FSI PROFESSIONAL Series User manual

OPERATIONS MANUAL
Foam Supplies, Inc. l Success Through Innovation l 1.800.325.4875 l www.foamsupplies.com

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TABLE OF CONTENTS
i
INTRODUCTION ................................................................................................................ 1
PROCESS DESCRIPTION .............................................................................................. 2-4
EQUIPMENT DESCRIPTION ....................................................................................... 6-11
Mix Probe Assembly ......................................................................................................... 7
SLUG PRO Gun Head Assembly ...................................................................................... 7
Flow Control Assembly .................................................................................................... 7
Hoses ................................................................................................................................ 8
Stratoflex Assembly ......................................................................................................... 8
Nitrogen Regulator(s) ....................................................................................................... 8
Heat Control Units............................................................................................................. 8
HB-01 (Single Digital Heat) Unit.................................................................................... 8
HB-02W (Dual Digital Heat) Unit .................................................................................. 8
Start Up Procedures for Heating Units ......................................................................... 9
Timer Units........................................................................................................................ 9
Equipment Photo Reference........................................................................................... 10
CHEMICAL PREPARATION STORAGE & HANDLING............................................... 12-15
Temperatures .................................................................................................................. 13
Cylinder Storage & Conditioning..................................................................................... 13
Shelf Life ......................................................................................................................... 13
Solvent ........................................................................................................................... 14
Nitrogen .......................................................................................................................... 14
Cylinder Sizes ................................................................................................................. 14
Delivery Options.............................................................................................................. 15
INSTALLATION & ASSEMBLY ..................................................................................... 16-19
Cylinder Preparation & Connection................................................................................. 17
Procedure for Connecting Cylinders............................................................................... 17
Nitrogen Connection ....................................................................................................... 17
Air Purge Connection ..................................................................................................... 17
Heating Unit Connection................................................................................................. 18
Timing Unit Connection ................................................................................................. 18
Timer Test Procedure ..................................................................................................... 18
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TABLE OF CONTENTS
ii
PRODUCTION & QUALITY CONTROL .......................................................... 20-29
INTRO ................................................................................................................. 21
SLUG PRO START UP PROCEDURE ............................................................... 22
Ratio Procedure ............................................................................................... 23
Throughput Procedure .................................................................................... 24
Reactivity Procedure........................................................................................ 25
String gel....................................................................................................... 25
Shot Time Procedure ...................................................................................... 26
Daily Q. C. Form ............................................................................................. 27
SLUG PRO SHUTDOWN PROCEDURE ........................................................... 28
CHANGING CHEMICAL CYLINDERS......................................................... 30-35
Cylinder Disconnect/Reconnect Procedure..................................................... 31
Cylinder Blow Down Procedure....................................................................... 32
For F-6000, F-5000 & F-4000....................................................................... 32
For F-1000 & F-300 ...................................................................................... 33
Sealing Empty Cylinders for Return to FSI ...................................................... 34
MAINTENANCE ........................................................................................... 36-43
Mix Tubes......................................................................................................... 37
Mix Tube Change Out Procedure ................................................................. 37
Mix Tube Cleaning Procedure....................................................................... 37
Mix Tube Schematic ..................................................................................... 37
SLUG PRO Mix Cartridge ................................................................................ 38
SLUG PRO Mix Cartridge Replacement Procedures ................................. 39-41
SLUG PRO Gun Assembly Schematic ............................................................ 42
Check Valves ................................................................................................... 43
Flow Controllers............................................................................................... 43
Hoses............................................................................................................... 43
