Cold Jet AERO 2 PCS 60 Operator's Maintenance Manual
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Cold Jet AERO 2 PCS 60 Operator's Maintenance Manual

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PCS 60
Operator & Maintenance Manual
Original Instructions [English]
May 2019

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Summary of Contents for Cold Jet AERO 2 PCS 60

  • Page 1 PCS 60 Operator & Maintenance Manual Original Instructions [English] May 2019...
  • Page 2 Cold Jet and the client and remains the exclusive property of Cold Jet. If you find any problems in the documentation, please report them to us in writing. Cold Jet does not warrant that this document is error-free.

  • Page 3: Table Of Contents

    Performance Applicator Components ......................9 Precision Applicator Components .......................10 Nozzles ................................11 Control Panel and HMI Screens ........................12 Operations ................................15 Troubleshooting Warnings and Error Codes ....................27 Cold Jet Connect™ ............................29 Maintenance ..............................30 Recommended Spare Parts ..........................34 Warranty ................................35 EU Declaration of Conformity ........................36 Schematics ................................37...
  • Page 5 AC VOLTS ___________________________________________________________________________________________________________ PHASE _______________________________________________________________________________________________________________ FREQUENCY ________________________________________________________________________________________________________ AMPS ________________________________________________________________________________________________________________ MAX OPERATION PRESSURE ______________________________________________________________________________________ MOTOR KW _________________________________________________________________________________________________________ Mo./Yr. ______________________________________________________________________________________________________________ SCCR _________________________________________________________________________________________________________________ Supplier Responsible for the Equipment: Cold Jet, LLC 455 Wards Corner Road Loveland, Ohio 45140 USA Phone: +1-800-777-9101 Website: www.coldjet.com...

  • Page 7: Introduction

    Operator & Maintenance Manual Introduction About This Manual This manual should be kept with the machine and be readily accessible to machine operators and maintenance personnel. This manual contains information on the safety, transportation, operation, and maintenance of this machine. The graphics used in this manual may show machine details that may be different than the actual machine.

  • Page 8: Safety

    Aero PCS 60 Safety General Safety Guidelines This machine is designed to comply with international design standards and the European Machinery Directives. Therefore, using the machine does not pose a risk to the operator when the instructions in this manual are followed carefully. However, certain precautions must be followed during its use.
  • Page 9 Operator & Maintenance Manual Electrostatic Discharge Dry ice blasting may create electrostatic discharges. This machine is fitted with effective electrostatic dischargers to prevent injury or damage. Also, the machine must be plugged into a properly grounded electrical outlet. It is recommended to avoid operating the machine near explosive or flammable material. Also, use a plastic shovel when handling dry ice to eliminate any additional static electricity.
  • Page 10 Ensure that expended dry ice pellet emissions are not in the vicinity of air ventilation. WARNING This machine has been designed for use with 3mm dry ice pellets recommended by Cold Jet. The use of other cleaning agents or chemicals may adversely affect the safety of the machine.
  • Page 11 Use only hoses, fittings and couplings recommended by Cold Jet. WARNING To ensure machine safety, use only original spare parts from Cold Jet or approved by Cold Jet. WARNING The applicator and applicator hose contain electrical connections. Do not immerse in water.

  • Page 12: Pcs 60 System Package

    Refer to the packing slip for a list of the components shipped with the machine. Contact Cold Jet if any damage has occurred to the shipping container or the machine (see “Contact Information” on page 43).

  • Page 13: Pcs 60 Data

    1in (25.4 mm) Performance Applicator with on/off; air only; light control Control/Display 7 in (17.7 cm) LCD screen with rotary encoder dial Communication IoT connectivity via a cellular 3G/LTE Global and Cold Jet Connect™ Integration Automation/Integration capable with PLC controlled system (Modbus protocol) by utilizing the optional Integration Kit...

  • Page 14: Pcs 60 Components

    Aero PCS 60 PCS 60 Components Hopper Lid Power Button Emergency Stop HMI Screen Rotary Encoder Dial Power Supply Connection Blast Cable Connection Blast Hose Connection Static Ground Reel Hopper Lid Safeguard Grate Supply Air Connection...

