DALUM CO2 User manual

DALUM CO2 Recovery Unit Manual
Edition: EN /2023 - Iteration: 1.12
https://www.dalumequipment.com

Table of Contents
CO2-Recovery Plant ii EN/2020
Congratulations on acquiring a Dalum CO2 Recovery Unit!
Now you are recovering natural CO2from your own traceable source and reducing CO2
emissions.i
Note: Please read these operating instructions carefully before commissioning this product.
We will be happy to assist you with any question you may have or if any clarification is required.

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CO2-Recovery Plant iii EN/2020
Table of Contents
1. Introduction.............................................................................................................. 6
1.1 Symbols............................................................................................................ 6
1.2 Use of This plant............................................................................................... 6
1.3 Operator Qualification.......................................................................................6
1.4 Important Safety Instructions ............................................................................7
1.5 Safety Components ..........................................................................................8
1.6 Danger Points and Dangerous Situations.........................................................8
1.7 Arrival, Unloading and Positioning....................................................................8
1.7.1 Arriva and unloading...................................................................................8
1.7.2 Positioning and erecting the Unit................................................................9
1.8 Moving Plant..................................................................................................... 9
1.8.1 Before Moving.............................................................................................9
1.8.2 Loading and Unloading.............................................................................10
2. DALUM CO2 Recovery Unit................................................................................... 11
2.1 Description of the Unit.....................................................................................11
2.2 Technical Data................................................................................................11
2.3 Electrical diagram ...........................................................................................12
2.4 Process diagram............................................................................................. 12
2.5 Components....................................................................................................13
2.6 Short description of components and their function........................................13
2.6.1 Control panel............................................................................................ 13
2.6.2 Electrical cabinet.......................................................................................13
2.6.3 Cooling Pump...........................................................................................14
2.6.4 Compressor..............................................................................................14
2.6.5 Gearmotor ................................................................................................15
2.6.6 Scrubber................................................................................................... 15
2.6.7 Condenser................................................................................................15
2.6.8 Dehydrator................................................................................................ 16
2.6.9 Sulfur filter ................................................................................................16
2.6.10 Water separator........................................................................................16
2.6.11 Liquid CO2collection tank.........................................................................16
2.6.12 Main Switch.............................................................................................. 16
2.7 Electrical components.....................................................................................17
2.7.1 Outside the electrical cabinet....................................................................17
2.7.2 Inside the electrical cabinet ...................................................................... 18
3. Installation.............................................................................................................. 19
3.1 Dalum CO2Recovery Unit location.................................................................19
3.2 Positioning the Unit.........................................................................................19
3.3 Unit Connection ..............................................................................................19
3.3.1 Gas Line Connection................................................................................20
3.3.2 Water line connection...............................................................................21

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CO2-Recovery Plant iv EN/2020
3.3.3 Drainage connection................................................................................. 21
3.3.4 Coolant connection...................................................................................22
3.3.5 Electricity connection................................................................................ 22
3.3.6 Tank connection .......................................................................................22
3.3.7 Internet connection...................................................................................23
3.3.8 UniCloud connection.................................................................................26
4. Operating the DALUM CO2 Recovery Unit .......................................................... 30
4.1 The different states that the Unit can enter.....................................................31
4.1.1 Running....................................................................................................31
4.1.2 Stopped.................................................................................................... 31
4.1.3 Holding .....................................................................................................31
4.1.4 Aborted.....................................................................................................31
4.2 Starting the CO2 recovery ............................................................................... 32
4.3 Mimic Diagram................................................................................................33
4.4 Stopping the Unit ............................................................................................ 34
4.5 Special functions.............................................................................................34
4.5.1 Forcing......................................................................................................34
4.5.2 Standby ON/OFF......................................................................................35
4.5.3 Depressurizing the system .......................................................................35
5. Inspection and Maintenance................................................................................. 36
5.1 Inspections and checks................................................................................... 36
5.2 Planned maintenance.....................................................................................37
6. Routine check ........................................................................................................ 38
7. Risk assessment.................................................................................................... 39
7.1 Chemical hazards:.......................................................................................... 39
7.2 Equipment malfunctions:................................................................................. 39
7.3 Pressure hazard:.............................................................................................39
7.4 Fire hazards:................................................................................................... 39
7.5 Regulatory compliance: ..................................................................................40
7.6 Cost-effectiveness: .........................................................................................40
8. Troubleshooting..................................................................................................... 41
8.1 Alarms and warnings ......................................................................................41
8.2 Special situations............................................................................................50
8.2.1 Power outage............................................................................................50
8.2.2 Start up.....................................................................................................50
8.2.3 After maintenance.....................................................................................50
8.3 Further trouble shooting Dalum CO2 unit: ......................................................50
9. Risk Assessment operating DALUM CO2Systems............................................. 54
9.1 Chemical hazards:............................................................................................... 54
9.2 Carbon Dioxide Hazards:.....................................................................................54

