Cold Jet PR750H User manual

PR750H Pelletizer
USER MANUAL
Original Instructions [English] 25-05-2023 Rev 5

Copyright © 2023 Cold et, DK
All rights reserved. Printed in the Denmark.
DUE TO CONTINUED PRODUCT DEVELOPMENT THIS INFORMATION MAY CHANGE WITHOUT
NOTICE. THE INFORMATION AND INTELLECTUAL PROPERTY CONTAINED HEREIN IS
CONFIDENTIAL BETWEEN COLD ET AND THE CLIENT AND REMAINS THE EXCLUSIVE PROPERTY
OF COLD ET. IF YOU FIND ANY PROBLEMS IN THE DOCUMENTATION, PLEASE REPORT THEM TO
US IN WRITING. COLD ET 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 ET.
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 ET IS NOT
LIABLE FOR TYPOGRAPHICAL ERRORS OR CHANGES TO SPECIFICATIONS PRESENTED.

PR750H
User manual
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CONTENT
INTRODUCTION 4
•
About the PR750H Pelletizer 4
SYSTEM DESCRIPTION 5
•
Functional description 5
•
System identification 6
•
Supplier responsible for the equipment 6
TECHNICAL DATA 7
SAFETY REGULATIONS
•
General Measures 8
•
Personnel Qualifications 8
•
Security and Risk 8
•
Danger of Suffocation 9
•
Static Electricity 9
•
Danger of Congelation 10
•
Pinch Point Hazard 10
•
Wear Protective Gloves 10
SAFETY OPERATION 11
•
Emergency stop 11
•
Machine safety 11
•
Liquid CO2 Leakage 11
•
Stop Production 11
•
Daily checkup before start-up 11
MACHINE STRUCTURE 12
MACHINE CONTROLS 13
•
PR750H HMI Screen 13
•
User Level HMI Screen. 17
REPAIR AND WARRANTY 19
•
Repair 19
MAINTENANCE 19
•
Degassing system: 19
•
Hydraulic station: 19
•
Safety device replacement intervals 19
•
Terms of Warranty 20
•
Cleaning the PR750H 20
INSTRUCTION – UNPACKING AND PREPARATIONS BEFORE INSTALLATION 22
•
End of life for the PR750H 24

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User manual
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PR750H
User manual
Version: 5
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Date: 2023.05.25
INTRODUCTION
This manual should be kept with the owner and be readily accessible for operation and maintenance. This manual contains
information for the safety, operation, and maintenance.
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
About the PR750H Pelletizer
The PR750H Pelletizer from Cold et presents a state-of-the-art dry ice Pelletizer with features for easy operation, swift
production shifts, and high capacity performance.
The PR750H produces high-quality dry ice pellets. This is secured by the closed chamber technology which also ensures
fast production shifts and an extremely short start-up time.
The automatic change of extruder plates eliminates downtime and reduces the loss of valuable CO
2
. The pellet length and
quality are optimized by the PR750 design, and it can produce two sizes of pellets without changing the extruder plates.
The PR750H has many technical features compared to existing products on the market.
The hydraulic unit uses logic controlled high-performance components for optimal output.
The machine parts are protected by a moisture-free enclosure, which also reduces the noise level to a minimum
(below 75 dB(a). The PR750H provides a non-stop supply of high-density dry ice pellets. The source of raw material for
the production of pellets is liquid carbon dioxide preserved at low temperatures in a storage tank.
The control system of the PR750H Pelletizer, based on Beckhoff Industrial PC and HMI system, offers maximum functionality
and a user-friendly interface. By selecting the pellet size required, production is started by pressing one button. ust-In-
Time production minimizes labor and waste during production.

