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Tomco DE89RB100-US Operation & Maintenance Manual

Carbon dioxide dry ice pelletizers
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CARBON DIOXIDE
DRY ICE PELLETIZER
MANUAL

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Summary of Contents for Tomco DE89RB100-US

  • Page 1 CARBON DIOXIDE DRY ICE PELLETIZER OPERATION & MAINTENANCE MANUAL...
  • Page 3 CARBON DIOXIDE DRY ICE PELLETIZER OPERATION & MAINTENANCE MANUAL Copyright © 1998 by TOMCO EQUIPMENT COMPANY All rights reserved. No part of this document may be reproduced by any means without the written permission of TOMCO EQUIPMENT COMPANY. Revision 8– Add Ice behind piston problem to page 5.4...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Introduction ................... 1.0 Tomco Equipment Company Carbon Dioxide Dry Ice Pelletizers ......1.1 Understanding Carbon Dioxide ................1.2 Learning More About Carbon Dioxide ..............1.5 Specifications ......................1.7 Section 2 - Carbon Dioxide Safety ..............2.0 General Safety Considerations ................

  • Page 7: Section 1 - Introduction

    SECTION INTRODUCTION...
  • Page 8 INTRODUCTION TOMCO EQUIPMENT COMPANY CARBON DIOXIDE DRY ICE PELLETIZERS Tomco has been a CO equipment specialist for over thirty years. Tomco manufac- tures Urethane Insulated CO Storage Units, Vacuum Insulated CO Storage Units, ISO Containers, CO Particle Filters, CO Vaporizers, CO...

  • Page 9: Understanding Carbon Dioxide

    INTRODUCTION UNDERSTANDING CARBON DIOXIDE Carbon dioxide is a chemical compound formed by combining one atom of carbon with two atoms of oxygen, and is expressed by the molecular formula CO . Carbon dioxide can exist in any one or all three states of matter: solid, liquid, and/or vapor; depending on conditions of temperature and pressure.
  • Page 10 INTRODUCTION following the liquid density curve, one finds that the liquid becomes less dense as the temperature increases and at 70 F (21.1 C), the liquid density is around 47 pounds per cubic foot (754 kg/m By comparing the pressure and liquid density at 70 F (21.1 C) [837.8 psig (57.8 bar) and 47.6 pounds per cubic foot (764 kg/m...
  • Page 11 INTRODUCTION Molecular Weight 44.01 lb/lb-mol 44.01 kg/kg-mol Vapor Pressure at 70 °F (21.1 °C) 838 psig 57.79 bar at 32 °F (0 °C) 491 psig 33.86 bar at 2 °F (-16.7 °C) 302 psig 20.83 bar at -20 °F (-28.9 °C) 200 psig 13.79 bar at -69.9 °F (-56.6 °C)

  • Page 12: Learning More About Carbon Dioxide

    INTRODUCTION LEARNING MORE ABOUT CARBON DIOXIDE An important part of maintaining a carbon dioxide dry ice pelletizer is understanding the properties of CO . Therefore, maintenance and service of your pelletizer should be performed only by a qualified carbon dioxide equipment technician. To start or increase your knowledge of carbon dioxide, we recommend that you be- gin with the pamphlets and literature from the CGA (Compressed Gas Association).

  • Page 13: Specifications

    INTRODUCTION CARBON DIOXIDE DRY ICE PELLETIZER SPECIFICATIONS METHOD OF OPERATION: The dry ice Pelletizer consists of a system for injecting liquid CO into a compression cylinder. The process of reducing the pressure on the liquid from approximately 300 psi (20.68 bar), below the Triple Point, to atmospheric pressure causes about 40% of the carbon dioxide to change to a solid.
  • Page 14 INTRODUCTION...

  • Page 15: Section 2 - Carbon Dioxide Safety

    SECTION CARBON DIOXIDE SAFETY...

