Cold Jet RE320 User manual

Recovery Unit RE320
USER MANUAL
Original Instructions [English] May 2023 Rev 1

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Copyright © 2023 Cold Jet, K
All rights reserved. Printed in the enmark.
UE TO CONTINUE PRO UCT EVELOPMENT THIS INFORMATION MAY CHANGE WITHOUT
NOTICE. THE INFORMATION AN INTELLECTUAL PROPERTY CONTAINE HEREIN IS
CONFI ENTIAL BETWEEN COL JET AN THE CLIENT AN REMAINS THE EXCLUSIVE PROPERTY
OF COL JET. IF YOU FIN ANY PROBLEMS IN THE OCUMENTATION, PLEASE REPORT THEM TO
US IN WRITING. COL JET OES NOT WARRANT THAT THIS OCUMENT IS ERROR-FREE.
NO PART OF THIS PUBLICATION MAY BE REPRO UCE , STORE IN A RETRIEVAL SYSTEM, OR
TRANSMITTE IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING,
RECOR ING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF COL JET.
THIS MANUAL REFLECTS THE PRO UCT CONFIGURATION AS WAS CURRENT AT THE TIME OF
ITS WRITING. AN ITEM’S ISPLAY IN THIS MANUAL OES NOT GUARANTEE THE ITEM’S
AVAILABILITY AT ANY TIME IN THE FUTURE. IMAGES SHOWN ARE FOR REPRESENTATION
PURPOSES ONLY. PRO UCTS MAY VARY FROM THE IMAGES ISPLAYE . COL JET IS NOT
LIABLE FOR TYPOGRAPHICAL ERRORS OR CHANGES TO SPECIFICATIONS PRESENTE .

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CONTENT
INTRODUCTION 4
SAFETY REGULATIONS 7
•
General Measures 7
•
Personnel Qualifications 7
•
Security and Risk 7
•
anger of Suffocation 8
•
Static Electricity 8
•
anger of Congelation 8
MACHINE STRUCTURE
MACHINE CONTROLS 13
•
Operation Panel 13
•
Liquid CO2 detector and reservoir 14
•
Main menu structure – RE320 UNI PLC 14
•
isplay Settings 15
AUTOMATION 16
•
Power supply and control protection system 16
•
Pressure protection system. 16
STARTING UP THE RECOVERY UNIT RE320 16
STOPPING THE RECOVERY UNIT RE320 UNI 17
•
Stopping without depressurizing the system. 17
•
epressurizing the system before stopping. 17
•
epressurizing the system if there is a power failure. 17
ALARM MESSAGES 18
MAINTENANCE 20
•
Maintenance intervals 20
•
Oil filter 20
•
Inspection and refill of CO2 compressor oil 21
•
Refilling CO2 compressor oil. 22
•
rainage of CO2 compressor oil 23
•
CO2 Pressure and venting 24
•
Insufficient refrigeration 24
•
Refrigerant condensation high pressure 25
•
Refrigerant evaporation low pressure. 26
•
Insufficient heat transmission in the CO2 condenser. 26
•
Terms of Warranty 26
•
Cleaning and Storage 27
SPARE PARTS LIST 28
TROUBLESHOOTING 30
DELIVERY REPORT 32
CONTACT INFORMATION 33

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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 Machine
The recovery RE320 UNI is especially designed to be connected to multiple types/brands of pelletizers, and not only the
PE80 Pelletizer.
This technology is the subject of Patent application No. 0408224.4.
To obtain long and trouble-free operation of the equipment we recommend reading this manual carefully. All new operators
of the equipment should also familiarize themselves with the content of this document.
Normal dry ice production uses liquid CO2 which when brought to normal atmospheric pressure, in e.g. a pelletizer converts
to one half snow and one half gas, called ‘revert’ gas. The snow is then compressed into dry-ice pellets.
But, by using the RE320 UNI Recovery Unit, the revert gas, which is usually lost into atmosphere, is collected and recycled
to make more pellets. This becomes a continuous process and will, as a result, reduce production costs by up to 50%.
Supplier responsible for the equipment
Cold Jet ApS
Industrivej 68
K-6740 Bramming
enmark
Phone: [phone]
Fax: [phone]
Homepage: www.coldjet.com

