Cold Jet IceTech Evolution Line Xcel 6 User manual

Manual
ENG-EL-MANUAL-Rev A

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IceTech A/S
Industrivej 62
DK-6740 Bramming
Copyright © 2016 by IceTech A/S
All rights reserved.

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Date Rev Document Description/Affected Pages
August 16,
2016
A SOP All
Revision History

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Contents
GENERAL INFORMATION 6
Dry And Thermal Cleaning Process 6
No Residual Blasting Media 6
DRY ICE BLASTING – How It Operates 6
Dry Ice Pellets 6
Method 6
Cleaning Eect 7
Thermal Eect 7
Kinetic Eect 7
SAFETY REGULATIONS 7
General 7
Personnel Qualications 7
Precautions during Blasting 8
Static Electricity 8
PACEMAKER Precautions 8
Explosive Hazard 8
Danger of Thrown Loose Objects 9
Noise 9
Dust 9
Protective Clothing 9
CO2Detector 10
CO2Concentrations 10
Low CO210
MACHINE ILLUSTRATIONS 11
LABELS ON THE MACHINE 15
Identication Plate 15
Warning Signs Label 15
CONTROL PANEL 16
BLASTING HOSE 17
ICEGUN EVOLUTION LINE W/LIGHT 18
STARTING THE DRY ICE BLASTING MACHINE 19
Setting Up 19

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Starting 20
SHUTTING DOWN THE DRY ICE BLASTING MACHINE 24
EMERGENCY STOP 24
PRECAUTIONS – BLASTING HOSE 25
Connection and Disconnection 25
Defective Blasting Hose 25
Blasting Hose Repair 26
PRECAUTIONS – ELECTRIC CONNECTION 26
Main Power Supply 26
OFF Button 26
Cover Plate at the Hopper Bottom 26
MAINTENANCE 27
Daily before Starting the Machine 27
After 100 Hours of Operation 27
After 500 Hours of Operation 27
REPAIR AND WARRANTY 28
Repair 28
Terms of Warranty 28
NOZZLE SELECTION AND AIR CONSUMPTION 29
Nozzle Diameter and Blast Pattern 29
Small Blast Pattern 29
Wide Blast Pattern 29
Nozzle Size 29
Air Consumption Table 29
Example of Use of the Table 29
Troubleshooting 32
Long Life Splitternets 33
Correct use of the 4 types of long-life splitternets. 33
Survey — Dosing Disc Types (kg/h) 34
EC Declaration 35

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GENERAL INFORMATION
The Evolution Line manual is for the Xcel 6 dry ice blasting machines produced by
IceTech. IceTech machines and accessories have been developed to supply cleaning
equipment which minimizes consequential cleaning costs and combines the best
characteristics of sand blasting and steam cleaning.
Dry And Thermal Cleaning Process
Dry ice blasting provides a dry cleaning process (similar to sand blasting), AND a ther-
mal cleaning process (familiar in steam cleaning).
The blasting media itself (dry ice pellets) sublimates; and in most cases, the process
can be used for cleaning components, machinery and plant equipment without
dismantling and often without having to cover adjacent plant equipment.
No Residual Blasting Media
Dry ice blasting provides a dry, gentle, but extremely ecient, cleaning process that
leaves no residual blasting media to be disposed of, and no undesired substances that
might penetrate into or be deposited on machines and plant components.
This means that cleaning with dry ice is an excellent alternative to cleaning with
traditional methods.
DRY ICE BLASTING – How It Operates
Dry Ice Pellets
The dry ice blasting machine uses small CO2”particles” as the blasting medium, called
dry ice pellets (CO2– the chemical symbol for carbon dioxide). In a machine commonly
known as a pelletizer, liquid CO2is used to produce hard and uniform dry ice pellets.
The pellets are approximately 3 mm (0.1 inch) in diameter and approximately 10 mm
(0.4 inch) in length – or rice-sized.
These dry ice pellets have a temperature of -79°C/-109°F. When used for dry ice blast-
ing, the pellets are blasted onto the object to be cleaned at a very high velocity. On
contact with the surface of the object, they immediately change from a solid to a
gaseous form as they heat up on impact. This change from a solid to a gaseous form,
the accompanying tremendous expansion in volume, the high kinetic energy and the
low temperatures are the most important factors which result in the loosening of the
contaminates.
Method
The dry ice blasting machine contains a dry ice pellet tank and a dosing unit, which
doses the dry ice pellets into the jet of compressed air. By means of the compressed
air, the dry ice is transported through a special blasting hose to the blasting gun and
nozzle. In the blasting gun, the air stream is accelerated, and the dry ice pellets leave

