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Patriot Megaject Innovator II Operation Manual

1. ABNORMAL CONDITIONS OBSERVED AND CORRECTED Abnormal Condition when corrected OPERATORS NAME DATE SIGN OFF WHEN START UP CHECKS ARE COMPLETED D MagnumVenusProducts Rev 04 2014 Page 36 Patriot Megaject Innovator Operations Manual DAILY SHUT DOWN CHECKLIST PATRIOT MEGAJECT INNOVATOR ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN AND MUST BE TICKED OFF AS COMPLETED THIS SEQUENCE FOLLOWS ON FROM DAILY START UP CHECKLIST ACTIVITY ACTIVITY TICK WHEN NO COMPLETED Priority Put on Respirator as specified for spray painting Protective Clothing Eye Protection and PVC Gloves 1 Close TAS Turbo Autosprue or pinch injection hose to close the mould Press the Reset button on the Counter to reset the counter Flush the injection head and hose or TAS Turbo Autosprue Disconnect the injection hose or TAS from the injection head Turn off the main air slide valve at the back of the unit On ABNORMAL CONDITIONS OBSERVED AND CORRECTED Abnormal Condition when corrected OPERATORS NAME DATE SIGN OFF WHEN SHUT DOWN CHECKS ARE COMPLETED D MagnumVenusProducts Rev 04 2014 Page 37 Patriot Megaject Innovator Il Operations Manual D Fluid Section Maintenance The standard Megaject Innovator uses the Patriot 1 1 4 Fluid Section Assembly PAT 5 12270 for detailed instructions f
2. 74 Patriot Megaject Innovator Operations Manual a Per mom n MagnumVenusProducts Rev 04 2014 Page 75 MagnumVenusProducts Patriot Megaject Innovator Operations Manual 04 2014 76 Patriot Megaject Innovator Operations Manual D Revision Information Revision Description Rev 04 2014 Document was created updated to reflect the new Innovator Il Control Box INV CB 100 configuration D MagnumVenusProducts Rev 04 2014 Page 77 Patriot Megaject Innovator Operations Manual MagnumVenusProducts CORPORATE HEADQUARTERS and MANUFACTURING 200A Perimeter Park Road Knoxville TN 37922 USA Tel 1 865 321 8809 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 E mail info mvpind com www mvpind com Included with this operations manual are the following component manuals PATRIOT POWERHEAD MANUAL PAT PH 3250 PATRIOT 1 1 4 FLUID SECTION MANUAL PAT LS 12270 PATRIOT CATALYST PUMP MANUAL PAT CP 0550 INNOVATOR Il MANUAL INV CB 100 Control Box MagnumVenusProducts Rev 04 2014 Page 78
3. 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 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
4. the restrictor controls how quickly the pressure builds within the circuit and therefore the time and speed in which the pump restarts The slower the flow of air through the restrictor the longer the pump will take to restart NOTE If this restrictor is fully wound in air flow will be blocked and the pump will not start Conversely if too higher flow of air is supplied to the circuit safe and correct operation of the machine cannot be guaranteed This flow control is set at factory and should not be adjusted CAT OPV ADJUSTMENT Fig 14 D MagnumVenusProducts Rev 04 2014 Page 32 Patriot Megaject Innovator Il Operations Manual Qi Operating Procedures 1 Pre Start Check List for Patriot Megaject Innovator 2 First Time Start Up for Patriot Megaject Innovator 3 Daily Start Up for Patriot Megaject Innovator 4 Daily Shut Down for Patriot Megaject Innovator The Check Lists are following MagnumVenusProducts Rev 04 2014 Page 33 Patriot Megaject Innovator Operations Manual PRE START CHECKLIST PATRIOT MEGAJECT INNOVATOR ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN AND MUST BE TICKED OFF AS COMPLETED ACTIVIT ACTIVITY COMPLETEE Y NO Priority Put on Respirator as specified for spray painting Protective Clothing Eye Protection and PVC Gloves Have all Tools and materials available for pre start checks Connect the 6mm air line to the to the air supply Slide the air valve on the back
5. 1 2 per month 18 per year or the maximum lawful rate whichever is less In the event of non payment Buyer agrees to pay Seller s reasonable attorney fees and court costs if any incurred by Seller to collect payment and all applicable interest charges Seller may apply payments to any outstanding invoices unless Buyer provides specific payment direction 4 TITLE AND RISK OF LOSS OR DAMAGE As to Goods delivered directly by Seller title passes upon delivery at the place Buyer receives possession and thereafter all risk of loss or damage shall be on Buyer All other sales are F O B point of shipment and Buyer takes title and assumes responsibility for risk of loss or damage at the point of shipment for such sales Claims for Goods damaged in transit are Buyer s sole responsibility when not delivered directly by Seller 5 QUOTATIONS All quotations expire thirty 30 days from the date of the quotation unless otherwise noted on the quotation This time limit applies even if Buyer uses the quotation to submit a job or project bid to any other party 6 ASSIGNMENT The Buyer s rights and responsibilities under any purchase order or these Terms amp Conditions shall not be assigned by Buyer without the express written consent of the Seller 7 RETURN OF GOODS 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 Subject to the foregoing Se
6. Foot Valve 4481 It is important to keep the inside of the flush tank clean and free of dirt debris and glass fiber as these can prevent the Pump Foot valve from sealing properly MagnumVenusProducts Rev 04 2014 Page 51 Patriot Megaject Innovator Operations Manual Qi Troubleshooting W ill not start inject or has stopped during injection sequenc gt Check incoming air supply Apply correct pressure and CFM to unit Stop button has been pushed Remote stop button pushed Restart injection sequence PPVS signal not being received Install jumper between PPVS supply and PPVS signal if no PPVS is being used Check signal coming from PPVS if installed Internal PPVS circuit check Check line 67 for leaks Check V08 output 41 for signal Should be on MPG circuit is engaged Check for blockage on resin delivery lines Check FC 03 for proper adjustment Check for air leaks on MPG valve and connection 1B 11 26 Internal MPG circuit check Check 26 for leaks Check 67 for leaks Check V14 output 62 for signal Should be on Check V15 output 05 for signal Should be on Stop sequence has been imitated Internal Stop sequence circuit check Check 16 for signal Should be off Remote stop button has malfunctioned Check 15 for signal Should be off CE NORM guard valve has malfunctioned Check 37 for signal Should off Stop pushbutt
7. Innovator uses the Patriot pumping system for accurate metering This manual provides information needed to properly operate and perform simple maintenance and repair on this equipment Step by step operations procedures are provided This manual includes Installation Start up and Shut Down instructions Step by step assembly and disassembly procedures are included for each component Please read this manual carefully Follow the steps in the order given otherwise you may damage the equipment or injure yourself Component Assemblies The Patriot Megaject Innovator consists of a number of components these components will have their own detailed manuals and drawings For complete repair and maintenance instruction please reference these manual Q Patriot Powerhead Manual PAT PH 3250 Q Patriot 1 1 4 Fluid Section Manual PAT LS 12270 RTM Patriot Metering Pump Manual PAT CP 0550 Innovator Manual Control Box INV CB 100 Megaject Injection Head ASSY 0427 MagnumVenusProducts Rev 04 2014 Page 15 Patriot Megaject Innovator Il Operations Manual Unit Overview CONTROL INJECTION GUN CATALYST JUG CATALYST OPV OVERPRESSURE VALVE 4 POWERHEAD SLAVE ARM CATALYST PUMP Fig 1 D MagnumVenusProducts Rev 04 2014 Page 16 Patriot Megaject Innovator Il Operations Manual CATALYST JUG amp RECIRCULATION NN SIGHT GLASS AIR FILTER CONNECT MAI
8. SECTION ASSY PAT SD 3100 PATRIOT SLAVE DRIVE ASSEMBLY PAT LS 12270 R SK SEAL KIT RTM SSB 0550 CATALYST PUMP ASSEMBLY PAT CP 0550 SK SEAL KIT PATRIOT CATALYST PUMP PAT CP INV INNOVATOR CATALYST JUG PAT PH 3250 3 1 4 PATRIOT POWERHEAD 2 STROKE ASSEMBLY PAT PH 3250 SK SEAL KIT 3 1 4 PATRIOT POWERHEAD 82004 01 SP4 PUMP ASSEMBLY 82009 01 MPG VALVE ASSEMBLY 22021 06 CATALYST OVERPRESSURE VALVE ASSEMBLY 83018 01 CAV CATALYST AUTO VALVE 83022 01 RAV RESIN AUTO VALVE ASSY 0424 INV CB 100 P PNEUMATIC DIAGRAMS MagnumVenusProducts Rev 04 2014 Page 54 Patriot Megaject Innovator Il Operations Manual 515 ME e Pd e _ INSTALLS a LEP DOWN 5 21 23 DET 8 S LB L e 2 a REV A 04 24 09 BT2 MagnumVenusProducts Rev 04 2014 Page 55 Patriot Megaject Innovator Il Operations Manual 2 PARIS 100 1 BODY 3 3 JPAT 5 1008 1 FLUID ROD 1 1 4 4 JPAT 5 1000 11 5 PAT L5 1007 3 916 VLS 2427 REPAIR KITS PART No DESCRIPTION PAT LS 12270 R SK SEAL KIT NOTE ASTERISKS DENOTE PARTS USED IN SEAL KIT MAGNUM VENUS PLASTECH PATRIOT RTM FLUID SECTION ASSY PAT LS 12270 RTM REV A 04 24 09 2 Qi MagnumVenusProducts Rev 04
