Thermo-Gen VFXSF Operating Manual

Transcription

1 Thermo-Gen VFXSF Operating Manual UNSMOKE SYSTEMS 4660 Elizabeth Street, Coraopolis, PA (412) (800) Fax: (412) unsmoke.com

2 THERMO-GEN WARRANTY This is a limited warranty as defined in the Consumer Product Warranty and Federal Trade Commission Improvement Act. This warranty gives you specific legal rights which may vary from state to state. Unsmoke Systems warrants all Thermo-Gen thermal fogging units to be free of defects in materials or workmanship to the original purchaser for a period of (1) one year, on labor and parts which are not subject to usual wear. This warranty does not cover units that have been abused or used in a manner inconsistent with the owners manual instructions. Use of other than UNSMOKE SYS- TEMS FORMULATIONS negates any warranty. UNSMOKE SYSTEMS warrants that UNSMOKE SYSTEMS FOR- MULATIONS are compatible with the equipment when used according to label instructions. Under no circumstances will the manufacturer or UNSMOKE SYS- TEMS be liable for damages due to incorrect stocking, faulty operation or application, nonobservance of chemical label directions. The manufacturer or UNSMOKE SYSTEMS under no circumstances will be responsible for damage(s) done to any property or persons. It is understood that the limit of seller liability for breach of any warranty shall be the invoice price of goods. This warranty begins on the date of consumer purchase. Receipt of warranty card by Unsmoke Systems initiates warranty. If warranty service is required for the Thermo-Gen unit, it must be sent prepaid to: UNSMOKE SYSTEMS 4660 Elizabeth Street Coraopolis, PA (412) (800) Fax: (412) unsmoke.com UNSMOKE Thermo-Gen VFXSF Operations Manual Copyright 1989, Revised 2005 Unsmoke Systems Coraopolis, PA Reproduction in any manner, in whole or in part, in English or other languages is prohibited. All rights reserved. Printed for Unsmoke Systems, in the United States of America 1

3 SAFETY PRECAUTIONS: Congratulations! You have purchased the Thermo-Gen VFXS, the world s most reliable thermal fog generator. 1. Never use pesticides, disinfectants, or odor counteractants for which label prohibits use in low or ultra low volume (thermal or cold fogging equipment) pesticide applicators. 2. Always post warning signs during application. Leave signs posted until after treated area has been ventilated. 3. Never smoke or use an open flame when working on or near Thermo- Gen units. 4. Always close the fuel tank before connecting or removing spark plug cap. 5. Never fill the fuel tank when the unit is hot. 6. Always remove the spark plug cap when transporting the unit or when the carburetor [Part #73] cover has been removed. 7. Never transport a hot machine inside a vehicle. 8. Always wear respirator and goggles when fogging. 9. Never ingest or inhale solutions or vapors. 10. Always follow label instructions on the pesticide, disinfectant, or odor counteractant product containers. 11. Never touch a hot exterior pipe (#47 diffuser) or allow it to make contact with plastic, etc. 12. Always ventilate area fogged at least 1 hour before re-entering. Follow re-entry periods as advised on the machine s, pesticide, disinfectant, or odor counteractant product labels. 13. Never invert or upset units which contains formulation or fuel. 14. Always wear eye protection and rubber gloves when mixing formulations or cleaning your machine. 15. Never clean a hot Thermo-Gen machine, always wait for the machine to cool down before using combustible materials. 16. Always store your Thermo-Gen machine in a clean, dry, dust free area. (Utilize the Thermo-Gen box). 17. Never store gasoline in the machine s fuel tank. 18. Always be sure that the Thermo-Gen machine is cool before storing. 19. Never apply a pesticide, disinfectant, or odor counteractant at application rates higher than what is specified on the product label. 20. Always read the pesticide, disinfectant, or odor counteractant label completely before use. 21. Always keep an ABC fire extinguisher handy when fogging combustible formulations. 2

