Cold Jet P1500 User manual

P1500 / P3000
Operation Manual
Original [EN] Revised July 2018

Copyright © 2018 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 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 initial prototypes.
An item’s display in this catalog 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.

Voltage: 200/400/460 Volts AC
Model No.: P1500/P3000
Control No.: 2A0270/2A0306
This manual illustrates the safety, operation, and maintenance features of the Cold Jet
Pelletizer P1500 and P3000.
At a distance of 3.28 ft (1 meter) and at a steady operating pace, the A-weighted emission
sound pressure level at workstations is 83 dB (A). The primary source of the sound is the
hydraulic pump/motor. The A-weighted emission sound power level emitted by the machinery
may also reach 83 dB (A). The peak C-weighted instantaneous sound pressure value at
workstations will not exceed 130 dB (A).
The build revision level is located on the machine’s data plate. All machine diagrams are
located on the inside of the electrical enclosure door.
The design contained in this manual was originated by, and is the exclusive property of Cold
Jet, LLC. It is not to be used in any way detrimental to the interests of Cold Jet. No part of this
design or manual may be reproduced, transmitted, stored in a retrieval system, or translated
into any other language or computer language, in whole or in part, in any form or by any
means, whether it be electronic, mechanical, magnetic, optical, manual or otherwise, without
the express written consent of Cold Jet.
Special Notes
All information contained within this manual, or information derived from exposure to the
technology or equipment supplied by Cold Jet remains “CONFIDENTIAL” between Cold Jet and
the purchaser or authorized user. Any unauthorized transfer of information to any person or
company not in the direct employ of Cold Jet, or not in the direct employ of, or for, the
purchaser or the authorized user, is strictly prohibited.

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 5
Contents
Quick Reference................................................................................................................................................7
Safety First......................................................................................................................................................7
About these Instructions ............................................................................................................................7
Start-Up ..........................................................................................................................................................8
Shut Down......................................................................................................................................................8
Standby Mode...............................................................................................................................................9
System Reset .................................................................................................................................................9
Operation & Storage Tips...........................................................................................................................9
Cold Jet Services............................................................................................................................................9
General Information ..................................................................................................................................... 10
Introducing the P1500/P3000 ................................................................................................................ 10
Before you Begin ....................................................................................................................................... 10
CO2Quality Requirements.................................................................................................................. 10
Pressure Requirements for the Liquid CO2Supply....................................................................... 10
Liquid CO2Insulation Requirements ................................................................................................ 10
Pelletizer Liquid CO2Connections for Vapor & Exhaust.............................................................. 11
Exhaust Venting..................................................................................................................................... 11
Placement and Spacing ....................................................................................................................... 11
Supply Valve Locations ........................................................................................................................ 11
Electrical Power Connection............................................................................................................... 11
Liquid CO2Storage Tank Recommendations ................................................................................. 11
Operating Modes....................................................................................................................................... 12
Purge........................................................................................................................................................ 12
Chill down ............................................................................................................................................... 12
Production .............................................................................................................................................. 12
Safety................................................................................................................................................................ 13
CO2Safety ................................................................................................................................................... 13
Extreme Cold.......................................................................................................................................... 13
Suffocation.............................................................................................................................................. 13
Electrostatic Discharge ........................................................................................................................ 13
Safety Precautions..................................................................................................................................... 14
Hose Safety Precautions ..................................................................................................................... 14
Electrical Safety Precautions............................................................................................................... 14
Know Your Machine ...................................................................................................................................... 15
Front ............................................................................................................................................................. 15
Back .............................................................................................................................................................. 16