  • Page 15: Performance Applicator Components

    Operator & Maintenance Manual Performance Applicator Components Standard Nozzle Applicator Controls Blast Hose Connection Applicator Control Cable Lights Trigger Trigger Safety...

  • Page 16: Precision Applicator Components

    Aero PCS 60 Precision Applicator Components Applicator Lights Trigger Trigger Safety Standard Nozzle Applicator Controls Blast Hose Connection Applicator Control Cable...

  • Page 17: Nozzles

    Operator & Maintenance Manual Nozzles There are several different styles of nozzles, depending on the application the PCS was ordered for. The table below can be used to help with initial settings as you set up the PCS 60 for operation. Precision Air Consumption Blast Swath...

  • Page 18: Control Panel And Hmi Screens

    Aero PCS 60 Control Panel and HMI Screens Using the Rotary Encoder Dial This PCS 60 uses a rotary encoder dial that allows the operator to navigate, select and adjust settings on the control panel screen. Navigate between options by turning the rotary encoder dial left or right;...
  • Page 19 Operator & Maintenance Manual There are 2 screen states for the PCS 60. A blue screen (home screen) which is the system operating and settings screen. A black screen indicates that the PCS 60 is in the advanced settings or the recipe screen. Changes can be made in each screen. Figure 2: Home Screen Figure 3: Settings Screen...
  • Page 20 Aero PCS 60 Figure 4: Hopper Level Indicator During operation, some items on the screen will indicate level or failure mode by changing colors. Green is normal, yellow or orange is a warning and red is critical and needs attention. The above illustration indicates the level of the dry ice in the hopper.

  • Page 21: Operations

    Operator & Maintenance Manual Operations Personal Protective Equipment (PPE) WARNING Only trained and or certified personnel should operate the PCS 60. WARNING Do not operate the PCS 60 without proper PPE. Prior to operating the PCS 60, or loading dry ice into the hopper, proper PPE must be used. It is recommended that each operator is trained on the proper use of PPE.
  • Page 22 Aero PCS 60 Figure 6: Setting Up the PCS 60 Compressed Air Supply For best results while blasting, incoming air supply must be as free of oil and dirt as possible. It is recommended that the incoming supply air— filters, oil filters, and water separators are continuously monitored to ensure the PCS 60 receives the air your machine use is specified for.
  • Page 23 Operator & Maintenance Manual Starting the PCS 60 Follow the instructions below to start the blasting job: 1. On the control panel, press the red power button to turn the PCS 60 on. The power button will turn blue and the Home screen will begin a calibration cycle which takes 20- 30 seconds.
  • Page 24 Aero PCS 60 Opening the cover will cause the PCS 60 to shut down automatically. The grate is a safeguard to prevent coming into contact with the doser at the bottom of the hopper. Hopper Lid Safeguard Grate c. Check the hopper for the presence of any foreign material or condensate and clean or remove as necessary.
  • Page 25 Operator & Maintenance Manual Use a lower feed rate when the air pressure is below 50 psi (3.4 bar). Follow the instructions below to start blasting dry ice particles: 1. On the performance or the precision applicator, press the air/ice control (II) to activate (green light ON).
  • Page 26 Aero PCS 60 1. Using a plastic scoop, remove any unused ice from the hopper then close the lid. CAUTION Be careful to avoid coming into contact with the doser at the bottom of the hopper 2. On the applicator: a.
  • Page 27 Operator & Maintenance Manual 4. Turn off the compressed air supply. The PCS 60 will automatically bleed any remaining pressure. There is no need to bleed the air pressure from the PCS 60. The PCS 60 automatically bleeds air pressure during proper shut down of the PCS 60.
  • Page 28 Aero PCS 60 Recipes The following screens describe the recipe functions for the PCS 60. Recipes are useful for saving optimal settings for the machine for different types of surfaces. This saves time when switching from one type of surface to another. Below describes how to save recipes and how to recall for use.
  • Page 29 Operator & Maintenance Manual Advanced Settings The advanced settings screen is for setting up preferences for the PCS 60 such as units of measure, thumper time and more. If dry ice begins clumping in the hopper the thumper frequency and time can be increased to help the flow of dry ice while blasting. Figure 9: Advanced Settings Screen 1.
  • Page 30 Aero PCS 60 Reset Screen The reset screen appears if the emergency stop has been activated or the safeguard grate has been removed. When the reset screen appears, first correct the issue. If the emergency stop has been activated reset the emergency stop by pulling it out. If the safeguard grate has been removed, re-install it.
  • Page 31 The PCS 60 is automatically connected via 3G/LTE service to the Cold Jet ConnectTM platform where you can view the machine’s operating conditions. In addition, through the machine’s control panel you can initiate Diagnostic Mode when working with Cold Jet’s technical service personnel which will...

