Cold Jet Aero2 PCS 60 Operator's Manual
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Cold Jet Aero2 PCS 60 Operator's Manual

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Summary of Contents for Cold Jet Aero2 PCS 60

  • Page 1 Original Instructions [English]...
  • 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

    Contents Introduction Safety Lock Out Tag Out PCS Description PCS 60 Data PCS 60 Components Applicators Nozzles Control Panel and HMI Screens Operation Compressed Air Supply Advanced Settings Cold Jet CONNECT Inspection Warranty Technical Schematics Contact Information...
  • Page 5 QR code: ASSEMBLY No. SERIAL No. ELECTRICAL No. AC VOLTS PHASE FREQUENCY AMPS MAX OPERATION PRESSURE MOTOR KW Mo./Yr. SCCC Supplier Responsible for the Equipment: Cold Jet, LLC 455 Wards Corner Road Phone: 1-800-777-9101 Loveland, Ohio 45140 USA Website: www.coldjet.com...

  • Page 7: Introduction

    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. Components of the machine may have been removed for illustrative purposes or the continuing improvement of the machine’s design may cause changes that are not included in this publication.

  • Page 9: Safety

    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. However, certain precautions must be followed during its use. To understand all the necessary precautions, the machine operator must read the entire manual before operating or performing maintenance on the machine.
  • Page 10 Electrostatic Discharge WARNING Dry ice blasting may create electrostatic discharges which may harm personnel. Ensure that the surfaces being cleaned are properly grounded with the supplied grounding cable. This machine is fitted with effective electrostatic dischargers to prevent injury or damage. It is recommended to avoid operating the machine near explosive or flammable material.
  • Page 11 Safety Labels The symbols used on the machine were developed by the International Organization for Standardization (ISO) and are defined below. These symbols may include yellow warning triangles, blue mandatory action circles, or red prohibited action circles. ***Replace any safety labels or warning signs if they become damaged, missing, or illegible.
  • Page 12 Safety Labels cont. Protective Earth/Ground Frame/Chassis Ground Terminal Cautions and Warnings Please review the following cautions and warnings before operating or performing maintenance on the machine. CAUTION Read the instructions before using the machine. Only qualified personnel should operate the PCS 60. WARNING Ensure adequate ventilation when operating this equipment to prevent the build-up of carbon dioxide gas.
  • Page 13 High pressure hoses, fittings and couplings are important for the safety of the machine. Use only hoses, fittings, and couplings supplied by Cold Jet. WARNING To ensure machine safety, use only original and replacement parts from Cold Jet. WARNING The applicator and applicator hose contain electrical connections. Do not immerse in water.
  • Page 14 Safety Label Locations...

  • Page 15: Lock Out Tag Out

    Steps for conducting a Lockout Tagout or “LO/TO” Throughout this manual, “Lockout Tagout” (LO/TO) will be referred to in instances when power must be removed from the machine. There are (6) universally accepted basics to this procedure. They are listed below but may not be limited to these (6) steps;...
  • Page 16 Reset Screen The reset screen appears if the Emergency Stop Button has been depressed (activated) or if the safety grate has been opened. If an emergency has occurred in which the Emergency Stop button has been depressed (activated), correct any issues that initially caused the emergency. When the issue(s) have been corrected, reset the Emergency Stop button by following the instructions on Page 14.

  • Page 17: Pcs Description

    PCS 60 System Description The PCS 60 may be supplied with the Performance Kit or the Precision Kit or both depending on what was ordered with the purchase of the machine. An optional Advanced Applicator is available for purchase upon request.

  • Page 18: Pcs 60 Data

    Automation/Integration capable with PLC Controlled system (Integration Integration upgrade is optional) Communication IoT connectivity via a cellular service and Cold Jet Connect ® Noise Level Noise level 50 dB(A) up to 137 dB(A) (See Maximum Sound Pressure Levels on page 70)

  • Page 19: Pcs 60 Components

    PCS 60 Components Power Button HMI Display The PCS 60: Emergency Stop Button Rotary Encoder Dial Power Cord Connection Applicator Cord Connection Blast Hose Connection Ground Reel Parking Brake Hose Whip Check Air Supply Connection...
  • Page 20 PCS 60 Machine in its typical Set-Up format...