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CO2-Recovery Plant v EN/2020
9.3 Pressure hazard: .................................................................................................55
9.4 Regulatory compliance:.......................................................................................56
9.5 Cost-effectiveness:..............................................................................................56
10.Ending notes.......................................................................................................... 58
10.1 List of documents available when buying a DALUM CO2 Recovery Unit .......58

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1. Introduction
This Dalum Beverage Equipment operation manual provides support for the setup and safe use
of the CO2recovery Unit.
This operating manual contains important information for the safe and correct setup, connection,
and operation of the product. Before installing and starting the device for the first time, you must
have read and understood all instructions in this manual.
Note: This document has been drafted and edited with the greatest care and according to our
best knowledge. The authors and publishers shall not be liable for the damage arising from
incorrect, incomplete, or misleading information in this document.
If something is not clear, please contact us and we will be happy to support our customer.
Any person who is entrusted with commissioning, operation, maintenance, and repair of this
machine must first have read and understood the operating instructions and safety information.
1.1 Symbols
The notes and symbols used in this manual have the following meaning.
Warning of high electrical voltages, shut off main switch before opening cover.
• Warning signs and symbols on the machine refer to possible danger points and must be
observed.
• Warning signs and symbols must not be removed from the machine.
• Damaged or illegible warning signs and symbols must be replaced without delay.
1.2 Use of This plant
This Unit is only intended exclusively for the recovery of CO2of high purity e.g., from yeast-
based fermentation of beer, cider, wine, or other alcoholic liquids. It must be placed indoor in
temperature ranges from 1°C to 35°C.
Any use of the plant beyond the above-mentioned application is not considered as intended,
therefore the manufacturer cannot be held liable for any damage resulting therefrom.
1.3 Operator Qualification
• Only trained staff may operate this machine.
•Training must be carried out in accordance with the Operating Instructions, and the Safety
Information, direct at the plant.
• Repair work may only be carried out by trained staff.
• The manufacturer is available for training. Please contact our customer service department.

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1.4 Important Safety Instructions
Hazard due to concentration of carbon dioxide!
Risk of suffocation and damage to health through carbon dioxide!
Low concentration (3-5 %) causes headaches and makes breathing difficult.
High concentration (7-10 %) causes headaches and nausea and leads to
unconsciousness.
Even higher concentration leads to unconsciousness and death.
The highest non-hazardous CO2 concentration is 5000 ppm. A higher
concentration is very dangerous to humans (German MAK Scale IV).
▪Operate the device only in well-ventilated spaces.
▪Installation of a CO2 gas detector is recommended.
Hazard due to electrical energy!
Unprotected electrical contacts, electrostatic processes, external effects on
electrical systems for example.
▪Only qualified specialists are allowed to carry out work on electrical
installations.
Personal protective equipment
Risk of injury from propelled parts!
▪ When operating the CO2-Recovery Plant, always wear safety goggles.
▪ All persons standing close to the CO2-Recovery Plant must wear suitable safety
goggles.
Risk of injury to the hands!
For example: Scratches, cuts, penetration wounds, burns and scalding due to hot or
cold sources of energy and/or the environment.
▪ Always wear suitable protective gloves when operating the CO2-Recovery Plant.
▪ Everybody in the vicinity of the CO2-Recovery Plant must wear suitable protective
gloves.
Risk of injury to the feet!
▪ Always wear suitable protective footwear when operating the CO2-Recovery
Plant.
▪ Everybody in the vicinity of the CO2-Recovery Plant must wear suitable protective
footwear.

