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Mini Pro Gelcoater Operations Manual

1. To prevent this spillage and leakage you should 1 Maintain your Magnum Venus Plastech System Check the gun several times daily for catalyst and resin packing or valve leaks REPAIR ALL LEAKS IMMEDIATELY 2 Never leave the gun hanging over or lying inside the mold A catalyst leak in this situation would certainly damage the part possibly the mold and may cause a fire 3 Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom sections and at the hose and fittings Replace if wear or weakness is evident or suspected 4 Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub against any of the hoses at any point If allowed to rub the hose will be cut through causing a hazardous leakage of material which could increase the danger of fire Also the material may spew onto personnel in the area MagnumVenusPlastech Rev 09 2012 Page 11 Mini Pro Gel Coater Operations Manual 2 7 Toxicity of Chemicals A Magnum Venus Plastech recommends that you consult OSHA Sections 1910 94 1910 106 1910 107 and NFPA No 33 Chapter 14 and NFPA No 91 B Contact your chemical supplier s and determine the toxicity of the various chemicals used as well as the best methods to prevent injury irritation and danger to personnel C Also determine the best methods of first aid treatment for each chemical used in your plant 2 8 Treatment of Chemical Injuries Great care sho
2. 40 Mini Pro Gel Coater Operations Manual Revision Information Rev 04 2010 Assembled This Manual Rev 09 2012 Updated the manual format and Address Added the Terms amp Conditions of Sale section to the manual Updated the drawings MagnumVenusPlastech Rev 09 2012 Page 41 Mini Pro Gel Coater Operations Manual Magnunr Venus Plastech MAGNUM VENUS PLASTECH CORPORATE HEADQUARTERS and MANUFACTURING 11692 56 Court Clearwater FL 33760 Tel 727 573 2955 Fax 727 571 3636 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 MVP Plastech UK Chilsworthy Beam Gunnislake Cornwall PL18 9AT UK Tel 44 0 1822 832621 Fax 44 0 1822 833999 www mvpind com Included with this operations manual are the following component manuals VPRO 45220 PRO PUMP MAINTENANCE AND REPAIR MANUAL PCP 2000 PRO LOW RANGE CATALYST PUMP MANUAL ATG 3500 REPAIR AND MAINTENANCE MANUAL or EMG 1000 amp EMG 1500 GEL COAT GUN MANUAL MagnumVenusPlastech Rev 09 2012 Page 42
3. 1 2 POLY TUBE 24 4105 1 01 1 TUBE FITTING 14 6701 16 EN 1 CAT JUG SUCTION HOSE DECAL 15 4105 8 1 1 CAT JUG NUT PIN WRENCH NOT SHOWN 16 4105 6 1 1 100 MESH SS SCREEN Catalyst Jug W Recirc W O Sight Tube 2000 4 PARTS LIST ITEM PARTNO QTY DESCRIPTION 1 4105 11 04 1 2 GAL CAT JUG W CAP 11 59371 1 1 CAT JUG TUBE FITTING Catalyst Jug W Recirc W O Sight Tube CJ 2000 4 R PARTS LIST ITEM PARTNO QTY DESCRIPTION 1A 4105 41 03 1 2 GAL CAT JUG W CAP 11 59371 1 1 CAT JUG TUBE FITTING Catalyst Jug W Recirc W Sight Tube CJ 2000 4 RS PARTS LIST ITEM PARTNO QTY DESCRIPTION 1B 4105 11 02 1 2 GAL CAT JUG W CAP 11A 4105 12 1 1 CAT JUG TUBE FITTING 18 4105 4 1 1 1 4 x 14 SIGHT TUBE 19 4105 9 1 1 SIGHT TUBE FLOAT 20 4105 5 1 1 SPLIT BUSHING 21 O S 010 1 O RING 22 4105 1 1 1 TUBE FITTING BODY Catalyst Jug W Recirc W Sight Tube CJ 2000 4 RSP PARTS LIST PARTNO QTY DESCRIPTION 1C 4105 44 05 1 2 GAL CAT JUG W CAP 11A 4105 12 1 1 CAT JUG TUBE FITTING 18 4105 4 1 1 1 4 x 14 SIGHT TUBE 19 4105 9 1 1 SIGHT TUBE FLOAT 20 4105 5 1 1 SPLIT BUSHING 21 5 010 1 O RING 22 4105 1 1 1 TUBE FITTING BODY MagnumVenusPlastech Rev 09 2012 Page 39 Mini Pro Gel Coater Operations Manual HSA 1000 SIPHON HOSE ASS Y 05 14 03 BT2 ITEM PART NLIMBER DESCRIPTION QUANTITY 3 1 HFL 1212J12J 8 HOSE 1 i 2 Pr SE IL2 12J STREET ELBOW 1 3 HSA 1001 PIPE 1 4 BF 14 467 BASKET FILTER 1 MagnumVenusPlastech Rev 09 2012 Page
4. 12 months for parts from the date of invoice For systems 12 months from start up or if earlier 18 months from the date of the Bills of Lading The warranty does not cover general wear and tear or damage due to negligence or improper use Seller s liability under the warranty shall be limited solely to repair or replacement costs and has no responsibility for reimbursing repair cost incurred by Buyer in connection with equipment without first giving written authorization for such charges Seller makes no express warranties except those set forth in this agreement and disclaims all other warranties expressed or implied including without limitation implied warranties of non infringement merchantability and fitness for a particular purpose Seller accepts no liability for loss of production loss of profits or other direct or indirect damages In any claim by the Buyer MagnumVenusPlastech Rev 09 2012 Page 4 Mini Pro Gel Coater Operations Manual against the Seller in respect of the goods the liability of the Seller shall be limited to the value of the goods e Many factors beyond Seller s control contribute to the success of Buyer s finished products such as raw materials used to manufacture the product Equipment is warranted to perform to specifications detailed in quotation but Seller is not liable for quality or quantity of finished products produced by Buyer e The country of origin is the United States of America Sale instal
5. Association 470 Atlantic Avenue Boston MA 02210 Research Report No 11 of the American Insurance Association deal with Fire Explosion and Health Hazards of Organic Peroxides It is published by American Insurance Association 85 John Street New York NY 10038 Local codes and authorities also have standards to be followed in the operation of your spraying equipment Your insurance carrier will be helpful in answering questions that arise in your development of safe procedures 1 2 Personal Safety Equipment Magnum Venus Plastech recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems Magnum Venus Plastech recommends that the user consult the state and local regulations established for all Safety equipment listed 2 0 Material Safety 2 1 Hazards Associated with Laminating Operations The major hazards which should be guarded against in polyester laminating operations are those associated with 1 The flammability and explosion dangers of the catalyst normally used Methyl Ethyl Ketone Peroxide MEKP 2 The flammability dangers of clean up solvents sometimes used Magnum Venus Plastech recommends that clean up solvents be non flammable and of resin diluents used such as styrene 3 The flammability dangers of catalyst diluents if used Magnum Venus Plastech recommends that catalyst not be diluted 4 The flammability dangers of the uncured liquid resins used 5