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Technical Data
Voltage 440-480 V AC
Frequency 60 Hz
Power 45 kW
Current 85 A
imensions L2420 * W1370 * H1640 mm
Weight 2000 kg
Power connection 85A 3 P + N + E
Refrigerant R452A
Compressor Oil Type PAO68 oil (Food grade)
Food grade compressor oil type PAO68 oil (Food grade)
Min. to max. temperature +5°C (+41°F) - +35°C (95°F)
Properties of Carbon Dioxide
Name Carbon dioxide
Chemical Formula CO2 (molecular structure: O=C=O)
English Carbonic acid, dry ice
French ioxyde de carbon, anhydride carbonique
German Kohlendioxid, Kohlensäure, Trockeneis
Spanish Acido carbonico
Molecular Weight Mco2 = 44,011 kg/kmol
Molecular norm volume Vmn = 22,263 m3/kmol
Specific gas constant Rco2 = 0,1889 kj/(kg *K)
ensity of the gas (0 C and 101.3 kPa, air = 1) Qn = 1977 KG/m3
Relative density of the gas (0 C and 101.3 kPa, air = 1) = 1529
Critical temperature Tcrit = 31 C
Critical pressure Pcrit = 73,83 bar
Critical density Qcrit = 466 kg/m3
Sublimation point Ts = -78,9 ºC at 0,981 bar
Triple point -56,6 ºC at 5,18 bar.
Temperature of disintegration more than app. 200 ºC [disintegration ratio nearly 0.032 vol
%

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Pressure Temperature Diagram
This phase diagram shows the three phases for carbon dioxide versus pressure and temperature.
Solid Carbon Dioxide / Dry Ice
Sublimation temperature 78.9 ºC (149.25.K) at p = 0,9807 bar
Latent heat of sublimation (Enthalpy of sublimation) 573,02 kJ/kg
Total enthalpy, increasing temperature from -78.9 ºC to 0 ºC 645 kJ/kg

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SAFETY REGULATIONS
General Measures
The 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 machine, 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.
Security and Risk
The machine is designed to comply with the EC eclaration 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 RE80-160-320”.
The machine may only be installed by authorized personnel with knowledge of the Council irectives 73/23/EEC and the
89/336/EEC and the 89/336/EEC (or similar directives in other parts of the world).

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Danger of Suffocation
ry 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
ry 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.
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.

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MACHINE STRUCTURE
1: Second stage CO2 compressor (item no. 22400004)
2: First stage CO2 Compressor(item no. 4C20290)
1. CO2 Gas cooler
2. Refrigerant condenser
3. Refrigerant accumulator
1
2
1
2
3

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Components for 3x400V; 50 Hz and 3x480;60 Hz
1. Breaker
2. Transformer
3. Contactor
4. Phase sequence protection relay
5. 24vdcc supply
6. PLC
7. Transformer & EKC 315a refrigerant regulator
8. Relays
. Main supply breaker
1 2
3 4 5
6 7
8
9

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Connection of the equipment
Power supply
The cable must be mounted locally to fit the local socket-de-sign. Take off the side cover and pull the cable with box out
under the frame and connect to your own power supply. Remember to turn off the main switch before applying power to
the unit.
Connecting the hoses
The connectors are different for each hose and will only fit into the right connections at the Recovery Unit, and at the
Pelletizer. Always ensure that the hoses are arranged as straight as possible i.e. with easy radius bends and avoiding
kinks which may increase pressure drop, or even stop flow.
1. 3/4” BSP Liquid CO2 from tank
2. 1/2” BSP Pressure equalization from pelletizer
3. 3/4” BSP Liquid CO2 to pelletizer
4. 1 ½” Pressure relief
5. 2” cam male CO2 revert gas from pelletizer
6. 2” cam male
Buffer tank
2 1 3 4 6
5

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Operating Limitations
RE320 UNI
•
For a standard configuration machine, the surrounding working temperature should be between -25°C and
40°C. (-13°F - 104°F)
•
The machine should never be stored in an ambient temperature exceeding 50ºC. (122°F)
•
When choosing a location for the Recovery Unit RE320 UNI, the room must be dry, clean and well ventilated.
•
Make certain that the Recovery Unit RE320 UNI is placed on a horizontal plane with a maximum slope of 2°C

•
It is not recommended to locate the Recovery in dusty and/or dirty surroundings. The CO2 gas cooling coil fins
can be covered with dirt and the performance of the Recovery will be reduced.
•
The perforated covers at the left side of the unit (looking from the electrical box) are for the air intake for the
CO2 gas cooler and for the condensing unit. The exhaust of hot air is on the right side of the unit (cover with
fans). The air intake side must have at least 2m of free space to any walls. The exhaust side must have at least
5m of free space. In any case proper air circulation has to be ensured, meaning that the hot air must not
circulate back to the air intake side.
Condensing system
•
The min./max. ambient temperatures for the Condensing unit are -25°C to 40 °C (-13°F to 104°F) at normal air
humidity.
•
The unit should never be stored in an ambient temperature exceeding 50°C.
•
The unit must be protected against direct sun and rain.
•
Air flow through the condenser coil is approx. 7300m³/h and requires a well-ventilated room or facility. If the
airflow is restricted the cooling capacity will decrease 2% per 1°C.
•
The foundation must be solid and as level as possible. Max. slope 2 °C.
•
The unit is only designed to operate with R452A refrigerant. Any other refrigerant can damage the compressor
and influence the capacity.

