CHEMICAL. TIE PLUGGER Model NETP-1 TABLE OF CONTENTS

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Derrick O’Brien’
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1 TABL OF CONTNTS Chemical Meteing quipment...2 Resin and ISO Chemicals...3 Dispensing Valve and Gun Assembly...4 Bleeding Ai Pessue fom Cylindes...5 Heat Contolles...6 NOT: Do NOT attempt to epai heat contolles. Contact Nodco Sevice fo assistance. STARTUP AND SHUTDOWN PROCDURS follow this peface. MAY/2006 ( D) Section C-1

TI PLUGGR Model NTP-1 MTRING QUIPMNT PROBLM TRANSFR PUMPS DO NOT OPRAT MTRING UNIT WILL NOT OSCILLAT (CYCL) TRAC LINS NOT HATING POSSIBL CAUS Inadequate hydaulic supply Blocked supply lines Resin o

2 TI PLUGGR Model NTP-1 MTRING QUIPMNT PROBLM TRANSFR PUMPS DO NOT OPRAT MTRING UNIT WILL NOT OSCILLAT (CYCL) TRAC LINS NOT HATING POSSIBL CAUS Inadequate hydaulic supply Blocked supply lines Resin o ISO pumps Bad/Contaminated lowe pump packings (pump motion is choppy not smooth) Contaminated checks (pump motion is much faste in one diection) Supply pumps Diectional contol valve not shifting Ai logic leaking ai Bleede buttons Blocked lines No electicity Heat contolle Themostat and/o tace line SOLUTION Check hydaulic supply Check fo blockage and eplace, if necessay. Open all ball valves (1, 2, 3, and 4) Check hydaulic pessue. Should ead 700 psi. If pessue is ok, disconnect lowe pump. If uppe pump opeates, eplace packings in lowe pump. If uppe pump does not opeate, ebuild o eplace. Replace packings and clean all moving pats. Disassembly pump and clean all check balls and seating sufaces. Check pump fo pope opeation and supply Check and clean ai opeatos. Check intenal spool fo feedom of movement. Check ai logic fo leaks Check fo pope opeation Check lines fo blockage Check fo electical powe. 1. Tun on 240V Contol Panel 2. Check voltmete at 240V contol panel. Should ead 240V 3. Tun on taceline contolle See Heat Contolle Toubleshooting. Check fo pope opeation Section C-2 MAY/2006 ( D)

3 RSIN AND ISO TROUBLSHOOTING SLOW CUR TIM IN RAILROAD TI Cold chemical Cold aiload ties (below 55 F) Off-atio chemical Intemittant chemical flow at dispensing valve Incease tace line tempeatue Incease tace line tempeatue Take atio check Check chemical flow at dispensing valve hose connections. NO CUR IN RAILROAD TIS Faulty pump pessues Off-atio chemical Diectional contol valve not shifting Faulty o-ings in dispensing valve Plugged ISO hose between mete and dispensing valve Blown ISO safety valve Cold chemical Ai in meteing system Adjust pump pessue o eplace pump Take atio check Clean o eplace Rebuild dispensing valve Replace hose Repai ISO Line blockage on output side of mete and eplace safety valve Incease tace line tempeatue Bleed ai fom system SOFT OR PARTIALLY CURD SPIKFAST Pump Diectional contol valve not shifting Faulty o-ings in dispensing valve Plugged ISO hose between mete and dispensing valve; o between pump and mete Blown ISO safety valve Check fo a smooth even stoke on pump Clean o eplace Rebuild dispensing valve Replace hose Repai ISO Line blockage on output side of mete and eplace safety valve SPIKFAST FOAMING xcess wate in hole Dispensing valve leaking Blown ISO safety valve Decease pump pessue and tace line tempeatue to decease chemical flow Tighten packing o eplace valve Repai ISO Line blockage on output side of mete and eplace safety valve MAY/2006 ( D) Section C-3

4 DISPNSING VALV AND GUN ASSMBLY TROUBLSHOOTING TI PLUGGR Model NTP-1 TOO MUCH FLOW Tace line tempeatue too high Reduce tempeatue RSIN flow contol open too much Tun in (CW) flow contol No ai o hydaulic pessue Check fo adequate ai o hydaulic pessue Plugged dispensing valve Inspect dispensing valve Chemical Tansfe Pumps tuned off Tun chemical tansfe pumps ON at Wok Box NO FLOW Mete switches and/o ball valves tuned off Tun on mete switches and/o ball valves Diectional o 4-way valve Repai o eplace Liquid end cap plugged Remove and clean SLOW FLOW Tigge valve Chemical Tansfe Pumps Cold chemical See Chemical Tansfe Pumps. DO NOT OPRAT! Tun on pe-heates and taceline heates at Wok Box. SPUTTRING FLOW Plugged dispensing valve o line Clea blockage in dispensing valve and/o lines Chemical supply empty Ai in mete lines Chemical Tansfe Pumps Fill totes Bleed ai fom system. Run system until ai is out of lines. See Bleeding Ai Pessue following this table. See Chemical Tansfe Pumps. DO NOT OPRAT! OFF-RATIO RSIN:ISO Lack of chemical Check esin and ISO chemical supplies MATRIAL NOT MIXING Remove and eplace Fluid shafts fouled o won DISPNSING VALV LAKS O-ings cut o ton OR DROOLS(It is ecommended to do a complete ebuild of Low ai pessue the dispensing valve when constant leaking o dooling occus.) Ai piston binding Clean o eplace Incease ai pessue Inspect and clean. Loosen cap scews on ai end cap while tiggeing valve until dooling stops Section C-4 MAY/2006 ( D)