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the nozzle of the blasting gun at very high velocity.
Cleaning Eect
The cleaning eect of dry ice blasting is based on three principles:
Thermal Eect
The dry ice pellets have a temperature of -79°C/-109°F, and impurities are therefore
cooled down drastically. The impurities shrink and loosen due to dierent thermal
expansion coecients.
Kinetic Eect
When the dry ice pellets leave the blasting gun nozzle they have high kinetic energy
and strike the impurities at a speed almost equivalent to the velocity of sound.
Sublimation Eect / Volume Expansion:
The dry ice pellets are being pressed into the brittle impurities and sublimate
immediately on contact. The resulting volume increase by a factor of approximately
700 contributes to tearing away the contaminant.
SAFETY REGULATIONS
General
This manual contains instructions and safety regulations which must be followed
while starting, operating and maintaining the dry ice blasting machine. It is important
that the manual is kept, so the operator always knows its exact location. It is also
important the owner makes certain that the operator reads, understands and follows
the contents of the manual.
Personnel Qualications
Personnel responsible for operation, servicing and maintenance must be suitably
qualied to perform these functions.
Special training in machine handling as well as in repair and maintenance is oered
by the manufacturer of the machine.
The owner of the machine must ensure that the person appointed to operate the dry
ice blasting machine fully understands and is able to follow the SAFETY REGULATIONS
dened in the following pages, and the WARNING SYMBOLS located on the machine.
Safety and Risk
The machine is constructed to comply with the standards and clauses contained
in the Declaration of Conformity and the terms of sale. Therefore, provided the
manufacturer’s instructions are followed, the machine will not pose any risk to the
operator.

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Precautions during Blasting
Air, CO2gas and dry ice pellets leave the gun nozzle at a very high
velocity (up to 300 m/s – 984 ft/s).
Therefore:
• do not aim the nozzle at a person(s) or in the direction of a
place(s) where other people work,
• remember, dry ice pellets can be deected back from the object
being cleaned,
• do not aim the nozzle in directions where damage might result.
Do not use the machine “for fun” and under no circumstances
should you aim the gun nozzle at persons or other living crea-
tures.
Static Electricity
Serious discharge of static electricity can occur. Always make sure
that objects to be cleaned are adequately earthed/grounded
and that this earthing/ grounding remains stable throughout the
whole cleaning process. The dry ice blasting machine is earthed/
grounded, from machine cabinet to blasting gun, and through
the main electricity connection on the rear side of the machine
– provided that the machine has been set up and connected as
described under STARTING THE DRY ICE BLASTING MACHINE page
15.
PACEMAKER Precautions
Do NOT use the dry ice blasting machine if you are wearing a
pacemaker. The dry ice blasting machine may cause pacemaker
malfunction.
Explosive Hazard
The machine must never be used in surroundings where there
is a danger of explosion. Despite optimum earthing/grounding
of both machine and cleaning object, static electricity can be
generated and create a spark.

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Danger of Congelation
At atmospheric pressure, CO2in a solid form has a temperature of
-79°C/-109°F or lower and can give rise to congelation when the
dry ice comes in contact with unprotected skin.
Danger of Thrown Loose Objects
There is a risk of dry ice pellets and small objects being deected
back during blasting. Therefore small objects must be rmly se-
cured before blasting. Loose objects must not be left in the area
where the cleaning process is taking place.
The operator must always wear approved protective goggles or
a protective shield when working with the dry ice blasting ma-
chine. This also applies to anybody near the workspace.
Noise
Because of the high air velocities in the gun nozzle during dry
ice blasting, the level of noise in the area where the operator
works may exceed the maximum permissible level. The owner is
responsible for keeping himself acquainted with, and informing
the operator of any precautions to be taken as to the application of
ear protection, because legislation on maximum permissible noise
levels varies from one country to another.
Dust
Certain types of dust have a tendency to accumulate during the
cleaning process. Therefore, we recommend that the operator
wears a dust mask or if necessary a breathing mask and industrial
protective clothing.
Protective Clothing
When using the dry ice blasting machine, the operator must wear
long-sleeved industrial protective clothing and gloves in order to
eliminate the risk of congelation when the dry ice comes in contact
with unprotected skin.