  • Page 16: General Safety Considerations

    CARBON DIOXIDE SAFETY The text in this section has been adapted from CGA (Compressed Gas Association) publication CGA G-6 – 1984: Carbon Dioxide. GENERAL SAFETY CONSIDERATIONS Gaseous carbon dioxide is an asphyxiant. Concentrations of 10% or more can pro- duce unconsciousness or death. Lower concentrations may cause headache, sweat- ing, rapid breathing, increased heart rate, shortness of breath, dizziness, mental de- pression, visual disturbances, and shaking.

  • Page 17: Rescue

    CARBON DIOXIDE SAFETY RESCUE Do not attempt to remove the individual without utilizing proper rescue equipment or you may also become a casualty. If the exposed person is unconscious, obtain assis- tance and put into effect the established emergency procedures. INHALATION FIRST AID Inhalation of gaseous carbon dioxide can adversely affect body function.
  • Page 19 SECTION INSTALLATION...
  • Page 20 250 to 300 psig (17.23 to 20.68 bar) is re- quired for satisfactory performance. Contact Tomco Equipment Co. if liquid CO pressure will be lower than 250 psig (17.23 bar). Contact Tomco Equipment Co. if liquid CO Dew point will be above –60°F (-51.1°C).
  • Page 21 3. Install a low-pressure check valve (no greater than 5 psi cracking pressure) on the exhaust port of each heat exchanger and vent to the outdoors using either a flexi- ble hose or suitable piping. Tomco Parts and Service can supply the check valves and piping if needed.
  • Page 22 INSTALLATION Note: U.S.D.A. approved equipment must use a food grade hydraulic fluid with similar properties (Citgo Clarion FG ISO 68 or equal). 5. Install conduit suitable for four wires between the top right side of the control panel (above the transformer) and the rear outer panel. Use wires that are the same size or larger than the largest gauge wires in the control panel.
  • Page 23 INSTALLATION...

  • Page 25: Section 4 - Operation & Maintenance

    SECTION OPERATION & MAINTENANCE...

  • Page 26: Manual Operation

    OPERATION & MAINTENANCE MANUAL OPERATION – SWITCH / PUSHBUTTON CONTROLS Note: Manual operation is not satisfactory for production purposes and should only be used to check the pelletizer for proper operation. For pelletizers that have two cylinders, do not operate both cylinders manually at the same time. 1.

  • Page 27: Automatic Operation

    NOTE: This procedure is not necessary on high capacity pelletizers. To start this type of machine, simply press the start button. On all other types of pellet izers manufactured by Tomco , it may be necessary to pre-charge the pelletizer before starting automatic operation.
  • Page 28 OPERATION & MAINTENANCE 4. Turn the MAN/AUTO switch to the AUTO (automatic) position. 5. If the pelletizer has two cylinders, place the A/B/A&B switch to the desired se- lection, either A or B for single cylinder operation, or A&B for dual cylinder op- eration.

