Instruction Manual 3771 Monarch Street • Frederick, CO 80530 • www.inteccorp.
CONTENTS FORCE/3 3.0 & 4.0 DP Table of Contents Machine Information......................................................................2 Introduction ....................................................................................3 Specifications ..................................................................................4 Electrical Drawings ........................................................................5 The System ..................................................................
2 MACHINE INFORMATION
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 insulation blowing equipment. 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.
Height 51" (129 cm) Width 31" (76 cm) Length 53" (130 cm) Weight 350 lbs (130kg) Hopper capacity 75 lbs (27kg) Hose size 3" (7.35 mm) Blower 5.7 diameter 2-stage 3.0 PSI (2 blowers) Blower 7.2 diameter 2 Stage 4.0 PSI (2 blowers) Drive motor 1-1⁄2 HP Transmission Worm gear/Chain Airlock 12" x 14" steel, 6 vanes Electrical 3.0 version 115V / 35 amp @ 60 Hz Electrical 4.
3.0 & 4.0 DP Electrical Drawings 110V STD.
ELECTRICAL DRAWINGS, CONT. FORCE/3 3.0 & 4.0 DP Electrical Drawings, Cont. 110V STD. CONTROL WITH NO VARIABLE SPEED.
The System 3.0 & 4.0 DP Three sub-systems make up your FORCE/3: THE AGITATOR AND AIRLOCK. The FORCE/3 uses a 1-1⁄2hp motor and is coupled to a worm gearbox to reduce the speed of the motor and increase torque. In addition to the motor and gearbox, chain and sprockets are used to further reduce the speed of the airlock. THE BLOWER MOTOR(S). The FORCE/3 3.0 is equipped with two 5.7" 128 CFM three stage blowers to push the material through the hose and into the attic with optimum pressure and output.
HOW THE SYSTEM WORKS FORCE/3 3.0 & 4.0 DP How the System Works AGITATOR: The five-arm agitator is essential in helping attain the high production rates by conditioning and sweeping the material into the airlock. AGITATOR MOTOR: The agitator motor is attached to the gearbox which produces the torque to power the Agitator and Airlock components. AIRLOCK: The airlock picks up and rotates the conditioned material into the air stream of the blowers.
3.0 & 4.0 DP How the System Works, Cont. VARIABLE SPEED CONTROL V.S.C.: The variable speed control regulates the airflow of the blowers. This feature is used when applying spraywall material or dense packing sidewalls. GEARBOX: The gearbox is driven by the agitator motor and rotates both the agitator and airlock components. This gearbox is permanently lubed for life and does not require any lube change. Periodically remove build up of insulation dust on gearbox and agitator motor to prevent overheating.
3.0 & 4.0 DP Set-Up and Operation OPERATION: The FORCE/3 is designed to handle bulk packaged insulation material. As material is loaded into the hopper the agitator breaks up and conditions the material for proper density while sweeping the material down into the airlock. The airlock rotates the material 180 degrees from the lower hopper opening into the airflow created by the blower system which discharges the material through the hose.
3.0 & 4.0 DP Set-Up and Operation, Cont. OPERATION FROM ELECTRICAL PANEL: Position both switches on the remote cord to the “on” position to allow control of the machine at the main electrical panel BLOWING IN THE ATTIC: Start the job at the farthest point from the entrance of the attic and work your way back to the entrance. Use the shortest hose possible to ensure maximum production and use the slide gate to optimize the air to product ratio.
SET-UP AND OPERATION, CONT. FORCE/3 3.0 & 4.0 DP Set-Up and Operation, Cont. slide gate and adding additional hose, contact the cellulose manufacturer for additional information and recommendations. HOPPER SAFETY: Safety is the most important consideration when using any machine. Failure to follow safety precautions may result in permanent injury or possible machine failure.
Safety First m 3.0 & 4.0 DP When working with insulation, always wear a long sleeve shirt, gloves and a hat. Wear goggles or safety glasses for eye protection and a 3M brand #8710 nose/mouth mask or equivalent for respiratory protection. m m m m m m m Never put your hands into the hopper while the machine is operating. Keep tools and foreign objects out of the hopper. Clean all material out of the hopper and the hose after each use. Never leave the machine unattended during operation.
OPERATIONAL GUIDELINES FORCE/3 3.0 & 4.0 DP Operational Guidelines BLOWING SIDEWALLS, CELLULOSE: When blowing sidewalls, use the following settings and recommendations as guidelines. Settings may change from job to job, material to material, or nozzle to nozzle. Hose length and humidity may affect your results. Two hole method, standard wall construction: 2" x 4" x 16" on center.
