Download GC-1021D - Fiberglass Choppers, Operation, English
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Operation Fiberglass Choppers GC-1021D ENG Fiberglass Roving Choppers For use with Polyester Resin, and Gel-Coat Maximum air pressure: 100 psi (0.7 MPa, 7 bar) Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. II 2 G Contents Warnings........................................................... 3 Important Safety Information.......................... 5 Grounding......................................................... 6 Set-Up................................................................ 7 Pressure Relief Procedure............................ 12 Start-Up........................................................... 13 Parts................................................................ 15 Assembly Drawings....................................... 16 Sub-Assembly Drawings............................... 20 Maintenance.................................................... 22 Accessories.................................................... 26 Technical Data................................................. 27 Graco Ohio Standard Warranty..................... 28 Graco Ohio Information................................. 28 2 GC-1021D 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 procedurespecific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable. • See Important Safety Information - MEKP, Polyester Resins and Gel-Coats and Spraying and Lamination Operations section of this manual. WARNING FIRE AND EXPLOSION HAZARD Changing Materials 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). • When changing equipment mul• Keepmaterials, work area flush free ofthe debris, including solvent, rags and gasoline. • to Doensure not plug orthoroughly unplug power cords, or turn power or light switches on or off when flammable tiple times it is clean. fumes are present. • Ground all equipment in the work area. See Grounding instructions. • Always clean the fluid inlet strainers after flushing. • Use only grounded hoses. • Hold firmlymanufacturer to side of grounded pail when triggering into pail. • Check with your gun material for chemical • If there is static sparking or you feel a shock, stop operation immediately. Do not use compatibility. equipment until you identify and correct the problem. • Keep a working fire extinguisher in the work area. Changing Materials • • Most materials use ISO on the A side, but some use ISO on the B side. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the Epoxies often have amines on the B (hardener) operating area of the equipment to help protect you from serious injury, including eye injury, side. Polyureas often havefumes, amines on the (resin) loss. This equipment includes but is not limited to: inhalation of toxic burns, andBhearing side. • Protective eyewear • Clothing and respirator as recommended by the fluid and solvent manufacturer • Gloves • Hearing protection SplatterMOVING Hazard PARTS HAZARD This section Moving is used parts with some RAM which could getother pushed of the drums of sealant. can pinch orplates amputate fingers and bodyout parts. • • • Keep clear of moving parts. Do not 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. WARNING SPLATTER HAZARD TOXIC FLUID OR FUMES HAZARD Hot or toxic can cause serious injury if splashed the eyesinorthe oneyes skin.orDuring blow off ofor platen, Toxic fluids fluid or fumes can cause serious injury or death ifinsplashed on skin, inhaled, splatter may occur. swallowed. Read MSDS’s air to know the specific hazards ofplaten the fluids are using. • • Use minimum pressure when removing fromyou drum. • • Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. Always wear impervious gloves when spraying or cleaning equipment. Burn Hazard GC-1021D For equipment used with heated material. 3 Skin Injection Hazard Use with high pressure equipment, generally equipment with pressure rating of 900 psi or higher. There sions of this section. 1) manual guns, 2) UL-1450 compliant equipment 3) automatic guns,/dispense val tion valves, 4) heated hoses. Since the text contains mostly “Do not” statements, the symbols have lines them. Warnings WARNING WARNING SKIN INJECTION HAZARD SKIN INJECTION HAZARD - Basic High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may l like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical atreatment. cut, but it is a serious injury that can result in amputation. Get immediate surgical treatm Do point gun at anyone at of any •• Do notnot point gun at anyone or at anyorpart thepart body.of the body. Do over the spray •• Do notnot put put youryour hand hand over the dispense outlet.tip. •• Do notnot stopstop or deflect leaks with yourwith hand, body, glove,body, or rag.glove, or rag. Do or deflect leaks your hand, •• Engage trigger lock when not Do not spray without tipspraying. guard and