Titan HELIX 0138011, HELIX 0138059 AP, HELIX 0138011 AP, HELIX 0138060, HELIX 0138060 AP Operating Manual

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Airless, high-pressure sprAying system

With surefire™ heAting system

OperAting mAnuAl

Models: 0138011 0138011 AP 0138013 0138013 AP 0138059 0138059 AP 0138060 0138060 AP

0117 • Form No. 0138966C

original operating manual

Airless units develop extremely high spraying pressures.

HELIXHELIX

Warning!

Attention: Danger of injury by injection!

Never put your ngers, 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. Do not treat a spraying injury as a harmless cut. In case of injury

to the skin through coating materials or solvents, consult a doctor immediately for quick and expert treatment. Inform the doctor 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 instructions regarding regular cleaning and maintenance of the unit must be strictly observed.

Before any work is done on the unit or for every break in work the following rules must be observed:

1. Release the pressure from spray gun and hose.

2. Secure the spray gun using the safety catch on the trigger.

3. Switch o unit.

4. Unplug the power cord from the unit.

Be safety conscious!

ContentS

HELIX

1 SAFETY REGULATIONS ___________________ 4

1.1 Explanation of symbols used _____________________4

1.2 Isocyanate (ISO) Conditions _____________________6

1.3 Electric safety _________________________________7

2 GENERAL DESCRIPTION __________________ 8

2.1 System congurations __________________________ 8

2.2 Clearance diagram _____________________________ 8

2.3 Electrical / generator requirements _______________9

3 SYSTEM DESCRIPTION __________________ 10

3.1 System diagram - without circulation _____________ 10

3.2 Component description - without circulation ______11

3.3 System diagram - with circulation _______________12

3.4 Component description - with circulation _________13

3.5 Installing the circulation kit (optional) ____________13

4 CONTROL PANEL _______________________ 14

4.1 Surere™ heater block control __________________15

4.2 Surere™ heated hose temperature control ________ 15

4.3 Component pump pressure control ______________16

4.4 Control Displays ______________________________ 16

4.5 Control Displays Error Messages _________________ 19

5 SETUP _________________________________ 20

5.1 Locate the system ____________________________20

5.2 Install the transfer pumps ______________________20

5.3 Connect the Surere™ heated hoses _____________21

5.4 Connect the electrical cord _____________________22

5.5 Ground the system ___________________________22

5.6 Lubricate the component pumps ________________22

7 SHUTTING DOWN _______________________ 25

7.1 Parking _____________________________________25

7.2 Flushing ____________________________________25

8 TROUBLESHOOTING ____________________ 26

8.1 Component pump ____________________________26

8.2 Surere™ heater block / hose heater controller errors ____________________ 27

9 SERVICING _____________________________ 30

9.1 Replacing the motor assembly __________________30

9.2 Replacing the gears ___________________________31

9.3 Replacing the transducers ______________________ 31

9.4 Replacing the PRIME/SPRAY valve _______________32

9.5 Inlet and outlet valves _________________________33

9.6 Packings ____________________________________34

9.7 Electrical schematic (0138013 / 0138059)_______ 36/37

9.8 Electrical schematic (0138011 / 0138060)_______ 38/39

SPARE PARTS LISTS __________________________ 40

Spare parts list for main assembly __________________ 40/41 Spare parts list for component pump assembly _______ 42/43 Spare parts list for drive assembly __________________ 44/45 Spare parts list for Surere™ heater block system _____ 46/47 Spare parts list for display assembly ________________ 48/49 Spare parts list for uid section ____________________ 50/51 Spare parts list for cart assembly ______________________ 52 Spare parts list for PRIME/SPRAY valve assembly _________53 Spare parts list for Surere™ heater block _______________ 54

WARRANTY _________________________________ 55

6 OPERATION ____________________________ 23

6.1 Startup _____________________________________23

6.2 Set temperature ______________________________ 23

6.3 Spraying ____________________________________24

6.4 Pressure relief procedure _______________________ 24

SaFetY regulationS

or solvents, consult a doctor immediately for quick and expert treatment. Inform the doctor

1 SAFETY REGULATIONS

HELIX

1.1

This manual contains information that must be read and understood before using the equipment. When you come to an area that has one of the following symbols, pay particular attention and make certain to heed the safeguard.

EXPLANATION OF SYMBOLS USED

This symbol indicates a potential hazard



that may cause serious injury or loss of life. Important safety information will follow.

This symbol indicates a potential hazard



to you or to the equipment. Important

tention

information that tells how to prevent damage to the equipment or how to avoid causes of minor injuries will follow.

Danger of skin injection



Danger of re from solvent and spray fumes



Danger of explosion from solvent, spray



fumes and incompatible materials

Danger of injury from inhalation of harmful



vapors

Danger of injury from burns



HAZARD: INJECTION INJURY

Attention: Danger of injury by injection! A high pressure stream produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation.

Do not treat a spraying injury as a harmless cut. In case of injury to the skin through coating materials

about the coating material or solvent used.

PREVENTION:

• NEVER aim the gun at any part of the body.

• NEVER allow any part of the body to touch the uid stream.

DO NOT allow body to touch a leak in the uid hose.

• NEVER put your hand in front of the gun.

• ALWAYS lock the gun trigger, shut the uid pump o

and release all pressure before servicing, cleaning the tip guard, changing tips, or leaving unattended. Pressure will not be released by turning o the engine. The PRIME/ SPRAY valve(s) or pressure bleed valve must be turned to their appropriate positions to relieve system pressure.

• All accessories must be rated at or above the maximum

operating pressure range of the sprayer. This includes guns, extensions, and hose.

HAZARD: EXPLOSION OR FIRE

Solvent and material fumes can explode or ignite. Severe injury and/or property damage can occur.

Danger of injury from electric shock



Notes give important information which



should be given special attention.

PREVENTION:

• Only spray coating materials with a ash point of at least

5 kelvin higher than the set temperature (minimum ash point is 38°C). The ash point is the lowest temperature at which vapors develop from the coating material. These vapors are sucient to form an inammable mixture over the air above the coating material.

• Do not use a material or solvent containing halogenated

hydrocarbons. Such as chlorine, bleach mildewcide, methylene chloride and trichloroethane. They are not compatible with aluminum. Contact the coating supplier about compatibility of material with aluminum.

• Do not use the unit in work places which are covered by

the explosion protection regulations.

• Provide extensive exhaust and fresh air introduction to

keep the air within the spray area free from accumulation of ammable vapors.

SaFetY regulationS

Solvents and other materials can be harmful if inhaled or come in contact with body. Vapors

Heated uids, when in conned areas such as spray hoses, can create a rapid rise in pressure due to thermal expansion. Over-pressurization

The spray hose can develop leaks from wear,

HELIX

• Avoid all ignition sources such as static electricity sparks,

electrical appliances, ames, pilot lights, hot objects, and sparks from connecting and disconnecting power cords or working light switches.

HAZARD: BURN HAZARD

Certain components of the equipment are heated and become hot during operation.

• Do not smoke in spray area.

• Place sprayer sucient distance from the spray object in a

well ventilated area. Flammable vapors are often heavier than air. Floor area must be extremely well ventilated. The pump contains arcing parts that emit sparks and can ignite vapors.

PREVENTION:

• To avoid severe burns and injury, do not touch heated uid

or equipment. Wait until the equipment has completely cooled.

• The equipment and objects in and around the spray area

must be properly grounded to prevent static sparks.

HAZARD: THERMAL EXPANSION

• Use only conductive or earthed high pressure uid hose.

Gun must be earthed through hose connections.

• Power cord must be connected to a grounded circuit

(electric units only).

can lead to a rupture and serious injury.

• Follow material and solvent manufacturer’s warnings and

instructions. Be familiar with the coating material’s SDS sheet and technical information to ensure safe use.

• Use lowest possible pressure to ush equipment.

• When cleaning the unit with solvents, the solvent should

never be sprayed or pumped back into a container with a small opening (bunghole). An explosive gas/air mixture can arise. The container must be earthed.

PREVENTION:

• During system heating, make sure PRIME/SPRAY valves are

set to SPRAY.

• Before each use, check all hoses for cuts, leaks, abrasion

or bulging of cover. Check for damage or movement of couplings. Immediately replace the hose if any of these conditions exist. Never repair a spray hose. Replace it with another earthed high-pressure hose.

HAZARD: HAZARDOUS VAPORS

can cause severe nausea, fainting, or poisoning.

PREVENTION:

• Wear respiratory protection when spraying. Read all

instructions supplied with the mask to be sure it will provide the necessary protection.

• All local regulations regarding protection against

hazardous vapors must be observed.

• Wear protective eyewear.

• Protective 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

kinking and abuse. A leak can inject material into the skin. Inspect the hose before each use.

PREVENTION:

: HIGH PRESSURE HOSE

• High-pressure hoses must be checked thoroughly before

they are used.

• Replace any damaged high-pressure hose immediately.

• Never repair defective high-pressure hoses yourself!

• Avoid sharp bends and folds: the smallest bending radius

is about 20 cm.

• Do not drive over the high-pressure hose. Protect against

sharp objects and edges.

• Never pull on the high-pressure hose to move the device.

• Do not twist the high-pressure hose.

• Use only compatible cleaning solutions.

• Lay the high-pressure hose in such a way as to ensure that

it cannot be tripped over.

Only use approved original-high-pressure hoses in order to ensure functionality, safety and durability.

SaFetY regulationS

HELIX

1.2 ISOCYANATE ISO CONDITIONS

HAZARD: GENERAL

This product can cause severe injury or property damage.

PREVENTION:

• Follow all appropriate local, state, and national codes

governing ventilation, re prevention, and operation.

