G2 GelCoat System (no Gun) User Manual
Contents
1. Section 4 Safety Information Notes 30 Section 4 Safety Information Limited Warranty Policy GLASCRAFT INC GlasCraft warrants to the original Purchaser of GlasCraft manufactured eguipment and parts that all GlasCraft manufactured eguipment and parts will conform to their published written specifications and be free of defects in workmanship and material for a period of one 1 year from the original date ofinstallation GlasCraft makes no warranty to anyone other than the original Purchaser If any GlasCraft manufactured part or eguipment is found to be defective in workmanship or material within the one year period from the date of installation as determined solely by GlasCraft GlasCraft in its sole discretion will either repair or replace the defective part or equipment at GlasCraft s cost including freight charges both ways or credit or refund the purchase price for the defective equipment or part A warranty claim will be honored only when 1 GlasCraft has been informed in writing of any such defect in workmanship or material within ten 10 days after discovery by the original Purchaser 2 An official of GlasCraft has issued a return authorization number and 3 The claimed defective equipment or part has been returned to GlasCraft by the original Purchaser freight prepaid with proper return authorization number s attached to GlasCraft Inc 5845 West 82nd Street Suite 102 Indianapolis IN 46278 U2. SN D E z s MAT f V ES a 11 REVISION D Section 3 General Information 21990 00 Parts List Part Number Description 12 REVISION C Section 3 General Information 32513 00 Material Pump Assembly DL SS UA a SI S os di di SA 56704 4342 04 E NONI ps 9 SSP 1I7l SZ e o o o NUTS SUPPLIED WITH 21463 44C AIR MOTOR 8 SSP 143 SE x SSP 142 H 7734 07 SSP 149 0 8 56 40C 9945 60 22320 00 209 jj i 7591 04 8462 15 e e 9 O E sasa 7729 07 14626 00 OV LOE 21192 00 8462 12 20260 00 19 REVISION A Section 3 General Information 32513 00 Material Pump Parts List Part Lade 5 16 STUD ae mas e 14 Part Se eaa ag 100 MESH FILTER 21219 00 REVISION A Section 3 General Information 23555 03 Air Manifold Assembly 20655 02 ISD 141 3 18318 02 SD 142 8115 06 1625 23 f 8115 06 Be 6782 03 LEN Gy LD 20183 00 AN LPA 143 21215 00 4342 02 Part Description Number p Part E 21402 00 3 WAY VALVE 4313 03 CROSS FITTING REVISION D Section 3 General Information GAM 268 Material Pick Up Kit Assembly ye y Gem Z AP 146 9 GAM 248 K e GAM 263 GAM 248 PICK UP TUBE GAM 263 FILTER 3161 HOSE FITTING 4341 15 ELBOW FITTING 8560 11 FITTING 8
3. Section 4 Safety Information General Safety 3 3 Grounding Grounding an object means providing an adequate path for the flow of an electrical charge from the ob ject to the ground An adequate path is one that per mits charge to flow from the object fast enough that it will not accumulate to the extent that a spark can be formed It is not possible to define exactly what will be an adequate path under all conditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed on all loose conductive objects in the spraying area This includes material containers and equipment GlasCraft recommends grounding straps be made of AWG No 18 stranded wire as a minimum and that larger wire be used where possible NFPA Bulletin No 77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm 106 ohms but that resistances as high as 10 000 meg ohms will produce an ade quate leakage path in some cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and 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
4. PSI pressure of nitrogen on the material drum 17 Section 3 General Information Options 21460 00 Heater Conversion Kit Assembly N09 OL G2 S6102 E N dd OL v0 961 0 EN and OL KO 70 961 d S1 729h8 00 12002 da wr 1 55 18 00 26861 01 REI REVISION F 18 Section 3 General Information Options 21460 00 Heater Conversion Kit Parts List Part er D 156 04 i RM 850 02 TEEFITTING 1 1462600 Amino 2 1462601 FNG 2 19891 00 19892 00 20027 00 ELBOWEFITTING 2080200 _RESINHEATER 2119200 BALLVALVE 21461 00 BRACKET 22425 00 4342 23 7734 10 LOCKWASHER 2 8165 1440 sorew 2 846215 Fme 2 8462 17 Fme fn 2945 400 screw 2 Les REVISION F Section 3 General Information Options LPA 165 Catalyst Bottle Assembly LPA 176 sl e DO LPA I167 21045 01 21044 0 1039 00 21040 00 Ss Jl ze Lo Number a JA 21039 00 TUBEADAPTER 1 20 REVISION N Section 3 General Information Options LPA 170 Catalyst Bottle Bracket Assembly I LPA 169 149401 Plo INCLUDES HEX NUTS Part Ee CP 126 U BOLT 2 LPA 169 BOTTLE SUPPORT 7486 07 WASHER 7734 07 LOCK WASHER 2 REVISION B Section 4 Safety Information General Safety Operating Your Polyester System Safel 1 0 Introduction Any t
