MODEL 9002 RIPENING SYSTEM USER MANUAL VERSION 2.00
Contents
1. not welded together by carbon If left too long it is difficult to remove the old catalyst and will require an exchange reactor Once the catalyst starts getting heavily carbonated it should be emptied by turning the machine upside down and shaking out the old catalyst It may be necessary to loosen the catalyst with a long thin screwdriver or skewer Once all the catalyst is removed the reactor can be refilled with a new catalyst pack taking care not to overtighten the exhaust nozzle when replacing When refilling some of the catalyst consist of triangular ceramic chips that should be put in first followed by the tubular active catalyst Due to the low cost of the catalyst it is better to change it sooner rather than later This will be done automatically if your machine is covered by a service contract or sent in for any service or repairs NB IF YOU LEAVE THE CATALYST TOO LONG IT MAY BE IMPOSSIBLE TO REMOVE THE OLD CATALYST IN WHICH CASE A COMPLETELY NEW REACTOR WILL HAVE TO BE PURCHASED WHICH IS THE MOST EXPEN SIVE COMPONENT IN THE MACHINE GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM OPERATION SERVICING FAULT FINDING Before returning a machine for repair a few simple checks should be carried out which could save you the transport costs amp downtime involved in sending a machine in to your service centre Condition No lights lit First check the electrical supply to y2. FLUID TANK EMPTY yellow Lamp will turn on to show that the ripening initiation process is completed Note It is important that the machine is level otherwise the fluid level sensor will not sense the low level condition properly amp not switch off WARNING INDICATORS TEMP TOO HI red light After start up the temperature will sometimes initially overshoot the correct set point causing the TEMP TOO HI red light to turn on This is no cause for alarm and should go out after a few minutes amp will not come on again This can also occur in the event of a power failure when power is restored This provides backup protection to avoid incorrect gas generation which could cause degraded ripening This also provides back up low fluid protection if the machine is not level VOLTS TOO HIGH red light If this light comes on it is an indication that the mains power supply voltage is too high above 260 Volts Normally the nominal voltage depending on country is from 220 to 250 Volts Normal variations in supply voltage should be within 6 UK to 10 S Africa It is unlikely that any country will have a supply that intentionally exceeds the 10 limit although under fault conditions or very heavily loaded distribution systems the voltage can exceed these limits late at night when the gas generator will still be working but most industrial amp domestic load is switched off In some developing countries these limits can al
3. as recommended by manufacturer 5 2 4 Replace damaged or worn door gaskets as necessary 5 2 5 Check rooms for gas tightness at least once a year GS90USR2 Page 15 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM RIPENING ROOM MAINTENANCE ELECTRICAL Check that your electrical panel has protection against Low voltage high voltage phase failure phase reversal and a three minute timer to prevent damage due to operation of the power company s auto reclosers Any of these faults will damage your compressors and air circulation fans If not we recommend that you ask your electrician to fit suitable equipment The VENTECH THREE PHASE LOAD PROTECTOR combines all these functions in unit and one unit can protect a multiple compressor installation If you use a standby generator if not already automatic have it converted for automatic starting and stopping AVENTECH AMF GENERATOR CONTROLLER can be retro fitted to virtually any electrically started generator to provide this facility oOo WEBSITES For further information on Ripeing amp other Post Harvest Technology matters we can recommend the following websites whose URLs are given VENTECHAGRIONICS http www ventechagrionics com Our website will contain downloadable copy of this manual in acrobat pdf format news amp other product information UNIVERSITY OF CALIFORNIA DAVIS The leading source of info on Post Harvest Technolog
4. moved onto the next room However for high volume ripening rooms there are available certain add on options as follows Gas Pipe Adaptor This option also permits mounting the generator outside the ripening room The GS90USR2 Page 3 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM UNPACKING amp INSTALLATION CHECKS exhaust nozzle of the generator can be replaced with a 1 8 NPT tube connector obtainable from any hydraulics supplier that allows connection to a gas pipe The gas pipe in turn can be connected to a gas manifold feeding individual rooms with the gas supply to each room controlled by a butterfly or ball valve This option is particularly useful for converting an existing bottled gas fed ripening room to catalytic generator operation External Tank Option This option can be used in conjunction with the previously described options to enable the gassing period to be extended by means of an external tank mounted outside the ripening room which increases the capacity of the generator thus extending the gassing time This external tank is connected to a 1 8 NPT bulkead connector on the side of the machine which is supplied as part of the external tank option kit and connected inside the machine directly to the solenoid valve replacing the tank The external tank can be manufactured locally to VENTECH specifications or supplied by VENTECH The tank capacity can be sized to suit local He
