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Spartan II PLC - Glas

1. 23228 00 7 EHH h A 3 22222 00 4 2 22212 02 as i RS 141 02 j 20196 00 5301 0 E 21678 00 2 dors 5301 01 view B 21669 00 22249 00 23212 00 23213 00 view C 22251 00 23014 00 SOME PARTS REMOVED FOR CLARITY 23019 02 23258 00 21145 00 1315 05 l A n d AR H 9 9 3 22263 00 A 21284 16 Li a 1134 01 off 21281 01 U 20655 04 q 20196 02 4 1315 06 8212 48F 8 8 I Hy 1486 03 7735 16C ru 1134 04 1134 03 9944 20C 1133 01 1133 0 1486 05 1134 06 view D view n m 2 5 5 1315 06 23281 00 9943 16 1134 04 VIEW 23279 00 ew B 1133 07 29 REVISION E
2. 3 Secure port Injector into mold opening or use the T Flush the system remote injection port a Press the air flush button 4 Press Start on the set up screen 5 Press Injection ON button 6 8 e e e b Press the solvent flush button e e 9 v el e e 9 Z Injection ON will NOT function until the catalyst pump has found the correct percentage a 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 T the air or solvent refer to the flush set up injection instructions to finish injection The start and stop buttons on gun and control RFID Option WRITING TAGS panel be pressed without changing the program If the 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 5 With scanner wand scan mold chip
3. 4 Turn the material and catalyst valves to the Injection position m CATALYST 7 Flush the gun head throughly 5 Depress the air switch button on the gun head to a Press the air flush button located on front control dispense mixed material It s strongly recommended panel 2 2 m b Press the solvent flush button located on front control panel 025 gallons per stroke 95cc per stroke c Press the air flush button 8 Assure that proper catalyzation was achieved When test material dispenses or during flushing operation make certain that dispensed material and or solvent is contained in a suitable container and that this material and or solvent is disposed of properly 13 Section 2 Operation New System Start Up Manual Injection Instructions 1 Turn recirculation switch to the OFF position Si 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 NX 95cc per stroke
4. 5 FLUSH SET UP SETUP 4 z 9 UP 2 5 MANUAL SET UP 3 SET UP 6 INJECTION SETUP MANUAL INJECTION 3 If Required Select desired percentage of catalyst by pushing the manual injection set up 3 Turn the air motor regulator slowly clockwise until a the pump cycles slowly FLUSH SET UP sETUP SETUP 4 UP 2 5 MANUAL SET UP 3 SET UP 6 INJECTION SET UP MANUAL INJECTION N 12 Section 2 Operation New System Start Up MANUAL INJECT SET UP SCREEN 2 en starting a new machine it is recommended to dispense a couple of strokes of resin into a suitable 2 container to ensure a proper flow of materials This is not required once the machine has been properly wet out 4 2 00 PUSH ORY ARROWS TO SELECT START Y POSITION PERCENT SETUPSELECT A 6 When finished turn catalyst amp resin valves 2 W on the gun head to recirculation position 1 lt 2 BEFORE FLUSHING RETURNS rue CATALYST PUMP WILL SCREEN 2 MOVE TO THE SELECTED POSITION
5. N0113A 070 10 78012 ISOH QI 271 3 N MVH19 9 2 1 70 6 184 SY N B 350H IS N 02 06102 yo ak 1 ais 8 2 5 Z m ME LI que 22823 DIEM 7 WIT 8 6 AJ 1 lan Q0 1 016 60 0 6 j 1SA1YLYO 0 06102 20 3339 26 8 90 6106 034 8 7016 L N 3018 c 6 MR NNYG 1534 150 3041034 150 08 6610 Section 3 General Information 23280 00 Spartan PLC Assembly 3339 6 90 22102 038 8 7016 JONVYO G1 02 ATBWISSYON 20 89912 3118 26 4 0 0 10 3018 2 6 IG 14 19 038 ct 6 10 46104 101134 dt 6 I 0clc 150 1SA1V1VO 0 06102 150 LSATVLY9 0 06102 00 67600 3911 MOTIJA 10 75016 JSOH lviu31VN 3031 ac 62 76912 20 67081 1S0H 1VIU31VN 02 56102 26 Section 3 General Information 23280 00 Spartan PLC Parts List Part Number 10773 12C Part Number 7957 32C Description Description lt SCREW 10773 14C SCREW 10773 28C SCREW 13424 01 CABLE TIE 16028 03 HITCH PIN 17440 00 GROUNDI
6. x 70 66902 00 75102 m 70 96102 5 3118 5071 gt gem 70 lt 0212 00 76102 00 GL262 7 00 18252 49 6118 00 2626222 AU 00 11252 N 62 1001 5 2 5 00 55252 90 1661 0 99 00 10522 0 96102 10 1262 10 65102 81 0 09904 A gt 00 81222 00 11122 311 10 107 00 906 22 10 0767 10 9 222 s 1 A a e 20 01262 00 0122 20 66100 m 2 0 2019 I YO SELI 202 805 12 i 10 6226 20 7511 lel Z 28 687 12 00 1981 M 00 79252 N p 5 22 00 96102 imus a ET P CN WOUJ 00 2812 525522 0 9G9 MM A p 00 612 2 S I 00 892 4 o x Esci rc 12011 00 66262 L a 00 19252 6 00 96102 7 10 55902 20 96102 E 00 922 480 2128 90 5511 0 33 MR 00 62812 lt 296 1088 20 96102 BN 1 4 70 66902 T A 5 5 chi 00 25252 c ol 77 00 96102 20 9114 X 00 69912 o 00 81222 00 11262 27 00 2812 9 10 21222 a 2826 70 2990 00 26861 00 712 lt 2 20 012 2 00 92 c0 pell 20 10262 01 7511 291 5611 00 22112 207 5518 Le 7296 REVISION 30 Section 3 General Information 23250 00 Spartan PLC Control Box 00Z Z 3M8 r L NI
7. ZI SOZIZ 3M8 22 5 0Z Z ania vi SOZIZ ama 8 i SOZiZ ania 8 1333 8 3M8 8 71 0212 13332 MOTA 26 6 61 lt 0212 133 1 20 20212 40102 N d H19N31 3715 THV2SY19 REVISION E Section 3 General Information 23250 00 Spartan PLC Control Box Parts List Part Number 11021 23 Part Number 22238 01 Description lt Description 2 lt PIPE PLUG POPPET VALVE 11021 24 PIPE PLUG 22249 00 AIR PURGE ACCU FLUSH DECAL 14638 02 RIVET 22251 00 SOLVENT FLUSH ACCU FLUSH DECAL 15229 01 BREATHER VENT 22256 00 ACTUATED TOGGLE VALVE 15544 02 BULKHEAD FITTING 22263 00 L ADJUSTABLE FITTING 18199 02 AIR REGULATOR 22506 00 TERMINAL 19892 00 COVER PLATE 22507 00 TERMINAL END COVE 19916 00 PUSH SWITCH 23072 00 MOMENTARY ILLUMINATED PUSH BUTTON 20655 04 ELBOW FITTING 23073 00 EMERGENCY STOP PUSH BUTTON 20735 01 ELBOW FITTING 23074 00 PUSH BUTTON COUPLING PLATE 1 20735 02 ELBOW FITTING 23075 01 INSCRIPTION 20735 03 ELBOW FITTING 23079 01 NORMALLY OPEN CONTACT BLOCK 20754 00 ELBOW FITTING 23079 02 NORMALLY CLOSE CONTACT BLOCK 20796 00 FITTING 23174 00 POWER 20796 02 FITTING 23201 01 PANEL 20796 03 FITTING 23201 02 PANEL 20796 04 FITTING 23203 00 PILOT OPERATED REGULATOR 21145 00 VENT PLUG 23204 00 PANEL MOUNT GAUGE 21164 02 2AMP FUSE 2
8. FLUSH SET UP SETUPA SETUP 4 SETUP 2 UP 5 MANUAL SET UP 3 SET UP 6 INJECTION SET UP MANUAL INJECTION 55 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 7 After the injection process turn both catalyst valve and material valve on the dispense gun to the FLUSH SET UP SET UP 1 SET UP 4 recirculation position _ SETUP 2 SET UP 5 MANUAL SET UP 3 SET UP 6 INJECTION SET UP N MANUAL INJECTION 4 Turn valves on gun head to injection k s HH CATALYST 14 Section 2 Operation New System Start Up 8 Flush the gun x If Adjustments need to be made on the timing of the Solvent See Flush set up a Press the air flush button located on front control panel Automatic Injection Instructions b Press the solvent flush button located on front 1 Make sure Manual Injection is NOT on control panel Manual Injection Box Blue ON Manual Injection Box Gray OFF c Press the air flush button 2 Press set up 1 through 6 There are up to 30 s
