Ventech 9002 Manuale utente

VENTECHAGRIONICSUSERMANUAL ISSUE2.00

MODEL 9002 FRUIT RIPENING SYSTEM

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GS90USR2

MODEL 9002 RIPENING SYSTEM

USER MANUAL

VERSION 2.00 JULY 2002

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VENTECHAGRIONICSUSERMANUAL ISSUE2.00

MODEL 9002 FRUIT RIPENING SYSTEM

GS90USR2

INDEX

Pages

1. Unpacking&Installationchecks. 2,3,4

2. Operation 5,6,7

3. Servicing 8,9&10

4. RipeningGuides 11,12,13,14

5. RipeningRoommaintenance 15,16

6. Instrumentation. 17

1UNPACKING&INSTALLATIONCHECKS

1.1 Remove machine from packaging & save packaging for re-use when returning

machine for servicing or warranty repairs.

1.2 Unscrew the tank lid & remove the mains lead which is packed inside.

1.3 Prior to connecting to electrical supply, it is recommended that the power outlet to

be used is checked for correct polarity & good earthing (grounding). There should

not be more than approx 50 milliVolts AC between the Neutral & Earth (Ground) pins

on the power outlet. The machine can operate safely with reversed live & neutral

supply, using a non polarised socket outlet as is used in continental Europe. The

machine has internal fuses in the LINE & NEUTRAL which are not user accessible

without dismantling.

1.4 If connecting by means of a three phase plug, ensure that the mains lead is

connected with the correct polarity to Live & Neutral and not across two phases. Also

ensure that the earth connection is properly connected.

INDEX / UNPACKING&INSTALLATIONCHECKS

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1.5 Mains Lead Colour Code

Live (Line) Brown

Neutral Blue

Earth (Ground) Yellow/Green

1.6 PowerRequirements

The maximum supply voltage is 280 Volts AC 50/60 Hz.

Above 260 Volts, operation is automatically interrupted to protect the components

from damage, with automatic resetting when supply returns to safe limits.

Nominal working voltage is 200 to 250 Volts at 1,2 Amps

Max power during warm up is 234 watts, and average power consumption over a

6 hour ripening cycle is 95 watts.

1.7 External current Protection.

No external protection is necessary, however if a fused plug such as the UK 13A

plug is used, any fuse from 4 - 13 A is suitable.

1.8 Having satisfied that the power supply is correctly connected, the machine can be

put into service. We recommend that the machine be placed in the ripening room

at a height of 3 ft ( 1 Metre ) above floor levels, preferably positioned so that

maximum air flows across the machine, & with a minimum space all round the

machine of 20" (500 mm). Also ensure the machine is clear of any fork lift trucks

or any other mechanical handling equipment that could cause damage.

1.9 Installation Options

The VENTECH FRUIT RIPENING SYSTEM is normally used as a portable unit

which is plugged into the room to be gassed, then moved onto the next room.

However for high volume ripening rooms, there are available certain add-on options

as follows:

1.9.1 Gas Pipe Adaptor

This option also permits mounting the generator outside the ripening room. The

UNPACKING & INSTALLATION CHECKS

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UNPACKING & INSTALLATION CHECKS

exhaust nozzle of the generator can be replaced with a 1/8 “ NPT tube connector

obtainable from any hydraulics supplier, that allows connection to a gas pipe.

The gas pipe in turn can be connected to a gas manifold feeding individual rooms, with

the gas supply to each room controlled by a butterfly or ball valve.

This option is particularly useful for converting an existing bottled gas fed ripening

room to catalytic generator operation.

1.9.2 External Tank Option

This option can be used in conjunction with the previously described options to enable

the gassing period to be extended by means of an external tank mounted outside the

ripening room, which increases the capacity of the generator thus extending the

gassing time.

This external tank is connected to a 1/8" NPT bulkead connector on the side of the

machine which is supplied as part of the external tank option kit, and connected inside

the machine directly to the solenoid valve, replacing the tank. The external tank can

be manufactured locally to VENTECH specifications, or supplied by VENTECH. The

tank capacity can be sized to suit local Health & Safety codes which is usually 20 Litres.

However this & other tanks can be in turn refilled automatically from a 210L drum

outside the building.

1.9.3 Option Panel

There is a small panel in the side of the electronics module which can be removed &

replaced with additional interface electronics for connection to an automatic remote

supervisory system, using a programmable logic controller (PLC) or computer, in

conjunction with external motorised damper valves & ethylene gas sensors.

