General instructions and User`s Manual for recycler DRESTER
Contents
1. 20 OIEMAINTENANGE diets tisse ie see PR e OUR LORI URDU II DH UP CHER Leste 22 WATER LEVEP aS ns DS 23 CC 23 IN CASE OF DISTILLATE OR CONDENSER 23 IN CASE OF ERROR MESSAGE UR I ROI LR CI CECI HP E Ue Eoo un Reuse cs 24 GENERAL INFORMATION CAUTION Read the General instructions and User s Manual before using the DRESTER 10500CS Do not use the equipment unless you fully understand the General instructions and User s Manual The User s Manual must be available when using the unit PURPOSE OF THE MACHINE The DRESTER 10500CS solvent recycler is an electronically controlled solvent recycler that is intended for recycling of the normal solvents used in a body shop only The DRESTER 10500CS allows for the contaminated solvent which is produced in a body shop to be reused by separating the contaminants from the solvent in a process called distillation By electronically controlling the distillation process the DRESTER 10500CS has got a very high recovery rate The DRESTER 10500CS uses a water cooled condenser with a fixed volume of water No tap water connection is needed These instructions will provide important information about the DRESTER 10500CS recycler and will describe how to use the recycler safely Read the entire2. 12 FLASH POINT eite tne EE Ho de ho BR eb ee eet eto e ebbe tbe 12 AUTO IGNITION TEMPERATURE AND TEMPERATURE 12 HEAT OF VAPORISATION x e ete he Ee bite de teta dede ite Diss 12 DISTILLATION TEMPERATURE s n 2 sp ss Eee nette bibi dete e beetles 13 13 HALOGENATED SOLVENTS 1 I EE RU ED PME t de ee iab dee Pet dee dee ie eti eene 14 IDENTIFICATION OF THE CONTAMINANTS IN THE SOL VENIT A 14 LIQUID CONTAMINANTS bte ete 14 SOLIDCONTAMINANTS ttti RED ed bett de ede ebd ee bete deb eode dele de bn eb tete os 14 DISTILLATION RESIDUES AND WASTE 15 Table 1 Temperature class and auto ignition 16 THE RECYCLING PROCESS eere esee esee tete tata tata tata tata tata tata ta tata ta tata tata tata tata satanas ta tata tata tanta 17 FIRST STEP DISTILLATION iiie hene e bee bie be eio eidem 17 SECOND STEP BAKING entes bbb sehe en eee ete emen 17 CONDENSATION s nnb eb ee bone tetti te bei aus s 17 PROCESS RISKS entente heim tate butt 18 FITTING OF 19 LOADINGAND ISTARTING 1 tete oiii 19 DISCHARGE OF CEEAN SOEVENLT 20 CE 20 INCASE OF POWER FAIEURE
3. CLASS 1 DIVISION 2 8 ft 2 5m DRESTER 10500CS Example for heavy gases and vapours TOP VIEW 8 ft 2 5m DRESTER 10500CS Picture 2 VENTILATION REQUIRED Picture 2 front view shows an example how heavy gases and vapors can collect in pits and other pockets due to the fact that these gases are heavier than air The DRESTER 10500CS if not installed in the open air must be installed in rooms which conform to the effective fire control laws and must have sufficient natural or artificial ventilation to prevent the formation of explosive gas vapor air mixtures The openings of the air channels have to be placed in such a way that the evacuation of emerging vapors does not cause any form of danger Air ventilators and their motor situated in hazardous locations or in outlet air channels must be approved for use in such locations and may therefore not cause sparks of any kind Verify ventilation arrangement with the authorities INSTALLATION ELECTRIC INSTALLATION The DRESTER 10500CS must be connected to a 200 240 V AC 2 phase 50 60 Hz power mains see manufacturers label on the side of the machine Check that the cable and control box have not been damaged during transport DRESTER 10500CS comes equipped with a 16 ft 5 m power cable The length 16 ft 5 m means that the connecting point for the mains can b
4. The heat of vaporisation is the amount of energy needed to transform one kilogram of material from the liquid phase into the gas phase It is expressed in kcal kg Examples of the heat of vaporisation TRICHLOROETHANE 57 kcal kg ACETONE 128 kcal kg ETHANOL 200 kcal kg WATER 540 kcal kg The recycling rate speed is dependent of the heat of vaporisation and the energy input A higher heat of vaporisation means a longer time of distillation 12 DENSITY OF PHASE Depending on relative densities in respect to air vapors of inflammable solvents can be divided into heavy when their relative density is higher than 1 1 heavier than air light when their relative density is lower than 0 9 lighter than air This parameter is important for knowing the extent of the danger area and for the positioning of the ventilation holes see chapter AREA CLASSIFICATION and REQUIRED VENTILATION DISTILLATION TEMPERATURE The boiling point of a liquid is the temperature at which the liquid is transformed into gas under normal atmospheric pressure 1013 hPa A solvent normally has one specific and constant boiling point A mixture of solvents has a temperature range in which it boils The different ingredients boil at different temperatures A polluted solvent normally boils at a higher temperature than a non polluted solvent The boiling point is independent of the heating source The bigger the temperature dif
5. When oil has cooled down to 135 57 C and the condenser is cold if not the display will read Cooling down Water still hot the recycler is ready for use again Green light will come on and the display will read Empty can before start Index yyy The lid of the boiler is safe to open DISCHARGE OF CLEAN SOLVENT Clean solvent can be discharged through the tap handle on the unit s right hand side picture 4 no 2 The clean solvent is always cool and can be discharged at any time even when the unit is operating It is important to avoid electrostatic sparks when discharging solvent Therefore before discharging clean solvent connect the tap handle s ground clamp to the receiving container Then push the tap handle s trigger and clean solvent is discharged through the pipe Note that the collecting container must be emptied before a new batch can be run USING THE STOP BUTTON If the STOP button is pressed during the recycling process the process will be aborted the recycler will go to cool down mode and the display will read Cycle aborted Temp XX IN CASE OF POWER FAILURE Should the mains power go down and come on again during the recycling operation one of the following things will happen Ifthe oil temperature is above 135 57 C and the oil temperature has not dropped more than 5 C during the power failure The recycling process will automatically continue where it was interrupted by