• Pulling the trigger causes a recoil force to the hand that is

holding the spray gun. The recoil force of the spray gun is particularly powerful when a high pressure has been set on the airless pump. When cleaning, set the pressure control to the lowest pressure.

• Use only manufacturer authorized parts. User assumes all

risks and liabilities when using parts that do not meet the minimum specications and safety devices of the pump manufacturer.

• ALWAYS follow the material manufacturer’s instructions

for safe handling of chemicals.

• Clean up all material and solvent spills immediately to

prevent slip hazard.

• Never leave this equipment unattended. Keep away from

children or anyone not familiar with the operation of airless equipment.

• Device weighs in excess of 36 kg. Three-person lift is

required.

• The device and all related liquids (i.e. hydraulic oil) must be

disposed of in an environmentally friendly way.

Important Information Regarding TwoComponent Material. Read before using the equipment.

ISOCYANATE ISO CONDITIONS

• Use only Methyldiisocyanates (MDI).

• Spraying materials that contain isocyanates (ISO) creates

mists, vapors and atomized particulates that are potentially harmful.

• Be familiar with the spray material’s SDS in order to

understand specic 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 sucient ventilation is not available, a supplied-air respirator must be available to everyone in the work area.

• AVOID ANY BARESKIN CONTACT WITH ISOCYANATES.

To prevent contact with isocyanates, all persons located within the spray area must be wearing the appropriate protective equipment, including chemically impermeable gloves, boots, aprons and goggles.

MATERIAL IGNITION

• Some materials may become self-igniting if applied too

thickly. Read material manufacturer’s warnings and material SDS.

KEEP SPRAY COMPONENTS SEPARATE

• Cross-contamination of individual spray materials can

result in cured material in uid lines which can cause severe injury and/or damage to the equipment.

• To prevent cross-contamination of the equipment wetted

parts, NEVER interchange Component A (isocyanate) parts with Component B (resin) parts.

MOISTURE SENSITIVITY

Isocyanates (ISO) are catalysts used in two-component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard abrasive crystals. These crystals will then contaminate the uid. Eventually a lm will form on the uid surface and the ISO will begin to gel, increasing in viscosity. Fluid contaminated with partially cured ISO , if used, will reduce spray performance and the overall life of the component wetted parts.

SaFetY regulationS

HELIX

1.3 ELECTRIC SAFETY

Electric models must be earthed. In the event of an electrical The amount of lm formation and the rate of crystalization varies depending upon the blend of ISO, the humidity and the temperature.

short circuit, earthing reduces the risk of electric shock by

providing an escape wire for the electric current. Connection

to the mains only through a special feed point, e.g. through an

error protection insallation with INF < 30 mA.

PREVENTION:

• Always use a sealed container with a desiccant dryer in

the vent, or a nitrogen atmosphere. NEVER store ISO in an open container.

• Use ONLY the moisture-proof hoses specically designed

for ISO that are supplied with your system. If new hoses need to be ordered, contact Titan Technical Service.

• Never ush reclaimed solvents through the system.

Reclaimed solvents can contain moisture. Always keep solvent containers closed when not being used to prevent moisture contamination.

• Never use solvent on one side if it has been contaminated

from the other side.

• Always lubricate threaded parts with ISO pump oil or

grease when reassembling.

• Always circulate a hose and pump that contains ISO at least

once a week to prevent the ISO from crystalizing.

CHANGING MATERIALS

• When changing spray materials, thoroughly ush the

equipment multiple times to ensure that it is fully clean.

• Always clean the uid inlet strainers after ushing.

• Check with your material manufacturer for chemical

compatibility.

• Most materials use ISO with Component A, but some use

ISO with Component B.

• Epoxies often have amines (hardener) with Component B.

Polyureas often have amines with Component B (resin).

FOAM RESINS WITH 245FA BLOWING AGENT

Some 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.

DANGER — Work or repairs at the electrical equipment may only be carried out by a skilled electrician. No liability is assumed for incorrect installation. Switch the unit o. Before all repair work, unplug the power plug from the outlet.

Danger of short-circuits caused by water ingressing into the electrical equipment. Never spray down the unit with high-pressure or highpressure steam cleaners.

OPERATING TEMPERATURE

This equipment will operate correctly in its intended ambient,

at a minimum between +10°C and +40°C.

RELATIVE HUMIDITY

The equipment will operate correctly within an environment

at 50% RH, +40°C. Higher RH may be allowed at lower

temperatures.

Measures shall be taken by the Purchaser to avoid the harmful

eects of occasional condensation.

ALTITUDE

This equipment will operate correctly up to 2100 m above

mean sea level.

TRANSPORTATION AND STORAGE

This equipment will withstand, or has been protected against,

transportation and storage temperatures of -25°C to +55°C and

for short periods up to +70°C.

It has been packaged to prevent damage from the eects of

normal humidity, vibration and shock.

general DeSCription

2 GENERAL DESCRIPTION

HELIX

The Helix Plural Component System is a dual, high pressure airless sprayer system that can be linked in order to spray multicomponent uids.

Model Voltage

(phase)

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 (13.3), 3 wire + ground

The spray gun provided with this system or sold individually is not Intertek approved.

3-phase circuit

breaker req’d

Hose

Watts

System

Watts

# Heating

Elements

2.1 SYSTEM CONFIGURATIONS

The Plural Component System is available in the following

conguration(s) which is based upon the number of heating

elements, hose length, electrical phases and the required

power cord (not supplied). Refer to the chart below.

Heated

Hose

Max Flow (gal/min)

Max Fluid

Pressure

Cord Specication

AWG (mm)

2.2 CLEARANCE DIAGRAM

When determining the location of the Helix system, use the diagram below to determine space clearance and mounting hole dimensions.

26.7” (678 mm)

28” (711 mm)

23.2” (589 mm)

47.2” (1199 mm)

29.4” (747 mm)

general DeSCription

HELIX

2.3 ELECTRICAL / GENERATOR REQUIREMENTS

It is recommended that the Helix System be used with a generator. This provides the exibility 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. Check the regulations in your country and contact your network operator before connecting the unit to a public electricity grid.

The Helix System requires a 208-240V capacity. Make sure the power source is rated to this specication.

When working at altitudes above 2100m, check the generator manufacturer’s specications for power loss oset.

If powering the Helix system with a generator, make sure the generator has ample power to

tention

Follow the steps below to determing if your generator is able to supply sucient power to the Helix system.

1. Perform this equation:

System Watts 13,300 x 1.25 = kVA (kilovolt / amperes)

2. If your generator’s kVA rating is higher than what was

If your generator’s kVA rating is lower than what was

run the system. An inadequate generator will cause RPM uctuations in the Component Pump motors during usage and can cause damage.

determined in the equation above, the generator will be able to power the system.

determined in the equation above, the generator WILL NOT be able to power the system. A larger generator is required.

SYStem DeSCription

3 SYSTEM DESCRIPTION

HELIX

3.1

SYSTEM DIAGRAM  WITHOUT CIRCULATION

Waste containers (not included) must be closed at the top.

SYStem DeSCription

HELIX

3.2 COMPONENT DESCRIPTION  WITHOUT CIRCULATION

ITEM DESCRIPTION FUNCTION

A Component Pump A In a two-component system, Component Pump A typically pumps the ISO or activator

material.

B Component Pump B In a two-component system, Component Pump B typically pumps the resin material.

C Surere™ Heater Block Material ows from the supply containers into the uid pumps, where the material is

pressurized to the desired pressure(s), based on the Control Panel settings. The Surere™ heater block heats the material on its way to the material pumps.

D 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 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 o in order to prevent material from entering the system.

H Supply hoses The two supply hoses deliver uid from the supply drums to the Component pumps.

I Dual heated hose The dual heated hose delivers spray material from the two Component Pumps to the

spray gun.

J Transfer pump The two transfer pumps pump material from the supply containers, into the supply

hoses and then to the Component Pumps. The transfer pumps are powered by an air compressor.

K Desiccant dryer The Desiccant dryers remove any moisture that is present in the air pockets left by the

removal of material from the supply drums.

L Transfer pump air hose The transfer pump air hose delivers air from the compressor to the transfer pumps.

SYStem DeSCription

3.3 SYSTEM DIAGRAM  WITH CIRCULATION

HELIX

SYStem DeSCription

HELIX

3.4 COMPONENT DESCRIPTION  WITH CIRCULATION

This conguration 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

A Component Pump A In a two-component system, Component Pump A typically pumps the ISO or activator material.

B Component Pump B In a two-component system, Component Pump B typically pumps the resin material.

C Surere™ Heater Block Material ows from the supply containers into the uid pumps, where the material is pressurized to

the desired pressure(s), based on the Control Panel settings. The Surere™ heater block heats the material on its way to the material pumps.

D 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 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 o in order to prevent material from entering the system.

H Supply hoses The two supply hoses deliver uid from the supply drums to the Component pumps.

I Dual heated hose The dual heated hose delivers spray material from the two Component Pumps to the spray gun.

J Transfer pump The two transfer pumps pump material from the supply containers, into the supply hoses and then

to the Component Pumps. The transfer pumps are powered by an air compressor.

K Desiccant dryer The Desiccant dryers remove any moisture that is present in the air pockets left by the removal of

material from the supply drums.

L* Circulation valves / hoses When open, the circulation valves (L1) allow material to circulate through the heater block and

back through the hoses (L2) into the supply containers. This allows the material to be heated more quickly.

M Transfer pump air hose The transfer pump air hose delivers air from the compressor to the transfer pumps.

N Agitator The agitator stirs the material on the resin (B) side material container.

3.5 INSTALLING THE CIRCULATION KIT

OPTIONAL

The circulation kit is available for separate purchase. Follow the steps below to install it.

