FORMULA X USER MANUAL GC1393 REVB
Contents
1. B I m age een de dee 00 266 2 n DL 00 91 2 sat de i e al s0 vr0l Sle Pd t EE 23750 01 Formula X Dispense Gun Parts List PART 13867 05 O RING 1 23758 00 REAR CAP PART NUMBER DESCRIPTION QTY REVISION B Operating Your Polyester System Safel 1 0 Introduction Any tool if used improperly can be dangerous Safety is ultimately the responsibility of those using the tool In like manner safe operation of polyes ter processes is the responsibility of those who use such processes and those who operate the equip ment This manual outlines procedures to be fol lowed in conducting polyester operations safely This system has been 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 for the safety of e2. Hose Trigger Air Line AAC Air Spray Head Assembly Note See gun assy drawings for part numbers and descriptions 16 Daily Maintenance WARNING Before attempting to perform any maintenance on this Spray Gun Relieve All Fluid and Air Pressures To relieve fluid and air pressures Push down Yellow slide valve P N 21402 00 to bleed off air to system Open P N 21228 00 on catalyst pump to recir culation position Open P N 21192 00 on bottom of material pump Verify the Trigger Lock is in the Locked posi tion It is recommended that the following service be performed on a daily basis 1 Valve Inspection Remove gear cover p n 23789 00 and inspect valves to see if there is any leakage on the top or bottom side of the valves if there is leakage with pressure relieved tighten packing nut p n 23764 00 1 8 to 1 4 turn until leak stops Verify that there is no leakage Parts Replacement Procedure Formula X Gun WARNING Before attempting to perform any maintenance on this Dispense Gun Relieve All Fluid and Air Pressures See previous page CAUTION Due to the different O Ring materials and lubricants used in the Formula X 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 Read each procedure entirely before beginning and refer to the illustration view
3. much Safety The reaction is unpredictable Prior use of an HHC sol vent without incident corrosion or explosion does NOT mean that such use is safe These solvents can be dan gerous alone as a clean up or flushing agent or when used as a component or a coating material There is no known inhibitor that is effective under all circumstances Furthermore the mixing of HHC solvents with other materials or solvents such as MEK alcohol and tolu ene May render the inhibitors ineffective The use of reclaimed solvents is particularly hazardous Reclaimers may not add any inhibitors Also the pos sible presence of water in reclaimed solvents could feed the reaction Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction Such coatings can be worn cracked scratched or too thin to prevent con tact There is no known way to make oxide coatings or to employ aluminum alloys which will safely prevent the chemical reaction under all circumstances Several solvent suppliers have recently begun promoting HHC solvents for use in coating systems The increasing use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans as Volatile Organic Compounds VOC s their low flam mability hazard and their not being classified as toxic or carcinogenic substances HHC solvents are very desir able in many respects WARNING Do not use Halogenated Hydrocarbon
4. solvents in pres surized fluid systems having aluminum or galvanized wetted parts NOTE GlasCraft is aware of NO stabilizers available to prevent Halogenated Hydrocarbon solvents from reaction under all conditions with aluminum components in a closed fluid system TAKE IMMEDIATE ACTION Halogenated Hydrocarbon solvents are dangerous when used with aluminum components in a closed fluid system supplier regarding the best non flammable clean up sol vent with the heat toxicity for your application If however you find it necessary to use flammable solvents they must be kept in approved electrically grounded containers Bulk solvent should be stored in a well ventilated sepa rate building 50 feet away from your main plant You should allow only enough solvent for one day s use in your laminating area NO SMOKING signs must be posted and observed in all areas of storage or where solvents and other flam mable materials are used Adequate ventilation as covered in OSHA Section 1910 94 and NFPA No 91 is important wherever sol vents are stored or used to minimize confine and ex haust the solvent vapors Solvents should be handled in accordance with OSHA Section 1910 106 and 1910 107 2 4 Catalyst Diluents GlasCraft spray up and gel coat systems currently pro duced are designed so that catalyst diluents are not re quired GlasCraft therefore recommends that diluents not be used This avoi
5. 2 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 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
