ivx3 injection valve 8010
Contents
1. d EE x Lower Spring Actuator Piston Assembly 5 EE 10 Remove the Lower Spring 7040 from the INT Cylinder Body 11 Replace the two Lip Seals 5836 on the Actuator Piston Assembly and lightly coat with MOLYKOTE 111 or SUPERLUBE grease 12 Replace the O ring 7044 lubricated with MOLYKOTE 111 or SUPERLUBE grease in the Actuator Bottom Bush 6983 Actuator amp Valve Assembly 1 Installthe Lower Spring 7040 onto the Lower Shaft 6977 of the Actuator Piston 6973 and push the assembly into the Int Cylinder Body 6974 The Lower Shaft goes through the hole in the bottom of the Int Cylinder Body N Pushing firmly screw the Int Cylinder Cap 6975 onto the Int Cylinder Body using the IVX3 Tools A amp B snug the Cap tight gt Install the Actuator INT Cylinder Body assembly with new Lip Seals 7039 into the Cylinder Body 6981 the Lower Shaft 6977 will go through the Bottom Bush 6983 Cylinder 6981 Int Cylinder Body 6974 MagnumVenusPlastech Rev 03 2012 Page 27 IVx3 Injection Valve Manual 4 Putthe Upper Spring 7041 into the Actuator Cylinder 6981 on top of the Int Cylinder Cap 6975 5 Installthe Cylinder Lid 6980 onto the Actuator Cylinder 6981 over the Upper Shaft 6976 the Upper Shaft will show in the Top Bush 6982 in the Cylinder Lid 6 Getthe four Machine Screws 7056 started into the Actuator Cylinder 6981 then pressing the Cylinder2. Follow the steps listed for testing the actuator with the fluid section removed but when testing for air leaks at the Bottom Bush 6983 apply soapy water to the Isolation Channel shown in the image below Isolation Channel Fluid Section Testing Vacuum Integrity 1 Ensure the Resin inlet and Purge outlet hoses are exhausted and not connected to any equipment Insert the Lower Valve Body 6986 nose into the universal insert on the top of the IVX3 Service Module Connect the Inject output on the top of the Service Module to the Inject signal port on the IVX3 Connect the Purge output on the top of the Service Module to the Purge signal port on the IVX3 Ensure the valve is not actuated no air supplied to either pilot and the valve is in the closed position Open the isolation valve on the Service Module and then adjust the vacuum level at the universal insert to the maximum level 80 vacuum If this level cannot be reached do the following a Check the test equipment by plugging the universal insert and ensuring a high vacuum can be achieved b Check the two O rings 3265 on the IVX3 are in good condition If this is not the problem the valve seal is leaking an unacceptable amount and the valve fluid section should be serviced MagnumVenusPlastech Rev 03 2012 Page 31 IVx3 Injection Valve Manual 7 Once a suitable vacuum level is reached close the isolation valve on the Service Module to iso
3. restriction in the supply line due to a closed valve from over pressurizing and bursting it Connect the outlet signal of the Connect the outlet signal of the PPVS INFUSION to the Injection port PPVS INFUSION to the Injection port of the IVX3 valve of the IVX3 valve PPVS INFUSION PPVS INFUSION MagnumVenusPlastech Rev 03 2012 Page 18 IVx3 Injection Valve Manual Operating Procedures NOTE Apply release agent to the internal 10mm bore of the valve inside the nose when the valve is actuated in the inject position shaft up most to prevent the seal sticking up Operating Procedures using PPVS 1 Put the IVX3 Valve in the Off mode CLOSED 2 Set MPG pressure and pump pressure Caution Do not exceed the Pressure Rating of the injection hose for the MPG or Pump pressure Note the ratio of the pump powerhead to fluid section in this calculation Put the IVX3 Valve in Purge mode PURGE 4 Start machine and wait for the resin to start to flow into the supply line prime valve resin flows into flush line 5 Now put the IVX3 Valve in the Off mode CLOSED Reset the counter before injecting into the mould for an accurate count 6 When you are ready to Inject put the Valve in Inject mode Inject position The PPVS should open and close the IVX3 valve automatically and when the valve is closed the machine should stop on the MPG 7 When the mould is full put the IVX3 Valve in the Off mode CLOSE
4. 7055 and thread it into the end of the Seal Upper Insert 6979 Use IVX3 Tool A or B on the flats of the Seal Upper Insert to stop it turning as you tighten the Slotted Screw Note It is important to follow the following steps carefully to ensure the seal is not damaged during the installation process 10 Apply Red Grease 6706 2 1 10z to the Seal Hard Wearing 7052 to ensure that it is well lubricated 11 Put the Valve into the Off mode by removing the air signal from the upper port This will pull the new Seal Hard Wearing 7052 partially back into the Upper Valve Body 6985 12 Remove the Lower Valve Body 6986 positioned to assist the maintenance process by unscrewing the single Machine Screw 7057 13 Carefully reinstall the Lower Valve Body 6986 over the Upper Valve Body 6985 press firmly over the Seal Hard Wearing 7052 14 Install the two Machine Screws 7057 through both Valve Bodies and tighten into the Actuator Cylinder 6981 15 Actuate the valve to the Purge position and then to the Off position 16 Actuate the valve the Inject position and then to the Off position 17 Repeat steps 15 amp 16 number of times to correctly seat the seal and check for correct valve operation Note Allow proper drying time for the thread lock compound before using the valve assembly MagnumVenusPlastech Rev 03 2012 Page 25 IVx3 Injection Valve Manual Actuator Repair To repair the Actua
