Internal-Mix System User Manual
Contents
1. Red Tubing S r 20190 00 Catalyst Hose Ld cS RALF 21694 25 Material Hose m Air Lines Clear Tubing mm Material Hoses Catalyst Hose Section 3 General Information Options Clear Tubing 1 4 in Clear Tubing 1 8 in Catalyst Bottle 20260 00 Recirculation Hose tape together with green material hose Do Not insert the hoses in the material drum until the system has been flushed Clear Tubing 3 8 in Solvent Pot GAM 268 01 Pick Up Kit 15 Section 3 General Information Options Formula Dispense Gun Formula Dispense Gun 12 a Remove the plug from the side of the air 23750 manifold and install the regulator kit 3 20 00 p n 22632 00 Be sure to teflon tape the threads b Attach all hoses and tubing as shown x This diagram is for displaying point to point W hook up ONLY and DOES NOT suggest actual routing of hoses and tubing All hoses and tubing should be routed neatly and free of any moving components lt gt 21179 00 Red Tubing 22632 00 TI IT 20190 00 Catalyst Hose 21694 25 Material Hose ag ms Air Lines gt Clear Tubing J mm Material Hoses Fluid Section 16 Catalyst Hose Section 3 General Information Options Clea2. 2 3 Clean Up Solvents and Resin Diluents N WARNING A hazardous situation may be present in your pressur ized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed pressurized fluid system pumps heaters fil ters valves spray guns tanks etc The explosion could cause serious injury death and or substantial property damage Cleaning agents coatings paints etc may contain Halogenated Hydrocarbon Solvents Some GlasCraft spray equipment includes aluminum or galvanized components and will be affected by Halogenated Hydrocarbon Solvents There are three key elements to the Halogenated Hydrocarbon HHC solvent hazard 1 The presence of HHC solvents 1 1 1 Trichloroethane and Methylene Chloride are the most common of these solvents However other HHC solvents are suspect if used either as part of paint or adhesives formulation or for clean up flushing 2 Aluminum or Galvanized Parts Most handling equipment contains these elements In contact with these metals HHC solvents could generate a corrosive reaction of a catalytic nature 3 Equipment capable of withstanding pressure When HHC solvents contact aluminum or 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
3. WASHER 7486 04 FLAT WASHER 20568 00 CASTER 2 Insert mast into base socket and secure with supplied bolts 663 MAST 7957 32F SCREWS 3 Slide catalyst jug bracket over the mast and DO NOT TIGHTEN MAST CATALYST JUG BRACKET LPA 170 BASE 18291 01 4 Loosen clamp bolts to expose pump mounting bracket Attach pump mounting bracket to the air motor Use blue loctite on the threads and tighten bolts as tight as possible PUMP MOUNTING BRACKET 19890 00 Section 1 Installation Equipment Assembly 5 Stand pump next to the mast and 6 Mount catalyst bottle approximately 26 from the top of install the pump mounting bracket the base plate to the bottom of the catalyst bracket Bm mM PUMP MOUNTING BRACKET 0 9 26 APPROX 0 5 BASE b Lift to desired height approximately 36 from the 1 top of the base to the bottom of the pump mount i ing bracket Use 3 4 wrench and tighten as tight
4. 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 GlasCraft makes no warranty as to any parts or equipment manufa
5. Applicable Section 1 Installation Introduction Before operating maintaining or servicing any GlasCraft system read and understand all of the technical and safety literature provided with GlasCraft products If you do not have the proper or related manuals and safety literature for your GlasCraft system contact your GlasCraft distributor or GlasCraft Inc In this GlasCraft technical and safety publication the following advisories will be provided where appropriate Is information about the procedure in progress t Is imperative information about equipment protection CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury N WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury ELECTRICAL SHOCK HAZARD Indicates a hazardous situation which if not avoided could result in electrical shock or serious injury The information in this document is intended only to indicate the components and their normal working relationship typical use Each assembly should be directed by a GlasCraft distributor or made from the GlasCraft Assembly instructions provided This manual provides information for the assembly opera tion maintenance and service of this GlasCraft product as used in a typical configuration While it lists standard specifi cations and procedures some deviations may be found In order to provide our
