SAINT-GOBAIN CertainTeed Volu-Matic 100 Original instructions
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Operation Manual
And Safety Information
Volu-Matic 100
Parts – Service – Accessories
863.294.3206 / 800.237.7841
www.certainteedmachineworks.com
PLEASE READ THIS MANUAL BEFORE PLACING YOUR NEW
VOLU-MATIC 100 INSULATION BLOWING MACHINE INTO SERVICE
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WARNING
Carbon monoxide poisoning from engine exhaust
can be fatal. Make sure exhaust is routed away
from air intake flanges and that the truck body is
well ventilated.
WARNING
Do not smoke when refueling the tank or operating
the machine. Fumes from fuel are explosive and can
be fatal. Follow all safety precautions when handling
any type of fuel.
WARNING
Recommended hose size, type, and length must be
used to achieve maximum results. CertainTeed
Machine Works cannot guarantee performance of
the Volu-Matic 100 machine if hoses are undersized,
worn, damaged, or hoses other than those we
recommend are used.
Warnings
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SPECIFICATIONS...............................................................................................................................................................4
INTRODUCTION.................................................................................................................................................................6
SAFETY..................................................................................................................................................................................8
OPERATION ........................................................................................................................................................................12
TROUBLESHOOTING .................................................................................................................................................... 20
PREVENTIVE MAINTENANCE................................................................................................................................... 24
PARTS DRAWINGS......................................................................................................................................................... 30
WARRANTY ....................................................................................................................................................................... 41
Table of Contents
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Specifications
MODELS:
Gasoline Engine Driven Insulation Blowing Machine
• Kohler Gasoline Engine - 14 HP single cylinder air cooled.
ALL MACHINES:
10” airlock, air volume control system, positive displacement blower, electro-magnetic clutches.
HEIGHT: 68"
LOAD HEIGHT: 54"
WIDTH: 46.5"
LENGTH: 54"
WEIGHT: 850 lbs
ELECTRICAL: 12V DC
MAXIMUM FEED RATES FOR CORRECT PRODUCT COVERAGE:
Cellulose: 15 - 20 pounds per minute
Fiberglass: 11 - 15 pounds per minute
Rockwool: 16 - 22 pounds per minute
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P/N DESCRIPTION QUANTITY
211050 ACCESSORY KIT
210453 MS12 STATOR BAR COVER PLATE 1 EA
210893 REMOTE CORD, DOUBLE POLE, 150' 1 EA
210031 STATOR BAR COVER PLATE 1 EA
Operation Manual 1 EA
210471 ACC/HOSE PACKAGE (Not Included)
162885 MARK II CLEAR HOSE 3" X 50' 3 EA
210991 HOSE SLEEVE, 3" 2 EA
162482 2.5"-3" WORM DRIVE HOSE CLAMP 6 EA
210977 MS/CH14 AIR INTAKE/EXHAUST KIT 1 EA
Accessory and Installation Kits
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Introduction
Several safety features are on the Volu-Matic 100 machine to ensure
operator safety. Study the safety section thoroughly so that all the
features concerning safety are understood.
This introduction is presented to provide a basic description of the
function and purpose of the Volu-Matic 100 machine.
The Volu-Matic 100 machine is principally designed to blow insulating
materials into attics of residential and commercial buildings, 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.
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VOLU-MATIC 100
The Volu-Matic 100 machine is normally mounted in the back of a contractor's truck or trailer and is powered
by a small industrial engine. The belt driven power train that drives all machine mechanisms, includes
electro-magnetic clutches that provide separate control of various functions on the machine. To allow the
person installing the insulation full control of the machine, a 12-volt electrical remote control system is
provided, which operates either through the provided hard wire remote cord and toggle switch, or with an
optional wireless remote control unit. The Volu-Matic 100 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 12-volt electrical circuit is powered by the machine's small industrial engine. The electrical control circuit
is protected with a 20 amp circuit breaker. A light illuminates when the master switch is turned on, indicating
that power is on for both the blower relay and remote control receptacle. When the remote cord switch is
moved toward the cord, power is sent through the emergency stop buttons to the blower relay, causing the
blower clutch to engage. When the remote cord switch is moved toward the end of the housing, power flows
to the blower and mechanism relays, causing both clutches to engage. The toggle switch in the remote cord
housing is labeled to identify these machine functions. The switches on the optional wireless remote control
unit are labeled on the transmitter 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 insulating material into the air stream
where it enters the hose and flows to the hose exit.
