Guardian A6-6000 IP User Manual
Contents
1. Pat C 5 GC0409 6 7 GC0437 109 GC0790 111 GC0999 120 GC1738 r21 KESAN y 0 02 03 E O 1 4 4 OJO h O 00 x a OO l O N N i MW NO iu B 38 602052 w 602107 141 GC2109 142 GC2110 8 0 Description ELBOW PLUG PIPE FITTING ADAPTER NPSM 1 4 X 1 4 HOSE ASSY SCREW BHDC SS 312 18X 00 SCREW CAP BTNHD SCREW SET SOC 7 16 20 X 3 8 RETAINER PLUG VENT RETAINER HOSE ASSY TRANSFORMER BOX CONTROL CONNECTOR JACK PANEL CIRCULAR HANGER PANEL CONTROL COVER HEATER FITTING BULKHEAD 1 4 NPT X 1 4 NPT NUT BULKHEAD 3 4 16 WHEEL MANIFOLD ASSY AIR MANIFOLD ASSY FLUID COUNTER WEIGHT EXTENSION STANDOFF NUT CONDUIT ELEC 1 2 GROMMET RUBBER 3 8 THRU 1 4PT GROMMET RUBBER 1 1 2 THRU 1 4PT WASHER FLAT WASHER FLAT FENDER WASHER FLAT STD WASHER FLAT STD WASHER FLAT STD WASHER LOCK SPRING WASHER LOCK SPRING WASHER LOCK SPRING A O Rei Part Den Tt nae Tor SCS rar aos sore 4 48 49 ao nor cono aso connector I 151 00766 SOLVENT RECEPTACLE 1 5 GC2092 NUT HEX STD 8 32 5 153 GC1740 BRACKET RECEPTACLE HOSE 158 00222 Source locally Part Description Qty FITTING REGULATOR AIR GAUGE AIR2. 33 Section 3 General Information Sub Assembly Drawings GC1714 GC1715 GC1716 GC1717 Heat Exchanger Assembly 405 402 IN ES 4 410 417 418 406 PLUG PIPE SOC 1 4 ZP 1 ISO KIT O RING kit includes 4 MODEL 406 WATTS ei AI GC0891 SCREW BHDC SS 112 40X 188 GC1715 GC0893 THERMOMETER THERMOCOUPLE VE 4 LOCITY HIGH POLY ELEMENT HEATER SEE TABLE SWITCH OVERTEMP OPENED SPRING COMPRESSION 86 OD 17 GC1716 GCos91 1500 WASHER LOCK SPRING 1 4 SCREW SHDC SS 250 20X1 750 k h T Not shown 34 Section 4 Safety Information Notes 35 Section 3 General Information Maintenance Daily Routine Maintenance 1 Visually inspect the system for leaks 2 Check desiccant dryer ensure proper functioning Replace dryer beads as necessary 3 Check and lube top of the fluid section Wipe off residual material and add a tablespoon of throat seal liquid TSL Weekly Maintenance 1 Place a small amount of grease on the air motor shaft 2 See related manuals 36 Section 3 General Information Troubleshooting A Do not place any part of the body in the path of the material spray Do not point the gun at or near other personnel Do not look into the Mixing Chamber orifice at any time Because of the hazardous materials used in this equipment it is recommended that the operator use an air mask goggles protective clothing and othe
3. GAUGE AIR FITTING ELBOW VALVE BALL BRACKET L MANIFOLD AIR CAP OILER GC0001 GASKET CAP OILER G GC1994 FITTING ELBOW G GC2016 FITTING PIPE TEE WASHER LOCK SPRING FITTING PIPE NIPPLE HEX FITTING PIPE NIPPLE HEX FITTING PIPE NIPPLE HEX SCREW GC1772 LABEL GLASCRAFT MANIFOLD GRDN 1 O Section 3 General Information Sub Assembly Drawings Control Panel Assembly 221 220 214 519 213 201 GC0584 COUNTER LCD 202 GC0599 FUSE 1 2 AMP 203 GC0601 FUSE 2AMP 204 115W684 MODULE HEATER CONTROL GUARDIAN 2 Jociere LENS ILLUMINATED O Z 23 GC1617 LENS YELLOW s Goro LENS GREEN gt Gore LED Yeoman s GC1624 LED GREEN 2 BIR BE 3 24 23 3 26 NO EG 2 3 2 2 5 21 1GC1626 BLOCK CONTACT NORMALLY OPEN 228 GC1627 BLOCK CONTACT NORMALLY 5 CLOSE 230 GC1779 CABLE PLUG ELEC FEMALE 231 GC1780 CABLE PLUG ELEC FEMALE 232 GC1782 CABLE PLUG ELECTRICAL 2 MALE 6 SM 233 GC1783 CABLE PLUG ELECTRICAL 1 MALE 236 15W687 MODULE HOSE CONTROL 1 GUARDIAN 213 GC1164 SOCKET RELAY 3 POLE 10AMP Source locally 32 REVISION C Section 3 General Information Sub Assembly Drawings GC1767 Electrical Assembly 306 307 308 303 310 311 313 309 FUSE SAMP CIRCUIT BRKR CIRCUIT DIN RAIL 20 2 FUSE FUSEHOLDER DIN RAIL Source locally
4. HI 2 SSI Fa LIL COIP ys AZ i LIP deso o AT N png Hen ses be Pew D 26 Eo E Some parts have been removed for clarity cart assembly A f a Ta o 3 k oe a 20 AS lt See Detail A 24 Section 3 General Information Assembly Drawings GC1820 GC1822 Unit Assembly 0 Oa G 22 ae POLY Heater Assy Receptacle B Receptacle B VA ane STA 25 Section 3 General Information Assembly Drawings GC1820 Parts List mer Pat Description aw Orven BUND T8SDIAX 4255 5 GC0434 SCREW BHDC SS 250 20X 875 FITTING ELBOW JIC 3 8NPTM X GC0797 LABEL DECAL LIVE WIRE 9 acosit CONNECTOR CONNECTOR r mat mus Tv et Terate POWER FT GAUGE PRESSURE 5000PSI a s s DUAL ROD POLY GC1718 PLATE BOTTOM GUARDIAN 17 CART ASSY GUARDIAN IP SEE 4 PAGE 30 GC1725 COVER HEATER S A5 6000 COVER SHELL FIBERGLASS RING PANEL CONTROL PUMP PUMP A6 GUARDIAN 21 GC1735 SERIES SEE PUMP MANUAL 313277 GC1746 WASHER FIBER 25 CONTROL PANEL GUARDIAN SEE 1 PAGE 32 GC1767 CONTROL A5 A6 6000IP 220V 1PH ss GC1789 LABEL DECAL GUARDIAN A6 6000 IP 35 L ccas wasannin si ss 2 e 1 e cara washer took spans GC2175 SCREW HXHD CS 500 13X2 000ZP GC2192 SCREW
5. Warnings The following warnings are for the setup use grounding maintenance and repair of this eguipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment e Use only grounded electrical outlets e Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords e Do not expose to rain Store indoors TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guide lines e Always wear impervious gloves when spraying or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to Protective eyewear e Clothing and respira
