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Cold Jet PR120H User Manual

Pelletizer
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PR120H Pelletizer
USER MANUAL
Original Instructions [English]
09-11-22 REV 5

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Summary of Contents for Cold Jet PR120H

  • Page 1 PR120H Pelletizer USER MANUAL Original Instructions [English] 09-11-22 REV 5...
  • Page 2 INFORMATION AND INTELLECTUAL PROPERTY CONTAINED HEREIN IS CONFIDENTIAL BETWEEN 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

    REPAIR AND WARRANTY Repair MAINTENANCE Degassing system Hydraulic station Terms of Warranty Cleaning the PR120H INSTRUCTION – UNPACKING AND PREPARATIONS BEFORE INSTALLATION End of life for the PR120H Notes Contact Information PR120H Version: Page: 2 of 26 User’s manual Date:...
  • Page 4 PR120H Version: Page: 3 of 26 User’s manual Date: 09.11.2022...

  • Page 5: Introduction

    The Cold Jet PR120H has a quick start-up that reduces downtime and loss of valuable CO2. This is secured by a start-up sequence purging the liquid line and using a special valve to fill the chamber.
  • Page 6 PR120H Version: Page: 5 of 26 User’s manual Date: 09.11.2022...

  • Page 7: System Description

    Liquid CO2 is fed from an external CO2 tank (not part of this description – see supplier information) through an insulated pipe to the Cold Jet PR120H. It is recommended to use a gas separator to eliminate gaseous CO2 from the liquid CO2.

  • Page 8: System Identification

    System Identification The machine is double marked with EU and UL approval. Example of a system identification, values and numbers may vary Supplier Responsible for the Equipment Cold Jet ApS Industrivej 68 DK-6740 Bramming Denmark Phone: +45 75 56 15 00 Homepage: www.coldjet.com...

  • Page 9: Technical Data - Safety Regulations

    Machine Dimensions: Length: 1150 mm / 45,3 in Width: 650 mm / 25,6 in Height: 1738 mm / 68,4 in Weight: 754 kg / 1662 lbs Noise level: below 75 dB(a) PR120H Version: Page: 8 of 26 User’s manual Date:...

  • Page 10: Technical Facts Of Frozen Co2

    :: 1½ times heavier than air :: The atmosphere consists of 0.03% CO exists in three forms: :: Gas, e.g. used in the food industry :: Liquid, kept under pressure :: Solid, dry ice PR120H Version: Page: 9 of 26 User’s manual Date:...

  • Page 11: Safety Regulations

    The owner of the machine shall make sure that the operator, who is to work with the Cold Jet PR120H, fully understands the importance of studying the content of the manual and complying with the SAFETY REGULATIONS described on the following pages as well as those placed on the machine.
  • Page 12 High CO concentrations 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. PR120H Version: Page: 11 of 26 User’s manual...
  • Page 13 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. Pinch Point Hazard If the plexiglass covers in front of the extruder plates are removed, the operator will be exposed to pinch point hazards. PR120H Version: Page: 12 of 26 User’s manual...
  • Page 14 How to Lift / Transport 1. The PR120H is supplied with thread holes for lifting eyes. Always use lifting eyes to lift the PR120H. 2. Always lift the Pelletizer according to the lifting Instruction in this manual.

  • Page 15: Safety Operation

    SAFETY OPERATION Emergency Stop All equipment is connected to the general emergency system for the Cold Jet PR120H. When an emergency-stop device is activated, all components located in the emergency zone will be disconnected from their power source. Machine Safety...

  • Page 16: Machine Structure

    MACHINE STRUCTURE PR120H 1 Pellets outlet sprout 2 Hydraulic station 3 Main hydraulic cylinder 4 Touch panel 5 Heat exchanger 6 Connection to external supply PR120H Version: Page: 15 of 26 User’s manual Date: 09.11.2022...

  • Page 17: Machine Operation Start-Up

    CO pipe are connected. Open ball valves for liquid CO supply and degassing. Turn the MAIN SWITCH on. To start up the Cold Jet PR120H, select the “Automatic mode” and press the “Start” button. PR120H Version: Page: 16 of 26 User’s manual...

