Instruction Manual: Serial No.: Voltage: 230 V Phase: 1 HZ: 50/60

INSTRUCTION MANUAL
for
ASCOJET 1502
DRY ICE BLASTING UNIT
Version 1.0
(From serial no. 05-224-01)
Serial No. : Voltage: 230 V Phase: 1 Hz: 50/60
Client:
Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Industriestr. 2, CH-8590 Romanshorn P.O.Box 16134, NZ-Christchurch
Tel. + 41 71 466 80 80 Fax + 41 71 466 80 66 Tel. + 64 3 349 7029 Fax + 64 3 349 4337
e-mail: ascojet@ascoco2.com www.ascojet.com e-mail: info@asco.co.nz
INTRODUCTION
This technical manual of ASCO is meant to be an aid in getting to know the dry
ice blasting unit better and in utilizing its possibilities for application in accordance
with its intended use. Furthermore, this manual contains important information for
safe, proper and economic operation.
All instructions are to be followed as written in order to avoid danger and damages
which could cause downtime and premature wear and tear on the dry ice blasting
unit.
In addition to the technical manual and the accident prevention regulations which
are valid and compulsory in the country and in the particular workplace where the
dry ice blasting unit is being used, the recognized special rules for safe and proper
working procedures are also to be followed. The technical manual must always be
within reach wherever the dry ice blasting unit is being used.
Each person involved with the set-up, start-up, operation, maintenance and repair
of the dry ice blasting unit in the user company must have first read and understood
the technical manual and especially the safety precautions.

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CONTENTS
page
1. General information 1
1.1 General 1
1.2 Cleaning with dry ice 1-4
2. Safety instructions 5
2.1 Identification of signs and symbols in the technical manual 5-6

2.2 Personnel qualification 6
2.3 Safety tips 6
2.3.1 Carbon dioxide concentrations 6-7
2.3.2 Clothing precautions 7-8
2.3.3 Handling of dry ice pellets 8
2.3.4 Cleaning objects 9
2.3.5 Blasting precautions 9-10
3. Start up/Shut down 11
3.1 Transport 11
3.2 Connecting the unit 11-13
3.3 Operating the unit 13-14
4. Maintenance 15
4.1 General 15
4.2 Maintenance interval 15-17

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CONTENTS
page
5. Faults and troubleshooting 18-20
6. Technical datasheet for ASCOJET 21
7. Technical documents 22
Appendix 1: Electrical diagram for ASCOJET 1502 22

Appendix 2: Pneumatic diagram for ASCOJET 1502 23
Appendix 3: Sound level 24
Appendix 4: Air preparation 25
Appendix 5: Air volume 26
Appendix 6: Spare parts list for ASCOJET 1502

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GENERAL INFORMATION page - 1 -
1. General Information
1.1 General
The ASCOJET dry ice blasting unit is built according to the latest technological
developments and recognized safety rules. Its use, however, can endanger life and limb of
the user of third parties, and can lead to considerable damage to the dry ice blasting unit
and other material assets if :
- it is operated by personnel not trained or instructed in its use,

- it is improperly used,
- it is improperly maintained or serviced.
This can result in the loss of all damage claims.
In the interest of further development, ASCO reserves the right to make changes at any
time, which, in keeping with the essential characteristics of the dry ice blasting unit described
here, may be necessary for increasing efficiency or for reasons relating to safety or to
normal business practice.
1.2 Cleaning with dry ice
Cleaning in the industry
In industrial processes pollution and adhesion of contaminants on equipment are inevitable.

The reliability of production related equipment, the quality of the products and the safety for
personnel are very important issues.
Plant Managers worldwide are therefore looking for new cleaning technologies which are
quality improving, cost saving and at the same time environmentally-safe. In this high tech
era the classical cleaning methods don’t always meet the cleaning needs or have important
drawbacks.
Some examples : - High pressure cleaning and the use of solvents and other
toxic chemicals increase disposal costs dramatically.
- Grit blasting has its limitations because it is abrasive and
there is always danger of grit entrapment in moving parts.
- Tedious manual labour (i.e. scraping, scrubbing,…) results
in a lot of man-hours and is thus very expensive.
Cleaning with dry ice offers you a perfect, environmentally-safe alternative.

