GC-1395G G2, Operation, English
Contents
1. NOILdO X VINNYOSA 134 00 2 922 N d HLIM 39V 1d3M ANY NOILdO X AGNI JN REVISION D 17 GC 1395G Assembly Drawings 21990 00 Assembly Part Description Number p Gowns Ga REVISION C GC 1395G Sub Assembly Drawings 32513 00 Material Pump Assembly S E YA ENT 2 ASSI e q s 7 9612 04 L z NG ING 4342 04 r SWR RN e P33 19 ih JE ANT SSP 5 v 3o 0 e NUTS SUPPLIED WITH SE 21465 44c AIR MOTOR P A SSP 143 N SSP 156 i SSP 42 e 7134 07 S SB 49203 8156 40C e e e 9945 60C e 2282000 e 209 K 38 e e e e _ i RM 850 02 38 7591 04 8462 15 1129 07 14626 00 N gt 21191 F e 4342 23 Pani b cei e nen 21192 00 8462 12 20260 00 REVISION A GC 1395G 19 20 Sub Assembly Drawings 32513 00 Material Pump Assembly Part as waste 909 100 MESH FILTER Part eee Ei REVISION A GC 1395G Sub Assembly Drawings 23555 03 Air Manifold Assembly 20655 02 ISD 141 3 21402 00 AN 4342 04 ud 8115 03 3 4313 03 8115 06 ISD 142 8115 06 18318 02 1625 23 f 20186 00 A 7597 04 A 20183 00 N LPA 143 21215 00 4342 02 Part m GC 1395G Part m RELIEF VALVE 3 WAY VALVE CROSS FITTING 4313 03 REVISION D 21 Sub Assembly Drawings GAM 268 Material Pick2. 91 for further guidance Grounding AVDNZZE This equipment needs to be grounded Ground the dispense gun through connection to an GlasCraft approved grounded fluid supply hose Check your local electrical code and related manuals for detailed grounding instructions of all equipment in the work area N A grounding wire and clamp are provided assembly p n 17440 00 with all FRP equipment GC 1395G Set Up 1 Remove the pump inlet safety cap and drain the 2 Attach clear pick up hose to the pump inlet fitting and testing oil into an open container Before operat tighten ing the material pump flush thoroughly with a clean suitable solvent to remove test fluid 3 Attach clear pick up hose to the pick up tube m N GlasCraft uses a test fluid that may not be compatible with some gel coats or resins Thus it is recommended 3 that the test fluid be flushed from the Material Pump Fluid Section N Pick up Tube Gp 1395G Set Up 4 Select a clean dry air supply 5 Attach a 3 8 or larger air hose to the Air Inlet on the yellow air lock out valve It is suggested that a quick disconnect fitting not be used for attaching air Quick disconnect fittings can severely limit air flow NSO Id Before t
3. etc because a hazardous chemical reaction may result between substituted parts and MEKP To prevent contact with MEKP appropriate personal protective equipment including chemically imperme able gloves boots aprons and goggles are required for everyone in the work area Polyester Resins and Gel Coats Spraying materials containing polyester resin and gel coats creates potentially harmful mist vapors and atomized particulates Prevent inhalation by providing sufficient ventilation and the use of respirators in the work area Read the material manufacturer s warnings and ma terial MSDS to know specific hazards and precautions related to polyester resins and gel coats To prevent contact with polyester resins and gel coats appropriate personal protective equipment including chemically impermeable gloves boots aprons and goggles are required for everyone in the work area Spraying and Lamination Operations Remove all accumulations of overspray FRP sand ings etc from the building as they occur If this waste is allowed to build up spillage of catalyst is more likely to start a fire If cleaning solvents are required read material manufacture s warnings and material MSDS to know specific hazards and precautions GlasCraft recom mends that clean up solvents be nonflammable GlasCraft recommends that you consult OSHA N Sections 1910 94 1910 106 1910 107 and NFPA No 33 Chapter 16 17 and NFPA No
4. operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to Protective eyewear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection 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 Store hazardous fluid in approved containers and dispose of it according to applicable guidelines Always wear impervious gloves when spraying or cleaning equipment GC 1395G Warnings like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point gun at anyone or at any part of the body Do not put your hand over the dispense outlet Do not stop or deflect leaks with your hand body glove or rag KO Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment SKIN INJECTION HAZARD N High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look MOVING PARTS HAZARD Ve Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts Do no
