Titan HELIX 0138011 Operating Manual Download

Page: 36 / 56

ServiCing

HELIX

9.7

elecTrIcAl SchemATIc (moDel 0138013 / 0138059)

0138935

0138936

0522599

0522543

805-401

0522524

0138600

0522515

0138603

0522513

0522576

0138516

0138514

0138516

0138514

0138516

0138514

0138516

0138514

0138516

0138514

0138604

0522109

0138602

0522577

0138602

0522064

0138991

0138989

0138988

0522122

)

0138935

0522599

0522524

805-401

0522543

0138600

0522515

0522109

0138513

0138512

0522123 (B)

Wiring

Black

Red

White

Green

Blue

Brown

Notes (refer to next page)

This end mounted to enclosure

To contact (0522532)

To surge protector

To relay (0522536)

To 2A breaker (0522068)

To hose heater

From 0138501 (thermocouple)

located in 0138270 (manifold)

Ground stud on display

To ground stud on enclosure

Summary of Contents for HELIX 0138011

Page 1: ...0117 Form No 0138966C Airless high pressure spraying system With surefire heating system Models 0138011 0138011 AP 0138013 0138013 AP 0138059 0138059 AP 0138060 0138060 AP OPERATING MANUAL ...

Page 2: ...about the coating material or solvent used The operating instructions state that the following points must always be observed before starting up 1 Faulty units must not be used 2 Secure the spray gun using the safety catch on the trigger 3 Ensure that the unit is properly earthed 4 Check allowable operating pressure of high pressure hose set and spray gun 5 Check all connections for leaks The inst...

Page 3: ...____________ 23 6 1 Startup______________________________________23 6 2 Set temperature_______________________________23 6 3 Spraying_____________________________________24 6 4 Pressure relief procedure________________________24 7 Shutting down________________________ 25 7 1 Parking______________________________________25 7 2 Flushing_____________________________________25 8 Troubleshooting_______...

Page 4: ...PREVENTION NEVER aim the gun at any part of the body NEVER allow any part of the body to touch the fluid stream DO NOT allow body to touch a leak in the fluid hose NEVER put your hand in front of the gun ALWAYS lock the gun trigger shut the fluid pump off and release all pressure before servicing cleaning the tip guard changing tips or leaving unattended Pressure will not be released by turning of...

Page 5: ...clothing gloves and possibly skin protection cream are necessary for the protection of the skin Observe the regulations of the manufacturer concerning coating materials solvents and cleaning agents in preparation processing and cleaning units HAZARD BURN HAZARD Certaincomponentsoftheequipmentareheated and become hot during operation PREVENTION To avoid severe burns and injury do not touch heated f...

Page 6: ...tentially harmful Be familiar with the spray material s SDS in order to understand specific hazards and necessary precautions that are related to the use of spray materials containing isocyanates Provide extensive exhaust and fresh air introduction to keep the air within the spray area free from harmful isocyanate vapors If sufficient ventilation is not available a supplied air respirator must be ...

Page 7: ... blowing agents will froth at temperatures above 90º F 33ºC when not under pressure especially if agitated To reduce frothing minimize preheating in a circulation system 1 3 Electric Safety Electric models must be earthed In the event of an electrical short circuit earthing reduces the risk of electric shock by providing an escape wire for the electric current Connection to the mains only through ...

Page 8: ...ng Elements Heated Hose Max Flow gal min Max Fluid Pressure Cord Specification AWG mm2 0138011 400V 3 40A minimum 2200 15000 3 200 61 m 2 3 3200 PSI 8 13 3 3 wire ground 0138013 208V 3 40A minimum 1800 13300 3 200 61 m 2 3 3200 PSI 8 13 3 3 wire ground 0138059 208V 3 40A minimum 2360 13860 3 100 31 m 2 3 3200 PSI 8 13 3 3 wire ground 0138060 400V 3 40A minimum 2890 15690 3 100 31 m 2 3 3200 PSI 8 ...

Page 9: ... 2100m check the generator manufacturer s specifications for power loss offset Attention If powering the Helix system with a generator make sure the generator has ample power to run the system An inadequate generator will cause RPM fluctuations in the Component Pump motors during usage and can cause damage Follow the steps below to determing if your generator is able to supply sufficient power to ...

Page 10: ...10 SYSTEM DESCRIPTION HELIX A E D F J H K J L L B H G I C 3 System Description 3 1 System Diagram without circulation Waste containers not included must be closed at the top ...

