Ice-Tech PR350H User manual

User’s Manual
Technical file
1
2
User’s manual
PR350H

User’s Manual
1
User’s manual
PR350H

Industrivej 62
DK-6740 Bramming
Denmark
Original
Version: 2.0
IceTech PR350H
User’s manual
Page:
1 of 20
Date: 2017.07.03
Init: JM
CONTENT
GENERAL INFORMATION 2
SYSTEM DESCRIPTION 3
•Functional description 3
•System identification 4
•Supplier responsible for the equipment 4
TECHNICAL DATA 5
TECHNICAL FACTS OF FROZEN CO26
SAFETY REGULATIONS 7
•General Measures 7
•Personnel Qualifications 7
•Security and Risk 7
•Danger of Suffocation 7
•Static Electricity 8
•Danger of Congelation 8
•Pinch Point Hazard 9
•Wear Protective Gloves 9
•How to Lift / Transport the IceMaker 9
SAFETY OPERATION 10
•Emergency stop 10
•Machine safety 10
MACHINE STRUCTURE 11
MACHINE OPERATION START-UP 12
MACHINE CONTROLS 14
LIQUID CO2LEAKAGE 17
STOP PRODUCTION 17
•Maintenance Daily 17
REPAIR AND WARRANTY 17
•Repair 17
•Terms of Warranty 17
INSTRUCTION – UNPACKING AND PREPARATIONS BEFORE INSTALLATION 18

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GENERAL INFORMATION
The IceMaker PR350H presents a state of the art dry ice pelletizer packed with features for easier operation, swift production
shifts and high capacity.
The IceMaker PR350H produces high quality dry ice pellets from stroke one. 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 also eliminates downtime and reduces loss of valuable CO2. The pellet length and
quality are optimized using the new pelletizer, and the complete version of the IceMaker PR350H can produce two sizes of
pellets without changing the extruder plates. The IceMaker PR350H contains lots of technical features compared to existing
products on the market.
The automatic change of extruder plates is an option for the IceMaker PR350H. The hydraulic unit use logic components
for higher performance.
The machine parts are protected by a moisture-free enclosure, which also reduces the noise level to a minimum (below 75
dB(A). The IceMaker PR350H 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 conserved at low temperature in a storage tank.
The control system of IceTech PR350H, based on Beckhoff Industrial PC and HMI system, offers maximum functionality
and a user-friendly user interface. By selecting the pellet size required, production is started by pressing one button. Just-
In-Time production minimizes labour and waste during production.

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User’s manual
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SYSTEM DESCRIPTION
This user’s manual covers the IceTech PR350H. The main parts are described in the machine structure section. Operating
instruction for add-ons can be found in separate instructions, and is not included in this manual.
Functional description
The main function of IceTech PR350H 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 in a normal production are as following and refer
to PI diagram P296-1-14201-B for IceTech PR350H:
1. Start up
2. Production
3. Standby
4. Shut down
At every start-up the hydraulic cylinder =G01-G1-MO1 for extruder piston is extracted to its maximum position to extrude
the CO2snow in the chamber in case of emergency stop or machine error.
Liquid CO2is fed from an external CO2tank (not part of this description – see supplier information) through an insulated
pipe to the IceTech PR750H. It is recommended to use a gas separator to eliminate gaseous CO2from the liquid CO2.
When the hydraulic cylinder =G01-G1-MO1 for extruder piston is retracted and hydraulic cylinder =G01-Q3-MO1 for
extruder plate changer is in middle position - CO2In valve =W01-Q1 and Injection valve =G01-Q1 will open and purge
gaseous CO2through the chamber, degassing filters and via degassing pipes to CO2out. 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 for the extruder piston will
extract until fast forward pressure set point is reached and the hydraulic cylinder will again retract. This will continue until
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 CO2In 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 IceTech PR350H in standby.
When maximum standby time is reached, the IceTech PR350H will run a shutdown sequence.
The shutdown sequence ensures that IceTech PR350H 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
maximum position and return to shut down set point 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 Jet ApS
Industrivej 62
DK-6740 Bramming
Denmark
Phone: [phone]
Fax: [phone]
Homepage: www.coldjet.com, www.icetechworld.com
Email: [e-mail]

