Trooper ADVANTAGE TR-100 Instruction Manual Download

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ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-0729 Fax: 317-881-1277 Service Fax: 317-885-8683

web site: www.AdvantageEngineering.com

Service Department email: [email protected]

TROOPER : Negative Pressure System

A. The

ADVANTAGE TROOPER

negative pressure unit is a fluid

circulating device utilizing a special

pump to create a negative pressure

inside the mold to stop any leak.

The above picture will give the reader

an overview of the major components

of the TROOPER system.

A - Gauge panel

B - Electrical panel door

C - Rocker switch and lights

D - Electrical panel

E - Air vent

F - Pump

G - Pump motor

H - Regulator (can’t be seen in

photograph)

1.2 INTRODUCTION

Summary of Contents for ADVANTAGE TR-100

Page 1: ...ted 11 13 INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 www AdvantageEnegineering com e mail sales AdvantageEngineering com ...

Page 2: ......

Page 3: ...500 COVERING INSTALLATION OPERATION MAINTENANCE N E G A T I V E P R E S S U R E U N I T TM ADVANTAGE ENGINEERING INC 525 East Stop 18 Road Greenwood IN 46142 317 887 0729 fax 317 881 1277 Service Department fax 317 885 8683 www AdvantageEnegineering com e mail sales AdvantageEngineering com ...

Page 4: ... 1 How an ADVANTAGE TROOPER works 15 4 2 Pressure drop across a mold 16 4 3 Mold leak simulation demo and operation check 17 4 4 Using mold heaters with TROOPER units 18 4 5 Fixing problem leaks multiple and cavity 20 4 6 Using ADVANTAGE TROOPER as a booster pump 21 5 TROUBLESHOOTING 22 5 1 Unit will not start power light off pressure lights off 22 5 2 Unit will not start power light on pressure l...

Page 5: ... 6 8 Setting and resetting the overload 30 6 9 Parts failure common causes 30 6 10 Replacement parts 32 6 11 Parts list TR 100 33 6 12 Parts list TR 200 34 6 13 Parts list TR 300 35 6 14 Parts list TR 400 36 6 15 Parts list TR 500 37 6 16 Electronic float switch assembly on TR 400 and TR 500 38 6 17 TROOPER flow diagram all models 39 6 18 TR 340 TR 400 TR 500 electrical pictorial 40 6 19 TR 100 TR...

Page 6: ...re to follow correct operating instructions may damage the unit B Please read your manual C CAUTION the following conditions will damage this unit a Running the unit at temperatures higher than 180 F b Using synthetic oils as a coolant fluid c Running with drain pressure less than 5 PSI below the FROM MOLD pressure d Reversing pump rotation D CAUTION DRAIN gauge must never show less than 5 PSI pre...

Page 7: ...System A The ADVANTAGE TROOPER negative pressure unit is a fluid circulating device utilizing a special pump to create a negative pressure inside the mold to stop any leak B The above picture will give the reader an overview of the major components of the TROOPER system A Gauge panel B Electrical panel door C Rocker switch and lights D Electrical panel E Air vent F Pump G Pump motor H Regulator ca...

Page 8: ...dard THREE WIRE cord UL approved and rated for 15 amps 4 230 460 VAC 3Ø units use a standard FOUR WIRE cord UL approved and rated for the amperage of the unit being wired 4 Electrical code requires power cords to be rated for 25 more than the Full Load Amperage FLA of the unit FLA for every unit is recorded on the motor serial plate 5 14 Gauge wire is adequate for all ADVANTAGE TROOPER negative pr...

Page 9: ... not light turn the power off and disconnect the power supply Swap any two 2 of the three 3 input wires at the terminal block DO NOT REMOVE THE GROUND E Reconnect the power supply and turn the power on The LED will now glow indicating that the unit is wired to the phase sequence required for correct motor rotation F NOTE it may be necessary to slightly lower the adjustment dial of the phase monito...

Page 10: ...RUCTIONS 3 1 START UP ADJUSTMENTS A A simplified version of the following instruction are silkscreened on the ADVANTAGE TROOPER cabinet for easy reference B Make all hose connections to the appropriate ports at the back of the ADVANTAGE TROOPER C Begin with the POWER switch in the OFF position FROM MOLD connection RETURN connection SUPPLY connection TO MOLD connection C When using the ADVANTAGE TR...

