Spartan System User Manual
Contents
1. 63 Dust Explosion Prevention 70 National Electrical Code 77 Static Electricity 91 Blower and Exhaust System 654 Plastics Industry Dust Hazards Type of Fire Extinguishing equipment recommended Fire Extinguisher code ABC rating number 4a60bc Extinguishing Media Foam Carbon Di oxide Dry Chemical Water Fog Copies of the above bulletins are available at a nominal charge from National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 Research Report No 11 of the American Insurance Association deals with Fire Explosion and Health Hazards of Organic Peroxides It is published by American Insurance Association 85 John Street New York New York 10038 Local codes and authorities also have standards to be followed in the operation of your spraying equip ment Your insurance carrier will be helpful in an swering questions that arise in your development of safe procedures 1 2 Personnel Safety Equipment GlasCraft recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems 7 HEARING HREATHING GLOVE REGU 1i MS zs EYE PROTECTION PROTECTION PROTECTION Section 4 Safety Information General Safety GlasCraft recommends that the user consult the state and local regulations established for all Safety equip ment listed 2 0 Material S2. T Attach solvent tank to solvent tank support rod with provided rubber strap Section 1 Installation Equipment Assembly 8 Attach the catalyst jug bracket to the mast Li 9 Attach the green material hose to the pick up tube and insert the tube into a bucket of clean solvent Recirculation hose from the gun SOLVENT CONTAINER SOLVENT WASTE CONTAINER 10 Attach the green material hose to the material pump 11 Insert the end of the recirculation hose into a waste container Section 1 Installation Equipment Assembly 12 Make sure solvent regulator is dialed to zero Turn knob fully counter clockwise 13 Carefully relieve any pressure in the solvent tank by slowly pulling the relief valve 14 After all the pressure is released from the tank open the lid and fill the tank with a suitible clean flushing solvent and close the lid securely 18 Before operating the material pump flush thoroughly with a clean suitible solvent to remove test fluid 15 Remove yellow guard using a 5 32 hex balldriver GlasCraft uses test fluid that may not be compatible with some resins It is recommended that the test fluid be flushed from the material pump fluid section Make sure hose fittings on the pick up hoses are tight 19 Safely fill the Catalyst Supply Bottle P N LPA 165 maximum two gallons with preferred M
3. NO SMOKING signs must be posted and observed in all areas of storage or where solvents and other flam mable materials are used Adequate ventilation as covered in OSHA Section 1910 94 and NFPA No 91 is important wherever sol vents are stored or used to minimize confine and ex haust the solvent vapors Solvents should be handled in accordance with OSHA Section 1910 106 and 1910 107 2 4 Catalyst Diluents GlasCraft spray up and gel coat systems currently pro duced are designed so that catalyst diluents are not re quired GlasCraft therefore recommends that diluents not be used This avoids the possible contamination which could lead to an explosion due to the handling and mixing of MEKP and diluent In addition it eliminates any problems from the diluent being contaminated through rust particles in drums poor quality control on the part of the diluent supplier or any other reason If however di luents are absolutely required contact your catalyst sup plier and follow his instructions explicitly Preferably the supplier should premix the catalyst to prevent possible on the job contamination while mixing N WARNING If diluents are not used it should be remembered that catalyst spillage gun hose and packing leaks are poten tially more hazardous since each drop contains a higher concentration of catalyst and therefore will react quicker with overspray and the like 2 5 Uncured Liquid Resin Re
4. 1 7016 ONIGAL IWHALWN 29 829 ONIGAL IVYNLYN t rs e pr ONIGAL lvgnlVN i 6 60 E de ISOH 1SA1V1VO ji 0 06102 131NI NIVN 4 11884355 NNI s 00 99912 2 350 NOII1V 10281238 08 66100 JSOH 1 amp 1 564 6912 18 455 dWAd lVISN3lVN L0 v980c REVISION W 15 Section 3 General Information Assembly Drawings 21650 00 Gun Hoses 10 cel0e 0 06102 60 7026 Jo 10 7G0Lz pue 10 210 1 x 0 06102 10 7S0le 654 6912 0 S6102 60 7016 20 266 REVISION W 16 Section 3 General Information Assembly Drawings 21650 00 Assembly Parts List Part n Part 713407 wasr fe Lo 5 8155 1600 wr ____ _ 9704 08 25 9704 11 055 240 scREw a 126 6 403 268 01 sc LPA 169 i SSP 167 01 55 160 01 55 172 55 173 17 REVISION W Section 3 General Information Sub Assembly Drawings 00 88910 00 09912 00 11910 0 ei 92 861 qu 90 01 70 0107 21661 00 Air Logic Assembly 00 159
5. contractor GlasCraft has a system package to meet your requirements FORMULA INTERNAL amp EXTERNAL MIX POLYESTER EQUIPMENT CHOPPER amp GELCOAT SYSTEMS NO NEEDLE IN THE SPRAY GUN INFINITELY ADJUSTABLE CATALYST PUMP INDY INTERNAL amp EXTERNAL MIX EQUIPMENT LOWEST LEVEL OF EMISSIONS AUTOMATIC EQUIPMENT FOR ROBOT APPLICATIONS SPARTAN CLOSED MOLD RTM EQUIPMENT HAND HELD amp DELUXE MODELS PROGRAMMABLE CATALYST PERCENTAGES SPECIALTY DISPENSE EQUIPMENT APD HIGH VISCOSITY POLYESTER PUTTY DISPENSE RCD RESIN CATALYST DISPENSE PFR PRESSURE FED ROLLERS For more information concerning any of these GlasCraft products contact your local authorized GlasCraft distributor or visit www glascraft com Quality and Performance GENUINE GLASCRAFT Glaserart DISPENSING EXCELLENCE ADS 5845 WEST 82nd STREET ADVANCED DISPENSE eee INDIANAPOLIS INDIANA 46278 www glascraft com U S A GC 1202 Phone 317 875 5592 REVISION W Fax 317 875 5456 E Mail sales glascraft com