Refer to section 2.2 for Clearance Diagram.

1. Make sure the system is turned o and depressurized.

2. Remove the two inlet plugs (Fig. 4, item 1) from the bottom

of the hose heater manifold. Remove return tubes (2).

3. Thread a shut-o valve (Fig. 3, item L1) from the circulation kit into each of the ports underneath the hose heater manifold. Thread the longer return tubes (Fig. 2, item F) underneath each of the PRIME/SPRAY valve manifolds.

4. Attach a hose to each of the shut-o valves. Run the hoses (Fig. 3, item L2) and return hoses (Fig. 3, item F)

back towards the material containers and thread into their respective ports on the desiccant dryers.

Control panel

854 45

4 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. If they are located on the left side of the panel, they serve the “A” side of the system. If they are located on the right, they serve the “B” side. If it is located in the middle, it serves the entire system.

HELIX

MAX

Clean

MAX

PSI

EZ-ZONE

8.8:8.8

Z O N

8 8.8:8.8

2 3

MIN

PSI

EZ-ZONE

ºF ºC

8.8:8.8

8 8.8:8.8

ºF ºC

Z O N E

EZ-ZONE

8.8:8.8

Z O N

8 8.8:8.8

ºF ºC

SEL

2 3

SEL

Clean

MIN

PSI

MAX

PSI

1 Heated hose temperature control This panel regulates the spray material temperature for the applicable heated hose.

2 Control Displays The displays show various menu screens that allow the user to customize and monitor pump

a A-side independent controller When the component pumps are unlinked, this controls Component Pump A.

b Master controller / B-side independent

controller

3 Component pump pressure control Adjusts the pump pressure of the applicable Component Pump.

4 ON/OFF switch, Component Pump This switch turns the applicable Component Pump ON and OFF.

5 ON/OFF switch, hose heater This switch turns the applicable hose heater ON and OFF.

6 Surere™ heater block control This panel regulates the temperature of the Surere™ heater block

7 Emergency Shuto Pushing this button will instantly shut down the system. However, pressing this button

8 ON/OFF switch, heater block This switch turns the heater block ON and OFF

operation using the function keys (1 - 4).

When the component pumps are linked, the master controller controls both component pumps. When the component pumps are unlinked, this controls Component Pump B only.

WILL NOT depressurize the system. Follow the Pressure Relief Procedure.

Control panel

HELIX

4.1 SUREFIRE™ HEATER BLOCK CONTROL

Refer to item 8 in section 4. The block heater control regulates the temperature of spray material as it passes through the heater block, prior to it reaching the heated hoses.

1 Temperature

display

2 Programming

buttons

3 Power

indicator

4 Temperature

setting

5 Temperature

adjustment

EZ-ZONE

8.8:8.8

Z O N

8 8.8:8.8

Shows actual temperature of the heater block.

These are non-functioning factory programming buttons. Do not use.

The ashing or steady “1” indicates sucient power is being delivered to the system’s electrical relay.

Shows the desired temperature of the heater block set by the operator

These buttons will increase ( p) or decrease ( q ) the temperature of the heater block. The temperature will change in increments of 1ºF. Press and hold the button to increase the increments by 1ºF and then 10ºF.

ºF ºC

4.2 SUREFIRE™ HEATED HOSE TEMPERATURE

CONTROL

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.

8.8:8.8

Z O N

8 8.8:8.8

1 Display Displays the current temperature of the

2 Programming

buttons

3 Power

indicator

4 Temperature

setting

5 Temperature

adjustment

heated hose set

These are non-functioning factory programming buttons. Do not use.

The ashing or steady “1” indicates sucient power is being delivered to the system’s electrical relay.

Shows the desired temperature of the heated hoses set by the operator

These buttons will increase ( p) or decrease ( q ) the temperature of the heated hose set. The temperature will change in increments of 1ºF. Press and hold the button to increase the increments by 1ºF and then 10ºF.

EZ-ZONE

ºF ºC

Refer to section 8.2 to review the controller error messages.

Decreased voltage under 230V AC may increase initial heat time.

Control panel

HELIX

4.3 COMPONENT PUMP PRESSURE CONTROL

Refer to item 2 in section 4. The following items control the pressure of the individual Component Pumps.

MIN

PSI

MAX

PSI

1 Pressure control knob Adjusts the pump pressure of the

applicable Component Pump when unlinked. When Component pumps are linked, the (B) pump pressure control knob will control the pressure of both pumps.

2 Component Pump ON/

OFF switch

PRESSURE CONTROL KNOB SETTINGS

Switches the Component Pump ON and OFF.

MIN

PSI

4.4 CONTROL DISPLAYS

Refer to item 2 in section 4. The graphic below applies to both the Component Pump (A) and Component Pump (B).

The Control Displays increase the functionality of the applicable Component Pump.

It consists of a display (1) and four function keys (2). The display shows various menu screens that allow the user to customize and monitor sprayer operation using the function keys.

When both component pumps are turned ON, the system will automatically link the two Component Pumps after 10 seconds. This means the Component Pump (A) control display will be controlled by the Component Pump (B) control display. When the component pumps are linked, the Component Pump (A) control display keys are disabled and will only be functional when the two Component Pumps are unlinked (see “Status Screen”).

The pressure control knob overrides the Control Display settings. Anytime the pressure control knob is turned, the sprayer pressure will change accordingly.

SET PSI 0 ACTUAL PSI 0

MAX

PSI

1 Minimum pressure setting

2 Black zone – no pressure generation

3 Maximum pressure setting

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

#3/q Key

#4/Select Key Pressing the #4 key selects the active menu screen

Pressing the #2 key performs a function described on the active menu screen or increases a value.

Pressing the #3 key performs a function described on the active menu screen or decrease a value.

or performs a function described on the active menu screen.

Control panel

SET PSI 0

L-SET PSI 0 ACTUAL PSI 0

RATIO - 64/64 +2 -3 STEP 4

STATUS = LINKED

STATUS = UNLINKED

ALARM RANGE +/- 750 PSI

ALARM STATUS: OFF

TOTAL CYCLES

SELECT-4MENU-1

CYCLES XXXX

RESET-3MENU-1

HELIX

MENU SCREENS

Several menu screens are available for the user to customize and monitor sprayer operation. They include Main Screen, Ratio*, Status* Alarm Range*, Alarm Status*, Total Cycles*, Job Cycles*, Unit Serial #, Timers, Job Timers, Service Time, Security Code*, and Prime.

Screens noted with an asterisk (*) are screens that apply to Component Pump (B) only. All other screens apply to both (A) and (B) pumps.

Main Screen

The Main Screen is the default screen for the control system at sprayer startup.

Pressing the #2 key switches between PSI, Bar, and MPa units of measure. Press the #1 key to scroll through the remaining menu screens.

(A) Pump Only - The “L-” before the “Set PSI” text on the Main Screen indicates that the two Component Pumps are linked.

For sprayers equipped with an nine-language Control Display:

Pressing the #2 key at the Main Screen switches between PSI, Bar and MPa units of measure.

Pressing the #3 key at the Main Screen changes the language of the text on the display. There are a total of nine languages available. Each time the #1 key is pressed, a dierent language will appear. The languages, in order of appearance, are: English, Spanish, Dutch, Danish, Swedish, German, French, Italian, and Portuguese.

Ratio Screen*

The Ratio screen on the (B) pump allows the user to see and/or adjust for slight dierences in viscosity and mix ratios between the (A) pump material and the (B) pump material.

Pressing the #2 key will increase the spraying ratio in increments of 1/64. Pressing the #3 key will decrease the spraying ratio in increments of 1/64. Pressing the #4 key will step up in increments from 1 to 16.

ACTUAL PSI 0

Status Screen*

The Status Screen shows the link status of the (A) pump and (B) pump.

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 unlink the two pumps, and the (A) pump and (B) pump will operate independently and the (A) pump control display keys will be enabled.

If the pumps have been unlinked, pressing the #2 key will link the two pumps back together, and the (A) pump will now be controlled by the (B).

Alarm Range Screen*

The Alarm Range Screen allows the user to adjust the allowable pressure discrepancy between the (A) and (B) pumps.

Pressing the #2 key will increase the allowable pressure discrepancy by 50 psi. Pressing the #3 key will decrease the allowable pressure discrepancy by 50 psi. The range is 250 psi

- 1000 psi.

Alarm Status Screen*

The Alarm Status Screen allows the user to switch ON or OFF the internal alarm that alerts the user to a non-allowable pressure imbalance.

Pressing the #2 key will turn the alarm ON. Pressing the #3 key will turn the alarm OFF.

If a pressure imbalance is detected in the system with the alarm status set to ON, the system will automatically shut down and the display will show a PSI Imbalance. Refer to Control Display Error Messages.

Total Cycles Screen*

The Total Cycles Screen shows the total number of piston cycles a component pump has performed during its lifetime.

Pressing the #3 key will reset the cycle count to zero. Pressing the #1 key will bring the control panel back to the Main Screen.

LINK-2 UNLINK-3

ON-2 OFF-3 EXT-4

Control panel

SECURITY CODE

ENTER OLD CODE

ENTER NEW CODE

PRIME

JOB CYCLES

CYCLES XXXX

UNIT SERIAL #

SELECT-4MENU-1

SER # XXXXXXXXXX MENU-1

TIMERS

ON TIME

XXXX

JOB TIMERS

SELECT-4MENU-1

JOB ON X

SERVICE TIME

SERVICE @ XX

HELIX

Job Cycles Screen*

The Job Cycles Screen shows the total number of piston cycles a component pump performs during a spray job.

Pressing the #3 key will reset the cycle count to zero. Pressing the #1 key will bring the control panel back to the Main Screen.