6. down into the bag The ring must slide into the recess of the boiler see reference pictures picture 9 Snap the bag retainer ring into position in the recess of the boiler Make sure the bag is tucked well behind the waste intake manifold see reference pictures picture 8 The bag should be replaced before each cycle LOADING AND STARTING 1 gt 6 Check that the green light on the control panel is on This means that the unit is cool and the of the boiler can be opened Open the lid Fit a new bag as described above Make sure that the solvent to be processed in the DRESTER 10500CS is identified and suited for recycling according to the chapter UNDERSTANDING THE PROCESS OF RECYCLING SOLVENTS in this manual Alternative 1 Pump loading Pump solvent into the DRESTER 10500CS IF NOT ALREADY LOADED This is done by placing the suction tube see reference pictures picture 4 no 4 in the container or gun cleaner to be emptied Press the foot pedal see reference pictures picture 4 no10 As long as the pedal is pressed the transfer pump will pump solvent into the recycler bag NOTE THE MAXIMUM LEVEL 5 US GALLON IS REACHED WHEN THE SOLVENT LEVEL REACHES THE CLAMPING RING FOR THE RECYCLER BAG see reference pictures picture 8 THE CLAMPING RING MUST BE PLACED IN THE BOILER RECESS see reference pictures picture 9 DO NOT OVERFILL Alternative 2 Manual loading Pour the solvent into the boiler Be careful
7. requires to be changed 15 Fuse Protection ASSEMBLY See separate Assembly instructions recycler DRESTER 10500 8 document no 13586 PLACING THE UNIT AREA CLASSIFICATION The DRESTER 10500CS is equipment with the following classification CLASS 1 DIVISION 1 ZONE 1 ref NFPA 70 and may therefore be placed in locations classified as Class 1 Division 1 Zone 1 If the DRESTER 10500CS is installed in locations classified as Class 1 Division 2 Zone 2 or in unclassified locations the area within 8 feet from the unit is to be classified as Class 1 Division 2 Zone 2 see picture 2 Within classified areas of Class 1 Division 1 Zone 1 and Class 1 Division 2 Zone 2 all equipment such as electrical items and ventilation equipment must be approved for the applicable Division Zone Equipment that generates naked flames or sparks e g welding or grinding equipment may not be used in these areas Smoking is not permitted If in any doubt contact the local fire service authorities for advice FIRE EXTINGUISHER A fire extinguisher dry chemical type ABC dry chemical type BC foam carbon dioxide or Halon must always be kept nearby when working with flammable solvents Do not use water DRAIN WATER PROTECTION The unit must be placed in a location where any accidental leakage of solvent is prevented from spreading into the drain water system CLASS 1 DIVISION 1 FRONT VIEW UE 8 ft 2 5m
8. than air and can spread a long way They may also collect in pits or other low areas Do not smoke eat or drink while close to the DRESTER 10500CS A fire extinguisher dry chemical type ABC dry chemical type BC foam carbon dioxide or Halon must always be kept nearby when working with flammable solvents Do not use water Make sure that the unit is properly grounded according to applicable laws and regulations DO NOT OPEN BOILER LID WHEN UNIT IS OPERATING AND THE GREEN LIGHT IS OFF If lid is opened while the unit is operating hot solvent vapors will escape and cause the gasket ring to swell and pop out of the lid DO NOT USE THE FOOT PEDAL FOR AUTOMATIC LOADING WHEN UNIT IS OPERATING AND THE GREEN LIGHT IS OFF DO NOT OVERFILL THE MAXIMUM BOILER CAPACITY IS 5 US GALLONS MAXIMUM LEVEL IS UP TO THE POSITION OF THE RECYCLER BAG CLAMPING RING SEE REFERENCE PICTURE 8 INTEGRATED USER FEATURES 3 2 1 The features described below are described in detail in chapter Operation of unit m p 8 9 Integrated pump for unloading the recycled solvent picture 1 no 1 Discharge handle picture 1 no 2 for emptying the clean recycled solvent The handle can be used while machine is operating Integrated pump for automatic loading of the machine picture 1 no 3 Suction tube picture 1 no 4 for convenient loading of solvent into the machine Stainless steel water condenser pict
9. the power failure If the oil temperature is below 135 57 C or the oil temperature has dropped more than 5 C during the power failure The recycling process will be interrupted yellow light will flash and the display will read Power failure Please restart Press START button and the recycling process will continue or press STOP button and the process will be aborted the recycler will go to cool down mode and the display will read Cycle aborted Temp If the recycler is in cool down mode i e the yellow light is flashing and the display reads Cooling down Temp XX The recycler will continue in the cool down mode 20 RECYCLING MODES The DRESTER 10500CS has got three different programmes that can be used Mode 1 Mode 2 and Mode 3 Mode 1 Mode 2 Mode 3 This program should be used if the solvent has a low percentage of solvents with low boiling points e g acetone Mode 1 uses a slightly increased level of power during the initial heating of the solvents This means that the cycle time is slightly shorter DEFAULT MODE This is the default program of the unit It can be used for the normal solvents and residues found in a body shop see chapter PERMITTED SOLVENTS Mode 2 uses a low level of power over a longer period of time This means that the cycle time is slightly longer but the efficiency rate higher This mode is also suitable for solvents containing a hig