1.9.4 Variable Gas Rate Control.

This option plate can also be removed & replaced with a variable rate control should

this be so desired.

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OPERATION

2OPERATION

2.1 Unscrew the lid of the tank & fill with 1 litre ( US 1 Quart ) of VENTECH ripening fluid

or an approved equivalent. The tank holds 1.5 Litres of fluid, but has a dead volume

of 0.25 L when the tank is empty. The tank can be filled up to the necj initially, but

otherwise 1 litre is sufficient for one ripening session.

WARNING - The ripening fluid is highly inflammable & of low flashpoint.

Disconnect from electrical supply by unplugging before filling.

Keep away from naked flame when filling & preferably fill in an open space or well

ventilated room.

The use of solvents not approved by VENTECH is not recommended since, although

apparently normal ripening will be achieved, accelerated degradation of system

components occur, resulting in expensive long term repair costs.

2.2 Place generator in ripening room & plug in to power outlet. The control panel status

lights will light as follows:

REACTOR HEATING`Green

SYSTEM NORMAL Green

CONTROL ON Green

TEMP LO Yellow

2.3 After about 10 minutes the Yellow LO TEMP light will go out & theSOV lamp will start

to flash briefly at approx 9 second intervals, accompanied by a click. This is the

solenoid valve opening allowing ripening fluid to be admitted to the reactor to be

converted to ethylene. Ethylene gas will be emitted from the nozzle on the top of the

machine.

CAUTION-THE EXHAUST NOZZLE OPERATESATOVER 300DEGC. DONOT

TOUCH WHENOPERATING OR FOR HALF AN HOUR AFTER SWITCHINGOFF!

After reaching operating temperature the HEAT & CONTROL lights will flash on & off

as the system enters pulse width modulation mode which gives proportional control of

the element temeperature. This gives very accurate control of the catalytic conversion

temperature, and by preventing temperature cycling of the element, gives longer

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element life than on-off control.

2.4 After approx 6 - 8 hours operation, the ripening fluid will have been used up & the

tank will be empty. At this point, the low fluid sensor will detect the out-of-fluid

condition, and switch off power to the reactor & the solenoid valve. The FLUID

TANK EMPTY(yellow Lamp) will turn on to show that the ripening initiation process

is completed

Note:

It is important that the machine is level, otherwise the fluid level sensor will not sense

the low level condition properly, & not switch off.

2.5 WARNINGINDICATORS.

2.5.1 TEMP TOO HI (red light )

After start-up, the temperature will sometimes initially overshoot the correct set-

point, causing theTEMP TOO HI red light to turn on. This is no cause for alarm and

should go out after a few minutes & will not come on again.

This can also occur in the event of a power failure when power is restored. This

provides backup protection to avoid incorrect gas generation which could cause

degraded ripening. This also provides back-up low fluid protection if the machine

is not level.

2.5.2 VOLTS TOO HIGH (red light)

If this light comes on it is an indication that the mains power supply voltage is too

high ( above 260 Volts )Normally, the nominal voltage, depending on country is

from 220 to 250 Volts. Normal variations in supply voltage should be within +/- 6%

(UK) to +/- 10% ( S Africa)

It is unlikely that any country will have a supply that intentionally exceeds the 10%

limit, although under fault conditions, or very heavily loaded distribution systems,

the voltage can exceed these limits late at night when the gas generator will still be

working but most industrial & domestic load is switched off. In some developing

countries, these limits can also be exceeded.

For this reason, the Ventech gas generator has a built-in protection circuit which will

automatically switch off once this safe working limit has been exceeded without

damage to the components. After supply has returned to normal, the HI VOLT light

will go out & normal operation will be resumed.

Note further that the VOLTS TOO HI indication is outside the control of the gas

generator. It is not a machine fault as such, being an external fault resulting from

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OPERATION

incorrect supply voltage.