Unit Serial # Screen

The Unit Serial # screen shows the sprayer’s serial number.

To select the Unit Serial # screen, press the #4 key.

Timers Screen

The Timers screen shows the total time the sprayer has been turned on as well as the total time the sprayer has been running (pumping).

To select the Timers screen, press the

RUN TIME

#4 key.

Job Timers Screen

The Job Timers screen allows the user to reset the “ON TIME” and “RUN TIME” to track time on specic jobs.

To select the Job TImers screen, press the #4 key. “JOB ON” screen will appear. Press #3 to reset. Press #1 to

JOB RUN X

continue to “JOB RUN” screen. Press #3 to reset. Press #1 to scroll through the remaining menu screens.

Service Time Screen

The Service Time screen allows the user to set a service time interval (in hours). Below the set time, the screens shows the current amount of hours on the sprayer since the last activation of the service timer. To select the Service Timer screen, press the #4 key.

To set the service time, press the #2

RUN HOURS XX

(up) and/or the #3 (down) keys to the desired time (run hours will increase/ decrease in increments of 1 for each time you press a key).

When the service time interval is set and met by the run hours, the display will show a “Service Required” screen. The pump will remain functional. To return to the Main Screen, press the #1 key. Doing so will reset the “Service @” and “Run Hours” displayed on the Service Screen back to 0.

Security Code Screen*

SELECT-4MENU-1

The Security Code screen allows the

CHANGE-2MENU-1

user to set a four digit security code to prevent unauthorized use of the sprayer. If a security code

RESET-3MENU-1

has been set, the control system display will ask for the code at startup. If the correct code is entered, the display will show the Main Screen and the sprayer will operate. If the wrong code is entered, the display will continue to ask for the correct code and the sprayer will be disabled. To set or change the security code, press the #2 key.

If the sprayer is new, no security code is set and the Main Screen will appear at startup. When setting a security code for the rst time, the “Enter Old Code Number” screen will appear, and you will need to enter “1111”.

SELECT-4MENU-1

Enter the old security code number

NUMBER

to access the screen that allows the code change. If the wrong code is

XXXX

entered, the display will continue to ask for the correct code and the security code cannot be changed.

Enter the new security code. Once the new code is entered, the display will automatically ask that the new code be re-entered for verication. If the same new code is re-entered,

RESET-3MENU-1

the display will conrm that the new

NUMBER XXXX

RE-ENTER NEW NUMBER XXXX

NEW CODE NUMBER ACCEPTED

code has been accepted and return to the Main Screen. If the

RESET-3MENU-1

new code is re-entered incorrectly, the display will return to the “Enter New Code Number” screen and the process will repeat.

If you forget or misplace your security code, you can call Titan customer service for assistance.

SELECT-4MENU-1

To inactivate the Anti-Theft Digital Lockout security function, enter “1111” at the “Enter New Code Number” screen (this is the default code that leaves the sprayer unlocked). As a result, the Main Screen will appear at sprayer startup.

Prime Screen

The Prime screen appears when the pressure control knob is set at the “MIN” setting.

If there is no action at any menu screen for 10 seconds, the display will go back to the Main Screen.

Control panel

CHECK

TRANSDUCER

CHECK

LOW

VOLTAGE

HIGH MOTOR

TEMPERATURE

HIGH MECHANICAL

PSI IMBALANCE UNLINK 3

HELIX

4.5 CONTROL DISPLAYS ERROR MESSAGES

The following error message screens appear whenever the Control Display detects a problem with the system. Once a problem occurs and the error message appears, the system will shut down.

Before proceeding, follow the Pressure Relief Procedure outlined 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 system before servicing!

Check Transducer Screen

The Check Transducer screen appears when the transducer has become disconnected or is defective. Take the sprayer to a Titan authorized service center for repair.

Check Potentiometer Screen

The Check Potentiometer screen

POTENTIOMETER

appears when the potentiometer has become disconnected or is defective. Take the sprayer to a Titan authorized service center for repair.

Low Voltage Screen

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

The High Motor Temperature screen 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

The High Mechanical Load screen

LOAD

appears when the sprayer shuts down because of high current or when the sprayer goes into current fold back mode. Take the sprayer to a Titan authorized service center for repair.

PSI Imbalance

The PSI Imbalance screen appears when there is a non-allowable pressure discrepancy between the (A) and (B) pumps while linked. If a PSI imbalance occurs, press the #3 key to unlink the two pumps. Once the pumps are unlinked, press the #1 key to return to the Main Screen.

Setup

HELIX

5 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 o while connecting any air hoses to the air supply.

5.1 LOCATE THE SYSTEM

1. Locate the system on a level surface. Refer to dimensions in section 2.2 for clearance and mounting hole dimensions.

2. Mount in a dry area.

3. For best results, the machine should be bolted into place.

5.2 INSTALL THE TRANSFER PUMPS

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.

5. Attach the transfer pump air hose to their individual air ttings.

6. Connect the other end of the transfer pump air hose to the powered air pressure supply.

Do not install shuto valves downstream of the prime tubes. The PRIME/SPRAY valves function as overpressure relief valves when set to SPRAY.

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)

b. With certain exceptions, the “B” component (resin)

2. Seal the container holding Component A material and

3. If necessary, install an agitator into the Component B

4. Make sure the Component A and Component B inlet

should be located on the “A” side of the system.

should be located on the “B” side of the system.

Consult the spray material’s manufacturer if you are unsure about which Component Pump is compatible with each individual spray component.

install the desiccant dryer in the vent hole.

material container.

valves are in the closed position (handle should be 90º to the valve).

Setup

HELIX

5.3 CONNECT THE SUREFIRE™ HEATED HOSES

CONNECT THE HEATED HOSES

The heated hose assembly and dual whip hose come pre-installed with the system and should

tention

1. Attach the JIC ttings (packaged separately with the

a. Connect the smaller JIC tting to the “A” side whip hose. b. Connect the larger JIC tting to the “B” side whip hose.

2. Remove the coupling block from the spray gun (refer to

3. Close gun manifold valves A and B.

tention

not be removed or disassembled unless it is being completely replaced.

Refer to the Helix Surere™ Dual Heated Hose Manual included with your system.

heated hose set) to their appropriate whip hoses.

the spray gun manual).

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 imbalance which can then lead to a material “crossover” inside the gun, leaving the gun inoperable.

4. Attach the 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 g. 11).

2. Attach one end of the feed hose to the inlet valve of Component pump A. Repeat for Component pump B with another hose.

3. Connect the other end of each hose to their appropriate transfer pumps (i.e. the “A” hose should run from Component pump A to the transfer pump installed into material supply drum “A”).

4. Make sure all connections are wrench tight.

5. Arrange the return hoses:

a. For non-circulation congurations (see gure 2, section

3.1), place a waste bucket underneath each of the return hoses.

b. For circulation conrgurations (see gure 3, section 3.3)

Attach the return hoses tubes to the dessicant dryers of the appropriate material supply drum (i.e. the “A” return tube for should run from Component pump A to the dessicant dryer installed into material supply drum “A”.

Setup

5.4 CONNECT THE ELECTRICAL CORD

HELIX

A 230V power cord is not included with the system. Make sure a grounded, 230V outlet is available in order to power the system.

It is recommended that the Helix System be used with a generator. This provides the exibility with not having to use the public power grid.

Power Cord Connector Requirements

Models 0138013/ 0138059 0138011 / 0138060

Connector Twistlock Twistlock

AMP 50 30

Number of Poles 3 4

Number of Wires 4 5

Phases 3 3

Voltage 250 VAC 400V

Recommended Manufacturer

LEVITON P/N CS8364C

LEVITON P/N 2823

Spray Gun The spray gun is grounded through the whip

hose ground wire. Do not spray without using the whip hose.

Fluid Supply Chambers

Object being sprayed

Waste Containers

Follow the local code.

Follow the local code. Only use metal containers placed on a grounded surface when ushing the system. Do not place metal waste containers on paper or cardboard surface. A non-conductive surface such as these can interrupt grounding continuity.

While ushing or relieving system pressure, ground the gun by holding it against the edge of the metal container. Failure to do so may lead to a static electric discharge, which may cause a re.

5.6 LUBRICATE THE COMPONENT PUMPS

1. Remove the cup cap with a straight-slot screwdriver.

2. Fill the cup reservoir with DOP (Dioctylphthalate) or

compatible plasticizer (Fig. 15) until the gauge (1) is showing that it is full.

If using a generator to power the system, refer to section 2.2 prior to plugging in the power cord.

1. First plug the adapter end of the supplied power cord into the power cord port located on the side of the block heater.

2. Plug the other end of the supplied power cord into a grounded, 230V outlet.

5.5 GROUND THE SYSTEM

Proper grounding (earthing) is important. The passage of some materials through the nylon uid hose will build up a static electric charge, which if discharged, could ignite solvent vapors present and create an explosion.

Component Grounding Method

System The system and heated hoses are grounded

through the power cord.

DOP (Dioctylphthalate) or a compatible plasticizer prevents increased wear and tear to

tention

3. Replace cup cap.

4. Press button (2) 2-5 times to prime the dispenser. Press

the packings and will keep spray material from crystalizing on the uid section.

once for every eight hours of usage to lubricate and protect the uid section.

1 2

operation

HELIX

6 OPERATION

Prior to startup, make sure the generator has fuel. Running out of fuel will cause electrical

tention

uctuations in the system that could result in damage to the electrical components of the system.

6.1 STARTUP

1. If using a generator, make sure the main breaker on the generator is in the OFF position.

2. If using a generator, start the generator. Allow it to run to full power.

3. If using an air compressor to power the transfer pumps, start the compressor, making sure the bleed valve is in the closed position on the compressor.