6. If any GlasCraft manufactured part or equipment is found to be defective in workmanship or material within the one year period from the date of installation as determined solely by GlasCraft GlasCraft in its sole discretion will either repair or replace the defective part or equipment at GlasCraft s cost including freight charges both ways or credit or refund the purchase price for the defective equipment or part A warranty claim will be honored only when 1 GlasCraft has been informed in writing of any such defect in workmanship or material within ten 10 days after discovery by the original Purchaser 2 An official of GlasCraft has issued a return authorization number and 3 The claimed defective equipment or part has been returned to GlasCraft by the original Purchaser freight prepaid with proper return authorization number s attached to GlasCraft Inc 5845 West 82nd Street Suite 102 Indianapolis IN 46278 U S A This warranty shall not apply to any equipment or parts that have been altered or repaired by anyone other than GlasCraft or to defects or damage resulting from improper installation misuse negligence accident or use not specified by GlasCraft This warranty shall not apply to any equipment where any parts or components were replaced by any parts or components not manufactured or supplied by GlasCraft The decision by GlasCraft shall be conclusive and binding on Purchaser GlasCraft does not warrant that
7. In addition the fire would burn hotter and longer Floor coverings if used should be non combustible Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product oversprayed chop or resin FRP sandings or any other material with MEKP To prevent this spillage and leakage you should 1 Maintain your GlasCraft System Check the gun several times daily for catalyst and resin packing or valve leaks REPAIR ALL LEAKS IMMEDIATELY 2 Never leave the gun hanging over or lying inside the mold A catalyst leak in this situation would certainly damage the part possible the mold and may cause a fire 31 3 Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom sections and at the gun and fittings Replace if wear or weakness is evident or suspected 4 Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO rub against any of the hoses at any point If allowed to rub the hoses may be cut through causing a hazardous leakage of material which could incr ease the danger of fire Also the material may spew onto personnel in the area 2 7 Toxicity of Chemicals GlasCraft recommends that you consult OSHA Sections 1910 94 1910 106 1910 107 and NFPA No 33 Chapter 14 and NFPA No 91 Contact your chemical supplier s and determine the toxicity of the various chemicals used as well as the best methods to prevent injury irritatio
8. a RECIRCULATION or 7 Place material pump pick up tube desired con tainer of material while keeping recirculation return hose in a waste container 12 Turn machine to recirculation ON Mex RECIRCULATION on oF gt 13 Let material pump cycle slowly until a steady stream of clean material is seen exiting the recir culation hose 14 Switch machine recirculation to OFF RECIRCULATION 5 D ON OFF amp 15 Secure recirculation hose in the material supply container gt Dispose of resin in the waste container in a proper manner Catalyst 1 Turn Catalyst Valve on the dispense gun to recirculation position arrow on valve should point away from gun block Z uc Make sure all the air is purged out of the catalyst pump on new Start up 2a Pull and rotate Pivot knob to disengage the catalyst drive arm b Turn the slave pump yellow ball valve to the open position Hand prime the pump until a steady stream of cat alyst flows back to the bottle d Close the ball valve Hand stroke the pump until it devel opes 50 60 PSI 3 Set the slave pump to 3 5 percent It is usually a general practice when starting up the system to let the system recirculate with the Catalyst Slave Pump set at 3 5 This ensures good catalyst volume movement through the system to remove air in the catalyst system
9. and that larger wire be used where possible NFPA Bulletin No 77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm 106 ohms but that resistances as high as 10 000 meg ohms will produce an ade quate leakage path in some cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and grounded to dissipate static electricity For further information see National Fire Protec tion Association NFPA 77 titled Recommended Practice on Static Electrical Refer especially to Sec tion 7 7 titled Spray Application of Flammable and Combustible Materials Check with local codes and authorities for other specific standards that might ap ply to your application gt GlasCraft provides a grounding wire and clamp as sembly p n 17440 00 with all FRP equipment 34 Never use hard materials such as wire pins etc To clear a plugged gun Hard materials can cause per manent damage Dab with a bristle brush blow back wards with air until clear while wearing a protective eye shield Repeat as many times as necessary Do not perform any maintenance or repairs until you have followed the precautions stated above If you as an equipment operator or supervisor do not feel that you have been adequately trained or instructed and that you la
10. arising from or relating to any goods manufactured by or purchased from GlasCraft may be brought more than one 1 year after the cause of action accrues 39 Section 4 Safety Information Technical Assistance Thank You for selecting GlasCraft spray equipment Should you have any questions or need technical assistance contact your factory authorized GlasCraft distributor Distributor Phone Contact For any issues your distributor cannot address the GlasCraft technical service department is always available to assist you with the operation of your spray equipment To help our technical representatives expedite your call and better address your questions please have the following information ready and available when you phone GlasCraft If your questions are not urgent You can e mail all correspondence to service glascraft com Model Air compressor size Compressor to system supply line Spray gun Serial number Pressure at the system Material pump Main air line volume Serial number System gauge pressures Catalyst pump AAC pressure Chopper Serial number Atomizing air pressure external mix Type of material Material pump pressure Type of catalyst Solvent flush pressure Catalyst percentage 40 Glascrare DISPENSING EXCELLENCE Date Purchased Distributor Contact Phone E mail GlasCraft manufactures a complete line of FRP spray systems If your application is in plant or a field