FORCE/3 3.0 & 4.0 DP Sidewall Tech Notes The information below is to be used as a guideline. Results may differ due to construction & material. 2" x 4" x 16" on center, 2.8 cubic feet per cavity CELLULOSE COVERAGE 1.6 pound material density, 18.7 pound bag Wall pack density 4.0 lbs Pounds per cavity 11.2 pounds 3.5 lbs 9.8 pounds 3.0 lbs 8.4 pounds Average yield with cellulose: 1.9 cavities per 18.7 pound bag FIBERGLASS COVERAGE Johns Manville Climate Pro, 25.5 pound bag Wall pack density 1.
SIDEWALL TECH NOTES, CONT. FORCE/3 3.0 & 4.0 DP Sidewall Tech Notes, Cont. CELLULOSE WET SPRAY Your Force/3 can apply both wall-spray and spray-on materials. There are many different types of material for these applications and depending upon the material your results will differ. The Force/3 has been designed to apply most materials and can recycle up to 50/50 blend of Dry/Wet cellulose material.
3.0 & 4.0 DP Operating With a Generator / Using Additional Extension Cords USING A GENERATOR: Both the Force/3 3.0 & 4.0 DP operate best when using a use a commercial sized generator. The start up requirement for both Force/3 machines is 10.5KW. Normal running wattage for the Force/3 3.0 is 4025 watts and the 4.0 DP is 4680 Watts. We recommend using a minimum wattage of 10.5KW.
3.0 & 4.0 DP Operating With a Generator / Using Additional Extension Cords, Cont. Cord Current Capacities, Type S & SVT Wire Size AWG 10 12 14 16 18 3 Conductor Amps 25 20 15 10 7 It is recommended that if you need additional cord to run the machine, use the next gage size up. (Note: in the electrical world, the lower the (gage) number the larger the wire size). Consult Intec for your specific needs or your local electrical distributor.
Maintenance 3.0 & 4.0 DP Preventative maintenance will help ensure the FORCE/3 gives you many years of satisfactory use. Clean the interior and exterior of the machine weekly to help maintain the longevity of the motor, blowers, gearbox and chain, as well as the finish. This machine has been designed to work in a dusty environment , however, without periodic cleaning and servicing the performance of the machine will decline or mechanical failure will occur.
MAINTENANCE, CONT. FORCE/3 3.0 & 4.0 DP Maintenance, Cont. AIRLOCK SEAL REPLACEMENT Removing airlock rotor assembly Prior to replacing the airlock seals make sure all electrical power to the machine is disconnected and the insulation material has been emptied. Tools required: Allen wrench, 7/16 socket, ratchet and wrench, #2 Phillips screwdriver. Remove side panels from machine using the #2 Phillips Airlock Seal screwdriver.
3.0 & 4.0 DP Maintenance, Cont. CHAIN TENSIONER The chain tension between the agitator and the airlock rotor is self-adjusting and should never need maintenance. GEARBOX The gearbox is sealed for life and should not require any maintenance. Periodically remove buildup of insulation dust from gearbox case to prevent overheating and ensure trouble free life. BLOWERS Keeping the blowers clean will help reduce the likelihood of overheating. Overheating will cause damage to the bearings and motor windings.
3.0 & 4.0 DP Maintenance, Cont. BLOWER BRUSH & REPLACEMENT The FORCE/3 blowers use carbon brushes for operation. These brushes need to be periodically inspected to ensure high performance. Replace brushes if they are 3/8 inch or shorter. Failure to replace short brushes may cause irreversible damage to the motor. Motor air intake Blower brush, 2 brushes per blower motor Vacuum air intake 22 MAINTENANCE, CONT. MAINTENANCE, CONT.
3.0 & 4.0 DP Troubleshooting Problem Cause Remedy Agitator does not operate Power cord is not receiving electricity Check circuit breaker or fuse box at electrical source. Loose power cord and or extension cord. Check to make sure all cord ends are in good physical condition and are in good electrical condition. (Electrical panel) Rocker switch Depress rocker switch on electrical panel to the is not in the “on” position. “on” position. .
3.0 & 4.0 DP Troubleshooting, Cont. Problem Cause Remedy Agitator does not operate Remote box/cord switch Disconnect electrical from power source. Using a voltfailed and or remote cord wire (conductor) has failed. meter test switch for continuity, if switch is good check each individual conductor in remote cord. Replace failed component with original factory part. Contactor coil (inside electrical) failed Have the system inspected by a qualified technician.