10. 2 400 752 ISOPROPYL GLYCOL 143 289 T2 345 653 METHYL ACETATE 58 136 T2 475 887 METHYL CELLOSOLVE 124 255 T3 285 545 METHYL CELLOSOLVE ACETATE 156 313 T2 377 711 METHYL GLYCOL ACETATE 137 152 279 300 T2 380 716 M E K METHYL ETHYL KETONE 80 176 T2 404 759 M I B K METHYL ISOBUTYL KETONE 117 243 T2 459 858 NAFTA A LIGHT FRACTION 130 165 266 329 T3 245 473 NAFTA B HEAVY FRACTION 150 220 302 428 250 482 126 259 4 220 428 PENTANOL 138 280 T2 327 621 n PROPANOL 98 208 T3 371 700 n PROPYL ALCOHOL 98 208 T3 371 700 TURPENTINE 152 170 306 338 T3 250 482 TOLUENE 111 232 T1 535 995 STYRENE 146 295 T2 490 914 WHITE SPIRIT 150 190 302 374 T3 254 489 XYLENE 140 284 T2 525 977 16 THE RECYCLING PROCESS FIRST STEP DISTILLATION With a distillation it is possible to separate volatile substances solvents and diluents from non volatile resins pigments glues etc or hardly volatile oil ink etc substances When boiling the mixture of solvents including contaminants only the volatile fraction evaporates and is condensed The contaminants remain on the bottom as residue The distillation process in the DRESTER 10500CS is performed at atmospheric pressure The boiling points as mentioned in table 1 are all at a pressure of 760 mmHg normal atmospheric pressure 1 atm SECOND STEP BAKING In this phase the working temperature is higher than the distillation temperature and normally not lower than 180 190
11. 3 US Gallons 20 liters 40 F 380 F 10 Celsius to 193 392 F 200 Celsius 104 F 40 Celsius 3 6 US gallons 13 6 liters Stainless steel Stainless steel Stainless steel Length 28 3 720 mm Operating height to boiler lid 40 6 1030 mm Max height to condenser lid 61 1550 mm Width 18 9 480 mm 231 165 105 kg as shipped with bags wrapping and box 187 Ibs 85 kg out of the box 264 lbs 120 kg topped up with water ready to use 7 hours full batch of lacquer thinner 5 hours cooling down At 68 F 20 C ambient temperature US pat no 6819 251 US pat no 6797 123 26 PICTURES Picture 1 Pneumatic installation Picture 1 Air inlet 14 female thread Picture 2 Filling of water condenser Picture 2 27 Picture 2 Filling of water condenser Picture 4 Integrated user features Picture 3 Picture 4 28 Picture 5 draining Note Make sure oil is cold before emptying Disconnect power before oil change 1 Place a collecting drum of at least 14 litres of volume under oil outlet 2 Remove oil plug Picture 5 29 Picture 6 Refilling oil Note Use a funnel in order to prevent spilling 1 Remove oil pipe cover 2 Refill oil 3 6 US gallons 13 6 litres Picture 6 30 Picture 7 Water change Note Disconnect power before water change Picture 7
12. 5 and drain out all of the oil Note It is highly recommended that once the oil is drained the heating element is removed and properly cleaned before proceeding with step 6 This will increase the lifespan of the heater and improve the function of the unit Contact your supplier for further advice Re Apply Teflon tape to lower oil cap and then refit it Remove the oil pipe cover see reference pictures picture 6 Refill oil no more than 3 6 US gallon 13 6 litres into the oil pipe Use DRESTER DIATHERMIC OIL DRESTER NO 10720 Use a funnel to avoid spilling oil into the machine If refilling oil of a different brand the minimum requirements of the oil are Cracking temperature higher than 320 C 608 F and viscosity close to 31cSt at 40 C 104 F and 5 3 cSt at 100 C 212 F Refit oil pipe cover Reconnect power Press the STOP and START button at the same time for 10 seconds keep STOP button pressed and step forward with the START button On the display you will step by step be able to choose Recycling mode 1 Recycling mode 2 Recycling mode 3 Resetting working hours Release the buttons when the display reading is Resetting working hours By doing this the working hours of the oil is reset and the machine is ready for use again 22 WATER LEVEL Check water level regularly The water level in the condenser must lie 2 3 from the top edge of the condenser If the water is not heate
13. C This is done in order to get the residues as solid as possible In this phase of drying the paint residues the distillate can become lightly coloured The reason is that some of the pigments escape from the residue and collects in the distillate container The light colouring has no major influence on the quality of the distillate especially if the distillate is used as washing liquid If for some reason a perfectly clean distillate is desired it is recommended that the distillate is emptied before the final step of baking in the process Use the tap handle on the side of the machine to empty the distillate see chapter Operation of unit CONDENSATION During the first and second step of distillation and baking the hot vapors are being led through the condenser The water in the condenser will absorb the energy in the vapors and thereby condensate it into a distillate The distillate is collected in the distillate container see picture 3 Condenser p water filled General function description of the DRESTER 10500CS Vapor path way Boiler Heater Distillate path way Picture 3 17 PROCESS RISKS The distillation process is normally done at atmospheric pressure Under normal conditions the vapors have a free path way through the condenser and down into the distillate container If this path way is blocked in any way the lid of the boiler works as a safety valve In case of an overpressure the g
14. G WITCH SUBSTANCES CAN BE RECYCLED AND THE RISKS INVOLVED IN THE RECYCLING PROCESS Ask your supplier for the MSDS Material Safety Data Sheet of each single product When distilling the product products one must take into account the chemical and physical properties paying special attention to the auto ignition temperature DEFINITIONS SOLVENT Liquid that without reacting chemically dissolves other substances it solutes forming a solution DILUENTS Diluents is a mixture of solvents RESIDUES What remains after the recycling heating process is done Normally paint sludge and a very low percentage of solvent MSDS MATERIAL SAFETY DATA SHEET Deliveries of solvents or diluents have to be accompanied by safety data sheets on witch is found name physical and chemical properties classification labelling toxicity legislation explosion limits rules for storage transport and treatment and the security measures that have to be taken when dealing with the substance 11 IDENTIFICATION OF THE SOLVENT DISTILLED When distilling solvents or diluents special attention has to be paid to the physical and chemical properties This chapter explains some of the most important properties FLASH POINT The flash point is the minimum temperature at which above a free liquid surface of a solvent a gas or vapor phase is formed The vapor formed will burn spontaneously f it comes in contact with a flame or a spark It 15 clear th