4 Thermo-Gen Operational Instructions DESCRIPTION The Thermo-Gen machine utilizes a reaction engine operating on the pulse-jet principle. METHOD OF OPERATION When starting, a controlled mixture of fuel and air is combined, forced into the combustion chamber, and is ignited by the spark plug. After starting and warming (5-15 seconds) the unit continues running automatically on auto-ignition without utilizing additional spark or electricity from the batteries. When the fog tap is opened, air pressure is directed through a pressurizing valve into the formulation tank. Air pressure transfers the formulation by hose through the fog tap and into the pulsating stream of hot engine exhaust gases. The kinetic and thermal energy of the engine gasses vaporize the injected fog solution into micro-size droplets. At the end of the fog pipe micro-fine aerosols are ejected and condense as a visible fog. The Thermo-Gen is a thermal fogger, a fogger which uses heat to produce fog droplets. WARNING - READ AND UNDERSTAND INSTRUCTIONS BEFORE STARTING OR OPERATING THIS MACHINE When you receive the Thermo-Gen unit, your first impulse will be to start the unit immediately. Before starting the unit, please carefully read the operating instructions completely to avoid potential problems. PREPARATION AND FILLING OF THE FUEL TANK Fill the fuel tank with clean, fresh gasoline. Leaded, unleaded, or premium gasoline may be utilized. The fuel tank holds 2.3 liters (approximately 2-1/2 quarts). The Thermo-Gen will operate for approximately 1-1/2 hours on a full tank or fuel. Normal fogging applications can be performed with 1 liter (34 ounces) or fuel or less. Always utilize the graduated fuel pitcher with strainer when filling the solution tank. The Thermo-Gen unit always starts and runs better on a fresh tank of gasoline. Figure 1 Figure 2 PREPARATION AND FILLING OF THE FORMULATION TANK - Test start unit prior to filling formulation tank - 1. Remove tank lid by unscrewing tank cap counterclockwise, pull out solution intake hose and filter and hang on holder. 2. Loosen the rubber tank fastener by tugging it downward. Remove the formulation tank in upright position. 3. The formulation tank has a maximum capacity of 9 liters (306 ounces). After filling the formulation tank use the lid attached to the tank to seal the formulation tank. 4. Re-attach the formulation tank to the unit, unscrew the tank lid, and insert the formulation hose and filter into the formulation tank and seal the formulation tank with the attached lid. Figure 3 3

5 PREPARATION FOR STARTING Press down on the primer [Part #210], you should be able to hear the buzzing sound of the electronic ignition system. If no sound is audible conduct systems check on starting system. Systems Check Instructions: Remove the spark plug cap [Part #209 A] from the sparkplug [Part #180], lift spark plug cap 2 mm (1.8 ) above spark plug and press primer. Jumping spark in spark plug cap makes a crackling sound, confirming that the entire system is operational. Reattach sparkplug cap to sparkplug. STARTING THE UNIT 1. Be sure that the fog tap [Part #120] is in the vertical/off position. 2. Turn the adjustable fuel needle valve [Part #103z] a half turn (counter clockwise) (See Figure 4). This starting point may vary considerably between machines and geographic location due to differences in atmospheric pressure and whether or not the machine is still warm from a recent start. When starting a cold machine open the fuel needle valve [Part #103z] slightly more, when starting a warm machine, slightly less. A. Push the orange primer ball [Part #210] down and hold it down for 1-2 seconds. Simultaneously have fingers ready on the fuel needle valve [Part #103] so Figure 4 that you can immediately open the fuel needle valve farther for full power (See Figure 5). B. The machine will start with a roar. Slightly open the fuel needle valve [Part #103] to keep the machine running. (If the machine stalls repeat step 2A). C. Open the fuel needle valve [Part #103] slightly farther. Notice that the machine sounds differently at various levels of adjustment. D. The fuel needle valve [Part #103] is adjusted to fill operating power when the unit makes the harshest sound. Figure 5 3. Occasionally the machine may accumulate air bubbles in the fuel line just below the carburetor. Air bubbles can occur during refueling and are caused by a lack of gas in the fuel line at the time of refueling. These air bubbles may cause the machine to run erratically. Remedial action for erratic operation caused by air bubbles is to while the unit is running lift the machine 2 off of the ground and gently tap the bottom of rear of the machine on the ground forcing air bubbles out of the fuel line. It may be necessary to re-adjust the fuel needle valve [Part #103z] to full power. 4. During the starting procedure it is possible to accidently flood the engine. (See instructions for clearing a flooded engine). 4

