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ICA740/760 Restrain Generator

Operators Handbook

Edition 1.2 29 Sept 2015

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ORIGINAL INSTRUCTIONS

The Restrain Company Ltd Unit 7 The Forum, Minerva Business Park Lynch Wood, Peterborough PE2 6FT UNITED KINGDOM www.restrain.eu.com

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1. Purpose: The ICA740/760 “Restrain Generator” is used for the production and maintenance of a stable atmosphere of ethylene within a cold store. The difference between ICA740 and ICA760 is the maximum generating capacity of the machine. The ICA740 has a maximum fuel conversion rate of 2.5 Litres/day and the larger ICA760 machine is 6.5 Litres/day The application and use of this product is the user’s responsibility and should be in accordance with relevant legislation. This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision.

2. Location: The “Restrain Generator” should be located within the store that is being treated. The minimum cold store temperature is –1 oC. This machine is not intended for use in temperatures below –1.0oC. For the ICA740 the room should be at least empty volume 150m³ (equivalent to approximately 40 one tonne boxes) for normal cold stores For the ICA760 the room should be at least empty volume 250m³ (equivalent to approximately 100 one tonne boxes) for normal cold stores The maximum size store depends on the standard of construction, room air leakage, and the target level of “Restrain”. This equipment has been used satisfactorily in good quality cold stores of 2000 tonne capacity for the 740 machine and 6000 tonnes for the 760 machine. The machine should be located at floor level or no greater than 1m above the floor in a position of good air circulation. It should be placed away from normal loading activity and protected by barriers from potential damage from fork lift trucks and similar hazards.

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The machine should be within 15 degrees of level and be stable. The machine must not be placed above or close to a source of ignition. As well as the Restrain atmosphere the machine output produces water in the form of vapour or steam depending on the surrounding environment. Some water will condense forming drips, which will fall on to the floor underneath the machine. This is substantially water and will evaporate. A small amount of adsorbent material under the outlet tube should be used to soak up this condensate.

3. Power Connection: The machine is fitted with a 13A plug to standard BS1363A. The plug is fitted with a 5A fuse, if the fuse is replaced it MUST by replaced by one of the same type and value. For use in continental Europe the machine is fitter with an approved European power cord If the supply cord is damaged it must be replaced with the same type by the manufacturer or its service agent or a similarly qualified person.

4. Maintenance: At least once per month the following items should be checked; · The connection cable has not been damaged.

· All covers are properly secured.

The Machine should be checked DAILY for correct operation. Caution:

Do not remove any operating covers while power is ON and machine is in operation. When servicing and replacing any parts with the covers removed completely disconnect the power cord from the machine.

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The catalyst housing contains a heater which is HOT. The furnace is well insulated and takes many hours to fall to a temperature that is safe to handle without protective gloves. The cover to this Box should only be removed by authorised service personnel.

5. Fuel: Only authorised “Restrain Fuel” should be used. This is exclusively supplied by the Restrain Company Ltd. The safe running & life expectancy of the “Restrain Generator” is dependant on the correct formulation of “Restrain Fuel” (ethanol) being used. Refer to the Restrain Fuel Safety sheet in Appendix 3 of this manual. WARNING: Restrain Fuel is flammable and therefore when handling the fuel the following precautions must be taken:

Turn machine OFF at the power connection.

NO SMOKING. Radios and Mobile phones must be switched OFF.

The tank of the 740 machine has a capacity of 9.5 Litres. The tank of the 760 machine has a capacity of 17 Litres Fill the tank carefully using the funnel provided to prevent spillage. If spillage occurs it should be contained within the “bund” area on the top of the tank. Clear any spilled fuel before proceeding and dispose of any soiled paper and rags carefully. After use and if the machine needs to be transported to another location empty and clean the tank IMORTANT NOTE The use of the “Restrain Fuel” is subject to Customs & Excise regulations. A manual log must be kept in the Fuel Cabinet. It should record the following:- 1) Volume, date of each delivery & be signed in. 2) Volume, date & allocation to each “Restrain Generator” using the unique

generator code. (Do NOT use store names in case generators are moved from one store to another!)

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6. Sensor Connections. The Ethylene sensor and operating protocol is housed in a separate unit that is connected to the Restrain Machine. For the operation of the sensor and crop protocols see the separate sensor manual Connect the sensor using the yellow CAT5 cable provided. The cable can be from 10 to 50m................the supplied sensor is 30m The sensor must be located remotely from the machine to maintain good control of the total room atmosphere. The location depends on the store layout and design and advice should be obtained from the installer. In installations where the room is periodically ventilated the machine can be stopped from generating ethylene while the ventilation is ON A switch can be fitted to the ventilation Louvre to stop the generator when the Louvre is open The machine can also be networked together with other machines and their operation monitored on a remote display. Details of this are shown in a separate instruction manual.