  • Page 29: Maintenance

    OPERATION & MAINTENANCE Note: Vapor venting from the bottom port at the rear of the compression cylinder is normal. Do not plug or restrict this port by any means. High capacity machines do not have this port. 9. To end dry ice production, push the STOP button. The pelletizer will complete the current cycle before stopping.
  • Page 30 OPERATION & MAINTENANCE MAINTENANCE AFTER THE FIRST 48 HOURS OF OPERATION Check the torque value on the die bolts, tie rod bolts, and web plate bolts according to Figures 4.3 on pages 4.13 - 4.16. If necessary re-torque following the procedures found on page 4.12. WEEKLY •...
  • Page 31 OPERATION & MAINTENANCE 2. Close the liquid process and vapor process isolation valves at the carbon dioxide storage unit and bleed pressure from each line. 3. Remove the extrusion die cover. 4. Remove the extrusion die. 5. Remove the rod coupling. 6.
  • Page 32 OPERATION & MAINTENANCE AFTER EVERY 10000 HOURS OF OPERATION Hydraulic Cylinder Rebuild (tie-rod cylinders only) Refer to Figures 4.2 on pages 4.8 - 4.11 for the exploded view of the hydraulic cylinder and compression cylinder major components. 1. Disconnect electrical power and follow your company’s lock out and tag out safety procedures.
  • Page 33 17. Reconnect the hydraulic hoses and check the hydraulic fluid level at the sight glass. Add hydraulic fluid as needed. WELDED CYLINDER REBUILD Contact Tomco for details. Piston Sleeve replacement procedure (this is a two (2) man operation.) 1.
  • Page 34 OPERATION & MAINTENANCE allowing it to fall to the floor. 10. Retract the hydraulic cylinder and insert a 4x4" about 50" long and extend the cylinder. Be sure to keep all hands and tools clear of the cylinder while doing this operation.
  • Page 35 OPERATION & MAINTENANCE 24. Check for proper limit switch operation at this point by manually extending and retracting the hydraulic cylinder. 25. Install the die. Follow the torque procedures outlined in section 4. 26. Install the head cover. Piston seal replacement procedure. Leaky seals can sometimes cause a hazardous situation and can allow air to be drawn into a recovery system.
  • Page 36 OPERATION & MAINTENANCE safety procedures. 11. Carefully pull the old seal off the piston. 12. Install the new seal on the piston as far as possible by hand. 13. Reconnect power to the machine and extend the cylinder. 14. Disconnect all electrical power and follow your company's lock out and tag out safety procedures.
  • Page 37 OPERATION & MAINTENANCE 6. Completely dry the filter screen with CO vapor or a dry air source. 7. Check all gaskets and replace any that are torn or cracked. 8. Reassemble in the reverse order. TRANSITION BOX GASKET FILTER SCREEN RETAINING PLATE FILTER SCREEN Figure 4.1.1 - Models DE89RB-100-US, HP-200 &...
  • Page 38 OPERATION & MAINTENANCE 4.13...
  • Page 39 OPERATION & MAINTENANCE 4.14...
  • Page 40 OPERATION & MAINTENANCE 4.15...
  • Page 41 OPERATION & MAINTENANCE 4.16...
  • Page 42 OPERATION & MAINTENANCE TORQUE PROCEDURES All Tomco Equipment Co. Dry Ice Pelletizers are designed and built to provide many years of service. However, these pelletizers undergo many cycles of severe loading and unloading. In order for the pelletizers to survive the fatiguing encountered with cyclic loading, it is imperative that key components are torqued evenly and adequately.
