low pressure spray foam proportioner

Transcription

1 OPERATING MANUAL low pressure spray foam proportoner Models: 0380 (00 hose) (50 hose) (00 hose) (00 hose, drum unt) (00 hose, drum unt) 087 Form No J

2 orgnal operatng manual HELIX Warnng! Attenton: Danger of njury by njecton! Arless unts develop extremely hgh sprayng pressures. 3 Never put your fngers, hands or any other parts of the body nto the spray jet! Never pont the spray gun at yourself, other persons or anmals. Never use the spray gun wthout safety guard. Do not treat a sprayng njury as a harmless cut. In case of njury to the skn through coatng materals or solvents, consult a doctor mmedately for quck and expert treatment. Inform the doctor about the coatng materal or solvent used. The operatng nstructons state that the followng ponts must always be observed before startng up:. Faulty unts must not be used.. Ensure that the unt s properly earthed. 3. Check all connectons for leaks. The nstructons regardng regular cleanng and mantenance of the unt must be strctly observed. Before any work s done on the unt or for every break n work the followng rules must be observed:. Release the pressure from spray gun and hose.. Swtch off unt. 3. Unplug the power cord from the unt. Be safety conscous!

3 HELIX Safety regulatons 4. Explanaton of symbols used 4. Isocyanate (ISO) Condtons 6.3 Electrc safety 7 General Descrpton 8. System confguratons 8. Mountng dagram 9.3 Electrcal / generator requrements 9 3 System Descrpton 0 3. System dagram - standard LP unt 0 3. Component descrpton - standard LP unt 3.3 System dagram - drum LP unt 3.4 Component descrpton - drum LP unt 3 4 Control Panel 4 4. Heated hose temperature control 5 4. Component pump pressure control Control Dsplays Control Dsplays Error Messages 8 5 Setup 9 5. Locate the system 9 5. Connect the materal supply hoses Connect the ar supply Connect the heated hoses Connect the electrcal cord Ground the system 5.7 Lubrcate the component pumps CONTENTS 6 Operaton 6. Startup 6. Set heated hose temperature 6.3 Sprayng Pressure relef procedure 3 7 Shuttng down 4 7. Parkng 4 7. Flushng 5 8 Troubleshootng 6 8. Component pumps 6 8. Heated hose controller errors Servcng Replacng the motor assembly Replacng the gears Inlet and outlet valves Packngs Electrcal schematc 34/35 Spare Parts Lsts 36 Spare parts lst for man assembly I 36/37 Spare parts lst for man assembly II 38/39 Spare parts lst for component pump assembly 40/4 Spare parts lst for dsplay assembly 4/43 Spare parts lst for the bracket kt 44/45 Spare parts lst for flud secton (Standard LP unts) 46/47 Spare parts lst for flud secton (Drum LP unts) 48/49 Warranty 50 3

4 SAFETY REGULATIONS HELIX Safety regulatons. Explanaton of symbols used Ths manual contans nformaton that must be read and understood before usng the equpment. When you come to an area that has one of the followng symbols, pay partcular attenton and make certan to heed the safeguard. Attenton Ths symbol ndcates a potental hazard that may cause serous njury or loss of lfe. Important safety nformaton wll follow. Ths symbol ndcates a potental hazard to you or to the equpment. Important nformaton that tells how to prevent damage to the equpment or how to avod causes of mnor njures wll follow. Danger of skn njecton Danger of fre from solvent and spray fumes Danger of exploson from solvent, spray fumes and ncompatble materals HAZARD: Injecton njury Attenton: Danger of njury by njecton! A hgh pressure stream produced by ths equpment can perce the skn and underlyng tssues, leadng to serous njury and possble amputaton. Do not treat a sprayng njury as a harmless cut. In case of njury to the skn through coatng materals or solvents, consult a doctor mmedately for quck and expert treatment. Inform the doctor about the coatng materal or solvent used. PREVENTION: NEVER am the gun at any part of the body. NEVER allow any part of the body to touch the flud stream. DO NOT allow body to touch a leak n the flud hose. NEVER put your hand n front of the gun. Gloves wll not provde protecton aganst an njecton njury. ALWAYS shut the flud pump off and release all pressure before servcng or leavng unattended. All accessores must be rated at or above the maxmum operatng pressure range of the sprayer. Ths ncludes guns, extensons, and hose. Danger of njury from nhalaton of harmful vapors Danger of njury from burns HAZARD: EXPLOSION OR FIRE Solvent and materal fumes can explode or gnte. Severe njury and/or property damage can occur. 4 Danger of njury from electrc shock Notes gve mportant nformaton whch should be gven specal attenton. PREVENTION: Do not use materals wth a flashpont below 38 C (00 F). Flashpont s the temperature at whch a flud can produce enough vapors to gnte. Do not use a materal or solvent contanng halogenated hydrocarbons. Such as chlorne, bleach mldewcde, methylene chlorde and trchloroethane. They are not compatble wth alumnum. Contact the coatng suppler about compatblty of materal wth alumnum. Do not use the unt n work places whch are covered by the exploson protecton regulatons. Provde extensve exhaust and fresh ar ntroducton to keep the ar wthn the spray area free from accumulaton of flammable vapors. Avod all gnton sources such as statc electrcty sparks, electrcal applances, flames, plot lghts, hot objects, and sparks from connectng and dsconnectng power cords or workng lght swtches. Do not smoke n spray area.