5. air should not exceed 100 psi 2 Turn the catalyst slave pump yellow ball valve to the open position 3 Hand prime the pump until a steady stream of catalyst flows back to the bottle 8 Remove Cap Catalyst Ring Spray Tip and Spacer from the gun refer to gun manual 4 Close the ball valve hand stroke the pump until it 9 Trigger the Gun until a steady material stream developes 100 200 PSI appears at the Nozzle Body The material regulator should initially be set not to exceed 10 PSI 5 Open the main air valve slowly 10 Once a steady material stream is achieved release trigger and re assemble all parts removed from the gun 6 Turn material regulator slowly clockwise until guage indicates 10 PSI The pump will cycle slowly and stall when the pump is full of material Cap P N LPA2 213 should be HAND TIGHTENED ONLY Never use a wrench or pliers to assemble tighten or remove this cap If threads are clean and lubricated properly hand assembly and removal will not be a problem Use of wrenches or pliers will likely cause serve damage to the threads and or Gun Head lt CAUTION gt A CAUTION Do not exceed 10 psi pressure on the Material Regulator until steady material flow has been established Section 2 Operation Start up Instructions 11 Slowly increase resin pressure regulator until P x Follow step 12 if optional catalyst bottle is being used desired spray pattern is achie
6. or stress at the entry and exits of the boom sections and at the gun and fittings Replace if wear or weakness is evident or suspected 4 Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub against any of the hoses at any point If allowed to rub the hoses may be cut through causing a hazardous leakage of material which could incr ease the danger of fire Also the material may spew onto personnel in the area 2 7 Toxicity of Chemicals GlasCraft recommends that you consult OSHA Sections 1910 94 1910 106 1910 107 and NFPA No 33 Chap ter 14 and 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 Such chemicals should be treated as if they hurt your skin and eyes and as if they are poison to your body For this reason GlasCraft recommends the use of protective clothing and eye wear in using polyester systems 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 even
7. the user and recommends that the precautions in this manual be included in any such program GlasCraft recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual GlasCraft recommends that the user consult the regulations established un der the Occupational Safety amp Health Act OSHA particularly the following sections e 1910 94 Pertaining to ventilation e 1910 106 Pertaining to flammable liquids e 1910 107 Pertaining to spray finishing operations 22 particularly Paragraph m Organic Peroxides and Dual Component Coatings Other standards and recognized authorities to con sult are the National Fire Protection Association NFPA bulletins as follows e NFPA No 33 Chapter 14 Organic Perox ides and Dual Component Materials e NFPA No 63 Dust Explosion Prevention e NFPA No 70 National Electrical Code e NFPA No 77 Static Electricity e NFPA No 91 Blower and Exhaust System e NFPA No 654 Plastics Industry Dust Hazards Type of Fire Extinguishing equipment recommended Fire Extinguisher code ABC rating number 4a60bc Extinguishing Media Foam Carbon Di oxide Dry Chemical Water Fog Copies of the above bulletins are available at a nominal charge from National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 Research Report No 11 of the American Insurance Association deals with Fire Explosion and Health H
8. 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 29 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 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 GlaSscrsfFE DISPENSING EXCELLENCE 5845 WEST 82nd STREET SUITE 102 INDIANAPOLIS INDIANA 46728 U S A PHONE 317 875 5592 FAX 317 875 5456