9. FUSES HHHH 4 7 5 JH 6 5 SERVO MOTOR MODULE 4 SERVER POWER SUPPLY 5 830 m h 0 24 Wc Y SUPPLY 74 29 0 9 o BLUE 9 BLUE BLACK servo TERMINAL STRIP 9 BLUE 9 BROWN SERVO MOTOR PROX 2 OPERATORS TOUCH SCREEN a TO GROUND LUG En 8 9 8 8 INPUT MODULE COUNTER 10 oo PRESS SWITCH 9 m PROX 3 12 mm 12 a PROX 1 La AIR PURGE 13 ES 9 SOLVENT 14 sTo 9 COUNTER RESET 15 5570 9 INJECT ON 16 S 9 INJECT OFF 17 Ss 9 e 18 GUN P B TE SWITCH 9 OFF ON 19 RECIRC SELECT SW 9 20 GUN INJECT 9 21 GUN INJECT o PRESS SWITCH 9 0 22 l START 9 4 3 o G ow 9 OUTPUT MODULE AIR MOTOR ON OFF VALVE 25 ITB 23 YAN 8 5 LLL AIR PURGE VALE 24 24 fco 10 COIL 4 NA 9 SOLVENT PURGE VALE 25 TE 25 lo 8 20 L5 XU c2 MAGIC BULLET VALVE 26 ITB 26 con 8 L6 VU MAIN AIR VALVE 27 m 27 8 8 34 Section 3 General Information 23250 00 Spartan II PLC Control Box Schematic REVISION E Section 3 General Information 21668 01 Spartan Gun Assembly ccu Pressure Valve 513 ts 00 81802 N p 0 8 L802 a v0 S 10c vO0 vELL 291 2128 TIZE GIWIAZ 7 00 69910 N E ie quiessy JO8UO 10 17956 00 80600 00 91910
10. 70 991 01 7611 27 6611 508 09 468 HLIM NAOHS MIIA 00 9502 Q 428 1661 T b TE ES 00 10122 00 01912 80 9871 A 21 761 zi 289 1561 WA N N INJNJIV ld 1V230 00 1 2 2 0LI Vd1 V 11130 335 i A NI ee 6 ki 88 ical S oc ocztz dos 00 1600 01 711 00 26861 2091 5619 00 1686 y J 1 1L01 00 192 lt 2 00 092 lt 2 00 65222 REVISION G Section 3 General Information 23280 00 Spartan PLC Assembly 221 lt 1101 INJW3IV 1d 1V 10 10 151 455 0 92091 80 9871 21 7511 AB on 11
11. 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 52 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 GIASCESA 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 8 EXTERNAL MIX POLYESTER EQUIPMENT CHOPPER 8 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 5845 WEST 82nd STREET
12. N REVISION 35 Section 3 General Information 21668 01 Spartan Gun Parts List Part Part BALVAVE RM 856 04 21667 00 BALL VALVE 36 REVISION E Section 3 General Information 21668 02 Spartan PLC Gun 8212 1 3 Part EP 20735 04 3 20796 02 20878 00 21454 00 21668 01 222130 2213 00 T7494 LOCK WASHER 6 stz6c s 37 REVISION Section 3 General Information 23547 01 Check Valve Assembly a Not included with 23547 01 assembly 22908 00 23524 01 22906 00 23540 00 S 21044 02 22904 00 A 21616 00 AX 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 38 REVISION E Section 3 General Information 20941 00 Catalyst Bottle Assembly im 20934 00 LPA 172 20390 00 20939 00 20940 00 21044 01 21039 00 21040 00 LPA 172 BOTTLE SUPPLY FILTER 20390 00 FITTING 20934 00 JUG CAP 39 REVISION G Section 3 General Information GAM 268 01 Material Pick Up Kit 20395 00 20398 02 20394 00 Part Filter Options Part Description Number P 20397 02 100 20397 03 50 20391 01 20 D Section 3 General Information 21654 01 Solvent Pot Assembly 23
13. 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 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 ZX WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury A ELECTRICAL SHOCK HAZARD Indicates a hazardous situation which if not avoided could result in electrical shock or serious injury The information in this document is intended only to indicate the components and their normal working relationship typical use Each assembly should be directed by a GlasCraft distributor or made from the GlasCraft Assembly instructions provided This manual provides information for the assembly opera tion maintenance and service of this GlasCraft product as used ina typical configuration While it lists standard specifi cations and procedures some deviations may be found In order to provide our users with the most up to date technolog
14. ADVANCED DISPENSE eee INDIANAPOLIS INDIANA 46278 www glascraft com U S A GC 1368 Phone 317 875 5592 REVISION G 1 Fax 317 875 5456 E Mail sales glascraft com
15. Yellow light on lt 8 HH 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 CATALYST 16 Section 2 Operation New System Start Up OPTIONAL MOLD SCAN TAG WRITE READ WAND 2 F n Daf 7 FLUSH SET UP SETUP SETUP 4 Z 22 7 SETUP 2 SETUP 5 2 9 MANUAL SETUP 3 MOLD SCAN Z EN n MOLD TAG WRITE Z SETUP MANUAL INJECTION START POSITION STOP POSITION PUSHFOR MOLD SCAN SETUP TOTAL STROKES 277 Z 2 00 3 00 2 Z WRITE WV Y MOLD SCAN FLUSH RETURN START POSITION TOTAL 2 STROKES 2 00 EJ 2 CYCLE STATUS BE s START SET UP SELECT VA 2 GY POP UP KEYPAD CO GO ENTER STROKES I EI c ea 09 Ga UP PE 2 00 ENTER PASSWORD 5208 00108 PUSH AFTER PASSWORD IS ENTERED SCREEN TAG WRITE WILL BE DISPLAYED 9100 PASSWORD
16. Do not use Halogenated Hydrocarbon solvents in pres Aa T y fluid f havi lumi 28 other reason If however diluents are absolutely required ict OE 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 ys GlasCraft is aware of NO stabilizers available to NWARNING V 2 fin od Hy sss SO Veni MOm t If diluents are not used it should be remembered that cat we se pk aaa ou A TE components alyst spillage gun hose and packing leaks are potentially more hazardous since each drop contains a higher aei q tration of catalyst and therefore will react quicker with over alogenate ydrocarbon solvents are dangerous spray and the like when used with aluminum components in a closed fluid system 2 5 Uncured Liquid Resin Consult your material supplier to determine whether Resin should be stored in a well ventilated building your solvent or coating contains Halogenated Hydrocar atleast 50 feet from your main plant In addition the bon Solvents storage temperature should not exceed 75 degrees F 45 Section 4 Safety Information In your main plant store only enough resin one day s production NO SMOKING signs must be posted and observed in all areas where resin is stored and or used Refer