5 HELIX SAFETY REGULATIONS Place sprayer suffcent dstance from the spray object n a well ventlated area. Flammable vapors are often heaver than ar. Floor area must be extremely well ventlated. The pump contans arcng parts that emt sparks and can gnte vapors. The equpment and objects n and around the spray area must be properly grounded to prevent statc sparks. Use only conductve or earthed hgh pressure flud hose. Power cord must be connected to a grounded crcut (electrc unts only). Follow materal and solvent manufacturer s warnngs and nstructons. Be famlar wth the coatng materal s SDS sheet and techncal nformaton to ensure safe use. Use lowest possble pressure to flush equpment. When cleanng the unt wth solvents, the solvent should never be sprayed or pumped back nto a contaner wth a small openng (bunghole). An explosve gas/ar mxture can arse. The contaner must be earthed. HAZARD: HAZARDOUS VAPORS Solvents and other materals can be harmful f nhaled or come n contact wth body. Vapors can cause severe nausea, fantng, or posonng. PREVENTION: Wear respratory protecton when sprayng. Read all nstructons suppled wth the mask to be sure t wll provde the necessary protecton. All local regulatons regardng protecton aganst hazardous vapors must be observed. Wear protectve eyewear. Protectve clothng, gloves and possbly skn protecton cream are necessary for the protecton of the skn. Observe the regulatons of the manufacturer concernng coatng materals, solvents and cleanng agents n preparaton, processng and cleanng unts. HAZARD: BURN HAZARD Certan components of the equpment are heated and become hot durng operaton. HAZARD: THERMAL EXPANSION Heated fluds, when n confned areas such as spray hoses, can create a rapd rse n pressure due to thermal expanson. Over-pressurzaton can lead to a rupture and serous njury. PREVENTION: Before each use, check all hoses for cuts, leaks, abrason or bulgng of cover. Check for damage or movement of couplngs. Immedately replace the hose f any of these condtons exst. Never repar a spray hose. Replace t wth another earthed hgh-pressure hose. HAZARD: Hgh Pressure Hose The spray hose can develop leaks from wear, knkng and abuse. A leak can nject materal nto the skn. Inspect the hose before each use. PREVENTION: Hgh-pressure hoses must be checked thoroughly before they are used. Replace any damaged hgh-pressure hose mmedately. Never repar defectve hgh-pressure hoses yourself! Avod sharp bends and folds: the smallest bendng radus s about 0 cm. Do not drve over the hgh-pressure hose. Protect aganst sharp objects and edges. Never pull on the hgh-pressure hose to move the devce. Do not twst the hgh-pressure hose. Use only compatble cleanng solutons. Lay the hgh-pressure hose n such a way as to ensure that t cannot be trpped over. Only use approved orgnal-hgh-pressure hoses n order to ensure functonalty, safety and durablty. PREVENTION: To avod severe burns and njury, do not touch heated flud or equpment. Wat untl the equpment has completely cooled. 5

6 SAFETY REGULATIONS HELIX HAZARD: GENERAL Ths product can cause severe njury or property damage. PREVENTION: Follow all approprate local, state, and natonal codes governng ventlaton, fre preventon, and operaton. Pullng the trgger causes a recol force to the hand that s holdng the spray gun. When cleanng, set the pressure control to the lowest possble pressure. Use only manufacturer authorzed parts. User assumes all rsks and labltes when usng parts that do not meet the mnmum specfcatons and safety devces of the pump manufacturer. ALWAYS follow the materal manufacturer s nstructons for safe handlng of chemcals. Clean up all materal and solvent splls mmedately to prevent slp hazard. Never leave ths equpment unattended. Keep away from chldren or anyone not famlar wth the operaton of arless equpment. Devce (man unt and spray hose) weghs n excess of 36 kg. Three-person lft s requred. The devce and all related lquds must be dsposed of n an envronmentally frendly way.. Isocyanate (ISO) Condtons Important Informaton Regardng Two- Component Materal. Read before usng the equpment. Isocyanate (ISO) Condtons Use only Methyldsocyanates (MDI). Sprayng materals that contan socyanates (ISO) creates msts, vapors and atomzed partculates that are potentally harmful. Be famlar wth the spray materal s SDS n order to understand specfc hazards and necessary precautons that are related to the use of spray materals contanng socyanates. Provde extensve exhaust and fresh ar ntroducton to keep the ar wthn the spray area free from harmful socyanate vapors. If suffcent ventlaton s not avalable, a suppled-ar resprator must be avalable to everyone n the work area. Avod any BARE-SKIN contact wth socyanates. To prevent contact wth socyanates, all persons located wthn the spray area must be wearng the approprate protectve equpment, ncludng chemcally mpermeable gloves, boots, aprons and goggles. Materal Ignton Some materals may become self-gntng f appled too thckly. Read materal manufacturer s warnngs and materal SDS. Keep Spray Components Separate Cross-contamnaton of ndvdual spray materals can result n cured materal n flud lnes whch can cause severe njury and/or damage to the equpment. To prevent cross-contamnaton of the equpment wetted parts, NEVER nterchange Component A (socyanate) parts wth Component B (resn) parts. Mosture Senstvty Isocyanates (ISO) are catalysts used n two-component foam coatngs. ISO wll react wth mosture (such as humdty) to form small, hard abrasve crystals. These crystals wll then contamnate the flud. Eventually a flm wll form on the flud surface and the ISO wll begn to gel, ncreasng n vscosty. Flud contamnated wth partally cured ISO, f used, wll reduce spray performance and the overall lfe of the component wetted parts. 6

7 HELIX SAFETY REGULATIONS The amount of flm formaton and the rate of crystalzaton vares dependng upon the blend of ISO, the humdty and the temperature. PREVENTION: Use ONLY Dow-approved cylnders. NEVER store ISO n an open contaner. Use ONLY the mosture-proof hoses specfcally desgned for ISO that are suppled wth your system. If new hoses need to be ordered, contact Dow Buldng Solutons at BLUE (583). Never flush reclamed solvents through the system. Reclamed solvents can contan mosture. Always keep solvent contaners closed when not beng used to prevent mosture contamnaton. Never use solvent on one sde f t has been contamnated from the other sde. Always lubrcate threaded parts wth ISO pump ol or grease when reassemblng. Changng Materals When changng from one Dow SPF materal to another, there s no need to flush the system. Always clean the flud nlet straners after flushng. Check wth your materal manufacturer for chemcal compatblty. Most materals use ISO wth Component A, but some use ISO wth Component B. Foam Resns wth 45fa Blowng Agent Some blowng agents wll froth at temperatures above 90º F (33ºC) when not under pressure, especally f agtated. To reduce frothng, mnmze preheatng n a crculaton system..3 Electrc Safety Electrc models must be earthed. In the event of an electrcal short crcut, earthng reduces the rsk of electrc shock by provdng an escape wre for the electrc current. Connecton to the mans only through a specal feed pont, e.g. through an error protecton nsallaton wth INF < 30 ma. DANGER Work or repars at the electrcal equpment may only be carred out by a sklled electrcan. No lablty s assumed for ncorrect nstallaton. Swtch the unt off. Before all repar work, unplug the power plug from the outlet. Danger of short-crcuts caused by water ngressng nto the electrcal equpment. Never spray down the unt wth hgh-pressure or hghpressure steam cleaners. Operatng Temperature Ths equpment wll operate correctly n ts ntended ambent, at a mnmum between +0 C and +40 C. Relatve Humdty The equpment wll operate correctly wthn an envronment at 50% RH, +40 C. Hgher RH may be allowed at lower temperatures. Measures shall be taken by the Purchaser to avod the harmful effects of occasonal condensaton. Alttude Ths equpment wll operate correctly up to 00 m above mean sea level. Transportaton and Storage Ths equpment wll wthstand, or has been protected aganst, transportaton and storage temperatures of -5 C to +55 C and for short perods up to +70 C. It has been packaged to prevent damage from the effects of normal humdty, vbraton and shock. 7