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1.5 Safety Components
The machine is equipped with the following safety component:
•Main Switch
•Flash Alarm
•Fused Electric Circuit
•Attention stickers on high voltage covers/valves.
•Pressure Relief Valves
For safety measures a CO2alarm should be installed in proximity of the CO2Unit. If, contrary to
expectations, a significant long-term leakage occurs in connection with the Dalum CO2Unit, the
CO2concentration will exceed the limit value and the alarm will start. Turn the Unit off with the
main switch, make sure to have the room ventilated well and leave the room. The CO2alarm
can also go off for other reasons that brings the concentration above the limit value of 1.5%, so
make sure to find the cause of the heighten CO2concentration.
1.6 Danger Points and Dangerous Situations
•Do not run the Unit without the compressor covers under any condition. If you notice that
the covers are loose; Turn the plant off, make sure the compressor is not moving. Then
tight them well before running the Unit again.
•This Unit is designed to run automatically, self-diagnosing and to automatically resume
production after stop, do not perform maintenance before turning the main switch off.
•In case of fire, do not open the control cabinet door and pull out the mains plug.
1.7 Arrival, Unloading and Positioning
Comply with transport regulations and have only people trained in goods handling and with
forklift license handling the CO2 Unit at arrival. . Dalum Beverage Equipment shall not be liable
for damage caused by non-compliance with the instructions and recommendations in this
chapter.
The safety instructions and the local accident prevention regulations in force must be observed
for all work.
1.7.1 Arriva and unloading
•At arrival of a DALUM CO2 Unit, packaging and product must be inspected for damages
and completeness according to the packing list. Have a copy of your signed transport
documents with all damages doted if any and send a Copy to DALUM on e-mail.
•The CO2 Unit will arrive in vertical position or in horizontal position on a wooden pallet
and packed in wooden crater. Unloading from the truck or trailer must be done with a
suitable forklift with sufficient carrying capacity, at least 600 kg.

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•Secure load on transport vehicle against sliding or falling off.
•Do not stand underneath suspended loads or in the loading area.
•Be careful and move slowly on a flat, level, and hard surface when unloading and make
sure to clear the working areas.
•On horizontal transported Units open the end cover of the wooden box mindedly and
check the delivery for completeness against the packing list.
1.7.2 Positioning and erecting the Unit.
•Move the CO2 Unit and axillary equipment to the area it will be installed in the transport
packaging by forklift or pallet lifter at lowest possible elevation.
•Remove the wooden box by unscrewing the panes side by side with an electric screwing
machine. Remove the planks screwed on to the machine.
•On horizontal transported CO2 Units leave the wooden panel the machine is resting on
but unscrew the wooden pallet.
•For vertically transported machines remove all panels and bring the machine to its
installation position by forklift or pallet lifter and remove remaining wood.
•If the unit will be placed with one side against a wall, place the dehydrator side to the
wall with at least 0,5 meters gap to the wall.
•The floor must be cleaned and relatively level, hard and resistant to water.
•For horizontally transported machines bring the Unit in front of the final mounting
position in 90 degrees angel to the wall and the dehydrators on the upper side as it was
transported from the factory. Clear the area completely.
•Gently raise the machine by hand by 4 persons standing at the side of the unit lifting on
the panel at the top end of the Unit. The machine is bottom heavy so the weight per
person is acceptable. Remove the remaining wooden panel.
•If space allow for a forklift the Unit can be erected using a strap fixed to the top frame
and a fork on the lift. Be careful not to damage any parts on the unit.
•Level the CO2 Unit by adjusting the screws on the sanitary machine supports until the
Water Scrubber is 100% vertical.
1.8 Moving Plant
1.8.1 Before Moving
•Disconnect the complete power supply to the Unit, even for short distances.
•Close the supply and return valves and relief the pressure from the Unit.
•Close the manual CO2 Storage Tank transfer valve on the tank and disconnect the liquid
transfer line at the CO2 Unit.
•Disconnect the fluids supply and return pipes as well as drainage pipes.
•Close the fluid ports (gas ports, water ports, and coolant ports).
•If transported horizontally lay down the unit on a pallet about 60 centimetres from the
Unit and make sure it is in balance before moving.