  • Page 43 OPERATION & MAINTENANCE TIE ROD Fastener - 5/8” - 18 UNF tie rod with matching hex nut Final Torque Value - 190 ft lbs (26 m kg) (258 Nm) TIE ROD TORQUE SEQUENCE WEB PLATE Fastener - 1/2” - 13 x 3” SHCS Final Torque Value - 50 ft lbs (7 m kg) (68 Nm) WEB PLATE TORQUE SEQUENCE...
  • Page 44 OPERATION & MAINTENANCE TIE ROD Fastener - 1” - 14 UNS tie rod with matching hex nut Final Torque Value - 700 ft lbs (97 m kg) (951 Nm) TIE ROD TORQUE SEQUENCE EXTRUSION DIE Fastener - 5/8” - 18 x 3 1/2” UNF Grade 8 SHCS Final Torque Value - 175 ft lbs (24 m kg) (238 Nm) EXTRUSION DIE TORQUE SEQUENCE...
  • Page 45 OPERATION & MAINTENANCE TIE ROD Fastener - 1 1/4” - 12 UNF Tie Rod with Matching Hex Nut Final Torque Value - 1250 ft lbs (173 m kg) (1699 Nm) TIE ROD TORQUE SEQUENCE EXTRUSION DIE Fastener - 1” - 14 x 6” UNF Grade 8 HHCS Final Torque Value - 475 ft lbs (66 m kg) (646 Nm) EXTRUSION DIE TORQUE SEQUENCE...
  • Page 46 OPERATION & MAINTENANCE TIE ROD Fastener - 1 1/8” - 12 UNF Tie Rod with Matching Hex Nut Final Torque Value - 950 ft lbs (131 m kg) (1291 Nm) TIE ROD TORQUE SEQUENCE EXTRUSION DIE Fastener - 3/4” - 16 x 3 1/2” UNF Grade 8 SHCS Final Torque Value - 280 ft lbs (39 m kg) (381 Nm) EXTRUSION DIE TORQUE SEQUENCE...
  • Page 47 OPERATION & MAINTENANCE TIE ROD Fastener - 1 1/2” - 12 UNF Tie Rod with Matching Hex Nut Final Torque Value - 1800 ft lbs (249 m kg) (2446 Nm) TIE ROD TORQUE SEQUENCE EXTRUSION DIE Fastener - 1” - 14 x 7” UNF Grade 8 HHCS Final Torque Value - 530 ft lbs (73 m kg) (720 Nm) EXTRUSION DIE TORQUE SEQUENCE...
  • Page 49 SECTION TROUBLE- SHOOTING...
  • Page 50 TROUBLESHOOTING All troubleshooting should only be performed by a qualified carbon dioxide service technician. Reference the appropriate Wiring Schematic Drawing and the appropri- ate Process and Instrumentation Diagram Drawing in the Appendix of this manual for component identification. PROBLEM POSSIBLE CAUSE REMEDY Compression cylinder pressure too high 1.
  • Page 51 4. Use hydraulic fluid with a lower vis- cold conditions) cosity or install a low density immer- sion heater suitable for hydraulic fluid (contact Tomco for more information) 5. Pump rotation reversed 5. Correct pump rotation - Note: Contin- ued operation of pump in wrong di- rection can damage pump 6.
  • Page 52 5. Use hydraulic fluid with a lower vis- cold conditions) cosity or install a low density immer- sion heater suitable for hydraulic fluid (contact Tomco for more information) 6. Pump coupling loose or worn 6. Tighten or replace Excessive wear or breakage of pump 1.
  • Page 53 Ice behind cold end compression piston 1. CO injector valve not closing com- 1. Repair or Replace. Note: Tomco pelletizers have a Force pletely. reduction System installed to prevent 2. Worn piston wear band. damage to piston and rod assembly’s.
  • Page 55 SECTION REPAIR & ADJUSTMENTS...
  • Page 56 REPAIR & ADJUSTMENTS All repairs and adjustments should be performed by a qualified carbon dioxide equip- ment service technician. The following applies to all single pump machines. HIGH-LOW PRESSURE COMPENSATOR ADJUSTMENT The high-low pressure compensator will provide the highest possible pump flow until a preset pressure is reached.
