23575-00 INDY-X Chopper Gun User Manual
Contents
1. 4 Verify the Trigger Lock is in the Locked position D If Spray Gun is leak tested be sure to dry gun thoroughly It is recommended that the following service be per formed on a daily basis 6 Never leave Spray Gun immersed in any liquid 1 The Gun is built at the factory with P N 21222 00 Lubricate This is a water soluble lubricate not affected by most solvents When maintaining the Gun it is recommended that this is used as outlined on Lubricate Page Clean the Gun using a brush and a appropriate clean solvent 2 Inspect Gun Valve Needle shafts making certain they are clean and free of over spray or foreign material Clean and lubricate as required 20 Maintenance Parts Replacement Procedure Indy Guns WARNING Before attempting to perform any maintenance on this Dispense Gun Relieve All Fluid and Air Pressures See previous page CAUTION Due to the different O Ring materials and lubricants used in the Dispense Guns NEVER SUBMERGE OR SOAK ANY dispense GUN IN ANY TYPE OF SOLVENT Submerging or soaking any Dispense Gun will immedi ately void the Gun warranty 1 Read each procedure entirely before beginning and refer to the illustration views as needed 2 Flush and clean all passages as they become accessible 3 Clean all parts before assembly 4 Replace all O Rings Valves and Seals with new parts from the appropriate kit 5 Inspect all parts f2. 1 After Reassembly adjust the two Set Screws A so there is 1 8 trigger pull past the front of the Trigger Lock B This ensures proper func tion of the Trigger Guard See Drawing 2 Adjust the Set Screws so Catalyst and Resin come out of the Gun correctly NO LEAD LAG 1 16 GAP PARALLEL NOT PARALLEL lt q 1 8 MIN 24 Maintenance GUN SERVICE Packing Nut Adjustment Procedure 1 Remove trigger assembly 2 Remove chopper air valve to allow access to packing nuts 25 26 Limited Warranty Policy GLASCRAFT INC GlasCraft warrants to the original Purchaser of GlasCraft manufactured equipment and parts that all GlasCraft manufactured equipment and parts will conform to their published written specifications and be free of defects in workmanship and material for a period of one 1 year from the original date of installation GlasCraft makes no warranty to anyone other than the original Purchaser If any GlasCraft manufactured part or equipment is found to be defective in workmanship or material within the one year period from the date of installation as determined solely by GlasCraft GlasCraft in its sole discretion will either repair or replace the defective part or equipment at GlasCraft s cost including freight charges both ways or credit or refund the purchase price for the defective equipment or part A warranty claim will be hon
3. 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 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 b
4. reserves the right to change or modify this product as it deems necessary Careful study and continued use of this manual will provide a better understanding of the equip ment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting Parts amp Illustrations MODEL 23575 00 INDY X CHOP DISPENSE GUN Impingement Dispense Tips The J5 tip is furnished with the Spray Gun For more information contact your distributor or GlasCraft Service Department Material Airless Spray Tip Options LPA2 147 XXXX Requires P N s LPA2 123S and LPA2 124S Repair Parts Kits Part Description Number P OU ORNGKT O O 23557 00 O RING KIT 23558 00 MAINTENANCE KIT Indy X Chop Impingement Dispense Tip Reference Chart Part Orifice Min Max Min Number Width in Width in Output Ibs Output Ibs 10 02 12 23 7 31 11 01 10 58 13 03 12 36 9 16 10 23 11 48 10 58 12 03 12 36 9 16 10 23 11 48 10 58 12 03 12 36 9 16 10 23 11 48 10 58 12 03 10 58 9 16 10 23 11 48 10 58 12 03 12 36 9 16 10 23 11 48 LS D x Indy X Chop Impingement Dispense Tip Reference Chart Airless Dispense Tip Reference Chart Part Number 014 Part Number LPA2 147 1525 0 015 1540 0 015 1550 0 015 1565 0 015 1825 0 018 1840 0 018 1850 0 018 1865 0 018 2125 0 021 2140 0 021 2150 0 021 2165 0 021 2325