6. C Section 3 General Information Sub Assembly Drawings 20794 01 Solvent Tank GI ttn 3165 Y 2 SOLVENT TANK 4 v DIP TUBE 18470 05 UP A 20120 00 50 14153 Flore 21035 00 2 EH 22 8 EZ 20324 00 Number Part a EXE Number _ Description 12 REVISION Section 3 General Information Options SSP 175 Safety Guard Kit 20188 16C 7734 06 5 177 e 20188 16C 7734 06 20188 16C 20188 16C 7734 06 7734 06 7486 13 lt SSP 173 20188 16C mu 7734 06 7486 13 2 20188 16 7734 06 SSP 172 4 i _____ gt 0188 16 SSP 176 7734 06 SSP 174 REMOVE PROTECTIVE FILM FROM BOTH SIDES OF THE SAFETY GLASS AND ATTACH IT TO THE COVER USING HARDWARE 5 20188 16C AND 7486 05 SSP 175 Part ee Description Qty SSP 172 SURROUND GUARD SSP 173 LEFT PUMP GUARD SSP 174 ANGLE BRACKET GUARD WINDOW RIGHT PUMP GUARD RIGHT FRONT PUMP GUARD SCREW FENDER WASHER WASHER LOCK WASHER 13 Section 3 General Information Options Indy Dispense Gun y DISp d Indy Dispense Gun 12 Attach all hoses and tubing as shown v 23550 00 This diagram is for displaying point to point ONLY and DOES suggest actual routing of hoses and tubing All hoses and tubing should be routed neatly and free of any moving components Fluid Section lt
7. io as possible C a BRACKET MG 45 APPROX 71 UT UT U 1 36 APPROX BL BASE Am 1 Section 1 Installation Equipment Assembly 10 Remove safety cap from the bypass valve and drain the testing oil into an open container Attach the bypass hose to the fitting and tighten BYPASS VALVE 21192 00 valve 20260 00 hose 11 Proceed to section 3 5 General Information Options of this manual to finish the system assem according to the dispense gun option you have chosen AN DO NOT proceed with section 2 1 new system start up until assembly is complete Section 2 Operation New System Start Up The following assumes that all connections are tight N Before turning on main air check all On Off Ball Valves making certain all Valves are in the Off position and set all regulators in their Off position Turn knob counter clockwise for OFF or reduced pressure setting 1 Select a clean dry air supply 2 Attach a 3 8 or larger air hose to the Air Manifold intet 5 Place the mixing element straight into the front gun nlet housing refer to spray gun user manual 6 Place the retaining nut along with the spray tip and spray tip spacer onto the gun housing refer to spray gun user manual T Push the slide valve to the open position 3 Attach grounding clamp assembly P N 17440 00 to the system mast clamp 8 Ope
8. solvents and other flammable ma terials are used Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction Such coatings can Adequate ventilation as covered in OSHA Section 1910 94 be worn cracked scratched or too thin to prevent con No 91 is important wherever solvents are stored tact There is no known way to make oxide coatings or or used to minimize confine and exhaust the solvent to employ aluminum alloys which will safely prevent the Solvents should be handled in accordance with OSH chemical reaction under all circumstances Section 1910 106 and 1910 107 Several solvent suppliers have recently begun promoting E HHC solvents for use in coating systems The increasing 2 4 Catalyst Diluents use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans GlasCraft spray up and gel coat systems currently produced as Volatile Organic Compounds VOC s their low flam are designed so that catalyst diluents are not required mability hazard and their not being classified as toxic GlasCraft therefore recommends that diluents not be used carcinogenic substances HHC solvents are very desir This avoids the possible contamination which could lead to able in many respects an explosion due to the handling and mixing of MEKP and diluent In addition it eliminates any problems from the di N WARNING luent being contami
9. 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 Heatappliedto MEKP orheat build up from contamination reactions can cause it to reach what is called its Self Accelerating Decomposition Temperature SADT Researchers have reported measuring pressure rates of rise well in excess of 100 000 psi per second when certain MEKP s reach their SADT For comparison the highest pressure rate of rise listed in NFPA Bulletin No 68 Explosion Venting is 12 000 psi per second for an explosion of 1296 acetylene and air The maximum value listed for a hydrogen explosion is 10 000 psi per second Some forms of MEKP if allowed to reach their SADT will burst even an open topped container This suggests that 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 use
10. three elements are present the result can be an extremely violent explosion the reaction can be sustained with very little aluminum or galvanized metal any amount of aluminum is too much Section 4 Safety Information General Safety GlasCraft recommends that you contact your solvent The reaction is unpredictable Prior use of an HHC sol supplier regarding the best non flammable clean up solvent vent without incident corrosion or explosion does NOT with the heat toxicity for your application mean that such use is safe These solvents can be dan gerous alone as a clean up or flushing agent or when _ If however you find it necessary to use flammable solvents used as a component or a coating material There is no they must be in approved electrically grounded con known inhibitor that is effective under all circumstances Furthermore the mixing of HHC solvents with other Bulk solvent should be stored in a well ventilated materials or solvents such as MEK alcohol and tolu separate building 50 feet away from your main plant ene may render the inhibitors ineffective You should allow only enough solvent for one day s use in The use of reclaimed solvents is particularly hazardous your laminating area Reclaimers may not add any inhibitors Also the pos sible presence of water in reclaimed solvents could feed NO SMOKING signs must be posted and observed in all the reaction areas of storage or where