  • Page 57 REPAIR & ADJUSTMENTS MINIMUM VOLUME CONTROL ADJUSTMENT The minimum volume control provides an adjustable minimum hydraulic pump volume regardless of hydraulic system pressure. The minimum volume control is preset at the factory but may need to be adjusted, particularly after pump repair or replacement or if supply voltage is not 60 Hz.
  • Page 58 REPAIR & ADJUSTMENTS 7. Using a 1/4” allen wrench, adjust the minimum volume control adjusting screw. Turn the screw clockwise to increase the amp reading or counterclockwise to de- crease the amp reading. Make adjustments in 1/4 turn increments. 8. Use the allen wrench to prevent the adjustment screw from turning and tighten the locknut.
  • Page 59 REPAIR & ADJUSTMENTS pump #2 should be adjusted where approx. inch of adjustment screw threads are ex- posed outside of the jam nut when the jam nut is locked in place (the max-volume control adjustment is the one closest to the reservoir) and (b) The adjustment screw of the min- volume control of pump #2 should be adjusted where approx.
  • Page 60 REPAIR & ADJUSTMENTS the relief valve to simulate rising pressure.) 7. After you have set the pressure switches you should adjust the relief valve clock wise until the relief setting is reading 3600-3800 PSI on gauge #23. Lock the re- lief valve jam nut and release control relay CR17.
  • Page 61 REPAIR & ADJUSTMENTS is to set the min-volume adjustment for the maximum flow without peaking over 60 amps. You will adjust the min-volume screw clockwise to increase the minimum flow which will increase the amp load and raise the peak amp reading on the ammeter. If the peak amp draw is above 60 amps as a result of the initial setting or your adjust- ment attempt then you can easily lower the setting by turning the minimum volume adjustment screw counter clockwise.
  • Page 62 REPAIR & ADJUSTMENTS 4. When the pressure switch shifts at 2900 PSI the cylinder continues to advance at an 18 GPM flow rate and the pressure increases (due to ice compression resistance) to approx. 3200-3600 PSI. The ice slug moves and extrudes ice through the die until the end of stroke limit switch (extend) is tripped.
  • Page 63 REPAIR & ADJUSTMENTS D. Directional valve #20 de-energizes and shifts to the center position (all ports closed) stopping the cylinder travel. 8. Valve #26 shifts to the center blocked position from the excess flow position (time delay following the stopping of the cylinder). 9.
  • Page 64 REPAIR & ADJUSTMENTS 3. Valve #26 (excess flow) Valve #26 is energized and shifted to the excess flow position 200 microseconds after valve 20 is shifted to the retract travel position. Dry Ice Extrusion Process (start-up) Note: When the cycle start is activated the microprocessor will determine if “A” cylin- der has been selected, "B"...
  • Page 65 REPAIR & ADJUSTMENTS B. If PS-1 does not sense pressure return to cool down cycle #5 of 5 C. The machine checks for a plug again (start of step 5) D. Repeat (up to 15 cycles) #5 of 5 1) If plug is present, go to normal cycle 2) If no plug is indicated after 15 cycles, the unit will shut down.

