Related Manuals for Titan HELIX 0138011
Summary of Contents for Titan HELIX 0138011
- Page 1 OperAting mAnuAl Airless, high-pressure sprAying system With surefire™ heAting system Models: 0138011 0138011 AP 0138013 0138013 AP 0138059 0138059 AP 0138060 0138060 AP 0117 • Form No. 0138966C...
- Page 2 HELIX HELIX original operating manual Warning! Attention: Danger of injury by injection! Airless units develop extremely high spraying pressures. Never put your fingers, hands or any other parts of the body into the spray jet! Never point the spray gun at yourself, other persons or animals. Never use the spray gun without safety guard.
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Page 3: Table Of Contents
HELIX ContentS SAfeTy regulATIoNS ___________________ 4 ShuTTINg DoWN _______________________ 25 Explanation of symbols used _____________________4 Parking _____________________________________25 Isocyanate (ISO) Conditions _____________________6 Flushing ____________________________________25 Electric safety _________________________________7 TrouBleShooTINg ____________________ 26 geNerAl DeScrIpTIoN __________________ 8 Component pump ____________________________26 System configurations __________________________8 Surefire™ heater block / Clearance diagram _____________________________8 hose heater controller errors ____________________27 Electrical / generator requirements _______________9... -
Page 4: Safety Regulations
HELIX SaFetY regulationS SAfeTy regulATIoNS hAZArD: INjecTIoN INjury explANATIoN of SymBolS uSeD Attention: Danger of injury by injection! A high This manual contains information that must be read and pressure stream produced by this equipment can understood before using the equipment. When you come to pierce the skin and underlying tissues, leading to an area that has one of the following symbols, pay particular serious injury and possible amputation. - Page 5 HELIX SaFetY regulationS • Avoid all ignition sources such as static electricity sparks, hAZArD: BurN hAZArD electrical appliances, flames, pilot lights, hot objects, and sparks from connecting and disconnecting power cords or Certain components of the equipment are heated working light switches. and become hot during operation.
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Page 6: Isocyanate (Iso) Conditions
HELIX SaFetY regulationS ISocyANATe (ISo) coNDITIoNS Important Information Regarding Two- hAZArD: geNerAl Component Material. Read before using the This product can cause severe injury or property equipment. damage. preveNTIoN: ISocyANATe (ISo) coNDITIoNS • Follow all appropriate local, state, and national codes •... -
Page 7: Electric Safety
Use ONLY the moisture-proof hoses specifically designed work, unplug the power plug from the outlet. for ISO that are supplied with your system. If new hoses need to be ordered, contact Titan Technical Service. Danger of short-circuits caused by water •... -
Page 8: General Description
HELIX general DeSCription geNerAl DeScrIpTIoN The Helix Plural Component System is a dual, high pressure SySTem coNfIgurATIoNS airless sprayer system that can be linked in order to spray multi- component fluids. The Plural Component System is available in the following configuration(s) which is based upon the number of heating elements, hose length, electrical phases and the required power cord (not supplied). -
Page 9: Electrical / Generator Requirements
HELIX general DeSCription elecTrIcAl / geNerATor requIremeNTS It is recommended that the Helix System be used with a generator. This provides the flexibility with not having to use the public power grid. When connected to the public, low-voltage network, it is possible that an approval of the network operator is required. -
Page 10: System Description
HELIX SYStem DeSCription SySTem DeScrIpTIoN SySTem DIAgrAm - WIThouT cIrculATIoN Waste containers (not included) must be closed at the top. -
Page 11: Component Description - Without Circulation
HELIX SYStem DeSCription compoNeNT DeScrIpTIoN - WIThouT cIrculATIoN ITem DeScrIpTIoN fuNcTIoN Component Pump A In a two-component system, Component Pump A typically pumps the ISO or activator material. Component Pump B In a two-component system, Component Pump B typically pumps the resin material. Surefire™... -
Page 12: System Diagram - With Circulation
HELIX SYStem DeSCription SySTem DIAgrAm - WITh cIrculATIoN... -
Page 13: Component Description - With Circulation
HELIX SYStem DeSCription compoNeNT DeScrIpTIoN - WITh cIrculATIoN This configuration is only possible with the purchase of circulation kit P/N 0138914, sold separately. The parts included in the kit are labeled with an asterisk (*). ITem DeScrIpTIoN fuNcTIoN Component Pump A In a two-component system, Component Pump A typically pumps the ISO or activator material. -
Page 14: Control Panel
HELIX Control panel coNTrol pANel The control panel contains all of the system controls that allow the sprayer to function properly, as well as being the main display panel that gives information about the system. Items 1 - 5 below are duplicated - one for each pump. -
Page 15: Surefire™ Heater Block Control
HELIX Control panel SurefIre™ heATer BlocK coNTrol SurefIre™ heATeD hoSe TemperATure coNTrol Refer to item 8 in section 4. The block heater control regulates the temperature of spray Refer to item 1 in section 4. The heated hose material as it passes through the heater block, temperature control maintains the temperature prior to it reaching the heated hoses. -
Page 16: Component Pump Pressure Control
HELIX Control panel compoNeNT pump preSSure coNTrol coNTrol DISplAyS Refer to item 2 in section 4. The following items Refer to item 2 in section 4. The graphic below control the pressure of the individual Component applies to both the Component Pump (A) and Pumps. - Page 17 HELIX Control panel meNu ScreeNS Several menu screens are available for the user to customize Status Screen* and monitor sprayer operation. They include Main Screen, STATUS = LINKED The Status Screen shows the link LINK-2 UNLINK-3 Ratio*, Status* Alarm Range*, Alarm Status*, Total Cycles*, Job status of the (A) pump and (B) pump.