5. 7 167 167 156 144 14 4 167 16 7 156 156 156 144 144 13 3 156 144 144 144 144 144 13 3 13 3 13 3 133 133 13 3 13 3 13 3 128 128 128 128 9 128 128 128 13 3 10 128 128 128 12 8 12 8 12 8 STORE 12 8 for delayed shipment VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM RIPENING GUIDES AVOCADOES Gas for 12 hours at 23 Deg C then ventilate Maintain temperature till ripe 2 3 days total Minimum safe storage temperature 4 5 to 13 Deg CITRUS Gas for 12 hours at 27 Deg then ventilate Maintain temperature till ripe 3 4 days total Minimum safe storage temperature 3 Deg MANGOES Wash in hot water at 53 to 55 Deg C for 5 mins then pack into lug boxes amp stack in ripening room Gas for 12 hours at 30 to 32 Deg C then ventilate Maintain temperature till ripe 2 days total Reducing temperature to 24 to 25 Deg C will extend ripening time to 2 1 2 to 3 days NB Mangoes can also be mixed with bananas which are ripened at 15 to 18 Deg C Gas for 12 hours at 27 Deg then ventilate Maintain temperature till ripe 3 4 days total Minimum safe storage temperature 10 to 13 Deg OTHER FRUITS Many oher fruits can be ripened with the VENTECH RIPENING SYSTEM Please contact us or your distributor agent for details TOBACCO Tobacco can be succesfully cured with a 15 reduction in curing time Please contact us or your distributor agent for a copy of our to
6. R BANANA RIPENING Day Ripening Schedule no of days 6 Humidity should be maintained at 80 to 95 RH Temperatures are pulp temperatures not air temperatures Ventilate ripening room for 10 20 minutes every 24 hours The VENTECH RIPENING SYSTEM will produce ethylene gas continuously for 6 8 hours Provide the room is reasonably gas tight the room can be kept closed for the remainder of the 24 hour period then refilled whilst the doors are opened for ventilation Maintain gassing until colour breaks Usually gassing only required for first day for rooms up to 600 box capacity 100 150 ppm of ethylene is required for initiating ripening Excess will not cause any harm The VENTECH GAS GENERATOR will produce in excess of the this amount for ripening rooms up to 600 box capacity The generator will switch itself off automatically when the alcohol is finished No harm will be done leaving in the room after gassing but it should be removed and stored in an office or dry store room once ripening is finished Ensure boxes are stacked on pallets with 500 mm space between adjacent stacks and walls to ensure good air circulation Page 12 GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM RECOMMENDED GUIDE FOR TOMATO RIPENING Day Ripening Schedule no of days 6 7 8 9 10 11 12 21 1 211 211 211 211 211 21 1 200 _ 200 183 183 183 16 7 156 156 15 6 183 183 16
7. VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM MODEL 9002 RIPENING SYSTEM USER MANUAL E VERSION 2 00 JULY 2002 GS90USR2 Page 1 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM INDEX UNPACKING amp INSTALLATION CHECKS INDEX Pages Unpacking amp Installation checks 2 3 4 Operation 5 6 7 Servicing 8 9 amp 10 Ripening Guides 11 12 13 14 Ripening Room maintenance 15 16 Instrumentation 17 UNPACKING amp INSTALLATION CHECKS Remove machine from packaging amp save packaging for re use when returning machine for servicing or warranty repairs Unscrew the tank lid amp remove the mains lead which is packed inside Prior to connecting to electrical supply it is recommended that the power outlet to be used is checked for correct polarity amp good earthing grounding There should not be more than approx 50 milliVolts AC between the Neutral amp Earth Ground pins on the power outlet The machine can operate safely with reversed live amp neutral supply using a non polarised socket outlet as is used in continental Europe The machine has internal fuses in the LINE amp NEUTRAL which are not user accessible without dismantling If connecting by means of a three phase plug ensure that the mains lead is connected with the correct polarity to Live amp Neutral and not acros
8. adation of system components occur resulting in expensive long term repair costs Place generator in ripening room amp plug in to power outlet The control panel status lights will light as follows REACTOR HEATING Green SYSTEM NORMAL Green CONTROL ON Green TEMP LO Yellow After about 10 minutes the Yellow LO TEMP light will go out amp the SOV lamp will start to flash briefly at approx 9 second intervals accompanied by a click This is the solenoid valve opening allowing ripening fluid to be admitted to the reactor to be converted to ethylene Ethylene gas will be emitted from the nozzle on the top of the machine CAUTION THE EXHAUST NOZZLE OPERATES OVER 300 DO NOT TOUCH WHEN OPERATING OR FOR HALF AN HOUR AFTER SWITCHING OFF After reaching operating temperature the HEAT amp CONTROL lights will flash on amp off as the system enters pulse width modulation mode which gives proportional control of the element temeperature This gives very accurate control of the catalytic conversion temperature and by preventing temperature cycling of the element gives longer VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM element life than on off control After approx 6 8 hours operation the ripening fluid will have been used up amp the tank will be empty At this point the low fluid sensor will detect the out of fluid condition and switch off power to the reactor amp the solenoid valve The
