CertainTeed Volu-Matic 200 Original instructions
1
Operation Manual
And Safety Information
Volu-Matic 200 Electric
Parts – Service – Accessories
863.294.3206 / 800.237.7841
www.certainteedmachineworks.com
PLEASE READ THIS MANUAL BEFORE PLACING YOUR NEW
VOLU-MATIC 300 INSULATION BLOWING MACHINE INTO SERVICE
2
WARNING
Recommended hose size, type, and length must be
used to achieve maximum results. CertainTeed
Machine Works cannot guarantee performance of
the Volu-Matic 200 Electric machine if hoses are
undersized, worn, damaged, or hoses other than those
we recommend are used.
Warning & Notes
3
SPECIFICATIONS................................................................................................................................................................4
INTRODUCTION..................................................................................................................................................................6
SAFETY...................................................................................................................................................................................8
INSTALLATION .................................................................................................................................................................. 12
OPERATION........................................................................................................................................................................ 14
PREVENTIVE MAINTENANCE.................................................................................................................................... 24
TROUBLESHOOTING ..................................................................................................................................................... 28
PARTS DRAWINGS .........................................................................................................................................................30
WARRANTY .......................................................................................................................................................................46
Table of Contents
4
Specifications
MODELS:
230 VAC, Three phase, 60 Hertz
480 VAC, Three phase, 60 Hertz
575 VAC, Three phase, 60 Hertz
ALL MACHINES:
7.5 horse power blower motor, 5 horse power mechanism motor, 24 volt remote control, 18" airlock feeder,
air volume control system, positive displacement blower, four speed transmission.
HEIGHT: 69"
LOAD HEIGHT: 59"
LENGTH: 72"
WIDTH: 48.25"
WEIGHT: 1300 lbs
ELECTRICAL: 12V DC
BLOWER VOLUME: 270 cfm @ 2 psi
MAXIMUM FEED RATES:
Cellulose: 70 - 80 lbs per minute @ 2.0 psi.
Fiberglass: 25 - 35 lbs per minute @ 3.5 psi.
Rockwool: 35 - 55 lbs per minute @ 4.5 psi.
5
P/N DESCRIPTION QUANTITY
ACCESSORY KIT
210985
Double Amp Remote Control Cord, 150ft – P/N 210888 1 EA
Stator Bar Cover Plate – P/N 210031 1 EA
Manual 1 EA
Accessory Kit
Check the accessory kit included with newly delivered machines that the following items were received for operation
6
Introduction
HOPPER
AREA
EMERGENCY
STOP BUTTONS
FRONT PANEL
BLOWING HOSE
CONNECTION
SAFETY
GUARDS
7
VOLU -MATIC 200
Several safety features are on the Volu-Matic 200 machine to ensure operator safety. Study the safety
section thoroughly so that all the features concerning safety are understood. Keep all these features
functional during machine operation.
This introduction is presented to provide a basic description of the function and purpose of the
Volu-Matic 200.
The Volu-Matic 200 machine is principally designed to blow insulating materials into attics of manufactured
housing, and can also be configured to blow side walls. The insulation material manufacturer's instructions
prevail when it comes to installing their product, since they guarantee the final results.
The Volu-Matic 200 machine is normally installed in Manufactured Housing plants or Research &
Development and Quality Control labs. The belt driven power train that drives all machine mechanisms,
includes electric motors that provide separate control of various functions on the machine. To allow the
person installing the insulation full control of the machine, a 24-volt electrical remote control system is
provided, which operates through the provided hard wire remote cord and toggle switch. The Volu-Matic
200 controls provide independent control of both the air that blows the material down the hose to its
destination, and the machine mechanisms that condition and feed the insulating material into that air stream.
The machine can be set at dierent speed settings with the transmission to match the applicators ability
and/or material characteristics.
The 24-volt electrical remote control circuit is controlled through a transformer located in the electrical
panel. The electrical control circuit is protected with adequately sized fuses. When the remote cord switch is
moved toward the cord, power is sent through the blower remote control relay's internal coil. This causes the
normally open contacts in the relay to close sending power to the blower motor starter. When the remote
cord switch is moved toward the end of the switch housing, power flows to the blower and mechanism
relay's internal coils. This causes the normally open contacts to close sending power to the respective motor
starters. The toggle switch in the remote cord housing is labeled to identify these machine functions.
The hopper area where material is deposited into the machine has a circulator to open and stir the material,
and an auger at the bottom for material feed. Material exits the auger and is conditioned by the shredder
before entering the airlock feeder. The airlock feeder deposits the material into the air stream where it enters
the hose and flows to the hose exit.
