Cold Jet PE50 User manual

The Cold Jet Project Lead and Customer Project Lead who will oversee the successful
installation of the pelletizer and maximize the performance of the new dry ice manufacturing
system:
Cold Jet Project Lead Telephone Email
Customer Project Lead Telephone Email
Pre
-
Installation
Guidelines & Checklist
Dry Ice Manufacturing System – Pelletizers
PE 0 | PE80

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Copyright © 2022 Cold Jet, DK
ALL RIGHTS RESER ED. PRINTED IN DENMARK.
DUE TO CONTINUED PRODUCT DE ELOPMENT THIS INFORMATION MAY CHANGE WITHOUT NOTICE. THE
INFORMATION AND INTELLECTUAL PROPERTY CONTAINED HEREIN IS CONFIDENTIAL BETWEEN COLD JET AND THE
CLIENT AND REMAINS THE EXCLUSI E 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 RETRIE AL 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 A AILABILITY AT ANY TIME IN THE FUTURE. IMAGES
SHOWN ARE FOR REPRESENTATION PURPOSES ONLY. PRODUCTS MAY ARY FROM THE IMAGES DISPLAYED. COLD JET
IS NOT LIABLE FOR TYPOGRAPHICAL ERRORS OR CHANGES TO SPECIFICATIONS PRESENTED.

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T ABLE OF C ONTENTS
Introduction 4
INSTRUCTION – UNPACKING AND PREPARATIONS BEFORE INSTALLATION 5
Unpacking and Examination for Transport Damages 5
Requirements on the Environment Surrounding the PE50/80 5
Pre-Installation by the Customer 6
Production Space Requirements 6
Liquid CO
2
Supply System 6
Liquid CO
2
Degasser System 7
Gas CO
2
Exhaust System 7
CO
2
battery 8
Electrical Service & Supply 8
REPAIR AND WARRANTY 9
Repair 9
MAINTENANCE 9
Terms of Warranty 10
Safety 11
Carbon Dioxide (CO
2
) and Dry Ice Properties 11
Dry Ice Production Process 11
Safety Hazards 11
Pre-Installation Checklist 12
Pre-Installation Conformation Form 13
Notes 14
Contact Information 15

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INTRODUCTION
Before any pelletizer can be installed, the owner/operator must prepare the site for installation and operation. It is the
owner’s responsibility to verify all the necessary preparations have been made to the installation site and meet the
specifications and guidelines detailed in this publication. This may include but is not limited to:
•Providing an indoor space with standard industrial flooring.
•Installing a liquid CO
2
tank and supply pipeline system up to the connection point at the pelletizer.
•Installing a gaseous CO
2
exhaust pipeline from the pelletizer to free vent at a safe position.
•Installing a power supply that is sufficient and up to code.
•Providing proper room ventilation and other CO
2
safety measures.
•Determine which options and other manufacturing accessories to add/prepare for maximizing production
performance and capabilities.
The owner is responsible for transmitting the specifications in this publication to other third-party contractors involved in
the pre-installation preparations of the site. Failure to properly prepare the site may delay the installation and/or optimal
performance of the pelletizer. The graphics used in this manual may show pelletizer details and installation components
that may be different than what is actually used. Components may have been removed for illustrative purposes or the
continuing improvement of the pelletizer’s design may cause changes that are not included in this publication.

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INSTRUCTION UNPACKING AND PREPARATIONS BEFORE INSTALLATION
This machine has been assembled and tested at Cold Jet's test center before being crated and shipped as one unit. Follow
the steps below to unpack and inspect the machine from the shipping container.
Unpacking and Examination for Transport Damages
1. Examine the transport box for any damages occurred during transportation.
2. Remove the top and side plates from the transport box.
3. Unbolt the 4 bolts that secure the PE50/80 to the pallet.
4. Examine the PE50/80 for external transport damages.
Requirements on the Environment Surrounding the PE50/80
o The PE50/80 must be sheltered from wind and weather.
o The ambient temperature must be minimum +5°C (+41°F).