8 GENERAL DESCRIPTION HELIX General Descrpton The Helx LP Heated Spray Foam Proportoner s a dual component arless sprayer system that can be lnked n order to spray mult-component fluds.. System Confguratons The Helx LP Heated Spray Foam Proportoner s avalable n the followng confguraton(s) whch s based upon hose length, electrcal phases and the requred power cord (not suppled). Refer to the chart below. Model Voltage (phase) Amps Hose Watts System Watts Heated Hose Mn. Heated Temp Max Heated Temp Max Flow (gal/mn) Mn Spray Pressure Max Spray Pressure Cord Specfcaton AWG (mm) V () (6 m) 3ºF 00ºF. 40 PSI 00 PSI 8 (3.3), wre + ground V () (46 m) 3ºF 00ºF. 40 PSI 00 PSI 8 (3.3), wre + ground V () (30 m) 3ºF 00ºF. 40 PSI 00 PSI 8 (3.3), wre + ground V () (6 m) 3ºF 00ºF. 40 PSI 00 PSI 8 (3.3), wre + ground V () (30 m) 3ºF 00ºF. 40 PSI 00 PSI 8 (3.3), wre + ground The spray gun provded wth ths system or sold ndvdually s not Intertek approved. 8

9 HELIX general DESCRIPTION. mountng dagram The Helx LP System comes wth hangng, L-style brackets for nstallaton. All suppled brackets must be nstalled n a manner that wll safely carry the weght of the unt. Make sure the bracket system s securely mounted (preferably to a wall stud) and wll support a mnmum of 00 lbs. The man unt of the system s very heavy. Mountng wll requre at least two people n order for t to be performed safely.. Install the ncluded, 48 hangng bracket onto a wall at the desred heght. Make sure the bracket s secured to the studs behnd the wall, and that t s level.. Hang the man unt from the bracket usng the clps on the rear of the unt (see nset, fg. ). 3. Secure your L-style brackets drectly underneath the man unt. leavng room for the rubber feet (fg., tem 5). 4. Place a rubber foot (fg., tem 5) on each of the mountng holes of the bracket system. 5. Algn the holes on the bottom of the man unt wth the rubber feet. Carefully set the unt onto the feet. 6. Usng the /-nch 5/6 bolts (), thread the four bolts through the lock washer (), flat washer (3) bracket (4), through the vbraton solators (5), and up nto the welded nuts and tghten securely..3 Electrcal / Generator Requrements Attenton It s recommended that the Helx System be used wth a generator. Ths provdes the flexblty wth not havng to use the publc power grd. When connected to the publc, low-voltage network, t s possble that an approval of the network operator s requred. Check the regulatons n your country and contact your network operator before connectng the unt to a publc electrcty grd. The Helx LP System requres a 08-40V capacty. Make sure the power source s rated to ths specfcaton. When workng at alttudes above 00m, check the generator manufacturer s specfcatons for power loss offset. If powerng the Helx LP system wth a generator, make sure the generator has ample power to run the system. An nadequate generator wll cause RPM fluctuatons n the Component Pump motors durng usage and can cause damage. Follow the steps below to determng f your generator s able to supply suffcent power to the Helx LP system.. Determne the Watt fgures on the Component Pumps. Ths can be found on the specfcaton labels located underneath the pumps near the flud secton.. Add the wattage that s requred by the Component Pumps (that fgure s 6,900 Watts). 3. Perform ths equaton: Watts Component A + Watt Component B + 6,900 x.5 = kva (klovolt / amperes) 4. If your generator s kva ratng s hgher than what was determned n the equaton above, the generator wll be able to power the system. If your generator s kva ratng s lower than what was determned n the equaton above, the generator WILL NOT be able to power the system. A larger generator s requred

10 SYSTEM DESCRIPTION HELIX 3 System Descrpton 3. System Dagram - standard LP unt I C J A F E B G (ISO) H (Resn) 0 D

11 HELIX SYSTEM DESCRIPTION 3. Component Descrpton - standard LP unt Ths graphc does not show the system properly mounted or secured as requred for use. Refer to secton. for recommendatons on mountng the Helx LP System. Mountng the system wll requre at least two people n order to be done safely. Item Descrpton Functon A Component Pump A In a two-component system, Component Pump A typcally pumps the ISO or actvator materal. B Component Pump B In a two-component system, Component Pump B typcally pumps the resn materal. C Control Panel The control panel contans all of the system controls that allow the sprayer to functon properly, as well as beng the man dsplay panel that gves nformaton about the system. D Dual heated hose The dual heated hose delvers spray materal from the two Component Pumps to the spray gun. E Inlet valves A-sde = / JIC fttng B-sde = 3/4 JIC fttng The nlet valves allow materal to be drawn from the materal contaners nto the system. They can be turned off n order to prevent materal from enterng the system and to keep unwanted materal from enterng the system. Shutoff valves should also be located at the materal contaners. F Supply hoses (not ncluded) The two supply hoses delver flud from the supply drums to the Component pumps. G H Materal contaners (not ncluded) G (ISO) = ISO cylnder, / JIC attachment. H (Resn) = Resn cylnder, 3/4 JIC attachment. The materal contaners are pressurzed vessels that once properly nstalled nto the system, wll delver sprayng materal to the component pumps va the supply hoses. Be sure the follow the materal manufacturer s nstructons regardng the safe handlng of the spray materal. I Ntrogen tank (not ncluded) The ntrogen tank provdes the pressure necessary to delver the spray materal from the materal contaners to the component pumps. J Ntrogen supply hoses (not ncluded) The ntrogen supply hoses delver ntrogen from the ntrogen tank to the materal contaners.

