23750-03 FORMULA Chopper Gun User Manual
Contents
1. To prevent this spillage and leakage you should 1 Maintain your GlasCraft System Check the gun several times daily for catalyst and resin packing or valve leaks REPAIR ALL LEAKS IMMEDIATELY 2 Never leave the gun hanging over or lying inside the mold A catalyst leak in this situation would certainly damage the part possible the mold and may cause a fire 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 resins catalyst and solvents used in polyester systems S2. S0 298 1 ZELT CN d 00 16Z Z 00 96 Z D 60 SEZOZ 60 9592 301 2128 20 298 1 mees 19260 991 8962 00 197 c 00 697 c 00 9LLE2 E L 00 088 REVISION C 00 8 Z 90 687 y 00 ZLLEZ 00 S96e2 Pap 00 ELL Z 00 v Z 00 78260 144774 L Section 3 General Information Assembly Drawings 23750 03 Formula X Chop Dispense Gun 00 06960 22027 abd Ov0 9111 S0 vvOLC 00 76960 wer a ap eer ST vo eee gt 00 rlec TE MAS el 00 98260 170 10460 10 92460 ASSV HLIM Q3r1adns LO S22E2 10 89260 O0 rLsoz 91 1 99 10 46960 REVISION C Section 3 General Information Assembly Drawings 23750 03 Formula X Chop Dispense Gun Part 23776 00 a 23778 00 23779 00 23780 00 l 23784 00 23786 00 23791 00 23792 00 23793 00 23796 00 23797 00 23798 00 23964 00 23965 00 2594 06 7486 05 7554 03 7554 05 7554 09 7554 10 7554 11 7554 14 7554 16 7554 21 7554 27 7554 28 7716 04C 7716 06C 7958 16C 8212 12F 8212 16F 8212 20F 8212 24F 8301 12C 9869 19 9936 04F A 63 19A Description Qtv BALL VALVE COMPRESSION SPRING STEEL BALL TAPERED SPRING RETAINING RING EXTERNAL ADAPTER COMPRESSION SPRING AIR GUN KIT SEAL KIT THREADED INSERT AIR SHIFTER CHOP HEAD GUARD TRIGGER PISTON ROLL PIN WASHER O RING O RING O RING O RING O RING O RING O RING O RING O
3. few seconds thus making the system incapable of operating Step 2 is a precautionary step and should be fol lowed whenever the emergency stop valve is acti vated to the stop mode Failure to do so will damage regulators and components when reactivating to the ON position 2 Turn all system regulators to OFF counter clockwise position Verify that the Catalyst Pressure Relief Line and the Resin Return Line are secured before relieving cata lyst and resin fluid pressure 3 Catalyst pressure in the Slave Pump can be eliminated by rotating the yellow valve handle on the Slave Pump 90 degrees to the ON position The ON position the valve handle is parallel in line with the valve body The OFF position the valve handle is perpendicu lar across the valve body 4 Resin pressure can be eliminated by rotating the yellow handled valve on the bottom of the fluid filter 90 degrees Place a container under the bottom of the valve to catch any resin that is ejected from the valve Section 4 Safety Information General Safety 3 2 General Safety Precautions Do not operate Fiberglass Chopper Guns with out protective covers in place The following general safety precautions should be Correct packing or valve seat leaks immediately followed when servicing or operating this equip Never immerse the gun in any liquid ment to ensure operator safety e Periodically check operation of catalys
4. 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 PER PRESSURE FED ROLLERS For more information concerning any of these GlasCraft products contact your local authorized GlasCraft distributor or visit www glascraft com Qualitv and Performance GENUINE GLASCRAFT Glascrart DISPENSING EXCELLENCE ADS N ken 5845 WEST 82nd STREET ADVANCED DISPENSE SYSTEMS INDIANAPOLIS INDIANA 46278 www glascraft com U S A Phone 317 875 5592 GC 1402 Fax 317 875 5456 REVISION C E Mail sales glascraft com
5. RING O RING SET SCREW SET SCREW SCREW SCREW SCREW SCREW SCREW SCREW SHOULDER SCREW SET SCREW O RING 21044 05 O RING CC 116 O RING CJ 136 CJ 137 LPA2 213 PG 18 O RING O RING END CAP TRIGGER REVISION C Section 3 General Information Maintenance Before attempting to perform any maintenance on this Spray Gun Relieve All Fluid and Air Pressures To relieve fluid and air pressures 1 Push down Yellow slide valve p n 21402 00 to bleed off air to system 2 Open p n 21228 00 on catalyst pump to recir culation position 3 Open p n 21192 00 on bottom of material pump 4 Verify the Trigger Lock is in the Locked posi tion It is recommended that the following service be performed on a daily basis 1 Valve Inspection Remove gear cover p n 23798 00 and inspect valves to see if there is any leakage on the top or bottom side of the valves if there is leakage with pressure relieved tighten packing nut p n 23764 00 1 8 to 1 4 turn until leak stops Verifv that there is no leakage Section 3 General Information Maintenance Parts Replacement Procedure 9 Lightly lubricate all O Rings with petroleum jellv 10 Check all springs for resilience They should Formula X Chop Gun return quickly to their original new length AN 11 Clean the exterior of the Gun and Hoses with an appropriate clean solvent and cloth or brush Before attempting to perform any maintenance on