6 INSTRUCTIONS FOR CLEARING A FLOODED ENGINE 1. Remove cap from fuel tank. 2. Turn fuel needle valve [Part #103] to the off position and depress the primer ball [Part #210] down 4 or 5 times. With each push of the primer ball the machine will roar or rumble until it is no longer flooded. Once the roaring has stopped the carburetor Part #63 is free of excess fuel. 3. Repeat the starting procedure being careful not to open the fuel needle [Part #103z] quite as far. Adjust the fuel needle valve Part #103 so machine operates with harshest sound. FOGGING Open fog tap by pushing forward to a horizontal position. When sufficient air pressure builds up in formulation tank until the machine will begin fogging. PROPER SHUTDOWN PROCEDURE 1. Close the fog tap [Part #120] (See Figure 6) 2. Always open formulation tank lid [Part #113] before turning fuel needle valve Part [#103z] to the off position. (See Figures 11 & 12) 3. Close fuel needle valve [Part #103z]. Do Not Overtighten. (See Figure 4) Figure 6 Figure 7 POTENTIAL FOR CORROSION: If proper shutdown procedure is not followed water based fogging formulations may corrode the entire fuel system resulting in eventual mechanical failure. POTENTIAL FOR CORROSION CONTINUED After fogging water based formulation, flushing the system is recommended. To flush the system remove the formulation tank [Part #114], clean and rinse the formulation tank [Part #114]. Fill formulation tank [Part #114] with 2 liters (68 ounces) of clean water. Start unit. Raise rear of unit approximately 5mm/2 inches. Open fog tap and flush system by fogging water for 2 minutes. Shut down unit following correct shutdown procedure. Remove formulation tank [Part #114], drain tank, add several ounces of isopropyl alcohol (rubbing alcohol) to tank, sloshing alcohol in tank will capture the remaining droplets of water, drain alcohol from formulation tank [Part #114], and reinstall formulation tank [Part #114]. PERIODIC FLUSHING IS RECOMMENDED 1. Drain the formulation tank. 2. Properly store leftover fogging solution. 3. Pour 1 liter/1 quart of kerosene, No. #2 fuel oil or diesel fuel into the formulation tank and slosh it around thoroughly inside the tank. 4. Take the machine outdoors and fog out excess flushing solution for several minutes. Then drain remaining flushing solution. 5. Clean fuel filter intake [Part #139z] as needed. 5