Page 11: ...oses when in the PRIME position Turning the PRIME SPRAY knob will relieve any pressure built up in the system F Prime hoses When the PRIME SPRAY knobs are set to PRIME spray material will circulate into the Component pumps and then out of the prime hoses G Inlet valves The inlet valves allow material to be drawn from the material containers into the system They can be turned off in order to preven...

Page 12: ...12 SYSTEM DESCRIPTION HELIX A E D F L1 J H K K J N M M B H L2 G I C 3 3 System Diagram with circulation ...

Page 13: ... 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 E PRIME SPRAY knob The PRIME SPRAY knob directs material to the spray hose when in the SPRAY position and to the prime hoses when in the PRIME position Turning the PRIME SPRAY knob will relieve any pressure ...

Page 14: ... Control Displays The displays show various menu screens that allow the user to customize and monitor pump operation using the function keys 1 4 a A side independent controller When the component pumps are unlinked this controls Component Pump A b Master controller B side independent controller When the component pumps are linked the master controller controls both component pumps When the compone...

Page 15: ...en 10ºF i Refer to section 8 2 to review the controller error messages 4 2 Surefire Heated Hose Temperature Control i Refer to item 1 in section 4 The heated hose temperature control maintains the temperature of the spray material once it passes through the heater block and into the heated hoses 1 EZ ZONE ºF ºC Z O N E 8 8 8 8 8 8 8 8 8 EZ 2 1 3 4 5 1 Display Displays the current temperature of th...

Page 16: ...essure will change accordingly Function Keys The function keys are numbered 1 4 Each key is labeled with an additional function as well 1 Menu Key Pressing the 1 key scrolls through the available menu screens or performs a function described on the active menu screen 2 p Key Pressing the 2 key performs a function described on the active menu screen or increases a value 3 q Key Pressing the 3 key p...

Page 17: ...rements of 1 64 Pressing the 4 key will step up in increments from 1 to 16 Status Screen STATUS LINKED LINK 2 UNLINK 3 The Status Screen shows the link status of the A pump and B pump STATUS UNLINKED LINK 2 UNLINK 3 When turning the system on the two pumps will automatically be linked which means the A pump is controlled by the B pump When the Status Screen is showing pressing the 3 key will unlin...

Page 18: ... the pressure control knob is set at the MIN setting i If there is no action at any menu screen for 10 seconds the display will go back to the Main Screen Job Cycles Screen JOB CYCLES SELECT 4 MENU 1 The Job Cycles Screen shows the total number of piston cycles a component pump performs during a spray job CYCLES XXXX RESET 3 MENU 1 Pressing the 3 key will reset the cycle count to zero Pressing the...

Page 19: ... is defective Take the sprayer to a Titan authorized service center for repair Low Voltage Screen LOW VOLTAGE The Low Voltage screen appears when the sprayer shuts down because of low input voltage Check the power supply and correct the problem Restart the system High Motor Temperature Screen HIGH MOTOR TEMPERATURE The High Motor Temperature screen appears when the temperature of the motor has ris...

Page 20: ...2 Install the Transfer Pumps i The transfer pumps draw material directly from the spray material container to component pumps in the system The transfer pumps are powered by an air compressor Refer to section 3 1 for the corresponding illustrations to the steps below 1 Install the transfer pumps into Component A and Component B supply containers a With certain exceptions the A component hardener s...

Page 21: ...e dual heated whip hose to the coupling block 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 coupling block B Resin A ISO 5 Tighten both hose connections with a wrench Connect the Supply Hoses 1 Make sure the valve handles on the inlet valves for both Component pumps are in the OFF position see fig 11 2 Attach one end of the feed hose to ...

Page 22: ...onnect the Electrical Cord i A 230V power cord is not included with the system Make sure a grounded 230V outlet is available in order to power the system i 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...

Page 23: ... Allow them to remain open until clean air free fluid comes from the valves 9 Close fluid valves A then B 6 2 Set temperature i Refer to section 4 to review temperature controls Equipment surfaces can become hot To avoid severe burn injury 1 Do not touch hot fluid or equipment 2 Allow equipment to cool completely before coming into contact with it 3 Wear gloves when dealing with temperatures in ex...

Page 24: ... is unbalanced unlink the pumps and then adjust the pressure to desired balanced pressure Once pressure is balanced re link the pumps 8 Open the coupling block valves A and B on the spray gun Attention NEVER open the manifold valves on the coupling block or trigger the spray gun if the pressure readings are unbalanced 9 Disengage the trigger safety refer to the spray gun instruction manual 10 Test...

