Ventech 9002 User manual

VENTECHAGRIONICSUSERMANUAL ISSUE2.00
MODEL 9002 FRUIT RIPENING SYSTEM
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MODEL 9002 RIPENING SYSTEM
USER MANUAL
VERSION 2.00 JULY 2002

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INDEX
Pages
1. Unpacking&Installationchecks. 2,3,4
2. Operation 5,6,7
3. Servicing 8,9&10
4. RipeningGuides 11,12,13,14
5. RipeningRoommaintenance 15,16
6. Instrumentation. 17
1UNPACKING&INSTALLATIONCHECKS
1.1 Remove machine from packaging & save packaging for re-use when returning
machine for servicing or warranty repairs.
1.2 Unscrew the tank lid & remove the mains lead which is packed inside.
1.3 Prior to connecting to electrical supply, it is recommended that the power outlet to
be used is checked for correct polarity & good earthing (grounding). There should
not be more than approx 50 milliVolts AC between the Neutral & Earth (Ground) pins
on the power outlet. The machine can operate safely with reversed live & neutral
supply, using a non polarised socket outlet as is used in continental Europe. The
machine has internal fuses in the LINE & NEUTRAL which are not user accessible
without dismantling.
1.4 If connecting by means of a three phase plug, ensure that the mains lead is
connected with the correct polarity to Live & Neutral and not across two phases. Also
ensure that the earth connection is properly connected.
INDEX / UNPACKING&INSTALLATIONCHECKS

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1.5 Mains Lead Colour Code
Live (Line) Brown
Neutral Blue
Earth (Ground) Yellow/Green
1.6 PowerRequirements
The maximum supply voltage is 280 Volts AC 50/60 Hz.
Above 260 Volts, operation is automatically interrupted to protect the components
from damage, with automatic resetting when supply returns to safe limits.
Nominal working voltage is 200 to 250 Volts at 1,2 Amps
Max power during warm up is 234 watts, and average power consumption over a
6 hour ripening cycle is 95 watts.
1.7 External current Protection.
No external protection is necessary, however if a fused plug such as the UK 13A
plug is used, any fuse from 4 - 13 A is suitable.
1.8 Having satisfied that the power supply is correctly connected, the machine can be
put into service. We recommend that the machine be placed in the ripening room
at a height of 3 ft ( 1 Metre ) above floor levels, preferably positioned so that
maximum air flows across the machine, & with a minimum space all round the
machine of 20" (500 mm). Also ensure the machine is clear of any fork lift trucks
or any other mechanical handling equipment that could cause damage.
1.9 Installation Options
The VENTECH FRUIT RIPENING SYSTEM is normally used as a portable unit
which is plugged into the room to be gassed, then moved onto the next room.
However for high volume ripening rooms, there are available certain add-on options
as follows:
1.9.1 Gas Pipe Adaptor
This option also permits mounting the generator outside the ripening room. The
UNPACKING & INSTALLATION CHECKS

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UNPACKING & INSTALLATION CHECKS
exhaust nozzle of the generator can be replaced with a 1/8 “ NPT tube connector
obtainable from any hydraulics supplier, that allows connection to a gas pipe.
The gas pipe in turn can be connected to a gas manifold feeding individual rooms, with
the gas supply to each room controlled by a butterfly or ball valve.
This option is particularly useful for converting an existing bottled gas fed ripening
room to catalytic generator operation.
1.9.2 External Tank Option
This option can be used in conjunction with the previously described options to enable
the gassing period to be extended by means of an external tank mounted outside the
ripening room, which increases the capacity of the generator thus extending the
gassing time.
This external tank is connected to a 1/8" NPT bulkead connector on the side of the
machine which is supplied as part of the external tank option kit, and connected inside
the machine directly to the solenoid valve, replacing the tank. The external tank can
be manufactured locally to VENTECH specifications, or supplied by VENTECH. The
tank capacity can be sized to suit local Health & Safety codes which is usually 20 Litres.
However this & other tanks can be in turn refilled automatically from a 210L drum
outside the building.
1.9.3 Option Panel
There is a small panel in the side of the electronics module which can be removed &
replaced with additional interface electronics for connection to an automatic remote
supervisory system, using a programmable logic controller (PLC) or computer, in
conjunction with external motorised damper valves & ethylene gas sensors.
1.9.4 Variable Gas Rate Control.
This option plate can also be removed & replaced with a variable rate control should
this be so desired.