6. Gun Manual MagnumVenusPlastech Rev 09 2012 Page 32 Mini Pro Gel Coater Operations Manual Parts Drawings MGS PRO 2 22 EXTERNAL MIX GEL COATER W ATG3500 MA 16 AIR MANIFOLD CJ 2000 CATALYST JUG ASSEMBLY HSA 1000 3 4 SIPHON ASSEMBLY MagnumVenusPlastech Rev 09 2012 Page 33 Mini Pro Gel Coater Operations Manual 5 A B 2 MAGNUM VENUS PRODUCTS D EXTERNAL GELCOAT W ATG 3500 MGS PRO 2 22 REV 8 4 03 JEM MagnumVenusPlastech Rev 09 2012 Page 34 Mini Pro Coater Operations Manual EXRERNAL GELCOAT W ATG 3500 MGS PRO 2 22 PARTS LIST ITEM PART NO QTY DESCRIPTION 1 85770 69 2 PUMP MNT BRKT 2 08690 1 MALE QUICK DISCONNECT 3 00817 2 NIPPLE 4 05627 2 COUPLING 5 05501 2 PIPE THREAD SEAL 6 FF 5000 100 2 RESIN FILTER W 100 MESH SC 2510 2 SURGE CHAMBER 8 HSA 1000 2 3 4 x 8 SIPHONE ASSY 9 PF SW 06 2 SWIVEL FITTING MxF 10 PF HN 08 06 4 NIPPLE 11 BV 44 HP 2 BALL VALVE 12 PF HN 04 04S 2 NIPPLE 13 PF HN 04 LI NIPPLE 14 ATG 3500 1 GELCOAT GUN ASSY 15 PCP 2000 RV 2 CAT PUMP ASSY 16 RV 1000 1500 1 RELIEF VALVE 17 01189 3 2 CATALYST HOSE ASSY 3 FT 18 08936 2 MALE QUICK DISCONNECT 19 7701 1 2 2 ELBOW FITTING 20 00036 2 STREET ELBOW 21 59440 3 1 2 GAL CAT JUG ASSY 22 85730 1 1 CAT JUG BRACKET 23 HAW 0344 5 2 AIR HOSE ASSY 5 FT 24 HAW 044M 20 2 HOSE ASSY 25 HA 0344 25 1 HOSE ASSY 25 FT 26 HC 0224 25 1 HOSE ASSY 1 8 x 25 FT 27 PR 1080 1 AIR MANIFOLD 28 VPRO 45220 2 GELCOAT
7. fluid pressure before attempting to remove components Pick up wand assembly Tighten assembly fittings leaking Resin filter clogged Disassemble and clean the resin filter See Chapter 7 Accumulator amp Filter Material too cold or air Heat material or increase pressure low pump pressure Narrow Fan Material too cold nozzle too Heat Material use smaller large or air pressure low nozzle or as a last resort increase pump pressure Resin filter clogged Disassemble and clean the resin filter Wide Fan Air pressure too high Lower pressure then increase pressure to the desired fan Nozzle too small or too wide Change nozzle Round fan Orifice in nozzle worn Push fine wire through orifice clogged or damaged from back side Use fingernail to clean material form V shaped notch in front Soak hardened material in solvent If notch is rough or worn replace nozzle Air assist pressure too high Decrease air assist pressure Excessive Misting Air pressure too high Reduce air pressure to gel coat pump Heavy pulsation Resin accumulator plugged Danger To prevent injury always relieve fluid pressure before attempting to remove components Disassemble accumulator and clean Pump jumps on upstroke Piston ball worn or not seating properly Replace piston ball and piston cups Be sure to lubricate ball and cups thoroughly with Red Grease See Chapter 6 Pro Pump Mag
8. for the flow of the electrical charge from the object to the ground An adequate path is one that permits charge to flow from the object fast enough that it will not accumulate to the extent that a spark can be formed It is not possible to define exactly what will be an adequate path under all conditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed on all loose conductive objects in the spraying area This includes material containers and equipment Magnum Venus Plastech recommends grounding straps be made of AWG No 18 stranded wire as a minimum and the larger wire be used where possible NFPA Bulletin No77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm 10 ohms but that resistance as high as 10 000 meg ohms will produce an adequate leakage path in some cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and grounded to dissipate static electricity For further information see National Fire Protection Association NFPA 77 titled Recommended Practice on Static Electrical Refer especially to section 7 7 titled Spray Application of Flammable and Combustible Materials Check with local codes and authorities for other specific standards that migh
9. have seat repaired if questionable Catalyst Check Valve CV 2000 not working correctly Check and Repair the Catalyst Check Valve CV 2000 No cure or slow over all cure Catalyst pump set at too low or too high of a percentage Move catalyst pump to a higher setting closer to the gel coat pump Be sure to attach the catalyst pump in a vertical position Catalyst supply below outlet fitting on jug Fill catalyst jug 1 3 full Quick pin not attached to pump or slave arm Install quick pin Be sure to attach the catalyst pump vertically Catalyst leak Check all fittings The catalyst system must be fluid tight Catalyst relief valve on catalyst pump is leaking Relieve pressure from Pro pump Clean and repair the Relief Valve Catalyst suction screen in catalyst jug clogged Clean catalyst suction screen and ensure that catalyst supply is not contaminated T MagnumVenusPlastech Rev 09 2012 Page 21 Mini Pro Gel Coater Operations Manual PROBLEM CAUSE SOLUTION Air lock in catalyst pump Remove air lock See Appendix Air Lock in the Catalyst Pump Catalyst pump piston seal worn or damaged Replace piston seal During reassembly be sure spring in seal faces top of pump Catalyst pump outlet body damaged Replace catalyst pump outlet body and piston seal During reassembly be sure spring in seal faces top
10. hazard The Catalyst MEKP may cause blindness skin irritation or breathing difficulty Keep hands away from face Keep food and drink away from work area WARNING Please refer to your catalyst manufacturer s safety information regarding the safe handling and storage of catalyst Wear appropriate safety equipment as recommended MagnumVenusPlastech Rev 09 2012 Page 14 Mini Pro Gel Coater Operations Manual Introduction This manual provides information needed to properly operate and perform simple maintenance and repair on this equipment Q Step by step operations procedures are provided Q This manual includes Installation Start up and Shut Down instructions Q Step by step assembly and disassembly procedures are included for each component Please read the manual carefully Follow the steps in the order given otherwise you may damage the equipment or injure yourself Major Components The Mini Pro Gel Coater consists of the following major components Resin Pump Fluid section and Air Motor Shift Block Assembly Catalyst Pump Assembly Gun Assembly OOOO Description of Controls for Spray unit Familiarize yourself with the Air Manifold controls which consist of the following regulators and gauges Q PUMP PRESSURE gauge and regulator This controls the main air pressure to the resin pump Air Motor ATOMIZING AIR gauge and regulator This is controls the air pressure to the catalyst nozzle on
