Dow FROTH-PAK Refill Systems User Manual

Download

FROTHPAK™ REFILL SYSTEMS

MANUAL

INSTALL MANUAL | United States | COMMERCIAL/RESIDENTIAL 2014 EDITION

Manual

Table of Contents

FROTHPAK™ Reﬁll System Installation .........................................................A1

Nitrogen Regulator Assembly.................................................................... A2

INSTAFLO™ Gun...............................................................................A3

Anti-crossover Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

Introduction ................................................................................................... 2

Section 1: System Information

1.1 Ordering Information ..........................................................................3

1.2 Reﬁll Accessories .............................................................................3

1.3 Anti-crossover Nozzles (25 Pack) ..............................................................4

1.4 Shipping Weights..............................................................................4

1.5 Tank Dimensions ..............................................................................4

1.6 Freight Classiﬁcation for Tank Return ..........................................................5

Section 2: Safety Precautions

2.1 Respiratory Protection.........................................................................6

2.2 Isocyanate-induced Occupational Asthma .....................................................6

2.3 Safety Clothing................................................................................6

2.4 Skin Contact ..................................................................................6

2.5 Eye Contact ...................................................................................6

2.6 Ingestion ......................................................................................7

2.7 Removal of Cured Foam on Skin ...............................................................7

2.8 Overﬁlling Restricted Spaces ..................................................................7

2.9 Chemical Information ..........................................................................7

2.10 Chemical Spills...............................................................................7

2.10.1 “A” Chemical .........................................................................7

2.10.2 “B” Chemical.........................................................................7

2.11 Cautions .....................................................................................7

2.11.1 Storage Temperature ................................................................7

2.11.2 Building Codes ......................................................................7

2.11.3 Surface Temperature Restrictions ....................................................7

2.11.4 Open Flame/Spark Source...........................................................7

2.11.5 Excessive Foam Dispensing..........................................................7

2.12 Training ......................................................................................7

Section 3: System Installation

3.1 Initial Tank Set-up .............................................................................8

3.2 Tank Positioning...............................................................................9

3.3 Nitrogen Regulator Installation................................................................ 9

3.4 Chemical Hose Installation....................................................................10

Section 4: Start-up Procedure

4.1 System Pressurization ........................................................................10

4.2 Calibration Instructions .......................................................................11

4.3 System Purging and Testing ..................................................................13

4.4 Nozzle Replacement..........................................................................13

Section 5: INSTAFLO™ Gun Operation...................................................................13

5.1 Spraying ....................................................................................13

5.2 INSTAFLO

™

Gun Operation .................................................................14

Section 6: Shut-down Procedure ................................................................... 14

Section 7: Storage................................................................................. 15

Section 8: Re-start Procedure ......................................................................15

8.1 System Pressurization .......................................................................15

8.2 System Purging and Testing .................................................................16

Section 9: Tank Change-over....................................................................... 16

9.1 “A” Tank Change-over........................................................................17

9.2 “B” Tank Change-over .......................................................................18

9.3 Tank Return ................................................................................. 18

9.4 System Pressurization .......................................................................19

9.5 System Purging and Testing .................................................................19

Section 10: Troubleshooting......................................................................... 19

10.1 Temperature .............................................................................19

10.2 Foam Color and Quality ....................................................................19

Section 11: Yield Notes ............................................................................. 21

11.1 Operator Technique ........................................................................ 21

11.2 Application.................................................................................21

11.3 Temperature ...............................................................................21

Section 12: Ratios and Output....................................................................... 22

Section 13: Anti-crossover Nozzles.................................................................. 22

Section 14: Nitrogen Regulator...................................................................... 22

14.1 Safety Information .........................................................................22

14.1.1 Instructions .......................................................................22

Section 15: Tank Heating ............................................................................23

15.1 Usage .....................................................................................23

15.2 Installation Procedure - Tank Heater Band.................................................. 23

15.3 Powerblanket warming equipment ......................................................... 23

15.4 Glas-Col Power Control Description and Operation ......................................... 23

Section 16: Arctic Pak Hose Replacement Set .......................................................24

16.1 General Information........................................................................ 24

16.2 Preparing and Installing the Arctic Pak ......................................................24

16.3 Spare Parts and Maintenance ..............................................................25

Section 17: Warranty................................................................................ 26

Section 18:

Dow Building Solutions

FROTHPAK™ Reﬁll

System Installation

PRECAUTIONS:

DO NOT breathe vapor or spray. Proper

Personal Protective Equipment and ventilation are required. See product (Material) Safety Data Sheet ((M)SDS) and Section 2 of this manual for further information. Follow all precautions for product.

INSTAFLO™ Gun

Anti-crossover Nozzle

8 In. Hoses

In-line On-off Ball Valves

30 Ft. Double nut Chemical Hoses

On-off Swivel Ball Valves

DO NOT expose container to temperatures above 120

DO NOT incinerate, cut, puncture, or weld on or near container.

DO NOT expose container to sparks or ﬂames.

A1

F (49oC).

Nitrogen Hoses

Dow Building Solutions

Chemical Filter

Tank Valves

Nitrogen Intake Tank Valves

Protective Plug: Remove and save for return shipment of empty tanks.

“A” Tank

Protective Plug: Remove and save for return shipment of empty tanks.

“B” Tank

A1

Dow Building Solutions

Nitrogen Regulator Assembly

(7.5 ft. nitrogen lines sold separately. Two lines required for system operation)

Pressure Gauge “A” Tank

Plastic Protective Cap. (Remove before attaching hoses)

Pressure Gauge Nitrogen Cylinder

“A” Tank Nitrogen Hose (mark hose ends with yellow & red electrical tape)

“A” Pressure Regulator

A2

Pressure Gauge “B” Tank

Dow Building Solutions

“B” Pressure Regulator

Plastic Protective Cap. (Remove before attaching hoses)

“B” Tank Nitrogen Hose (mark hose ends with yellow & blue electrical tape)

WARNINGS:

NEVER use oxygen regulators on cylin-

ders of which the gas pressure exceeds 3000 pounds per square inch.

NEVER use oil or petroleum base grease on regulator, inlet connection, or cylinder valve. An explosion or ﬁre could result. The lubricant used on this regulator adjusting screw is Dow-Corning No. 44 silicone grease which is a non-petroleum base grease.

NEVER stand in front of, or behind a regulator while opening the cylinder valve.

DO NOT use WD40 INSTAFLO

Trademark of the WD40 Company.

™

Gun parts.

or DC44 on any

A2

INSTAFLO™ Gun

Nozzle Ejector

Anti-crossover Nozzle

Safety

Trigger

A3

Dow Building Solutions

Anti-crossover Nozzles

(See page 3 for part numbers)

Fan Caulking Cone Pour Calibration

Nozzle Opening Nozzle Opening Nozzle Opening Nozzle Opening Nozzle Opening

A4

Dow Building Solutions

Introduction

The FROTHPAK™ Reﬁll System is a polyurethane foam

dispensing system for users who require large quantities of foam. The system consists of “A” and “B” chemical tanks, chemical ﬁlters, a high pressure regulator, nitrogen lines, chemical dispensing hoses, and a Gun/Hose Assembly Kit.

The system requires dry nitrogen for chemical tank pressuriza-

tion and is not supplied.

The FROTHPAK™ Reﬁll System is designed for

ease-of-use. The following instructions should be followed strictly to ensure maximum equipment performance and efﬁciency.

FROTHPAK™ Foam Insulation and Sealant

Application guidelines as provided by Dow Building Solutions should be followed exactly in order to ensure compliance with building codes and worker safety regulations. Read all information bulletins, (Material) Safety Data Sheets ((M)SDS) and “Product Information” sheets. The SDS is available at www.building.dow.com/na/en/literature/index.htm.

Application of this product is considered a “low pressure” process. It is recommended that workers obtain spray foam training. Workers must be respirator ﬁt tested. Employers must have a documented respiratory and personal protective equipment (PPE) plan. See Section 2 for further PPE information.

Reﬁll Systems

Manual

FROTHPAK™ Foam Insulation and Sealant contain isocyanate, polyol and hydroﬂurocarbon blowing agents. See section 2 for further PPE information. Do not breathe vapor or spray. Use only with supplied air or an approved air purifying respirator equipped with an organic vapor sorbent and a particle ﬁlter to maintain exposure levels below ACGIH, OSHA, WEEL or other applicable limits. For situations where the atmospheric levels may exceed the level for which an air purifying respirator is effective, use a positive-pressure air supplying respirator. The spray foam applicator, and anyone within 25 feet of the applicator, must use an approved air purifying respirator equipped with an organic vapor sorbent and a particle ﬁlter at a minimum. If there is ever a doubt as to the potential limits for worker exposure, Dow always recommends using the highest level of worker protection. Additionally, use barrier tape to mark the working perimeter and install warning signs.

It is important to ensure that the spray area is well ventilated during application and one hour after spraying. Ventilation in Air Changes per Hour (ACH):

• During application a minimum of 10 ACH is required. Cross ventilation is recommended with negative pressure in the spray area and exhaust to a secured empty area. A commercial ventilation unit is recommended for increased ventilation rates.

• Continue to ventilate area for at least 1 hour after the job is completed at no less than 10 ACH.

• Re-entry into an application site less than 1 hour post spray with proper ventilation requires the use of an approved air purifying respirator equipped with an organic vapor sorbent and a particle ﬁlter.

• Ensure ventilation hose output is in a safe and secure location that will not be accessible to individuals without proper PPE in a 25 foot radius and is not near an air intake for a structure.

Safe Use and Training videos are available on line at:

http://building.dow.com/na/en/tools/training/

System Information

1.1 Ordering Information

System Density / Type “A” Tank Part# / Color “B” Tank Part# / Color

1,2

17 Gallon System:

27 Gallon System:

60 Gallon System:

120 Gallon System:

350 Gallon System:

1 Formerly marked with a green colored stripe

2 Includes a Bill of Lading for tank return and a chemical ﬁlter

1.75 Foam Sealant