17. Type of Fire Extinguishing equipment recommended Fire Extinguisher code ABC rating number 4a60bc Extinguishing Media Foam Carbon Di oxide Dry Chemical Water Fog Copies of the above bulletins are available at a nominal charge from National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 Research Report No 11 of the American Insurance Association deals with Fire Explosion and Health Hazards of Organic Peroxides It is published by American Insurance Association 85 John Street New York New York 10038 Local codes and authorities also have standards to be followed in the operation of your spraying equip ment Your insurance carrier will be helpful in an swering questions that arise in your development of safe procedures 1 2 Personnel Safety Equipment GlasCraft recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems EYE HEARING PROTECTION PROTECTION CAUTION GLOVES REQUIRED IN THIS AREA BREATHING PROTECTION Section 4 Safety Information 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
18. and grounded to dissipate static electricity For further information see National Fire Protec tion Association NFPA 77 titled Recommended Practice on Static Electrical Refer especially to Sec tion 7 7 titled Spray Application of Flammable and Combustible Materials Check with local codes and authorities for other specific standards that might ap ply to your application GlasCraft provides a grounding wire and clamp 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 x All statements information and data given herein are believed to be accurate and reliable but are pre 49 sented without guaranty warranty or res
19. 3 General Information 23280 00 Computer Cable Connections 23296 00 OUT TO SERVO MOTOR a o ou 25 gt amp q 5 CN CN e om gt gt 8 lt E a a a o 2 o 23295 00 28 REVISION G Section 3 General Information 23250 00 Spartan PLC Control Box 15544 02 4342 04 9612 16 23257 00 TM 23282 00 21402 00 8115 03 23228500 ASSEMBLE 50 DECAL EL RM 18199 02 IS ORIENTED THIS WAY RI 23204 00 27727 23019 02 23012 00 H 23015 01 2 23014 00 lt gt 23013701 A 23229 00 ME view A B yvIEW 77 view D 23211 00 PA SS o On ces Es M 6F 6 23201 01 19916 00 1134 04 23236 00 DO 9 o 23208 00 1133 01 vi 23209 00 S s
20. 5811 S 10 061 455 An 2 211 4552 TE 2 UR 81 455 58 291 1058 p 123 00 16961 00 56252 n 272 5566 ME 9 00 68861 sona Qn 00 81282 611 455 00 N 00 962 2 00 52 lt 2 01 PELL e E 00 162 2 2091 6618 H 10 69262 10759058 00 69262 en Section 3 General Information 23280 00 Spartan PLC Assembly 20188 16C 1486 13 N REVISION Section 3 General Information 23280 00 Spartan PLC Assembly Z 3001 3018 2 5 21 20212 3911 3018 2 5 21 60210 w YE AN RA A lemel NEZ emel NEZ 30 getto 0 0 0c12 101134 4 60 50616 lt 27 49312 3070 4871 28 629 403 51474 3105 3339 60 50616 f N
21. Safety Manual It is very important for the safety of employees involved in the operation that equipment operators mainte nance and supervisory personnel understand the requirements for safe operation Each user should examine his own operation de velop his own safety program and be assured that his equipment operators follow correct procedures GlasCraft hopes that this manual is helpful to the user and recommends that the precautions in this manual be included in any such program GlasCraft recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual GlasCraft recommends that the user consult the regulations established un der the Occupational Safety amp Health Act OSHA particularly the following sections 1910 94 Pertaining to ventilation 1910 106 Pertaining to flammable liquids 1910 107 Pertaining to spray finishing operations 42 Section 4 Safety Information 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 NFPA No 33 Chapter 14 Organic Perox ides and Dual Component Materials NFPA No 63 Dust Explosion Prevention NFPA No 70 National Electrical Code NFPA No 77 Static Electricity NFPA No 91 Blower and Exhaust System NFPA No 654 Plastics Industry Dust Hazards
22. UP SET UP 1 SET UP 4 SET UP 2 SET UP 5 MANUAL SET UP 3 SET UP 6 INJECTION SET UP MANUAL INJECTION Section 2 Operation New System Start Up Solvent Flush Programing 9 Follow the instructions below for touch screen operations Z Before initial operation of any internal mix system gt make certain the solvent flush set up is fully SCREEN 2 operational SYSTEM SET UP SCREEN 4 x Since the system is an internal mix system mixer requires flushing with air solvent air after each dispense Or before the mixed material starts to gel P 5 Make sure solvent regulator is dialed to zero Turn knob fully counter clockwise and turn the PLUSH SET UP y SETUE SE yk SET UR ball valve to the closed position SETUP 2 SET UP 5 MANUAL SET UP 3 SET UP 6 INJECTION SET UP MANUAL INJECTION LO PUSH FOR FLUSH SET UP SCREEN CU SCREEN 3 SCREEN WHEN FLUSH UP IS SELECTED 6 Carefully relieve any pressure in the solvent tank by slowly pulling the relief valve FLUSH SET UP AIR FLUSH SOLVENT FLUSH TIME SECONDS TIME SECONDS BACK T After all the pressure is released from the tank open PUSH the li
23. be relied upon to prevent the explosive reaction Such coatings can Adequate ventilation as covered in OSHA Section 1910 94 be worn cracked scratched or too thin to prevent con and NFPA No 91 is important wherever solvents are stored tact There is no known way to make oxide coatings or used to minimize confine and exhaust the solvent va to employ aluminum alloys which will safely prevent the pors Solvents should be handled in accordance with OSH chemical reaction under all circumstances Section 1910 106 and 1910 107 Several solvent suppliers have recently begun promoting E HHC solvents for use in coating systems The increasing 2 4 Catalyst Diluents use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans GlasCraft spray up and gel coat systems currently produced as Volatile Organic Compounds VOC s their low flam are designed so that catalyst diluents not required mability hazard and their not being classified as toxic or GlasCraft therefore recommends that diluents not be used carcinogenic substances HHC solvents are very desir This avoids the possible contamination which could lead to able in many respects an explosion due to the handling and mixing of MEKP and diluent In addition it eliminates any problems from the di NWARNING luent being contaminated through rust particles in drums oor quality control on the part of the diluent supplier or an