15. General instructions and User s Manual for recycler DRESTER 10500CS DOCUMENT NO 11587 REV 060125 APPROVED PAGE 1 33 TABLE OF CONTENTS GENERAL INFORMA TION 4 PURPOSE OE THE MACHINE u tie qtti D IR dep NOE IPIS LED RICHIE Qe UESTRE LIP ART 4 ETILXPPROVALP eol etae ipe deron asque Us Ie iet Egs 4 PERMITIEDSOE VENTS 5 4 di etatieao dioe citet de tree arius aN tec Le Ae E Ra EUR UIS 4 INTEGRATED USER FEATURES aoa tate sii Oe RC I EUIS a DES Las AER age 6 INTEGRATED SAFETY FEATURES incusat ttetetiectsies Io reete tas 7 AREA CLASSIFICATION tete eee ee bo ete Ue et bt eed 7 FIRE EXTINGUISHER ives ro ttti tee bo b etie esee fatta 7 DRAIN WATER PROTECTION iiia e b e d e t ee detects 7 VENTILATION REQUIRED i Idi edd ee i bU ete dese 9 ELECTRIC INSTALLATION iioi ie ite tee vb eee eds 9 PNEUMATIC INSTALLATION duties ebd eet es 9 GROUNDING SSO Gaun edes aet e o be bt ted o bit e tee Susupi 9 FILLING OF WATER 10 OPERATING INSTRUCTIONS 10 PERSONNEEB PROTECTION t Sit et od t e te eod be B eec ees 10 UNDERSTANDING THE PROCESS OF RECYCLING SOLVENTS 11 GENERAL m bien uet ee 11 DEFINITIONS Sasa pa hie dpt doe ende 11 IDENTIFICATION OF THE SOLVENT TO BE DISTILLELD
16. Water outlet A Picture 8 Fitting of bag Vapor manifold E Picture 8 Clamping ring Maximum solvent level 3l Picture 9 Clamping ring recess and maximum level n Picture 9 L Clamping ring recess Maximum solvent level Picture 11 In case of distillate or condenser contamination Picture 10 Remove four 32 Picture 12 Cleaning level indicator Picture 11 33
17. asses will escape between boiler and lid see picture 4 If gasses escape between boiler and lid the machine has to be stopped and the cause of the overpressure has to be taken away The condenser can become blocked by for example foam from the distillation process Each product produces foam during boiling To insure a clean distillate and an unblocked condenser the foam level may never reach the level of the vapor manifold The difference between loading capacity and the boiler volume is in most cases big enough not to cause any problem rco NS ly Picture 4 The most important factors for formation of foam are The bigger the difference between boiling point of the solvent and the temperature of the heating oil in the jacket the bigger the formation of foam Physical and chemical properties of the solvent e Pressure at which the distillation is performed Working under vacuum increases the formation of foam The deeper the vacuum the bigger the formation of foam It is strictly prohibited to use the DRESTER 10500CS under vacuum with vacuum devices e Physical and chemical properties of the contaminants In some cases paint residues of the same type but of different colour can have different foaming characteristics Reducing the risk of foaming by Letting the dirty solvent rest f
18. at the lower the flash point the higher the risk when handling the solvent AUTO IGNITION TEMPERATURE AND TEMPERATURE CLASS inflammable solvents have a specific auto ignition temperature The auto ignition temperature is the minimum temperature at which the solvent in contact with air catches fire spontaneously and where the burning process proceeds without input of energy from the outside TO PREVENT AUTO IGNITION THE MAXIMUM SURFACE TEMPERATURE WHEN THE MACHINE IS FUNCTIONING SHOULD NEVER BE HIGHER THAN THE AUTO IGNITION TEMPERATURE OF THE TREATED SOLVENT These temperatures are arranged into six groups or TEMPERATURE CLASSES CLASS MAXIMUM SURFACE TEMPERATURE Tl 450 C T2 300 C SUB DIV T2A 280 C T2B 260 C 2 230 T2D 215 C T3 200 C SUB DIV T3A 180 C T3B 165 C T3C 160 C T4 135 C 15 100 C T6 85 C The DRESTER 10500CS is classified as class T3 equipment see name plate on the side of the machine This means that the unit can be used to distil recycle solvents belonging to T1 T2 and T3 However there are exceptions to this rule Some substances may even if they are classified as T1 T2 or T3 react in a dangerous way when recycled in T3 classified equipment see table 1 for some examples Consult your supplier or a professional chemist if in any doubt Examples of auto ignition temperature temperature class and distillation temperatures are given in Table 1 HEAT OF VAPORISATION
19. ate the machine Two fire extinguishers must always be kept nearby when working with flammable solvents Read chapter SAFETY INFORMATION and take necessary measurements before use 10 UNDERSTANDING THE PROCESS OF RECYCLING SOLVENTS GENERAL It is impossible to design a distillation unit that can treat any type of solvent or waste Every solvent or diluents se chapter DEFINITIONS has got its own unique properties When different solvents are being mixed with contaminants like paint and pigments as in the case in a body shop the properties and behaviour when boiled or heated might cause unwanted effects It is therefore absolutely necessary to know in advance the chemical and physical properties of the product or products that are to be treated Since the distillation of inflammable solvents can lead to fire hazards and can create potentially explosive atmospheres security measures have to be taken against fire and explosions DRESTER 10500CS IS INTENDED TO RECYCLE THE NORMAL SOLVENTS USED IN A BODY SHOP CONTAMINATED WITH SOLID CONTAMINANTS AND NOT LIQUID SEE CHAPTER IDENTIFICATION OF THE CONTAMINANTS IN THE SOLVENT IT MAY NOT BE USED TO DISTIL RECYCLE SOLVENTS CONTAINING NITROCELLULOSE OR ANY OTHER SUBSTANCES THAT CAN UNDERGO DANGEROUS CHEMICAL REACTIONS OR THAT CAN CAUSE FIRE OR EXPLOSIONS WHEN HEATED UP TO 200 C 392 F IT IS EXTREMELY IMPORTANT THAT ANY USER READS AND UNDERSTANDS THE FOLLOWING CHAPTERS EXPLAININ