9. 2014 Page 56 Patriot Megaject Innovator Il Operations Manual MAGNUM VENUS PLASTECH SLAVE DRIVE ASSEMBLY PAT SD 3100 REV 02 25 13 D MagnumVenusProducts Rev 04 2014 Page 57 Patriot Megaject Innovator Operations Manual ITEM PART NUMBER QTY DESCRIPTION 1 50 3101 1 55 2 50 3102 1 SLAVE ARM 3 PAT 5D 3103 CLEVIS BLOCK 4 5 050 20 4 SOCKET HEAD CAP SCREW 5 1 03 20 1 ROLL PIN 5 02 08 1 ROLL PIN 7 0 04 16 55 1 QUICK FIN 102966 _ 2 AIRCRAFT BOLT 10 50 3108 1 11 50 3105 1 KNOB 42 50 3107 1 ALIGNMENT PLATE 13 F HB 04C 16 2 HEXBOLT 714 FHC 2 HEXNU 15 04 19 1 AIRCRAFT BOLT 16 F 58 06 20 1 SHOULDER BOLT 17 F LN 05C 11 Lock NUT 18 _ 50 3109 CLEVIS BLOCK 1 19 F LN O4F 3 LOCK NUT Er c 50 313 0 1 MAGNUM VENUS PLASTECH SLAVE DRIVE ASSEMBLY PAT SD 3100 REV 02 25 13 D MagnumVenusProducts Rev 04 2014 Page 58 Patriot Megaject Innovator Operations Manual PAT LS 12270 R SK PATRIOT SEAL KIT RTM lt EPAIR KIT 1 25 FLUID SECTION 2 gt A 7 1 PC 5 1014 SEAL 55 1 PES PAT LS 1016 SEAL ASSY 1 PC f O E 035 O RING MagnumVenusProducts Rev 04 201
10. 27 210 Ean 05030504 A x H 0747 093 O RING 2 e vom Assy 0425 CAV Assembly Assy 0447 CAV Assembly 0493 0496 BOOY See drawing 83018 XX See drawing 83013 XX 958910603 SPRING _ 1489 0489 SEAL Sr miens SEAL 0490 0490 RETANER Fig 15 D MagnumVenusProducts Rev 04 2014 Page 42 Patriot Megaject Innovator Operations Manual Catalyst Auto Valve Assembly CAV see figure 16 amp 17 Assy 0425 CAV Assembly See drawing 83018 XX for correct part numbers fay est 6150 48 A E E E 1 Es 7 E 1 M i d r H E P 6150 i s Q gt E 1 hr T 7 14 Tuer iss Jur 1 Fig 16 Servicing Notes see figure 16 amp 17 The catalyst auto valve needs little servicing as all components are suitable for both MEKP and recommended AAP catalysts The movement of the spool as indicated from the aluminium air cylinder end should be between 4 and 5 mm Any less or greater can cause Catalyst to flow incorrectly so ensure this movement is observed to be correct by measurement using callipers after service and before using the machine in production Take care not to damage or scratch the spool internal body 6369 when O ring 3316 needs replacing The valve should only need servicing if air or catalyst is noted to weep from between the air cylinder 6078 and S
11. 4 Page 59 Patriot Megaject Innovator Il Operations Manual ae MOTE USE BLUE LOCTITE THREADLOCKER WHEN ATTACHING BALL JOINT LINKAGE TO SHAFT ITEM 20 Te INSTALLS LIP DOWN 20 NE 16 3 CRE NOTE USE BLUE LOCTITE pun THREADLOCKER WHEN 10 ATTACHING PISTON SHAFT gt 2 __ 2 ue a up S 15 MAGNUM VENUS PLASTECH PATRIOT CATALYST PUMP PAT CP 0550 REV A 02 22 13 D MagnumVenusProducts Rev 04 2014 Page 60 Patriot Megaject Innovator Il Operations Manual Parts List ae 1 PAT CP 0502 1 BODY 2 PAT CP 0504 BALL JOINT LINKAGE _ GUIDE LOCK NUT SS BALL 27 16 AR EL RS A EE REPAIR KIT PAT CP 0550 SK ASTERISKS DENOTE PARTS IN KIT MAGNUM VENUS PLASTECH PATRIOT CATALYST PUMP PAT CP 0550 REV A 02 22 13 Qi MagnumVenusProducts Rev 04 2014 Page 61 Patriot Megaject Innovator Il Operations Manual 0550 5 SEAL KIT 1 PC 0 5 014 O RING 2 PC 0 5 013 O RING 1 PCS 0 5 010 O RING 1 7304 1 1 PISTON SEAL 1 PC 0507 LEAK SPACER nm 2 PCS PAT CP 0501 CUP SEAL 1 5 4102 8 1 PISTON GUIDE MagnumVenusProducts Rev 04 2014 Page 62 Patriot Megaject Innovator Operations Manual MAGNUM VENUS PLASTECH PATRIOT 2 GALLON CATALYST JUG INNOVATOR PAT CJ INV REV B 01 27 2014 SHEET 1 4 Magn
12. ES ITEM PART DESCRIPTION ITEM PART QTY DESORPTION 1 5304 21 1 1 FLUSH VALVE SPLIT SEAL 20 5104 02 40 1 FLUSH ELBOW ASSEMBLY 2 504 22 1 1 FLUSH VALVE 3 5104 23 1 p FLUSH SEAL BODY a 504 26 1 1 FLUSH VALVE SEAL 1 FLUSH VALVE 8203 2 3 1 COMPRESSION SPRING O E 008 t CURING 5504 25 1 1 FLUSH VALVE BUTTON a wara 1 GRIP RMG 1 587 18 1 t BACK WP RING 1 1 12 58717 1 AUTO FLUSH BOC 13 024355 L Ema 1 PUSH STEM 15 7304 2 1 3 SEAL 16 7701 63 2 BARS FITTING 17 T703 2 1 2 HOSE CLAMP iB TRL 102 i ELBOW F TTIPKG 19 1 O RING Fig 21 MagnumVenusProducts Rev 04 2014 Page 49 Patriot Megaject Innovator Il Operations Manual Qi SP4 Solvent Pump SP4 Solvent Pump Assembly The SP4 performs a 200cc solvent purge followed by an air purge to thoroughly clean and purge the injection head and mixer It is contained in a 3 gallon Stainless Steel flush tank During the flush cycle only the SP4 solvent pump will be pressurized to force out the solvent contained inside and then purges with air for the reminder of the flush cycle The SP4 is activated by pressing the Flush button on the control panel and will operate for 30 to 60 seconds The duration of the flush purge cycle can be adjusted as previously noted in the Control Box Configuration section Fig 12 Connecting the SP4 Connect the yellow outlet tube from the outlet side
13. INDER CAV END STOP CAV SPOOL O RING AVC FRONT BUSH SILICONE NRV SEAL INTERNAL SPRING MAXS HEAD CAV SPACER CAV FRONT BUSHING CAV REAR BUSHING CAV INTERNAL NRV 1 8 BSP 1 4 ELBOW DRAWING NUM 83018 01 ASST NUM 9071 AXSY 0425 Page 72 Patriot Megaject Innovator Operations Manual PARTS LIST PART NUMBER DESCRIPTION 0250 1 4 x 3 8 UNION ELBOW MALE STUD SWIVEL 4 5 TAS TOPSHAFT TAS BOTTOM SHAFT ITAS RAV PISTON TAS NOSE SCREW TAS 5 STROKE LIMITER _ LIP SEAL TAS RAV NOSE SEAL TAS BUSH _ M4 X 20 SET SCREW TASIRAV NOSE RAV SHAFT O RING RAV CYLINDER BODY RAV CYLINDER LID 1 4 x 3 8 BSP UNION RING TAS BUSH 5 WASHER TAS RAV NOSE O RING CAT PUMP 0 RING 20cc PUMP 1 1 1 1 1 1 1 1 1 1 Ble 5 gn im 21 A B BLUE LOCTITE C D TAPE AND GOO GREASE ALL RINGS AND SEALS GREASE INTERNAL THREAD ON RAV BODY TITLE MKVIRAV DRAWING NUM 83022 01 DRAW BY DAINAN BOSHOFF ASSY NUM 3071 ASSY D424 D MagnumVenusProducts Rev 04 2014 Page 73 Patriot Megaject Innovator Operations Manual D MagnumVenusProducts Rev 04 2014 Page
14. IPMENT IN WHICH ANY SUCH GOODS MAY BE INSTALLED AND WHICH IS NOT REQUIRED PURSUANT TO THESE TERMS amp CONDITIONS THE FURNISHING OF SUCH ADVICE OR ASSISTANCE WILL NOT SUBJECT SELLER TO ANY LIABILITY WHETHER BASED ON CONTRACT WARRANTY TORT INCLUDING NEGLIGENCE OR OTHER GROUNDS 17 BUYER S USE OF GOODS Many factors beyond Seller s control contribute to the success of the Buyer s finished products such as raw materials used to manufacture the products Seller is not liability for the quality or quantity of finished products produced by Buyer with the use of the Goods 18 EXPORTS If Goods are sold for export Seller s standard terms amp condition for export sales if any shall also apply Acceptance of export orders is not valid unless confirmed in writing by Seller Buyer and not Seller is responsible for compliance with all United States export control rules and regulations Buyer shall not name Seller as shipper or exporter of record in connection with the export of any Goods purchased from Seller 19 INSTALLATION Installation of the Goods is the responsibility of Buyer unless otherwise indicated in the quotation or invoice provided to Buyer Notwithstanding the foregoing however Seller will provide installation supervision personnel within thirty 30 days of Buyer s request If an installation for which the Seller is to participate is delayed by the Buyer more than six 6 months after the date of shipment of the Goods or if Buyer s facil
15. N AIR HERE FLUSH TANK Fig 2 RAV RESIN AUTO VALVE FLUSH VALVE CAV CATALYST AUTO VALVE CATALYST OPV OVERPRESSURE VALVE Fig 3 D MagnumVenusProducts Rev 04 2014 Page 17 Patriot Megaject Innovator Operations Manual Getting Started 1 Unpack unit 2 Attach Pickup Hoses to the inlet of the pump Note Be sure the Flush Tank connections are correct or the Equipment will be damaged It is important not to fill the Flush Tank more than 3 4 full or solvent can get in the air system and cause damage Double check all hose fittings and connections are tight The repair and maintenance of several components will require the use of removable Loctite amp 243 or equivalent thread lock compound Lithium grease Lubriplate 08465 and Red Grease 6706 2 1 Connecting the system to air source The machine is supplied with inline filter and should be connected to an un lubricated air supply Ensure the maximum inlet air pressure marked on the filter is not exceeded 1Mpa 10 bar 145 A sleeve valve is provided on the rear of the enclosure so that air may be isolated from the control box Air should be removed from the machine when it is not in use by sliding the isolation valve sleeve away from the control box NOTE Upon air supply loss either by the sleeve valve or loss of mains pressure once the supply is re energized all controls will revert to an OFF state This is a safety feature so that none o
16. NDEMNITY RIGHTS AS SUCH VENDOR MAY CUSTOMARILY GIVE WITH RESPECT TO SUCH GOODS d LIMITATIONS THERE ARE NO OTHER WARRANTIES WRITTEN OR ORAL EXPRESS IMPLIED OR BY STATUTE SELLER SPECIFICALLY DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE NO REPAIR OF GOODS OR OTHER COSTS ARE ASSUMED BY SELLER UNLESS AGREED TO IN ADVANCE IN WRITING 16 LIMITATIONS OF LIABILITY UNLESS APPLICABLE LAW OTHERWISE REQUIRES SELLER S AND ANY VENDOR S TOTAL LIABILITY TO BUYER BUYER S CUSTOMERS OR TO ANY OTHER PERSON RELATING TO ANY PURCHASES GOVERNED BY THESE TERMS amp CONDITIONS FROM THE USE OF THE GOODS FURNISHED OR FROM ANY ADVICE INFORMATION OR ASSISTANCE PROVIDED BY SELLER BY ANY METHOD INCLUDING A WEB SITE IS LIMITED TO THE PRICE OF THE GOODS GIVING RISE TO THE CLAIM NEITHER SELLER NOR ITS VENDORS SHALL BE LIABLE FOR ANY SPECIAL INCIDENTAL DIRECT CONSEQUENTIAL OR PENAL DAMAGES INCLUDING BUT NOT LIMITED TO BACKCHARGES LABOR COSTS COSTS OF REMOVAL REPLACEMENT TESTING OR INSTALLATION LOSS OF EFFICIENCY LOSS OF PROFITS OR REVENUES LOSS OF USE OF THE GOODS OR ANY ASSOCIATED GOODS DAMAGE TO ASSOCIATED GOODS LATENESS OR DELAYS IN DELIVERY UNAVAILABILITY OF GOODS COST OF CAPITAL COST OF SUBSTITUTE GOODS FACILITIES OR SERVICES DOWNTIME OR CLAIMS FROM BUYER S CUSTOMERS OR OTHER PARTIES IF SELLER FURNISHES BUYER WITH ADVICE OR OTHER ASSISTANCE WHICH CONCERNS ANY GOODS SUPPLIED HEREUNDER OR ANY SYSTEM OR EQU