12 SYSTEM DESCRIPTION HELIX 3.3 System Dagram - drum LP unt C H A J I B E H J F G ISO I F Resn G D

13 HELIX SYSTEM DESCRIPTION 3.4 Component Descrpton - drum LP unt Ths graphc does not show the system properly mounted or secured as requred for use. Refer to secton. for recommendatons on mountng the Helx LP System. Mountng the system wll requre at least two people n order to be done safely. Item Descrpton Functon A Component Pump A In a two-component system, Component Pump A typcally pumps the ISO or actvator materal. B Component Pump B In a two-component system, Component Pump B typcally pumps the resn materal. C Control Panel The control panel contans all of the system controls that allow the sprayer to functon properly, as well as beng the man dsplay panel that gves nformaton about the system. D Dual heated hose The dual heated hose delvers spray materal from the two Component Pumps to the spray gun. E Inlet valves A-sde = / JIC fttng The nlet valves allow materal to be drawn from the materal contaners nto the system. They can be turned off n order to prevent materal from enterng the system. B-sde = 3/4 JIC fttng F Supply hoses The two supply hoses delver flud from the supply drums to the Component pumps. G Pressure relef hoses These hoses act as the pressure relef mechansm for the LP system. Any excess flud pressure wll cause spray materal to be automatcally released nto the pressure relef hoses and crculate back to the materal contaners. H Transfer pump The two transfer pumps pump materal from the supply contaners, nto the supply hoses and then to the Component Pumps. The transfer pumps are powered by an ar compressor. I Desccant dryer The Desccant dryers remove any mosture that s present n the ar pockets left by the removal of materal from the supply drums. J Transfer pump ar hose The transfer pump ar hose delvers ar from the compressor to the transfer pumps. 3

14 Z Z control panel HELIX 4 Control Panel The control panel contans all of the system controls that allow the sprayer to functon properly, as well as beng the man dsplay panel that gves nformaton about the system. Items - 6 below are duplcated - one for each pump. If they are located on the left sde of the panel, they serve the A sde of the system. If they are located on the rght, they serve the B sde. If t s located n the mddle, t serves the entre system. 7 (A) (B) (A) EZ-ZONE ºF ºC 8.8:8.8 O 8 NE 8.8:8.8 EZ EZ-ZONE ºF ºC 8.8:8.8 O 8 NE 8.8:8.8 EZ (B) 3(A) MIN PSI (BAR) ON O OFF ON O OFF ON O OFF ON O OFF MIN PSI (BAR) 3(B) MAX PSI (BAR) MAX PSI (BAR) 4(A) 5(A) 4(B) 5(B) 6(A) 6(B) Heated hose temperature control Ths panel regulates the spray materal temperature for the applcable heated hose. Control Dsplays The dsplays show varous menu screens that allow the user to customze and montor pump operaton usng the functon keys ( - 4). A A-sde ndependent controller When the component pumps are unlnked, ths controls Component Pump A. B Master controller / B-sde ndependent controller When the component pumps are lnked, the master controller controls both component pumps. When the component pumps are unlnked, ths controls Component Pump B only. 3 Component pump pressure control 4 ON/OFF swtch, Component Pump 4 Adjusts the pump pressure of the applcable Component Pump when unlnked. When the Component pumps are lnked, the Component Pump B pump pressure control knob wll control the pressure of both pumps. Ths swtch turns the applcable Component Pump ON and OFF. 5 ON/OFF swtch, hose heater Ths swtch turns the applcable hose heater ON and OFF. 6 Lubrcaton area These slots n the front cover allow you to properly lubrcate the component pumps as needed. 7 Emergency Shutoff Pushng ths button wll nstantly shut down the system. The relef valves nstalled below each component pump wll then releve any pressure left n the system.

15 HELIX Control panel 4. Heated Hose Temperature Control 4. Component Pump Pressure Control Refer to tem n secton 4. (prevous page). The heated hose temperature control mantans the temperature of the spray materal as t passes through the heated hoses. Refer to tem n secton 4. (prevous page). The followng tems control the pressure of the ndvdual Component Pumps. EZ-ZONE ºF ºC 8.8:8.8 Z O NE 8 8.8: MIN PSI (BAR) MAX PSI (BAR) ON O OFF EZ 5 Dsplay Dsplays the current temperature of the heated hose set Programmng buttons 3 Power ndcator 4 Temperature settng 5 Temperature adjustment These are non-functonng factory programmng buttons. Do not use. The flashng or steady ndcates suffcent power s beng delvered to the system s electrcal relay. Shows the desred temperature of the heated hoses set by the operator These buttons wll ncrease ( p) or decrease ( q ) the temperature of the heated hose set. The temperature wll change n ncrements of ºF. Press and hold the button to ncrease the ncrements by ºF and then 0ºF. Pressure control knob Component Pump ON/OFF swtch Adjusts the pump pressure of the applcable Component Pump when unlnked. When Component pumps are lnked, the (B) pump pressure control knob wll control the pressure of both pumps. Swtches the Component Pump ON and OFF. Pressure Control Knob Settngs MIN PSI (BAR) Refer to secton 8. to revew the controller error messages. 3 MAX PSI (BAR) Decreased voltage under 30V AC may ncrease ntal heat tme. Mnmum pressure settng Black zone no pressure generaton 3 Maxmum pressure settng 5