Strat Assemblies.............................................................................................. 43
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TABLE OF CONTENTS
iii
TROUBLESHOOTING ............................................................................................... 44-51
Chemical Flow Characteristics ................................................................................ 45-46
Leaks........................................................................................................................ 46-47
Foam Characteristics ............................................................................................... 48-49
Technical Service ........................................................................................................... 50
Troubleshooting Checklist.............................................................................................. 51
SAFETY & HANDLING ................................................................................................ 52-57
General........................................................................................................................... 53
Clothing.......................................................................................................................... 53
Cylinders ........................................................................................................................ 54
Strats (Filters) ................................................................................................................. 54
Hoses ............................................................................................................................. 54
Ball Valves ...................................................................................................................... 54
ENVIRONMENTAL & DISPOSAL INFORMATION ..................................................... 55-57
A-SIDE Spills & Disposal................................................................................................ 55
B-SIDE Spills & Disposal................................................................................................ 56
EQUIPMENT DRAWINGS & PARTS........................................................................... 58-75
Standard Unit ................................................................................................................. 60
Mix Tube Assembly ........................................................................................................ 61
Mix Probe Parts.............................................................................................................. 62
SLUG PRO Gun Head ................................................................................................... 63
SLUG PRO Gun Head Parts .......................................................................................... 64
Flow Control Assembly ............................................................................................. 65-66
Dual Nitrogen Regulator Assembly ............................................................................... 67
Single Nitrogen Regulator Assembly ............................................................................. 68
Filter Assembly .............................................................................................................. 69
Filter Assembly Parts .................................................................................................... 70
Basic Spare Parts...................................................................................................... 71-74
Miscellaneous Parts ....................................................................................................... 75
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INTRODUCTION
1
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. Several of the
procedures covered in this manual are also demonstrated in Equipment Videos on
our website at www.foamsupplies.com/equipment/slug.
The FSI foam equipment you have is relatively simple to operate in comparison to
other urethane foaming equipment, when operated and maintained in accordance
with this manual. It provides for manual or automatic dispensing of urethane foam
by the liquid-blown or froth methods.
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PROCESS DESCRIPTION

3
Rigid polyurethane foams are formed by the reaction of certain isocyanate compounds with hydroxyl
bearing polyols. Isocyanate (ISO) and polyol (Resin) chemically react to form multi-branched polymer
chains when mixed together in the presence of catalysts and other additives. The generic chemical
name for these compounds is polyurethane.
FSI produces polyurethane chemical systems for use in the manufacturing of cellular plastics
(polyurethane foams). These are two-component systems normally designated “A” and “B”. The “A”
component (ISO) is an MDI polymeric isocyanate. The “B” component (Resin) consists primarily of
polyol, necessary additives, catalysts and a blowing agent.
THE PROCESS AND THE REACTION
In the FSI foam process, the two basic components (the A-SIDE and the B-SIDE) are pressurized in
separate vessels. The chemical systems have blowing agents blended into one or both components.
The two chemicals are then fed through a dispensing tube in a controlled ratio and dispensed. Once
dispensed, the exotherm and sudden decrease in pressure initiate the formation of polyurethane foam.
The foam continues to expand as heat is generated from the chemical reaction of the isocyanate and
polyol. The foam expands until the polymer has obtained sufficient strength to withstand the pressures
of the expanding gases. The final product is a homogeneous cellular product composed of many tiny
closed cells. The percent of closed cells, usually 90 to 96%, determines the efficiency of the foam.
THE TEMPERATURE
Temperature is of utmost importance in processing urethane chemicals. It is essential to control the
reaction by controlling chemical temperatures because this assists in maintaining productivity and
efficiency. Lack of control over chemical temperature results in loss of time, lower productivity, higher
cost, and in some cases, loss of product.
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. Refer to Product Data Sheet (PDS) for specific operating
chemical temperatures for your system.
PROCESS DESCRIPTION
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PROCESS DESCRIPTION
4
LIQUID-BLOWN AND FROTH SYSTEMS AND EQUIPMENT
FSI liquid-blown and froth chemicals are contained in pressurized cylinders with the isocyanate
component labeled A-component, or A-SIDE, and the polyol component labeled B-component, or
B-SIDE. The color code for the A-SIDE is RED. The color code for the B-SIDE is BLUE. F-6000
(350-gallon) and F-5000 (303-gallon) cylinders are color coded on the top rings of the cylinder. Detailed
cylinder schematics and descriptions are given later in this manual.