6. any repairs on the Gun ALL AIR and FLUID PRESSURES SHOULD BE RELIEVED TO ZERO BLEED OFF A GUN 1 Side Block Material Valve turned on 2 Bore hole of Mixing Chamber clean 3 Filter Strainer Screen clean 4 Side hole in Mixing Chamber clean B MATERIAL TEMPERATURE 1 Too high a temperature on resin side can cause a blowing agent to pre expand in either the Hose or the Primary Heater C HOSES 1 Make sure that the Hoses are not plugged TROUBLESHOOTING A POOR SPRAY PATTERN xx To troubleshoot a poor spray pattern you must NW understand the factors that affect the spray pattern A TEMPERATURE 1 Too warm a material temperature will cause a separation fingering in the pattern 2 Too cold a material temperature will cause a stream effect B PRESSURE 1 Too high a pressure will cause excessive overspray and or separation fingering 2 Too low a pressure will cause a stream effect C CONTAMINATION IN THE MIXING CHAMBER 1 A foreign object in the Mixing Chamber will cause a poor pattern Correct problem s immediately IZ 39 Section 3 General Information Options GC0174 Transfer Kit Supplied with Unit GC1240 GC1233 na GC0479 ans GC1747 x Wp a Na GC2208 GC2199 TRANSFER PUMP PURCHASED SEPARATELY TRANSFER PUMP TRANSFER PUMP ISO AIRLINE POLY AIRLINE MAIN DRUM MIXER AIR AIR OPTIONAL A SIDE MATE
7. component functions and operation of the machine 1 Adjust air regulator to 20 psi to fill system Air motor will cycle slowly to fill pumps heaters and hoses and stop Pre Operation Check List A Check that all fittings are securely tight B Check electrical hook up gualified electrician recommended C Main power switch on control box should be switched to OFF position D Air regulator turned counter clock wise to OFF position E Hose control and primary heater control to OFF position NS Do not place any part of the body in the path of the material spray Do not point the gun at or near other personnel Do not look into the mixing chamber orifice at any time Because of the hazardous materials used in this equipment it is recommended that the operator use PROBLER P2 an air mask goggles protective clothing and other MAKE SURE VALVES ARE OFF safety equipment as prescribed by current regulations recommendations of the chemical suppliers and the laws in the area where the equipment is being used Initial Start Up Procedure With all material and air lines connected and power cable attached the system is now ready for start up 15 Section 2 Operation Start Up Instructions 3 Place separate clean containers under each indi 6 Clean and lubricate side blocks and seals thoroughly vidual side block Slowly open material valves and re assemble on gun Make certain that the side black arrow forw
8. pressure increases above 3000 psi If a high pressure situation develops the sensor will detect this and immediately engage the hold in circuit This will disengage power to the air motor and will also turn the heaters off On the control box panel there are three yellow lighted push buttons marked over pressure One of these push buttons will be illuminated after the monitoring sensor engages indi cating where the problem is located ISO Poly or Hose In the over pressure situation the system will remain shut down until it is manually reset At this point it is necessary to determine if the problem is an over pressure situation When the sensor engages the system will be frozen giv ing you the pressure readings at the time the problem was detected Inspect the fluid pressure gauges in an over pressure situ ation one of the fluid pressure gauges will be significantly higher than the other gauge A When main power to unit is on the console will have wires that are live Disconnect or turn off main power source be fore opening console to make any repairs Before performing any repairs on the system ALL AIR and FLUID PRESSURES SHOULD BE RELIEVED TO ZERO BLEED OFF 37 Section 3 General Information Troubleshooting Over Pressure Problem Correction 1 Determine if the problem is high pressure related 2 Relieve system material pressure 3 Turn off main power 4 Fix the problem area a Po
9. AUTION Always clean the fluid inlet strainers after flushing To prevent cross contamination of the eguipment s wet ted parts never interchange component A isocyanate Check with your material manufacturer for chemical and component B resin partrs The gun is shipped with compatibility the A side on the left The fluid manifold fluid hous l ing side seal assembly check valve cartridge and mix Most materials use ISO on the A side but some use chamber are marked on the A side ISO on the B side e Epoxies often have amines on the B hardener side Foam Resins with 245 fa Polyureas often have amines on the B resin side Blowing Agents New foam blowing agents will froth at temperatures above 90 33 C when not under pressure especially if agitat ed To reduce frothing minimize preheating in a circulation system Section 1 Installation Standard Eguipment Model A6 6000 IP Part Description Number p GC1820 A6 6000 IP UNIT 220V 1PH F GC1822 A6 6000 IP UNIT 220V 3PH F GCP2R1 PROBLER P2 GUN GC0393 48 FT HEATED HOSE ASSEMBLY 313274 USER MANUAL 206995 FLUID TSL 1 AT BOTTLE GC0174 TRANSFER KIT A5 AND A6 DOES NOT INCLUDE TRANSFER PUMPS Purchased Separately Recommended Repair Parts Part Number GC1748 HEATER REPAIR KIT Description Related Manuals Part Description Number p 312766 T1 2 1 RATIO TRANSFER PUMP MANUAL 213277 MATERIAL PUMPS MANUAL Material Ra
