Instruction Manual - Manufacturing Insulation blowing ...€¦ · Instruction Manual Insulation blowing machine ... cool clean air from outside the truck / trailer to ensure that

Instruction Manual

Insulation blowing machine

Original Language – English

Intec — 4040 Kodiak Court, Frederick, CO 80504 USA

T: 303-833-6644 Web: www.inteccorp.com Email: [email protected] T: 800-666-1611 Rev Date: 20170218

Instruction Manual | 1

T: 303-833-6644 or 800-666-1611 www.inteccorp.com Original Language - English

Introduction Thank you for purchasing an Intec insulation system. Since 1977, both professional contractors and do-it-yourself equipment users have looked to Intec as the industry leader in the design and manufacture of innovative, portable, professional grade insulation blowing equipment. Now many of these individuals are also profiting thru the use of our high powered vacuums that are Engineered for High Productivity and Built-to-Last for High Value Generation. At Intec, we take pride in making your job as easy and profitable as possible. The right system for your needs: Intec strives to provide you with the best combination of portability, functionality, and installation versatility to surpass your desired success. • FORCE BLOWING MACHINES – Powered by Electric, Gas, or Diesel: From lightweight polyethylene units with removable hoppers, to larger units with increased production rates and installation versatility, all of our durable systems are made to maximize your profit generating potential. • VORTEC VACUUMS – Powered by Gas or Electric: Engineered for High Productivity and Built to Last for High Value Generation, Intec’s VORTEC high powered vacuums provide the highest value offered in today’s marketplace. With various sizes and gas or electric power options, we have a vacuum that will enable you to profitably grow your business. Best-in-class Customer Service: Total ease of use extends beyond your initial purchase of an Intec system to your evolving needs thru the entire lifecycle. Both before and after the sale service is important to keep you running at peak operating capabilities. Intec’s technical team provides installation assistance in addition to maintenance suggestions and trouble-shooting support. In addition to blowing machines, Intec produces a range of accessories that will increase your productivity when dense packing, damp spraying, and installing net and blow. Thank you for partnering with Intec. We appreciate the confidence and trust you have placed in us, and wish you many profit-generating opportunities!

Ray Lavallee President, Intec



Table of Contents

INTRODUCTION ........................................................................................... 1

SYMBOLS .................................................................................................... 3

SAFETY FIRST ............................................................................................... 3

HOW THE SYSTEM WORKS ................................................................................. 4

Initial System Set-Up: ............................................................................................................................................. 7

System Operation: ................................................................................................................................................ 10

MAINTENANCE ............................................................................................ 12

TROUBLESHOOTING ....................................................................................... 14

ELECTRICAL DRAWINGS ................................................................................... 19

FORCE 5280 with wired remote ............................................................................................................................. 19

FORCE 5280 with wireless and wired remote ........................................................................................................... 20

MAKING A CLAIM FOR DAMAGE OR LOSS ............................................................... 21

WARRANTY ................................................................................................ 22



Symbols SYMBOL SYMBOL MEANING

Danger Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

Warning Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

Caution Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury.

Safety First

Remove engine key and press emergency stop inward prior to working on the equipment. Failure to do so could result in injury or death. Never operate equipment with guards (ex: chain, engine access, etc.) off. Never operate equipment with engine access door open. Never operate equipment while standing in water as electrical shock may result.

When working with insulation, always wear a long sleeve shirt, gloves and a hat. Wear goggles or safety glasses for eye protection. Wear a mask for respiratory protection.

Never put your hands into the hopper or machine outlet while the machine is operating.

Keep tools and foreign objects out of the hopper.

Never leave the machine unattended during operation. Disconnect all power to the machine when unattended.

Never operate the equipment with the access panels off, possible injury may occur.

Prior to use, inspect remote cord to ensure no damage exists.



How the System Works

OVERVIEW: Cellulose, Fiberglass, or Stone Wool insulation is loaded into the hopper. The agitator has two functions: (a) it breaks-up the insulation to start the conditioning process, and (b) transports the insulation to the shredder box. The shredder box conditions the fibers to allow for proper density & coverage. From the shredder box, the insulation enters the airlock. The airlock transports the insulation into the airstream created by the blower system. Insulation is discharged from the airlock, through the machine outlet, and into the hose. The insulation is further conditioned as it travels through the hose. An introduction to key components of the system follows: Loading Platform: The loading platform acts as a shelf to support the bag of insulation being loaded into the hopper. Hopper: The hopper contains the insulation.

Control Panel: The main controls of the system are gathered together in a user-friendly panel. Reviewing each item from left to right: Emergency Stop: Push in when desiring to stop all

operation of the machine; will also stop the HONDA engine. Pull out when desire to run the machine.