11. in lower part of the pump See Chapter 6 Pro Pump Piston rod worn or scored Replace piston rod See Chapter 6 Pro Pump No Gel coat delivery on down stroke Foot valve spring retainer or foot valve ball damaged or dirty Clean or replace foot valve spring retainer and foot valve ball Be sure to lubricate ball thoroughly with Red Grease See Chapter 6 Pro Pump Hose leaks at fittings Fitting loose Tighten fitting Check all fittings for leaks before operating MagnumVenusPlastech Rev 09 2012 Page 24 Mini Pro Gel Coater Operations Manual PROBLEM CAUSE SOLUTION Fitting or nipple damaged Danger To prevent injury always relieve fluid pressure before attempting to remove components Replace damaged parts Crimped hose Danger To prevent injury always relieve fluid pressure before attempting to remove components If the hose has been sharply bent the plastic liner may be ruptured Remove and replace hose Slow Cure on one side of the fan Turbulent Mixer partly clogged or damaged Clean or replace the Turbulent Mixer Distribution Ring partly clogged Remove the mix chamber and clean the distribution ring Mix Housing damaged Replace as needed Fingers heavy lines in the spray fan Gel Coat too cold Increase gel coat temperature Use Inline resin heater Pump air pressure too low
12. pressure relief valve vents some catalyst may spray out which could cause eye injury For this reason and many others anyone whose job puts them in an area where this vented spray might go should always wear full eye protection even when laminating operations are not taking place Safety in handling MEKP depends to a great extent on employee education proper safety instructions and safe use of the chemicals and equipment Workers should be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users should make every effort to A Store MEKP in a cool dry place in original containers away from direct sunlight and away from other chemicals B Keep MEKP away from heat sparks and open flames MagnumVenusPlastech Rev 09 2012 Page 8 Mini Pro Gel Coater Operations Manual C Prevent contamination of MEKP with other materials including polyester over spray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels D Never add MEKP to anything that is hot since explosive decomposition may result E Avoid contact with skin eyes and clothing Protective equipment should be worn at all times During clean up
13. red grease on the o rings and threads before installing the spray tip catalyst tip and retainer 1 Install the Gel Coat Spray Tip into the front of the gun block 2 Install the Catalyst Tip over the Spray Tip Use caution not to damage the o rings on the front of the gun block 3 Install the retainer to secure Catalyst Tip and Spray Tip in place 4 Spray a test pattern Slowly make gel coat pump pressure adjustments until a fairly uniform pattern is achieved There should be slight horns lines on either side of the spray fan For the ATG 3500 Gel Coat Gun Slowly open the air assist needle valve located on the side of the gun handle until a soft uniform pattern is achieved One of the most important concepts is to use just enough pressure to the power head to establish a good spray fan and no more Then use the Air Assist to fine tune or do final adjustment to the spray pattern MagnumVenusPlastech Rev 09 2012 Page 19 Mini Pro Gel Coater Operations Manual Daily Start up amp Shut down Daily Start Up 1 2 Check all hoses for damage Check all material supplies and fill or replace as needed Open main inlet air valve on the manifold Check pump pressure if adjustment is needed remove the pin from the slave arms amp catalyst pump bearing block this will prevent over pressure in the catalyst system Slowly turn up the pump air pressure to the operating pressure Note Always lean the catalys
14. the gun This is normally set to 18 25psi 1 1 5 bar Q RESIN DUMP VALVE This located at the bottom of the Filter Body This is used to relieve gel coat pressure MagnumVenusPlastech Rev 09 2012 Page 15 Mini Pro Gel Coater Operations Manual Getting Started Air Requirements Clean dry compressed air must be available at 90 100 psi 6 7 bar and a minimum volume of 10 CFM 0 3 m Air must be provided through an air hose with a diameter of 0 5 inch 1 3 cm or greater Lubrication Throughout this manual directions are given for lubricating various parts of the Pro Pump There are three types of lubricant used o Ifthe part contacts resin use MVP Red Grease 6706 2 1 Ifthe part is located where it will contact air use Lubriplate 08465 Q Throat Seal Oil TSL 3200 used in the oil reservoir of the pump Other Supplies Q Solvent for cleaning Asmall Chip Paint Brush for cleaning Small cup or container for the solvent Q Wet Gel Gauge to determine Gel Coat thickness MagnumVenusPlastech Rev 09 2012 Page 16 Mini Pro Gel Coater Operations Manual Installation and Setup 1 Unpack unit amp components report any damaged or missing items 2 Assemble unit mount Pump to the cart install Catalyst Pump onto the Slave Arms 3 Install Catalyst Jug into the Catalyst jug bracket 4 Connect the Relief Valve tube to the top port in the Catalyst Jug 5 Con
15. 6 2 STAGE FILTER Wee eee eee ye INCLUDED BUT NOT SHOWN B O6C 40 U BOLT F U F SW 06 SPLIT WASHER F HN 06C HEX NUT MagnumVenusPlastech Rev 09 2012 Page 37 Mini Pro Gel Coater Operations Manual MAGNUM VENUS PRODUCTS Catalyst Jug Assy W Recirc W O Sight Tube Catalyst Jug Assy W Recirc W O Sight Tube Catalyst Jug Assy W Recirc W Sight Tube Catalyst Jug Assy W Recirc W Sight Tube CJ 2000 4 CJ 2000 4 R CJ 2000 4 RS CJ 2000 4 RSP REV D ADDED CJ 2000 4 TO DRAWING 4 16 04 JEM E ADDED CJ 2000 4 RSP TO DWG 03 21 06 BT2 F ITEM 12 WAS QTY 12 11 14 07 BT2 G ADDED ITEM 5 DELETED ITEM 7 02 01 08 BT2 MagnumVenusPlastech Rev 09 2012 Page 38 Mini Pro Gel Coater Operations Manual Common Assembly Parts For Catalyst Jug W Recirc W O Sight Tube 8 CJ 2000 4 Catalyst Jug W Recirc W O Sight Tube CJ 2000 4 R Catalyst Jug W Recirc W Sight Tube CJ 2000 4 RS Catalyst Jug W Recirc W Sight Tube CJ 2000 4 RSP PARTS LIST ASSOCIATED PARTS AND ASSEMBLIES ITEM PARTNO QTY DESCRIPTION ITEM PARTNO QTY DESCRIPTION 2 8801 1 100 1 100 MESH 2 GAL CAT JUG SCREEN 5 8802 1 1 1 3 4105 10 1 1 FILTER SCREEN NUT 8 6701 4 EN 1 CONTAMINATES CAUTION DECAL 4 4105 7 1 1 60 MESH SS SCREEN 9 6701 15 EN 1 DAILY MONTHLY INTST DECAL 10 0 5 016 1 O RING 17 4105 2 01 1 1 2 x 4 FEED LINE 12 7701 2 2 2 1 2 SUCTION HOSE CLAMP 23 4105 12 01 1 OUTLET FITTING 13 01419
16. Manual w SAFETY amp WARNING INFORMATION OPERATING YOUR POLYESTER SYSTEM SAFELY 1 Introduction Any tool if used improperly can be dangerous Safety is ultimately the responsibility of those using the tool In like manner safe operation of polyester processes is the responsibility of those who use such processes and those who operate the equipment This manual outlines procedures to be followed in conducting polyester operations safety This system has been specifically designed for use of Polyester Resin Gel Coat and Methyl Ethyl Ketone Peroxides MEKP applications Other formulations or blends considered for use in this equipment is strictly prohibited without the expressed consent by Magnum Venus Plastech Inc Magnum Venus Plastech cannot eliminate every danger nor foresee every circumstance that might cause an injury during equipment operation Some risks such as the high pressure liquid stream that exits the spray tip are inherent to the nature of the machine operation and are necessary to the process in order to manufacture the end product For this reason ALL personnel involved in polyester operations should read and understand the Safety Manual It is very important for the safety of employees involved in the operation that equipment operators maintenance and supervisory personnel understand the requirements for safe operation Each user should examine his own operation develop his own safety program and be assured that his equi