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PRE-INSTALLATION BY THE CUSTOMER
Pre-Installation of the machine at the site must be carried out by the owner/operator.
Machine owner/operators are responsible for the physical installation, utility connections, and CO
2
supply required to put
a new machine into service.
For an overview of a typical dry ice production system, refer to "Dry Ice Production System" on page 6.
Production Space Requirements
•Adequate ventilation, natural or forced, must be provided to prevent the build-up of CO
2
during production.
•A system to monitor CO
2
levels that will alert personnel when CO
2
levels become too high and pose a danger.
•The machine shall be sheltered from the wind and weather and operate in an environment with an ambient
temperature between 5°C and 43°C (41°F and 109°F).
•The machine must be placed on a horizontal, concrete floor with adequate load carrying capacity.
•The physical distance from the pelletizer to walls, columns or any firm/solid object in the must not be less than
1 meter
Liquid CO
2
Supply System
Cold Jet recommends the supply line for the liquid CO
2
from the storage tank to the pelletizer to be direct (with limited
bends) and well insulated. This will help prevent the formation of gas and maintain the temperature of the liquid CO
2
thus
improving the performance of the pelletizer.
It is the responsibility of the installer of the liquid CO
2
supply system to determine the best supply line route and the
insulation needed.
Liquid CO
2
supply systems PE50 PE80
Supply pressure (min
-
max)
13
-
18 bar
,
-
30 to
-
20 C (189
-
261 psi
,
-
22 to
-
4 F)
Optimum performance range 16-18 bar, -24° to -26° C (232-290 psi, -11°F to -15°F)
Supply pressure range
+/
-
2.0 bar (29 psi)
Flow rate
-
minimum
150 kg/hr
200 kg/hr
Pelletizer design pressure / PR setting
24.1 bar
Liquid CO
2
line size recommended ID
12.7 mm (0.5 in)
Liquid CO
2
connection at pelletizer
EU: 3/8
-
inch BSP
-
60° cone
Liquid CO
2
Line insulation
Min. 50 mm
(3.0 in) Industrial Insulation
-
(Urethane Foam
-
P C/Alu jacket)
NOTE: If the liquid CO
2
supply line is serving more than one pelletizer, other CO
2
consuming machinery, or is longer than
25 m (82 ft) the owner should consult with the CO
2
piping contractor for an optimal design for a stable and gas-free liquid
CO
2
supply to the pelletizer.
NOTE: For CO
2
tank installation and the liquid CO
2
supplier the recommended supply pressure settings are 16-18 bar, -
24°C to -26°C (232-290 psi, -11°F to -15° F) for optimized output performance and quality. The liquid CO
2
quality in use
must meet general purity requirement of commercial industrial/food grade specifications and must be free of oil and have
a purity of minimum 99.9%. For optimum performance and high-density pellets quality the water (H
2
O) content should
not exceed 35 ppmv and not be less than 5 ppmv - or equivalent to a dew point temperature of -66°C to -51°C (-86.8°F
to -59.8°F). If only very dry CO
2
is present please contact Cold Jet for optimal special extrusion process design and settings.
Please note that the CO
2
tank capacity must always be in proportion to the actual dry ice pellet production rate! (it takes
about 2,5 kg of LCO
2
to produce 1 kg of dry ice)

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Liquid CO
2
Degasser System
In order to achieve a consistent, high-quality supply of liquid CO
2
to the pelletizer, Cold Jet recommends the installation of
an automatic gas venting system, such as the Armstrong Kit.
Installing an automatic gas venting system will improve the performance of the pelletizer and increase dry ice production.
The installation of the Armstrong Kit, or similar system, is optional and is the responsibility of the installer of the liquid CO
2
supply system and piping up to the pelletizer connection.
Gas CO
2
Exhaust System
An exhaust pipeline with an internal diameter greater than 25,4 mm (1 inch) is installed to facilitate the exhaust CO
2
gas
from the dry ice production process. The exhaust CO
2
gas must be vented at a safe location outside of the building with a
weatherproof outlet that prevents rainwater or other contaminants from blocking or creating back-pressure to the
pelletizer.
Additionally, the CO
2
exhaust could have a temperature as low as -27°C (-16.6°F) which may generate condensation. Cold
Jet recommends installing an Armaflex insulation or similar product to prevent this condensation from dripping down onto
the machine or production room floor.

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CO
2
battery
When operating our PE50 pelletizer from a battery, it is important to select the correct type of battery.
We need to use the upside-down version to keep an optimal production, as Dry ice is made from liquid.
These battery’s come with a special outlet fitting and therefore it is crucial to get a reduction from the gas supplier. This
reduction must end with a 3/8” BSP 60° cone fitting. This should be connected to the inlet side of the pressure reducer.
(1)
The battery needs to be connected to a pressure reducer (TP700000) as the pressure is approx. 50 bars in the battery
and the pelletizers safety valve will open at 24,1 bar. We recommend having a working pressure between 16-18 bar on
the pelletizer.
The pressure reducing kit (TP700000) comes with a gas vent to optimize the flow of liquid to the pelletizer. The excess
gas must be carried outside for safety reasons together with the exhaust gas from the pellet
1. Inlet from battery
2. Shut-off valve
3. Inlet pressure gauge
4. Outlet pressure gauge
5. Adjustable knob for outlet pressure (16-18 bar)
6. Gas release
7. Outlet to PE50 pelletizer
Electrical Service & Supply
The Pelletizer requires a three-phase power supply. The power source must be grounded:
•For machines in the US: use a Solidly Grounded WYE Source.
•For machines outside US: use a TN-S grounding acc. to IEC 60364.
•All phases must be balanced, and voltages must be within ±10%.