24. material while keeping recirculation return hose in hose in a waste container 10 Section 2 Operation New System Start Up 15 Turn machine to recirculation ON 2 Turn the catalyst valve on the dispense gun to recir culation position arrow on valve should point away S 8 from gun block 16 Let material pump cycle slowly until a steady stream of clean material is seen recirculation hose 17 Switch machine recirculation to OFF A make sure all the air is purged out of the catalyst 9 No 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 18 Secure recirculation hose in the material supply valve to the open position container C Hand prime the pump until a steady stream of cat X Dispose of resin in the waste container a proper alyst flows back to the bottle manner d Close the ball valve Catalyst Start Up 1 Safely fill the catalyst supply bottle P N LPA 165 4 Set the catalyst slave pump to 3 0 percent maximum two gallons with preferred MEKP catalyst to a minimum level of at least two inches above the Z For system that have PAC Progressive Automatic catalyst bottle outlet fitting E gt Catalyst refer to manual injection procedures for instructions on how to set the
25. polyester overspray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels 4 Never add MEKP to anything that is hot since explosive decomposition may result 5 Avoid contact with skin eyes and clothing Protective equipment should be worn at all times During clean up of spilled MEKP personal safety equipment gloves and eye protection must be worn Fire fighting equipment should be at hand and ready 6 Avoid spillage which can heat up to the point of self ignition 7 Repair any leaks discovered in the catalyst system immediately and clean up the leaked catalyst at once in accordance with the catalyst manufacturer s instructions 8 Use only original equipment or equivalent parts from GlasCraft in the catalyst system i e hoses fittings etc because a dangerous chemical reaction may result between substituted parts and MEKP 9 Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries should never be returned to the supply tank such catalyst should be diluted with copious quantities of clean water and disposed of in accordance with the catalyst manufacturer s 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 NWARNIN
26. to OSHA Section 1910 94 1910 106 1910 107 and consult resin suppliers for more detailed informa tion Adequate ventilation as covered in OSHA Section 1910 94 and NFPA No 91 is important wherever sol vents are stored or used to minimize confine and ex haust the solvent vapors Resin must never be stored in an area where MEKP is stored or used Open top drums should not be used due to possible contamination and possible catalyzation from overspray or spillage of MEKP into drum which could not only se verely damage the polyester spray system but might also cause the drum of resin to ignite When spraying test patterns or purging the gun always remove the test samples and waste from the building im mediately and dispose of them in accordance with your material supplier s recommendations 2 6 Cured Laminate Overspray and Laminate Sandings Accumulation Remove all accumulations of overspray FRP sandings etc from the building as they occur If this waste is al lowed to build up spillage of catalyst is more likely to start a fire In addition the fire would burn hotter and longer Floor coverings if used should be non combustible Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product oversprayed chop or resin FRP sandings or any other material with MEKP To prevent this spillage and leakage you should 1 Maintain your GlasCraft System Check the gun several times daily
27. used Methyl Ethyl Ketone Peroxide MEKP 2 The flammability dangers of clean up solvents sometimes used GlasCraft recommends that clean up solvents be nonflammable and of resin diluents used such as styrene 3 The flammability dangers of catalyst diluents if used GlasCraft recommends that catalyst not be diluted 4 The flammability dangers of the uncured liquid resins used 5 The combustibility dangers of the cured laminate accumulations of overspray and laminate sandings 6 The toxicity dangers of all the chemicals used in laminating operations with respect to ingestion inhalation and skin and eye hazards 2 2 Catalyst Methyl Ethyl Ketone Peroxide MEKP is among the more hazardous materials found in commercial channels The safe handling of the unstable reactive chemicals presents a definite challenge to the plastics industry the highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage transportation handling processing and disposal MEKP 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 MEKP and from possible trace impurities left from the manufacture of the chemicals bu
28. 1234 Pen 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 THE TAG READ BUTTON WILL BE ACTIVATED Z RFID tag pin 23290 00 Yo RFID tag carrier p n 23291 00 17 Section 2 Operation New System Start Up 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 a 3 Press Start Located on Touch Screen li 4 Press Injection ON Located on front control panel or on gun Injection ON 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 Sequen
29. 283 00 DECAL PLACEMENT Part mss so mowe zzzssoo TANK WARNING DECAL 1 __ gasowmmmwe wwe mms sus isoers wwwseeuumom sw eux 41 Operating Your Polyester System Safely 1 0 Introduction Any tool if used improperly can be dangerous Safety is ultimately the responsibility of those using the tool In like manner safe operation of polyes ter processes is the responsibility of those who use such processes and those who operate the equip ment This manual outlines procedures to be fol lowed in conducting polyester operations safely This system has been specifically designed for use of Polyester Resin Gel Coat and Methyl Ethyl Ke tone Peroxides MEKP applications Other formu lations or blends considered for use in this equip ment is strictly prohibited without the expressed consent by GlasCraft Inc GlasCraft Inc cannot eliminate every danger nor foresee every circumstance that might cause an in jury during equipment operation Some risks such as the high pressure liquid stream that exits the spray tip are inherent to the nature of the machine operation and 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
30. 3205 00 SELF RELIEVING PRESSURE REGULATOR 21203 02 YELLOW TUBING 1 4 IN 23208 00 SELECTOR SWITCH 21203 03 RED TUBING 1 4 IN 23209 00 ADAPTER VALVE 21203 04 BLUE TUBING 1 4 IN 23210 02 TUBE REDUCER 21203 05 GREEN TUBING 1 4 IN 23214 00 FITTING 21203 12 BLUE TUBING 5 32 IN 23215 00 MANIFOLD 21203 13 YELLOW TUBING 5 32 IN 23226 00 PRESSURE MOTOR AIR DECAL 21203 14 BLUE TUBING 3 8 IN 23228 00 ON OFF ACCU PRESSURE DECAL 21284 16C SCREW 23229 00 ACCU PRESSURE X 2 DECAL 21287 01 HEX NUT 23230 00 REMOTE INJECTION PORT DECAL 21308 20C SCREW 23232 00 PRESSURE SWITCH 21402 00 3 WAY VALVE 23233 00 NEEDLE VALVE 21454 00 MOUNTING BRACKET 23236 00 STROKE COUNTER RESET DECAL 21489 48C SCREW 23237 00 FITTING 21604 01 PLASTIC TUB PLUG 23237 01 FITTING 21669 00 CHECK VALVE 23257 00 CONTROL BOX 21678 00 RECIRCULATION DECAL 23258 00 PLATE EXTENSION 1 21722 00 MOUNTING BRACKET 23263 00 SMARTSTEP DRIVE 21823 00 DIN RAIL 23264 00 TERMINAL BLOCK 1 21861 00 CONDUCTOR CONNECTOR 23265 00 POWER SUPPLY 21889 00 FUSEHOLDER 23266 00 CPU 22104 00 EMERGENCY STOP DECAL 23267 00 22117 00 TERMINAL BLOCK 23268 00 OUTPUT RELAY 22171 01 SWITCH BLOCK 23270 00 POWERSUPPLY 22174 01 SWITCH BLOCK COVER 2327 1 00 TOUCHSCREEN 22178 00 ON OFF SWITCH 23272 00 SELECTOR SWITCH 22212 01 BULKHEAD FITTING 23273 00 SELECTOR KNOB 22212 02 BULKHEAD FITTING 23274 00 STATION MANIFOLD 22218 00 PUSH ON HOSE FI