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1.8.2 Loading and Unloading
•Comply with transport regulations.
•Be careful and move slowly when loading with or without lifting gear and clear the
working areas.
•When loading or unloading the machine with lifting gear e.g., forklifts or pallet lifter,
ensure lifting capacity is sufficient, about 600 kg.
•Do not stand underneath suspended loads or in the loading area.
•Only use suitable transport vehicles with sufficient carrying capacity.
•Secure load on transport vehicle against sliding or falling off.
•Remove all parts attached for transport purposes and all packaging before the Unit is
started up after unloading.
•The machine can be transported vertically or horizontally, if horizontally it should lay
down on the compressor side with the frame resting on a Euro pallet about 60
centimeters from the bottom of the machine shoes or the bottom of the wooden transport
crates the machine is delivered in. If the machine is transported vertically, it can be lifted
on the bottom frame with a pallet lifter as the unit has a low point of gravity. Make sure
the machine is in balance on the lifting device before moving and move slowly.

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2. DALUM CO2 Recovery Unit
2.1 Description of the Unit
The CO2Recovery unit from Dalum Beverage Equipment is a sustainable and compact solution
for craft breweries to generate their own CO2from the fermentation of their craft beers. The
CO2-Recovery plant produces from 0 kg/h up to 15 kg/h of liquid CO2based on your
requirements.
The Craft Breweries need to connect the CO2feed gas line, electrical power, water, coolant, and
the CO2-Recovery plant will deliver pure CO2> 99.9 % v/v at the outlet of the plant.
The CO2-Recovery plant consists of a multistage oil free compressor, fluid pumps, low-pressure
scrubber, dehydrators, heat exchangers, reboiler, solenoid valves, water separators, carbon
filter, control panel, level, pressure and temperature sensors as well as a dewpoint sensor. To
protect the plant against overpressure, the machine is equipped with pressure relief valves.
The plant is smart enough to run in an automatic mode. It is programed to run is specific
conditions, in safe and efficient mode.
2.2 Technical Data
Output Capacity
From 0 to 15 kg/h CO2at 35-40 bar
Purity
According to EIGA food grade CO2specification but improved
to 99,98% CO2purity.
Electric Power Consumption
2.5 kw
Voltage
3-phase 400Vac + N +PE
Frequency
50 Hz
Rated Current
10 A
Pressure
Up to 46 bar
Weight
350 kg
Dimensions (L x W x H)
1000 X 1000 X 2900 mm
Sound level
Below 70 dB
Control
PLC with B/W screen
Coolant connection
Min 1.5 bar pressure difference, -2 ±3°C, ½ inch connection
Water supply connection
Min 1 bar, maximum temperature 10°C, ½ inch connection

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2.3 Electrical diagram
The Electrical diagram is added as an Appendix to the manual or as a separate file.
2.4 Process diagram

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2.5 Components
2.6 Short description of components and their function
Most of the parts are designed by Kim Dalum and made by Dalum Beverage Equipment, if more
specific information is needed for any of these components, please contact Dalum Beverage
Equipment. For components made outside the company we refer to their manuals –contact us
if needed and we provide manuals on request.
2.6.1 Control panel
The Unit’s control panel is a Unitronics V350 an advanced programmable logic controller
integrated with a color touchscreen. Dalum Beverage Equipment has developed software,
making it possible to control and monitor your Unit from the touch screen and with several
options for online monitoring and control via PC and smart phone –further explained in section
4 Operating the DALUM CO2 Recovery Unit. For further information about the PLC, we refer to
the Unitronics manual.
2.6.2 Electrical cabinet
The electrical cabinet contains the main part of the electrical components used on the Unit. The
enclosure provides a degree of protection to personnel against incidental contact with live
electrical equipment. It also provides protection for the enclosed equipment against specific
environmental conditions. Please see section 2.7 for more information about the electrical
components.