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The customer is responsible for the electrical installation of the pelletizer. This includes the power cable and main circuit
breaker which meet the specifications below. The main circuit must be suitable for proper lock out / tag out in
accordance with international and national standards and requirements.
Electrical Service & Supply PE50 PE80
oltage AC/ Frequency (EU 50Hz) 3 x 400 AC/50Hz
Average Power Consumption 3 kW
Rated Current (Imax) 16 A
REPAIR AND WARRANTY
Repair
The repair/replacement of the following parts can be made by the owner’s qualified personnel:
•Filter for the liquid CO
2
•Degassing filter on the extruder
•Piston on the extruder
When making repairs/replacements, use only original Cold Jet spare parts.
MAINTENANCE
Cleaning the PE50/80
The following steps are necessary when the PE50/80 needs to be cleaned.
●Disconnect the power.
●Protect all electronic equipment.
●clean by means of a wiper moistened with a cleaning material (degreaser) suitable for stainless steel.
●Do not pressure wash.

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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 Cold Jet 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 safety may become
invalid:
●If repairs are made using non-Cold Jet 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.

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SAFETY
Carbon Dioxide (CO
2
) and Dry Ice Properties
At a temperature of -15°C (5°F) under normal atmospheric pressure, carbon dioxide has a density of 1.87 kg/m3 (0.12
lb/ft3) and is 1.5 times heavier than air. It is a colorless and odorless gas with a slightly pungent odor at higher
concentrations and spreads along the ground.
Carbon dioxide gas will collect in low-lying areas such as pits and cellars.
Dry Ice Production Process
The expansion of liquid carbon dioxide at pressures between 15-18 bar (217.6-261.1 psi) to atmospheric pressure is how
the pelletizers produce CO
2
-snow at a temperature of -78.5°C (-109.3°F). The CO
2
-snow is then compressed to form high-
density dry ice pellets.
Safety Hazards
Dry ice is extremely cold and may cause severe frost bite or tissue damage when in direct contact with exposed skin.
Always wear protective gloves and clothing when handling dry ice. CO
2
is classified as a non-flammable and non-toxic gas.
It is normally present in the atmospheric air at a level of approximately 0.04%. It is a normal product of metabolism being
held in bodily fluids and tissues where it forms part of the bodies normal chemical environment. Higher concentrations can
cause suffocation. Operate the pelletizer in a well-ventilated work area with continuous CO
2
-level monitoring. The effects
of CO
2
are entirely independent of the effects of oxygen deficiency. Therefore, CO
2
concentrations at 3-5% causes
headaches, fast breathing and discomfort while higher concentrations may cause unconsciousness, suffocation or
respiratory arrest. The legal exposure limit set by OSHA is a 0.5% average over an 8-hour workday.
Always use a CO
2
monitoring/alarm system when working with machinery that emits CO
2
in a confined room/space.
Operation and maintenance should only be performed by authorized and trained personnel.
Below are some basic safety guidelines:
•Follow local governing codes to ensure a minimum standard of safety.
•Wear protective gloves, safety glasses, and ear plugs.
•Operate the pelletizer in a well-ventilated work area with a CO
2
monitoring/alarm system.