trigger guard installed. •• Follow Pressure Relief Procedure in spraying. this manual, when you stop spraying and before cleaning, Engage trigger lock when not checking, or servicing equipment. • Follow Pressure Relief Procedure in this manual, when you stop spraying and before c checking, or servicing equipment. EQUIPMENT MISUSE HAZARD SKIN HAZARD Use with UL1450 Compliance MisuseINJECTION can cause death or serious -injury. notnot aim the gun at, or spray any or person or animal. •DoDo operate the unit when fatigued under the influence of drugs or alcohol. •• Do not exceed the maximum working pressure or temperature rating of theFor lowest rated system Keep hands and other body parts away from the discharge. example, do not try to sto component. See Technical Data in all equipment manuals. any part of the body. • Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data • Always use the nozzle tip guard. Do not spray without nozzle tip guard in place. in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete • information Use Graco nozzle tips. request MSDS forms from distributor or retailer. about your material, Use equipment caution when cleaning and changing nozzleparts tips.immediately in the case the nozzle tip clo •• Check daily. Repair or replace worn or damaged withwhere genuine manufacturer’s replacement parts only.Relief Procedure for turning off the unit and relieving the spraying, follow the Pressure • Do not alter or modify equipment. before removing the nozzle tip to clean. •• Use equipment its intended purpose. Call your distributor for information. Do not leaveonly theforunit energized or under pressure while unattended. When the unit is not • Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. off the unit and follow the Pressure Relief Procedure for turning off the unit. • Do not kink or over bend hoses or use hoses to pull equipment. • High-pressure spray is able to work inject toxins into the body and cause serious bodily injury. • Keep children and animals away from area. that injection occurs,safety get immediate • Comply with all applicable regulations. surgical treatment. • • • • • 4 Check hoses and parts for signs of damage. Replace any damaged hoses or parts. This system is capable of producing XXXX psi. Use Graco replacement parts or accesso rated a minimum of XXXX psi. Always engage the trigger lock when not spraying. Verify the trigger lock is functioning pr Verify that all connections are secure before operating the unit. Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the con GC-1021D 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 materials, which includes, but is not limited to polyester overspray, polymerization accelerators and promoters, and non-stainless metals. Even small amounts of contaminates can make MEKP explosive. This reaction 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 contamination reactions can cause it to reach what is called its Self-Accelerating Decompisition Temperature (SADT), which can cause fire or explosion. Spills should be promptly removed, so no residues remain. Spillage can heat up to the point of selfignition. 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 recommended that the storage temperature remain below 86° F (30° C). Heat will increase the potential for explosive decomposition. Refer to NFPA 432. Keep MEKP away from heat, sparks and open flames. GC-1021D Current catalysts are premixed and do not require any diluents. GlasCraft strongly recommends that diluents not be used. Diluants add to the possibility of contaminates entering the catalyst system. Never dilute MEKP with acetone or any solvent since this can produce an extremely shock-sensitive compound which can explode. Use only original equipment or equivalent parts from GlasCraft in the catalyst system (i.e.: hoses, fittings, etc.) because containing a hazardous chemical reaction Spraying materials isocyanates creates may result between partsand and atomized MEKP. potentially harmful substituted mists, vapors, particTo prevent contact with MEKP, appropriate personal ulates. protective equipment, including chemically impermeable gloves, boots, aprons and goggles are required Read material manufacturer’s warnings and material for everyone in the work area. MSDS to know specific hazards and precautions related to isocyanates. Isocyanate Conditions Polyester Resins and Gel-Coats Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area. Spraying materials containing polyester resin and gel-coats creates potentially harmful mist, vapors and To prevent contact with isocyanates, appropriate peratomized particulates. Prevent inhalation by providing sonal protective equipment, including chemically sufficient ventilation and the use of respirators in the impermeable gloves, boots, aprons, and goggles, is work area. also required for everyone in the warnings work area. Read the material manufacturer’s and material MSDS to know specific hazards and precautions related to polyester resins and gel-coats. To prevent contact with polyester resins and gelcoats, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons and goggles are required for everyone in the work area. • • • • • • K B Material Self-ignition To we an Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings Spraying Lamination Operations and material and MSDS. Fo B Moisture Sensitivity of Remove all accumulations of overspray, FRP sandIsocyanites ings, etc. from the building as they occur. If this waste Isocyanites (ISO) catalysts in istwo component is allowed to build are up, spillage of used catalyst more likely foam and polyurea coatings. ISO will react with moisture to start a fire. (such as humidity) to form small, hard, abrasive crystals, If cleaning solvents are required, read material which become warnings suspended the fluid. Eventually manufacture’s andinmaterial MSDS to know a film will form on the surface and the ISO will begin to gel, specific hazards and precautions. (GlasCraft recomincreasing viscosity. If used, partially cured ISO mends thatinclean-up solvents be this nonflammable.) will reduce performance and the life of all wetted parts. The amountrecommends of film formation and rate of crystalliGlasCraft that you consult OSHA zation varies depending on the blend of ISO, the Sections 1910.94, 1910.106, 1910.107 and NFPA humidity, and the16,17, temperature. No. 33, Chapter and NFPA No. 91 for further guidance. To prevent exposing ISO to moisture: 5 Som abo if ag circ Grounding Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS. Moisture Sensitivity of This equipment needs to be grounded. Isocyanites Ground the(ISO) dispense throughused connection a Isocyanites aregun catalysts in twoto component GlasCraft approvedcoatings. grounded ISO fluid will supply hose. foam and polyurea react with moisture (such as humidity) to form small, hard, abrasive crystals, Check your local electrical code and related manuals a film which become suspended in the fluid. Eventually forform detailed grounding instructions of allwill equipment will on the surface and the ISO begin toingel, the work area. increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts. NOTICE To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts. Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system. The amount of film formation and rate of crystalliA grounding and clamp provided, zation varieswire depending onare the blend of ISO, the assembly p/n 17440-00 with all FRP equipment. humidity, and the temperature. To prevent exposing ISO to moisture: Rev. G 6/17/2008 6 21 GC-1021D Some foam blowing agents will froth at temperatures Moisture Sensitivity of above 90°F (33°C) when not under pressure, especially B if agitated. To reduce frothing, minimize preheating in a Isocyanites Som Moisture Sensitivity of circulation system. Isocyanites (ISO) are catalysts used in two component abo Set-Up foam and polyurea coatings. ISO will react with moisture if ag Isocyanites (such as humidity) to form small, hard, abrasive crystals, Isocyanites (ISO) are catalysts used in glass two component Mounting 8. Adjust Chopper mount until chopped enters spray which becomeInstructions suspended in the fluid. Eventually a film foam and polyurea coatings. ISO will react with moisture pattern at desired entry location. Chopped glass should B-410, LPA 2 Gun will form on the surface and the ISO will begin to gel, (such as humidity) to form small, hard, abrasive crystals, be uniformly entering the spray pattern resulting in an increasing in viscosity. If used, this partially cured ISO which become suspended in the fluid. Eventually a film evenly distributed resin spray and chopped glass patwill reduce performance and the life of all wetted parts. will form surface and the ISO will begin to gel, ternon on the the test substrate. Theamount followingofMounting Instructions The film formation and pertain rate oftocrystalliincreasing in viscosity. If used, this partially cured ISO mounting a Model B-410 onto a Model Model zation varies depending on the blendLPA, of ISO, the will reduce performance and the life of all wetted parts. LPA-II Spray humidity, andGun. the temperature. The film formation ratepiece of crystalliTestamount sprayingof should be done onand a clean of paper To prevent exposing ISO to moisture: zation varies and depending blend of ISO, the or cardboard disposedon of the properly. humidity, and the temperature. 1. Remove Set Screw, P/N D-145-08C from the Gun body located where the Chopper is mounted and reTo prevent exposing ISO to moisture: place at the top of the handle. (see Fig. 1) Rev. G 6/17/2008 21 2. Attach the Chopper assembly into the mounting hold and tighten with the Chopper snout pointing down into the resin spray pattern. The correct adjust-Rev. G 6/17/2008 ments for glass entering the pattern will be done when the spray test is completed. 3. Chopper “On/Off” Lever, P/N B-310-11, located on the base of the Chopper mount, should be in the “OFF” position. (see Fig. 2) 4. Thread roving from box through the Roving Guidance system and into the back of the Chopper Feed Bar, P/N B-210-15. It is suggested that the top feed hole be used if only one strand of glass is being used. Mounting Instructions B-410, & B-510, Indy Gun 23550-00 1. The B-410 / 510 Chopper Assy. Mounts to Cutter Pivot Tube, P/N 21491-00 on Chopper Rotating Mount, P/N 23513-00. Tighten down Bar, P/N B-310-4 with Screws, P/N 8212-16F. P/N, 17798-XX Hose attaches to fitting P/N 1880-00 in back of gun. 5. After all components have been securely installed, turn on main air supply slowly until fully on. D-145-08C Fig. 1 6. Activate the Chopper “On/Off” Lever to the “On” position. (see Fig. 2) 7. Depressing the Gun Trigger fully, a spray pattern of resin and catalyst with chopped glass should now be present. GC-1021D circ 7 Set-Up 2. The Slide Valve, P/N 20086-01 controls air to the Gun for the Chopper. Sliding it forward turns the air on, while sliding it back, turns the air off. Chopper Air Requirements 100 PSI / 8 CFM Adjusting Speed & Blower Air 1. The Blower Air is adjusted by the Thumb Screw, P/N B 210-32A2. Only a small amount of air is required to: a. Cool Chopper Head. b. Assist in Dispersing chop. Speed Control / Muffler 1. The Muffler Assembly controls the Amount, and Speed of air exhausting the Air Motor. 2. As the Speed Knob, P/N 21563-01 and Machine Screw, P/N 21567-24F is turned out, the Air Motor speed increases. 3. Once it is set, Lock the Knob / Screw down with the 3. The Gun Trigger is staged: ¼ pull on the trigger will actuate material only. Full back on the trigger actutes the Chopper and Material. The Stager can be adjusted by adjusting the Set screw, P/N 23532-01 in the Gun Trigger, p/n 23503-00. Body, P/N 21561-00. Adjusting Chopper Mount 1. Loosen Screw, P/N 8212-16F to twist the Chopper side to side on the Pivot Tube, P/N 21491-00. Retighten once it is set. Loosen screws 2. Loosen Screw, P/N 20188-16C to pivot the Chopper up & down on the Chopper Bracket, P/N 23512-00. Retighten once it is set. Loosen 8 GC-1021D atomized by providing sufficient Toparticulates prevent cross-contamination of theventilaequipment’s foam and polyurea coatings. ISO will react with moisture tion in the workparts, area. never If sufficient ventilation is not A (isocy• wetted interchange component (such as humidity) to form small, hard, abrasive crystals, available, a supplied-air respirator is required anate) and component B (resin) parts.for which suspended in the fluid. Eventually a film Somebecome materials may become self-igniting if applied everyone in the work area. will form on the surface and the ISO will begin to gel, too thickly. Read material manufacturer’s warnings • increasing in viscosity. and material MSDS. If used, this partially cured ISOTo prevent contact with isocyanates, appropriate perwill reduce performance and the life of all wetted parts. sonal equipment, including chemically 2. Air protective Hose P/N 17798-XX attaches to fitting, P/N impermeable gloves, boots, aprons, and goggles, is The amount of film formation and rate of crystalli- 1880-00 on back of gun. For B-510 for everyone in the work area.at temperatures zation depending on the blend of ISO, the also required Loosenvaries Lock Nut, P/N 7729-04, Pivot Chopper Some foam blowing agents will froth humidity, and the temperature. Mount to desired angle, Retighten P/N 7729-04. above 90°F (33°C) when not under pressure, especially Once general position can be found, fine tuning can if agitated. To reduce frothing, minimize preheating in a To prevent exposing ISO to moisture: be adjusted by moving the chute, P/N B-510-22. circulation system. Isocyanites (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture 3. The Snout, P/Nto 23543-00 is standard with the Indy (such as humidity) form small, hard, abrasive crystals, To System. The end of the Snout is adjustable. Optional which become suspended in the fluid. Eventually a film w snouts thethe B-410 Rev.form G 6/17/2008 21 will onare theavailable surfacefor and ISOonly, will which begininclude to gel, an the B-210-91 and B-210-92. increasing in viscosity. If used, this partially cured ISOSome materials may become self-igniting if applied will reduce performance and the life of all wetted parts.too thickly. Read material manufacturer’s warnings and material MSDS. The film formation ratepiece of crystalliTest amount spraying of should be done onand a clean of zation depending on the blend of ISO, the paper varies or cardboard and disposed of properly. humidity, and the temperature. So To prevent exposing ISO to moisture: ab Mounting Instructions if a B-410, B-510, Indy-X Gun 23575-00 circ Isocyanites (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture 3. The Cutter Valve Lever, P/N B-310-11 controls air (such as humidity) to form small, hard, abrasive crystals, Rev. G 6/17/2008 21 1. The B-410 / B-510 Chopper Assembly mounts to flow to the chopper. Perpendicular to the which become suspended in the fluid. Eventually a film Cutter Pivot Tube, P/N 21491-00 on Chopper Valve, Chopper Valve = Air On. on the surface and the ISO will begin to gel, P/N 23569-00. Once Chopper is set, tighten Cutter will form Inline with Valve = Air OFF. increasing in viscosity. If used, this partially cured ISO Clip, P/N B-310-4 with Screws. will reduce performance and the life of all wetted parts. Set-Up Moisture Sensitivity of Isocyanites Foam Resins with 245 fa Blowing Agents Material Self-ignition F B Moisture Sensitivity of Isocyanites The of film formation rate crystalliThis amount is a positive ON/OFF valve. and It does notofregulate zation varies depending on the blend of ISO, the Air Flow. humidity, and the temperature. To prevent exposing ISO to moisture: Rev. G 6/17/2008 GC-1021D K B 9 Isocyanites (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, increasing in viscosity. If used, this partially cured ISO 4. The Catalyst Atomizing Air Line connects to Connec- will reduce performance and the life of all wetted parts. tor Fitting, P/N 20796-00. When the gun is triggered, The amount of film formation and rate of crystalliFor B-510 Line Air will run the Chopper Motor and regulated air zation varies depending on theFine blend of ISO, A general position can be found. tuning of thethe will flow thru to the atomized circuit. humidity, and the temperature. Glass angle can be adjusted by moving the Chute Set-Up P/N, B-510-22. To prevent exposing ISO to moisture: Centering Adjust Loosen Bar Screws, P/N 8212-16F and Twist Chopper Rev. G right 6/17/2008 left or to desired location, then retighten P/N 8212- 16F Shoulder Screw. Bar Chopper Air Requirements 100 PSI @ 8 CFM Adjusting Speed & Blower Air 1. The blower air is adjusted by the Thumb Screw, P/N B-210-32A2. a small amount of air is required to: Mounting Instructions B-410, B-510, Formula Gun 23750-00 1. The B-410 / B-510 Chopper Assembly mounts to Cutter Pivot Tube, P/N 21491-00. Once the Chopper is set, tighten Cutter Clip, P/N B-310-4 with Screws. a. Cool Chopper Head b. Assist in Dispersing chop. Adjusting Chopper Mount Angle Adjust: 1. Loosen Lock Nut, P/N 7729-04, Pivot Chopper Mount to desired Angle. Retighten, P/N 7729-04 Hex Nut. Lock Nut 10 GC-1021D Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates. ISO, such as those supplied with your system. • Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use. • Never use solvent on one side if it has been contam- Prevent inhalation of isocyanate mists, vapors, and Set-Up atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not 2. Air Hose P/N 17798-XX attaches to fitting, P/N available, a supplied-air respirator is required for 1880-00 on back of gun. everyone in the work area. Chopperinated Air Requirements from the other side. 100 PSI / 8 CFM • Always lubricate threaded parts with ISO pump oil To prevent contact with isocyanates, appropriate peror grease when reassembling. Adjusting Speed & Blower Air sonal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is 1. The Blower Air is adjusted by the Thumb Screw, P/N Balso required for everyone in the work area. 210-32A2. Only a small amount of air is required to: a. Cool Chopper Head. b. Assist in Dispersing chop. Material Self-ignition Keep Components A and B Separate NOTICE Speed / Muffler ToControl prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocy- Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS. Moisture Sensitivity of Isocyanites component (resin) parts. 1. The anate) Muffler and Assembly controlsBthe Amount, and Speed of air exhausting the Air Motor. Foam Resins with 245 fa P/N 21567-24F is turned out, the Air Motor speed inBlowing Agents creases. 2. As the Speed Knob, P/N 21563-01 and Machine Screw, Some foam blowing agents will froth at temperatures above (33°C) when/ Screw not under 3. Once it is 90°F set, Lock the Knob downpressure, with the especially if agitated. To reduce frothing, minimize preheating in a Body, P/N 21561-00. circulation system. Isocyanites (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moistureAdjusting Chopper Mount (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film 1. Loosen Screw, P/N 8212-16F to twist the Chopper side 3. The Cutter Valve, P/N 23776-00 controls the air to side on the Pivot Tube, P/N 21491-00. Retighten once will form on the surface and the ISO will begin to gel, flow to the chopper. it is set. increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts. The of film formation ratenot ofregulate crystalliThisamount is a positive ON/OFF valve.and It does zation varies depending on the blend of ISO, the Air Flow. humidity, and the temperature. To prevent exposing ISO to moisture: Rev. G 6/17/2008 21 2. Loosen Screw, P/N 7958-16C to pivot the Chopper up & down on the Chopper Bracket, P/N 23512-00. Retighten once it is set. GC-1021D 11 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. 3. Open P/N 21192-00 on bottom of material pump. 12 GC-1021D Start-Up Air Requirements All GlasCraft Choppers require 8 CFM (cubic feet per minute) @ 100 PSI. of dry, filtered, compressed air. The air supply hose to the Chopper must be new and have at least a 5/16” inside diameter. Notice Do not attempt to use lower air pressures or a smaller hose as erratic operation may result. Notice Do not wet the roving or attempt to feed frayed roving into the Chopper as this may cause it to wrap around the feed roller and jam. 2. The Motor Oiler is located on the forward port of the Air Motor. It is recommended that the Oiler Felt, P/N 378, be lubricated with Air Motor Oil, P/N 562. Depending on use, it is generally recommended that two or three drops of oil be placed on the Felt every other day. Chopper Operation Models B-410 / B-510 1. To introduce roving to the Chopper, cut the free end of the roving cleanly and double it over approximately one inch from the end. Feed into one of the three holes provided in the back of the cutter while running at moderate speed. B-410 B-410 B-510 GC-1021D B-510 13 Start-Up 3. The Muffler/Speed Control is located on the rear port of the Air Motor. Adjustment of Knob, P/N 21563-01 controls the Air Motor speed and determines the cutting rate. Adjust this valve until the desired glass content is achieved. Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS. Moisture Sensitivity of Isocyanites Isocyanites (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, increasing in viscosity. If used, this partially cured ISO B-510 will reduce performance and the life of all wetted parts. B-410 The amount of film formation and rate of crystalliThis Valve should be at least openof at ISO, all times zation varies depending onslightly the blend the or the Chopper maytemperature. tend to fill and jam. humidity, and the To prevent exposing ISO to moisture: 5. Adjust this valve until a good glass/resin fan results with a minimum of drop-off. If an excessive amount of bypass air is used, the roving may filamentize or cotton, causing various wet-out problems. Rev. G 6/17/2008 6. When desired adjustment has been made, lock Thumb Screw, P/N B-210-32A2, in place by tightening Lock Nut, P/N B-210-32A1. Do not over-tighten! Roving Cut-Length Adjustment B-510 4. The Chopper Blower Control Valve is located on the rear of the Back Plate. Adjustment of Thumb Screw, P/N B-210-32A2 controls the amount of bypass air which serves to vary the dispersion of the cut roving as it leaves the Chopper. The cut length of the roving fibers may vary from 1/2” to 4” depending upon the number of blades in the cutting head. The cutting head has a circumference of 4” and is divided by eight slots at 1/2” intervals. Any number of blades may be omitted to achieve cut-lengths greater than 1/2” or blends of lengths. The most popular length in use today is 1”, which may be achieved with four equally spaced blades. The chopper is delivered to you set in this matter. Mask FilterEar Relieve all air pressure from the system before attempting any repair or maintenance procedures on this equipment. Do not operate the Chopper with the cover or guard removed. The blades may fly free if improperly installed. B-410 14 GC-1021D T w a F B So ab if a cir Parts Fiberglass Roving Choppers B-410 & B-510 Standard Equipment Part Number Description B-410 Fiberglass Chopper GC-1021 USER MANUAL Standard Equipment Part Number Description B-510 Fiberglass Chopper GC-1021 USER MANUAL GC-1021D 15 Assembly Drawings 124377 16 124377 124377 B-410-13 B-310-24-2 B-410 Chopper REVISION R GC-1021D Assembly Drawings B-410 Chopper Part Number Description 378 FELT OILER 13076-10 O-RING 13076-11 O-RING 17390-02 SPRING WASHER 5133-62MD SNAP RING 7606-05 O-RING 7733-13 NUT 7734-06 LOCK WASHER 7958-48C MACHINE SCREW 8160-12C SET SCREW 8212-16F MACHINE SCREW Part Number Description Qty. 9944-16C MACHINE SCREW 21561-00 LOCK NUT 1 21568-00 MUFFLER ASSEMBLY 21562-00 FELT WASHER 2 AM-100-1 AIR MOTOR ASSEMBLY 21563-01 SPEED KNOB 1 B-210-10A AIR MOTOR SPACER 21564-00 MUFFLER TUBE 1 B-210-14A NUT GUARD 21567-24F SCREW 1 B-210-14B SNAP RING 7486-23 WASHER 1 B-210-14C GUARD LINER B-210-14E CHOPPER GUARD B-210-15-1 FEED BAR B-210-15-2 BUSHING B-210-16A CUTTING BLADE BAR B-210-16B RET.BAR SPRING B-210-16C CUTTER HEAD B-210-16E CUTTING HEAD BOLT B-210-16F SNAP RING B-210-17 CUTTING HEAD BLADE B-210-32A2 THUMB SCREW B-210-32B CONTROL BLOCK NUT B-210-71 CHOPPER PARTS KIT B-210-91 CUTTER GUARD SNOUT B-310-24-2 ECCENTRIC NUT B-310-30 CHOPPER BLOWER TUBE B-310-4 Description Qty. B-210-17 CUTTING HEAD BLADE 100 B-210-21W SMALL WHITE RUBBER WHEEL 1 5133-62MD SNAP RING 2 CUTTER CLIP B-410-01 AIR MOTOR TUBE B-410-02-3 NUT CAP B-410-07 TEE SWAGE PIPE FITTING B-410-13 CUTTER BACK PLATE GC-1021 USER MANUAL GC-1021D Part Number REVISION R 17 Assembly Drawings B-510 Chopper REVISION D 18 GC-1021D Assembly Drawings B-510 Chopper Part Number Description Part Number Description 378 FELT OILER B-510-17 COMPRESSION SPRING 13076-10 O-RING B-510-18 COMPRESSION SPRING 13076-11 O-RING B-510-19 RETAINING RING 16828-01 RETAINING RING B-510-20 GUARD CASTING 17390-01 SPRING WASHER B-510-21 TURN KNOB 7486-03 WASHER B-510-22 CHOPPER CHUTE 7606-05 O-RING B-510-23 SCREW 7734-06 LOCK WASHER B-510-24 COVER INSERT 8160-08C SET SCREW B-510-25 1 in. CUTTING HEAD BLADE 8160-12C SET SCREW B-510-71 CUTTER SPARE PARTS KIT 8212-12F SCREW GC-1021 USER MANUAL 8212-16F SCREW 9944-12C SCREW 9944-16C SCREW 9944-36C SCREW 21568-00 CHOPPER MUFFLER ASSEMBLY 23531-02 SHOULDER SCREW 23535-01 SNAP RING Part Number Description Qty. 21561-00 LOCK NUT 1 21562-00 FELT WASHER 2 21563-01 SPEED KNOB 1 21564-00 MUFFLER TUBE 1 AM-100-2 AIR MOTOR ASSEMBLY B-210-10A AIR MOTOR SPACER B-210-16F SNAP RING 21567-24F SCREW 1 B-210-17 CUTTING HEAD BLADE 7486-23 WASHER 1 B-210-32A1 LOCK NUT B-210-32A2 THUMB SCREW B-210-32B CONTROL BLOCK NUT B-310-4 CUTTER CLIP B-410-01 AIR MOTOR TUBE B-410-02-3 NUT CAP B-410-07 TEE SWAGE PIPE FITTING B-510-01 BACK PLATE B-510-02 SLIDING LOCK B-510-03 ADJUSTMENT KNOB B-510-04 ADJUSTMENT WASHER B-510-05 FEED BAR B-510-08 LARGE WHITE RUBBER WHEEL B-510-09 ROLLER HUB B-510-11 IDLER BEARING B-510-14 ANGLE WEDGE CUTTER HEAD B-510-15 ANGLE WEDGE INSERT B-510-16 BLOWER TUB GC-1021D REVISION D 19 Sub-Assembly Drawings AM-100 Air Motor (Used with B-410 Chopper) AM-109 AM-109 Gasket Gasket AM-114 AM-115 Rear Cap Front Cap 5133-62MD AM-113 Snap Ring Seal N/A N/A AM-112 Bearing B-210-23 Tire Shaft NOTE: End Cap (Not Shown) N/A B-210-23A Roll Pin AM-110 AM-103 Rotor Vane R oll Pin REVISED 2/98 REPAIR KIT: AM-120 20 GC-1021D Sub-Assembly Drawings AM-100-2 Air Motor (Used with the B-510 Chopper) AM-109 AM-109 Gasket G asket AM-114 AM-115 Rear Cap Front Cap AM-113 Seal N/A N/A AM-112 Bearing NOTE: End Cap (Not Shown) N/A AM-110 AM-103 R oll Pin Rotor Vane REPAIR KIT: AM-120 GC-1021D 21 Isocyanites if agitated. To reduce frothing, minimize preheating in ifa a Isocyanites circulation system. Isocyanites (ISO) are catalysts used in two component Isocyanites (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, will form on the surface and the ISO will begin to gel, Blade Replacement 2. To re-insert Blades, place in slot, sharp edge out. increasing in viscosity. If used, this partially cured ISOincreasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts. will reduce performance and the life of all wetted parts. cir Maintenance The amount of film formation and rate of crystalliRefer to Figuredepending 7 illustrationonduring the following zation varies the blend of ISO, the Blade Replacement instructions. humidity, and the temperature. To prevent exposing ISO to moisture: Mask FilterEar UseGextreme caution when replacing cutter blades to Rev. 6/17/2008 avoid severe injury or amputation. B-410 1. Using a small slotted-blade screwdriver, carefully pry out the Blade Retainer Bar, P/N B-210-16A, Retainer Bar Spring, P/N B-210-16B and the Blade, P/N B-210-17. Be careful not to lose these small parts as they come free of the slot. Clean slots before replacing Blades. The amount of film formation and rate of crystalliIt is very important that the on Blade held of against zation varies depending thebe blend ISO, the the side of the slot which will contact the Anvil Roller first. humidity, and the temperature. To prevent exposing ISO to moisture: 3. Next, place in the Blade Retainer Bar, P/N B-210-16A and install Spring, P/N B-210-16B with a screwdriver or needle-nose pliers. Rev. G 6/17/2008 B-510 1. Using a 1/8” Allen Wrench, loosen and remove P/N, B-510-23 screw. This will allow removal of P/N, B-51015 wedge insert. 2. Remove old blade. 3. Clean slot on P/N, B-510-14 as necessary. 4. Install new blade. Set insert in properly. 5. Reinstall P/N, B-510-23 screw and snug tightly. 22 GC-1021D 21 Maintenance CORRECT BLADE ASSEM BLY LARGE RECTANGULAR NOTCH VISIBLE BLADE CUTTER HEAD BLADE RETAINER BAR THIS MUST BE VISIBLE WHEN GUARD ASSEMBLY IS REMOVED. CUTTER HEAD RETAINER BAR SPRING INCORRECT BLADE ASSEM BLY INSTALL BLADE FROM THIS POSITION ONLY! BLADE BLADE RETAINER BAR RETAINER BAR SPRING SMALL NOTCH THIS SIDE OF ASSEM BLY MUST FACE CUTTER PLATE CUTTER HEAD CUTTER HEAD B-210-16A BLADE RETAINER BAR B-210-16B RETAINER BAR SPRING B-210-17 BLADE CORRECT BLADE ASSEM BLY Fig. 7 GC-1021D 23 Maintenance Anvil Sleeve Replacement If the Chopper fails to cut properly with new blades, the anvil roller needs replaced. 1. Remove Retaining Ring, P/N 5133-62MD with a screwdriver. Care must be taken not to spring the Retaining Ring excessively. 2. Slide or pry off the old anvil roller and install a replacement by pressing it in place. To prevent the blades from making deep cuts in roller’ surface, be sure to rotate the roller as it is pressed on. Notice Do not use a hammer when installing a new sleeve as permanent damage may result. 3. Replace the Retaining ring with ordinary pliers. 4. Operate the Chopper for a minute or so with the cover in place, to run the new anvil roller. The Chopper should now start and run freely. Chopper Adjustments Should adjustments be necessary, they may be accomplished by simply loosening either the Cutting Head or the Idler Bearing, rotating the Eccentric Nut in the back and retightening. B-510 Adjustments The B-510 adjustments are set at the factory during final inspection of the unit. This adjustment is set without running glass roving through the chopper. It is also important to remember that the chopper head is the drive mechanism of the assembly, adjustments are being made to the Rubber Roller, P/N B-510-08 and Idler Bearing, P/N B-510-11. After feeding in the strands of roving “In Process” adjustments may be required. This adjustment is dependent on the type of glass roving being used and the number of strands. Adjust as follows: 1. Shut off air supply to chopper. 2. Loosen Lock Screw, P/N 9944-16C for the Rubber Roller, P/N B-510-08. 3. Loosen Adjustment Knob, P/N B-510-03 for the P/N B-510-08. This action will allow the glass in between the Cutter Head and Roller to relax and move roller away from Cutter Head slightly. 4. Retighten Lock Screw, P/N 9944-16C. 5. Loosen Lock Screw, P/N 9944-16C for the Idler Bearing, P/N B-510-11. 6. The Idler Bearing should now find its setting with the spring pressure applied to it. B-410 Adjustments 7. Retighten Lock Screw, P/N 9944-16C. 1. Cutting head should have sufficient squeeze to cut properly. Excessive Anvil Squeeze or roll interference will overload the motor or create starting problems. Insufficient Squeeze will result in incomplete cutting. 2. Idler Bearing should be adjusted so there is only slight contact with the Anvil Roller. Excessive pressure will create motor drag and cause starting problems. Insufficient squeeze will allow the roving not to feed or drop out of the chopper when it is stopped. 24 8. Turn air supply on to chopper and operate, verify glass is consistently cut to length. Chopper Air Motor Notice The clearances in this Motor range are from 0.0015 to 0.002 and are extremely critical. For this reason, it is advisable that the Motor NEVER be disassembled in the shop! GC-1021D Maintenance Model B-410 / B-510 The Air Motor on your Chopper is precision built and under normal operation will last hundreds of hours of continuous use with proper care. It is recommended that the Oiler Felt, P/N 378, be lubricated with Air Motor Oil, P/N 562. Depending on use, it is generally recommended that two or three drops of oil be placed on the Felt every other day. Before cutting glass: 1) RELIEVE AIR PRESSURE TO CHOPPER. 2) Remove Chopper Guard and carefully wipe clean excess oil on Guard, Anvil Sleeve, etc. 3) Replace Guard. GC-1021D 25 Accessories B-510-71 Repair Kit Part Number Description Qty. B-510-25 BLADES 100 B-510-08 LARGE WHITE RUBBER WHEEL 1 B-210-71 Repair Kit Part Number Description Qty. B-210-17 BLADES 100 B-210-21W SMALL WHITE RUBBER WHEEL 1 5133-62MD SNAP RING 2 AM-120 Repair Kit Part Number Description Qty. AM-103 VANE 8 AM-109 GASKET 2 AM-112 BEARING 2 AM-113 SEAL 1 7606-17 O-RING 1 Chopper Snout Options Part Number 26 Description Gun 23543-00 OPEN SNOUT INDY / FORMULA 23543-01 CLOSED SNOUT INDY / FORMULA 23543-02 OPEN SNOUT INDY X B-210-91 CLOSED SNOUT (NARROW) LPA2 / INDY / FORMULA B-210-92 CLOSED SNOUT (WIDE) LPA2 / INDY / FORMULA GC-1021D Technical Data GC-1021D Category Data Maximum Air Inlet Pressure 100 psi (0.7 MPa, 7 bar) Maximum Fluid temperature 100° F (38° C) Dimensions B-410 6.93 L X 5.32 W X 3.84 H (176.02 X 135.13 X 97.54 mm) Dimensions B-510 6.90 L X 5.52 W X 5.67 H (175.26 X 140.21 X 144.02 mm) Weight B-410 2.75 Lbs. Weight B-510 3.05 Lbs. Sound Pressure B-410 65.03 dB(A) Sound Pressure B-510 91.35 dB(A) Sound Power, measured per ISO 9614-2 B-410 85.4 dB(A) Sound Power, measured per ISO 9614-2 B-510 86.84 dB(A) 27 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, misapplication, 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 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 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 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. 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. Toll Free: 1-800-746-1334 or Fax: 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. MM GC-1021 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 01/2011