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2.6.3 Cooling Pump
For the cooling water circulation, a Wilo Star-Z NOVA or GRUNDFOS Comfort PM is being
used. These are well-tested, efficient, and high hygiene safety pumps. For more information on
the pumps, we refer to the product manuals, which can be found on wilo.com.
2.6.4 Compressor
The three-stage oil free compressor is designed by Kim Dalum. It is manufactured in stainless
steel to improve its lifespan and keep the product clean and the fact that it is oil free eliminates
the risk of contaminating the CO2. Every component is food grade quality and qualified.
Furthermore, this compressor is very low noise compared to other compressors on the market,
which gets the Unit down to a noise level of maximum 65dB. The compressor compresses the
gas to a pressure of 35-45Bar which in accordance with the temperature of 0-5oC makes sure
that the CO2 is in liquid state.
For further information on the compressor contact Dalum Beverage Equipment.
Note: Parts of the compressor will require maintenance. See inspection and maintenance
section.

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2.6.5 Gearmotor
The Gearmotor installed on the DALUM CO2 Recovery Unit is a Sumitomo Cyclo®6000. The
performance data is: 1,5KW 4 Pole 3 Phase 230/400 V 50 HZ 1430 1/min.
For further information on the motor we refer to the Sumitomo Drive Technologies product
manual.
Note: Make sure that the Gearmotor has sufficient oil level
2.6.6 Scrubber
The scrubber is one of the stages for purifying the CO2. It is the first component that the gas
from the fermentation tank enters. There are many kinds of scrubbers, but the scrubber used on
the DALUM CO2 Unit is designed by Kim Dalum. The gas is washed/flushed with fresh water
and flowing through a filter, thereby removing some of the unwanted substances/molecules from
the brewing process.
For further information on the scrubber contact Dalum Beverage Equipment.
2.6.7 Condenser
The condenser is where the CO2 changes from gas state to liquid state. It consists of two pipes,
one with the product (CO2) and one with cooling. The gaseous CO2 enters from the bottom and
when cooled and pressurized sufficiently it changes to liquid state and flows backwards
assisting the cooling process of the gas state CO2 and flowing down to the Liquid CO2
collection tank. Excess gas passing through the condenser is used to flush through the
dehydrators or blown through the blow off valve if the pressure surpasses 45bar.
Note: The dewpoint sensor is located just before the condenser, and this is important to
guarantee the purity of the CO2 produced by the Unit. If the dewpoint sensor value gets out if its
boundaries the Unit will stop.

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2.6.8 Dehydrator
The dehydrators are extracting any unwanted liquids from the gas, the gas enters from the
bottom and passes through activated carbon, and after that passes through a very absorbent
desiccant –activated alumina. When the desiccant is close to reaching its maximum absorption
levels, they need to be dried. This is when the system changes to the second dehydrator and
initiate heating/drying on the first dehydrator. While one dehydrator is running, the other one is
regenerating. Designed by Kim Dalum.
Note: At some point maintenance is needed to change these orbs to keep the purity of the
product.
2.6.9 Sulfur filter
This is another stage for purification of the CO2. The sulfur filter lets the CO2 pass but filters
many other unwanted substances on the way through. This is designed by Kim Dalum and built
by Dalum Beverage Equipment.
2.6.10 Water separator
The water separators separate water from the gas, there is a separator for every stage on the
compressor. Designed by Kim Dalum and built by Dalum Beverage Equipment.
2.6.11 Liquid CO2collection tank
The Liquid CO2 collection tank is collection the liquid CO2 from the condenser, and when there
is enough it is discharged to the brewery’s CO2 storage tank. Designed by Kim Dalum and built
by Dalum Beverage Equipment.
2.6.12 Main Switch
The main switch is located under the control panel. It serves two purposes: one as a
disconnecting means for service entrance and two as a disconnecting means for fault and
safety measures. If you suspect anything is wrong, power to the Unit can be disconnected by
this switch.