9. 612 08 BAND CLAMP 16 REVISION E Section 3 General Information Maintenance Routine Care For long term storage of your spray system it is e recommended that the following procedure be followed Y gt 1 Make certain all air and material valves are in their GlasCraft recommends the use of OFF position GlasCraft TGC FRP TOOL 8 GUN CLEANER for gt cleaning of spray guns spray tips rollers brushes hoses a etc gt flushing internal mix spray guns hoses and pumps as well as any general shop clean up GlasCraft recommends that you contact your material 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 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 Consult your local authorized GlasCraft distributor for more information concerning system storage 2 Inspect Pump Shafts on Material and Catalyst Pumps making certain they are clean and free of over spray or foreign material Clean and lubricate as required 3 Inspect Gun Valve Needle Shafts making certain they are clean and free of over spray or foreign material Clean and lubricate as required See Gun User Manual WARNING Do not exceed 3
10. GlaScrFsft DISPENSING EXCELLENCE G2 Gel Coat External Mix System lt Z lt gt EL Y Table Of Contents Section 1 Installation SES lat eieiei de n GE 1 1 2 Standard EGUIPM SE A uyan a anaes E 2 a aku u u E E a mua a S h m Sag a Ni saata N A 1 4 Equipiment Assemblyx uu iaa Tan ui asa Sans Pasu talco Skalaar 3 Section 2 Operation 2 RER erte 5 2 2 SNUECOWA INSHMUCHONS ascitis illo ii cold cui as 8 2 3 Daily Start Up INSTUCHONS o Leta a DEA EEA es 9 Section 3 General Information Bel Assembly DAWN Gi ka ceo 10 A A O 13 SS Mantena MCE AAA mu TO 17 3 4 Troubleshooting a u l e at Mu aaa t a a AE AM N A OPI WA o do N 18 Section 4 Safety Information 4 1 General Safety nta leas ol ad add e 22 ALAN OS A aida 30 4 3 Limited Warrenty POMO ae 31 4 4 Technical ASSISTANCE uu AAA AAA A AA dE ITA oad AAA O AAA 32 FOr YOU Reference uu ua u usu u u sa n sima aada aal INSIDE BACK COVER N A Not Applicable Section 1 Installation Introduction Introduction Before operating maintaining or servicing any GlasCraft system read and understand all of the technical and safety literature provided with GlasCraft products If you do not have the proper or related manuals and safety literature for your GlasCraft system contact your GlasCraft distributor or GlasCraft Inc In this GlasCraft technical and safety publication the following advisories will be provided where appropriate 4 I
11. ICULAR 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 31 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 authorized GlasCraft distributor Distributor Phone Contact For any issues your distributor cannot address the GlasCraft technical service department is always available to assist you with the operation of your spray equipment To help our technical representatives expedite your call and better address your questions please have the following information ready and available when you phone GlasCraft If your questions are not urgent You can e mail all correspondence to service glascraft com Model Air compressor size Compressor to system supply line Spray gun S
12. Pump Lube Cup should be emptied cleaned and refilled with clean compatible lubricant Section 2 Operation Daily Start Up Instructions 5 Engauge Catalyst drive arm to Material Pump 1 Pull and rotate Pivot knob to disengage the catalyst drive arm Knob 2 Turn the catalyst slave pump yellow ball valve to the open position 3 Hand prime the pump until a steady stream of catalyst flows back to the bottle 4 Close the ball valve hand stroke the pump until it developes 50 PSI Section 3 General Information 21990 00 Assembly 328 1662 10 06861 00 V9861 00 2886L 00 89 02 r 0 98rZ Ob veZZ CFE CR LO L628L E 00 06102 in III REVISION D C 00 2S02 00 2502 SOL LVO 00 9Z9p1 A18IW3SSV dINNd 00 ELSZE a LO revel ONIGNL w b ONIANL 2E G U Z0 061 dSS Z0 091 dSS ATANISSV diNNd JAWIS Z0 ZSL dSS E ESF 7 A A18W3SSV afi tae GTO3INVN HIV me 1 e e0 sssez KAR 4 3 CS d LK y GL vi Section 3 General Information 21990 00 Assembly 7 ca KI s OM Q A MORA 9704 83 s KOE gt lt m N 8 A lt E O z e D O gt 3 2 Z O LL Z 2 DE lt O DE LL vu LLI E ei m d Su 4 2 Sy ES Lo E we Ge z za A E a Je S ZE A x NW d zu SF
13. 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 KH Ki KS The ONT 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 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 containers 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 Cataly
14. 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 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 PART
15. aft com U S A GC 1395 Phone 317 875 5592 REVISION D Fax 317 875 5456 E Mail sales glascraft com
