioncircles,orredprohibitedactioncircles.
DangerofSuffocation
DryicepelletsareCO2insolidform.Atordinaryatmosphericpressure,CO2canonlyexistinthissolidform
attemperaturesof‐79°C(‐110°F)orlower.Therefore,duringdryiceproduction,theCO2willimmediately
beheatedandthustransformfromsolidformintogasform.
Pleasenote:
SincethespecificgravityofCO2ishigherthanthatofordinaryatmosphericair,theairwithitscontentsof
oxygenwillbereplacedbyCO2ifthedryiceproductionistakingplaceinsmallorinsufficientlyventilated
rooms.
Therefore,pleasenotethefollowing:
1.LowCO2concentrations(3‐5%)causeheadachesandfastbreathing.
2.CO2concentrationsof(7‐10%)causeheadachesandnauseaandmayresultinunconsciousness.
3.HigherCO2concentrationsresultinunconsciousnessandatworstitmaycausesuffocation.

HighCO2concentrationsmayresultinunconsciousnessduetodisplacementofoxygen.Therefore,always
makesuretoprovidesufficientventilationoftheworkingarea,andalwaysavoidproducingdryiceinsmall
rooms.

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User’s manual
Version: 1.0
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

StaticElectricity
Dryicecancauseelectrostaticdischarges.However,theequipmentbondedtogroundtominimize
electrostaticdischarge,andthewarningsignisonlymeanttoinstructtheoperatortoavoidplacingthe
equipmentinroomscontainingexplosivegasses.
Also,itisrecommendedtouseaplasticshovelinthedryicecontainer.
DangerofCongelation
CO2insolidformhasatemperatureof‐79°C/‐110°Forloweratatmosphericpressureandcantherefore
causeseriouscongelationinjuries.
IMPORTANT!
Thedryiceisextremelycold;therefore,donottouchpartsofthemachinewhichareindirectcontactwith
thedryicewithoutwearingappropriateprotectiveclothingandgloves.
WearProtectiveGloves
Duringworkwiththeconveyorsystem,theoperatormustwearprotectiveglovesinordertoavoidcontact
withthedryiceorwithpartsofthemachinewhichareindirectcontactwiththedryice.









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User’s manual
Version: 1.0
Page: 15 of 30
Date: 24.04.2022
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
SAFETY OPERATION
EmergencyStop
AllequipmentisconnectedtothegeneralemergencysystemfortheCOMBIPCS110DUAL.
Whenanemergency‐stopdeviceisactivated,allcomponentslocatedintheemergencyzonewillbe
disconnectedfromtheirpowersource.
MachineSafety
Therearemachinesafetymeasuresinthefollowingareas:

Extruderunit
Extruderplatechanger

Inthisarea,theprotectionisestablishedwithcovers.
Thecoversareprovidedwithlockingscrews,sothattheycanonlyopenwhenusingpropertools.

RequiredperformancelevelPLr=cImplementedincategory=Cat3.

Thereisdangerofcongelation/frostbitesbytouchingmachinepartscooleddownbydryice.
Topreventcongelation,theentiremachineenclosureisprovidedwithlocksandrequiresspecialtoolsto
open.
LiquidCO2Leakage
IfliquidCO2isleakingfromanypointoftheCO2pipesystem,theCO2supplymustbestoppedimmediately.
Localizetheleakageandrepair.
StopProduction
1. Themachineisstoppedbypressingthe“Start/Stop”button.
NOTE:Thiswillactivatetheshutdownprocedure.
2. TheCO2valveonthemachineinletwillautomaticallyclose.Itisrecommendedtoclosethemanual
valveonthemountingkitbefore leavingthemachineunusedforalongerperiodoftime.
3. Cutoffthemainelectricsupply.
NOTE:
DonotshutoffthemainswitchonthecabinetinsidethemachinebeforetheinletCO2pressureisZERO.
TheCO2pressurecanbecheckedonthe“Processvalues”page.
DailyCheckupBeforeStart‐up
1. Checktheoillevelinthesightglass.
2. Checkthepipesystemforleaks.
3. Checktheoperationtimesinceserviceintervals.


COMBI PCS 110 DUAL
User’s manual
Version: 1.0
Page: 16 of 30
Date: 24.04.2022
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

MACHINESTRUCTURE
COMBIPCS110DUAL

1. Touchpanel/Emergencystop.
2. Dryiceblastingpipe.
3. Electricalconnections.
4. Pipeconnections.
5. Lighttower.

1
2
2
3
4
5

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


MACHINECONTROL
ThisnextsectiondescribesthefunctionsoftheHMIScreenfortheoperatorlevel.TheCOMBIPCS110
DUAL,canonlyoperatewithexternalsignals.

BeforestartingthemachinealwayschecktheCO2linesandthepowersupplyareconnected.Thenturnon
themachine.
FrontPage

Fromthefrontpageyouhavetheoptiontogototheotherpages.Whenyouareonanyotherpageand
needtoreturntothefrontpagepressthebuttonforthefrontpage. 

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Version: 1.0
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

StartUp
Whenthemachineisturnedon,italwaysneedstobereset.Thisisdonebypushingthe
buttonfortheAlarmpage.

WhenyouareontheAlarmpage,thealarmlistmustbereset,whichisdonebypressingtherestbutton.(it
maybenecessarytopressthebuttonrepeatedly).

Afterresettingthealarm,returntothemainpage.
Nowitispossibletostartthemachinebypressingthestartbutton.
Thestart/stopbuttonshowsanindicationofthestatusofthemachine.
Whenthebuttonisred,themachineisshuttingdown.
Whenthebuttonisyellow,themachineisinstandby.
Whenthebuttonisgreen,themachineisoperating.




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

Whenthemachinestarts,itwillalwaysrunanemptyingcycletoremoveolddryicetoensurethebest
qualityofdryiceisusedforyourprocess.Thestartbuttonwillbeyellow,andtheemptyingbuttonswillbe
green.

ChangeofUserLevel
Themachinealwaysstartsinoperatormode,itstherefornecessarytochangeuserlevelfromoperator
leveltouserlevel.
Whenchanginguserlevelstartbypressingthebuttonfor
“changeofuserlevel”onthefrontpage.
Wheninthepagefor“changeofuserlevel”tabthefieldfor
usernameandakeyboardwillpopuponthescreen.Thesamewilloccurwhentabbingthefieldfor
password.