6. Failure to do so will damage regulators and components when reactivating to the ON position 2 Turn all system regulators to OFF counter clockwise position NOTE Verify that the Catalyst Pressure Relief Line and the Resin Return Line are secured before relieving cata lyst and resin fluid pressure 3 Catalyst pressure in the Slave Pump can be eliminated by rotating the yellow valve handle on the Slave Pump 90 degrees to the ON position NOTE The ON position the valve handle is parallel in line with the valve body The OFF position the valve handle is perpendicu lar across the valve body 4 Resin pressure can be eliminated by rotating the yellow handled valve on the bottom of the fluid filter 90 degrees Place a container under the bottom of the valve to catch any resin that is ejected from the valve 3 2 General Safety Precautions The following general safety precautions should be followed when servicing or operating this equip ment to ensure operator safety When filling catalyst container protective eye equipment must be worn to protect against injuries Always maintain adequate material levels to prevent loss of prime during system operation At the first sign of a leak stop operations acti vate emergency stop valve back off air regula tors and open all bleed valves to remove all pressure from the gun hoses pump catalyst system and any other li
7. GlaScrsft DISPENSING EXCELLENCE Formula X Gun External Mix Low Emission Dispense Gun aa Craft DISPENSING EXCELLENCE 5845 WEST 82ND STREET INDIANAPOLIS INDIANA 46278 U S A Phone 317 875 5592 Fax 317 875 5456 Email gcisales glascraft com An ISO 9001 Approved Web www glascraft com Company lt SS Z lt as A YS SS Table Of Contents Introduction About Ihis M nU l 3 2 akas is eege da 1 Parts amp Illustrations standard Equipment amp Repair Kits viii een nn ini 2 Dispense Tip Reference Chart 3 23 50 01 Formula X Dispense GUlvurcianinia ada a 5 Safety Operating Your Polyester System Satety iii ic ie 8 Operation How The Gun Works einem er ne ena ean ine dabei 16 DELE E TTT 17 Maintenance Parts Replacement Procedure nenn 18 Hose le EE 18 EIERE 18 Material Valve Assembly Procedure voii a E 19 NOTES ontario oido 20 Limited Warranty Policy u 220 ide 24 Technical Assistance oocicicoci nciccnonacanonanitaridr nro cerraran cion dinarama SEENEN 25 For Your Reference aaa INSIDE BACK COVER About This Manual Before operating maintaining or servicing any GlasCraft system read and understand all of the technical and safety literature provided with GlasCraft products If you do not have the prop er or related manuals and safety literature for your GlasCraft system contact your GlasCraft distributor or GlasCraft Inc In this GlasCraft techni
8. Y 2 Never leave the gun hanging over or lying inside the mold A catalyst leak in this situation would certainly damage the part possible the mold and may cause a fire 3 Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom sections and at the gun and fittings Replace if wear or weakness is evident or suspected 4 Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub against any of the hoses at any point If allowed to rub the hoses may be cut through causing a hazardous leakage of material which could incr ease the danger of fire Also the material may spew onto personnel in the area 2 7 Toxicity of Chemicals GlasCraft recommends that you consult OSHA Sections 1910 94 1910 106 1910 107 and NFPA No 33 Chap ter 14 and NFPA No 91 Contact your chemical supplier s and determine the toxicity of the various chemicals used as well as the best methods to prevent injury irritation and danger to personnel Also determine the best methods of first aid treatment for each chemical used in your plant 2 8 Treatment of Chemical Injuries Great care should be used in handling the chemicals resins catalyst and solvents used in polyester systems Such chemicals should be treated as if they hurt your skin and eyes and as if they are poison to your body For this reason GlasCraft recommends the use of protective clothing and eye wear in using po
9. altered or repaired by anyone other than GlasCraft or to defects or damage resulting from improper installation misuse negligence accident or use not specified by GlasCraft This warranty shall not apply to any equipment where any parts or components were replaced by any parts or components not manufactured or supplied by GlasCraft The decision by GlasCraft shall be conclusive and binding on Purchaser GlasCraft does not warrant that any equipment or parts sold to Purchaser meet or comply with any local state federal or other jurisdiction s regulations or codes GlasCraft does not warrant that any equipment or part sold to Purchaser when used individually or in concert with any other part equipment device component or process does not infringe on any patent rights of any third party GlasCraft only warrants that it has no specific knowledge of any such infringement GlasCraft makes no warranty as to any parts or equipment manufactured by others Purchaser shall look solely and only to the manufacturer of such parts or equipment with respect to any warranty claims GlasCraft hereby assigns to Purchaser the original manufacturer s warranties to all such equipment and parts to the full extent permitted THE AFORESAID WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IM PLIED SPECIFICALLY THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH WARRANTIES ARE SPECIFICALLY DISCLAIMED GlasCraft shall not b