11. users with the most up to date technology possible we are constantly seeking to improve products If technological change occurs after a product is on the market we will implement that technology in future production and if practical make it available to current users as a retrofit up date or supplement If you find some discrepancy between your unit and the available documen tation contact your GlasCraft distributor to resolve the difference GlasCraft Inc reserves the right to change or modify this product as it deems necessary Careful study and continued use of this manual will pro vide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting Section 1 Installation Standard Equipment Model Internal Gel Coat System Standard Equipment Part Em 20864 05 MATERIAL PUMP ASSEMBLY 11 1 RATIO 55 160 02 GAM 268 01 2169428 17440 00 23558 00 17798 25 20190 00 21054 01 20794 01 19890 01 18291 01 casters 20638 00 CASTERS GC 1317 MANUALS Section 1 Installation Equipment Assembly If the cart mast amp boom or wall mount options are being used be sure they are completely assembled and proceed to step 4 Tools Required 1 Standard wrench amp socket set 2 Standard hex key set 3 Tape measure or yard stick All Required tools are standard sizes 7755 42 NUT 7754 1010
12. 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 22 3 Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom sections and at the gun and fittings Replace if wear or weakness is evident or suspected 4 Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub against any of the hoses at any point If allowed to rub the hoses may be cut through causing a hazardous leakage of material which could incr ease the danger of fire Also the material may spew onto personnel in the area 2 7 Toxicity of Chemicals GlasCraft recommends that you consult OSHA Sections 1910 94 1910 106 1910 107 and NFPA No 33 Chapter 14 and 91 Contact your chemical supplier s and determine the toxicity of the various chemicals used as well as the best methods to prevent injury irritation and danger to personnel Also determine the best methods of first aid treatment for each chemical used in your plant 2 8 Treatment of Chemical Injuries Great care should be used in handling the chemicals res ins catalyst and solvents used in polyester systems Such chemicals should be treated as if they hurt y
13. 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 Equipment GlasCraft recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems EYE HEARING PROTECTION PROTECTION CAUTION GLOVES REQUIRED IN THIS AREA BREATHING PROTECTION Section 4 Safety Information General Safety GlasCraft recommends that the user consult the state and local regulations established for all Safety equip ment listed 2 0 Material Safety 2 1 Hazards Associated with Laminating Operations The major hazards which should be guarded against in polyester laminating operations are those associated with 1 The flammability and explosi
14. Glascrart Internal System Low Emission Internal Mix Gel Coat lt Z lt gt as Zi YS Table Of Contents Section 1 Installation 1 1 IAtroduction area a a 1 1 2 Standard E uipmMent Ace ge Poe ed 2 LEX 1 4 Eg ipfment ASSembly iio 3 Section 2 Operation 2 1 New System Start up Instructions 6 2 2 Shutdown Instructions mta etum ee 9 2 3 Daily Start Up Instructions he De er Lenker N A Section 3 General Information 3 1 Assembly Drawings e robur Ren N A 3 2 Sub Assembly Drawings ree e t dt ORE Dr RE ee E e E ERU ORI 10 3 3 EMI UP 14 3 A Troubleshootirig 2 2 62 E et e rete NG ccm Lineare N A FO PUONS f Mt 15 Section 4 Safety Information 4 1 General 24 4 2 Notes Eta ioi e lin ese indice cae eee ele 32 4 3 Limited Warranty Policy 2 ses es vanor et a ed TER HERD E Rr Ben 35 4 4 Technical 55151 2 220 aA he RN a eed ee ei ee eee 36 For Your Reference oe cade a eae eee dee ee ae eee DEI INSIDE BACK COVER N A None
15. HIGH VISCOSITY POLYESTER PUTTY DISPENSE RCD RESIN CATALYST DISPENSE PRESSURE FED ROLLERS Quality and Performance GENUINE GLASCRAFT Glaserart DISPENSING EXCELLENCE ADS 5845 WEST 82nd STREET ADVANCED DISPENSE eee INDIANAPOLIS INDIANA 46278 www glascraft com U S A GC 1317 Phone 317 875 5592 REVISION March 2008 Fax 317 875 5456 E Mail sales glascraft com
16. ctured 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 Section 4 Safety Information Technical Assistance Thank You for selecting GlasCraft spray equipment Should you have any questions or need technical assistance contact your factory authorized GlasCraft distributor Distributor Phone Contact For any issues your distributor cannot address the GlasCraft technical service departmen