Page 11: ...IN line a The RETURN DRAIN line should always be opened first Because the pump is positive displacement if it is run without the return line open excessive pressure will build up and possibly rupture the drain line hose or cause internal pump damage b After waiting a moment for internal pressure to balance you can read your system drain pressure in the DRAIN gauge at the front of the ADVANTAGE TRO...

Page 12: ...he regulator original set up only a Watch the mold at the leak point and slowly turn the regulator screw in clock wise until water begins to leak out b Now slowly turn the regulator screw out counter clock wise until the leak stops and continue an additional one half turn c The ADVANTAGE TROOPER is now adjusted for the maximum coolant flow through the mold Continuing to back out the regulator scre...

Page 13: ...s pumping against When the unit is turned off the reading becomes inaccurate as internal pressures balance E CAUTION DRAIN gauge should never show less than five 5 PSI below TO MOLD pressure while unit is running or pump may be damaged See appendix Parts Failure Stator F Static pressure readings of house system may be obtained by turning the unit off Shut off the DRAIN and leave the SUPPLY open to...

Page 14: ...eing damaged by running dry D DRAIN PRESSURE TOO HIGH this indicator light will come on when the unit has shut down because the drain pressure is greater than the pumping capacity of the unit The high pressure shut off switch protects the motor from being damage by excessive strain E FOR ADDITIONAL INFORMATION OR PROBLEM SOLVING REFER TO THE TROUBLESHOOTING GUIDE 3 4 SHUT DOWN STORAGE A The follow...

Page 15: ...ospheric pressure and outgoing pressure The available draw or vacuum capability of the pump outgoing pressure remains constant Atmospheric pressure also remains constant Therefore the control we have for stopping leaks is the incoming pressure The pressure regulator inside the ADVANTAGE TROOPER is used to limit the incoming water pressure to the leak C When using an ADVANTAGE TROOPER the water is ...

Page 16: ...inimum coolant flow B The ADVANTAGE TROOPER in this example can pull a maximum vacuum of about 12 PSI on the FROM MOLD line This determines the overall pressure differential on only 12 PSI C The coolant pressure must be zero only at the point of the leak Therefore by having the coolant enter the mold at the point farthest from the leak much of the pressure drop can take place before the leak This ...

Page 17: ... mold D Open the DRAIN line first E Then open the SUPPLY line F Turn the power on G With a jumper hose between the TO MOLD and FROM MOLD ports the suction of the pump may draw some fluid through the regulator even through it is closed Pinch the jumper hose closed The FROM MOLD gauge should show a vacuum of more that 24 inches of mercury H Be sure the regulator screw is backed out If you wish you m...

Page 18: ...CLUSION a You have thoroughly checked the operation of the ADVANTAGE TROOPER negative pressure unit Following and understanding the procedure outlined how an ADVANTAGE TROOPER works will help in the future when dealing with negative pressure cooling b Remember that a mold is much more complex than the simple jumper hose used in the Mold Leak Simulation Yet in general the same procedure should be f...

Page 19: ...e is to control the total pressure in the system The flow control valve allows a constant relief of pressure downstream of the regulator even when the mold heater does not need cooling or the drain is shut off F Start up procedure mold heater with TROOPER 1 Set the TROOPER regulator to maximum vacuum screw backed out 2 Adjust the mold heater regulator as high as possible without over loading the T...

Page 20: ...e section 4 1 How a TROOPER works B LEAKS INTO MOLD CAVITY 1 In a few cases if the leak is directly into the cavity or core the draw of the part when the mold opens or upon ejection CONNECTIONS FOR ADVANTAGE TROOPER UNIT USED WITH MOLD HEATER DO NOT RUN UNIT WITH WATER OVER 180 F NOTES A When supply pressure is greater than 45 PSI use regulator valve as noted It must be set so that coolant pressur...

Page 21: ...in production before a final adjustment can be made 2 In extreme cases it may be necessary to shut the flow off just prior to the mold opening to eliminate any leakage This can be done by installing a solenoid on the TO MOLD line that is closed by one of several methods the clamp open signal from the molding press or a cycle timer or a parting switch between mold halves The most effective signalli...