20. d by running the unit for longer period of time there is a risk that mould will develop In the case of mould developing or if the water smells bad the water must be changed Water change is carried out as follows 1 Disconnect power 2 Place a collecting drum big enough to contain 10 US gallons 40 litres under the water outlet see reference pictures picture 7 on the left side of the unit Alternative Lead the water to a drainage system Remove condenser lid Remove the water plug and drain water Re apply Teflon tape and refit the water plug Refill tap water up to 2 3 from the top edge Refit the condenser lid Reconnect power CHANGING THE CAN LEVEL SETTING The DRESTER 10500CS has a default safety setting for the can level The can level is the electronically measured solvent level in the distillate container The default setting works with most of the solvents found in a body shop If however the default safety setting needs to be changed it is possible to do so Contact your supplier for further advice IN CASE OF DISTILLATE OR CONDENSER CONTAMINATION If the distillate container for some reason should become contaminated with pigments or polluted solvent see chapter THE DISTILLING PROCESS it needs to be cleaned Cleaning is carried out as follows 1 Make sure the distillate container is empty The display will show Ready to start Mode 1 or mode 2 mode 3 If container is not empty em
21. e placed outside the hazardous location generated by the unit as described in chapter AREA CLASSIFICATION Should however the connection to the electrical main lie within any hazardous location the power cable must be connected in a way approved for such location The cable can be used in hazardous locations together with cable fittings such as Appleton s TMCX6550 or Crouse Hinds IXTMCX165 Installation in a hazardous location must be done by a professional electrician in accordance with applicable standards and regulations PNEUMATIC INSTALLATION The unit must be connected to compressed air of 7 12 bar 110 180 psi When in use operating the load or discharge pumps the unit consumes approx 150 litres min 6 cfm of air The air connection 1 4 female thread is on the lower right side of the unit see reference pictures picture 1 To prevent pressure drops the air line and couplings must be adequately dimensioned The regulator on the unit is pre set to 5 bar 80 psi The compressed air supplied to the unit must be clean and dry and free from oil If it is not first led through a water trap and filter it may cause damage to the pneumatic components of the unit and will invalidate any warranty claims GROUNDING Make sure that the unit is properly grounded according to applicable laws and regulations PREPARATIONS FOR USE FILLING OF WATER CONDENSER Before the machine can be operated for the first time the water condens
22. emperature control system has monitored too high oil temperature Correction Allow the recycler to cool down Otherwise Contact your supplier for support Error code 15 H20 temp high Means that the condenser hence the water is too hot Correction Check the water level in the condenser top up with water if the level is low if level is OK allow it to cool down or replace the water if quick cool down is desired Error Level indicator Means abnormal reading of the level indicator Correction Make sure the level indicator is not grounded nor has any metal contact Make sure the level indicator is clean Otherwise replace the level indicator or the cable to the level indicator 25 TECHNICAL DATA MANUFACTURED BY MODEL HAZARDOUS LOCATIONS TEMP CODE ELECTRICAL PROTECTION FUSE PROTECTION VOLTAGE CURRENT POWER POWER CABLE LENGTH CAPACITY OPERATING TEMPERATURE Celsius ANALOG SAFETY CIRCUIT CUT OFF TEMP MAX AMBIENT TEMPERATURE DIATHERMIC OIL VOLUME MATERIAL BOILER MATERIAL CONDENSER MATERIAL DISTILLATE CONTAINER DIMENSIONS WEIGHT RECYCLING TIME PER CYCLE PATENTS HEDSON TECHNOLOGIES AB HAMMARVAGEN 4 S 232 37 Arl v SWEDEN Tel 46 40 53 42 00 Fax 464043 29 01 DRESTER 10500CS Class 1 Division 1 Groups C D T3 Intrinsic protection amp explosion proof 10 A delayed action 200 240 VAC single phase 50 60 Hz max 9 A 1 9 kW 16 feet 5 m 5
23. er must be filled with normal tap water see reference pictures picture 2 The condenser has fixed volume of approximately 10 US gallons 37 litres Fill the condenser with water until the water level is 2 3 from the top Fit the lid see reference pictures picture 3 The water is used to absorb the energy in the vapor of the distilled recycled solvent and thereby shifting the phase of the solvent from vapor to fluid condensation Under normal conditions a recycling process heats up the water in the condenser to a medium temperature of approx 60 C 140 F and thus preventing any build up of bacteria in the water During normal operation the temperature of the water will increase reaching its highest temperature at the top of the condenser The specially designed lid reduces the water loss to a minimum Check the water level once a month especially when the unit is used in warm conditions 25 C 40 C 77 F 104 F OPERATING INSTRUCTIONS Operating instructions should be formulated on the basis of this manual and translated into the language spoken by the employees It should always be available close to the machine To avoid confusion the employees must be informed about the properties of the solvent currently being processed in the machine PERSONNEL PROTECTION Always wear protective solvent resistant gloves when handling solvents Personnel suffering from chronic respiratory problems or allergies to solvents must not oper
