Cold Jet AERO 2 PCS 60 User manual

Original Instructions [English] May 2019
PCS 60
Operator & Maintenance Manual

Copyright © 2019 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 condential between Cold Jet
and the client and remains the exclusive property of Cold Jet. If you nd 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 reects the product conguration 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 specications presented.

Operator & Maintenance Manual
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Contents
Introduction ........................................................................................................................................................1
Safety ....................................................................................................................................................................2
PCS 60 System Package...................................................................................................................................6
PCS 60 Data ........................................................................................................................................................7
PCS 60 Components.........................................................................................................................................8
Performance Applicator Components .........................................................................................................9
Precision Applicator Components...............................................................................................................10
Nozzles...............................................................................................................................................................11
Control Panel and HMI Screens...................................................................................................................12
Operations ........................................................................................................................................................15
Troubleshooting Warnings and Error Codes............................................................................................27
Cold Jet Connect™ ...........................................................................................................................................29
Maintenance.....................................................................................................................................................30
Recommended Spare Parts..........................................................................................................................34
Warranty ............................................................................................................................................................35
EU Declaration of Conformity.......................................................................................................................36
Schematics ........................................................................................................................................................37
Contact Information........................................................................................................................................43

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System Identication
Locate the tag(s) 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. ______________________________________________________________________________________________________________
SCCR_________________________________________________________________________________________________________________
Supplier Responsible for the Equipment:
Cold Jet, LLC
455 Wards Corner Road
Loveland, Ohio 45140 USA
Phone: [phone]
Website: www.coldjet.com

Operator & Maintenance Manual
1
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 dierent 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.
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 other applications.
yThe Advanced Air-Flow System reduces pressure loss as the air ows straight through
the system which also decreases sublimation and loss of the dry ice particles.
yThe Blast Pressure Control System can be regulated digitally from the 7” HMI color
screen on the control panel or certain applicators.
yThe Sure Flow System with Dynamic Agitation is designed to keep warm air, moisture,
and debris out of the hopper while keeping the dry ice owing. The level of dry ice
in the hopper can be monitored from the HMI screen of the control panel or certain
applicators.
yThe Advanced Direct Drive Feeding System is a two-stage feeding system that improves
feed rate consistency and maximizes dry ice particle integrity.
yThe Particle Control System (PCS) allows the operator to control the size of dry ice
particles being blasted from 0.3 mm micro-particles to 3.0 mm pellets. The PCS is
designed to precision-cut dry ice pellets into diamond-shaped particles.
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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2
Safety
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 carefully. 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 and maintenance should only be performed by authorized and trained personnel.
Below are some basic safety guidelines:
yFollow local governing codes to ensure a minimum standard of safety.
yWear protective gloves, eye protection, and hearing protection.
yOperate the machine in a well-ventilated work area.
yFollow the prescribed maintenance schedule (see “Maintenance” on page 38).
yStart up and shut down the machine according to the instructions in this manual.
yDo not operate a machine that is damaged or in disrepair.
yDo not store objects on top of machine hopper.
CO2Safety
This machine uses dry ice (CO2in 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) supplied with the delivery of dry ice
and follow all the recommendations and guidelines listed therein.
Operate the pelletizer in a well-ventilated work area with continuous CO2-level monitoring.
The eects of CO2 are entirely independent of the eects of oxygen deciency. Therefore,
CO2 concentrations at 3-5% causes headaches, fast breathing and discomfort while higher
concentrations may cause unconsciousness, suocation 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 CO2monitoring/alarm system when working with machinery that emits CO2in a
conned room/space.

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Electrostatic Discharge
Dry ice blasting may create electrostatic discharges. This machine is tted with eective
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 ammable material. Also,
use a plastic shovel when handling dry ice to eliminate any additional static electricity.
Safety Labels
The symbols used on the machine were developed by the International Organization for
Standardization (ISO) and are dened below. These symbols may include yellow warnings
triangles, blue mandatory action circles, or red prohibited action circles.
Symbol Denition
General Warning
Cold Temperature Warning
Pressurized Material Ejection Hazards
Electrostatic Discharge Warning
Hand Crushing Warning
Asphyxiation Warning
Wear protective gloves.
Wear hearing protection.
Wear eye protection.