Page 25: ... the 1 key on the Control Display The CREEP MODE screen will now appear 3 Slowlyturnthepressurecontrolknobclockwisetoincrease the pressure The crankshaft slider assembly will begin to move very slowly 4 Wait until the crankshaft slider starts moving downward When it begins its downstroke turn the Component A PRIME SPRAY valve to SPRAY 5 When the crankshaft slider reaches the bottom dead center of ...

Page 26: ...s external fluid leak 5 There is an internal fluid section leak packings are worn and or dirty valve balls are worn 6 Worn valve seats 7 Motor powers but fails to rotate 8 Transfer pumps not supplying material 1 Turn the pressure control knob clockwise to increase the pressure setting 2 Clean or replace the PRIME SPRAY valve 3 Check the inlet valve feed hose connection Tighten or wrap the threads ...

Page 27: ...arm source 1 Check cause of under temperature 2 Clear latched alarm 3 Establish correct alarm set point 4 Set alarm source to proper setting E Alarm High Sensor input above high alarm set point AL H 1 AL H 2 AL H 3 AL H 4 1 Temperature is greater than alarm set point 2 Alarm is set to latching and an alarm occurred in the past 3 Incorrect alarm set point 4 Incorrect alarm source 1 Check cause of o...

Page 28: ...e feature 2 Set digital input to function othe than autotune if desired O No heat cool action Output does not activate load 1 Output function is incorrectly set 2 Control mode is incorrectly set 3 Output is incorrectly wired 4 Load power or fuse is open 5 Control set point is incorrect 6 Incorrect controller model for application 1 Set output function correctly 2 Set control mode appropriately Ope...

Page 29: ...current and or ensure current trip set point is correct 2 Check that the load current is proper Correct cause of undercurrent and or ensure current trip point is correct V Current Error Load current incorrect C Er 1 Short solid state or mechanical relay 2 Open solid state or mechanical relay 3 Current transformer load wire associated to wrong output 4 Defective current transformer or controller 5 ...

Page 30: ... Remove the motor controller 12 8 Loosen and remove the four motor baffle screws 13 Remove the motor baffle 14 9 Loosen and remove the three motor mounting screws 15 10 Pull the motor out 9 of the gearbox housing 16 11 With the motor removed inspect the gears in the gearbox housing for damage or excessive wear Replace the gears if necessary 12 Install the new motor 9 into the gearbox housing 13 Se...

Page 31: ...Follow steps 11 22 in Replacing the Motor Assembly to replace the motor and control panel 1 3 2 4 9 3 Replacing the Transducers Fig 19 20 1 Disconnect the power cord 2 Loosen the hex nut fig 19 item 1 in between the PRIME SPRAY manifold and the heater block Loosen it just enough so that it can be moved by hand 1 i Component Pump B has been removed from the graphic below for instructional purposes ...

Page 32: ...PRAY manifold screws 9 11 Reconnect the hoses at the block heater valves 6 and the fluid section 7 12 Replace the front top cover 3 and the rear top cover 4 Secure with the screws 4 5 2 3 8 10 9 6 7 11 12 9 4 Replacing the PRIME SPRAY valve i Perform the following procedure using PRIME SPRAY valve replacement kit P N 800 915 1 Use a drift punch of 2 mm to remove the grooved pin Fig 22 item 1 from ...

Page 33: ...e on the back of the fluid section cylinder 8 Loosen and remove the inlet valve housing 1 from the cylinder 2 9 Remove bearing ring 9 O ring 8 O ring 7 inlet valve seat 6 inlet valve ball 5 upper ball guide 4 and spring 3 10 Clean all the parts with the corresponding cleaning agent Check the inlet valve housing 1 inlet valve seat 6 and inlet valve ball 5 for wear and replace the parts if necessary...

Page 34: ...ve the upper support ring 8 and upper packing assembly 5 from the top of the cylinder 1 10 Remove the adapter 6 and lower packing assembly 7 from the bottom of the cylinder Attention Be careful not to scratch score or otherwise damage the cylinder during removal of the packings 2 1 3 5 8 6 7 4 9 10 11 Clean the cylinder 1 Inspect the cylinder for damage and replace if necessary 12 Place the cylind...