  • Page 21: Applicators

    Applicators: The Performance Applicator Nozzle Applicator Controls LED Lights Blast Hose Connection Trigger Applicator Control Cable Precision Applicator Components LED Lights Applicator Controls Nozzle Trigger Blast Hose Applicator Control Connection Cable...
  • Page 22 The applicator trigger has a safety button that must be depressed first before the trigger will activate. Trigger Push red safety button inward 3-Function Precision and Performance Applicator Controls Air + Ice (Blast) Air - Only Air + Ice (Blast) Air –...
  • Page 23 Performance Applicator Nozzles There are several unique styles of nozzles, depending on the application the PCS 60 was ordered for. The table below can be used to help with initial settings as you set up the PCS 60 for operation. Low and Standard Flow Nozzles These straight nozzles have standard air consumption rate of 100 cfm or less at 80 psi.
  • Page 24 Specialty Nozzles These nozzles have various configurations for special applications and operation. Blast Swath Nozzle & Angle Part # Feed rate Length Material Air Consumption Swath Orientation Polymer 0.25 in 12 x 2 in 70cfm @ 80psi 2E0361 Coated SST lbs./min 112HK (0.6 cm)
  • Page 25 Precision Applicator Nozzles Nozzle Part # Blast Swath Feed Rate Length Material Air Consumption MC13 0.13 in 0.1-0.4 lbs/min 6 in 12cfm @80 psi (0.3 13865-126 Polymer (Yellow) (.3 cm) .05-0.2 kg/min (15.2 cm) /min 5.5 bar) 0.19 in 0.2-1.0 lbs/min 6 in 30cfm @80 psi (0.8 MC19 (White)
  • Page 26 Optional, Advanced Applicator Components Note: uses the same nozzle selection as the Performance Applicator LED Lights Air + Ice Air Only (Blast) Air Pressure Feed Rate Air Pressure Feed Rate DOWN DOWN Particle Size Particle Size DOWN The following details are about the onboard functions of the Advanced Applicator’s feed rate, blast pressure, and particle size: Increase/decrease feed rate: This adjusts in increments of 0.2 lbs.

  • Page 27: Control Panel And Hmi Screens

    Control Panel and HMI Screens This PCS 60 uses a rotary encoder dial that allows the operator to navigate, select and adjust settings on the control panel screen. You must first press the rotary encoder to activate navigation. Navigate between options by turning the rotary encoder dial left or right; this will highlight the option in blue. Once the desired option is highlighted, simply press the dial to select it;...
  • Page 28 There are two screen states for the PCS 60. A blue screen (such as the Home screen) which indicates system operating screens. A black screen indicates that the PCS 60 is in the Advanced Settings screens. Changes can be made in each screen. Home Screen shown Note: The upper left icon indicates which screen is active Settings Screen shown...
  • Page 29 During operation, some display items on the screen will change color. Green is normal, yellow (or orange) is a warning and red is critical that needs attention. For example, the illustration below indicates the possible different levels of dry ice in the hopper and how they may change. GREEN because hopper is full to mid full...