10. IO pongase en contacto con el distribuidor de Graco 41 Section 4 Safety Information Technical Assistance Thank You for selecting GlasCraft spray eguipment Should you have any guestions 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 eguipment To help our technical representatives expedite your call and better address your guestions please have the following information ready and available when you phone GlasCratt If your guestions are not urgent You can e mail all correspondence to service glascraft com For Air Powered Systems Model Air compressor size Serial number CFM generated Type of spray gun Pressure at the system Serial number Hydraulic Pneumatic Is your eguipment Dynamic fluid pressure Single phase Three phase ISO POLY What is the inbound voltage Spray gun chamber size to your eguipment Material being sprayed Temperature setting ISO Viscosity ISO POLY Temperature setting POLY Approximate material temperature Temperature setting HOSE 42 Glasccrart DISPENSING EXCELLENCE Date Purchased Distributor Contact Phone E mail GlasCraft manufactures a complete line of polyurethane foam and polyurea coating spray systems If your application
11. Install feed pumps purchased separately in POLY and ISO material drums bk 39 filter purchased separately to the outlet of both pumps Be sure to use teflon tape on the threads Section 1 Installation Eguipment Assembly 7 Seal component A drum and use desiccant dryer 8 See transfer pump manual for setup instructions 9 Remove the metal caps from the material pumps Material Drum 10 Connect one end of each material hose to the inlet fittings located on the back of the machine It is highly recommended that you label the POLY hose with BLUE tape and the ISO hose with RED tape to ensure that you don t put the wrong transfer pump in the opposite material drum 10 Section 1 Installation Eguipment Assembly 11 Connect the other end of the material hoses to there correct transfer pumps Ensure that they are not reversed and tighten securely POLY Material Inlet Fitting 12 Attach the other end of the airlines to the far right regulator on the machines air manifold ISO Material Inlet Fitting ISO Material Drum 11 Section 1 Installation Eguipment Assembly AA AA Main power from power source should be disconnected At HOM A A a N or turned off to console before making hose connections Trigger Air EEHON B il NN SS LR A IV NN ZEN NA attach only one way 14 Connect the yellow heat plug to the 13 Connect the
12. MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts Keep clear of moving parts Do not operate eguipment with protective guards or covers removed Pressurized eguipment can start without warning Before checking moving or servicing eguip ment follow the Pressure Relief Procedure in this manual Disconnect power or air supply BURN HAZARD Eguipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or eguipment Wait until eguipment fluid has cooled completely Isocyanate Hazard To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container Keep the ISO lube pump reservoir filled with Graco Spraying materials containing isocyanates creates Throat Seal Liquid TSL Part 206995 The lubricant potentially harmful mists vapors and atomized creates a barrier between the ISO and the atmosphere particulates e Use moisture proof hoses specifically designed for Read material manufacturer s warnings and ISO such as those supplied with your system material MSDS to know specific hazards and precautions related to isocyanates e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when Prevent inhalation of isocyanate mists vapors and not in use atomized particulates by providing suffic
13. RIAL HOSE B SIDE MATERIAL HOSE o Z The transfer kit attaches the same way for both L gt ISO amp POLY side Use teflon tape on NPT threads 40 Section 4 Safety Information Limited Warranty Policy Graco Standard Warranty Graco warrants all eguipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited waranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the eguipment determined by Graco to be defective This warranty applies only when the eguipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitu tion of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco
14. SHDC SS 164 32X 375SST 42 GC2203 FITTING CONNECTOR Ret Pan Description Tag 44 HOSE TUBNG P E 500 OD 1 5 NATURAL ras Gos UE DECAL 50 gt as 302584 LABEL DECAL POLY 2 ar 602965 LABEL DECAL HOSE ae G02965 LABEL DECAL MAN 2 ag Go0e05 SWITCH PRESSURE men 2 Source locally Go __ ScREW SELF TAP 190 x 1 000 SS aio A Replacement Danger and warning labels tags and cards are available at no cost 26 Section 3 General Information Assembly Drawings GC1820 Generic System Schematic him k BF OOO SPS Ii HO K H E B F E ii m E hi Eb Ti E E EEEE E B HdE A0ZZ ONY Hdl A0Z2 DILWWSAHDS DIHINJO dl NVIGHYVND ER amp 27 Section 3 General Information Assembly Drawings GC1820 System Schematic 220V Single Phase MLS e s L E m l ee 220 VOLT SINGLE PHASE ONLY 28 Section 3 General Information Assembly Drawings GC1820 System Schematic 220V Three Phase hal Sa a h MAA Li MAINO 3SYHd LIOA Oce Tai Ti Section 3 General Information Sub Assembly Drawings Cart Assembly IP 151 152 140 136 Some Parts Removed For Clarity de Attach air line for gun here iaa X 8 Detail A 30 Section 3 General Information Sub Assembly Drawings Cart Assembly IP BH
15. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verifi cation of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MAN UFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motor
16. USER MANUAL Glass DISPENSING EXCELLENCE GUARDIAN A6 6000 IP Dispensing System For use with non flammable foam and polyurea Not for use in explosive atmospheres Maximum fluid working pressure 2200 psi 15 2 MPa 152 bar Important Safety Instructions Read all warnings and instructions in this manual Save these instructions An 150 5001 ppr6 s Compary Table Of Contents Section 1 Installation Ag an ola e Po ser ate ear a eet at AN nan Man maa oma aa asia 1 Standar Se Teic mm c c c c m m m mrm mm m rmcm m mmrmrmrmrmrmrmrmrmrmmmmmm mmmm mrmmrmmmmmrmmrmmmrmrmrmmmmmmmmmmmmmmmmrmmrmmmmrmmmmmrmmmmmmmi 5 i sceil CAN OS amimmmmmmmmrmmmmmyimmmmmmmmmmmmmmmmmmrmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmrmmmmmmmmmmmmmmmmmmmmmmmmmmmmm mmmmmmmcWcmmkMMH 6 Moo Oi uu o Au Ce o e 7 A o PT OO PRE O 5 a 9 Section 2 Operation clon pibe an non Sena aan BIASA es 15 Ms an NA NA A 20 Section 3 General Information Assembly DraWI gS an Ann oia 24 SUD SSS I Dir yi y cross ba ask hatanuaqaa uastanaya piano 30 Nl ill naas Banana pan 36 TOUDE OA abia 37 PP oo nm RED aa 40 Section 4 Safety Information Limited Warranty Policy 22 oo oo oom coni02ees0omomensnnedae toc Ka bias Pama ons asa 41 MCG ATA i Bi ii u uuu uu ul U ke eee eis Pa asin AA a aa a NA Pa EA AE ENI 42 For Your Referensi an batted kate era Naba INSIDE BACK COVER
17. ard on each side block to allow block screws are tightened securely trapped air to escape the hose and material to flow Into the containers until all air is purged from the 7 Refer to material manufacturers operating instructions material system for proper preparation of material i e mixers etc 8 Leave air regulator at 20 psi xXx Remember to dispense one to two gallons of material to clear the system of grease and plasticizer that was used during factory testing 4 Close manual material valves Material pressure gauges should now register approximately equal pressure If one side registers considerably more pressure than the other side go to the high pres sure side and bleed off some pressure by slightly opening the manual material valve on the side block over the container Bleed pressure until both sides are approximately the same pressure 10 Turn on Hose Control a Push in the green power buiton b Press up or down arrow buttons on the controller until desired temperature setting is achieved 5 Dispose of waste material properly and in accor dance with chemical suppliers instructions and local state and federal regulations Before re assembling side blocks lubrication can be W gt applied by dabbing a white lithium grease into holes inside of gun front housing and wiping grease over side block seals Grease will purge itself when air valve is turned on at gun and gun is triggered 16 Sectio
18. cessary to install an appropriate plug on the end of the cable GlasCraft will not supply this plug as we are unaware of which style will be needed c Consult the data sheet for the specific unit being installed to determine the proper breaker size needed Install a y d You will need to run an air line to the area where the machine will be placed consult the data sheet the specific unit being installed to determine much clean dry air will be needed to supply the machine lf the air line is under 25 ft use a minimum of 1 2 in 1 D pipe or hose If the air line is longer than 25 ft use a minimum of 3 4 in pipe or hose Anything smaller than these diameters will severly affect the machine s performance as Do not use any quick disconnect fittings on the main air line going to the machine Check your air compressor to make sure it is W capable of supplying the maximum amount of air that the machine requires All GlasCraft equipment is rated at 25 CFM cubic foot per minute 708 liters at 90 100 psi 62 0 7 MPa 6 3 7 7 bar do not exceed 125 psi 0 86 MPa 8 6 bar Move material drums to the area that the equipment will be placed ensuring that they are not sitting directly on the floor Simply place the drums on top of a palate or similar device so the drum bottoms will not be in contact with any cold surfaces Open all boxes that came with the machine and verify that all items are accounted for
19. ct the entire system for leaks 7 Turn off main air supply and main power 3 Flip retract switch to the retract position and trigger the gun until pumps are in the down position 4 Perform gun maintenance See gun manual 20 Section 2 Operation Shut Down Instructions 8 Coil heated hoses with a minimum four foot diameter 2 Use a suitable solvent to flush the fluid circuits To to avoid kinking and subsequent damage to the determine the compatibility of solvents with material internal electrical wiring being used Always check with material supplier 9 Check and lube top of the fluid section 3 Increase transfer pump pressure until fluid movement occurs Wipe off residual material and add a tablespoon If fluid movement does NOT occur 100 psi of TSL throat seal liquid NW of air on transfer pumps increase main pump pressure until the main proportioner SLOWLY starts cycling 4 Once primary material is flushed from the system reduce the main air pressure to zero or flip the retract switch to the retract position and trigger the gun until the pumps are in the down position 5 If the solvent used to flush the system also contains placticizer ensure that all primary material is flushed from the system and close the ball valves the gun A 6 Leave the pumps in the full down stroke position with approximately 200 500 psi on the fluid gauges Do not bleed fluid pressure from the syste