Page 35: ...he bottom of the lower packing is fully outside the packing around the piston rod after insertion of the piston rod 23 Remove the piston insertion tool from the top of the piston rod 4 24 Replace the cylinder 1 back into the fluid section clamp on the gear housing Make sure to slide the top of the piston rod extension into the T slot 9 on the slider assembly 10 25 Push the lever on the underside o...

Page 36: ...6 1 2 2 2 2 2 1 1 1 1 3 5 2 1 2 2 0138935 0522599 0522524 805 401 0522543 0138600 0522515 0522515 0522109 1 6 6 1 2 6 1 2 2 1 1 1 1 1 1 6 2 1 2 1 1 1 2 2 2 2 2 4 2 1 2 6 a h f b b e b b b b c a d i 0138513 0138512 c 0522123 B Wiring 1 Black 2 Red 3 White 4 Green 5 Blue 6 Brown Notes refer to next page a This end mounted to enclosure b To contact 0522532 c To surge protector d To relay 0522536 e To...

Page 37: ...4 597 0138513 A 0138522 9800078 0522109 800 437 0138424 Helix B 0138950 Helix A 0138949 i 0138612 0138601 0522582 0138514 2 0138516 0138467 0522062 0522109 0522109 0138522 9800078 800 437 0138424 0522108 0522062 e e c 0138513 B c 0138512 0153314 0153314 f b m a l g a l i Notes refer to previous page a This end mounted to enclosure b From switches c From c previous page d From d previous page e Fro...

Page 38: ...6 6 1 1 2 1 1 2 2 2 2 3 2 1 1 2 5 1 2 1 2 1 2 6 6 2 5 1 1 1 2 6 1 5 1 5 1 5 1 1 6 2 1 1 1 1 1 2 6 a 0138604 4 h 0138513 0138513 0138512 c d c f j j k e b b b b l l b i 1 1 2 5 g d 0138523 k Wiring 1 Black 2 Red 3 White 4 Green 5 Blue 6 Brown Notes refer to next page a This end mounted to enclosure b To contact 0138523 c To surge protector d To power distributor block e To 2A breaker 0522068 f To h...

Page 39: ...o p q r 800 437 9800078 0522109 0138522 0138424 0138424 800 437 9800078 0522109 1 2 4 4 1 1 1 1 1 1 2 1 5 5 1 5 1 1 1 2 2 5 1 1 5 4 6 6 4 0153314 4 5 6 5 2 1 2 1 4 1 2 Notes refer to previous page a This end mounted to enclosure b From switches c From c previous page Notes refer to previous page d From d previous page e From Emergency Stop 0522516 f From f previous page Notes refer to previous pag...

Page 40: ...40 HELIX Spare parts diagram main assembly 1 2 3 4 5 7 6 8 9 11 10 12 13 29 30 17 14 15 16 28 20 21 22 23 24 26 25 27 19 18 ...

Page 41: ... 8 Pos Helix A B Description 16 805 250A Face plate oiler assembly 2 17 700 139 Screw 8 18 756 088 Washer 4 19 860 002 Lock washer 4 20 9805438 Screw 4 21 Surefire heater block assembly 22 PRIME SPRAY valve assembly 2 23 770 601 Washer 4 24 9821503 Lock washer 4 25 9805437 Screw 4 26 0138666 Hose A side 0138473 Hose B side 27 800 904 Bleed hose 2 28 0138852 Label A side 0138853 Label B side 29 013...

Page 42: ...42 HELIX Spare parts diagram component pump assembly 1 3 4 7 6 2 8 5 2 10 11 12 13 9 16 15 14 6 17 19 21 20 22 18 23 24 ...

Page 43: ...9800340 9800340 Ground screw 2 12 Drive assembly 13 0138466 0138465 Power cord assembly 14 0552554A 0552554A Panel 15 0138872 0138872 Label 16 700 139 700 139 Screw 4 17 9894274 9894274 Spring 2 18 805 464 805 464 Retainer 19 9805362 9805362 Bolt 2 20 0558795 0558795 Plate 21 9821503 9821503 Lock washer 2 22 858 625 858 625 Screw 23 0138039A 0138277A Fluid section assembly 24 0138667 805 297 Hose ...

Page 44: ...44 HELIX Spare parts diagram drive assembly 4 5 6 1 2 3 7 8 9 10 11 18 17 12 13 14 15 16 ...

