INTRODUCTION This manual is designed to provide the necessary information for the installation, operation and service of FSI foam dispensing units. It is important to read it thoroughly and to use it for reference whenever necessary. Familiarity with this manual will allow you to obtain maximum operating results, and will provide continuous assurance of quality polyurethane foam.
Page 8
Generally the chemical should be maintained at 80°F (±5°F) throughout the year, unless otherwise specified by FSI. All SLUG PRO guns must have heated hoses. Hoses should be kept off cold floors. Whenever possible, heated fixtures should be utilized. If heated fixtures are impractical, the creation of a heated area of at least 80°F is beneficial.
Page 9
The 240 to 245 p.s.i. blanket is maintained through a regulator unit(s) from bulk or bottled nitrogen. This pressure drives the chemical through a cylinder-to-hose connection (Stratoflex fitting, filter assembly, hoses, & SLUG PRO gun body) on both the “A” and “B” side. (NOTE: FSI DOES NOT supply nitrogen. Nitrogen must be secured from an outside supplier.) The chemical streams impinge in the SLUG PRO Mix Cartridge at approximately 120 p.s.i.
EQUIPMENT DESCRIPTION FSI manufactures the liquid-blown and froth foam dispensing equipment to exacting standards. The SLUG PRO gun is a precision instrument designed for dispensing polyurethane foam systems. Although extremely durable, reasonable care in handling should be exercised to prevent abuse.
HEAT CONTROL UNITS FSI utilizes two different types of heating units, an HB-01 (Single Digital Heat) Unit and a HB-02W (Dual Digital Heat) Unit. The HB-01 is used in conjunction with heat tape for 45 ft. and longer gun units. The HB-02W is used in conjunction with two heat cables (cal-rods) on 25 ft.
EQUIPMENT DESCRIPTION TIMING UNITS FSI utilizes several different types of timing units to adapt to various production methods and schedules. Timing units allow for manual operation if specific timed shots do not suit the application. Timing units are also designed so hook up is simplistic.
Refer to Product Data Sheet (PDS) for specific operating chemical temperatures for your system. CYLINDER STORAGE AND CONDITIONING FSI chemical systems should not be stored at temperatures below 50°F or above 90°F. Chemical temperature conditioning should be done slowly to insure even temperature throughout the mass. Remember temperature conditioning can take from 12-48 hours depending on cylinder size.
FSI owned and maintained cylinders are available in a variety of sizes, including bulk, for maximum flexibility. The cost of handling and the proper disposal of used drums can be avoided by using FSI refillable cylinders. FSI cylinders have been manufactured in accordance with the standard of American Society of Mechanical Engineers (ASME) and Department of Transportation (DOT).
It is imperative that the following information is read thoroughly and understood before connecting the SLUG PRO gun to the chemical cylinders, and any initial assembly, disassembly, or maintenance of the FSI foam unit. CYLINDER PREPARATION AND CONNECTION Ensure that A-SIDE (Isocyanate) and B-SIDE (polyol) chemical cylinders are placed together in the same environmental temperature.
6. Press trigger again, but before the timer counts down 10 seconds, press the trigger again to stop the count. If the count does not stop, the timer and/or connections are not functioning properly. THE FSI FOAM UNIT IS NOW READY FOR TEST AND OPERATION! www.foamsupplies.com www.ecomatetechnology.com...
PRODUCTION AND QUALITY CONTROL Quality Control (Q.C.) procedures are of utmost importance in manufacturing operations. Following the procedures will assure the quality of urethane foam in the product. The procedures are as follows: 1. SLUG PRO START-UP PROCEDURE 2. RATIO PROCEDURE 3.
PRODUCTION AND QUALITY CONTROL SLUG PRO START-UP PROCEDURES Read through all the steps before starting procedure. Please refer to the appropriate IMPORTANT SDS for proper safe handling including the use of safety glasses, protective gloves, and respirator protection where needed. For any reason if you do not understand, or are uncertain of any or all procedures and instructions given to you by Foam Supplies, Inc.
PRODUCTION AND QUALITY CONTROL RATIO PROCEDURE RATIO: The weight comparison of the output of ISO (A) to the output of POLYOL (B). Necessary items: • 30 gallon or larger plastic bag • Gram scale • Calculator RATIO PROCEDURE: 1. Insure the mix tube is not attached to the mix cartridge. Open both the ISO (A) and POLYOL (B) ball valves, take a “short shot”...
PRODUCTION AND QUALITY CONTROL THROUGHPUT PROCEDURE THROUGHPUT: The number of pounds per minute (PPM) dispensed from the SLUG PRO dispensing unit. It is the weight of foam from a 10 or 6 second timed shot expressed in lbs./min. Necessary items: •...
PRODUCTION AND QUALITY CONTROL REACTIVITY PROCEDURE REACTION PROFILE: The sequential stages, that is, the String-Gel and Tack-Free times, from the time the ISO (A) and POLYOL (B) are mixed/dispensed until the urethane reaction is complete. REACTION PROFILE Q.C. – Measuring, recording and comparing the stages and comparing to the specific system Technical Data Sheet.
PRODUCTION AND QUALITY CONTROL SHOT TIME PROCEDURE Shot times are determined from three factors: 1. VOLUME of void to be filled. 2. Desired IN-PLACE DENSITY. 3. Gun THROUGHPUT. PROCEDURE: 1. Calculate VOLUME of object to be foam filled. Example: Volume of Cube = Length x Width x Height 2.
PRODUCTION AND QUALITY CONTROL SLUG PRO SHUT-DOWN PROCEDURES Read through all the steps before starting procedure. Please refer to the appropriate IMPORTANT SDS for proper safe handling including the use of safety glasses, protective gloves, and respirator protection where needed. For any reason if you do not understand, or are uncertain of any or all procedures and instructions given to you by Foam Supplies, Inc.
12. Tighten Stratoflex fittings until fully engaged. Make sure that the ball valves are held in place and do not turn during connection. NOTE: When fully engaged, the Strat assembly will not rotate. 13. Prepare depleted cylinders for return to FSI. (See pages 33-35) www.foamsupplies.com www.ecomatetechnology.com...
CHANGING CHEMICAL CYLINDERS CYLINDER BLOW DOWN PROCEDURE FOR F-6000 & F-5000 Empty cylinders being returned to Foam Supplies, Inc. for refilling must be sealed and the pressure relieved to 75 p.s.i froth systems or 25 p.s.i. for liquid-blown systems. EAR PROTECTION IS REQUIRED DURING BLOW DOWN DUE TO EXCESS NOISE! WELL VENTILATED AREA, PROTECTIVE EYEWEAR AND GLOVES REQUIRED! 1.
CHANGING CHEMICAL CYLINDERS CYLINDER BLOW DOWN PROCEDURE FOR F-1000 & F-300 Empty cylinders being returned to Foam Supplies, Inc. for refilling must be sealed and the pressure relieved to 75 p.s.i. for froth systems and 25 p.s.i. for liquid-blown systems. EAR PROTECTION IS REQUIRED DURING BLOW DOWN DUE TO EXCESS NOISE! WELL VENTILATED AREA, PROTECTIVE EYEWEAR AND GLOVES REQUIRED! 1.
CHANGING CHEMICAL CYLINDERS SEALING EMPTY CYLINDERS FOR RETURN Empty cylinders being returned to Foam Supplies, Inc. for refilling must be sealed and the pressure relieved to 75 p.s.i. for froth systems and 25 p.s.i. for liquid-blown systems. This procedure is necessary in preventing possible contamination in the cylinder fittings.
MAINTENANCE ALWAYS WEAR PROTECTIVE EYEWEAR AND GLOVES WHEN PERFORMING ANY MAINTENANCE. MAINTENANCE OF THE SLUG PRO GUN SHOULD BE PERFORMED ON ONLY ONE SIDE (A-SIDE or B-SIDE) AT A TIME. FOR EXAMPLE, PERFORM MAINTENANCE ON THE A-SIDE ONLY AND PUT BACK TOGETHER BEFORE WORKING ON THE B-SIDE.
MAINTENANCE SLUG PRO MIX CARTRIDGE The SLUG PRO Mix Cartridge should be cleaned and greased at Start-Up/Shut-Down and all breaks. O-RINGS CHEMICAL PORT GUN OUTPUT www.foamsupplies.com www.ecomatetechnology.com 1.800.325.4875...
MAINTENANCE MIX CARTRIDGE REPLACEMENT PROCEDURES Read through all the steps before starting procedure. IMPORTANT For any reason if you do not understand, or are uncertain of any or all procedures and instructions given to you by Foam Supplies, Inc. and its representatives, please contact our Application Specialist before attempting procedures.
Page 45
MAINTENANCE MIX CARTRIDGE REPLACEMENT PROCEDURES (continued) 7. Remove old grease with rag. 8. Apply Vaseline or lithium grease to No need to use spray cleaner. receiver (U-frame) walls. 9. Inspect new mix cartridge. Make sure all three O-rings are installed and not damaged (smaller O-ring on top and larger O-rings on each side).
Page 46
MAINTENANCE MIX CARTRIDGE REPLACEMENT PROCEDURES (continued) 12. Re-attach air line. 11. Re-install T-cap and 4 bolts. 13. Grease gun through grease fitting until it flows from weep hole under receiver (U-frame). 14. SLUG PRO is now ready for quality control process. SLUG PRO is now ready for quality control process.
MAINTENANCE DATE DESCRIPTION CHG QTY OF SL2-30 FROM 2 TO 6, CHG QTY OF G-6-1 FROM 8 TO 4 9/16/16 CHG P/N SL2-38BR TO SL2-39BR, 1/17/18 CHG SL2-35 FROM 1/4-20 X 2-3/4 TO 1/4-20 X 3 CHG 24 P/N TO SL2-412W, CHG 26 P/N TO CSA-2, 10/31/18 RMV BRASS NIPPLE, ADDED HEX NIPPLE SLUG PRO GUN HEAD...
Within the Strat assemblies are filters. The filters are canister type with removable filter screen barrels. It is rare that filters need replacement but replacement can occur. The SLUG PRO gun must be depressurized before servicing or replacing the filters. Contact FSI for assistance with depressurizing any equipment and replacement of filters. Filters CANNOT be used interchangeably.
7. Turn on nitrogen at 240– 245 p.s.i. Problem: Crystals continually plug A-SIDE flow controller. Probable cause: 1. A-SIDE has plated on the inside of the chemical line due to moisture contamination. Corrective action: 1. Replace A-SIDE chemical hose. Contact FSI for assistance. www.foamsupplies.com www.ecomatetechnology.com 1.800.325.4875...
2. Cracks or leaks in chemical lines. Call FSI Application Specialist before correcting. Corrective Actions: 1. Tighten fittings firmly. 2. Replace cracked or damaged hose. DO NOT USE OTHER HOSES APART FROM THOSE SUPPLIED BY FSI. The hoses are special high-pressure hoses. Call FSI Technical Service Dept. before correcting. www.foamsupplies.com www.ecomatetechnology.com...
TROUBLESHOOTING Problem: Nitrogen regulator leaks Probable Causes: 1. Quick-connect from nitrogen regulator assembly not fully engaged. 2. O-ring defective in quick-connect fitting. 3. Nitrogen hose fittings not firmly tightened and secured. 4. Nitrogen regulator assembly not fully engaged into nitrogen bottle. Corrective Actions: 1.
Page 53
TROUBLESHOOTING e) Mix Tube restricted causing excess backpressure. Change mix tube. f) The most common cause is the A-SIDE chemical port of the Mix Cartridge is clogged. Close all ball valves, disconnect A-SIDE wing, retract rod, and clear out hole with correct drill bit. Replace Mix Car- tridge if needed.
Page 54
TROUBLESHOOTING Problem: Cured foam is streaked or has excessively coarse or "glassy" cell structure. Probable causes: 1. A-SIDE and B-SIDE chemicals are too cold for operation. 2. Poor mix. 3. Water or solvent in air purge line or residual solvent in gun head. Corrective actions: 1.
The above information is needed before FSI can attempt to evaluate and solve problems. Again this information will allow FSI to assist you more quickly and save YOU time. It is in FSI’s best interest and yours to cooperate and solve problems together.
TROUBLESHOOTING TROUBLESHOOTING CHECKLIST FOR FSI CHEMICAL SYSTEMS AND EQUIPMENT CHEMICAL SYSTEM_________________________ SHIP DATE__________________ NATURE OF ISSUE_________________ NITROGEN PRESSURE IN CYLINDERS______________________ CHEMICAL LEVELS IN TANKS________________ FOR F-5000 and F-6000, check level gauge. For F-300 and F-1000, check total number of seconds shot or weight of cylinder on scale.
Minimize the exposure of A-SIDE components to atmosphere. Always contact FSI for assistance in relieving pressure on cylinders and equipment. DON’T GUESS! If unsure of anything, don’t hesitate to call for assistance. FSI is dedicated to helping its customers. CLOTHING Wear protective eyewear (safety glasses).
BALL VALVES Ball valves are used in many parts of the FSI equipment. Ball valves have been selected to allow the best flow and the least pressure drop. Ball valves are made with special seals to prevent the reactive chemicals from damaging their function.
SAFETY AND HANDLING SPILL & DISPOSAL PROCEDURES – ISOCYANATE (ISO or A) Read through all the steps before starting procedure. Please refer to the appropriate IMPORTANT SDS for proper safe handling including the use of safety glasses, protective gloves, and respirator protection where needed. For any reason if you do not understand, or are uncertain of any or all procedures and instructions given to you by Foam Supplies, Inc.
SAFETY AND HANDLING SPILL & DISPOSAL PROCEDURES – POLYOL (B) Read through all the steps before starting procedure. Please refer to the appropriate IMPORTANT MSDS for proper safe handling including the use of safety glasses, protective gloves, and respirator protection where needed. For any reason if you do not understand, or are uncertain of any or all procedures and instructions given to you by Foam Supplies, Inc.
EQUIPMENT DRAWINGS & PARTS MIX TUBE ASSEMBLY SLUG PRO MIX CARTRIDGE MIX TUBE COLLAR BELL END OF MIX TUBE MIX ELEMENT www.foamsupplies.com www.ecomatetechnology.com 1.800.325.4875...
EQUIPMENT DRAWINGS & PARTS SLUG PRO GUN HEAD DATE DESCRIPTION ROUND-STYLE FLOW CONTROLLERS CHG QTY OF SL2-30 FROM 2 TO 6, CHG QTY OF G-6-1 FROM 8 TO 4 9/16/16 CHG P/N SL2-38BR TO SL2-39BR, 1/17/18 CHG SL2-35 FROM 1/4-20 X 2-3/4 TO 1/4-20 X 3 CHG 24 P/N TO SL2-412W, CHG 26 P/N TO CSA-2, 10/31/18 RMV BRASS NIPPLE, ADDED HEX NIPPLE...
EQUIPMENT DRAWINGS & PARTS SLUG PRO GUN HEAD PARTS (ROUND-STYLE FLOW CONTROLLERS) ITEM DESCRIPTION Socket Head Cap Screw 1/4-20 x 3/4 SL2-30 Gun Handle with trigger guard SL2-16 SL2-UFRAME i f i Socket Head Cap Screw 1/4-20 x 1 G6-1 Iso Ball Valve Assembly - Red SEE CHART Poly Ball Valve Assembly - Blue...
EQUIPMENT DRAWINGS & PARTS SLUG PRO GUN HEAD DATE DESCRIPTION Y-STYLE FLOW CONTROLLERS CHG QTY OF SL2-30 FROM 2 TO 6, CHG QTY OF G-6-1 FROM 8 TO 4 9/16/16 CHG P/N SL2-38BR TO SL2-39BR, 1/17/18 CHG SL2-35 FROM 1/4-20 X 2-3/4 TO 1/4-20 X 3 CHG 24 P/N TO SL2-412W, CHG 26 P/N TO CSA-2, 10/31/18 RMV BRASS NIPPLE, ADDED HEX NIPPLE...
EQUIPMENT DRAWINGS & PARTS SLUG PRO GUN HEAD PARTS (Y-STYLE FLOW CONTROLLERS) ITEM DESCRIPTION Socket Head Cap Screw 1/4-20 x 3/4 SL2-30 Gun Handle with trigger guard SL2-16 Set Screw 1/4-20 x 3/4 SL2-SS U-Frame Body SL2-UFRAME Removable Orifice SEE CHART Wing O Ring SL29 Socket Head Cap Screw 1/4-20 x 1...
PRODUCTION AND QUALITY CONTROL FLOW CONTROL ASSEMBLY (Y-STYLE) OUTPUT OF FLOW CONTROLLER CAN VARY. PLEASE ORDER CAREFULLY. 60-PPM FLOW CONTROLLER ITEM # PART # DESCRIPTION ½" Check Valve NU11 ½" FPT Swivel x ½" MPT SL2-FCR60 Y Flow Controller (ISO) Red SL2-FCB60 Y Flow Controller (Poly) Blue TF60005...
Page 75
PRODUCTION AND QUALITY CONTROL FLOW CONTROL ASSEMBLY (Y-STYLE) OUTPUT OF FLOW CONTROLLER CAN VARY. PLEASE ORDER CAREFULLY. 15-PPM FLOW CONTROLLER ITEM # PART # DESCRIPTION " Check Valve NU11-2 " FPT Swivel x ½" MPT SL2-FCR15 Y Flow Controller (ISO) Red SL2-FCB15 Y Flow Controller (Poly) Blue ½"...
Page 76
EQUIPMENT DRAWINGS & PARTS DUAL NITROGEN REGULATORS ITEM # PART # DESCRIPTION High Pressure Regulator 0-400 p.s.i. Gauge NA30 0-4000 p.s.i. Gauge ¼" Run Tee ¼" MPT x ¼" JIC Male Adapter H910 " x 10' Synflex Hose " JIC x ¼" MPT www.foamsupplies.com www.ecomatetechnology.com 1.800.325.4875...
Page 77
EQUIPMENT DRAWINGS & PARTS SINGLE NITROGEN REGULATORS ITEM # PART # DESCRIPTION High Pressure Regulator 0-400 p.s.i. Gauge 0-4000 p.s.i. Gauge ¼" Run Tee ¼" MPT x ¼" JIC Male Adapter H910 " x 10' Synflex Hose " JIC x ¼” MPT "...
Page 78
EQUIPMENT DRAWINGS & PARTS FILTER ASSEMBLY 100 120 FITTINGS FITTINGS FOR 1-¼" STRAT FOR ½" CONNECTIONS TANK CONNECTION STRAT VARIES WITH SYSTEM SIZE CONNECTIONS www.foamsupplies.com www.ecomatetechnology.com 1.800.325.4875...
Need help?
Do you have a question about the SLUG PRO and is the answer not in the manual?
Questions and answers