4. Turn the breaker on the generator to ON. Switch both of the Component Pump ON/OFF switches to ON. (these are the outermost ON/OFF switches located on the control panel).

Do not turn on the block heater or hose heater ON/OFF switches ON yet. Turning the hose

tention

heaters on when there is no uid in the hoses can cause damage to the hoses.

6.2 SET TEMPERATURE

Refer to section 4 to review temperature controls.

Equipment surfaces can become hot. To avoid severe burn injury:

1) Do not touch hot uid or equipment.

2) Allow equipment to cool completely

3) Wear gloves when dealing with

1. Set the temperature of the heater block:

a. Switch the heater block ON/OFF switch to ON (this is the

ON/OFF switch in the middle of the control panel).

b. Using the heater block controls, set the heater block

to the desired temperature. Press the (p) button until the bottom set of numbers (1) shows the desired temperature.

before coming into contact with it.

temperatures in excess of 110ºF (43ºC)

EZ-ZONE

Z O N

8 110

ºF ºC

2 13

5. Turn the PRIME/SPRAY valves on both of the Component Pumps to SPRAY.

6. Open the uid inlet valves. Check for leaks.

7. Place the coupling block (with hoses attached) over two

separate, grounded waste containers. Make sure the ports on the manifold each aim into a dierent container.

NEVER mix components A and B during startup. Use two separate grounded waste containers to keep Component A and Component B separate.

8. While holding the coupling block over the waste containers, slowly open uid valves A then B. Allow them to remain open until clean, air-free uid comes from the valves.

9. Close uid valves A then B.

The top number (2) on the heater block displays the actual temperature. When the light (3) goes out, the block heater is suciently heated.

2. Set the temperature of the heated hoses (repeat each of the following steps for both A and B hoses):

a. Switch the heated hose ON/OFF switches to ON (these

b. Using the heated hose controls, set the heated hoses

c. The temperature settings of the heated hoses can also

are the switches immediately on either side of the heater block switch in the middle of the control panel).

to the desired temperature. Press the ( until the bottom set of numbers (1) shows the desired temperature.

be adjusted to balance spraying pressures as well as the desired ratio.

Adjusting the hose heat should ONLY be a secondary method of achieving the correct ratio. Use the Ratio Screen on the Control Display rst.

button

operation

HELIX

6.3 SPRAYING

Refer to the safety information in the beginning of this manual for injury prevention guidelines. Refer to the safety and operation instructions of the gun manual.

1. Engage the trigger safety (refer to the spray gun instruction manual).

2. Make sure the valves A / B on the coupling block are closed.

3. Reattach the coupling block (with hoses attached) to the

spray gun.

4. Connect the end of the air hose that is closest to the pump to an air supply (the air hose is housed within the velco sheathing that also contains the dual heated hoses). Connect the other end of the air hose to the spray gun. Make sure the air valve on the air hose (if any) is open.

5. Make sure the PRIME/SPRAY valves on the component pumps are set to SPRAY.

6. Verify that the temperature readings are showing the desired temperatures.

7. Verify pressure readings:

a. Check pressure gauges mounted on the front of the

system, or

b. For each component pump, go to the Control Display

Main Screen on the control panel.

Always close the manifold valves if the system is idle for more than 1 minute under heat and/or

tention

pressure. Failure to do so can cause a pressure imbalance which can then lead to a material “crossover” inside the gun, leaving the gun inoperable.

Make sure the Component Pump pressures are balanced prior to opening the manifold valves and resuming spraying.

6.4 PRESSURE RELIEF PROCEDURE

Perform the Pressure Relief Procedure when shutting down for any reason.

1. Engage the trigger safety (refer to the spray gun instruction manual).

2. Close the manifold valves A and B on the spray gun.

3. Perform all of these steps on both component pumps:

a. Turn the pressure control knob fully counterclockwise to

b. Turn the PRIME/SPRAY knob to PRIME.

4. Disconnect the spray gun air supply line.

minimum.

The pressures shown on either the gauges or the Control Display Screens should be within 200 PSI. If pressure 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.

NEVER open the manifold valves on the coupling block or trigger the spray gun if the pressure

tention

9. Disengage the trigger safety (refer to the spray gun

10. Test your spray on a piece of scrap wood or cardboard.

readings are unbalanced.

instruction manual).

Adjust pressure and temperatures as necessary to achieve desired results.

Shutting Down

HELIX

7 SHUTTING DOWN

7. Turn the ON/OFF switches for both Component Pumps to

It is important to the system’s electrical reliability to maintain steady electrical voltage during

tention

1. Perform the Pressure Relief Procedure (section 6.4).

2. Turn the block heater ON/OFF switch to OFF (this is the

3. Turn both hose heater A and B ON/OFF switches to OFF

4. Switch o the air compressor and any other auxiliary

5. Open the bleed valve on the air compressor in order to

6. Turn the Component (A) and Component (B) inlet valve

7. Shut down the transfer pumps as required.

shutdown. Failure to follow these procedures can cause voltage uctuations that can damage the equipment and void the warranty.

switch located in the center of the control panel).

(these are the switches on either side of the heater block ON/OFF switch).

equipment, if being used.

relieve pressure and remove any water that may have formed in the tank.

handles to the closed position (handle should be 90º to the valve).

7.1 PARKING

OFF.

8. Switch the generator OFF. Allow generator dwell time, per the manufacturer recommendations.

7.2 FLUSHING

Flush the system in a well-ventilated area. Do not turn on hose heaters or block heater when ushing with ammable solvents.

If the new Isocyanate being introduced is compatible with Polyol, it is not necessary to ush the (A) side.

1. Flush out the old uid with new uid, or ush the old uid with a compatible solvents prior to introducing a new uid (check with the old uid manufacturer in order to determine a compatible ushing solvent).

2. Always use the lowest possible pressure when ushing the sprayer. Make sure the Component Pump pressure control knobs are turned as far counterclockwise as possible in the “MIN PSI” yellow zone.

3. Use only moisture-free solvents when ushing the system.

Perform the following steps on the (A) Component Pump ONLY unless otherwise specied. The following must be done in order to prevent spray material build-up on the (A) side Component Pump uid section.

1. Turn the pressure control knob to “MIN PSI” setting in the yellow zone. The Control Display should say “PRIME”.

2. Press the #1 key on the Control Display. The “CREEP MODE” screen will now appear.

3. Slowly turn the pressure control knob clockwise to increase 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, deadcenter of its stroke, turn the pressure control knob fully counterclockwise. The crankshaft/slider assembly should stop.

6. Press the cup button 6-8 times to lubricate the piston on both (A) and (B) Component Pumps.

troubleShooting

8. TROUBLESHOOTING

HELIX

8.1

COMPONENT PUMPS

Problem Cause Solution

A. The unit will not run. 1. The unit is not plugged in to a power source.

B. The unit will not build or

maintain pressure.

C. Fluid leakage at the upper

end of the uid section.

2. Tripped breaker.

3. The pressure is set too low (pressure control knob set at minimum setting does not supply power to unit).

4. Faulty or loose wiring.

5. Excessive motor temperature.

6. ON/OFF switch is defective.

1. The pressure control knob is not set properly.

2. Material ows from the return hose when the PRIME/SPRAY valve is in the SPRAY position.

3. Air leak in material feed hoses.

4. There is external uid leak.

5. There is an internal uid 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. The upper packings are worn.

2. The piston rod is worn.

1. Plug the power cord into a grounded, 230V outlet.

2. Reset the breaker.

3. Turn the pressure control knob clockwise to

4. Inspect or take to an authorized service center.

5. Allow motor to cool.

6. Replace the ON/OFF switch.

1. Turn the pressure control knob clockwise to

2. Clean or replace the PRIME/SPRAY valve.

3. Check the inlet valve / feed hose connection.

4. Check for external leaks at all connections.

5. Clean the valves and service the uid section

6. Reverse or replace the valve seats following the

7. Take unit to a authorized service center.

8. Check air supply and valves, or service the transfer

1. Repack the pump following the steps in section

2. Replace the piston rod following the steps in

supply power to the unit and increase the pressure setting.

increase the pressure setting.

Tighten or wrap the threads with Teon tape.

Tighten connections, if necessary.

following the steps in section 9.5 and 9.6 in this manual.

steps in section 9.5 and 9.6 in this manual.

pumps.

9.5 and 9.6 in this manual.

section 9.5 and 9.6 in this manual.

troubleShooting

HELIX

8.2 SUREFIRE™ HEATER BLOCK / HOSE HEATER CONTROLLER ERRORS

Problem Cause Solution

A. Alarm will not clear or Reset with

keypad or digital input.

B. Alarm will not activate output. 1. Alarm silencing is active

C. Alarm Error. Alarm status cannot

be determined due to a lack of sensor input.

AL.E 1 AL.E 2 AL.E 3 AL.E 4

D. Alarm Low. Sensor input below

low alarm set point.

AL.L 1 AL.L 2 AL.L 3 AL.L 4

1. Alarm latching is active

2. Alarm set to incorrect output

3. Alarm is set to incorrect source

4. Sensor input is out of alarm set point range

5. Alarm set point is incorrect

6. Alarm is set to incorrect type

7. Digital input function is incorrect

2. Alarm blocking is active

3. Alarm is set to incorrect output

4. Alarm is set to incorrect source

5. Alarm set point is incorrect

6. Alarm is set to incorrect type

1. Sensor improperly wired or open

2. Incorrect setting of sensor type

3. Calibration corrupt

1. Temperature is less 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. Reset alarm when process is within range or disable latching

2. Set output to correct alarm source instance

3. Set alarm source to correct input instance

4. Correct cause of sensor input out of alarm range

5. Set alarm set point to correct trip point

6. Set digital input function and source instance

1. Disable alarm silencing, if required

2. Disable alarm blocking, if required

3. Set output to correct alarm source instance

4. Set alarm source to correct input instance

5. Set alarm set point to correct trip point

6. Set alarm type to correct type

1. Correct wiring or replace sensor

2. Match setting to sensor used

3. Check calibration of controller

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

F. Error Input. Sensor does not

provide a valid signal to controller

Er. ,1

G. Limit will not clear or Reset with

keypad or digital input

H. Limit Error. Limit status cannot be

determined due to a lack of sensor input, limit will trip.

L ,.E 1

I. Limit Low. Sensor input below low

limit set point.

L ,.L 1

J. Limit High. Sensor input above

high limit set point.

L ,.h 1

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. Sensor improperly wired or open

2. Incorrect setting of sensor type

3. Calibration corrupt

1. Sensor input is out of limit set point range

2. Limit set point is incorrect

3. Digital input function is incorrect

1. Sensor improperly wired or open

2. Incorrect setting of sensor type

3. Calibration corrupt

1. Temperature is less than limit set point

2. Limit outputs latch and require Reset

3. Incorrect alarm set point

1. Temperature is greater than limit set point

2. Limit outputs latch and require Reset

3. Incorrect alarm set point

1. Check cause of over temperature

2. Clear latched alarm

3. Establish correct alarm set point

4. Set alarm source to proper setting

1. Correct wiring or replace sensor

2. Match setting to sensor used

3. Check calibration of controller

1. Correct cause of sensor input out of limit range

2. Set limit set point to correct trip point

3. Set digital input function and source instance

1. Correct wiring or replace sensor

2. Match setting to sensor used

3. Check calibration of controller

1. Check cause of under temperature

2. Clear limit

3. Establish correct limit set point

1. Check cause of over temperature

2. Clear limit

3. Establish correct limit set point

troubleShooting

HELIX

K. Loop Open Error. Open Loop

Detect is active and the process value did not deviate by a userselected value in a user specied period with PID at 100%.

LP.o1 LP.o2

L. Loop Reversed Error. Open Loop

Detect is active and the process value is headed in the wrong direction when the output is activated based on deviation value and user-selected value.

LP.r1 LP.r2

M. Ramping Error. Controller is

ramping to new set point.

rP 1 rP 2

N. Autotuning Error. Controller is

autotuning the control loop.

F U

U 1

O. No heat/cool action. Output does

P. No display indication or LED

Q. No serial communication. Cannot

F U

U 2

not activate load.

illumination.

establish serial communications with the controller.

1. Setting of Open Loop Detect Time incorrect.

2. Setting of Open Loop Detect Deviation incorrect.

3. Thermal loop is open.

4. Open Loop Detect function not required but activated.

1. Setting of Open Loop Detect Time incorrect.

2. Setting of Open Loop Detect Deviation incorrect.

3. Output programmed for incorrect function.

4. Thermocouple sensor wired in reverse polarity.

1. Ramping feature is activated. 1. Disable ramping feature if not required.

1. User started the autotune function.

2. Digital input is set to start autotune.

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. Power to controller is o

2. Fuse open

3. Breaker tripped

4. Safety interlock switch open

5. Separate system limit control activated

6. Wiring error

7. Incorrect voltage to controller

1. Address parameter incorrect

2. Incorrect protocol selected

3. Baud rate incorrect

4. Parity incorrect

5. Wiring error

6. EIA-485 converter issue

7. Incorrect computer or PLC communications port

8. Incorrect software setup

9. Termination resistor may be required

1. Set correct Open Loop Detect Time for application.

2. Set correct Open Loop Devation value for application.

3. Determine cause of open thermal loop: misplaced sensors, load failure, loss of power to load, etc.

4. Deactivate Open Loop Detect feature.

1. Set correct Open Loop Detect Time for application.

2. Set correct Open Loop Devation value for application.

3. Set output function correctly.

4. Wire thermocouple correctly (red wire is negative).

1. Wait until autotune completes or disable autotune feature.

2. Set digital input to function othe than autotune, if desired.

1. Set output function correctly.

2. Set control mode appropriately (Open vs. Closed Loop).

3. Correct output wiring.

4. Correct fault in system.

5. Set control set point in appropriate control mode and check source of set point: remote, idle, prole, closed loop, open loop.

6. Obtain correct controller model for application.

1. Turn on power

2. Replace fuse

3. Reset breaker

4. Close interlock switch

5. Reset limit

6. Correct wiring issue

7. Apply correct voltage, check part number

1. Set unique addresses on network

2. Match protocol between devices

3. Match baud rate between devices

4. Match parity between devices

5. Correct wiring issue

6. Check settings or replace converter

7. Set correct communication port

8. Correct software setup to match controller

9. Place 120  resistor across EIA-485 on last controller

troubleShooting

HELIX

R. Process does not control to set

point. Process is unstable or never reaches set point.

S. Temperature runaway. Process

value continues to increase or decrease past set point.

T. Device Error. Controller displays

internal malfunction message at power up.

100 rETn

U. Heater Error.

h. Er

V. Current Error. Load current

incorrect.

C. Er

W. Menus inaccessible. Unable to

access:

Set Oper FCtY ProF

menus or particular prompts in

Home Page.

X. EZ-Keys do not activate required

function.

Y. Value too low to be displayed in 4

digit LED display.

1. Controller not tuned correctly.

2. Control mode is incorrectly set.

3. Control set point is incorrect.

1. Controller output incorrectly programmed

2. Thermocouple reverse wired

3. Controller output wired incorrectly

4. Short in heater

5. Power controller connection to controller defective

6. Controller output defective

1. Controller defective

2. Miss wired input or ground loop

1. Current through load is above current trip set point.

2. Current through load is below current trip set point.

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. Noisy electrical lines.

1. Lockout or Security set to incorrect level

2. Digital input set to lockout keypad

3. Custom parameters incorrect

1. EZ-Key function incorrect

2. EZ-Key function instance not correct

3. Keypad malfunction

1. Incorrect setup 1. Check scaling of source data

1. Perform autotune or manually tune system.

2. Set control mode appropriately (Open vs. Closed Loop).

3. Set control set point in appropriate control mode and check source of set point: remote, idle, prole, closed loop, open loop.

1. Verify output function is correct (heat or cool)

2. Correct sensor wiring (red wire negative)

3. Verify and correct wiring

4. Replace heater

5. Replace or repair power controller

6. Replace or repair controller

1. Replace or repair controller

2. Correct wiring or remove ground loop circuit

1. Check that the load current is proper. Correct cause of overcurrent 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.

1. Replace relay.

2. Replace relay.

3. Route load wire through current transformer from correct output, and go to the Source Output Instance parameter (Setup Page, Current Menu) to select the output that is driving the load.

4. Replace or repair sensor or controller.

5. Route wires appropriately, check for loose connections, add line lters.

1. Check lockout setting in Factory Page

2. Change state of digital input

3. Change custom parameters in Factory Page

1. Verify EZ-Key function in Setup Menu

2. Check that the function instance is correct

3. Replace or repair controller

vAL.L

Z. Value too high to be displayed in 4

digit LED display.

1. Incorrect setup 1. Check scaling of source data

vAL.H

ServiCing

9 SERVICING

Before proceeding, follow the Pressure Relief Procedure outlined previously in this manual.

tention

9.1 REPLACING THE MOTOR ASSEMBLY FIG. 17

1. Disconnect the power cord.

2. Loosen and remove the two motor shroud screws (1).

3. Loosen and remove the three belly pan screws (3). Remove

4. Loosen and remove the two motor cover screws (5).

5. Disconnect all wires between the motor and the sprayer.

6. Disconnect the wires between the motor (9) and the

7. Loosen and remove the two motor controller screws (11).

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!

All service instructions apply to both Component A and Component B pumps, unless otherwise specied. If ordering a new motor controller (Fig. 17, item 12), make sure to order it for the correct Component Pump (see “Drive Assembly” in the Spare Parts List section, page 88-89).

Remove the motor shroud (2).

the belly pan (4).

Remove the motor cover (6).

control panel.

Remove the motor controller (12).

HELIX

8. Loosen and remove the four motor bae screws (13). Remove the motor bae (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. Secure the motor with the three motor mounting (15)

screws.

14. Reconnect the wires between the sprayer and the new motor (refer to the Electrical Schematic, section 9.7).

15. Place the bae (14) over the end of the motor assembly (9). Secure with the four motor bae screws (13).

16. Place motor controller (12) back into place behind the motor bae (14). Secure with the two motor controller screws (11).

17. Reconnect all wires between the motor and sprayer.

18. Reconnect the wires between the motor and the control

panel.

19. Place the motor cover back over the motor controller. Secure with the two (5) motor cover screws.

20. Put the belly pan (4) back in place and secure with the three belly pan screws (3).

21. Slide the motor shroud (2) over the motor assembly (9).

22. Secure the motor shroud (2) with the two motor shroud

screws (1).

3 4

12 11

6 5

ServiCing

HELIX

9.2 REPLACING THE GEARS FIG. 18

1. Follow steps 1-10 in Replacing the Motor Assembly to

remove the motor and control panel.

2. Inspect the armature gear (1) on the end of the motor for damage or excessive wear. If the gear is completely worn out, replace the motor assembly.

3. Remove and inspect the 1st stage gear (2) and 2nd stage gear (3) assemblies for damage or excessive wear. Replace, if necessary.

4. Inspect the front gear box assembly (4) for damage or excessive wear. If damaged or worn, replace the front gear box assembly.

Clean and rell the gear box cavity up to the rear face of each gear with Lubriplate (P/N 314-171).

5. Reinstall the motor into the gearbox housing.

6. Follow steps 11-22 in Replacing the Motor Assembly to

replace the motor and control panel.

9.3 REPLACING THE TRANSDUCERS FIG. 19/20

1. Disconnect the power cord.

2. Loosen the hex nut (g. 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.

Component Pump (B) has been removed from the graphic below for instructional purposes only. You will not have to remove the component pump to complete these steps.

3. Loosen and remove the two screws (g. 20, item 2) that secure the front top cover (3) to the heater block and the four screws (4) that secure the rear top cover (5) to the heater block. Remove both covers from the heater block.

4. Disconnect the hose from the uid section (6). Disconnect the hose from the valve at the front of the heater block (7). Leave the hoses attached to the PRIME/SPRAY manifold (8).

4 5

6 7

ServiCing

HELIX

9.4 REPLACING THE PRIME/SPRAY VALVE

5. Loosen and remove the two PRIME/SPRAY knob manifold screws (9). Be careful not to lose the at or lock washers.

6. Pull the PRIME/SPRAY manifold (8), with tranducer assembly (10) still attached forward. The transducer connection should be visible inside the heater block at the rear (11).

7. Disconnect the transducer cord from rear of the connector inside the heater block (11).

8. Fully unthread the transducer assembly (10) from the PRIME/SPRAY manifold (8).

9. Thread the new transducer assembly (10) into the PRIME/ SPRAY manifold (8). Run the transducer wire through the grommit (12) in the front of the heater block and reconnect to its connection at the rear of the heater block (11).

10. Replace the PRIME/SPRAY manifold (8). Secure with the two PRIME/SPRAY manifold screws (9).

11. Reconnect the hoses at the block heater valves (6) and the uid section (7).

12. Replace the front top cover (3) and the rear top cover (4). Secure with the screws.

4 5

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 the relief valve handle (2).

2. Remove the relief valve handle (2) and cam base (3).

3. Using a wrench, remove the valve housing (4).

4. Ensure that the seal (5) is seated correctly, then screw

the new valve housing (4) completely into the block (6). Tighten securely with a wrench.

5. Align the cam base (3) with the hole in the block (6). Lubricate the cam base with grease and slide on the cam base.

6. Bring the hole in the valve shaft (7) and in the relief valve handle (2) into alignment.

7. Insert the grooved pin (1) to secure the relief valve handle in position.

6 7

ServiCing

HELIX

9.5 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. Remove the four screws in the front cover and then remove the front cover.

Danger of crushing - do not reach with the ngers or tool between the moving parts.

2. Turn the pressure control knob to minimum pressure. The Control Display screen should say “PRIME”.

3. Press the #1 key on the Control Display control panel. The “CREEP MODE” screen will now appear.

4. Slowly turn the pressure control knob clockwise to increase the pressure. The crankshaft/slider assembly will begin to move very slowly.

5. When it reaches the bottom, dead-center of its stroke, turn the pressure control knob back to minimum pressure. The crankshaft/slider assembly should stop.

6. Unplug the power plug from the outlet.

7. Unscrew the connection hose from the nipple on the back

of the uid 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. If the worn inlet valve seat (6) is unused on one side, install it the other way around.

3 5

6 7 8 9

11. Screw out outlet valve housing (Fig. 23, item 10) from the piston (11) with 3/8 inch hexagon socket head wrench.

12. Remove the upper seal (16), upper ball guide (15), outlet valve ball (13), washer (14) and outlet valve seating (12).

13. Clean all the parts with the corresponding cleaning agent. Check outlet valve housing (10), outlet valve seat (12), outlet valve ball (13) and upper ball guide (15) for wear and replace parts if necessary. If the worn outlet valve seat (12) is unused on one side, install it the other way around.

14. Carry out installation in the reverse order.

15. If you plan to replace the uid section packings, move on

to section 9.6. If not, reassemble uid section in the reverse order of how it was disassembled.

15 14 13

12 10

ServiCing

9.6 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 uid section.

4. Slide the uid section forward to remove it from the gear housing.

5. Place the uid section cylinder upright in a vise by clamping on the wrench ats (Fig. 24, Item 2).

Do not over-tighten the vise. Damage to the cylinder may occur.

tention

6. Using a wrench, remove the upper seal retainer (Fig. 24, Item 3).

7. Slide the piston rod (4) out through the bottom of the cylinder (1).

8. Inspect the piston rod for wear and replace if necessary.

9. Remove 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.

HELIX

3 8 5

tention

Be careful not to scratch, score, or otherwise damage the cylinder during removal of the packings.

11. Clean the cylinder (1). Inspect the cylinder for damage and replace if necessary.

12. Place the cylinder upright (1) in a vise by clamping on the wrench ats (2).

13. Locate the new upper and lower packings and remove the pre-form tools. Save the upper packing pre-form tool for use as the piston insertion tool later in this procedure.

Do not remove the pre-form tools from the upper and lower packings until immediately before they are installed into the cylinder.

14. Lubricate upper packing (5) and lower packing (7) with machine grease.

15. Insert upper packing (Fig. 25) with O-ring and protruding lip (11) downward.

ServiCing

HELIX

16. Insert upper support ring (8) on top of the upper packing (5)

17. Thread the upper seal retainer (3) into the cylinder (1).

18. Rotate the cylinder in the vise so that the bottom end is

facing up.

19. Insert the lower packing (Fig. 26) partially into the bottom of the cylinder with the large beveled edge (12) facing toward the cylinder (beveled edge will be facing up when the cylinder is upright).

20. Push the lower packing assembly (Fig. 24, Item 7) into position using the lower packing insertion tool (see Fluid Section Assembly parts list for lower packing insertion tool P/N).

Coat the piston insertion tool (i.e. upper packing pre-form tool) and the piston rod with grease before inserting them into the cylinder.

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 into the cylinder. Tighten the inlet valve housing until the o-ring engages, then continue to tighten until snug. Once snug, tighten an additional 1/8–1/4 turn.

28. Attach the high-pressure hose to the nipple on the back of the cylinder and tighten by hand. Do not kink the hose.

Make sure the hose does not touch the cart frame. If it does, reposition the nipple by turning the cylinder until the hose is clear of the frame and the nipple is within 45º of the back of the unit.

29. Install front cover.

21. Place the piston insertion tool over the top of the piston

rod (4).

22. Insert the piston rod (4) into the bottom of the cylinder (1), through the lower packing assembly (7), through the upper packing assembly (5), and out through the upper seal retainer (3).

Make sure the raised lip on the 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 uid 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 of the unit toward the rear of the sprayer to lock the uid section back into place.

26. Insert the adapter (6) into the bottom of the cylinder (1).

ServiCing

0522543

9.7 ELECTRICAL SCHEMATIC MODEL 0138013 / 0138059

HELIX

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 2A breaker (0522068)

f To hose heater

g From 0138501 (thermocouple)

located in 0138270 (manifold)

h Ground stud on display

i To ground stud on enclosure

0522599

0138935

0522109

805-401

0138516

0138514

0522524

0522123 (B)

0138602

0522064

0138600

0138516

0522515 0522515

0138514

0138936

0138935

0138989

0138602

0522577

0138988

0138602

0138991

0522576

1 1

0522122 (A)

0138600

0138603

0522513

0522515

0138516

0138514

0138516

0138514

0522599

0522524

0522543

0522515

0522109

0138516

0138514

0138512

0138513

805-401

0138604

ServiCing

HELIX

Notes (refer to previous page)

a This end mounted to enclosure

b From switches

c From “c”, previous page

Helix B

0138950

d From “d”, previous page

e From Emergency Stop (0522516)

f From “f”, previous page

0138492

0138960

g To controller (0138542)

h From “h”, previous page

i Ground stud on enclosure

0138961

0138501

0138522

j To “Y1” on 0138936 controller

k To “W1” on 0138936 controller

l Assemble into key slot in

enclosure

m From relay coil above

0522066

0138607

704-211 (3X)

0138515

0153639

0138606

0138604

0138605

0138607

0522075

0522066

0138603

0522068

0138467

0522062

0522109

0522108

05220650522065

0522424

0522109

9800078

704-597

800-437

0138513 (”B”)

0138424

0153314

0522064

0138516

0138514

0138962

0138612

0138601

0138612

0522582

0138515

0138991

0138601

0522109

0138522

9800078

20138516

0138467

0522062

0522424

0522108

0522109

0138514

Helix A

0138949

704-597

9812335 (5X)

0138604

0138513 (”A”)

800-437

0522062 (”B”)

0138605

0138512

0138424

0522062 (”A”)

4 4

0153314

ServiCing

9.8 ELECTRICAL SCHEMATIC MODEL 0138011 / 0138060

HELIX

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 hose heater

g From 0138501 (thermocouple)

located in 0138270 (manifold)

h Ground stud on display

i To ground stud on enclosure

j From Y terminal contactor

k From X terminal contactor

l From Z terminal contactor

0522599

0138935

0522543

0522109

805-401

0522524

0522123

0138602

0138600

0522064

05225150522515

0522138

0522139

0138513

0138936

0138935

0522599

0522513

0138603

0522515

0522524

0138989

0138523

0522122

0522576

0138600

0522543

0522577

0138602

0138988

0138602

0522515

0522109

0522138

0522139

0138523

0138512

0138513

805-401

ServiCing

HELIX

0138492

0138604

0522135

Notes (refer to previous page)

a This end mounted to enclosure

b From switches

c From “c”, previous page

0138960

0138501

0138964

0138605

0138606

0138607

0522075

0138607

704-211 (3x)

