Related Manuals for Cold Jet RE-CO2 160
Summary of Contents for Cold Jet RE-CO2 160
- Page 1 Recovery Unit RE-CO USER MANUAL Original Instructions [English] May 2024 Version 4...
- Page 2 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.
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Page 3: Table Of Contents
CONTENT INTRODUCTION SAFETY REGULATIONS • General Measures • Personnel Qualifications • Security and Risk • Danger of Suffocation • Static Electricity • Danger of Congelation MACHINE STRUCTURE MACHINE CONTROLS • Operation Panel • Liquid CO2 detector and reservoir • Main menu structure – RE-CO 160 UNI PLC •... -
Page 4: Introduction
160 UNI Recovery Unit, the revert gas, which is usually lost into atmosphere, is collected and recycled to make more pellets. This becomes a continuous process and will, as a result, reduce production costs by up to 50%. Supplier responsible for the equipment Cold Jet ApS Industrivej 68 DK-6740 Bramming Denmark... -
Page 5: Technical Data
Technical Data Voltage 380-415 V AC Frequency 50 Hz Power 24 kW Current 41 A Dimensions L2420 * W1370 * H1640 mm Weight 1350 kg Power connection 63A 3 P + N + E CEE 2-525 Refrigerant R452A Compressor Oil Type POE32 oil Food grade compressor oil type PAO68 oil (Food grade) - Page 6 Pressure Temperature Diagram Pressure- Temperature phase diagram for CO Solid Carbon Dioxide / Dry Ice Sublimation temperature 78.9 ºC (149.25.K) at p = 0,9807 bar Latent heat of sublimation (Enthalpy of sublimation) 573,02 kJ/kg Total enthalpy, increasing temperature from -78.9 ºC to 0 ºC 645 kJ/kg RE-CO Version:...
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Page 7: Safety Regulations
SAFETY REGULATIONS General Measures The manual contains instructions for starting up, operating, and servicing the machine. The operator must follow all instructions in this manual. The owner must make sure that the operator understands the contents of this manual and follows its guidelines and safety regulations. -
Page 8: Danger Of Suffocation
Danger of Suffocation Dry ice pellets are CO in solid form. At ordinary atmospheric pressure, CO can only exist in this solid form at temperatures of -79°C (-110°F) or lower. Therefore, during dry ice production, the CO will immediately be heated and thus transform from solid form into gas form. -
Page 9: Machine Structure
MACHINE STRUCTURE 1: Second stage CO2 compressor (item no. 22400000) 2: First stage CO2 Compressor(item no. 22400004) 1. CO2 Gas cooler (item no. 36359584) RE-CO Version: Page: 9 of 39 User manual Date: 2024.05.08... - Page 10 2. St.1 motor 7,5kW 50/60Hz (item no. 22103010) 3. St.2 motor 4kW 50/60Hz 4. Complete refrigiation unit condenser Bitzer (item no. 22103008) 1: CO2 Gas cooler (item no. 36359584) 2: Check valve NRV16 (item no. 34739502) Components for 3x220V; 60 Hz 1: Main switch 2: Motor protection 4,7A 3: Motor protection 39A...
- Page 11 9: Contactor DILM50 10: Contactor DILM40 11: Contactor DILM7-01 12: Contactor DILM32-01 13: Contactor DILM32-01 14: Contactor DILM7-01 15: Main PLC 16: EPROM for PLC 17: Slave module PLC 18: Relays 24V DC 19: Relays 230V AV 20: PT1000 to 4-20mA converter 21: EKC315A controller 22: Transformer 230V/24V 23: Phase monitoring relay...
- Page 12 1: Main Switch 2: Motor protection 4,7A 3: Motor protection 0,75A 4: Motor protection 18A 5: Motor protection 15A 6: Motor protection 31A 7: Motor protection 2,5A 8: Motor protection 2,5A 9: Motor protection 5A 10: Motor protection 0,75A 11: Transformer 240V/24V 12: Softstarter 25A 13: Softstarter 15A 14: Contactor DILM7-01...