17. erglass chopper to protect against hearing loss 7 Tm since noise levels can be as high as 116 dB decibels 2 The ON position the valve handle is parallel in line This equipment should only be operated or serviced by with the valve body technically trained personnel The OFF position the valve handle is perpendicular across the valve body N WARNING Never place fingers hands or any body part near or di rectly in front of the spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DI RECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PER SON TREAT THE GUN AS IF IT WERE A LOADED PIS TOL Resin pressure can be eliminated by rotating the yellow handled valve on the bottom of the fluid filter 90 degrees Place a container under the bottom of the valve to catch any resin that is ejected from the valve 23 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 rem
18. for the safety of employees involved in the operation that equipment operators mainte nance and supervisory personnel understand the requirements for safe operation Each user should examine his own operation de velop his own safety program and be assured that his equipment operators follow correct procedures GlasCraft hopes that this manual is helpful to the user and recommends that the precautions in this manual be included in any such program GlasCraft recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual GlasCraft recommends that the user consult the regulations established un der the Occupational Safety amp Health Act OSHA particularly the following sections 1910 94 Pertaining to ventilation 1910 106 Pertaining to flammable liquids 1910 107 Pertaining to spray finishing operations 18 Section 4 Safety Information General Safety particularly Paragraph m Organic Peroxides and Dual Component Coatings Other standards and recognized authorities to con sult are the National Fire Protection Association NFPA bulletins as follows 33 Chapter 14 Organic Perox ides and Dual Component Materials 63 Dust Explosion Prevention 70 National Electrical Code 77 Static Electricity 91 Blower and Exhaust System 654 Plastics Industry
19. he cycle rate should slow indicating the pump is primed Close the recirculation valve C Hand prime the pump until a steady stream ofcat alyst flows back to the bottle d Close the ball valve hand stroke the pump until it devel opes 300 400 PSI x If you are using the optional Formula gun set the trigger air regulator to 100 psi The trigger air IS NOT to exceed 100 psi Recirculation Valve Resin Pump Regulator 10 Trigger the Gun into a container until all the air is purged from the resin side of the system It may be necessary to Hand stroke the Catalyst Pump several times while the gun is triggered to positively deliver a steady stream of catalyst let go of the trigger and hand stroke pump again to develop 300 400 PSI STOP a Solvent flush the gun STOP Do not exceed 20 psi pressure on the Material Regulator Regulator until steady material flow has been established Section 2 Operation Shut Down Instructions 2 Push down the yellow slide valve P N 21402 00 on the inlet air to bleed off air on system Due to the different O Ring materials and lubricants used in the Guns NEVER SUBMERGE OR SOAK ANY dispense GUN IN ANY TYPE OF SOLVENT Submerging or soaking any Gun will immediately void the Gun warranty 1 Activate trigger lock to stop the trigger from being activated Refer to gun manuals if needed 3 Turn catalyst yel
20. ination 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 times During clean up of spilled MEKP personal safety equipment gloves and eye protection must be worn Fire fighting equipment should be at hand and ready 6 Avoid spillage which can heat up to the point of self ignition 7 Repair any leaks discovered in the catalyst system immediately and clean up the leaked catalyst at once in accordance with the catalyst manufacturer s instructions 8 Use only original equipment or equivalent parts from GlasCraft in the catalyst system i e hoses fittings etc because a dangerous chemical reaction may result between substituted parts and MEKP 9 Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries should never be returned to the supply tank such catalyst should be diluted 20 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
21. low ball valve P N 21228 00 to Open Recirculation position to dump psi and close the valve Push in and rotate trigger lock p n 23774 00 to stop the trigger from being activated 4 Pressure should be maintained on the resin hose If you are using the Indy gun install the night plug p n 23527 00 Refer to gun manuals for service and maintenance Rotate trigger lock to stop the trigger from being activated Indy Gun Section 3 General Information Sub Assembly Drawings LPA 165 Bottle 161 21045 01 21044 0 21039 00 21040 00 9104 11 Part e LPA 167 1 BOTTLE nc LPA 172 SCREEN 2109900 __TUBEADAPTER 3 zoo ana ren mwene s REVISION N Section 3 General Information Sub Assembly Drawings GAM 268 01 Material Pick Up Kit 20395 00 20398 02 20394 00 Part we 20394 00 PICK UP TUBE 20395 00 ELBOW FITTING 20397 01 MESH FILTER 20398 02 MATERIAL HOSE Filter Options Part Description Number 20397 02 100 MESH 20397 03 50 MESH 20391 01 10 REVISION D Section 3 General Information Sub Assembly Drawings 23555 00 Air Manifold 18318 02 20186 00 8115 03 SM 14626 01 ES VENTED SIDE MUS lt gt DECAL E 14 8115 03 3364 03 20655 04 21119 00 Part Number 11 REVISION