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 6
Extrusion Cylinder ..................................................................................................................................... 17
Hydraulic Unit............................................................................................................................................. 18
Control Panel.............................................................................................................................................. 19
Gauge Panel (P1500) ................................................................................................................................ 20
Gauge Panel (P3000) ................................................................................................................................ 21
Gauges ......................................................................................................................................................... 22
Chamber Pressure................................................................................................................................ 22
Liquid CO2Injection Pressure ............................................................................................................ 22
Liquid CO2Pressure ............................................................................................................................. 22
Vapor CO2Pressure.............................................................................................................................. 22
Hydraulic Pressure................................................................................................................................ 22
Valve Types.................................................................................................................................................. 23
Liquid Bleed Valve................................................................................................................................. 23
Vapor Purge Valve................................................................................................................................. 23
Liquid CO2Supply Valve....................................................................................................................... 23
Top Injector Valve Assembly............................................................................................................... 23
Preventative Maintenance........................................................................................................................... 24
Weekly Checklist ........................................................................................................................................ 24
Incidental Malfunctions................................................................................................................................ 24
General Malfunctions ............................................................................................................................... 24
Chamber Pressure................................................................................................................................ 24
Liquid CO2Injection Pressure ............................................................................................................ 24
Liquid CO2Supply Pressure................................................................................................................ 24
CO2Vapor Pressure.............................................................................................................................. 25
Hydraulic Pressure................................................................................................................................ 25
Oil Filter Pressure.................................................................................................................................. 25
CO2Vapor Pressure.............................................................................................................................. 25
No Piston Movement................................................................................................................................ 25
Pellet Quality............................................................................................................................................... 26
Low Pellet Output...................................................................................................................................... 26
CO2Snow behind the Piston................................................................................................................... 27
Specifications.................................................................................................................................................. 27
Warranty .......................................................................................................................................................... 28
Contact Information...................................................................................................................................... 31

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 7
Quick Reference
Safety First
•DO NOT touch the dry ice with your bare hands!
•TURN ON ventilation before operating the Pelletizer.
•BE SURE that the Pelletizer exhaust is routed out of the building.
•FOLLOW written procedure for start-up and shutdown.
•ENSURE that all gauges are within their operating ranges.
•NEVER tighten or loosen a hose that is pressurized.
About these Instructions
The P3000 is essentially two P1500s combined onto one frame. The instructions in this manual
are for both the P1500 (one panel, two cylinders) and the P3000 (two panels, four cylinders).
Therefore, instructions should be applied to both control panels when operating a P3000.

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 8
Start-Up
1. Open the liquid CO2supply and vapor CO2supply valves.
2. Turn the Main Power switch [1] to the ON positon.
3. Verify the E-Stop button [3] is not depressed.
4. Turn the Chamber Power switches [2] to the OFF (O) position.
5. Press the Reset button [4].
6. Turn the Chamber Power switches [2] to the ON (I) position.
Shut Down
1. Turn the Chamber Power switches [2] to the OFF (O) position.
2. Turn the Main Power switch [1] to the OFF positon.
3. Close the liquid CO2and vapor CO2supply valves.

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 9
Standby Mode
NOTE: The machine should only be put into standby mode for short breaks.
1. To put the machine into standby mode, turn the Chamber Power switches [2] to the
middle position (standby mode).
2. To take the machine out of standby mode, turn the Chamber Power switches [2] to the
ON (I) position.
System Reset
1. To reset the machine, turn the Chamber Power switches [2] to the OFF (O) position.
2. Press the Reset button [4].
Operation & Storage Tips
•ONLY put dry ice pellets in pellet boxes. Dry ice snow will reduce the quality of the
pellets.
•CLOSE and seal the pellet box, when filling is complete, to prevent air circulation over
the pellets.
•PERIODICALLY check the CO2supply pressure and the hourly production rate of the
Pelletizer.
•STORE pellet boxes out of direct sunlight.
•KEEP the pellet box lid CLOSED when not filling.
•DO NOT use pellet boxes that have holes or cracks. Make sure the interior of the box is
clean and dry.
Cold Jet Services
•Equipment upgrades
•Maintenance services and training
•Parts and Customer Service (see Contact Information)
•48-hour pellet delivery: [phone] or [phone] ext. 343
•Engineered solutions