17. NG mudo S 1 lM IEX P OTWAE ENG _______ _ MASTER MOT wE _ 0 0 0 jJ MISI 2 ICH SUE EE 1 4 0 11 PISTON 3 1 I M Hex XT PER DOCK a ewe Rx 30 4 AN 000 00 0 0 0 X ___________ _ _ 777 _ 1 3 O EE 7 amc o Fox CKETHEADCAPACHEW To ________ HH n 2 MM LY i 745 TER MM RN 4 i is 15098 7 47 3 4 TT 2 1 BAUR 54 a ________ se 7 55 7 ee 0 0 1 43 ll EME _______ _ E NT E 3k ASTERISKS DENOTE PARTS INCLUDED 3250 5 SEAL KIT PART QTY DESRIFTION Mi 1 RESET PUTTON ASSY PAT PH SB i SHIFT ASSY MAGNUM VENUS PLASTECH 3 1 4 PATRIOT POWER HEAD REV A MagnumVenusProducts Rev 04 2014 Page 67 Patriot Megaject Innovator Il Operations Manual p RIN O MagnumVenusProducts Rev 04 2014 Page 68 N
18. 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 or 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 4 Resin pressure in the resin pump 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 MagnumVenusProducts Rev 04 2014 Page 13 Patriot Megaject Innovator Operations Manual 3 2 Grounding Grounding an object means providing an adequate path 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 lo
19. OR INSTRUCTED AND THAT YOU LACK THE TECHNICAL KNOWLEDGE TO OPERATE OR PERFORM MAINTENANCE ON A PIECE OF MAGNUM VENUS PRODUCTS EQUIPMENT PLEASE CALL MAGNUM VENUS PRODUCTS 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 PRODUCTS DISTRIBUTOR OR MAGNUM VENUS PRODUCTS NOTICE 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 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 MagnumVenusProducts Rev 04 2014 Page 14 Patriot Megaject Innovator Il Operations Manual Introduction The Patriot Megaject
20. OTES USE TAPE TO SEAL THREADS OF FITTINGS AND 4475 ENSURE THE VALVE 4461 CAN MOVE FREELY OM THE WIRE GUIDE 44627 AND THAT IT 15 ALIGNED WITH THE HOLE IN THE LOWER PLATE THE FOOT VALVE O RING 04654 MUST MAKE GOOD SEAL ARDUND THIS HOLE WHEN THE UNIT 1 PRESSURTSED AND THEREFORE GOOD ALIGNMENT 15 ESSENTIAL ES OUTLET To mx HEAD ENSURE THERE ARE SHARP EDGES ON END PLATES ____ ____ Y PART NUMBER DESCRIPTION 5P4 UPPER END PLATE 6589 SM TUBE spa LOWER END PLATE 6685 M x 130 5 5 SOCKET CAP HEAD 037 _ 5585 RING EPDM 52 07MM ID x 2 62 3293 _ 1 8 BSP 1 8 BSP FEMALE 0203 ps MALE TEE 6 1 8 BSP ELBOW 3660 6 1 8 BSP QF ELBOW FS 3482 5 53 SOLVENT PUMP SLUG GUIDE W 4481 lopss SOLVENT PUMP FOOT VALVE en 4475 SOCKET HEAD x B LONGAJ 044 RING RESIN QUICK CONNECTOR MagnumVenusProducts Patriot Megaject Innovator Operations Manual TELE SPs Pune ASSEMOLT ee VENUS PLASTECH LTD 2010 CO OT SCALE WORK PAOM Rev 04 2014 Page 69 Patriot Megaject Innovator Operations Manual SOCKET CAP HEAD 5 X 50MM PTFE DIAPRAGM _ 4 1 8 BSP MS O RING I 5 5 SHAFT SPRING MPG TITLE INNOVATOR MPG BLOCK ASSY DRAWING NUM 82009 01 BRAWN STEPHEN WA
21. PUMP SUPPLY SLEEVE VALVE CHARGING HOSE Fig 7 MagnumVenusProducts Rev 04 2014 Page 27 Patriot Megaject Innovator Operations Manual CONTROL BOX CONFIGURATION The user can adjust the Flush timer duration the MPG response time and RGA stroke timer and Alarm volume The procedures for doing this are described in the following sub sections Use the air circuit for your machine controls to identify the location of the components that require adjustment Many components in the control box are labeled to aid identification and therefore locating items that may require adjustment should be relatively straight forward with the aid of a circuit diagram The internals of a typical Innovator control box are shown in figures 8 Some components have been marked for illustrative purposes however it must be emphasized that the appropriate air circuit should always be used as the definitive PULSE VAVLE VALVE BANK 4 VALVE BANK 1 Ss VALVE BANK 3 VALVE BANK 2 EXTERNAL CONNECTIONS mt VALVE BANK 3 FLOW CONTROL BANK Fig 8 Qi MagnumVenusProducts Rev 04 2014 Page 28 Patriot Megaject Innovator Operations Manual RGA adjustment The time between strokes permitted to pass before the RGA alarms and the volume of the alarm whistle can be adjusted by the user The pneumatic RGA control is located bottom center on the flow control ban Fig 9 The mech
22. Patriot Megaject Innovator Il Operation Manual MagnumVenusProducts Rev 04 2014 Patriot Megaject Innovator Operations Manual MagnumVenusProducts CORPORATE HEADQUARTERS and MANUFACTURING 200A Perimeter Park Road Knoxville TN 37922 USA Tel 1 865 321 8809 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 E mail info mvpind com www mvpind com MagnumVenusProducts Rev 04 2014 Page 2 Patriot Megaject Innovator Operations Manual Table of Contents TERMS amp CONDITIONS OF SALE SAFETY amp WARNINGS INTRODUCTION CONTROL BOX INSTRUCTIONS CONTROL BOX CONFIGURATION OPERATING PROCEDURES FLUID SECTION MAINTENANCE amp REPAIR CATALYST PUMP MAINTENANCE amp REPAIR PATRIOT POWERHEAD INJECTION HEAD amp MIXER ASSEMBLY SP4 FLUSH ASSEMBLY TROUBLESHOOTING PARTS DRAWINGS REVISION INFORMATION D MagnumVenusProducts Rev 04 2014 15 19 28 33 38 39 40 41 50 52 54 77 3 Patriot Megaject Innovator Operations Manual Terms amp Conditions of Sale GSSC Inc s Terms amp Conditions of Sale Terms amp Conditions 5882844 1 ACCEPTANCE Acceptance of any purchase order from a customer or potential customer Buyer is subject to credit approval by GSSC Inc Seller acceptance of the purchase order by Seller and when applicable any manufacturer vendor or other
23. RDEN FART NUM 457 043 REV i MAGNUM VENUS PLASTECH LTD DIMENSIONS IN MM MAGNUM VENUS PLASTECH LTD 2010 DO HOT SCALE WORK FROM DIMENSIONS MagnumVenusProducts Rev 04 2014 Page 70 Patriot Megaject Innovator Operations Manual PARS USI _ PART NUMBER DESCRIPTION 1 0338 WASHER M6 D 0645 ELBOW MALE STUD _ SWIVEL 4 5 PLUG 1 2 B US IER 1 10671 pM O P VALVE BLUE CATALYST O P VALVE LOWER BODY CATALYST VALVE ROD 8 1034 CATALYST O P VALVE SLEEVE 9 1 1035 ICAT O P VALVE __ UPPER BODY E i CATALYST O P p VAE PISTON n 316 RING OPV SHAFT RED SILICONE 10 A DRILL HOLE IN CENTER pa AM SEAL AND BLUE LOCTITE 32 i e759 MSS SBARB ARE GREASE O RINGS DRAWING NUM 22021 05 DRAWN EY DAINAN BOSHOFF D MagnumVenusProducts Rev 04 2014 Page 71 A B C AND GOO D BLUE LOCTITE E DRILL 5 5mm HOLE GREASE ALL ORTNGS AND SEALS Patriot Megaject Innovator Operations Manual PARTS LIST PART NUMBER 5 16 1 1 1 1 1 1 1 1615 17 18 19 20 21 L 22 2 6369 16370 6150 TITLE DATE 22 04 2013 D MagnumVenusProducts Rev 04 2014 DESCRIPTION 4MM MS SWIVEL RED SILICONE SPRING CAV TAS RAV SHAFT O RING MAIN BODY SEAL SPOOL VALVE CAV PISTON CYL
24. REASE ALL O RINGS AND SEALS GREASE INTERNAL THREAD ON RAV BODY TITLE RAV DRAWING NUM 83022 01 DR AWN DAINAN BOSHONF BOT Cet Fig 18 To replace the Main Seal 5873 remove Hex Head Screw 5832 Seal 5837 and Washer 6059 Replace Seal 5837 with the recess against the screw head Use a small amount of removable thread lock compound on the 5mm of exposed threads nest to Seal and Washer only Do not over tighten Hex Head Screw 1 1 1 1 1 1 1 1 1 1 13 2 6004 RAV SHAFT RING 1 1 1 1 1 1 2 1 Note Seal 5837 would normally be replaced by removing Nose Block 5852 first However it can be accessed replaced by unscrewing the Screw 5832 without removing the Nose Block 5852 If the shaft turns whilst removing Screw apply signal air pressure to open connector 6080 this aids locking the shaft against rotation It is essential that screw is not over tightened and only a small amount of locking compound is used After renewing Seal ensure correct operation and sealing efficiency between open and closed positions before production use MagnumVenusProducts Rev 04 2014 Page 45 Patriot Megaject Innovator Operations Manual 2 To replace Shaft Seal 6004 remove Main Seal 5837 Disconnect Signal Pressure Unscrew to remove Cylinder Top 6167 Caution the top is under spring pressure Remove Spring 5825 and Limiter 5835 Pull Piston Shaft 5827 upwards Eithe
25. Seller reserves the right to cancel any order or to require full or partial payment in advance without liability to Seller in the event of i insolvency of the Buyer ii the filing of voluntary petition in bankruptcy by Buyer iii the appointment of a Receiver or Trustee for the Buyer iv the execution by Buyer of an assignment for benefit of creditors or v past due payment on previous shipments to Buyer by Seller Seller reserves the right to cancel Buyers credit at any time for any reason 11 INTERPRETATION RESPONSIBILITY PRODUCT USE AND SAFETY Seller does not guarantee that the Goods it sells conform to any plans and specifications or intended use When plans and specifications are involved Buyer is solely responsible for verifying Seller s interpretations of such plans and specifications and it is Buyer s sole responsibility to assure that Seller s Goods will be acceptable for any specific job When Seller offers substitute Goods on any proposal Buyer is solely responsible for confirming their acceptability 12 DELIVERY Shipping dates given in advance of actual shipment are approximate and not guaranteed All contract dates and timelines begin upon receipt by Seller of a purchase order Buyer s acceptance of these Terms amp Conditions and the payment of any required down payment 13 EXCUSABLE DELAYS Seller shall have no liability if its performance is delayed or prevented by causes beyond its reasonable control including without lim