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The technology
The ASCOJET equipment uses little pellets of carbon dioxide as blasting media. Liquid
carbon dioxide (CO2) is expanded in a production unit into carbonic snow which is extruded
under high pressure through a die. That way we produce hard and identical shaped CO2
pellets (approx. 3 mm diameter and 4 mm length). The dry ice pellet has a temperature of
- 79 °C and has a very special feature.
By adding energy it transforms immediately from solid to gaseous state. This feature we
are using with the dry ice cleaning technology.
From a portable unit the pellets are transformed by compressed air to a blasting gun. In
this gun the CO2 pellets are accelerated (max. 300 m/s) and blasted upon the surface to
be cleaned.
Cleaning action of CO2 pellets
The cleaning action of carbon dioxide is based on two principles i.e. thermo-shock and
kinetic energy.
- thermo-shock: CO2 pellets have a temperature of -79 C and every material

has a different shrinking factor. Therefore the adhesion
between contaminant and substratum will loosen.
- kinetic energy: To remove the contaminant a little extra energy is needed.

This energy is supplied by the pellets themselves. The pellet
penetrates through the contaminant and when it hits the base
surface, it turns immediately from solid to gaseous state
(=sublimation). This produces an increase in volume (factor
500) by which the kinetic energy is converted to a lateral
release which acts as a ”gas wedge” that lifts the contaminant.
In some applications thermo-shock will be more important (i.e.
bitumen, resins, glues) in others the kinetic energy (i.e.
coatings).

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The benefits
CO2 cleaning has some important benefits opposed to other cleaning methods.
- reduces waste dramatically

CO2 sublimes in the atmosphere and the removed contaminant - if not recycable -
is the only waste left. No blasting media are to be disposed.
- non-abrasive
CO2 pellets have the hardness of chalk. There are no changes of surface dimension
and no damage to the substrate.
- dry
The pellets evaporate immediately at impact.
- fast
In a lot of applications in-place cleaning is possible. Disassembly and downtime are
drastically reduced.
- safe
By eliminating the use of solvents and hazardous chemicals this cleaning technology
is safe for personnel and environment.
- compactness & mobility

The equipment is designed out of a user's point of view. It is light, mobile,
maintenance free, reliable and easy to operate.

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Applications
CO2 pellets are non-toxic, non-conductive and non-abrasive. Therefore this technology
has a broad range of applications in all kinds of industries.
- food processing
- plastic processing
- nuclear decontamination
- petrochemicals
- foundries
- chemicals
- printing
- textiles
- automotive
and everywhere oil, grease, resins, adhesives, paint, ink, bitumen, wax and other
contaminants are to be removed.

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SAFETY INSTRUCTIONS page - 5 -
2. Safety instructions
This technical manual contains basic tips which are to be followed during set-up, operation
and servicing. Therefore, it is of utmost importance that it is read by the assembly
technician before installation and start-up as well as by the specialist/operator in charge,
and it must always be within reach at the place where the dry ice blasting unit is being
used.
2.1 Identification of signs and symbols in the technical manual
The safety tips contained in this technical manual, whose disregard could endanger
people and machines, are indicated by a general danger sign and the additional
markings Danger! and Attention!
Safety sign in accordance with DIN 4844-W9
The warning against electrical voltage has the following special marking :
Safety sign in accordance with DIN 4844-W8
Safety tips printed directly on the dry ice blasting unit must
be followed at all times and must be kept completely legible.
Attention :
This sign refers to a procedure or sequence of particular

interest or importance. All tips must be followed to ensure
proper use of the dry ice blasting unit.