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 10
General Information
Introducing the P1500/P3000
•The Cold Jet P1500/P3000 is an industrial strength dry ice extruder designed to force
CO2snow into pellets and/or nuggets of variable size.
•The P1500/P3000 produces pellets for dry ice blasting, produce nuggets for
preservation of perishable items and other applications.
•The P1500/P3000 requires 3-phase AC power and a liquid CO2tank for operation. See
the data plate on the machine for the voltage, current, and frequency specifications.
•The P1500/P3000 can be fitted with a series of die plates to vary the diameter of the
dry ice pellets and an ice cutting extension to cut the pellets to precise lengths.
•The P1500/P3000 contains an innovative injection and extrusion system to produce the
highest density and longest lasting pellets in the industry.
•The pellets are produced by injecting liquid CO2into the Pelletizer extrusion cylinder
where a solid CO2is formed.
•A ram presses the solid CO2through the die plate to form pellets or nuggets.
•The P1500 is able to produce up to 1200 lb/hr (590 kg/hr) of dry ice pellets. The P3000
is able to produce up to 2400 lb/hr (1090.9 kg/hr) of dry ice pellets.
•The pellets must be stored in the proper containers to minimize sublimation (returning
to a gaseous state).
Before you Begin
CO2Quality Requirements
•Standard “Food Quality” liquid CO2is required.
•Moisture content must be between 1 ppm and 10 ppm.
•Regularly inspect all tanks for moisture or petroleum contamination.
Pressure Requirements for the Liquid CO2Supply
•The Liquid CO2supply must be selected and maintained at a constant pressure
between 210 to 290 psig (14.5 to 19.99 bar) with a variance of +/-10 psig (+/-.69 bar).
•If the supply pressure varies by more than +/-10 psig (+/-.69 bar), Cold Jet will not be
held responsible for lost production.
Liquid CO2Insulation Requirements
•CO2vaporization in the supply lines, caused by poor insulation, will reduce Pelletizer
output.
•0-50 ft (0-15 m) - use Rubatex (or its equivalent) with minimum thickness of half the
pipe’s diameter.
•50-100 ft (15-30 m) - use at least 6 in. (152 mm) urethane foam with a hard plastic
outer shell (or its equivalent).

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 11
•Over 100 ft (30 m) - use a “Loop” system (auxiliary liquid CO2pump and vapor-to-tank
return line).
Pelletizer Liquid CO2Connections for Vapor & Exhaust
•CO2liquid supply line: 3/4” (19 mm) JICM
•CO2vapor supply line: 1/2” (13 mm) JICM
•CO2vapor exhaust line: 2” (51 mm) PVC
•CO2vapor recovery line (when applicable): 2” (51 mm) copper tube
Exhaust Venting
•Any structure housing a Pelletizer must have an air circulation system.
•Route the Vapor CO2to an exhaust system or vent it to an outside source.
•The exhaust backpressure must be less than 1 psig (.07 bar).
•Use a 2” (51 mm) conduit when exhaust pipe is 30 ft (9 m) or less.
•Use a 3” (76 mm) conduit when exhaust pipe is more than 30 ft (9 m)
•The pipe can be PVC, flexible hose, copper pipe, stainless steel pipe, or sheet metal
ducting.
Placement and Spacing
•The Pelletizer needs to be installed on a level floor with adequate load bearing to
support it.
•Allow a minimum of 60” (1.5 m) of space in front of the Pelletizer for pellet boxes.
Supply Valve Locations
•A safety pressure relief valve must exist between the Pelletizer and the supply line shut
off valves.
•The liquid and Vapor CO2shut-off valves and electrical disconnect must be near the
Pelletizer within easy reach of the operator.
Electrical Power Connection
•Cold Jet requires a qualified electrician to install power to the Pelletizer.
•The Pelletizer has been pre-wired for your requested voltage and frequency.
•You must provide the correct hard conduit and four-wire, three-phase power wiring.
Liquid CO2Storage Tank Recommendations
•Use a tank large enough to accept a full truckload of CO2.
•A refrigerator and vaporizer (heater) are needed to balance the CO2temperature and
pressure. Ideal storage conditions are 290 psig (19.99 bar) at 0oF (-18oC).
•The refrigeration should turn on at 295 psig (20.3 bar) and turn off at 285 psig (19.7
bar).
•The vaporizer should turn on at 270 psig (18.62 bar) and turn off at 280 psig (19.3 bar).