PR750H
User manual
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SYSTEM DESCRIPTION
This operator manual covers the PR750H operating instructions. The main parts are described in the machine structure
section. Operating/User instruction for add-ons can be found in other materials not included in this manual.
Functional description
The main function of the PR750H is to produce dry ice pellets from liquid carbon dioxide. This is performed by
a sequence of operations executed by the Beckhoff IPC. The main steps during normal production are as follows and refer
to PI diagram 2A0510 and 2A0511 for PR750H:
1. Start-up
2. Production
3. Standby
4. Shut down
At every start-up, the hydraulic cylinder =G01-G1-MO1 for the extruder piston is extracted to its maximum position to
extrude the CO
2
snow in the chamber in case of an emergency stop or machine error.
Liquid CO
2
is fed from an external CO
2
tank (not part of this description – see supplier information) through an insulated
pipe to the PR750H. It is recommended to use a gas separator to expel gaseous CO
2
from the liquid CO
2
.
When the hydraulic cylinder =G01-G1-MO1 for extruder piston is retracted and hydraulic cylinder =G01-Q3-MO1 for
extruder plate changer is in the middle position - CO
2
In valve =W01-Q1 and Injection valve =G01-Q1 will open and purge
gaseous CO
2
through the chamber, degassing filters via degassing pipes to the CO
2
out. When temperature =W01-TT1 in
the liquid CO2 is -14°C injection will proceed until the timer is reached. The degassing valve =G01-Q5 on the extruder
chamber will open to reduce chamber pressure before the hydraulic cylinder =G01-G1-MO1 so the 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 plug thickness is reached the hydraulic cylinder =G01-Q3-MO1 for the
extruder plate changer will move to the selected extruder plate position and production will commence.
In production mode CO
2
In valve =W01-Q1 and the Injection valve =G01-Q1 will open until the timer is reached. The
degassing valve =G01-Q5 on the extruder chamber will open to reduce chamber pressure before the hydraulic cylinder
=G01-G1-MO1 for the extruder piston will extract until plug set point is reached and the hydraulic cylinder will again retract.
This cycle will continue until a different step is selected. During production, it is possible to set the PR750H on standby.
When the maximum standby time is reached, the PR750H will run a shutdown sequence.
The shutdown sequence ensures that PR750H is stopped in a proper position to empty the extruder chamber of dry ice
snow and avoid moisture in the extruder chamber. The hydraulic cylinder =G01-Q3-MO1 for the extruder plate changer
will move to the selected position and the hydraulic cylinder =G01-G1-MO1 for the extruder piston will extract to the
maximum position and return to shut down setpoint position. The hydraulic cylinder =G01-Q3-MO1 for the extruder plate
changer is in the middle position and all valves are closed.

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System identification
System is marked with:
Supplier responsible for the equipment
Cold et ApS
Industrivej 68
DK-6740 Bramming
Denmark
Phone: [phone]
Fax: [phone]
Homepage: www.coldjet.com

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TECHNICAL DATA
Rated Output:
kg/h: up to 750
lbs/h: up to 1653
lbs of high-quality dry ice pellets, depending on the extruder plate applied
Pellet Size:
Diameter:
mm: 1,7 – 3 – 6 – 10 – 16
inch: 0.07 – 0.12 – 0.24 - 0.39 - 0.62
Inlet Liquid CO
2
Pressure:
Liquid CO2 Supply System PR750H
Supply Pressure (Min-Max) 13-18 bar (189-261 psi)
Supply Pressure Range +/- 1.0 bar (14.5 psi)
Supply Pressure (Recommended PBU Setting) 15-16 bar (218-232 psi)
Liquid CO
2
Dryness Fraction:
The water content should not exceed 35 ppm and should not be less than 5 ppm – or equivalent to a dewpoint
temperature of -66°C to -51°C (-86.8°F to -59.8°F).
NOTE:
The liquid CO
2
supply must be completely free of oil and must have a minimal purity of 99.9%.
Liquid CO
2
Supply Pipe:
Internal diameter 20 mm (0.8 inch), very well insulated with a minimum number of bends and fittings.
NOTE: If over 20 m (65.6 feet) in length, use an internal diameter of 25 mm (1 inch).
Power Supply:
3 x 380-480 V AC + PE, 50-60Hz,
TN-S Earthing system
Imax. 32 A
Or
3 x 220 V AC + PE, 50-60Hz,
TN-S Earthing system
Imax. 45 A
Rated power:
17,3kW / 22,8 Hp @3 x 400V AC
20,0kW / 26,8 Hp @3 x 480V AC
Machine Dimensions:
Length: 1500 mm / 59 in
Width: 1500 mm / 59 in
Height: 1800 mm / 71 in
Height: 1845 mm / 73.6 in (incl. ext. legs)
Weight: 1700 kg / 3747 lbs
Noise level: below 75 dB(a)

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SAFETY REGULATIONS
General Measures
The PR750H manual contains instructions for starting up, operating, and servicing the machine. The operator must follow
all instructions in this manual. The owner must make 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 installation, operation, service, and maintenance must be adequately trained to install
and operate this machinery.
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 PR750H, fully understands the
importance of studying the contents of this manual and comply with the SAFETY REGULATIONS described on the
following pages as well as those placed on the machine.
Contraindications
Cold et Machines are designed to operate for long periods of time. The machine is designed with an HMI that enables
the operator to act upon errors that might occur during operation. The machine should only be operated with the doors
closed.
Entering the machine, for service purposes etc. should be done in a way that allows the Contained CO2 to reach a safe
level and the temperature to fall for certain areas.
Machines with moving parts inside can cause injury, therefore they are designed with door switches that disable the
machines from running when opened/activated.
Security and Risk
The PR750H is designed 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.
It is important that the operator follows the safety signs posted on the machine and the safety regulations described in
this manual and that the operator reads and understands the contents of this manual before starting up the machine.
Installation must be carried out according to the instruction” Preinstallation PR120H-350H-750H”.
The machine may only be installed by authorized personnel with knowledge of the Council Directives BT 2014/35/EU and
EMC 2014/30/EU (or similar directives in other parts of the world).

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Danger of Suffocation
Dry ice pellets are CO
2
in solid form. At ordinary atmospheric pressure, CO
2
can only exist in this solid form at
temperatures of -79°C (-110°F) or lower. Therefore, during dry ice production, the CO
2
will immediately be heated and
thus transform from solid form into gas form.
Please note:
Since the specific gravity of CO
2
is higher than that of ordinary atmospheric air, the air with its contents of oxygen will be
replaced by CO
2
if the dry ice production is taking place in small or insufficiently ventilated rooms.
Therefore, please note the following:
1. Low CO
2
concentrations (3-5%) may cause headaches and rapid breathing.
2. CO
2
concentrations of (7-10%) may cause headaches and nausea and may result in unconsciousness.
3. Higher CO
2
concentrations will result in unconsciousness and suffocation.
High CO
2
concentrations may result in unconsciousness due to the displacement of oxygen. Therefore, always provide
sufficient ventilation of the working area, and avoid producing dry ice in small rooms.
Static Electricity
Dry ice can cause electrostatic discharges. However, the equipment is bonded to the ground to minimize electrostatic
discharge, and the warning sign is meant to instruct the operator to avoid placing the equipment in rooms containing
explosive gasses.
It is recommended to use a plastic shovel in the dry ice container.

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Danger of Congelation
CO
2
in 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.
Pinch Point Hazard
If the plexiglass covers in front of the extruder plates are removed, the operator will be exposed to pinch point hazards.
Wear Protective Gloves
While working with the conveyor system, the operator must wear protective gloves to avoid contact with the dry ice or
with parts of the machine which are in direct contact with the dry ice.

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SAFETY OPERATION
Emergency stop
All equipment is connected to the general emergency system for PR750H.
When an emergency-stop device is activated, all components located in the emergency zone will be disconnected from
their power source.
Machine safety
There are machine safety measures in the following areas:
•Extruder unit
•Extruder plate changer
In these areas, protective covers are in place.
The covers are provided with locking screws to deter removal.
Required performance level PLr = c Implemented in category = Cat3.
There is a danger of congelation/frost bite by touching machine parts cooled down by dry ice.
To prevent congelation the entire machine enclosure is provided with locks that require special tools to open.
Liquid CO2 Leakage
If liquid CO
2
is leaking from any point of the CO
2
pipe system, the CO
2
supply must be stopped immediately. Localize the
leakage and repair.
Stop Production
1. The machine is stopped by pressing the “Start / Stop” button.
NOTE: This will activate the shutdown procedure.
2. The CO
2
valve on the machine inlet will automatically close. It is recommended to close the manual valve on the
mounting kit before leaving the machine unused for a longer period of time.
3. Cut off the main electric supply.
NOTE:
Do not shut off the main switch on the cabinet inside the machine before the inlet CO
2
pressure is ZERO. The CO
2
pressure can be checked on the “Process values” page.
Daily checkup before start-up
1. Check the oil level in the sight glass.
2. Check the pipe system for leaks.
3. Check the operation time since last service.

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MACHINE STRUCTURE
PR750H
1 Pellet outlet sprout
2 Hydraulic station
3 Main hydraulic cylinder
4 Touch panel
5 Extruder plate cylinder
6 Extruder plate changer
7 Connection to an external supply, CO
2
in and Out
1
2
3
4
5
7
6
6
1
5

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MACHINE CONTROLS
The PR750H is controlled from an HMI screen. The next section will describe the function of the HMI.
PR750H HMI Screen
1. Homepage
2. Start, stop, and pause
3. Manuel/automatic
4. Process values
5. Alarm and history page
6. Login page
7. Operation time and service time
. Nickname
9. Hardware status
10. Info page
1
10
7
4
2
3
5
9
6
8

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1 Start-up page
This page can be activated from any page by pressing
the “Home button” in the lower right-hand corner.
The main page shows if the extruder is selected by
the color of the die plate above/under the outlet
sprout is green. If the die plate is grey then it has not
been selected. It also displays which extruder plate is
selected, indicated on the die plate. It is possible to
run with 1 or 2 sides.
Active Inactive
2 Start, stop, and pause
The main functions can be activated by pressing one
of the three buttons on the main screen.
By activating the “Start / Stop” button the machine
starts or stops when in operation mode. When
activating the PR750H, the standby buttons will be
visible. Activating standby mode the PR750H will go
into a pause mode.
When the PR750H is in a standby mode, the HMI
screen changes the start buttons color to yellow. If
the pause time exceeds the set pre-entered set point,
the machine will automatically run a stop cycle and re-
enter operation mode after the cycle is done.
3 Manual/Automatic
By activating the “mode select” button, it is possible
to choose between automatic mode and manual
mode.
The default selection is automatic mode, which must
be selected for production. In manual mode, the
PR750H can be turned off.

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4 Process values
By pressing the “gauge” button the “process values”
page is activated. The page contains a 2-column
display of real-time process values (PV). The
corresponding “Set Values” (SV) are displayed next to
the PV for comparison. During production, the PV will
vary inside the given SV window.
The operating hours, time to service, and the
cumulated strokes for the extruder are also displayed
on this page.
5 Alarm
The Alarm page displays alarms for both Pelletizer and
Dosing Unit. By pushing the “Alarm” button the active
alarms are shown on the screen. When an alarm
occurs the alarm buttons exclamation mark will
change from black to red. To reset the alarms press
the reset button.
Alarms must be reset before production can continue.
When an alarm is reset the text will
Disappear. If the text does not
Disappear by pushing the reset button this means that
the error has not been corrected. For more
information please see the appendix Alarm list
The History page shows the last 1000 alarms of the
PR750H.
6 Password protection
Some functions are password protected. To change
these values the User must log in.
By activating the “User” button a login window and a
keyboard appears on the screen.
Select the user level and enter the corresponding
password.
Press OK to proceed and cancel to exit.
To remove the keyboard, press X in the upper right
corner.
The code for User-level is:
This sector can also be used to change the language.
User name Password
User ColdjetPR2020

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9 Hardware status
These pages give information about the Hardware
status for some of the electrical components. If there
are no faults in the system, all the Address lines will
be white. If there is a fault in a component, its
address line will become red.
10 Info page
Info page divided into 2 pages, PG1 and PG2.
PG1 is the Production log, and it has the last 1000
productions.
PG 2 shows information such as Device, PLC,
Software, and TeamViewer ID.

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User Level HMI Screen.
This section will describe the extra options when the machine is logged in on User Level.
11. Set Point Values
12. Manual Mode
11
12

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11. Set Point Values
By pressing the “toothed wheel” button the “Setpoint”
(SV) page is activated.
The “set point” page contains 3 pages, PG 1, G01, and
G02. These pages display set values for the current
Dry Ice production. Fixed setpoints are password
protected and have hardcoded limits to avoid unsafe
production.
A special feature is the option to select an individual
pillow size for 3, 10, and 16mm extruder plates. For
example, when changing the 3 mm extruder plate to a
16mm extruder plate, the program automatically uses
the new setpoint for the pillow size.
12 Manual mode
By activating the “mode select” button, it is possible
to choose between automatic mode and single mode.
The default selection is automatic mode, which must
be selected for production. In single mode the
components can be operated individually.
Manual mode controls
By activating the “Manual mode” button, the manual
operation page will appear. On this page, it is possible
to access the function in single mode, i.e. operating
the components one by one.
This page should only be operated by well-trained
staff and with reference to P&I diagram.
The components will be activated by pressing the
buttons. When the component is activated and
working properly, the button will turn green showing
“Component OK”.
Most components have names like “purge valve” and
moving the hydraulic cylinders can be done by starting
the hydraulic motor and pressing the arrow buttons.
The hydraulic valves have numbers corresponding to
the P&I diagram.

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REPAIR AND WARRANTY
Repair
The repair/replacement of the following parts must be made by qualified personnel:
•Oil, filter on the hydraulic system.
•Filter for the liquid CO
2
.
•Degassing filter on the extruder.
•Piston ring on the extruder.
When making repairs/replacements, use only original Cold Jet spare parts.
MAINTENANCE
Inspections to be carried out every week: Hydraulic station:
Inspect for oil leakages, Check hoses, fittings, valves, and connections for leakages. Reseal if necessary. Check the oil level,
in the sight glass on the hydraulic tank side. Refill if necessary.
Degassing system:
Check the degassing system. Check the degassing for snow particles at the CO2 outlet (can only be done when dry ice is
being produced)
Snow particles at the CO2 outlet indicate that the degassing filter is damaged. Replace the filter and gasket as described
under in this manual.
Inspections to be carried out every 400 hours / 3 months: Liquid CO2 filter:
Hydraulic station:
Check the oil. Drain a small quantity of oil – 1 dl – from the hydraulic tank. Inspect the oil visually. If the oil is not clear,
bright, and light yellow it must be changed. Get a particle analysis of the oil if in doubt about the contamination degree.
Cold et recommends that the owner has a spare parts package in stock, so repairs can be made quickly and with little loss
of production time.
For each service interval there is a list of necessary procedures and the Cold et article no. for spare parts package. For
more information about the procedures and maintenance look at I appendix: Mechanical maintenance PR750H/PR350H.
Safety device replacement intervals
The expected lifetime is 20 years or 100,000 couplings on electromechanical components (contactors and relays) whichever
is the grater.
Table 1. Table for mechanical maintenance Pelletizer PR750H
Service interval Hours/Month Procedure no. Cold et article no. Spare parts
package.
2000 Hours / 12 Months. 1,2,3,4,6,11 501891