- Page 18 “Enter New Code Number” screen and the process will #3 to reset. Press #1 to scroll through the remaining menu repeat. screens. If you forget or misplace your security code, you can call Titan customer service for assistance. Service Time Screen SERVICE TIME...
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Page 19: Control Displays Error Messages
HIGH MOTOR The High Motor Temperature screen TEMPERATURE appears when the temperature of the motor has risen too high. Take the sprayer to a Titan authorized service center for repair. high mechanical load HIGH MECHANICAL The High Mechanical Load screen... -
Page 20: Setup
HELIX Setup SeTup In order to prevent accidental startup, make sure the system’s power cord is not connected during setup, until instructed to do so. Make sure the air pressure supply is shut off while connecting any air hoses to the air supply. locATe The SySTem 1. -
Page 21: Connect The Surefire™ Heated Hoses
HELIX Setup 4. Attach the dual heated whip hose to the coupling block. coNNecT The SurefIre™ heATeD hoSeS a. Secure the “A” hose to the “A” side of the coupling block. b. Secure the “B” hose to the “B” side (or “R” side) of the coNNecT The heATeD hoSeS coupling block. -
Page 22: Connect The Electrical Cord
HELIX Setup coNNecT The elecTrIcAl corD Spray Gun The spray gun is grounded through the whip A 230V power cord is not included with the hose ground wire. Do not spray without using system. Make sure a grounded, 230V outlet is the whip hose. -
Page 23: Operation
HELIX operation operATIoN SeT TemperATure Prior to startup, make sure the generator has fuel. Running out of fuel will cause electrical fluctuations in the system that could result in Refer to section 4 to review temperature controls. Attention damage to the electrical components of the system. -
Page 24: Spraying
HELIX operation SprAyINg Always close the manifold valves if the system is idle for more than 1 minute under heat and/or pressure. Failure to do so can cause a pressure Refer to the safety information in the beginning Attention imbalance which can then lead to a material of this manual for injury prevention guidelines. -
Page 25: Shutting Down
HELIX Shutting Down ShuTTINg DoWN 7. Turn the ON/OFF switches for both Component Pumps to It is important to the system’s electrical reliability OFF. to maintain steady electrical voltage during 8. Switch the generator OFF. Allow generator dwell time, per shutdown. -
Page 26: Troubleshooting
HELIX troubleShooting TrouBleShooTINg compoNeNT pumpS problem cause Solution The unit will not run. The unit is not plugged in to a power source. Plug the power cord into a grounded, 230V outlet. Tripped breaker. Reset the breaker. The pressure is set too low (pressure control knob Turn the pressure control knob clockwise to set at minimum setting does not supply power to supply power to the unit and increase the... -
Page 27: Surefire™ Heater Block / Hose Heater Controller Errors
HELIX troubleShooting SurefIre™ heATer BlocK / hoSe heATer coNTroller errorS problem cause Solution Alarm will not clear or Reset with Alarm latching is active Reset alarm when process is within range or keypad or digital input. Alarm set to incorrect output disable latching Alarm is set to incorrect source Set output to correct alarm source instance... - Page 28 HELIX troubleShooting Loop Open Error. Open Loop Setting of Open Loop Detect Time incorrect. Set correct Open Loop Detect Time for Detect is active and the process Setting of Open Loop Detect Deviation application. value did not deviate by a user- incorrect.
- Page 29 HELIX troubleShooting Process does not control to set Controller not tuned correctly. Perform autotune or manually tune system. point. Process is unstable or never Control mode is incorrectly set. Set control mode appropriately (Open vs. reaches set point. Closed Loop). Control set point is incorrect.
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Page 30: Servicing
HELIX ServiCing ServIcINg 8. Loosen and remove the four motor baffle screws (13). Before proceeding, follow the Pressure Relief Remove the motor baffle (14). Procedure outlined previously in this manual. 9. Loosen and remove the three motor mounting screws Additionally, follow all other warnings to reduce (15). -
Page 31: Replacing The Gears
HELIX ServiCing replAcINg The geArS (fIg. 18) replAcINg The TrANSDucerS (fIg. 19/20) 1. Follow steps 1-10 in replacing the motor Assembly to 1. Disconnect the power cord. remove the motor and control panel. 2. Loosen the hex nut (fig. 19, item 1) in between the PRIME/ 2. -
Page 32: Replacing The Prime/Spray Valve
HELIX ServiCing replAcINg The prIme/SprAy vAlve 5. Loosen and remove the two PRIME/SPRAY knob manifold Perform the following procedure using PRIME/ screws (9). Be careful not to lose the flat or lock washers. SPRAY valve replacement kit P/N 800-915. 6. Pull the PRIME/SPRAY manifold (8), with tranducer assembly (10) still attached forward. -
Page 33: Inlet And Outlet Valves
HELIX ServiCing INleT AND ouTleT vAlve Before proceeding, follow the Pressure Relief Procedure outlined previously in this manual. Additionally, follow all other warnings to reduce the risk of an injection injury, injury from moving parts or electric shock. Always unplug the sprayer before servicing! 1. -
Page 34: Packings
HELIX ServiCing pAcKINgS 1. Remove inlet valve housing in accordance with the steps in Section 9.5. 2. It is not necessary to remove the outlet valve. 3. Pull the lever on the underside of the sprayer toward the front of the sprayer. This will un-clamp the entire fluid section. - Page 35 HELIX ServiCing 16. Insert upper support ring (8) on top of the upper packing 27. Making sure that the bearing ring (Fig. 22, item 9) and O-rings (Fig. 22, items 7-8) are lubricated and in place, reassemble the inlet valve assembly and and thread it 17.
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Page 36: Electrical Schematic (0138013 / 0138059)
HELIX ServiCing elecTrIcAl SchemATIc (moDel 0138013 / 0138059) Wiring Notes (refer to next page) Black This end mounted to enclosure To contact (0522532) White To surge protector Green To relay (0522536) Blue To 2A breaker (0522068) Brown To hose heater From 0138501 (thermocouple) located in 0138270 (manifold) Ground stud on display... - Page 37 HELIX ServiCing Notes (refer to previous page) This end mounted to enclosure From switches From “c”, previous page From “d”, previous page From Emergency Stop (0522516) From “f”, previous page To controller (0138542) From “h”, previous page Ground stud on enclosure To “Y1”...
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Page 38: Electrical Schematic (0138011 / 0138060)
HELIX ServiCing elecTrIcAl SchemATIc (moDel 0138011 / 0138060) Wiring Notes (refer to next page) Black This end mounted to enclosure To contact (0138523) White To surge protector Green To power distributor block Blue To 2A breaker (0522068) Brown To hose heater From 0138501 (thermocouple) located in 0138270 (manifold) Ground stud on display... - Page 39 HELIX ServiCing Notes (refer to previous page) Notes (refer to previous page) Notes (refer to previous page) This end mounted to enclosure From “d”, previous page To controller (0138542) From switches From Emergency Stop (0522516) From “h”, previous page From “c”, previous page From “f”, previous page Ground stud on enclosure To “Y1”...
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Page 40: Spare Parts Lists
SpAre pArTS DIAgrAm HELIX mAIN ASSemBly... - Page 41 HELIX Description Description pos. helix A / B pos. helix A / B ------- Cart assembly 805-250A Face plate / oiler assembly (2) ------- Control panel assembly 700-139 Screw (8) ------- Pump assembly, A side 756-088 Washer (4) 0521238 Surefire™ heated hose assembly, 200’ 860-002 Lock washer (4) 0138296...
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Page 42: Spare Parts List For Component Pump Assembly
SpAre pArTS DIAgrAm HELIX compoNeNT pump ASSemBly... - Page 43 HELIX pos. helix A helix B Description 805-625 805-625 Motor shroud 700-681 700-681 Screw (3) 0138957A 0138957A Belly pan assembly 9802266 9802266 Screw (2) 0138519 0138518 Plug 9812320 9812320 Nut (6) 805-286A 805-286A Lever assembly 805-287A 805-287A Clevis assembly (2) 9802266 9802266 Screw (2)
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Page 44: Spare Parts List For Drive Assembly
SpAre pArTS DIAgrAm HELIX DrIve ASSemBly... - Page 45 HELIX pos. helix A helix B Description 700-283 700-283 Screw (4) 0558572A 0558572A Slider assembly 805-248A 805-248A Slider housing 0558342A 0138956A Housing assembly 800-525 800-525 Gasket 0558362A 0558362A 3rd stage gear 0558363A 0558363A 2nd stage gear 9821503 9821503 Lock washer (3) 700-287 700-287 Screw (3)
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Page 46: Spare Parts List For Surefire™ Heater Block System
SpAre pArTS DIAgrAm HELIX heATer BlocK ASSemBly... - Page 47 HELIX helix A / B helix A / B Description helix A / B helix A / B Description 0138011 0138013 0138011 0138013 0138060 0138059 0138060 0138059 pos. pos. ------- ------- Display assembly 0522068 0522068 Circuit breaker, 2 A 9805436 9805436 Set screw 704-211A...
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Page 48: Spare Parts List For Display Assembly
SpAre pArTS DIAgrAm HELIX DISplAy ASSemBly... - Page 49 HELIX helix A / B helix A / B Description 0138011 0138013 0138060 0138059 pos. 0138462A 0138462A Display cover 730-260 730-260 Screw (4) 9812335 9812335 Nut (2) 9812334 9812334 Nut (6) 9822646 9822646 Washer (6) 805-401 805-401 Display (2) 0138527 0138527 Spacer (6) 700-139...
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Page 50: Spare Parts List For Fluid Section
SpAre pArTS DIAgrAm HELIX fluID SecTIoN... - Page 51 HELIX helix A helix B Description pos. 0138039A 0138277A 0138899 805-545 Retainer 805-551 805-551 Spacer 0509123A 0509123A Upper packing 0138898 805-519 Cylinder 805-587 805-587 Fitting 9871189 9871189 O-ring 0558582A 0558582A Lower packing 0558564A 0558564A Piston rod 800-348 800-348 Upper seal 0507452 0507452 Upper ball guide...
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Page 52: Spare Parts List For Cart Assembly
SpAre pArTS DIAgrAm HELIX cArT ASSemBly Description pos. helix A / B 0138288A Cart assembly (includes items 3-5) 0294635 Plug (4) 670-109 Wheel (2) 0295687 Spacer (4) 800-019 Axle cap (2) -
Page 53: Spare Parts List For Prime/Spray Valve Assembly
SpAre pArTS DIAgrAm HELIX prIme/SprAy vAlve ASSemBly Description pos. helix A helix B 800-437 800-437 Transducer assembly 0138424A 0138424A PRIME/SPRAY assembly manifold 700-537 700-537 Gasket 0558727 0558727 Bypass valve assembly, includes item 3 700-252B 700-252B Cam base 0138499 0138498 Relief valve knob 700-759 700-759 Groove pin... -
Page 54: Spare Parts List For Surefire™ Heater Block
SpAre pArTS DIAgrAm HELIX SurefIre™ heATer BlocK Description pos. helix A / B 0138638A Heater block, top (includes item 2 and 10) 0138639A Heater block, middle (includes item 2) 0138640A Heater block, bottom (includes item 2 and 10) 0138469 Reducer fitting (2) 0138960 Firestick rod 0138497... -
Page 55: Warranty
HELIX warrantY WArrANTy Titan Tool, Inc., (“Titan”) warrants that at the time of delivery to the original purchaser for use (“End User”), the equipment covered by this warranty is free from defects in material and workmanship. SySTem WArrANTy: Two year (24 months) manufacturer’s Defects: With the exception of any special, limited, or extended warranty published by Titan, Titan’s obligation under this warranty is limited... - Page 56 uNITeD STATeS SAleS & ServIce INTerNATIoNAl WeB: www.titantool.com WeB: www.titantool-international.com phoNe: 1-844-458-1215 emAIl: international@titantool.com fAx: 1-800-528-4826 fAx: 1-763-519-3509 1770 Fernbrook Lane Minneapolis, MN 55447...