5. ANY MAINTENANCE OR REPAIRS UNTIL YOU HAVE FOLLOWED THE PRECAUTIONS STATED ABOVE IF YOU AS AN EQUIPMENT OPERATOR OR SUPERVISOR DO NOT FEEL THAT YOU HAVE BEEN ADEQUATELY TRAINED OR INSTRUCTED AND THAT YOU LACK THE TECHNICAL KNOWLEDGE TO OPERATE OR PERFORM MAINTENANCE ON A PIECE OF MAGNUM VENUS PLASTECH EQUIPMENT PLEASE CALL MAGNUM VENUS PLASTECH BEFORE OPERATING OR PERFORMING MAINTENANCE ON THE EQUIPMENT IF YOU HAVE ANY QUESTIONS REGARDING THE ABOVE PRECAUTIONS OR ANY SERVICE OR OPERATION PRECEDURES CALL YOUR MAGNUM VENUS PLASTECH DISTRIBUTOR OR MAGNUM VENUS PLASTECH NOTICE All statements information and data given herein are believed to be accurate and reliable but are presented without guaranty warranty or responsibility of any kind express or implied The user should not assume that all safety measures are indicated or that other measures are not required DANGER Contaminated catalyst may cause Fire or Explosion Before working on the catalyst pump or catalyst accumulator wash hands and tools thoroughly Be sure work area is free of dirt grease or resin Clean catalyst system components with clean water only DANGER Eye skin and respiration 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 appro
6. Assembly 1 Replace all old or damaged O rings with new ones from the Spares Kit 8011 Apply a coal of lubrication to the O rings using Red Grease 6706 2 1 1oz With the new O rings 7049 amp 7044 installed slide the Valve Bush 7052 onto the Lower Shaft 6977 Apply a drop of removable thread lock compound to the end of the Seal Upper Insert 6978 and thread it into the end of the Lower Shaft 6977 of the Actuator tighten using IVX3 Tools A and B Install the Upper Valve Body 6985 over the Lower Shaft 6977 and press it firmly over the Valve Bush 7052 amp O ring 7049 so that it is flat against the Actuator Cylinder 6981 Attach the Lower Valve Body 6986 to the Upper Valve Body 6985 using one of the Machine Screws 7057 Position the Lower Valve Body as shown below and tighten the screw Supply air to the actuator to place the valve in the Purge position so that the Seal Upper Insert 6978 is visible above the Upper Valve Body 6985 With a new O ring 6988 installed on the Seal Upper insert 6978 carefully press the new Seal Hard Wearing 7051 onto the Seal Upper Insert and O ring MagnumVenusPlastech Rev 03 2012 Page 24 IVx3 Injection Valve Manual 8 With a new O ring 6988 installed on the Seal Lower Insert 6979 press this into the end of new Seal Hard Wearing 7051 9 Apply a drop of removable thread lock compound to the end of the Slotted Screw
7. HHC solvents with other materials or solvents such as MEKP alcohol and toluene may render the inhibitors ineffective B The use of reclaimed solvents is particularly hazardous Reclaimers may not add any inhibitors Also the possible presence of water in reclaimed solvents could feed the reaction C Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction Such coatings can be worn cracked scratched or too thin to prevent contact There is no known way to make oxide coatings or to employ aluminum alloys which will safely prevent the chemical reaction under all circumstances D Several solvent suppliers have recently begun promoting HHC solvents for use in coating systems The increasing use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans as Volatile Organic Compounds VOC s their low flammability hazard and their not being classified as toxic or sino substances HHC solvents very desirable many respects WARNING Do not use Halogenated Hydrocarbon solvents in pressurized fluid systems having aluminum or galvanized wetted parts NOTE Magnum Venus Plastech is aware of NO stabilizers available to prevent Halogenated Hydrocarbon solvents from reaction under all conditions with aluminum components in closed fluid system IMMEDIATE ACTION Halogenated Hydrocarbon solvents are dangerous when used with aluminum component
8. Inject position Ensure the actuator shaft assembly moves freely through its full range of travel and that the top of the shaft is visible in the upper slot of the Top Bush 6982 Move the switch on the Service Module to the center to exhaust the air from the Inject port Ensure the IVX3 shaft assembly moves freely back to the un actuated position Operate the switch on the Service Module and put the valve in the Purge position Ensure the actuator shaft assembly moves freely through its full range of travel and that the top of the shaft is visible only in the lower slot of the Top Bush 6982 Move the switch on the Service Module to the center to exhaust the air from the Inject port Ensure the IVX3 shaft assembly moves freely back to the un actuated position Carry out steps 3 6 a number of times to ensure correct operation Put the IVX3 into the Purge position and then squirt some soapy water around the Top Bush 6982 to check for air leaks Put the IVX3 into the Inject position and then squirt some soapy water around the Bottom Bush 6983 to check for air leaks 10 If there are any noticeable leaks check for and remedy any of the following a Bush is tightened and thread locker applied b O Ring is in good condition c Bushis in good condition d Actuator shaft is not damaged scored etc MagnumVenusPlastech Rev 03 2012 Page 30 IVx3 Injection Valve Manual Actuator Testing Fluid Section Fitted