Another feature on the Volu-Matic 100 machine is a slide gate that when adjusted, 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.
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Safety
The Volu-Matic 100 insulation blowing machine has
full guarding and electrical disconnects for your safety.
Every Volu-Matic 100 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.
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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.
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All Volu-Matic 100 machines are factory equipped with side, front, and rear guards. The top of the machine does
not require guarding when correctly mounted in the contractor's truck or trailer. If the machine is installed so that
the top is exposed, such as in a manufacturing plant, or in an open top trailer installation, a top guard will have to
be equipped.
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The front guard 1is designed to hinge up for access to your machine for maintenance and troubleshooting.
This guard must never be opened while your Volu-Matic 100 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 engine. If the engine does 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 restart the engine after the guard is
closed for machine operation. If the safety switch or guard should become damaged, replace them, to
ensure safety while operating your Volu-Matic 100 machine.
There are two emergency stop buttons 3 & 4 that will completely shut the engine down.
Either red button will stop the engine 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 stops must be twisted out (on) for normal operation. 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.
You will have to restart the engine after the emergency stop buttons
are twisted out (on) for machine operation. If any safety switch
should become damaged, replace it; keep your machine safe.
During machine operation, always turn o the "rocker type" master
switch 5(light indicates switch is on), unplug the remote cord
from the receptacle 6, and shut the engine down 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 material down into
the hopper. The Volu-Matic 100 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 levels exceed 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 100 machine to protect
everyone 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 or death.
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Operation
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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 hopper is free of foreign materials.
3. Check for presence of oil from the engine, blower, and gearbox indicating a leak. Look in the service
manual for proper levels and type of oil to use in each component.
4. Check material conditioning slide gate and air bleed control valve position. Check the recommended start
settings chart for proper position.
5. Make sure all guards are in place and securely latched.
WARNING: always operate your machine with the truck or trailer sitting on a level surface. Operating the
machine when it is not level will lead to failure of some machine components. The oil level in the engine,
blower, and gearbox may not lubricate internal parts properly when the truck or trailer is sitting on
an incline.
OPERATION MATERIAL HOSE DIAMETER HOSE LENGTH
Open Blow
Cellulose
Fiberglass
Rockwool
3" 150' Minimum
Side Wall
Cellulose
Fiberglass
Rockwool
Reduce end of hose
to 2-1/2" 150' Minimum
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PRELIMINARY START-UP CHECKS
1. Make sure hopper is free of foreign materials.
2. Clear the area in front of the airlock feeder outlet for testing.
3. Move the toggle switch 7to the center (o) position and plug the remote cord 8shipped with newly
delivered machines into the receptacle
4. Twist emergency stop buttons 3 & 4 out (on) for operation. This is a twist lock connection.
5. Start the engine in accordance with manufacturer's literature and increase engine speed until the throttle
is at full stroke. The engine will run 3600 rpm.
6. Turn on the master switch 5light indicates the switch is on.
7. Cycle the toggle switch in the remote cord housing toward the cord and the blower will come on, check
that air does exit the airlock feeder outlet. With the blower operating satisfactorily, cycle the switch
toward the end of the housing and the blower and machine mechanisms will operate simultaneously.
8. Take some time to get to know the Volu-Matic 100 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 engine stops. Twist emergency stop button out, restart the engine and start the machine again. Push
in the other emergency stop button and check that the engine stops. If the remote toggle switch was
cycled o, then cycle the toggle switch for the drives to come on once the engine is restarted. Repeat the
process opening the front guard.
9. For any problems encountered during preliminary start-up procedures, check the troubleshooting section
or call CertainTeed Machine Works, 800-237-7841
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WARNING: If at any time the drives do not stop when an emergency stop button is pushed in (o), request
that maintenance be performed on the safety system.