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• This dot refers to working and/or operational steps. The steps are
to be carried out in the order of their appearance from top to bottom.
- Enumerations are marked with the sign of a hyphen.
2.2 Personnel qualifications
The personnel involved in operation, maintenance, inspection and assembly must

have the corresponding qualifications to do this work. Areas of responsibility and
supervision of the personnel must be precisely established by the operator. Should
the personnel not possess the necessary knowledge, then they must be trained
and instructed. If necessary, this training may be carried out by the manufacturer/
supplier at the request of the operator of the dry ice blasting unit. Futher, the operator
is to make sure that the personnel completely understands the contents of this
technical manual.
2.3 Safety tips
2.3.1 Carbon dioxide concentrations
Low concentrations (3 - 5 %) cause headaches and rapid respiration.

Concentrations of 7 - 10 % cause headaches and nausea which can lead to
unconsciousness. Higher concentrations lead to unconsciousness and
suffocation.
Danger !
The maximal acceptable concentration level of CO2 is 5000 ppm. Higher

concentrations are harmful for the human body (MAK-scale IV).
Work in adequate ventilated working areas only!

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Attention !
We strongly advise the use of a CO2 detector in working areas.
2.3.2 Clothing precautions
Danger !
Always wear protective goggles when operating the equipment. Also

personnel working near the blasting place should wear proper eye
protection
Danger !
Always wear adequate hearing protection when operating the

equipment. By preference wear a combination of ergonomic ear plugs
and ear phones. Due to high pressures and high volumes of compressed
air, the noise while blasting can go up to a level of approx. 109 dBA. (see
table in ”Technical documents)

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Danger !
Wear industrial gloves and shoes.
Attention !
The above mentioned safety pictograms are also present on the housing
of the dry ice blasting machine.
2.3.3 Handling of dry ice pellets
Danger !
Solid carbon dioxide has a temperature of -79 °C and therefore can

cause severe freeze burns. Therefore, always read thoroughly the safety
information sheet provided by your dry ice supplier.
Attention !
CO2 pellets are extremely cold which implies that all the parts of the
machine (air-lock, hopper, pellet hose,...) which come directly in contact
with the pellets should NEVER be touched without proper protective
clothing.

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2.3.4 Cleaning objects
Attention !
- Small objects should be fixed or mounted properly before blasting.

Do not leave loose parts in blasting area.
- Some residus tend to pulverise while cleaning. If the maximum work
concentration of 6 mg/m3 (fine dust) is exceeded, a mask must be
worn.
Danger !
Severe static electrical discharges are possible.

Always provide a good earthing to the objects to be cleaned.
2.3.5 Blasting precautions
Danger !
- The nozzle of the gun discharges gases and CO2 pellets at very
high velocities (up to 300 m/s). Never aim the gun at persons or in
the directions where personnel works.
- After releasing the trigger, low pressure transport air (max. 3 bar)
continues to flow through the nozzle in order to empty the pellet
hose. Always keep the gun pointed in a safe direction untill all
airflow has stopped.
- At maximal blasting pressure, the nozzle has a reactive thrust of

approx. 6 kg in the opposite direction of the airflow. In order to
anticipate the reactive thrust, always take a wide stance (feet
approx. 60 cm apart) and lean into the direction where the nozzle
points.

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- The pellet transport hose is a special cold-resistant, silicone-rich

hose but will eventually (i.e. after a long blasting session) become
hard. Make sure to handle the hose assembly gently. Damage
to the hose assembly can lead to injuries.

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START UP / SHUT DOWN page - 11 -
3. Start up / Shut down
3.1 Transport
After the dry ice blasting unit has been delivered, it must be checked for damage
which may have occurred during transport. If necessary, the transport company
must be informed to register the damage.
The dry ice blasting machine is always delivered with blasting hose assembly, gun
and nozzle. Check if all parts have been delivered.
Attention !
To avoid oil leakage from the gearbox, the dry ice blasting unit must whenever
possible be transported on its wheels.
In case the dry ice blasting unit needs to be transported on its side, always replace
the ventilated plug* on the oil filler of the gearbox by a completely closed plug!
Attention!
Before use replace the completely closed plug by the ventilated plug!
* This plug is installed close to the dry ice outlet.
3.2 Connecting the unit
Attention !
All pipe and wire connections are to be tightened! Before connecting, the pipes
must be checked for presence of abraded material from the threading, solderbeads
or other similar impurities. Breakdown resulting from faulty installation does not fall
under ASCO’s warranty obligation.