22. n the air valve p n 3165 on the solvent tank and adjust the solvent pressure to 90 PSI 6 BAR Open the ball valve p n 18470 05 on the solvent tank Next open ball valve p n 23518 00 on the gun to verify that solvent will flow out of the front of the gun thru the dispense tip then close the valve Attach here N Do not exceed 20 PSI on the material regulator until a steady material flow has been established 4 Securely attach Clamp P N 7749 00 to permanently grounded rod or pipe 7749 00 NM Regulator GROUNDING ROD OR PIPE 7750 04 13193 00 gt SYSTEM Section 2 Operation New System Start Up b Once primed increase the resin PSI until a desired SSP 160 02 spray pattern is achieved 9a Pull and rotate Pivot knob to disengage the catalyst drive arm c After all pressure adjustments have been completed a finial spray test should be made Spray a test shot sample on a clean piece of paper The shot should be approximately five feet in length You can now check desired gel times and uniformity of curing b Turn the slave pump yellow ball valve to the open position d Flush the gun thoroughly with solvent after use 11 Make sure that the resin pump recirculation valve is off and that the bypass hose is in back in the the drum adjust the resin pump regulator to 20 PSI 1 5 BAR the pump will start to slowly cycle Allow the pump to load t
23. nated through rust particles in drums oor quality control on the part of the diluent supplier or an Do not use Halogenated Hydrocarbon solvents in pres EA y y ized fluid f havi lumi Ivana dd other reason If however diluents are absolutely required ir deis SUSHI anes contact your catalyst supplier and follow his instructions ex plicitly Preferably the supplier should premix the catalyst to prevent possible the job contamination while mixing GlasCraft is aware of NO stabilizers available to N WARNING A nn d 22 Hy a t If diluents are not used it should be remembered that cat reag x pk aaa is IR alyst spillage gun hose and packing leaks are potentially more hazardous since each drop contains a higher concen 22 22 d tration of catalyst and therefore will react quicker with over alogenate Ydrocarbon solvents are dangerous spray and the like when used with aluminum components in a closed fluid system 2 5 Uncured Liquid Resin Consult your material supplier to determine whether Resin should be stored in a well ventilated building your solvent or coating contains Halogenated Hydrocar at least 50 feet from your main plant In addition the bon Solvents storage temperature should not exceed 75 degrees F 21 Section 4 Safety Information General Safety In your main plant store only enough resin for one day s production NO SMOKING signs must be posted a
24. nd observed in all areas where resin is stored and or used Refer to OSHA Section 1910 94 1910 106 1910 107 and consult resin suppliers for more detailed informa tion Adequate ventilation as covered in OSHA Section 1910 94 and NFPA No 91 is important wherever sol vents are stored or used to minimize confine and ex haust the solvent vapors Resin must never be stored in an area where MEKP is stored or used Open top drums should not be used due to possible contamination and possible catalyzation from overspray or spillage of MEKP into drum which could not only se verely damage the polyester spray system but might also cause the drum of resin to ignite When spraying test patterns or purging the gun always remove the test samples and waste from the building im mediately and dispose of them in accordance with your material supplier s recommendations 2 6 Cured Laminate Overspray and Laminate Sandings Accumulation Remove all accumulations of overspray FRP sandings etc from the building as they occur If this waste is al lowed to build up spillage of catalyst is more likely to start a fire In addition the fire would burn hotter and longer Floor coverings if used should be non combustible Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product oversprayed chop or resin FRP sandings or any other material with MEKP To prevent this spillage and leakage you should