31. G A hazardous situation may be present in your pressur ized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed pressurized fluid system pumps heaters fil ters valves spray guns tanks etc The explosion could cause serious injury death and or substantial property damage Cleaning agents coatings paints etc may contain Halogenated Hydrocarbon Solvents Some GlasCraft spray equipment includes aluminum or galvanized components and will be affected by Halogenated Hydrocarbon Solvents There are three key elements to the Halogenated Hydrocarbon HHC solvent hazard 1 The presence of HHC solvents 1 1 1 Trichloroethane and Methylene Chloride are the most common of these solvents However other HHC solvents are suspect if used either as part of paint or adhesives formulation or for clean up flushing 2 Aluminum or Galvanized Parts Most handling equipment contains these elements In contact with these metals HHC solvents could generate a corrosive reaction of a catalytic nature 3 Equipment capable of withstanding pressure When HHC solvents contact aluminum or galva nized parts inside a closed container such as a pump spray gun or fluid handling system the chemical reaction can over time result in a build up of heat and pressure which can reach explosive proportions When all three elements are present the result can be an extremely vio
32. Glascrart DISPENSING EXCELLENCE partan PLC RTM Injection System DISPENSING EXCELLENCE 5845 WEST 82ND STREET INDIANAPOLIS INDIANA 46278 U S A Phone 317 875 5592 Fax 317 875 5456 Email gcisales glascraft com Web www glascraft com lt LD Z lt ma 2 YS LD Table Of Contents Section 1 Installation 1 1 IntreduetlO e Ee eee 1 122 Stanidard EQquIPMENt OL 2 1 3 System Installation ii 3 Section 2 Operation 2 1 New System Start up Instructions 5 2 2Shut dOowrlnstruetlOnS eae Me deu 19 2 3 Operation notes sr iE a ma a 20 2 4 ROUTING Care eae uha oe oou 21 Section 3 General Information 3 1 Assembly Drawings a en ea ee edge edd ce deve eee ne den 22 3 2 Sub Assembly Drawings rre te Ee asad Oen E EEG UE E CORDE e ERA 38 Section 4 Safety Information 4 1 Operating Your Polyester System Safely 42 4 2 NOUS ico SE EAE EE tis 50 4 3 Limited Warranty Policy 51 4 4 Technical Assistance Avoided e einer ero UR 52 For Your Reference INSIDE BACK COVER Section 1 Installation Introduction
33. NG CLAMP 18245 02 HEAT SHRINK TUBING 19845 00 FRP LITERATURE 19882 00 MAST CAP 19889 00 MOUNTING ADAPTER 19891 00 PIPE CLAMP 19892 00 COVER PLATE 20188 16C SCREW 20190 30 CATALYST HOSE 30FT 20195 30 MATERIAL HOSE 3 8 ID 20368 00 SWIVEL CASTER 3 IN 20569 00 G2 SUPPORT MAST 20732 01 RED TUBING 5 32 IN N 20732 02 4 15 2 BLUE TUBING 5 32 IN 3 20732 06 GREEN TUBING 5 32 IN 20864 06 SPARTAN PUMP 20941 00 CATALYST JUG 7957 32F 20945 00 RECIRC CATALYST ASSEMBLY 7957 48C 21054 01 NYLON TUBING 8155 160C 21203 02 YELLOW TUBING 1 4 IN 21203 03 RED TUBING 1 4 IN 9704 11 P E TUBING 9704 83 RED P E TUBING 9944 20C crew GAM 268 01 PICK UP TUBE 21203 05 GREEN TUBING 1 4 IN 21203 12 BLUE TUBING 5 32 IN 21203 13 YELLOW TUBING 5 32 21203 15 SCRI SCRI SCRI SCRI SCRI 8212 20F SCRI SCRI SCRI ORANGE TUBING 5 32 IN SCRI SCRI EW EW EW EW EW EW EW EW EW EW 21654 02 SOLVENT TANK 21663 00 MOUNTING BLOCK 21668 02 SPARTAN II PAC GUN 21670 00 TANK SUPPORT 21674 00 GUIDE HOSE 21694 25 MATERIAL HOSE 22701 00 MX 2 BASE 23231 00 SPARTAN II DECAL 23250 00 CONTROL BOX 23251 00 MOUNTING BRACKET 23252 00 SERVO COUPLER 23253 00 SLAVE SLIDER 23254 00 SSP MOUNT 23255 00 SERVO ADAPTER PLATE 23256 00 ADJUSTMENT ROD 23259 00 HEX ADAPTER 23260 00 RECISION ROD 23261 00 SUPPORT RAIL 23262 00 SERVO MOTOR 27 REVISION G Section
34. Ne 1 cowpumNrr 2 SPADESOCKETTERMINALLUG 2 socket renmin 6 emo mso RupseReRoMMET 1 73eo6 RupmReRoMuET mes ____ 2 reo FENpERwAsHER 2 mem ws ____ 6 rene swe 1 mes 2 7 mew 6 ore 1 mem rockwaAsHER 6 7402 rockwAsHER 2 rockwAsHER 7 rockwAsHER mo rockwesHER 4 4 79002 ooPeRWREW4BACK mmm s sa 1 sexe s sew 2 eeoteec wemermme 1 mer sowo 2 7 e wme299 armer 1 1 cospeRP 1 33 REVISION E 115 VOLTS 1 PH ooo uu EMERGENCY STOP nnn 3 1 2 2 3 121 151 lal FU FU FU FL 2
35. TTING 23275 00 SOLENOID VALVE 22222 00 INJ EMERGENCY ACCU SHOT DECAL 23276 00 SOLENOID VALVE 32 REVISION E Section 3 General Information 23250 00 Spartan PLC Control Box Parts List Part Nimib t Description 23277 00 SOLENOID VALVE 23279 00 RUBBER SEAL 23281 00 NYLON BRACKET 23282 00 SPARTAN II PAC DECAL 23287 00 AIR FILTER 23287 01 AIR FILTER 3800 08 COPPER WIRE 18 BLACK 4342 01 ELBOW FITTING 4342 04 ELBOW FITTING 5307 01 CONDUIT NUT 5754 01 SPADE SOCKET TERMINAL LUG 5754 05 SPADE SOCKET TERMINAL LUG 6782 03 FITTING 7315 05 RUBBER GROMMET 7315 06 RUBBER GROMMET 7486 03 WASHER 7486 05 FENDER WASHER 7486 28 WASHER 7597 06 SWIVEL FITTING 7733 04 HEX NUT 7733 06 HEX NUT 7733 07 HEX NUT 7733 12 HEX NUT 7734 01 LOCK WASHER 7734 02 LOCK WASHER 7734 03 LOCK WASHER 7734 04 LOCK WASHER 7734 06 LOCK WASHER 7734 10 LOCK WASHER 7735 16C SCREW 7750 02 COPPER WIRE 14 BLACK 7966 03 FITTING 8115 02 FITTING 8115 03 FITTING 8115 04 FITTING 8155 40C SCREW 8212 48F SCREW 8301 96C SCREW 9672 16 NIPPLE FITTING 9943 16F SCREW 9944 20C SCREW ISD 141 3 MINI REGULATOR MPB 208 AIR FILTER RM 856 05 ELBOW FITTING RS 141 01 CORD GRIP RS 141 02 CORD GRIP 1 2 1 o 1 29326200 sPARmANWPACDECAL 1 meno 0 1 ARPER ooPERWREWeBLAK gmowmmmNeo gmowmmm
36. WASTE 7 Attach the green material hose CONTAINER to the material pump 8 Insert the end of the recirculation hose into a wast container Section 2 Operation New System Start Up Console Functions EMERGENCY STOP Shuts off operation Twist red knob to reset emergency stop start button must be pushed to restart 201 SYSTEM START BUTTON AIR PURGE Push Button POWER SWITCH ACCU PRESSURE X2 Pressure ACCU PRESSURE Regulator 4 MAGIC BULLET 6 9 I II I NETT Er may LAU 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 New System Start Up 1 Open the air valve by pushing the yellow slide on the valve 2 Turn on the main power 3 Press the start button Section 2 Operation New System Start Up START UP SCREEN WHEN POWER IS TURNED ON PLEASE PRESS INITIALIZE SYSTEM INITIALIZE SYSTEM NOT FOR USE IN EXPLOSIVE AREAS 4 Push for set up screen SYSTEM SET UP SCREEN FLUSH SET