10. cal and safety publica tion the following advisories will be provided where appropriate NOTE Is information about the procedure in progress CAUTION Is imperative information about equipment protection WARNING Is imperative information about personal safety The information in this document is intended only to indicate the components and their normal working relationship typical use Each assembly should be directed by a GlasCraft distributor or Introduction made from the GlasCraft assembly instructions provided This manual provides information for the assem bly operation maintenance and service of this GlasCraft product as used in a typical configu ration While it lists standard specifications and procedures some deviations may be found In order to provide our users with the most up to date technology possible we are constantly seeking to improve products If technological change occurs after a product is on the market we will implement that technology in future pro duction and if practical make it available to cur rent users as a retrofit up date or supplement If you find some discrepancy between your unit and the available documentation contact your GlasCraft distributor to resolve the difference GlasCraft Inc reserves the right to change or modify this product as it deems necessary Careful study and continued use of this manual will provide a better understanding of the equip ment and
11. city 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 15 Never use hard materials such as wire pins etc To clear a plugged gun Hard materials can cause per manent damage Dab with a bristle brush blow back wards with air until clear while wearing a protective eye shield Repeat as many times as necessary Do not perform any maintenance or repairs until you have followed the precautions stated above If you as an equipment operator or supervisor do not feel that you have been adequately trained or instructed and that you lack the technical knowledge to operate or perform maintenance on a piece of glascraft equip ment please call glascraft inc Before operating or performing maintenance on the equipment If you have any questions regarding the above pre cautions or any service or operation procedures call your glascraft distributor or glascraft inc NOTICE All statements information and data given herein are believed to be accurate and reliable but are pre sented without guaranty warranty or responsibility of any kind expressed or implied The user should not assume that all safety measures are indicated or that othe
12. d MEKP to anything that is hot since explosive decomposition may result 5 Avoid contact with skin eyes and clothing Protective equipment should be worn at all times During clean up of spilled MEKP personal safety equipment gloves and eye protection must be worn Fire fighting equipment should be at hand and 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 10 with copious quantities of clean water and disposed of in accordance with the catalyst manufacturer s instructions The extent to which the user is successful in accomplishing these ends and any additional recom mendations by the catalyst manufacturer determines largely the safety that will be present in his operation 2 3 Clean Up Solvents and Resin Diluents WARNING A hazardous situation may be present in your pressur ized fluid system Hydrocarbon Solvents can cause an explosion when
13. ds the possible contamination which could lead to an explosion due to the handling and mixing of MEKP and diluent In addition it eliminates any problems from the diluent being contaminated through rust particles in drums poor quality control on the part of the diluent supplier or any other reason If however di luents are absolutely required contact your catalyst sup plier and follow his instructions explicitly Preferably the supplier should premix the catalyst to prevent possible on the job contamination while mixing Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocar bon Solvents GlasCraft recommends that you contact your solvent 11 WARNING If diluents are not used it should be remembered that catalyst spillage gun hose and packing leaks are poten tially more hazardous since each drop contains a higher concentration of catalyst and therefore will react quicker with overspray and the like 2 5 Uncured Liquid Resin Resin should be stored in a well ventilated building at least 50 feet from your main plant In addition the stor age temperature should not exceed 75 degrees F Safety In your main plant store only enough resin for one day s production NO SMOKING signs must be posted and observed in all areas where resin is stored and or used Refer to OSHA Section 1910 94 1910 106 1910 107 and consult resin supplier