26. anical timer is shown in figure 10 Turn the knob to adjust the timer to the required time between 20 300 seconds The dial shows seconds divided by 10 therefore to set the timer to 100 seconds adjust the dial to 10 RGA TIMER 5A Fig 9 TIMER ADJUSTMENT E Qi MagnumVenusProducts Rev 04 2014 Page 29 Patriot Megaject Innovator Il Operations Manual Figure 11 Whistle Volume FCO1 The RGA alarm whistle volume can be changed by adjusting the flow controller that is in line with the whistle WHISTEL VOLUME Fig 11 Flush Timer adjustment The flush timer duration can be increased or decreased by adjusting the flush timer restrictor This controls the rate of airflow out of the timer circuit reservoir and the speed that the pressure falls in order to actuate the automatic flush stop valve To set the timer simply adjust the restrictor and then time the flush cycle Continue this procedure until the desired flush time is obtained Times of over 60 seconds are achievable with this circuit NOTE If the restrictor is fully wound in air flow will be blocked and the timer will not operate Qi MagnumVenusProducts Rev 04 2014 Page 30 Patriot Megaject Innovator Operations Manual MPG Adjustment The characteristics of the MPG control circuit can be modified by adjusting the MPG restrictor This component controls the rate at which air is supplied t
27. atalyst 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 To prevent this spillage and leakage you should 1 Maintain your Magnum Venus Products 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 an
28. ations Other formulations or blends considered for use in this equipment is strictly prohibited without the expressed consent by Magnum Venus Products Inc Magnum Venus Products 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 equipment operators follow correct procedures Magnum Venus Products 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 Products recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual Magnum Venus Products 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
29. by way of motion as a defense or otherwise in any such suit action or proceeding any claim that it is not subject personally to the jurisdiction of the above named courts that its property is exempt or immune from attachment or execution that the suit action or proceeding is brought in any inconvenient forum that the venue of the suit action or proceeding is improper or that these Terms amp Conditions or the subject matter hereof may not be enforced in or by such court and waive and agree not to seek any review by any court of any other jurisdiction which may be called upon to grant an enforcement of the judgment of any such Florida state or federal court The parties hereby consent to service of process by registered mail at the address to which notice is to be given The exclusive venue for any proceeding under these Terms amp Conditions shall be solely in any state court in Pinellas County Florida or the Federal District Court for the Middle District of Florida Tampa Division sitting in Tampa Florida Buyer acknowledges that the prices for Goods offered hereunder are in part dependent on Buyer s consent to jurisdiction in Florida and exclusive venue in Pinellas County Florida or the Federal District Court for the Middle District of Florida Tampa Division sitting in Tampa Florida and without Buyer s consent to this jurisdiction and venue provision the prices for the Goods may be higher 23 GENERAL Any representation affirmation of
30. cal 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 the event of 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 that 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 MagnumVenusProducts Rev 04 2014 Page 12 Patriot Megaject Innovator Operations Manual 3 0 Equipment Safety WARNING Magnum Venus Products suggests that personal safety equipment such as EYE
31. d 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 MagnumVenusProducts Rev 04 2014 Page 11 Patriot Megaject Innovator Operations Manual 2 7 Toxicity of Chemicals A Magnum Venus Products 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 should 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 Products 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 chemi
32. d 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 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 re
33. e container from the mixing head and that air is purged etc Once this has been done ensure the resin is correctly catalyzed by performing cup tests prior to using the machine to inject a mold Prior to and during operation in injection mode use the pump pressure regulator and gauge to suitably adjust the air pressure supply to the pump and control the pump speed Set the MPG set pressure to the required pressure Once the injection has begun the pump will stop running when the fluid pressure at the injection head exceeds this setting When the injection line pressure reduces below the MPG set pressure the machine will continue to inject Adjust the predetermining counter to set the number of required pump strokes for the injection See figure 5 for an overview of the predetermining stroke counter To change the preset count press and hold the white button with arrow decal while pressing one of the black buttons under the preset count corresponding with the digit to be modified NOTE The machine cannot be started in inject mode if a previous injection has stopped automatically when the shot count has been reached and the stroke count has not been reset Press the reset button on the predetermining counter to reset the count and allow the machine to be started See figure 5 Press the inject button to start the machine in inject mode The machine cannot be started in inject mode if it is operating in recirculation or flush modes The injecti
34. eaction 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 EE 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 substantial property damage Cleaning agents coatings paints etc may contain Halogenated Hydrocarbon Solvents Some Magnum Venus Products 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 adh
35. esives 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 MagnumVenusProducts Rev 04 2014 Page 9 Patriot Megaject Innovator 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 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 c
36. essure gauge the internal diaphragm moves the MPG piston PETON outward and leaks air from the line connected to the 2 control circuit As the level flow of air pressure is reduced by the RESIN MPG the piloted regulator the supply pressure to the OUTLET DIAPHRAM pump is reduced in effect slowing it down Once the air pressure in the control circuit has dropped below approximately 15 psi the pump will shut off In the case of the Pro gun configuration the gun will also close Once the pressure has been restored either by fluid being drawn into the mold recirculation engaged or blockage cleared from output line the system will start up again NOTE The MPG control is active in recirculation or injection mode It is normal to hear air leaking from the MPG block when the MPG is operational MagnumVenusProducts Rev 04 2014 Page 23 Patriot Megaject Innovator Operations Manual Injection mode Before an injection is started ensure all external connections to the mold etc are correctly made Also ensure that resin and catalyst lines are correctly primed and that the required levels of materials are available Ensure the level of fluid in the flush tank is sufficient to clean the machine after the injection Injection mode cannot be entered while recirculating or flushing NOTE When the system is initially primed with resin and catalyst ensure the machine is run in inject mode and resin is collected in a suitabl
37. f the valves or components will energize unexpectedly and create an unsafe situation MagnumVenusProducts Rev 04 2014 Page 18 Patriot Megaject Innovator Operations Manual CONTROL BOX INSTUCTIONS Overview of controls The Innovator control panel is shown in figure 4 Controls have been grouped based upon function to make the system as user friendly as possible Reference the Innovator Manual for complete details on the Innovator Control Box A brief overview of controls is as follows Emergency Stop Push button Press this button in the event of an emergency to place the system in a safe state Twist and pull to release and allow machine operation Pump pressure Pressure gauge This is the air pressure being supplied to the pump Regulator Adjust this to control the air pressure being supplied to the pump and set the pump speed Flush Alarms OP VALVE Indicator will turn red if overpressure state exists RGA ALARM Indicator will turn red if gel alarm timer has expired Pushbutton Press this button to operate the flush cycle Mold Pressure Guard Preset level gauge Control signal air pressure being supplied to Mold Pressure Guard MPG control Regulator Use this to adjust the MPG control signal air pressure Start Stop Controls e Inject Press to start the machine in inject mode Recirculate Press to start the machine in recirculation mode Stop Pre