37. alysts If at any time the pressure relieve valve on top of the catalyst tank should vent the area should be evacuated at once and the fire department called The venting could be the first indication of a heat and therefore pressure build up that could eventually lead to an explosion Moreover if a catalyst tank is sufficiently full when the pressure relief valve vents some catalyst may spray out which could cause eye injury For this reason and many others anyone whose job puts them in an area where this vented spray might go should always wear full eye protection even when laminating operations are not taking place 43 Section 4 Safety Information Safety in handling MEKP depends to a great extent on employee education proper safety instructions and safe use of the chemicals and equipment Workers should be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users 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
38. catalyst pump to 396 A using the touch screen Remove the catalyst bottle P N 20941 00 from catalyst it ls isuelly acaneral practice when starina tie The bottle bracket P N LPA 169 for filling The bottle should yag up system to let system recirculate with the catalyst be placed at or below lowest level for safe filling Never slave pump set at 3 0 This ensures good catalyst fill the catalyst bottle while mounted in bracket as 211 volume movement through the system to remove air personal injury from catalyst spillage could result in the catalyst system 5 Re engage the catalyst pivot knob This step is not necessary if the system is equipt with PAC option 11 Section 2 Operation New System Start Up 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 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 W ot 2 Turn machine to recirculation ON
39. cer The injection ON will restart sequencer TAG WRITE READ WAND Z22228 25 57 CATALYST 6 FLUSH SYSTEM TAG READ 15 ACTIVATED a Press Air Flush Button 2 7 L Z 4 READ MOLD SCAN TAG WRITE e FLUSH 4 2 e e 9 START POSITION STOP POSITION A TOTAL A Z IEEE STROKES LI U LLTU t 200 21 3 00 57 STOPPED 7 b Press Solvent Flush Button START SETUPSEECT stop 2 77 gt 9 2 5 4 9 e e e 1 USING THE TAG READ WRITE WAND SCAN THE MOLD CHIP THAT IS TO BE INJECTED THE WRITTEN CHIP DATA WILL BE EE 7 THE SCREEN PRESS START TO POSITION SERVO MOTOR WHEN READY TO INJECT i kiy ki EON ECT PRESS INJECT ON BUTTON AT THE GUN Press Air Flush Button 8 _ After Injection Sequencer has been completed Yo the pump will stop and Flush indicator will flash SATIS gt lt x If Adjustment needs to be made on the timing of the gt Air or Solvent See Flush Set Up 18 Section 2 Operation Shut Down Procedure 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 and cleaned to assure trouble free 7 Shut down main air supply by closing yellow lock out start
40. d and fill the tank with a suitable clean flushing POP UP POP UP solvent and close the lid securely KEY P DS RETURNS TO KEY PADS AIR FLUSH SET UP peo 8 Turn solvent regulator clockwise to approximately SECONDS SEREEN 2 SECONDS 80 psi and turn the ball valve to the open position THE TIME SETTINGS THAT ARE 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 for air flush initial set up 3 5 seconds is recommended for solvent flush initial set up Section 2 Operation New System Start Up 10 Place injection nozzle over a proper waste con 2 Before operating the material pump flush thoroughly tainer Press the solvent button located on the with a clean suitable solvent to remove test fluid 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 remaining solvent amp GlasCraft uses test fluid that may not be compatible from the gun head with some resins Then it is recommended that the test fluid be flushed from the material pump fluid section 4 Z Make sure hose fittings on the pick up hoses are tight 3 Place the material pick up tube into a container of clean suitable solvent IURI 11 Exhaust air through the gun head until traces of solvent have been diss
41. ed with particles To ensure that the catalyst system is totally hydraulically tight it is expedient after a period of shut down that the pro cedures in the instructions for commissioning the catalyst stream should be repeated 20 Section 2 Operation Routine Care GlasCraft recommends that you contact your gel coat Routine Care 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 21 gt 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 your material suppliers as well as GlasCraft Consult your local authorized GlasCraft distributor for more information concerning system storage Section 3 General Information 23280 00 Spartan PLC Assembly REVISION G
42. els can be as high as 116 dB decibels The ON position the valve handle is parallel in line This equipment should only be operated or serviced by with the valve body technically trained personnel The OFF position the valve handle is perpendicular across the valve body Never place fingers hands or any body part near or di rectly in front of the spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DI RECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PER SON TREAT THE GUN AS IF IT WERE A LOADED PIS TOL 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 47 3 2 General Safety Precautions The following general safety precautions should be followed when servicing or operating this equip ment to ensure operator safety When filling catalyst container protective eye equipment must be worn to protect against injuries Always maintain adequate material levels to prevent loss of prime during system operation At the first sign of a leak stop operations acti vate emergency stop valve back off air regula tors and open all bleed valves to remove all pressure from the gun hoses pump catalyst system and any other liquid co
43. 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 manufacturer s warrantie