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OPERATION
2OPERATION
2.1 Unscrew the lid of the tank & fill with 1 litre ( US 1 Quart ) of VENTECH ripening fluid
or an approved equivalent. The tank holds 1.5 Litres of fluid, but has a dead volume
of 0.25 L when the tank is empty. The tank can be filled up to the necj initially, but
otherwise 1 litre is sufficient for one ripening session.
.
WARNING - The ripening fluid is highly inflammable & of low flashpoint.
Disconnect from electrical supply by unplugging before filling.
Keep away from naked flame when filling & preferably fill in an open space or well
ventilated room.
The use of solvents not approved by VENTECH is not recommended since, although
apparently normal ripening will be achieved, accelerated degradation of system
components occur, resulting in expensive long term repair costs.
2.2 Place generator in ripening room & plug in to power outlet. The control panel status
lights will light as follows:
REACTOR HEATING`Green
SYSTEM NORMAL Green
CONTROL ON Green
TEMP LO Yellow
2.3 After about 10 minutes the Yellow LO TEMP light will go out & theSOV lamp will start
to flash briefly at approx 9 second intervals, accompanied by a click. This is the
solenoid valve opening allowing ripening fluid to be admitted to the reactor to be
converted to ethylene. Ethylene gas will be emitted from the nozzle on the top of the
machine.
CAUTION-THE EXHAUST NOZZLE OPERATESATOVER 300DEGC. DONOT
TOUCH WHENOPERATING OR FOR HALF AN HOUR AFTER SWITCHINGOFF!
After reaching operating temperature the HEAT & CONTROL lights will flash on & off
as the system enters pulse width modulation mode which gives proportional control of
the element temeperature. This gives very accurate control of the catalytic conversion
temperature, and by preventing temperature cycling of the element, gives longer

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element life than on-off control.
2.4 After approx 6 - 8 hours operation, the ripening fluid will have been used up & the
tank will be empty. At this point, the low fluid sensor will detect the out-of-fluid
condition, and switch off power to the reactor & the solenoid valve. The FLUID
TANK EMPTY(yellow Lamp) will turn on to show that the ripening initiation process
is completed
Note:
It is important that the machine is level, otherwise the fluid level sensor will not sense
the low level condition properly, & not switch off.
2.5 WARNINGINDICATORS.
2.5.1 TEMP TOO HI (red light )
After start-up, the temperature will sometimes initially overshoot the correct set-
point, causing theTEMP TOO HI red light to turn on. This is no cause for alarm and
should go out after a few minutes & will not come on again.
This can also occur in the event of a power failure when power is restored. This
provides backup protection to avoid incorrect gas generation which could cause
degraded ripening. This also provides back-up low fluid protection if the machine
is not level.
2.5.2 VOLTS TOO HIGH (red light)
If this light comes on it is an indication that the mains power supply voltage is too
high ( above 260 Volts )Normally, the nominal voltage, depending on country is
from 220 to 250 Volts. Normal variations in supply voltage should be within +/- 6%
(UK) to +/- 10% ( S Africa)
It is unlikely that any country will have a supply that intentionally exceeds the 10%
limit, although under fault conditions, or very heavily loaded distribution systems,
the voltage can exceed these limits late at night when the gas generator will still be
working but most industrial & domestic load is switched off. In some developing
countries, these limits can also be exceeded.
For this reason, the Ventech gas generator has a built-in protection circuit which will
automatically switch off once this safe working limit has been exceeded without
damage to the components. After supply has returned to normal, the HI VOLT light
will go out & normal operation will be resumed.
Note further that the VOLTS TOO HI indication is outside the control of the gas
generator. It is not a machine fault as such, being an external fault resulting from