5 Damaged seals in font seal BACKING UP body INTO OPPOSIT SID Out of Chemical Check chemical supply NO FLUSH FLUID Supply pumps Diectional contol valve Flush pump off Plugged dispensing valve o check valve mpty flush tank Flush Pump See Chemical Tansfe Pumps. DO NOT OPRAT! Tun pump on Clea blockage in dispensing valve and/o lines Fill flush tank. Repai o eplace pump BLDING AIR PRSSUR FROM CYLINDRS If toubleshooting indicates that excessive ai is in the system, you must bleed the ai pessue as follows: 1. Pull the dispensing valve tigge and w atch the cy linde shaft diection of tavel. 2. If the shaft moves fom left to ight, depess the left bleede button and elease ai. If the shaft moves fom ight to left, depess the ight bleede button and elease ai. 3. Hold the button down, eleasing ai until the mete shaft stops mov ing. Watch the A pessue gauge. When the gauge eads zeo, elease the bleede button. The mete w ill change diection. Switch to the othe bleede button and complete the opeation at the othe end of the stoke. You w ill be moving the cylinde pistons to the bottom (maximum distance) of thei stoke. When the piston is bottomed, it foces any tapped ai out of the mete. 4. Complete this opeation fiv e o six times. Replease the dispensing valve tigge as equied duing this opeation. MAY/2006 ( D) Section C-5

6 HAT CONTROLLR TROUBLSHOOTING TI PLUGGR Model NTP-1 NOT: The tempeatue displayed on the digital eadout is not always the same as the tempeatue of the Spikefast deliveed at the mixing tube. NOT: Raiload pesonnel should neve touch o attempt to adjust the heat contolle modules. This is to be done by NORDCO cetified technicians only. Taceline Heat Unit not tuned on Check ON/OFF sw itch on the font of the Contolle Box does panel. The sw itch must be in the ON not display position. atic o fluctuating (apid change, especially up o down) digital eadout Display cicuit beake tipped. Tace line o heat contolle module defective. Open the mete box cove. Make cetain the cicuit beake on top of the display module is in the ON position. Remove and ev ese tace lines at plugins on the heat contolle. (These ae located on the back side of the heat contolle box. ) If fluctuations tansfe to the opposite display, the TRAC line is defective If the fluctuations emain in the same display, the Heat Contolle module is defective. LD s will not light No powe to contolle Check powe line connections Some segments of the display o LD s ae not lit o ae eoneously lit. LD s defective Poo connection Replace LD display o lamp Check connections Pocess display Senso beak eo Check wiing connection Replace RTD o senso Sb Pocess display C S Pocess display L L Pocess display H L Check Sum o: values in memoy may have been changed accidentally Low Limit o. The pocess value is below the limit ange. High Limit o. The pocess value is above the high limit ange. Check pogam fo pope input Check and econfigue contol paametes Incoect input type selected Replaced senso. Readjust Lo.SC Incoect input type selected Replaced senso. Readjust hi.sc Section C-6 MAY/2006 ( D)

7 Pocess display Oveflow eo. Data out of Check fo electical noise O Y ange duing execution of softwae pogam. Display unstable Analog potion o A-D convete Replace elated components o boad defective Themocouple, RTD o senso defective Check themocouple, RTD o senso. Intemittent connection of senso Check senso wiing connections Display goes in evese diection (counts down scale as pocess wams) No heat o output wiing Revesed input wiing of senso No heate powe (output), incoect output device used. Output device defective Check and coect. Check output wiing and output device. Replace output device Heat o output stays on but indicato eads nomal Display blinks, enteed values change by themselves Open fuse outside of the instument Output device shoted, o powe sevice shoted. lectomagnetic intefeence (MI), o Radio Fequency Intefeence (RFI) PROM defective Replace output fuse Check and eplace Suppess acing contacts in system to eliminate high voltage spike souces.; Sepaate senso and contolle wiing fom dity powe lines, gound heates. Replace PROM MAY/2006 ( D) Section C-7

DNFTR DIGITAL NO-FLOW TIMER U.S. PAT. NO. 5,835,372

DNFTR DIGITAL NO-FLOW TIMER U.S. PAT. NO. 5,835,372 MODEL PG-PS C -SWITCH GN-GND. VIO - OPEN - N.O. VIO - SHOT - N.C. -PG-PS MONITOS MOVEMENT OF DIVIDE VALVE PISTON FO DEPENDABLE "TIMED" SHUTDOWN POTECTION CLOSED LOOP O OPEN LOOP OPEATION INSTALLS DIECTLY