Guardian A5-6000 User Manual
Contents
1. POLY Material Inlet Fitting b Attach the quick disconnect fittings to the male receivers on the transfer pumps ISO Material Inlet Fitting 12 Attach the other end of the airlines to the far right regulator on the machines air manifold ISO Material Drum 11 Section 1 Installation Equipment Assembly 13 If the optional scuff jacket is being 16 Connect the 1 4 in air line on the hose assembly to used highly recommended sold separately the air line whip hose on the front of the machine install it over each individual section of hose 17 before proceeding any further Securely tape both ends of scuff jacket to the hose assembly 14 Locate the thermal couple wire protruding from the B side fitting on the front of the machine Un coil the wire and lay it out straight 17 Connect electrical wires using electrical connectors installed on unit Electrical Connector p lt Cap plugs Ferrules A AS Main power from power source should be disconnected or turned off to console before making hose Setscrews connections 15 Feed the the thermal couple wire into the B side portion of the hose and pull the rest of the hose up A until you can connect the hose to the front of the See Heated Hose manual 309572 for detailed machine Tighten the hose securely being careful instructions of connecting heated hoses not to twist the hose in an un natural bend Refe2. everyone in the work area e Always park pumps when you shutdown To prevent contact with isocyanates appropriate personal protective equipment 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 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 x The amount of film formation and rate of crystal 2 lization varies depending on the blend of ISO the humidity and the temperature Material Self ignition Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing Some materials may become self igniting if applied to thickly Read material manufacturer s warnings and e Check with your material manufacturer for chemical material MSDS compatibility e Most materials use ISO on the A side but some use Keep Components A and B ISO on the B side e Epoxies ofte
3. GROMMETAUBBER ne GROMMET RUBBER eve __ WASHER FLAT STD n ase SCREW tase CONNECTOR x Purchase locally Pat Description ay cos 110 130 k aaa NUT CONDUIT CH W XP 2 2 GCO755 VALVE BALL VALVE BALL FITTING PIPE TEE GC2016 FITTING PIPE TEE O 30 Section 3 General Information Sub Assembly Drawings Control Panel Assembly Part Deseri PO PRAL BIWO 213 GC1164 SOCKET RELAY 3 POLE 10AMP ma onr TERMINAL zuer Ir 215 GC1173 COVER END TERMINAL 2 in 2 OUT GC1609 BUTTON MOMENTARY BUTTON EMERGENCY STOP PLATE COUPLING GC1608 BUTTON LATCHED 010 Ok H Woo L T ee E 31 dT Q FJI Oll QIQ 00 220 236 Fi N ob LI Key GC1622 LED YELLOW 24V GC1624 LED GREEN 24V 227 GC1626 BLOCK CONTACT NORMALLY OPEN GC1627 BLOCK CONTACT NORMALLY CLOSE GC1779 CABLE PLUG ELEC FEMALE 2 2 2 232 GC1782 CABLE PLUG ELECTRICAL MALE GC1783 2 15W687 MODULE HOSE CONTROL x Purchase locally CABLE PLUG ELECTRICAL MALE 21 GC1780 CABLE PLUG ELEC FEMALE 33 36 Section 3 General Information Sub Assembly Drawings GC2440 220V 1 Phase Electrical Assembly 313 314 314 314 met pan Teran W os Kon a 312 GC1088 RELAY CONTACTOR 1 MECHANICAL 25A 313 GC1262 RELAY CONTACTOR 1 MECHANICAL
4. POWER LOCK HEATED HOSE 246050 WHIP HOSE ASSEMBLY 313268 USER MANUAL 206995 FLUID TSL 1 QT BOTTLE GC0174 TRANSFER KIT A5 AND A6 UNITS DOES NOT INCLUDE TRANFER PUMPS Purchase separately Recommended Repair Parts KAN E GC1748 HEATER REPAIR KIT Related Manuals L NE n 312766 T1 2 1 RATIO TRANSFER PUMP INSTRUCTIONS PARTS 309572 HEATED HOSE INSTRUCTIONS PARTS 313277 MATERIAL PUMPS INSTRUCTIONS Material Ratio Material Viscosity Output Operating Temperatures Maximum air working pressure Maximum fluid working pressure Electrical Requirements Compressed Air Requirements Heaters Maximum Hose Length Shipping Weight Overall Dimensions Section 1 Installation Technical Data 1 1 Fixed 200 2000 Centipoise Cops AMBIENT Pumps Rated 042 Gallons Per Cycle 159 Liters Per Cycle 32 F 0 C 180 82 C 100 psi 0 69 MPa 6 9 bar 16 1 RATIO 1600 psi 11 0 MPa 110 bar 50 A 208 240 VAC 50 60 hz Single Phase cable 6 AWG 2 wire GND 20 A 208 240 VAC 50 60 hz Three Phase cable 8 AWG 3 wire GND 20 A 380 VAC 50 hz Three Phase cable 12 AWG 4 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
5. 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 then shut off 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 Ab 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 lf there is static sparking or you feel a shock stop operation immediately Do not use equip ment until you 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