16 control panel HELIX 4.3 Control Dsplays Refer to tem n secton 4. The graphc below apples to both the Component Pump (A) and Component Pump (B). Menu Screens Several menu screens are avalable for the user to customze and montor sprayer operaton. They nclude Man Screen, Vs- Comp (Vscosty Compensaton)*, Status* Alarm Range*, Alarm Status*, Total Cycles*, Job Cycles*, Unt Seral #, Tmers, Job Tmers, Servce Tme, Securty Code*, and Prme. The Control Dsplays ncrease the functonalty of the applcable Component Pump. It conssts of a dsplay () and four functon keys (). The dsplay shows varous menu screens that allow the user to customze and montor sprayer operaton usng the functon keys. Screens noted wth an astersk (*) are screens that apply to Component Pump (B) only. All other screens apply to both (A) and (B) pumps. SET PSI 0 ACTUAL PSI 0 When both component pumps are turned ON, the system wll automatcally lnk the two Component Pumps after 0 seconds. Ths means the Component Pump (A) control dsplay wll be controlled by the Component Pump (B) control dsplay. When the component pumps are lnked, the Component Pump (A) control dsplay keys are dsabled and wll only be functonal when the two Component Pumps are unlnked (see Status Screen ). The pressure control knob overrdes the Control Dsplay settngs. Anytme the pressure control knob s turned, the sprayer pressure wll change accordngly. Man Screen The Man Screen s the default screen for the control system at sprayer startup. SET PSI 0 ACTUAL PSI 0 Pressng the # key swtches between PSI, Bar, and MPa unts of measure. Press the # key to scroll through the remanng menu screens. (A) Pump Only - The L- before the Set PSI text on the Man Screen L-SET PSI ACTUAL PSI 0 0 ndcates that the two Component Pumps are lnked. Vs-Comp (Vscosty Compensaton) Screen* Vs-Comp screen on the (B) <The pump allows the user to see and/or VIS-COMP - 00% -NEXT adjust for slght dfferences n vscosty between the (A) pump materal and the (B) pump materal. Pressng the # key wll ncrease the sprayng rato n ncrements of % (up to 05%). Pressng the #3 key wll decrease the sprayng rato n ncrements of % (down to 95%). A Vs-Comp of 05% yelds 5% more of (A) pump materal. A Vs-Comp of 95% yelds 5% less of (A) pump materal. Functon Keys The functon keys are numbered 4. Each key s labeled wth an addtonal functon as well. #/Menu Key #/p Key #3/q Key #4/Select Key Pressng the # key scrolls through the avalable menu screens or performs a functon descrbed on the actve menu screen. Pressng the # key performs a functon descrbed on the actve menu screen or ncreases a value. Pressng the #3 key performs a functon descrbed on the actve menu screen or decrease a value. Pressng the #4 key selects the actve menu screen or performs a functon descrbed on the actve menu screen. Status Screen* The Status Screen shows the lnk status of the (A) pump and (B) pump. STATUS = LINKED LINK- UNLINK-3 STATUS = UNLINKED When turnng the system on, the two LINK- UNLINK-3 pumps wll automatcally be lnked, whch means the (A) pump s controlled by the (B) pump. When the Status Screen s showng, pressng the #3 key wll unlnk the two pumps, and the (A) pump and (B) pump wll operate ndependently and the (A) pump control dsplay keys wll be enabled. If the pumps have been unlnked, pressng the # key wll lnk the two pumps back together, and the (A) pump wll now be controlled by the (B). 6

17 HELIX Control panel Alarm Range Screen* ALARM RANGE The Alarm Range Screen allows the +/- 750 PSI user to adjust the allowable pressure dscrepancy between the (A) and (B) pumps. Pressng the # key wll ncrease the allowable pressure dscrepancy by 0 ps. Pressng the #3 key wll decrease the allowable pressure dscrepancy by 0 ps. The range s 00 ps - 50 ps. Alarm Status Screen* The Alarm Status Screen allows the user to swtch ON or OFF the ALARM STATUS: OFF ON- OFF-3 EXT-4 nternal alarm that alerts the user to a non-allowable pressure mbalance. Pressng the # key wll turn the alarm ON. Pressng the #3 key wll turn the alarm OFF. If a pressure mbalance s detected n the system wth the alarm status set to ON, the system wll automatcally shut down and the dsplay wll show a PSI Imbalance. Refer to Control Dsplay Error Messages. Total Cycles Screen* TOTAL CYCLES The Total Cycles Screen shows the MENU- SELECT-4 total number of pston cycles a component pump has performed durng ts lfetme. CYCLES XXXX Pressng the #3 key wll reset the MENU- RESET-3 cycle count to zero. Pressng the # key wll brng the control panel back to the Man Screen. Job Cycles Screen* The Job Cycles Screen shows the total number of pston cycles a component pump performs durng a spray job. CYCLES Pressng the #3 key wll reset the MENU- cycle count to zero. Pressng the # key wll brng the control panel back to the Man Screen. Unt Seral # Screen The Unt Seral # screen shows the sprayer s seral number. To select the Unt Seral # screen, press the #4 key. JOB CYCLES SELECT-4 MENU- XXXX RESET-3 UNIT SERIAL # MENU- SELECT-4 SER # XXXXXXXXXX MENU- Tmers Screen The Tmers screen shows the total tme the sprayer has been turned on as well as the total tme the sprayer has been runnng (pumpng). To select the Tmers screen, press the #4 key. Job Tmers Screen The Job Tmers screen allows the user to reset the ON TIME and RUN TIME to track tme on specfc jobs. To select the Job TImers screen, press the #4 key. JOB ON screen wll appear. Press #3 to reset. Press # to contnue to JOB RUN screen. Press TIMERS MENU- SELECT-4 ON TIME RUN TIME XXXX XXXX JOB TIMERS MENU- SELECT-4 JOB ON MENU- JOB RUN MENU- X RESET-3 X RESET-3 #3 to reset. Press # to scroll through the remanng menu screens. Servce Tme Screen The Servce Tme screen allows the user to set a servce tme nterval (n hours). Below the set tme, the screens shows the current amount SERVICE TIME MENU- SELECT-4 of hours on the sprayer snce the last actvaton of the servce tmer. To select the Servce Tmer screen, press the #4 key. To set the servce tme, press the # (up) and/or the #3 (down) keys to the desred tme (run hours wll ncrease/ decrease n ncrements of for each tme you press a key). RUN HOURS XX XX When the servce tme nterval s set and met by the run hours, the dsplay wll show a Servce Requred screen. The pump wll reman functonal. To return to the Man Screen, press the # key. Dong so wll reset the and Run Hours dsplayed on the Servce Screen back to 0. Securty Code Screen* The Securty Code screen allows the user to set a four dgt securty code SECURITY CODE MENU- CHANGE- to prevent unauthorzed use of the sprayer. If a securty code has been set, the control system dsplay wll ask for the code at startup. If the correct code s entered, the dsplay wll show the Man Screen and the sprayer wll operate. If the wrong code s entered, the dsplay wll contnue to ask for the correct code and the sprayer wll be dsabled. To set or change the securty code, press the # key. 7