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The following sequence is to be followed for connecting the unit:
• Connect the hose assembly to the couplings on the ASCOJET. The connections
are also indicated on the housing of the machine. (see picture 3.1)
Picture 3.1
• Connect the hose assembly to the couplings of the gun.
• Connect the ASCOJET to the compressed air supply (picture 3.2). Several
options are possible in the choice of compressed air (see 7. Technical
documents: Appendix 4: Air preparation")
Picture 3.2
• Connect the unit to a standard 230V monophase electrical source.
The ASCOJET is now ready to start the blasting session.

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Attention !
- Make sure there are no kinks or bends in the hose assembly.

- Make sure that all electrical connectors never come into contact with
moisture or water.
- Compressed air may never exceed 10 bar.
- Read thoroughly in "7. Technical documents: Appendix 4: Air preparation” in
order to blast with air that meets the demand of the dry ice blasting machine.
3.3 Operating the unit
After connecting the dry ice blasting machine properly, the following sequence is to
be followed when operating the unit:
• Place the unit in a ”dry” place and lock the brakes of the wheels.
• Make sure the emergency stop is pulled out (see picture 3.3)
Hourmeter
Regulation of
transport
pressure Regulation of dry
Regulation of ice consumption
blasting with display
pressure Emergency stop
button
Picture 3.3
• Slowly open the valve of the compressed air supply and observe the pressure
build-up on the manometer of the dry ice blasting machine. A too abrupt
pressure build-up is to be avoided.
• At machines with pressure regulation, the pressure can be changed by turning

the hand wheel on the control panel. The pressure can be changed during
operation of the machine.

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• At machines with the regulation of the pellet consumption a certain consumption

can be preset by the switch mounted on the control panel. The consumption
can be changed during operation.
• Open the hopper lid and fill the hopper with fresh CO2 pellets. The hopper
contains approx. 40 litres of CO2 pellets.
• Point the gun towards the object to be cleaned, hold the gun with both hands,
take a proper stance (see 2.3.5 blasting precautions) and squeeze the trigger.
• When using the OHS gun (item no. 906052) the maximum working
pressure should not exceed 6 bar.
Attention !
Never run the unit empty ( i.e. without CO2 pellets); this will lead to unnecessary
wear of the teflon sealer discs.
open closed
Attention !
Always use ”fresh” CO2 pellets. Using pellets older then 24 hours will cause excessive
moisture in the hopper and this may result in freezing of the pellet distributor (see 5
faults & troubleshooting).
Make sure that only CO2 pellets are introduced into the hopper. Any foreign materi-
al in the hopper will lead to serious damage in the distributor system.

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MAINTENANCE page - 15 -
4. Maintenance
4.1 General
As the ASCOJET dry ice blasting machine is built out of a user's point of view and
according to the latest technological developments, the unit is basically maintenance
free.
Only if the performances of the dry ice blasting machine are no longer satisfactory ,
maintenance is necessary. However, we advise you to check the unit, at regular
intervals, as described hereunder.
4.2 Maintenance interval
Check the pellet distributor system for excessive air leakage every 100 operating
hours or every 3 months whichever comes first.
How can excessive air leakage be detected ?

Put some CO2 pellets into the hopper and operate the unit. If CO2 and air come
back into the hopper, you have excessive air leakage.
In case of an excessive air leakage, the tension on the pellet distributor needs to be
readjusted.
Danger !
Prior to maintenance following steps have to be followed :
- In order to avoid unexpected rotating of the distributor, always disconnect

the machine from the electrical power supply!
- Check always that the dry ice blasting machine is depressurised!