5. 0 023 2340 0 023 2350 0 023 2365 0 023 2625 0 026 2640 0 026 2650 0 026 2665 0 026 3125 0 031 3140 0 031 3150 0 031 3165 0 031 3625 0 036 3640 0 036 3650 0 036 3840 0 038 3850 0 038 4325 0 043 4340 0 043 4350 0 043 4365 0 043 5225 0 052 Note Use p n LPA2 123S and p n LPA2 124S when using LPA2 147 XXXX and 23047 XX 4 series spray tips 022 23575 00 Indy X Chop Dispense Gun 21505 00 PN 13076 06 771 1104 08 4 23531 00 Be A 63 19A Sees 21456 00 Co 20508 00 1 Catalyst seat assembly p n 23544 00 2 Material seat assembly p n E 135 3 Material needle valve assembly p n 23545 00 5 REVISION E 23575 00 Indy X Chop Dispense Gun I 00 96102 00 LISEC 00 00 81S 0 el L0 2 LIM NI GIONTINI 00 868 0 00 0881 00 116 2 r 60 198 1 N S N N i Le 9 LIM NI 0300 TONI 20 C0 0 gt 10 255 2 80 19881 E A 20 652 107 21 8 REVISION E 23575 00 Indy X Chop Dispense Gun V6I 9 Y AAR 00 v66tc 00 2652 V 910 9111 j 302 2128 SCH 7 A 9 1 f2 10 6860c e lo 00 88602 xN 9 ei 12 2 d1 00 98502 Gr S00E2 V 10130 338 Use p n LPA2 123S and p n LPA2 124S Note REVISION E when using LPA2 147 XXXX and 23047 XX series spray tips 23575 00 Indy X Chop Dispense Gun SEE DETAIL A 23531 01 23532 01 e a 23503 00 23504 00 hl 23505 00 8212 16F Zo 23509 00 23536 00
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 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 O
7. 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 12 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 explosive in nature Heat applied to MEKP or heat build up from contamination reactions can cause it to reach what is called its Self Accelerating Decomposition Temperature SADT Researchers have reported measuring pressure rates of rise well in excess of 100 000 psi per second when certain MEKP s reach their SADT For comparison the highest pressure rate of rise listed in NFPA Bulletin No 68 E
8. 23506 00 23534 00 NN 23507 00 23535 00 AD P d 8212 16F 23508 00 XO REVISION E 23575 00 Indy X Chop Dispense Gun V UIN 01 SSL 90 911L 00 986 2 N 90 yy012 00 696 2 Es 00 6LS 2 on tc 00 195 2 IDP AA Ke ge 0 9111 ET 06 ZN 00 99582 OM ES KEE 01 7661 00 996 2 9 255 et 482 766 Ov0 91LL 00 LLSEC 70 62LL 1 01 8 SE 00 16712 10 7881 REVISION E 23575 00 Indy X Chop Parts List Part number est Je nummer Pm Je 11021 41 PIPE PLUG 2 23535 00 SNAP RING 13076 06 O RING 23536 00 HANDLE REST 13867 03 O RING 23537 00 NEEDLE VALVE 13867 05 O RING 1 23539 00 MAIN BLOCK ni o 13867 07 O RING SC 23552 01 INDY X DECAL 2 13867 09 O RING 1 23554 00 SEAT WASHER SS 15845 01 BALL DRIVER WER 23556 00 TEFLON WASHER zm 18383 02 1 4 IN SST BALL KE 23567 00 COMPRESSION SPRING 1 1880 00 FITTING 1 23568 00 COMPRESSION SPRING 1 20506 00 NEEDLE 2 23569 00 CHOPPER VALVE RES 20507 00 PACKING RETAINER 23576 00 CHOPPER MOUNT Es 20508 00 MATERIAL DISK 23577 00 VALVE CAP ni 20509 00 PACKING NUT 23578 00 CHOPPER PISTON MOUNT 1 20511 00 NEEDLE COLLET 23579 00 AIR SHIFTER RS 20514 00 FITTING 23588 00 AIR SHIFTER INSERT ES 20585 01 CATALYST RING 23589 00 AIR SHIFTER PISTON Es 20586 00 NOZZLE SEAL 23592 00 FRONT HEAD ni 20588 00 RETAINING SEAL 23593 00 HEAD ADAPTER ni 20796 00 CONNECTOR FITTNG 23594 00 AIR ASSIST INSERT RES 21044 05 O RING 23597 01 FITTING RES 21456 00 PACKING HOUSING
9. 2594 02 ROLL PIN RES 21491 00 CUTTER PIVOT TUBE 2594 12 ROLL PIN 1 21505 00 VALVE SEAT RETAINER 623 RC TUBING 23503 00 TRIGGER 7554 07 O RING 2 23504 00 PULL HANDLE 7554 08 O RING ni 23505 00 GUN HANDLE 7554 10 O RING 2 23506 00 HANDLE ADAPTER 7554 11 O RING t3 3 23507 00 INDY 2 GUN HANDLE 7704 08C SET SCREW BA 23508 00 TRIGGER LOCK 7716 04C SET SCREW oa 23509 00 TRIGGER GUARD 7729 04 HEX NUT ES 23510 00 NEEDLE GUARD 8212 16F SCREW oa 23511 00 SOLVENT ADAPTER 8212 20F SCREW EZ 23514 00 GUN PIN 8212 40F SCREW 1 23516 00 FITTING 9943 28F SCREW 2 23517 00 REDUCER FITTING A 63 19A O RING 3 23518 00 BALL VALVE B 310 11 CUTTER VALVE LEVER 1 23520 00 CATALYST FITTING C 327 AIR VALVE os 23531 01 SHOULDER SCREW CC 116 O RING EZ 23532 01 SET SCREW CJ 136 O RING 2 23533 01 SET SCREW D 108 SEAT WASHER ni 23534 00 DETENT PIN E 123 VALVE SEAT RETAINER 1 GC 1379 FRP SPRAY SET UP MANUAL 1 GC 1388 USER MANUAL BN LPA2 213 END CAP ni eb CD NIw1l1 fai Operating Your Polyester System Safel 1 0 Introduction Any tool if used improperly can be dangerous Safety is ultimately the responsibility of those using the tool In like manner safe operation of polyes ter processes is the responsibility of those who use such processes and those who operate the equip ment This manual outlines procedures to be fol lowed in conducting polyester operations safely This system has been specificall