  • Page 18: Machine Controls

    MACHINE CONTROLS PR120H 1 Start up page This page can be activated from any page by pressing the “Home button” in the lower right hand corner. 2 Start /Stop By activating the “Start / Stop” button, the machine starts or stops when in group mode.
  • Page 19 The operating hours, time to service calculated capacity is also displayed on this page. 7 Alarm The Alarm page displays alarms for PR120H. By pushing the “Alarm” button, the active alarms are shown on the screen. The alarm text will be written in red.
  • Page 20 In general, it is recommended leaving the machine with the main power on and avoiding turning the power off direct on the main power switch. This is for protecting the PLC computer not wearing out, due to sudden power cut off. PR120H Version: Page: 19 of 26 User’s manual...

  • Page 21: Repair And Warranty

    Get a particle analysis of the oil if in doubt about the contamination degree. Cold Jet recommends that the owner has a spare parts package in stock, so repairs can be made quickly and with little loss of production time.

  • Page 22: Terms Of Warranty

    Protect all electronic equipment. ● All surfaces can be cleaned with a degreaser and acid-free oil. If the bottom of the PR120H is full of water/oil there is a drain plug on the backside of the PR120H. Always close the drain after use.

  • Page 23: Instruction - Unpacking And Preparations Before Installation

    The minimum clear distances must be observed to provide sufficient space for opening the cabinet doors and servicing the PR120H. Installation of the PR120H The installation of the PR120H must be carried out by one of Cold Jet’s service technician, or by a technician approved by Cold Jet. PR120H...
  • Page 24 DRAWING No. A1 Correct Handling of Cold Jet PR120H Minimum load capacity of forklift truck: 800kg/1764 lbs Minimum fork length: 0.8 m The PR120H is supplied with thread holes for lifting eyes. Always use lifting eyes to lift the PR120H. PR120H Version:...

  • Page 25: End Of Life For The Pr120H

    DRAWING No. A2 End of life for the PR120H When the PR120H is at the end of its life, the following steps are required. Disconnect the power Disconnect the CO Drain the PR120H oil For handing of the PR120H read section Error! Reference source not found..

  • Page 26: Notes

    NOTES PR120H Version: Page: 25 of 26 User’s manual Date: 09.11.2022...

  • Page 27: Contact Information

    Phone (US): +1-800-777-9101 455 Wards Corner Road Phone (Outside US): +1(513)576-8981 Loveland, Ohio 45140 Email: service@coldjet.com Canada - Cold jet Canada Phone: +1-800-337-9423 Ext. 501 1727 Industrial Road, Unit 1 After Hours Support: +1-(513) 576-8981 Cambridge, Ontario N3H 5G7 Email: service@coldjet.com...
  • Page 28 PR120H Pelletizer MAINTENANCE AND REPAIR Original Instructions [English] 13-12-2022 Rev 5...
  • Page 29 CONFIDENTIAL BETWEEN 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 30 Get a particle analysis of the oil if in doubt about the contamination degree. Cold Jet recommend the owner to have a spare part package in stock, so repairs can be made quickly and with a very little loss of production time.
  • Page 31 This table includes all the service intervals from 0 hours to 20000 hours. For each service interval there will be listed which procedures is necessary to perform and the Cold Jet article no. for spare parts package. Table 1. Table for mechanical maintenance Pelletizer PR120H Service interval Hours/Month Procedure no.
  • Page 32 PROCEDURE FOR CHANGING GASKETS IN HYDRAULIC CYLINDERS ON PR120H ............. 8 PROCEDURE FOR CHANGING THE HYDRAULIC CYLINDER ON PR120H ..............10 PROCEDURE FOR CHANGING DANFOSS EV3 AND EV15 VALVES + SOLENOIDS ON PR120H ......... 12 PROCEDURE FOR CHANGING THE EXTRUDER PISTON ON PR120H ..............13 PROCEDURE FOR CHANGING REFILL FILTER ON PR120H ..................
  • Page 33 1. Procedure for changing CO filter and gasket on a PR120H This section will describe how to change the CO filter and gasket on a PR120H. During this operation it’s important to activate the emergency stop button! Disassembling the CO...
  • Page 34 It is very important to be careful and not get any dust or dirt into the filter housing under this this could block the Danfoss solenoid valves Operation, 2. Procedures for changing degassing filters on PR120H During this operation it’s important to activate the emergency stop button! Version:...
  • Page 35 [1] and reassemble the extruder unit. The screws [5] are to be tightening equally, and not so tight that rubber gasket is broken. At production startup, it’s important to check if the degassing sleeves are tightened correctly. Version: PR120H Page: 6 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...
  • Page 36 3. PROCEDURE FOR CHANGING HYDRAULIC RETURN OIL FILTER ON PR120H During this operation it’s important to activate the emergency stop button! Procedure step by step 1. Dismount the 4 screws [1] from the return oil filter housing [3]. 2. Remove the housing top plate [2].

  • Page 37: Procedure For Changing Gaskets In Hydraulic Cylinders On Pr120H

    4. PROCEDURE FOR CHANGING GASKETS IN HYDRAULIC CYLINDERS ON PR120H 1. Piston 4. Piston rod 3. Cylinder tube 2. Cylinder top During this operation it’s important to activate the emergency stop button! Important! For operators safety the hydraulic cylinder has to be disconnected from the hydraulic system before dismounting.
  • Page 38 14. The hydraulic cylinder has to be checked for any leaks and is then ready to be mounted on the machine again. BEFORE STARTING PRODUCTION THE HYDRAULIC MOTION SHOULD BE CHECKED IN SINGLE MODE! Version: PR120H Page: 9 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...

  • Page 39: Procedure For Changing The Hydraulic Cylinder On Pr120H

    5. PROCEDURE FOR CHANGING THE HYDRAULIC CYLINDER ON PR120H During this operation it’s important to activate the emergency stop button! The hydraulic cylinder Disassembling the hydraulic cylinder from the process unit is done by first removing the 4 pcs. bolts [1] fixing the process unit the machine frame.
  • Page 40 Install the counter nuts [2] and reassemble the process unit. Mount the hoses and plugs. Refill the hydraulic oil if necessary. BEFORE STARTING PRODUCTION THE HYDRAULIC MOTION SHOULD BE CHECKED IN SINGLE MODE! Version: PR120H Page: 11 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...

  • Page 41: Procedure For Changing Danfoss Ev3 And Ev15 Valves + Solenoids On Pr120H

    6. PROCEDURE FOR CHANGING DANFOSS EV3 AND EV15 VALVES + SOLENOIDS ON PR120H During this operation it’s important to activate the emergency stop button! Disassembling and replace a Danfoss EV15 valve and solenoid Remove the pipe by loosening the 2 flare nuts [1] dismount the plug on the solenoid and pull of the solenoid [2], loosen the flare nut on this pipe [3], remove the EV15 valve [4].

  • Page 42: Procedure For Changing The Extruder Piston On Pr120H

    7. PROCEDURE FOR CHANGING THE EXTRUDER PISTON ON PR120H During this operation it’s important to activate the emergency stop button! Follow instructions from Procedure 5 for disassembling the hydraulic cylinder and piston. The extruder piston Place the hydraulic cylinder on a workbench. Disassemble the piston from the hydraulic cylinder by loosening the 8 pcs.

  • Page 43: Procedure For Changing Refill Filter On Pr120H

    8. PROCEDURE FOR CHANGING REFILL FILTER ON PR120H Procedure step by step 1. Dismount the 6 screws [2] from the refill filter [1]. 2. Replace the refill filter. Make sure to replace the gasket [3] 3. Mount the 6 screws [2] again tightening evenly and firmly.

  • Page 44: Procedure For Changing Hydraulic Pump Or Repair On Pr120H

    During this operation it’s important to activate the emergency stop button! Changing or repairing the hydraulic pump This operation is only to be carried out by Cold Jet service technician or by an Cold Jet approved company such as Bosch / Rexroth.

  • Page 45: Procedure For Changing Oil On Hydraulic Station On Pr120H

    10. PROCEDURE FOR CHANGING OIL ON HYDRAULIC STATION ON PR120H 1. Hydraulic tank 3. Cover plate 1. Ball valve During this operation it’s important to activate the emergency stop button! Procedure step by step 1. Remove the oil. Drain out off this ball valve pos. 1. The used oil must be deposited at an approved station for environmental waste.

  • Page 46: Procedure For Replacement Of Gaskets In Pneumatic Ball Valves

    [1.2] by loosening the 4 screws [1.4], and place it on a desk. During this operation it’s important to activate the emergency stop button! Maintenance and assembly of pneumatic actuator Version: PR120H Page: 17 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...
  • Page 47 10. Remove the pinion [12] cam [11] and internal washer [10] from the body of the actuator, with downward force to the top of pinion 11. Clean the components of the actuator perfectly Version: PR120H Page: 18 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...
  • Page 48 In spring return actuators, it will be necessary to insert the spring cartridges appropriately in their lodgings of the end caps according to the quantity of the springs you use (see detail). Version: PR120H Page: 19 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...
  • Page 49 2. Turn the valve to closed position, and the ball can be removed. 3. Loosen the nut [12] and remove the washers [10] and seals [8] Version: PR120H Page: 20 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...
  • Page 50 Stainless Steel - AISI 304 Bolt Stainless Steel - AISI 304 Stainless Steel - AISI 304 Locking Device Stainless Steel - AISI 304 Anti-Static Device Stainless Steel - AISI 304 Version: PR120H Page: 21 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...
  • Page 51 Install the complete valve unit [1.2] by tightening the 4 screws [1.4]. Connect the flexible hose [1.7] and plug in the electrical connection and the pneumatic tube [1.1] for the actuator. Note: Inspect for leaks during production start. Version: PR120H Page: 22 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...

  • Page 52: Operating In Single Mode Control

    1. Start the hydraulic pump 2. Move the pistons using valve 2 FWD and RWD buttons Check that there are no leaks on the hydraulic station. The operation is complete. Version: PR120H Page: 23 of 24 MECHANICAL MAINTENANCE Date: 2022.12.13...
  • Page 53 Pelletizer PR120H ALARMLIST 07-11-2022 Rev 2 Original Instructions [English]...
  • Page 54 CONFIDENTIAL BETWEEN 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 55 Use table for troubleshooting to fix the error. In general, Cold Jet recommend that the cause of errors is investigated as soon as they appear and that the machine is not being operating until the error is identified or fixed.
  • Page 56 Error. EtherCAT bus Chamber pressure G01-TP1 Error. Disconnected Chamber pressure G01-TP1 Error. Short circuit Chamber pressure G01-TP1 Error. Chamber pressure G01-TP1 Error. PV larger than SP Chamber pressure G01-TP1 Error. PV less than SP Chamber pressure G01-TP1 Error. EtherCAT bus Linear encoder G01-TG1 Error.
  • Page 57 Error. Both 1 and 2 Hydraulic motor HU01-G1-MO1 Error. Both BG1 and BG2 Hydraulic motor HU01-G1-MO1 Error. Max actiontime Hydraulic motor HU01-G1-MO1 Error. Circuit breaker Hydraulic motor HU01-G1-MO1 Error. Inverter Hydraulic motor HU01-G1-MO1 Error. Hardware Hydraulic motor HU01-G1-MO1 Error. Hydraulic valve 1 HU01-Q1 Error.
  • Page 58 Error. Disconnected Liquid CO2 pressure transmitter W01-TP1 Error. Short circuit Liquid CO2 pressure transmitter W01-TP1 Error. Liquid CO2 pressure transmitter W01-TP1 Error. PV larger than SP Liquid CO2 pressure transmitter W01-TP1 Error. PV less than SP Liquid CO2 pressure transmitter W01-TP1 Error.
  • Page 59 TROUBLE SHOOTING TABLE Troubleshooting Alarm test Description Both_1_AND_2 Program error. More than one group started at a time. Contact IceTech technical support. Both_BG1_AND_BG2 Both sensors are active and shouldn't be. Investigate if both sensors are actually active and replace damaged component if needed.
  • Page 60 Check if the is a short circuit in the component or the wiring to the component. PV_Larger_Than_SP Actual process value is larger than set point Check setpoint on HMI and investigate why the process value is too high. PV_Less_Than_SP Actual process value is less than set point Check setpoint on HMI and investigate why the process value is too low.
  • Page 61 Max. purge time exceeded If purge limit within the given max. purge time this error occur. Check if liquid CO is available. Check if liquid CO2 filter is blocked, clean or replace if necessary. If this error happen frequently it could indicate that the liquid supply line is not properly insulated and/or that a degassing valve is required to achieve proper CO supply.
  • Page 62 NOTES Version: R1000H Page: Alarmlist Date: 07.11.2022...
  • Page 63 CONTACT INFORMATION Version: R1000H Page: Alarmlist Date: 07.11.2022...
  • Page 64 PR120H Pelletizer OPERATOR MANUAL Original Instructions [English] 19-01-2023 Rev 3...
  • Page 65 CONFIDENTIAL BETWEEN 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 66 CONTENT INTRODUCTION About the PR120H • SYSTEM DESCRIPTION Functional description • System identification • Supplier responsible for the equipment • TECHNICAL DATA - SAFETY REGULATIONS SAFETY REGULATIONS General Measures • Personnel Qualifications • Security and Risk • Safety Labels •...