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Volu-Matic 100 Recommended Start Settings Chart
OPERATION MATERIAL SLIDE GATE AIR BLEED PRESSURE
Open Blow
Cellulose 6" 2.0—3.5 psi
Fiberglass 6" 2.0—3.5 psi
Rockwool 5" 4.5—5.5 psi
Side Wall
Cellulose 5" 1.0—2.5 psi
Fiberglass 5" 1.0—2.5 psi
Rockwool 4" 1.5—1.75 psi
Note: 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. Set the industrial engine speed for machine operation. Reduce machine speed approximately 20 percent
for side wall operation
2. Vary the air bleed pressure first. If you cannot get the desired results by opening or closing the air control
lever handle, then...
3. Vary the slide gate next. If you cannot get the desired results by closing or opening the slide gate, 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.
WARNING: always operate your machine with the truck or trailer sitting on a level surface. Operating the
machine when it is not level will lead to failure of some machine components. The oil level in the engine,
blower, and gearbox may not lubricate internal parts properly when the truck or trailer is sitting on
an incline.
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GETTING STARTED
1. Connect hose as shown in the following drawing for a particular operation. Make sure hose connections at
the airlock feeder outlet are connected firmly with band clamps and that the hose does not have a short
radius bend.
3” blowing hose,
minimum 150’
3” rubber
hose sleeve
3 - 2.5” reducer.
2.5” blowing hose,
minimum 150’
For side wall operation, connect hose to
airlock feeder as shown in the drawing.
For maximum open blow operation,
connect hose to airlock feeder
Note: hose connections are generally
made at the truck box or trailer through
wall connection established at installation.
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2. Make sure the emergency stop buttons are pushed in (o) and the remote cord toggle switch 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 10 while monitoring system pressure on
the air gauge 11 . The system back pressure must be read while the Volu-Matic 100 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 begin to 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 or the blowing
hose could clog because of insucient air volume.
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5. To adjust the gate 12 , refer to the chart and select the proper setting for the material to be blown and
particular operation. Pull the alignment pin 13 out in order to move the slide gate to the proper position.
Insert alignment pin into the hole when the slide gate is moved to the desired number 14 . The scale is
calibrated in half inch increments.
6. Load the machine from a standing position on the floor depositing bags of material on the shelf. Do not
build scaolding or use a foot stool to load material into the Volu-Matic 100 machine. This moves the
operator closer to the rotating components in the hopper and provides a way to lose balance and fall.
Load one to two bags of material into the hopper being particularly careful not to leave pieces of bag in
the hopper since this will clog and stall the machine. Make sure to keep the hopper full during operation
without overloading and having the material overflowing onto the floor.
WARNING: Do not attempt to remove any foreign object from the machine until it is completely shut
down; master switch turned o, emergency stop buttons pushed in, remote cord unplugged, and the
engine shut down. Failure to do so will result in serious injuries by the rotating components in the hopper
or on the machine.
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7. Twist emergency stop buttons out (on) for operation.
8. Start engine and increase speed with engine throttle.
9. Take the end of the blowing hose and remote cord to the job's starting point. Engage remote cord for air
and material to begin the insulation blowing process.
10. Upon completion of the open blow operation, use air only function for the following;
• clear all material out of hose.
• level o insulation mounds.
• blow o duct work and clear out air handler drip pan.
• blow material from recessed lights.
• blow material out of sots.
COVERAGE
Coverage may be defined as the maximum allowable square feet covered per bag at a minimum specified
depth and weight per square foot at a given “R” value. A manufacturer might recommend that the material be
blown at a rate of 72.5 sq./ft. per bag at a depth of 11.5” and a weight 0.427 lbs per sq. ft. to achieve an
insulation value of R-30. Fiber must be worked or conditioned by your Volu-Matic 100 machine to achieve
coverage.
Coverage decreases when feed rates are too low and material is overworked by the machine mechanisms (or
the wrong hose is used) rolling the fibers into tight little balls. Coverage will also decrease if feed rates are too
high, allowing material to pass through the machine before it has been opened to the proper density.
A stator bar 17 is installed in the shredder housing of every new machine. The stator bar can help increase
coverage, but it can also decrease coverage and slow the feed rate of the machine. Adjustments can be made
by removing or adding the stator bar. If the stator bar is not used, the cover plate must be installed in its place.
This adjustment should be done only after various settings of the air bleed control valve, slide gate, and
transmission speed do not gain desired results.
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Troubleshooting
Table of contents