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CO2Detector
The presence of a CO2detector is recommended in areas of lim-
ited ventilation such as rooms, closed tanks, etc. The CO2detector
can be installed to interrupt the blasting process before the CO2
concentration exceeds a prescribed limit.
CO2Concentrations
Dry ice pellets are CO2in a solid form. At normal atmospheric
pressure, CO2can only exist in a solid form at a temperature of
-79°C/-109°F or lower.
When CO2is used as a blasting medium, it becomes heated
and changes into a gaseous form. As CO2has a higher specic
gravity than ordinary atmospheric air, inhaled air will contain CO2
– especially if the blasting process takes place in small or partly
closed rooms.
In such conditions, there is a risk of the oxygen content of inhaled
air being replaced by CO2. Therefore, it is essential to make sure the
room is well ventilated when dry ice blasting.
Low CO2
• low CO2concentrations (3-5%) result in headaches and rapid
breathing,
• CO2concentrations of 7-10% produce headaches and nausea,
and may lead to unconsciousness,
• higher CO2concentrations lead to unconsciousness and in the
worst case – suocation.
As stated above, high CO2concentrations can displace oxygen
and result in unconsciousness. Therefore, avoid using the dry ice
blasting machine in spaces/rooms where ventilation is limited.
Read the safety data sheet provided by the dry ice supplier
and follow the instructions given.

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MACHINE ILLUSTRATIONS
1. Control panel
2. Signal cable connection
3. Connection for blasting hose
4. Top lid for the hopper

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1. Dry ice hopper
2. Blasting hose connection
3. Electrical box
4. Pneumatic vibrator
5. Dosing system

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1. Power cable
2. Air ltration unit with regulation
3. Exhaust pipe
4. Flanged connection
5. Transformer

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1. Supply air hose connection
2. Cable holder and power cord
Important!
When lifting with a forklift truck, make sure that the forks are inserted all the way under
the machine frame itself. When using a crane for lifting, a yoke with straps under the
cabinet frame must be used. Ensure that wheels and wheel brakes do not become
damaged.

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LABELS ON THE MACHINE
Identication Plate
Warning Signs Label

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CONTROL PANEL
1. Supply air pressure
2. Blasting pressure
3. Blasting pressure control
4. Reset button
5. On/O button
6. Dry ice consumption control
7. Emergency Stop

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BLASTING HOSE
1. Hose coupling – for connection on front of the dry ice blasting machine
2. Signal cable – for connection on front of the dry ice blasting machine
3. Signal cable – for connection to the blasting gun
4. Hose coupling – for connection to the blasting gun
The IceTech blasting hose is made of an abrasion resistant, conductive
natural and synthetic rubber.

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ICEGUN EVOLUTION LINE W/LIGHT
1. Light
2. Safety switch
3. Two-step trigger
4. Signal cable
5. Standard Round Nozzle - interchangeable
6. Nozzle adapter
Technical Specications:
Dim. (mm/inch) without nozzle:
Length: 270 / 10.63
Width: 60 / 2.36
Height: 225 / 8.86
Weight without nozzle:
1.1 kg / 2.42 lbs

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STARTING THE DRY ICE BLASTING MACHINE
Setting Up
1. Make sure the machine is on a level, horizontal
surface, and that the wheel brakes are applied.
2. Plug the blasting hose couplings into the socket
on the front of the machine and the blasting gun,
respectively. Check to make sure the hose couplings
are correctly connected.
3. Connect the signal cable at both ends of the blasting
hose with the sockets on the front of the machine
and the blasting gun.

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Starting
When the machine has been set up as described above (points 1-5), the following pro-
cedure shall be followed before the cleaning process has begun:
4. Connect the main power supply.
5. Connect the compressed air supply.
6. Check carefully to ensure that the dosing unit is
dry and clean at the hopper outlet.