Liquid-blown and froth systems are dispensed through specifically designed equipment and do not
require pumps or any mechanically driven parts. The chemicals are shipped at 25 p.s.i. or 75 p.s.i. For
safety, each cylinder is equipped with a pressure relief valve set at 275 p.s.i. The cylinders should be
placed in an area (typically a “conditioning room”) where the chemical can be maintained at proper
temperatures. Operating nitrogen pressure for the cylinders and equipment is 240 to 245 p.s.i.
IMPORTANT: CYLINDERS MUST BE BROUGHT TO RECOMMENDED TEMPERATURE BEFORE
ADDITIONAL PRESSURE IS ADDED!
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. The
combined chemicals pass through an FSI mix tube and into the desired part to be foamed.
FIXTURE DESIGN
When designing fixtures, extreme care should be taken to avoid creating a heat sink, a condition in
which the fixture and surrounding mass draws heat from the chemical reaction. Remember that excess
heat or cold is devastating to the chemical reaction and subsequently to production. Keep in mind the
differences in pressuresbetween pour systems and froth systems. Pressure differentials should be taken
into consideration when designing fixtures, molds, and parts for manufacturing. Historically, fixtures
have been designed to withstand 20-30 p.s.i.
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EQUIPMENT DESCRIPTION

7
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.
Cleaning and maintenance should be done on a regular basis to insure proper function and longevity
of the equipment.
The complete unit consists of the following basic components:
1. MIX PROBE ASSEMBLY
2. SLUG PRO GUN HEAD
3. FLOW CONTROL ASSEMBLY
4. HOSES
5. STRATOFLEX ASSEMBLY
6. NITROGEN REGULATOR(S)
7. HEAT CONTROL UNITS
8. TIMING UNITS
MIX PROBE ASSEMBLY
The isocyanate and polyol chemicals complete the mixing process by passing through a specific
size mix element. Mixing action is accomplished by sub-dividing the stream of chemicals into many
different layers so thin that the chemicals are literally blended together. Mixing is further increased by
air nucleation.
Mix tubes are size-specific for the 6, 15, 30, 45 & 60-PPM (Pound Per Minute) dispensing units. The
tubes consist of a polypropylene tube and a polypropylene, butterfly-style-mixing element. The mix
tube attaches to the gun by the threads on the mix cartridge.
SLUG PRO GUN HEAD
The main body of the SLUG PRO gun consists of an air-open/air-closed cylinder, mix cartridge, rod,
and handle. All are machined from the 2024T6 hardened aircraft aluminum. This allows for minute
tolerances and easy interchangeability. These parts are the same for all of the different gun outputs.
The right and left wings bring the two chemical streams together into the SLUG PRO mix cartridge.
The air cylinder and wings allow the unit to operate without solvent. The gun head also consists of
ball valve units for chemical supply streams, a trigger switch, a constant-flow air purge valve, nitrogen
supply slide safety valve, and an air-solenoid air-block assembly.
FLOW CONTROL ASSEMBLY
The flow controllers are the center of the mechanical system. Flow controllers maintain the ratio of the
isocyanate and polyol components. Flow controllers are size-specific for the 6, 15, 30, 45 & 60-PPM
gun outputs.
EQUIPMENT DESCRIPTION
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EQUIPMENT DESCRIPTION
8
HOSES
The equipment has two chemical supply hoses. The hoses are made of braided stainless steel and are
Teflon-lined. Each hose is made to withstand pressures well above the SLUG PRO gun operating pressure.
This adds to the safety of the gun since operating pressures should not exceed 245 p.s.i. Hoses are either
heated by cal-rod units or by heat tape depending on the length of the hose. 25 ft. hoses are heated by
cal-rod mechanisms. 45 ft. hoses and greater are heated by heat tape. Each hose is color-coded, red on
isocyanate (A-SIDE), and blue on polyol (B-SIDE).