Operation Selector Switch: This dial allows you to operate the machine as you desire. o REMOTE - The first postion to the left provides for operation thru the wired remote. o OFF - The second position stops the agitator & blower. The HONDA engine will still operate. o BLOWER – The third position turns the blower on. o BLOWER / AGITATOR – The fourth position turns both the blower and agitator on.

CIRCUIT BREAKER: Protects the electronics to ensure appropriate operation. When pushed in the machine is ready to start and operate.

REMOTE CORD: Receptacle for Intec’s wired remote.



Wired Remote: Intec’s wired remote – with exclusive shock absorbing urethane jacketed controls – provides for control of the system. You can control the blower only, or blower and agitator, from the wired remote. Blower Motor Air Inlet Filter: The Blower Motor Filter ensures that clean air is being used for intake air to the blower. Blower Motor: The Blower Motor powers the insulation thru the airlock, insulation blowing hose, and to its desired application location. Kunkle Valve: The Kunkle Valve is a pressure relief valve to protect your blower motor from over-pressurizing and self-destructing. The Kunkle Valve is set to automatically open if internal blower pressure exceeds 7 psi. If this pressure is achieved, the Kunkle Valve will open, discharge air until the internal pressure of the blower motor is lowered, and then close & re-set for future use. Note: 1 valve per unit; two pictures to assist with locating. One-Way Valve: A One-Way Valve protects your blower motor from potential insulation backing up into the blower. This valve will shut if air or contaminants flow in a backwards direction.



Air Flow Regulator: The Air Flow Regulator allows the user to adjust the air setting in order to lower flow. Some applications, such as spray-on, may benefit from lower airflow. Lower airflow is achieved by placing the Air Flow Regulator towards the horizontal position. Other applications, such as attic insulation install, benefit from maximum airflow to quicken the installation process. Maximum airflow is achieved by placing the Air Flow Regulator towards the vertical position Engine Fresh Air Inlet Hose: The Engine Fresh Air Inlet Hose provides cool clean air from outside the truck / trailer to ensure that your HONDA engine is appropriately cooled. The clean air from outside also prevents fibrous particles from being pulled into your engine’s cooling fins. Utilize Intec’s Air Inlet mounting plates to attached the hose coming from machine to fresh air. NOTE: Never run engine w/out the air inlet hose attached. Doing so will draw insulation into your engine’s cooling fins which will drastically reduce the life of your engine. Agitators: The agitators condition the fibrous insulation in addition to moving the insulation into the shredder box. Shredder Box: Final mechanical insulation processing is performed in the shredder box. Material Flow Gate: Located between the shredders and the airlock, the Material Flow Gate allows insulation to fall into the airlock. The gate is opened fully during typical attic installations. Close the gate slightly to increase the conditioning of the insulation and alter ratio of insulation to airflow.



Airlock: The airlock transfers the insulation from the agitation system into the airstream without coming into contact with the blower. Insulation is discharged from the airlock through a 4” outlet. Note: The picture shown depicts the airlock with front plate removed to also show airlock seals. Set up and Operation

Initial System Set-Up:

Once you obtain delivery of your FORCE 5280, you will need to mount the system into a truck or trailer. Four items to assist in your actions follow: A. Maintain or remove the two extra beams: Intec shipped your system with

two extra beams that are positioned on each end of your system running the entire depth of the FORCE 5280. These were placed to assist in moving the system with a fork lift or pallet jack. Removing both of these beams once you have the system close to its final position will provide for a lower insulation loading height.

B. Engine Fresh Air Inlet mounting plates: These mounting plates enable you to connect the 10” hose provided with your system (and connected to the HONDA engine) to a fresh, clean air source outside of your vehicle. Recommendation is to:

a. Cut a 10” diameter hole into the side wall or floor of your truck /

trailer. NOTE: be sure to cut in a non-load bearing area.



b. Mount the Outside Plate (on the outside of the truck) and Inside Plate (on the inside of the truck) – sandwiching the wall or floor -- with four nuts.

c. Hose Ring: The Hose Ring will mount to the Inside Plate.

Once mounted and hardware is tightened, you are ready to fasten the open side of the Fresh Air Inlet to the 10” diameter hose.

Upon completion, you will now have fresh, clean air from outside your vehicle used to cool the HONDA

engine.