9. alth amp Safety codes which is usually 20 Litres However this amp other tanks can be in turn refilled automatically from a 210L drum outside the building Option Panel There is a small panel in the side of the electronics module which can be removed amp replaced with additional interface electronics for connection to an automatic remote supervisory system using a programmable logic controller PLC or computer in conjunction with external motorised damper valves amp ethylene gas sensors Variable Gas Rate Control This option plate can also be removed amp replaced with a variable rate control should this be so desired GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM OPERATION OPERATION Unscrew the lid of the tank amp fill with 1 litre 051 Quart of VENTECH ripening fluid or an approved equivalent The tank holds 1 5 Litres of fluid but has a dead volume of 0 25 L when the tank is empty The tank can be filled up to the necj initially but otherwise 1 litre is sufficient for one ripening session WARNING The ripening fluid is highly inflammable amp of low flashpoint Disconnect from electrical supply by unplugging before filling Keep away from naked flame when filling amp preferably fill in an open space or well ventilated room The use of solvents not approved by VENTECH is not recommended since although apparently normal ripening will be achieved accelerated degr
10. anas according to the following schedule then hold at 14 5 Deg C for delayed shipment Ensure that bananas are not chilled as this can cause damage To be able to provide your customers with a steady supply of good quality ripe bananas they must be harvested when green Mature green bananas will ripen after they are picked just as they would on the plant A low concentration of ethylene gas is mixed with the air in a ripening room and the temperature and relative humidity are controlled The banana ripens naturally and nothing is added to change the natural appearance or taste of the fruit The banana itself produces ethylene when ripening and adding external ethylene just triggers the natural ripening process No ecological hazard is produced and ethylene gas is ozone friendly No CFCs are produced as by products in the VENTECH RIPENING SYSTEM or any other environment hostile by products TRANSPORTATION AND HANDLING To prevent chill damage and loss of flavor the pulp temperature of the banana should never be below 14 4 degrees C while in transit Bananas should always be handled with care They are quite tough but can be easily damaged Do not let bananas stay in cold or hot storage areas during truck to truck truck to rail transfers during transit The ideal temperature range is 14 18 degrees GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM RIPENING GUIDES RECOMMENDED GUIDE FO
11. anufacturers who do not offer such comprehensive protection Note that it is extremely unlikely that this will occur since a lightning strike or surge greater than the capacity of the ultra fast surge diodes will normally blow one or other VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM OPERATION the mains fuses INDICATOR LAMPS COLOUR CODES Green Normal operation modes Yellow Temporary operating modes such as low fluid or low temp on startup HEBVICING Abnormal operating modes Catalyst Changing The catalyst used in the machine will need changing after after between 6 amp 12 months use Due to the restrictions imposed by Customs amp Excise departments the Ventech Ripening Fluid contains de naturants which will eventually poison the catalyst causing reduced gas generation We also recommend that if you have problems ripening that you check the gas levels with witha gas sampler such as the GASTEC details of which are at the end of the manual This is supplied by us amp it is possible that a group of ripeners in one area share the cost of one kit since it is only used infrequently We recommend that the user checks the catalyst once a month after the first six months operation from new or after a catalyst change and examine the catalyst by unscrewing the exhaust nozzle when cold and viewing the catalyst which consists of small white tubes filling the reactor These should be loose amp