3.0 & 4.0 DP Troubleshooting, Cont. Problem Cause Remedy Decreased material throw from hose Worn airlock seals. Inspect seals for tears or cuts. See maintenance section to replace Kink in hose. Run hose as straight as possible to help maintain production. Excess air leaking into hopper. Inspect seals for tears or cuts. See maintenance section to replace. Machine does not run. No power. Check source of electrical power. Possible tripped circuit breaker.
3.0 & 4.0 DP Troubleshooting, Cont. Problem Cause Remedy Blower does not operate Blower switch on main panel is “off”. Depress switch to “on”, use remote box switch to operate. Blown fuse. Remove panel below electrical control. Locate blower fuse(s) and replace with 15amp slo blo type fuse. Remote switch for blower motor has failed. Replace with original factory part. Loose power cord/extension Check condition of electrical plug. cord at electrical system. Loose wire in electrical system.
3.0 & 4.0 DP Troubleshooting Cont. Problem Cause Remedy Agitator trips circuit breaker at main panel. Low voltage. FORCE/3 requires a minimum of 36 amps @115V. Relocate power cord(s) to 20 amp circuit(s). Incorrect size extension cord. For an additional 50’, use 10/3 cord. For 100’ use 8/3 cord. Forcing material into hopper. Do not push down on insulation while filling hopper. Wet insulation (recycled) material in hopper. See page 16 for further information.
3.0 & 4.0 DP Making a Claim for Damage or Loss These goods were carefully packed and thoroughly inspected before leaving our factory. The carrier upon acceptance of the shipment assumed responsibility for its safe delivery. Inspect shipment carefully on the arrival for damage to contents, shortages or equipment. Save the container and packing material for inspection, in case of damage. Claims for loss or damage sustained in transit must, therefore, be made upon the carrier, as follows: 1.
Returns 3.0 & 4.0 DP We at INTEC sincerely hope the merchandise you have just received is in excellent condition and satisfies your expectations. If not, please read the instructions that apply to your particular situation. MERCHANDISE IS DAMAGED. If the carrier is UPS: Keep the merchandise in the original packing materials and carton. Call UPS office at 800-742-5877 or go to http://www.ups.com/content/ us/en/index.jsx to notify them of the damaged package.
3.0 & 4.0 DP Returns, Cont. SHIPMENTS TO FACTORY All shipments to the factory must have a RMA number on the outside of the carton. You will be given a RMA number when you contact the Sales or the Shipping Department. The RMA is the only way to track and assure that your request is handled properly. If you received an invoice with your merchandise, please include a copy of the invoice with all returned materials.
3.0 & 4.0 DP How to Receive Replacement Parts Under Warranty When you call INTEC, please have available the model number and serial number of your machine, as well as a description of the defective part or an explanation of the defect. We will give you a Return Merchandise Authorization (RMA) number and instructions to return the defective part. All shipments to INTEC must be sent via UPS, except in the case of complete machines, when a common carrier should be used.
Warranty 3.0 & 4.
3.0 & 4.0 DP One Year Warranty, Cont. 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 nondefective parts will be returned to purchaser, freight collect. Manufacturer will supply replacement parts prior to purchaser, freight collect.
A Glossary 3.0 & 4.0 DP R-VALUE: The resistance (R) to heat or cold. The higher the RValue, the greater the resistance and the better the insulation factor. SETTLEMENT: Insulation will settle after being blown. The FORCE/3 blows near settled density. Consult the chart on the material bag for coverage and install accordingly. COVERAGE: Every bag of material comes with a coverage chart detailing R Value ratings. Average ratings for various materials are: Cellulose: R = 3.7 per inch Rockwool: R = 2.
3.0 & 4.0 DP A Glossary, Cont. COMMON INSULATION VALUES Material Thickness R-Value Air Space 1” 1.01 Cellulose loose fill 1” 3.70 Celotex 1” 3.03 Concrete block 8”, hollow 1.11 Fiberglass batt 1 3 ⁄2” 11.0 Fiberglass batt 8” 19.0 Fiberglass loose fill 1” 2.2 Rockwool batt 3 ⁄4” 11.0 Rockwool loose fill 1” 2.60 Plywood 1 ⁄2” .62 Polyurethane board 1” 6.25 Vermiculite 1” 2.13 35 GLOSSARY, CONT. GLOSSARY, CONT.