20. echnical and safety publication the following advisories will be provided where appropriate X Information about the procedure in progress lt k dl Is imperative information about equipment protection A CAUTION Indicates a hazardous situation that can result in minor or moderate injury N WARNING Indicates a hazardous situation that can result in death or serious injury AX ELECTRICAL SHOCK HAZARD Indicates a hazardous situation that can result in electr ical 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 lf a technological change occurs after a prod uct is on the market we will implement that technology in future production and if practical make it available to cur rent users as a retrofit update or supplement If you find a discrepancy between your unit and the available docu mentation contact your GlasCraft distributo
21. hose assembly to the unit The swivel fittings on the Hose assembly are sized differently and will Wo outlet on the front of the unit 15 Connect trigger air line to the air regulator at the system air manifold 16 Connect the thermocouple plug to the outlet on the back of the unit 222233 12 Section 1 Installation Eguipment Assembly GC0705 Extension hose 17 Continue adding extra hose lengths if necessary Machine End KKK gt _y The GlasCraft System is factory assembled If PELAN ETA I OPO Nu any questions arise concerning air or electrical connections please refer to illustrations located in the forward portion of this User Manual or contact our GlasCraft distributor y Machine End AHF Required Tools i i HL LN Opened end wrenches 5 8 3 4 13 16 1 B i ot ae sol a Lay hoses out straight TL s LT _ w r D aA Nil LN IAL b Couple hoses together with supplied union fittings and tighten finger tight C Hold crimp fitting hex 3 4 and union fitting together allowing the hose to hold it s natural line e Using the appropriate wrench A side 3 4 B side 13 16 tighten swivel fitting to union not allowing crimp fitting or union to turn Repeat on opposite side of union ea N AS I HN s ys E AL q E lo e This practice is required on all connection points 1 Hose Y machine 2 Hose gun 3 Adding addit
22. identify and correct the problem Keep a working fire extinguisher in the work area PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all eguipment manuals Use fluids and solvents that are compatible with eguipment wetted parts See Technical Data in all eguipment manuals Read fluid and solvent manufacturer s warnings For complete informa tion about your material reguest MSDS forms from distributor or retailer Check eguipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify eguipment Use eguipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull eguipment Keep children and animals away from work area Comply with all applicable safety regulations
23. ient ventila tion in the work area If sufficient ventilation is not e Never use solvent on one side if it has been contami available a supplied air respirator is required for nated from the other side everyone in the work area e Always park pumps when you shutdown To prevent contact with isocyanates appropriate personal protective eguipment including chemically e Always lubricate threaded parts with Part 217374 ISO impermeable gloves boots aprons and goggles is pump oil or grease when reassembling also required for everyone in the work area Material Self Ignition Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component foam and polyurea coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increas ing in viscosity If used this partially cured ISO will reduce performance and the life of all wetted parts The amount of film formation and rate of crystal YA lization varies depending on the blend of ISO the humidity and the temperature Keep Components A and B Changing Materials Sepa rate e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean C
24. ional hose sections GC0393 Standard hose d Attach the yellow power plugs Gun End e Attach the thermocouple extension cable p n 21998 00 13 Section 1 Installation Eguipment Assembly 18 Connect the hose assembly to the spray gun as shown 19 All connections should now be tight jiran a e K eo AS dl RASS gt LN 9 ais O 9 AA When Main Power to system console is on the white and black wires in the console are always live Disconnect or turn off Main Power source before opening console to make any repairs or before making any electrical repair of any type to the system AA If you do not understand the electrical hook up described above consult your local GlasCraft distributor OR a qualified electrician a Electrical connections must be checked on a Th m i i periodic basis 20 Connect the white and black wires of the Power cord to a single phase of 208 240 VAC 50 60 HZ The green wire should be connected to GROUND WHITE 208 240 VAC 50 60 HZ SINGLE PHASE BLACK 50 AMP MIN POWER CORD GREEN r GROUND 14 Section 2 Operation Start Up Instructions A Filling The System Never leave machine unattended while system power is on or system is running System running is defined as preheat cycle of the hose heat primary heaters or any pump operation Machine operators must be familiar with the