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MACHINE CONTROLS
The operation panel at the front of the RE320 UNI includes the following functions.
Operation Panel
1: isplay
2: Manual start button
3: Manual stop button
4: Emergency stop button
Pressure Gauge Panel
1: CO2 Gas high pressure - Pressure after 2nd stage compression
2: CO2 Gas pressure - Pressure after 1st stage compression
3: CO2 Gas pressure from pelletiser
1
2 3
4
1
2
3

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Normal gauge readings during operations
These are the readings you would expect to see after the Recovery has cooled down and commenced stable operation
(after 10-15 minutes)
•
Refrigeration Condensing Pressure: Between 13 and 22 bar.
•
Refrigeration Evaporation Pressure: Between 1 and 2 bar.
•
CO2 Gas Pressure from Pelletizer: Between 0,1 and 0,8 bar.
•
Pressure after 1st stage compression: Between 4 and 5 bar.
•
CO2 High Pressure: Between 16 and 20 bar.
Liquid CO2 detector and reservoir
The liquefied CO2 flows to a small reservoir containing a level sensor. The level sensor gives a signal to the control
system when liquid CO2 is detected, and a red light shows. The green light indicates that the level detector is electrically
supplied.
•
Function:
o
Green light = Power on
o
Red light = Liquid CO2
Main menu structure – RE320 UNI PLC
1. Cooling pressures
1
2
3
4
5
6
7
8
9 1

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2. CO2 pressures
3. CO2 temperatures 1st and 2nd stage.
4. Working hours counter
5. Time and date
6. Status on Recovery
7. Settings
8. Alarm log
9. I/O status
10. Home button.
Display Settings
The display has got a screensaver installed. This screensaver can be locked as seen on the small symbol on above
picture. If this happens then press in each of the 4 corners and it will unlock.
Language, brightness and date and time can be adjusted in the setting menu.

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AUTOMATION
Power supply and control protection system
A voltage monitoring relay in the panel stops the recovery and lights up the electrical failure lamp on the panel. The relay
switches off if the voltage is too low, the phases order is wrong, or a phase is missing.
Pressure protection system.
The recovery will only run if the revert gas hose from the pelletizer is pressurized (0.1-0,8 bar (1.45-8.7 Psi)). The
pressure is constantly measured in order to prevent air from entering the Recovery. When the pressure drops to 0,1 bar,
the internal pressure relief is opened in order to keep the unit running (in case some small disturbance between the
pelletizer and Recovery takes place).
When the pressure drops down to 0,0 bar the CO2 compressors stop after 60 seconds. Message “CO2 INLET LOW”
shows on the display. The refrigeration part in the unit keeps working for a maximum of 30 minutes. If the pressure rises
back the unit will start automatically (immediately if the refrigeration part was still running or after few minutes if the
whole machine was stopped (see the starting and stopping sequence described page 18).
If the pressure rises above 0,8 bar, the AV304 valve is opened in order to drop the CO2 gas. When the pressure keeps
rising and reaches 1,0 bar, second valve - AV302 – opens in order to lower the pressure.
STARTING UP THE RECOVERY UNIT RE320
•
Check equipment visually before starting to ensure that all hoses and cables are properly connected.
•
Ensure that the main power has been turned on for min. 2 hours. **
•
If “STOP” status shows on the display push the green “ON” button – the status should change for “WAIT”
•
As soon as the pelletizer starts running and revert gas pressure exceeds 0,2bar, the start-up sequence is
initiated on the Recovery Unit. Some blow-off will occur until the Recovery has stabilized (ab 60 seconds). After
that time message “REA Y” will show on the display.
•
The unit can be started manually by pressing the “ON” button or if not then it will start automatically after 5
minutes. uring production some minor intermediate blow-off can occur due to variations in production, high
surrounding temperatures or too big pelletizer capacity compared to the Recovery capacity.
•
Caution - At start up after more than 3 hours of stand still the power has to be turned on for min. 2 hours due
to the crankshaft heating in the Cooling unit of the RE320. Any attempt to start earlier will damage the
compressor of the Cooling unit.