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incorrect supply voltage.
2.5.2(Cont)
AMACHINESHOWINGTHISINDICATIONSHOULDNOTBERETURNEDFORSERVICE
WITHOUT FIRST CHECKING THAT THE SUPPLY VOLTAGE IS IN FACT TOO HIGH, BY
MEASURINGWITHADIGITALVOLTMETER, PREFERABLYOVERALONGPERIODOF
TIME.PLEASEREMEMBERTHATTHISCONDITIONWILLOCCURINTERMITTENTLY&
IT IS IMPORTANT TO HAVE YOUR MACHINE CONNECTED TO THE SUPPLY WHEN
CHECKING. FOREXAMPLEIF YOU ARE USINGTHEMACHINE AT NIGHT, WHENTHE
VOLTAGE IS NORMALLY HIGHER & YOU SEE THIS INDICATION, YOU MIGHT THEN
CALL AN ELECTRICIAN FIRST THING THE FOLLOWING MORNING ( WHEN THE
VOLTAGE IS NORMALLY LOWEST) & HE WILL THEN REPORT THAT THE VOLTAGE
IS NORMAL
2.5.3 TANK TEMP TOO HI ( Red light )
This light will be lit if the temperature at the bottom of the reactor exceeds safe limits,
and when lit, switches off power to the reactor & solenoid valve. This can be caused
by several reasons.
(a) Machine not level.
This results in the ripening fluid not being able to flow into the reactor when nearly
empty. Since the cooling effect of the ripening fluid is no longer applied to the base
of the reactor, the temperature will tend to rise, with the risk of damage to the reactor
element terminals. This protection, by removing power to the element, maintains the
temperature within safe limits & therefore provides protection, should the machine not
level & also provides back-up low alcohol protection & back-up over temperature
protection in case of failure of the element control circuit & switching device.
(b) Element failure
The element, as most heating elements has a finite working life and will eventually
require replacement. When it eventually fails, it can possibly overheat, by-passing the
control system. Normally this will be picked up by the TEMP TOO HIGH protection,
but should this fail for any reason, the TANK TEMP TOO HI protection will provide
backup protection and prevent any risk of fire or damage to the metalwork of the
machine.
(c) Total control failure
In the event of a direct lightning strike of magnitude too great for the lightning
protection, the HI TEMP protection may fail and the TANK TEMP TOO HI protection
provides back-up protection to prevent dangerous high temperatures occuring which
could cause a fire. This has happened on more than one occasion with machines made
by other manufacturers who do not offer such comprehensive protection.
Note that it is extremely unlikely that this will occur, since a lightning strike or surge
greater than the capacity of the ultra fast surge diodes will normally blow one or other

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the mains fuses.
2.5.4 INDICATOR LAMPS COLOUR CODES
Green Normal operation modes
Yellow Temporary operating modes such as low fluid or low temp on startup.
Red Abnormal operating modes.
months operation from new or after a catalyst change, and examine the catalyst by
unscrewing the exhaust nozzle, when cold, and viewing the catalyst, which
consists of small white tubes filling the reactor. These should be loose & not welded
together by carbon. If left too long, it is difficult to remove the old catalyst, and will
require an exchange reactor. Once the catalyst starts getting heavily carbonated,
it should be emptied by turning the machine upside down and shaking out the old
catalyst. It may be necessary to loosen the catalyst with a long thin screwdriver or
skewer. Once all the catalyst is removed, the reactor can be refilled with a new
catalyst pack, taking care not to overtighten the exhaust nozzle when replacing.
When refilling, some of the catalyst consist of triangular ceramic chips that should
be put in first, followed by the tubular active catalyst.
Due to the low cost of the catalyst, it is better to change it sooner, rather than later.
This will be done automatically, if your machine is covered by a service contract,
or sent in for any service or repairs
NB: IF YOU LEAVE THE CATALYST TOO LONG, IT MAY BE IMPOSSIBLE TO
REMOVE THE OLD CATALYST, IN WHICH CASE A COMPLETELY NEW
REACTOR WILL HAVE TO BE PURCHASED, WHICH IS THE MOST EXPEN-
SIVE COMPONENT IN THE MACHINE.
3SERVICING
3.1 CatalystChanging
The catalyst used in the machine will need changing after after between 6 & 12
monthsuse. Due to therestrictionsimposed by Customs &Excisedepartments, the
Ventech Ripening Fluid contains de-naturants which will eventually poison the
catalyst causing reduced gas generation. We also recommend that if you are
haveproblemsripening,thatyoucheckthegaslevelswithwitha gassampler
such as the GASTEC details of which are at the end of the manual.
This is supplied by us, & it is possible that a group of ripeners in one area share
the cost of one kit, since it is only used infrequently.
We recommend that the user checks the catalyst once a month after the first six