25. is in plant or a field contractor GlasCraft has a system package to meet your requirements GUARDIAN AIR POWERED A5 amp A6 SERIES EQUIPMENT 6000 OR 12000 WATTS OF HEAT 1600 2200 OR 3000 PRESSURE SET UPS AVAILABLE MH MH Il amp MH III HYDRAULIC POWERED SYSTEMS UP TO 45 LBS MINUTE OUTPUT EXCELLENT PERFORMANCE AND RELIABILITY GUARDIAN MMH MOBILE MODULAR HYDRAULIC SYSTEMS SPECIFICALLY DESIGNED FOR ANY TYPE OF SPRAY RIG GIVE COMPLETE UTILIZATION OF FLOOR SPACE IN MOBILE RIG PROBLER P2 SPRAY GUN IMPINGEMENT MIX AIR PURGE OPTIONAL NOZZLE FOR SPRAYING STUD WALLS POURING amp STREAM JET uality and Performance GENUINE GLASCRAFT Glas teliti FEED MGR raft DISPENSING EXCELLENCE P P O BOX 1441 sa aa MINNEAPOLIS MN 55440 1441 www glascraft com Phone 612 623 6921 Toll Free 1 800 328 0211 313274B Fax 612 378 3505
26. m 7 If plasticizer is required to chase out solvent cycle main pumps until the system is full of plasticizer then Extended Shut Down Procedure close valves and leave the pumps in the full down stroke position with 200 500 psi The following procedure is for long extended shut down periods xX Power should be disconnected and all air regulators turned down to zero 1 Remove side blocks from the gun and relieve pressure from the system PROBLER P2 21 Section 2 Operation Shut Down Instructions 8 Turn off main air supply and disconnect air line from 2 Adjust main air regulator to 20 psi the system 9 Coil the heated hoses with a minimum four foot diameter to avoid kinking and subseguent damage to the internal electrical wiring 10 For gun shut down follow the procedure from the gun manual 11 The length of time a system is shut down and the climate conditions it s stored in will determine how often the system should be purged and refilled Usually every 2 4 weeks the following procedure should be followed Purge and Refill Procedure 1 Connect the main air line to the system PROBLER P2 22 Section 2 Operation Shut Down Instructions 5 Open both side blocks simultaneously into separate A A containers and dispense approximately 1 1 2 2 gallons of material from each side or until all Before performing any repairs on any part of the system plasticizer is purged from the s
27. n 2 Operation Start Up Instructions 11 Turn on the ISO amp POLY heater control 12 Adjust main air regulator to material suppliers a Push in green power button specifications b Press up or down arrow buttons on the controller until desired temperature setting is achieved A Straighten hose out flat to avoid uneven heating and damage to internal wiring of the Hose Assembly sx Allow enough time for hose to warm up approximately Ne 15 20 minutes Remember that the heated hose does not have a delta rating The heated hose s func tion IS to maintain the heat generated by the primary heaters during system operation and preheat material during initial start up The hose should be set to maintain a temperature close to the set point of the heaters A ON OFF Due to the expansion of urethanes when heated it is imperative that on cold start up of the system that the 14 Relieve any excess pressure by triggering the gun heaters be turned on and allowed to reach operating temperatures before the main pump air regulator is adjusted to the desired spray pressure If you do not x The emergency stop switch is located on the bottom allow the heaters to reach operating temperature before right side of the control panel when depressed it will adjusting air pressure the material pressure will exceed shut down the power and activate the air dump valve the set point of the over pressure switches causing the To reset t
28. nsfer Pumps B OPTIONAL TRANSFER PUMP S 1 Is it operating 2 Is air turned on to Transfer Pump 3 Regulated pressure where it should be 4 Severe contamination of pump shaft on isocya nate side This indicates that the pump shaft is not being lubricated Check Filter of Transfer Pump Before diagnosing a faulty Transfer Pump be sure and check all items just listed under Transfer Pump On C FILTER ASSEMBLY 1 Check fluid filter at inlet to Proportioning Pumps if applicable D PROPORTIONING PUMPS 1 Determine whether the burst appears on the Pump s up or down stroke a If burst appears on UP stroke check UPPER Ball Seat and Cups b If burst appears on DOWN stroke check LOWER Ball Seat Follow the procedures in the order given Remember W that repairs should be made as soon as possible Don t leave the unit open to air any longer than necessary as this will lead to further problems such as moisture entering the system and causing the isocyanate to crystallize After the unit has been exposed to the atmosphere it should be run long enough to displace the material that was in the unit when it was opened up NEVER inspect filter assemblies at time of shut down 4 In troubleshooting a restriction problem where the material pressure gauge on the missing material side is higher than normal start at the point farthest from the unit and work backward Check obvious and easy things first Before performing
