Cold Jet IceTech R1000H User manual

User’s Manual
Technical file
1
2
User’s manual
IceTech R1000H

User’s Manual
1
User’s manual
IceTech R1000H

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
1.0
Page:
1 from 23
Date:
30.08.17
Init.:
JM
TABLE OF CONTENTS
GENERAL INFORMATION......................................................................................................... 3
SYSTEM IDENTIFICATION ....................................................................................................... 4
TECHNICAL DATA ................................................................................................................... 5
TECHNICAL FACTS OF FROZEN CO2......................................................................................... 6
SAFETY REGULATIONS............................................................................................................ 7
General Measures........................................................................................................... 7
Personnel Qualifications .................................................................................................. 7
Security and Risk............................................................................................................ 7
Danger of Suffocation ..................................................................................................... 7
Static Electricity.............................................................................................................. 8
Danger of Congelation .................................................................................................... 8
Pinch Point Hazard.......................................................................................................... 9
Danger of burns ............................................................................................................. 9
Wear Protective Gloves ................................................................................................... 9
How to Lift / Transport the IceMaker...............................................................................10
MACHINE STUCTURE SL1000H................................................................................................11
MACHINE OPERATION START-UP............................................................................................12
MACHINE CONTROLS.............................................................................................................15
STOP PRODUCTION ...............................................................................................................18
REPAIR AND WARRANTY........................................................................................................18
Repair ..........................................................................................................................18
Terms of Warranty ........................................................................................................18
COMMUNICATION WITH EXTERNAL EQUIPMENT .....................................................................19
Communication to IceTech R1000H –Input.....................................................................20
Communication from IceTech R1000H –Output...............................................................20
INSTRUCTION - UNPACKING AND PREPARATIONS BEFORE INSTALLATION ...............................22
Unpacking and Examination for Transport Damages .........................................................22
Requirements on the Environment Surrounding the IceMaker............................................22
How to Lift / Transport the IceMaker...............................................................................22
Floor Characteristics and Minimum Clear Distances...........................................................22
Installation....................................................................................................................22
DRAWING NR. A1..........................................................................................................23
DRAWING NR. A2..........................................................................................................23

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
1.0
Page:
2 from 23
Date:
30.08.17
Init.:
JM

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
1.0
Page:
3 from 23
Date:
30.08.17
Init.:
JM
GENERAL INFORMATION
IceTech’s R1000H pellet-to-slice reformer is a fully automatic machine, with the flexibility to reform dry ice pellets or
nuggets into robust dry ice slices in customer specific dimensions, with up to 1000 slice press cycles per hour. Designed to
diversify dry ice production capabilities, the R1000H allows to produce from 0,25 kg slice up to 3,0 kg mini block maintaining
the highest capacity of the machine.
Using the recipe program, slice thickness can be changed during production. Slice format is changed in less than
15 minutes by using the Quick-Change Press Head. During production slice thickness is constantly monitored and optimized.
The R1000H is powered by a Beckhoff industrial PC with 15” touch panel for intelligent control. Using servo technology
ensures fast and precise motion control. When connected to the internet, R1000H enables Cold Jet CONNECTTM for remote
support and maintenance of uptime and performance.

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
1.0
Page:
4 from 23
Date:
30.08.17
Init.:
JM
SYSTEM IDENTIFICATION
System is marked with:
Supplier responsible for the equipment:
Cold jet ApS
Industrivej 62
DK-6740 Bramming
Denmark
Phone: [phone]
Fax: [phone]
Homepage: www.coldjet.com

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
1.0
Page:
5 from 23
Date:
30.08.17
Init.:
JM
TECHNICAL DATA
Rated Output:
125 x 125 x 22,2 mm (5” x 5” x 0,875”)
Up to 2000 slices/ hour
kg/h: 1140 kg/ hour
lbs/h: 2511 lbs/ hour
125 x 125 x 50,8 mm (5” x 5” x 2”)
up to 1000 slices/ hour
kg/h: 1303 kg/ hour (Thickness: 50,8 mm)
lbs/h: 2870 lbs/ hour (Thickness: 2”)
of high quality dry ice slices, depending on the size of slice chosen
Weight: 2545 kg /5610 lbs
CE: Power Supply
Main control:
3 x 400 V AC + PE, 50Hz
Imax: 63 A
System earthing: TN-S
Heater control:
3 x 400 V AC + PE, 50Hz
Imax: 63 A
System earthing: TN-S
UL: Power Supply
Main control:
3 x 480 V AC + PE, 60Hz
Imax: 63 A
25kA rms symmetrical,
480V max.
Heater control:
3 x 480 V AC + PE, 60Hz
Imax: 50 A
25kA rms symmetrical,
480V max.
Machine Dimensions (mm/inch):
Length: 1950 / 76,8
Width: 1500 / 59
Height: 2030 / 80
Noise level: below 75 dB(A)

