FAST-CAT

[Pages:20]FAST-CATTM Liquid Polymer Dispensing System Parts Manual & Operating Instructions

(COMPRESSOR NOT INCLUDED) Disclaimer: Actual products and colors may vary from the images displayed here.

FAST-CATTM Liquid Polymer Dispensing System

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Equipment Highlights

FAST-CATTM dispensing equipment in combination with Five Star Products is a proprietary pavement repair, rehab and construction system available only from select trained and authorized re-sellers. And while the FAST-CATTM dispensing system could be used with other plural component, ultra low viscosity (10 ? 250 cps) non-heated polymer systems, FAST-CATTM is the only approved dispensing system for Five Star Products due to its ease of use and low maintenance features. FASTCATTM is unique in that it does not incorporate complex, and costly to maintain, heating elements as are needed for many lower quality polymer systems. Each FAST-CATTM system includes initial 3-day on-site training at customer facility and or job site.

FAST-CATTM & Five Star Products, Inc. Benefits:

? WATER-THIN POLYMERs ? SELF PRIMING - NO MEASURING ? NO MIXING NO & LOW ODOR PRODUCTS ? LITTLE TO NO WASTE ? SOAPY WATER CLEANUP PROVEN TRACK RECORD (13 year+ repairs made on state/federal highway system)

- 3-Day ON-SITE TRAINING PROGRAM -

FAST-CATTM Equipment Highlights:

1 set 3 ft Adjustable Height Material Transfer Feed Pipes 1 set8 ft Color Coded, Chemically Resistant (Nylon/Teflon lined) Material Transfer Feed Hoses 1 set50 ft. Color Coded, Chemically Resistant (Nylon/Teflon lined) Delivery Hoses 1 set50 ft. Chemically Resistant Flush System Hoses (compressed air and water) 1 ea. 2+ gallon Pressure Vessel with Input/Output Lines, with Fluid Pressure Gauge and Regulator 1 ea. 3-way Valve for Flush System 1 ea. Braided Flush Line to Check Valve Flush System 1 ea. Dispensing Gun equipped with Flush Orifice for On-Demand Soapy Water Clean Up 1 ea. Single On/Off Gun Valve System 1 ea. Variable Fluid Flow Controller on Gun 1 ea. Dispensing Gun with Manifold 1 setAluminum Inserts and O-Rings for Gun Manifold 1 setDual 3 gpm spur gear pumps with pressure relief bypass & chemically resistant seals 1 ea. ? hp electrically powered motor with Master On/OFF and Speed/Volume Controller Box 1 ea. Stainless Steel mixer with collapsible propellers 1 ea. Spare Parts Kit (Chem Line, Gun Manifold Head, Gun Rebuild Kit, O-Rings) 1 ea. Tool Kit (Adjustable wrenches, hex wrench set, Channel-Lock Pliers, Teflon tape, small probe tool, utility knife,

universal drum wrench, chem line plugs, tool box) 1 ea. Dedicated Compressed Air Flush System 20 ea.....Mixing Nozzles 3 ea. Retaining Nuts for Mixing Nozzles LS On-site Training on FAST-CATTM setup, maintenance and use in conjunction with installation techniques and meth-

ods unique to Five Star? polymer products for a variety of pavement repair situations.

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FAST-CATTM Liquid Polymer Dispensing System

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Operating Procedures

Air/Water Flush System

FAST-CATTM is comprised of an electric powered motor connected to two (2) gear-spur pumps that dispense ultra-low viscosity, co-reactive liquids through a static mixing nozzle. The 3-way purge valve on top of the gun assembly supplies compressed air and soapy water for on-demand cleaning of the static mixing nozzles.

IMPORTANT: DO NOT USE WATER IN THE PUMPS.

SOAPY WATER IS ONLY TO BE USED IN THE 2-1/2 GALLON PRESSURE TANK TO CLEAN NOZZLES. WATER WILL DAMAGE PUMPS!!! KEEP TRANSFER HOSES IN POLYMER PRODUCTS OR FLUSHING FLUID. NEVER USE WATER or SOLVENTS for FLUSHING PUMPS!!!!

HELPFUL HINTS

Never run pumps completely dry and NEVER purge pumps with solvent or water. Solvent or water will damage bearings in pumps. PUMPS ARE EXPENSIVE!!!! Use only Five Star Products approved products in FAST-CATTM pumps. Call Five Star Products' Tech Support if you have any doubts or questions.