17. Mini Pro Gel Coater Operations Manual d MagnumVenusPlastech Rev 09 2012 Mini Pro Gel Coater Operations Manual MagnumVenusPlastech CORPORATE HEADQUARTERS and MANUFACTURING 11692 56 Court Clearwater FL 33760 Tel 727 573 2955 Fax 727 571 3636 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 MVP Plastech UK Chilsworthy Beam Gunnislake Cornwall PL18 9AT UK Tel 44 0 1822 832621 Fax 44 0 1822 833999 www mvpind com MagnumVenusPlastech Rev 09 2012 Page 2 Mini Pro Gel Coater Operations Manual Table of Contents SECTION TERMS amp CONDITIONS OF SALE SAFETY amp WARNINGS INTRODUCTION GETTING STARTED PRIMING the UNIT DAILY START UP amp SHUT DOWN TROUBLE SHOOTING GUIDE AIR LOCK IN THE CATALYST PUMP PUMP REPAIR PROCEDURES CATALYST PUMP REPAIR PROCEDURES GEL COAT GUN REPAIR PROCEDURES PARTS DRAWINGS REVISION INFORMATION MagnumVenusPlastech Rev 09 2012 Page 15 16 18 20 21 28 30 31 32 33 41 Page 3 Mini Pro Gel Coater Operations Manual Terms amp Conditions of Sale Customs duties import and export licenses and certificates if required and all local taxes are excluded from this offer If US state and local taxes are applicable and not included in equipment invoice such amount may be invoiced later Delivery dates or shipping schedules are approximate and base
18. PUMP 29 01446 8 0FT 1 4 POLY TUBE 30 MP 2535 1 MALE RUN POLY TEE 31 HA 0644 10 1 AIR HOSE ASSY 32 7701 7 1 1 FEMALE QUICK DISCONNECT 33 HA 0224 25 1 AIR HOSE ASSY 34 HA 0224 25 2 STREET ELBOW 35 6703 02 020 1 UNIT GROUNG 36 CM 1052 1 FITTING 37 CM 1005 1 BALL VALVE 38 F HB 04C 32 2 BOLT 39 CM 1053 1 PLUG 40 CM 1051 1 MANIFOLD BLOCK 41 CPRV 1002 A 1 FITTING 42 CM 1054 1 FITTING 43 CM 1056 1 FITTING LE F HN 04C 2 NUT 45 F SW 04 2 LOCK WASHER 46 O S 013 7 O RING 4T MS 2052 30 2 TUBE TSL 800 1 TSL 1 2 PT 6706 2 1 1 WHITE GREASE NOT SHOWN VHPC 2200 SK 1 SEAL KIT NOT SHOWN MagnumVenusPlastech Rev 09 2012 Page 35 Mini Pro Coater Operations Manual MA 16 AIR MANIFOLD FOR EXTERNAL MIX F I T GELCOAT SYSTEM 03 24 03 BT2 MagnumVenusPlastech Rev 09 2012 Page 36 Mini Pro Gel Coater Operations Manual MA 16 SYSTEM AIR MANIFOLD 03 24 03 CUSTOMER PARTS KEY ITEM PART DESCRIPTION QTY ITEMS SOLD SEPARATELY PF SW OBM DAF SWIVEL ADAPTER AG B2 100 AIR GUAGE 100 PF HN O6 NIPPLE PF HP 08 HEX PLUG PF ME 08 MALE ELBOW NOR O6 AIR REGULATOR MA 2001 MANIFOLD HA 0666 3 AIR HOSE 06 AIR FILTER BV BFBF LP REL 3 8 BALL VALVE PF HN 08 04 NIPPLE MPM 2585 ELBOW MPM 2052 30 TUBE PF RB 08 04 BLISHING PF HN 08 0B NIPPLE NOR OB RK REGULATOR REPAIR KIT NOF O6 K 1 SIGHT GLASS KIT FOR NOF 06 NOF D6 B FILTER ELEMENT FOR NOF 06 CO 4 LJ nJ OPTIONAL MOD 10
19. Slowly increase the pump pressure in 5psi 1 2 bar increments and check spray fan Air Assist pressure is too low Slowly Increase Air Assist pressure as needed Pump has short travel stuttering near top or bottom of stroke Valve block is not shifting all the way or shifting before completing a full stroke Check air supply to shift block it should be 90 100psi 6 7bar Replace Actuator Valve MPM 2589 or Valve VPRO 2003 as needed MagnumVenusPlastech Rev 09 2012 Page 25 Mini Pro Gel Coater Operations Manual Basic Troubleshooting for AT Guns Problem Possible Cause s Recommended Solution Air leaking from exhaust port on back handle while trigger is OFF position O ring material worn or cut O rings on catalyst piston worn or cut O rings on trigger valve worn or cut Replace O rings Air leaking from exhaust port on back of handle while trigger in OFF or ON position O rings on trigger valve worn or cut O rings on catalyst valve and or material piston worn or nicked Replace O rings Catalyst leaking from catalyst tip while gun is sitting not being triggered O rings on catalyst valve worn or cut Replace O rings Catalyst leaks from week hole on catalyst side of gun O rings on catalyst valve worn or cut Replace O rings Catalyst leaks from week hole on catalyst side of gun O rin
20. The combustibility dangers of the cured laminate accumulations of over spray and laminate sandings 6 The toxicity dangers of all the chemicals used in laminating operations with respect to ingestion inhalation and skin and eye hazards MagnumVenusPlastech Rev 09 2012 Page 7 Mini Pro Gel Coater Operations Manual 2 2 Catalyst Methyl Ethyl Ketone Peroxide MEKP is among the more hazardous materials found in commercial channels The safe handling of the unstable reactive chemicals presents a definite challenge to the plastics industry The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage transportation handling processing and disposal MEKP is a single chemical Various polymeric forms may exist which are more or less hazardous with respect to each other These differences may arise not only from different molecular structures all are nevertheless called MEKP and from possible trace impurities left from the manufacture of the chemicals but may also arise by contamination of MEKP with other materials in its storage or use Even a small amount of contamination with acetone for instance may produce an extremely shock sensitive and explosive compound Contamination with promoters or materials containing promoters such as laminate sandings or with any readily oxi
21. arm 9 Close the gun MagnumVenusPlastech Rev 09 2012 Page 28 Mini Pro Gel Coater Operations Manual Optional Process The air bubble can be quickly removed if the PRO RECIRC option is installed on this equipment Simply open the recirculation valve and hand prime catalyst back to the catalyst jug until there is a bubble free flow then return the recirculation valve back to flow out the gun MagnumVenusPlastech Rev 09 2012 Page 29 Mini Pro Gel Coater Operations Manual Pump Repair Procedures The Mini Pro Gel Coat system uses the VPRO 45220 Pump assembly for repair and maintenance instructions reference the manual VPRO 45220 Series Pump Manual MagnumVenusPlastech Rev 09 2012 Page 30 Mini Pro Gel Coater Operations Manual Catalyst Pump Repair The Mini Pro Gel Coat system uses the PCP 2000 Catalyst Pump assembly for repair and maintenance instructions reference the manual PCP 2000 Catalyst Pump Manual Low Range MagnumVenusPlastech Rev 09 2012 Page 31 Mini Pro Gel Coater Operations Manual Gel Coat Gun Repair The Mini Pro Gel Coat system comes standard the ATG 3500 Gel Coat Assembly for repair and maintenance instructions reference the manual ATG 3500 Repair and Maintenance Manual The EMG 1000 Gel Coat gun is an option on the Mini Pro Gel Coat system for detailed repair and Maintenance instructions reference the manual EMG 1000 amp EMG 1500 Gel Coat