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3.2 FAULT FINDING
Before returning a machine for repair a few simple checks should be carried out, which
could save you the transport costs & downtime involved in sending a machine in to your
service centre.
3.3 Condition - No lights lit
3.3.1 First check the electrical supply to your machine, and if you have testmeter check that
you have mains supply across the two outside pins on the connector that plugs into the
socket.
3.3.2 f there is supply, then disconnect the supply cord & check the mains fuses. There are
two mains fuses in the supply to the machine, plus one in the mains plug if using a 13A
(UK) square pin plug. The 13A plug can be fused 4 -1 3A HRC fuse. The supply fuses
in the machine are 5X20 Amp 3.14A or 4.0A Ultra Fast fuses. If you use the normal fast
blow glass fuses. you will now have the same amount of surge protection. so replace
these by the correct type as soon as possible. Check the mains cord first but swopping
it with a computer or electric kettle cord
3.3.3 These fuses are in a small drawer in the side of the power inlet connector. They are
accessed by first removing the mains cable, then pulling the drawer open using a finger
nail, small knife or small screwdriver. If either fuses is blown, it should be replaced.
3.3.4 If nothing is found wrong & you have spare electronic boards proceed as follows:
3.3.5 Removal of electronic boards
Remove the four M8 X 8 countersink screws retaining the cover of the electronics
module, Remove the two grey ribbon cables by unplugging. Unscrew the 4 X M3X6
screws retaining the top PCB. This is the control board ( the one with 9 lights). Remove
the two green terminal strips in the bottom (Power Board) by pulling down to unplug.
There is no need to undo the terminal screws. Now unscrew the 4 nickel plated pillars
to release the power board. Refiiting is the reverse of removal. The two ribbon cables
are marked PL1 & PL2.
3.3.6 If after carrying out the above process, the machine is still not functioning, it will have
to be returned to the factory.
3.4 Condition - Lights on but no heating or valve operation.
3.4.1 Remove electronics cover as previous described and with the mains power discon-
nected, check the fuses om the power board. You can get at them with the control board
in place, but it is easier to remove it. The left hand fuse is for the reactor fude & the right
hand one for the solenoid valve. The ratings are 2.0 & 1.o A respectively. They are
normally fast blow glass 5 X 20 mm fuses

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3.4.2 Re-check the machine and if heating, run for a couple of hours on test before putting
back into service. If the fuse blows again, return the machine for service for element
replacement.
Note:
The supply line fuses generally only blow because of power surges or lightning.
Generally line surges blow the Line fuse, & Lighytning surges blow the Neutral fuse.
The power board fuses generally only blow due to element failure of short circuit
solenoid coil. Solenoid failure is extremely rare, as the solenoid is only open for a
fratcion of a second at a time.
It is most unusual for an element failure to blow the inlet fuses as well, although it
can happen, However if the element is blown as a result of a lightning strike, it will
blow both fuses.
PLEASE DO NOT REPLACE FUSES BY A LARGER TYPE IF THEY BLOW. ONLY
REPLACE A FUSE ONCE, THEN IF IT BLOWS AGAIN, RETURN MACHINE FOR
SERVICE. IF THE INLET FUSE BLOWS AGAIN AFTER SEVERAL HOURS OPERA-
TION,THISCOULDBECAUSEDBYREPEATEDMAINSSURGES,ESPECIALLYIFIT
ISDURINGTHUNDERSTORMS.
FAILURE TO OBSERVE THIS COULD RESULT IN ADDITIONAL DAMAGE.
If, after carrying out the above fuse checks, the machine is still not heating (indicated
by the LOW TEMP light staying lit), the you need to return the machine to have the
reactor element replaced.
3.5 Condition - lights lit, but incorrect operation.
First check through the chapter on operation, for a description of the status lights
operation. If this does not resolve the problem, generally this is due to a fault on the
control board caused by surge damage. If you have a spare card, try replacing it,
otherwise return the whole machine for service. Caution - the jumper at the bottom
of the card must be placed in theDIS position ( right hand side)unless you adjust the
R7 control, which requires the use of a digital multimeter.
IMPORTANT - ALLOW MACHINE TO COOL DOWN FOR TWO HOURS BEFORE
PUTTINGINTO THE POLYSTYRENEPACKAGING TO RETURN FORSERVICE.