5. INCREASE 2 25PSI OMOD INCREASE 3 30PSI OT D INCREASE 4 s5pst D O CORRECT Final pressure typically ranges from 30 45 PSI 2 1 3 1 bar depending on material used Fig 3 12 Slowly increase Air Assist Air Pressure Regulator until tails disappear from spray pattern See Fig 4 Typical Spray Pattern Development with Air Assist STEP AIRASSIST PATTERN PRESSURE ADJUSTMENT ADJUSTMENT 1 CLOSED C D INCREASE 2 15PS COC DO INCREASE 3 30PSI _ CORRECT Final air assist adjustment is complete when tails are elimated and a uniform spray pattern is achieved Final pressure typically ranges from 30 45 PSI 2 1 3 1 bar depending on material used Fig 4 GC 1395G 13 Safely fill the Catalyst Supply Bottle P N LPA 165 maximum two gallons with preferred MEKP catalyst to a minimum level at least one inch above the catalyst bottle outlet fitting Remove Catalyst Bottle P N LPA 167 1 from Catalyst Bottle Bracket P N LPA 169 for filling Bottle should be placed at or below waist level for safe filling Never fill Catalyst Bottle while mounted in Bracket as personal injury from catalyst spillage could result 14 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 11 Start Up 15 As soon as all air is eliminated simultaneously 19 Re
6. Up Kit Assembly 4341 15 3161 8560 11 3161 8612 08 AP 146 gi GAM 248 a Part m BN ly AP 146 HOSE GFT 1 1 2 1 1 2 RI ti GAM 263 GAM 248 PICK UP TUBE GAM 263 FILTER 4341 15 ELBOW FITTING 8560 11 FITTING 8612 08 BAND CLAMP EN E HEC 3161 HOSEFITTING 2 ee ER REVISION E GC 1395G Maintenance Before attempting to perform any maintenance on this System Relieve All Fluid and Air Pressures See Previous page See Indy and Formula gun manuals for daily maintenance and parts replacement procedures 1 Clean filter at resin pump When opening pump relief valve make sure all resin and air is evacuated from surge bottle Fluid Filter Assembly 2 Inspect and clean filter on pick up wand Cc f Filter GC 1395G 23 Accessories 21460 00 Heater Conversion Kit Assembly GC 1395G Accessories 21460 00 Heater Conversion Kit Assembly Part Number Description GCC47O 8462 15 FITTING PIPE NIPPLE HEX 1 2 X 3 8 NPT GC 1395G 29 Accessories LPA 165 Catalyst Bottle Assembly LPA 167 1 21045 01 21044 01 21039 00 21040 00 D 9704 11 y Part EM LPA 167 1 BOTTLE 1 LPA 172 SCREEN LPA 176 21089 00 21040 00 104401 SEAL 1 eroas MEXNUT 26 REVISION N GC 1395G Accessori
7. 1395G Shut Down Shut Down Instructions 1 Turn the main air valve to Off position 2 Turn catalyst yellow ball valve P N 21228 00 to Open Recirculation position to dump psi and close the valve 3 Pressure should be maintained on the resin hose 4 Refer to the manual to remove and clean the gun head parts These parts should be cleaned thoroughly inspected for wear or damage O Rings replaced if needed and placed aside for later re as sembly at next start up 5 Clean and inspect all internal and external threads of the Gun Head After cleaning dry and lubricate all threads with a light coat of petroleum jelly Make certain that the resin orifice on the inside of the Gun Head and the catalyst orifice on the outside of the Gun Head are covered with a small amount of the lubricant to prevent hardening and or migration GC 1395G 6 Use a light coating of petroleum jelly on all threads and o rings during re assembly 7 Material pump should be stopped with Pump Shaft in UP position Shaft should be cleaned of any over spray or foreign material 8 Material Pump Lube Cup should be emptied cleaned and refilled with clean compatible lubricant 9 Material pump should now be cycled so that shaft is left in DOWN positon during shut down period Failure to cycle Pump Shaft to DOWN position may result in over spray or leaked material to dry or harden on Shaft When Pump is next operated severe damage
8. Operation GLASCRAFT COMPOSITES EQUIPMENT BY GRACO 32 GC 1395G Gel Coat External Mix System For use with Polyester Resin and Gel Coat Part 21990 00 Maximum fluid working pressure 1300 psi 9 MPa 90 bar Maximum air pressure 100 psi 0 7 MPa 7 bar Important Safety Instructions Read all warnings and instructions in this manual Save these instructions C IS E Contents Warnings War ning cde gt aga e E gabag ae a E aa NG EN aa E NE nu aaa E A aaa 3 G n ral SAV aaa kaga dn TES 5 INTOQUCUO ARR RE PE AN Ta NET NAN KA NANG ah NGAEN E Ri 6 Set up Setup Instructions rallo 7 Pi ssur Relief Instructions ssaa anali 9 Start Up INSTITUCION Sii ito 10 o NG ais oie E NG Pn Sonat a a a MILLE IU asec nee ne 13 Daily Stareupinsirictions saang a u uku A dois o ed Ras E bra a sasakii DUE 14 PANS P A 15 As ssembly DraWiIngsS na asana iaia aid 16 SUP ASSEMDIV DFawings sa saa cfg Ka d an a int erm Dorv IR ANA ti a dud fucco uns gra 19 Maintenance Maintenance saa bana nak A EER 23 o TS a NG na an GN ah sereni si ii ao ae ee iii ie dang a thee a ed li 24 Technical Data Ttech ical Data ERRORES DURCH 28 Graco Ohio Standard Warranty aaa anana nana aana aana anana aaa nent ener 30 Graco Ohio Information ca a e e e e de 30 N A Non Applicable 2 GC 1395G Warnings The following warnings are for the setup use grounding m