2.5.2(Cont)

AMACHINESHOWINGTHISINDICATIONSHOULDNOTBERETURNEDFORSERVICE

WITHOUT FIRST CHECKING THAT THE SUPPLY VOLTAGE IS IN FACT TOO HIGH, BY

MEASURINGWITHADIGITALVOLTMETER, PREFERABLYOVERALONGPERIODOF

TIME.PLEASEREMEMBERTHATTHISCONDITIONWILLOCCURINTERMITTENTLY&

IT IS IMPORTANT TO HAVE YOUR MACHINE CONNECTED TO THE SUPPLY WHEN

CHECKING. FOREXAMPLEIF YOU ARE USINGTHEMACHINE AT NIGHT, WHENTHE

VOLTAGE IS NORMALLY HIGHER & YOU SEE THIS INDICATION, YOU MIGHT THEN

CALL AN ELECTRICIAN FIRST THING THE FOLLOWING MORNING ( WHEN THE

VOLTAGE IS NORMALLY LOWEST) & HE WILL THEN REPORT THAT THE VOLTAGE

IS NORMAL

2.5.3 TANK TEMP TOO HI ( Red light )

This light will be lit if the temperature at the bottom of the reactor exceeds safe limits,

and when lit, switches off power to the reactor & solenoid valve. This can be caused

by several reasons.

(a) Machine not level.

This results in the ripening fluid not being able to flow into the reactor when nearly

empty. Since the cooling effect of the ripening fluid is no longer applied to the base

of the reactor, the temperature will tend to rise, with the risk of damage to the reactor

element terminals. This protection, by removing power to the element, maintains the

temperature within safe limits & therefore provides protection, should the machine not

level & also provides back-up low alcohol protection & back-up over temperature

protection in case of failure of the element control circuit & switching device.

(b) Element failure

The element, as most heating elements has a finite working life and will eventually

require replacement. When it eventually fails, it can possibly overheat, by-passing the

control system. Normally this will be picked up by the TEMP TOO HIGH protection,

but should this fail for any reason, the TANK TEMP TOO HI protection will provide

backup protection and prevent any risk of fire or damage to the metalwork of the

machine.

In the event of a direct lightning strike of magnitude too great for the lightning

protection, the HI TEMP protection may fail and the TANK TEMP TOO HI protection

provides back-up protection to prevent dangerous high temperatures occuring which

could cause a fire. This has happened on more than one occasion with machines made

by other manufacturers who do not offer such comprehensive protection.

Note that it is extremely unlikely that this will occur, since a lightning strike or surge

greater than the capacity of the ultra fast surge diodes will normally blow one or other

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OPERATION

the mains fuses.

2.5.4 INDICATOR LAMPS COLOUR CODES

Green Normal operation modes

Yellow Temporary operating modes such as low fluid or low temp on startup.

Red Abnormal operating modes.

months operation from new or after a catalyst change, and examine the catalyst by

unscrewing the exhaust nozzle, when cold, and viewing the catalyst, which

consists of small white tubes filling the reactor. These should be loose & not welded

together by carbon. If left too long, it is difficult to remove the old catalyst, and will

require an exchange reactor. Once the catalyst starts getting heavily carbonated,

it should be emptied by turning the machine upside down and shaking out the old

catalyst. It may be necessary to loosen the catalyst with a long thin screwdriver or

skewer. Once all the catalyst is removed, the reactor can be refilled with a new

catalyst pack, taking care not to overtighten the exhaust nozzle when replacing.

When refilling, some of the catalyst consist of triangular ceramic chips that should

be put in first, followed by the tubular active catalyst.

Due to the low cost of the catalyst, it is better to change it sooner, rather than later.

This will be done automatically, if your machine is covered by a service contract,

or sent in for any service or repairs

NB: IF YOU LEAVE THE CATALYST TOO LONG, IT MAY BE IMPOSSIBLE TO

REMOVE THE OLD CATALYST, IN WHICH CASE A COMPLETELY NEW

REACTOR WILL HAVE TO BE PURCHASED, WHICH IS THE MOST EXPEN-

SIVE COMPONENT IN THE MACHINE.

3SERVICING

3.1 CatalystChanging

The catalyst used in the machine will need changing after after between 6 & 12

monthsuse. Due to therestrictionsimposed by Customs &Excisedepartments, the

Ventech Ripening Fluid contains de-naturants which will eventually poison the

catalyst causing reduced gas generation. We also recommend that if you are

haveproblemsripening,thatyoucheckthegaslevelswithwitha gassampler

such as the GASTEC details of which are at the end of the manual.

This is supplied by us, & it is possible that a group of ripeners in one area share

the cost of one kit, since it is only used infrequently.