  • Page 67: Section 7 - Appendix

    SECTION APPENDIX...

  • Page 68: Glossary

    APPENDIX GLOSSARY Carbon Dioxide The chemical compound formed by combining one atom of carbon with two atoms of oxygen The molecular formula for carbon dioxide Critical Point The temperature and pressure above which a chemical compound can only exist as a supercritical fluid - for Carbon Dioxide: 87.9 ºF (31.1 ºC) and 1070.6 psig (73.8 bar) Dew Point The temperature at which water dissolved in carbon dioxide...

  • Page 69: References

    APPENDIX REFERENCES Compressed Gas Association 1725 Jefferson Davis Hwy. Suite 1004 Arlington, VA 22202-4102 USA Phone: (703) 412-0900...

  • Page 70: Warranty

    DISCLAIMS ALL OTHER WARRANTIES, EXCEPT TITLE, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This warranty excludes products, accessories, parts or attachments that are not manufactured by TOMCO except to the extent of the warranty from the original manufacturer assigned by TOMCO .

  • Page 71: Replacement Parts & Ordering Information

    APPENDIX REPLACEMENT PARTS & ORDERING INFORMATION PART NUMBER DESCRIPTION 267302 Filter Screen, 1 1/2” x 6” (38.1 mm x 152.4 mm) 328703 Piston Wearband 3328-2 Rod Seal 3329-2 Rod Bearing 3320-4 Hydraulic Cylinder Rebuild Kit 318593 Hydraulic Fluid Filter 3284-7 Compression Cylinder Piston 2043-A1 1/2”...
  • Page 72 APPENDIX PART NUMBER DESCRIPTION 267302 Filter Screen, 1 1/2” x 6” (38.1 mm x 152.4 mm) 328713 Piston Wearband 3328-2 Rod Seal 3329-2 Rod Bearing 3320-4 Hydraulic Cylinder Rebuild Kit 318593 Hydraulic Fluid Filter 3284-7 Compression Cylinder Piston 2043-A 1/2” Injection Ball Valve 2040 Injection Ball Valve Actuator 1080-91...
  • Page 73 APPENDIX PART NUMBER DESCRIPTION 267303 Filter Screen, 3 1/2” x 10” (88.9 mm x 254 mm) 328711 Piston Wearband 3325 Rod Seal 3327 Rod Bearing 3320-6 Hydraulic Cylinder Rebuild Kit 318593 Hydraulic Fluid Filter 3286 Compression Cylinder Piston 2043-A 1/2” Injection Ball Valve 2040 Injection Ball Valve Actuator 1080-91...
  • Page 74 APPENDIX PART NUMBER DESCRIPTION 267303 Filter Screen, 3 1/2” x 10” (88.9 mm x 254 mm) 328711 Piston Wearband 3325 Rod Seal 3327 Rod Bearing 3320-8 Hydraulic Cylinder Rebuild Kit 318593 Hydraulic Fluid Filter 3286 Compression Cylinder Piston 2043-A 1/2” Injection Ball Valve 2040 Injection Ball Valve Actuator 1080-91...
  • Page 75 APPENDIX PART NUMBER DESCRIPTION 267303 Filter Screen, 3 1/2” x 10” (88.9 mm x 254 mm) 328711 Piston Wearband 3325 Rod Seal 3327 Rod Bearing 3320-6 Hydraulic Cylinder Rebuild Kit 318593 Hydraulic Fluid Filter 3286 Compression Cylinder Piston 2043-A 1/2” Injection Ball Valve 2040 Injection Ball Valve Actuator 1080-91...
  • Page 76 APPENDIX PART NUMBER DESCRIPTION 267303 Filter Screen, 3 1/2” x 10” (88.9 mm x 254 mm) 328711 Piston Wearband 3325 Rod Seal 3327 Rod Bearing 3320-8 Hydraulic Cylinder Rebuild Kit 318593 Hydraulic Fluid Filter 3286 Compression Cylinder Piston 2043-A 1/2” Injection Ball Valve 2040 Injection Ball Valve Actuator 1080-91...
  • Page 77 APPENDIX PART NUMBER DESCRIPTION 267303 Filter Screen, 3 1/2” x 10” (88.9 mm x 254 mm) 328712 Piston Wearband 3325 Rod Seal 3327 Rod Bearing 3320-7 Hydraulic Cylinder Rebuild Kit 318593 Hydraulic Fluid Filter 3286-7 Compression Cylinder Piston 2043-A 1/2” Injection Ball Valve 2040 Injection Ball Valve Actuator 1080-91...
  • Page 78 APPENDIX PART NUMBER DESCRIPTION 267302 Filter Screen, 1 1/2” x 6” (38.1 mm x 152.4 mm) 328713 Piston Wearband 3328-2 Rod Seal 3329-2 3 1/4” (82.55 mm) Rod Bearing 3329 1 3/4” (44.45 mm) Rod Bearing 3320-4 Hydraulic Cylinder Rebuild Kit 318593 Hydraulic Fluid Filter 328020...
  • Page 79 APPENDIX PART NUMBER DESCRIPTION Cold end seal kit Hydraulic cylinder seal kit 3293075 Dies, 3/4” pellet standard 1080-91 Limit Switch Piston Sleeve Hydraulic Oil Filter Filter Screen Vent Box Filter Screen Retainer Filter Screen O-ring 1/4-20X1 1/2” SS SHCS 1/4-20X1 1/8” SS SHCS 3735-1 120V Panel Bulb 1/2”...
  • Page 80 APPENDIX You can contact TOMCO EQUIPMENT CO. for parts and service 24 hours a day, 7 days a week at: TOMCO EQUIPMENT COMPANY 3340 Rosebud Road Loganville, Georgia 30052 USA Telephone (770) 979-8000 · Toll Free in the U.S. (800) 832-4262 (770) 985-9179 Parts &...
  • Page 81 APPENDIX NOTES 7.14...
  • Page 82 APPENDIX NOTES 7.15...

  • Page 83: Customer Questionnaire

    APPENDIX CUSTOMER QUESTIONNAIRE Please Complete and Mail to: TOMCO EQUIPMENT COMPANY Name Engineering Department 3340 Rosebud Rd. Company Loganville, GA 30052 USA Phone Date or fax to: Application (770) 985-9179 How did you receive this manual? Was the manual . . .
  • Page 84 APPENDIX 11. Evaluate how descriptive or detailed key manual components are. Complete the following statements using a 1 to 4 scale. 1 is not descriptive and detailed, 4 is very descriptive and highly detailed. The headings in this manual were The sub-headings in this manual were The instructions in this manual were The illustrations, graphics in this manual were...

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