External-Mix System User Manual
Contents
1. N A None Applicable Section 1 Installation 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 K Is information about the procedure in progress ze T 4 p CAUTION hy 15 imperative information about equipment protection CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury 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 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 p2. 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 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 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 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
3. your glascraft distributor or glascraft inc All statements information and data given herein 34 are believed to be accurate and reliable but 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 reguired MBit GlaSer rft 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 ING GlasCraft warrants to the original Purchaser of GlasCraft manufactured eguipment and parts that all GlasCraft manufactured eguipment 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 ofinstallation GlasCraft makes no warranty to anyone other than the original Purchaser If any GlasCraft manufactured part or eguipment 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
4. Maintenance Notes 17 Section 3 General Information Options Indy X Dispense Gun Indy X Dispense Gun 12 Attach all hoses and tubing as shown This diagram is for displaying point to gt point hook up ONLY and DOES gt suggest actual of hoses Gs tubing All hoses and tubing should be NI SN routed neatly and free of any moving ja components Air Manifold MPB 209 Air Hose LH Lec Lo N ZH Jd HYHA 1 I 20190 00 Catalyst Hose lt J DEI Okt Oly aL E 9704 53 AAC Black Tubing BE YA 9704 83 Atomize Red Tubing s Air Lines Clear Tubing mm Material Hoses 18 Catalyst Hose Section 3 General Information Options Clear Tubing 1 4 in Clear Tubing 1 8 in 20195 25 Material Hose tul 44 AESMA all Catalyst Bottle 20260 00 Recirculation Hose tape together with green material hose Do Not insert the hoses in the material drum until the system has been flushed AU Clear Tubing 3 8 in GAM 268 01 Pick Up Kit Material Pump 19 Section 3 General Information Options Formula X Dispense Gun 12 a Remove the plug from the side of the air manifold and install the regulator kit p n 22632 00 Besure to teflon tape the
5. Never use a wrench or pliers to assemble tighten or remove this cap If threads are clean and lubricated properly hand assembly and removal will not be a problem Use of wrenches or pliers will likely cause severe damage to the threads and or Gun Head JN 11 Slowly increase resin pressure regulator until desired Do not exceed 20 psi pressure on the Material spray pattern is achieved See Fig 3 Regulator until steady material flow has been established SSP 160 02 8a Pull and rotate Pivot knob to disengage the catalyst drive arm b Turn the slave pump yellow ball valve to the open position AIRLESS TIPS Typical Spray Pattern Development Hand prime the pump without Air Assist until a steady stream ofcat alyst flows back to the bottle STEP RESIN PATTERN PRESSURE PRESSURE ADJUSTMENT d Close the ball valve hand stroke the pump until it devel 1 20 PSI opes 50 60 PSI INCREASE 9 Trigger the Gun into a container until all the air is 2 2529 OOOOO INCREASE purged from the resin side of the system It may be necessary to Hand stroke the Catalyst Pump 3 30 PSI C3 INCREASE several times while the gun is triggered to positively 4 5 DO CORRECT FINAL PRESSURE TYPICALLY RANGES FROM 30 TO 45 PSI DEPENDING ON MATERIAL USED Fig 3 Section 2 Operation Start Up Instructions 12 Slowly increase Air Assist Air Pressure Regulator x lf catalyst
6. Pick Up Kit 5220 A 20398 02 B 20394 00 e Filter FilterOptions Part Description Number P 20397 02 100 MESH 20391 0 20397 03 50 MESH 13 REVISION D Section 3 General Information Sub Assembly Drawings MPB 375 Air Manifold 20182 00 DECAL 1884 01 21402 00 8318 02 E 8115 03 18199 02 208 DECAL VENTED SIDE WHEN CLOSED Runs 20032 00 CP 126 1486 07 J OT 1134 01 inme 20188 20 EN TII 8115 03 Z 4342 04 9612 12 DECAL 8115 03 e 8115 03 1625 23 h 3165 NO 20183 00 20186 00 20181 00 DECAL el DECAL TT 3165 OO 18318 02 TL 18318 02 lt 18199 02 IB Lg 4342 04 M 4342 04 MPB 209 Part Number Description Part Number 20183 00 20185 00 20186 00 ATOMIZE DECAL CHOPPER DECAL MAT L DECAL 9672 12 ELBOW FITTING WASHER LOCK WASHER ELBOW FITTING FITTING FITTING 14 REVISION J Section 3 General Information Sub Assembly Drawings ACV 100 01 Catalyst Valve Dispense Guns M 124 1591 0 20306 00 Description Number Teens ORING 15 REVISION A Section 3 General Information Maintenance Routine Care gt GlasCraft recommends the use of GlasCraft TGC gt FRP Tool 8 Gun Cleaner for the cleaning of
7. 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 e 1910 94 Pertaining to ventilation e 1910 106 Pertaining to flammable liquids e 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 e NFPA No 33 Chapter 14 Organic Perox ides and Dual Component Materials No 63 Dust Explosion Prevention No 70 National Electrical Code 77 Static Electricity No 91 Blower and Exhaust System No 654 Plastics Industry Dust Hazards e Type of Fire Extinguishing eq
8. know the chemi cals and treatment before an accident occurs Treatment for swallowing a chemical frequently depends upon the nature of the chemical f Refer to your System User Manual for complete and detailed operating instructions and service information 3 0 Equipment Safety NWARNING GlasCraft suggest that personnel safety equipment such as EYE GOGGLES GLOVES EAR PROTECTION and RESPIRATORS be worn when servicing or operating this equipment Ear protection should be worn when operat ing a fiberglass chopper to protect 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 NWARNING Never place fingers hands or any body part near or di rectly 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 DI RECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PER SON TREAT THE GUN AS IF IT WERE A LOADED PIS TOL The following steps should be followed in order to stop the machinery in an emergency situation 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 th
9. 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 eguipment 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 should make every effort to 1 Store MEKP in a 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 o
10. pattern is too narrow until tails disappear from spray pattern See Fig 4 gt increase catalyst atomizing air in 5 PSI increments If catalyst pattern is too wide decrease catalyst atomizing air in 5 PSI increments 14 After all pressure adjustments have been completed a final spray test should be made Spray a test shop sample on a clean piece of paper This shot should be approximately five feet in length You can now check for desired gel time and uniformity of curing AIRLESS TIP Typical Spray Pattern Development with Air Assist STEP AIRASSIST PATTERN PRESSURE ADJUSTMENT ADJUSTMENT 1 CLOSED CO C 2 CO INCREASE 2 15PS DO INCREASE 3 30 PSI FINAL AIR ASSIST ADJUSTMENT IS COMPLETE WHEN TAILS ARE ELIMINATED AND A UNIFORM SPRAY PATTERN IS ACHIEVED FINAL PRESSURE TYPICALLY RANGES FROM 30 TO 45 PSI DEPENDING ON MATERIAL USED Fig 4 lt x IF A NEEDLE GUN IS BEING USED E Catalyst Slave Pump Check and make certain that Spray Gun Material and Catalyst Needles activate at exactly the same time Catalyst Needle should never lead Material Needle as a loss of Catalyst system prime could result 13 While triggering the Gun examine the atomized catalyst making certain it is properly entering the Gelcoat pattern Section 2 Operation Shut Down Instructions Shut Down Instructions 4 Pressure should be maintained on the resin hose 5 Use a light coating of p
11. threads Formula X Dispense Gun b Attach all hoses and tubing as shown This diagram is for displaying point to point hook up gt ONLY and DOES NOT suggest actual routing of hoses and tubing All hoses and tubing should be routed neatly and free of any moving components Part Description Number D 156 22 MATERIAL HOSE 22695 03 WHIP HOSE 22696 01 FITTING Manifold y S AIO MPB 209 Air Hose N 9704 53 Black Tubing BC 20190 00 Catalyst Hose 25 Na SS FF 9704 03 Trigger Air Tubing IR 9704 83 Atomize Red Tubing s Air Lines Clear Tubing mm Material Hoses 20 Catalyst Hose Section 3 General Information Options Clear Tubing 1 4 in Clear Tubing 1 8 in 20195 25 Material Hose 137 DB l Catalyst Bottle 20260 00 Recirculation Hose tape together with green material hose Do Not insert the hoses in the material drum until the system has been flushed AU Clear Tubing 3 8 in GAM 268 01 Pick Up Kit Material Pump 21 Section 3 General Information Options LPA II Dispense Gun 12 Attach all hoses and tubing as shown _ This diagram is for displaying point to gt point hook up ONLY and DOES NOT suggest actual routing of
12. wrench amp socket set 2 Standard hex key set 3 Tape measure or yard stick All Required tools are standard sizes 1 Attach casters to base plate CATALYST JUG BRACKET LPA 1 70 7755 42 NUT 7754 1010 WASHER 7486 04 FLAT WASHER BASE 18291 01 20568 00 CASTER 4 Loosen clamp bolts to expose pump mounting bracket Attach pump mounting bracket to the air motor Use blue loctite on the threads and tighten bolts as tight as possible 2 Insert mast into base socket and secure with supplied bolts PUMP MOUNTING BRACKET 19090 OU Section 1 Installation Eguipment Assembly 5 a Stand pump assembly next to the mast and install the pump mounting bracket 6 Mount catalyst bottle approximately 26 from the top of the base plate to the bottom of the catalyst bracket PUMP MOUNTING 26 APPROX b Lift to desired height approximately 36 from the top of the base to the bottom of the pump mount ing bracket Use 3 4 wrench and tighten as tight as possible PUMP MOUNTING BRACKET 45 APPROX 7 Attach air manifold MPB 375 approximately 3 from the top ofthe air motor to the bottom of the air manifold and tighten u bolts BASE HiL d K JRZ L ac Co lt gt gt UU 20 gt lt 3 Section 1 Installation Eguipment Ass
13. 5 174 REMOVE FILM FROM BOTH SIDES OF THE SAFETY GLASS AND ATTACH IT TO THE COVER USING HARDWARE P N S 20188 16C AND 7486 05 55 175 SSP 172 SURROUND GUARD SSP 173 LEFT PUMP GUARD SSP 174 ANGLE BRACKET 26 Operating Your Polyester System safely 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 eguip 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 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 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
14. 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 is not a single chemical Various polymeric forms may exist which are more or less hazardous with respect to each other These differences may arise not only from different molecular structures all are nevertheless called and from possible trace impurities left from the manufacture of the chemicals
15. USER MANUAL Glascrsft DISPENSING EXCELLENCE External System External Mix Gel Coat Table Of Contents Section 1 Installation Em 1 1 2 Standard EgulplTielil cesse cease etas Este URS icc a uM Du iM VEMM S 2 TI 1 4 EGUIDIMENUASSEIMDIY secte rin 3 Section 2 Operation AAA 6 2 2 Shut down IMNSWUCHON Mx MU ODE a IPM taani 9 2 3 Dally Start Ub Instlcllolis s oda acess 10 Section 3 General Information 5 1 ASSEMIDIV GS M N A 3 2 OUD ASSeImply m Rc 11 BISHER EET TE OQ t a 16 E Meo a N A 3 F D I T D mI 18 Section 4 Safety Information 4 1 General Safely mmm 27 4 2 NOLES EE aiad 35 4 3 Limited Warranty Poll6y aaa 39 4 4 TEENMICALASSISTANGE 40 FOr YOU ISO TOF GTI CO ES INSIDE BACK COVER
16. 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 GlasCraft provides a grounding wire and clamp Ni assembly p n 17440 00 with all FRP equipment 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 precautions stated above If you as an eguipment operator or supervisor do not feel that you have been adeguately trained or instructed and that you lack the technical knowledge to operate or perform maintenance on a piece ofglascraft eguip ment please call glascraft inc Before operating or performing maintenance on the eguipment If you have any guestions regarding the above pre cautions or any service or operation procedures call
17. YST PUMP INDY INTERNAL 8 EXTERNAL MIX EOUIPMENT LOWEST LEVEL OF EMISSIONS AUTOMATIC FOR ROBOT APPLICATIONS SPARTAN CLOSED EOUIPMENT HAND HELD 8 DELUXE MODELS PROGRAMMABLE CATALYST PERCENTAGES SPECIALTY DISPENSE APD HIGH VISCOSITY POLYESTER PUTTY DISPENSE RCD CATALYST DISPENSE PFR PRESSURE FED ROLLERS For more information concerning any of these GlasCraft products Olid Qui IOC di 10 All C DULOL Old d 0148 Quality and Performance GENUINE GLASCRAFT Glascrart DISPENSING EXCELLENCE INDIANAPOLIS INDIANA 46278 www glascraft com U S A GC 1369 Phone 317 875 5592 REVISION December 2007 Fax 317 875 5456 E Mail sales glascraft com
18. ay eguipment Should you have any guestions 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 15 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 Giascrart 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 contractor GlasCraft has a system package to meet your reguirements FORMULA INTERNAL 8 EXTERNAL MIX POLYESTER EOUIPMENT CHOPPER amp GELCOAT SYSTEMS NO NEEDLE IN THE SPRAY GUN INFINITELY ADJUSTABLE CATAL
19. cals 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 an 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 3 1 Emergency Stop Procedures NWARNING Contact a doctor immediately in the event of any injury and give him the information you have collected If your information includes first aid instructions administer first aid immediately while you are contacting the doctor Fast treatment of the outer skin and eyes that contact such chemicals generally includes immediate and thor ough washing of the exposed skin and immediate and continuous flushing of the eyes with lots of clean water for at least 15 minutes or more These general instruc tions of first aid treatment however may be incorrect for some chemicals that is why you must
20. ctor before disassembly or filling If you have any doubt that fluid pressure is relieved call your GlasCraft distributor or GlasCraft Inc before proceeding with any disassembly Use only 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 Section 4 Safety Information General Safety 3 3 Grounding Grounding an object means providing an adeguate path for the flow of an electrical charge from the ob ject to the ground An adeguate 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 eguipment GlasCraft recommends grounding straps be made of AWG No 18 stranded wire as a minimum 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 guate leakage path in some cases
21. d Resin Diluents NWARNING 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 fil ters 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 galva nized 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
22. 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 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 pa
23. eir low flam hazard and their not being classified as toxic or carcinogenic substances HHC solvents are very desir able in many respects NWARNING Do not use Halogenated Hydrocarbon solvents in pres surized fluid systems having aluminum or galvanized wetted parts f GlasCraft is aware of NO stabilizers available to gt 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 30 GlasCraft recommends that you contact your solvent supplier regarding the best non flammable clean up solvent 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 con tainers Bulk solvent should be stored in a well ventilated separate building 50 feet away from your main plant You should allow only enough solvent for one day s use in your laminating area NO SMOKING signs must be posted and observed in all areas of storage or where solvents and other flammable ma terials are used Adequate ventilation as covered in OSHA Section 1910 94 and No 91 is important wherever solvents are st
24. embly 10 Remove safety cap from the bypass valve and drain the testing oil into an open container Attach the bypass hose to the fitting and tighten 8 Remove fitting and replace with plug p n 1625 23 2 SO gt T BYPASS VALVE 21192 00 valve 20260 00 hose 11 Proceed to section 3 5 General Information Options of this manual to finish the system assembly according to the dispense gun option you have choosen DO NOT proceed with section 2 1 new system start up until assembly is complete 9 Install supplied fittings Make sure the arrow on the check valve is pointing down BUSHING ADAPTER CHECK VALVE CONNECTOR FITTING Section 2 Operation Start Up Instructions The following assumes that all connections are tight b Before turning on main air check all On Off Ball Valves making certain all Valves are in the Off position and set New System Start Up Instructions all regulators in their Off position Turn knob counter clockwise for OFF or reduced pressure setting 1 Select a clean dry air supply 4 5 Remove the red plastic Protective Cap from the nozzle end of the head assembly Lightly lubricate all threads 2 Attach a 3 8 or larger air hose to the Air Manifold and O Rings with a petroleum jelly before assembly Inlet Do not use quick disconnect fittings E x On systems equipped Catalyst Slave Pump Before continuing Gun Start Up Instruction
25. etroleum jelly on all threads and v o rings during re assembly Due to the different O Ring materials and lubricants used in the Guns NEVER SUBMERGE OR SOAK ANY dispense GUN IN ANY TYPE OF SOLVENT Submerging or soaking any Gun will immediately void the Gun warranty Y Refer to gun manuals for service and maintenace 1 Activate trigger lock to stop the trigger from being activated 2 Push down the yellow slide valve P N 21402 00 on the inlet air to bleed off air on system 3 Turn catalyst ball valve P N 21228 00 to Open and then back to closed Recirculation position to dump psi Section 2 Operation Daily Start Up Instructions 1 Push up on the yellow slide valve P N 21402 00 on to allow air to the system 2 Follow steps 7 14 for New System Start Up Instructions to complete the daily start up 10 Section 3 General Information Sub Assembly Drawings LPA 165 Bottle 112 161 2104550 21044 0 2 0 5 deg 21040 00 m LPA 167 1 BOTTLE LPA 172 SCREEN 11 REVISION Section 3 General Information Sub Assembly Drawings LPA 170 Catalyst Bottle Bracket PRODUCT STRUCTURE INDEX PART NUMBER a INCLUDES NUTS 1486 01 169 12 REVISION Section 3 General Information Sub Assembly Drawings GAM 268 01 Material
26. his 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 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 NOT 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 Chap ter 14 and 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 irritation 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 chemi
27. hoses and tubing All hoses and tubing should be routed neatly and free of any moving components Air Manifold MPB 209 m ON Air Hose A le zm Ok 9704 53 4 Jk f Black Tubing e A 5 de IH CP 124 25 Catalyst 9704 83 Atomize Tubing s Air Lines Clear Tubing mm mm Material Hoses 22 Catalyst Hose Section 3 General Information Options Clear Tubing 1 4 in Clear Tubing 1 8 in 20195 25 Material Hose TT i DA Catalyst Bottle 20260 00 Recirculation Hose tape together with green material hose Do Not insert the hoses in the material drum until the system has been flushed m gt Clear Tubing 3 8 in GAM 268 01 Pick Up Kit Material Pump 23 Section 3 General Information Options 770 Cart 154 MAST 24 Section 3 General Information Options 768 Wall Mount Section 3 General Information Options SSP 175 Safety Guard Kit 20188 16C 7734 06 55 177 A 20188 16C 7734 06 20188 16 he 20188 16C 7734 06 7734 06 7486 13 222 22 NN N N SSP 173 SSP 178 SN AN NY 20188 16C 7734 06 7486 13 NN SN N 20188 16C 7734 06 55 172 8 20188 16 7734 06 SSP 176 4
28. of a leak stop operations acti vate emergency stop valve back off air regula tors and open all bleed valves to remove all pressure from the gun hoses pump catalyst system and any other liquid containers Solvent Pot Pressure Relief e Turn Solvent Pressure Regulator counter clock wise ccw until regulator handle stops e Open Petcock valve to bleed Solvent Tank pressure completely e Catalyst Injector Pressure Relief e Refer to Catalyst Injector User Manual for proper pressure relief e Never operate a Fiberglass System with fixed Pinch Point guards removed from system 33 Do not operate Fiberglass Chopper Guns with out protective covers in place Correct packing or valve seat leaks immediately Never immerse the gun in any liquid Periodically check operation of catalyst alarms to make sure they are operation properly Frequently check condition of hoses Replace worn hoses and other parts before they fail Catalyst fluid nozzles and seals MUST be in good condition at all times to prevent internal and external leaks Inspect periodically and replace as needed or at intervals of three to four months Use catalyst nozzle seal only once to prevent possible leakage of catalyst into air passages of gun Make absolutely certain that all pressure has been relieved from the gun before disassembly from the hoses before loosening any fittings from the material or catalyst pump before disassembly from the catalyst inje
29. ored or used to minimize confine and exhaust the solvent va pors 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 produced are designed so that catalyst diluents are not required 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 di luent being contaminated through rust particles in drums poor quality control on the part of the diluent supplier or any other reason If however diluents are absolutely required contact your catalyst supplier and follow his instructions ex plicitly Preferably the supplier should premix the catalyst to prevent possible on the job contamination while mixing If diluents are not used it should be remembered that cat alyst spillage gun hose and packing leaks are potentially more hazardous since each drop contains a higher concen tration of catalyst and therefore will react quicker with over spray and the like 2 5 Uncured Liquid Resin Resin should be stored in a well ventilated building at least 50 feet from your main plant In addition the storage 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 prod
30. rocedures 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 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 Eguipment Model External Gel Coat System Standard Eguipment 20864 05 55 160 02 GAM 266 0 20195 25 17440 00 375 LPA 165 19890 00 9704 53 TUBING 1 4 30 9704 83 RED TUBING 1 4 ATOMIZED AIR 30 FT Material Spray Nozzles See gun manuals for spray tip options Section 1 Installation Eguipment Assembly a Ifthe cart mast amp boom or wall mount options 3 Slide catalyst jug bracket over the mast and DO 2 being used besure they are completely NOT TIGHTEN assembled and proceed to step 4 Tools Required 1 Standard
31. rt 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 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 spr
32. s refer to Catalyst Slave Pump User Manual GC 1337 for Catalyst Slave Pump Start Up Catalyst Slave Pump Start Up is to be performed along with Spray Gun Start Up 6 Turn the Resin Pump recirculation Valve to the OPEN position Open Air valve for the Resin Pump regulator and turn the Regulator clockwise until the gauge reads 20 psi or the pump starts slowly cycling 3 Attach Grounding clamp Assembly P N 17440 00 to Allow the pump to Load or cycle rate slows This the system indicates the pump is primed Close the Recirculation Valve Attach here 4 Securely attach Clamp P N 7749 00 to permanently grounded rod or pipe 7749 00 9654 00 Recirculation valve MA GROUNDING ROD OR PIPE AN 7750 04 131 d gt TOSYSTEM Section 2 Operation Start Up Instructions T and Atomizing Air Regulator at 15 20 10 Once a steady material stream is achieved release psi increase if needed the trigger clean front of gun head and assemble the cap p n LPA2 213 catalyst ring p n LPA2 120G If you are using the optional Formula gun set the material spray nozzle p n LPA2 147 XXXX airless trigger air regulator to 100 psi The trigger air spray tip 23047 XX non atomized spray tip and IS NOT to exceed 100 psi spray nozzle seal P N LPA2 121G onto the gun head body gt optional Formula S gun trigger air cap P N LPA2 213 should be HAND TIGHTENED ONLY
33. spray guns spray tips rollers brushes hoses etc Flushing spray guns hoses and pumps as well as any general shop clean up It is recommended that the following service be performed on a weekly basis 1 Inspect and lubricate the catalyst slave pump linkage refer to catalyst slave pump manual 2 Inspect the pump shafts on the material and catalyst pumps making certain they are clean and free of over spray or foreign material Clean and lubricate as required 3 Inspect the gun valve needle shafts making certain they are clean and free of over spray or foreign material Clean and lubricate as required For long term storage of your spray system it is recommended that the following procedures be followed 1 Place dry nitrogen in the material drums and secure drums AN Do not exceed 3 psi of nitrogen on the material drum 2 Make sure all the air and material valves are in the OFF position GlasCraft recommends that you contact your gel coat 4 gt and or resin supplier concerning material pot life during extended shut down periods The decision as to whether or not to leave material in the system should be based on information from your material supplier as well as GlasCraft Consult you local authorized GlasCraft distributor for more information concerning system storage x Refer to specific user manuals for detailed componet 3 maintenance instructions 16 Section 3 General Information
34. 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 solvent 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 VOC s th
35. ther 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 29 with copious quantities of clean water and disposed of in accordance with the catalyst manufacturer s instructions 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 an
36. uction NO SMOKING signs must be posted and observed 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 MEKP 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 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 t
37. uipment 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 eguip ment Your insurance carrier will be helpful in an swering guestions that arise in your development of safe procedures 1 2 Personnel Safety Eguipment GlasCraft recommends the following Personal Safety Eguipment for conducting safe operations of the Polyester Systems GLOVES REQUIRED IN THIS AREA EYE HEARING PROTECTION PROTECTION BREATHING PROTECTION Section 4 Safety Information General Safety GlasCraft recommends that the user consult the state and local regulations established for all Safety eguip ment listed 2 0 Material Safety 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
38. us making the system incapable of operating x Step 2 is a precautionary step and should be followed gt whenever the emergency stop valve is activated 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 7 Verify that the Catalyst Pressure Relief Line and the X Resin Return Line are secured before relieving catalyst 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 line with the valve body 32 The OFF position the valve handle is perpendicular 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 The following general safety precautions should be followed when servicing or operating this eguip ment to ensure operator safety e When filling catalyst container protective eye equipment must be worn to protect against injuries Always maintain adequate material levels to prevent loss of prime during system operation e the first sign
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