We recommend that the user checks the catalyst once a month after the first six

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OPERATION / SERVICING

3.2 FAULT FINDING

Before returning a machine for repair a few simple checks should be carried out, which

could save you the transport costs & downtime involved in sending a machine in to your

service centre.

3.3 Condition - No lights lit

3.3.1 First check the electrical supply to your machine, and if you have testmeter check that

you have mains supply across the two outside pins on the connector that plugs into the

socket.

3.3.2 f there is supply, then disconnect the supply cord & check the mains fuses. There are

two mains fuses in the supply to the machine, plus one in the mains plug if using a 13A

(UK) square pin plug. The 13A plug can be fused 4 -1 3A HRC fuse. The supply fuses

in the machine are 5X20 Amp 3.14A or 4.0A Ultra Fast fuses. If you use the normal fast

blow glass fuses. you will now have the same amount of surge protection. so replace

these by the correct type as soon as possible. Check the mains cord first but swopping

it with a computer or electric kettle cord

3.3.3 These fuses are in a small drawer in the side of the power inlet connector. They are

accessed by first removing the mains cable, then pulling the drawer open using a finger

nail, small knife or small screwdriver. If either fuses is blown, it should be replaced.

3.3.4 If nothing is found wrong & you have spare electronic boards proceed as follows:

3.3.5 Removal of electronic boards

Remove the four M8 X 8 countersink screws retaining the cover of the electronics

module, Remove the two grey ribbon cables by unplugging. Unscrew the 4 X M3X6

screws retaining the top PCB. This is the control board ( the one with 9 lights). Remove

the two green terminal strips in the bottom (Power Board) by pulling down to unplug.

There is no need to undo the terminal screws. Now unscrew the 4 nickel plated pillars

to release the power board. Refiiting is the reverse of removal. The two ribbon cables

are marked PL1 & PL2.

3.3.6 If after carrying out the above process, the machine is still not functioning, it will have

to be returned to the factory.

3.4 Condition - Lights on but no heating or valve operation.

3.4.1 Remove electronics cover as previous described and with the mains power discon-

nected, check the fuses om the power board. You can get at them with the control board

in place, but it is easier to remove it. The left hand fuse is for the reactor fude & the right

hand one for the solenoid valve. The ratings are 2.0 & 1.o A respectively. They are

normally fast blow glass 5 X 20 mm fuses

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SERVICING

3.4.2 Re-check the machine and if heating, run for a couple of hours on test before putting

back into service. If the fuse blows again, return the machine for service for element

replacement.

Note:

The supply line fuses generally only blow because of power surges or lightning.

Generally line surges blow the Line fuse, & Lighytning surges blow the Neutral fuse.

The power board fuses generally only blow due to element failure of short circuit

solenoid coil. Solenoid failure is extremely rare, as the solenoid is only open for a

fratcion of a second at a time.

It is most unusual for an element failure to blow the inlet fuses as well, although it

can happen, However if the element is blown as a result of a lightning strike, it will

blow both fuses.

PLEASE DO NOT REPLACE FUSES BY A LARGER TYPE IF THEY BLOW. ONLY

REPLACE A FUSE ONCE, THEN IF IT BLOWS AGAIN, RETURN MACHINE FOR

SERVICE. IF THE INLET FUSE BLOWS AGAIN AFTER SEVERAL HOURS OPERA-

TION,THISCOULDBECAUSEDBYREPEATEDMAINSSURGES,ESPECIALLYIFIT

ISDURINGTHUNDERSTORMS.

FAILURE TO OBSERVE THIS COULD RESULT IN ADDITIONAL DAMAGE.

If, after carrying out the above fuse checks, the machine is still not heating (indicated

by the LOW TEMP light staying lit), the you need to return the machine to have the

reactor element replaced.

3.5 Condition - lights lit, but incorrect operation.

First check through the chapter on operation, for a description of the status lights

operation. If this does not resolve the problem, generally this is due to a fault on the

control board caused by surge damage. If you have a spare card, try replacing it,

otherwise return the whole machine for service. Caution - the jumper at the bottom

of the card must be placed in theDIS position ( right hand side)unless you adjust the

R7 control, which requires the use of a digital multimeter.

IMPORTANT - ALLOW MACHINE TO COOL DOWN FOR TWO HOURS BEFORE

PUTTINGINTO THE POLYSTYRENEPACKAGING TO RETURN FORSERVICE.

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