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 12
•Facilities with large and/or multiple tanks (i.e. 220 tons) may only have over-pressure
safety valves. In these situations, there are several factors to consider:
oLength and diameter of supply line.
oType and quality of insulation on the supply line.
oNumber of machines drawing liquid from the supply line.
oIs a liquid loop system being used?
NOTE: Large ice production facilities are generally considered on an individual basis.
Operating Modes
Purge
When starting the unit from main power off, it will enter a “purge cycle” using high-pressure
vapor only to dry out the extrusion cylinder and the exhaust screens before allowing the CO2
liquid to enter this area. This is done for ten strokes on each cylinder.
Chill down
The next phase is the chill down for up to twenty strokes on each cylinder. Liquid CO2is
introduced to the cylinder through the bottom electric solenoid valve only. This phase may be
shortened if the hydraulic pressure switch senses extrusion pressure as required to push the
ice through the die.
Production
The unit will automatically shift into full production and the top ball valve assembly actuates to
provide a higher liquid flow rate.

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 13
Safety
CO2Safety
Symbol
Definition
Danger of Suffocation
Danger of Electrostatic Discharge
Danger of Congelation
Pinch Point Hazard
Danger of Burns
Wear Protective Gloves
Wear Eye Protection
Extreme Cold
This machine uses CO2liquid and gas to create dry ice (CO2in solid form). The temperature of
dry ice is -78°C (-109°F). Avoid coming into direct contact with dry ice as it may cause severe
tissue damage.
Suffocation
CO2can displace oxygen from the surrounding atmosphere. Therefore, operating the machine
in a well-ventilated work area is recommended. Use a CO2monitoring device if using the
machine in a confined workspace.
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 shovel when handling dry ice to eliminate any additional static electricity.

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 14
Safety Precautions
The Cold Jet P1500/P3000 is safe to operate. However, certain precautions must be taken
during use:
•NEVER OPERATE the unit without first reading the Operator Manual.
•NEVER operate the unit unless trained or authorized to do so.
•NEVER EXPOSE bare skin to CO2pellets or liquid.
•NEVER OPERATE without proper ear and eye protection.
•NEVER operate in a confined space without a ventilation system that maintains OSHA
CO2concentration levels (5,000 ppm).
•NEVER ATTEMPT to run the unit if it is damaged.
•ALWAYS disconnect the main power to the unit BEFORE performing maintenance
services.
•ALWAYS check gauges, when starting the unit, to verify the unit is working properly.
•DO NOT change pressure flow rate settings once they have been set.
•ALWAYS turn off the main power to the Pelletizer if it is to remain unused for an
extended time.
Hose Safety Precautions
•ALWAYS tighten hose fittings with a wrench.
•NEVER OPERATE equipment if the fittings have only been hand tightened.
•NEVER USE hoses above the recommended working pressure.
Electrical Safety Precautions
•UNLESS YOU ARE COLD JET TRAINED as a service technician, you should NEVER
attempt to work on the unit's electrical components.
•Do not operate equipment with electrical parts exposed.
•Do not operate equipment that has had safety circuits “jumpered” or rendered
inoperable.
•Follow the guidelines set forth in the governing codes of your local/national body as a
minimum standard for ensuring safety.

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 15
Know Your Machine
For illustrative purposes, only the P1500 is shown. See About these Instructions for more
information.
Front
1. Control Panel
2. Main Power Switch
3. Chamber Pressure Switches
4. Top Injector Valve
5. Extrusion Cylinders
6. Gauges Panel
7. Hydraulic Oil Tank
8. Sight Gauge

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 16
Back
1. Top Injector Valve Assembly
2. Vapor CO2Supply
3. Liquid CO2Supply
4. Hydraulic Unit
5. Liquid Bleed Valve
6. Vapor Purge Valve
7. Liquid CO2Supply Valve

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 17
Extrusion Cylinder
1. Hydraulic Cylinder
2. Liquid CO2Flow Control Valve
3. Tie-Rod Guards
4. Extrusion Cylinder
5. Exhaust Collectors

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 18
Hydraulic Unit
1. Hydraulic Oil Tank
2. Oil Filter
3. Oil Temperature Sensor
4. Oil Level Sensor
5. Cooling Fan Sensor
6. Hydraulic Directional Control Valve Solenoid
7. Directional Control Valve

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 19
Control Panel
1. Main Power Switch
2. Chamber Power Switches
3. Emergency Stop
4. Reset

Operation Manual P750/P1500/P3000
Cold Jet, LLC Page 20
Gauge Panel (P1500)
1. Chamber Pressure
2. Chamber Pressure
3. Liquid CO2Injection Pressure
4. Liquid CO2Pressure
5. Vapor CO2Pressure
6. Hydraulic Pressure