ICA732 Digital Restrain Sensor Accumulator Operators Handbook
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1 ICA732 Digital Restrain Sensor Accumulator Operators Handbook Edition Sept 2013 I The Restrain Company Ltd Unit 7 The Forum, Minerva Business Park Lynch Wood, Peterborough PE2 6FT UNITED KINGDOM ORIGINAL INSTRUCTIONS 1
2 1. Purpose: The ICA 732 Digital Restrain sensor is for use with the ICA740/760 Restrain generator to control and maintain a stable ethylene concentration within a Potato store. The sensor includes a highly sensitive electrochemical detector and digital electronics to provide the needed intelligence to control the output and operation of the Restrain machine in order to maintain the required ethylene regime 2. Handling: The measuring sensor is extremely sensitive and easily damaged by exposure to high levels of hydrocarbon gas. The sensors are supplied in sealed plastic containers or sealed gas proof bags and should remain packed until required for operation. WARNING The Restrain Sensor for measuring the ethylene levels in store must be kept away from Restrain Fuel (ethanol) & chemical cleaning materials at all times. (Even when switched off or in transport). Fumes from the fuel will permanently damage the sensor. For protection against contamination the sensors are transported and stored in a sealed plastic container or a gas sealed bag. They should be removed from the packing and placed in position only when machine is about to be started up. The sensor can also be affected by forklift exhaust fumes. Incorrect readings will be obtained when these are operating in the vicinity, but are not of high enough concentrations under normal operating conditions to cause permanent damage to the Sensor 3. Position: The sensor and machine is supplied with a 30m connection cable. The Sensor should be located at a position of good air circulation towards the centre of the potato store and at least 15m away from the machine. Protect the machine and cable from potential damage from fork trucks and store loading/unloading activity 2
3 4. Connection: Connect the sensor to the machine together using the CAT5 connection cable provided. Alternative cable lengths can be used with a maximum of 50m and a minimum of 10m Connection to Restrain Machine Built in Temperature sensor Socket for CO2 detector The optional CO2 detector can be connected to the sensor through the socket provided. Details for this are in the CO2 sensor instruction manual. In the 732 system the ambient room temperature is monitored from the black aluminium heat collector shown above. There is no separate probe. 3
4 % Restrain 5. Operational Protocol When using the Restrain System in Ware Potatoes* the Slow Start programme must be used. This should be selected when ethylene is being introduced to a stock of ware potatoes for the first time. The RESTRAIN Store Management protocol shown in appendix 1 in MUST always be followed. When set to the Slow Start programme the Restrain Generator automatically and gradually increases the level of ethylene in the store from a starting level of 0.2% Restrain (0.1 ppm ethylene) to 20% Restrain (10 ppm ethylene) over a 20 day period. This is to ensure the most efficient operation of the machine and to avoid high respiration levels of the potatoes which could be detrimental. Care should be taken before commencing the Slow Start to ensure that the store atmosphere is clear of internal combustion engine fumes. Accumulator Slow Start Programme etc Days 4
5 6. Operation: The Day number in the slow start programme is shown on the blue digital display. {From time to time the blue display will flicker...this is normal and occurs when the memory is being updated} The default setting for a new sensor is : To reset the sensor to the default setting push the RESET switch for about 10 seconds. To operate the push buttons use a small screwdriver or similar. Insert into hole and push gently To set the day required push the ADVANCE switch. Hold for 5 seconds to start, the day will then advance on every push and release of the button. 5
6 The day settings start at -5 and increase to 0 and then to 1 and so on. The machine will start the slow start sequence on day 1 The negative days allow setting up to 5 days before the actual start is required. The day count is retained when power is removed but the count does not advance without power. The day change is counted as 24Hrs from the time of starting. It does not change at any set time of day. The slow start lasts for 19 days, after that the days stop counting, the display reads 2- and the control level remains at the maximum 30% Restrain. If for any reason the day has to be changed press the RESET as described above and set again as required. 7. Lifetime: The Restrain detector and supporting battery has a limited life of typically 18 months. The label in the window indicated the sensor expiry date. The sensor section is replaceable and is illustrated here. See separate instructions for replacement. The sensor stops operating when the expiry date is exceeded 8. Maximum machine output rate: In normal operation the ethylene output from the generator is regulated from the sensor and its rate will depend on the setpoint and the measured value in the room. If the room is small and the control is overshooting the maximum output from the machine can be reduced. A switch within the ICA732 sensor is used to limit the ethylene output of the generator. This switch has 16 positions and reduces the maximum output in 16 equal steps as below> 6
7 Position 0 is full output Position 8 is half output Position C is 1/4 Output Position E is 1/8 Output Position F is 1/16 Output The output from the sensor to the machine is digital and numbered 1 to 64 with 1 being OFF and 64 being the machines maximum rate. This number is displayed on the machine; see the machine instructions about how to view this. 9. Green indicator light. The green indicator light flashes at about 3 times/second when in slow start operation The green indicator light flashes at about 1 per second when slow start is finished and in normal operation. The green indicator light is off when the expiry date has been exceeded The green indicator light flashes at about 10 times/second when fitted with an uncalibrated sensor card. 7
8 Appendix 1 Restrain System Prepack Ware Potato Storage Protocol October 2007 onwards (issue date ) Minimising the respiration rate increase in the stored crop during the introduction of ethylene is important. Following the simple steps below will enable you to use Restrain system successfully. The RESTRAIN machine and sensor should have been serviced and calibrated by an authorised engineer before the storage season is started. 1) The potato crop must be of good quality and settled in store and reached the holding temperature. 2) Only the pre-programmed Slow Start Up Restrain program should be used on prepack potatoes. 3) Restrain can only be introduced when the crop shows signs the first signs of eye movement. 4) When ethylene is introduced air must be circulated continuously within the store for the first 3 weeks to avoid the localised build up of carbon dioxide. (Elevated carbon dioxide above 0.5% increases respiration rates). 5) Flush the store daily with fresh air if carbon dioxide levels are likely to exceed 0.5%. If you are unsure please contact Restrain Company and we will check your store for you. 6) For Restrain treatments before 1 st November please contact Restrain Company so that respiration rates and store CO2 levels can be checked. 8
9 7) After 1 st November all varieties can be treated without contacting Restrain Company with the exception of Maris Piper, King Edward, and Marfona. 8) For Restrain treatments before 1 st January of Maris Piper, King Edward, and Marfona please contact Restrain Company so that respiration rates and store CO2 levels can be checked. 9) All varieties can be treated after January 1 st without contacting Restrain Company. 10) Restrain may be used later in the storage season following CIPC to avoid the need for a second application and high CIPC residues. Use of Ambient Air To minimise fuel usage during ambient air use there are two options:- An additional controller which turns off the Restrain System whilst out side air is being used can be fitted. The Restrain Generator can be set on the existing settings to limit the fuel usage and not operate at maximum fuel rates. Please contact Restrain Company Limited if you require either option. 1.1 Store Unloading The Restrain Generator should be left in operation until all of the potatoes have been removed from store & marketed. An interval of 3 days between removal from store and consumption should be observed. 9
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