38. fact and course of dealing promise or condition in connection therewith or usage of trade not contained herein shall not be binding on either party If any provision hereof shall be unenforceable invalid or void for any reason such provision shall be automatically voided and shall not be part of these Terms amp Conditions and the enforceability or validity of the remaining provisions of these Terms amp Conditions shall not be affected thereby TO THE EXTENT NOT CONTRARY TO APPLICABLE LAW THE FOLLOWING SHALL APPLY 24 Buyer waives any available homestead exemption as well as any and all requirements or rights with regard to notice demand presentment IMPORTANT NOTICE THIS INSTRUMENT PERMITS SELLER TO OBTAIN AND USE YOUR INDIVIDUAL CREDIT HISTORY FOR CREDIT EVALUATION PURPOSES MagnumVenusProducts Rev 04 2014 Page 5 Patriot Megaject Innovator Il Operations Manual SAFETY amp WARNING INFORMATION OPERATING YOUR POLYESTER SYSTEM SAFELY 1 Introduction Any tool if used improperly 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 applic
39. ft block gt Faulty RGA 03 valve shuttle Check 60 for signal Should go on off with pulses from powerhead gt Faulty counter Check 60 for signal Should go on off with pulses from powerhead Cat OP circuit does not stop pump gt FC 04 not adjusted properly Adjust flow control Remove 21 from Catalyst Overpressure valve start pump slowly turn FC 04 until pump stops MPG will not stop pump on overpressure Reduce MPG pressure from panel gt FC 04 not adjusted properly Adjust flow control Remove 26 from MPG valve start pump slowly turn in FC 06 until pump stops Gel Alarm time incorrect gt 03 not adjusted properly Adjust flow control until gel alarm is set correctly Gel Alarm not working gt FC 03 not adjusted properly Adjust flow control until gel alarm is set correctly Check 02 51 for signal Should be off pulsing when pumping On when not pumping Check 02 output 52 for signal Should be off pulsing when pumping On when not pumping Flush dwell time incorrect gt FC 05 not adjusted properly Adjust flow control until flush dwell is set correctly Flush not working gt 05 not adjusted properly Adjust flow control until flush dwell is set correctly MagnumVenusProducts Rev 04 2014 Page 53 Patriot Megaject Innovator Il Operations Manual Parts Drawings PAT LS 12270 RTM RTM INNOVATOR FLUID
40. gards 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 MagnumVenusProducts Rev 04 2014 Page 8 Patriot Megaject Innovator 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 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 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 Products in the catalyst system i e hoses fitting etc because a dangerous chemical r
41. h 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 SMOKING signs must be posted and observed in all areas of storage or where solvents and other flammable materials are used MagnumVenusProducts Rev 04 2014 Page 10 Patriot Megaject Innovator 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 Products spray up and gel coat systems currently produced are designed so that catalyst diluents are not required Magnum Venus Products 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 c
42. itation acts of nature labor disputes government priorities transportation delays insolvency or other inability to perform by any Vendor or any other commercial impracticability In the event of any such delay the date of delivery or performance shall be extended for a period equal to the time lost by reason of delay If Goods are held or stored beyond the delivery date for the convenience of Buyer such Goods shall be so stored at the risk and expense of Buyer 14 CLAIMS Claims for any nonconforming Goods must be made by Buyer in writing within ten 10 days of Buyer s receipt of such Goods and must state with particularity all material facts concerning the claim then known to Buyer Failure by Buyer to give notice within such ten 10 day period shall constitute an unqualified acceptance of such Goods by Buyer and a waiver of any right to reject or revoke acceptance of such Goods MagnumVenusProducts Rev 04 2014 Page 4 Patriot Megaject Innovator Operations Manual 15 WARRANTIES SELLER S WARRANTIES Seller warrants that all Goods sold shall mechanically operate as specified and shall be free from faults in respect to materials and workmanship for a period of i for parts twelve 12 months from the date of invoice and ii for systems twelve 12 months from start up or if earlier eighteen 18 months from the date of the bill of lading Seller also warrants that the Goods shall upon payment in full by Buyer for the Good
43. ity materials or parts are not prepared for installation for such period of time Seller shall be entitled to invoice the Buyer for the anticipated installation costs up to 1 250 per day plus expenses for each of Seller s installations technicians which are on site 20 ANTI MONEY LAUNDERING RESTRICTIONS Seller rejects questionable purchase orders and payments Except for pre approved credit arrangements Seller rejects third party payments cashiers checks money orders and bank drafts Seller accepts only checks imprinted with Buyer s name wire transfers originated in Buyer s account letters of credit with Buyer as account party and credit or debit cards in Buyer s name All payments must be by single instrument in the amount of the invoice less credits from banks acceptable to Seller 21 GOVERNING LAW These Terms amp Conditions and all disputes related to it shall be governed by the laws of the State of Florida United States of America without giving effect to its conflict of law rules 22 JURISDICTION AND VENUE The parties hereby irrevocably submit to the jurisdiction of the state courts of the State of Florida and to the jurisdiction of the United States District Court for the Middle District of Florida for the purpose of any suit action or other proceeding related to arising out of or based upon these Terms amp Conditions or in any way related to arising out of or involving sale of Goods hereunder waive and agree not to assert
44. 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 MagnumVenusProducts Rev 04 2014 6 Patriot Megaject Innovator Il 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 1 National Fire Protection 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 Products recommends the fol
45. ller shall accept returns of Goods for any reason for a period of thirty 30 days following shipment for exchange or refund of the purchase price provided that such Goods must be unused and are subject to a 15 restocking charge which may be increased or decreased in the Seller s sole discretion depending on the reason for such return Any Goods which were special ordered by Buyer are may not be returned and any such Goods which are returned are subject to a restocking cancellation fee of 10096 of the cost of the Goods Goods shall be deemed accepted by Buyer and cannot thereafter be returned if Buyer fails to object to the Goods within thirty 30 days after the Goods are received by Buyer 8 CANCELLATION The Buyer may cancel any purchase order prior to shipment of the Goods by mutual agreement of the parties and upon payment to Seller of reasonable and proper cancellation charges 9 TERMINATION Seller may terminate the whole or any part of any purchase order if there is a material breach of these Terms amp Conditions In the event of any such breach the Seller will provide Buyer with written notice of the nature of the breach and the Seller s intention to terminate for default In the event Buyer does not cure such failure within ten 10 days of such notice Seller may by written notice terminate the purchase order provided that Buyer shall continue its performance to the extent not terminated 10 CHANGE IN BUYER S FINANCIAL CONDITION
46. lowing Personal Safety Equipment for conducting safe operations of the Polyester Systems Magnum Venus Products 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 Products 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 Products recommends that catalyst not be diluted 4 The flammability dangers of the uncured liquid resins used 5 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 MagnumVenusProducts Rev 04 2014 Page 7 Patriot Megaject Innovator 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 ind
47. lve in the catalyst circuit the control circuit will detect the over pressure condition and stop the pump from running In injection or recirculation modes this is equivalent to pressing the stop button For example if during an injection the catalyst system is over pressurized the injection will stop the TAS Pro gun will close and the system will shut down A visual indicator Fig 4 is provided on the face of the control box which will change from black to red in the event of a catalyst over pressure condition To reset the over pressure control circuit the catalyst pressure must be relieved and the reason for the condition must be remedied before the machine can be operated in injection or recirculation modes MagnumVenusProducts Rev 04 2014 Page 21 Patriot Megaject Innovator Operations Manual RGA Resin Gel Alarm The machine features a RGA Resin Gel Alarm system designed to alert the operator to the risk of catalyzed resin curing in the machine or mold during an injection or prior the machine being flushed and cleaned When the inject button is pressed and the machine starts in injection mode the RGA becomes active It monitors the time between pump strokes during an injection and if the user adjustable preset time is exceeded an audible alarm will sound and the visual RGA indicator Fig 4 on the control panel will change from black to red The alarm is reset when the pump stroke changes direction in injectio
48. n mode however in this case the RGA will continue to monitor the pump strokes and will alarm again if the preset time between pump strokes is once again exceeded An example of this would be if the machine stalled during an injection due to a higher than normal back pressure in the injection line The operator may increase the injection pressure to make the pump stroke and therefore reset the alarm and complete the injection The is de activated so that it stops monitoring pump strokes and cancels active visual audible alarms by either flushing the machine or pressing the RGA reset button The RGA reset button is accessed on the side of the control panel and can be pressed by inserting a small screwdriver or equivalent through the hole marked reset This is not intended to be used in normal operation and is provided as a means to silence the alarm if the pump cannot run and the machine cannot be flushed A user configurable pneumatic timer which can be adjusted between 20 300 seconds 0 3 5 minutes is located in the control box In addition a factory set timer of between 30 60 seconds is included in the RGA circuit to limit the switching rate of the circuit These two timers need to time out in sequence in order for the alarm to trigger In practice if the mechanical timer is set to 5 minutes if the duration of a pump stroke was to exceed around 5 5 6 minutes during an injection the alarm would trigger Mag
49. numVenusProducts Rev 04 2014 Page 22 Patriot Megaject Innovator Operations Manual Flush Press the flush button to clean the injection head The operator cannot initiate a flush when the machine is in injection mode therefore accidental flushing of the system into a mold during an injection is not possible The flush system has an automatic timer function that will stop the flush cycle automatically The default duration of the flush is set between 30 60 seconds during manufacture however this can be adjusted by the user if required The flush cycle can be stopped at any time by pressing the stop button CAUTION Before the flush button is pressed ensure that the outlet from the mixing head is directed to a suitable waste container Mold Pressure Guard MPG The machine features a Mold Pressure Guard MPG which is used to control the maximum allowable pressure at the mixing head This can be utilized to provide line pressure control during an injection or as a safety mechanism to prevent the line pressure from exceeding the maximum working pressure of the injection line to the mold CONTROL CIRCUIT The MPG block is supplied with 2 air lines One air line supplies air from the MPG pressure regulator on RESIN MPG SUPPLY the control panel The other is connected to an INLET internal circuit on the control box When fluid pressure at the injection head exceeds the a MPG preset level shown on the MPG pr
50. o the pump speed control circuit When the MPG leaks air more air than can be supplied through this restrictor the pressure in the circuit falls and the pump stops When the circuit is once again sealed the restrictor controls how quickly the pressure builds within the circuit and therefore the time and speed in which the pump restarts The slower the flow of air through the restrictor the longer the pump will take to restart NOTE If this restrictor is fully wound in air flow will be blocked and the pump will not start Conversely if too higher flow of air is supplied to the circuit safe and correct operation of the machine cannot be guaranteed This flow control is set at factory and should not be adjusted The response of the pump can further be slowed if required by the addition of an air reservoir to the circuit Contact MVP for further information e e y ON 4 4 gt gt gt d E MPG ADJUSTMENT Fig 13 Qi MagnumVenusProducts Rev 04 2014 Page 31 Patriot Megaject Innovator Operations Manual Catalyst Over Pressure Adjustment The characteristics of the CAT O P control circuit can be modified by adjusting the CAT O P restrictor This component controls the rate at which air is supplied to the bleed control circuit When the CAT O P leaks air more air than can be supplied through this restrictor the pressure in the circuit falls and the pump stops When the circuit is once again sealed
51. of the cabinet to OPEN position Twist amp Pump E Stop to allow machine operation Check all catalyst amp resin fitting to be sure they are tight Fill pump packing nut 1 3 full with PAT LS OIL Fill the Catalyst Jug at least 1 2 full of catalyst Secure the Pick up wand to the pump inlet Place the Resin Pick up wand in the resin supply container Place the end of the Resin Return Hose in the resin container Fill the Solvent Flush Tank 3 4 full Place the appropriate container under the Injection Head and Test the Flush system by pressing the Flush Button OO NOR N A gt e _ gt N THE UNIT IS NOW READY TO BE STARTED UP GO TO FIRST TIME START UP PATRIOT MEGAJECT INNOVATOR ABNORMAL CONDITIONS OBSERVED AND CORRECTED Abnormal Condition when corrected OPERATORS NAME DATE SIGN OFF WHEN PRE START CHECKS ARE COMPLETED D MagnumVenusProducts Rev 04 2014 Page 34 Patriot Megaject Innovator Operations Manual FIRST TIME START UP CHECK LIST PATRIOT MEGAJECT INNOVATOR ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN AND MUST BE TICKED OFF AS COMPLETED THIS SEQUENCE FOLLOWS ON FROM PRE START CHECKLIST PATRIOT MEGAJECT INNOVATOR ACTIVIT ACTIVITY TICK WHEN Y NO COMPLETED Priority Put on Respirator as specified for spray painting Protective Clothing Eye Protection and PVC Gloves Turn the pump regulat
52. of the solvent pump through the outlet fitting to the flush neck on the flush valve of the injection gun Connect the red 4mm tube to the fitting on the inlet side of the quick exhaust Connect the 1 4 pump inlet air tube to the other side of the inlet quick exhaust Yellow outlet tube connects from injection gun flush valve to the outlet of the SP4 solvent pump 1 4 Pump inlet air tube Flush Tank Fig 22 MagnumVenusProducts Rev 04 2014 Page 50 Patriot Megaject Innovator Operations Manual On the inside of the flush tank the there are two 2 connections to the flush pump The pump inlet air tube connects to the inlet side of the SP4 solvent pump through the inlet fitting The Yellow flush tube from the injection gun mix head extends down through the outlet side fitting and connects to the outlet of the solvent pump INLET OUTLET TO MIX HEAD Fig 23 Note it is important that the solvent level in the tank be at no less then 1 3 full or so that there is 25mm 1 of solvent above the SP4 solvent pump This will allow the SP4 solvent pump to properly refill with solvent after each use EL SP4 Solvent Pump Air Vent tube this exhausts air from the SP4 through the flush valve and protects air system for solvent contamination Fig 24 Maintenance The 5 4 Solvent Pump is basically maintenance free however it might be necessary to replace the O ring 0464 on the Pump
53. on has malfunctioned Check 39 for signal Should be off Pulse valve S01 has malfunctioned See below Check 49 for signal Should be off Catalyst Overpressure circuit is engaged See below Check 48 for signal Should be off Predetermined counter has not reset or malfunctioned See below CE NORM guard has been opened Close CE NORM guard Check NORM guard valve proper operation Pulse valve has malfunctioned Internal Pulse valve circuit check Check 36 for signal Should not on e Note This valve also resets all circuits to off when air pressure to the system is moved from an off state to on If circuits are not resetting on startup then this valve is faulty MagnumVenusProducts Rev 04 2014 Page 52 Patriot Megaject Innovator Operations Manual Catalyst Overpressure circuit is engaged check indicator on panel Check for blockage in catalyst delivery lines Check FC 04 for proper adjustment Check for air leaks on Catalyst Overpressure valve and connection 1 7 21 Internal Catalyst Overpressure circuit check Check 21 for leaks Check VOS output 49 for signal Should not be on Predetermined counter not counting or skipping counts Will not count in recirculation mode gt 03 not adjusted properly Adjust FC 03 for proper flow gt Faulty signals from powerhead shift block Repair or replace powerhead shi