14. e 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 23 Thank You for selecting GlasCraft spray equipment Should you have any questions or need technical assistance contact your factory authorized GlasCraft distributor Distributor Phone Contact For any issues your distributor cannot address the GlasCraft technical service department is always available to assist you with the operation of your spray equipment To help our technical representatives expedite your call and better address your questions please have the following information ready and available when you phone GlasCraft If your questions are not urgent You can e mail all correspondence to service glascraft com Model Spray gun Serial number Material pump Serial number Catalyst pump Chopper Serial number Type of material Type of catalyst Catalyst percentage 24 Air compressor size Com
15. ea should be evacuated at once and the fire department called The venting could be the first indication of a heat and therefore pressure build up that could eventually lead to an explosion Moreover if a catalyst tank is sufficiently full when the pressure relief valve vents some catalyst may spray out which could cause eye injury For this reason and many others anyone whose job puts them in an area where this vented spray might go should always wear full eye protection even when laminating operations are not taking place Safety Safety in handling MEKP depends to a great extent on employee education proper safety instructions and safe use of the chemicals and equipment Workers should be thoroughly informed of the 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 contamination of MEKP with other materials including polyester overspray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels 4 Never ad
16. ervice and Assembly Procedures NOTE If Seal P N 23763 00 and Packing Disks P N 23721 03 are removed from the Gun Body GlasCraft recom mends that these parts always be replaced with NEW seals and packing disks Material Valve Assembly Procedure 19 4 5 6 Ensure bores are clean before building material valves Insert bearing p n 23768 00 into gun body Insert seal p n 23763 00 into gun body Ensure holes in seal are aligned with holes in gun body Place teflon washers p n 23721 03 on top and bottom of fluid valve p n 23762 00 Lubricate outside of fluid valve p n 23762 00 with a generous amount of Aqua lube 21266 00 and insert into seal with holes aligned with holes in the gun body Insert bearing p n 23768 00 into gun body 7 a Use 7 16 six point socket to first snug P N 23764 00 to hand tight continue turn past snug Torque reading 20 ft Ibs 88 Newton b Loosen turn and return until snug continue Y turn past snug Torque reading 25 ft lbs 110 Newton C Loosen turn and return until snug continues 1 8 turn past snug Torque reading 30 ft Ibs 133 Newton With piston p n 23755 00 pushed back in on posi tion Place teflon washers p n 23721 03 followed by gears p n 23775 00 and tighten set screw Activate air and retract gun trigger Loosen P N 23764 00 until valve rotate alternate adjustment if both valves were adjusted 20 21 2
17. ine GlasCraft replacement parts when repairing your system Substitutes may not be the proper material or may not fit the system and may cause dangerous operating conditions and the failure of other components Safety 3 3 Grounding Grounding an object means providing an adequate path for the flow of an electrical charge from the ob ject to the ground An adequate path is one that per mits charge to flow from the object fast enough that it will not accumulate to the extent that a spark can be formed It is not possible to define exactly what will be an adequate path under all conditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed on all loose conductive objects in the spraying area This includes material containers and equipment GlasCraft recommends grounding straps be made of AWG No 18 stranded wire as a minimum and that larger wire be used where possible NFPA Bulletin No 77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm 106 ohms but that resistances as high as 10 000 meg ohms will produce an ade quate leakage path in some cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and grounded to dissipate static electri
18. ing 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 EI py EYE HEARING BREATHING GLOVE REQUIRED 1 PROTECTION PROTECTION PROTECTION 1 M3 dis Safety GlasCraft recommends that the user consult the state and local regulations established for all Safety equip ment listed 2 0 Material Safety 2 1 Hazards Associated with Laminating Operations The major hazards which should be guarded against in polyester laminating operations are those associated with 1 The flammability and explosion dangers of the catalyst normally used Methyl Ethyl Ketone Peroxide MEKP 2 The flammability dangers of clean up solvents sometimes used G
19. lasCraft 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 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 amoun
20. lyester systems However users should be prepared in the event of such an injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals may have WARNING Contact a doctor immediately in the event of any in jury and give him the information you have collected If your information includes first aid instructions ad minister first aid immediately while you are contact ing the doctor Fast treatment of the outer skin and eyes that con tact such chemicals generally includes immediate and thorough washing of the exposed skin and im mediate and continuous flushing of the eyes with lots of clean water for at least 15 minutes or more These general instructions of first aid treatment however may be incorrect for some chemicals that is why you must know the chemicals and treatment before an accident occurs Treatment for swallow ing a chemical frequently depends upon the nature of the chemical NOTE Refer to your System User Manual for complete and detailed operating instructions and