6. by gears p n 23775 01 and tighten set screw 9 Activate air and retract gun trigger Loosen P N 23764 00 until valve rotate alternate adjustment if both valves were adjusted Section 3 General Information Options Dispense Tip Reference Chart Part RIT Note Use p n LPA2 120G and p n LPA2 121G when using LPA2 147 XXXX and 23047 XX series spray tips 10 Section 3 General Information Options Dispense Tip Reference Chart LPA2 147 XXXX Requires Seal P N 20333 00 and Retainer P N 22274 00 Part LPA2 147 1525 0 015 1540 0 015 1550 0 015 Part Ls LPA2 147 6225 0 062 6240 0 062 6250 0 062 6265 0 062 1565 0 015 1825 0 018 7240 0 072 1840 0 018 7250 0 072 1850 0 018 7840 0 078 1865 0 018 2125 0 021 2140 0 021 Note Use p n LPA2 120G and p n LPA2 121G 2150 0 021 when using LPA2 147 XXXX and 23047 XX 2165 0 021 series spray tips 2325 0 023 2340 0 023 2350 0 023 2365 0 023 2625 0 026 2640 0 026 2650 0 026 2665 0 026 3125 0 031 3140 0 031 3150 0 031 3165 0 031 3625 0 036 3640 0 036 3650 0 036 3840 0 038 3850 0 038 4325 0 043 4340 0 043 4350 0 043 4365 0 043 Indicates that these tips 5225 0 052 are made with A2 tool steel 5240 0 052 5250 0 052 5265 0 052 Part ES 23005 TC6 0 060 TO7 TE7 TG7 AA E 0X 11 Section 3 General Information Options Impingement Dispense Tip Reference Chart Part Orifice Min Max Min Max Number Wi
7. 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 thatthe 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 13 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 NFPA No 33 Chapter 14 Organic Perox ides and Dual Component Materials NFPA No 63 Dust Explosion Prevention NFPA No 70 National Electrical Code e NFPA No 77 Static Electricity NFPA No 91 Blower and Exhaust System NFPA No 654 Plastics Industry Dust Hazards Type o
8. to Catalyst Injector User Manual for before proceeding with any disassembly proper pressure relief e Use only genuine GlasCraft replacement parts when Never operate a Fiberglass System with repairing your System Substitutes may not be the fixed Pinch Point guards removed from system proper material or may not fit the system and may cause dangerous operating conditions and the failure of other components 19 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 s
9. your GlasCraft system contact your GlasCraft distributor or GlasCraft Inc In this GlasCraft technical and safety publication the following advisories will be provided where appropriate Is information about the procedure in progress Is imperative information about equipment protection CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury A WARNING Indicates a hazardous situation which if not avoided could result in death or serious injurv NELECTRICAL 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 in a typical configuration While it lists standard specifi cations and procedures some deviations may be found In order to provide our users with the most up to date technology possible we are constantly seeking to improve products If 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 dat
10. Glascrart Formula X Chop External Mix Low Emission L SS Z lt gt as Zi YS SS Table Of Contents Section 1 Installation 1 1 Introducti n EE 1 1 2 Standard Equipment eerte eate cule Ba debat 2 1 3 Speciflcations 5 5 ave oe Me cs A a VA A ae ta An N A 1 4 Equipment Assembly eo t co ten Ad LEI 3 Section 2 Operation 2 1 Start up Instr ctions A eda ved deel eles el de ees N A KN BEE een E Ed ee N A 2 3 Daily Start Up Instructions ii ii base eet A ae Ha Hr nen open en enden N A Section 3 General Information 3 1 Assembly Drawings 522 oet ete tenete erus to e Um d tee E a lot a He ba baja a a Fa 4 3 2 Sub Assembly Drawings eter e ce dote ene ENNEN Eed N A 3 9 Maintenance ti nece ett teat teque e I UR edu E 7 3 4 Troubleshooting tc t eoe de t t aede etae e n d ula eee eu etae B a uela eee eee deed N A Ri e EE 10 Section 4 Safetv Information 4 1 General Safety oil ad a dtt g a ra 12 4 2 Notes is i De RB DH Dali 20 4 3 Limited Warranty Policy nsa d e ee rn I Baur 23 4 4 Technical Assistance sisien 2 circo ei ren Syd Fe oe ne l e i 24 For Your Reference Uie A Dr ll INSIDE BACK COVER N A 7 Non 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