44. et up options depending on the system FLUSH SET UP SETUP SETUP 4 SET UP 2 SET UP 5 MANUAL SET UP 3 SET UP 6 INJECTION SET UP MANUAL INJECTION SCREEN WHEN SET UP 1 THRU 6 IS SELECTED 2 m REPEAT SET UP STEPS e FOR SET UP 2 THRU 6 SET UP 1 CONFIGURATION FLUSH FLASHES WHEN TOTAL EUSH STROKES HAVE BEEN REACHED IT WILL ALSO FLASH IF STOP START POSITION STOP POSITION IS PUSHED A TOTAL A PUSH AOR ARROWS 2 00 2 00 PUSH ARROWS TO SELECT THE CYCLE STATUS TO SELECT THE ENDING STARTING CATALYST w STOPPED CATALYST PERCENT PERCENT 77 AFTER THE REQUIRED 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 POSITIONING PROGRAM WILL START OVER TO 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 ea SELECTED ao a 025 gallons per stroke 95cc per stroke CS PRESS 15 Section 2 Operation New System Start Up
45. for catalyst and resin packing or valve leaks REPAIR ALL LEAKS IMMEDIATELY 2 Never leave the gun hanging over or lying inside the mold A catalyst leak in this situation would certainly damage the part possible the mold and may cause a fire 3 Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom sections and at the gun and fittings Replace if wear or weakness is evident or suspected 4 Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub against any of the hoses at any point If allowed to rub the hoses may be cut through causing a hazardous leakage of material which could incr ease the danger of fire Also the material may spew onto personnel in the area 2 7 Toxicity of Chemicals GlasCraft recommends that you consult OSHA Sections 1910 94 1910 106 1910 107 and NFPA No 33 Chapter 14 and NFPA No 91 Contact your chemical supplier s and determine the toxicity of the various chemicals used as well as the best methods to prevent injury irritation and danger to personnel Also determine the best methods of first aid treatment for each chemical used in your plant 2 8 Treatment of Chemical Injuries Great care should be used in handling the chemicals 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 GlasC
46. ipated 1 4 Place the recirculation hose into a suitable solvent Resin Start UP waste container 1 Fill material pump lube cup with proper pump lube 5 Turn main valve on the gun head to the recirculation position Towards the hoses 1 26 44 HHB Section 2 Operation New System Start Up 6 Turn the material air regulator OFF counter clock 9 The pump should cycle clean solvent through the wise system and out the recirculation hose 10 End recirculation when solvent appears reason ably clean OFF 1 SID 7 Switch machine recirculation to ON 2 8 z 9 11 Remove material pump pick up tube from solvent container and dry thoroughly 12 Switch machine recirculation to wise until gauge indicates 10 PSI or until pump cycles slowly 8 Turn the material injection regulator slowly clock 13 When solvent has stopped exiting the recirculation hose end recirculation OFF W 9 DJ r r 14 Place material pick up tube in desired container of
47. lent explosion the reaction can be sustained with very little aluminum or galvanized metal any amount of aluminum is too much Section 4 Safety Information GlasCraft recommends that you contact your solvent The reaction is unpredictable Prior use of an HHC sol supplier regarding the best non flammable clean up solvent vent without incident corrosion or explosion does NOT with the heat toxicity for your application mean that such use is safe These solvents can be dan gerous alone as a clean up or flushing agent or when If however you find it necessary to use flammable solvents used as a component or a coating material There is they must be kept in approved electrically grounded con known inhibitor that is effective under all circumstances tainerSs Furthermore the mixing of HHC solvents with other Bulk solvent should be stored in a well ventilated materials or solvents such as MEK alcohol and tolu separate building 50 feet away from your main plant ene may render the inhibitors ineffective You should allow only enough solvent for one day s use in The use of reclaimed solvents is particularly hazardous your laminating area Reclaimers may not add any inhibitors Also the pos sible presence of water reclaimed solvents could feed NO SMOKING signs must be posted and observed in all the reaction areas of storage or where solvents and other flammable ma terials are used Anodized or other oxide coatings cannot
48. lso cause all the system for at least 15 minutes or more These general instruc air to bleed out of the system in a matter of a tions of first aid treatment however may be incorrect for few seconds thus making the system some chemicals that is why you must know the chemi incapable of operating cals and treatment before an accident occurs Treatment for swallowing a chemical frequently depends upon the Step 2 is a precautionary step and should be followed nature of the chemical whenever the emergency stop valve is activated to the stop mode Failure to do so will damage regulators __ Refer to your System User Manual for complete and components when reactivating to the ON position and detailed operating instructions and service information 2 Turn all system regulators to OFF counter clockwise position Verify that the Catalyst Pressure Relief Line and the 3 0 Equipment Safety Wto Resin Return Line are secured before relieving catalyst and resin fluid pressure WARNING GlasCraft suggest that personnel safety equipment such 3 Catalyst pressure in the Slave Pump can be as EYE GOGGLES GLOVES EAR PROTECTION and eliminated by rotating the yellow valve handle RESPIRATORS be worn when servicing or operating this on the Slave Pump 90 degrees to the ON equipment Ear protection should be worn when operat position ing a fiberglass chopper to protect against hearing loss t since noise lev
49. n from the standard operation usually requires 7749 00 more maintenance to the equipment and material formulation to assure consistent results For example the use of fillers in resins amp w Refer to specific user manuals if available for N 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 TOSYSTEM 2 Attach 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 A air flow Whenever flammable or combustible liquids are transfered from one container to another both containers shall be effectively bonded and grounded to dissipate static electric ity For further information see NFPA 77 Recommended Practice on Static Electricity 5 Plug the electrical cord into a 110 outlet Before turning on main air Li a check all fittings making certain they are securely wass tightened Li b Make sure all regulators are set to zero all the way to the left This should be done before air or material of any kind is introduced into the system Section 1 Installation 6 Attach the green material hose to the pick up tube and insert the tube into a bucket of clean solvent lt w Recirculation hose from the gun SOLVENT CONTAINER SOLVENT
50. ntainers Solvent Pot Pressure Relief Turn Solvent Pressure Regulator counter clock wise ccw until regulator handle stops Open Petcock valve to bleed Solvent Tank pressure completely Catalyst Injector Pressure Relief Refer to Catalyst Injector User Manual for proper pressure relief Never operate a Fiberglass System with fixed Pinch Point guards removed from system 48 Section 4 Safety Information Do not operate Fiberglass Chopper Guns with out protective covers in place Correct packing or valve seat leaks immediately Never immerse the gun in any liquid Periodically check operation of catalyst alarms to make sure they are operation properly Frequently check condition of hoses Replace worn hoses and other parts before they fail Catalyst fluid nozzles and seals MUST be in good condition at all times to prevent internal and external leaks Inspect periodically and replace as needed or at intervals of three to four months Use catalyst nozzle seal only once to prevent possible leakage of catalyst into air passages of gun Make absolutely certain that all pressure has been relieved from the gun before disassembly from the hoses before loosening any fittings from the material or catalyst pump before disassembly from the catalyst injector before disassembly or filling If you have any doubt that fluid pressure is relieved call your GlasCraft distributor or GlasCraft Inc before proceeding with any disassembl
51. oved from the system It is absolutely essential that both streams of material are pumped to the head without air or gas entrapped For example if air is drawn into the resin stream through the resin pump inlet system i e via bad connection or filter end coming out of resin surface then this air if not purged out of the machine by recirculating on by pass will naturally go to the head through the mixer and into the RTM mold This fault condition will manifest itself in the molded part having very small bubbles almost in a froth like state on the upper side of the molded part once the mold is opened The reason for these bubbles being so small is due to the fact that air coming through the mixer with the resin is mixed and frothed before finally entering the mold Air or gas in the catalyst stream leads to a different type of fault in the molded part This condition will be manifest by observing when opening the mold after injection and supposed cure that there are wet patches of uncured or semi gelled resin in the molded part The causes attributed to this are 1 Air is drawn in by the catalyst pump through a bad connection on the inlet stream from the catalyst container or pump inlet connection 2 Catalyst contamination in the pump system causing oxidation resulting in peroxide gas bubbles being generated within the supposedly hydraulic sealed system of the catalyst 3 The catalyst pump has faulty seals or is contaminat
52. ponsibility 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 GlasCraft warrants to the original Purchaser of GlasCraft manufactured equipment and parts that all GlasCraft manufactured equipment and parts will conform to their published written specifications and be free of defects in workmanship and material for a period of one 1 year from the original date of installation GlasCraft makes no warranty to anyone other than the original Purchaser 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
53. raft recommends the use of protective clothing and eye wear in using polyester systems However users should be prepared in the event of such an injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals may have 46 Section 4 Safety Information 3 1 Emergency Stop Procedures 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 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 Fast treatment of the outer skin and eyes that contact enters the machine should be pushed to such chemicals generally includes immediate and thor the OFF closed position To do this simply ough washing of the exposed skin and immediate and push on the lever protruding out the side of continuous flushing of the eyes with lots of clean water the valve This will a
54. s 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 51 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 phone GlasCraft
55. t may also arise by contamination of the MEKP with other materials in its storage or use Even a small amount of contamination with acetone for instance may produce an extremely shock sensitive and explosive compound Contamination with promoters or materials containing promoters such as laminate sandings or with any readily oxidizable material such as brass or iron will cause exothermic redox reactions which 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 cat
56. up the next time the system is to be operated valve 1 Confirm that both ball valves are in the recirculation position OO 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 TI pump and hoses be flushed with a neat resin and that the neat resin is flowing through the system and exiting the material recirculation hose thoroughly before shut down procedures are completed 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 2 Operation Operation Notes Operation Notes x Before altering catalyst percentage by moving the gt catalyst pump to a new desired location on the ratio arm ALWAYS ensure that the catalyst recirculation valve is turned to the recirculation position and the air pressure is rem
57. y Use only genuine GlasCraft replacement parts when repairing your system Substitutes may not be the proper material or may not fit the system and may cause dangerous operating conditions and the failure of other components Section 4 Safety Information 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
58. y 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 MODEL 23280 00 Standard Equipment Part Description Number 23280 00 Spartan PLC 17440 00 Grounding Clamp Assembly GC 1368 Section 1 Installation The Spartan II PLC comes complete and fitted with all 3 Attach Grounding Clamp Assembly P N 17440 00 to resin hoses catalyst bottle and filters The injection System Use a convenient Nut and Bolt to secure Lug head is fully connected to the machine circuit and P N 13193 00 to system tested and secured against leaks prior to dispatch 4 Securely attach Clamp P N 7749 00 to permanently _ The following instructions are to be used as a guide grounded rod or pipe gt for consistent and continual operation Any devia tio

Spartan II PLC - Glas

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