ALWAYS open the dispensing valves (push handle forward) on the gun assembly (MVE-01) before turning the motor on and ALWAYS turn the motor off before closing the valve.

Other than that, read the startup and shutdown procedures for more details, or call your Five Star Products' supplier for assistance.

STEPS

1. Unscrew large wing nuts on Pressure Tank (ST-A) and remove Tank lid. 2. Fill Tank Liner approximately ? full with clean water. 3. Add small amount of Liquid Dish Soap (i.e. Joy, Palmolive, whatever your preference) 4. Place lid on Tank and hand tighten wing nuts equally to create air tight seal. 5. Connect hoses (fittings will only allow one way to connect hoses from air compressor to tank and tank to air line and the

water line leading to 3-way valve on top of gun. If not, call your FAST-CATTM supplier for phone consultation.) 6. Connect hoses, at gun side, to elbows on either side of 3-way valve. 7. Connect FAST-CATTM to power source (115V, AC outlet or portable generator). 8. Make Sure MVE-01 is closed (MV7 knob pulled back to closed position). 9. Turn 3-way valve, on top of gun, right and left to determine which line is air only vs. soapy water. (air and water will only

come out one hole of gun). 10. Once familiar with operation of air and soapy water purge operation return 3-way valve to center to stop flow of air and

water. 11. With air/water valve off (pointing straight in center), begin your normal operation of equipment (priming pump and lines) 12. Now when purging material from plastic mixing nozzle, pull MV7 knob back to close valve, then turn 3-way valve to allow

small amount of soapy water into nozzle, then turn 3-way valve the other direction to purge with air only. Repeat twice to "scrub" nozzle clean.

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Operating Procedures

13. Allow air only to flow through nozzle for 30 to 60 seconds to dry mixing nozzle. 14. When ready to make another repair, close 3-way valve stopping air flow, push MV7 knob forward to open valve-gun and

pour small amount of liquid polymer through nozzle into waste bucket, then make repairs as usual. 15. Follow SHUT DOWN Procedures when done using machine.

Start-up Procedures

1. Open Flush Tank (ST-A). Pour in small amount of liquid dishwashing soap. Add clean water to Tank (3/4 full). Then re-attach top to Flush Tank (ST-A).

2. Place a plastic garbage bag into a 5 gallon pail for later use as Waste Container. 3. Place Drum Siphon Hoses (P38) into Product Barrels (ensure that blue & white color coded drum fittings are matched to

product barrels) 4. Connect Pump to electric power source (i.e. generator). 5. Connect Air Compressor line to Flush Tank System (operate Tank @ 50 psi). 6. Make sure Pump is NOT running and that the Purge valve (B23-1/8) is off (pointing straight ahead toward gun (MVE-

01). 7. Attach gun manifold (RTM2 ? make sure all parts are in RTM2) to MVE-01.

Do NOT attach "A" & "B" fluid lines to gun (MVE-01), yet. 8. Remove Plugs from Delivery Lines (at front near gun). 9. Turn on Pump @ Power Box (LWE27) which is mounted on frame (LWE-1). 10. Push MV7 knob forward to open "A" & "B" valves on gun. 11. Turn LWE48 on to begin siphoning Product from Barrels, running machine until Product is siphoned from containers and

pumped through "A" & "B" Fluid Delivery Lines, visually verifying equal flow of "A" & "B" Product through lines. 12. Turn LWE48 off to stop Product flow.

NOW CONNECT "A" & "B" Fluid Delivery Lines to B27 fittings on gun 13. Turn LWE48 on to start Product flow, running machine to verify equal flow of "A" & "B" Product (Five Star? Rapid Surface

Repair Products) through gun (MVE-01). 14. Turn LWE48 off to stop Product flow. 15. Close "A" & "B" valves on gun (pull MV7 back toward handle ?LWE47-) 16. Attach plastic mixing nozzle (RT12) to manifold (RTM2) using retaining nut (RT11). 17. Push MV7 knob forward to open "A" & "B" valves on gun 18. Turn LWE48 on to start Product flow through nozzle, pouring 6 ? 8 oz of Product into a waste container and 3 ? 4 oz into

a small test cup. 19. Turn LWE48 off to stop Product flow. 20. Close "A" & "B" valves on gun (pull knob ?MV7- back toward handle ? LWE47-) 21. Purge nozzle (RT12) into waste container (turn purge valve ?B23-1/8- left then right, two or three times). Then, turn the

purge valve to allow air (not the soapy water) to flow through nozzle for 1 minute. 22. Check test cup to verify product has set up properly. 23. If Product has set up in test cup you're ready to apply product in a repair. 24. Turn the Purge Valve (B23-1/8) off to stop flow of air. 25. Follow steps # 18-19, then shoot Product as needed to make your repairs.

