FROTH-PAK™ Refill Systems Manual i n sta l l m a n u a l | United States | C O MME R C I A L / R e s i d e n t i a l 2014 Edition Manual
Table of Contents FROTH-PAK™ Refill System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Nitrogen Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 INSTA-FLO™ Gun . . . . . .
Section 5: INSTA-FLO™ Gun Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.1 Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dow Building Solutions FROTH-PAK™ Refill System Installation INSTA-FLO™ Gun 8 In. Hoses In-line On-off Ball Valves 30 Ft. Double nut Chemical Hoses Anti-crossover Nozzle PRECAUTIONS: DO NOT breathe vapor or spray. Proper Personal Protective Equipment and ventilation are required. See product (Material) Safety Data Sheet ((M)SDS) and Section 2 of this manual for further information. Follow all precautions for product. DO NOT expose container to temperatures above 120oF (49oC).
Dow Building Solutions Nitrogen Hoses Chemical Filter Nitrogen Intake Tank Valves Protective Plug: Remove and save for return shipment of empty tanks. “A” Tank Tank Valves Protective Plug: Remove and save for return shipment of empty tanks.
Dow Building Solutions Nitrogen Regulator Assembly Pressure Gauge Nitrogen Cylinder (7.5 ft. nitrogen lines sold separately. Two lines required for system operation) Pressure Gauge “A” Tank Plastic Protective Cap.
Dow Building Solutions Pressure Gauge “B” Tank WARNINGS: NEVER use oxygen regulators on cylinders of which the gas pressure exceeds 3000 pounds per square inch. “B” Pressure Regulator Plastic Protective Cap. (Remove before attaching hoses) “B” Tank Nitrogen Hose (mark hose ends with yellow & blue electrical tape) NEVER use oil or petroleum base grease on regulator, inlet connection, or cylinder valve. An explosion or fire could result.
™ INSTA-FLO Gun Nozzle Ejector Anti-crossover Nozzle Safety Trigger A-3
Dow Building Solutions Anti-crossover Nozzles (See page 3 for part numbers) Fan Caulking Cone Pour Calibration Nozzle Opening Nozzle Opening Nozzle Opening Nozzle Opening Nozzle Opening A-4
Dow Building Solutions Introduction The FROTH-PAK™ Refill System is a polyurethane foam dispensing system for users who require large quantities of foam. The system consists of “A” and “B” chemical tanks, chemical filters, a high pressure regulator, nitrogen lines, chemical dispensing hoses, and a Gun/Hose Assembly Kit. The system requires dry nitrogen for chemical tank pressurization and is not supplied. The FROTH-PAK™ Refill System is designed for ease-of-use.
Dow Building Solutions System Information 1.1 Ordering Information System Density / Type “A” Tank Part# / Color “B” Tank Part# / Color 17 Gallon System: 1.75 Foam Sealant 1.75 Foam Insulation (Class A) 341167 / white w/red stripe1,2 340334 / white w/red stripe1,2 345347 / white w/blue stripe 11096260 / white w/purple stripe 27 Gallon System: 1.75 Foam Sealant 1.
Dow Building Solutions 1.3 Anti-crossover Nozzles (25 Pack) Part# Output / Lbs. Min Nozzle Type Front / Back - Nozzle Color 259212 Low / 2lbs. Min Caulking Green / Yellow 259219 259211 259216 Medium / 4lbs. Min Medium / 4lbs. Min Medium / 4lbs. Min Cone Caulking Fan Clear / White (Included in FROTH-PAK kits) Green / White Blue / White (Included in FROTH-PAK kits) 259218 259215 High / 6-7lbs. Min High / 6-7lbs.
Dow Building Solutions 1.6 Freight Classification for Tank Return CAUTION: The contents of both tanks are pressurized with Fluorinated Hydrocarbons (HFC’s). The “A” tank contains polymeric isocyanates and the “B” tank contains polyols with amines. Mark each bill of lading as follows: Full Tanks CHEMICAL UNDER PRESSURE, N.O.S. (1,1,1,2-TETRAFLUOROETHANE), Class 2.
Dow Building Solutions Section 2 Safety Precautions • Continue to ventilate area for at least 1 hour after the job is completed at no less than 10 ACH. WARNING: The FROTH-PAK™ cylinders contain isocyanate, hydrofluorocarbon blowing agent and polyols under pressure. Read and follow these instructions and the Safety Data Sheets (SDSs) (formerly MSDSs or Material Safety Data Sheets) carefully before use.