25. nformation and data given herein are believed to be accurate and reliable but are pre sented without guaranty warranty or responsibility of any kind expressed or implied The user should not assume that all safety measures are indicated or that other measures are not required Glascrart DISPENSING EXCELLENCE 5845 WEST 82nd STREET SUITE 102 INDIANAPOLIS INDIANA 46728 U S A PHONE 317 875 5592 FAX 317 875 5456 Section 4 Safety Information Notes 26 Section 4 Safety Information Limited Warranty Policy GLASCRAFT INC GlasCraft warrants to the original Purchaser of GlasCraft manufactured equipment and parts that all GlasCraft manufactured equipment and parts will conform to their published written specifications and be free of defects in workmanship and material for a period of one 1 year from the original date of installation GlasCraft makes no warranty to anyone other than the original Purchaser If any GlasCraft manufactured part or equipment is found to be defective in workmanship or material within the one year period from the date of installation as determined solely by GlasCraft GlasCraft in its sole discretion will either repair or replace the defective part or equipment at GlasCraft s cost including freight charges both ways or credit or refund the purchase price for the defective equipment or part A warranty claim will be honored only when 1 GlasCraft has been informed in writing
26. nother 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 GlasCraft provides a grounding wire and clamp gt assembly p n 17440 00 with all FRP equipment 25 Never use hard materials such as wire pins etc To clear a plugged gun Hard materials can cause per manent damage Dab with a bristle brush blow back wards with air until clear while wearing a protective eye shield Repeat as many times as necessary Do not perform any maintenance or repairs until you have followed the precautions stated above If you as an equipment operator or supervisor do not feel that you have been adequately trained or instructed and that you lack the technical knowledge to operate or perform maintenance on a piece of glascraft equip ment please call glascraft inc Before operating or performing maintenance on the equipment If you have any questions regarding the above pre cautions or any service or operation procedures call your glascraft distributor or glascraft inc X All statements i
27. on dangers of the catalyst normally used Methyl Ethyl Ketone Peroxide 2 The flammability dangers of clean up solvents sometimes used GlasCraft recommends that clean up solvents be nonflammable and of resin diluents used such as styrene 3 The flammability dangers of catalyst diluents if used GlasCraft recommends that catalyst not be diluted 4 The flammability dangers of the uncured liquid resins used 5 The combustibility dangers of the cured laminate accumulations of overspray and laminate sandings 6 The toxicity dangers of all the chemicals used in laminating operations with respect to ingestion inhalation and skin and eye hazards 2 2 Catalyst Methyl Ethyl Ketone Peroxide MEKP is among the more hazardous materials found in commercial channels The safe handling of the unstable reactive chemicals presents a definite challenge to the plastics industry the highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage transportation handling processing and disposal MEKP is not a single chemical Various polymeric forms may exist which are more or less hazardous with respect to each other These differences may arise not only from different molecular structures all are nevertheless called MEKP and from possible trace impurities left from
28. our skin and eyes and as if they are poison to your body For this reason GlasCraft recommends the use of protective clothing and eye wear in using polyester systems However users should be prepared in the event of such an injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals may have Section 4 Safety Information General Safety 3 1 Emergency Stop Procedures Contact a doctor immediately in the event of any injury and give him the information you have collected Ifyour information includes first aid instructions administer first aid immediately while you are contacting the doctor The following steps should be followed in order to stop the machinery in an emergency situation 1 The yellow air valve located where the air Fast treatment of the outer skin and eyes that contact enters the machine should be pushed to such chemicals generally includes immediate and thor the OFF closed position To do this simply ough washing of the exposed skin and immediate and push on the lever protruding o
29. ove 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 24 Section 4 Safety Information General Safety Do not operate Fiberglass Chopper Guns with out protective covers in place Correct packing or valve seat leaks immediately Never immerse the gun in any liquid Periodically check operation of catalyst alarms to make sure they are operation properly Frequently check condition of hoses Replace worn hoses and other parts before they fail Catalyst fluid nozzles and seals MUST be in good condition at all times to prevent internal and external leaks Inspect periodically and replace as needed or at intervals of three to four months Use catalyst nozzle seal only once to prevent possible leakage of catalyst into air passages of gun Make absolutely certain that all pressure has been relieved from the gun before disassembly from the hoses before loosening any fittings from the material or catalyst pump before disassembly from the catalyst injector before disassembly or filling If you have any doubt that fluid pressure i