9. adjust catalyst calibration as required This release the Trigger and stop stroking Pump Arm setting should be determined by the type of resin and catalyst being used 16 Check and make certain that Spray Gun Material EE and Catalyst Needles activate at exactly the same 20 Re adjust catalyst atomizing air pressure to approxi time mately 40 PSI 2 8 bar Failure to activate the Catalyst Valve at the Gun Catalyst Needle should never lead Material Needle as when the Pump is cycling will result in an over a loss of Catalyst system prime could result pressurization of the Catalyst Pump and the automatic opening on the Pressure Relief Valve 17 Engage Catalyst drive arm to Material Pump 21 While triggering the Gun examine the atomized catalyst making certain it is properly entering the material pattern Knob N If catalyst pattern is too narrow increase catalyst atomizing air in 5 PSI 0 3 bar increments If catalyst pattern is too wide decrease catalyst atomizing air in 5 PSI 0 3 bar increments 22 After all pressure adjustments have been complet ed a final spray test should be made Spray a test shot sample on a clean piece of paper This shot should be approximately five feet in length You can now check for desired gel time and uniformity of curing 18 Adjust catalyst atomizing air pressure to 25 PSI 1 7 bar This pressure may be adjusted to achieve desired catalyst droplet size 12 GC
10. aintenance and repair of this eguipmeni The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable e See Important Safety Information MEKP Polyester Resins and Gel Coats and Spraying and Lamination Operations section of this manual FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent 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 See Grounding instructions Use only grounded hoses e Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem e Keep a working fire extinguisher in the work area PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the
11. es LPA 170 Catalyst Bottle Bracket Assembly INCLUDES HEX NUTS CP 126 U BOLT LPA 169 BOTTLE SUPPORT Part p 4 4 7486 07 WASHER 4 7734 07 LOCKWASHER 4 REVISION B GC 1395G 27 28 Technical Data Category Maximum Fluid Working Pressure Maximum Air Inlet Pressure Typical Flow Rate of Pattern Guns Maximum Fluid Temperature B Component Resin Inlet Size Sound Pressure Sound Power measured per ISO 9614 2 Dimensions Weight Wetted Parts Data C Catalyst Chemically coated aluminum stainless steel chemically resistant o rings Resin Carbon steel carbide chemically resistant o rings GC 1395G Notes GC 1395G 29 Graco Ohio 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 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 equipment 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 misappl
12. ication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompat ibility 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 distributor 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 equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury
13. may be done to Upper Pump Seals 13 Daily Start up 5 Engage Catalyst drive arm to Material Pump 1 Pull and rotate Pivot knob to disengage the catalyst drive arm Knob 2 Turn the catalyst slave pump yellow ball valve to the open position 3 Hand prime the pump until a steady stream of catalyst flows back to the bottle 4 Close the ball valve Hand stroke the pump until it developes 30 50 PSI 2 TO 3 BAR GC 1395G Parts Model G2 System Part Description Number p 20190 00 Catalyst Hose Assembly 25 ft GC 1395G 15 Assembly Drawings 338 2962 ace 1 10 06861 Ev L a L O Q 21990 00 Assembly GC 1395G a Q n gt LU DC 00 89 0 70 982 OL VELL A tell 10 1628L 00 2S02 00 2502 SOL LVO A Gz G6 e 00 9 lt 971 3 A I 00 06 102 4 LL y0L6 Lo peyel Y ONIANL L 0H 29 Hed ONIANL 8 L A18IN3SSV did Z0 061 dSS oo ersce c0 091 dSS A18IW3SSV diNnd 3AV1S 20 418 dSS X18N3SSV Q IO3INVIN HIV 0 SGG c 16 Assembly Drawings 21990 00 Assembly 2v8 Zi mat s ka Va pa 7 1 10 E D UN NA aS E JUSTAS Y TM lt IJIK eg 0 6 u CIOSINVW UIV Wows 438 2 SZ91 N d SAOWSY ATINO NNO VINNYOA V
14. n accelerators and promot ers and non stainless metals Even small amounts of contaminates can make MEKP explosive This re action may start slowly and gradually build up heat which can accelerate until fire or an explosion result This process can take from seconds to days Heat applied to MEKP or heat build up from con tamination reactions can cause it to reach what is called its Self Accelerating Decompisition Tempera ture SADT which can cause fire or explosion Spills should be promptly removed so no residues remain Spillage can heat up to the point of self ignition Dispose in accordance with manufacture s recommendation Store MEKP in a cool dry and well ventilated area in the original containers away from direct sunlight and away from other chemicals It is strongly recom mended that the storage temperature remain below 86 F 30 C Heat will increase the potential for ex plosive decomposition Refer to NFPA 432 Keep MEKP away from heat sparks and open flames GC 1395G Current catalysts are premixed and do not require any diluents GlasCraft strongly recommends that dilu ents not be used Diluants add to the possibility of con taminates entering the catalyst system Never dilute MEKP with acetone or any solvent since this can pro duce an extremely shock sensitive compound which can explode Use only original equipment or equivalent parts from GlasCraft in the catalyst system i e hoses fit tings
15. 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 GC 1395G Important Safety Information Methyl Ethyl Ketone Peroxide MEKP MEKP is among the more hazardous materials found in commercial channels Proper 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 and gel coats also produces the hazards which require great care and caution in its storage transportation handling processing and disposal Workers must be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regards to contamination and heat They must 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 MEKP is flammable and potentially explosive as well as potentially damaging to the eyes and skin Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to MEKP Contaminated MEKP can become explosive Prevent contamination of MEKP with other materi als which includes but is not limited to polyester overspray polymerizatio
16. pport directement ou indirectement avec les proc dures concern es Graco Ohio Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 1 800 746 1334 or Fax 1 330 966 3006 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English GC 1395 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO OHIO INC 8400 PORT JACKSON AVE NW NORTH CANTON OH 44720 Copyright 2008 Graco Ohio Inc is registered to ISO 9001 www graco com Revised 08 2010
17. t operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals e 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 information about your material request MSDS forms from distributor or retailer e 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 e Keep children and animals away from work area Comply with all applicable safety regulations it PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents
18. to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS 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 or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en ra
19. urning on main air check all fittings making certain they are securely tightened This should be done before air or material of any kind is introduced into the system 6 Attach Grounding Clamp Assembly P N 17440 00 to System Use a convenient Nut and Bolt to secure Lug P N 13193 00 to slave pump 7 Securely attach Clamp P N 7749 00 to permanently grounded rod or pipe 7749 00 9654 00 GROUNDING ROD OR PIPE Boo O gt TO SLAVE PUMP NW Whenever flammable or combustible liquids are transfered from one container to another both containers shall be effectively bonded and grounded to dissipate static electric ity For further information see NFPA 77 Recommended Practice on Static Electricity 8 Fill material pump lube cup with proper pump lube GlasCraft recommends you contact your material supplier for their recommendation of a lubricant that will be suitable for use with your material Attach Here GC 1395G Pressure Relief Procedure To relieve fluid and air pressures 1 Push down Yellow slide valve P N 21402 00 to bleed off air to system 2 Open P N 21228 00 on catalyst pump to recirculation position GC 1395G 10 Start Up 7 Formula Gun Only Adjust the trigger air regulator 1 Pull and rotate Pivot knob to 100 PSI 7 bar to disengage the catalyst drive arm 2 Turn the catalyst slave pump
20. yellow ball valve to the open position 3 Hand prime the pump until a steady stream of catalyst flows back to the bottle Glessihe ballvava Hand from the gun refer to gun manual stroke the pump until it developes 30 40 PSI 9 Trigger the Gun until a steady material stream 2 3 bar appears at the Nozzle Body The material regulator should initially be set not to exceed 10 PSI 0 7 bar 5 Open the main air valve slowly 10 Once a steady material stream is achieved release trigger and re assemble all parts removed from the gun 6 Turn material regulator slowly clockwise until guage indicates 10 PSI 0 7 bar The pump will cycle slowly and stall when the pump is full of material Cap P N LPA2 213 should be HAND TIGHTENED ONLY Never use a wrench or pliers to assemble tighten or remove this cap If threads are clean and lubricated properly hand assembly and removal will not be a problem Use of wrenches or pliers will likely cause serve damage to the threads and or Gun Head Do not exceed 10 PSI 0 7 bar pressure on the Material Regulator until steady material flow has been established GC 1395G Start Up 11 Slowly increase resin pressure regulator until N Follow step 12 if optional catalyst bottle is being used desired spray pattern is achieved See Fig 3 Typical Spray Pattern Development without Air Assist STEP RESIN PATTERN PRESSURE PRESSURE ADJUSTMENT 1 20PSI OOOO
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