22. at is why you must know the chemicals and treatment before an accident occurs Treatment for swallowing a chemical frequently depends upon the nature of the chemical NOTE Refer to your System User Manual for complete and detailed operating instructions and service information MagnumVenusPlastech Rev 09 2012 Page 12 Mini Pro Gel Coater Operations Manual 3 0 Equipment Safety WARNING Magnum Venus Plastech suggests that personal safety equipment such as EYE GOGGLES GLOVES EAR PROTECTION and RESPIRATORS be worn when servicing or operating this equipment Ear protection should be worn when operating a fiberglass chopper to protect against hearing loss since noise levels can be as high as 116 dB decibels This equipment should only be operated or serviced by technically trained personnel WARNING Never place fingers hands or any body part near or directly in front of the spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PISTOL 3 1 Emergency Stop Procedures The following steps should be followed in order to stop the machinery in an emergency situation 1 The ball valve located where the air enters the power head of the resin pump should be moved to the OFF or closed position To do this simply rotate the lever on the
23. ball valve 90 degrees Doing this will cause all the system air to bleed out of the system in a matter of a few seconds making the system incapable of operating NOTE Step 2 is a precautionary step and should be followed whenever the above mentioned ball valve is activated to the stop mode Failure to do so can damage the regulators and components on reactivating to the ON position 2 Turn all system regulators to the OFF position counter clockwise position NOTE Verify that the Catalyst relief line located on the catalyst manifold and the resin return line located on the resin filter are secured relieving catalyst and resin fluid pressure 3 Catalyst pressure in the catalyst pump can be eliminated by rotating the ball valve on the catalyst manifold 90 degrees to the open or on position Note The open or on position is when the ball valve handle is parallel in line with the ball valve body The closed or off position is when the ball valve handle is perpendicular across the ball valve body A 4 Resin pressure in the resin pump can be eliminated by rotating the ball valve on the resin filter 90 degrees to the open or on position Place a container under the ball valve to catch any resin that is ejected out of the valve MagnumVenusPlastech Rev 09 2012 Page 13 Mini Pro Gel Coater Operations Manual 3 2 Grounding Grounding an object means providing an adequate path
24. d upon the most recent information available at the time of order Dates may be adjusted upon receipt of subsequent information or modification of order Seller will ship prior to the delivery date if possible but not without Buyer s consent on Advanced Equipment sales All contract dates and timelines begin upon receipt at MVP of customer purchase order signed Terms and Conditions of Sale if applicable and down payment per quotation if applicable If shipments are delayed by the Buyer or because the Buyer s account is in arrears payments shall become due on the date when the Seller is prepared to make shipment Products held by the Seller for the Buyer shall be at the risk and expense of the Buyer Damages defects or shortages must be communicated immediately to MVP Discrepancy in pricing and or quantities on invoices must be reported within 30 days of the invoice date Claims made 30 days or more following the invoice date will not be honored Permission to return items must be requested and granted in advance No credit will be given if items are returned prior to requesting and receiving permission All returns are subject to a restocking fee The standard 15 charges may be increased or decreased depending on the reason for the return Special ordered items may not be returned Seller warrants that the mechanical operation of the goods as specified shall be free from faults in respect to materials and workmanship for a period of
25. dizing material such as brass or iron will cause exothermic redox reactions which can become explosive in nature Heat applied to MEKP or heat build up from contamination reactions can cause it to reach what is called its Self Accelerating Decomposition Temperature SADT Researchers have reported measuring pressure rates of rise well in excess of 100 000 psi per second when certain MEKP s reach their SADT For comparison the highest pressure rate of rise listed in NFPA Bulletin NO 68 Explosion Venting is 12 000 psi per second for an explosion of 1296 acetylene and air The maximum value listed for a hydrogen explosion is 10 000 psi per second Some forms of MEKP if allowed to reach their SADT will burst even an open topped container This suggests that it is not possible to design a relief valve to vent this order of magnitude of pressure rate of rise The user should be aware that any closed container be it a pressure vessel surge chamber or pressure accumulator could explode under certain conditions There is no engineering substitute for care by the user in handling organic peroxide catalysts If at any time the pressure relieve valve on top of the catalyst tank should vent the area should be evacuated at once and the fire department called The venting could be the first indication of a heat and therefore pressure build up that could eventually lead to an explosion Moreover if a catalyst tank is sufficiently full when the
26. duced are designed so that catalyst diluents are not required Magnum Venus Plastech therefore recommends that diluents not be used This avoids the possible contamination which could lead to an explosion due to the handling and mixing of MEKP and diluents In addition it eliminates any problems from the diluents being contaminated through rust particles in drums poor quality control on the part of the diluents suppliers or any other reason If however diluents are absolutely required contact your catalyst supplier and follow his instructions explicitly Preferable the supplier should premix the catalyst to prevent possible on the job contamination while mixing WARNING If diluents are not used it should be remembered that catalyst spillage gun hose and packing leaks are potentially more hazardous since each drop contains a higher concentration of catalyst and therefore will react quicker with over spray and the leak 2 5 Cured Laminate Overspray and Laminate Sandings Accumulation A Remove all accumulations of overspray FRP sandings etc from the building as they occur If this waste is allowed to build up spillage of catalyst is more likely to start a fire in addition the fire would burn hotter and longer B Floor coverings if used should be non combustible C Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product over sprayed chop or resin FRP sandings or any other material with MEKP