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FAST-CATTM Liquid Polymer Dispensing System

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Operating Procedures

Standard Shut Down (between use)

1. Close fluid Delivery Line valve (pull handle back of MVE-01 gun) 2. Remove both LW200 Hex bolts from Aluminum Manifold 3. Remove Aluminum Manifold from Gun 4. Remove elbow, spring and ball from Aluminum Manifold 5. Place Aluminum Manifold & associated parts in container of Acetone 6. Allow parts to soak in Acetone for 3 - 5 minutes 7. Remove items from Acetone 8. Clean inside and out of Aluminum Manifold and elbow, spring & ball using wire brush and small probe. Make sure elbow

is clear of obstructions (i.e., clear of solidified or crystallized liquid) 9. Set parts aside until next use.

DO NOT re-attach Aluminum Manifold to Gun until next use

Store Machine and Product in Dry, Heated Storage Facility

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Frequently Asked Questions

FAQs

Q. What is the FAST-CATTM? A. FAST-CATTM is designed for state, county and city road maintenance crews

and contractors for dispensing Five Star Products rapid setting polymer products to quickly and effectively repair pavement.

Q. What repairs can be made with the FAST-CATTM? A. Repairs in concrete and asphalt pavements including patching, sealing & re-

surfacing spalls, potholes, mismatched slabs, corner breaks, random cracks, expansion joint reconstruction, joint sealing, bridge deck overlays, crack healing/sealing concrete slabs and bridge decks and traffic loop sealant installation.

Q. How is the FAST-CATTM powered? A. The FAST-CATTM is electrically powered. Plug it into a standard 120 Volt, 10

amp outlet or to a portable generator with 10+ amp ( 2,500+ watt) minimum capacity.

Q. How does the FAST-CATTM work? A. Gear driven pumps powered by an electric motor siphon Five Star? Rapid

Surface Repair "A" & "B" liquids from their individual containers. Flow rate is precisely controlled from a slow dribble up to three gallon per minute volume through a small dial mounted on the delivery manifold (gun). Combining "A" & "B" liquids through a static mixing nozzle at the delivery manifold initiates rapid cure. When a repair is completed, the gun is turned off to stop the flow of liquid. A valve is opened on the gun to flush the nozzle with compressed air and soapy water making it ready for the next repair.

Q. How is the FAST-CATTM cleaned? A. . After the FAST-CATTM is stopped for the day, the static mixer is removed from

the gun (delivery manifold), delivery manifold is removed (2 screws) and wiped clean...takes about 3 minutes.

Q. What does the FAST-CATTM system include? A. Includes pump system mounted on aluminum plate; 50' color-coded delivery

hoses and 8' Material Transfer Feed hoses & Feed Pipes, 2+ gallon Pressure Vessel with Input/Output Lines with Fluid Pressure Gauge & Regulator, 3-way valve for Soapy Water Flush System, Variable flow Gun, Spare Parts Kit. OPTIONAL: System may be mounted in enclosed trailer complete with wiring and plumbed with air. May include optional prep equipment & tools.

Specifications

? 1:1 Ratio Gear-driven Fluid Pumps ? 1/2 HP, 120V, Electric Motor ? Integral Air/Water Flush System ? 50 ft. Chemical, Air and Water

Purge Lines

? 3 GPM Fluid Pump Flow Rate ? Abrasion Resistant Hose Set

Sleeve

? "A" & "B" Shut-off Valves at Gun ? Color Coded Siphon Transfer

Hoses

? Fluid Flow Rate Control Dial at

Gun

? Variable Speed for Pouring or

Spraying

? Flush System Controlled at Gun ? 2+ Gallon Pressure Vessel Flush

System

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Troubleshooting

PROBLEM

1. No Power 2. Power On ? Motor Won't Turn 3. "A" / "B" Pump(s) Won't Turn

Manually

4. FAST-CATTM Dispensing Off-Ratio

SOLUTION

? Plug-in / Turn on FAST-CATTM ? Check / Test / Replace Fuse ? Check and Test Power Source ? On/Off Light bulb burned out. Replace. ? Test / Replaced Controller Card. Call Factory.