Remote Standby switch (Louvre)

Same cable as 75 style machine

Yellow Cable to type 73x Sensor

Remote monitoring and network.

Data connection Blue cable

Note: The square RJ45 connectors are for interconnecting Restrain system

components.

They are compatible with regular CAT 5 connection cables but not designed to

connect to standard computers or Ethernet networks.

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7. Start up. Before operation, check that the machine is safely positioned and the sensor correctly located and connected. Ensure that the fuel tank contains at least 5L of RESTRAIN fuel Check that the fuel tap at the bottom of the tank is ON. Tap handle Vertical

Turn ON power. No further operation will take place until the catalyst has achieved operating temperature. (This will be approximately 30 minutes). Warm up in progress indicated by rotating bars in status display.

8. Operation.

Display select button

OK light

Main Display Machine Status

Display

Fuel Display

Display type

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Press Button to select required Display Value.

%R % Restrain in room atmosphere.........default

reading

PPM Ethylene PPM reading only available if “Ripen”

sensor is connected

% CO2 Room %CO2 reading if CO2 sensor

is connected to the ethylene sensor

oC Room temperature; degree C from sensor

L/D Fuel consumption rate in Litres per day

Average over the last 24 Hours from power ON

L Litres of fuel used by machine since start up

(Reset to zero by service engineer only)

L with flashing LED (For engineer use: Indicates the fuel

production rate as requested from the sensor; Numbers 1 to 64 1= Off 64 = full rate)

Press again to return to top..............automatic return to %R after 60 seconds.

! Status display

This number displays the operating status of the machine

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Rotating bars...................Furnace Warm up (note, no other display is

active during warm up)

0 Standby..........In remote standby (louvers) or waiting for slow start to

begin

2 Run..............Machine running normally...........also green OK light ON

3 Ethylene Low............Machine running normally but ethylene low

4 Ethylene High............Machine running normally but ethylene high

5 CO2 High..........The CO2 reading from the 714 sensor exceeds 2%

6 Fuel Fault..............Tank empty or fuel turned off or blocked

7 Ethylene sensor fault..............Ethylene sensor disconnected or faulty

8 Heater Fault.........Machine fails to reach operating temperature after

specified time.

9 Furnace control Fault.................Faulty furnace temperature probe or

control

The green “OK” light has a 30minute delay before turning OFF when ethylene is out of range.

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Fuel level gauge.........updates periodically when injection sequence running. (Please note: The gauge is not activated until restrain generation commences after power ON)

Fuel greater than ¾ full

Fuel greater than ½ full Fuel greater than ¼ full Fuel less than ¼ full Flash

Fuel Empty All Flash

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9. Decommissioning and movement When the use of the equipment is no longer required and the machine moved to a new location proceed as follows:

Turn the machine off and disconnect from power source. Allow to cool down for at least 12 hours.

Turn the fuel tap to OFF Empty the remaining fuel back into the container in which it was supplied

NOTE: FLAMMABLE LIQUID see section 5 NOTE: Fuel quantities to be accounted for to meet customs regulations

Rinse out tank with 5 L water and empty Pack machine back into the original packaging for transport

Keep sensor away from fuel and place back into the sealed plastic in which it was sent

Do not attempt to transport or move machine without first emptying the Fuel tank.

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Appendix 1 Fuel safety data sheet.

SAFETY DATA SHEET

1 IDENTIFICATION OF THE SUBSTANCE

Trade Name Restrain Fuel

Product Trivial Name Ethyl Alcohol

Chemical name: Ethanol

IDENTIFICATION OF THE COMPANY

Restrain Company Ltd.

Lawrence House Transfesa Road Paddock Wood Kent TN12 6UT 08700-271620

2 COMPOSITION

CAS No: 64-17-5

EC No. 200-578-6

3 HAZARDS IDENTIFICATION

Flammability: Highly flammable liquid.

Eye: Irritating on contact with the eyes. Harmful

Skin: Prolonged contact may be irritating to the skin, causing drying

and cracking. Dermatitis may result from repeated, prolonged

skin contact. Highly

Flammable

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4 FIRST AID MEASURES

Eye: Immediately wash out eye thoroughly with large amounts of water

until irritation stops. Seek Medical Advice. Do not wear contact

lenses when working with this product.

Skin: Should this liquid contact the skin , flush the contaminated area with water

promptly. If the liquid penetrates the clothing remove the clothing and flush

the skin with water. If irritation persists after washing get medical help.

Ingestion: If the liquid has been swallowed, induce vomiting if person is conscious.

Get medical attention immediately.

5 FIRE - FIGHTING MEASURES

The liquid is Highly Flammable.

Extinguishing Media: Foam, carbon dioxide, chemical powder.

6 ACCIDENTAL RELEASE MEASURES

Should the Restrain Liquid be spilled or accidentally released, the following steps should

be taken:

The area of spillage or release needs adequate ventilation.

All sources of heat or ignition must be removed.