  • Page 33: Troubleshooting Warnings And Error Codes

    PCS 60 to prevent damage to the system or a error serious in nature has occurred in which case you will need to contact Cold Jet Customer Service. The PCS 60, in error shut down mode, will continue powered up but will not operate.
  • Page 34 7. If the error code is still present and the PCS 60 defaults to the idle mode, the system will automatically transmit information to the Cold Jet Customer Support Team. 8. Shut the PCS 60 down and contact Customer Support (see Contact Information page...

  • Page 35: Cold Jet Connect

    In the increasingly smart connected world, technology makes it easier to support and maintain your Cold Jet equipment. As part of our commitment to the support of your dry ice blasting machine, it comes with its own personal support site through MyColdjet.com and a link to Cold Jet ConnectTM –...

  • Page 36: Maintenance

    Aero PCS 60 Maintenance WARNING Prior to any maintenance or inspection procedures, ensure that the PCS 60 is powered down and the power source is disconnected. Ensure that the air supply is closed, bled off, and the air supply hose is disconnected from the PCS 60.
  • Page 37 Operator & Maintenance Manual Monthly Check the air filter element and replace if needed, using Cold Jet part number 4I0308. Remove the Air Discharge Line ii. Remove the Filter Housing and replace air filter if necessary. Figure 10: Access to Air Filter...
  • Page 38 Aero PCS 60 Filter Housing 4. Disconnect the airline from the bottom of the filter housing by pushing on the outside ring and pulling on the air hose. 5. Push upward and turn the filter housing about a 1/4-1/2 turn counter-clockwise and pull down on the housing to remove.
  • Page 39 Operator & Maintenance Manual 7. Remove the filter element and replace. 8. Thread the retaining nut securely back onto the filter. 9. Inspect and replace the O-Ring on the filter housing if necessary. 10. Apply a small amount of silicon lubricant to the O-Ring. 11.

  • Page 40: Recommended Spare Parts

    Aero PCS 60 Applicator Light Replacement 1. Shut down the PCS 60. 2. Disconnect the blast hose and applicator control cable from the applicator. 3. Remove the two Phillips head screws to the LED light cover (same on both sides). 4.

  • Page 41: Warranty

    Operator & Maintenance Manual Warranty Cold Jet® (“CJ”) warrants its products (“Equipment”) provided under this Agreement to be free from defects in materials and workmanship for a period of 12 months (90 days on used equipment), under normal use, maintenance and service as stipulated in the Operator’s Manual, Commissioning, and Operator Training. At the discretion of CJ, failure to complete Installation, Commissioning, and Operator Training shall result in forfeit of warranty rights.

  • Page 42: Eu Declaration Of Conformity

    EN ISO 13857:2008  EN ISO 13732-3:2008    Person in the European Community authorized to compile the technical documentation: Cold Jet Sp.zo.o,  Product Development Manager Maciej Doczekała, Łukowska 12, Oborniki 64-600, Poland  Place and Date of Issue: Loveland, USA on February 19, 2019 ...

  • Page 43: Schematics

    Operator & Maintenance Manual Schematics Assembly Drawing with Pneumatic Schematics [2A0338] ..............51 Electrical Schematics [6G0536] ......................... 55...
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  • Page 49: Contact Information

    1727 Industrial Road, Unit 1 After Hours Support: +1-800-777-9101 Cambridge, Ontario N3H 5G7 Email: service@coldjet.com Latin America - Cold Jet Latinoamérica Phone: +52 (81) 1097-0445 San Alberto 404 P2 Col. Residencial After Hours Support: +1 (513) 576-8981 Santa Barbara Email: soporte@coldjet.com...

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