C. Fresh Air Inlet for Blower Motor: Intec has shipped your system with an inlet air filter for the blower motor. To reduce the sound of the blower motor in your truck / trailer, you may utilize the fresh air Inlet kit for the blower motor. Recommendation is to:

a. Drill a 3” hose to mount the floor mount (or can use for a wall mount) using appropriate fasteners. Note that the floor mount comes with a screen to prevent objects from entering. You can remove the current hose clamp holding the screen in place, cover with the air inlet hose, and then fasten a hose clamp to hold both the air inlet hose and screen in place.

Side view Top view

Inside Plate Outside Plate



b. If your blower currently has a blower inlet air filter, unscrew from the 90 degree elbow.

c. Install the black iron pipe for blower hose inlet into the 90 degree elbow. This is the elbow from which the inlet air filter (if provided with your system) was installed.

d. Slip one hose clamp on one end of the air inlet hose. Now position this end of the hose over the smooth end of the black iron pipe and tighten hose clamp to fasten hose.

e. Slip the second hose clamp on the other end of the air inlet hose. Position this end of the hose over the floor mount and tighten hose clamp to fasten hose.

D. Exhaust Extension Mounting pipe: Intec provides you with the capability to

extend your HONDA engine’s exhaust outlet in order to exhaust thru the bottom of your truck / trailer. To do this, we provide:

a. Mounting Pipe – this is to be inserted into the hole made on the floor of your truck / trailer.

b. Flexible Exhaust pipe & hose clamp – one end of this flexible exhaust pipe is connected to the HONDA approved muffler on your HONDA GX 660 V-Twin. The other end is routed thru the Mounting Pipe referenced above.



System Operation:

1. Prior to starting machine, look into hopper to ensure that no foreign object is in the hopper.

2. Check air filters – Blower Motor inlet air and HONDA engine -- to ensure clean.

3. Attach 4” blowing hose to the machine’s outlet. Attach your insulation blowing hose and bring the outlet end to the desired installation location.

4. Check gas tank and place gas into tank as required. a. NOTE: Do not leave fuel in tank when not using system for over 1 week. Fuel goes stale

quickly; stale fuel will cause issues with the carburator and create some nuisance activities.

5. Lower Loading Platform - Remove pin from the right side of loading tray and pull down into open position.

6. Pull the Emergency Stop out, place Selector Switch in OFF,

and ensure that circuit breaker is ‘in’ (i.e. not tripped).

7. Pull the HONDA engine’s chock to place in the ON position.

8. Push the throttle lever 1/3rd to ½ of the way up.

9. Open Material Flow Gate and pin to hold in the desired position.

10. Remote Cord – If using the wired remote to control the machine, insert the wired remote’s male end into the receptacle on the control panel.

11. Load insulation into hopper. 12. Turn HONDA engine key to start the engine; let go of key once engine starts.



13. Press the choke in once engine has warmed up (typically with in 15 seconds).

14. Operation Selector Switch: a. Move to the left – REMOTE -- if desiring

to control the machine by the remote. i. Then turn on the BLOWER

control of the remote. b. Move to BLOWER -- if desire to control

system by the control panel.

15. Set the Air Flow Regulator to the desired amount of air flow. This adjustment can also be made when actually blowing insulation thru the system.

16. Turn the BLOWER / AGITATOR button “ON” to move insulation thru the system.

17. Install insulation.

SHUT DOWN

1. It is recommended to remove insulation from the airlock when not using the system. Removing the insulation ensures that seals will last longer as they will not be bent out of position. This can be accomplished by:

Running insulation out of the hopper and through the system, or

Closing the slide gate and letting the airlock spin for 3-5 seconds prior to shutting the BLOWER / AGITATOR button.

2. Shut the AGITATOR / BLOWER button, yet leave the blower on to blow the insulation out of the hose.

3. Turn the HONDA engine throttle to idle, leave in this position for approximately for 30 seconds to allow for appropriate engine cool down prior to shutting engine.

4. Turn HONDA engine key to the OFF position.

5. Disconnect wired remote as beneficial.

Complete



Maintenance Preventative maintenance will provide for many years of trouble-free use. The intent of this maintenance overview is to provide you with an understanding of maintenance items required on your FORCE 5280. This 1-pager is not intended to replace the details found in either the HONDA or Howden / Roots Operational & Maintenance manuals.

Overview Chart:

Refer to the HONDA and Howden / Roots Operational & Maintenance manuals provided with you blowing machine for complete maintenance requirements, or warranties may be voided. Electronic copies can be obtained on Intec’s website at http://www.inteccorp.com/intec-manuals/. NOTES: 1. HONDA engine oil: Intec ships HONDA engines with either 5W – 30 or 10W – 30. 2. Gas – 86 octane rating or higher. Remove gas from system if will sit for 1 week. Stale gas will cause

issues with your HONDA’s fuel system. 3. Grease – see Howden / Roots manual for grease recommendations.

http://www.inteccorp.com/intec-manuals/



4. Howden / Roots URAI blower with slash lubrication: Gearbox – see page 8 of your Howden / Roots Operational & Maintenance manual.