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2.7 Electrical components
Most of the electrical components can be found in the electrical cabinet, but some are also
mounted in various places on the Unit. The DALUM CO2 Recovery Unit has both a high
voltage 230V circuit and low voltage 24V circuit.
2.7.1 Outside the electrical cabinet
Solenoid valves –used to control flow from the PLC.
Note: The valves can be checked by observing that the light
comes on in the plug on the valve when the valve is
activated e.g., manually in Force ON. A noticeable CLICK
sound should be observed when the valve is turned on/off.
Note: Many of these valves have a high voltage connection, and they are marked with the
lightning warning sign.
Heating elements –used on the dehydrators. These are hidden by the isolation.
Note: Follow the temperatures of these on the Mimic Diagram in the PLC program.
Sensors –used in various places and for various purposes to make it possible for the Dalum
CO2 Unit to be self-diagnosing. Pressure, temperature, dewpoint, level, and rotation as some of
the conditions being monitored by sensors on the DALUM CO2 Unit.
Warning light –used to indicate when there is a fault, and the Unit needs attention.
Cooling water pump –generating flow in the cooling circuits (see picture in 2.6.3).

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2.7.2 Inside the electrical cabinet
PLC and expansion modules
The PLC is what makes the connection between the programmed digital part and the physical
part of the Unit. In this case more inputs and outputs than the PLC has are needed, so there
have been added expansion modules to expand the capability of the PLC.
Variable-Frequency Drive (VFD)
The VFD is used to control the AC motor speed and torque. Based on its communication with
the PLC the speed of the motor is adjusted at all times to fit the production capacity.
Router
If the router is connected to internet, it is possible for Dalum Beverage Equipment to monitor
and analyze performance of the Unit.
Fuses
For safety reasons the system has fuses to provide overcurrent protection.
For more information on the electrical components, we refer to their manuals or you can contact
Dalum Beverage Equipment.
Automatic fuse
Contactor
24V supply
VFD Fuse
Router
VFD
Expansion modules
Low voltage circuit
High voltage circuit
High Voltage fuses
Main Switch
PLC

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3. Installation
All work covered in this section must be carried out by a qualified and trained technician. Dalum
Beverage Equipment shall not be liable for damage caused by non-compliance with the
instructions and recommendations in this chapter.
The safety instructions and the local accident prevention regulations in force must be observed
for all work.
3.1 Dalum CO2Recovery Unit location
•Firm and level floor of sufficient strength.
•The CO2-Recovery Unit has been designed for operation indoor, at temperature range
5°C to 40°C.
•The access area for operation and maintenance must be at least 1 m on all sides.
•Fermented gases, power supply, coolant, water supply, and drainage points are
available.
•Working in enclosed, unventilated spaces presents a suffocation risk due to high carbon
dioxide concentration.
•When working in a closed space, ensure that there is adequate ventilation to keep the
carbon dioxide concentration in the ambient air below a dangerous level.
•We highly recommend installing CO2sensors.
3.2 Positioning the Unit
•See section 1.7 for unloading and positioning of the Unit.
•Make sure that the Unit is placed vertically and leveled properly.
•The Unit must always stand firmly on all four legs and be as level as possible.
•If required, adjust the height of the 4 legs and tighten them well.
•Replace the transport plug in the gearbox with a vent screw and fill lubrication oil on the
gear motor if needed.
3.3 Unit Connection
All connections must be connected by competent persons observing the locally applicable
accident prevention regulations.

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3.3.1 Gas Line Connection
The raw gases collected from the fermentation of beer has a high concentration of carbon
dioxide.
To avoid the risk of suffocation and damage to health, follow the instruction listed in section 1.4
important safety instruction.
The collected foam may contain some sticky particles, which may affect the performance of
check valves and the flow of fluids passage.
CO2Recovery Unit from Dalum Beverage Equipment comes with two options. Foam detector
and single foam trap or double foam detector connected in series.