18 control panel HELIX If the sprayer s new, no securty code s set and the Man Screen wll appear at startup. When settng a securty code for the frst tme, the Enter Old Code Number screen wll appear, and you wll need to enter. 4.4 Control Dsplays Error Messages The followng error message screens appear whenever the Control Dsplay detects a problem wth the system. Once a problem occurs and the error message appears, the system wll shut down. Enter the old securty code number to access the screen that allows the code change. If the wrong code s entered, the dsplay wll contnue ENTER OLD CODE NUMBER to ask for the correct code and the securty code cannot be changed. Enter the new securty code. Once the new code s entered, the dsplay wll automatcally ask that the new code be re-entered for verfcaton. If the same new code s re-entered, the dsplay wll confrm that the new ENTER NEW CODE NUMBER XXXX RE-ENTER NEW NUMBER XXXX NEW CODE NUMBER ACCEPTED code has been accepted and return to the Man Screen. If the new code s re-entered ncorrectly, the dsplay wll return to the Enter New Code Number screen and the process wll repeat. If you forget or msplace your securty code, you can call Ttan customer servce for assstance. Before proceedng, follow the Pressure Relef Procedure outlned n ths manual. Addtonally, follow all other warnngs to reduce the rsk of an njecton njury, njury from movng parts or electrc shock. Always unplug the system before servcng! Check Transducer Screen CHECK The Check Transducer screen appears TRANSDUCER when the transducer has become dsconnected or s defectve. Take the sprayer to a Ttan authorzed servce center for repar. Check Potentometer Screen The Check Potentometer screen appears when the potentometer has CHECK POTENTIOMETER become dsconnected or s defectve. Take the sprayer to a Ttan authorzed servce center for repar. To nactvate the Ant-Theft Dgtal Lockout securty functon, enter at the Enter New Code Number screen (ths s the default code that leaves the sprayer unlocked). As a result, the Man Screen wll appear at sprayer startup. Low Voltage Screen The Low Voltage screen appears when the sprayer shuts down LOW VOLTAGE because of low nput voltage. Check the power supply and correct the problem. Restart the system. Hgh Motor Temperature Screen HIGH MOTOR The Hgh Motor Temperature screen TEMPERATURE appears when the temperature of the motor has rsen too hgh. Take the sprayer to a Ttan authorzed servce center for repar. Hgh Mechancal Load The Hgh Mechancal Load screen appears when the sprayer shuts HIGH MECHANICAL LOAD down because of hgh current or when the sprayer goes nto current fold back mode. Take the sprayer to a Ttan authorzed servce center for repar. 8 PSI Imbalance The PSI Imbalance screen appears when there s a non-allowable PSI IMBALANCE UNLINK 3 pressure dscrepancy between the (A) and (B) pumps whle lnked. If a PSI mbalance occurs, press the #3 key to unlnk the two pumps. Once the pumps are unlnked, press the # key to return to the Man Screen.

19 HELIX Setup 5 Setup In order to prevent accdental startup, make sure the system s power cord s not connected durng setup, untl nstructed to do so. Make sure the ar pressure supply s shut off whle connectng any ar hoses to the ar supply. 5. Locate the System. Locate the system on a level surface. Refer to dmensons n secton. for mountng hole dmensons.. Mount n a dry area. 3. For best results, the machne should be bolted nto place. 5. Connect the Materal Supply Hoses The materal drums wll provde spray materals to the component pumps va a supply hose for each contaner. The contaners must be connected to a separate ntrogen tank to provde enough pressure to get materal to flow. Refer to secton 3. for the correspondng llustratons to the steps below.. Arrange the materal drums accordng to the followng: a. Wth certan exceptons, the A component (hardener) should be located on the A sde of the system. b. Wth certan exceptons, the B component (resn) should be located on the B sde of the system.. Make sure the valve handles on the nlet valves for both Component pumps are n the OFF poston (see fg. 9). 3. Attach one end of the feed hose to the nlet valve of Component pump A. Repeat for Component pump B wth another hose. 4. Connect the other end of each hose to ther approprate materal contaner. (.e. the A hose should run from Component pump A to the materal supply drum A ). 5. Connect the supply hoses that run from the separate ntrogen tank to the materal drums. Make sure the shutoff valve for the ntrogen tank s n the OFF poston. 9

20 setup HELIX 5.3 Connect the Ar Supply 5.5 Connect the Electrcal Cord The system must be connected to an ar compressor that wll provde the necessary ar power for the spray gun. If there s no ar supply, there wll not be suffcent pressure to spray.. Connect the ar supply hose to the fttng located underneath the man unt. A 30V power cord s not ncluded wth the system. Make sure a grounded, 30V outlet s avalable n order to power the system. A Twstlock power plug (P/N 05597) s ncluded wth the unt It s recommended that the Helx System be used wth a generator. Ths provdes the flexblty wth not havng to use the publc power grd. When connected to the publc, low-voltage network, t s possble that an approval of the network operator s requred. Check the regulatons n your country and contact your network operator before connectng the unt to a publc electrcty grd. 5.4 Connect the Heated Hoses Attenton The heated hose assembly and dual whp hose come pre-nstalled wth the system and should not be removed or dsassembled unless t s beng completely replaced. Refer to the Surefre Helx LP Heated Hose Manual ncluded wth your system.. Attach the dual heated whp hose to the fttngs on the spray gun. a. Secure the A hose to the A sde of the spray gun. b. Secure the B hose to the B sde (or R sde) of the spray gun. c. Secure the ar supply hose to the ar hose connecton of the spray gun.. Tghten both hose connectons wth a wrench. 3. Thread the ar hose nto the rear of the gun manfold. 4. Remove the couplng block from the spray gun (refer to the spray gun manual). 5. Close gun manfold valves A and B. Power Cord Connector Requrements Connector Twstlock AMP 50 Number of Poles 3 Number of Wres 4 Phases Voltage 5 / 50 VAC Recommended Manufacturer Hubbell P/N CS-6364C If usng a generator to power the system, refer to secton.3 pror to pluggng n the power cord.. Frst plug the adapter end of the power cord nto the power cord port located on the bottom sde of the unt.. Plug the other end of the power cord nto a grounded, 30V outlet. 0

21 HELIX setup 5.6 Ground the system Component System Spray Gun Flud Supply Chambers Object beng sprayed Waste Contaners Proper groundng (earthng) s mportant. The passage of some materals through the nylon flud hose wll buld up a statc electrc charge, whch f dscharged, could gnte solvent vapors present and create an exploson. Groundng Method The system and heated hoses are grounded through the power cord. The spray gun s grounded through the whp hose ground wre. Do not spray wthout usng the whp hose. Follow the local code. Follow the local code. Follow the local code. Only use metal contaners placed on a grounded surface when flushng the system. Do not place metal waste contaners on paper or cardboard surface. A non-conductve surface such as these can nterrupt groundng contnuty. 5.7 Lubrcate the Component Pumps. Fll both upper seal retaner reservors wth DOP (Doctylphthalate) or compatble plastczer (Fg. ). Attenton DOP (Doctylphthalate) or a compatble plastczer prevents ncreased wear and tear to the packngs and wll keep spray materal from crystalzng on the flud secton.. Repeat ths procedure after each use. Whle flushng or relevng system pressure, ground the gun by holdng t aganst the edge of the metal contaner. Falure to do so may lead to a statc electrc dscharge, whch may cause a fre.

22 operaton HELIX 6 Operaton Attenton Pror to startup, make sure the generator has fuel. Runnng out of fuel wll cause electrcal fluctuatons n the system that could result n damage to the electrcal components of the system. 6. Set temperature Refer to secton 4. to revew temperature controls. 6. Startup. If usng a generator, make sure the man breaker on the generator s n the OFF poston.. If usng a generator, start the generator. Allow t to run to full power. DO NOT use the IDLE feature of the generator. 3. If usng an ar compressor to provde ar power to the spray gun, start the compressor, makng sure the bleed valve s n the closed poston on the compressor. 4. If usng a ntrogen tank to provde pressure to the materal contaners, open the valve on the tank that wll allow the gas to flow nto the materal contans. 5. Turn the breaker on the generator to ON. Swtch both of the Component Pump ON/OFF swtches to ON. (these are the outermost ON/OFF swtches located on the control panel). Attenton Do not turn on the hose heater ON/OFF swtches ON yet. Turnng the hose heaters on when there s no flud n the hoses can cause damage to the hoses. 6. Make sure the heated hose and ar supply hose are attached securely to the spray gun. Each connecton needs to be secure n order to avod ar or materal leakage. 7. Open the flud nlet valves. Check for leaks. 8. Purge the flud from each hose usng the calbraton nozzle. 9. The system s now prmed and you are ready to set the materal temperature. Equpment surfaces can become hot. To avod severe burn njury: ) Do not touch hot flud or equpment. ) Allow equpment to cool completely before comng nto contact wth t. 3) Wear gloves when dealng wth temperatures n excess of 0ºF (43ºC). Set the temperature of the heated hoses (repeat each of the followng steps for both A and B hoses): a. Swtch the heated hose ON/OFF swtches to ON (these are the swtches mmedately on ether sde of the heater block swtch n the mddle of the control panel). b. Usng the heated hose controls, set the heated hoses to the desred temperature. Press the (p) button untl the bottom set of numbers () shows the desred temperature. c. The temperature settngs of the heated hoses can also be adjusted to balance sprayng pressures as well as the desred Vscosty Compenson (Vs-Comp). Adjustng the hose heat should ONLY be a secondary method of achevng the correct Vs- Comp. Use the Vs-Comp Screen on the Control Dsplay frst.

23 HELIX operaton 6.3 Sprayng 6.4 Pressure Relef Procedure Refer to the safety nformaton n the begnnng of ths manual for njury preventon gudelnes. Perform the Pressure Relef Procedure when shuttng down for any reason.. Make sure the ar valve on the spray gun (f present) s open all the way to allow maxmum ar flow.. Verfy that the temperature readngs are showng the desred temperatures. 3. Verfy pressure readngs: For each component pump, go to the Control Dsplay Man Screen on the control panel. The pressures shown on the Control Dsplay Screens should be wthn 5 PSI. If pressure s unbalanced, unlnk the pumps, and then adjust the pressure to desred balanced pressure. Once pressure s balanced, re-lnk the pumps.. Turn the pressure control knob for both component pumps to mnmum.. Close the flud nlet valves on both component pumps so no more flud enters the system. 3. Trgger the spray gun to releve pressure n the spray hoses. Verfy that the pressure on both pumps drops to 0. Attenton Do not dsconnect ar supply from the spray gun. Ar should flow through the system untl t s completely shut down. NEVER trgger the spray gun f the pressure readngs are unbalanced. Attenton 4. Test your spray on a pece of scrap wood or cardboard. Adjust pressure and temperatures as necessary to acheve desred results. 3

24 shuttng down HELIX 7 Shuttng Down Attenton It s mportant to the system s electrcal relablty to mantan steady electrcal voltage durng shutdown. Falure to follow these procedures can cause voltage fluctuatons that can damage the equpment and vod the warranty.. Perform the Pressure Relef Procedure (secton 6.4).. Turn both hose heater A and B ON/OFF swtches to OFF. 3. Swtch off the ar compressor and any other auxlary equpment, f beng used. 4. Open the bleed valve on the ar compressor n order to releve pressure and remove any water that may have formed n the tank. 5. Close the flud nlet valves on the supply tanks (handles should be perpendcular to the valve. 6. Turn the Component (A) and Component (B) nlet valve handles to the closed poston (handle should be 90º to the valve). 7. Shut down the ntrogen tank as requred. 7. Parkng Perform the followng steps on the (A) Component Pump ONLY unless otherwse specfed. The followng must be done n order to prevent spray materal buld-up on the (A) sde Component Pump flud secton.. Turn the Component Pump A pressure control knob fully counterclockwse to mnmum settng.. Close the flud nlet valves on both component pumps so no more flud enters the system. 3. Turn the Component Pump B ON/OFF swtch to OFF. 4. Make sure the Component Pump A ON/OFF swtch s stll ON. 5. Wat several seconds untl the COMM LOST screen appears on the Component Pump A dsplay. When t appears, press the #3 button to unlnk the two Component Pumps. 6. Make sure the crankshaft/slder assembly of the A pump s n the bottom, dead-center poston: a. Turn the Component Pump A pressure control knob slghtly clockwse untl the pump begns to run. Through the vents n the front cover on the man unt, observe the crankshaft/slder assembly as t moves. b. Turn the knob quckly to mnmum to stop the crankshaft/slder. Note the poston of the crankshaft/ slder. c. Repeat as necessary untl the crankshaft/clder assembly stops at the bottom, dead center poston. d. Once bottom, dead-center poston s acheved, Component Pump A s parked. It s not necessary to repeat ths procedure for Component Pump B. 7. Turn the Component Pump A ON/OFF swtch to OFF. 8. Fll both upper seal retaner reservors wth DOP (Doctylphthalate) or compatble plastczer (see Fg. ). 4