30. r Tubing 1 4 in Clear Tubing 1 8 in Catalyst Bottle 20260 00 Recirculation Hose tape together with green material hose Do Not insert the hoses in the material drum until the system has been flushed Clear Tubing 3 8 in Solvent Pot GAM 268 01 Pick Up Kit 17 Operating Your Polyester System Safely 1 0 Introduction Any tool if used improperly can be dangerous Safety is ultimately the responsibility of those using the tool In like manner safe operation of polyes ter processes is the responsibility of those who use such processes and those who operate the equip ment This manual outlines procedures to be fol lowed in conducting polyester operations safely This system has been specifically designed for use of Polyester Resin Gel Coat and Methyl Ethyl Ke tone Peroxides MEKP applications Other formu lations or blends considered for use in this equip ment is strictly prohibited without the expressed consent by GlasCraft Inc GlasCraft Inc cannot eliminate every danger nor foresee every circumstance that might cause an in jury during equipment operation Some risks such as the high pressure liquid stream that exits the spray tip are inherent to the nature of the machine operation and are necessary to the process in or der to manufacture the end product For this rea son ALL personnel involved in polyester operations should read and understand the Safety Manual It is very important
31. r 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 19 Section 4 Safety Information General Safety Safety in handling MEKP depends to a great extent on employee education proper safety instructions and safe use of the chemicals and equipment Workers should be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users should make every effort to 1 Store MEKP in a cool dry place in original containers away from direct sunlight and away from other chemicals 2 Keep MEKP away from heat sparks and open flames 3 Prevent contam
32. s 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 Section 4 Safety Information General Safety 3 3 Grounding Grounding an object means providing an adequate path for the flow of an electrical charge from the ob ject to the ground An adequate path is one that per mits charge to flow from the object fast enough that it will not accumulate to the extent that a spark can be formed It is not possible to define exactly what will be an adequate path under all conditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed 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 a
33. t is always available to assist you with the operation of your spray equipment To help our technical representatives expedite your call and better address your questions please have the following information ready and available when you phone GlasCraft If your questions are not urgent You can e mail all correspondence to service glascraft com Model Air compressor size Compressor to system supply line Spray gun Serial number Pressure at the system Material pump Main air line volume Serial number System gauge pressures Catalyst pump AAC pressure Chopper Serial number Atomizing air pressure external mix Type of material Material pump pressure Type of catalyst Solvent flush pressure Catalyst percentage 28 Glascrare 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 DISPENSE EQUIPMENT APD
34. ut the side of continuous flushing of the eyes with lots of clean water the valve This will also cause all the system for at least 15 minutes or more These general instruc air to bleed out of the system in a matter of a tions of first aid treatment however may be incorrect for few seconds thus making the system some chemicals that is why you must know the chemi incapable of operating cals and treatment before an accident occurs Treatment for swallowing a chemical frequently depends upon the nature of the chemical Step 2 is a precautionary step and should be followed whenever the emergency stop valve is activated to the stop mode Failure to do so will damage regulators and components when reactivating to the ON position Refer to your System User Manual for complete and detailed operating instructions and service information 2 Turn all system regulators to OFF counter clockwise position Verify that the Catalyst Pressure Relief Line and the Resin Return Line are secured before relieving catalyst and resin fluid pressure 3 0 Equipment Safety GlasCraft suggest that personnel safety equipment such 3 Catalyst pressure in the Slave Pump can be as EYE GOGGLES GLOVES EAR PROTECTION and eliminated by rotating the yellow valve handle RESPIRATORS be worn when servicing or operating this on the Slave Pump 90 degrees to the ON equipment Ear protection should be worn when operat position ing a fib
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