29. r safety equipment as prescribed by current regulations recommendations of the chemical sup pliers and the laws in the area where the equip ment is being used The system will dispense liguid at high pressure when Gun Trigger is activated Read and note WARNINGS contained in this User Manual and the Probler P2 Gun User Manual GC 1386 A The Polyol will expand in the Hose if any normal operating pressures are bled off whenever the mate rial is above approximately 75 degrees F Hot Polyol hoses should never be bled by any method to zero pressure for two reasons 1 The seals in the Gun rely on high pressure to make their seal The high pressure cannot be maintained if the pumps are attempting to apply this pressure through a hose full of expanded froth therefore the Gun seal may leak 2 Re starting immediately after hot Polyol has ex panded in the system may result in spraying sub stantial amounts of bad foam This will continue un til the expanded Polyol in the primary Heater and the Hose has been completely purged Over Pressure System Protection The system incorporates monitors for high pressure monitoring These monitoring devices will prevent the system from continued operation if high pressure situations develop There are pressure sensors located on each propor tioning pump The high pressure sensor is located at the outbound of the fluid section The high pressure monitoring sensor will engage if fluid
30. r to resolve the difference Careful study and continued use of this manual will pro vide a better understanding of the eguipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting Section 4 Safety Information Notes Section 1 Installation Eguipment Assembly Guardian Line Installation Guide lt GlasCraft Systems are factory assembled If any guestions arise concerning air or electrical connections please refer to illustrations located in the forward portion of this User Manual or contact your GlasCraftt distributor 1 Locate Guardian a Locate Guardian on a level surface b Do not expose Guardian to rain AX CAUTION Bolt Guardian to original shipping palet before lifting c Use the wheels to move Guardian to a fixed location or bolt to shipping pallet and move with forklift d To mount on a truck bed or trailer bolt directly to truck or trailer bed 2 Advanced preparation a Before beginning any installation ensure that the applicator has the desired power supply available i e 220V single phase 380V three phase within 10 ft of were the machine is to be placed If the machine needs to be further that 10 ft from the power supply additional lengths of properly sized electrical cable will be required AS Never use a smaller gauge size than supplied by the factory b Depending on the electrical setup it may be ne
31. s switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment here under or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 PARA EFETUAR ENCOMENDAS OU PARA ASSISTENCIA TECNICA contate o seu distribuidor da Graco POUR PLACER UNE COMMANDE OU DEMANDER DU SERVICE contactez votre distributeur Graco PARA REMITIR UN PEDIDO O SOLICITAR SERVIC
32. tential high pressure causes Restriction Overheating material in static position ISO filter at gun 5 Re start system for operation x Once the power has been turned off and problem NW solved and the main power is turned on again the over pressure lighted buttons will automatically be reset A If you do not understand the electrical hook up de scribed above consult your local GlasCraft distributor OR a gualified electrician It is recommended that a qualified licensed electrician should install power to the supply disconnect You should always follow all local or national electrical codes Disconnect power source BEFORE attempting any re pairs or opening the Control Boxes Access to internal parts is limited to qualified personnel ONLY Place Main Power Switch in OFF position BEFORE dis connecting power cables This equipment is not approved for use in hazardous locations as set forth in the National Electrical Code Article 500 and Sub Part S of the OSHA Standards Material Or Mechanical Problem Troubleshooting Procedure By following this procedure you should be able to locate and cure problems easily Remember however 38 that a successful operator must know e WHAT GOOD MATERIAL LOOKS LIKE e HOW THE EQUIPMENT NORMALLY OPERATES e WHAT PATH THE MATERIALS FOLLOW THROUGH THE EQUIPMENT e KNOWLEDGE OF THESE TROUBLESHOOTING PROCEDURES x Always start with step one never skip any por