Page 22: ...icates an electrical fault in the control circuitry of the TROOPER All components should be thoroughly checked before restarting E On three phase units in very rare cases the transformer itself may be bad This can be checked by reading secondary coil output voltage F On models TR400 and TR500 check the motor starter overload see appendix for wiring diagram Because these models do not require the a...

Page 23: ...unit shuts down to protect itself from running dry Both the supply gauge and the low pressure switch are connected to internal supply lines after the strainer therefore both will indicate a clogged strainer With constant use the screen should be checked at least once a week DO NOT RUN WITHOUT A STRAINER SCREEN Even clean looking water can contain abrasive sediments that will ruin the internal part...

Page 24: ...n 5 PSI and 10 PSI D DO NOT RESTRICT THE DRAIN LINE ON ADVANTAGE TROOPER UNITS THAT DO NOT HAVE A HIGH PRESSURE SWITCH 1 The following units do not have a high pressure switch the motor starter overload provides the necessary protection TR400 will shut off between 45 PSI and 50 PSI TR500 will shut off between 45 PSI and 50 PSI 5 6 HIGH PRESSURE SWITCH CHECK A Some ADVANTAGE TROOPER units have a hi...

Page 25: ...ck disconnect fitting that leaks air under negative pressure vacuum because it will seal under positive pressure C If the above checks have been done and the FROM MOLD gauge still does not show a vacuum the gauge may be bad 5 8 EXCESSIVE AIR OR FOAM IN THE RETURN LINE A Ethylene glycol ant freeze is being used the action of the pump may cause the fluid to foam inside the pump Air trapped in foam c...

Page 26: ...9 B AT PUMP 1 If unit leaks between pump halves and bolts are tight stator may be damaged and should be replaced See section 6 2 Parts Failure common causes on page 29 5 11 HOSE COLLAPSES A Use a hose that is rated for vacuum and temperature Be sure that there are no sharp turns or loops in the hoses 5 12 WATER DRAINS CONSTANTLY FROM VENT LINE A On the TR 100 TR 200 and TR 300 1 The mechanical flo...

Page 27: ...ply to the point where the unit will shut down to protect from running dry Running without a screen can allow abrasive water sediments to destroy the internal parts of the pump 6 2 DRAIN FOR STORAGE A Refer to section 3 4 Shutdown and storage on page 14 6 3 SPECIFICATIONS AND PERFORMANCE DATA ALL UNITS SPECIFICATIONS AND PERFORMANCE DATA MODEL TR100 TR200 TR300 TR400 TR500 MAXIMUM BACK PRESSURE PS...

Page 28: ... questions call ADVANTAGE ENGINEERING INC at 317 887 0729 6 5 CAPACITY 6 6 WEIGHT DIMENSIONS PORT SIZES CAPACITY IN GALLONS PER MINUTE WITH VARYING BACK PRESSURE MODEL TR100 TR200 TR300 TR400 TR500 0 5 0 9 2 14 8 24 0 52 0 10 4 6 8 4 13 9 23 0 47 0 30 4 1 6 4 11 8 22 0 36 0 50 3 4 4 2 9 2 19 0 25 0 70 2 8 100 150 PSI WEIGHT DIMENSIONS PORTSIZES MODEL TR100 TR200 TR300 TR400 TR500 WEIGHT 120lbs 54 ...

Page 29: ...V PHASE MONITOR SLA 220 ASA SLA 380 ASA SLA 440 ASA PART E REV RLY220 E REV RLY380 E REV RLY440 C To change the voltage 1 Replace motor overload with correct one for the new voltage see chart below Refer to appendix Overload Setting and Resetting for proper adjustment procedures 2 Replace the phase monitor with correct one for the new voltage see chart below Refer the section 1 B Checking the phas...

Page 30: ...shut the unit down when the motor is over stressed or malfunctioning Be sure the unit is in proper working order before pressing the reset button F Reasons for the overload to trip 1 Phase loss 2 Repeated cycling from improper supply or return pressures May be caused by clogged strainer supply screen 3 Motor has exceeded normal life expectancy 4 On single phase units motor capacitor or centrifugal...

Page 31: ... dry low pressure switch improperly set less than 8 PSI 4 Boiling water steam in pump Stator often fails first Refer to appendix Boiling points of water under vacuum 5 Abrasive particles in system water especially when unit is run without supply F OVERLOAD causes of failure 1 Particulate contaminants jam moving parts or short contacts 2 Repeated on off cycling has fused contacts check that the ove...

