Spartan III System User Manual
Contents
1. 23014 00 23204 00 23019 02 23012 00 H 23015 01 23014 00 4 23019 01 m 23229 00 L 20186 02 view Qc B viewC view D 6 23211 00 PA SS 20735 01 23201 02 9943 16 19916 00 23201 01 7134 04 23236 00 9 o 23208 00 1133 07 v 23209 00 J 5 23228 00 7 2 0 2222 91 22222 00 411132 22212 02 LU 85 141 02 20196 00 5307 01 85 141 0 21618 00 T view B 21669 00 22249 00 23212 00 23213 00 view 22251 00 a SOME PARTS REMOVED FOR CLARITY 23258 00 145 00 20655 04 7 H 1 22263 00 21284 160 1134 01 eR 21281 01 20655 04 d 20196 02 d 7315 06 1 I UI U HE T EE 1135 16C C 1134 04 1131 03 9944 20 1133 01 1133 08 1486 05 1134 06 view D view A H CH f ij 5 gt Ez 1315 06 23281 00 9943 16F 1134 04 23219 00 VIEW B 1133 01 27 23251 00 21402 02. 9 Switch machine recirculation to 2 8 z 9 13 Remove material pump pick up tube from solvent container and dry thoroughly A 14 Switch machine recirculation to ON wise until gauge indicates 10 PSI or until pump cycles slowly 10 Turn the material injection regulator slowly clock 15 When solvent has stopped exiting the recirculation hose end recirculation OFF ty 9 DEN KEW KIRE HEK SET GE 16 Place material pick up tube in desired container of material while keeping recirculation return hose in hose in a waste container 10 Section 2 Operation Start Up Instructions 17 Turn machine to recirculation ON 18 Let material pump cycle slowly until a steady stream of clean material is seen exiting the recirculation hose 19 Switch machine recirculation to OFF 20 Secure recirculation in the material supply container amp d Dispose of resin in the waste container in a proper manner Catalyst Start Up 1 Safely fill the catalyst supply bottle P N LPA 165 maximum two gallon
3. NED has found the correct percentage 7 r5 c Press the Air Flush button again After the injection sequence has been completed the pump will stop and the flush Indicator will flash If an adjustment needs to be made on the timing of _ If additional material is required Follow the manual air solvent refer the flush set up 8 NED injection instructions to finish injection The start and stop buttons on the gun and control RFID Option WRITING TAGS NED panel be pressed without changing the program Ifthe stop button is pressed the program will be 1 Select Mold scan aborted and the start button must be pressed to 2 Select Tag Write reset the program 3 Enter password 1234 enter button 4 Select Start position Stop position and Total 6 Turn the catalyst and resin valves on the gun to the Strokes recirculation position before flushing 025 gallons per stroke 95cc per stroke n 5 With scanner wand scan mold chip Yellow light on rh c 8 scanner will verify scanning Repeat steps 1 3 and 4 for all mold chips 7 Select Return Tag Read 8 Scan each chip to verify settings 16 Section 2 Operation Start Up Instructions OPTIONAL MOLD SCAN WRITE READ WAND
4. Press the Air button again 8 Assure that proper catalyzation was achieved CAUTION When making test material dispenses or during flushing operation make that dispensed material solvent is contained in suitable container and that this material and or solvent is disposed of properly Section 2 Operation Start Up Instructions Manual Injection Instructions 1 Turn recirculation switch to the OFF position CATALYST 5 Insert port injector into mold opening 2 Press manual injection Located on Touch Screen 6 Depress the air switch button trigger on gun head to dispense mixed material 025 gallons per stroke NED 95cc per stroke FLUSH SET UP sETUP SETUP 4 UP 2 SET UP 45 MANUAL SET UP 3 SET UP 6 INJECTION SETUP MANUAL INJECTION M 3 Select desired percentage of catalyst by pushing the manual Injection Set Up Once desired catalyst percent is selected press start to move the pump to the selected position T After the injection process turn both catalyst valve and material valve on the dispense gun to the
5. FLUSH SET UP 1 SET UP 4 recirculation position SET UP 2 SET UP 45 TT MANUAL SET UP 3 SET UP 6 INJECTION SET UP 5 MANUAL INJECTION 4 Turn valves on gun head to injection k s EB CATALYST 14 Section 2 Operation Start Up Instructions 8 Flush the system If Adjustments need to be made on the timing of the a Press the Air Flush button Air Solvent See Flush set up page 8 Automatic Injection Instructions 9 1 Make sure Manual Injection is NOT on Manual Injection Box Blue ON Manual Injection Box Gray OFF 2 Press set up 1 through 6 There are up to 30 set up options depending on the e system 8 Press the Solvent Flush button 8 Er We S N WAE FLUSH SET UP SET 1 SET UP 4 c Press the Air Flush button again SET UP 2 SETUP AE MANUAL SET UP 3 SET UP 6 INJECTION SET UP MANUAL INJECTION SCREEN WHEN SET UP 1 THRU 6 IS SELECTED SET UP STEPS B FOR SET UP 2 THRU 6 SET UP 1 CONFIGURATION FLUSH FLASHES WHEN TOTAL EUSH STROKES HAV
6. 1 0 IN 90 22 A 6 00 17602 01 711 00 26861 2091 5519 00 16861 Section 3 General Information Options 23280 00 3 ASSEMBLY 0 968 7766 00 81 911 455 0 82091 10 061 455 0 54 lt 2 10 69080 201 lt 1101 117120 00 192 2 gt 00 09262 4 00 6522 80 9871 21 7511 LI C6LL d ef 277 JI Za up Z 971 455 402 2128 591 1058 2 226 1561 gt A 00 66262 00 9522 00 0522 00 1262 10 6922 00 69262 1N3H30V1d 19230 0 151 455 1101 REVISION 01 11 2091 5518 00 16861 TUT TUT 43 272 5566 00 68861 2 00 2686 Section 3 General Information Options 23280 00 3 ASSEMBLY 20188 16C 1486 13 4
7. HESE 2 EN CNN HEZE 125 HER KENA p NEN Ezan ES EN 2 2 EN 2208 12222 EN HEBE EN EN HEVE Section 3 General Information Sub Assembly Drawings 23250 00 SPARTAN 3 CONTROL BOX RUBBER SEAL NYLON BRACKET COPPER WIRE 18 BLACK ASSEMBLY Part Description Number SPARTAN II PAC DECAL ELBOW FITTING SOLENOID VALVE AIR FILTER ELBOW FITTING CONDUIT NUT SPADE SOCKET TERMINAL LUG SPADE SOCKET TERMINAL LUG RUBBER GROMMET RUBBER GROMMET FENDER WASHER SWIVEL FITTING 7733 07 HEX NUT 7733 12 HEX NUT LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER COPPER WIRE 14 BLACK NIPPLE FITTING MINI REGULATOR MPB 208 AIR FILTER ELBOW FITTING CORD GRIP RS 141 02 CORD GRIP 31 REVISION E 23250 00 SCHEMATIC 115 VOLTS 1 PH n uu r re EMERGENCY STOP 3 15152 1 2 2 3 FU FU FU tu 2 AMP FUSE