  • Page 31: Operation

    3. Examine the machine for any external damage that may have occurred during transport. 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 69).
  • Page 32 To transport the PCS 60, use the methods illustrated below: Do not strap over the console or above the front handlebar as this could damage the screen and/or components for operating the PCS 60. See above illustration to correctly strap the PCS 60 to a wall, floor, or pallet.
  • Page 33 WARNING Do not lift the PCS 60 using the front handlebar, upper handlebar, or the lower bumper as there will be no stability which could cause damage to equipment or harm to personnel. ▪ To store the PCS 60, see section “Shutting Down the PCS 60” on Page 46. Personal Protective Equipment (PPE) WARNING Only trained personnel should operate the PCS 60.
  • Page 34 Setting Up the PCS 60 WARNING Improper installation of hoses and adapters to the PCS 60 can cause damage to the machine or the applicators. WARNING Follow LO/TO procedures and shut off the air pressure while attaching or disconnecting hoses or fitting to the machine. Prior to disconnecting the air supply hose, ensure that the supply air pressure has been shut off and pressure bled from the hose.
  • Page 35 Follow the instructions below to set up the PCS 60: Set the parking brake by pressing down on the center of the brake pad. Lift to release. Note: The machine should not be in motion when the parking brake is applied. Parking Brake *** To be applied when machine is NOT in...
  • Page 36 Attaching the hoses using the Quick Disconnect Fittings (QDC) a. Align the quick disconnect male end with the female end. b. Ensure the notch in the locking collar aligns with the lock and pull the spring-loaded collar back so that the male end of the QDC can be inserted into the female fitting. Insert the male fitting and release the collar.
  • Page 37 Attach an applicator to the blast hose and control cable using the two supplied wrenches. WARNING Do not use the applicator body or handle for leverage when tightening the applicator blast hose to the applicator. Always use two wrenches to prevent damaging the applicator and fittings WARNING Do not tape, tie, or bind the applicator blast hose and the...
  • Page 38 Attach a nozzle to the applicator. CAUTION Ensure that both the nozzle and Applicator Blast Hose are tight and secured to the applicator prior to operating the machine. Attach the ground reel to the article that is being cleaned. a. Pull out the ground reel to the distance needed to attach to the material being blasted.

  • Page 39: Compressed Air Supply

    PCS 60 receives the air required for proper machine function. If these air quality specifications are not met, yet are continued to be used with Cold Jet, LLC equipment, the warranty will be nullified.
  • Page 40 Achieving any given air-purity specification can be challenging but it is possible with the combination of proper equipment. Cold Jet, LLC offers equipment to help separate water from compressed air. A Coalescent Air Filter, or CAF, (2M0039) is a good entry level tool to help separate water from compressed air.
  • Page 41 And, if it is possible to cool the air even further such as using a Cold Jet aftercooler, more moisture is turned to water that can be separated from the compressed air.
  • Page 42 Starting the PCS 60 With power cord, air supply hose, blast hose, applicator control cord properly connected, and safety precautions understood, it is now time to start blasting. WARNING Never blast the display screen area of the PCS 60 with dry ice as this will cause permanent damage to the screen.
  • Page 43 Purging the system: Press “I” (air-only) button once. This will initiate the system for air only. On the applicator, the blue LED indicator light will come on. Air-Only c. Push the Air-Only button once to deactivate the applicator. Always purge the system with compressed air during start-up, after breaks, and before loading dry ice.
  • Page 44 7. Close the lid. Safety Grate removed in this illustration Doser Rotor Safety Grate Opening the safety grate will cause the PCS 60 to shut down automatically. The grate is a safeguard to prevent the operator and undesirable objects from coming into contact with the doser rotor at the bottom of the hopper.
  • Page 45 1. While the machine is at the Home Screen, use the rotary encoder dial on the machine console, navigate to the feed rate indicator on the home screen and adjust it to the minimum setting. Note: There are limitations to how much ice can be fed through the system. The maximum feed rates in the PCS 60 change on the HMI depending on what sized particle is selected.
  • Page 46 Blasting Dry Ice Particles For optimum performance: Position the PCS 60 and blast hose to prevent kinking and allow for maximum • maneuverability. Hold the nozzle perpendicular to and about 2 – 6 inches (5 cm to 15 cm) from •...
  • Page 47 Note: During normal operation, the machine will bleed air for 1.5 seconds for every 30 minutes of accumulated blast or air only time. This is to purge moisture from the pneumatic control circuit. Shutting Down the PCS 60 Follow the instructions below to shut down the PCS 60: 1.
  • Page 48 8. Turn off the compressed air supply. The PCS 60 will automatically bleed any remaining pressure. ***Each air supply is unique to the user. Turning off the air supply may require closing air-lines, shut-off valves, disconnection of power through an electrical switch(es) and/or shutting down mobile gasoline/diesel compressors.
  • Page 49 7. Write the number down and keep it in a safe place. If the password is lost, a call must be made to Cold Jet Customer Service. 8. The green “lock icon” in the upper left corner will change to red.
  • Page 50 Recipes (Optional) The following steps describe the recipe functions for the PCS 60. Recipes are useful for saving optimal settings for the machine for diverse 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. To access the Recipe screen: From the Home screen, use the rotary encoder dial to navigate to the Settings screen.