6. 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 pressure increases above 2000 psi lf 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
7. 6000 WATT HEATER 310 ft 94 5 m Each Section 50 ft x 3 8 in I D 428 Ibs 194 kg Section 1 Installation Equipment Assembly Guardian Line Installation Guide GlasCraft Systems are factory assembled If any 2 questions arise concerning air or electrical connections please refer to illustrations located in the forward portion of this User Manual or contact your GlasCraft distributor 1 Locate Guardian a Locate Guardian on a level surface b Do not expose Guardian to rain Bolt Guardian to orginanl shipping pallet 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 and 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 lf the machine needs to be further that 10 ft from the power supply additional lengths of properly sized electrical cable will be required Never use a smaller gauge size than supplied by the factory Depending on the electrical setup it may be necessary 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 Consult the data sheet for the specific unit
8. brown e L3 black e L4 blue e GROUND green H1 PRIMARY H2 75V 60V 45V 30V 15V COM TO HOSE CONNECTIONS HOSE LENGTH 50 FT 100 FT COM 150 FT DO NOT 200 FT MOVE 250 FT 300 FT 13 Section 2 Operation Start Up Instructions AA 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 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 qualified 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 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 PROBLER P2 an air mask goggles protective clothing and other MAKE SURE VALVES ARE OFF safety equipment as prescribed by current regulations recommen
9. 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 redaction du presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires executes 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 ASSIST NCIA 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 SERVICIO p ngase en contacto con el distribuidor de Graco 41 Section 4 Warranty and Reference 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 Glas
10. 2 Ss 510 li 508 BS 517 518 906 Ret ren Description oy isomoner soe warts Ton eS a ER soa ees screw om kan wove m wars av EE lt Not Shown 3 5 Section 3 General Information Maintenance Daily Routine Maintenance 1 Visually inspect the system for leaks 2 Check desiccant dryer to 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 TSL Weekly Maintenance 1 Place a small amount of grease on the air motor shait 2 See related manuals 36 Section 3 General Information Troubleshooting 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 other 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 liquid at high pressure when Gun Trigger is activated Read and note WARNINGS contained in this User Manual and the Probler P2 Gun User Manual 313213 The Polyol will expand in the Hose if any normal operating pressures are bled off whenever the mate
11. 4 POLE 314 GC1651 CLAMP END TERMINAL 4 UNIVERSAL GC1030 BLOCK TERMINAL 316 GC1033 SPACER BLOCK TERMINAL 317 GC1036 COVER BLOCK TERMINAL xe Purchase locally 32 Section 3 General Information Sub Assembly Drawings GC1758 220V 3 Phase Electrical Assembly mor pan Teran L os nona f 312 GC1088 RELAY CONTACTOR 1 MECHANICAL 25A 313 GC1262 RELAY CONTACTOR 1 MECHANICAL 4 POLE 314 GC1651 CLAMP END TERMINAL 4 UNIVERSAL xe Purchase locally 33 Section 3 General Information Sub Assembly Drawings GC1760 220V 3 Phase Electrical Assembly 414 402 407 414 403 411 ES Ile pouou L 401 GCO0601 FUSE 2AMP bd ke BLOCK TERMINAL CURRENT HIGH 410 GC1033 SPACER BLOCK TERM 2 CURRENT HIGH GC0859 FUSE FUSEHOLDER DIN 411 GC1036 COVER BLOCK TERM 1 RAIL CURRENT HIGH 401 oon atene a Jar 406 408 GC0851 CIRCUIT BRKR DIN RAIL GC1000 FUSE 63AMP TAB BOLTED GC1014 RELAY SOLID STATE 63A 408 GC1015 RELAY SOLID STATE 50A 414 GC1651 CLAMP END TERMINAL 4 UNIVERSAL 415 GC1262 RELAY CONTACTOR 1 MECHANICAL 4 POLE 416 GC1088 RELAY CONTACTOR 1 MECHANICAL 25A 413 GC1061 COVER BLOCK SWITCH ON 1 OFF 4POL xe Purchase locally 34 Section 3 General Information Sub Assembly Drawings GC1714 GC1715 GC1716 GC1717 Heat Exchanger Assembly 905 503 50