10. E GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PIS TOL 16 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 NOTE 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 NOTE Verify that the Catalyst Pressure Relief Line and the Resin Return Line are secured before relieving cata lyst and resin fluid pressure 3 Catalyst pressure in the Slave Pump can be eliminated by rotating the yellow valve handle on the Slave Pump 90 degrees to the ON position NOTE The ON position the valve handle is parallel in line with the valve body The OFF position the valve handle is perpendicu lar across the valve body 4 Resin pressure can be eliminated by rotating the yellow handled valve on the bo
11. ENSE 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 Craft DISPENSING EXCELLENCE ADS S 5845 WEST 82nd STREET ADVANCED DISPENSE FYSTEMS INDIANAPOLIS INDIANA 46278 www glascraft com U S A GC 1388 Phone 317 875 5592 REVISION E Fax 317 875 5456 E Mail sales glascraft com
12. Glascrart DISPENSING EXCELLENCE Indy X Chop External Mix Low Emission Dispense Gun Craft DISPENSING EXCELLENCE 5845 WEST 82ND STREET INDIANAPOLIS INDIANA 46278 U S A Phone 317 875 5592 Fax 317 875 5456 Email gcisales glascraft com An ISO 9001 Approved Web www glascraft com Company lt gt Z lt gt as SS YS gt Table Of Contents Introduction About This Manual L A Ee Eed 1 Parts amp Illustrations Impingement DISPENSE TIPS c Nie 2 Material Airless Spray Tip Options rer rr rss enar rr rr nns rr sr RAR RR RR RR nennen nter nnne nennen enne RR RR non 2 Repair Pants ET 2 Dispense Tip Reference Chart pp 3 23575 00 Indy X Chop Dispense GUM irreali EENS 6 Safety Operating Your Polyester System Safety be 11 Operation HOW The GUN Re 1 cem E P 19 Daily Maint nanCe na B 20 Parts Replacement Procedure pp 21 EI ER e 26 Limited Warranty Policy pp 27 Technical Assistance ere resan ran nr renare RAR RR n nnn RSKR annan RR RDR RR Rn nana 28 For Your Reference INSIDE BACK COVER About This Manual Before operating maintaining or servicing any GlasCraft system read and understand all of the technical and safety literature provided with GlasCraft produc
13. 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 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 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
14. SHA 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 event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals may have 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 instruction
15. ain 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 the handling and mixing of MEKP and diluent In addition it eliminates any problems from the diluent being contaminated through rust particles in drums poor quality control on the part of the diluent supplier or any other reason If however di luents are absolutely required contact your catalyst sup plier and follow his instructions explicitly Preferably the supplier should premix the catalyst to prevent possible on the job contamination while mixing Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocar bon Solvents GlasCraft recommends that you contact your solvent 14 WARNING
16. e 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 Spray gun Serial number Material pump Serial number Catalyst pump Chopper Serial number Type of material Type of catalyst Catalyst percentage 28 Air compressor size Compressor to system supply line Pressure at the system Main air line volume System gauge pressures AAC pressure Atomizing air pressure external mix Material pump pressure Solvent flush pressure GlaSc ft DISPENSING EXCELLENCE Date Purchased Distributor Contact Phone E mail GlasCraft manufactures a complete line of FRP spray systems If your application is in plant or a field contractor GlasCraft has a system package to meet your requirements FORMULA INTERNAL amp EXTERNAL MIX POLYESTER EQUIPMENT CHOPPER amp GELCOAT SYSTEMS NO NEEDLE IN THE SPRAY GUN INFINITELY ADJUSTABLE CATALYST PUMP INDY INTERNAL amp EXTERNAL MIX EQUIPMENT LOWEST LEVEL OF EMISSIONS AUTOMATIC EQUIPMENT FOR ROBOT APPLICATIONS SPARTAN CLOSED MOLD RTM EQUIPMENT HAND HELD amp DELUXE MODELS PROGRAMMABLE CATALYST PERCENTAGES SPECIALTY DISP