25 HELIX Shuttng down 7. Flushng Flush the system n a well-ventlated area. Do not turn on hose heaters when flushng wth flammable solvents. If the new Isocyanate beng ntroduced s compatble wth Polyol, t s not necessary to flush the (A) sde.. Flush out the old flud wth new flud, or flush the old flud wth a compatble solvents pror to ntroducng a new flud (check wth the old flud manufacturer n order to determne a compatble flushng solvent).. Always use the lowest possble pressure when flushng the sprayer. Make sure the Component Pump pressure control knobs are turned as far counterclockwse as possble n the MIN PSI zone. 3. Use only mosture-free solvents when flushng the system. 5

26 troubleshootng HELIX 8 Troubleshootng 8. Component Pumps Problem Cause Soluton A. The unt wll not run.. The unt s not plugged n to a power source.. Blown fuse. 3. The pressure s set too low (pressure control knob set at mnmum settng does not supply power to unt). 4. Faulty or loose wrng. 5. Excessve motor temperature. 6. ON/OFF swtch s defectve.. Plug the power cord nto a grounded, 30V outlet.. Replace the fuse. 3. Turn the pressure control knob clockwse to supply power to the unt and ncrease the pressure settng. 4. Inspect or take to an authorzed servce center. 5. Allow motor to cool. 6. Replace the ON/OFF swtch. B. The unt wll not buld or mantan pressure. C. Flud leakage at the upper end of the flud secton.. The pressure control knob s not set properly.. Ar leak n materal feed hoses. 3. There s external flud leak. 4. There s an nternal flud secton leak (packngs are worn and/or drty, valve balls are worn). 5. Worn valve seats 6. Motor powers but fals to rotate 7. Flud supply valves not open. 8. Ntrogen pressure too low. 9. Ar pressure not suffcent. 0. Defectve pressure relef valve.. The upper packngs are worn.. The pston rod s worn.. Turn the pressure control knob clockwse to ncrease the pressure settng.. Check the nlet valve / feed hose connecton. Tghten or wrap the threads wth Teflon tape. 3. Check for external leaks at all connectons. Tghten connectons, f necessary. 4. Clean the valves and servce the flud secton followng the steps n secton 9.3 and 9.4 n ths manual. 5. Reverse or replace the valve seats followng the steps n secton 9.3 and 9.4 n ths manual. 6. Take unt to a authorzed servce center. 7. Open the flud supply valves. 8. Increase the ntrogen pressure or replace the ntrogen tank. 9. Increase the ar compressor pressure. 0. Take the system to an authorzed Ttan servce center for repar.. Repack the pump followng the steps n secton 9.3 and 9.4 n ths manual.. Replace the pston rod followng the steps n secton 9.3 and 9.4 n ths manual. 6

27 HELIX troubleshootng 8. Hose heater controller errors Problem Cause Soluton A. Alarm wll not clear or Reset wth keypad or dgtal nput.. Alarm latchng s actve. Alarm set to ncorrect output 3. Alarm s set to ncorrect source 4. Sensor nput s out of alarm set pont range 5. Alarm set pont s ncorrect 6. Alarm s set to ncorrect type 7. Dgtal nput functon s ncorrect B. Alarm wll not actvate output.. Alarm slencng s actve. Alarm blockng s actve 3. Alarm s set to ncorrect output 4. Alarm s set to ncorrect source 5. Alarm set pont s ncorrect 6. Alarm s set to ncorrect type C. Alarm Error. Alarm status cannot be determned due to a lack of sensor nput.. Sensor mproperly wred or open. Incorrect settng of sensor type. Reset alarm when process s wthn range or dsable latchng. Set output to correct alarm source nstance 3. Set alarm source to correct nput nstance 4. Correct cause of sensor nput out of alarm range 5. Set alarm set pont to correct trp pont 6. Set dgtal nput functon and source nstance. Dsable alarm slencng, f requred. Dsable alarm blockng, f requred 3. Set output to correct alarm source nstance 4. Set alarm source to correct nput nstance 5. Set alarm set pont to correct trp pont 6. Set alarm type to correct type. Correct wrng or replace sensor. Match settng to sensor used AL.E AL.E AL.E 3 AL.E 4 3. Calbraton corrupt 3. Check calbraton of controller D. Alarm Low. Sensor nput below low alarm set pont. AL.L AL.L AL.L 3 AL.L 4 E. Alarm Hgh. Sensor nput above hgh alarm set pont. AL.H AL.H AL.H 3 AL.H 4 F. Error Input. Sensor does not provde a vald sgnal to controller Er., G. Lmt wll not clear or Reset wth keypad or dgtal nput H. Lmt Error. Lmt status cannot be determned due to a lack of sensor nput, lmt wll trp. L,.E I. Lmt Low. Sensor nput below low lmt set pont. L,.L J. Lmt Hgh. Sensor nput above hgh lmt set pont. L,.h. Temperature s less than alarm set pont. Alarm s set to latchng and an alarm occurred n the past 3. Incorrect alarm set pont 4. Incorrect alarm source. Temperature s greater than alarm set pont. Alarm s set to latchng and an alarm occurred n the past 3. Incorrect alarm set pont 4. Incorrect alarm source. Sensor mproperly wred or open. Incorrect settng of sensor type 3. Calbraton corrupt. Sensor nput s out of lmt set pont range. Lmt set pont s ncorrect 3. Dgtal nput functon s ncorrect. Sensor mproperly wred or open. Incorrect settng of sensor type 3. Calbraton corrupt. Temperature s less than lmt set pont. Lmt outputs latch and requre Reset 3. Incorrect alarm set pont. Temperature s greater than lmt set pont. Lmt outputs latch and requre Reset 3. Incorrect alarm set pont. Check cause of under temperature. Clear latched alarm 3. Establsh correct alarm set pont 4. Set alarm source to proper settng. Check cause of over temperature. Clear latched alarm 3. Establsh correct alarm set pont 4. Set alarm source to proper settng. Correct wrng or replace sensor. Match settng to sensor used 3. Check calbraton of controller. Correct cause of sensor nput out of lmt range. Set lmt set pont to correct trp pont 3. Set dgtal nput functon and source nstance. Correct wrng or replace sensor. Match settng to sensor used 3. Check calbraton of controller. Check cause of under temperature. Clear lmt 3. Establsh correct lmt set pont. Check cause of over temperature. Clear lmt 3. Establsh correct lmt set pont 7