Guardian A5-6000 System
Contents
1. DRUM MIXER AIR OPTIONAL VA ISO SIDE ISO SIDE MATERIAL HOSE POLY SIDE AIR HOSE l POLY SIDE 1 m MATERIAL HOSE n 2 2 1 7 4 H 180 amp POLY side Use teflon tape on threads 39 REVISION A Section 3 General Information Options 17666 05 Transfer Kit 22663 02 22642 01 P gach Pound D 8560 11 8462 10 TRANSFER PUMP TRANSFER PUMP ISO AIRLINE POLY AIRLINE N MAIN DRUM MIXER OPTIONAL B SIDE MATERIAL HOSE MATERIAL HOSE he transfer kit attaches the same way for both 50 amp POLY side Use teflon tape on NPT threads 40 REVISION A Section 4 Warranty and Reference Information Notes 41 Section 4 Warranty and Reference Information Technical Data Material Ratio 1 1 Fixed Material Viscosity 200 2000 Centipoise Cps AMBIENT Output Pumps Rated 042 Gallons Per Cycle 159 Lite2. KNOWLEDGE OF THESE TROUBLESHOOTING PROCEDURES Always start with step one never skip any portion of these procedures The material pressure gauges are to be used for troubleshooting purposes only The pressures registered on one gauge will not necessarily maich the other This difference can be caused by variance in materials temperatures viscosities etc 1 Identify the missing material 2 Check the material pressure gauge on the missing material side a If the missing material gauge reads HIGHER than normal there is a RESTRICTION problem between the gauge and the Mixing Chamber tip in the Gun b If the missing material gauge reads LOWER than normal there is a STARVATION problem between the gauge and the material supply system Problems may be cyclic in that they will appear first on only one stroke of the Proportioning Pump Check the pressure gauges during one of these bursts of missing materials and always stop spraying while you are getting a burst of good material 3 Concern yourself only with the material pressure on the missing material side In troubleshooting a STARVATION problem where the pressure gauge on the missing material side is LOWER than normal start at the point farthest from the unit and work forward Check the obvious and easy things first 37 Section 3 General Information Troubleshooting A MATERIAL DRUMS 1 Material in drums 2 Material temperature a If the material
3. lt 2 lt gt eA Y Craft DISPENSING EXCELLENCE GUARDIAN A5 6000 Dispensing System For use with non flammable foam and polyurea Not for use in explosive atmospheres Maximum fluid working pressure 1760 psi 12 3 MPa 119 7 bar Important Safety Instructions Read all warnings and instructions in this manual Save these instructions An ISO 9001 Approved Company Section 1 Installation Warnings Introduction Standard Equipment Equipment Assembly Section 2 Operation Start up Instructions Shut down Instructions Section 3 General Information Assembly Drawings Sub Assembly Drawings Maintenance Troubleshooting Options Section 4 Warranty and Reference Information Technical Data Limited Warranty Policy Technical Assistance For Your Reference N A Non Applicable 16 19 41 42 43 44 INSIDE BACK COVER The following warnings for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock Turn off and disco
4. 16 17 18 i 27 REVISION F Section 3 General Information Assembly Drawings 23475 XX System Schematic 220V Three Phase 5 Lor g MAN fr m rs MAIN 3 XX 3 9 GERM 8 is 16 2 pe E 1 9 RODS L 4 NM PR Tae 34 T 2 Ty dk T3 9e m auk wx 4 224 13 2 J2 14 gt 716 4852 38SR FLUID BLOCKS POLY 28 REVISION F Section 3 General Information Assembly Drawings 23475 XX System Schematic 380V Three Phase GND N N A S MAN Im 4 2 MAN 2 3 N N amp 5 6 Tu 7 rea 5 2 p 8 32 1 9 8 11 1 11 1 108 ASSR 79 RODS 55 N 274 s L 8 8 29 10 3 PR PES LY 814 10 5 6 2 12 P 2 B5 1113943 POLY 208 2888 e 5 N 224 13 2 4 L sp pu 15 e 38 4 y L 8 5 A 1 A PL 23 16 3 15 9 15 24852 4 17 1 3 isv N 22 4 5 16 18 2 18 7 7 3114 fo 48 p i POLY 19 20 21 22 29 REVISION F 23450 XX Hybrid Assembly 23482 00 Ju 7 1759 1134 08 23483 00 V 23416 00 1 20188 12
5. 20188 12 7 7734 06 21809 01 20188 12 1 27 23495 00 SOME PARTS REMOVED FOR CLARITY SOME PARTS REMOVED FOR CLARITY 21145 01 AIR LINE N HERE 22502 00 83 141 02 5307 01 9507 1134 03 8301 12 9507 03 1315 09 22142 00 17 18101 01 8156 32 SEE DETAIL 1486 07 SOME PARTS REMOVED FOR CLARITY 20226 00 Hu 30 REVISION D Section 3 General Information Sub Assembly Drawings 23450 XX Hybrid Assembly Part int Number Description Qty RS 141 02 CORD GRIP 4 4 161 01 1 10009 19 ELBOW FITTING 2 17702 00 PILOT LAMP 1 18101 01 FITTING 1 19507 03 AIR HOSE 1 20188 12 SCREW 14 20226 00 SCREW 1 21119 00 TRANSFORMER 1 21145 01 VENT PLUG 7 21809 07 MATERIAL HOSE 2 21866 00 COUPLING PLATE 1 21886 00 LAMP MOUNTING BLOCK 1 22142 00 TRANSFORMER 1 22150 02 PILOT LIGHT 1 22162 00 CONNECTOR 1 22163 00 AMMETER 1 wn 22502 00 PANEL JACK 2 Number Description Qty 23448 00 HANGER 2 1017 00 FITTING 3 23451 00 2 18199 02 AIR REGULATOR 2 23452 00 BRACKET 1 18318 02 GAUGE 2 23455 00 2 WHEEL CART 1 18318 04 AIR GAUGE 1 23462 00 FITTING 2 20655 04 ELBOW FITTING 1 23463 00 BULKHE