17. e 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 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 18 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 super
18. e needle assemblies 5 22 Maintenance GUN SERVICE Dispense Gun Component Service and Assembly Procedures NOTE If Packing P N 20507 00 and Packing Disks P N 20508 00 are removed from Needle and Packing Housing Glas Craft recommends that these parts always be replaced with NEW packings and pack ing disks A 63 19A O Ring 20507 00 i Retainer 20509 00 RL Ca m E Packing Nut t L en 20506 00 WV 14 O fi Material Needle n 9 6 23537 00 j 7 Needle Valve Spring f Um SV 21456 00 Sa Packing Housing 20508 00 Packing Disc 21222 00 Lube NEEDLE ASSEMBLY 1 Ensure spring is seated on needle shoulder 2 Insert needle into housing p n 21456 00 3 Lubricate a teflon packing disk with red lube lag d p n 21222 00 and slide into housing M 2 4 Lubricate retainer p n 20507 00 with red lube O B and slide it into the housing with the flat side entering E 9 the housing first Concave side entering the housing last P 7 5 Lubricate the remaining 4 teflon disc and slide them into 9 d the housing 6 Lubricate the tip of packing nut p n 20509 00 screw it into the housing and tighten until you hear a POP TORQUE TO 150 in Ibs 7 Instal and lube o ring p n A 63 19A and Re install needle assembly 23 Maintenance GUN SERVICE Set Screw Adjustment Procedure
19. ections 1910 94 Pertaining to ventilation e 1910 106 Pertaining to flammable liquids e 1910 107 Pertaining to spray finishing operations Safety particularly Paragraph m Organic Peroxides and Dual Component Coatings Other standards and recognized authorities to con sult are the National Fire Protection Association NFPA bulletins as follows NFPA No 33 Chapter 14 Organic Perox ides and Dual Component Materials NFPA No 63 Dust Explosion Prevention NFPA No 70 National Electrical Code NFPA No 77 Static Electricity NFPA No 91 Blower and Exhaust System 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 Hazards of Organic Peroxides It is published by American Insurance Association 85 John Street New York New York 10038 Local codes and authorities also have standards to be followed in the operation of your spraying equip ment Your insurance carrier will be helpful in an swering questions that arise in your development of safe procedures 1 2 Personnel Safety Equip
20. en 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 13 with copious quantities of clean water and disposed of in accordance with the catalyst manufacturer s instructions The extent to which the user is successful in accomplishing these ends and any additional recom mendations by the catalyst manufacturer determines largely the safety that will be present in his operation 2 3 Clean Up Solvents and Resin Diluents WARNING A hazardous situation may be present in your pressur ized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed pressurized fluid system pumps heaters fil ters valves spray guns tanks etc The explosion could cause serious injury death and or substantial property damage Cleaning agents coatings paints etc may contain Halogenated Hydrocarbon Solvents Some GlasCraft spray equipment includes aluminum or galvanized components and will be affected by Halogenated Hydrocarbon Solvents There are three key elements to the Halogenated Hydrocarbon HHC solvent hazard 1 The presence of HHC solvents 1 1 1 Trichloroethane and Methylene Chloride are the most common of these solvents However other HHC solvents are suspect if used either as part of paint or adhesives form