11. acking disks Tighten all threaded parts securely but not excessively upon assembiv O rings can fail if subjected to any of the following conditions a Swelling coming in contact with solvent or oil from compressor b Cut sharp unlubricated edge in gun head or handle c Sticky contaminated with oil water solvent catalyst resin or gel coat d Chaffing dry sliding surfaces needs lubrication Section 3 General Information Maintenance Ensure bores are clean before building material valves Insert bearing p n 23768 01 into gun body Insert seal p n 23763 00 into gun body Ensure holes in seal are aligned with holes in gun body 4 Place teflon washers p n 23721 04 on top and bottom of fluid valve p n 23743 00 5 Lubricate outside of fluid valve p n 23743 00 with a generous amount of Aqua lube 21266 00 and insert into seal with holes aligned with holes in the gun body 6 Insert bearing p n 23768 01 into gun body T a Use 7 16 six point socket to first snug P N 23764 00 to hand tight continue turn past snug Torque reading 20 ft lbs 88 Newton b Loosen turn and return until snug continue 14 turn past snug Torque reading 25 ft lbs 110 Newton c Loosen turn and return until snug continues 1 8 turn past snug Torque reading 30 ft Ibs 133 Newton 8 With piston p n 23755 00 pushed back in on posi tion Place packing disks p n 23721 04 followed
12. dth in Width in up 0929 Output E Se 28005 04 0010 __7_ 16 5 16 5 1002 BU 0 040 6 21 401 am EB 0000 6 155 861 1203 G4 00400 6 24 401 916 pK 00490 PPI 16 0000 8 28 621 1203 MG 0060 9 38 433 1148 00 pop ME cun MS Operating Vour Polvester Svstem Safel 1 0 Introduction Anv tool if used improperlv can be dangerous Safetv is ultimatelv the responsibilitv of those using the tool In like manner safe operation of polves ter processes is the responsibilitv of those who use such processes and those who operate the equip ment This manual outlines procedures to be fol lowed in conducting polvester operations safelv This svstem has been specificallv 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 Safety Manual It is very
13. e day s production NO SMOKING signs must be posted and observed in all areas where resin is stored and or used Refer to OSHA Section 1910 94 1910 106 1910 107 and consult resin suppliers for more detailed informa tion Adequate ventilation as covered in OSHA Section 1910 94 and NFPA No 91 is important wherever sol vents are stored or used to minimize confine and ex haust the solvent vapors Resin must never be stored in an area where 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
14. e 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 Formula X Chop Dispense Gun 23750 03 Standard Equipment Part Description Number p 23750 03 FORMULA X CHOP DISPENSE GUN GC 1402 USER MANUAL Repair Kits Part Number 23792 00 23793 00 23732 00 i 8 258 209 15 C C U m 10 545 267 84 n mm 3 484 88 49 Approximate Weight Ib kg wm Gun Only 2 lbs 14 0z 1 30 kg Optional B 410 2 lbs 120z 1 25 kg Optional B 510 3 Ibs 80z 1 39 kg Section 1 Installation Equipment Assembly How the Gun Works Hose Attachment Atomized Air The Formula X Chop Gun is an revolutionary design that Red reduces operator fatigue through reduced gun weight and enhanced maneuverabi
15. ed Methyl Ethyl Ketone Peroxide MEKP 2 The flammabilitv 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 flammabilitv 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 14 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 chem
16. efund the purchase price for the defective equipment or part A warranty claim will be honored only when 1 GlasCraft has been informed in writing of any such defect in workmanship or material within ten 10 days after discovery by the original Purchaser 2 An official of GlasCraft has issued a return authorization number and 3 The claimed defective equipment or part has been returned to GlasCraft by the original Purchaser freight prepaid with proper return authorization number s attached to GlasCraft Inc 5845 West 82nd Street Suite 102 Indianapolis IN 46278 U S A This warranty shall not apply to any equipment or parts that have been altered or repaired by anyone other than GlasCraft or to defects or damage resulting from improper installation misuse negligence accident or use not specified by GlasCraft This warranty shall not apply to any equipment where any parts or components were replaced by any parts or components not manufactured or supplied by GlasCraft The decision by GlasCraft shall be conclusive and binding on Purchaser GlasCraft does not warrant that any equipment or parts sold to Purchaser meet or comply with any local state federal or other jurisdiction s regulations or codes GlasCraft does not warrant that any equipment or part sold to Purchaser when used individually or in concert with any other part equipment device component or process does nat infringe on any patent rights of any third pa