27. gs on catalyst valve worn or cut Replace O rings No catalyst is coming from gun Catalyst air piston is not actuating Check for clogged catalyst air passages small holes underneath back cylinder Note There is more than one passageway from holes Plugged catalyst restrictor allen screw with orifice located in front of catalyst valve Clean and clear orifice in front of catalyst valve Plugged catalyst passageway in head of gun or catalyst tips Inspect clean and clear passageways No catalyst flow to gun See Slave Pump Trouble Shooting Material is leaking from tip front of gun Loose diffuser seat Tighten diffuser seat 1 4 to 1 2 turn at a time until snug and then one more 1 4 turn Over tightening of diffuser seat may cause bindng of material needle Worn needle and or seat Replace worn items O ring on diffuser nicked or cut Replace O rings T MagnumVenusPlastech Rev 09 2012 Page 26 Mini Pro Gel Coater Operations Manual Loose diffuser seat Adjust until snug Then Material is leaking from turn 1 4 to 1 2 turn more weep hole on material side Don t over tighten of gun Worn needle packing Replace packing and adjust as indicated above MagnumVenusPlastech Rev 09 2012 Page 27 Mini Pro Gel Coater Operations Manual Catalyst Pump Air Lock DANGER Fluids under High Pressure Before performi
28. l property damage Cleaning agents coatings paints etc may contain Halogenated Hydrocarbon Solvents Some Magnum Venus Plastech spray equipment includes aluminum or galvanized components and will be affected by Halogenated Hydrocarbon Solvents A There are three key elements to the Halogenated Hydrocarbon HHC solvent hazard a The presence of HHC solvents 1 1 1 Trichloroethane and Methylene Chloride are the most common of these solvents However other HHC solvents are suspect if used either as part of paint or adhesives formulation or for clean up flushing b Aluminum or Galvanized Parts Most handling equipment contains these elements In contact with these metals HHC solvents could generate a corrosive reaction of a catalytic nature b Equipment capable of withstanding pressure When HHC solvent contacts aluminum or galvanized parts inside a closed container such as a pump spray gun or fluid handling system the chemical reaction can over time result in a build up of heat and pressure which can reach explosive proportions MagnumVenusPlastech Rev 09 2012 Page 9 Mini Pro Gel Coater Operations Manual When all three elements are present the result can be an extremely violent explosion The reaction can be sustained with very little aluminum or galvanized metal any amount of aluminum is too much A The reaction is unpredictable Prior use of an HHC solvent without incident corrosion or explosion does NOT mean
29. lation and all rights of the parties are governed by the laws of the state of Florida Venue with regard to any litigation shall be in Pinellas County Florida The parties agree to waive all rights to trial by jury as to any and all disputes e The goods remain the property of the Seller until full payment is received e Sale of equipment is subject to application and issuance of proper US Government export license and regulations if applicable e Installation of equipment is responsibility of Buyer and Seller with cost responsibility and number of days provided as detailed in original customer Quotation Seller will provide installation supervision personnel within 30 days of customer request If installation is delayed by the Buyer more than six months from the date of shipment or if customer facility or material parts are not prepared for installation seller will invoice full installation costs up to 1 250 a day plus expenses for each MVP installation technician on site Seller has the option to waive this fee at its discretion e Parties shall be excused for delays caused by embargoes acts of civil or military authorities Acts of God or other circumstances beyond the reasonable control of the parties Notification of such delays must be made in writing within ten days of occurrence e Our agreement supersedes any previous agreement and applies in full MagnumVenusPlastech Rev 09 2012 Page 5 Mini Pro Gel Coater Operations
30. nect the Feed tube from the Catalyst jug outlet to the Catalyst pump Inlet 6 Connect the Catalyst hose to the Catalyst Pump outlet 7 Install Gel coat Filter amp Surge Chamber assembly 8 Attach the Gel coat hose to the Outlet of the Filter assembly 9 Install Air Manifold connect Air Hose to Powerhead amp Air Supply to the Shift Block 10 Attach hose fittings catalyst atomizing hose and gun air supply 11 Attach Pickup Hoses to the Inlet of the pump 12 Double check all hose fittings and connections are tight Note it is important to be sure all fittings and connections are tight to prevent catalyst or gel coat leaking MagnumVenusPlastech Rev 09 2012 Page 17 Mini Pro Gel Coater Operations Manual Priming the Unit Priming Gel Coat to Gun NOTE The resin pump was tested using oil It may require up to 1 2 gallon 1 2 liters of gel coat to be run through the unit to purge any remaining oil from the system 1 2 Fill the Reservoir cavity 1 2 full with TSL oil or suitable oil Insert the gel coat suction wand into container of gel coat Clamp or tape the return hose coming from the bottom of the in line filter to the pickup wand and into the drum pail Remove the Catalyst Tip and Spray Tip from the front of the gel coat gun Position the gun over an appropriate container and with the gun trigger locked in the open position slowly increase pump regulator pressure until pump is running at a slo
31. ng any service and repair on this equipment be sure to relieve air and fluid pressure DANGER Always wear appropriate eye protection when working with this equipment WARNING When removing hoses place a rag over the hose before loosening it What is an Air Lock An air lock is an air bubble in the catalyst pump that prevents catalyst flow The piston body moves inside the bubble of air instead of pumping catalyst If you have determined that there is an air lock in your catalyst pump follow the procedures in this section 1 Relieve line pressure from the catalyst pump by locking the gun open over an empty bucket Leave the gun in this position WARNING Relieve pressure from the catalyst pump before continuing 2 Remove the catalyst hose from the nipple on the catalyst pump WARNING When removing hose place a rag over the hose and fitting before loosening it 3 Remove the quick pin from the catalyst bearing block and upper slave arm 4 Tilt the pump toward the resin pump to release the bubble NOTE If the bubble does not appear in the inlet tube remove the lower quick pin and turn the pump upside down 5 Slowly hand pump the catalyst into a suitable container until catalyst spurts from the nipple an equal amount on both the upstroke and down stroke 6 Reconnect the catalyst hose to the nipple 7 Hand pump the catalyst pump until catalyst comes out through the gun 8 Install the pump and quick pin into the slave