24. esence of heavy metals like lead chrome cadmium etc For the official classification of the waste one has to contact an authorised laboratory for analyses 15 Table 1 Shows example of temperature classes This is not a list of solvents approved for recycling in the Drester 10500CS SOLVENT DISTILLATION TEMP AUTOIGNITION TEMPERATURE C CLASS TEMPERATURE F ACETONE 56 133 T1 535 995 AMYL ACETATE 126 155 259 311 T2 375 707 BENZENE 80 176 T1 560 1040 BUTANOL n 118 244 T2 366 691 2 BUTANONE 80 176 T2 404 759 BUTYL ACETATE 128 262 T2 370 698 sec BUTYL ALCOHOL 101 214 T2 390 734 BUTYL CARBITOL 234 453 T3 228 442 BUTYL CELLOSOLVE 173 343 T4 239 462 BUTYL CELLOSOLVE ACETATE 192 378 T3 280 536 BUTYL DIGLYCOL 234 453 T3 228 442 BUTYL GLYCOL 173 343 T3 239 462 CARBINOL 65 149 T2 385 725 CELLOSOLVE 143 289 T4 235 455 CELLOSOLVE ACETATE 156 313 T2 377 711 CYCLOHEXANE 81 178 T3 260 500 CYCLOHEXANOL 162 324 T3 300 572 CYCLOHEXANONE 155 311 T2 419 786 DICHLOROETHANE 84 183 T2 412 774 1 2 DICHLOROPROPANE 56 133 T1 555 1031 DIMETHYLFORMAMIDE DMF 153 307 T2 445 833 ETHYL ACETATE 79 174 T2 427 801 ETHYL BENZENE 136 277 T2 380 716 ETHYL GLYCOL ACETATE 156 313 T2 377 711 sim ETHYLENE CHLORIDE 84 183 T2 412 774 HEXAMETHYLENE 81 178 T3 260 500 n HEXANE 70 158 T3 240 464 ISOBUTYL ACETATE 119 246 T2 420 788 ISOBUTYL ALCOHOL 111 232 T2 430 806 ISOPROPANOL 83 181 T2 400 752 ISOPROPYL ACETATE 89 192 T2 460 860 ISOPROPYL ALCOHOL 83 181 T
25. ference between heating source and boiling point the faster the evaporation process will take place more violent boiling More energy is put into the process hence the faster evaporation During the distillation process it is common practice to take the heating temperature 30 to 40 higher than the boiling point of the solvent Although the rate of evaporation can be sped up by having a bigger temperature difference this can lead to foaming of the polluted solvent inside the boiler If the foam reaches up to the vapor manifold it could lead to fouling of the condenser and of the produced distillate Eventually this can even lead to blocking of the condenser ACIDITY In the DRESTER 10500CS all relevant metal parts that come in contact with solvent and solvent vapors are made of stainless steel AISI 304 The DRESTER 10500CS with the stainless steel construction is suitable for the distillation of neutral and slightly acid solvents Inflammable solvents chetones alcohols glycols esters aromats are neutral when they are newly bought They can become acid for the following reasons 1 Through oxidation due to long and or wrong storage Before doing a distillation especially when the solvents have been stored for a long time the acidity pH should be checked 2 Acidification during the distillation process a With thermo instable solvents the acidification occurs above a certain temperature critical temperature Check with your s
26. h level of substances with low boiling points 50 80 C 122 176 F e g acetone Mode 2 also reduces the risk of foaming Mode 3 can be used when the acetone level or other substances with a low boiling temperature of the solvent is very low The cycle time in this mode is shorter When green light is on the different modes can be set the following way Press the STOP and START button at the same time for 10 seconds keep STOP button pressed and step forward with the START button On the display you will step by step be able to choose Recycling mode 1 Recycling mode 2 Recycling mode 3 Resetting working hours Release the buttons when the display is reading the above chosen mode or feature By doing this the last showed mode or feature is set 21 MAINTENANCE OIL MAINTENANCE The unit will automatically indicate when it requires an oil change the display will read Oil change due Press start By pressing the START button you can continue to use the recycler The pictures referred to in the text below can be fund in reference pictures at the end of this manual Oil change is carried out as follows l 3 8 9 Make sure oil is cold Disconnect power Place a collection pan under the lower oil tap see referenced pictures picture 5 The collecting pan drum must be big enough to take 3 6 US Gallons 13 6 litres of oil Remove the oil plug see referenced pictures picture
27. il is malfunctioning Correction Contact your supplier for support Error code 2 probe faulty Means that the other of the 2 temperature probes for oil is malfunctioning Correction Contact your supplier for support Error code 3 2 probe faulty Means that the temperature probe for the condenser is malfunctioning Correction Contact your supplier for support Error code 4 is not used Error code 5 is not used Error code 6 is not used Error code 7 is not used Error code 8 is not used 24 Error code 9 probe diff Means reading of temperature from the two temperature probes for oil differs too much Correction Contact your supplier for support Error code 10 Check oil level Means that the oil temperature rises too fast Correction Check for oil leaks under and around the If the unit 15 leaking oil contact your supplier for further advice Otherwise Make sure that the oil volume is 3 6 US Gallon 13 6 litres This is done by following step 1 9 in chapter Change Error code 11 Check fuses Means that the oil temperature rises too slowly because of heater power failure Correction Contact your supplier for support Error code 12 is not used Error code 13 Circuits faulty Means faulty computer Correction Contact your supplier for support Error code 14 Oil temp to high Means the Analog t