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Symbol Denition
Read operator and maintenance manual.
Do not operate without Safeguard Grate/guard in place.
No foreign objects allowed inside machine.
CO2is in use.
Protective Earth/Ground
Frame/Chassis Terminal
There may be other safety labels or warning signs on the machine that contain additional
information regarding potential safety hazards not explained in this manual. Operators and
maintenance personnel should familiarize themselves with these safety labels and warning
signs.
Replace any safety labels or warning signs if they become damaged, missing, or illegible.
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 qualied 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 conned
space, a CO2 detector should be used to monitor for excessive unsafe
levels of CO2 gas, and provide a suitable warning.
WARNING Ensure that expended dry ice pellet emissions are not in the vicinity of
air ventilation.
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 aect the safety of the machine.

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WARNING High pressure jets can be dangerous if subject to misuse. The jet must
not 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
personal protective equipment.
WARNING Do not direct the jet against yourself or others in order to clean clothes
or foot-wear.
WARNING High pressure cleaners shall not be used by children or untrained
personnel.
WARNING High pressure hoses, ttings and couplings are important for the safety
of the machine. Use only hoses, ttings and couplings recommended by
Cold Jet.
WARNING To ensure machine safety, use only original spare parts from Cold Jet or
approved by Cold Jet.
WARNING The applicator and applicator hose contain electrical connections. Do not
immerse in water.
WARNING Do not use the machine if a supply cord or important parts of the
machine are damaged, e.g. safety devices, high pressure hoses,
applicator.
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 has to be kept dry and o the ground. It is
recommended that this is accomplished by means of a cord reel which
keeps the socket at least 60 mm above the ground.
WARNING Always switch o the mains disconnecting switch, or unplug the mains
power cord when leaving the machine unattended.

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6
PCS 60 System Package
The PCS 60 may be supplied with the Performance Kit or the Precision kit or both depending
on what was ordered. The applicator kits are as follows:
Performance Kit
y3/4 in or 1in Performance Applicator
yPerformance nozzle
yNozzle handle
y1in Air supply hose 25 ft (7.62 meters)
y3/4 in or 1in Hybrid-Flex blast hose 20 ft (6.09 meters)
yHose carrier
yHose wrap
yStatic Bond Cable and Collar
Precision Kit
y1/2 in Precision Applicator
y2 precision nozzles
y1in Air supply hose 25 ft (7.62 meters)
y1/2 in Hybrid-Flex blast hose 20 ft (6.09 meters)
yHose carrier
yHose Wrap
yStatic Bond Cable and Collar
Unpacking the PCS 60 System
This machine has been assembled and tested as one unit prior to shipment. Follow the steps
below to inspect and unpack the machine from the shipping container.
1. Examine the shipping container for any damages that may have occurred during
transport.
2. Remove the machine, recyclable box(es) that contain accessories, and the packaging
can be recycled.
3. Examine the machine for any external damage that may have occurred during
transport.
4. Remove the back housing of the machine and examine the machine for any internal
damage that may have occurred during transport.
Refer to the packing slip for a list of the components shipped with the machine. Contact
Cold Jet if any damage has occurred to the shipping container or the machine (see “Contact
Information” on page 43).

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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 251 lb (113.85 kg)
Blast Medium 3 mm dry ice pellets
Hopper Capacity 60 lb (27 kg)
Power
Requirement 110/220 VAC (50/60 Hz)
Air Supply Pressure
Range 40-145 psi (2.8-10 bar)
Air Flow Range 12-100 cfm at 80 psi (0.33-2.83 m3/min at 5.5 bar)
Air Flow Path ¾ in (19 mm) straight-through
Blast Pressure
Range 20-145 psi (1.4-10 bar)
Variable Feed Rate 0-4 lb/min (0-1.8 kg/min)
Variable Particle
Size 3 mm to 0.3 mm (PCS included)
Air Hose 1in (25.4 mm) Air Supply Hose
Blast Hose
½ in (12.7 mm) Advanced combination material ex hose (low ow)
¾ in (19 mm) Advanced combination material ex hose (medium ow)
1in (25.4 mm) Advanced combination material ex hose (standard)
Applicator
½ in (12.7 mm) Precision Applicator with on/o; air only; light control
¾ in (19 mm) Performance Applicator with on/o; air only; light control
1in (25.4 mm) Performance Applicator with on/o; air only; light control
Control/Display 7 in (17.7 cm) LCD screen with rotary encoder dial
Communication IoT connectivity via a cellular 3G/LTE Global and Cold Jet Connect™
Integration
(Optional)
Automation/Integration capable with PLC controlled system (Modbus
protocol) by utilizing the optional Integration Kit
Noise Level
Noise level 60 dB(A) up to 130 dB(A)
The PCS 60 has many features such as Nozzle selection, air pressure settings, hose
sizes and pellet size. The material or materials and surrounding environment will also
be key to actual sound pressure levels at the machine or the blast area.