12. Craft technical service department is always available to assist you with the operation of your spray equipment To help our technical representatives expedite your call and better address your questions please have the following information ready and available when you phone GlasCraft If your questions are not urgent please call 1 800 328 0211 Model Serial number Type of spray gun Serial number Is your equipment Three phase Single phase What is the inbound voltage to your equipment Temperature setting ISO Temperature setting POLY Temperature setting HOSE 42 For Air Powered Systems Air compressor size CFM generated Pressure at the system Hydraulic Pneumatic Dynamic fluid pressure ISO POLY Spray gun chamber size Material being sprayed Viscosity ISO POLY Approximate material temperature Clase Ft 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 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 Ill HYDRAULIC POWERED SYSTEMS UP TO 45 LBS MINUTE OUTPUT EXCELLENT PERFORMANCE AND RELIABILITY GUARDIAN MMH MOBILE MODULAR HYDRAU
13. E P E 0 500OD NATURAL 1 4 FT 50 5 52 3 2 5 5 55 261821 CONNECTOR HEATED HOSE yx Purchase locally Not Shown A Replacement Danger and Warning labels tags and cards are available at no cost 24 Section 3 General Information Assembly Drawings POL BPE OCH a BS Gt EM SZ SR SR in SR RX 9 E BReRPSESESRSTe H SHS EF a Pee a mi au ah ei e a Serr ei el x d ei ge i E jk n r G L gt D d G m Es O wn CH AL m gt E d KI KI CH eeh U GA H x Oo BS GA H L 25 Section 3 General Information Assembly Drawings 220 VOLTS SINGLE PHASE ONLY Section 3 General Information Assembly Drawings 220 VOLTS 3 PHASE ONLY Section 3 General Information Assembly Drawings B a ee a SS ZS e Y B M hk bi MN ai al E a J pi 7 Li JE r TET en A EWA TH luh A 1 9 454 RTE Pi m BN SCT RH BR A TNO 3JS5vHd JIYHI LION OBE Section 3 General Information Sub Assembly Drawings Cart Assembly 136 107 143 Detail A 29 Section 3 General Information Sub Assembly Drawings Cart Assembly Pet T ter Aw 102 Tarn 108 GC0585 TRANSFORMER TOUCH SAFE 1 RETAINER PLUG VENT RETAINER GC0790 HOSE ASSY 111 GC0999 TRANSFORMER BOX CONTROL 112 GC1040 CONNECTOR 113 GC1042 AMMETER 30A 114 15W209 JACK PANEL CIRCULAR Q y o ieee
14. 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 Potential high pressure causes Restriction Overheating material in static position ISO filter at gun 5 Re start system for operation Once the power has been turned off and problem solved and the main power is turned on again the over pressure lighted buttons will automatically be reset If you do not understand the electrical hook up de scribed above consult your local GlasCraft distributor OR a qualified electrician It is rec
15. LIC 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 Quality and Performance GENUINE GLASCRAFT GISCFSFA DISPENSING EXCELLENCE ND Pee DISPENSE GRACO INC pilin P O BOX 1441 www glascraft com MINNEAPOLIS MN 55440 1441 313268B Phone 612 623 6921 Toll Free 1 800 328 0211 A GRACO COMPANY Fax 612 378 3505
16. USER MANUAL GIISCFSFA DISPENSING EXCELLENCE GUARDIAN A5 6000 Dispensing System For use with non flammable foam and polyurea Not for use in explosive atmospheres Maximum fluid working pressure 1600 psi 11 0 MPa 110 bar Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Table Of Contents Section 1 Installation le ee E 1 PEE OO ier OI EE 5 Standard Te CUNO PIS EE 6 TECON e ra nira secon rte a n Ba NG EN EA Na e e E af mla A KA KAN a A AT A TA aa EA KENA SL ef BADE Aa a aaa aaa a pwo ik a WG le a kaa 7 E GUIDE AAS SEN E 8 Section 2 Operation Ki S ie AS NW EWO EE 14 SAY OT ANSEYE ONI E 18 Section 3 General Information Assembly DIawings E 22 I FS SOI EIERE 29 WA GAN MO NT ANNO EE 36 RIE e ele WAG EE 37 OPO satang aaa Bean ena ga ebang aran a re grees cena hea tz wetter pate enc ee n ye E bald gs dk ana cose ee a e a E E pa aa am a a 40 Section 4 Warranty and Reference Information Limited Warranty Policy EE 41 Technical Assistance kai ke kit kon pon EE ee Ee EE eka e set kak k kinan 42 For Your Reference i e e e e kk tt tt kt nn NNN ENNEN INSIDE BACK COVER Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific ri
17. and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equip ment 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 acci dent tampering or substitution 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 This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco dis tributor for verification 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 equip ment does not disclos
18. being installed to determine the proper breaker size needed 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 how much clean dry air will be needed to supply the machine If the air line is under 25 ft use a minimum of 1 2 in I 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 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 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 90 100 psi 0 62 0 7 MPa 6 3 7 7 BAR do not exceed 125 PSI 0 86 MPa 8 6 bar e gt 2 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 pallet or similar device so the drum bottoms will not be in contact with any cold surfaces 3 Open all boxes that came with the machine and verify that all items are accounted for 4 Install Y filters provided in transfer kit GC0174 into outlets of both transfer pumps purchase separately Be sure to use PTFE tape on the threads Section 1 Installation Equipment Assembly 7 Make