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STOPPING THE RECOVERY UNIT RE320 UNI
Stopping without depressurizing the system.
•
The Recovery and pelletizer can be stopped at any time. It is not advisable to switch off the power or use the
emergency stop button without first emptying the Recovery of liquid CO2.
•
The liquid CO2 will evaporate through the safety valve. The purpose of the safety valve is to protect the
Recovery and the surroundings against damage caused by too high CO2 pressure. The safety valve is not
supposed to be used regularly. If the power is switched on the CO2 vapor will evacuate through the blow-off
solenoid valve.
•
The Recovery Unit, Pelletizer and the hoses are under pressure. O NOT attempt to disconnect any hoses
before depressurizing.
Depressurizing the system before stopping.
1. Close liquid CO2 valve at vessel.
2. The pelletizer and CO2 part of the Recovery stops automatically after a short time from the moment when the
supply of liquid from the tank has been closed. After the pelletiser has stopped, it is advisable to turn also the
Recovery unit off by pressing the “OFF” button. The message STOP will show on the display. The machine will
not restart unless the “ON” button is depressed.
CAUTION: After manual shut – off (by pressing the OFF button) the unit will not restart automatically. The
status “STOP” will be displayed on the panel. If the “OFF” button will not be pressed, the Recovery will also shut
down automatically with “C02 INLET LOW” message on the display, but it is possible that the unit will try to
restart several times.
3. Now it is possible to disconnect the depressurized hoses.
Note: Some overpressure must be expected. isconnect with caution.
Depressurizing the system if there is a power failure.
1. Close liquid CO2 valve at vessel.
2. The automatic valve system of the PE80 will ensure that close-down and depressurization will commence
correctly.
3. WAIT until the pressure has dropped (no more gas coming out).
4. Now it is possible to disconnect the depressurized hoses.

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ALARM MESSAGES
If an alarm turns the recovery off the above message will be displayed. Press the screen for further details!
Here is a list of possible messages.
Message Explanation Notes
Emergency stop Emergency stop is pressed Release the
emergency stop
Phase sequence protection Check all 3 phases on the recovery
Change two phases
CO2 compressor protection Check the settings and status on the
motor protection relay in the
electrical box.
CO2 fan protection Check the settings and status on the
motor protection relay in the electrical
box.
Too much oil in filters
Check oil level in filters
Open ball valve and empty filters
Remember to refill if necessary
Low oil level Check oil level on the CO2 compressors
High temperature 1st stage
The 1st stage compressors temperature
is above 130 degrees Centigrade.
Wait until the unit gets colder
High temperature 2nd stage
The 1st stage compressors temperature
is above 130 degrees Centigrade.
Wait until the unit gets colder
Cooling compressor protection Check the settings and status on the
motor protection relay in the electrical
box.

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Cooling compressor internal
protection
Internal motor protection compressor
condensing unit is switch off.
Turn off the electrical power to the
recovery unit to reset the failure.
o not try to disassemble the unit! Contact a
refrigeration engineer.
Cooling fan protection Motor protection inside the condensing
unit fans
The fans are placed on the Refrigeration
condenser. Check if the fan runs freely.
Cooling low pressure
There is low pressure in the refrigerant
line.
Check the refrigerant level.
NB.: When the unit closes, it will make a
“To low pressure cooling failure” error
o not try to disassemble the unit! Contact a
refrigeration engineer
Cooling high pressure
There is low pressure in the refrigerant
line.
Check the refrigerant level Manually reset
the pressure switch
Cooling compressor oil diff
switch
To low oil level in the compressor
condensing unit
Manually reset the pressure switch

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MAINTENANCE
Accessing the equipment by unauthorized or untrained individuals can lead to physical injury or damage to property. The
system consists of two separate sub-systems. The CO2 sub-system is cooled by R452A refrigerant. ue to the
environmental impact of R452A, repair of the refrigeration parts must be conducted only by suitably trained, equipped
and authorized personnel.
Maintenance intervals
Planned preventative maintenance should be carried out to ensure long-term reliability.
Weekly: Check hoses and cables for damage.
Check safety valve does not blow-off during production.
Monthly: Check oil level at compressors: there should be between ½ to 3/4 level at the
compressors’ oil sight-glasses. (At stop only)
Check for oil leakage (oil on framework or floor)
Clean the condensing (cooling) coil fins for cleanliness.
Check that the sight glasses underneath the filters are not filled with oil.
6 months Remove side cover, check tubing, compressors, and cable for visual damage.
12 months: Change oil filters.
Check tension of belt drives with Optikrik I tension gauge Inspection of solenoid valves
vent off system.
Inspection of condensing unit by authorized refrigeration company
24 months: Complete oil change CO2 Compressors
Function test of safety components pressure and electrical
Oil filter
The oil filters are changed in as follows:
isconnect piping at the bottom of the filters.
If necessary, disconnect the fitting around the lower part of the filter.
Unscrew by hand the lower part of the filter. Take out the filter and replace with new.
Filter system Unscrewing filter New filter