11. parts inside a closed container such as a pump spray gun or fluid handling system the chemical reaction can over time result in a build up of heat and pressure which can reach explosive proportions When all three elements are present the result can be an extremely violent explosion the reaction can be sustained with very little aluminum or galvanized metal any amount of aluminum is too much Section 4 Safety Information General Safety The reaction is unpredictable Prior use of an HHC sol vent without incident corrosion or explosion does NOT mean that such use is safe These solvents can be dan gerous alone as a clean up or flushing agent or when used as a component or a coating material There is no known inhibitor that is effective under all circumstances Furthermore the mixing of HHC solvents with other materials or solvents such as MEK alcohol and tolu ene may render the inhibitors ineffective The use of reclaimed solvents is particularly hazardous Reclaimers may not add any inhibitors Also the pos sible presence of water in reclaimed solvents could feed the reaction Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction Such coatings can be worn cracked scratched or too thin to prevent con tact There is no known way to make oxide coatings or to employ aluminum alloys which will safely prevent the chemical reaction under all circumstances Several solven
12. 10 209 1861 00 21100 E 0 01222 90 t 25 109 0 01200 020 9102 80 01000 10 70910 10 68104 1 91 0 00 11102 0 66102 0 55902 c 12011 LL PELL 00 980 90 511 00 6691 9 7 75 109 60 66900 60 01000 020 9102 10 70912 80 01000 00 08100 00 01220 0 55102 80 01000 10 69277 0 55902 00 9661 0 6118 REVISION P 18 Section 3 General Information Sub Assembly Drawings 21661 00 Air Logic Connections MAIN AIR INLET D m i TO SOLVENT TANK 20132 01 mi WLLLHL i 20731 04 C ne EZ NW Lj ae a oi 20732 02 H E TO AIR MOTOR E puro S 20732 01 9704 11 m TO GUN AIR pem TRIGGER 19 REVISION P Section 3 General Information Sub Assembly Drawings 21668 00 Spartan Gun Assembly gt gt ce is included with 21662 00 22909 00 is not inclu
13. 2 N pro Section 3 General Information Assembly Drawings 3015 1 918 0 9 1188355 105 00 75912 10 061 455 A18N3SSV 455 10 091 455 Nu 20 66181 20 81881 11 2196 21650 00 Unit Assembly 8 355 dWAd ISATVIVO 2021 09 295 e 104 yy LEEL OD 905 e 104 y MALA 11083 11843557 21901 00 19912 00 01912 A18N3S SY 1SATVIV 00 12602 MALA WOVE A18H3SSV dW d TWIU31VH yx 10 09802 REVISION W 13 Section 3 General Information Assembly Drawings 21650 00 Unit Assembly SSP 177 SSP 172 22 20188 16 41 3 E 0188 160 1134 06 E ic Coy 1134 06 1486 13 1486 05 557 119 20188 16 7 20188 15 1486 05 PARTS REMOVED FOR CLARITY REVISION W 14 ings Assembly Drawi Section 3 General Information ONT GAL MOT103A ON ONT EAL 3018 9NIgnL 3018 Ge neus dir ISOH 1541 1 2 S ONT EAL 21650 00 Assembly Hose Connections 10 5012 e oNI8nl 038 10 2 102 v0 1 10c 0 0610c
14. EKP catalyst to a minimum level of at least two inches above the Catalyst Bottle Outlet Fitting N WARNING Remove Catalyst Bottle P N 20941 00 from Catalyst Bottle bracket P N LPA 169 for filling Bottle should be placed at or below lowest level for safe filling Never fill Catalyst bottle 16 Fill material pump lube cup with proper pump lube while mounted in bracket as personal injury from catalyst spillage could result 5 Section 2 Operation Start up Instructions Start up Instructions The following instructions are to be used as a guide for consistent and continual operation Any deviation from the standard operation usually requires more maintenance to the equipment and material formulation to assure consistent results For example the use of fillers in resins Solvent 3 way valve Before initial operation of any internal mix system make certain the solvent flush set up is fully operational 1 Turn solvent regulator clockwise to approximately 65 psi 3 Exhaust air through the gun head until traces of solvent have been dissipated 2 Place injection nozzle over a proper waste container Since the system is an internal mix system the mixer re Turn 3 way valve on top of the solvent tank so the arrow quires flushing with air solvent air after each dispense is pointing up for air purge for solvent turn the
15. Glascrart Spartan RTM Injection System lt Z lt eA Zi YS Table Of Contents Section 1 Installation 1 1 InisorelUrei o Ee IEEE 1 1 2 Standard err ert ee arare calet e es ee ed added ie 2 1 3 Specification 5 e Mq E aeneo tat oce des o patate eH dedos N A 1 4 Equipment Assemibly oerte pe eo agen ea ter ec Lud pet eet tub det ee 3 Section 2 Operation 2 1 Start p Instr ctlOns s cuo eio toit ete dba teen 6 2 2 Sh t down 11 Section 3 General Information 3 1 Assembly Drawiths tet seek 12 3 2 Sub Assembly Drawings 18 3 3 e Cat 25 3 4 Troubleshooting ede 26 3 5 Section 4 Safety Information 4 1 General Safety mec tu ete eO ee akties 27 4 2 M uM 35 4 3 Limited Warranty PORGY reet te OD ha cot ieget redet e ise
16. Section 2 Operation Start up Instructions 4 Re engage the catalyst pivot knob N Make sure that the knob engages inside the catalyst drive ih arm slot Failure to do so will cause damage to the catalyst C drive arm SF a J Ul p a NI Recirculation Mode Start Up The Recirculation Mode should be used in initial start up or when air bubbles are observed coming through the 1 Both Catalyst Valve and Material Valve on the Dispense ends of the Recirculation Hoses Gun should be in the Recirculation position Injection Instructions 1 Switch machine to injection set recirculation to off ez _ NEY RECIRCULATION AD ON ER C 2 Turn valves on gun head to injection ne Sal Mex RECIRCULATION V ON gt 3 Turn air motor pressure regulator slowly clockwise until pump cycles slowly Section 2 Operation Start up Instructions CAUTION The valves should only be in the injection position during injection 3 Select desired percentage of catalyst and position the catalyst slave pump to that setting 4 Depress air switch button trigger on gun head to dis CAUTION pense mixed material When making test material dispenses or during flushing op e