12. bacco curing guide GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM RIPENING ROOM MAINTENANCE RIPENING ROOM MAINTENANCE A good preventative maintenance program is the best way to avoid ripening room problems We would like to recommend the following TEMPERATURE CONTROLLERS AND PROGRAMMERS Regular calibration checks should be carried to avoid incorrect ripening room temperatures Check capillary tubing to be sure it is free of kinks Capillary tube amp bulb temperature controllers should be replaced if possible with an electronic temperature controller preferably with a digital display reading to 0 1 Deg Thermocouple type controllers should be avoided since the accuracy is not so good at low temperatures Platinum resistance Pt100 type controllers are best The capilliary type controller has too high a differential Difference between switching off and switching on to give accurate temperature control and the capilliary tube is easily damaged and cannot be replaced If damaged the complete instrument has to be replaced An independent high low temperature alarm amp chart recorder is recommended especially if you are in an area that has a high incidence of power failures 52 AIR HANDLING amp LEAKS 5 2 1 Evaporator amp condensor coils should cleaned at least every 6 months 5 2 2 Check drain lines regularly 5 2 3 Check compressors fan motors belts etc and service
13. can be caused by several reasons Machine not level This results in the ripening fluid not being able to flow into the reactor when nearly empty Since the cooling effect of the ripening fluid is no longer applied to the base of the reactor the temperature will tend to rise with the risk of damage to the reactor element terminals This protection by removing power to the element maintains the temperature within safe limits amp therefore provides protection should the machine not level amp also provides back up low alcohol protection amp back up over temperature protection in case of failure of the element control circuit amp switching device Element failure The element as most heating elements has a finite working life and will eventually require replacement When it eventually fails it can possibly overheat by passing the control system Normally this will be picked up by the TEMP TOO HIGH protection but should this fail for any reason the TANK TEMP TOO HI protection will provide backup protection and prevent any risk of fire or damage to the metalwork of the machine Total control failure In the event of a direct lightning strike of magnitude too great for the lightning protection the HI TEMP protection may fail and the TANK TEMP TOO HI protection provides back up protection to prevent dangerous high temperatures occuring which could cause a fire This has happened more than one occasion with machines made by other m
14. hough it can happen However if the element is blown as a result of a lightning strike it will blow both fuses PLEASE DO NOT REPLACE FUSES BY ALARGER TYPE IF THEY BLOW ONLY REPLACE A FUSE ONCE THEN IF IT BLOWS AGAIN RETURN MACHINE FOR SERVICE IF THE INLET FUSE BLOWS AGAIN AFTER SEVERAL HOURS OPERA TION THIS COULD BE CAUSED BY REPEATED MAINS SURGES ESPECIALLY IF IT IS DURING THUNDERSTORMS FAILURE TO OBSERVE THIS COULD RESULT IN ADDITIONAL DAMAGE If after carrying out the above fuse checks the machine is still not heating indicated by the LOW TEMP light staying lit the you need to return the machine to have the reactor element replaced Condition lights lit but incorrect operation First check through the chapter on operation for a description of the status lights operation If this does not resolve the problem generally this is due to a fault on the control board caused by surge damage If you have a spare card try replacing it otherwise return the whole machine for service Caution the jumper at the bottom of the card must be placed in the DIS position right hand side unless you adjust the R7 control which requires the use of a digital multimeter IMPORTANT ALLOW MACHINE TO COOL DOWN FOR TWO HOURS BEFORE PUTTING INTO THE POLYSTYRENE PACKAGING TO RETURN FOR SERVICE GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM RIPENING GUIDES BANANAS For best taste ripen ban
15. our machine and if you have testmeter check that you have mains supply across the two outside pins on the connector that plugs into the socket f there is supply then disconnect the supply cord amp check the mains fuses There are two mains fuses in the supply to the machine plus the mains plug if using a 13A UK square pin plug The 13A plug can be fused 4 1 3A HRC fuse The supply fuses in the machine are 5X20 Amp 3 14A or 4 0A Ultra Fast fuses If you use the normal fast blow glass fuses you will now have the same amount of surge protection so replace these by the correct type as soon as possible Check the mains cord first but swopping it with a computer or electric kettle cord These fuses are in a small drawer in the side of the power inlet connector They are accessed by first removing the mains cable then pulling the drawer open using a finger nail small knife small screwdriver If either fuses is blown it should be replaced If nothing is found wrong amp you have spare electronic boards proceed as follows Removal of electronic boards Remove the four M8 X 8 countersink screws retaining the cover of the electronics module Remove the two grey ribbon cables by unplugging Unscrew the 4 X M3X6 screws retaining the top PCB This is the control board the one with 9 lights Remove the two green terminal strips in the bottom Power Board by pulling down to unplug There is no need to undo the terminal screws Now
16. s two phases Also ensure that the earth connection is properly connected GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM UNPACKING amp INSTALLATION CHECKS Mains Lead Colour Code Live Line Brown Neutral Blue Earth Ground Yellow Green Power Requirements The maximum supply voltage is 280 Volts AC 50 60 Hz Above 260 Volts operation is automatically interrupted to protect the components from damage with automatic resetting when supply returns to safe limits Nominal working voltage is 200 to 250 Volts at 1 2 Amps Max power during warm up is 234 watts and average power consumption over a 6 hour ripening cycle is 95 watts External current Protection No external protection is necessary however if a fused plug such as the UK 13A plug is used any fuse from 4 13 A is suitable Having satisfied that the power supply is correctly connected the machine can be put into service We recommend that the machine be placed in the ripening room at a height of 3 ft 1 Metre above floor levels preferably positioned so that maximum air flows across the machine amp with a minimum space all round the machine of 20 500 mm Also ensure the machine is clear of any fork lift trucks or any other mechanical handling equipment that could cause damage Installation Options The VENTECH FRUIT RIPENING SYSTEM is normally used as a portable unit which is plugged into the room to be gassed then
17. so be exceeded For this reason the Ventech gas generator has a built in protection circuit which will automatically switch off once this safe working limit has been exceeded without damage to the components After supply has returned to normal the HI VOLT light will go out amp normal operation will be resumed Note further that the VOLTS TOO HI indication is outside the control of the gas generator It is not a machine fault as such being an external fault resulting from GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM OPERATION incorrect supply voltage 2 5 2 Cont A MACHINE SHOWING THIS INDICATION SHOULD NOT BE RETURNED FOR SERVICE WITHOUT FIRST CHECKING THAT THE SUPPLY VOLTAGE IS IN FACT TOO HIGH BY MEASURING WITH A DIGITAL VOLTMETER PREFERABLY OVER ALONG PERIOD OF TIME PLEASE REMEMBER THAT THIS CONDITION WILL OCCUR INTERMITTENTLY amp IT IS IMPORTANT TO HAVE YOUR MACHINE CONNECTED TO THE SUPPLY WHEN CHECKING FOR EXAMPLE IF YOU ARE USING THE MACHINE AT NIGHT WHEN THE VOLTAGE IS NORMALLY HIGHER amp YOU SEE THIS INDICATION YOU MIGHT THEN CALL AN ELECTRICIAN FIRST THING THE FOLLOWING MORNING WHEN THE VOLTAGE IS NORMALLY LOWEST amp HE WILL THEN REPORT THAT THE VOLTAGE IS NORMAL 2 5 3 TANK TEMP TOO Red light This light will be lit if the temperature at the bottom of the reactor exceeds safe limits and when lit switches off power to the reactor amp solenoid valve This
18. unscrew the 4 nickel plated pillars to release the power board Refiiting is the reverse of removal The two ribbon cables are marked PL1 amp PL2 If after carrying out the above process the machine is still not functioning it will have to be returned to the factory Condition Lights on but no heating or valve operation Remove electronics cover as previous described and with the mains power discon nected check the fuses om the power board You can get at them with the control board in place but it is easier to remove it The left hand fuse is for the reactor fude amp the right hand for the solenoid valve The ratings are 2 0 4 1 0 A respectively They normally fast blow glass 5 X 20 mm fuses VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM SERVICING 3 4 2 Re check the machine and if heating run for a couple of hours on test before putting back into service If the fuse blows again return the machine for service for element replacement Note The supply line fuses generally only blow because of power surges or lightning Generally line surges blow the Line fuse amp Lighytning surges blow the Neutral fuse The power board fuses generally only blow due to element failure of short circuit solenoid coil Solenoid failure is extremely rare as the solenoid is only open for a fratcion of a second at a time It is most unusual for an element failure to blow the inlet fuses as well alt
19. y http postharvest ucdavis edu COMMONWEALTH AGRICULTURAL BUREAU CAB http www cabi org CHIQUITA BANANAS http www chiquita com FOOD amp AGRICULTURAL ORGANSIATION _http www fao org Any other new or ineresting amp relevant websites amp these above will be listed in the LINKS section of our website GS90USR2 VENTECH AGRIONICS USER MANUAL ISSUE 2 00 MODEL 9002 FRUIT RIPENING SYSTEM RIPENING ROOMINSTRUMENTATION Se Contrelied pro vides stcble accurate 2 ee eee aoe __ Hubber inlet to fit the detector tube without ip breaker Juil in tip braaker cupturse braken class tins Light wa ght rigged pimp in seal gasket desigr provides pump vacuum 256 Caunter Allaws the user lo keep track cf multiple strokes pump volume Guide mark _ Strong hande for a 5 secure grip DIGITAL 7 1 BYVENTECH AGRIONICS Call us for details TEL 27 0 15 962 4203 or 4953 FAX 27 0 15 962 4110 email ventech lantic net DIGITAL MAX MIN HUMIDITY METER GS90USR2 Page 17
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