Trooper ADVANTAGE TR-100 Manual de usuario

NEGATIVE PRESSURE UNIT

I.O.M. #08A 9/95 updated 11/13

INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: 317-881-1277

Service Department fax: 317-885-8683

www.AdvantageEnegineering.com

e-mail: [email protected]

INSTRUCTION MANUAL

TROOPER NEGATIVE PRESSURE

UNITS

TR-100 TR-200 TR-300 TR-350 TR-400 TR-500

COVERING

INSTALLATION

OPERATION

MAINTENANCE

NEGATIVE PRESSURE UNIT

ADVANTAGE ENGINEERING, INC. 525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: 317-881-1277 Service Department fax: 317-885-8683

www.AdvantageEnegineering.com e-mail: [email protected]

Page: 4

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142

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

web site: www.AdvantageEngineering.com

Service Department email: [email protected]

TROOPER : Negative Pressure System

TABLE OF CONTENTS

1 GENERAL 6

1.1 Safety 6

1.2 Introduction 7

2 INSTALLATION 8

2.1 Connecting a power cord 8

2.2 Checking the phase monitor (3Ø units) 9

2.3 Connections to a mold 9

3 OPERATOR INSTRUCTIONS 10

3.1 Startup and adjustments 10

3.2 Gauge reading check 12

3.3 Pressure indicating lights 13

3.4 Shut down and storage 14

4 BASIC FUNCTION AND OPERATION 15

4.1 How an ADVANTAGE TROOPER works 15

4.2 Pressure drop across a mold 16

4.3 Mold leak simulation

(demo and operation check) 17

4.4 Using mold heaters with TROOPER units 18

4.5 Fixing problem leaks (multiple and cavity) 20

4.6 Using ADVANTAGE TROOPER as

a booster pump 21

5 TROUBLESHOOTING 22

5.1 Unit will not start - power light off -

pressure lights off 22

5.2 Unit will not start - power light on -

pressure lights off 22

5.3 Unit shuts on and off -

pressure lights on 22

5.4 Unit shuts on and off

pressure lights off 23

5.5 Low pressure switch check 24

5.6 High pressure switch check 24

5.7 Unit looses vacuum 25

5.8 Excessive air or foam in the return line 25

5.9 No coolant flow: higher mold temperature

on TROOPER line 25

5.10 Unit leaks at pump or motor housing 26

5.11 Hose collapses 26

5.12 Water drains constantly from vent line 26

Page: 5

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142

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

web site: www.AdvantageEngineering.com

Service Department email: [email protected]

TROOPER : Negative Pressure System

6 APPENDICES 27

6.1 Maintenance procedures 27

6.2 Drain for storage 27

6.3 Specifications and performance data

(all units) 27

6.4 Operating temperature 27

6.5 Capacity 28

6.6 Weight / dimensions / port sizes 28

6.7 Changing voltage 28

6.8 Setting and resetting the overload 30

6.9 Parts failure - common causes 30

6.10 Replacement parts 32

6.11 Parts list - TR-100 33

6.12 Parts list - TR-200 34

6.13 Parts list - TR-300 35

6.14 Parts list - TR-400 36

6.15 Parts list - TR-500 37

6.16 Electronic float switch assembly

on TR-400 and TR-500 38

6.17 TROOPER flow diagram (all models) 39

6.18 TR-340, TR-400, TR-500 electrical

(pictorial) 40

6.19 TR-100, TR-200, TR-300 3Ø electrical

(pictorial) 41

6.20 TR-100, TR-200, TR-300 1Ø electrical

(pictorial) 42

6.21 TR-350, TR-400, TR-500 3Ø AC ladder

diagram 43

6.22 TR-100, TR-200, TR-300 3Ø AC ladder

diagram 44

6.23 TR-100, TR-200, TR-300 1Ø AC ladder

diagram 45

6.24 Boiling point of water at various pressures 46

Page: 6

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142

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

web site: www.AdvantageEngineering.com

Service Department email: [email protected]

TROOPER : Negative Pressure System

1.0 GENERAL

1.1 SAFETY

A. Failure to follow correct operating instructions may damage the unit.

B. Please read your manual.

C. CAUTION: the following conditions will damage this unit:

a. Running the unit at temperatures higher than 180°F

b. Using synthetic oils as a coolant fluid

c. Running with “drain” pressure less than 5 PSI below the

‘FROM MOLD’ pressure.

d. Reversing pump rotation

D. CAUTION: ‘DRAIN’ gauge must never show less than 5 PSI

pressure while unit is running or pump may be damaged.

(see troubleshooting section for more details).

Page: 7

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142

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

web site: www.AdvantageEngineering.com

Service Department email: [email protected]

TROOPER : Negative Pressure System

A. The ADVANTAGE TROOPER

negative pressure unit is a fluid

circulating device utilizing a special

pump to create a negative pressure

inside the mold to stop any leak.