7 STANDARD GENERAL OPERATING PROCEDURES 1. Always operate your machine at the harshest sound level. 2. Always release the pressure on the formulation tank by loosening the tank lid. 3. Clean machine after each use. 4. Flush machine after each use. Your Thermo-Gen has only three requirements to function: IGNITION SPARK - FUEL - AIR Your Thermo-Gen unit has neither pistons, rings, nor valves to wear out as does an ordinary internal combustion engine, the Thermo-Gen must be cleaned and maintained in order to operate properly. REQUIREMENT (1) IGNITION SPARK A strong, hot spark is a requirement for proper starting. Occasionally the electrode on the spark plug may become heavily soiled. Or it may be damaged by rough handling. Annually clean or replace the spark plug as required. The proper gap is the thickness of a 10 US coin. Electricity is provided by four (4) D sized batteries. Replace the batteries annually or as required. The electrical system of the Thermo-Gen unit is very similar to that of a standard flashlight. Eventually, the tension spring inside the grey battery housing tube will relax and not make proper contact. As with a flashlight simply disassemble, unscrew the sheet metal screw, and pull out the tension spring to improve contact. Note: To check spark, remove the spark plug from the resonator, reinstall the spark plug cap onto the plug and touch the electrode of the spark plug into the stainless steel cooling jacket. Depress the orange primer Sectional view ball. A blue spark between the electrode of the spark of carburetor plug and the spark plug tip should be visible. REQUIREMENT (2) FUEL Premium, regular or unleaded gasoline may be used. Fill the unit with fresh gasoline before each use. The unit always starts and performs best on a full, fresh tank of gasoline. Prolonged storage of gasoline in the unit s fuel tank can result in condensation which can adversely affect the machine s starting and overall performance. Use of a fuel conditioner helps preserve gasoline between uses and helps improve winter starting. Two ounces of fuel conditioner is sufficient for a tankful. Store gasoline in plastic fuel storage cans between uses to prevent rust particles from clogging fuel needle valve [Part #103]. Figure 8 TEST FOR PROPER OPERATION OF FUEL SYSTEM A. Remove fuel needle valve [Part #103] from the carburetor [Part #63]. B. Remove the spark plug, push down on the orange primer ball. A mist of gasoline should be visible spraying up from the needle valve hole in the carburetor body. If no fuel is visible check the fuel line for leaks. ADDITIONAL MAINTENANCE TIPS AND REQUIREMENTS A1. DO NOT substitute round fuel hose for the oval fuel hose [Part #96] below the red fuel valve [Part #7980]. The oval fuel hose [Part #96] acts as a fuel pump and is essential for proper operation. A2. Occasionally the red fuel valve [Part #7980] may be damaged, replace as required. 6

8 REQUIREMENT (3) AIR Proper combustion requires the proper amount of air, at the proper place, and at the right time. Maintenance on the AIR SYSTEM is performed every 25 hours of operation by simply replacing the diaphragm [Part #72]. (Your machine is equipped with a spare diaphragm. The diaphragm is cupped slightly to the outside refer to repair diagram for proper diaphragm installation technique). PLEASE FEEL FREE TO CONTACT US FOR 24-HOUR TECHNICAL ASSISTANCE: Unsmoke Systems 4660 Elizabeth Street Coraopolis, PA (412) (800) Figure 9 Reference Number: 63b Description: Carburetor body, red 70 Support Plate 72 Membrane, teflon 73 Membrane thread 75 Nut M6 DIN 985 S302 Starting nozzle 7

9 Figure 10 Resonator Side Reference Number: Description: 1 Support 6 Retaining bow (fastened with rivets at support) 13 Rubber holder 14 Plastic feet 31 Resonator 47 Conus diffuser 46 Sheet metal screw B 3,9 x 9,5 DIN Cooling jacket 57 Lid closed 58 Lid with ventilation slots (spot-welded) 60 Holding device for cooling jacket 61 Tube dip size Carburettor (red) 187 Battery pipe 189 Holding device for battery pipe 209a Spark plug cap 210 Primer 225 Sling 309 Hexagon head screw M5 x 40 DIN Tooth lock washer 5 DIN Distance cylindrical tube 31 long 8

10 Figure 11 Formulation/Solution System (shown without solution cutoff safety device) Reference Number: Description: 113 Lid with bore hole 114 Fog solution tank 10 liter 115 Passage 120K Fog top (boll tap) 121 Hexagon nut M z Fog solution pipe K-20, K-10/0, K-22 G, K y Fog solution hose 140 mm (Viton) 123 Tooth lock washer size z Pressure pipe Ms 129 Supporting spring long 139 z Suction piece for solution tank 140 Fog solution hose Won, 420 mm 141 Fog solution hose Viton, 210 mm 141a Supporting spring short 142 Air tube 210 mm (black) 149 Dosing nozzles (sizes see table) 151 Nozzle cone, 50 mm 152 Distance cylindrical tube K-10 = 11,5 mm long (1 x) 152 Distance cylindrical tube K-22 = 10,0 mm long (2 x) 153 Gasket 10/14/1 Cu 154 Air tube 75 mm (black) 155 Air tube 32 mm (black) 177 Gasket 8x1 Cu 8583 Pressure valve (green) 9

