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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