32. numVenusPlastech Rev 09 2012 Page 23 Mini Pro Gel Coater Operations Manual PROBLEM CAUSE SOLUTION Pump dives on down stroke Foot valve spring retainer or foot valve ball damaged or dirty Clean or replace foot valve spring retainer and foot valve ball Be sure to lubricate ball thoroughly with Red Grease See Chapter 6 Pro Pump Pick up wand assembly not tight Tighten or seal joints of pick up wand Air in material Agitate material to remove air Low output on upstroke Piston cups piston ball or pump cylinder worn Inspect the piston cups piston ball and pump cylinder Clean and replace any damaged components See Chapter 6 Pro Pump Pump does not run Silencers on valve block plugged Turn off air to pump and unscrew silencers Clean silencers and re install Actuator valve or socket cap screw at shift block broken Replace the broken cartridge valve or socket cap screw See Chapter 6 Pro Pump Pro pump or hose plugged Danger To prevent injury always relieve fluid pressure before attempting to remove components Disassemble and clean Pro pump Replace any worn parts Replace hose as required Air not connected Check that air hose is connected at manifold and regulator is at 20 psi or more Air restricted Straighten any kinks in air hoses Material in oil reservoir Packing worn Replace packing set
33. of pump Prevent by connecting catalyst pump vertically Catalyst pump check valve blocked or stuck Disassemble check valve and remove blockage Catalyst hose plugged Danger In the next steps you will be dealing with fluids under high pressure Catalyst will be sprayed from the hose fitting when the fitting is loosened Follow safety instructions read the Safety amp Warning section in the beginning of this manual Relieve pressure from the system Replace the catalyst hose with new one Resin or gel coat too cold Consult your materials supplier for proper temperature Maintain a draft free environment of about 70 degrees F An auxiliary heat source may be required to reduce gel time Piston cups piston ball or pump cylinder worn Inspect the piston cups piston ball and pump cylinder Clean and replace any damaged components See Chapter 6 Pro Pump Low output on upstroke of Pro pump Screen of pump pick up wand blocked Unscrew screen from hose and clean No fan constant low output or fast cure Resin filter blocked Disassemble and clean filter body and screen with solvent MagnumVenusPlastech Rev 09 2012 Page 22 Mini Pro Gel Coater Operations Manual PROBLEM CAUSE SOLUTION Resin hose plugged Flush hose with solvent If material is hard replace hose Danger To prevent injury always relieve
34. of spilled MEKP personal safety equipment gloves and eye protection must be worn Firefighting equipment should be at hand and ready F Avoid spillage which can heat up to the point of self ignition G Repair any leaks discovered in the catalyst system immediately and clean up the leaked catalyst at once in accordance with the catalyst manufacturer s instructions H Use only original equipment or equivalent parts from Magnum Venus Plastech in the catalyst system i e hoses fitting etc because a dangerous chemical reaction may result between substituted parts and MEKP Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries should never be returned to the supply tank such catalyst should be diluted with copious quantities of clean water and disposed of in accordance with the catalyst manufacturer s instructions The extent to which the user is successful in accomplishing these ends and any additional recommendations by the catalyst manufacturer determines largely the safety that will be present in his operation 2 3 Clean Up Solvents and Resin Diluents WARNING A hazardous situation may be present in your pressurized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed pressurized fluid system pump heaters filters valves spray guns tanks etc The explosion could cause serious injury death and or substantia
35. pment operators follow correct procedures Magnum Venus Plastech hopes that this manual is helpful to the user and recommends that the precautions in this manual be included in any such program Magnum Venus Plastech recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual Magnum Venus Plastech recommends that the user consult the regulations established under the Occupational Safety amp Health Act OSHA particularly the following sections 1910 94 Pertaining to Ventilation 1910 106 Pertaining to flammable liquids 1910 107 Pertaining to spray finishing operations particularly Paragraph m Organic Peroxides and Dual Component Coatings Other standards and recognized authorities to consult are the National Fire Protection Association NFPA bulletins as follows NFPA No 33 Chapter 14 Organic Peroxides and Dual Component Materials NFPA No 63 Dust Explosion Prevention NFPA No 70 National Electrical Code NFPA No 77 Static Electricity NFPA No 91 Blower and Exhaust System NFPA No 654 Plastics Industry Dust Hazards MagnumVenusPlastech Rev 09 2012 Page 6 Mini Pro Gel Coater Operations Manual Type of Fire Extinguishing equipment recommended Fire Extinguisher code ABC rating number 4a60bc Extinguishing Media Foam Carbon Dioxide Dry Chemical Water Fog Copies of the above bulletins are available at a nominal charge from National Fire Protection
36. t apply to your application NEVER USE HARD MATERIALS SUCH AS WIRE PINS ETC TO CLEAR A PLUGGED GUN HARD MATERIALS CAN CAUSE PERMANENT DAMAGE DAB WITH A BRISTLE BRUSH BLOW BACKWARDS WITH AIR UNTIL CLEAR WHILE WEARING A PROTECTIVE EYE SHIELD REPEAT AS MANY TIMES AS NECESSARY DO NOT PERFORM ANY MAINTENANCE OR REPAIRS UNTIL YOU HAVE FOLLOWED THE PRECAUTIONS STATED ABOVE IF YOU AS AN EQUIPMENT OPERATOR OR SUPERVISOR DO NOT FEEL THAT YOU HAVE BEEN ADEQUATELY TRAINED OR INSTRUCTED AND THAT YOU LACK THE TECHNICAL KNOWLEDGE TO OPERATE OR PERFORM MAINTENANCE ON A PIECE OF MAGNUM VENUS PLASTECH EQUIPMENT PLEASE CALL MAGNUM VENUS PLASTECH BEFORE OPERATING OR PERFORMING MAINTENANCE ON THE EQUIPMENT IF YOU HAVE ANY QUESTIONS REGARDING THE ABOVE PRECAUTIONS OR ANY SERVICE OR OPERATION PRECEDURES CALL YOUR MAGNUM VENUS PLASTECH DISTRIBUTOR OR MAGNUM VENUS PLASTECH NOTICE All statements information and data given herein are believed to be accurate and reliable but are presented without guaranty warranty or responsibility of any kind express or implied The user should not assume that all safety measures are indicated or that other measures are not required DANGER Contaminated catalyst may cause Fire or Explosion Before working on the catalyst pump or catalyst accumulator wash hands and tools thoroughly Be sure work area is free of dirt grease or resin Clean catalyst system components with clean water only DANGER Eye skin and respiration