Dow Building Solutions 2.6 Ingestion If swallowed, give large amounts of liquids. DO NOT induce vomiting. Seek medical attention. 2.7 Removal of Cured Foam on Skin FROTH-PAK™ foam will adhere to most surfaces and skin. Avoid ALL skin contact. Wear gloves and protective clothing. Cured foam is difficult to remove. Cured foam must be mechanically removed or allowed to wear off in time. 2.8 Overfilling Restricted Spaces Avoid overfilling restricted spaces.
Dow Building Solutions Section 3 System Installation NOTE: Dry nitrogen is used for pressurizing the Refill System and is not supplied. It may be obtained for a nominal rental charge from any local welding supplier. Order standard size (industrial grade) cylinder with CGA 580 nitrogen fitting. Refer to FROTH-PAK™ Refill System Installation drawing, page A1. 3.1 Initial Tank Set-up 1) Be sure that the tanks are at the optimum temperature of 70 –80 degrees F., minimum 60–65 degrees.
Dow Building Solutions b) Attach the B side (blue) hose to the B side ball valve and make sure to keep the ball valve in the upward position and in the closed position. Tighten to about 30 lb-ft. Do not over tighten. 9) Unroll chemical hoses and remove any kinks in the hose. a) Attach the shutoff valves to the end of the hoses on the A and B side. Make sure the arrow on the shutoff valves is directed towards the gun. Tighten to about 30 lb-ft but do not over tighten.
Dow Building Solutions 3.4 Chemical Hose Installation 1. Verify that the chemical tank valves are closed. The handle should be perpendicular to the valve. Remove the chemical valve plugs from the “A” and “B” tanks and place the plugs on top of the tank. 2. Carefully remove all of the vaseline in the “A” chemical tank valve. 3. Remove the chemical filters from the canvas bags on top of each tank.
Dow Building Solutions 5. Turn the right regulator stem clockwise to the proper pressure setting of the “B” tank (120-160 psi – Do not go over 225psi) (see section 12). If a hissing sound occurs, further tighten the yellow-coded nitrogen line connection to the nitrogen regulator assembly and/or the nitrogen intake valve connection on the “B” tank using an adjustable wrench. If the right gauge fails to indicate a pressure setting, contact your Dow Chemical Sales Representative. 6.
Dow Building Solutions 13. The nozzles are a tight fit. Typically you will hear two clicks. Ensure that the yellow catch is fully latched over the extension on the nozzle. c) Now set the A and B side regulators to their initial pressure. Turn the handle clockwise to increase the pressure. A good starting point is 160–170 PSI on the A Side and 140–150 PSI on the B Side. Higher hose lengths will require higher pressures.
Dow Building Solutions • Go back to the regulator for the hose you disconnected and turn the handle counterclockwise all the way out. This chart is for the cone and fan type nozzles. Other specialty nozzles may have different elapsed paused times. • Reconnect the nitrogen line and tighten. • Open the tank valve and read the pressure on the tank. It should be at least 40 – 50 PSI lower than when you started.
Dow Building Solutions 5. Let the foam cure (a minute or two) Look for an even tan color foam. Watch to see that it rises 3 or 4 times the original thickness. Make sure the foam has cured and is firm. 6. If the foam looks unusual, verify the calibration settings and that the tanks are 70 – 80 degrees. (Minimum 60 – 65 degrees). Then remove the nozzle and purge material into a waste container for 15 – 30 seconds. Clean the face of the gun, insert a new nozzle and perform a test spray again. 7.
Dow Building Solutions Shut-down Procedure 1. Remove the used nozzle by pushing down on the nozzle ejector. 6. DO NOT store near chimneys or heat vents. 2. Apply petroleum jelly to the face of the INSTA-FLO™ Gun. 7. If a partially used system remains inactive for a period of time, the system should be pressurized and purged every two weeks. This will prevent crystallization of the chemical in the hoses. 3. Reinsert the used nozzle. This provides an airtight seal during storage. 8.
Dow Building Solutions 3. Verify that the nitrogen cylinder pressure using the center gauge of the nitrogen regulator assembly. The system WILL NOT operate efficiently if the pressure falls below 500 psi. If below 500 psi, replace the nitrogen cylinder. 4. Turn the left regulator stem clockwise to the proper pressure setting of the “A” tank (120–160psi – Do not go over 225psi) (see section 12).