54. on head will open the Pro gun TAS signal will pressurize and the pump will run To stop the machine and leave inject mode press the stop button If the predetermining counter reaches the user set shot count the machine will stop automatically If a PPVS sensor is being used the pump will stop when the mould pressure reaches set point When the mould pressure drops to an acceptable level the pump will run once again MagnumVenusProducts Rev 04 2014 Page 24 Patriot Megaject Innovator Operations Manual Recirculation mode Prior to and during operation in recirculation mode use the pump pressure regulator and gauge to suitably adjust the air pressure supply to the pump and control the pump speed Press the recirculate button to start the machine the pump will run and resin and catalyst will be pumped around the system and returned to source Recirculation mode cannot be entered when the machine is injecting or flushing To stop the machine press the stop button NOTE The catalyst over pressure valve is active during recirculation Guard Interlocks If the machine is fitted with a slave arm guard that does not require a tool to open the guard will be fitted with an interlock to stop the pump running when it is opened In this case if the guard is open or not correctly closed the machine will not operate in injection or recirculation modes Opening the guard while the pump is operating will have the same effect as p
55. or Repair amp Maintenance of this fluid section please reference the manual Patriot 1 1 4 Fluid Section Manual PAT LS 12270 D MagnumVenusProducts Rev 04 2014 Page 38 E 2 1 5 1 T T 15 5 1227 055 FLIUD SECTION PAT LS 12270 and PAT CP 0550 Rev 04 2014 e D MagnumVenusProducts Page 39 Patriot Megaject Innovator Il Operations Manual D Powerhead Maintenance The standard Megaject Innovator uses the Patriot 3 1 4 Powerhead Assembly PAT PH 3250 for detailed instructions for Repair amp Maintenance of this fluid section please reference the manual Patriot Powerhead Manual PAT PH 3250 D MagnumVenusProducts Rev 04 2014 Page 40 Patriot Megaject Innovator Il Operations Manual Qi Injection Gun amp Mixer Following in this section are the instructions for the items listed below Auto Head Assembly Catalyst Auto Valve Assembly CAV Resin Auto Valve Assembly RAV Head Mixer amp Mould Pressure Guard MPG Automatic Flush Valve Assembly O1 BR NN MagnumVenusProducts Rev 04 2014 Page 41 Patriot Megaject Innovator Operations Manual Injection Head Assembly ASSY 0427 see figure 15 Recommended Spare Parts A up Assy 0424 RAV Assembly See drawing 83022 XX rc Sobvert Plush vere 58142 58742 1 7701 6 3 8 f 6593 sw j pc ER 3 5 55
56. or to zero Adjust the catalyst percentage required with the slide arm Knob With all the material containers properly filled Press the Recirculation Button on the control panel Slowly increase the pump regulator so that the pump strokes slowly and evenly Allow the pump to recirculate until the flow of Resin and Catalyst back to there respective containers is free of bubbles Press the Stop button to take the unit out of recirculation mode NIO A Test the catalyst and resin to the Injection head Place a suitable container under the injection head and press the Inject button After 4 or 5 strokes press the Stop button Check that the material properly cures Properly dispose of the catalyst and resin gt Flush the Injection head as necessary into the appropriate container ABNORMAL CONDITIONS OBSERVED AND CORRECTED Abnormal Condition when corrected OPERATORS NAME DATE SIGN OFF WHEN START UP CHECKS ARE COMPLETED D MagnumVenusProducts Rev 04 2014 Page 35 Patriot Megaject Innovator Operations Manual DAILY START UP PATRIOT MEGAJECT INNOVATOR ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN AND MUST BE TICKED OFF AS COMPLETED THIS SEQUENCE FOLLOWS ON FROM FIRST TIME START UP CHECKLIST ACTIVITY ACTIVITY TICK WHEN NO COMPLETED Priority Put on Respirator as specified for spray painting Protecti
57. ose conductive objects in the spraying area This includes material containers and equipment Magnum Venus Products 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 might 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
58. ould 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 their low flammability hazard and their not being classified as toxic or carcinogenic substances HHC solvents are very desirable many respects WARNING Do not use Halogenated Hydrocarbon solvents in pressurized fluid systems having aluminum or galvanized wetted parts NOTE Magnum Venus Products is aware of NO stabilizers available 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 Products recommends that you contact your solvent supplier regarding the best non flammable clean up solvent wit
59. r cut Seals off Shaft without scratching grooves in shaft and replace or replace Shaft 5828 complete with Seals fitted Shaft 5828 may be unscrewed form Shaft 5827 by firmly gripping both close to piston 5830 Reassemble using a small amount of thread lock compound on threads and PTFE sealer paste on Shaft end next to piston base hole 5830 Do not grip and turn shaft beneath O ring seal grooves Caution For safety reasons Always ensure that the Resin Auto valve is locked into the head top position with the two securing lock M5 screws 4081 MagnumVenusProducts Rev 04 2014 Page 46 Patriot Megaject Innovator Operations Manual Head Mixer and Mould Pressure Guard MPG see fig 19 amp 20 Standard Machine 0705 amp Dwg 22404 5 Drawn arh issue 3 07 06 Issue 4 06 08 Issue 5 07 09 rw Assy Nos added Part change 0060 plastech TT Ltd 2002 Assy 0060 Assy 0060 0060 5658 Assy 0423 MPG Assembly Dwg 82009 see fig 20 0619 s 0251 0619 0791 Note it is normal for air to leak from this point during machine use Fig 19 MagnumVenusProducts Rev 04 2014 Page 47 Patriot Megaject Innovator Operations Manual Mixer Tubes see figure 19 Mixer tubes will only require replacement if partial or full gelation sedimentation has occurred in the injection head They cannot be repaired and must be replaced To replace first
60. r listed on any related invoice and is responsible for additional applicable shipping and handling charges taxes duties and charges for import and export licenses and certificates All prices quoted by Seller are subject to change without notice Seller will generally collect applicable taxes along with the purchase price unless Buyer submits a valid tax exemption certificate and indicates which Goods are covered by it Prices on special order Goods may be subject to change before shipment In order to be corrected any discrepancies in pricing and or quantities on invoices must be reported by Buyer within thirty 30 days of the invoice date 3 PAYMENT Payment terms are 30 days net from the invoice date or upon such other terms approved by Seller in writing Retainage shall not apply and Buyer shall not hold back any retainage from Seller even if retainage is part of any contract between Buyer and any other party Payment is not contingent on Buyer s ability to collect or obtain funds from any other party Credit card sales are billed at the time of purchase Buyer expressly represents it is solvent at the time it places any purchase order with Seller Seller in its sole discretion may determine that Buyer s financial condition requires full or partial payment prior to manufacture or shipment If Buyer fails to make any payment when due Seller reserves the right to suspend performance Buyer agrees to pay a charge on all amounts past due at the rate of
61. remove Mould Pressure Guard MPG signal pipes and remove mixer shroud from head Remove mixer tube from inside shroud Lightly grease new mixer tube shroud threads with silicon grease ensure shroud internal O ring 0749 is in position and replace in mixer shroud Re attach to mixer head and reconnect MPG pipes ITEM QTY PART NUMBER DESCRIPTION 1 1 0731 MPG BLOCK SEAT 0733 MPG TOP BLOCK 0733 SPOOL MPG 035 WASHER M10 0314 _ SOCKET CAP HEAD M5 X 50MM 01931 PTFE DIAPRAGM 0619 _ 4MM 1 8 BSP MS 0750 RING I 5 5 SHAFT 0598 SPRING MPG MKII 0740 O RING MPG II ie nam umi us f 10 TITLE HROVETOR MPG BLOCK ASSY DRAWING NUM 2008 01 STEPHEN WARDER DATE 15 02 2011 MAGNUM VENUS PLASTECH LTD DIMENSIONS IH MM VENUS PLASTECH LTO 2002 MOT SCALE FROM IHERNSTONS MagnumVenusProducts Rev 04 2014 Page 48 Patriot Megaject Innovator Operations Manual Automatic Flush Valve Assembly 58742 1 see fig 21 The Automatic Solvent Flush Valve may be serviced NOTE however the important use of thread lock compound between parts 3 and 8 These two parts need to be disassembled if the main solvent seal 19 needs renewing so ensure that a thread lock compound is used when reassembling AS 18 12 en 17 w 4 a AY 11 B 1 20 Automatic Flush Valve Assembly 58742 1 FARTS LIST OPTIONAL PARTS AND ASSEMBLI
