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Summary of Contents for Aquila RE80
- Page 1 ORIGINAL Instruction manual for Recovery unit RE80 By Aquila Triventek Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 2: Table Of Contents
Phase sequence protection compressor protection fan protection Too much oil in filter Low oil level High temperature 1st stage High temperature 2nd stage Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... - Page 3 TECHNICAL DATA 12.1 Proporties of carbon dioxide 12.2 Electrical charge 12.3 Safety parts identification EC DECLARATION OF CONFORMITY GUARANTEE DELIVERY REPORT Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 4: Introduction
We are pleased that you have chosen the Recovery Unit RE80 by Aquila Triventek A/S for your company. The recovery RE80 is especially designed to be connected to the Aquila Triventek Dry Ice Pelletizer type PE80, and cannot be used for other purpose. - Page 5 Ensure all national / local regulations are observed. The European Industrial Gas Association (EIGA), see www.eiga.org/, provides useful background material and guides to good practice. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 6: Safety Data For Recovery Unit Re80
As CO gas is heavier than air, please be aware of CO build-up in lower working areas. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 7: Equipment For Operation
1 x 5 control cable. Cat 5 patch cable The Recovery Unit RE80 and must be handled carefully to avoid shock damage to mechanical and electrical components. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... - Page 8 Compressor / FK 30/32,5K - 22400001 Second stage CO compressor / FK 20/245N - 22400002 Plug housing Female socket N.B.: For reference to the RE-numbers please see Parts Identification for RE80 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 9 St.1 motor 7,5kW 50/60Hz 44010132 St.2 motor 4kW 50/60Hz 22103008 Gas cooler 36359484 Filterhousing ----------- Complete refrigiation unit condenser Bitzer 36329626 N.B.: For reference to the RE-numbers please see Parts Identification for RE80 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 10 RE80006 RE80010 RE80015 Gas cooler 36359484 Solenoid valve EVR6 34439301 Solenoid coil 230V AC Check valve NRV16 34739502 N.B.: For reference to the RE-numbers please see Parts Identification for RE80 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 11 1p solid state relay 24VDC/230V 1p 240VDC interface relay PT1000 to 4-20mA converter Transformer Power supply 24VDC Terminal fuse plug Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 12: Connection Of The Equipment
5: 1” cam male Buffer tank 6: Pressure relief 7: Main electrical power supply cable Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 13: Operating Limitations
The Recovery Unit RE80 can only be used in the conjunction with the Pelletizer PE80 and no other equipment. Use the Recovery Unit RE80 only for the designed purpose and follow the guidelines described in this manual. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 14: Operation Panel
The operation panel at the front of the RE80 includes the following functions: Buttons: Display Manual start button Manual stop button Indicator lamps Emergency stop button Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 15: Pressure Gauge Panel
The green light indicates that the level detector is electrically connected. Function: Green light = Liquid Green + yellow light = No Liquid CO Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 16: Automation
If the pressure rises above 0,8 bar, the AV304 valve is opened in order to drop the CO2 gas. When the pressure keeps rising and reaches 1,0 bar, second valve - AV302 – opens in order to lower the pressure. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 17: Main Menu Structure
PRESSURE ... BAR COOLING EVAP. PRESSURE ... BAR GAS PRESSURE ... BAR HIGH PRESSURE ... BAR BRIGHTNESS < DOWN UP > Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... - Page 18 At start up after more than 3 hours stand still the power has to be turned on for min. 2 hours due to the crankshaft heating in the Cooling unit of the RE80. Any attempt to start earlier will damage the compressor of the Cooling unit.
- Page 19 WAIT until the pressure has dropped (no more gas coming out). Now it is possible to disconnect the depressurised hoses. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 20: Alarm Messages
Check the settings and status on the motor protection in the electrical box. See page 11 CO2 COMPRESSOR PROTECTION Press “ OFF “ to clear the error Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 21: Fan Protection
Check oil level on the CO compressors See page 27-28 LOW OIL LEVEL Refill if necessary Press “ OFF “ to clear the error Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 22: High Temperature 1St Stage
Check the settings and status on the motor protection (A1-F4) in the electrical box. COOLING COMPRESSOR See page 11 PROTECTION Press “ OFF “ to clear the error Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 23: Cooling Internal Protection
Press “ OFF “ to clear the error Do not try to disassemble the unit Contact a refrigeration engineer. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 24: Cooling High Pressure
Press “ OFF “ to clear the error Do not try to disassemble the unit Contact a refrigeration engineer Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 25: Maintenance
Complete oil change CO Compressors Function test of safety components pressure and electrical 7.2 Oil filter The oil filters are changed in as follows: Disconnect piping at the bottom of the filters. If necessary disconnect the fitting around the lower part of the filter. Unscrew by hand the lower part of the filter. Take out filter and replace with new. Filter system Unscrewing filter New filter Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 26: Inspection And Refill Of Co Compresor Oil
When changing oil it should always be the same type as supplied with the system by Aquila Triventek (see chapter 12 Technical data). The Recovery Unit RE80 has a Oil differential switch build in. If the oil pressure is too low in the CO compressors, the error message “Low Oil Pressure”... - Page 27 CO compressors. Take care not to over fill. Factory filling: Stage 1 = 1,8 litres Stage 2 = 0,9 litres Both sight glasses has to be between ½ to ¾ full during stand still Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 28 2 compressor and at the end of stage 1 compressor. Also when inspecting check the sight glasses under the oil filters. Only small amounts of oil are accepted in the sight glasses. Only in the ones pointed out with the red dots Open ball valve to empty filters Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 29: Pressure And Venting
3. High pressure vent off during operation. 19,5bar vent off pressure High pressure transmitter 0 – 25bar safety valve 24,1bar 6. Manual vent off valve (service depressurizing) Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 30: Maintenance And Inspection Of Refrigeration System
Condenser coil Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 31: Refrigerant Evaporation Low Pressure
Air and moisture can enter the hoses during pauses in production. Water is usually only a problem if the hoses have been disconnected while they are cold. Oil will only occur if there has been malfunction in the Recovery. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 32: Solution For Improving Heat Transmission In The Co 2 Condenser
If the equipment has become dirty, clean by means of a wiper moistened with a cleaning material (degreaser) Fan and cooling surface: The condenser (cooling) coil fins can be cleaned with compressed air and/or by careful brushing. 9 Storage The equipment can be stored in temperatures of - 5°C to +40°C (23°F - 104°F). Please note, that temperature changes (e.g. overnight) of >20°C (68°F) might cause condensation (dew) inside the electronics, which can cause damage to the equipment. If condensation is suspected then place the equipment in a warm room (+15°C to +22°C) for 1 hour before use. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 33: Recommended Spare Parts List
34439101 Solenoid valve ¼” EVR3 34639224 Safety relief valve 24,1bar 34422201 Valve head AKV 22302002 Solenoid coil 230V AC Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... - Page 34 0 – 25 bar Liquid CO2 level sensor 21401001 Solid state relay 21101010 Pressure switch 60091605 Sensor PT 1000 60091606 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 35 Recommended spare parts list Sparepart no. Description Picture Safty valve 34639219 V-belt XPA 1307 461307A0 Solenoid valve EVR 6 LC02 34439203 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 36: Troubleshooting
Turn the phase inverter in the socket with in display a screwdriver Low voltage Check setting of voltage monitoring relay. Measure voltage at the equipment. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... - Page 37 19-19.5 bar. The high pressure vent off has to be adjusted to a low flow in order not to overload the oil separating filters See how to do this in chapter 7 concerning maintenance Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 38 In all other situations we kindly ask you to contact the appointed distributor or Aquila Triventek A/S for further instructions Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 39: Technical Data
Compressor Oil type (Food grade) Compressor PAO 68 Food grade compressor oil type (Food grade) Min. to max. temperature -10°C (-13°F) 40°C (104°F) Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 40: Proporties Of Carbon Dioxide
Latent heat of sublimation (Enthalpy of sublimation) r = 573,02 kJ/kg Total enthalpy, increasing temperature ≈ 645 kJ/kg from -78.9 ºC to 0 ºC Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 41: Electrical Charge
12.2 Electrical charge Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... - Page 42 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 43 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 44 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 45 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 46 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 47 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 48 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 49 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 50 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 51 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 52 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 53 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 54 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
- Page 55 Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com...
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Page 56: Ec Declaration Of Conformity
- Part 1: General requirements. Aquila Triventek A/S Responsible Mr. Torben Andreasen Nørre Åby 10/12-2021 Place Date Signature Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 57: Guarantee
Equipment, which has been repaired by unauthorized persons without our written consent, is not covered by this guarantee. Warranty claims from third parties are not covered by this guarantee. Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... -
Page 58: Delivery Report
Warranty of the above equipment will not be effective before this form has been completed, properly signed and this original returned within 20 days of delivery to Aquila Triventek A/S Industrivej 9 DK-5580 Nørre Aaby Denmark Comments: Aquila Triventek A/S · Industrivej 9 · DK-5580 Noerre Aaby · Tel. +45 70 22 12 92 · info@aquila-triventek.com · www.aquila-triventek.com... - Page 59 Preventive Maintenance RE80...
- Page 60 Caution. Before any service actions depressurize and turn off power supply. Extreme caution in the area of the compressors due to hot pipe work coursed by high temperature discharge gas RE80 maintenance check list: 1month Description Guideline ref. No. Comments Inspec.
- Page 61 Caution. Before any service actions depressurize and turn off power supply. Extreme caution in the area of the compressors due to hot pipe work coursed by high temperature discharge gas RE80 maintenance check list: 3 month Description Guideline ref. No.
- Page 62 Caution. Before any service actions depressurize and turn off power supply. Extreme caution in the area of the compressors due to hot pipe work coursed by high temperature discharge gas RE80 maintenance check list: 12 month Description Guideline ref. No.
- Page 63 Maintenance guidelines: 1 month RE-SG-9001 Inspection of oil level CO compressors: The two CO each has the one crankshaft with independent oil charge. During compression some of this oil is pulled together with the CO gas. Under normal conditions this oil will fully drained out of the gas in the oil separation filters. In case of filters failure or leakage in the system the oil level could drop and create risk of compressor break down.
- Page 64 Maintenance guidelines: 3 months RE-SG-9002 Cleaning CO gas cooler and condenser coil: The CO gas cooler and refrigeration condenser are air cooled coils made out of copper pipes with aluminium fins. The cooling fins needs to be cleaned regularly in order to keep the heat transfer between air and gas at the optimum.
- Page 65 Maintenance guidelines: 6 months RE-SG-9003 Inspection of belt drives: Both CO compressors are driven by belt drives. These belts will need attention in order to insure best power transfer possible from motor to compressor. For tension control of the belts use an “Optikrik I tension gauge”. Caution.
- Page 66 RE-SG-9003 Inspection of belt drives: Push down on the Optikrik towards the belt until a clicking noise is heard from the gauge The belt tension in Newton can be seen at the point of intersection. Belt Tension table Stage 1 50Hz Stage 2 50Hz Stage 1 60 Hz Stage 2 60Hz...
- Page 67 RE-SG-9004 : Inspection of Valve heads There is located three AKV solenoid valves In the vent off manifold at the back side of the RE80. AV335 AV371 AV304 Identification of valves Remove the coil Disassemble the valve The valve seat and spring must be intact. The seat will show signs of wear in the form of marks from the nozzle.
- Page 68 RE to PE and leave it of 2. Run trough the normal start up procedure for PE and RE When the PE80 production is up to 100% start the RE80 and wait. The CO gas will now be vented out of the connection for recovered CO on the RE80.
- Page 69 Maintenance guidelines: 12 months RE-SG-9006 : Replacement of CO oil filters: The CO gas is compressed in two stages and during this compression work some of the lubrication oil from the compressors will be carried on with the CO gas into the pipe system.
- Page 70 Maintenance guidelines: 12 months RE-SG-9007 Oil change CO compressors: It is recommended to do a full oil change once every 12 months. This is to insure safe operation of the system and long lifetime on the 2 CO compressors in the system. Before oil change read this guide and the user manual section 6.3 Caution! Before any opening of the system Turn of the power supply...
- Page 71 Every 3 years or 10.000 to 12.000 operation hours the oil has to be changed in the Bitzer refrigeration compressor Any service on the cooling system of the RE80 has to be carried out by a certified refrigeration engineer/company. It is recommended to contact the local Bitzer distributor...
- Page 72 Maintenance guidelines: 24 months RE-SG-9009 Inspection CO compressor shaft seals: The two CO compressors are open drive type and are equipped with shaft seals behind each belt drive disc. These seals are mechanical seals so wear in period of 200 to 300 hours is normal.
- Page 73 RE-SG-9010 Second inspection of belt drives: After 24 months of operation the belts on each compressor/motor has to undergo a thorough inspection for wear or damage. Replace if damaged or worn. Inspect the edges and inside of the belt for damage If the belts show signs of damage replace them and apply a full set of new belts.
- Page 74 RE-SG-9011 Function test motor protection devises: In order to insure safe operation of the motor protection devises these devises has to be activated manually once a year. I standby mode turn the black knob by hand until it trips by it self The knob will trip into position by it self and stay there.
- Page 75 Maintenance guidelines: 24 months RE-SG-9011 Inspection of wire connections: All wire connections in terminals etc. has to be inspected for damage, loose connection to avoid “hotspot” and risk of electrical short circuit due to melting cable insulation. Check that all wire connections are properly tighten Check the insulation on cable in hazards areas such as all cable outside the electrical box.
- Page 76 Check the liquid CO hoses supplied with the RE80 for sharp bends, flat spots, burst and signs of damage. Damaged hoses are a high risk area and can course injury or damage to the equipment.
- Page 77 Servicelog:...
- Page 78 Note: if there is a power failure the Recovery Unit, Pelletizer and hoses will be under pressure. DO NOT attempt to disconnect any hoses before depressurising. Aquila Triventek A/S • Industrivej 9 • DK-5580 Noerre Aaby • Denmark • Tel: +45 70 22 12 92 • aquila@triventek.com • www.aquila-triventek.com...
- Page 79 See how to do in chapter 6 concerning maintenance Aquila Triventek A/S • Industrivej 9 • DK-5580 Noerre Aaby • Denmark • Tel: +45 70 22 12 92 • aquila@triventek.com • www.aquila-triventek.com...
- Page 80 Aquila Triventek A/S • Industrivej 9 • DK-5580 Noerre Aaby • Denmark • Tel: +45 70 22 12 92 • aquila@triventek.com • www.aquila-triventek.com...
- Page 81 Please sign, date and return this together with the recording of history of the machine and return to Triventek. Date Signature Aquila Triventek A/S • Industrivej 9 • DK-5580 Noerre Aaby • Denmark • Tel: +45 70 22 12 92 • aquila@triventek.com • www.aquila-triventek.com...
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