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The following sequence is to be followed when readjusting the tension :
• Remove the housing panels (see pictures 4.1 to 4.4)

- remove the panels on both sides
- open the lid and unscrew the shaft
- unscrew and remove the hopper
Picture 4.1 Picture 4.2
Picture 4.3 Picture 4.4

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• Dissassemble the distribution unit by removing the 6 nuts on the top of the
upper distributor plate. To reach the rotor, both the upper distributor plate and
upper teflon disc must be lifted of. Hereafter the rotor and the lower teflon disc
can be removed. Clean all parts of the distribution unit with a clean cloth. Before
assembling in reverse order, check whether the teflon discs have no damages
like holes, cracks or scratches that lead from the inside of the plate to the out-
side. Check if the spring washers are ok. Mount the spring washers pairwise in
reverse order (each stack of springwashers contains 3 pairs of 2 springwashers
and 1 normal washer on top) and tighten the units equally by hand (without
force). Afterwards, use a key and thighten the nuts by making exactly two full
turns. This is the ideal tension of the distributor system.
Nut and
springwashers
Picture 4.5
After properly readjusting, air should only be leaking out of the hole in the upper
distributor plate. This leakage is the discharge of the compression chambers of the
rotor disc! Using new teflon discs, a very small leakage between the teflon discs and
the rotor is possible. This will disappear after a few hours.
Danger!
Work on electrical installations may only be done by a specialist or by other persons

instructed in this type of work as long as they are under the instruction and supervision
of a specialist. The general rules for working with electricity must be followed !

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FAULTS AND TROUBLESHOOTING page - 18 -
5. Faults and troubleshooting
The pellet flow has stopped
Possible cause Solution
• No pellets in the hopper Fill the hopper with pellets
• The pellet hose is twisted. Check the pellet hose and uncoil if necessary.
• The pellet hose is clogged. Check for CO2 plug inside the pellet hose.
If so, remove pellet hose and let dry ice
evaporate. Then check if transport air
pressure is not too low. If necessary, reset
pressure valve at 3 bar. (see picture 5.1)
Regulation of
Picture 5.1 transport pressure
• Ice inside blasting gun. Control air supply for dewpoint and oil
or moisture contents.
• The quality of the pellets is bad Check the inside of the hopper. When icy,
(too old, too much moisture) de-ice it and also clean the top of the pellet
distributor.

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• Transport air is leaking into

the hopper. See 4.2 Maintenance intervals
• The pellet distributor does not

function anymore.
- Machine is frozen Clean the hopper and the teflon discs
- A foreign object has fallen Check the hopper and the pellet distributor.
into the hopper. Remove the object or debris and replace the
necessary parts if damaged.
When pulling the gun trigger, the machine doesn't start
• Bad power source Check if power source is properly functioning.
• Short circuit in connectors or Check by elimination and replace

control cable. damaged parts.
• Overcharge of the electric Reset the unit by disconnecting the current

motor for approx. 60 seconds. Check whether the unit
is frozen.

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The blast air pressure drops
· Malfunction in compressor Check the air pressure supply.

or air preparation.
· Malfunctioning of blasting Check, dismantle and clean or replace

valve. the blasting valve. (see picture 5.2)
Picture 5.2
Picture 5.2: Reducing valve of ASCOJET 1502 with pressure regulation

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TECHNICAL DATA SHEET FOR ASCOJET Page - 21 -
6. Technical Data sheet for ASCOJET
Measurements: 780 x 550 x 960 mm
Weight: approx. 113kg
Content of pellet container: approx. 40 litres dry ice pellets
Blasting pressure: max. 10 bar
Transport pressure: max. 6 bar
Dry ice consumption: 25 - 85 kg/hr

(low dry ice consumption due to double
hose - and low pressure pellet transport
system)
Power consumption: 800 W nominal
Connections: Input R 1”
Output 1 1/16"-12 JIC
7/8"-12 JIC

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TECHNICAL DOCUMENTS page - 22 -
Appendix 1: Electrical Diagram for ASCOJET 1502

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Transport air
Blasting air
Ball valve
Appendix 2: Pneumatic Diagram for ASCOJET 1502
Opening valve
Opening valve
Solenoid valve
Solenoid valve
Manometer
Manometer
Reduction valve
Reduction valve
Inlet compresed air

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Appendix 3: Emitted sound
Level of emitted sound measured outside,1 m behind user at an average dry ice consumption.
Pressure [bar] Sound level [dBA]
2 88
3 93
4 96
5 98
6 99
7 100
8 101
9 106
10 109

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Appendix 4: Air preparation
Attention!
In order to ensure proper functioning of the ASCOJET, make sure that:
- compressed air NEVER exceeds 10 bar.