16. azards 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 HR EATH ING EYE HEARING PROTECTEOW AROTESTI N PROTECTION E Section 4 Safety Information General Safety GlasCraft recommends that the user consult the state and local regulations established for all Safety equip ment listed 2 0 Material Safety 2 1 Hazards Associated with Laminating Operations The major hazards which should be guarded against in polyester laminating operations are those associated with 1 The flammability and explosion dangers of the catalyst normally used Methyl Ethyl Ketone Peroxide MEKP 2 The flammability dangers of clean up solvents sometimes used GlasCraft recommends that 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 lamina
17. catalyst atomizing air pressure to 25 PSI This pressure may be adjusted to achieve desired catalyst droplet size Section 2 Operation Shut Down Instructions Shut Down Instructions 8 Material pump should now be cycled so that shaft is left in DOWN positon during shut down period 1 Turn the main air valve to Off position lt CAUTION gt Failure to cycle Pump Shaft to DOWN position may result in over spray or leaked material to dry or harden on Shaft When Pump is next operated severe damage may be done to Upper Pump Seals 2 Pressure should be maintained on the resin and catalyst hose 3 Refer to the manual to remove and clean the gun head parts These parts should be cleaned thoroughly inspected for wear or damage O Rings replaced if needed and placed aside for later re as sembly at next start up 4 Clean and inspect all internal and external threads of the Gun Head After cleaning dry and lubricate all threads with a light coat of petroleum jelly Make certain that the resin orifice on the inside of gt the Gun Head and the catalyst orifice on the outside of the Gun Head are covered with a small amount of the lubricant to prevent hardening and or migration 5 Use a light coating of petroleum jelly on all threads and o rings during re assembly 6 Material pump should be stopped with Pump Shaft in UP position Shaft should be cleaned of any over spray or foreign material 7 Material
18. ding on material used Fig 4 Section 2 Operation Start up Instructions 15 As soon as all air is eliminated simultaneously 19 Re adjust catalyst calibration as required This release the Trigger and stop stroking Pump Arm setting should be determined by the type of resin and catalyst being used 16 Check and make certain that Spray Gun Material and Catalyst Needles activate at exactly the same 20 Re adjust catalyst atomizing air pressure to approxi time mately 40 PSI ox Failure to activate the Catalyst Valve at the Gun X Catalyst Needle should never lead Material Needle as gt when the Pump is cycling will result in an over a loss of Catalyst system prime could result pressurization of the Catalyst Pump and the automatic opening on the Pressure Relief Valve 17 Engauge Catalyst drive arm to Material Pump 21 While triggering the Gun examine the atomized catalyst making certain it is properly entering the material pattern gt If catalyst pattern is too narrow Increase catalyst atomizing air in 5 PSI increments Knob If catalyst pattern is too wide decrease catalyst atomizing air in 5 PSI increments 22 After all pressure adjustments have been complet ed a final spray test should be made Spray a test shot sample on a clean piece of paper This shot should be approximately five feet in length You can now check for desired gel time and uniformity of curing 18 Adjust
19. ean dry air supply 5 Attach a 3 8 or larger air hose to the Air Inlet on the yellow air lock out valve xr It is suggested that a quick disconnect fitting not gt be used for attaching air Quick disconnect fittings can severely limit air flow A CAUTION Before turning on main air check all fittings making certain they are securely tightened This should be done before air or material of any kind is introduced into the system 6 Attach Grounding Clamp Assembly P N 17440 00 to System Use a convenient nut and bolt to secure lug P N 13193 00 to system 7 Securely attach Clamp P N 7749 00 to permanently grounded rod or pipe 7749 00 9654 00 SA GROUNDING ROD OR PIPE N Te O TO SYSTEM A CAUTION 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 8 Fill Material Pump Lube Cup with a clean compatible lubricant XK NS GlasCraft recommends you contact your material supplier for their recommendation of a lubricant that will be suitable for use with your material Section 2 Operation Start up Instructions 7 Formula Gun Only Adjust the trigger air regulator 1 Pull and rotate Pivot knob to 100 psi to disengage the catalyst drive arm The trigger