Another feature on the Volu-Matic 200 machine is a slide gate that when adjusted, can lengthen the time
the material is in the hopper area, which conditions the material. The slide gate is used to control both feed
rate and material conditioning. Air volume is controlled independently with a manually operated valve, to
help optimize material coverage
8
Safety
The Electric Insulation Blowing Machine has full guarding
and electrical disconnects for your safety. Every Volu-Matic
200 machine has this warning displayed in a prominent
place. Do not remove, modify, or deface the warning label!
WARNING: If any foreign object should enter the
machine; push an emergency stop button in (o), turn
o the master switch, unplug the remote control cord,
and shut the machine engine or power source down
before retrieving the object. Never reach into the
machine while it is operating.
BEFORE YOU RUN THIS MACHINE...
PLEASE STUDY THE REST OF THIS MANUAL
9
Other wrning signs, cution signs,
nd dnger signs re displyed so
tht the opertor is wre of other
hzrds ssocited with the use
of the mchine. You will see the
following wrnings on the mchine.
Do not remove, modify, or defce
the wrning lbels!
The purpose of this sign is to make the operator
aware that they may lose balance and fall.
10
All electric machines are factory equipped with side, front, and rear guards. The top of the machine is not
guarded for normal operation. If the machine is installed in a manufacturing plant or other type of building
where people are above the machine hopper, a top guard will have to be equipped.
1 2
5
3
4
The front guard 1 is designed to hinge up for access to your machine for maintenance and troubleshooting.
This guard must never be opened while your Volu-Matic 200 machine is in operation - there are shafts
under the guard, which are still rotating. If this guard is opened, a safety switch 2is mounted to the guard
which will stop the electric motors that drive chain driven mechanisms and the blower. If the motors do not
shut o or stop when the guard is lifted up, you should request that maintenance be performed on the
safety system. You will have to push the reset button 3in order to restart the machine after the guard is
closed. If the safety switch or guard should become damaged, replace them to ensure safety while operating
your Volu-Matic 200 machine.
11
There are two emergency stop buttons 4& 5that will completely shut the machine down. Either red
button will stop both electric motors that drive all machine mechanisms when pushed in (o) overriding
all other controls. If the mechanisms do not shut o or stop when either button is pushed, request that
maintenance be performed on the safety system. The emergency stop buttons must be pulled out (on) for
normal operation. You will have to push the reset
button 3in order to restart the machine after the
emergency stop is pulled back out.
"Knowledge of the location and function of these
emergency stops is emphasized."
These buttons should be used for any of the
following type of emergencies:
– unauthorized individual getting too close
to the machine.
– objects falling into machine.
– a machine component breaks.
– a material hose becomes disconnected.
– anything requiring immediate stopping
of the machine.
During machine operation, always move the
disconnect switch 6to the o (down) position,
move the selector switch 7to the o (middle) position,
and unplug the remote cord from the receptacle 8
before removing any guards for any reason.
During machine operation, always stand on the floor to deposit material into the hopper. Under no
circumstances should your hand, arm, stick, or broom be used to move or force feed material down into the
hopper. The Volu-Matic 200 machine is a self-feeding design requiring no outside assistance for smooth flow.
Operators should wear hearing protection if the machine noise makes them uncomfortable or noise
level exceeds acceptable standards. CertainTeed Machine Works recommends that the operator wear
an approved dust mask or respirator for their protection. Safety features are incorporated into the
Volu-Matic 200 machine to protect from serious injury. Operate your machine according to the outlined
instructions in this manual with all safety features in place and working properly. Operating the machine
in an unsafe manner can result in serious injury and/or death.
6
3 8
7
12
Installation
47.94
59.86
7.50
TYP
1.00 TYP
4.00
10.00
15.50
6.50
Guard
Machine Base Frame
Mounting Holes - 4 Places
Electrical Panel
Disconnect
Switch
Airlock Outlet – Center Line
Power Cord Connection
At 65" From Floor
Max Switch Throw
ELECTRIC V200E
SITE PLAN VIEW
DO NOT SCALE DRAWING
SHEET: 1 OF 1
9/9/2022
J.E.S.
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:12
REV
DWG. NO.
B
SIZE
TITLE:
NAME
DATE
CHECKED
DRAWN BY
FINISH
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
1/32"
ANGLE
1
TWO PLACE DECIMAL
.03
THREE PLACE DECIMAL
.01
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
CERTAINTEED MACHINE WORKS. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
CERTAINTEED MACHINE WORKS IS
PROHIBITED.
SAP#
MATERIAL
13
The Volu-Matic 200 is designed for operation in a manufacturing or industrial plant. Use the following guide
when considering location in the plant for machine operation.
1. Locate machine to facilitate the blowing operation. Consider minimum hose length suggested for
operation and the hose routing to prevent kinks in the hose.
2. Make sure adequate room is available for loading the machine. See operation section.
3. Refer to the following drawing for mounting hole locations and electrical power cord connection.
Remove all crating from the machine frame.
4. Purchase and install a top guard if the Volu-Matic 200 is located in a manner where people are above
the machine.
5. Have a qualified industrial electrician connect power to the disconnect switch and ground to electric panel
through strain relief. Check the following chart for proper wire size and type
WIRE LENGTH WIRE SIZE
50 Feet 18/4
100 Feet 16/4
150 Feet 16/4
14
Operation
15
PRELIMINARY CHECKS
1. Check the following table for the proper hose size, type, and length for a particular operation. All hose
couplings must be thin wall, 1/16 inch maximum, to minimize restrictions. Thin wall couplings can be
purchased from CertainTeed Machine Works.
Note: Follow fiber manufacturer instructions for hose setup
2. Make sure that hopper area is empty.
3. Check for presence of oil from the blower and transmission indicating a leak.
4. Check material conditioning slide and air bleed valve position. Check the recommended start settings
chart for proper position.
5. Make sure all guards are in place and securely latched.
PRELIMINARY START-UP CHECKS
1. Move the disconnect handle 6to the up (on) position and make sure the emergency stop buttons
4& 5are pulled out (on) and press the reset button 3 . Leave the selector switch 7in the o
(middle) position. Clear the area in front of the airlock feeder outlet 9for testing. Press the green start
button 10 to check blower rotation, see arrow on drive motor. Check that air does exit the airlock outlet.
Turn the selector switch to machine to check the mechanism motor rotation. All Volu-Matic 200 machines
are prewired for the correct rotation at the factory. If rotation is incorrect, have a qualified electrician
interchange two current carrying leads at the power source to change rotation.
2. With all rotations correct, shut the machine down completely. Place the transmission 11 into first gear,
see getting started section.
3. Move the toggle switch 12 to the center (o) position and plug the remote cord 13 shipped with newly
delivered machines into the receptacle 8, this is a twist lock connection.
4. Power up the machine as in step one. Press the green start button
10 and the blower will start. Turn selector switch 7to remote
and the blower will stop. Cycle the toggle switch in the remote
cord housing toward the cord and the blower will come on. With
the blower operating satisfactorily, cycle the switch toward the
end of the housing and the blower and machine mechanisms will
operate simultaneously.
OPERATION MATERIAL HOSE DIAMETER HOSE LENGTH
Open Blow
Cellulose
Fiberglass
Rockwool
3-1/2" Minimum 150' Minimum
Side Wall
Cellulose
Fiberglass
Rockwool
2-1/2" Minimum
3" Minimum
3" Minimum
150' Minimum
13
12
16
5. Become knowledgeable about the components of the Volu-Matic 200 machine. Engage and disengage
the remote cord noticing the drives start and stop. With machine running, push one emergency stop
button and check that the drives stop. Pull emergency stop button out, push the reset button and start
the machine again. Push in the other emergency stop button and check that the drives stop. If the remote
toggle switch was cycled o, then cycle the toggle switch for the drives to come on.
6. For any problems encountered during preliminary start-up procedures, check the Troubleshooting section
or call CertainTeed Machine Works at 800-237-7841.
11
9
5
3
4
8
10
7
6
17
VOLU-MATIC 200 RECOMMENDED START SETTINGS CHART
Note 1: Use these settings as a starting guide only. Variations between materials of the same type and
variations between batches from the same manufacturer may require dierent settings than those suggested.
Remember, the material manufacturer’s instructions prevail since they guarantee the final results.
GENERAL INSTRUCTIONS:
1. Vary the air bleed pressure first. If you cannot get the desired results by opening or closing the air control
lever handle, then...
2. Vary the slide gate next. If you cannot get the desired results by closing or opening the slide gate, then...
3. Go to the next highest or lowest speed on the transmission. If you cannot get the desired results changing
the speed, then...
4. Add or remove stator bar. If you cannot get the desired results by adding or removing the stator bar, then
start with varying the air pressure again.
OPERATION MATERIAL SLIDE GATE TRANSMISSION
GEAR AIR BLEED
PRESSURE
Open Blow
Cellulose 16" 3rd 2.0 – 3.5 psi
Fiberglass 12" 3rd 2.0 – 3.5 psi
Rockwool 12" 2nd 4.5 – 5.5 psi
Side Wall
Cellulose 8" 1st 1.0 – 2.5 psi
Fiberglass 8" 2nd 1.0 – 2.5 psi
Rockwool 6" 1st 1.5 – 1.75 psi
18
GETTING STARTED
1. Use the preliminary and startup checks
as a check list on your Volu-Matic 200
machine each day before proceeding to
the job site. At the job site, connect hose
at the through wall connection firmly
with band clamps and make sure the
hose does not have a short radius bend.
A short radius bend will result in poor
coverage, excessive hose and feeder
wear, and/or plugged hoses. Use thin
wall couplings and reducers, 1/16 inch
maximum, to minimize restrictions.
THIS
NOT THIS
The Volu-Matic 200 machine will not perform to specifications when held back by undersized and restrictive
hoses, couplings, and reducers. For open blow operations, use a 25 foot to 50 foot length of 4 inch diameter
hose at the air lock feeder outlet connection if excessive high air pressure is experienced using all 3-1/2 inch
diameter hose.
Repeated warnings about choice of hose
may seem to be an attempt to sell our
brand, but we must stress the importance
of proper hose selection for the type of
material and operation. A rough bore
corrugated hose is necessary for blown
fibers since smooth bore rubber or plastic
will roll shredded material into small tight
balls. Your Volu-Matic 200 machine has
been engineered, when properly adjusted,
to condition fibers for optimum coverage.
Improper hose selection will degrade fibers
conditioned by the machine and reduce
insulation value in blown material. Do not
deviate from hose diameters, types, or
length, as specified in the table.
For maximum open blow
operation, connect a
minnimum of 25 ft 4" hose
to airlock feeder outlet.
Use 4 - 3.5 Reducer when
using the minimum
recommended hose
diameter of 3.5".
4" or 3.5" blowing hose,
minimum 150 feet.
Note: Hose connections are
generally made at the truck box
Through wall connection
Established at installation.
For side wall operation,
connect hose to airlock feeder
as shown in the drawing
Note: Add 3 - 2.5 reducer for
side wall operation using 2.5
inch hose.
4 inch rubber hose sleeve
4 - 3.5 reducer
3.5 inch rubber
hose sleeve
3.5 - 3 reducer
3 inch blowing hose,
minimum 150 ft.
19
2. Make sure the emergency stop buttons 4& 5are pushed in (o) and the remote cord toggle switch 12
is in the center (o) position.
3. Use the recommended start settings chart to adjust machine for the type of insulation you are using and
particular operation
4. Air flow rate may be controlled with the air bleed control valve 14 while monitoring system pressure on
the air gauge 15 . The system back pressure must be read while the Volu-Matic 200 machine is operating
with full length and proper hose while material is being blown.
Always start the adjustment with the air bleed control valve in the fully closed position. If the air flow and
pressure deliver the desired results with the valve closed, then do nothing to the valve. As you begin to
open the valve, air is bled o from the exit of the blower preventing flow of all air to the airlock feeder. As
you open the valve, be careful to not open completely during open blow or the blowing hose could clog
because of insucient air volume.
CAUTION: As you open the valve, be careful not to open completely during open blow operation or the
blowing hose could clog because of insucient air volume.
5. To adjust the slide gate 16 , refer to the chart and select the proper setting for the material to be blown and
particular operation. Lift the handle 17 out of the notch and move to the left to open the slide gate. Place handle
in notch that matches with the desired setting on the scale 18 . The scale is calibrated in inches of opening.
6. To adjust the transmission 11 , refer to the chart and select an appropriate gear for material and type of
operation. Shift the lever 19 into gear in accordance with decal instructions on the machine front panel. Since
the transmission is not synchronous, it may be necessary to pull the gears through by hand using the pulley 20
so that gears mesh /allowing you to change them. This should never be attempted or gears shifted while the
machine is operating.
14
15
18 17 16
20
WARNING: Never attempt to change gears while the Electric Volu-Matic 200 machine is in operation.
Always change gears when the machine is completely shut down. Failure to do so can result in serious
personal injuries or a severely damaged transmission.
STAND ON FLOOR TO LOAD MATERIAL INTO THE HOPPER!
Gears Decal Instructions
14
21
11
19
20
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