? Check / Test / Replace Fuse ? Check / Test Power Source ? Machine subjected to surge in electricity? Call Factory. ? Unplug Machine from Power Source, then try turning pumps and drive belt

manually by hand.

? Remove pump from mount (unscrew 4 mounting bolts). Try turning shaft by

hand.

? If still unable to turn, disassemble pump by removing two pump bolts. Clean

pump thoroughly.

? Reassemble pump with new gaskets / o-rings. ? Turn pump shaft manually to verify repair. ? Re-attach pump to mounts. ? Turn on FAST-CATTM. ? Prime Pump(s). Turn speed control on to full speed until solid streams visible

? no air / no "spitting."

? Verify on-ratio. Remove chem. Hoses from pumps, turn on machine, collect

liquid samples from pumps, equal quantities collected? If yes, re-attach

hoses. Begin using.

? Check / Tighten / Re-Tape fittings / Hose connections using Teflon "plumb-

ers" tape or Teflon Thread Sealant Paste

? Check / Clean gun and manifold. Remove obstructions. ? Check / Replace Feed Line / Chem Line Hoses ? Remove pressure relief screw. Apply Teflon Thread Sealant (available in

gel/paste grade). Reattach pressure relief screw. Re-set pump pressure to

900 psi fluid pressure.

? Remove Shaft Seal Bearings and replace with two new manufacturer ap-

proved, chemically resistant shaft seals, pre-treated with silicon grease

lubricant.

? Re-attach pump to mounts. ? Turn on FAST-CATTM. ? Prime Pump(s). Turn speed control on to full speed until solid streams visible

? no air / no "spitting.

? Verify on-ratio. Remove chem. hoses from pumps, turn on machine, collect

liquid samples from pumps. Have equal quantities been collected? If Yes,

re-attach hoses. Begin using.

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Troubleshooting

PROBLEM

5. Machine Runs at Full Speed Regardless of Speed Control Position

6. Product Won't Set-Up / Remains Liquid

7. Product Inconsistent in Cure (i.e. Does not gel / solidify consistently)

8. Product Bubbles / Rises While Curing

9. Product "Spits" / Surges as Dispensed

10. FAST-CATTM Loses Prime Between Uses

11. Product Leaking from Gun

SOLUTION

? Check Speed Control Solder Connections. Open Speed Control box beneath

gun.

? Re-solder if connections are bad. ? Check / Test / Replace Speed Control Dial Device (especially if dials spins

360?+)

? Check / Test Electrical Wire (most likely a broken wire with insulation). To

Test: Unplug wire at Speed Control Box near gun, then plug into connector near motor. If Speed Control Dial now functions properly, replaced defective wire section between motor and gun.

? Perform ratio test. Remove hoses from gun, place each hose into separate

container, turn up speed control, check quantities of each liquid dispensed.

? Test product from each container. Draw equal sample from each container.

Hand-mix together.

? If Manual Test / Hand-Mix test samples set-up, review FAST-CATTM Dispensing

Off-Ratio section.

? If Manual Test reveals inconsistent result, mix "A" & "B" components sepa-

rately, then manually re-test (i.e. draw samples, hand-mix together).

? Review Product Won't Set Up section ? Evaluate site condition thoroughly. Is moisture present? If yes, dry damp

substrate. Re-apply product.

? Replace Static Mixing Nozzle. Older used nozzles may be retaining moisture

from purge process in the buildup of cured polymer on missing elements.

? Moisture is present ? Check substrate (is it damp/wet?). Torch to dry. ? Check 3-way Flush Valve on gun for leak. ? Check / Test product (manually test / hand-mix) ? Review FAST-CATTM Dispensing Off-Ratio section ? Replace Static Mixing Nozzle. Older used nozzles may be retaining moisture

from purge process in the buildup of cured polymer on missing elements.

? Review FAST-CATTM Dispensing Off-Ratio section

? Review FAST-CATTM Dispensing Off-Ratio section. Usually requires shaft seal

replacement.

? Check all fittings and hose connections.

? Remove TRM2-SP Manifold from Gun. Make sure White o-rings and alumi-

num inserts installed in Manifold or install new o-rings / inserts.

? Tighten hex bots on RTM2-SP Manifold when attached to gun.

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