11 Figure 12 10

12 Fuel System Reference Number: Description: 63 Carburettor compl., black with membrane valve a. adjusting screw 63a Carburettor, black without membrane valve 63b Carburettor, black body 66 Fuel nozzle size (Specify Size) 67 Ring slot nozzle 68 Membrane valve with starting nozzle assembled 70 Support plate for all types 72 Membrane (2 x) 73 Membrane thread for all types 75 Countemut M6 DIN Gasket 6/12/1 78 Abil-gasket 91 Hexagon head screw M6x18 DIN Tooth lock washer A6 Ø DIN Hexagon nut M6 DIN Tube dip size 8 96 x Tube, transparent 96y Fuel hose, oval 97 Tube dip size 9 103a Knurled washer 103b Locking screw 103c Threaded spindle ring 103 z Adjusting screw compl. with 0-ring 111 Ring piece for carburettor 165 Fuel tank 165a Lid for tank 166 z Connection nipple 167 CORBIN tube dip 168 Aeration piece 169z Suction piece for fuel 170 Hose for suction piece 174z Hexagon nut M1O DIN Hexagon nut M8 DIN 439 (B) 176 Gasket 10/14/I 178 Air tube 80 mm 222 Air tube 40 mm S 301 Block valve 1 x blue, 1 x grey S302 Starting nozzle S310 Hose S311 Hose 7980 Fuel valve, red/red without tubes 7980a Fuel valve, red/red with tubes 11

13 Figure 13 Electrical System Reference Number: Description: 1 Support 183 Ignition Device 184 Micro roller switch 185 Battery 1,5 V 186 Sparking plug M14 x 1,25 EA 1,1 mm 193 Butterfly screw M5 x 10 DIN Hexagon nut M5 DIN Tooth lock washer 5 DIN Contact piece with cable (negative pole) 203 Ignition cable, red 204 Ignition cable with ring, black 207 Cylinder head screw M5, Ms 209 Tooth lock washer A5 209a Spark plug cap 212 Connection piece M12 at primer 213 Filister head screw M5 DIN Hexagon nut M12, flat DIN Plastic washer 13 Ø 223 Membrane for return valve 223a Return valve with membrane 223b Return valve without membrane 226 Polyamide screw M5 12

14 Figure 15 Figure 14: A photograph of the safety cutoff system Inlet of fog solution revolve to adjust tightness of closing valve Reference Number: Description: 1 Fog solution conduit with valve assembly 2 Valve piston assembly 3 O-ring Hifluor 2,57 x 1,78 4 Adapter 5 Tube carrier 6 Threaded adapter 7 Diaphragm assembly 8 O-ring 9 Valve spring 10 Expansion 11 Socket 12 Flat headed screw DIN 965 M3x6 13 Set screw DIN 914 M4x6 14 Fillister head screw DIN 84 M3x4 15 Gasket Cu 10x14x1 16 Screw plug 17 Screw fitting 8x1 R 1/8 18 Relief valve 0,48 (blue/grey)