8. 10 17956 00 80600 00 91910 N REVISION E 33 Section 3 General Information 21668 01 Spartan Gun Parts List Part Part BALVAVE RM 856 04 21667 00 BALL VALVE 34 REVISION E Section 3 General Information Sub Assembly Drawings 21668 02 Spartan 3 Gun 8212 Part NN Number 20735 04 ELBOW FITTING 20796 02 CONNECTOR FITTING 20878 00 21454 00 MOUNTING BRACKET 21665 01 22213 01 22213 02 7734 04 TOCK WASHER 6 8212160 screw es 39 REVISION A Section 3 General Information Sub Assembly Drawings 23547 01 CHECK VALVE ASSEMBLY C Not included with 23547 01 assembly 52908 00 23524 01 22906 00 23540 00 S 21044 02 22904 00 21616 00 A TIGHTEN NUT TO SHOW 1 2 TO THREAD USE PURPLE LOCTITE 222 ON THREADS 21664 00 21675 00 Solvent Air Purge Resin Check Valve Assembly Check Valve Assembly 36 REVISION E Section 3 General Information Sub Assembly Drawings 20941 00 CATALYST BOTTLE ASSEMBLY m 20934 00 LPA 172 20939 00 20390 00 20940 00 21044 01 21039 00 21040 00 202 20940 00 SUPPLY 21039 00 FITTING 21040 00 ELBOW FITTING 37 REVISION Section 3 General Information Sub Assembly Drawings GAM 268 01 MATERIAL PICK UP KIT 20395 00 4 20398 02 20394 00 Part 223 Filter Options Part Descript
9. 8 8 8 1 USING THE TAG READ WRITE WAND SCAN THE MOLD CHIP THAT IS TO BE INJECTED THE WRITTEN CHIP DATA WILL BE ON g THE SCREEN PRESS START POSITION SERVO MOTOR WHEN READY TO INJECT PRESS INJECT ON BUTTON AT THE GUN OR CONTROL BOX c Press Air Flush button again If Adjustment needs to be made on the timing of the After Injection Sequencer has been completed V Air or Solvent See Flush Set Up page 8 ND pump will stop and Flush indicator will flash 18 Section 2 Operation Shut Down Instructions Shut Down Procedure 6 If you are using fillers mixed into the resin remember on periods of shut down the fillers can settle to the The purpose of the shut down procedure is to verify bottom of the pump and pipe works that all critical parts of the system i e the mixing area M have been checked cleaned to assure trouble free 7 Shut down main air supply by closing yellow lock out start up the next time the system is to be operated valve 1 Confirm that both ball valves are in the recirculation position I H LI 8 Slowly bleed the air pressure from the tank by lifting the ring on the relief valve If using a filled resin it is suggested that the material we pump and hoses be flushed with a neat resin and that the neat resin is flowing thr
10. REVISION G 11 gt 803 0340 33 51878 3105 REVISION 1911 3119 28 6 21 0212 3901 3018 25 6 21 50212 Section 3 General Information Options 23280 00 3 ASSEMBLY MOTTIA 070 5771 10 75012 833849 2 5 ui JSOH 01 12 1 90 2102 RD n V aT N aga 0 00212 3 _ N 30319 8 598 9016 i 11 9006 n M N 20 60012 J pee N lt an s 0 06102 LO PA 3018 2 5 222 20 2 102 2 5 UE 9 V 931 070 8 1 Wazen 4 9 1 9 dd gt 0 e se 9 ka ecc 10 2102 f 3 80310 8 Vg 1 n oo EZ MEER E j ade 12 2 ISOH 11183141 4 E 05 66102 REVISION JONVYO 2 6 61 50212 MOTTIA 28 6 3 1 0212 390H LSATYLVD 3801 17 1 20 25102 ISOH 16114182 2 13389 26 5 0 06102 JS
11. 3018 6 6 26 6 1011 A18N3SSV NNO 40 89912 e 1118 58 5 60 68106 034 2 lt 6 10 26104 26 6 61 60212 JSOH 1541 1 2 0 06102 JSOH 15404190 0 06102 00 5760 3901 4971 10 75014 JSOH Q I 92 769 6 20 57281 JSOH 19183140 08 66102 REVISION 24 Section 3 General Information Assembly Drawings 23280 02 SPARTAN 3 ASSEMBLY 25295 00 110 2 TOUCH SCREEN 25 REVISION A Sec 3 1 Section 3 General Information Assembly Drawings 23280 02 3 ASSEMBLY Part 2205 Part e 19889 00 7733 12 NUT 19891 00 7733 14 NUT 19892 00 7733 42 NUT 26 REVISION A Section 3 General Information Sub Assembly Drawings 23250 00 SPARTAN 3 CONTROL BOX ASSEMBLY 23282 00 23251 00 22104 00 22118 00 1 23013 00 00 18199 02
12. Turn on the main power 3 Press the start button Section 2 Operation Start Up Instructions START UP SCREEN WHEN POWER IS TURNED ON PLEASE PRESS INITIALIZE SYSTEM INITIALIZE SYSTEM NOT FOR USE EXPLOSIVE AREAS 4 Push for set up screen SYSTEM SET UP SCREEN FLUSH SET UP SET UP 1 SET UP 4 SET UP 2 SETUP 5 MANUAL SETUP 3 UP 6 INJECTION SET UP MANUAL INJECTION Section 2 Operation Start Up Instructions Solvent Flush Programing Z Before initial operation of any internal mix system make certain the solvent flush set up is fully operational Since the system is an internal mix system the mixer requires flushing with air solvent air after each dispense Or before the mixed material starts to gel 5 Make sure solvent regulator is dialed to zero Turn knob fully counter clockwise and turn the ball valve to the closed position e 225 223 6 Carefully relieve any pressure in the solvent tank by slowly pulling the relief valve 7 After all the pressure is released from the tank open the lid and fill the tank with a suitable clean flushing solvent and close the lid securely 8 Turn solvent regulator clockwise to approximately 80 ps
13. 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 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 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 mate
14. THE TAG READ BUTTON WILL BE ACTIVATED RFID tag p n 23290 00 gt RFID tag carrier p n 23291 00 17 Section 2 Operation Start Up Instructions RFID Option READ TAGS 5 Turn the catalyst and resin valves on the gun to the recirculation position BEFORE FLUSHING 1 select mold scan 2 With scanner wand scan mold chip 3 Press Start Located on Touch Screen 4 Press Injection ON Located on front control panel or on gun Injection will not function until the catalyst pump has found the correct percentage Injection OFF Located on front control panel or gun will NOT reset Injection Sequencer The injection ON will restart sequencer TAG WRITE READ WAND T 1 CATALYST 6 FLUSH SYSTEM TAG READ IS ACTIVATED a Press Air Flush button 2 2 77 V LLL 6 P4 amp TAG READ MOLD TAG WRITE e 77 FLUSH n 9 START POSITION STOPPOSITION A TOTAL 5 STROKES T T 4 2 00 2 3 00 STOPPER b Press Solvent Flush button START SETUPSELECT STOP Z 2 27772 74
15. hopes that this manual is helpful to the user and recommends that the precautions in this manual be included in any such program GlasCraft recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual GlasCraft recommends that the user consult the regulations established un der the Occupational Safety amp Health Act OSHA particularly the following sections 1910 94 Pertaining to ventilation e 1910 106 Pertaining to flammable liquids e 1910 107 Pertaining to spray finishing operations 49 Section 4 Safety Information General Safety particularly Paragraph m Organic Peroxides and Dual Component Coatings Other standards and recognized authorities to con sult are the National Fire Protection Association NFPA bulletins as follows 33 Chapter 14 Organic Perox ides and Dual Component Materials 63 Dust Explosion Prevention lt 70 National Electrical Code 77 Static Electricity 91 Blower and Exhaust System lt 654 Plastics Industry Dust Hazards Type of Fire Extinguishing equipment recommended Fire Extinguisher code ABC rating number 4a60bc Extinguishing Media Foam Carbon Di oxide Dry Chemical Water Fog Copies of the above bulletins are available at a nominal charge from National Fire Protection Association 470 At