6. Purchased Distributor Contact Phone E mail GlasCraft manufactures a complete line of polyurethane foam and polyurea coating spray systems If your application is in plant or a field contractor GlasCraft has a system package to meet your requirements GUARDIAN AIR POWERED 5 amp SERIES EQUIPMENT 6000 OR 12000 WATTS OF HEAT 1600 2200 OR 3000 PRESSURE SET UPS AVAILABLE MH II amp MH HYDRAULIC POWERED SYSTEMS UP TO 45 LBS MINUTE OUTPUT EXCELLENT PERFORMANCE AND RELIABILITY GUARDIAN MMH MOBILE MODULAR HYDRAULIC SYSTEMS SPECIFICALLY DESIGNED FOR ANY TYPE OF SPRAY RIG GIVE COMPLETE UTILIZATION OF FLOOR SPACE IN MOBILE RIG PROBLER P2 SPRAY GUN IMPINGEMENT MIX AIR PURGE OPTIONAL NOZZLE FOR SPRAYING STUD WALLS POURING amp STREAM JET For more information concerning any of these GlasCraft products contact your local authorized GlasCraft distributor or visit www glascraft com ARS ADVANCED DISPENSE SYSTEMS www glascraft com GC 1391 REVISION F A GRACO COMPANY Quality and Performance GENUINE GLASCRAFT o Craft DISPENSING EXCELLENCE GRACO INC BOX 1441 MINNEAPOLIS MN 55440 1441 Phone 612 623 6921 Toll Free 1 800 328 0211 Fax 612 378 3505
7. air on transfer pumps increase main pump pressure until the main proportioner SLOWLY starts cycling Once primary material is flushed from the system reduce the main air pressure to zero or flip the retract switch to the retract position and trigger the gun until the pumps are in the down position If the solvent used to flush the system also contains placticizer ensure that all primary material is flushed from the system and close the ball valves at the gun Leave the pumps in the full down stroke position with approximately 200 500 psi 1 4 3 4 MPa 14 35 bar on the fluid gauges If plasticizer is required to chase out solvent cycle main pumps until the system is full of plasticizer then close valves and leave the pumps in the full down stroke position with 200 500 psi 1 4 3 4 MPa 14 35 bar Section 2 Operation Shut Down Instructions 8 Turn off main air supply and disconnect air line from 2 Adjust main air regulator to 20 psi the system 9 Generously coat the exposed transfer pump shafts with lithium grease 10 Coil the heated hoses with a minimum four foot diameter to avoid kinking and subsequent damage to the internal electrical wiring 11 For gun shut down follow the procedure from the gun manual 12 The length of time a system is shut down and the climate conditions it s stored in will determine how often the system should be purged and refilled Usually every 2 4 weeks the follow
8. the GlasCraft Assembly instructions provided This manual provides information for the assembly opera tion maintenance and service of this GlasCraft product as used in a 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 a technological change occurs after a prod uct is on the market we will implement that technology in future production and if practical make it available to cur rent users as a retrofit update or supplement If you find a discrepancy between your unit and the available docu mentation contact your GlasCraft distributor to resolve the difference GlasCraft Inc reserves the right to change 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 Model A5 6000 Part Description Number 23475 5 6000 UNIT 23950 02 PROBLER P2 GUN 246075 POWER LOCK HEATED HOSE 246055 WHIP HOSE ASSEMBLY 23473 00 HEATER REPAIR KIT GC 1391 USER MANUAL 59934 04 DIOCTYL PHTHALATE 1 QT 261821 REQUIRED TO COMPLETE THE HOSE ELECTRICAL CIRCUIT Section
9. the original Purchaser 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 GlasCraf
10. 0 in Ibs 6 78 Nem 13 Section 1 Installation Equipment Assembly 28 Add extra hose lengths if necessary Required Tools Opened end wrenches 3 4 in a Lay hoses out straight Couple hoses together with supplied union fittings and tighten finger tight C Hold crimp fitting hex 3 4 in and union fitting together allowing the hose to hold its natural line Using 3 4 in wrenchs to tighten swivel fitting to union not allowing crimp fitting or union to turn Repeat on opposite side of union This practice is required on all connection points 555555554 55555554 1 Hose and machine 2 lt 3 Adding additional hose sections 14 Section 1 Installation Equipment Assembly 29 Connect the supplied swivel fitting p n 23825 00 to the trigger air line before attaching the hose assembly to the gun 30 Connect hose assembly and the gun as shown The fittings on the hose assembly are sized differently and will attach only one way 31 Fluid and air connections between the system and gun should now be complete and tight 51 08 SS AA 32 If more than 50 ft of hose is used the transformer tap When main power to system console is on the white setting will need to be set for proper hose length The and black wires in the console are always live sticke
11. 01 SOLID STATE RELAY 22143 00 63 AMP FUSE 22146 02 SOLID STATE RELAY 22146 01 SOLID STATE RELAY 22171 01 ON OFF SWITCH BLOCK 22146 02 SOLID STATE RELAY 22174 01 ON OFF SWITCH BLOCK COVER 22171 03 ON OFF SWITCH BLOCK 22201 01 MECHANICAL CONTACTOR 22174 03 ON OFF SWITCH BLOCK COVER 22709 02 MECHANICAL CONTACTOR 22201 01 MECHANICAL CONTACTOR 23307 00 TERMINAL END CLAMP 22709 02 MECHANICAL CONTACTOR 23307 00 TERMINAL END CLAMP 33 Section 3 General Information Sub Assembly Drawings 23479 Electrical Assembly 22109 02 23301 00 23301 00 22146 02 22146 0 21889 00 22111 02 22114 02 21823 00 23479 03 Noni Description Qty 21164 02 2 AMP FUSE 2 21823 00 DIN RAIL 2 4 21888 06 CIRCUIT BREAKER 3 21889 00 FUSEHOLDER 2 22119 00 FUSE BLOCK 1 22143 00 63 AMP FUSE 1 22146 01 SOLID STATE RELAY 1 22146 02 SOLID STATE RELAY 2 22157 00 TERMINAL BLOCK 1 22158 00 TERMINAL BLOCK SPACER 2 22159 00 TERMINAL BLOCK COVER 1 22171 02 ON OFF SWITCH BLOCK 1 22174 02 ON OFF SWITCH BLOCK COVER 1 22201 01 MECHANICAL CONTACTOR 1 22709 02 MECHANICAL CONTACTOR 1 23307 00 TERMINAL END CLAMP 4 34 Section 3 General Information Sub Assembly Drawings 23445 XX ISO 23446 XX POLY Heat Exchanger Assembly 1959 58 1134 06 23442 00 21074 00 9 2 13016
12. 1 Installation Equipment Assembly Guardian Line Installation Guide 2 Move material drums to the area that the equipment will be placed ensuring that they are not sitting directly on the floor Simply place the drums on top of a palate or similar device so the drum bottoms will not be in contact with any cold surfaces GlasCraft Systems are factory assembled If any questions arise concerning air or electrical connections please refer to illustrations located in the forward portion of this User Manual or contact your GlasCraft distributor 3 Open all boxes that came with the machine and verify that all items are accounted for 1 Advanced preparation 4 Lay out the 17666 05 Transfer Kit this will come in a a Before beginning any installation ensure that the large bag inside the main box applicator has the desired power supply available i e 220V single phase 380V three phase within 10 ft of were the machine is to be placed If the machine needs to be further that 10 ft from the power supply additional lengths of properly sized electrical cable will be required A Never use a smaller gauge size than supplied by the factory b Depending on the electrical setup it may be necessary to install an appropriate plug on the end of the cable GlasCraft will not supply this plug as we are unaware of which style will be needed c Consult the data sheet for the specific unit being installed to determine the prope
13. 18 P 20653 00 11021 23 E 22108 00 3016 18 1134 01 21068 06C 23443 00 7734 06 23445 00 ISO 23446 00 POLY a A WATTS ory Part ipti 23445 00 22018 500 2 Number i 23445 02 22019 0 150 11021 23 PLUG 1 13076 18 O RING 4 20653 00 FITTING 1 bur 5 QTY 2106860 23446 00 22019 00 1500 2 21074 00 THERMOCOUPLE 1 23416 02 22019 02 150 2 22019 00 FIRE ROD 2 22108 00 OVERTEMP SWITCH 2 22633 00 COMPRESSION SPRING 2 23442 00 1 23443 00 1 23444 00 HEATER BODY 1 23483 01 ELECTRIC PLUG 2 23484 01 ELECTRIC PLUG 2 23486 01 ELECTRIC PLUG 2 23487 01 ELECTRIC PLUG 2 7734 01 LOCK WASHER 4 7734 06 LOCK WASHER 12 7959 56 SCREW 12 23445 REVISION F 35 23446 REVISION E Section 3 General Information Maintenance Daily Routine Maintenance 1 Visually inspect the system for leaks 2 Check desiccant dryer beads to insure they are still purple and have not changed to pink 3 Check and lube top of the fluid section Wipe off residual material and add a tablespoon of DOP DBP Weekly Maintenance 1 Place a small amount of grease on the air motor shaft 2 See related manuals 36 Section 3 General Information Troubleshooting Over Pressure Problem Correction 1 Determine if the problem is high pre
14. 6 03 WIRE 21110 00 6 WIRE 8847 08 WIRE 21129 00 TRANSFORMER DECAL 9704 11 TUBING 21150 00 TERMINAL LUG 21819 00 LIVE WIRE DECAL 21830 00 PRESSURE SWITCH 21839 00 DIN CONNECTOR 21874 00 THERMOCOUPLE 21953 32 SCREW 22178 00 ON OFF POWER SWITCH 22502 00 CIRCULAR PANEL JACK 22509 00 CONTROL CABLE 23445 00 23446 00 23447 00 BOTTOM PLATE 23450 GUARDIAN HYBRID ASSEMBLY 23453 00 HEATER COVER 23454 00 FIBERGLASS SHELL 23457 00 CONTROL PANEL RING 23460 00 GUARDIAN PUMP ASSEMBLY 23468 00 HOSE 23469 00 RIVET NUT 23470 00 FIBER WASHER 23477 00 GUARDIAN DECAL 23478 01 CONTROL PANEL ASSEMBLY 23479 ELECTRICAL ASSEMBLY 23481 00 BLACK DECAL 3201 LUG RING 3795 00 TERMINAL LUG RING 25 REVISION F Section 3 General Information Assembly Drawings me pin aun face 3 u 2 5 i POLY 2coNT 112158 Son ele 4 Test Hat Ped om a N ae aa 26 REVISION F Section 3 General Information Assembly Drawings 23475 XX System Schematic 220V Single Phase E MAIN 3 gx 3 4 5 8 7 8 o 9 4 10 7 3 12 8 2 4 45
15. AD NUT 2 21666 01 BALL VALVE 1 22487 00 WHEEL 2 23449 00 L BRACKET 1 29074200 1 23459 00 AIR MANIFOLD 1 23476 00 FLUID MANIFOLD 1 308 OILER CAP 2 23482 00 MANIFOLD DECAL 1 399 OILER CAP GASKET 1 5307 01 CONDUIT NUT 4342 04 ELBOW FITTING 1 5307 03 CONDUIT NUT 1 6782 03 TEE FITTING 1 5983 01 COFTEFUPIN 2 7734 07 LOCK WASHER 2 7315 09 RUBBER GROMMET 2 811503 FITTING 2 7315 11 RUBBER GROMMET 1 811506 FITTING 2 7486 07 WASHER 3 8115 07 FITTING 1 WASHER 1 8156 24 SCREW 2 7486 27 WASHER 5 7733 14 4 7734 03 LOCK WASHER 5 7734 06 LOCK WASHER 14 7734 07 LOCK WASHER 6 7735 400 SCREW 1 8156 320 SCREW 6 8160 12 SET SCREW 4 8301 120 SCREW 4 31 REVISION D Section 3 General Information Sub Assembly Drawings 23478 01 Control Panel Assembly 23015 i 23074 00 23018 01 P nui 0 23019 02 T 22414 00 23070 00 23075 05 23076 03 23074 00 23018 03 23019 0 o 23456 01 22104 00 21823 00 1 22111 07 22422 0 22423 0 21164 02 3 880 8 0889 22506 00 22501 00 Um Description Gty Net Description Qty 21112 00 COUNTER 1 23486 02 FEMALE PLUG 2 21164 00 1 2 AMP FUSE 3 23486 03 FEMALE PLUG 1 21164 02 2 AMP FUSE 1 23487 02 MALE PLUG 2 21356 02 CONTROL 3 23487 03 MALE MALE 1 21823 00 DIN RAIL 875 5 122 PR
16. IMARY DECAL 1 21872 00 ISO DECAL 1 5 127 HOSE CONTROL DECAL 2 21873 00 POLY DECAL 1 23070 00 PUSH BUTTON 2 21889 00 FUSEHOLDER 4 23071 00 PUSH BUTTON 3 22104 00 EMERGENCY STOP DECAL 1 23073 00 EMERGENCY STOP 1 22117 00 TERMINAL BLOCK JUMPER 2 23079 01 OPEN CONTACT BLOCK 5 22414 00 CYCLE COUNTER DECAL 1 23079 02 CLOSE CONTACT BLOCK 5 22422 01 RELAY 4 23074 00 COUPLING PLATE 6 22423 01 RELAY SOCKET 4 23075 03 3 22506 00 TERMINAL 6 23075 05 VO 2 22507 00 END COVER 3 23078 01 YELLOW LED 3 22753 01 OVERPRESSURE DECAL 3 23078 03 GREEN LED 2 23456 01 CONTROL PANEL 1 23076 01 YELLOW CAP 3 23076 03 GREEN CAP 2 32 REVISION C Section 3 General Information Sub Assembly Drawings 23479 Electrical Assembly 23479 01 23479 02 22146 02 22109 02 emra 22146 01 21164 02 21888 09 BE 21888 06 IU 888 06 3 888 0 B 23479 01 23479 02 Description ee Description 21164 02 2 AMP FUSE 21164 02 2 AMP FUSE 21823 00 DIN RAIL 21823 00 DIN RAIL 21888 06 CIRCUIT BREAKER 21888 06 CIRCUIT BREAKER 21889 00 FUSEHOLDER 21888 09 CIRCUIT BREAKER 22119 00 FUSE BLOCK 21889 00 FUSEHOLDER 22143 00 63 AMP FUSE 22119 00 FUSE BLOCK 22146
17. ST 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 43 Section 4 Warranty and Reference 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 For Air Powered Systems Model Air compressor size Serial number CFM generated Type of spray gun Pressure at the system Serial number Hydraulic Pneumatic 15 your equipment Dynamic fluid pressure Single phase Three phase ISO POLY What is the inbound voltage Spray gun chamber size to your equipment Material being sprayed Temperature setting ISO Viscosity ISO POLY Temperature setting POLY Approximate material temperature Temperature setting HOSE 44 DISPENSING EXCELLENCE Date
18. ated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely Isocyanate Hazard DN We Spraying materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate personal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component foam and polyurea coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increas ing in viscosity If used this partially cured ISO will reduce performance and the life of all wetted parts The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the tem
19. ct switch to the retract position and trigger the gun until pumps are in the down position 4 Perform gun maintenance See gun manual 19 Section 2 Operation Shut Down Instructions 8 Coil heated hoses with a minimum four foot diameter to avoid kinking and subsequent damage to the internal electrical wiring 9 Check and lube top of the fluid section Wipe off residual material and add a tablespoon of DOP DBP A Do not bleed fluid pressure from the system Extended Shut Down Procedure There are many different procedures that are being followed for extended machine shut down Because the system is designed to be compatible with most urethane formulations GlasCraft recommends that the system should be stored with urethanes instead of solvents plasticizers etc Certain considerations have to be adhered to when an extended shut down is being performed The following procedure is for long extended shut down periods Power should be disconnected and all air regulators turned down to zero 1 4 5 7 20 Remove side blocks from the gun and relieve pressure from the system PROBLER P2 Use a suitable solvent to flush the fluid circuits To determine the compatibility of solvents with material being used Always check with material supplier Increase transfer pump pressure until fluid movement occurs If fluid movement does NOT occur 100 psi 0 7 MPa 7 bar of
20. e point farthest from the unit and work backward Check obvious and easy things first A Before performing any repairs on the gun ALL AIR and FLUID PRESSURES SHOULD BE RELIEVED TO ZERO BLEED OFF A GUN 1 Side block material valve turned on 2 Bore hole of mixing chamber clean 3 Filter strainer screen clean 4 Side hole in mixing chamber clean B MATERIAL TEMPERATURE 1 Too high a temperature on resin side can cause a blowing agent to pre expand in either the hose or the primary heater HOSES 1 Make sure that the Hoses are not plugged TROUBLESHOOTING A POOR SPRAY PATTERN To troubleshoot a poor spray pattern you must understand the factors that affect the spray pattern A TEMPERATURE 1 Too warm a material temperature will cause a separation fingering in the pattern 2 Too cold a material temperature will cause a stream effect B PRESSURE 1 Too high a pressure will cause excessive overspray and or separation fingering 2 Too low a pressure will cause a stream effect CONTAMINATION IN THE MIXING CHAMBER 1 A foreign object the mixing chamber will cause a poor pattern Correct problem s immediately 38 Section 3 General Information Options 17666 04 Diaphragm Transfer Pump Kit TO MATERIAL DRUM 4341 15 Lt aps i2et 2044 90 8580 1 TO INLET ON MAIN PUMP
21. eral more times to purge any material remaining in gun Turn OFF air switch 7 Unless system is to be returned to service at once follow DAILY SHUT DOWN PROCEDURE 22 Section 3 General Information Assembly Drawings 23475 XX Unit Assembly SOME PARTS HAVE BEEN REMOVED FOR CLARITY GLAS CRAF P N 23419 03 A SOME PARTS HAVE REMOVED FOR CLA BEEN amy 23 REVISION F Section 3 General Information Assembly Drawings 23475 XX Unit Assembly 2109 01 21094 01 0188 12C 20188 12 1134 06 4 1734 06 0188 12 30 HEATER ASSY POLY HEATER ASSY 24 REVISION F Section 3 General Information Assembly Drawings 23475 XX Parts List Part CP Part Number Description Number Description RS 118 ISO DECAL 3800 03 WIRE RS 119 POLY DECAL 3800 08 WIRE RS 124 01 MAIN DECAL 7208 02 WIRE NUT RS 126 HOSE CURRENT DECAL 7208 04 WIRE NUT 14638 02 RIVET 7361 00 TERMINAL LUG RING 17883 08 WIRE 7486 05 WASHER 19818 02 TERMINAL LUG 7486 28 WASHER 20188 12 SCREW 7734 06 LOCK WASHER 20188 20 SCREW 7734 10 LOCK WASHER 20188 28 SCREW 8155 64 SCREW 20895 00 CABLE 8560 03 FITTING 21094 01 ELBOW FITTING 884
22. ing procedure should be followed Purge and Refill Procedure 1 Connect the main air line to the system PROBLER P2 21 Section 2 Operation Shut Down Instructions 5 Open both side blocks simultaneously into separate containers and dispense approximately 1 1 2 2 A gallons of material from each side or until all Before performing any repairs on any part of the system plasticizer is purged from the system Stop the pumps in the down position PLACE ALL CONTROLS ON THE MACHINE AND THE MAIN POWER SOURCE IN THE OFF POSITION AND DISCONNECT THE ELECTRICAL POWER CABLE FROM THE MAIN POWER SOURCE C 6 Close both side blocks simultaneously and wipe off residue from the side block seals Regrease and attach both blocks to the gun 7 Mix and properly dispose of purge material A Before performing any repairs on the system ALL AIR and FLUID PRESSURES SHOULD BE RELIEVED TO ZERO BLEED OFF To Relieve Air And Fluid Pressures System Console 1 Turn OFF valves that supply material to the pumps 2 Turn OFF main air regulator on air motor Gun 1 Open both Side block material valves 2 Turn ON air switch 3 Point gun into a clean suitable container and trigger gun until material flow stops 4 Fluid pressure gauges must read zero 0 if not trigger gun until the fluid pressure gauges do read zero 0 pressure 5 Turn OFF side block material valves 6 Trigger gun sev
23. into the bung holes making sure to lubricate the threads with vaseline or grease thus enabling easy removal when needed 9 Make sure that the red caps have been removed from the bottom of the pumps and then slide the transfer pumps into the collars Tighten the wing nuts on the collars securing the transfer pumps in place Loosen the 3 8 in vent plugs on both drums allowing for ventilation If using a desiccant dryer on the A side install it now Section 1 Installation Equipment Assembly 11 Connect one end of each material hose to the inlet fittings located on the back of the machine It is highly recommended that you label the POLY hose with BLUE tape and the ISO hose with RED tape to ensure that you don t put the wrong transfer pump in the opposite material drum POLY Material Drum 12 Connect the other end of the material hoses to there correct transfer pumps Ensure that they are not reversed and tighten securely 10 Section 1 Installation Equipment Assembly 13 a Install the female quick disconnect fittings p n 22642 01 on to the air lines p n 17798 10 that came in the transfer kit Besure to use teflon tape on the threads POLY Material Inlet Fitting b Attach the quick disconnect fittings to the male receivers on the transfer pumps 150 Material Inlet Fitting 14 Attach the other end of the airlines to the far right regulator on the machines a
24. ir manifold Iso Material Drum 11 Section 1 Installation Equipment Assembly 15 If the optional scuff jacket p n FM 494 is being 18 Connect the 1 4 in air line on the hose assembly to used highly recommended sold separately the air line whip hose one the front of the machine install it over each individual section of hose before proceeding any further Securely tape both ends of scuff jacket to the hose assembly 16 Locate the thermal couple wire protruding from the B side fitting on the front of the machine Un coil the wire and lay it out straight 19 Connect the electrical wires Ensure the wire ends are 5 8 in 625 mm long If they are not use a sharp pair of scissors to strip all four wire ends to the correct length Strip Length 17 Feed the the thermal couple wire into the B side This illustration is not to scale 0 RR portion of the hose and pull the rest of the hose up until you can connect the hose to the front of the machine Tighten the hose securely being careful not to twist the hose in an un natural bend Refer to the last page in this installation guide for instructions on how to secure hoses properly A A Main power from power source should be disconnected or turned off to console before making hose connections Be careful do not cut or nick any copper strands If more than five strands are cut or nicked trim and re strip the wires New hoses are p
25. is to cold especially at the bottom of the drum it will raise the viscosity of the material and stall Transfer Pumps B OPTIONAL TRANSFER PUMP S 1 Is it operating 2 Is air turned on to transfer pump 3 Regulated pressure where it should be 4 Severe contamination of pump shaft on isocya nate side This indicates that the pump shaft is not being lubricated Check Filter of transfer pump Before diagnosing a faulty transfer pump be sure and check all items just listed under Transfer Pump FILTER ASSEMBLY 1 Check fluid filter at inlet to proportioning pumps if applicable D PROPORTIONING PUMPS 1 Determine whether the burst appears on the Pump s up or down stroke a If burst appears on UP stroke check UPPER ball Seat and cups b If burst appears on DOWN stroke check LOWER Ball Seat Follow the procedures in the order given Remember that repairs should be made as soon as possible Don t leave the unit open to air any longer than necessary as this will lead to further problems such as moisture entering the system and causing the isocyanate to crystallize After the unit has been exposed to the atmosphere it should be run long enough to displace the material that was in the unit when it was opened up NEVER inspect filter assemblies at time of shut down 4 In troubleshooting a restriction problem where the material pressure gauge on the missing material side is higher than normal start at th
26. nnect power cord before servicing equipment Use only grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords Do not expose to rain Store indoors TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDS s to know the specific hazards of the fluids you are using Store hazardous fluid in approved containers and dispose of it according to applicable guide lines Always wear impervious gloves when spraying or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to Protective eyewear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Clo
27. or serious injury not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete informa tion about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equip ment follow the Pressure Relief Procedure in this manual Disconnect power or air supply BURN HAZARD Equipment surfaces and fluid that s he
28. osition E Hose control and primary heater control to OFF position N Do not place any part of the body in the path of the material spray Do not point the gun at or near other personnel Do not look into the Mixing Chamber orifice at any time Because of the hazardous materials used in this equipment it is recommended that the operator use PROBLER P2 an air mask goggles protective clothing and other MAKE SURE VALVES ARE OFF safety equipment as prescribed by current regulations recommendations of the chemical suppliers and the laws in the area where the equipment is being used Initial Start Up Procedure With all material and air lines connected and power cable attached the system is now ready for start up 16 Section 2 Opera 3 Place separate clean containers under each indi vidual side block Slowly open material valves black arrow forward on each side block to allow trapped air to escape the hose and material to flow into the containers until all air is purged from the material system sampa Remember to dispense one to two gallons of material to clear the system of grease and plasticizer that was used during factory testing 4 Close manual material valves Material pressure gauges should now register approximately equal pressure If one side registers considerably more pressure than the other side go to the high pres sure side and bleed off some pre
29. ow enough time for hose to warm up approximately 15 20 minutes Remember that the heated hose does not have a delta rating The heated 8 func lion is to maintain the heat generated by the primary heaters during system operation and preheat material during initial start up The hose should be set to maintain a temperature close to the set point of the heaters ON OFF Due to the expansion of urethanes when heated it is imperative that on cold start up of the system that the 14 Relieve any excess pressure by triggering the gun heaters be turned on and allowed to reach operating temperatures before the main pump air regulator is adjusted to the desired spray pressure If you do not The Emergency Stop Switch is located on the bottom allow the heaters to reach operating temperature before right side of the control panel when depressed it will adjusting air pressure the material pressure will exceed shut down the power and activate the air dump valve the set point of the over pressure switches causing the To reset turn handle on push button system to shut down 15 The system is now ready for operation 18 Section 2 Operation Shut Down Instructions Daily Shut Down Procedure 5 Reduce main air regulator pressure to zero 1 Turn off hose and heater controllers 6 Visually inspect the entire system for leaks 7 Turn off main air supply and main power 3 Flip retra
30. perature To prevent exposing ISO to moisture Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container Keep the ISO lube pump reservoir filled with Graco Throat Seal Liquid TSL Part 206995 The lubricant creates a barrier between the ISO and the atmosphere Use moisture proof hoses specifically designed for ISO such as those supplied with your system Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use Never use solvent on one side if it has been contami nated from the other side Always park pumps when you shutdown Always lubricate threaded parts with Part 217374 ISO pump oil or grease when reassembling Keep Components A Separate CAUTION To prevent corss contamination of the equipment s wet ted parts never interchange component A isocyanate and component B resin partrs The gun is shipped with the A side on the left The fluid manifold fluid hous ing side seal assembly check valve cartridge and mix Foam Resins with 245 fa Blowing Agents New foam blowing agents will froth at temperatures above 90 F 33 C when not under pressure especially if agitat ed To reduce frothing minimize preheating in a circulation system chamber are marked on the A side Changing Materials When changing materials flush the equipment mul tiple
31. r breaker size needed d You will need to run an air line to the area where the machine will be placed consult the data sheet the specific unit being installed to determine much clean dry air will be needed to supply the machine If the air line is under 25 ft use a minimum of 1 2 in 1 0 pipe or hose If the air line is longer than 25 ft use a minimum of 3 4 in pipe or hose Anything smaller than these diameters will severly affect the machine s performance Do not use any quick disconnect fittings on the main air line going to the machine Check your air compressor to make sure it is capable of suppling the maximum amount of air that the machine requires All GlasCraft equipment is rated at 25 CFM cubic foot per minute 708 liters 90 100 psi 0 62 0 7 MPa 6 3 7 7 BAR do not exceed 125 PSI 0 86 MPa 8 6 bar Section 1 Installation Equipment Assembly 5 Remove the red plastic caps that cover the material 7 Install a male quick disconnect fitting to air inlet of inlets on the bottom of the pumps and the air inlets both pumps Besure to use teflon tape on the threads on the air motor portion of the pumps k AV 6 Install a filter to the oulet of both pumps Besure to use teflon tape on the threads Section 1 Installation Equipment Assembly 8 Remove the 2 inch bung caps on both the A and B 10 Remove the metal caps from the material pumps side drums Install the transfer pump collars
32. r on the front cover will say which tap to move Disconnect or turn off main power source before the wire to DO NOT MOVE THE COMMON LEG opening console to make any repairs or before making any electrical repair of any type to the system A A If you do not understand the electrical hook up described above consult your local GlasCraft distributor OR a qualified electrician Electrical connections must be checked on a periodic basis 208 240 volt single phase L1 L2 GROUND 208 240 volt three phase L1L2 L3 GROUND 380 volt three phase 11 black L2 brown L3 black L4 blue GROUND green CONNECTIONS HOSE LENGTH E sor EM asv DONO sov MOVE sov 75 15 Section 2 Operation Start Up Instructions N Filling The System Never leave machine unattended while system power systems Tunning 1 Adjust Air Regulator to 20 PSI to fill system Air System running is defined as preheat cycle of the hose heat primary heaters or any pump operation Machine operators must be familiar with the component functions and operation of the machine Motor will cycle slowly to fill Pumps Heaters and Hoses and stop Pre Operation Check List Check that all fittings are securely tight B Check electrical hook up qualified electrician recommended C Main power switch on control box should be switched to OFF position D Air regulator turned counter clock wise to OFF p
33. re stripped to the correct length remove the insulation to expose the bare wire 20 Ensure the strip length is correct by fitting the ferrule over the exposed wire The ferrule should be flush with the end of the wire Incorrect Incorrect Correct 12 Section 1 Installation Equipment Assembly To reach approximately 60 in Ibs 6 78 complete 4 5 revolutions with the hex wrench after the set screw contacts the ferrule If the wire is short of the ferrule end adjust the strip length accordingly If bare is protruding from the ferrule trim it flush to the end of the ferrule 21 Remove the ferrule and apply oxide inhibitor to the bare wire 22 Reinsert the wire in the ferrule and apply more oxide inhibitor to the ferrule and wire end 25 Repeat steps 21 through 24 for remaining ee Re torque all four set screws to 60 in Ibs 6 78 Nem The set screws will be approxitmately flush with the connector 26 Insert the cap plugs over the set screws 23 Pair the electrical wires as follows lt plugs A Hose to A Hose B Hose to B Hose When connecting the first hose to the proportioner wire painting does not make a difference Setscrews 24 Insert one wire from the heated hose into the connector Ensure that the ferrule is mating with the connector insert and attach the set screw 27 Repeat steps 21 through 26 for additional hoses Torque the set screw to 6
34. rs Per Cycle Operating Temperatures 32 F 0 C 180 82 C Maximum fluid working pressure 16 1 RATIO 1600 psi 100 psi Air Max Working PSI 1760 psi Note Overpressure switches are factory set at 2200 PSI Purging Constant Automatic Pneumatic Solvent free Constant Electrical Requirements 50 A 208 240 VAC 50 60 hz Single Phase 20 208 240 VAC 50 60 hz Three Phase 20 A 380 VAC 50 hz Three Phase Compressed Air Requirements Base Unit 1 0 GAL PER MINUTE 17 CFM Q 100 psi 1 5 GAL PER MINUTE 24 CFM Q 100 psi 2 0 GAL PER MINUTE 33 100 psi NOTE As output is increased achieved w chamber Size on gun or spray tip pressure drop will be greater Heating capability will also drop Heaters 6000 WATT HEATER Maximum Hose Length 300 ft Each Section 50 ft x 3 8 in 1 0 Shipping Weight 428 Lbs Overall Dimensions Section 4 Warranty and Reference Informatio mited Warranty Pol 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
35. se material shutoff valves when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment 2 EN ie AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help pre vent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equip ment until you identify and correct the problem Keep a working fire extinguisher in the work area gt PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage EQUIPMENT MISUSE HAZARD Misuse can cause death
36. ssure by slightly opening the manual material valve on the side block over the container Bleed pressure until both sides are approximately the same pressure n Start Up Instructions Clean and lubricate side blocks and seals thoroughly and re assemble on gun Make certain that the side block screws are tighten securely Refer to material manufacturers operating instructions for proper preparation of material i e mixers etc Leave air regulator at 20 PSI 10 Turn on Hose Control 5 Dispose of waste material properly and in accor dance with chemical suppliers instructions and local state and federal regulations Before re assembling side blocks lubrication can be applied by dabbing a white lithium grease into holes inside of gun front housing and wiping grease over side block seals Grease will purge itself when the air valve is turned on at gun and gun is triggered 17 a Push in the green power button b Press up or down arrow buttons on the controller until desired temperature setting is achieved Section 2 Operation Start Up Instructions 11 Turn on the ISO amp POLY Heater control 12 Adjust main air regulator to material suppliers a Push in green power button specifications b Press up or down arrow buttons on the controller until desired temperature setting 15 achieved Straighten hose out flat to avoid uneven heating and damage to internal wiring of the Hose Assembly All
37. ssure related 2 Relieve system material pressure 3 Turn off main power 4 Fix the problem area a Potential high pressure causes Restriction Overheating material in static position ISO filter at gun 5 Re start system for operation Once the power has been turned off and problem solved and the main power is turned on again the over pressure lighted buttons will automatically be reset If you do not understand the electrical hook up de scribed above consult your local GlasCraft distributor OR a qualified electrician It is recommended that a qualified licensed electrician should install power to the supply disconnect You should always follow all local or national electrical codes Disconnect power source BEFORE attempting any re pairs or opening the Control Boxes Access to internal parts is limited to qualified personnel ONLY Place Main Power Switch in OFF position BEFORE dis connecting power cables This equipment is not approved for use in hazardous locations as set forth in the National Electrical Code Article 500 and Sub Part S of the OSHA Standards Material Or Mechanical Problem Troubleshooting Procedure By following this procedure you should be able to locate and cure problems easily Remember however that a successful operator must know WHAT GOOD MATERIAL LOOKS LIKE HOW THE EQUIPMENT NORMALLY OPERATES WHAT PATH THE MATERIALS FOLLOW THROUGH THE EQUIPMENT
38. t 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 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 LO
39. times to ensure it is thoroughly clean Always clean the fluid inlet strainers after flushing Check with your material manufacturer for chemical compatibility Most materials use ISO on the A side but some use ISO on the B side Epoxies often have amines on the B hardener side Polyureas often have amines on the B resin side 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 Information about the procedure in progress 16 imperative information about equipment protection N CAUTION Indicates a hazardous situation that can result in minor or moderate injury N WARNING Indicates a hazardous situation that can result in death or serious injury 4 ELECTRICAL SHOCK HAZARD Indicates a hazardous situation that can 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
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