21. mployees 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 e 1910 94 Pertaining to ventilation e 1910 106 Pertaining to flammable liquids e 1910 107 Pertaining to spray finishing operations Safety particularly Paragraph m Organic Peroxides and Dual Component Coatings Other standards and recognized authorities to con sult are the National Fire Protection Association NFPA bulletins as follows NFPA No 33 Chapter 14 Organic Perox ides and Dual Component Materials e NFPA No 63 Dust Explosion Prevention NFPA No 70 National Electrical Code NFPA No 77 Static Electricity NFPA No 91 Blower and Exhaust System NFPA No 654 Plastics Industry Dust Hazards e Type of Fire Extinguishing equipment recommended Fire Extinguisher code ABC rat
22. pressor to system supply line Pressure at the system Main air line volume System gauge pressures AAC pressure Atomizing air pressure external mix Material pump pressure Solvent flush pressure Glascr rt 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 reguirements FORMULA INTERNAL amp EXTERNAL MIX POLYESTER EQUIPMENT CHOPPER 8 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 HIGH VISCOSITY POLYESTER PUTTY DISPENSE RCD RESIN CATALYST DISPENSE PFR PRESSURE FED ROLLERS For more information concerning any of these GlasCraft products contact your local authorized GlasCraft distributor or visit www glascraft com Quality and Performance GENUINE GLASCRAFT Craft DISPENSING EXCELLENCE ADS S 5845 WEST 82nd STREET ADVANCED DISPENSE SYSTEMS INDIANAPOLIS INDIANA 46278 www glascraft com U S A Phone 317 875 5592 GC 1393 Fax 317 875 5456 REVISION B E Mail sales glascraft com
23. process resulting in more efficient operation longer trouble free service and faster easier troubleshooting Standard Equipment amp Repair Kits MODEL 23750 01 FORMULA X DISPENSE GUN Standard Equipment PART NUMBER DESCRIPTION 23750 01 FORMULA X SPRAY GUN GC 1393 USER MANUAL Repair Kits PART NUMBER DESCRIPTION 23792 00 GUN AIR KIT 23793 00 GUN SEAL KIT 23781 00 GUN FLUID VALVE KIT Material Spray Nozzles The LPA2 147 2150 tip is furnished standard with system For more information contact your distributor or GlasCraft Service Department Formula X Gun Dispense Tip Reference Chart PART NUMBER ORIFICE Note Use p n LPA2 120G and p n LPA2 121G when using LPA2 147 XXXX and 23047 XX series spray tips Formula X Gun Dispense Tip Reference Chart PART NUMBER ORIFICE Sale Use p n LPA2 120G and p n LPA2 121G when using LPA2 147 XXXX and 23047 XX series spray tips LPA2 147 XXXX Requires Seal P N 20333 00 and Retainer P N 22274 00 4 PART NUMBER ORIFICE LPA2 147 6225 0 062 6240 0 062 6250 0 062 6265 0 062 7240 0 072 7250 0 072 7840 0 078 23750 01 Formula X Dispense Gun 23191 00 1554 09 1554 09 7554 10 tho a N 20796 00 ES KH 8212 16F 23787 00 20735 05 1554 05 044 05 We 2594 06 2318 00 23772 00 9869 19 23773 00 eech Ei 23965 00 23774 00 PG 18 8301 REVISION B 23750 01 Formula X Dispense Gun REVISION
24. quid 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 14 Safety Do not operate Fiberglass Chopper Guns with out protective covers in place Correct packing or valve seat leaks immediately Never immerse the gun in any liquid Periodically check operation of catalyst alarms to make sure they are operation properly Frequently check condition of hoses Replace worn hoses and other parts before they fail Catalyst fluid nozzles and seals MUST be in good condition at all times to prevent internal and external leaks Inspect periodically and replace as needed or at intervals of three to four months Use catalyst nozzle seal only once to prevent possible leakage of catalyst into air passages of gun Make absolutely certain that all pressure has been relieved from the gun before disassembly from the hoses before loosening any fittings from the material or catalyst pump before disassembly from the catalyst injector before disassembly or filling If you have any doubt that fluid pressure is relieved call your GlasCraft distributor or GlasCraft Inc before proceeding with any disassembly Use only genu
25. r measures are not required Glasrcrsrt DISPENSING EXCELLENCE 5845 WEST 82nd STREET SUITE 102 INDIANAPOLIS INDIANA 46728 U S A PHONE 317 875 5592 FAX 317 875 5456 How the Gun Works The Formula X Gun is an revolutionary design that re duces operator fatigue through reduced gun weight and enhanced maneuverability The Formula X Gun is designed to be a true high volume low pressure gun The ports in the gun are large to allow for less back pressure and high flow of material This is further achieved with large material hoses and low ra tio pump standard 11 1 by properly setting the material pump pressure 85 100 PSI matching a spray tip that will deliver desired output and useable spray pattern not atomizing the material The gun is very user friendly Example Because of the variables involved material viscosity sheer of material ambient temperature re quired output your pressure setting will vary CAUTION 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 NOTE Lightly lubricate all threads and o rings with a petroleum jelly before assembly Trigger Lock Push in and rotate trigger lock p n 23774 00 to stop the trigger from being activated Hose Attachment Atomized Air Material Hose Catalyst