Aero2PCS 60
8
PCS 60 Components
Hopper Lid
Blast Cable Connection
Power Supply Connection
Blast Hose Connection
Static Ground Reel
Emergency Stop
HMI Screen
Rotary Encoder Dial
Power Button
Safeguard Grate
Supply Air Connection
Hopper Lid

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Performance Applicator Components
Standard Nozzle
Applicator Controls
Blast Hose Connection
Applicator Control Cable
Trigger
Trigger Safety
Lights

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Precision Applicator Components
Applicator Lights
Trigger Trigger Safety
Standard Nozzle
Applicator Control Cable
Blast Hose Connection
Applicator Controls

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Nozzles
There are several dierent styles of nozzles, depending on the application the PCS was
ordered for. The table below can be used to help with initial settings as you set up the PCS 60
for operation.
Precision
Nozzles
Air Consumption
@80 psi (5.5 bar)
Blast Swath Length Dry Ice Feed
Rate
Material
(MC13) Yellow 12 CFM
0.3 m3/min
0.13 in
3.2 mm
6 in
15 cm
0.1-0.4 lbs/min
.05-0.2 kg/min Plastic
(MC19) White 30 CFM
0.8 m3/min
0.19 in
4.7 mm
6 in
15 cm
0.2-1.0 lbs/min
0.1-0.5 kg/min Plastic
(MC31) Blue 50 CFM
1.5 m3/min
0.31 in
7.9 mm
6 in
15 cm
0.5-1.2 lbs/min
0.2-0.6 kg/min Plastic
Fan Nozzles
(MC47) 25 CFM Fan
0.7 m3/min
0.47 in
11.9 mm
6 in
15 cm
0.2-1 lbs/min
0.1-0.5 kg/min
Plastic &
Aluminum
(MC28) 25 CFM Fan
0.7 m3/min
.28 in
0.7 cm
6 in
15.2 cm
.2-1 lbs/min
0.1-0.5 kg/min
Plastic &
Aluminum
(MC35) 25 CFM Fan
0.7 m3/min
0.35 in
8.9 mm
6 in
15 cm
0.2-1 lbs/min
0.1-0.5 kg/min
Plastic &
Aluminum
(MC88) 30 CFM Fan
0.9 m3/min
0.88 in
22 mm
5 in
12.7 cm
0.5-1.2 lbs/min
0.2-0.6 kg/min
Plastic &
Aluminum
(MC88F)
25 CFM Fragmenting
Fan
0.7 m3/min
0.88 in
22 mm
5 in
12.7 cm
0.2-1 lbs/min
0.1-.05 kg/min Plastic &
Aluminum
Performance Nozzles
(323S1) 50 CFM
1.4 m3/min
0.6 in
1.5 cm
6 in
15.2 cm
1-3 lbs/min
0.5-1.4 kg/min
Anodized
Aluminum

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Control Panel and HMI Screens
Using the Rotary Encoder Dial
This PCS 60 uses a rotary encoder dial that allows the operator to navigate, select and adjust
settings on the control panel screen. Navigate between options by turning the rotary encoder
dial left or right; this will highlight the option in green. Once the desired option is highlighted,
simply press the dial to select it; this will highlight the option in red. With the option selected
(red), turn the rotary encoder dial left or right to adjust the setting then press again to accept.
Some options can be adjusted directly from the home screen while other options can be found
on other screens. To access these other screens using the rotary encoder dial, navigate to
the settings screen and press to select. Continue to navigate through the screens (i.e. recipe,
status, applicator, advanced, reset, settings) and adjust the settings as needed by turning and
pressing the rotary encoder dial.
When not being used, the screen on the control panel will display a screen saver with feed
rate, particle size, air pressure, blast pressure and hopper level. Simply press or turn the rotary
encoder dial to bring up the home screen.
Figure 1: Control Panel and Rotary Encoder Dial

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There are 2 screen states for the PCS 60. A blue screen (home screen) which is the system
operating and settings screen. A black screen indicates that the PCS 60 is in the advanced
settings or the recipe screen. Changes can be made in each screen.
Figure 2: Home Screen
Figure 3: Settings Screen

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Figure 4: Hopper Level Indicator
During operation, some items on the screen will indicate level or failure mode by changing
colors. Green is normal, yellow or orange is a warning and red is critical and needs attention.
The above illustration indicates the level of the dry ice in the hopper.
Figure 5: Numeric Color Indicator
Numbers change states much like the hopper levels. White is normal, orange is warning, and
red is critical.