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Page 13: Power Supply
22: Main PLC 23: EPROM for PLC 24: Slave module PLC 25: Relays 24V DC 26: Relays 230V AV 27: PT1000 to 4-20mA converter 28: EKC315A controller 29: Transformer 230V/24V 30: Phase monitoring relay Connection of the equipment Power supply The cable must be mounted locally to fit the local socket-de-sign. -
Page 14: Operating Limitations
1: 3/8” BSP Pressure equalisation from pelletizer (only for PE80 pelletizer) 2: 1/2” BSP Liquid CO2 to pelletizer 3: 1/2” BSP Liquid CO2 from tank (only with PE80 pelletizer) 4: 1 ½” cam male CO2 revert gas from pelletizer 5: 1 ½”” cam male Buffer tank 6: Pressure relief 7: Main electrical power supply cable... - Page 15 Condensing system • The min./max. ambient temperatures for the Condensing unit are -25°C to 40 °C (-13°F to 104°F) at normal air humidity. • The unit should never be stored in an ambient temperature exceeding 50°C. • The unit must be protected against direct sun and rain. •...
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Page 16: Machine Controls
MACHINE CONTROLS The operation panel at the front of the RE-CO 160 UNI includes the following functions. Operation Panel 1: Display 2: Manual start button 3: Manual stop button 4: Emergency stop button Pressure Gauge Panel 1: CO2 Gas pressure from pelletiser 2: CO2 Gas pressure - Pressure after 1st stage compression 3: CO2 Gas high pressure - Pressure after 2nd stage compression RE-CO... -
Page 17: Liquid Co2 Detector And Reservoir
Normal gauge readings during operations These are the readings you would expect to see after the Recovery has cooled down and commenced stable operation (after 10-15 minutes) • Refrigeration Condensing Pressure: Between 13 and 22 bar. • Refrigeration Evaporation Pressure: Between 1 and 2 bar. •... -
Page 18: Main Menu Structure - Re-Co
Main menu structure – RE-CO 160 UNI PLC Cooling pressures CO2 pressures CO2 temperatures 1st and 2nd stage. Working hours counter Time and date Status on Recovery Settings Alarm log I/O status 10. Home button. Display Settings RE-CO Version: Page: 18 of 39 User manual Date:... - Page 19 The display has got a screensaver installed. This screensaver can be locked as seen on the small symbol on above picture. If this happens then press in each of the 4 corners and it will unlock. Language, brightness and date and time can be adjusted in the setting menu. RE-CO Version: Page:...
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Page 20: Automation
AUTOMATION Power supply and control protection system A voltage monitoring relay in the panel stops the recovery and lights up the electrical failure lamp on the panel. The relay switches off if the voltage is too low, the phases order is wrong, or a phase is missing. Pressure protection system. -
Page 21: Stopping The Recovery Unit Re-Co 2 160 Uni
STOPPING THE RECOVERY UNIT RE-CO 160 UNI Stopping without depressurizing the system. • The Recovery and pelletizer can be stopped at any time. It is not advisable to switch off the power or use the emergency stop button without first emptying the Recovery of liquid CO2. •... -
Page 22: Alarm Messages
ALARM MESSAGES If an alarm turns the recovery off the above message will be displayed. Press the screen for further details! Here is a list of possible messages. Message Explanation Notes Emergency stop Emergency stop is pressed Release the emergency stop Phase sequence protection Check all 3 phases on the recovery Change two phases... - Page 23 Cooling compressor internal Internal motor protection compressor Do not try to disassemble the unit! Contact a protection condensing unit is switch off. refrigeration engineer. Turn off the electrical power to the recovery unit to reset the failure. Cooling fan protection Motor protection inside the condensing unit fans The fans are placed on the Refrigeration...
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Page 24: Maintenance
MAINTENANCE Accessing the equipment by unauthorized or untrained individuals can lead to physical injury or damage to property. The system consists of two separate sub-systems. The CO2 sub-system is cooled by R452A refrigerant. Due to the environmental impact of R452A, repair of the refrigeration parts must be conducted only by suitably trained, equipped and authorized personnel. - Page 25 Filter system Unscrewing filter New filter RE-CO Version: Page: 25 of 39 User manual Date: 2024.05.08...
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Page 26: Inspection And Refill Of Co2 Compressor Oil
320 UNI is food grade oil which complies with 21469 and are NSF H1 registered. When changing oil, it should always be the same type as supplied with the system by Cold Jet The Recovery Unit RE-CO 160 UNI has an Oil differential switch built in. If the oil pressure is too low in the CO2 compres- sors, the error message “Low Oil Pressure”... -
Page 27: Refilling Co2 Compressor Oil
Refilling CO2 compressor oil. CO2 compressor oil is refilled at the oil tank for the stage 2 compressor.* The stage 1 compressor is refilled by opening or unscrewing the copper pipe** using the small funnel*** and fill oil. Fill with oil according to the picture and description ”oil level” below St. -
Page 28: Drainage Of Co2 Compressor Oil
Both sight glasses must be between ½ to ¾ full during stand still. Drainage of CO2 compressor oil Important: The CO2 compressor oil can only be drained if the Recovery is completely depressurized. The CO2 compressor oil is drained at the end of each compressor. When inspecting check the sight glasses under the oil filters. -
Page 29: Co2 Pressure And Venting
CO2 Pressure and venting To maintain a safe working pressure during operation CO2 is vented off. The safety valve blows off at 24,1 bar and is only activated if the normal blow-off valve fails. Top manifold: CO2 vent off valves Bottom manifold: CO2 pressure handling manifold Low pressure vent off during start up and standby operation with Pelletizer Middle stage vent off during operation and standby operation with Pelletizer. - Page 30 RE-CO Version: Page: 30 of 39 User manual Date: 2024.05.08...
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Page 31: Insufficient Refrigeration
Insufficient refrigeration Insufficient refrigeration can be identified by reading the two pressure gauges for the refrigeration. Contact your local refrigerant technician for work on cooling circuit. Refrigerant condensation high pressure Refrigeration condensing pressure readings should be approximately 10°C above surrounding temperatures. If for example the surrounding temperature is 25°C, the reading on the pressure gauge should be approximately 35°C. -
Page 32: Refrigerant Evaporation Low Pressure
Cold Jet technician or by the owner’s qualified personnel who has been trained by Cold Jet in the repair and maintenance of Cold Jet dry ice blasting and dry ice production machines and accessories. -
Page 33: Cleaning And Storage
Cleaning and Storage Cleaning If the equipment has become dirty, clean by means of a wiper moistened with a cleaning material (degreaser). The condenser (cooling) coil fins can be cleaned with compressed air and/or by careful brushing. Storage The equipment can be stored in temperatures of - 5C to +40C (23F - 104F). Please note, that temperature changes (e.g. overnight) of >20C (68F) might cause condensation (dew) inside the electronics, which can cause damage to the equipment. -
Page 34: Spare Parts List
SPARE PARTS LIST Part No. Description Image 35319352 Filter insert type G9/25ZP 35319353 Filter insert type G9/25XP 36115055 PA068 oil 34439101 Solenoid valve ¼” 34639224 Safety relief valve 24,1bar 34422201 Valve head AKV 22302002 Solenoid coil 230V AC RE-CO Version: Page: 34 of 39 User manual... - Page 35 Part No. Description Image 21102002 Pressure transmitter 0 – 2,5 bar 21102025 Pressure transmitter 0 – 25 bar 21401002 Liquid CO2 level sensor 21101010 Solid state relay 60091605 Temperature transmitter 60091606 Sensor PT 1000 34639219 Safety valve 1,5 bar 461307A0 V-belt XPA 1307 34439202 Solenoid valve EVR 10 LC02...
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Page 36: Troubleshooting
Due to dirty condenser (cooling) coil fins Low Pressure Cooling error message Evaporation pressure below 0 bar Restart the RE-CO2 160 UNI. If this in display does not work, please repeat 2-3 times. If the message still displays, please contact a cooling engineer... - Page 37 Problem Cause Solution bad adjustment of high pressure the Low oil pressure on CO2 compressors high pressure blow-off valve. The safety valve must open at 20 bar. If it opens at a lower pressure it should be renewed. If the safety valve opens during production at 20 bars the vent-off flow control valve is not adjusted correctly.
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Page 38: Delivery Report
Delivery report - to be completed by the owner I have received Operation and maintenance manual for Recovery RE-CO2 160 UNI The equipment has been delivered to me in a satisfactory condition, and I fully understand that the warranty is for a period of 12 months after the date of delivery. -
Page 39: Contact Information
Phone (After hours): +1(513)440-3619 Email: service.eu@coldjet.com Email: service.eu@coldjet.com Spain – Cold jet Madrid Poland – Cold Jet Sp. Z o.o. C/ Oporto, Portal, 3 ul. Łukowska 12, Oborniki, Pol.Ind. Europolis Poland, 64-600 28232 Las Rozas de Madrid, Madrid, Spain Phone: +48 798 33 88 00...
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