Page 32: ...tch E SW L PRS BD High pressure switch E SW H PRS L1 On off switch E SW ROCKER Indicator lights E P LGT RED3000 Motor starter relay E CNTR AEG Transformer E TRANS V050 Solenoid Valve E SLND1 4 Float switch see appendix float switch assembly Overload see appendix changing voltage for part number Phase monitor see appendix changing voltage for part number 6 10 REPLACEMENT PARTS 8 PSI 5 Boiling water...

Page 33: ...LG 2 Suction housing R SCTNL23 21 Stator R STRL1 22 Rotor R RTRL1 24 Flexible joint 1Ø RFLXL23T 24 Flexible joint 3Ø RFLXL23P 45 Rotor pin R PINL234 46 Shaft Pin R PINL234 69 Mechanical seal R SEAL123 69 Mechanical seal R SEAL123 70 Motor 1Ø R MTRL21RM 70 Motor 3Ø R MTRL23RM 72 Motor support R L4 MOTSUP 77 Slinger run R SLNGRNGL23 112 Screw cap 8 req H S10 24x58SPH 112A Screw hex head 4 req H B38 ...

Page 34: ...scharge housing R BDYCSTL23FLG 2 Suction housing R SCTNL23 21 Stator R STRL2 22 Rotor R RTRL2 24 Flexible joint 1Ø RFLXL23T 24 Flexible joint 3Ø RFLXL23P 45 Rotor pin R PINL234 46 Shaft Pin R PINL234 69 Mechanical seal R SEAL123 70 Motor 1Ø R MTRL21RM 70 Motor 3Ø R MTRL23RM 77 Slinger ring R SLNGRNGL23 112 Screw cap 8 req H S10 24x58SPH 112A Screw hex head 4 req H B38 16X1SH 135 Stator ring N A 21...

Page 35: ...Discharge housing R BDYCSTL23FLG 2 Suction housing R SCTNL23 21 Stator R STRL3 22 Rotor R RTRL3 24 Flexible joint 1Ø N A 24 Flexible joint 3Ø RFLXL23P 45 Rotor pin R PINL234 46 Shaft Pin R PINL234 69 Mechanical seal R SEAL123 70 Motor 1Ø R MTRL31RM 70 Motor 3Ø R MTRL33RM 77 Slinger ring R SLNGRNGL23 112 Screw cap 8 req H S10 24x58SPH 112A Screw hex head 4 req H B38 16X1SH 135 Stator ring N A 215 L...

Page 36: ...L4 2 Suction housing R SCTNL4 21 Stator R STRL4 22 Rotor R RTRL4 24 Flexible joint RFLXL4 45 Rotor pin R PINL234 46 Shaft Pin R PINL234 69 Mechanical seal R SEALL354 70 Motor R MTRL4RM 72 Motor support R L4 MOTSUP 77 Slinger ring R SLNGRNGL4 103 Nuts 2 req H N38 16SH 112 Screw hex head H B38 16X112SH 112A Screw hex head 4 req H B38 16X1SH 112B Screw hex head 2 req H B38 16X2SH 215 Lock washer H W3...

Page 37: ...ousing R BDYCSTL5 2 Suction housing R SCTNL5 21 Stator R STRL5 22 Rotor R RTRL5 24 Flexible joint RFLXL5 45 Rotor pin R PINL5 46 Shaft Pin R PINL5 69 MECHANICAL SEAL R SEALL5 69A Seal spacer R SELSPA L5 70 Motor R MTRL5RM 77 Slinger run R SLNGRNGL5 103 Nuts 2 req H N38 16SH 112 Screw hex head H B38 16X112SH 112A Screw hex head 4 req H B38 16X1SH 112B Screw hex head 2 req H B38 16X2SH 215 Lock wash...

Page 38: ...Engineering com Service Department email service AdvantageEngineering com TROOPER Negative Pressure System 6 16 ELECTRONIC FLOAT SWITCH ASSEMBLY TR 400 1 Electrical connection 2 Shrink tubing and compression fitting 3 Upper tank casting 4 Inlet 5 Nipple 6 coupling 7 Baffle 8 Float 10 Float switch level 11 Copper pipe sleeve 12 Lower tank casting 13 Tank cap ...