17. The following instructions are to be used as a guide 1 for consistent and continual operation Any devia tion from the standard operation usually requires more maintenance to the equipment and material GROUNDING ROD formulation to assure consistent results For OR PIPE example the use of fillers in resins 1 Select a clean dry air supply O 2 Attach a 3 8 or larger air hose to the Air Inlet on the gt yellow air lock out valve CAUTION Whenever flammable or combustible liquids are transfered from one container to another both containers shall be effectively bonded and grounded to dissipate static electric ity For further information see NFPA 77 Recommended Practice on Static Electricity It is suggested that a quick disconnect fitting not be used 9 Remove the pump inlet saftey cap and drain the for attaching air Quick disconnect fittings can severely testing oil into an open container limit air flow 6 Attach 4 casters with provided lock washer washer and nut Attach solvent tank support rod on back left caster CAUTION Before turning on main air check all fittings making certain 25 they are securely tightened This should be done before air or material of any kind introduced into the system 3 Attach Grounding Clamp Assembly P N 17440 00 to System Use a convenient Nut and Bolt to secure Lug d P N 13193 00 to system
18. afety 2 1 Hazards Associated with Laminating Operations The major hazards which should be guarded against in polyester laminating operations are those associated with 1 The flammability and explosion dangers of the catalyst normally used Methyl Ethyl Ketone Peroxide MEKP 2 The flammability dangers of clean up solvents sometimes used GlasCraft recommends that clean up solvents be nonflammable and of resin diluents used such as styrene 3 The flammability dangers of catalyst diluents if used GlasCraft recommends that catalyst not be diluted 4 The flammability dangers of the uncured liquid resins used 5 The combustibility dangers of the cured laminate accumulations of overspray and laminate sandings 6 The toxicity dangers of all the chemicals used in laminating operations with respect to ingestion inhalation and skin and eye hazards 2 2 Catalyst Methyl Ethyl Ketone Peroxide MEKP is among the more hazardous materials found in commercial channels The safe handling of the unstable reactive chemicals presents a definite challenge to the plastics industry the highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage transportation handling processing and disposal 28 MEKP is not a single chemical Various polymeric forms may exist whi
19. alve to bleed Solvent Tank from the catalyst injector before disassembly or pressure completely filling Catalyst Injector Pressure Relief e f you have any doubt that fluid pressure is e Refer to Catalyst Injector User Manual for relieved call your GlasCraft distributor or proper pressure relief GlasCraft Inc before proceeding with any Never operate a Fiberglass System with disassembly fixed Pinch Point guards removed from system Useonly genuine GlasCraft replacement parts when repairing your system Substitutes may not be the proper material or may not fit the system and may cause dangerous operating conditions and the failure of other components 33 Section 4 Safety Information General Safety 3 3 Grounding Grounding an object means providing an adequate path for the flow of an electrical charge from the ob ject to the ground An adequate path is one that per mits charge to flow from the object fast enough that it will not accumulate to the extent that a spark can be formed It is not possible to define exactly what will be an adequate path under all conditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed on all loose conductive objects in the spraying area This includes material containers and equipment GlasCraft recommends grounding straps be made of AWG No 18 stranded wire as a minimum
20. and thorough washing of the exposed skin and im mediate and continuous flushing of the eyes with lots of clean water for at least 15 minutes or more These general instructions of first aid treatment however may be incorrect for some chemicals that is why you must know the chemicals and treatment before an accident occurs Treatment for swallow ing a chemical frequently depends upon the nature of the chemical Refer to your System User Manual for complete and detailed operating instructions and service informa tion 3 0 Equipment Safety GlasCraft suggest that personnel safety equipment such as EYE GOGGLES GLOVES EAR PROTEC TION and RESPIRATORS be worn when servicing or operating this equipment Ear protection should be worn when operating a fiberglass chopper to pro tect against hearing loss since noise levels can be as high as 116 dB decibels This equipment should only be operated or serviced by technically trained personnel N WARNING Never place fingers hands or any body part near or directly in front of the spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PIS TOL 32 3 1 Emergency Stop Procedures The following steps should be followed in order to stop the machinery in an emergency situatio
21. any equipment or parts sold to Purchaser meet or comply with any local state federal or other jurisdiction s regulations or codes GlasCraft does not warrant that any equipment or part sold to Purchaser when used individually or in concert with any other part equipment device component or process does not infringe on any patent rights of any third party GlasCraft only warrants that it has no specific knowledge of any such infringement GlasCraft makes no warranty as to any parts or equipment manufactured by others Purchaser shall look solely and only to the manufacturer of such parts or equipment with respect to any warranty claims GlasCraft hereby assigns to Purchaser the original manufacturer s warranties to all such equipment and parts to the full extent permitted THE AFORESAID WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IM PLIED SPECIFICALLY THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH WARRANTIES ARE SPECIFICALLY DISCLAIMED GlasCraft shall not be liable for any loss or expense resulting from damage or accidents caused by improper use or ap plication of materials manufactured or sold by GlasCraft or its distributors or agents UNDER NO CIRCUMSTANCES SHALL GLASCRAFT S LIABILITY EXCEED THE AMOUNT PUR CHASER PAID FOR THE CLAIMED DEFECTIVE EQUIPMENT OR PART UNDER NO CIRCUM STANCES SHALL GLASCRAFT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES OR FOR LOST PROFITS No action
22. are necessary to the process in or der to manufacture the end product For this rea son ALL personnel involved in polyester operations should read and understand the Safety Manual It is very important for the safety of employees involved in the operation that equipment operators mainte nance and supervisory personnel understand the requirements for safe operation Each user should examine his own operation de velop his own safety program and be assured that his equipment operators follow correct procedures GlasCraft hopes that this manual is helpful to the user and recommends that the precautions in this manual be included in any such program GlasCraft recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual GlasCraft recommends that the user consult the regulations established un der the Occupational Safety amp Health Act OSHA particularly the following sections 1910 94 Pertaining to ventilation 1910 106 Pertaining to flammable liquids 1910 107 Pertaining to spray finishing operations 27 Section 4 Safety Information General Safety particularly Paragraph m Organic Peroxides and Dual Component Coatings Other standards and recognized authorities to con sult are the National Fire Protection Association NFPA bulletins as follows 33 Chapter 14 Organic Perox ides and Dual Component Materials
23. ce The following general safety precautions should be Correct packing or valve seat leaks immediately followed when servicing or operating this equip the gun in any liquid ment to ensure operator safety e Periodically check operation of catalyst alarms to make sure they are operation properly When filling catalyst container protective eye Frequently check condition of hoses Replace worn equipment must be worn to protect against hoses and other parts before they fail injuries Catalyst fluid nozzles and seals MUST be in good Always maintain adequate material levels to condition at all times to prevent internal and prevent loss of prime during system operation external leaks Inspect periodically and replace At the first sign of a leak stop operations acti as needed or at intervals of three to four months vate emergency stop valve back off air regula Use catalyst nozzle seal only once to prevent tors and open all bleed valves to remove possible leakage of catalyst into air passages all pressure from the gun hoses pump catalyst of gun system any other liquid containers Make absolutely certain that all pressure has been Solvent Pot Pressure Relief relieved from the gun before disassembly from the e Solvent Pressure Regulator counter clock hoses before loosening any fittings from the wise ccw until regulator handle stops material or catalyst pump before disassembly Open Petcock v
24. ch are more or less hazardous with respect to each other These differences may arise not only from different molecular structures all are nevertheless called MEKP and from possible trace impurities left from the manufacture of the chemicals but may also arise by contamination of the MEKP with other materials in its storage or use Even a small amount of contamination with acetone for instance may produce an extremely shock sensitive and explosive compound Contamination with promoters or materials containing promoters such as laminate sandings or with any readily oxidizable material such as brass or iron will cause exothermic redox reactions which can become explosive in nature Heat applied to MEKP or heat build up from contamination reactions can cause it to reach what is called its Self Accelerating Decomposition Temperature SADT Researchers have reported measuring pressure rates of rise well in excess of 100 000 psi per second when certain MEKP s reach their SADT For comparison the highest pressure rate of rise listed in NFPA Bulletin No 68 Explosion Venting is 12 000 psi per second for an explosion of 12 acetylene and air The maximum value listed for a hydrogen explosion is 10 000 psi per second Some forms of MEKP if allowed to reach their SADT will burst even an open topped container This suggests that it is not possible to design a relief valve to vent this order of magnitude of pressure
25. ck the technical knowledge to operate or perform maintenance on a piece of glascraft equip ment please call glascraft inc Before operating or performing maintenance on the equipment If you have any questions regarding the above pre cautions or any service or operation procedures call your glascraft distributor or glascraft inc NOTICE All statements information and data given herein are believed to be accurate and reliable but are pre sented without guaranty warranty or responsibility of any kind expressed or implied The user should not assume that all safety measures are indicated or that other measures are not required Glascrart DISPENSING EXCELLENCE 5845 WEST 82nd STREET SUITE 102 INDIANAPOLIS INDIANA 46728 U S A PHONE 317 875 5592 FAX 317 875 5456 Section 4 Safety Information Notes 35 Section 4 Safety Information Notes 36 Section 4 Safety Information Notes 37 Section 4 Safety Information Notes 38 Section 4 Safety Information Limited Warranty Policy GLASCRAFT INC GlasCraft warrants to the original Purchaser of GlasCraft manufactured equipment and parts that all GlasCraft manufactured equipment and parts will conform to their published written specifications and be free of defects in workmanship and material for a period of one 1 year from the original date of installation GlasCraft makes no warranty to anyone other than the original Purchaser
26. d make every effort to 1 Store in cool dry place in original containers away from direct sunlight and away from other chemicals 2 Keep MEKP away from heat sparks and open flames 3 Prevent contamination of MEKP with other materials including polyester overspray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels 4 Never add MEKP to anything that is hot since explosive decomposition may result 5 Avoid contact with skin eyes and clothing Protective equipment should be worn at all times During clean up of spilled MEKP personal safety equipment gloves and eye protection must be worn Fire fighting equipment should be at hand and ready 6 Avoid spillage which can heat up to the point of self ignition 7 Repair any leaks discovered in the catalyst system immediately and clean up the leaked catalyst at once in accordance with the catalyst manufacturer s instructions 8 Use only original equipment or equivalent parts from GlasCraft in the catalyst system i e hoses fittings etc because a dangerous chemical reaction may result between substituted parts and MEKP 9 Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries should never be returned to the supply tank such catalyst should be diluted with copious quantities of clean water and disposed of in accordance with the catalyst manufacturer s instruc
27. ded with 23547 01 Mixing nozzle part number 20625 00 d ce d 4 os gt Se 2 55658 5 1 3 s 59 Ss T 2 Z O 6 5 T N gt 5 ER N E Cu 20 REVISION E Section 3 General Information Sub Assembly Drawings 21668 00 Spartan Gun Parts List Part me 19881 00 20305 00 20735 04 20810 00 20878 00 20879 00 21044 00 21464 00 21465 320 21935 00 21652 00 21656 00 21962 00 21664 00 21665 00 21667 00 21675 00 2 21676 00 22904 00 22906 00 22908 00 NUT 22909 00 2352420 23640 00 7697 04 7734 04 7966 17 811403 8212 16C 8660 03 866022 24 REVISION E Section 3 General Information Sub Assembly Drawings GAM 268 01 Material Pick Up Kit 20395 00 E HB 20398 02 20394 00 Part ae Filter Options Part Description Number 20397 02 100 MESH 20397 03 50 MESH 20391 01 22 REVISION D Section 3 General Information Sub Assembly Drawings 20941 00 Catalyst Bottle Assembly 20934 00 11 20945 00 20390 00 20940 00 21044 01 21039 00 21040 00 Part Description Number LPA 172 BOTTLE SUPPLY FILTER 20390 00 FITTING 20934 00 JUG CAP 20940 00 SUPPLY BOTTLE 21039 00 FITTING 21040 00 ELBOW FITTING Shown for connection purposes only 21045 01 HEX NUT Not included with 20941 00 assembly 9704 11 NATURAL TUBING 23 REVISION G Section 3 Gene
28. er on periods of shut down the fillers can settle to the bottom of the pump and pipe works 7 Shut down main air supply by closing yellow lock We out valve If using a filled resin it is suggested that the material pump and hoses be flushed with a neat resin and that the neat resin is flowing through the system and exiting the material recirculation hose thoroughly before shut down procedures are completed 2 Flush gun head with solvent and air purge thoroughly 3 Material pump should be stopped with pump shaft in up position and shaft should be cleaned of any contaminants 8 Slowly bleed the air pressure from the tank by lifting the ring on the relief valve Failure to cycle Pump Shaft to DOWN position may result in contaminants to dry or harden on shaft When 4 Material pump lube cup should be cleaned of old lube pump is next operated severe damage may be done to and refilled with new pump lube 11 upper pump seals Section 3 General Information Assembly Drawings 21650 00 Unit Assembly 3015 LHOLY 125 1561 x 18084 10 9971 791 402 297 556 00 68861 00 26861 00 16861 2091 5619 272 6666 00 68861 00 26861 00 16861 REVISION W 70 997 01 711 WOVE 00 99202 teen 5 10 6950
29. eshooting Troubleshooting Before altering catalyst percentage by moving the cata lyst pump to a new desired location on the ratio arm AL WAYS ensure that the catalyst recirculation valve is turned to the recirculation position and the air pressure is removed from the system It is absolutely essential that both streams of material are pumped to the head without air or gas entrapped For example if air is drawn into the resin stream through the resin pump inlet system i e via bad connection or filter end coming out of resin surface then this air if not purged out of the machine by recirculating on by pass will naturally go to the head through the mixer and into the RTM mold This fault condition will manifest itself in the molded part having very small bubbles almost in a froth like state on the upper side of the molded part once the mold is opened The reason for these bubbles being so small is due to the fact that air coming through the mixer with the resin is mixed and frothed before fi nally entering the mold Air or gas in the catalyst stream leads to a different type of fault in the molded part This condition will be manifest by observing when opening the mold after injec tion and supposed cure that there are wet patches of uncured or semi gelled resin in the molded part The causes attributed to this are 1 Air is drawn in by the catalyst pump through a bad connection on the inlet stream from the catalyst contai
30. n 1 The yellow air valve located where the air enters the machine should be pushed to the OFF closed position To do this simply push on the lever protruding out the side of the valve This will also cause all the system air to bleed out of the system in a matter of a few seconds thus making the system incapable of operating Step 2 is a precautionary step and should be fol lowed whenever the emergency stop valve is acti vated to the stop mode Failure to do so will damage regulators and components when reactivating to the ON position 2 Turn all system regulators to OFF counter clockwise position Verify that the Catalyst Pressure Relief Line and the Resin Return Line are secured before relieving cata lyst and resin fluid pressure 3 Catalyst pressure in the Slave Pump can be eliminated by rotating the yellow valve handle on the Slave Pump 90 degrees to the ON position The ON position the valve handle is parallel in line with the valve body The OFF position the valve handle is perpendicu lar across the valve body 4 Resin pressure can be eliminated by rotating the yellow handled valve on the bottom of the fluid filter 90 degrees Place a container under the bottom of the valve to catch any resin that is ejected from the valve Section 4 Safety Information General Safety 3 2 General Safety Precautions Do not operate Fiberglass Chopper Guns with out protective covers in pla
31. n and danger to personnel Also determine the best methods of first aid treatment for each chemical used in your plant 2 8 Treatment of Chemical Injuries Great care should be used in handling the chemicals resins catalyst and solvents used in polyester systems Such chemicals should be treated as if they hurt your skin and eyes and as if they are poison to your body For this reason GlasCraft recommends the use of protective clothing and eye wear in using polyester systems However users should be prepared in the event of such injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals may have Section 4 Safety Information General Safety N WARNING Contact a doctor immediately in the event of any in jury and give him the information you have collected If your information includes first aid instructions ad minister first aid immediately while you are contact ing the doctor Fast treatment of the outer skin and eyes that con tact such chemicals generally includes immediate