33. tio Material Viscosity Output Operating Temperatures Maximum Air Working Pressure Maximum Fluid Working Pressure Electrical Reguirements Compressed Air Requirements Heaters Maximum Hose Length Shipping Weight Overall Dimensions Section 1 Installation Specifications 1 1 Fixed 200 2000 Centipoise Cos AMBIENT Pumps Rated 042 Gallons Per Cycle 159 Liters Per Cycle 32 F 0 C 1802 82 C 100 psi 0 69 MPa 6 9 bar 22 1 RATIO 2200 psi 15 2 MPa 152 bar 50 A 208 240 VAC 50 60 hz Single Phase cable 6 AWG 2 wire GND 25 A 208 240 VAC 50 60 hz Three Phase cable 10 AWG 3 wire GND Base Unit 1 0 GAL PER MINUTE 17 CFM 100 PSI 1 5 GAL PER MINUTE 24 CFM 100 PSI 2 0 GAL PER MINUTE 33 CFM 100 PSI NOTE As output is increased achieved w chamber size on gun or spray tip pressure drop will be greater Heating capability will also drop 6000 WATT HEATER 200 ft 61 m Each Section 50 ft x 1 4 in 1 D 440 Ibs 200 kg m 26 174 Section 1 Installation Introduction Before operating maintaining or servicing any GlasCraft system read and understand all of the technical and safety literature provided with GlasCraft products If you do not have the proper or related manuals and safety literature for your GlasCraft system contact your GlasCraft distributor In this GlasCraft t
34. tion of these procedures The material pressure gauges are to be used for troubleshooting purposes only The pressures registered on one gauge will not necessarily match the other This difference can be caused by variance in materials temperatures viscosities etc 1 Identify the missing material 2 Check the material pressure gauge on the missing material side a If the missing material gauge reads HIGHER than normal there is a RESTRICTION problem between the gauge and the Mixing Chamber tip in the Gun b If the missing material gauge reads LOWER than normal there is a STARVATION problem between the gauge and the material supply system sx Problems may be cyclic in that they will appear first on k only one stroke of the Proportioning Pump Check the pressure gauges during one of these bursts of missing materials and always stop spraying while you are getting a burst of good material 3 Concern yourself only with the material pressure on the missing material side In troubleshooting a STARVATION problem where the pressure gauge on the missing material side is LOWER than normal start at the point farthest from the unit and work forward Check the obvious and easy things first Section 3 General Information Troubleshooting A MATERIAL DRUMS 1 Material in drums 2 Material temperature a If the material is to cold especially at the bottom of the drum it will raise the viscosity of the material and stall Tra
35. tor as recommended by the fluid and solvent manufacturer e Gloves Hearing protection SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Close material shutoff valves and shutoff or disconnect air supply when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment Warnings FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help pre vent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equip ment until you
36. urn handle on push button system to shut down 15 The system is now ready for operation 17 Section 2 Operation Start Up Instructions Change Temperature Controller Display 2 Scroll through the Setup Menu by pressing the LA Units Fhrenheit or Celsius button until the display reads C F press LA button 3 times 220 V units are factory set to display temperature readings in degrees Fahrenheit 380 V units are factory set to display A Bec and hold ine SET button to display the current tempertature readings in degrees Celsius unit setting of C of F Th ispl h ith the fol SET A o mm press the Y lowi I Aing Pine sore button to switch to the desired unit setting C or F 1 On the Watlow SD31 controller press and hold 5 Release the ay buiten the W and EA buttons simultaneously for 3 seconds until the display reads SET This is the Pena Setup Menu Eas 6 Press the button to exit the Setup Menu the temperature display unit is now changed 7 Complete steps 1 6 for all three controllers ISO POLY HOSE s a Do not change any other settings in the Setup Menu AS The settings have been factory programmed for opti mal performance 18 Section 2 Notes 19 Section 2 Operation Shut Down Instructions Daily Shut Down Procedure 1 Turn off hose and heater controllers 5 Reduce main air regulator pressure to zero 6 Visually inspe
37. ystem Stop the pumps in the down position PLACE ALL CONTROLS ON THE MACHINE AND THE MAIN POWER SOURCE IN THE OFF POSITION AND DISCONNECT THE ELECTRICAL POWER CABLE FROM THE MAIN POWER SOURCE 6 Close both side blocks simultaneously and wipe off residue from the side block seals Regrease and attach both blocks to the gun 7 Mix and properly dispose of purge material Before performing any repairs on the system ALL AIR and FLUID PRESSURES SHOULD BE RELIEVED TO ZERO BLEED OFF To relieve Air and Fluid pressures System Console 1 Turn OFF valves that supply material to the pumps 2 Turn OFF main air regulator on air motor Gun 1 Open both side block material valves 2 Turn ON air switch 3 Point gun into a clean suitable container and trigger gun until material flow stops 4 Fluid pressure gauges must read zero 0 if not trigger gun until the fluid pressure gauges do read zero 0 pressure 5 Turn OFF side block material valves 6 Trigger gun several more times to purge any material remaining in gun Turn OFF air switch 7 Unless system is to be returned to service at once follow DAILY SHUT DOWN PROCEDURE 23 Section 3 General Information Assembly Drawings GC1820 GC1822 Unit Assembly o Pe s ORO NO ETE A O A lt A Z NI UG L SIS e ES SE TP gt A Igo sit Ce A kikar T Li ill ne
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