  • Page 51: Advanced Settings

    Advanced Settings Note: The PCS 60 has a patented agitation system called “SureFlow”. It is comprised of vibration, thumping and a pair of ram-rods. When the machine is plugged in, SureFlow’s “Sleep Mode” is automatically enabled; however, the vibration and thumper/ramrods are NOT active: “Enabled”...
  • Page 52 The hopper vibration on/off (C) operates based on the hopper temperature values when dry ice is detected in the hopper. The adjustments below can only be made when “C” is on. a. (D) adjusts the number of seconds, in increments of 5, that the vibrator will activate (a cycle).
  • Page 53 To initiate the diagnostic mode, hold the rotary encoder button down for (8) seconds. The Cold Jet CONNECT® icon (7) will turn white, indicating that the diagnostic mode has been activated. The diagnostic mode will time-out after 5 minutes of inactivity with the machine (for example, no motors have run).

  • Page 54: Cold Jet Connect

    *Cold Jet blasters continuously monitor internal systems. These systems may cause error codes to display periodically. These error codes are transmitted to Cold Jet to help improve blaster efficiency and performance. This feature is called “Cold Jet Connect.” Cold Jet CONNECT ®...
  • Page 55 QR Code location QR Code location The image below shows the Cold Jet CONNECT® Home Page. Clicking the menu icon in the upper left- hand corner will allow you to access items such as on-line manuals, warranty information, and technical service contacts.
  • Page 56 Once the Menu Button is selected, the menu appears on the left-hand side of the screen as shown below. Now, select the “CONNECT® Analytics” button. Clicking on “CONNECT® Analytics” button will bring you to the following page. Click the “Machine Login” button and enter your “Authentication Code”...
  • Page 57 Once successfully logged in, the following page is shown. To learn more about each of the analytics shown, access the user guide by clicking the “Help” icon in the top right-hand corner of the screen.

  • Page 58: Inspection

    Inspection WARNING Prior to any maintenance or inspection procedures, ensure that the PCS 60 is turned off and the power source is disconnected. Follow all LO/TO procedures. Ensure that the air supply is closed, bled off, and the air supply hose is disconnected from the PCS 60 Daily Inspect the hopper area for any dirt or debris.
  • Page 59 Optional Service Agreements:...

  • Page 60: Warranty

    Warranty Policy Cold Jet, LLC® (“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 for used equipment), under normal use, maintenance and service as stipulated in the Operator’s Manual, Commissioning, and Operator Training.
  • Page 61 Aero2 PCS 60 XXXXXXXXX Cold Jet Sp.zo.o, Slawomir Kucharski, Lukowska 12, Oborniki 64-600, Poland...

  • Page 63: Technical Schematics

    Technical Schematics Dimensional Drawing with Pneumatic Schematics [2A0338] 62-64 Electrical Schematics 65-70...
  • Page 64 Pneumatic Schematic...
  • Page 65 Pneumatic Schematic cont.
  • Page 66 Electrical Schematic, Note: This schematic pertains to all IoT protocols...
  • Page 67 Electrical Schematic cont.
  • Page 68 Electrical Schematic cont.
  • Page 69 Electrical Schematic cont.
  • Page 70 Electrical Schematic cont.
  • Page 71 Electrical Schematic cont.
  • Page 72 PCS 60 Maximum Acoustic Emissions Microphone positions below: Microphone 1 Microphone 5 Microphone 4 Microphone 2 Microphone 3 Readings used maximum air pressure and the highest flow nozzle.
  • Page 73 NOTES:...

  • Page 74: Contact Information

    +81 3 6869 2665 Phone: +1 800-337-9423 Fax: +81 3 6869 2666 Fax: +1 513-831-1209 China (Shanghai) Belgium - Europe Headquarters Cold Jet Dry Ice Equipment (Shanghai) Cold Jet BVBA Co., Ltd. Address: Address: Zone 1 Researchpark 330, B-1731 Room 111, Building 1 Zellik, Belgium Jindu Road No.

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