32. ner or pump inlet connection 2 Catalyst contamination in the pump system causing oxidation resulting in peroxide gas bubbles being generated within the supposedly hydraulic sealed system of the catalyst 3 The catalyst pump has faulty seals or is contami nated with particles To ensure that the catalyst system is totally hydraulically tight it is expedient after a period of shut down that the procedures in the instructions for commissioning the catalyst stream should be repeated 26 Operating Your Polyester System Safel 1 0 Introduction Any tool if used improperly can be dangerous Safety is ultimately the responsibility of those using the tool In like manner safe operation of polyes ter processes is the responsibility of those who use such processes and those who operate the equip ment This manual outlines procedures to be fol lowed in conducting polyester operations safely This system has been specifically designed for use of Polyester Resin Gel Coat and Methyl Ethyl Ke tone Peroxides MEKP applications Other formu lations or blends considered for use in this equip ment is strictly prohibited without the expressed consent by GlasCraft Inc GlasCraft Inc cannot eliminate every danger nor foresee every circumstance that might cause an in jury during equipment operation Some risks such as the high pressure liquid stream that exits the spray tip are inherent to the nature of the machine operation and
33. provides information for the assembly opera tion maintenance and service of this GlasCraft product as used ina typical configuration While it lists standard specifi cations and procedures some deviations may be found In order to provide our users with the most up to date technology possible we are constantly seeking to improve products If technological change occurs after a product is on the market we will implement that technology in future production and if practical make it available to current users as a retrofit up date or supplement If you find some discrepancy between your unit and the available documen tation contact your GlasCraft distributor to resolve the difference GlasCraft Inc reserves the right to change or modify this product as it deems necessary Careful study and continued use of this manual will pro vide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting Section 1 Installation Standard Equipment Spartan System Standard Equipment Part n Section 1 Installation Equipment Assembly The Spartan comes complete and fitted with all 4 Securely attach Clamp P N 7749 00 to permanently resin hoses catalyst bottle and filters The injection grounded rod or pipe head is fully connected to the machine circuit and tested and secured against leaks prior to dispatch 7749 00 9654 00 e
34. ral Information Sub Assembly Drawings 21654 00 Solvent Tank Assembly 11021 23 20720 00 20655 02 4342 01 1596 01 ISD 141 3 21669 00 SEE im A 50 142 20263 00 20365 00 1892 01 8115 01 20324 00 DETAIL A Part E xen xem ___ 3m 24 REVISION D Section 3 General Information Maintenance Maintenance It is recommended that the following service be performed weekly basis 1 Inspect and lubricate Catalyst Slave Pump Linkage See Catalyst Slave Pump User Manual 2 Inspect Pump Shafts on Material and Catalyst Pumps making certain they are clean and free of overspray or foreign material Clean and lubricate as required For long term storage of your injection system it is recom mended that the following procedures be followed 1 Place dry nitrogen in the material drums and secure drum 2 Make certain all air and material valves are in their OFF position GlasCraft recommends that you contact your gel coat and or resin supplier concerning material pot life during extended periods of shut down The decision as to whether or not to leave material in your system should be based on informa tion from your material suppliers as well as GlasCraft Consult your local authorized GlasCraft distributor for more information concerning system storage 25 Section 3 General Information Troubl
35. rate of rise The user should be aware that any closed container be it a pressure vessel surge chamber or pressure accumulator could explode under certain conditions There is no engineering substitute for care by the user in handling organic peroxide catalysts If at any time the pressure relieve valve on top of the catalyst tank should vent the area should be evacuated at once and the fire department called The venting could be the first indication of a heat and therefore pressure build up that could eventually lead to an explosion Moreover if a catalyst tank is sufficiently full when the pressure relief valve vents some catalyst may spray out which could cause eye injury For this reason and many others anyone whose job puts them in an area where this vented spray might go should always wear full eye protection even when laminating operations are not taking place Section 4 Safety Information General Safety Safety in handling MEKP depends to a great extent on employee education proper safety instructions and safe use of the chemicals and equipment Workers should be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users shoul
36. ration make certain that dispensed material and or solvent is contained in a suitable container and that this material and or solvent is disposed of properly 7 Flush gun head thoroughly Turn 3 way valve on top of the solvent tank so the arrow is pointing up for air purge for solvent turn the valve so the arrow is pointing down Wi When starting the machine it is recommended to dispense a couple of strokes of resin into a suitable container to ensure a proper flow of materials Also test for proper gel and cure times 5 Release air switch button trigger to stop material flow 3 way valve 6 When finished turn valves on gun head to recirculation position D Ki HH E m C 10 Section 2 Operation Shut Down Instructions Shut Down Procedure 5 Material pump should now be cycled so that shaft is The purpose of the shut down procedure is to verify that all left in down position during shut down period critical parts of the system i e the mixing area have been 47 checked and cleaned to assure trouble free start up the next Ju time the system is to be operated y 1 Turn both ball valves on gun head to OFF 90 197 6 If you are using fillers mixed into the resin remem b
37. sin should be stored in a well ventilated building at least 50 feet from your main plant In addition the stor age temperature should not exceed 75 degrees F Section 4 Safety Information General Safety In your main plant store only enough resin for one day s production NO SMOKING signs must be posted and observed in all areas where resin is stored and or used Refer to OSHA Section 1910 94 1910 106 1910 107 and consult resin suppliers for more detailed informa tion Adequate ventilation as covered in OSHA Section 1910 94 and NFPA No 91 is important wherever sol vents are stored or used to minimize confine and ex haust the solvent vapors Resin must never be stored in an area where is stored or used Open top drums should not be used due to possible contamination and possible catalyzation from overspray or spillage of MEKP into drum which could not only se verely damage the polyester spray system but might also cause the drum of resin to ignite When spraying test patterns or purging the gun always remove the test samples and waste from the building im mediately and dispose of them in accordance with your material supplier s recommendations 2 6 Cured Laminate Overspray and Laminate Sandings Accumulation Remove all accumulations of overspray FRP sandings etc from the building as they occur If this waste is al lowed to build up spillage of catalyst is more likely to start a fire
38. t 39 4 4 Technical Assistance dak e seres ob sore a ee oec aedes ubt tete lo qoem eene 40 For Your Reference ort teet i das D e ad a Ree a a aan Re INSIDE BACK COVER N A Not Applicable Section 1 Installation Introduction Introduction Before operating maintaining or servicing any GlasCraft system read and understand all of the technical and safety literature provided with GlasCraft products If you do not have the proper or related manuals and safety literature for your GlasCraft system contact your GlasCraft distributor or GlasCraft Inc In this GlasCraft technical and safety publication the following advisories will be provided where appropriate Is information about the procedure in progress Is imperative information about equipment protection CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury N WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury A ELECTRICAL SHOCK HAZARD Indicates a hazardous situation which if not avoided could result in electrical shock or serious injury The information in this document is intended only to indicate the components and their normal working relationship typical use Each assembly should be directed by a GlasCraft distributor or made from the GlasCraft Assembly instructions provided This manual
39. t suppliers have recently begun promoting HHC solvents for use in coating systems The increasing use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans as Volatile Organic Compounds their low flam mability hazard and their not being classified as toxic or carcinogenic substances HHC solvents are very desir able in many respects N WARNING Do not use Halogenated Hydrocarbon solvents in pres surized fluid systems having aluminum or galvanized wetted parts E GlasCraft is aware of NO stabilizers available to prevent Halogenated Hydrocarbon solvents from reaction under all conditions with aluminum components in a closed fluid system TAKE IMMEDIATE ACTION Halogenated Hydrocarbon solvents are dangerous when used with aluminum components in a closed fluid system Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocar bon Solvents GlasCraft recommends that you contact your solvent 30 supplier regarding the best non flammable clean up sol vent with the heat toxicity for your application If however you find it necessary to use flammable solvents they must be kept in approved electrically grounded containers Bulk solvent should be stored in a well ventilated sepa rate building 50 feet away from your main plant You should allow only enough solvent for one day s use in your laminating area
40. tions The extent to which the user is successful in accomplishing these ends and any additional recom mendations by the catalyst manufacturer determines largely the safety that will be present in his operation 2 3 Clean Up Solvents and Resin Diluents N WARNING A hazardous situation may be present in your pressur ized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed pressurized fluid system pumps heaters filters valves spray guns tanks etc The explosion could cause serious injury death and or substantial property damage Cleaning agents coatings paints etc may contain Halogenated Hydrocarbon Solvents Some GlasCraft spray equipment includes aluminum or galvanized components and will be affected by Halogenated Hydrocarbon Solvents There are three key elements to the Halogenated Hydrocarbon HHC solvent hazard 1 The presence of HHC solvents 1 1 1 Trichloroethane and Methylene Chloride are the most common of these solvents However other HHC solvents are suspect if used either as part of paint or adhesives formulation or for clean up flushing 2 Aluminum or Galvanized Parts Most handling equipment contains these elements In contact with these metals HHC solvents could generate a corrosive reaction of a catalytic nature 3 Equipment capable of withstanding pressure When HHC solvents contact aluminum or nized
41. valve so before the mixed material starts to gel the arrow is pointing down Repeat air purge to blow solvent through the gun head Section 2 Operation Start up Instructions Resin 5 Turn the material injection regulator slowly clockwise until gauge indicates 10 PSI or until pump cycles slowly 1 Detach the catalyst slave pump from the material pump Pull and rotate knob to disengage the catalyst drive arm 6 Pump should cycle clean solvent through the system and out the recirculation hose 2 Turn main valve on the gun head to the recirculation m T End recirculation when solvent appears reasonably position clean OFF 8 Lt ES 22 4 RECIRCULATION 257 C bod 3 Turn the material air regulator fully counter clockwise 8 Remove material pump pick up tube from solvent in container and dry thoroughly M EL hm uU H 7 E N W C 2 9 Switch machine recirculation to RECIRCULATION ON 4 Switch machine recirculation to ON P oF 2 7 RECIRCULATION Section 2 Operation Start up Instructions p 10 When solvent has stopped exiting the recirculation hose end recirculation OFF
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