Cleaning Clean the interior and exterior of the machine weekly by wiping with a rag and/or blowing with compressed air; this will help maintain the longevity of the mechanical components in addition to the system’s finish. The machine has been designed to work in a dusty environment. However, without periodic cleaning and maintenance, the performance of the machine will decline potentially leading to failure.

Airlock and Seals The airlock assembly is one the most important items to keep in good condition. Foreign objects in the airlock can cause damage and reduce the machine’s production. Seal failure is the most common airlock assembly failure. Seal failure prevents the airlock from holding the proper pressure. Seal failure will reduce the machine’s production. A machine with seal failure will have air blow out of the airlock into the hopper, reducing the amount of air exiting the machine outlet. It is recommended to visually inspected seals each week to ensure proper running condition. Replace airlock seals if a cut or tear is evident. Airlock seals should be replaced every 3 to 6 months, dependent on use. Visit www.inteccorp.com or contact Intec for replacement instructions.

Fresh Air Inlets Check prior to each use to ensure no obstruction will prevent clean air to the HONDA engine or Roots blower.

Chain Clean and lubricate the chain once per year. Use a dry lubricant when lubricating the chain; do not use oil as oil will attract foreign particles like dust to chain. If the machine is often used in dusty conditions, then clean and lubricate the chain more frequently than once per year.

HONDA ENGINE See HONDA’s manual and follow recommended maintenance. A few items to ensure that you follow are: Check oil level prior to each job. Check air filter to ensure clean prior to using. If the machine is often used in dusty conditions, then ensure that the engine’s cooling fins are clean

to allow for proper cooling. Blowing engine’s cooling fins with compressed air often a good method of cleaning.



TroubleShooting

Problem Likely Cause Remedy

Engine will turn, yet not start No fuel in tank. Ensure appropriate level of gas in tank.

Engine choke is in OFF position. Pull engine choke out … into the ON position.

Emergency stop button has not been pulled out.

Pull out emergency stop bottom.

Machine’s circuit breaker has tripped.

Push to reset circuit breaker.

Bad / stale fuel in system. Consult HONDA engine manual.

HONDA engine on, yet insulation not coming out of machine.

Slide gate is closed. Open slide gate to desired position.

BLOWER or AGITATOR is not on. Ensure BLOWER or BLOWER / AGITATOR is on.

No / little insulation in hopper. Check hopper and fill with insulation as desired.

Insulation blockage in hose. Turn system off, remove hose and clear blockage.

Air pocket in hopper is preventing insulation from feeding into agitators.

Disconnect electrical power. Redistribute insulation material inside hopper.

Foreign material causing jam in hopper.

Shut engine, press in Emergency Stop, clear jam, and restart system.

Agitator does not run. Agitator belt is slipping. Apply tension to belt.

Shear pin – to the right side of agitator closest to wall by shredder entrance – is broken.

Replace shear pin.



Problem Likely Cause Remedy

Insulation not coming out of machine as fast as desired.

Air Flow Regulator not set at maximum setting.

Turn the Air Flow Regulator so the switch is in the down position.

Material Flow Gate setting not at maximum setting.

Open Material Flow Gate all the way (i.e. hole #0).

Hose diameter is tapered down from initial 4” diameter.

Run as much 4” diameter hose as possible for maximum production. Running smaller diameter hose will decrease production rates.

Airlock seal is worn. Inspect airlock seals for cuts and wear. Have a qualified technician replace airlock seals.

See “HONDA engine on, yet insulation not coming out of machine.” for more options.

Insulation exiting hose is dribbling out.

Heavy insulation material. Push Material Flow Gate in 1-2 holes.

Turn the Air Flow Regulator down towards maximum flow.

Kink in hose. Straighten hose.



Specifications Weight FORCE 5280

1,441 lbs; 655 kg

Main Motor HONDA GX 660 V-Twin - gas

Blower Motor Howden Roots URAI 36

Gas Tank

5 gallon



Electrical Drawings FORCE 5280 with wired remote



FORCE 5280 with wireless and wired remote



Making a Claim for Damage or Loss

Your Intec products were carefully packed and thoroughly inspected before leaving our factory. We understand that damage to or defects with your system may unfortunately occur. Please inspect your shipment carefully upon arrival and save the shipping containers and packaging materials in case of damage.