26. s as needed 2 Flush and clean all passages as they become accessible 3 Clean all parts before assembly 4 Replace all O Rings Valves and Seals with new parts from the appropriate kit 5 Inspect all parts for wear or damage and replace as required with new GENUINE GlasCraft REPLACEMENT PARTS from your authorized GlasCraft Distributor 6 Inspect all threads for wear or damage and replace as required 7 Tighten all threaded parts securely but not excessively upon assembly 8 O rings can fail if subjected to any of the following conditions a Swelling coming in contact with solvent or oil from compressor b Cut sharp unlubricated edge in gun head or handle c Sticky contaminated with oil water solvent catalyst resin or gel coat 18 Maintenance d Chaffing dry sliding surfaces needs lubrication 9 Lightly lubricate all O Rings with petroleum jelly 10 Check all springs for resilience They should return quickly to their original new length 11 Clean the exterior of the Gun and Hoses with an appropriate clean solvent and cloth or brush Hose Removal 1 Remove Resin Hose with an 11 16 wrench Hold delivery tube with an 11 16 wrench 2 Remove Catalyst Hose with a 9 16 wrench Hold delivery tube with a 9 16 wrench NOTE Tape a clean polyethylene bag over the end of each Hose to prevent spillage and to keep clean Gun Service Dispense Gun Component S
27. s 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 1 Maintain your GlasCraft System Check the gun several times daily for catalyst and resin packing or valve leaks REPAIR ALL LEAKS IMMEDIATEL
28. service informa tion 3 0 Equipment Safety WARNING GlasCraft suggest that personnel safety equipment such as EYE GOGGLES GLOVES EAR PROTEC TION and RESPIRATORS be worn when servicing or operating this equipment Ear protection should be worn when operating a fiberglass chopper to pro tect against hearing loss since noise levels can be as high as 116 dB decibels This equipment should only be operated or serviced by technically trained personnel WARNING Never place fingers hands or any body part near or directly in front ofthe spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PIS TOL 13 Safety 3 1 Emergency Stop Procedures The following steps should be followed in order to stop the machinery in an emergency situation 1 The yellow air valve located where the air enters the machine should be pushed to the OFF closed position To do this simply push on the lever protruding out the side of the valve This will also cause all the system air to bleed out of the system in a matter of a few seconds thus making the system incapable of operating NOTE Step 2 is a precautionary step and should be fol lowed whenever the emergency stop valve is acti vated to the stop mode
29. t of contamination with acetone for instance may produce an extremely shock sensitive and explosive compound Contamination with promoters or materials containing promoters such as laminate sandings or with any readily oxidizable material such as brass or iron will cause exothermic redox reactions which can become explosive in nature Heat applied to MEKP or heat build up from contamination reactions can cause it to reach what is called its Self Accelerating Decomposition Temperature SADT Researchers have reported measuring pressure rates of rise well in excess of 100 000 psi per second when certain MEKP s reach their SADT For comparison the highest pressure rate of rise listed in NFPA Bulletin No 68 Explosion Venting is 12 000 psi per second for an explosion of 12 acetylene and air The maximum value listed for a hydrogen explosion is 10 000 psi per second Some forms of MEKP if allowed to reach their SADT will burst even an open topped container This suggests that it is not possible to design a relief valve to vent this order of magnitude of pressure rate of rise The user should be aware that any closed container be it a pressure vessel surge chamber or pressure accumulator could explode under certain conditions There is no engineering substitute for care by the user in handling organic peroxide catalysts If at any time the pressure relieve valve on top of the catalyst tank should vent the ar
30. 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 galva nized parts inside a closed container such as a pump spray gun or fluid handling system the chemical reaction can over time result in a build up of heat and pressure which can reach explosive proportions When all three elements are present the result can be an extremely violent explosion the reaction can be sustained with very little aluminum or galvanized metal any amount of aluminum is too
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