62. ressing the stop button Once the guard is closed the machine will operate normally MagnumVenusProducts Rev 04 2014 Page 25 Patriot Megaject Innovator Operations Manual Control box user connections Side of control box see Fig 6 Signal connections are also supplied to the side of the control enclosure and are illustrated in figure 4 The connections are as follows e PPVS SUPPLY Use this to connect a PPVS This line becomes active once the injection cycle is initiated TAS RTM ONLY Use this to connect a TAS or similar valve to the machine This line becomes active once the injection cycle is initiated PPVS SIGNAL This is the return signal from the PPVS when used Once this port Receives a signal it will start the pump system If the PPVS blocks the signal the pump will stop and the Pro gun will close If using the Megaject version the dispense head will stay open NOTE There must be a signal present on the PPVS signal for the machine to inject If no PPVS is to be used then the supplied jumper must be installed between the PPVS supply and the PPVS signal for the unit to function properly IXv3 FLUSH Once the flush cycle is imitated this line will move the IXv3 into the flush position This line is active until the next injection cycle is started Fig 6 D MagnumVenusProducts Rev 04 2014 Page 26 Patriot Megaject Innovator Il Operations Manual Rear of control box
63. s be free and clear of any security interests or liens Buyer s exclusive remedy for breach of such warranties shall be limited to repair replacement costs or termination of any security interests or liens and Seller shall have no responsibility for reimbursing repair costs incurred by Buyer in connection with Goods without first giving written authorization for such charges In any claims by the Buyer against the Seller in respect of the Goods the liability of the Seller shall be limited to the value of the Goods This warranty applies only to Goods properly used and maintained and does not apply to any Goods which are misused or neglected or which has been installed operated repaired altered or modified other than in accordance with instructions or written authorization by Seller This warranty does not apply to any Goods not manufactured by Seller and Buyer s sole warranty with respect to such Goods shall be that of the Seller s Vendor if any b VENDOR S WARRANTIES Seller shall assign to Buyer any Vendor warranties and or remedies provided to Seller by its Vendor c INTELLECTUAL PROPERTY INFRINGEMENT SELLER DISCLAIMS ANY AND ALL WARRANTIES AND OR INDEMNIFICATIONS AGAINST INFRINGEMENT OF ANY INTELLECTUAL PROPERTY RIGHTS OF ANY NATURE SELLER SHALL IF GIVEN PROMPT NOTICE BY BUYER OF ANY CLAIM OF INTELLECTUAL PROPERTY INFRINGEMENT WITH RESPECT TO ANY GOODS SOLD HEREUNDER REQUEST THE APPLICABLE VENDOR TO GRANT FOR THE BUYER SUCH WARRANTY OR I
64. ss to stop the machine in injection recirculation or flush modes Stroke Counter Seta predetermined stroke count for the machine to stop at MagnumVenusProducts Rev 04 2014 Page 19 INJECTION BUTTON RESET BUTTON DIGIT LOCKOUT STRCKE COUNIT MagnumVenusProducts P atriot Megaject Innovator Il Operations Manua STOP BUTTON RECIRCULATION BUTTON Fig 4 CURRENT COUNT DISPLAY PRESET COUNT DISPLAY DIGIT MODIFIERS Fig 5 Rev 04 2014 Page 20 Patriot Megaject Innovator Operations Manual Machine operations Before the system can be used the air isolation sleeve valve must be moved to the position and the E Stop must be released When air is initially supplied all controls should automatically reset to their non operational state NOTE Residual pressures may remain in the system even though the E Stop has been activated and the air supply has been removed from the machine The various controls and operational modes are described in the following sections Emergency Stop When the E Stop has been activated the machine will enter a safe state If the machine is injecting recirculating or flushing the E Stop is equivalent to pressing the stop button To de activate the E Stop twist and pull to release Catalyst Over Pressure protection The machine features catalyst over pressure protection In addition to the industry standard inclusion of a pressure relief va
65. tainless steel body 6067 In this case the O ring 3316 should be renewed If catalyst appears to weep back to the catalyst bottle during injection mode then the internal spool O rings 6004 need replacing If catalyst is observed to weep from the injection nozzle during recirculation mode then the small front O ring 6079 needs replacing MagnumVenusProducts Rev 04 2014 Page 43 Patriot Megaject Innovator Operations Manual B Recirculation PE NECNON E Illustration of Catalyst Auto valve cross section showing catalyst flow correct position of air actuator for A injection flow And B recirculation flow Fig 17 D MagnumVenusProducts Rev 04 2014 Page 44 Patriot Megaject Innovator Il Operations Manual RAV Instructions for use and Maintenance see figure 18 PARTS LIST QTY PARTNUMBER DESCRIPTION 1 10250 1 4 x 3 8 BSP UNION 2 0645 ELBOW MALE STUD SWIVEL 582 7 TAS TOP SHAFT 5828 TAS BOTTOM SHAFT 5830 TAS RAV PISTON 2832 NOSE SCHEV 5835 TAS STROKE LIMITER 5836 LIP SEAL 383 i TAS RAV NOSE SEAL 5838 TAS BUSH 5350 M4 X 20 SCREW 5852 TAS RAV NOSE 6166 RAV CYLINDER BODY 6167 RAV CYLINDER LID 9007 1 4 x 3 8 BSP UNION 5905 O RING TAS BUSH 15059 ITAS WASHER 5825 TAS RAV NOSE 3265 RING CAT PUMP 14433 10 RING 2062 PUMP 14 15 16 17 18 19 20 7 21 1 4 8 BLUE LOCTITE C D AND GOD G
66. third party that provides goods to Seller for resale to Buyer Vendor If Seller in its sole discretion determines that Buyer s credit becomes unsatisfactory or it has reasonable grounds for insecurity Seller reserves the right upon notice to Buyer to demand adequate assurance of due performance from Buyer and or terminate any purchase order with no liability to Seller BY REQUESTING A QUOTE FROM SELLER ACCEPTING AN INVOICE FROM SELLER OR PRESENTING A PURCHASE ORDER TO SELLER BUYER CONFIRMS THAT THESE TERMS amp CONDITIONS SHALL GOVERN ALL PURCHASES OF PRODUCTS OR MATERIALS PROVIDED TO BUYER BY SELLER GOODS GOODS SOLD BY SELLER ARE EXPRESSLY SUBJECT TO THE TERMS AND CONDITIONS SET FORTH HEREIN AND ANY DIFFERENT OR ADDITIONAL TERMS OR CONDITIONS SET FORTH IN A PURCHASE ORDER OR SIMILAR COMMUNICATION RECEIVED FROM BUYER ARE OBJECTED TO AND SHALL NOT BE BINDING UPON SELLER UNLESS SPECIFICALLY AGREED TO IN WRITING BY AN AUTHORIZED CORPORATE OFFICER OF SELLER NO SELLER EMPLOYEE OR AGENT HAS THE AUTHORITY TO MODIFY THESE TERMS amp CONDITIONS VERBALLY SELLER OBJECTS TO AND REJECTS ANY TERMS BETWEEN BUYER AND ANY OTHER PARTY AND NO SUCH TERMS INCLUDING BUT NOT LIMITED TO ANY GOVERNMENT REGULATIONS OR FLOWDOWN TERMS SHALL BE A PART OR INCORPORATED INTO ANY PURCHASE ORDER FROM BUYER SELLER UNLESS AGREED TO IN WRITING BY AN AUTHORIZED REPRESENTATIVE OF SELLER 2 PRICES AND TAXES Buyer agrees to pay the prices quoted by Seller o
67. umVenusProducts Rev 04 2014 Page 63 Patriot Megaject Innovator Il Operations Manual PART NUMBER Q E501 1 100 1 100 MESH CAT JUG SCREEN 1 SCREEM NUT 1 2 4 zm 5 H amp 8 ER 14 15 6 16 6 17 18 Eu 20 663 21 22 les ASSOCIATED PARTS AND ASSEMBLIES 194 8802 1 1 1 CAP ONLY 23 4105 2 01 1 1 2 x 4 FEED LINE 24 3105 12 01 1 OUTLET FITTING 25 4105 1 01 TUBE FITTING MAGNUM VENUS PLASTECH PATRIOT 2 GALLON CATALYST JUG INNOVATOR PAT CIHINV REV B 01 27 2014 SHEET 3 72 MagnumVenusProducts Rev 04 2014 Page 64 Patriot Megaject Innovator Il Operations Manual 2 MOTE A LIGHT COAT OF SUPER 0 LURE 15 RECOMMENDED M a Jj ON THE UPPER AND LOWER SIGNAL VALVES INSTALL ITEM 8 FLANGE DOWN gt gt INSTALL ITEM 8 FLANGE UP E sains ITEM 24 WITH COUMTERBORE DOWN REMOVABLE LOCTITE ON THREAD OF ITEM 23 MAGNUM VENUS PLASTECH 3 1 1 4 PATRIOT POWER HEAD PAT PH 3250 A 05 24 11 D MagnumVenusProducts Rev 04 2014 Page 65 Patriot Megaject Innovator Il Operations Manual E USE REMOVABLE LOCTITE ON THREADS OF TEM 30 MAGNUM VENUS PLASTECH 3 1 4 PATRIOT POWER HEAD PAT PH 3250 REV A 05 24 11 D MagnumVenusProducts Rev 04 2014 Page 66 Patriot Megaject Innovator Operations Manual a PAT PH 3250 PARTS LIST HOWER END CAP EXPRESSION SPRI
68. ustry 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 gt sandings or with any readily oxidizing 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 secon
69. ve Clothing Eye Protection and PVC Gloves 1 Check all hoses for damage 2 Check all material supplies and fill or replace as needed 3 Open main air supply slide valve on the back of the control box 4 Press the recirculation button and allow the unit to recirculate for at least 20 strokes or until no bubbles are seen returning to the catalyst jug from the recirculation tube Check that the catalyst percentage is set properly Check resin pump pressure and adjust as necessary Check the MPG set pressure and adjust as necessary Set the desired number of counts on the Counter Display Press the Stop button to take the unit out of recirculation mode It is always a good idea to do gel test each morning and balance the fluid pressures So place the appropriate container under the injection head and press the Inject button and pump 2 or 3 strokes Then press the Stop button Press the Reset button on the Counter to reset the counter to zero 12 Flush the injection head as necessary 13 The unit is ready to inject a part connect the injection hose to the injection head and press the Inject button If using a TAS Turbo Autosprue PPVS or other options properly connect the control line to the control box 14 When the injection is complete press the Reset button on the counter and connect to the next part or flush 15 Flush the injection head as necessary

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