The following table provides you with appropriate actions to take when certain issues are realized.

ISSUE Action to Take

1 DAMAGE in Transit A Visible PRIOR to unpacking (Damage to carton or

packing material). File Claim with appropriate freight carrier.

B Visible AFTER unpacking (Only apparent when unpacked).

File Claim with appropriate freight carrier.

C Shortage (# containers does not agree to transportation bill).

File Claim with appropriate freight carrier.

When items leave our warehouse, the shipper assumes responsibility. It is the responsibility

of the consignee to file a claim. Proper documentation is necessary to support the claim. Please inspect all items properly prior to signing for them.

2 Items received not correct A Incorrect items received. Contact Intec Customer Service B Incomplete order received (not backordered). Contact Intec Customer Service 303.833.6644 ext. 101 [email protected]

3 Issue within the warranty period

A Troubleshooting (machine or part not operating as intended).

Contact Intec Customer Service

B Replacement part(s). Contact Intec Customer Service Intec can assist with troubleshooting your issue, and

can get you back up and running. If warranty parts are required, a return material authorization (RMA) will be issued by technical service.

303.833.6644 ext. 101 or

[email protected]

4 Issue outside of warranty period A Replacement part, troubleshooting. Contact Intec Customer Service B Need assistance from a service center. Contact Intec Customer Service 303.833.6644 ext. 101

Shipping Department Intec 4040 Kodiak Court Frederick, CO 80504

phone: 303-833-6644, 800-666-1611 fax: 303-833-6650 email: [email protected] website: www.inteccorp.com

mailto:[email protected]



Warranty It is expressly understood and agreed that no officer, agent, salesman or employee of the manufacturer Intec (MANUFACTURER) has the authority to obligate the MANUFACTURER by any terms, stipulations, or conditions not herein expressed; that all previous representations and agreements, either verbal or written, referring to the machinery and equipment, which is the subject of this Warranty, are hereby superseded and canceled, and that there are no promises or agreements outside of the Warranty agreement. Further-more, the MANUFACTURER hereby disclaims any implied warranties of merchantability, or implied war-ranties of fitness for a particular purpose.

With the above understanding, the MANUFACTURER provides the following two (2) Year Limited Warranty, and no other, for its insulation blowing machines (MACHINES):

a) MANUFACTURER warrants to the original purchaser that the MACHINE is well made, of good material and durable; but only if the MACHINE is operated and maintained in accordance with the Instruction Manual. This Warranty is void if the MACHINE is not so operated and maintained, or if the MACHINE is used for blowing materials other than those which are intended to be used with the MACHINE.

b) MANUFACTURER guarantees the MACHINE to be free from manufacturing defects at the time of shipment, and to remain free from defects when operated under normal use, for a period of two (2) year sfrom the date of factory shipment, with the exception of the blowers, electrical and air lock components, which are warrantied for a period of ninety (90) days from date of factory shipment.

c) This Warranty shall not apply to any MACHINE or component part which, in the opinion of the MANUFACTURER, has been altered, subject to misuse, negligence, accident or operated beyond factory rated capacity. All requested Warranty work should be performed at MANUFACTURER’s factory or by an Authorized Factory Service Facility. Failure to have the Warranty work done at MANUFACTURER’S factory or by an Authorized Factory Service Facility will void this Warranty. MANUFACTURER will bear full responsibility to repair or replace, at its option, without charge to the original purchaser, any part that, in the MANUFACTURER’S opinion, is found to be defective.

d) All parts claimed defective by original purchaser shall be returned, properly identified, to MANUFACTURER’s factory or Authorized Factory Service facility, freight prepaid. All replacement, repaired or non-defective parts will be returned to purchaser, freight collect. MANUFACTURER will supply replacement parts prior to purchaser, freight collect. MANUFACTURER will supply replacement parts prior to receipt of any parts claimed defective, only with the understanding that such replacement parts will be shipped to purchaser at the then prevailing price of said part, C.O.D., freight collect. MANUFACTURER will reimburse cost of any such part only after receipt and inspection, and finding said part defective.

e) MANUFACTURER’s liability is expressly limited to the repair or replacement of defective parts set forth in this Warranty. All other damages and warranties, statutory or otherwise, being waived are original purchaser as a condition of sale and purchase of said machines. Furthermore, the MANUFACTURER shall not be liable for damages or delays caused by defective material or workmanship.

Documents

Instruction Manual - Manufacturing Insulation blowing ...€¦ · Instruction Manual Insulation blowing machine ... cool clean air from outside the truck / trailer to ensure that