B. The above picture will give the reader

an overview of the major components

of the TROOPER system.

A- Gauge panel

B - Electrical panel door

C - Rocker switch and lights

D- Electrical panel

E- Air vent

F- Pump

G - Pump motor

H - Regulator (can’t be seen in

photograph)

1.2 INTRODUCTION

Page: 8

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142

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

web site: www.AdvantageEngineering.com

Service Department email: [email protected]

TROOPER : Negative Pressure System

2.0 INSTALLATION

2.1 CONNECTING A POWER CORD

A. CAUTION: electrical connections should only be done by qualified

persons who are familiar with proper electrical safety procedures.

B. CHOOSING THE CORRECT WIRE

1. The voltage and phase of the ADVANTAGE TROOPER is

labeled at the power cord mounting hole at the back of the

terminal block.

2. For safety, ALWAYS use a

properly grounded cord.

3. 110/22/ VAC, 1Ø units: use

a standard THREE WIRE

cord, UL approved and rated

for 15 amps.

4. 230/460 VAC, 3Ø units: use

a standard FOUR WIRE

cord, UL approved and rated

for the amperage of the unit

being wired.

4. Electrical code requires

power cords to be rated

for 25% more than the Full

Load Amperage (FLA) of the

unit. FLA for every unit is

recorded on the motor serial

plate.

5. 14 Gauge wire is adequate

for all ADVANTAGE

TROOPER negative pressure

units.

6. The unit may also be wired directly to a fuse box. Always

be sure that the fuses used do not exceed the FLA rating of

the motor.

6. The power cord should be connected to the terminal block

located at the inside rear of the electrical box.

7. Mount the cord with the appropriate strain relief through the

hole provided.

8. Be sure that the ground wire of the power cord is connected

to the same position on the terminal block as the green

Terminal Block

Motor data plate

Page: 9

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142

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

web site: www.AdvantageEngineering.com

Service Department email: [email protected]

TROOPER : Negative Pressure System

ground wire of the ADVANTAGE TROOPER.

2.2 CHECKING THE PHASE MONITOR (3Ø UNITS ONLY)

A. All three phase ADVANTAGE

TROOPERS units are equipped

with a phase monitor to protect the

pump against damage caused by

phase loss, low voltage and phase

reversal.

B. After connecting the power cord,

leave the electrical box cover open

so that the phase monitor is in view.

C. Plumbing connections are

unnecessary at this point. Be sure

that ADVANTAGE TROOPER power

switch is in the “off” position. Running the unit without fluid will

damage the stator. Connect the power supply, leave the unit “off”.

The indicator LED on the top of the phase monitor should glow.

D. If the indicator LED does not light, turn the power off and disconnect

the power supply. Swap any two (2) of the three (3) input wires at

the terminal block (DO NOT REMOVE THE GROUND).

E. Reconnect the power supply and turn the power on. The LED will

now glow, indicating that the unit is wired to the phase sequence

required for correct motor rotation.

F. NOTE: it may be necessary to slightly lower the adjustment dial

of the phase monitor to prevent nuisance tripping. CAUTION:

lowering the adjustment dial setting more than 10-12 degrees below

the precise setpoint may interfere with the proper operation of the

phase monitor.

G. Turn the power off. tighten down the screws on the electrical box

cover. The ADVANTAGE TROOPER is now protected against

phase reversal, phase loss and low voltage power faults.

2.3 CONNECTIONS TO A MOLD

A. For maximum efficiency and life of the ADVANTAGE TROOPER

unit, use hoses that are the same diameter as the ports to which

they are connected.

B. “Quick Release” fittings that are not vacuum rated, are not

recommended, as they will severely impair the use of the

ADVANTAGE TROOPER as a leak stopper and when using “water

transfer”.

Phase monitor

Page: 10

ADVANTAGE ENGINEERING, INC.

525 East Stop 18 Road Greenwood, Indiana 46142

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

web site: www.AdvantageEngineering.com

Service Department email: [email protected]

TROOPER : Negative Pressure System

3.0 OPERATING INSTRUCTIONS

3.1 START UP & ADJUSTMENTS

A. A simplified version of the following instruction are silkscreened on

the ADVANTAGE TROOPER cabinet for easy reference.

B. Make all hose connections to the appropriate ports at the back of

the ADVANTAGE TROOPER.

C. Begin with the ‘POWER’ switch in the ‘OFF’ position.

‘FROM MOLD

connection ‘RETURN’

connection

‘SUPPLY’

connection

‘TO MOLD’

connection

C. When using the ADVANTAGE TROOPER as a leak stopper you

will have maximum coolant flow when the “TO MOLD” line is

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