20. erial 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 32 GlaScrFsfFE DISPENSING EXCELLENCE Date Purchased Distributor Contact Phone E mail GlasCraft manufactures a complete line of FRP spray systems lf your application is in plant or a field contractor GlasCraft has a system package to meet your requirements FORMULA INTERNAL EXTERNAL MIX POLYESTER EQUIPMENT CHOPPER 8 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 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 PFR PRESSURE FED ROLLERS For more information concerning any of these GlasCraft products contact your local authorized GlasCraft distributor or visit www glascraft com Quality and Performance GENUINE GLASCRAFT GlaScrsFt DISPENSING EXCELLENCE ADS 5845 WEST 82nd STREET ADVANCED DISPENSE e INDIANAPOLIS INDIANA 46278 www glascr
21. g 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 24 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 AN 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 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 Ha
22. he 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 one 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
23. jury 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 Prevent contamination of MEKP with other materials including polyester overspray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels 4 Never add MEKP to anything that is hot since explosive decomposition may result 5 Avoid contact with skin eyes 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 fightin
24. logenated 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 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 c
25. 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 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
26. n 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 AN WARNING Never place fingers hands or any body part near or directly in front of the spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PIS TOL 27 Section 4 Safety Information General Safety 3 1 Emergency Stop Procedures The following steps should be followed in order to stop the machinery in an emergency situation 1 The yellow air valve located where the air enters the machine should be pushed to the OFF closed position To do this simply push on the lever protruding out the side of the valve This will also cause all the system air to bleed out of the system in a matter of a few seconds thus making the system incapable of operating A CAUTION 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 lt K Verify that the Catalyst Pressure Relief Line and the
27. nts 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 25 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 used 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 t
28. o 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 Model G2 System 21990 00 G2 SSP External mix gel coat system 32513 00 Material pump assembly 13 1 ratio Refer to material pump manual SSP 160 02 Catalyst slave pump assembly Refer to SSP manual 20195 25 Material Hose Assembly 25 ft U Part Description Number p 20190 00 Catalyst Hose Assembly 25 ft Section 1 Installation Equipment Assembly 1 Remove the pump inlet safety cap and drain the 2 Attach clear pick up hose to the pump inlet fitting and testing oil into an open container Before operat tighten ing the material pump flush thoroughly with a clean suitable solvent to remove test fluid 3 Attach clear pick up hose to the pick up tube P D e 4 GlasCraft uses a test fluid that may not be compatible with some gel coats or resins Thus it is recommended 3 that the test fluid be flushed from the Material Pump Fluid Section N Pick up Tube Section 1 Installation Equipment Assembly 4 Select a cl
29. omponent 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 low flam mability hazard and their not being classified as toxic or carcinogenic substances HHC solvents are very desir able in many respects A WARNING Do not use Halogenated Hydrocarbon solvents in pres surized fluid systems having aluminum or galvanized wetted parts K A W GlasCraft is aware of NO stabilizers available to prevent Halogenated Hydrocarbon solvents from reaction under all conditions with aluminum compone