Cleanup personnel must be provided with appropriate respiratory

protection and protective clothing.

Use sand or vermiculite to absorb the liquid.

Place used absorbent materials in closed containers for disposal.

Wash spill area with water.

7 HANDLING AND STORAGE

Keep the Restrain Liquid away from all sources of heat and ignition.

Wear chemical resistive gloves and chemical safety goggles.

Protective clothing should be worn as required.

Store in a dry, locked storage area not subject to extremes of temperature.

Keep away from water and foodstuffs.

Store well away from sparks, flames and oxidizing materials.

Smoking is not allowed in the vicinity of either liquid or gas.

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8 EXPOSURE CONTROLS / PERSONAL PROTECTION

Ensure measures are taken to eliminate possibility of sparks, flames, ignition

in area of use.

Observe normal precautions for handling chemicals.

Avoid eye and skin contact with the liquid.

Wear appropriate personal protective equipment (as follows).

Wash thoroughly after handling.

Wear Chemical Safety Goggles.

An all in one chemical - resistant suit should be available.

A NIOSH/MSHA approved cartridge respirator can be worn should the

gas cause irritation.

9 PHYSICAL and CHEMICAL PROPERTIES

Restrain Liquid: Virtually colorless with an acetone odor.

10 STABILITY and REACTIVITY

Stability:

Stable under normal handling conditions.

Avoid the following conditions: Heat, sparks, open flames, contact with oxidizing materials.

Reactivity:

Incompatible with strong oxidizers, potassium dioxide, bromine pentafluoride, acetyl

bromide, acetyl chloride, platinum, sodium.

11 TOXICOLOGICAL INFORMATION

Causes skin irritation.

Causes eye irritation.

Harmful if ingested.

May be harmful if absorbed through the skin.

12 ECOLOGICAL INFORMATION

Product should not be allowed to enter drains or water courses.

Do not dispose on ground. Remove to suitable landfill.

13 DISPOSAL CONSIDERATIONS

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This product is flammable and must be disposed of accordingly.

Special landfill or incineration may be used. Do not dispose into waterways or

sewers or onto the ground.

14 TRANSPORT INFORMATION

United Nations No: UN

1170

Packaging group: II

Shipping name: Ethanol

Highly Flammable

15 REGULATORY INFORMATION

Classification and labeling The product is classified in accordance with the

Chemicals(Hazard Information and Packaging for

Supply) Regulations (CHIP 3)

HIGHLY

FLAMMABLE HARMFUL

Risk: R11 Highly Flammable

Safety: S(1/2) Keep locked up and out of reach of children

S16 Keep away from sources of ignition - No Smoking

S36/37 Wear suitable protective clothing inc. gloves

S45 In case of accident or if you feel unwell, Seek medical

advice immediately (Show label where possible)

16 OTHER INFORMATION

Restrain Fuel should always be stored in conditions appropriate to a highly

flammable liquid.

Up to 50 liters of Restrain fuel may be kept in a working area in a suitable bin

or cupboard that is of fire resisting structure and is designed to retain spills

and marked Highly

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flammable

Quantities of more than 50 liters should be kept in secure areas designated for

flammable storage and separate from normal working areas and with good ventilation

Further details can be found in the following Health & Safety Executive publications:

available from HMSO

L135 Storage of Dangerous substances; Approved code of practice

Dangerous Substances and Explosive Atmospheres Regulations 2002

HSG51 The storage of flammable liquids in Containers

Empty Restrain fuel containers should be washed out with water and disposed

of or recycled as for standard plastic containers.

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Appendix 2 Fuel COSSH assessment

COSSH ASSESMENT

Activity

Handling Restrain Fuel containers & filling the Restrain Generator

Reason For Activity

To maintain a stable atmosphere of ethylene in a store

Status Of the Person doing the activity

Store Manager

Product

Restrain Fuel ( Ethanol)

Hazard Identification

Harmful. Highly Flammable

Risk Assessment

Causes eye irritation.

Ingestion can cause nausea, vomiting and inebriation.

Contact with the skin is unlikely to cause appreciable irritation even on repeated contact.

Unlikely to be absorbed in harmful amounts through contact with the skin.

Instructions

Always use a funnel to fill the Restrain Generator

Discharge the Restrain fuel from the can avoiding "glugging" which can cause splashes.

Avoid close eye contact. Wear glasses or goggles if required.

Do not smoke.

Switch off your mobile phone

Return part full cans to the flammable liquid storage cabinet.

First Aid

Eyes -irrigate thoroughly with water.

Lungs-remove from exposure, rest & keep warm.

Skin-wash with water & remove contaminated clothing.

Mouth-wash out & give plenty of water to drink.

Spillage

All sources of heat or ignition must be removed.

Use sand or vermiculite to absorb the liquid.

Place used absorbent materials in closed containers for disposal.

Disposal of containers

Containers should be pierced and placed in appropriate waste disposal.

Assessor

Signature Date