Page 45: ... 0558362A 3rd stage gear 7 0558363A 0558363A 2nd stage gear 8 9821503 9821503 Lock washer 3 9 700 287 700 287 Screw 3 10 0558737A 0558737A Motor assembly 11 805 460 805 460 Motor baffle 12 700 139 700 139 Screw 4 13 0138971 0138972 Electronic control assembly 14 9802266 9802266 Screw 2 15 0522051 0522051 Capacitor assembly 16 770 099 770 099 Tie wrap 17 0522040 0522040 Wire assembly 18 9822106 982...

Page 46: ...46 HELIX Spare parts diagram Heater Block Assembly 1 2 3 4 42 5 6 21 9 13 12 11 10 10 18 19 10 10 10 14 15 16 17 10 8 7 10 20 22 23 24 25 10 26 27 29 30 31 32 33 38 39 40 41 34 35 36 37 28 ...

Page 47: ...0524353 Nut 20 0138453 0138453 Top enclosure rear Pos Helix A B 0138011 0138060 Helix A B 0138013 0138059 Description 21 0522068 0522068 Circuit breaker 2 A 22 704 211A 704 211A Circuit breaker 12 A 3 23 9800340 9800340 Screw 6 24 0522582 0522582 Contact 40A 25 9812335 9812335 Nut 3 26 0138962 0138962 Relay 27 0138446A 0138446A Rear enclosure with insulation 28 9805287 9805287 Screw 4 29 0138964 0...

Page 48: ...48 HELIX Spare parts diagram Display Assembly 1 25 25 26 25 25 23 22 24 12 13 14 15 16 17 18 20 21 19 11 11 7 8 9 10 6 5 4 3 2 ...

Page 49: ...11 0138935 0138935 Controller 2 12 0138936 0138936 Controller 13 0522516 0522576 Emergency stop button 14 700 175 700 175 Cap 2 15 700 159 700 159 Control knob 2 16 0138863 0138863 Control knob label 2 17 700 176 700 176 Nut with seal 2 18 704 293 704 293 Mounting plate 2 19 0138457A 0138457A Display weldment with label 20 0138510 0138510 Spacer 4 21 0522524 0522524 Relay 2 22 0522543 0522543 Pote...

Page 50: ...50 HELIX Spare parts diagram fluid section 1 2 3 4 7 8 15 16 17 18 19 20 21 22 23 9 10 11 12 13 14 5 6 ...

Page 51: ...502 9841502 Outlet valve ball 12 0507454 0507454 Washer 13 0294516 0294516 Outlet valve seat 14 800 336 800 336 Outlet valve retainer 15 0509511 0509511 Adapter 16 0138411 0138411 Lower ball guide 17 0138406 0138406 Spring 18 51519 51519 Inlet valve ball 19 00310 00310 Inlet valve seat 20 800 332 800 332 O ring Viton 21 800 333 800 333 Backup ring 22 9871218 9871218 Inlet valve seal 23 0138481 013...

Page 52: ...52 HELIX Spare parts diagram Cart Assembly 1 2 3 4 5 Pos Helix A B Description 1 0138288A Cart assembly includes items 3 5 2 0294635 Plug 4 3 670 109 Wheel 2 4 0295687 Spacer 4 5 800 019 Axle cap 2 ...

Page 53: ... Helix B Description 1 800 437 800 437 Transducer assembly 2 0138424A 0138424A PRIME SPRAY assembly manifold 3 700 537 700 537 Gasket 4 0558727 0558727 Bypass valve assembly includes item 3 5 700 252B 700 252B Cam base 6 0138499 0138498 Relief valve knob 7 700 759 700 759 Groove pin ...

Page 54: ... top includes item 2 and 10 0138639A Heater block middle includes item 2 0138640A Heater block bottom includes item 2 and 10 2 0138469 Reducer fitting 2 3 0138960 Firestick rod 4 0138497 Spacer 2 5 9822558 Retainer ring 2 6 0138501 Thermocouple 7 0138492 Thermostat 8 9805280 Screw 4 9 860 002 Washer 4 10 9871228 O ring 2 ...

Page 55: ...d warranty published by Titan Titan s obligation under this warranty is limited to replacing or repairing without charge the Helix Motors to Titan s reasonable satisfaction are shown to be defective within forty eight 48 months after sale to the End User This warranty applies only when the unit is installed and operated in accordance with the recommendations and instructions of Titan This warranty...

Page 56: ...Sales service international WEB www titantool com Phone 1 844 458 1215 Fax 1 800 528 4826 1770 Fernbrook Lane Minneapolis MN 55447 web www titantool international com EMAIL international titantool com Fax 1 763 519 3509 ...

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