19. cor Be Peni Ore Powe Poon dance with chemical suppliers instructions and b Press up or down arrow buttons on the controller local state and federal regulations until desired temperature setting is achieved E Before re assembling side blocks lubrication can be YE 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 the air valve is turned on at gun and gun is triggered 15 Section 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 Straighten hose out flat to avoid uneven heating and damage to internal wiring of the Hose Assembly Allow enough time for hose to warm up approximately 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 _ _ 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
20. dations 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 14 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 forward 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 es Remember to dispense one to two gallons of YE 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 5 Dispose of waste material properly and in ac
21. e 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 INCLUD ING 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 FIT NESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COM PONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors 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 hereunder or the furnishing performance or use of any products
22. lter 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 E Follow the procedures in the order given Remember 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 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 no
23. luid movement does NOT occur 100 psi 0 7 MPa 7 bar 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 at the gun 6 Leave the pumps in the full down stroke position with approximately 200 500 psi 1 4 3 4 MPa 14 35 bar on the fluid gauges 7 If plasticizer is required to chase out solvent cycle main pumps until the system is full of plasticizer then close valves and leave the pumps in the full down stroke position with 200 500 psi 1 4 3 4 MPa 14 35 bar 19 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 Generously coat the exposed transfer pump shafts with lithium grease 10 Coil the heated hoses with a minimum four foot diameter to avoid kinking and subsequent damage to the internal electrical wiring 11 For gun shut down follow the procedure from the gun manual 12 The length of time a system is shut down and the climate conditions it s stored in will determine how often the
24. n have amines on the B hardener side Sepa rate Polyureas often have amines on the B resin side CAUTION To prevent cross contamination of the equipments wet ted parts never interchange component A isocyanate and component B resin parts The gun is shipped with the A side on the left The fluid manifold fluid hous ing side seal assembly check valve cartridge and mix chamber are marked on the A side Foam Resins with 245 fa Blowing Agents New foam blowing agents will froth at temperatures above 90 F 83 C when not under pressure especially if agitat ed To reduce frothing minimize preheating in a circulation system Section 1 Installation Introduction Introduction Before operating maintaining or servicing any GlasCraft system read and understand all of the technical and safety literature provided with GlasCraft products If you do not have the proper or related manuals and safety literature for your GlasCraft system contact your GlasCraft distributor In this GlasCraft technical and safety publication the following advisories will be provided where appropriate Information about the procedure in progress Is imperative information about equipment protection CAUTION Indicates a hazardous situation that can result in minor or moderate injury Indicates a hazardous situation that can result in death or serious injury AAN ELECTRICAL SHOCK HAZARD Indicates a hazardous situation
25. ock 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 21 Section 3 General Information Assembly Drawings Guardian A5 6000 Assemblies Eau IG a jeni a iW E po d Yi v d d L SA iG wa sie LI VI a H Detail A Some parts have been removed for clarity Supplied with cart assembly See Detail A Some parts have been removed for clarity Pan Phases Voltage 22 Section 3 General Information Assembly Drawings Red Tubing Blue Tubing 23 Section 3 General Information Assembly Drawings Parts Ret Part Desorption ay o emen fe Peer akena ues 3 8 NPTM X 3 4 UNF S 7a WIRE 6 THAN aerer re Tans LABEL TRANSFORMER LI rae __ SOREW SEL TAP 2IN A0 RE 15W209 JACK PANEL CIRCULAR 16 18 GC1181 GAUGE PRESSURE 2 3000PSI BACK MT 19 GC1714 HEATER ASSY HEATER 1 DUAL ROD ISO 20 GC1716 HEATER HEATER 1 DUAL ROD POLY 1500 o GC1718 PLATE BOTTOM 22 CART ASSY SEE PG 29 GC1725 COVER HEATER 26 GC1734 PUMP ASSY SEE MANUAL 1 313277 z none a Ret Pan Description Tom AN e PANEL ASSY PAGE RER ELECTRICAL ASSY PAGE fon WASHERAAT W a S aa 48x HOS
26. oller simultaneously until the display reads SET This is the Setup menu 2 Press the down arrow button to scroll through the setup menu until the display reads C F 17 Section 2 Operation Shut Down Instructions Daily Shut Down Procedure 5 Reduce main air regulator pressure to zero 1 Turn off hose and heater controllers 6 Visually inspect 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 18 Section 2 Operation Shut Down Instructions 8 Coil heated hoses with a minimum four foot diameter to avoid kinking and subsequent damage to the internal electrical wiring 9 Check and lube top of the fluid section Wipe off residual material and add a tablespoon of TSL Do not bleed fluid pressure from the system Extended Shut Down Procedure The following procedure is for long extended shut down periods Power should be disconnected and all air regulators YE turned down to zero 1 Remove side blocks from the gun and relieve pressure from the system PROBLER P2 2 Use a suitable solvent to flush the fluid circuits To determine the compatibility of solvents with material being used Always check with material supplier 3 Increase transfer pump pressure until fluid movement occurs e If f
27. ommended 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 that a successful operator must know WHAT GOOD MATERIAL LOOKS LIKE e HOW THE EQUIPMENT NORMALLY OPERATES WHAT PATH THE MATERIALS FOLLOW THROUGH THE EQUIPMENT KNOWLEDGE OF THESE TROUBLESHOOTING PROCEDURES E Always start with step one never skip any portion of YE 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 p
28. 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 e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete informa tion about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Use equipment 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 equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start
29. r to the last page in this installation guide for N Heated hose length including whip hose must instructions on how to secure hoses properly be 60 ft 18 3 minimum A 18 Add extra hose lengths if necessary TI 12 Section 1 Installation Equipment Assembly 19 Connect hose assembly and the gun as shown The fittings on the hose assembly are sized differently and will attach only one way 20 Pressure check hose See Heated Hose manual 309572 Pressure check for leaks If you do not find any leaks wrap hose and electrical connections to prevent damage AVAN 21 If more than 50 ft of hose is used the transformer tap setting will need to be set for proper hose length The sticker on the front cover will say which tap to move the wire to DO NOT MOVE THE COMMON LEG 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 A A If you do not understand the electrical hook up described above consult your local GlasCraft distributor OR a qualified electrician Electrical connections must be checked on a NE periodic basis e 208 240 volt single phase e L1 L2 GROUND e 208 240 volt three phase e L1 L2 L3 GROUND e 380 volt three phase e L1 black e L2
30. roblem 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 1 Problems may be cyclic in that they will appear first on YE 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 38 Section 3 General Information Troubleshooting A MATERIAL DRUMS 1 Material in drums 2 Material temperature a If the material is too cold especially at the bottom of the drum it will raise the viscosity of the material and stall Transfer 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 6 Before diagnosing a faulty transfer pump be sure O1 and check all items just listed under Transfer Pump C FILTER ASSEMBLY 1 Check fluid fi
31. sk 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 e 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 e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e 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
32. sure that the plastic caps have been removed from the bottom of the pumps and then slide the transfer pumps into the collars Tighten the collars securing the transfer pumps in place Loosen the 3 8 in vent plugs on both drums allowing for ventilation If using a desiccant dryer on the A side install it now 5 Install a male quick disconnect fitting to air inlet of both pumps Besure to use PTFE tape on the threads P 6 Remove the 2 inch bung caps on both the A and B side drums Install the transfer pump collars bung adapters into the bung holes making sure to lubricate the threads with vaseline or grease thus enabling easy removal when needed 8 Remove the metal caps from the material pumps Section 1 Installation Equipment Assembly 9 Connect one end of each material hose provided in transfer kit GCO1 74 to the inlet fittings located on the back of the machine t 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 POLY Material Drum 10 Connect the other end of the material hoses to the correct transfer pumps Ensure that they are not reversed and tighten securely 10 Section 1 Installation Equipment Assembly 11 a Install the female quick disconnect fittings on to the Y in air lines that came in the transfer kit Be sure to use PTFE tape on the threads
33. 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 20 Section 2 Operation Shut Down Instructions 5 Open both side blocks simultaneously into separate containers and dispense approximately 1 1 2 2 A ZAN gallons of material from each side or until all Before performing any repairs on any part of the system plasticizer is purged from the system 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 bl
34. t plugged TROUBLESHOOTING A POOR SPRAY PATTERN a To troubleshoot a poor spray pattern you must N 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 paitern ge Correct problem s immediately E 39 Section 3 General Information Options GCO174 Transfer Kit Supplied with unit GC1240 GC1233 mu GC0479 oe GC1747 GC2208 GC2199 TRANSFER PUMP TRANSFER PUMP ISO AIRLINE Transfer Pump POLY AIRLINE purchase separately MAIN DRUM MIXER AIR AIR OPTIONAL A Hi NS Z NG SAT Di Y a SEN A SIDE MATERIAL HOSE B SIDE MATERIAL HOSE DO OO 02 The transfer kit attaches the same way for both ISO 8 POLY side Use PTFE tape on NPT threads 40 Section 4 Warranty and Reference Information Limited Warranty Policy Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material
35. that can result in electrical shock or serious injury The information in this document is intended only to indicate the components and their normal working relationship typical use Each assembly should be directed by a GlasCraft distributor or made from the GlasCraft Assembly instructions provided This manual provides information for the assembly opera tion maintenance and service of this GlasCraft product as used in a typical configuration While it lists standard specifi cations and procedures some deviations may be found In order to provide our users with the most up to date technology possible we are constantly seeking to improve products If 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 distributor to resolve the difference 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 A5 6000 ren Description GC1750 A5 6000 UNIT 220V 1PH F GC1752 A5 6000 UNIT 220V 3PH F GC1753 A5 6000 UNIT 380V 3PH C GCP2R2 PROBLER P2 GUN 246075
36. 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 02 The Emergency Stop Switch is located on the bottom allow the heaters to reach operating temperature before YE 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 turn handle on push button system to shut down 15 The system is now ready for operation 16 Section 2 Operation Start Up Instructions Change Temperature Controller Display Units 3 Press and hold the SET button to display the current Fahrenheit to Celsius setting of C or F The 220V units are factory set to display temperature units in Fahrenheit and 380V units are set to display temperature 4 units in Celsius Hold down the SET button and press the up arrow button to switch the unit setting to either G or FE To change display temperature units 5 Release the SET button 6 Press the Infinity button to exit the Setup menu and save the unit display change 7 Complete steps 1 6 for all three controllers ISO POLY and HOSE gt Do not change any other settings in the Setup menu These settings are factory programmed for optimal performance 1 Press and hold the up and down arrow buttons on the contr
37. without warning Before checking moving or servicing equip ment follow the Pressure Relief Procedure in this manual Disconnect power or air supply BURN HAZARD Equipment surfaces and fluid thats heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment 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 sufficient 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
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