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
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Page:
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Date:
30.08.17
Init.:
JM
TECHNICAL FACTS OF FROZEN CO2
Dry ice is frozen carbon dioxide (CO2). It is much denser and colder than traditional ice. Dry ice is -79°C (-109.3°F).
Traditional ice is 0°C (32°F). In addition, dry ice does not melt, it sublimates. Sublimation is the process of going directly
from solid form into gas form. Dry ice by-passes the liquid form, hence the “dry” ice.
The first step in producing dry ice is to turn the carbon dioxide gas into a liquid. This is done by compressing the CO2and
removing excess heat. Next, the pressure is reduced over the liquid carbon dioxide by sending it through a snow valve
(expansion valve). As the liquid evaporates, it absorbs heat, causing some of the CO2to freeze into dry ice snowflakes. The
dry ice snow is then exposed to compaction first in to pellet form and then reformed by a large press to form blocks/slices.
Dry ice is much heavier than traditional ice, weighing 1.7 times as much. CO2is a natural substance produced by the
combustion of organic compounds and is exhaled by humans and other living beings.
Pressure- Temperature phase diagram for CO2
CO2is:
:: Non-toxic
:: Transparent
:: Odourless gas under atmospheric pressure and temperature
:: 1½ times heavier than air
:: The atmosphere consists of 0.03% CO2
CO2exists in three forms:
:: Gas, e.g. used in the food industry
:: Liquid, kept under pressure
:: Solid, dry ice

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
1.0
Page:
7 from 23
Date:
30.08.17
Init.:
JM
SAFETY REGULATIONS
General Measures
The IceTech R1000H 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 IceTech R1000H, fully understands
the importance of studying the content of the manual and complying with the SAFETY REGULATIONS described on the
following pages as well as those placed on the machine.
Security and Risk
The IceTech R1000H 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.
It is important that the operator carefully follows the safety signs on the machine and the safety regulations described later
in this manual and that the operator reads and understands the content of this manual before starting up the machine.
Installation must be carried out according to the instruction ”Unpacking and preperations 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).
Danger of Suffocation
Dry ice slices are CO2in solid form. At ordinary atmospheric pressure, CO2can only exist in this solid form at temperatures
of -79°C (-110°F) or lower. Therefore, during dry ice production, the CO2will immediately be heated and thus transform
from solid form into gas form.
Please note:
SINCE THE SPECIFIC GRAVITY OF CO2IS HIGHER THAN THAT OF ORDINARY ATMOSPHERIC AIR, THE AIR
WITH ITS CONTENTS OF OXYGEN WILL BE REPLACED BY CO2IF THE DRY ICE PRODUCTION IS TAKING
PLACE IN SMALL OR INSUFFICIENTLY VENTILATED ROOMS.

Industrivej 62
DK-6740 Bramming
Denmark
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IceTech R1000H
Operator Manual for Reformer
Version:
1.0
Page:
8 from 23
Date:
30.08.17
Init.:
JM
Therefore, please note the following:
1. Low CO2concentrations (3-5%) cause headaches and fast breathing.
2. CO2concentrations of (7-10%) cause headaches and nausea and may result in unconsciousness.
3. Higher CO2concentrations result in unconsciousness and at worst it may cause suffocation.
High CO2concentrations 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.
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
CO2in 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.

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
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Page:
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Date:
30.08.17
Init.:
JM
Pinch Point Hazard
If the covers on IceTech R1000H is removed, the operator will be exposed to pinch point hazard.
Danger of burns
If the covers on IceTech R1000H is removed, the operator will be exposed to very hot components.
It is recommended to monitor temperatures on the HMI and not remove covers before temperatures are at below +35°C
/ 95°F.
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.

Industrivej 62
DK-6740 Bramming
Denmark
Original
IceTech R1000H
Operator Manual for Reformer
Version:
1.0
Page:
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23
Date:
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Init.:
JM
How to Lift / Transport the IceMaker
1. The IceMaker is supplied with thread holes for lifting eyes. Always use lifting eyes to lift the IceMaker.
2. Always lift the IceMaker according to the lifting Instruction in this manual.
3. Lifting over persons and animals is prohibited.
4. Always use a forklift truck to transport the IceMaker.
5. Pick up the IceMaker from the side as shown in the drawings.
6. Transport the IceMaker upright.
7. Make sure that the forks are sufficiently long to fully engage the IceMaker.
8. Always check that the forks are adjusted to maximum width.

Industrivej 62
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Operator Manual for Reformer
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Date:
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MACHINE STUCTURE SL1000H

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Operator Manual for Reformer
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Date:
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MACHINE OPERATION START-UP
1. MAINS
Turn the MAIN SWITCH on and wait for the HMI
to boot.
2. Reset alarms
Open the alarm page and press the reset button to
reset alarms. If alarms cannot be reset use
troubleshooting in the alarms section in the technical
file.
3. Automatic mode
To start production on the R1000H reformer, the
machine must be in an a utomatic mode.