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User’s manual
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TECHNICAL DATA
Rated Output:
kg/h: up to 350
lbs/h: up to 772
of high quality dry ice pellets, depending on the extruder plate applied
Pellet Size:
Diameter:
mm: 3 - 10 or 16
inch: 0.11 - 0.39 or 0.62
Cylindrical - length varying from:
mm: 50 to 100 / inch: 1.96 to 3.93
Inlet Liquid CO2Pressure:
bar: 16 - 22
psi: 232 - 319
Liquid CO2Dryness 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 CO2supply must be completely free of oil and must have a purity of min. 99.9%.
Liquid CO2Supply Pipe:
Internal dia. 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, always use an internal dia. of 25 mm (1 inch).
Power Supply:
3 x 400 V AC + PE, 50Hz,
TN-S Earthing system
Imax. 32 A
480V AC Solidly Grounded Wye Source
3 Phase + GND wire, 60Hz
Imax. 32 A
Control Panel SCCR: 25kA rms symmetrical 480VAC Max.
Rated power:
16,6kW / 21,5 Hp
Machine Dimensions:
Length: 1500 / 59
Width: 1000 / 39
Height: 1800 / 71
Height: 1845 / 73.6 (incl. ext. legs)
Weight: 1150kg / 2535 lbs
Noise level: below 75 dB(a).

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TECHNICAL FACTS OF FROZEN CO2
Dry ice is frozen carbon dioxide (CO2). It is much denser and colder than traditional ice. Dry ice is -79°C (-109.3°F).
Traditional ice is 0°C (32°F).
In addition, dry ice does not melt - it sublimates. Sublimation is the process of going directly from solid form into gas form.
Dry ice by-passes the liquid form, hence the “dry” ice.
The first step in producing dry ice is to turn the carbon dioxide gas into a liquid. This is done by compressing the CO2and
removing excess heat. Next, the pressure is reduced over the liquid carbon dioxide by sending it through a snow valve
(expansion valve). As the liquid evaporates it absorbs heat causing some of the CO2to freeze into dry ice snowflakes.
The dry ice snow is then exposed to compaction by a large press to form blocks. Dry ice is much heavier than traditional
ice, weighing 1.7 times as much. CO2is a natural substance produced by the combustion of organic compounds and
is exhaled by humans and other living beings.
Pressure- Temperature phase diagram for CO2
CO2is
:: Non-toxic
:: Transparent
:: Odourless gas under atmospheric pressure and temperature
:: 1½ times heavier than air
:: The atmosphere consists of 0.03% CO2
CO2exists in three forms
:: Gas, e.g. used in the food industry
:: Liquid, kept under pressure
:: Solid, dry ice

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SAFETY REGULATIONS
General Measures
The IceTech PR350H manual contains instructions on starting up, operating and servicing the machine. The operator must
follow the instructions in the manual. Moreover it is important that the owner makes 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 mounting, operation, service and maintenance must be adequately qualified to take care
of such job functions.
If the employees do not possess sufficient know-ledge, 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 IceTech PR350H, fully understands
the importance of complying with the SAFETY REGULATIONS described on the following pages as well as those placed on
the machine, and the importance of carefully studying the contents of the manual.
Security and Risk
The IceTech PR350H is designed so as 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 carefully.
It is important that the operator carefully follows the safety signs on the machine and the safety regulations described later
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 ”Unpacking and preparations before installation”.
The machine may only be installed by authorized personnel, that is electricians with knowledge of the Council Directives
73/23/EEC and the 89/336/EEC and the 89/336/EEC (or similar directives in other parts of the world).
Danger of Suffocation
Dry ice pellets are CO2in solid form. At ordinary atmospheric pressure, CO2can only exist in this solid form at temperatures
of -79°C (-110°F) or lower. Therefore, during dry ice production, the CO2will immediately be heated and thus transform
from solid form into gas form.
Please note:
Since the specific gravity of CO2is higher than that of ordinary atmospheric air, the air with its contents of oxygen will be
replaced by CO2if the dry ice production is taking place in small or insufficiently ventilated rooms.

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Therefore, please note the following:
1. Low CO2concentrations (3-5%) cause headaches and fast breathing.
2. CO2concentrations of (7-10%) cause headaches and nausea and may result in unconsciousness.
3. Higher CO2concentrations result in unconsciousness and at worst it may cause suffocation.
High CO2concentrations may result in unconsciousness due to displacement of oxygen. Therefore, always make sure to
provide sufficient ventilation of the working area, and always avoid producing dry ice in small rooms.
Static Electricity
Dry ice can cause electrostatic discharges. However, the equipment bonded to ground to minimize electrostatic discharge,
and the warning sign is only meant to instruct the operator to avoid placing the equipment in rooms containing explosive
gasses.
Also, it is recommended to use a plastic shovel in the dry ice container.
Danger of Congelation
CO2in 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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Pinch Point Hazard
If the plexiglass covers in front of the extruder plates are removed, the operator will be exposed to pinch point hazard.
Wear Protective Gloves
During work with the conveyor system, the operator must wear protective gloves in order to avoid contact with the dry
ice or with parts of the machine which are in direct contact with the dry ice.
How to Lift / Transport the IceMaker
1. The IceMaker is supplied with thread holes for lifting eyes. Always use lifting eyes to lift the IceMaker.
2. Always lift the IceMaker according to the lifting Instruction in this manual.
3. Lifting over persons and animals is prohibited.
4. Always use a forklift truck to transport the IceMaker.
5. Pick up the IceMaker from the side as shown in the drawings.
6. Transport the IceMaker upright.
7. Make sure that the forks are sufficiently long to fully engage the IceMaker.
8. Always check that the forks are adjusted to maximum width.

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User’s manual
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SAFETY OPERATION
Emergency stop
All equipment is connected to the general emergency system for IceTech PR350H.
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, the protection is established with covers.
The covers is provided with locking screws, so that it can only open when using proper tools.
Required performance level PLr = c Implemented in category = Cat3.
There is danger of congelation / frost bites by touching machine parts cooled down by dry ice.
To prevent congelation the entire machine enclosure is provided with locks and requires special tools to open.

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MACHINE STRUCTURE
PR350H
1 Pellets outlet sprout
2 Hydraulic station
3 Main hydraulic cylinder
4 Touch panel
5 Extruder plate cylinder
6 Extruder plate changer
7 Connection to external supply
1
2
4
5
6
3
7

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MACHINE OPERATION START-UP
PR350H
Make sure that the CO
2
, power supply and
exhaust CO2pipe are connected. Open the
ball valves on the mounting kit.
Turn the MAIN SWITCH on.
1
2
4
3
1
2

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Make sure the correct extruder plates are
installed in the extruder plate changer and
select which extruder plate to use on the
“Extruder plate changer” page.
3
4
To start up the IceTech PR350H,
select the “Automatic mode” and
press the “Start” button.

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MACHINE CONTROLS
PR350H
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
colouring the outlet sprout green. If the outlet sprout
is gray then it has not been selected. It also displays
which extruder plate is selected, indicated on the
outlet sprout.
Active Inactive
Main functions
The main functions can be activated by pressing one
of the three wide buttons on the main screen.
By activating the “Start / Stop” button the machine
starts or stops when in group mode.
2 Extruder plate changer
By activating the “Extruder plate changer” button, the
extruder plate changer page will show which extruder
plates are available for production.
It is possible to select between upper extruder plate,
lower extruder plate and medium-closed position, in
which production is stopped. The extruder plate
selection can be made before and during production.
During production stops it is possible to physically
change the extruder plates. After this operation it is
important to change the extruder plate value in the
select box according to the extruder plate installed.