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PRE-INSTALLATION CHECKLIST
The owner should use the checklist below to prepare for the installation of their pelletizer. It is the owner’s responsibility
to verify all the necessary preparations have been made to the installation site and meet the specifications and guidelines
detailed in this publication.
Check off each item in the checklist as pre-installation preparations are completed. Once the checklist is complete, the
owner or responsible party will sign and date the Pre-Installation confirmation form and return it to Cold Jet.
Completed Task
 Installation of a CO
2
tank, filled up with CO
2
. The following specifications are observed:
The water content of the CO
2
does not exceed 35 ppm and is not less than 5 ppm – or equivalent to a
dew point temperature between -66°C and -51°C.
•
The liquid CO
2
supply is completely free of oil and has a purity of min. 99.9%.
 The installation site of the pelletizer is indoors, well-ventilated, with sufficient
clearances on all sides (including the top).
 The installation of the CO
2
supply tank is complete and has been filled by the owner-selected CO
2
supplier (refer to "Liquid CO
2
Supply System" on page 7).
Please note that the CO
2
tank capacity must always be in proportion to the actual dry ice pellet
production rate! (it takes about 2,5 kg of LCO
2
to produce 1 Kg of dry ice).
 The supply pipeline has been installed and meets the specifications described in "Liquid CO
2
Supply
System" on page 7.
 The supply pipe has to be suitable for a temperature of -45°C and a supply pipe pressure of 40 bar
(580 psi).
 Internal diameter max. Ø 3/8”.
 At the end of the pipeline a conic reduction to 3/8” (male thread) has to be installed, in order to attach
to a flexible hose (provided with the pelletizer) used to connect the rigid pipeline to the LCO
2
inlet on
the pelletizer itself. The length of the flexible pipe or hose is between 1 to 5 m and will be adapted to
the specific conditions on the production site.
 The supply pipe is installed so as to be protected from being damaged by vehicles, etc.
 Before reaching the pelletizer, the pipeline must have an upwards inclination of 2 %.
 The pipeline has to be designed so as to minimize the risk of gas accumulations (gas pockets). It MUST
be as SHORT and STRAIGHT as possible, avoiding bends and changes of direction. RECOMMENDED
MAX. LENGTH: 25 m.
BENDS OR DEFLEXIONS MUST NOT BE RIGHT ANGLED!!! The recommended radius of the bending
would be equal to 5 x the internal diameter of the pipe.
 If the pelletizer were to be installed inside a building and next to a wall, Cold Jet recommends to place
a closing/opening valve on the LCO
2
pipeline close to the pelletizer, on the section between the pelletizer
and the inner side of the wall, in order to have the possibility of a quick interruption of the LCO
2
flow
to the pelletizer, instead of having to exit the building and stop the flow from the main valve at the
tank.
 Cold Jet does also recommend to place a degassing or safety valve on the outer section of the LCO
2
pipeline, between the tank and the building (outside the building, in order to evacuate the CO
2
gas in
the open air).
 The degassing pipe (for the evacuation into the open space of the revert gas resulting from dry ice
production) must have an internal diameter of Ø 1”. The following specifications are observed:
The type of material chosen for the degassing pipe is suitable for a temperature of -60°C and for a
pressure of 1 bar (14.5 psi).
A OID bends or any obstacles that might provoke the formation of snow or ice plugs.
 The exhaust pipeline has been installed and meets the specifications described in "Gas CO
2
Exhaust
System" on page 8.
 The physical distance from the pelletizer to walls, columns or any firm/solid object in the must not be
less than 1 meter.
 Electrical connections have been established (3 x 400 + EARTH, unless otherwise agreed upon). The
max. power requirement of the pelletizer is 16 amp.
 The electrical connections are in compliance with the regional specifications described in "Electrical
Service & Supply" on page 10.

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Pre-Installation Conformation Form
I hereby verify the pre-installation preparations listed above have been completed.
Customer: _________________________________________________________________________________________
Order: ___________________________________________________________________________________________
Owner/Contact: ____________________________________________________________________________________
Signature: _________________________________________________________________________________________
Date: _____________________________________________________________________________________________
Notes/Remarks to Cold Jet: ___________________________________________________________________________
Email the signed form to the to the Cold Jet project lead named on the front page

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NOTES

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CONTACT INFORMATION
Find the customer support and technical services contact information for your region in the table below.
USA Cold jet 24-Hour Customer Support
(World Headquarters) Phone (US): [phone]
455 Wards Corner Road Phone (Outside US): [phone]
Loveland, Ohio 45140 Email: [email protected]
Canada - Cold jet Canada Phone: [phone] Ext. 501
1727 Industrial Road, Unit 1 After Hours Support: [phone]
Cambridge, Ontario N3H 5G7 Email: [e-mail]
Latin America, Cold Jet Latinoamérica Phone: [phone]
Calle Sinaloa, 901-3. After Hours Support: + 1 [phone]
Colonia: Nuevo Repueblo Email: [e-mail]
Monterrey, NL, Mexico
CP: 66480
Belgium Cold jet bvba Phone: [phone]
(European Headquarters) After Hours Support: [phone]
Zona 1 Researchpark 330 Email: [e-mail]
B-1731 Zellik
Germany Cold jet GmbH Phone: [phone]
Obere Industrie Strasse 1 After Hours Support: [phone]
54595 Wiensheim
Spain Cold jet Madrid Phone: [phone]
Edificio Foro de Somosaguas, After Hours Support: [phone]
Planta 2 Oficina 14 Email: [e-mail]
Pinar de Somosaguas 89 Bis
28223 Pozuelo de Alarcón
China Phone: [phone]
Room 113, Building 2 After Hours Support: [phone]
Huguang East Road No. 89 Email: [e-mail]
Minhang, Shanghai 201108
Japan/APAC Phone: [phone]
1-20-4 Ishiwara, Sumida After Hours Support: [phone]
Tokyo 130-0011 Email: [email protected]m