  • Page 68: Introduction

    The Cold Jet PR120H has a quick start-up that reduces downtime and loss of valuable CO2. This is secured by a start-up sequence purging the liquid line and using a special valve to fill the chamber.

  • Page 70: System Description

    Liquid CO2 is fed from an external CO2 tank (not part of this description – see supplier information) through an insulated pipe to the Cold Jet PR120H. It is recommended to use a gas separator to eliminate gaseous CO2 from the liquid CO2.

  • Page 71: System Identification

    System identification The machine is double marked with EU and UL approval. Example of a system identification, values and numbers may vary Supplier responsible for the equipment Cold Jet ApS Industrivej 68 DK-6740 Bramming Denmark Phone: +45 75 56 15 00 Homepage: www.coldjet.com...

  • Page 72: Technical Data - Safety Regulations

    Machine Dimensions: Length: 1150 mm / 45,3 in Width: 650 mm / 25,6 in Height: 1738 mm / 68,4 in Weight: 754 kg / 1662 lbs Noise level: below 75 dB(a) Version: PR120H Page: 3 of 14 User’s manual Date: 2023.01.19...

  • Page 74: Safety Regulations

    The owner of the machine shall make sure that the operator, who is to work with the Cold Jet PR120H, fully understands the importance of studying the content of the manual and complying with the SAFETY REGULATIONS described on the following pages as well as those placed on the machine.

  • Page 75: Safety Labels

    High CO concentrations may result in unconsciousness due to the displacement of oxygen. Therefore, always provide sufficient ventilation of the working area, and avoid producing dry ice in small rooms. Version: PR120H Page: 6 of 14 User’s manual Date:...

  • Page 76: Static Electricity

    Pinch Point Hazard If the plexiglass covers in front of the extruder plates are removed, the operator will be exposed to pinch point hazards. Version: PR120H Page: 7 of 14 User’s manual Date:...

  • Page 77: Wear Protective Gloves

    How to Lift / Transport 1. The PR120H is supplied with thread holes for lifting eyes. Always use lifting eyes to lift the PR120H. 2. Always lift the Pelletizer according to the lifting Instruction in this manual.

  • Page 78: Safety Operation

    “Process values” page. Daily checkup before start-up Check the oil level in the sight glass. Check the pipe system for leaks. Check the operation time since service intervals. Version: PR120H Page: 9 of 14 User’s manual Date: 2023.01.19...

  • Page 80: Machine Structure

    MACHINE STRUCTURE PR120H 1 Pellets outlet sprout 2 Hydraulic station 3 Main hydraulic cylinder 4 Touch panel 5 Heat exchanger 6 Connection to external supply Version: PR120H Page: 11 of 14 User’s manual Date: 2023.01.19...

  • Page 81: Machine Operation Start-Up

    CO pipe are connected. Open ball valves for liquid CO supply and degassing. Turn the MAIN SWITCH on. To start up the Cold Jet PR120H, select the “Automatic mode” and press the “Start” button. MACHINE CONTROLS PR120H Version: PR120H...
  • Page 82 The “set point” section contains 3 pages display of set values for the current dry ice production. Fixed set points are password protected and have hardcoded limits to avoid unsafe production. Version: PR120H Page: 13 of 14 User’s manual Date:...
  • Page 83 The operating hours, time to service calculated capacity is also displayed on this page. 7 Alarm The Alarm page displays alarms for PR120H. By pushing the “Alarm” button, the active alarms are shown on the screen. The alarm text will be written in red.
  • Page 97 Description: Creator: ColdJet ApS REV. REV. DESCRIPTION DESCRIPTION DATE DATE P&I-Diagram for IceMaker PR120H Date: Replaced valves to 24 VDC 06-12-2017/LM Industrivej 62 12-08-2014 CE/UL 3x400V AC 50 HZ/3x480V AC 60 Hz. DK-6740 Bramming 28-03-2018/JVM General update of valves and drawing text Rev: TLF.
  • Page 98 7/9/2020 Tag-numbers for IceMaker PR120H P294-1-11991-G CE/UL 3x400V AC 50 HZ/3x480V AC 60 Hz. IceTech Varenummer Digital I/O Analog I/O ASPECT ASPECT DESCRIPTION TAG DESCRIPTION Beskrivelse Datablad relative links DIPR120H Dry Ice Production Unit DIPR120H=V01 Armstrong Kit Option DIPR120H=V01 Filter unit...

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