- an aftercooler, oil filter and water separator are installed.
- the content of oil does not exceed 4 milligram/m3 compressed air.
Possible 3 options in order of preference
Compressor Aftercooler, oil filter & water separator
1. Adsorption drier pres. dewpoint min. <-20°C Input compressed air
2. Freeze drier pressure dewpoint min. +6°C Input compressed air
3. Filter station* Input compressed air
* The filter station is used in case there are no filters installed or the existing oil filter and water separator are
underdimensioned.

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Appendix 5: Air volume
The freely available air volume flowing through the standard blasting gun type MHP equipped
with its round barrel nozzle was measured at the corresponding blasting pressure.
An air preparation plant type AP16 with aftercooler was used to treat the compressed air.
Pressure [bar] Air volume [m3/min]*
4 3.7
5 4.2
6 4.6
7 5
8 5.4
9 5.8
10 6.2
* The above data are approx. figures only and may change because of differing equipment
and/or installation.

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INSTRUCTION MANUAL

Serial No. : Voltage: 230 V Phase: 1 Hz: 50/60

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

2.1 Identification of signs and symbols in the technical manual 5-6

3. Start up/Shut down 11

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

5. Faults and troubleshooting 18-20

6. Technical datasheet for ASCOJET 21

Appendix 1: Electrical diagram for ASCOJET 1502 22

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

- it is operated by personnel not trained or instructed in its use,

1.2 Cleaning with dry ice

Cleaning in the industry

In industrial processes pollution and adhesion of contaminants on equipment are inevitable.

Cleaning with dry ice offers you a perfect, environmentally-safe alternative.

Cleaning action of CO2 pellets

- thermo-shock: CO2 pellets have a temperature of -79 C and every material

- kinetic energy: To remove the contaminant a little extra energy is needed.

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

- reduces waste dramatically

- compactness & mobility

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

2.1 Identification of signs and symbols in the technical manual

Safety sign in accordance with DIN 4844-W9

Safety sign in accordance with DIN 4844-W8

This sign refers to a procedure or sequence of particular

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

- Enumerations are marked with the sign of a hyphen.

2.2 Personnel qualifications

The personnel involved in operation, maintenance, inspection and assembly must

2.3 Safety tips

2.3.1 Carbon dioxide concentrations

Low concentrations (3 - 5 %) cause headaches and rapid respiration.

The maximal acceptable concentration level of CO2 is 5000 ppm. Higher

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

We strongly advise the use of a CO2 detector in working areas.

2.3.2 Clothing precautions

Always wear protective goggles when operating the equipment. Also

Always wear adequate hearing protection when operating the

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

Wear industrial gloves and shoes.

2.3.3 Handling of dry ice pellets

Solid carbon dioxide has a temperature of -79 °C and therefore can

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

2.3.4 Cleaning objects

- Small objects should be fixed or mounted properly before blasting.

Severe static electrical discharges are possible.

2.3.5 Blasting precautions

- At maximal blasting pressure, the nozzle has a reactive thrust of

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

- The pellet transport hose is a special cold-resistant, silicone-rich

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

3. Start up / Shut down

* This plug is installed close to the dry ice outlet.

3.2 Connecting the unit

Switzerland (Head Office) ASCO CARBON DIOXIDE LTD New Zealand

The following sequence is to be followed for connecting the unit:

• Connect the hose assembly to the couplings of the gun.

• Connect the unit to a standard 230V monophase electrical source.

The ASCOJET is now ready to start the blasting session.