28. instructions before using the DRESTER 10500CS For safe use it is important that the DRESTER 10500CS and the used solvent are handled properly It is important that you follow the instructions carefully ETL APPROVAL The DRESTER 10500CS has been tested and listed by ETL for use in both USA and Canada ETL s listing no 3078958 It has been tested and approved in accordance with the following standards UL 2208 First Edition August 24 2001 UL 1203 Third Edition April 30 2004 UL913 Sixth Edition August 9 2004 UL 157 Second Edition March 8 1996 CSA 22 2 No 88 1958 CSA 22 2 No 30 M1986 CSA 22 2 No 0 91 CAN CSA 22 2 No 157 92 PERMITTED SOLVENTS On the market there are numerous solvents and these instructions cannot account for them all Only use the DRESTER 10500CS with solvents intended for spray gun cleaning such as lacquer thinner Lacquer thinner is a generic term for solvent mixtures typically containing such ingredients as e g Acetone Toluene Xylene iso Butanol The DRESTER 10500CS can be used with solvents classified as Group IIA according to IEC 60079 20 Never use any solvent if it is not provided with an MSDS Material Safety Data Sheet Read the MSDS carefully and follow all the instructions and procedures provided in the MSDS If unsure or if more information is needed concerning the solvent please contact your solvent supplier SAFETY INFORMATION Hazards may arise from improper
29. nd dangerous reactions can be caused by 1 The presence of peroxides formed in presence of oxygen and in absence of stabilisers during storage of solvents like tetrahydrofuran ethyl ether and chetones can cause unwanted reactions 2 Explosions by heating of nitro substances nitro methane nitro aromats or substances containing nitrate nitric acid esters 3 Explosions due to the presence of nitrocellulose in certain paints SEE CHAPTER IDENTIFICATION OF THE SUBSTANCE TO BE DISTILLED 4 Presence of metal complexes that can be explosive in dry form 5 Strongly oxidising substances nitric acid chromates perchlorates in presence of oxidisable substances 6 Possibility of catalytic reactions in the solvent due to the presence of rust azo substances colour pigments or the possibility for decay of certain substances cancerogenous aromatic amines from azo substances DISTILLATION RESIDUES AND WASTE PROCESSING In general the distillation residues consist of a mixture of solvents and contaminants They are considered as waste and have to be processed according to the laws of the country CHECK CAREFULLY WITH THE APPROPRIATE AUTHORITY TO ENSURE THAT THE WASTE IS HANDLED ACCORDING TO THE APPLICABLE LAWS AND REGULATION YOU MAY NEED INFORMATION FROM THE PAINT MANUFACTURER WHEN DOING SO During the classification one has always got to pay attention to the percentage of organic solvents special attention also has to be paid to the pr
30. not to spill any solvent into the vapor manifold behind the plastic bag or on top of the unit NOTE THE MAXIMUM LEVEL IS REACHED WHEN THE SOLVENT LEVEL REACHES THE CLAMPING RING FOR THE RECYCLER BAG DO NOT OVERFILL also see chapter FOAMING Close the lid and secure 19 7 If the display reads Ready to start Mode 1 or mode 2 mode 3 proceed to step 8 If the display reads Empty can before start Index Index is of interest for the manufacturer only you must unload the collecting container to make space for the new solvent that is to be processed The unloading is done by using the discharge handle see picture 1 no 1 Make sure that the container that is to be loaded is grounded with the clamp from the tap handle Press the trigger of the discharge handle and unload the clean solvent until the container is empty and the pump is pumping air The display will now read Ready to start Mode 1 or mode 2 mode 3 8 Press START button yellow light will come on and the display will read Recycling Temp XX Temp XX indicates the temperature of the diathermic oil 9 Atthe very end of the recycling process the display will read Baking Temp meaning that the process is in its last 20 minutes 10 Once the recycling is complete the unit will automatically shut off the yellow light will begin to flash and the display will read Cooling down Temp XX 11
31. or before distilling it up to 48 hours Load the boiler with less solvent than usual This will reduce the formation of foam Change to mode 1 see chapter OPERATION SOLVENT LOSS Although the DRESTER 10500CS has got an extremely high efficiency rate it is inevitable that some solvent loss occurs The distillation process consists of two phases evaporation followed by condensation In solvent mixtures a fraction of the low boiling substances is lost during use due to natural evaporation During distillation a fraction of the high boiling solvents is lost because of the fact that they remain in the residue They are simply not vaporised due to the fact that they have a boiling point higher than 200 C 392 F In practice the low and high boiling fractions of the solvent mixture will decrease in percentage It is therefore good practice to dilute the distillate regularly with fresh product 18 OPERATION OF UNIT FITTING OF BAGS 1 wr 9 Check that green light on control panel is on This means that unit is cool and the lid of the boiler can be opened Open the lid Remove the bag retainer ring Remove the used bag Should it stick to the bottom press START and let the recycler warm up for 5 minutes Press STOP and gently pull out the bag and clean the boiler Open a new bag and place inside boiler Tuck the bag well down to the bottom of the boiler Squeeze the bag retainer ring and place it
32. pty it completely with the discharge handle reference pictures picture 4 no 2 2 Disconnect power 3 Remove the four screws attaching the foot pedal see reference pictures picture 10 to the bottom plate 4 Take the distillate container out of the machine Leave all hoses and attachments in place 5 Clean the condenser and the hoses by flushing clean solvent into the vapor manifold see reference pictures picture 8 Remove the three clips on the container flange and take off the lid Clean the distillate container Clean the level indicator see reference pictures picture 11 Fit the lid and clips back onto the container 10 Place container back into the machine Make sure no hoses are blocked 11 Fit the pedal back onto the bottom plate with the four screws 9 ID 23 IN CASE OF ERROR MESSAGE The DRESTER 10500CS is monitored for malfunctions of hardware of software as well as of recycling data In case of malfunction the recycling process will be interrupted red light will flash and the following messages can be read on the display Should this happen push START and STOP buttons at the same time The display will then read Turn off power and repair error It is a good idea to turn the power off and on again to check whether error message remains Contact your supplier for further advice and error correction Error code 1 probe faulty Means that one of the 2 temperature probes for o