21. event 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 WARNING Do not use Halogenated Hydrocarbon solvents in pres surized fluid systems having aluminum or galvanized wetted parts NOTE GlasCraft is aware of NO stabilizers available to prevent Halogenated Hydrocarbon solvents from reaction under all conditions with aluminum components in a closed fluid system TAKE IMMEDIATE ACTION Halogenated Hydrocarbon solvents are dangerous when used with aluminum components in a closed fluid system 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 m
22. ly setting the material pump pressure matching a spray tip that will deliver desired output and useable spray pattern not atomizing the material The AAC Air gun is very user friendly Black tubing Example Because of the variables involved Chopper Air Line material viscosity sheer of material ambient Catalyst Hose Red air hose temperature required output your pressure Black hose setting will vary Material Hose Black hose Lock Trigger Rotate trigger lock to stop the trigger from being activated 19 Daily Maintenance WARNING 3 Inspect the Gun Packings Needles and Seats for Before attempting to perform any maintenance on this catalyst or material leakage If leakage does occur Spray Gun Relieve All Fluid and Air Pressures correct at once If material leaks or drips out of the nose of the gun this indicates that there is a bad needle seat condition If material leaks out of the back of the needle stem this indicates loose or 1 Push down Yellow slide valve P N 21402 00 to bleed worn packings and may be repacked by tightening off air to system the packing nuts P N 20509 00 1 8 turn each until leak stops Test trigger to verify spring can return needle to seat To relieve fluid and air pressures 2 Open P N 21228 00 on catalyst pump to recirculation position 4 Maintain a reasonable stock level of wear items 3 Open P N 21192 00 on bottom of material pump such as Packings Seals and O Rings
23. ment GlasCraft recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems esq EYE HEARING HREATHING GLOVE REQUIRED PROTECTION PROTECTION PROTECTION H3 ws 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 laminate accumulations of overspray and laminate sandings 6 The toxicity dangers of all the chemicals used in laminating operations with respect to ingestion inhalation and skin and eye hazards 2 2 Catalyst Methyl Ethyl Ketone Peroxide MEKP is among the more hazardous materials found in commercial channels The safe handling of the unstable reactive chemicals presents a definite
24. or wear or damage and replace as required with new GENUINE GlasCraft REPLACEMENT PARTS from your authorized GlasCraft Distributor 6 Inspect all threads for wear or damage and replace as required 7 Tighten all threaded parts securely but not excessively upon assembly 8 O rings can fail if subjected to any of the following conditions a Swelling coming in contact with solvent or oil from compressor b Cut sharp unlubricated edge in gun head or handle c Sticky contaminated with oil water solvent catalyst resin or gel coat d Chaffing dry sliding surfaces needs lubrication 9 Lightly lubricate all O Rings with petroleum jelly 10 Check all springs for resilience They should return quickly to their original new length 11 Clean the exterior of the Gun and Hoses with an appropriate clean solvent and cloth or brush Hose Removal 1 Remove Resin Hose with an 11 16 wrench Hold delivery tube with an 11 16 wrench 2 Remove Catalyst Hose with a 9 16 wrench Hold delivery tube with a 9 16 wrench 3 Remove Air Flush Block with an 5 32 Allen wrench Remove block watch for spring and ball from Air Valve NOTE Tape a clean polyethylene bag over the end of each Hose to prevent spillage and to keep clean Maintenance Needle amp Pin Removal Procedures Remove needle collets GUN SERVICE 1 Remove set screws 2 3 4 Remove needle guard Remove pins Remov