37. t pump away from the gel coat pump towards the connecting arm when it is unpinned from the slave arms this will help prevent damage to the catalyst pump 5 6 T 8 Replace the Pin into the Slave arm and catalyst pump bearing block Check atomizing air pressure adjust as necessary It should be set to 18 25psi 1 1 5 bar Lubricate the spray tip o rings stud o rings and gun front threads Install nozzle catalyst tip and retaining ring onto the front of the gun Daily Shut Down 1 2 Wipe the face of the nozzle and catalyst tip with solvent Turn off the main air ball valve at the air manifold Remove the Catalyst tip and Spray tip clean with solvent Wipe the gun face clean with a rag or brush clean with solvent Hang the gun with the gun block exit holes facing downwards MagnumVenusPlastech Rev 09 2012 Page 20 Mini Pro Gel Coater Operations Manual Trouble Shooting Guide The most common problems with the equipment are diagnosed by analyzing the cured part NOTE Many problems are the direct result of a failure to maintain the equipment PROBLEM CAUSE SOLUTION Slow cure during upstroke S S Ball in catalyst pump piston body not seating Clean ball and inspect seat Replace ball piston seal or piston body if questionable Slow cure during down stroke S S Ball in catalyst pump inlet body not seating Clean ball and inspect seat Replace ball or
38. that such use is safe These solvents can be dangerous alone as a clean up or flushing agent or when used as a component or a coating material There is no known inhibitor that is effective under all circumstances Furthermore the mixing of HHC solvents with other materials or solvents such as MEKP alcohol and toluene may render the inhibitors ineffective B The use of reclaimed solvents is particularly hazardous Reclaimers may not add any inhibitors Also the possible presence of water in reclaimed solvents could feed the reaction C Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction Such coatings can be worn cracked scratched or too thin to prevent contact There is no known way to make oxide coatings or to employ aluminum alloys which will safely prevent the chemical reaction under all circumstances D Several solvent suppliers have recently begun promoting HHC solvents for use in coating systems The increasing use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans as Volatile Organic Compounds VOC s their low flammability hazard and their not being classified as toxic or carcinogenic substances HHC solvents very desirable many respects WARNING Do not use Halogenated Hydrocarbon solvents in pressurized fluid systems having aluminum or galvanized wetted parts NOTE Magnum Venus Plastech is aware of NO stabilizers a
39. uld be used in handling the chemicals resins catalyst and solvents used in polyester systems Such chemicals should be treated as if they hurt your skin and eyes and as if they are poison to your body For this reason Magnum Venus Plastech recommends the use of protective clothing and eye wear in using polyester systems However users should be prepared in the event of such an injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals have WARNING Contact your doctor immediately in the event of any injury and give him the information you have collected If your information includes first aid instructions administer first aid immediately while you are contacting your doctor Fast treatment of the outer skin and eyes that contact such chemicals generally includes immediate and thorough washing of the exposed skin and immediate and continuous flushing of the eyes with lots of clean water for at least 15 minutes or more These general instructions of first aid treatment however may be incorrect for some chemicals th
40. vailable to prevent Halogenated Hydrocarbon solvents from reaction under all conditions with aluminum components in closed fluid system TAKE IMMEDIATE ACTION Halogenated Hydrocarbon solvents are dangerous when used with aluminum components in a closed fluid system A Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocarbon Solvents B Magnum Venus Plastech recommends that you contact your solvent supplier regarding the best non flammable clean up solvent with the heat toxicity for your application C If however you find it necessary to use flammable solvents they must be kept in approved electrically grounded containers D Bulk solvent should be stored in a well ventilated separate building 50 feet away from your main plant E You should allow only enough solvent for one day s use in your laminating area F NO SMOKING signs must be posted and observed in all areas of storage or where solvents and other flammable materials are used MagnumVenusPlastech Rev 09 2012 Page 10 Mini Pro Gel Coater Operations Manual G Adequate ventilation as covered in OSHA Section 1910 94 and NFPA No 91 is important wherever solvents are stored or used to minimize confine and exhaust the solvent vapors H Solvents should be handled in accordance with OSHA Section 1910 106 and 1910 107 2 4 Catalyst Diluents Magnum Venus Plastech spray up and gel coat systems currently pro
41. w but steady rate Allow pump to run until a steady stream of gel coat is being dispensed Close the gun and brush the front of the gun head clean with solvent Slowly increase gel coat pump pressure to 100 psi 7 bar Allow the unit to set under static load for 15 to 30 minutes to seat the resin packing set Turn the pump regulator to zero Slowly open the ball valve at the bottom of the resin filter to drain the fluid pressure MagnumVenusPlastech Rev 09 2012 Page 18 Mini Pro Gel Coater Operations Manual Priming Catalyst to Gun 1 Remove the catalyst tip and spray tip from the front of the gun 2 Tighten the catalyst packing nut 1 8 to 1 4 of a turn to snug packing 3 Fill the catalyst jug 74 full purge the air out of the catalyst feed line by slightly tilting the catalyst jug toward the outlet fitting 4 Lock or hold the gun trigger in the open position over an appropriate container 5 Remove the pin from the slave arm and catalyst pump bearing block Use the priming knob to hand prime catalyst out to the gun until a steady stream is achieved 6 Release the trigger to close the gun 7 Replace the pin into the slave arm and catalyst pump bearing block be sure that the catalyst pump is positioned at the correct percentage Note Be sure the top and bottom of the catalyst pump are set to the same percentage on the slave arm to prevent damage to the catalyst pump Gun Set Up amp Spray Note Use a little

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