Cold Jet COMBI PCS 110 DUAL User manual

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.
COMBI PCS 110 DUAL
Operator’s Manual
Version:
1.0
Page:
1 of 28
Date:
10.05.2021

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
C02Safety 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 CO2Leakage 15
Stop Production 15
Daily Checkup Before Start-up 15
MACHINE STRUCTURE 16
MACHINE CONTROL 17
Front Page 17
Start Up 18
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Process Values 19
Manual Mode Control 19
Language Selection 20
Shutdown 21
Daily Maintenance 21
TERMS OF WARRANTY 22
Notes 23
Contact Information 24
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COMBI PCS 110 DUAL
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INTRODUCTION
This manual should be kept with the machine and be readily accessible to machine operators. 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
The COMBI PCS 110 DUAL from Cold Jet presents a revolutionary alternative to existing dry ice production
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
CO2flows into the machine in a regulated manner and is transformed into CO2snow which is then pressed
through an extruder plate by means of the horizontal movement of a hydraulically driven piston.
The produced dry ice is then led into the two buffer tanks and blasted when activated by the control
system. The COMBI PCS 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, which enables higher CO2utilization and
a better liquid CO2ratio.
COMBI PCS 110 DUAL
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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 ice blasted, can overset a
noise level of 100 dB(a) depending on how the blasting function is installed and used.
The control system of the COMBI PCS 110 DUAL, is based on the Beckhoff Industrial PLC and HMI system,
which offers maximum 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.
COMBI PCS 110 DUAL
Operator’s Manual
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1.0
Page:
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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 through the
documentation packet or Cold Jet CONNECT.
1. Start up.
2. Production.
3. Blasting.
4. Standby.
5. Emptying.
6. Shutdown.
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 CO2snow in the chamber in case of an emergency stop or machine error.
Liquid CO2is fed from an external CO2tank (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 CO2from 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 – CO2in valve =(W01-Q1) and injection
valve =(G01-Q1) will open and purge gaseous CO2through the chamber, and the degassing filters and via
degassing pipes to CO2out. When the temperature =(W01-TT2) in the liquid CO2is -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 CO2in 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
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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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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: [phone]
Homepage: www.coldjet.com
Email:inf[email protected]
COMBI PCS 110 DUAL
Operator’s Manual
Version:
1.0
Page:
9 of 28
Date:
10.05.2021