33. stillation may lead to contamination of the distillate In presence of water one has to pay attention to the distillation behaviour formation of azeotropes Azeotropes is a mixture of liquids that has a constant boiling point because the vapor has the same composition as the liquid mixture The boiling point of an azeotropic mixture may be higher or lower than that of any of its components The components of the solution cannot be separated by simple distillation SOLID CONTAMINANTS The most common solid contaminants are resins pigments paints and polymers The advantage of solid contaminants is that when they are not already classified as toxic and noxiuos they can simply be transported to a controlled waste dump on the condition that the percentage of solvent does not exceed that of the maximum limit posed legally in each country Paint residues can give a light colouring to distillate in the drying phase see chapter The distilling process In most cases however this light colouring does not give any problems when reusing the distillate 14 DANGEROUS REACTIONS The chemical substances that are normally treated in a bodyshop can be heated up to maximum working temperature of the distillation unit 200 C without any problem However one has to pay close attention to the presence of other substances that can undergo dangerous chemical reactions or that can cause fire or explosions Unwanted a
34. upplier about the acidification properties dependant on temperature b Acidification due to changes of the residue this generally occurs during the baking phase of the distillation Distilling recycling acid solvents will invalidate any warranty claims The recycler bags Drester no 10550 used to collect the residues may dissolve when distilling acid solvents 13 HALOGENATED SOLVENTS Halogenated solvents even stabilized can acidify during normal use as washing liquid and also during distillation Check the pH and neutralize the solvent if necessary IDENTIFICATION OF THE CONTAMINANTS IN THE SOLVENT The identification of the contaminants that are in the solvent to be distilled is just as important as the identification of the solvent The chemical substances that are normally treated hydrocarbons chlorinated hydrocarbons esters glycols chetones and alcohols and most of the common contaminants pigments glue ink and oil can be heated up to the maximum working temperature of the distillation unit 200 C without any problem However one has to pay close attention to the presence of other substances that can undergo dangerous chemical reactions or that can cause fire or explosions This chapter gives some examples of reactions that can occur however each case has to be examined individually LIQUID CONTAMINANTS The most common liquid contaminants are oil ink and water The presence of liquid contaminants during di
35. ure 1 no 5 with a fixed volume No tap water connection needed No electric motor with cooling fan in the machine Electronically controlled recycling process with a very high efficiency rate picture 1 no 6 Simple single button operation No setting of time and temperature picture 1 no 7 Large and low situated stainless steel boiler means convenient manual loading of solvent and removal of waste collecting bags picture 1 no 8 Stainless steel distillate container picture 1 no 9 for the collection of recycled solvent 10 Foot valve to operate the loading pump for the suction tube INTEGRATED SAFETY FEATURES 1 Monitoring of the level in the distillate container picture 1 no 9 If not empty the recycler cannot be started thus minimizing the risk of overfilling and accidental leakage 2 Condenser design that gives cool solvent 3 Water as cooling media 4 Condenser temperature monitored 5 Unit operates with very low counter pressure from the condenser 6 Top notch solvent recovery rate 7 Solvent separated from cooling media 8 Self setting recycling data independent of the operator 9 Intrinsically safe electronics 10 Automatic shut off when cycle is complete 11 STOP button for manual shut off at any time 12 Separate Analogue electronic circuit to shut down the recycler if overheating 13 Two temperature probes to monitor oil temperature 14 The unit will automatically indicate when oil
36. use of the DRESTER 10500 5 Hazards may also arise from improper handling or recycling of solvent In order to maintain the high safety standard of the DRESTER 10500CS it is important that these instructions are followed Do not operate the DRESTER 10500CS until you have read and fully understood this entire instructions manual The DRESTER 10500CS should be installed as described in these instructions The DRESTER 10500CS should be used as described in these instructions The DRESTER 10500CS should be maintained as described in these instructions Only original spare parts may be used These instructions must be available and in legible condition in close proximity to the unit These instructions must be translated into the langue spoken by the users Do not modify or in any way alter the DRESTER 10500CS Do not operate the DRESTER 10500CS unless the working area is properly vented Do not operate the unit if the extraction of vapors is insufficient see chapter PLACING THE UNIT Avoid contact with liquid and vapor Refer to the solvents MSDS Material Safety Data Sheet Wear chemical goggles or similar to protect eyes Wear chemical resistant gloves to prevent skin contact Wear chemical resistant clothing to protect against spills or splash Personnel suffering from respiratory problems or allergies to solvents used may not operate the machine Clean up spills immediately Certain solvent vapors are heavier
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