15 Figure 16 Formulation flow allowed Formulation flow cut off 14

16 Warning: Read, understand and respect these safety precautions before operating machine. Failure may lead to a fire hazard. Operator must view the instructional video and/or be trained by Unsmoke Systems authorized personnel. - Check the functional safety of the machine each time before using it. For stationary operation, ensure machine is properly supported. - Never refuel machine when the machine is hot! - Be careful not to place fuel into the solution tank! - When filling one of the tanks or when inspecting the carburettor, smoking is prohibited in the immediate environment. - Never let the machine run without supervision. Operator shall close the fogging tap immediately after sudden stop of engine. - Do not fog in rooms where there is a danger of dust explosion. (e.g. grain mills) - Do not fog directly into a pipe with a similar diameter as the fogging pipe of the unit (cooling effect of the unit is interrupted and a combustible concentration of aerosols may occur). - Do not fog with combustible liquids into pipes or tunnels without ventilation because of fire and explosion hazard. - Do not fog any liquids with a flash point of less than 167ºF. - When fogging combustible liquids use only machines equipped with an automatic cut off device for the fogging liquid. - Never exceed quantity specified on formulation label instructions when fogging within enclosed spaces. - If a combustible atmosphere is established a source of ignition may cause fire (e.g. electric sparks). Therefore such sources have to be eliminated or turned off. - When fogging any liquids a fire extinguisher shall be kept near the unit. - Do not transport hot machines in enclosed vehicles. Never ship the machine with fuel or agent in the tank. If there is still fuel in the tank during transportation, the machine must be upright and secured against tilting. - Do not touch the fogging pipe while the engine is running and up to 30 minutes after run. Do not touch the protection jacket (cooling jacket) for 30 minutes after stopping the engine (danger of injury due to radiated heat)! - Immediately eliminate and clean up machine-related leakage or spillage. - Have the machine periodically serviced by a qualified technician or return to Unsmoke Systems for service and repair. - Observe the instructions for use supplied by the pesticide manufacturer. - When fogging, use protective equipment such as protective clothing, proper respiratory protection, protective gloves, and ear protectors as applicable. The type and quality of the protective equipment to be used depends on each country s safety and legal requirements. In Europe the filter cartridge for the gas mask (full-face mask) must meet the protection category A2 B2-P3 as a minimum requirement. 15

17 Brief Operating Instructions: Start Fogging: 1. Wait until the machine is cool before filling the fuel tank. (minimum 1/2 full) with normal or unleaded gasoline. Gas should have room temperature (minimum 10 C - 40 F). 2. Open adjustable screw on carburetor a max. 1/2 turn, if unit is warm, 1/3 turn. 3. Slowly press primer down several times until unit rumbles and starts. Adjust to a rough harsh around (this allows the machine to achieve the most efficient output and optimal cooling effect). ATTENTION! Unit should never run with a high pitched sound (high frequency) because this leads to a loss of power and overheating. a) If the unit does not start after pumping approx. 5 times and no rumbling or roaring can be heard the carburetor probably is flooded. In this case open lid of fuel tank and pump several times until unit runs. Replace lid immediately. 4. As soon as machine is running with a powerful harsh sound open fog tap. If necessary adjust again motor sound. Stop fogging: 1. Loosen lid of chemical tank while motor is running (pressure escapes allowing chemical pipes to be sucked out). Point the end of the fogging pipe (exhaust pipe) downwards until no more fog is produced. 2. Close fog tap. 3. Stop engine by gently closing the adjustable screw. Attention (After fogging materials other than UNSMOKE THERMO-55): 1. After fogging detach and rinse out chemical tank. Refill with a small amount of water or cleaning solution to fog away left over residues. 2. Observe detailed operating instruction and safety regulations. UNSMOKE SYSTEMS 4660 Elizabeth Street Coraopolis, PA (412) (800) Fax: (412) unsmoke.com 16

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19 ADDITIONAL MAINTENANCE FUEL NEEDLE VALVE MAINTENANCE Periodically lubricate the "O" ring on the fuel needle valve Part #103. Lubricate both the "O" ring and the threads. The proper lubricant is silicone grease which is available at most automotive parts stores. FUEL HOSES AND VALVES Insure that fuel hoses and valves are properly aligned. TESTING FUEL VALVE To test red fuel valve part #7980 simply attach a rubber hose to the end of the valve and blow. If air escapes or if it does not open and close smoothly with each breath of air, it is defective and requires replacement. FUEL FILTER/INTAKE Periodically clean fuel intake filter by spraying with aerosol carburetor cleaner. CONTAMINATION IN FUEL FORMULATION TANK Drain fuel formulation tank. Clean interior of tank by spraying with aerosol carburetor cleaner. NOZZLE MAINTENANCE A. SOLUTION INJECTOR NOZZLES Periodically remove residue build-up on solution injector nozzles part #151 by running a long 5/32" drill bit in and out of the injector nozzles (hold drill bit with vise grips.) B. DOSING NOZZLES Your Thermo Gen unit is equipped with 3 interchangeable fog nozzles. Most applications can be made with the size 10 nozzle. Discretion is advised prior to using larger nozzles. 18