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3 Mode select
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.
Single mode controls
By activating the “Single 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 real 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.
4 Set point
By pressing the “toothed wheel” button the “Setpoint”
(SV) page is activated.
The “set point” page contains a 2 column display of
set values for the current Dry Ice production. Fixed
set points 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.

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5 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.
6 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. The alarm text will
be written in red.
Alarms must be reset before the production can
continue. When an alarm is reset the text turns green.
If the text does not change from red to green by
pushing the reset button it means that the error has
not been corrected.
To remove a reset alarm, select the row and press
“Acknowledge”. Another option is to press
“Acknowledge all” which removes all the alarms.
7 Password protection
Some functions are password protected, ie. setpoints.
To change these values the operator must login.
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.

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LIQUID CO2LEAKAGE
If liquid CO2is leaking from any point of the CO2 pipe system, the CO2supply must be stopped immediately. Localize the
leakage and see to it that the damage is remedied.
STOP PRODUCTION
1 The machine is stopped by pressing the “Start / Stop” button.
NOTE:
This will activate the shutdown procedure.
2 The CO2valve 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 electricity supply.
NOTE:
Do not shut off the main switch on the cabinet inside the machine before the inlet CO2pressure is ZERO. The CO2
pressure can be checked on the “Process values” page.
Maintenance Daily
(Before start-up)
1 Check the oil level in the sight glass container.
(After shut-down)
2 Check the pipe system for leaks.
REPAIR AND WARRANTY
Repair
The repair/replacement of the following parts can be made by the owner’s qualified personnel:
•Oil, filter on the hydraulic system.
•Filter for the liquid CO2.
•Degassing filter on the extruder.
•Piston ring on the extruder
When making repairs/replacements, use only original IceTech spare parts.
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 IceTech 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-IceTech spare parts.
•If repairs are made by unqualified personnel.
•If repairs are unsatisfactory due to lack of relevant tools and equipment.

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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.
INSTRUCTION – UNPACKING AND PREPARATIONS BEFORE INSTALLATION
Your new IceMaker has been assembled as one unit. In order to avoid damages during transport the IceMaker has been
bolted onto the transport pallet.
Unpacking and Examination for Transport Damages
1. Examine the transport box for any damages occurred during transportation.
2. Remove the straps that secure the transport box to the pallet.
3. Remove the top and side plates from the transport box.
4. Remove the straps that secure the IceMaker to the pallet.
5. Unbolt the 4 bolts that secure the IceMaker to the pallet.
6. Examine the IceMaker for external transport damages.
7. Open the cabinet door at the control panel and examine the IceMaker for internal transport damages.
Requirements on the Environment Surrounding the IceMaker
•The IceMaker must be sheltered from wind and weather.
•The ambient temperature must be min. +5°C (+41°F).
How to Lift / Transport the IceMaker
IceMaker PR350H: Drawing no. A1
•The IceMaker is supplied with thread holes for lifting eyes. Always use lifting eyes to lift the IceMaker.
•Always lift the IceMaker according to the lifting Instruction in this manual.
•Lifting over persons and animals is prohibited.
•Always use a forklift truck to transport the IceMaker.
•Pick up the IceMaker from the side as shown in the drawings.
•Transport the IceMaker upright.
•Make sure that the forks are sufficiently long to fully engage the IceMaker.
•Always check that the forks are adjusted to maximum width.
PR350H:
Min. load capacity of forklift truck: 1150 kg /2535 lbs
Min. fork length: 1.0 m
Floor Characteristics and Minimum Clear Distances
IceMaker PR350H: Drawing no. A2
•The IceMaker must be placed on a horizontal concrete floor with an adequate load-carrying capacity, free from
crack formation and suitable for bolting the IceMaker to it.
•The minimum clear distances must be observed to provide sufficient space for opening the cabinet doors and
servicing the IceMaker.
Installation of the IceMaker
The installation of the IceMaker must be carried out by one of Cold Jet’s service technician, or by a technician approved
by Cold Jet.