16. 0 ASSEMBLE SO DECAL IS ORIENTED THIS WAY 15544 02 4342 04 9672 16 REVISION E ings Sub Assembly Drawi 5 hu G 2 T gt I e 5 o 23250 00 SPARTAN 3 CONTROL BOX 70 96106 3118 7 pem 00 75102 00 1826 00 61262 60 96102 AN 90 1651 0 96102 70 96102 70 55902 10 5 lt 102 e 10 6102 0 10 8222 20 014 lt 2 00 9610 197 2128 70 55902 00 712 lt 4 ASSEMBLY 10 70912 cr 70 5511 LM I 0 62261 20 7511 297 69712 os 00 96102 011138 NOUS 03831 gc pm 5527 00 812 2 E N 92 12011 00 65252 70 56902 20 96102 A 00 7571 90 5511 ea v 50 711 26 996 1088 20 96102 P VI xA H r 00 96102 27 B 00 81222 Ja 10 21222 mec 70 5590 j 00 71262 20 1
17. 0 16861 00 17600 18 2091 5518 Section 3 General Information Assembly Drawings 23280 02 3 ASSEMBLY REVISION A Section 3 General Information Assembly Drawings 23280 02 SPARTAN 3 ASSEMBLY a L TOD lt 9 20188 16 5 ve a a WEE SN zw MES A ana dips SSP 114 1486 13 20188 16C N 4 0 SSP 172 REVISION Section 3 General Information Assembly Drawings 23280 02 SPARTAN 3 ASSEMBLY 5 32 BLUE TUBE 5 32 BLUE TUBE 21203 12 227777 SOME PARTS REMOVED CLARITY 20190 30 pa 2 CATALYST HOSE 20190 30 PARA HOSE 9104 03 1 4 O D CLEAR N AN KON C Tu dy LU LJ gt oo Lu AAD 724 eu OO IIO SE D rx Za lt 3 RO J Oy o SETA OM o2 an CN e Ez 5 now T om 2 NG REVISION A Section 3 General Information Assembly Drawings 23280 02 3 ASSEMBLY 3339 6 8 90 25106 038 7 1 8 7016
18. 0252 2 2 7296 00 75102 0759907 VIE UG 60 00 26861 00 9c c 01 7511 207 5619 20 0120 0 7 11 291 511 00 22112 00 1060 00 1110 00 90800 00 0120 90 711 202 80 lt 12 00 19810 00 7920 00 2810 00 89280 00 19280 00 8920 00 82810 00 99060 00 48464 20 79112 00 68814 00 62814 60 8597 86 9871 10 11144 10 71122 REVISION E N Section 3 General Information Sub Assembly Drawings 23250 00 SPARTAN 3 CONTROL BOX ASSEMBLY oo z z 20 50212 21 lt 0212 3M8 22 5 2 21 50212 ania vi soziz ama 8 1333 8 3M8 8 71 0212 13332 MOTA 28 5 61 lt 0212 13337 1 20 20212 40102 N d H19N31 3715 6 19 REVISION E Section 3 General Information Sub Assmbly Drawings 23250 00 SPARTAN 3 CONTROL BOX ASSEMBLY Part Number r r r z EEM HET Description lt Number Description 22218 00 PUSH ON HOSE FITTING 23229 00 ACCU PRESSURE K 2 DECAL 30 REVISION E 1 2 1 2 8 22222 00 INJ EMERGENCY ACCU SHOT DECAL 7
19. 3 SET UP 6 INJECTION SET UP MANUAL INJECTION N 12 Section 2 Operation Start Up Instructions MANUAL INJECT SET UP SCREEN MANUAL INJECTION CONFIGURATION POSITION A 2 00 y 2 24 PUSH START THE CATALYST PUMP WILL THEN MOVE TO THE SELECTED POSITION PUSH ORY ARROWS TO SELECT START POSITION PERCENT SETUPSELECT START _ 2 2 72 4 22 RETURNS SETUP SCREEN 2 4 Turn the material and catalyst valves to the Injection position H 5 Depress the air switch button on the gun head to dispense mixed material t s strongly recommended at this time to do a couple of test shots in a suitable cup to confirm proper gel time 025 gallons per stroke NED 95cc per stroke 13 When starting a new machine it is recommended to 2 dispense a couple of strokes of resin into a suitable container to ensure a proper flow of materials This is not required once the machine has been properly wet out 6 When finished turn catalyst amp resin valves on the gun head to recirculation position BEFORE FLUSHING CATALYST T Flush the system a Press the Air Flush button
20. 53 00 23254 00 23255 00 23256 00 23259 00 23260 00 23261 00 23262 00 1 616 MEN 4 1 4 3 6 3 4 1 1 1 3 3 ty 3 7 2 4 3 8 4 4 4 2 2 3 1 2 2 1 1 2 2 Number 8155 160C GAM 268 01 SSP 157 01 CALIBRATION DECAL SSP 190 01 Part Description 9 lt 23269 00 NORMALLY OPEN SENSOR 23269 01 CLOSED SENSOR 23278 00 ROLLER BEARING 23295 00 TOUCH SCREEN CABLE 23296 00 SERVO MOTOR CABLE 23297 00 TERMINAL SERVO CABLE 23298 00 CPU SERVO BLOCK CABLE 3923 02 SPIRAL WRAP 7486 04 WASHER 7486 05 WASHER 7486 08 WASHER 7486 13 WASHER 7733 12 HEX NUT 7733 14 HEX NUT 7733 17 HEX NUT 7733 42 HEX NUT 7734 06 LOCK WASHER 7734 07 LOCK WASHER 7734 10 LOCK WASHER 7734 12 LOCK WASHER 7957 32C SCREW 7957 32F SCREW 7957 48C SCREW 7958 56C SCREW SCREW 8212 20F SCREW 8301 16C SCREW 9704 11 P E TUBING 9704 83 RED P E TUBING 9944 20 SCREW 9944 32C SCREW 9955 24C SCREW FM 494 EXPANDABLE SLEEVING N G 403 RUBBER TARP STRAP PICK UP TUBE GC 1368 USER MANUAL LPA 170 BOTTLE SUPPORT 55 112 SLAVE PLATE EXTENSION SSP 115 DRIVE ARM 55 148 RELEASE 55 172 SURROUND GUARD SSP 173 LEFT PUMP GUARD SSP 174 GUARD ANGLE BRACKET SSP 176 UARD WINDOW SSP 177 REAR RIGHT PUMP GUARD SSP 178 FRONT RIGHT PUMP GUARD SLAVE PUMP REVISION Operating Your Polyester System
21. 5845 WEST 82nd STREET ADVANCED DISPENSE INDIANAPOLIS INDIANA 46278 www glascraft com U S A GC 1368 Phone 317 875 5592 REVISION H Fax 317 875 5456 E Mail sales glascraft com
22. E BEEN REACHED IT WILL ALSO FLASH IF STOP START POSITION STOP POSITION IS PUSHED 2 TOTAL A PUSH AOR YARROWS 2 00 2 00 PUSH AOR YARROWS TO SELECT THE CYCLE STATUS SELECT THE ENDING STARTING CATALYST w STOPPED CATALYST PERCENT PERCENT 77 THE REGUIRED PERCENT AND STROKES ARE ENTERED PRESS START TO START THE CATALYST PUMP PUSHING STOP WILL STOP THE PROGRAM THE START BUTTON MUST BE PUSHED AGAIN AND THE PROGRAM WILL START OVER TO POSITIONING AVOID RESETTING THE PROGRAM RETURNS TO USE THE START AND STOP BUTTONS SET UP SCREEN ON THE CONSOLE AND OR GUN AND INJECTION DURING THE INJECTION PROCESS PROGRAMMING pop up KEY PADS FOR TOTAL STROKES 13 C2 C3 C4 waiki SELECTED C83 025 gallons per stroke NED 95cc per stroke 29 PRESS 15 Section 2 Operation Start Up Instructions 3 Secure port Injector into mold opening or use the 7 Flush the system remote injection port a Press the Air Flush button 4 Press Start on the set up screen P 5 Press Injection ON button 6 9 TETI e b Press the Solvent Flush button 6 6 6 of CJ e 6 9 Injection will NOT function until the catalyst pump
23. GlaSCr art NSING EKCE Spartan 3 RTM Injection System lt Z lt Zi YS Table Of Contents Section 1 Installation 1 1 Introduction 2 422 MA sens ae Vek A aaa aa 1 1 2 Standard EGuipmennt u ee itt eter i teet ala n SAE a yar n nan ee 2 1 3 5 5 nu ia serda cT N A 1 4 EquipmentAssembly iz 2 Aali dia n en d d dine ead be Ki 3 Section 2 Operation 2 1 Start up INStruGtiONS 5 2 2 ie ets cds tius Keye una mas a AE 19 Section 3 General Information 3 1 Assembly Drawings tie e eol KANEA gg e e Ege ee e A 20 3 2 ub Assembly DrawinGS a asas x te eee i ene quq eee ERR UE UR COR dal Tu ARA eh aie 27 3 3 Maintenance uu a erede ce eee pedet dt dde cet ettet uere se Dope desee d 40 3 4 tt nere rte ctr aet eco e pr eto WR An ba tardes be ede etu c ee Det it Itb eda e peg 41 3 5 HIT 42 Section 4 Safety Information 4 1 General Safelty ium mcenia 49 4 2 NOI6S ng pr tuta 57 DG 59 4 4 TECHNICAlASSISTANCE ee 60 For Your R
24. OH 1VI9ILVN Q I ac 90 2 102 138 7 62 76912 9 v016 1gN3SSY NNO gt n 67281 2 LLR lt L HEL 525555555505 Se eee 3118 4254 60 6106 038 2 6 10 25106 JSOH 1VIYILVW 02 56102 Section 3 General Informat 0 081 23280 00 3 ASSEMBLY S 7296 Section 3 General Information Options 23280 00 COMPUTER CABLE CONNECTIONS 23296 00 our TO SERVO MOTOR 04 9 94 Q zs 888 1 5 72 N N 04 O O 1 gt 8 o lt n gt 2 4 ou 2 2 22 O gt 23295 00 47 REVISION G Section 3 General Information Options 23280 00 3 ASSEMBLY Part Number 10773 12C Description 10773 14C 10773 28C 13424 01 16028 03 17440 00 18245 02 19845 00 19882 00 19889 00 19891 00 19892 00 20188 16C 20190 30 20195 30 20368 00 20569 00 20732 01 20732 02 20732 06 20864 06 20941 00 20945 00 21044 06 N N 23231 01 23250 00 23251 00 23252 00 232
25. S HHHH 4 7 s JH 6 5 SERVO MOTOR MODULE 4 SERVER POWER SUPPLY 5 I piss 4 530 6 SUPPLY 74 29 5 0 9 C BLUE 9 BLUE BLACK servo TERMINAL STRIP 9 BLUE 9 BROWN SERVO MOTOR PROX 2 OPERATORS TOUCH SCREEN ES TO GROUND LUG 8 9 8 8 INPUT MODULE COUNTER 10 of PRESS SWITCH 9 m PROX 3 2 12 PROX 1 AIR PURGE 9 13 earn 9 SOLVENT 14 sTo 9 COUNTER RESET e 15 9 INJECT ON 16 5776 9 INJECT OFF 17 e 9 18 GUN P B oe es 9 OFF 19 RECIRC SELECT SW 9 20 GUN INJECT SWITCH 9 21 GUN INJECT OFF PRESS SWITCH 9 XL 22 51 5 START 9 4 3 ow 9 OUTPUT MODULE AIR MOTOR ON OFF VALVE 23 TE 23 ZA 8 LI PURGE VALE 24 ME 24 fco 10 COIL 4 Ned 9 SOLVENT PURGE VALVE 25 TE 25 LX 8 20 co 57 9 2 MAGIC BULLET VALVE 26 TE 26 40 m e 2 5 MAIN AIR SALVE 27 TE 27 ak 8 e 8 NA 32 Section 3 General Information Sub Assembly Drawings REVISION E Section 3 General Information 21668 01 Spartan Il Gun Assembly ccu Pressure Valve 513 ts 00 81802 N p 0061806 70 52 04 vO0 vELL 291 2128 1 226 49 12 7 00 69910 N E ie quiessy
26. 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 equip ment This manual outlines procedures to be fol lowed in conducting polyester operations safely This system has been specifically designed for use of Polyester Resin Gel Coat and Methyl Ethyl Ke tone Peroxides 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 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
27. _ 2 j Daf 2 FLUSH SET UP SET UP 1 SETUP 4 Z 4 4 2 SETUP 5 2 9 MANUAL SETUP 3 MOLD SCAN 2 EDETEN MOLD TAG WRITE Z SETUP MANUAL INJECTION 2 2 START POSITION STOP POSITION PUSH FOR MOLD SCAN SET UP TOTAL STROKES 277 Z 2 00 3 00 2 Z WRITE WV Y MOLD SCAN RETURN START POSITION TOTAL 2 STROKES 2 00 EJ 2 CYCLE STATUS BE s START SET UP SELECT 77 L 77 POP UP KEYPAD CO OD ENTER STROKES I EI c GL 09 G UP 502006 ENTER PASSWORD 8 71 C5 PUSH AFTER PASSWORD IS ENTERED SCREEN TAG WRITE WILL BE DISPLAYED 9100 AR C PASSWORD 1234 nen 1 ENTER START PERCENTAGE STOP POSITION PERCENTAGE AND TOTAL STROKES 2 AFTER PARAMETERS ARE ENTERED TAKE READ WRITE WAND AND SCAN MOLD CHIP ORANGE LIGHT WILL APPEAR 3 REPEAT STEPS 1 amp 2 FOR EACH ADDITIONAL MOLD CHIP MAKE SURE TO CHANGE DATA EACH TIME BEFORE WRITING MOLD CHIPS 4 WHEN ALL MOLD CHIPS HAVE BEEN WRITTEN AND SCANNED TO MOLD CHIPS PRESS RETURN THE MOLD SCAN SCREEN WILL APPEAR AND
28. ad through the mixer and into the RTM mold This fault condition will manifest 3 The catalyst pump has faulty seals or is itself in the molded part having very small bubbles contaminated with particles almost in froth like state on the upper side of the molded part once the mold is opened The reason for To ensure that the catalyst system is totally hydraulically these bubbles being so small is due to the fact that air tight it is expedient after a period of shut down that the pro coming through the mixer with the resin is mixed and cedures in the instructions for commissioning the catalyst frothed before finally entering the mold stream should be repeated 41 Section 3 General Information Options 23280 00 3 ASSEMBLY REVISION 70 99 71 01 711 24 68 11 508 09 495 HLIM NMOHS MILA 00 89602 1286 1881 0 8 w hf 00 10122 20 v6912 I 00 01912 90 991 B 21 PELL 297 1661 90 79902 00 69602 VS N Z 21 1 j 80 96 00 099122 j Wanaya 1930 1 011 991 10 16262 d 00 71912 SX NG i 1 130 315 2 M vl LL Y So 47
29. ary if the system is equiped with the PAC option 11 Section 2 Operation Start Up Instructions Recirculation Mode Start Up 4 Continue to cycle the machine until a steady stream of catalyst appears out of the return tube 1 Both the catalyst valve and the material valve on the and is free of any air bubbles dispense gun should be in the recirculation position Towards the hoses The recirculation mode should be used in initial gt start up or when air bubbles are observed coming through the ends of the recirculation hoses Initial Injection Instructions 1 Turn Recirculation Switch to the OFF position ot 2 Turn machine to recirculation ON 5 FLUSH SET UP SET UP 1 SET UP 4 z 9 UP 2 5 MANUAL SETUP 3 SET UP 46 INJECTION SETUP MANUAL INJECTION 3 Required Select desired percentage of catalyst by pushing the manual injection set up 3 Turn the air motor regulator slowly clockwise until E the pump cycles slowly FLUSH SET UP SET UP 1 SET UP 4 UP 2 5 MANUAL SETUP
30. d 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 hoses fittings etc because dangerous chemical reaction may result between substituted parts and 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 51 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 and Resin Diluents WARNING A hazardous situation may be present in your pressur ized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum galvanized components in a closed pressurized fluid system pumps heaters fi
31. d 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 50 Section 4 Safety Information General Safety Safety in handling MEKP depends to a great ektent on employee education proper safety instructions and safe use the chemicals and equipment Workers should be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users 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 other materials including polyester overspray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels 4 Never add MEKP to anything that is hot since explosive decomposition May result 5 Avoid contact with skin eyes an
32. dard specifi cations and procedures some deviations may be found In order to provide our users with the most up to date technology possible we are constantly seeking to improve products If technological change occurs after a product is on the market we will implement that technology in future production and if practical make it available to current users as a retrofit up date or supplement If you find some discrepancy between your unit and the available documen tation contact your GlasCraft distributor to resolve the difference GlasCraft Inc reserves the right to change or modify this product as it deems necessary Careful study and continued use of this manual will pro vide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting Section 1 Installation Standard Equipment Spartan 3 System Standard Equipment Part Description Number p 17440 00 SSP 190 01 20190 50 20195 30 20569 00 22701 00 20941 00 20946 00 21054 01 2165402 21694 25 Section 1 Installation Equipment Assembly The Spartan 3 comes complete and fitted with all resin hoses catalyst bottle and filters The injection head is fully connected to the machine circuit and tested and secured against leaks prior to dispatch _ The following instructions to be used as a guide u for consistent and continual operation Any devia tion f
33. ed 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 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 manufacture
34. eferenten 2 tte aa ekey KA EN A INSIDE BACK COVER N A Not 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 GlasCraft Inc In this GlasCraft technical and safety publication the following advisories will be provided where appropriate x Is information about the procedure in progress CAUTION Is imperative information about equipment protection N 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 stan
35. g aluminum or galvanized wetted parts GlasCraft is aware of NO stabilizers available to prevent Halogenated Hydrocarbon solvents from reaction under all conditions with aluminum components in a closed fluid system TAKE IMMEDIATE ACTION Halogenated Hydrocarbon solvents are dangerous when used with aluminum components in a closed fluid system Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocar bon Solvents 52 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 NFPA No 91 is important wherever solvents are stored 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
36. g instructions and service information 3 0 Equipment Safety 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 A WARNING 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 DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PISTOL 3 1 Emergency Stop Procedures 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 thus making the system incapable of operating Step 2 is a precautionary step and should be followed X whenever the emergency stop valve is activated to the stop mode Failure to do so will damage regulator
37. i and turn the ball valve to the open position 9 Follow the instructions below for touch screen operations SCREEN 2 SYSTEM SET UP SCREEN FLUSH SET UP SETUP 1 SET UP 4 SET UP 2 SET UP 5 MANUAL SET UP 3 SET UP 6 INJECTION SET UP MANUAL INJECTION PUSH FOR FLUSH SET UP SCREEN SCREEN 3 SCREEN WHEN FLUSH SET UP IS SELECTED FLUSH SET UP AIR FLUSH TIME SECONDS SOLVENT FLUSH TIME SEGONDS BACK BUSH d POP UP POP UP KEY PADS RETURNS TO KEY PADS SET UP SOLVENT SCREEN 2 FLUSH SECONDS Pa THE TIME SETTINGS THAT ON THIS SCREEN WILL NOT CHANGE EVEN WHEN POWER IS TURNED OFF SETTINGS CAN ONLY CHANGE BY OPERATOR IN FLUSH SET UP SCEEN USING KEY PADS 10 15 seconds is recommended air flush initial X set up 3 5 seconds is recommended for solvent flush initial NED set up Section 2 Operation Start Up Instructions 10 Place injection nozzle over a proper waste con 3 Replace yellow guard using a 5 32 hex balldriver tainer Press the solvent button located on the front of the control panel to assure proper flush Press the air flush button located on the front of the control panel to purge any re
38. im Also determine the best methods of first aid treatment for mediately and dispose of them in accordance with your each chemical used in your plant material supplier s recommendations 2 8 Treatment of Chemical Injuries 2 6 Cured Laminate Overspray and Laminate Sandings Accumulation Great care should be used in handling the chemicals res ins catalyst and solvents used in polyester systems Such chemicals should be treated as if they hurt your skin and eyes and as if they are poison to your body For this reason GlasCraft recommends the use of protective clothing and eye wear in using polyester systems 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 However users should be prepared in the event of such an injury Precautions include Floor coverings if used should be non combustible Spilled or leaked catalyst may cause a fire if it comes 1 Know precisely what chemicals you are using and contact with an FRP product oversprayed chop or resin obtain information from your chemical supplier on FRP sandings or any other material with MEKP what to do in the event the chemical gets onto your skin or into the eyes or is swallowed To prevent this spillage and leakage you should 2 Keep this information
39. ion Number p 20397 02 100 MESH 20397 03 50 MESH 20397 01 38 REVISION D Section 3 General Information Sub Assembly Drawings 21654 01 SOLVENT ASSEMBLY 23283 00 DECAL PLACEMENT Part mss 1 musco zumo TANK WARNING DECAL 1 an oues weeumaRm eux 39 Section 3 General Information Maintenance GlasCraft recommends that you contact your gel coat Maintenance It is recommended that the following service be performed on a weekly basis 1 Inspect and lubricate Catalyst Slave Pump Linkage See Catalyst Slave Pump User Manual 2 Inspect Pump Shafts on Material and Catalyst Pumps making certain they are clean and free of foreign material Clean and lubricate as required For long term storage of your injection system it is recommended that the following procedures be followed 1 Place dry nitrogen in the material drums and secure drum 2 Make certain all air and material valves are in their OFF position 40 and or resin supplier concerning material pot life during extended periods of shut down The decision as to whether or not to leave material in your system should be based on information from you
40. l 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 adhesives formulation for 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 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
41. lantic Avenue Boston MA 02210 Research Report No 11 of the American Insurance Association deals with Fire Explosion and Health Hazards of Organic Peroxides It is published by American Insurance Association 85 John Street New York New York 10038 Local codes and authorities also have standards to be followed in the operation of your spraying equip ment Your insurance carrier will be helpful in an swering questions that arise in your development of safe procedures 1 2 Personnel Safety Equipment GlasCraft recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems EYE HEARING PROTECTION PROTECTION CAUTION GLOVES REQUIRED IN THIS AREA BREATHING PROTECTION Section 4 Safety Information General Safety GlasCraft recommends that the user consult the state and local regulations established for all Safety equip ment listed 2 0 Material 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 Methyl Ethyl Ketone Peroxide MEKP 2 The flammability dangers of clean up solvents sometimes used GlasCraft recommends that solvents be nonflammable and resin diluents used such as styrene 3 The flammability dangers of catalyst diluents
42. maining solvent from the gun head 4 Before operating the material pump flush thoroughly with a clean suitable solvent to remove test fluid 11 Exhaust air through the gun head until traces of solvent have been dissipated q GlasCraft uses test fluid that may not be compatible XX with some resins Then it is recommended that the test fluid be flushed from the material pump fluid section Resin Start Up 1 Remove yellow guard using a 5 32 hex balldriver ST L J Make sure hose fittings on the pick up hoses tight 5 Place the material pick up tube into a container of clean suitable solvent 6 Place the recirculation into suitable solvent waste container 7 main valve the gun head to the recirculation position Towards the hoses Hi Section 2 Operation Start Up Instructions 8 Turn the material air regulator OFF counter clock 11 The pump should cycle clean solvent through the wise system and out the recirculation hose 12 End recirculation when solvent appears reason ably clean OFF 1
43. ne GlasCraft If your questions are not urgent You can e mail all correspondence to service glascraft com Model Spray gun Serial number Material pump Serial number Catalyst pump Chopper Serial number Type of material Type of catalyst Catalyst percentage 60 Air compressor size Compressor to system supply line Pressure at the system Main air line volume System gauge pressures AAC pressure Atomizing air pressure external mix Material pump pressure Solvent flush pressure Glascrare DISPENSING EXCELLENCE Date Purchased Distributor Contact Phone E mail GlasCraft manufactures a complete line of FRP spray systems If your application is in plant or a field contractor GlasCraft has a system package to meet your requirements FORMULA INTERNAL amp EXTERNAL MIX POLYESTER EQUIPMENT CHOPPER amp GELCOAT SYSTEMS NO NEEDLE IN THE SPRAY GUN INFINITELY ADJUSTABLE CATALYST PUMP INDY INTERNAL amp EXTERNAL MIX EQUIPMENT LOWEST LEVEL OF EMISSIONS AUTOMATIC EQUIPMENT FOR ROBOT APPLICATIONS SPARTAN CLOSED MOLD RTM EQUIPMENT HAND HELD amp DELUXE MODELS PROGRAMMABLE CATALYST PERCENTAGES SPECIALTY DISPENSE EQUIPMENT APD HIGH VISCOSITY POLYESTER PUTTY DISPENSE RCD RESIN CATALYST DISPENSE PRESSURE FED ROLLERS Quality and Performance GENUINE GLASCRAFT Glascrart DISPENSING EXCELLENCE ADS
44. or responsibility of any kind expressed or implied The user should not assume that all safety measures are indicated or that other measures are not required Glascrart DISPENSING EXCELLENCE 5845 WEST 82nd STREET SUITE 102 INDIANAPOLIS INDIANA 46728 U S A PHONE 317 875 5592 FAX 317 875 5456 Limited Warranty Policy GLASCRAFT INC warrants to the original Purchaser GlasCraft manufactured equipment and parts that all GlasCraft manufactured equipment and parts will conform to their published written specifications and be free of defects in workmanship and material for a period of one 1 year from the original date of installation GlasCraft makes no warranty to anyone other than the original Purchaser 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 claim
45. ough the system and exiting the material recirculation hose thoroughly before shut down procedures are completed CAUTION Failure to cycle Pump Shaft to DOWN position may result in contaminants to dry or harden on shaft When the pump is next operated severe damage may be done to upper pump seals 2 Flush gun head with solvent and air purge thoroughly 3 Material pump should be stopped with pump shaft in up position and shaft should be cleaned of any contaminants 4 Material pump lube cup should be cleaned of old lube and refilled with new pump lube 5 Material pump should now be cycled so that shaft is left in down position during shut down period 19 Section 3 General Information Assembly Drawings 23280 02 SPARTAN 3 ASSEMBLY S 8V09 455 HLIM NMOHS MIIA 368 1961 A 188385 V dANd 1VIH31VN 90 79806 00 28861 70 9891 01 y 11 1181355 00 99202 th A T8N3SSY 00 10122 dWd 15 113132414 14330 10 151 455 10 091 455 113132414 12340 V0 1 c c A 18N3SS Y 10 052 lt 2 Q REVISION A X08 1041802 07 9 No 99201912 20 A 18W3SSV LSATVLVI 00 26861 0
46. ounded 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 gt 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 the precautions stated above If you as an equipment operator or supervisor do not feel that you have been adequately trained or instructed and that you lack the technical knowledge to operate or perform maintenance on a piece of glascraft equip ment please call glascraft inc Before operating or performing maintenance on the equipment If you have any questions regarding the above pre cautions or any service or operation procedures call your glascraft distributor or glascraft inc All statements information and data given herein NED are believed to be accurate and reliable but pre 56 sented without guaranty warranty
47. pected all areas where resin is stored and or used Refer to Section 1910 94 1910 106 1910 107 4 Arrange the hoses fiberglass roving guides and consult resin suppliers for more detailed informa so that the fiberglass strands DO rub tion against any of the hoses at any point If allowed to rub the hoses may be cut through causing a Adequate ventilation as covered in OSHA Section leakage of di salen eu 2 1910 94 and 91 is important wherever so 886 the danger of fire Also the material may vents are stored or used to minimize confine and spew onto personnel in the area haust the solvent vapors Resin must never be stored in an area where MEKP is 2 7 Toxicity of Chemicals stored or used GlasCraft recommends that you consult OSHA Sections drums should not be used due to possible 1910 94 1910 106 1910 107 33 contamination and possible catalyzation from overspray Chapter 14 91 or spillage of MEKP into drum which could not only se verely damage the polyester spray system but might Contact your chemical supplier s and determine the also cause the drum of resin to ignite toxicity of the various chemicals used as well as the best methods to prevent injury irritation and danger to When spraying test patterns or purging the gun always personnel remove the test samples and waste from the building
48. r material suppliers as well as GlasCraft Consult your local authorized GlasCraft distributor for more information concerning system storage Section 3 General Information Troubleshooting Troubleshooting Air gas in the catalyst stream leads to different type of fault in the molded part This condition will be manifest by observing when opening the mold after injection and supposed cure that there are wet patches Before altering catalyst percentage by moving the of uncured or semi gelled resin in the molded part The catalyst pump to a new desired location on the ratio causes attributed to this are arm ALWAYS ensure that the catalyst recirculation valve is turned to the recirculation position and the air pressure is removed from the system 1 Air is drawn in by the catalyst pump through a bad connection on the inlet stream from the catalyst container or pump inlet connection It is absolutely essential that both streams of material are pumped to the head without air or gas entrapped For example if air is drawn into the resin stream through 2 Catalyst contamination in the pump system causing the resin pump inlet system i e via bad connection or oxidation resulting in peroxide gas bubbles being filter end coming out of resin surface then this air if generated within the supposedly hydraulic sealed not purged out of the machine by recirculating on by system of the catalyst pass will naturally go to the he
49. r 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 59 Thank You 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 pho
50. removed from system 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 55 Section 4 Safety Information General Safety 3 3 Grounding Grounding an object means providing an adequate path for the flow of an electrical charge from the ob ject to the ground An adequate path is one that per mits charge to flow from the object fast enough that it will not accumulate to the extent that a spark can be formed It is not possible to define exactly what will be an adequate path under all conditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed on all loose conductive objects in the spraying area This includes material containers and equipment GlasCraft recommends grounding straps be made of AWG No 18 stranded wire as a minimum and that larger wire be used where possible NFPA Bulletin No 77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm 106 ohms but that resistances as high as 10 000 meg ohms will produce an ade quate leakage path in some cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and gr
51. rials containing promoters such as laminate sandings or with any readily oxidizable material such as brass or iron will cause exothermic redox reactions which 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 1296 acetylene and air The maximum value listed for a hydrogen explosion is 10 000 psi per second Some forms of MEKP if allowed to reach their SADT will burst even an open topped container This suggests that itis 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 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 coul
52. rom the standard operation usually requires more maintenance to the equipment and material formulation to assure consistent results For example the use of fillers in resins Q Z Refer to specific user manuals if available for detailed component start up and shut down instruc tions 1 Select a clean dry air supply It is very important to have a clean air supply 2 Attach a 3 8 or larger air hose to the Air Inlet on the yellow air lock out valve Quick disconnect fittings should not be used because they can severely limit air flow CAUTION Before turning on main air a check all fittings making certain they are securely tightened b Make sure all regulators are set to zero turn all the way to the left This should be done before air or material of any kind is introduced into the system 3 Attach Grounding Clamp Assembly P N 17440 00 to System Use a convenient Nut and Bolt to secure Lug P N 13193 00 to system 4 Securely attach Clamp P N 7749 00 to permanently grounded rod or pipe 7749 00 9654 00 N GROUNDING ROD OR PIPE 131 gt SYSTEM A CAUTION Whenever flammable or combustible liquids transfered from one container to another both containers shall be effectively bonded and grounded to dissipate static electric ity For further information see NFPA 77 Recommended Practice on Static Electricity 5 Plug
53. s and components when reactivating to the ON position N 2 Turn all system regulators to OFF counter clockwise position Verify that the Catalyst Pressure Relief Line and the Wto 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 in line with the valve body 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 54 Section 4 Safety Information General Safety 3 2 General Safety Precautions Do not operate Fiberglass Chopper Guns with out protective covers in place The following general safety precautions should be Correct packing seat leaks immediately followed when servicing or operating this equip Never immerse the gun in any liquid ment to ensure operator safety Periodically check operation catalyst alarms to make sure they are operation properly When filling catalyst container protective eye Frequently check condition of hoses Replace worn equipment must be worn to protect against hoses and other part
54. s with preferred MEKP catalyst to a minimum level of at least two inches above the catalyst bottle outlet fitting AN WARNING Remove the catalyst bottle P N 20941 00 from catalyst bottle bracket P N LPA 169 for filling The bottle should be placed at or below lowest level for safe filling Never fill the catalyst bottle while mounted in bracket as personal injury from catalyst spillage could result 2 Turn the catalyst valve on the dispense gun to recir culation position arrow on valve should point away from gun block Make sure all the air is purged out of the catalyst pump on new start up 3a Pull and rotate pivot knob to disengage the catalyst drive arm b Turn the catalyst slave pump yellow ball valve to the open position C Hand prime the pump until a steady stream of catalyst flows back to the bottle d Close the ball valve 4 Set the catalyst slave pump to 3 0 percent 4 It is usually a general practice when starting up the gt system to let the system recirculate with the catalyst slave pump set at 3 0 This ensures good catalyst volume movement through the system to remove air in the catalyst system 4 For systems that have Progressive Automatic Catalyst see manual injection procedures on the next page for instructions on how to set the catalyst pump to 396 using the touch screen 5 Re engage the catalyst pivot knob This step is not necess
55. s before they fail injuries Catalyst fluid nozzles and seals MUST be in good Always maintain adequate material levels to condition at all times to prevent internal and prevent loss of prime during system operation external leaks Inspect periodically and replace Atthe first sign of a leak stop operations acti as needed or at intervals of three to four months vate emergency stop valve back off air regula Use catalyst nozzle seal only once to prevent tors and open all bleed valves to remove possible leakage of catalyst into air passages all pressure from the gun hoses pump catalyst of gun system any other liquid containers Make absolutely certain that all pressure has been Solvent Pot Pressure Relief relieved from the gun before disassembly from the Turn Solvent Pressure Regulator counter clock hoses before loosening any fittings from the wise ccw until regulator handle stops material or catalyst puMp before disassembly from Open Petcock valve to bleed Solvent Tank the catalyst injector before disassembly or filling pressure completely e If you have any doubt that fluid pressure is Catalyst Injector Pressure Relief relieved 2 e Refer to Catalyst Injector User Manual for call your GlasCraft distributor or GlasCraft Inc proper pressure relief before proceeding with any disassembly Never operate a Fiberglass System with Use only genuine GlasCraft replacement parts when fixed Pinch Point guards
56. 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 ZA WARNING 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 3 Inspect resin and catalyst hoses daily for wear or production stress at the entry and exits of the boom sections and at the gun and fittings Replace if wear or NO SMOKING signs must be posted and observed in weakness is evident or sus
57. the electrical cord into a 110 outlet 6 Attach 4 casters with provided lock washer washer and nut Attach solvent tank support rod on back left caster 7 Attach solvent tank to solvent tank support rod with provided rubber strap Section 1 Installation Equipment Assembly 8 Attach the catalyst jug bracket to the mast 9 Attach the green material hose to the pick up tube and insert the tube into a bucket of clean solvent Recirculation hose from the gun SOLVENT CONTAINER SOLVENT WASTE 10 Attach the green material hose CONTAINER to the material pump 11 Insert the end of the recirculation hose into a waste container Section 2 Operation Start Up Instructions Console Functions EMERGENCY STOP Shuts off operation Twist red knob to reset emergency stop start button must be pushed to restart 2 2 SYSTEM START AIR PURGE Button POWER SWITCH ACCU PRESSURE X2 Pressure Gauge ACCU PRESSURE Regulator 4 T MAGIC BULLET 6 6 6 EZ 14 may LAU SNG PT FT y 2 ACCU PRESSURE ON OFF SWITCH STROKE COUNTER Reset Push Button MOLD INJECTION TOUCH SCREEN On Push Button RECIRCULATION MOLD INJECTION ON OFF SWITCH Off Push Button SOLVENT PURGE Push Button Section 2 Operation Start Up Instructions 1 Open the air valve by pushing the yellow slide on the valve 2
58. together and easily available 1 Maintain your GlasCraft System Check the gun so that it may be used by those administering first several times daily for catalyst and resin packing aid or treating the injured person or valve leaks REPAIR ALL LEAKS IMMEDIATELY 3 Be sure the information from your chemical supplier includes instructions on how to treat 2 Never leave the gun hanging over or lying inside any toxic effects the chemicals may have the mold A catalyst leak in this situation would certainly damage the part possible the mold and may cause a fire 53 Section 4 Safety Information General Safety WARNING 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 know the chemi cals and treatment before an accident occurs Treatment for swallowing a chemical frequently depends upon the nature of the chemical Refer to your System User Manual for complete gt and detailed operatin
59. 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 relied upon to prevent the explosive reaction Such coatings can be worn cracked scratched or too thin to prevent con tact There is 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 their low flam mability hazard and their not being classified as toxic or carcinogenic substances HHC solvents are very desir able in many respects N WARNING Do not use Halogenated Hydrocarbon solvents in pres surized fluid systems havin
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