Page 39: ... Service Fax 317 885 8683 web site www AdvantageEngineering com Service Department email service AdvantageEngineering com TROOPER Negative Pressure System 6 17 TROOPER FLOW DIAGRAM ALL MODELS PRESSURE REGULATOR LOW PRESSURE SWITCH FILTER BY PASS LINE PUMP LUBRICATION PUMP DRAIN FROM MOLD SUPPLY TO MOLD AIRVENT ...

Page 40: ...nt email service AdvantageEngineering com TROOPER Negative Pressure System F FX X1 X2 H2 H3 H4 H1 TRANSFORMER L2 L1 L3 13 T2 T1 T3 14 M1 STARTER SP4 b178 OL1 M1 M2 M3 96 98 97 95 F81 FLOAT 8OL1 L1 PM1 TB1 L1 L2 L2 L1 L2 L3 1 2 3 4 5 6 7 8 PHASE MONITOR C NO NC PS1 GROUND POWER 9 10 6 6 11 R 5 10 15 12 14 16 13 13 5 9 4 L1 L2 4 L3 L3 MTR1 9 8 6 18 TR 350 TR 400 TR 500 ELECTRICAL PICTORIAL ...

Page 41: ...eEngineering com TROOPER Negative Pressure System F FX X1 X2 H2 H3 H4 H1 TRANSFORMER L2 L1 L3 13 T2 T1 T3 14 M1 STARTER SP4 b178 OL1 M1 M2 M3 96 98 97 95 MTR1 L1 PM1 TB1 L1 L2 L2 L1 L2 L3 1 2 3 4 5 6 7 8 PHASE MONITOR GROUND POWER 9 10 6 11 R 14 R 10 12 13 5 9 4 L1 L2 C NO NC PS1 6 5 4 C NO NC PS2 15 14 5 L3 L3 HIGH PRESSURE LOW PRESSURE 13 A2 LT1 LT2 LOW HIGH 8 9 6 19 TR 100 TR 200 TR 300 3Ø ELEC...

Page 42: ...w AdvantageEngineering com Service Department email service AdvantageEngineering com TROOPER Negative Pressure System 6 20 TR 100 TR 200 TR 300 1Ø ELECTRICAL PICTORIAL L2 L1 L3 13 T2 T1 T3 14 M1 STARTER SP4 M1 M2 L1 TB1 L1 L2 POWER 6 11 R 14 R 5 4 C NO NC PS1 6 5 4 C NO NC PS2 15 14 5 L3 HIGH PRESSURE LOW PRESSURE 10 LT1 LT2 LOW HIGH 9 13 81 MTR1 ...

Page 43: ... service AdvantageEngineering com TROOPER Negative Pressure System 6 21 TR 350 TR 400 TR 500 3Ø AC LADDER DIAGRAM MTR1 OL1 OL1 OL1 T1 T2 T3 MS1 MS1 MS1 3 4 5 L1 L2 L3 PM1 PHASE MONITOR H1 H4 H3 H2 T1 X1 X1 120V POWER PHASE S1 9 8 1 4 PS1 6 6 96 95 11 4 4 5 16 FU1 1A PM1 OL1 LOWPRESSURE 14 16 FLOAT PS1 LOWPRESSURE R LT1 LOWPRESSURE 4 13 13 15 13 R 5 12 MS1 LTS1 POWERON SOL1 L1 L2 L3 240V 3PH 60HZ ...

Page 44: ...d Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Fax 317 885 8683 web site www AdvantageEngineering com Service Department email service AdvantageEngineering com TROOPER Negative Pressure System 6 22 TR 100 TR 200 TR 300 3Ø AC LADDER DIAGRAM ...

Page 45: ...d Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Fax 317 885 8683 web site www AdvantageEngineering com Service Department email service AdvantageEngineering com TROOPER Negative Pressure System 6 23 TR 100 TR 200 TR 300 1Ø AC LADDER DIAGRAM ...

Page 46: ... Greenwood Indiana 46142 317 887 0729 Fax 317 881 1277 Service Fax 317 885 8683 web site www AdvantageEngineering com Service Department email service AdvantageEngineering com TROOPER Negative Pressure System 6 24 BOILING POINT OF WATER AT VARIOUS PRESSURES ...

Page 47: ...END ADVANTAGE ENGINEERING INC RE 11 13 ...

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