30. ool 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 personnelinvolved in polyester operations should read and understand the Safety Manual It is very important for the safety of employees involved in the operation that equipment operators mainte nance and supervisory personnel understand the requirements for safe operation Each user should examine his own operation de velop his own safety program and be assured that his equipment operators follow correct procedures GlasCraft hopes that this manual is helpful to
31. plosive 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 organic peroxide catalysts If at any time the pressure relieve valve on top of the catalyst tank should vent the area should be evacuated at once and the fire department called The venting could be the first indication of a heat and therefore pressure build up that could eventually lead to an explosion Moreover if a catalyst tank is sufficiently full when the pressure relief valve vents some catalyst may spray out which could cause eye in
32. s information about the procedure in progress Is imperative information about eguipment protection AN CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury AN WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury AN 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 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 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 t
33. st Injector User Manual for proper pressure relief Never operate a Fiberglass System with fixed Pinch Point guards removed from system 28 Section 4 Safety Information General Safety 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 disassembly Use only genuine GlasCraft replacement parts when repairing your system Substitutes may not be the proper material or may not fit the system and may cause dangerous operating conditions and the failure of other components
34. t 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 AN WARNING Contact a doctor immediately in the event of any in jury 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 chemicals and treatment before an accident occurs Treatment for swallow ing a chemical frequently depends upon the nature of the chemical oi x 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 whe
35. te 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 23 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 but may also arise by contamination of the MEKP with other materials in its storage or use Even a small amount of contamination with acetone for instance may produce an extremely shock sensitive and explosive compound Contamination with promoters or materials containing promoters such as laminate sandings or with any readily oxidizable material such as brass or iron will cause exothermic redox reactions which can become ex
36. ved See Fig 3 x Typical Spray Pattern Development 13 Safely fill the Catalyst Supply Bottle P N LPA 165 without Air Assist maximum two gallons with preferred MEKP catalyst to a minimum level at least one inch above the catalyst bottle outlet fitting STEP RESIN PATTERN PRESSURE PRESSURE ADJUSTMENT A CAUTION Remove Catalyst Bottle P N LPA 167 1 from Catalyst 1 20 PSI OMODO INCREASE Bottle Bracket P N LPA 169 for filling Bottle should be placed at or below waist level for safe 2 25 PSI INCREASE Ka COD Se filling 3 30 PSI CC e INCREASE Never fill Catalyst Bottle while mounted in Bracket as personal injury from catalyst spillage could result 4 35Ps DO gt O CORRECT 14 Trigger the Gun into a container until all the air is Final pressure typically ranges from 30 to 45 PSI purged from the resin side of the system It may be depending on material used necessary to Hand stroke the Catalyst Pump several times while the gun is triggered to positively Fig 3 12 Slowly increase Air Assist Air Pressure Regulator until tails disappear from spray pattern See Fig 4 Typical Spray Pattern Development with Air Assist STEP AIRASSIST PATTERN PRESSURE ADJUSTMENT ADJUSTMENT 1 CLOSED O CC gt OO INCREASE 2 5s OC DO INCREASE 3 30 PSI Css CORRECT Final air assist adjustment is complete when tails are elimated and a uniform spray pattern is achieved Final pressure typically ranges from 30 to 45 PSI depen
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