Dow Building Solutions 9.1 “A” Tank Change-over 5. When ready for this, be sure the tank valves are closed on the empty tanks. Bleed off any pressure in the lines by pulling the trigger of the gun while aimed into a waste container. 6. Disconnect the lines and transfer to the new set. Be sure to have on proper protective equipment as some residual material will be in the lines. 7. Back out the regulator valve handles (counterclockwise) and then proceed with the calibration process as outlined above. 8.
Dow Building Solutions 11. Reconnect the “A” on-off valve to the filter of the new “A” tank. Tighten with an adjustable wrench. 12. Remove the filter from the empty “A” tank and dispose accordingly. 13. Reconnect the plug on the empty “A” tank to the chemical valve. Tighten with an adjustable wrench. 14. Depressurize the empty “A” tank by slowly opening the nitrogen intake valve. 15.
Dow Building Solutions 9.4 System Pressurization 1. Open the nitrogen bottle valve by turning the knob on top of the cylinder counter-clockwise. If a hissing sound occurs, further tighten the nitrogen regulator valve stem with an adjustable wrench. 2. Verify that nitrogen cylinder pressure using the center gauge of the nitrogen regulator assembly. The system WILL NOT operate efficiently if the pressure falls below 500 psi. If below 500 psi, replace the nitrogen cylinder. 3.
Dow Building Solutions 3. Dispense chemicals in an appropriate container and examine the chemical streams. If the streams are equal, the problem existed in the nozzle. Continue with steps 4-7 below. If the problem is not corrected, the blockage exists in the system. Continue with CAUTION – below step 7. 12. If the flow was adequate from both hoses, the problem was with the INSTA-FLO™ Gun/Hose Assembly. Discard the old INSTA-FLO Gun/Hose Assembly and replace with a new one according to steps 13-20.
Dow Building Solutions Section 11 Yield Notes 25. Re-open the on-off valve located near the filter and allow the chemical to flow in an appropriate container. If the chemical flow is unobstructed, the blockage exists in the chemical hose which must be replaced. Board foot yields are based on the free rise of the total weight of the chemicals in the tanks. Many factors affect the yield in field applications. 11.1 Operator Technique 26. If the blockage persists, examine the tank filter.
Dow Building Solutions Section 12 Section 14 Ratios and Output Nitrogen Regulator 14.1 Important - Safety Information Density PSI (A / B) Nominal Output* Nominal Ratio (A : B) 1.75 1.75 120 / 120 3.6 lbs/min 1.0 : 1.0 140 / 140 4.0 lbs/min 1.0 : 1.0 *Using cone type nozzle with chemicals at 75°F (24°C). Do not increase pressure over 225psi. PRV set @ 250psi. NOTE: Checking the system output and chemical ratio can determine whether the system is in good operating condition.
Dow Building Solutions Section 15 Tank Heating 15.1 Usage In places where the FROTH-PAK™ Refill System is used where the ambient temperature is below 65°F (18°C), an external source to heat the chemical in the tanks may be required. Heating bands are available for both the 17 gallon and the 60 gallon tanks, through: McMaster-Carr www.mcmaster.
Dow Building Solutions This control effectively regulates heating mantles, tapes and cords. Minitrol may also be used for small furnaces or ovens, hot plates, dies or other applications requiring infinite control. The control should not be exposed to ambient temperatures above 125°F (52°C). In addition to Minitrol, stock is maintained on variable transformers and automated controls.
Dow Building Solutions unheated hoses. The only difference here is to make sure whenever checking the flow or purging an Arctic Pak hose make sure that a grey backed or white backed calibration nozzle is attached to the gun. 7. Now that chemical is contained within the hoses, turn the controller to its lowest setting and plug the heater controller into a standard 110vAC outlet capable of continuously providing 15 amps of service.
Dow Building Solutions Polyol Hose: The polyol hose is terminated at each end with Parker Series 55¼” JIC Female Swivel fittings (carbon steel or stainless steel only). Blue end of hose color coding shall be maintained using colored tape, or a colored heat shrink sleeve as used in the electrical industry, or by other means. Fittings shall be crimped in place using Parker approved tooling and procedures.
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In the U.S. The Dow Chemical Company Dow Building Solutions 1605 Joseph Drive, 200 Larkin Center Midland, Michigan 48674 In Canada Dow Chemical Canada ULC Dow Building Solutions Suite 2100, 450 – 1st St., SW Calgary, AB T2P 5H1 Technical Information: 1-866-583-BLUE (2583) (English) 1-800-363-6210 (French) dowbuildingsolutions. com sprayfoamatdow.