25. ored only when 1 GlasCraft has been informed in writing of any such defect in workmanship or material within ten 10 days after discovery by the original Purchaser 2 An official of GlasCraft has issued a return authorization number and 3 The claimed defective equipment or part has been returned to GlasCraft by the original Purchaser freight prepaid with proper return authorization number s attached to GlasCraft Inc 5845 West 82nd Street Suite 102 Indianapolis IN 46278 U S A This warranty shall not apply to any equipment or parts that have been altered or repaired by anyone other than GlasCraft or to defects or damage resulting from improper installation misuse negligence accident or use not specified by GlasCraft This warranty shall not apply to any equipment where any parts or components were replaced by any parts or components not manufactured or supplied by GlasCraft The decision by GlasCraft shall be conclusive and binding on Purchaser GlasCraft does not warrant that any equipment or parts sold to Purchaser meet or comply with any local state federal or other jurisdiction s regulations or codes GlasCraft does not warrant that any equipment or part sold to Purchaser when used individually or in concert with any other part equipment device component or process does not infringe on any patent rights of any third party GlasCraft only warrants that it has no specific knowledge of any such infringement GlasC
26. raft makes no warranty as to any parts or equipment manufactured by others Purchaser shall look solely and only to the manufacturer of such parts or equipment with respect to any warranty claims GlasCraft hereby assigns to Purchaser the original manufacturer s warranties to all such equipment and parts to the full extent permitted THE AFORESAID WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IM PLIED SPECIFICALLY THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH WARRANTIES ARE SPECIFICALLY DISCLAIMED GlasCraft shall not be liable for any loss or expense resulting from damage or accidents caused by improper use or ap plication of materials manufactured or sold by GlasCraft or its distributors or agents UNDER NO CIRCUMSTANCES SHALL GLASCRAFT S LIABILITY EXCEED THE AMOUNT PUR CHASER PAID FOR THE CLAIMED DEFECTIVE EQUIPMENT OR PART UNDER NO CIRCUM STANCES SHALL GLASCRAFT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES OR FOR LOST PROFITS No action arising from or relating to any goods manufactured by or purchased from GlasCraft may be brought more than one 1 year after the cause of action accrues 27 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 servic
27. rds that may result from improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users should make every effort to 1 Store MEKP in a cool dry place in original containers away from direct sunlight and away from other chemicals 2 Keep MEKP away from heat sparks and open flames 3 Prevent contamination of MEKP with other materials including polyester overspray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels 4 Never add MEKP to anything that is hot since explosive decomposition may result 5 Avoid contact with skin eyes and clothing Protective equipment should be worn at all times During clean up of spilled MEKP personal safety equipment gloves and eye protection must be worn Fire fighting equipment should be at hand and reagy 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 betwe
28. s 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 NOTE Refer to your System User Manual for complete and detailed operating instructions and service informa tion 3 0 Equipment Safety WARNING GlasCraft suggest that personnel safety equipment such as EYE GOGGLES GLOVES EAR PROTEC TION and RESPIRATORS be worn when servicing or operating this equipment Ear protection should be worn when operating a fiberglass chopper to pro tect against hearing loss since noise levels can be as high as 116 dB decibels This equipment should only be operated or serviced by technically trained personnel 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 TH
29. ts If you do not have the prop er or related manuals and safety literature for your GlasCraft system contact your GlasCraft distributor or Glas Craft Inc In this GlasCraft technical and safety publica tion the following advisories will be provided where appropriate NOTE Is information about the procedure in progress CAUTION Is imperative information about equipment protection WARNING Is imperative information about personal safety 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 Introduction made from the GlasCraft assembly instructions provided This manual provides information for the assem bly operation maintenance and service of this GlasCraft product as used in a typical configu ration While it lists standard specifications 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 pro duction and if practical make it available to cur rent users as a retrofit up date or supplement If you find some discrepancy between your unit and the available documentation contact your GlasCraft distributor to resolve the difference GlasCraft Inc
30. ttom 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 Catalyst Injector User Manual for proper pressure relief Never operate a Fiberglass System with fixed Pinch Point guards removed from system 17 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
31. ulation 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 Safety The reaction is unpredictable Prior use of an HHC sol vent without incident corrosion or explosion does NOT mean that such use is safe These solvents can be dan gerous alone as a clean up or flushing agent or when used as a component or a coating material There is no known inhibitor that is effective under all circumstances Furthermore the mixing of HHC solvents with other materials or solvents such as MEK alcohol and tolu ene may render the inhibitors ineffective The use of reclaimed solvents is particularly hazardous Reclaimers may not add any inhibitors Also the pos sible presence of water in reclaimed solvents could feed the reaction Anodized or other oxide coatings cannot be relied upon to pr
32. visor 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 Glascrart DISPENSING EXCELLENCE 5845 WEST 82nd STREET SUITE 102 INDIANAPOLIS INDIANA 46728 U S A PHONE 317 875 5592 FAX 317 875 5456 O Model 23575 00 Hose Attachment How the Gun Works The Indy X Chop Gun is an evolutionary de sign that reduces operator fatigue through re Atomizing Air duced gun weight enhanced maneuverability Red tubing The Indy X Chop Gun is a straight forward simple design having fewer parts and o rings than any other gun in its class The Indy X Chop is designed to be a true high volume low pressure gun The ports in the gun are large to allow for less back pressure and easy flow of material This is further achieved with large material hoses and proper
33. xplosion 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 injury For this reason and many others anyone whose job puts them in an area where this vented spray might go should always wear full eye protection even when laminating operations are not taking place 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 haza
34. y designed for use of Polyester Resin Gel Coat and Methyl Ethyl Ke tone Peroxides MEKP applications Other formu lations or blends considered for use in this equip ment is strictly prohibited without the expressed consent by GlasCraft Inc GlasCraft Inc cannot eliminate every danger nor foresee every circumstance that might cause an in jury during equipment operation Some risks such as the high pressure liquid stream that exits the spray tip are inherent to the nature of the machine operation and are necessary to the process in or der to manufacture the end product For this rea son ALL personnel involved in polyester operations should read and understand the Safety Manual It is very 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 develop his own safety program and be assured that his equipment operators follow correct proce dures GlasCraft hopes that this manual is helpful to the user and recommends that the precautions in this manual be included in any such program GlasCraft recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual GlasCraft recommends that the user consult the regulations established un der the Occupational Safety amp Health Act OSHA particularly the following s
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