1 1

0138961

0522137

0138515

Helix B

0138950

0522137

0138603

0522068

Notes (refer to previous page)

d From “d”, previous page

e From Emergency Stop (0522516)

f From “f”, previous page

Notes (refer to previous page)

g To controller (0138542)

h From “h”, previous page

i Ground stud on enclosure

j To “Y1” on 0138936 controller

k To “W1” on 0138936 controller

l Assemble into key slot in enclosure

m To block heater switch

n Connect wire from restick to

thermostat

o To terminal 3, E-stop switch

0138522

p To circuit breaker (0522068)

q To power distribution block

(0138523

r To block heater relay (0138962)

0138467

0522062

0522109

0522108

0522065

0522424

0522109

9800078

704-597

800-437

0138513 (”B”)

0138424

0153314

0522064

0138516

0138514

0138523

0138601

0138962

0522140

0138612

0522582

0138612

0522140

0138991

0522576

0138603

0522109

0138522

704-597

9800078

9812335 (5X)

0138604

800-437

0522062 (”B”)

0138513 (”A”)

0138605

0138512

0138424

0522062 (”A”)

0153314

0522062

0522065

“A”

“B”

Helix A

0138949

0138467

0522109

0522424

0522108

SPARE PARTS DIAGRAM

MAIN ASSEMBLY

HELIX

10 11

18 19 20

23 24 25

13 14

6 7 8

HELIX

Pos. Helix A / B Description

1* ------- Cart assembly

2* ------- Control panel assembly

3* ------- Pump assembly, A side

4 0521238 Surere™ heated hose assembly, 200’

0138296 Surere™ heated hose assembly, 100’

5 0138597 Plug (2)

6 0138489 Relief valve (2)

7 424-671 Tee tting (2)

8 0090447 Elbow (2)

9 805-333 Front cover handle (2)

10 9805317 Screw (2)

11 805-332 Rear cover handle (2)

12* ------- Pump assembly, B side

13 0138037 Port cover (2)

14 700-139 Screw (4)

15 9805348 Screw (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* ------- Surere™ 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 0138285 Y strainer valve assembly (2)

30 0138038 Y strainer screen (2)

* See separate listing

When ordering any part number, you will receive a quantity of 1 of that part. If multiples of any part need to be ordered, please specify when ordering.

SPARE PARTS DIAGRAM

COMPONENT PUMP ASSEMBLY

HELIX

15 16

HELIX

Pos. Helix A Helix B Description

1 805-625 805-625 Motor shroud

2 700-681 700-681 Screw (3)

3 0138957A 0138957A Belly pan assembly

4 9802266 9802266 Screw (2)

5 0138519 0138518 Plug

6 9812320 9812320 Nut (6)

7 805-286A 805-286A Lever assembly

8 805-287A 805-287A Clevis assembly (2)

9 9802266 9802266 Screw (2)

10 805-462 805-462 Electronic cover

11 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

* See separate listing

This parts list applies for both Pump A and Pump B. Items 5 and 13 are installed in dierent locations, depending upon the pump.

SPARE PARTS DIAGRAM

DRIVE ASSEMBLY

HELIX

Pos. Helix A Helix B Description

1 700-283 700-283 Screw (4)

2 0558572A 0558572A Slider assembly

3 805-248A 805-248A Slider housing

4 0558342A 0138956A Housing assembly

5 800-525 800-525 Gasket

6 0558362A 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 bae

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 9822106 Washer

SPARE PARTS DIAGRAM

HEATER BLOCK ASSEMBLY

HELIX

6 7

8 9

18 19

22 23

28 29

30 31 32 33

34 35

38 39 40

HELIX

Helix A / B

0138011

Pos.

1* ------- ------- Display assembly

2 9805436 9805436 Set screw

3 862-401 862-401 Jam nut

4 9800340 9800340 Screw (4)

5 0522424 0522424 EMI lter, 20A (2)

6 0293489 0293489 Nut (4)

7 0522109 0522109 Wire assembly (2)

8 0138522 0138522 Communication cable

9 0138493 0138493 Top enclosure, front

10 730-260 730-260 Screw (24)

11 0138534 0138534 Nut

12 0138533 0138533 Strain relief

13 0138471 0138471 Grommit (2)

14 0138452 0138452 Hose heater cover

15 0138482 0138482 Enclosure door assembly,

0138060

Helix A / B

0138013 0138059

Description

front

Helix A / B

0138011

Pos.

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

28 9805287 9805287 Screw (4)

29 0138964 0153639 Receptacle

30 0138509 0138509 Strain relief (2)

31 9805440 9805440 Screw (4)

32 0138467 0138467 Receptacle, 15A

33 9800084 9800084 Plug

34 9800086 9800086 Screw lock (4)

35 9800078 9800078 Coupler (2)

0138060

Helix A / B

0138013 0138059

Description

insulation

16 0138451 0138451 Enclosure door, front,

middle

17 0138494 0138494 Enclosure door, front,

bottom

18 9822106 9822106 Washer

19 0524353 0524353 Nut

20 0138453 0138453 Top enclosure, rear

36 0138449A 0138449A Enclosure weldment with

insulation

37 0138485 0138485 Plug (8)

38 9805439 9805439 Screw (8)

39 9821503 9821503 Lock washer (4)

40 770-601 770-601 Washer (4)

41* 0138691A 0138691A Heater block assembly, 3

stack

42 0138523 ------- Power distribution block

* See separate listing

SPARE PARTS DIAGRAM

DISPLAY ASSEMBLY

7 6

5 4

HELIX

14 15

16 17 18

22 23

25 25 26

25 25

HELIX

Helix A / B

0138011

Pos.

1 0138462A 0138462A Display cover

2 730-260 730-260 Screw (4)

3 9812335 9812335 Nut (2)

4 9812334 9812334 Nut (6)

5 9822646 9822646 Washer (6)

6 805-401 805-401 Display (2)

7 0138527 0138527 Spacer (6)

8 700-139 700-139 Screw (2)

9 0522577 0522577 Relay, 30A

10 855-914 855-914 Lock nut (2)

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)

0138060

Helix A / B

0138013 0138059

Description

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 Potentiomenter assembly

23 9822631 9822631 Washer (4)

24 855-914 855-914 Nut (4)

25 0522515 0522515 Circuit breaker, 12A (4)

26 0522513 0522513 Circuit breaker, 1.5A

SPARE PARTS DIAGRAM

FLUID SECTION

HELIX

Helix A

Pos.

0138039A

1 0138899 805-545 Retainer

2 805-551 805-551 Spacer

3 0509123A 0509123A Upper packing

4 0138898 805-519 Cylinder

5 805-587 805-587 Fitting

6 9871189 9871189 O-ring

7 0558582A 0558582A Lower packing

8 0558564A 0558564A Piston rod

9 800-348 800-348 Upper seal

10 0507452 0507452 Upper ball guide

11 9841502 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

Helix B

0138277A

Description

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 0138481 Inlet valve housing

805-267A 805-267A Piston assembly (includes items

0558981 0558981 Fluid section service kit (includes

8-14)

items 2-3, 7, 9, 11, 13, 18 and 20-22)

SPARE PARTS DIAGRAM

CART ASSEMBLY

HELIX

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)

HELIX

PRIME/SPRAY VALVE ASSEMBLY

SPARE PARTS DIAGRAM

Pos. Helix A 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

5 700-252B 700-252B Cam base

6 0138499 0138498 Relief valve knob

7 700-759 700-759 Groove pin

item 3

SPARE PARTS DIAGRAM

SUREFIRE™ HEATER BLOCK

HELIX

8 9

Pos. Helix A / B Description

1 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)

2 0138469 Reducer tting (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)

warrantY

HELIX

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 to replacing or repairing without charge those parts which, to Titan’s reasonable satisfaction, are shown to be defective within twenty-four (24) 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 does not apply in the case of damage or wear caused by abrasion, corrosion or misuse, negligence, accident, faulty installation, substitution of non-Titan component parts, or tampering with the unit in a manner to impair normal operation. This warranty excludes normal wear items and consumables such as, lters, piston, packings, tips, etc.

HELIX MOTOR WARRANTY:

Four Year (48 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 to replacing or repairing without charge the Helix Motors, to Titan’s reasonable satisfaction, are shown to be defective within fortyeight (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.

Defective parts are to be returned to an authorized Titan sales/service outlet. All transportation charges, including return to the factory, if necessary, are to be borne and prepaid by the End User. Repaired or replaced equipment will be returned to the End User transportation prepaid.

THERE IS NO OTHER EXPRESS WARRANTY. TITAN HEREBY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES INCLUDING, BUT NOT LIMITED TO, THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, TO THE EXTENT PERMITTED BY LAW. THE DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD SPECIFIED IN THE EXPRESS WARRANTY. IN NO CASE SHALL TITAN LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED TO THE EXTENT PERMITTED BY LAW.

TITAN MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY TITAN. THOSE ITEMS SOLD, BUT NOT MANUFACTURED BY TITAN (SUCH AS GAS ENGINES, SWITCHES, HOSES, ETC.) ARE SUBJECT TO THE WARRANTY, IF ANY, OF THEIR MANUFACTURER. TITAN WILL PROVIDE THE PURCHASER WITH REASONABLE ASSISTANCE IN MAKING ANY CLAIM FOR BREACH OF THESE WARRANTIES.

Note on disposal:

In observance of the European Directive 2002/96/EC on waste electrical and electronic equipment and implementation in accordance with national law, this product is not to be disposed of together with household waste material but must be recycled in an environmentally friendly way!

Titan or one of our dealers will take back your used Titan waste electrical or electronic equipment and will dispose of it for you in an environmentally friendly way. Please ask your local Titan service centre or dealer for details or contact us direct.

UNITED STATES 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

Titan HELIX 0138011, HELIX 0138059 AP, HELIX 0138011 AP, HELIX 0138060, HELIX 0138060 AP Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual