FoamPRO Mfg F1000 User Manual

CONTENTS

Section

INSTALLATION 1.0 ................................................................................................. 2

Connecting the hose/dispenser assembly to the chemical cylinders 1.1.............2

Connecting the red "A" hose to the "A" chemical cylinder 1.2 ..............................2

Connecting the red "B" hose to the "B" chemical cylinder 1.2...............................4

Connecting the nitrogen hoses 1.3.................................................................................4

STARTUP | CALIBRATION 2.0................................................................................ 6

Startup 2.1 .............................................................................................................................6

Calibration of A:B ratio 2.2............................................................................................12

MAINTENANCE | SERVICE 3.0............................................................................22

Air Injection System 3.1.................................................................................................. 22

Trigger (D300) 3.1.1..........................................................................................................24

Handle (D201) 3.1.2.......................................................................................................... 24

Air Cylinder/ Piston Assembly (D300) 3.1.3............................................................... 26

Carrier Assembly (D500) 3.2.1....................................................................................... 40

Chemical Valve Service (D503R & D503B) 3.2.2...................................................... 40

Filter Screen Service (D504) 3.2.3 ................................................................................ 42

Check Valve Service 3.2.4 ............................................................................................... 44

Mix Cartridge Service (D603 or Optional Cartridge) 3.2.5.................................... 46

Mix Cartridge Removal and Cleaning (D603 or Optional Cartridge) 3.2.6....... 48

SHUTDOWN 4.0 ................................................................................................... 52

Shutdown Procedure 4.1................................................................................................. 52

TROUBLESHOOTING 5.0 ...................................................................................... 54

PARTS LIST 6.0 .....................................................................................................55

FOAMPRO® F1000

INSTALLATION

1.0

1.1

Usually the Foampro dispenser is shipped to customers with the hose assembly already connected to the dispenser. If your Foampro dispenser is not connected to the hose assembly:

Attach the red “A” hose to the Hose Connection Fitting (D507) on the left side of the dispenser, just behind the red valve.

Attach the blue “B” hose to the Hose Connection Fitting (D507) on the right side of the dispenser, just behind the blue valve.

Attach the gray air pressure line to the quick connect fitting at the rear of the dispenser.

(See diagram 3A)(See diagram 3A)

(See diagram 3A)

(See diagram 3A)(See diagram 3A)

(See diagram 3A)

(See diagram 3A)(See diagram 3A)

(See diagram 3A)

(See diagram 3A)(See diagram 3A)

Connecting theConnecting the

Connecting the

Connecting theConnecting the

hose/dispenserhose/dispenser

hose/dispenser

hose/dispenserhose/dispenser

assembly to theassembly to the

assembly to the

assembly to theassembly to the

chemical cylinders:chemical cylinders:

chemical cylinders:

chemical cylinders:chemical cylinders:

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

1.2

Connecting the redConnecting the red

Connecting the red

Connecting the redConnecting the red

"A" hose to the "A""A" hose to the "A"

"A" hose to the "A"

"A" hose to the "A""A" hose to the "A"

chemical cylinder:chemical cylinder:

chemical cylinder:

chemical cylinder:chemical cylinder:

Lay out the dispenser/hose assembly. Place the cylinders of “A” chemical and “B” chemical in a position where the

hoses can be connected without strain.

Be sure all valves on both of the cylinders, and the hoses are closed before connecting or disconnecting hoses, or removing caps or plugs from cylinder.

After checking to be sure all valves on the cylinder are closed, remove the cap from the outlet of the chemical valve. handy so that it can refitted to the cylinder after the cylinder is empty.

Remove the plug from the filter end of the red "A" hose Keep the plug handy- it will be needed to reseal the hose after the hose is disconnected from the cylinder.

Connect the red "A" hose to the outlet of the chemical valve on the "A" component cylinder.

(See diagram 3B)(See diagram 3B)

(See diagram 3B) Keep the cap

(See diagram 3B)(See diagram 3B)

(See diagram 3B).

(See diagram 3B)(See diagram 3B)

FOAMPRO® F1000

INSTALLATION

Diagram 3A

1.2

Nitrogen

Supply

Hose

Nitrogen

Valve

Pressure

Relief

Valve

Cylinder Valves - 17 Gal.

Cylinder

Chemical

Valve

Hose Filter

Chemical

Valve

Diagram 3B

Closed

Open

Chemical

Valve

Positions:

FOAMPRO® F1000

INSTALLATION

1.2

Connecting the blueConnecting the blue

Connecting the blue

Connecting the blueConnecting the blue

"B" hose to the "B""B" hose to the "B"

"B" hose to the "B"

"B" hose to the "B""B" hose to the "B"

chemical cylinder:chemical cylinder:

chemical cylinder:

chemical cylinder:chemical cylinder:

To connect the blue "B" hose to the "B" chemical cylinder: After checking to be sure that all valves on the cylinder are closed, remove the plug from the outlet of the chemical valve it can be refitted to the cylinder after the cylinder is empty.

Remove the cap from the filter end of the blue "B" hose. Keep the plug handy it will be needed to reseal the hose after the hose is disconnected from the cylinder.

Connect the blue "B" hose to the outlet of the chemical valve on the "B" chemical cylinder.

Connect the dispenser air line to an air regulator 100 to 125 psi with moisture separator and filter.

(See diagram 5A).(See diagram 5A).

(See diagram 5A). Keep the plug handy so that

(See diagram 5A).(See diagram 5A).

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1.3

Connecting theConnecting the

Connecting the

Connecting theConnecting the nitrogen hoses:nitrogen hoses:

nitrogen hoses:

nitrogen hoses:nitrogen hoses:

TE:TE:

TE:

TE:TE:

Compressed air that contains high levels of water or oil can adversely affect the performance and service life of some of the parts of the Foampro dispenser. This is particularly important when using portable compressors. Be sure to drain the compressor of any water prior to use. Also, it is recommended that an in line air filter and moisture separator are used to remove oil from the compressed air source.

Place the nitrogen cylinder near the chemical cylinders, being sure to secure the nitrogen cylinder so that it cannot be accidentally knocked over.

Connect the nitrogen regulator to the nitrogen cylinder using the threaded pressure fitting on the rear of the nitrogen regulator assembly.

(See diagram 5B)(See diagram 5B)

(See diagram 5B)

(See diagram 5B)(See diagram 5B)

Connect the red hose leading from the nitrogen regulator assembly to the nitrogen fitting on the "A" chemical cylinder . It will be fitted with a quick connect fitting that will simply snap into place.

page)page)

page)

page)page)

(See diagram 3B, previous(See diagram 3B, previous

(See diagram 3B, previous

(See diagram 3B, previous(See diagram 3B, previous

Connect the blue hose leading from the nitrogen regulator assembly to the nitrogen fitting on the "B" chemical cylinder. It will be fitted with a quick connect fitting that will simply snap into place.

FOAMPRO® F1000

(See diagram 5A)(See diagram 5A)

(See diagram 5A)

(See diagram 5A)(See diagram 5A)

Pressure

Relief

Valve

Nitrogen

Supply

Hose

Nitrogen

Valve

Cylinder

Chemical

Valve

Hose Filter

Chemical

Valve

INSTALLATION

1.3

Diagram 5A

Closed

Chemical

Cylinder Valves - 60 Gal.

Open

Filter

Chemical

Valve

Positions:

Diagram 5B

FOAMPRO® F1000

STARTUP | CALIBRATION

2.0

Make sure all installation steps have been completed prior to startup and calibration. Make sure that the chemicals are at the correct operating temperature, usually 70° to 90° F.

2.1

Startup:Startup:

Startup:

Startup:Startup:

1 | Be sure that all valves are closed. would include: The valve on top of the nitrogen cylinder. The nitrogen valve on top of both chemical cylinders ("A" Chemical and "B" Chemical).

grams 6A & 7A)grams 6A & 7A)

grams 6A & 7A) The chemical outlet valve on top of both chemical cylinders

grams 6A & 7A)grams 6A & 7A)

("A" chemical and "B" chemical) on the filter end of both the red "A" component hose and the blue "B" component hose. chemical valve on the F1000 dispenser

(See diagrams for valve locations)(See diagrams for valve locations)

(See diagrams for valve locations) This

(See diagrams for valve locations)(See diagrams for valve locations)

(See dia-(See dia-

(See dia-

(See dia-(See dia-

(See diagrams 6A & 7A)(See diagrams 6A & 7A)

(See diagrams 6A & 7A) The chemical valve

(See diagrams 6A & 7A)(See diagrams 6A & 7A)

(See diagram 6A & 7A)(See diagram 6A & 7A)

(See diagram 6A & 7A) Both the red chemical valve and the blue

(See diagram 6A & 7A)(See diagram 6A & 7A)

(See diagram 7B).(See diagram 7B).

(See diagram 7B).

(See diagram 7B).(See diagram 7B).

Diagram 6A

Nitrogen

Supply

Hose

Nitrogen

Valve

Pressure

Relief

Valve

Cylinder Valves - 17 Gal.

Cylinder

Chemical

Valve

Hose Filter

Chemical

Valve

Closed

Open

Chemical

Valve

Positions:

FOAMPRO® F1000

Pressure

Relief

Valve

Nitrogen

Supply

Hose

Nitrogen

Valve

Cylinder

Chemical

Valve

Hose Filter

Chemical

Valve

STARTUP | CALIBRATION

2.1

Diagram 7A

Closed

Chemical

Cylinder Valves - 60 Gal.

Open

Filter

Chemical

Valve

Positions:

Diagram 7B

FOAMPRO® F1000

STARTUP | CALIBRATION

2.1

2 | Turn on the air supply to the dispenser, and check for leaks.

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TE:

TE:TE:

3 | Remove Mix Cartridge Plug (D620) if one is in place until calibration steps are completed.

4 | Open both of the air injection valves (D704, D705) if the air passes freely through the dispenser. Re-close both of the air injection valves, as they must be closed to complete the calibration of the dispenser.

5 | Turn the adjustment valves on both nitrogen regulators leading to the "A" chemical and the "B" chemical counterclockwise two full turns.

9B)9B)

9B)

9B)9B)

6 | Open the valve on top of the nitrogen cylinder, and check for leaks. 7 | Adjust the "A" component nitrogen regulator (one with the red hose) to 190

psi (starting point) by turning clockwise 8 | Adjust the "B" component nitrogen regulator (one with the blue hose) to

140 psi (starting point) by turning clockwise

The chemical cylinders are equipped with a pressure overload relief valve that will open if the pressure of the cylinder exceeds approximately 220 psi. Do not adjust nitrogen pressure on the chemical cylinders to approach 220 psi.

(See diagram 9B)(See diagram 9B)

(See diagram 9B)

(See diagram 9B)(See diagram 9B)

(See diagram 9B)

(See diagram 9B)(See diagram 9B)

. .

. Do not install nozzle

. .

(See diagram 9A)(See diagram 9A)

(See diagram 9A) to see

(See diagram 9A)(See diagram 9A)

(See diagram(See diagram

(See diagram

(See diagram(See diagram

FOAMPRO® F1000

STARTUP | CALIBRATION

2.1

Diagram 9A

Diagram 9B

FOAMPRO® F1000

STARTUP | CALIBRATION

2.1

9 | Open the nitrogen valves on both chemical cylinders ( "A" component and

"B" component). 10 | Open the chemical valves on both chemical cylinders ( "A" component and

"B" component). fittings.

11 | Open the chemical valves on the filter end of the hose assembly for both the "A" component and "B" component. leaks. Tighten any leaking fittings.

12 | Position a garbage can with a plastic liner at the work area. 13 | Make sure mixing cartridge plug is removed. 14 | Open the red valve and the blue valve on the F1000 dispenser.

(See diagram 1(See diagram 1

(See diagram 1

(See diagram 1(See diagram 1

(See diagram 1

(See diagram 1(See diagram 1

(See diagram 1

(See diagram 1(See diagram 1

0A)0A)

0A)

0A)0A)

1A & 11A & 1

1A & 1

1A & 11A & 1

1A & 1

1A & 11A & 1

1B)1B)

1B)

1B)1B)

1B) 1B)

1B) Check for leaks. Tighten any leaking

1B) 1B)

(See diagram 1(See diagram 1

(See diagram 1

(See diagram 1(See diagram 1

1A & 11A & 1

1A & 1

1A & 11A & 1

1B) 1B)

1B) Check for

1B) 1B)

Diagram 10A

15 | While aiming the F1000 into the trash can, pull the trigger on the F1000 dispenser for 10 seconds, dispensing the foam into the trash can liner. If your F1000 is brand new, you may have to pull the trigger for a longer period to purge the air out of the hoses. If your F1000 dispenser was put into storage with the hoses full of chemicals, you may have to dispense foam for longer than 10 seconds to be sure that the chemicals that were stored in the hoses is fully flushed out by fresh chemicals from the chemical cylinders.

FOAMPRO® F1000

Nitrogen

Supply

Hose

Nitrogen

Valve

STARTUP | CALIBRATION

2.2

Diagram 11A

Closed

Pressure

Relief

Valve

Cylinder Valves - 17 Gal.

Pressure

Relief

Valve

Nitrogen

Supply

Hose

Nitrogen

Valve

Cylinder

Chemical

Valve

Hose Filter

Chemical

Valve

Cylinder

Chemical

Valve

Hose Filter

Chemical

Valve

Open

Chemical

Valve

Positions:

Diagram 11B

Closed

Chemical

Cylinder Valves - 60 Gal.

Filter

Open

Chemical

Valve

Positions:

FOAMPRO® F1000

STARTUP | CALIBRATION

2.2

Calibration ofCalibration of

Calibration of

Calibration ofCalibration of

A:B ratio:A:B ratio:

A:B ratio:

A:B ratio:A:B ratio:

Proper mixing of the “A” and “B” component chemicals in the correct proportions is important in producing foam. Foams produced with an improper proportion of “A” to “B” chemical can in some cases affect foam properties.

When and how often should the A:B ratio be checked?

•At the beginning of the workday.

•When a new cylinder of “A” or “B” component is installed.

•When a new cylinder of nitrogen is installed.

•About halfway through the normal workday.

•When the temperature in the work area increases or decreases by more than 10 degrees. If the temperature of the chemicals changes, the viscosity of the chemicals changes. This viscosity change can have an effect on the A:B ratio.

•If a noticable change takes place in the foam being produced.

•After any restriction in the chemical flow is removed, for example cleaning the filters or the ports in the mixing cartridge in the F1000 will likely increase the flow of chemical which in turn may change the A:B ratio.

•When a new mixing cartridge is installed.

1 | Make sure that the F1000 dispenser is correctly installed to the chemical cylinders, nitrogen cylinders, and compressed air supply as described in the Startup procedures above. Check all hose connections to be sure that there are no leaks. Make sure the air injection on/off valve is closed. For calibration, remove the plastic nozzle.

(See diagram 13A)(See diagram 13A)

(See diagram 13A)

(See diagram 13A)(See diagram 13A)

FOAMPRO® F1000

2 | Place a 32oz paper cup on a scale, and tare the scale to read zero. 3 | Open the "A" (red) chemical valve and close the "B" chemical (blue) valve on

the F1000 dispenser. 4 | Using a stop watch, or optional timer, trigger the F1000 dispenser for exactly

3 seconds, directing the flow of the "A" chemical into the paper cup on the scale. Record the weight of "A" chemical dispensed.

5 | Critical Step- Purging the mix cartridge: After measuring the weight of the dispensed "A" chemical in step 4, open the both "B" chemical (blue) valve and the "A" chemical (red) valve on the F1000 dispenser. Then, while directing the flow of the dispenser into a trash can, trigger the F1000 dispenser for a few seconds to dispense a mixture of "A" and "B" chemicals into the trash can. This step is important because it will reduce plugging of the mix cartridge.

(See diagram 13B)(See diagram 13B)

(See diagram 13B)

(See diagram 13B)(See diagram 13B)

(See diagram 13B)

(See diagram 13B)(See diagram 13B)

STARTUP | CALIBRATION

2.2

Diagram 13A

Diagram 13B

FOAMPRO® F1000

STARTUP | CALIBRATION

2.2

6 | Close the "A" chemical (red) valve on the F1000 dispenser, leaving the "B"

chemical (blue) valve open.

7 | Place a 32 oz. paper cup on a scale, and tare the scale to read zero. 8 | Using a stop watch, or optional timer, trigger the F1000 dispenser for exactly

3 seconds, directing the flow of the "B" chemical into the paper cup on the scale. Record the weight of "B" chemical dispensed.

9 | Purge the mix cartridge once again as outlined in step 5 above. 10 | Calculate the A:B chemical ratio by dividing the weight of the "A" chemical

obtained from step 4 by the weight of the "B" chemical obtained in step 8.

(See diagram 15A)(See diagram 15A)

(See diagram 15A)

(See diagram 15A)(See diagram 15A)

Example:

"A" chemical (3 second shot) weighs 41 grams "B" chemical (3 second shot) weighs 37 grams 41 grams ÷ 37 grams = 1.11 A:B ratio

Most Polypro formulations should be run with an A:B ratio in the range of 1.00 to 1.15. Consult the technical data sheet for the Polypro formulation you are running- it will list the best A:B ratio for that particular product (See Ratio

Calibration Charts on pages 18 - 21). 11 | If the A:B chemical ratio obtained in step 10 is too high, ie above 1.15,

adjust the nitrogen pressure on the "B" chemical up by 10 psi and repeat the calibration procedure starting at step 1. If the A:B ratio obtained in step 10 was too low, ie below 1.00, the adjust the nitrogen pressure on the "A" chemical up by 10 psi and repeat the calibration procedure. It may be necessary make more than one adjustment to the nitrogen pressure of the "B" chemical before reaching the correct A:B ratio. It is advisable to adjust the nitrogen pressure on the B" component in order to adjust the A:B ratio, not the nitrogen pressure on the "A" chemical.

12 | It may be necessary during the calibration process to reduce the nitrogen pressure on one of the chemical cylinders. This situation occurs when the proper A:B component ratio cannot be achieved without raising the pressure on one of the cylinders to its maximum pressure of 220 psi. REMEMBER: Each of the

chemical cylinders is equipped with a pressure relief valve that will automatically open if the nitrogen pressure on the cylinder exceeds 220 psi.

FOAMPRO® F1000

Use the following steps to reduce nitrogen pressure on the cylinder. SAFETY GLASSES SHOULD BE WORN DURING THIS PROCEDURE.

STARTUP | CALIBRATION

2.2

Diagram 15A

FOAMPRO® F1000

STARTUP | CALIBRATION

2.2

1 - Close nitrogen valve on the chemical cylinder. 2 - Using the nitrogen pressure adjustment valve for the chemical cylinder being adjusted, turn the adjustment valve counterclockwise two full turns.

(See diagram 17A)(See diagram 17A)

(See diagram 17A)

(See diagram 17A)(See diagram 17A)

3 - Locate the pressure relief valve on the chemical cylinder being adjusted.

(See diagrams 16A & 16B)(See diagrams 16A & 16B)

(See diagrams 16A & 16B)

(See diagrams 16A & 16B)(See diagrams 16A & 16B)

4 - Pull upward on the ring of the pressure relief valve for 2 or 3 seconds, then release the ring to allow the valve to close. A burst of pressure will escape from the valve. 5 - Open the nitrogen valve on the chemical cylinder.

16B)16B)

16B)

16B)16B)

6 - Using the nitrogen pressure adjustment valve for the chemical cylinder being adjusted, turn the valve clockwise to the desired pressure.

(See diagram 17A)(See diagram 17A)

(See diagram 17A)

(See diagram 17A)(See diagram 17A)

Following these steps should result in a decrease in the pressure on the chemi-

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TE:TE:

TE:

TE:TE:

cal cylinder.

(See diagrams 16A & 16B)(See diagrams 16A & 16B)

(See diagrams 16A & 16B)

(See diagrams 16A & 16B)(See diagrams 16A & 16B)

(See diagrams 16A &(See diagrams 16A &

(See diagrams 16A &

(See diagrams 16A &(See diagrams 16A &

Diagram 16A

(Left)

Diagram 16B

(Right)

Before using the F1000 dispenser, you will need to install the plastic nozzle onto the Mix Cartridge. The valves on the Air Injection System will have to be opened so that air is passing freely.

The Air Injection System is comprised of two valves, an On/Off Valve (D704) and a Needle Valve (D703) that are connected to the F1000 by a series of simple 1/8” fittings. (See Diagram 17B) The Air Injection System serves three purposes. The air flowing into the Mix Cartridge (D603) helps:

• the mixing of the “A” and “B” chemicals

• propel the chemicals out of the nozzle,

• keep the Mix Cartridge (D603) clear of curing foam.

The Needle Valve (D703) can be adjusted by turning the knob to control the amount

Pressure

Relief Valve

Nitrogen

Supply

Hose

Nitrogen

Valve

Cylinder

Chemical

Valve

Hose Filter

Chemical

Valve

Closed

Open

Pressure

Relief Valve

Nitrogen

Supply

Hose

Nitrogen

Valve

Cylinder

Chemical

Valve

Hose Filter

Chemical

Valve

Chemical

Filter

Closed

Open

FOAMPRO® F1000

Cylinder Valves - 17 Gal.

Chemical

Valve

Positions:

Cylinder Valves - 60 Gal.

Chemical

Valve

Positions:

STARTUP | CALIBRATION

of air flowing through the system. Different uses of the F1000, for example spraying foam, may require a higher flow of air than pouring foam. Experience in using the F1000 will help the user determine what air flow level suits their needs.

Once the proper amount of airflow through the Air Injection System has been achieved, the F1000 dispenser is ready for use. Foam product can be dispensed by depressing the trigger.

After using the F1000 dispenser, if it is to momentarily sit idle for more than a few minutes, either let air flow through the Air Injection System, or place a few drops of solvent into the open end of the plastic nozzle. Keep the plastic nozzle pointed upward so the solvent remains and prevents any foam product from curing in the end of the nozzle or mix cartridge. If the F1000 dispenser is to be shut down or stored for a long period of time, follow the procedure for Shutdown described in Section 4.1.

Diagram 17A

2.2

Diagram 17B

FOAMPRO® F1000

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FoamPRO Mfg F1000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual