698-00324 Froth Pak Refill - Fomicom

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TMRefill SystemsOperating ManualDOW EUROPE GmbHBachtobelstrasse 3, 8810Horgen, Switzerland% : 800 3 694 6367www.dow.com

TABLE OF CONTENTSDRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1-A4Refill System Installation (Full set Connected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1.1Refill System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1.2Nitrogen Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2.1Nitrogen Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2.2Insta-Flo gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1SECTION 1: SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1 Densities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.3 Refill Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.4 Refill Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.5 Anti-Crossover Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.6 Shipping Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.7 Tank Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.8 Freight Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2SECTION 2: SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.1 Ventilation Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.2 Sensitisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.3 Safety Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.4 Skin Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.5 Eye Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.6 Ingestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.7 Removal of Cured Foam on Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.8 Overfilling Restricted Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.9 Chemical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.10 Chemical Spills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.10.1 “ISO Side Chemical” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.10.2 “Polyol Side Chemical” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.11 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.11.1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.11.2 Building Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.11.3 Surface Temperature Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.11.4 Open Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.11.5 Excessive Foam Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4SECTION 3: SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.1 Tank Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.2 Nitrogen Regulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.3 Chemical Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.4 System Pressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63.5 System Purging and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73.6 Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7SECTION 4: START-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.1 System Pressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.2 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.3 System Purging and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94.4 Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

TABLE OF CONTENTS CONT.SECTION 5: INSTA-FLO GUN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10SECTION 6: SHUT-DOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10SECTION 7: STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11SECTION 8: RE-START PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118.1 System Pressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118.2 System Purging and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128.3 Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13SECTION 9: TANK CHANGE-OVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139.1 “ISO” Tank Change-Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139.2 “POLYOL” Tank Change-Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149.3 Tank Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159.4 System Pressurisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159.5 System Purging and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159.6 Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16SECTION 10: TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1610.1 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1610.2 Foam Color and Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16SECTION 11: YIELD NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1911.1 Operator Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1911.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1911.3 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19SECTION 12: RATIOS AND OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19SECTION 13: NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20SECTION 14: REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2014.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2014.1.1 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20SECTION 15: WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

REFILL SYSTEM INSTALLATIONFull set connectedA-1.1

ON-OFFVALVESPRECAUTIONS: DO NOT breathe vapor or spray. Use only in a well ventilated area or with properrespiratory protection. Wear eye/face protection and other suitable protective clothing. Empty containers containing product residue. Follow allprecautions for product. Keep away from sparks and flames. Do not expose container to temperatures above 120oF (49oC). DO NOT incinerate, cut, puncture, or weld on or near container.INSTA-FLOGUNANTICROSSOVERNOZZLEIN-LINE ON-OFFVALVESA-1.2ISO TankCHEMICALTANK VALVESTANKFILTERPolyol TankPROTECTIVE PLUG: Remove and save for returnshipment of empty tanks.TANKFILTERNITROGENINTAKE TANKVALVESNITROGENHOSESREFILL SYSTEM INSTALLATION

ISO REGULATORSTEMPRESSURE GAUGEISO TANK.A-2.1PRESSURE GAUGENITROGEN CYLINDERPart # 238107NITROGEN REGULATORPOLYOL REGULATORSTEMPRESSURE GAUGEPOLYOL TANK

A-2.2

To engage the safety on the gun, pushthe white lever down.Always engage the safety on the gunwhen the gun is not in use and whenchanging nozzles.PRECAUTIONS:A-3Part # 158336INSTA-FLO GUNSAFETYTRIGGERANTICROSSOVERNOZZLENOZZLEEJECTOR

white187918Back CapColorPart #* Other outputs availableclearFront TubeColorNS Cone/Spray187912yellowA-4clear greenCaulking187989blackclearPour NozzleNOZZLES187915whiteclear blueFan/Spray

INTRODUCTIONINTRODUCTIONThe FROTH-PAK Refill System is a polyurethane foam dispensing system for large foam users. Thesystem consists of “ISO” and “POLYOL” chemical tanks, chemical filters, a high pressure regulatorand nitrogen lines, chemical dispensing hoses, and the INSTA-FLO Gun. The system requires drynitrogen for chemical tank pressurization and is not supplied with the system.The FROTH-PAK Refill System is designed for ease-of-use. The following instructions should be followed strictly to assure maximum equipment performance and efficiency.SECTION 1SYSTEM INFORMATION1.1 DensitiesSYSTEMFROTH-PAK 30 QR HFC B2 Polyol/FROTH-PAK HFC IsocyanateFROTH-PAK 30 SR HFC B2 Polyol/FROTH-PAK HFC IsocyanateDENSITY (kg/m3)30301.2 Ordering InformationFP 1900 SYSTEMISO TANKPOLYOL TANKPart NumberPart Number248050247497248050248326RISE TIME30 seconds60 seconds1.3 Refill EquipmentPART #238107158420158403DESCRIPTIONHigh Pressure Regulator1*2.3m hose for Nitrogen Line30 FT. Gun Hose Assembly (GHA-30)Includes: 1 - INSTA-FLO Gun with 20cm hoses, 2 - 9m double nut hoses, 2 - In-lineon-off valves, 2 - On-off valves, 1 - Wrench 9/16", 2 - 90o angles.1.4 Other Refill AccessoriesPART #158336DESCRIPTIONINSTA-FLO Gun with 20cm Hoses1.5 Anti-crossover NozzlesEach part # mentioned below corresponds to one pack of 25 nozzles.CALIBRATION NOZZLESSPRAY NOZZLESPART #DESCRIPTIONPART # DESCRIPTION187915GC Fan White Back187909Calibration Nozzle, Yellow BackSpray, Flat Wide Area Coverage187910Calibration Nozzle, White BackSpray Paint Finish187907Calibration Nozzle, Black BackNS White/Back, Sray, Medium187918Coverage187912Caulking Yellow Back, UltraFine Coverage187989Pour Black Back, High VolumeFillingSystem should be calibrated with the calibration nozzle corresponding to the same color as the spraynozzle used for application.1

1.6 Shipping WeightsFP 1900 (70 Liters)Empty Tank with fittingsChemicalTotal Tank WeightTOTAL SYSTEM WEIGHT34.5 kg62.5 kg97 kg194 kg1.7 Tank DimensionsFP 190037.5 cm Diameter * 92 cm Height1.8 Freight ClassificationRoad & RailProper shipping name:Truck/Rail ADR/RIDClassification CodePacking Group1956 COMPRESSED GAS, N.O.S. (contains 1,1,1,2Tetrafluoroethane (HFC-134a)):2Label : 2: 1A:-Kemler CodeTremcard Nr. CEFIC: 20UN Number: 20G1A: 1956SeaProper shipping name: COMPRESSED GAS, N.O.S. (contains 1,1,1,2Tetrafluoroethane (HFC-134a))Sea - IMO/IMDG Class : 2.2UN Nr: 1956Label : 2.2Packing Group:EMS: 2-04Marine Pollutant: N (Y/N)AirProper shipping nameAir-ICAO/IATA ClassSub ClassPacking GroupRemarks: COMPRESSED GAS, N.O.S. (contains 1,1,1,2Tetrafluoroethane (HFC-134a)): 2.2UN Nr: 1956Label : NFG::Pack Instr. Passenger: 200Pack Instr. Cargo: 200: Sample shipment not allowed by mail.SECTION 2SAFETY PRECAUTIONSWARNINGThese instructions are designed to protect users who follow the safety precautions and wearrecommended protective equipment. However, accidents may result from misuse, carelessness, ordisregard of cautions and warnings contained within this manual. “Material Safety Data (MSD)sheets are available from The Dow Chemical Company. MSD sheets are provided to help customerssatisfy their own handling, safety and disposal needs and those that may be required by locallyapplicable health and safety regulations. MSD sheets are updated regularly, therefore, please request2

and review the most current MSD sheet before handling or using any product. These are availablefrom the nearest Dow sales office.”2.1 Ventilation RequiredUse only in a well ventilated area or with proper respiratory protection. Do not smoke. Do not breathvapor or spray. In unventilated areas, it is recommended that respirators not be removed for at least 15minutes after use.2.2 SensitisationInhalation of vapors or mist at concentrations in excess of permissible limits may result in the development of respiratory sensitisation. Skin contact with diisocyanates may play a role in respiratory sensitisation. Once sensitised, a person may experience a hypersensitive reaction when exposed to very low concentrations of diisocyanate. Anyone who has been sensitised in the past should not operate nor be inclose proximity to the operation of these systems.2.3 Safety ClothingDepending on the potential for exposure some of the following personal protective equipment may berequired: Safety glasses, chemical goggles or face shields, gloves, aprons or coveralls, footwear, chemical protective jackets and or pants.2.4 Skin ContactAvoid contact with skin. May cause irritation or sensitisation. If skin contact occurs: Remove contaminated clothing; wash skin with soap and water. If irritation occurs or persists, seek medical attention.2.5 Eye ContactAvoid contact with eyes. Causes irritation. If contact with eyes occur, flush with clean, low pressurewater for 15 minutes while holding eyelids open. Seek medical attention.2.6 IngestionIf swallowed, do not induce vomiting, seek medical attention immediately.2.7 Removal of Cured Foam on SkinAvoid skin contact. Cured foam is difficult to remove but is not a health hazard. To remove foamfrom the skin, wash with soap and water and rub carefully.2.8 Overfilling Restricted SpacesAvoid overfilling restricted spaces. The reaction of these chemicals causes expansion and may exertenough force to cause an uncontrolled stream of foam, spraying the work area and possiblythe operator.2.9 Chemical InformationFor more specific information about the chemical components in the ISO and Polyol tanks, refer tothe appropriate Material Safety Data Sheet (MSDS). KEEP OUT OF REACH OF CHILDREN.3

2.10 Chemical Spills2.10.1 ISO Side ChemicalIf chemical liquid spills from the tank, hose, or gun, provide proper ventilation and isolatethe spill area. Dike the area and soak up the spill with an oil absorbent material (vermiculite,sawdust, etc.). Neutralize the spillage area with a solution of 90% water, 2% dishwashingdetergent, and 8% ammonia. The amount of this solution should be in excess of the volumeof the spill. Allow the mixture to react for at least 10 minutes. Collect in an open top wastecontainer and treat with additional ammonia solution. Remove the container to a safe place,loosely cover, and allow it to stand at least 24 hours. Dispose of the waste container in accordance with federal, state, and local regulations.2.10.2 Polyol Side ChemicalIf the chemical spills from the tank, hose, or gun, dike the area and soak up the spillage withan oil absorbent material (vermiculite, sawdust, etc.). Wash the residue from the surface withsoap and water. Discard in accordance with federal, state, and local regulations.2.11 Cautions2.11.1 StorageRecommended storage temperature: 15o - 27oc. Storage below 15oc is not recommended.Do not store at temperatures above 50oc. Do not puncture or incinerate even after use.2.11.2 Building CodesIn many areas, building codes may restrict the use of cellular plastics or polyurethane foam inexposed, interior finishing material applications. Under certain application code, the use ofthese materials may be prohibited. The foam produced by this product is organic and mayconstitute a fire hazard if improperly applied. Consult local building codes.2.11.3 Surface Temperature RestrictionsPolyurethane foam should not be used in direct contact with chimneys, heat vents, steampipes, or other surface areas that exceed 115oC. The foam should not be left exposed orinadequately protected for both interior and exterior finishing materials. It is stronglyrecommended in all applications that the foam be protected by approved facings and coatings.2.11.4 Open FlameDo not smoke or operate the system in close proximity to an open flame. Welding on or nearcured polyurethane foam requires special precautions. Consult FPC for instructions.2.11.5 Excessive Foam DispensingDo not apply excessive thicknesses at one time as this may result in spontaneous combustion.For thickness greater than two inches of cured foam, dispense foam in multiple layers,allowing the foam to dissipate the heat between sprayings.4

SECTION 3SYSTEM INSTALLATIONNote: Dry nitrogen is used for pressurising the refill system and is not supplied. It may beobtained for a nominal rental charge from any local welding supplier. Order standard size(industrial grade) cylinder.* REFER TO FROTH-PAK REFILL SYSTEM DRAWING, SECTION A-13.1 Tank Positioning1.Position the “ISO” tank to the left and the “POLYOL” tank to the right. This is thestandard in the polyurethane industry.2.Place a nitrogen cylinder between the “ISO” and “POLYOL” tanks.3.Secure the nitrogen cylinder to prevent it from falling if bumped.3.2 Nitrogen Regulator Information4.Remove the orifice protector on the nitrogen cylinder. Insert the nitrogen regulatorassembly stem into the orifice and hand tighten. Snug firmly using an adjustablewrench. Be careful not to strip the brass fitting.5.VERIFY that the valve stems are freewheeling. This indicates that the regulator stemsare backed out.6.The two female pipe connections are the pressure relief outlets. The nitrogen outputfrom the regulators is through the two JIC fittings set with a 90 angle. The nitrogenhoses will connect between the JIC fittings of the regulator and the pressure vessel.Refer to SECTION A-2.7.Connect the red nitrogen line on the left JIC fitting on the nitrogen regulatorassembly. Snug firmly with an adjustable wrench.8.Locate the nitrogen intake valve on the “ISO” tank. VERIFY that thevalve is closed. The handle should be perpendicular to the valve.9.Connect the quick connect valve of the nitrogen line to the nitrogen intakevalve of the ISO tank.10.Connect the other nitrogen line to the right JIC fitting on the nitrogenregulator assembly. Snug firmly with an adjustable wrench.11.Locate the nitrogen intake valve on the “POLYOL” tank. VERIFY thatthe valve is closed. The handle should be perpendicular to the valve.12.Connect the quick connect valve of the nitrogen line to the nitrogen intakevalve of the POLYOL tank.3.3 Chemical Hose Installation13.VERIFY that the chemical tank valves are closed. The handle should be perpendicularto the valve. Remove the chemical valve plugs from the “ISO” and “POLYOL” tanksand place the plugs on top of the tank.5

14.Carefully remove all of the vaseline in the “ISO” chemical tank valve using a small headscrewdriver.15.Remove the fluid filters from the bag on top of the tank. VERIFY that the filterand the cartridge are free by shaking the filter until you hear a clicking sound.Note: Air blown into this end will pass freely through the filter.16.Connect a filter to each tank chemical valve with the filter arrows pointing away fromthe tanks. The arrows represent the chemical flow. Tighten the filters with theadjustable wrench. The filter prevents chemical from flowing back into the tank.17.Uncoil the chemical lines. Tape them together every few feet with tape.18.Connect the ISO red chemical hose to the 90 angle. Connect the ISO on-off valve tothe other side of the 90 angle. Tighten the connections with an adjustable wrench.19.Connect the other chemical hose to the 90 angle. Connect the Polyol on-off valve tothe other side of the 90 angle. Tighten the connections with an adjustable wrench.20.Take the on-off valves with the swivel ends and connect them to the filters of eachtank. Tighten the connection s with an adjustable wrench.21.Connect an in-line on-off valve to the other end of each chemical hose. VERIFY thatthe arrows on each valve point away from the hose being connected. (Arrow indicateschemical flow.) Tighten each connection with two adjustable wrenches.22.Connect the INSTA-FLO Gun hose assembly to the in-line valve of each hose,“ISO red hose” to “ISO red hose”, the unlabeled hose to the unlabeled hose.Tighten each connection using two adjustable wrenches.23.ENGAGE THE SAFETY ON THE INSTA-FLO GUN.24.Apply petroleum jelly to the chemical ports on the face of the gun.3.4 System Pressurisation25.VERIFY that the valve stems on the regulator are backed out and are free wheeling.26.Open the nitrogen bottle valve by turning the knob on top of the cylinder. If a hissingsound occurs, further tighten the nitrogen regulator valve stem at the back of theregulator with an adjustable wrench.27.VERIFY the nitrogen cylinder pressure using the center gauge of the nitrogen regulatorassembly. The system will not operate efficiently if the pressure falls below 500 psi. Ifbelow 500 psi, replace the N2 cylinder.28.Turn the left regulator stem clockwise to pressurize the “ISO” tank. Contact yourDistributor/Dow Chemical Sales Representative for the proper pressure setting. If ahissing sound occurs, further tighten the nitrogen line connection to the nitrogenregulator assembly using an adjustable wrench. If the left gauge fails to indicate apressure setting, contact your Distributor/Dow Chemical Sales Representative.29.Turn the right regulator stem clockwise to pressurize the “POLYOL” tank. Contactyour Distributor/Dow Chemical Sales Representative for the proper pressure setting. Ifa hissing sound occurs, further tighten the nitrogen line connection to the nitrogenregulator assembly using an adjustable wrench. If the right gauge fails to indicate apressure setting, contact your Distributor/Dow Chemical Sales Representative.30.Slowly open the nitrogen line valve and nitrogen intake valve of each tank. The valvehandles should be parallel with the nitrogen lines.6

31Slowly turn on the chemical tank valve of each tank. The valve handles should beparallel to the chemical lines. VERIFY that the filter connection of each tank is tightand that no chemical leaks are present.32.Slowly turn on the on-off valves. The handles should be parallel to the chemical lines.VERIFY that the connections of each valve are tight and that no chemical leaksare present.33.Slowly turn on the in-line on-off valves. The handles should be parallel to the chemicallines. VERIFY that the connections of each valve are tight and that no chemical leaksare present.34.VERIFY that the INSTA-FLO Gun safety is engaged and that petroleum jelly has beenapplied to the chemical ports on the gun face.3.5 System Purging and Testing35.Wear chemical resistant gloves and protective eyewear when operating the system. Useonly in well ventilated areas. With insufficient ventilation, wear suitable respiratoryprotection.36.Disengage the gun safety and dispense chemicals in an appropriate container. This is toVERIFY proper chemical flow and purges air from the lines.37.ENGAGE THE SAFETY ON THE GUN. The safety should be engaged wheneverthe gun is not in use.38.Clean any chemical from the gun face using a rag.39.Reapply petroleum jelly to the chemical ports of the gun face.40.Insert an unused nozzle with the key slot down. Push in firmly until the nozzle ejectoris seated over the back rim of the nozzle.41.Disengage the safety on the gun.42.Dispense foam to VERIFY proper chemical mixing. If improper mixing or poor foamquality, refer to the TROUBLESHOOTING Section.3.6 Nozzle Replacement43.The life of a nozzle depends on elapsed time and chemical temperature. Replace apreviously used nozzle if elapsed time is exceeded.44.To replace the used nozzle, ENGAGE THE SAFETY ON THE GUN.45.Push down the nozzle ejector. The used nozzle should eject.46.Reapply petroleum jelly to the chemical ports of the gun face.47.Insert an unused nozzle with the key slot down. Push in firmly until the nozzle ejectoris seated over the back rim of the nozzle.48.The FROTH-PAK Refill System is ready for operation.7

SECTION 4START-UP PROCEDURE4.1 System Pressurisation1.VERIFY that the valve stems on the regulator are backed out and are free wheeling.2.Open the nitrogen bottle valve by turning the knob on top of the cylinder. If a hissingsound occurs, further tighten the nitrogen regulator valve stem at the back of theregulator with an adjustable wrench.3.VERIFY the nitrogen cylinder pressure using the center gauge of the nitrogen regulatorassembly. The system will not operate efficiently if the pressure falls below 500 psi. Ifbelow 500 psi, replace the nitrogen cylinder.4.Turn the left regulator stem clockwise to the proper pressure setting of the “ISO” tank .If a hissing sound occurs, further tighten the nitrogen line connection to the nitrogenregulator assembly using an adjustable wrench. If the left gauge fails to indicate apressure setting, contact your Distributor/Dow Chemical Sales Representative.5.Turn the right regulator stem clockwise to the proper pressure setting of the“POLYOL” tank. If a hissing sound occurs, further tighten the nitrogen lineconnection to the nitrogen regulator assembly using an adjustable wrench. If the rightgauge fails to indicate a pressure setting, contact your Distributor/Dow Chemical SalesRepresentative.6.Slowly open the nitrogen line valve and nitrogen intake valve of each tank. The valvehandles should be parallel with the nitrogen lines.7.Slowly turn on the chemical valve of each tank. The valve handles should be parallel tothe chemical lines. VERIFY that the filter connection of each tank is tight and that nochemical leaks are present.8.Slowly turn on the on-off valves. The handles should be parallel to the chemical lines.VERIFY that the connections of each valve are tight and that no chemical leaksare present.9.Slowly turn on the in-line on-off valves. The handles should be parallel to the chemicallines. VERIFY that the connections of each valve are tight and that no chemical leaksare present.10.VERIFY THAT THE INSTA-FLO GUN SAFETY IS ENGAGED and remove theused nozzle by pushing down the nozzle ejector.11.Apply petroleum jelly to the chemical ports of the gun face.4.2 Calibration InstructionsEquipment needed: Scale capable of weighing in gramsPaper bags (sandwich bags)Calibration nozzlesPressure gauges1.Ensure chemical temperature in tanks and lines are 20o - 25o C.2.Set pressures at recommended settings8

3.Ensure chemical is flowing properly through dispenser without the nozzle in place4.Know the bag weight so the weights may be tarred out of the total weight of thechemical, i.e.WeightBag Weight(ISO)188gms-08gms180gms(POLYOL)170gms180 divided by 162 equals 1.11 ratio-08gms162gms5.Place calibration nozzle in the dispenser. Before dispensing material into bags, pulltrigger to ensure material is flowing properly through both tubes.6.Hold two bags together, place one tube in each bag and pull trigger for six to eightseconds.7.Weigh bags separately. Always divide the weight of (ISO) by the weight of(POLYOL), i.e (ISO)/(POLYOL). If the ratio is too high increase the pressure of the“POLYOL” tank, and if the pressure is too low increase the pressure of the “ISO” tank.8.Most acceptable ratios are 1.05 to 1.15.Notes: If verification of readings of the regulator is necessary, install pressure gauges inline with the regulator. Verify both sides. To verify corresponding pressures of tanks,install pressure gauges in line with each tank. Perform this task on the nitrogen inletvalve. Should pressure need to be reduced in a tank, slowly bleed off pressure. NEVERbleed below 120 psi.4.3 System Purging and Testing9.Wear chemical resistant gloves and protective eyewear when operating the system.Use only in well ventilated areas. With insufficient ventilation, wear suitablerespiratory protection10.Disengage the gun safety and dispense chemicals in an appropriate container.This is to VERIFY proper chemical flow.11.ENGAGE THE SAFETY ON THE GUN.12.Clean any chemical from the gun face using a rag.13.Reapply petroleum jelly to the chemical ports of the gun face.14.Insert an unused nozzle with the key slot down. Push in firmly until the nozzle ejectoris seated over the back rim of the nozzle.15.Disengage the sa

The FROTH-PAK Refill System is designed for ease-of-use. The following instructions should be fol-lowed strictly to assure maximum equipment performance and efficiency. SYSTEM INFORMATION 1.1 Densities SYSTEM DENSITY (kg/m3) FROTH-PAK 30 QR HFC B2 Polyol/FROTH-PAK HFC Isocyanate 30 FROTH-PAK

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