17. emicals and treatment before an accident occurs Treatment for swallow ing a chemical frequently depends upon the nature of the chemical Refer to your System User Manual for complete and detailed operating instructions and service informa tion 3 0 Equipment Safety GlasCraft suggest that personnel safety equipment such as EYE GOGGLES GLOVES EAR PROTEC TION and RESPIRATORS be worn when servicing or operating this equipment Ear protection should be worn when operating a fiberglass chopper to pro tect against hearing loss since noise levels can be as high as 116 dB decibels This equipment should only be operated or serviced by technically trained personnel N WARNING Never place fingers hands or any body part near or directly in front ofthe spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PIS TOL 18 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
18. esin Diluents N WARNING A hazardous situation may be present in your pressur ized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed pressurized fluid system pumps heaters filters valves spray guns tanks etc The explosion could cause serious injury death and or substantial property damage Cleaning agents coatings paints etc may contain Halogenated Hydrocarbon Solvents Some GlasCraft spray equipment includes aluminum or galvanized components and will be affected by Halogenated Hydrocarbon Solvents There are three key elements to the Halogenated Hydrocarbon HHC solvent hazard 1 The presence of HHC solvents 1 1 1 Trichloroethane and Methylene Chloride are the most common of these solvents However other HHC solvents are suspect if used either as part of paint or adhesives formulation or for clean up flushing 2 Aluminum or Galvanized Parts Most handling equipment contains these elements In contact with these metals HHC solvents could generate a corrosive reaction of a catalytic nature 3 Equipment capable of withstanding pressure When HHC solvents contact aluminum or 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 res
19. f 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 gua HEARING HREATHING GLOVE REGU ECTS EYE PROTECTION PROTECTION PROTECTION Section 4 Safety Information General Safety GlasCraft recommends that the user consult the state and local regulations established for all Safety equip ment listed 2 0 Material 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 us
20. ic peroxide catalysts If at any time the pressure relieve valve on top of the catalyst tank should vent the area should be evacuated at once and the fire department called The venting could be the first indication of a heat and therefore pressure build up that could eventually lead to an explosion Moreover if a catalyst tank is sufficiently full when the pressure relief valve vents some catalyst may spray out which could cause eye injury For this reason and many others anyone whose job puts them in an area where this vented spray might go should always wear full eye protection even when laminating operations are not taking place Section 4 Safety Information General Safety Safety in handling MEKP depends to a great extent on employee education proper safety instructions and safe use of the chemicals and equipment Workers should be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users 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
21. icals 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 mav produce an extremelv shock sensitive and explosive compound Contamination with promoters or materials containing promoters such as laminate sandings or with anv readilv oxidizable material such as brass or iron will cause exothermic redox reactions which can become explosive in nature Heat applied to MEKP or heat build up from contamination reactions can cause it to reach what is called its Self Accelerating Decomposition Temperature SADT Researchers have reported measuring pressure rates of rise well in excess of 100 000 psi per second when certain MEKP s reach their SADT For comparison the highest pressure rate of rise listed in NFPA Bulletin No 68 Explosion Venting is 12 000 psi per second for an explosion of 12 acetylene and air The maximum value listed for a hydrogen explosion is 10 000 psi per second Some forms of MEKP if allowed to reach their SADT will burst even an open topped container This suggests that it is not possible to design a relief valve to vent this order of magnitude of pressure 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 organ
22. lity The Formula X Chop Gun is designed to be a true high Chopper Air volume low pressure gun The ports in the gun are large Red to allow for less back pressure and high flow of material Material Hose This is further achieved with large material hoses and Black low ratio pump standard 11 1 by properly setting the Catalyst Hose material pump pressure 85 100 PSI matching a spray Stainless Steel tip that will deliver desired output and usable spray pat tern not atomizing the material The gun is very user Trigger Air friendly Clear Example Because of the variables involved material viscosity sheer of material ambient temperature re AAC Air quired output your pressure setting will vary Black Before turning on main air check all On Off Ball Valves making certain all Valves are in the Off position and set all regulators in their Off position Turn knob counter clockwise for OFF or reduced pressure setting 1 4 OD Tubing Lightly lubricate all threads and o rings with a petroleum jelly before assembly Spray Head Assembly Trigger Lock Push in and rotate trigger lock p n 23774 00 to stop the trigger from being activated Note See gun assy drawings for part numbers and descriptions Section 3 General Information Assembly Drawings 23750 03 Formula X Chop Dispense Gun 90 77010 60 SE20Z 00 8682 910 9142 IEL LOEB Y 00 00 v96 c
23. low flam mability hazard and their not being classified as toxic or carcinogenic substances HHC solvents are very desir able in many respects 7 WARNING Do not use Halogenated Hydrocarbon solvents in pres surized fluid systems having 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 GlasCraft recommends that you contact your solvent supplier regarding the best non flammable clean up sol vent with the heat toxicity for your application If however you find it necessary to use flammable solvents they must be kept in approved electrically grounded containers Bulk solvent should be stored in a well ventilated sepa rate building 50 feet away from your main plant You should allow only enough solvent for one day s use in your laminating area NO SMOKING signs must be posted and observed in all areas of storage or where solvents and other flam mable materials are used Adequate ventilation as covered in OSHA Section 1910 94 and NFPA No 91 is important wherever sol vents are stored or u
24. materials including polyester overspray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels 4 Never add MEKP to anything that is hot since explosive decomposition may result 5 Avoid contact with skin eyes and clothing Protective equipment should be worn at all times During clean up of spilled MEKP personal safety equipment gloves and eye protection must be worn Fire fighting equipment should be at hand and ready 6 Avoid spillage which can heat up to the point of self ignition 7 Repair any leaks discovered in the catalyst system immediately and clean up the leaked catalyst at once in accordance with the catalyst manufacturer s instructions 8 Use only original equipment or equivalent parts from GlasCraft in the catalyst system i e hoses fittings etc because a dangerous chemical reaction may result between substituted parts and MEKP 9 Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries should never be returned to the supply tank such catalyst should be diluted 15 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 R
25. ome cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and grounded to dissipate static electricity For further information see National Fire Protec tion Association NFPA 77 titled Recommended Practice on Static Electrical Refer especially to Sec tion 7 7 titled Spray Application of Flammable and Combustible Materials Check with local codes and authorities for other specific standards that might ap ply to your application ue il GlasCraft provides a grounding wire and clamp as sembly p n 17440 00 with all FRP equipment 20 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
26. or operation procedures call your glascraft distributor or glascraft inc NOTICE All statements information and data given herein are believed to be accurate and reliable but are pre sented without guaranty warranty or responsibility of any kind expressed or implied The user should not assume that all safety measures are indicated or that other measures are not required Glascrart DISPENSING EXCELLENCE 5845 WEST 82nd STREET SUITE 102 INDIANAPOLIS INDIANA 46728 U S A PHONE 317 875 5592 FAX 317 875 5456 Section 4 Safety Information Notes 21 Section 4 Safety Information Notes 22 Section 4 Safety Information Limited Warranty Policy GLASCRAFT INC GlasCraft warrants to the original Purchaser of GlasCraft manufactured equipment and parts that all GlasCraft manufactured equipment and parts will conform to their published written specifications and be free of defects in workmanship and material for a period of one 1 year from the original date of installation GlasCraft makes no warranty to anyone other than the original Purchaser 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 r
27. rty GlasCraft only warrants that it has no specific knowledge of any such infringement GlasCraft makes no warranty as to any parts or equipment manufactured by others Purchaser shall look solely and only to the manufacturer of such parts or equipment with respect to any warranty claims GlasCraft hereby assigns to Purchaser the original manufacturer s warranties to all such equipment and parts to the full extent permitted THE AFORESAID WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IM PLIED SPECIFICALLY THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH WARRANTIES ARE SPECIFICALLY DISCLAIMED GlasCraft shall not be liable for any loss or expense resulting from damage or accidents caused by improper use or ap plication of materials manufactured or sold by GlasCraft or its distributors or agents UNDER NO CIRCUMSTANCES SHALL GLASCRAFT S LIABILITY EXCEED THE AMOUNT PUR CHASER PAID FOR THE CLAIMED DEFECTIVE EQUIPMENT OR PART UNDER NO CIRCUM STANCES SHALL GLASCRAFT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES OR FOR LOST PROFITS No action arising from or relating to any goods manufactured by or purchased from GlasCraft may be brought more than one 1 vear after the cause of action accrues 23 Section 4 Safety Information Technical Assistance Thank You for selecting GlasCraft spray equipment Should you have any questions or need technical assistance contact your factory authori
28. sed to minimize confine and ex haust the solvent vapors Solvents should be handled in accordance with OSHA Section 1910 106 and 1910 107 2 4 Catalyst Diluents GlasCraft spray up and gel coat systems currently pro duced are designed so that catalyst diluents are not re quired GlasCraft therefore recommends that diluents not be used This avoids the possible contamination which could lead to an explosion due to the handling and mixing of MEKP and diluent In addition it eliminates any problems from the diluent being contaminated through rust particles in drums poor quality control on the part of the diluent supplier or any other reason If however di luents are absolutely required contact your catalyst sup plier and follow his instructions explicitly Preferably the supplier should premix the catalyst to prevent possible on the job contamination while mixing N WARNING If diluents are not used it should be remembered that catalyst spillage gun hose and packing leaks are poten tially more hazardous since each drop contains a higher concentration of catalyst and therefore will react quicker with overspray and the like 2 5 Uncured Liquid Resin Resin should be stored in a well ventilated building at least 50 feet from your main plant In addition the stor age temperature should not exceed 75 degrees F Section 4 Safety Information General Safety In your main plant store only enough resin for on
29. t alarms to make sure they are operation properly When filling catalyst container protective eye Frequently check condition of hoses Replace worn equipment must be worn to protect against hoses and other parts before they fail injuries e Catalyst fluid nozzles and seals MUST be in good Always maintain adequate material levels to condition at all times to prevent internal and prevent loss of prime during system operation external leaks Inspect periodically and replace At the first sign of a leak stop operations acti as needed or at intervals of three to four months vate emergency stop valve back off air regula Use catalyst nozzle seal only once to prevent tors and open all bleed valves to remove possible leakage of catalyst into air passages all pressure from the gun hoses pump catalyst of gun system and any other liquid containers Make absolutely certain that all pressure has been Solvent Pot Pressure Relief relieved from the gun before disassembly from the e 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 lf you have any doubt that fluid pressure is relieved Catalyst Injector Pressure Relief call your GlasCraft distributor or GlasCraft Inc Refer
30. this Dispense Gun Relieve All Fluid and Air Pressures See previous page When servicing the System remove remove Air Tank e pressure from Solvent Tank This is achieved by pulling Pop Off Pin UP and holding until pressure bleeds off Due to the different O Ring materials and lubricants used in the Formula X Chop Guns NEVER SUBMERGE OR SOAK Ose Removal ANY dispense GUN 1 Remove Resin Hose with an 11 16 wrench IN ANY TYPE OF SOLVENT Hold delivery tube with an 11 16 wrench Submerging or soaking any Gun will immediately void the Gun warranty 2 Remove Catalyst Hose with a 9 16 wrench 1 Hold delivery tube with a 9 16 wrench Read each procedure entirely before beginning and refer to the illustration views as needed Tape a clean polyethylene bag over the end of each Hose to prevent spillage and to keep clean Flush and clean all passages as they become accessible Clean all parts before assembly Gun Service Replace all O Rings Valves and Seals with new e e e SE BE Dispense Gun Component Service and Assembly Procedures Inspect all parts for wear or damage and replace as required with new GENUINE GlasCraft REPLACEMENT PARTS from your authorized GlasCraft Distributor If Seal p n 23763 00 and Packing Disks p n 23721 04 are removed from the Gun Body GlasCraft recommends Inspect all threads for wear or damage and that these parts always be replaced with NEW seals and replace as required p
31. uch chemicals should be treated as if they hurt your skin and eyes and as if they are poison to your body For this reason GlasCraft recommends the use of protective clothing and eye wear in using polyester systems However users should be prepared in the event of such an injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals may have Section 4 Safety Information General Safety N WARNING Contact a doctor immediately in the event of any in jurv and give him the information you have collected If your information includes first aid instructions ad minister first aid immediately while you are contact ing the doctor Fast treatment of the outer skin and eyes that con tact such chemicals generally includes immediate and thorough washing of the exposed skin and im mediate and continuous flushing of the eyes with lots of clean water for at least 15 minutes or more These general instructions of first aid treatment however may be incorrect for some chemicals that is why you must know the ch
32. ult can be an extremely violent explosion the reaction can be sustained with very little aluminum or galvanized metal any amount of aluminum is too much Section 4 Safety Information General Safety The reaction is unpredictable Prior use of an HHC sol vent without incident corrosion or explosion does NOT mean that such use is safe These solvents can be dan gerous alone as a clean up or flushing agent or when used as a component or a coating material There is no known inhibitor that is effective under all circumstances Furthermore the mixing of HHC solvents with other materials or solvents such as MEK alcohol and tolu ene may render the inhibitors ineffective The use of reclaimed solvents is particularly hazardous Reclaimers may not add any inhibitors Also the pos sible presence of water in reclaimed solvents could feed the reaction Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction Such coatings can be worn cracked scratched or too thin to prevent con tact There is no known way to make oxide coatings or to employ aluminum alloys which will safely prevent the chemical reaction under all circumstances Several solvent suppliers have recently begun promoting HHC solvents for use in coating systems The increasing use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans as Volatile Organic Compounds VOC s their
33. zed GlasCraft distributor Distributor Phone Contact For any issues your distributor cannot address the GlasCraft technical service department is always available to assist you with the operation of your spray equipment To help our technical representatives expedite your call and better address your questions please have the following information ready and available when you phone GlasCraft If your questions are not urgent You can e mail all correspondence to service glascraft com Model Air compressor size Compressor to system supply line Spray gun Serial number Pressure at the system Material pump Main air line volume Serial number System gauge pressures Catalyst pump AAC pressure Chopper Serial number Atomizing air pressure external mix Type of material Material pump pressure Type of catalyst Solvent flush pressure Catalyst percentage 24 GlaScrF5FE 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 GELCOAT SYSTEMS NO NEEDLE IN THE SPRAY GUN INFINITELY ADJUSTABLE CATALYST PUMP INDY INTERNAL EXTERNAL MIX EQUIPMENT LOWEST LEVEL OF EMISSIONS AUTOMATIC EQUIPMENT FOR ROBOT APPLICATIONS SPARTAN
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