Industrivej 62
DK-6740 Bramming
Denmark
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Operator Manual for Reformer
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Date:
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Init.:
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4. Recipe selection
Before starting, ensure that correct slice size and
thickness has been selected.
Please ensure that slice recipe corresponds to the tool
installed before starting up.
5. Operation start
Press start button to initiate production.
6. Adjustment of the slice weight:
During production the weight of the slice can be
increased by pressing on (+) and reduced by pressing
on (-). R1000H will automatically maintain the
selected slice weight/thickness by adjusting the pellet
dosing volume.

Industrivej 62
DK-6740 Bramming
Denmark
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Operator Manual for Reformer
Version:
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Date:
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Init.:
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7. Operation Standby
If you wish to cancel the production, press the Set
Standby button.
The machine goes into standby for 15 minutes.
If production isn’t resumed it will run the shutdown
procedure emptying hopper and conveyors.
During Standby, operation can be resumed by
pressing on Start.
8. Operation Stop
If you wish to stop the machine, press on the Stop
button. R1000H will run a shutdown procedure and
empty hopper and conveyors.

Industrivej 62
DK-6740 Bramming
Denmark
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Operator Manual for Reformer
Version:
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Date:
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Init.:
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MACHINE CONTROLS
Start page:
This page can be activated from all other pages by
clicking on the “Home button” in the lower right-hand
corner.
Mode selector:
To run the production, the mode selector must be in
automatic mode.
To run the machine in manual mode, the machine
must be in a single (hand) mode.
Start/Standby/Stop:
The Start/Stop button shows an indication of the
status of the slice system:
When the button is red, the machine is not running.
When the button is yellow, the machine is in standby.
When the button is green, the machine is operating.
The slice system is put in standby by pressing the
pause button.
Process values:
Pressing the “show” button shows a page with the
current process values of the machine.
The page consists of two columns with process values
(PV) and the associated Set points (SP), which are
displayed for comparison.
During production the PV values will move within the
values indicated in the SV window.
Here total operation time, operation time since last
service and the number of slices produced are
displayed.

Industrivej 62
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Operator Manual for Reformer
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Date:
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Set points:
Pressing the “gear wheel” button brings you to the
Set points (SP) page.
The Set points are protected by a password and have
established limits to protect the machine against
unintended operation.
Single (hand) mode control:
Pressing the Single (hand) button displays a page
with manual control.
On this page it is possible to operate the machine’s
individual components. The components are
activated by pressing the respective buttons.
Most components have descriptive names, for
example, “hyd. motor” and others have numbers,
which can be identified in the machine’s P&I diagram.
Manual operation may only be conducted by trained
staff!
Recipe page
To load a new recipe, press search and select the
recipe you prefer. Press load to use the selected
recipe.
Recipe page 2
Select if process unit 1, 2 or both is to be used for
slice production.

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Date:
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Alarm:
By pressing the “alarm” button, the current alarms
will be displayed on the screen.
When an alarm is reset, the text is removed. All
alarms must be reset before production can be
resumed.
By pressing the History tab it is possible to see the
alarm history.
Info page:
The info page displays a log of the recent production.
Date, time start, time stop, Slices produced and how
the production was stopped.
Password protection:
Certain functions are password protected, such as Set
Points. To change these values the operator must be
logged in on the machine. Pressing the user button
displays a log-in window and a keyboard on the
screen. Select the user level and enter the
corresponding password. Press OK to continue or
Cancel to end. Remove the keyboard by pressing X in
the upper right-hand corner.

Industrivej 62
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Operator Manual for Reformer
Version:
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23
Date:
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Init.:
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STOP PRODUCTION
1. The machine is stopped by pressing the “Start / Stop” button.
NOTE:
This will activate the shutdown procedure.
2. Cut off the main electricity supply.
NOTE:
Do not shut off the main switch on the cabinet inside the machine before hoppers and conveyors are empty.
Maintenance Daily
(Before start-up)
1. Check the oil level in the sight glass container.
(After shut-down)
2. Check the hydraulic pipes and hoses for leaks.
REPAIR AND WARRANTY
Repair
The repair/replacement of the spare parts can be made either by a Cold Jet technician or by the owner’s qualified personnel.
When making repairs/replacements, use only original IceTech spare parts.
Terms of Warranty
In order to comply with the terms of the warranty, and for safety reasons, repairs other than those stated above require
relevant tools and equipment and therefore must always be made either by a Cold Jet technician or by the owner’s qualified
personnel who has been trained by Cold Jet in the repair and maintenance of IceTech dry ice blasting and dry ice production
machines and accessories. Beyond the necessary knowledge, the person concerned must have appropriate tools and
equipment, as well as the auxiliary materials required, at his disposal.
The liability of the manufacturer under the terms of the CE endorsement, as regards to safety, may be invalid:
• If repairs are made using non-IceTech spare parts.
• If repairs are made by unqualified personnel.
• If repairs are unsatisfactory due to lack of relevant tools and equipment.
In such cases, the liability of the manufacturer will be solely confined to any manufacturing faults/errors made prior to the
machine being delivered and before repairs/replacements have been made.