STRATOFLEX ASSEMBLY
Stratoflex assemblies consist of a filter and temperature gauge. Stratoflex assemblies are located at the end
of the hose assemblies. Temperature gauges on the Stratoflex assemblies are color coded like the cylinders
(Red = A-SIDE, Blue = B-SIDE). A Stratoflex (Strat) assembly is the device that connects to the chemical
cylinder. Each Strat assembly indicates temperature of chemical and filters possible contaminants. Optimal
operating temperature for most FSI chemical systems is 80°F(±5°F). Temperature readings should be taken
while, or soon after, chemical is flowing to indicate accurate chemical temperature. Refer to your specific
system for temperature parameters located on page 13.
Two Stratoflex sizes exist (½"and 1¼"). Typically ½"Strats are used with F-1000 or smaller cylinders. Both
½"and 1¼" Strats can be used with F-6000 and F-5000 cylinders. When using 1¼"Strats it is impossible
to connect the SLUG PRO gun to the chemical cylinders incorrectly. This is due to the reverse fitting system
between the gun and cylinders. A reverse fitting system does not exist when ½"Strats are utilized. Therefore,
it is important to use extreme caution when connecting ½"Strats to chemical cylinders because connecting
incorrectly (“crossing-over”) is possible. Follow the color coding, matching the A-SIDE (Red to Red) and the
B-SIDE (Blue to Blue).
IMPORTANT: IF COLOR-CODING IS IGNORED, CROSSOVER WILL OCCUR AND THE ENTIRE SLUG
PRO GUN UNIT, HOSES, AND CYLINDERS WILL BE RUINED! CONTACT FSI
IF UNCERTAIN HOW TO CONNECT GUN TO THE TANKS!
NITROGEN REGULATOR(S)
The regulators are the energy source which operate the entire dispensing unit. SLUG PRO equipment
regulator systems typically consist of two high-pressure regulators. The first high-pressure regulator is
connected to only one chemical cylinder. The second high-pressure regulator is connected to one chemical
cylinder and the ¼"air cylinder line. Some 6 & 15-PPM users are able to use one regulator to pressurize both
chemical cylinders and the air cylinder.
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. gun units. Both heating units are
designed so hook up is simplistic.
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EQUIPMENT DESCRIPTION
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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.
MT TIMER
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EQUIPMENT DESCRIPTION
10
STANDARD UNIT
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CHEMICAL PREPARATION
STORAGE & HANDLING

Temperature is critical when dispensing urethane foam. To insure proper processing and productivity,
FSI chemical systems should be preheated and maintained at 80°F(±5°F). With use of F-1000 cylinders,
temperature conditioning takes approximately 12–24 hours in an 85°F heat-controlled room. When F-6000
and F-5000 cylinders are used, temperature conditioning takes approximately 24–48 hours in an 85°F heat-
controlled room. Temperature might vary from the above parameters on special urethane systems. Operation
outside desired range will affect ratio and reactivity of foam system.
IMPORTANT: NEVER APPLY DIRECT HEAT TO ANY CYLINDER!
(Example: Drum, Band and Queen Bee heaters should never be used.)
IMPORTANT: TEMPERATURE CONDITIONING OF CYLINDERS MUST BE COMPLETED PRIOR TO
PRESSURIZING!
IMPORTANT: WHEN HEATING OR RE-HEATING A CYLINDER WITH THE FILTER ASSEMBLY
CONNECTED, IT IS IMPERATIVE THAT THE CHEMICAL BALL VALVE ON THE TANK BE
OPEN! THIS WILL PREVENT DAMAGE TO FILTER ASSEMBLY!
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.
IMPORTANT: NEVER APPLY DIRECT HEAT TO ANY CYLINDER!
(Example: Drum, Band and Queen Bee heaters should never be used.)
IMPORTANT: TEMPERATURE CONDITIONING OF CYLINDERS MUST BE COMPLETED PRIOR TO
PRESSURIZING!
IMPORTANT: WHEN HEATING OR RE-HEATING A CYLINDER WITH THE FILTER ASSEMBLY
CONNECTED, IT IS IMPERATIVE THAT THE CHEMICAL BALL VALVE ON THE TANK BE
OPEN! THIS WILL PREVENT DAMAGE TO FILTER ASSEMBLY!
SHELF LIFE
Liquid-blown and froth systems have a shelf life of approximately six months, dependent upon the system.
Orders for chemical systems should be placed to maintain inventory for a period not to exceed sixty days. A
variety of cylinder sizes are available to accommodate individual requirements. Refer to product information
sheets for specifics.
TEMPERATURES
13
CHEMICAL PREPARATION, STORAGE & HANDLING
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CHEMICAL PREPARATION, STORAGE, & HANDLING
14
SOLVENT
Use only DK 817 (Dipropylene glycol monomethyl ether, also known as glycol ether) as the cleaning agent.
Any other solvent used is done so at the user’s risk, bearing in mind that considerable damage could result.
Use of other solvents could damage the equipment. Solvents should only be stored, used, transferred, or
disposed of in well-ventilated areas. DO NOT allow solvent vapors to accumulate in areas near open flames,
electric heaters or hot surfaces. NO SMOKING should be observed while using or handling any solvents.
Refer to your SDS for proper handling and disposal.
NITROGEN
USE ONLY CLEAN, DRY NITROGEN supplied from pressurized bottles, cylinders, or bulk to pressurize the
chemical cylinders and operate the SLUG PRO dispensing equipment. To maintain and control pressures,
use only the regulator(s) supplied with FSI equipment. The regulator(s) should be set at 240–245 p.s.i. in
order to pressurize the A-SIDE and B-SIDE chemical cylinders. The regulator(s) also supply the SLUG PRO
gun air cylinder.
When properly used, one 220 cubic foot nitrogen cylinder will service approximately 500 lbs. of FSI foam.
(NOTE: FSI DOES NOT supply nitrogen. Nitrogen must be secured from an outside supplier.)
IMPORTANT: CHEMICAL CYLINDERS MUST BE CONDITIONED TO OPERATING TEMPERATURE
BEFORE PRESSURIZING TO 240–245 p.s.i. NEVER INCREASE TEMPERATURE TO
CYLINDERS AFTER PRESSURIZING TO 240–245 p.s.i.
CYLINDER SIZES
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). Cylinders are designed to operate at a working
pressure of 240–245 p.s.i. and are automatically vented to exhaust at a pressure less than twenty percent
above the operating pressure.
Each fitting port on cylinders is fitted with both automatic self-sealing couplings and manual positive shut
off valves except the safety pressure relief valve (PRV) which according to Federal Regulations must have
direct, uninterrupted access to the cylinder interior.
CYLINDER DIMENSIONS
F-6000 6½'L x 3½'W x 5'H with built-in metal pallet.
F-5000 6½'L x 3¼'W x 5'H with built-in metal pallet.
F-1000 Approximately 2' Dia. x 4'H.
ALL CYLINDERS ARE MARKED WITH ORANGE TAGS WHICH READ AS FOLLOWS:
TAG #1: “CYLINDER MUST BE DEPRESSURIZED TO 75 p.s.i. FROTH/25 p.s.i. LIQUID-BLOWN
BEFORE SHIPPING.”
TAG #2: “CHEMICAL IN CYLINDERS MUST BE BROUGHT TO OPERATING TEMPERATURES
BEFORE PRESSURIZING TO 240 p.s.i.”
TAG #3: “USE ONLY DRY NITROGEN TO PRESSURIZE CYLINDERS.”
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CHEMICAL PREPARATION, STORAGE, & HANDLING
15
DELIVERY OPTIONS
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