9. Lid 6980 down firmly screw two of the Screws opposite each other down finish tightening the other two Screws 7 Apply air alternately to the Purge and Inject signal ports and in ensure the actuator operates correctly See Chapter 7 for further information on testing 8 Re assemble the fluid section of the valve by following the steps detailed in Chapter 5 Test the IVX3 Valve to be sure it operates properly and that there are no air leaks etc Please see Chapter 7 for instructions on how to test the valve MagnumVenusPlastech Rev 03 2012 Page 28 IVx3 Injection Valve Manual Valve Testing After an IVX3 has been serviced MVP recommends that it should be fully tested before itis used in production The following items are required to test the valve e 8018 IVX3 SERVICE MODULE shown below Soapy water We recommend that during a service the actuator assembly is first tested prior to fitting the fluid section NOTE See the IVX3 Service Module manual for more detailed instructions on its use for testing the IVX3 MagnumVenusPlastech Rev 03 2012 Page 29 IVx3 Injection Valve Manual Actuator Testing Fluid section removed T Connect the Purge output on the top of the Service Module to the purge signal port on the IVX3 Connect the Inject output on the top of the Service Module to the inject signal port on the IVX3 Operate the switch on the Service Module and put the valve in the
10. is published by American Insurance Association 85 John Street New York NY 10038 Local codes and authorities also have standards to be followed in the operation of your spraying equipment Your insurance carrier will be helpful in answering questions that arise in your development of safe procedures 1 2 Personal Safety Equipment Magnum Venus Plastech recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems Magnum Venus Plastech recommends that the user consult the state and local regulations established for all Safety equipment listed 2 0 Material Safety 2 1 Hazards Associated with Laminating Operations The major hazards which should be guarded against in polyester laminating operations are those associated with 1 The flammability and explosion dangers of the catalyst normally used Methyl Ethyl Ketone Peroxide MEKP 2 The flammability dangers of clean up solvents sometimes used Magnum Venus Plastech recommends that clean up solvents be non flammable and of resin diluents used such as styrene 3 The flammability dangers of catalyst diluents if used Magnum Venus Plastech recommends that catalyst not be diluted 4 The flammability dangers of the uncured liquid resins used 5 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 r
11. lying inside the mold A catalyst leak in this situation would certainly damage the part possibly the mold and may cause a fire 3 Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom sections and at the hose and fittings Replace if wear or weakness is evident or suspected 4 Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub against any of the hoses at any point If allowed to rub the hose will be cut through causing a hazardous leakage of material which could increase the danger of fire Also the material may spew onto personnel in the area 2 7 Toxicity of Chemicals A Magnum Venus Plastech recommends that you consult OSHA Sections 1910 94 1910 106 1910 107 and NFPA No 33 Chapter 14 and NFPA No 91 B Contact your chemical supplier s and determine the toxicity of the various chemicals used as well as the best methods to prevent injury irritation and danger to personnel C Also determine the best methods of first aid treatment for each chemical used in your plant MagnumVenusPlastech Rev 03 2012 Page 11 IVx3 Injection Valve Manual 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 Plastech recommends the use o
12. not cover general wear and tear or damage due to negligence or improper use Seller s liability under the warranty shall be limited solely to repair or replacement costs and has no responsibility for reimbursing repair cost incurred by Buyer in connection with equipment without first giving written authorization for such charges Seller makes no express warranties except those set forth in this agreement and disclaims all other warranties expressed or implied including without limitation implied warranties of non infringement merchantability and fitness for a particular purpose Seller accepts no liability for loss of production loss of profits or other direct or indirect damages In any claim by the Buyer MagnumVenusPlastech Rev 03 2012 Page 4 IVx3 Injection Valve Manual against the Seller in respect of the goods the liability of the Seller shall be limited to the value of the goods e Many factors beyond Seller s control contribute to the success of Buyer s finished products such as raw materials used to manufacture the product Equipment is warranted to perform to specifications detailed in quotation but Seller is not liable for quality or quantity of finished products produced by Buyer e The country of origin is the United States of America Sale installation and all rights of the parties are governed by the laws of the state of Florida Venue with regard to any litigation shall be in Pinellas County Florida The parties ag
13. 1MM X 1 6MM 6 1 7 1 O RING 17 6MM X 2 4MM O RING 5 6MM X 2 4MM IVX3 SEAL HARD WEARING IVX3 SEAL UPPER INSERT IVX3 SEAL LOWER INSERT M3 X 12MM S STEEL SLOT CSK SCREW O RING 5 1MM X 1 6MM O RING CATALYST PUMP MAGNUM VENUS PLASTECH LTD TITLE IVX3 VALVE ONLY PART NUM ASSY 0483 REV DRAWN BY STEPHEN WARDEN MagnumVenusPlastech SHEET 2 2 DATE 23 09 2011 Rev 03 2012 Page 40 IVx3 Injection Valve Manual Revision Information Revision Description Rev 12 2011 Created IVX3 Injection Valve Manual Rev 03 2012 Maintenance procedures revised chapter on testing added and drawing updated The Terms amp Conditions Section was also added Updated the manual format MagnumVenusPlastech Rev 03 2012 Page 41 IVx3 Injection Valve Manual Magnunr Venus Plastech MAGNUM VENUS PLASTECH CORPORATE HEADQUARTERS and MANUFACTURING 11692 56 Court Clearwater FL 33760 Tel 727 573 2955 Fax 727 571 3636 TECHNOLOGY CENTER and WEST COAST MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 MAGNUM VENUS PLASTECH LTD Chilsworthy Beam Gunnislake Cornwall PL18 9AT UK Tel 44 0 1822 832621 Fax 44 0 1822 833999 www mvpind com MagnumVenusPlastech Rev 03 2012 Page 42
14. D and stop the machine 8 Put the Valve in Purge mode PURGE and then flush Leave the IVX3 Valve in the Purge mode PURGE unit the material is gelled NOTE Leave IVX3 valve in purge mode with air on the actuator while the resin cures this stops resin curing in the valve NOTE If the valve seal sticks in the purge position after an injection just supply air to the inject position airline to driver the actuator upwards Then operate the valve between purge and inject positions a number of times and ensure inside of nose is clean and the valve moves freely MagnumVenusPlastech Rev 03 2012 Page 19 IVx3 Injection Valve Manual Fluid Valve Repair NOTE It is important to have the correct parts drawing for the item you are working on This will assist in identifying the correct part numbers for the assembly being rebuilt IVX3 Spares Kit 8011 IVX3 Tool Kit 8012 Flat Tip Screw Driver for 7057 Flat Tip Screw Driver for 7055 Red Grease 6706 2 1 102 The IVX3 Tool Kit 8012 comprises of two specialized tools IVX3 Tool A and IVX3 Tool B These tools are required for the correct maintenance of the valve Spanner for shaft flats Use band to keep tools together for storage Sp W ras ush Ring spanner for cylinder cap Hard Wearing Seal Quick Change 1 Apply air to the actuator to move the valve to the Inject position 2 Remove the two 2 Machine Screws 7057 from the bottom of the va
15. IVX3 INJECTION VALVE 8010 MagnumVenusPlastech Rev 03 2012 IVx3 Injection Valve Manual La MagnumVenusPlastech CORPORATE HEADQUARTERS and MANUFACTURING 11692 56 Court Clearwater FL 33760 Tel 727 573 2955 Fax 727 571 3636 TECHNOLOGY CENTER and WEST COAST MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 MVP PLASTECH UK Chilsworthy Beam Gunnislake Cornwall PL18 9AT UK Tel 44 0 1822 832621 Fax 44 0 1822 833999 www mvpind com a MagnumVenusPlastech Rev 03 2012 Page 2 IVx3 Injection Valve Manual TABLE OF CONTENTS SECTION Page TERMS amp CONDITIONS OF SALE 4 SAFETY amp WARNING INFORMATION 6 INTRODUCTION 15 OVERVIEW 16 IVX3 INJECTION VALVE CONNECTIONS 17 OPERATING PROCEDURES 19 FLUID VALVE REPAIR 20 ACTUATOR REPAIR 26 TESTING 29 PARTS DRAWINGS 34 REVISION INFORMATION 41 42 MagnumVenusPlastech Rev 03 2012 Page 3 IVx3 Injection Valve Manual Terms amp Conditions of Sale Customs duties import and export licenses and certificates if required and all local taxes are excluded from this offer If US state and local taxes are applicable and not included in equipment invoice such amount may be invoiced later Delivery dates or shipping schedules are approximate and based upon the most recent information available at the time of order Dates may be adjusted upon receipt of subsequent information or modification of order Seller will
16. any leaks discovered in the catalyst system immediately and clean up the leaked catalyst at once in accordance with the catalyst manufacturer s instructions H Use only original equipment or equivalent parts from Magnum Venus Plastech in the catalyst system i e hoses fitting etc because a dangerous chemical reaction may result between substituted parts and MEKP Catalyst accumulated from the purging of hoses or the measurement of fluid output dewene N should never be returned to the supply tank such catalyst should be diluted with copiou 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 Plastech spray equipment includes aluminum or galvanized components and will be affected by Halogenated Hydr
17. ch what is called its Self Accelerating Decomposition Temperature SADT Researchers have reported measuring pressure rates of rise well in excess of 100 000 psi per second when certain MEKP s reach their SADT For comparison the highest pressure rate of rise listed in NFPA Bulletin NO 68 Explosion Venting is 12 000 psi per second for an explosion of 12 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
18. d position 5 Connect the IVX3 Purge Outlet to the indicator on the Service Module or a pressure gauge 6 Connect the IVX3 Resin Inlet to the pressure output on the Service Module 6 7 bar 87 100 PSI and check the indicator gauge If pressure is seen here the valve is leaking between the resin Inlet and Purge outlet MagnumVenusPlastech Rev 03 2012 Page 32 IVx3 Injection Valve Manual 7 Apply soapy water to the seal in the Lower Valve Body 6986 and look for bubbling that would imply a leak do not point the resin outlet directly at yourself It is acceptable to have a small leak here 8 Operate the IVX3 to the Purge position the indicator gauge should now show pressure Once again apply soapy water to the seal and check for leaks There should not be any leaks here if the valve is in good condition 9 Apply soapy water to the fluid section where the Lower Valve Body 6986 and Upper Valve Body 6985 join and check for leaks 10 Apply soapy water to the fluid section where the Upper Valve Body 6985 and Actuator Cylinder 6981 join and check for leaks particularly at the isolation channel A leak here could indicate a problem with the Valve Bush 7052 or fitted O rings 11 Point the IVX3 away from yourself and operate to the Inject position air should vent out of the resin Inject port Close the valve 12 Operate the IVX3 between the Closed Inject Purge Closed positions a number of times and ensure the
19. ditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed on all loose conductive objects in the spraying area This includes material containers and equipment Magnum Venus Plastech recommends grounding straps be made of AWG No 18 stranded wire as a minimum and the larger wire be used where possible NFPA Bulletin No77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm 10 ohms but that resistance as high as 10 000 meg ohms will produce an adequate leakage path in some cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and grounded to dissipate static electricity For further information see National Fire Protection Association NFPA 77 titled Recommended Practice on Static Electrical Refer especially to section 7 7 titled Spray Application of Flammable and Combustible Materials Check with local codes and authorities for other specific standards that 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
20. e 37 IVx3 Injection Valve Manual PARTS LIST ITEM QTY PART NUMBER DESCRIPTION 6981 IVX3 ACTUATOR CYLINDER 1 1 6980 IVX3 ACTUATOR CYLINDER LID 7056 M4 X 16 SLOT CHEESE MACHINE SCREW DIN 84 ST ST 5 1 6975 IVX3 ACTUATOR INT CYL CAP 6 1 6953 JVGACTUATORPISTON 8 1 6977 IVX3 LOWER SHAFT 9 1 692 IVXGACTUATORTOPBUSH 10 1 6983 IVX3 ACTUATOR BOTTOM BUSH 11 1 12 2 5850 M4 X 20 SOCKET SET SCREW 7039 PNEUMATIC SEAL 1 75X2X0 137IN TAS LIP SEAL 14 2 7044 ORING 5 6MM X 2 4MM 15 1 7045 ORING 1 987IN X 0 103IN IVX3 LOWER SPRING 17 1 7041 IVX3 UPPER SPRING MAGNUM VENUS PLASTECH LTD TITLE IVX3 ACTUATOR PART NUM ASSY 0473 REV A DRAWN BY STEPHEN WARDEN SHEET 2 2 DATE 16 03 2012 lt MagnumVenusPlastech Rev 03 2012 Page 38 IVx3 Injection Valve Manual USE LOCTITE 243 BLUE OR EQUIVALENT aaa 0 0 4 USE LOCTITE 243 BLUE OR EQUIVALENT MAGNUM VENUS PLASTECH LTD TITLE IVX3 VALVE ONLY PART NUM ASSY 0483 REV DRAWN BY STEPHEN WARDEN SHEET 1 2 DATE 23 09 2011 MagnumVenusPlastech Rev 03 2012 Page 39 PART NUMBER IVx3 Injection Valve Manua PARTS LIST DESCRIPTION ASSY 0473 IVX3 ACTUATOR 6985 IVX3 UPPER VALVE BODY 7042 7057 M5 X 40 SLOT CHEESE MACHINE SCREW DIN 84 A2 ST ST 7052 IVX3 VALVE BUSH HARD WEARING IVX3 LOWER VALVE BODY O RING 14
21. espect to ingestion inhalation and skin and eye hazards MagnumVenusPlastech Rev 03 2012 Page 7 IVx3 Injection Valve Manual 2 2 Catalyst Methyl Ethyl Ketone Peroxide MEKP is among the more hazardous materials found in commercial channels The safe handling of the unstable reactive chemicals presents a definite challenge to the plastics industry The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage transportation handling processing and disposal MEKP is a single chemical Various polymeric forms may exist which are more or less hazardous with respect to each other These differences may arise not only from different molecular structures all are nevertheless caled MEKP and from possible trace impurities left from the manufacture of the chemicals but may also arise by contamination of MEKP with other materials in its storage or use Even a small amount of contamination with acetone for instance may produce an extremely shock sensitive and explosive compound Contamination with promoters or materials containing promoters such as laminate sandings or with any readily 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 rea
22. f protective clothing and eye wear in using polyester systems However users should be prepared in the event of such an injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals have WARNING Contact your doctor immediately in the event of any injury and give him the information you have collected If your information includes first aid instructions administer first aid immediately while you are contacting your doctor Fast treatment of the outer skin and eyes that contact such chemicals generally includes immediate and thorough washing of the exposed skin and immediate and continuous flushing of the eyes with lots of clean water for at least 15 minutes or more These general instructions of first aid treatment however may be incorrect for some chemicals 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 se
23. following steps carefully to ensure the seal is not damaged during the installation process 11 Apply Red Grease 6706 2 1 10z to the Seal Hard Wearing 7052 to ensure that it is well lubricated 12 Put the Valve into the Off mode by removing the air signal from the upper port This will pull the new seal partially back into the Upper Valve Body 6985 13 Remove the Lower Valve Body 6986 positioned to assist the maintenance process by unscrewing the single Machine Screw 7057 14 Carefully reinstall the Lower Valve Body 6986 over the Upper Valve Body 6985 press firmly over the Seal Hard Wearing 7052 15 Install the two Machine Screws 7057 through both Valve Bodies and tighten into the Actuator Cylinder 6981 16 Actuate the valve to the Purge position and then to the Off position 17 Actuate the valve the Inject position and then to the Off position 18 Repeat steps 16 amp 17 a number of times to correctly seat the seal and check for correct valve operation Note Allow proper drying time for the thread lock compound before using the valve assembly MagnumVenusPlastech Rev 03 2012 Page 22 IVx3 Injection Valve Manual Disassembly 1 Remove and replace the two O rings 3265 on the Nose of the Lower Valve Body 6986 Apply a light coat of the Lubrication to the two O rings 2 Supply air to the actuator to move the valve to the Inject position 3 Remove the two 2 Machine Screws 7057 from t
24. he bottom of the valve 4 Carefully remove the Lower Valve Body 6986 from the Upper Valve Body 6985 5 Re attach the Lower Valve Body 6986 to the Upper Valve Body 6985 using one of the Machine Screws 7057 Position the Lower Valve Body as shown below and tighten the screw 6 Apply air to the actuator to move the valve to the Purge position and fully expose the seal 7 Use IVX3 Tool A or B on the flats of the Seal Upper Insert 6978 to stop it turning as you unscrew the Slotted Screw 7055 from the end of the Seal Upper Insert 8 Remove the Seal Hard Wearing 7052 from the Seal Upper Insert 6978 and press out the Seal Lower Insert 6979 using the Machine Screw 7057 9 Exhaust the air from actuator to return the valve to the Off position 10 Remove the Lower Valve Body 6986 positioned to assist the maintenance process by unscrewing the single Machine Screw 7057 11 Carefully but firmly pull the Upper Valve Body 6985 off the assembly the Valve Bush 7052 will be left on the end of the Lower Shaft 6977 retained by the Seal Upper Insert 6978 lt MagnumVenusPlastech Rev 03 2012 Page 23 IVx3 Injection Valve Manual 12 Using the Tools and B remove the Seal Upper Insert 6978 from the end of the Lower Shaft 6977 of the actuator 13 Slide the Valve Bush 7052 off the end of the Lower Shaft 6977 14 Check all parts for wear and replace any damage or worn items
25. he responsibility of those using the tool In like manner safe operation of polyester processes is the responsibility of those who use such processes and those who operate the equipment This manual outlines procedures to be followed in conducting polyester operations safety This system has been specifically designed for use of Polyester Resin Gel Coat and Methyl Ethyl Ketone Peroxides MEKP applications Other formulations or blends considered for use in this equipment is strictly prohibited without the expressed consent by Magnum Venus Plastech Inc Magnum Venus Plastech cannot eliminate every danger nor foresee every circumstance that might cause an injury during equipment operation Some risks such as the high pressure liquid stream that exits the spray tip are inherent to the nature of the machine operation and are necessary to the process in order to manufacture the end product For this reason ALL personnel involved in polyester operations should read and understand the Safety Manual It is very important for the safety of employees involved in the operation that equipment operators maintenance and supervisory personnel understand the requirements for safe operation Each user should examine his own operation develop his own safety program and be assured that his equipment operators follow correct procedures Magnum Venus Plastech hopes that this manual is helpful to the user and recommends that the precautions in this manual be included in an
26. iluents In addition it eliminates any problems from the diluents being contaminated through rust particles in drums poor quality control on the part of the diluents suppliers or any other reason If however diluents are absolutely required contact your catalyst supplier and follow his instructions explicitly Preferable the supplier should premix the catalyst to prevent possible on the job contamination while mixing WARNING If diluents are not used it should be remembered that catalyst spillage gun hose and packing leaks are potentially more hazardous since each drop contains a higher concentration of catalyst and therefore will react quicker with over spray and the leak 2 5 Cured Laminate Overspray and Laminate Sandings Accumulation A Remove all accumulations of overspray FRP sandings etc from the building as they occur If this waste is allowed to build up spillage of catalyst is more likely to start a fire in addition the fire would burn hotter and longer B Floor coverings if used should be non combustible C Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product over sprayed chop or resin FRP sandings or any other material with MEKP To prevent this spillage and leakage you should 1 Maintain your Magnum Venus Plastech System Check the gun several times daily for catalyst and resin packing or valve leaks REPAIR ALL LEAKS IMMEDIATELY 2 Never leave the gun hanging over or
27. ivated to the stop mode Failure to do so can damage the regulators and components on reactivating to the ON position 2 Turn all system regulators to the OFF position counter clockwise position NOTE Verify that the Catalyst relief line located on the catalyst manifold and the resin return line located on the resin filter are secured relieving catalyst and resin fluid pressure 3 Catalyst pressure in the catalyst pump can be eliminated by rotating the ball valve on the catalyst manifold 90 degrees to the open or on position Note The open or on position is when the ball valve handle is parallel in line with the ball valve body The closed or off position is when the ball valve handle is perpendicular across the ball valve body 4 Resin pressure in the resin pump can be eliminated by rotating the ball valve on the resin filter 90 degrees to the open or on position Place a container under the ball valve to catch any resin that is ejected out of the valve MagnumVenusPlastech Rev 03 2012 Page 13 IVx3 Injection Valve 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 con
28. late the vacuum source from the IVX3 s injection port Ideally the level on the vacuum gauge should remain stationary and the vacuum should be maintained 8 Actuate the IVX3 to the Purge position the vacuum level should decrease slightly as the seal moves In this position the vacuum level should again be maintained NOTE It is important that the valve does not leak in the purge position as in production air could be drawn into the part during the curing cycle 9 Operate the valve a number of times between the Closed and Purge positions and ensure the vacuum level is maintained 10 Operate the valve to the Inject position the vacuum should be exhausted and the gauge should fall to zero NOTE Once a suitable vacuum level has been achieved the vacuum generator source can be turned off If the valve is not leaking this level will be maintained Fluid Section Testing Pressure WARNING During pressure testing ensure the IVXS3 s resin injection port is directed away from yourself and others Some of the tests will vent air through this port 1 Place the IVX3 on a bench ensure the injection port is not connected for example into the universal insert on the top of the IVX3 Service Module 2 Connect the Inject output on the top of the Service Module to the Inject signal port on the IVX3 3 Connect the Purge output on the top of the Service Module to the Purge signal port on the IVX3 4 Ensure the IVX3 is in the close
29. lve 3 Carefully remove the Lower Valve Body 6986 from the Upper Valve Body 6985 lt MagnumVenusPlastech Rev 03 2012 Page 20 IVx3 Injection Valve Manual 4 Re attach the Lower Valve Body 6986 to the Upper Valve Body 6985 using one of the Machine Screws 7057 Position the Lower Valve Body as shown below and tighten the screw 5 Apply air to the actuator to move the valve to the Purge position and fully expose the seal as shown below 6 Use IVX3 Tool A or B on the flats of the Seal Upper Insert 6978 to stop it turning as you unscrew the Slotted Screw 7055 from the end of the Lower Insert 6979 7 Remove the Seal Hard Wearing 7052 from the Seal Upper Insert 6978 and press out the Seal Lower Insert 6979 using the Machine Screw 7057 8 Replace the O Ring 6988 on the Seal Upper Insert 6978 and Seal Lower Insert 6979 applying Red Grease 6706 2 1 10z to both 9 Install the new Seal Hard Wearing 7051 onto the Upper Insert 6978 and install the Lower Insert 6979 into the end of the new Seal Hard Wearing 10 Apply a drop of removable thread lock compound to the end of the Slotted Screw 7055 and thread it into the end of the Seal Upper Insert 6978 Use IVX3 Tool A or B on the flats of the Seal Upper Insert to stop it turning as you tighten the Slotted Screw MagnumVenusPlastech Rev 03 2012 Page 21 IVx3 Injection Valve Manual Note It is important to follow the
30. ocarbon Solvents A There are three key elements to the Halogenated Hydrocarbon HHC solvent hazard a The presence of HHC solvents 1 1 1 Trichloroethane and Methylene Chloride are the most common of these solvents However other HHC solvents are suspect if used either as part of paint or adhesives formulation or for clean up flushing b Aluminum or Galvanized Parts Most handling equipment contains these elements In contact with these metals HHC solvents could generate a corrosive reaction of a catalytic nature b Equipment capable of withstanding pressure When HHC solvent contact 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 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 MagnumVenusPlastech Rev 03 2012 Page 9 IVx3 Injection Valve Manual 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
31. ow the steps in the order given otherwise you may damage the equipment or injure yourself During Disassembly As you disassemble the equipment lay out the components in the correct order and direction and have all component drawings available to refer to prior to disassembly MagnumVenusPlastech Rev 03 2012 Page 15 IVx3 Injection Valve Manual Overview Purge Outlet Hose Resin Purge Input Hose with QD connector IVX3 Valve Mode Overview OFF Mode this is the default mode the injection purge and input ports are blocked Closed no fluid can move through the valve Injection Mode by applying an air signal to the Injection signal port the valve will open allowing material into the mold through the Universal insert port Purge Mode by applying an air signal to the Purge signal port the valve will allow resin or solvent through to the Purge port MagnumVenusPlastech Rev 03 2012 Page 16 IVx3 Injection Valve Manual Connections Stand Alone Injection Valve When used as a stand alone injection valve it can be remotely controlled To put the IVX3 into Injection mode send a constant 6 bar 90psi air signal to the Injection Signal port Remove the air signal and the valve will return to the Off mode To put the IVX3 into Purge mode send a constant 6 bar 90psi air signal to the Purge signal port Again remove the air signal and the valve will return to the Off mode Purge
32. priate safety equipment as recommended MagnumVenusPlastech Rev 03 2012 Page 14 IVx3 Injection Valve Manual Introduction The was designed specifically as part of the Flex Molding process to streamline the infusion process by reducing the number of valves needed The IVX3 is a pneumatically activated three position valve Inject Off and Purge The IVX3 is compatible with the MVP universal mold insert and suitable for use in other closed mold applications such as RTM Light When used in conjunction with the PPVS vacuum control valve the IVX3 can automate the infusion process whether used with a single resin channel or multiple resin channel configuration NOTE It is important to have the correct parts drawing for the item you are working on This will assist in identifying the correct part numbers for the assembly being rebuilt The reassembly will require the use of removable Loctite amp or equivalent thread lock compound Use Super O Lube SUPERLUBE or MOLYKOTE 111 grease for the actuator O rings Use Red Grease 6706 2 1 102 or Magnum Gun Lube GL 200 202 for the Fluid Valve NOTE Before starting any service work release fluid and air pressure from system NOTE The IVX3 valve is closed in its non actuated position and therefore can trap pressure not exhausted from the fluid ports Take care when removing lines connected to the ports or when actuating the valve Please read the manual carefully Foll
33. ree to waive all rights to trial by jury as to any and all disputes e The goods remain the property of the Seller until full payment is received e Sale of equipment is subject to application and issuance of proper US Government export license and regulations if applicable e Installation of equipment is responsibility of Buyer and Seller with cost responsibility and number of days provided as detailed in original customer Quotation Seller will provide installation supervision personnel within 30 days of customer request lf installation is delayed by the Buyer more than six months from the date of shipment or if customer facility or material parts are not prepared for installation seller will invoice full installation costs up to 1 250 a day plus expenses for each MVP installation technician on site Seller has the option to waive this fee at its discretion e Parties shall be excused for delays caused by embargoes acts of civil or military authorities Acts of God or other circumstances beyond the reasonable control of the parties Notification of such delays must be made in writing within ten days of occurrence e Our agreement supersedes any previous agreement and applies in full MagnumVenusPlastech Rev 03 2012 5 IVx3 Injection Valve Manual SAFETY amp WARNING INFORMATION OPERATING YOUR POLYESTER SYSTEM SAFELY 1 Introduction Any tool if used improperly can be dangerous Safety is ultimately t
34. rvice information MagnumVenusPlastech Rev 03 2012 Page 12 IVx3 Injection Valve Manual 3 0 Equipment Safety WARNING Magnum Venus Plastech suggest that personal safety equipment such as EYE GOGGLES GLOVES EAR PROTECTION and RESPIRATORS be worn when servicing or operating this equipment Ear protection should be worn when operating a fiberglass chopper to protect against hearing loss since noise levels can be as high as 116 dB decibels This equipment should only be operated or serviced by technically trained personnel WARNING Never place fingers hands or any body part near or directly in front of the spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PISTOL 3 1 Emergency Stop Procedures The following steps should be followed in order to stop the machinery in an emergency situation 1 The ball valve located where the air enters the power head of the resin pump should be moved to the OFF or closed position To do this simply rotate the lever on the 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 act
35. s in a closed fluid system A Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocarbon Solvents B Magnum Venus Plastech recommends that you contact your solvent supplier regarding the best non flammable clean up solvent with the heat toxicity for your application C If however you find it necessary to use flammable solvents they must be kept in approved electrically grounded containers D Bulk solvent should be stored in a well ventilated separate building 50 feet away from your main plant E You should allow only enough solvent for one day s use in your laminating area F NO SMOKING signs must be posted and observed in all areas of storage or where solvents and other flammable materials are used 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 MagnumVenusPlastech Rev 03 2012 Page 10 IVx3 Injection Valve Manual 2 4 Catalyst Diluents Magnum Venus Plastech spray up and gel coat systems currently produced are designed so that catalyst diluents are not required Magnum Venus Plastech therefore recommends that diluents not be used This avoids the possible contamination which could lead to an explosion due to the handling and mixing of MEKP and d
36. shaft is moving freely NOTE When testing is complete residual pressure can remain in the hoses connected to the Resin inlet and Purge outlet take care when dis connecting the valve e MagnumVenusPlastech Rev 03 2012 Page 33 IVx3 Injection Valve Manual Zo Parts Drawings 8010 IVX3 Injection Valve Assembly ASSY 0473 IVX3 Actuator Assembly ASSY 0483 IVX3 Fluid Valve Only Assembly MagnumVenusPlastech Rev 03 2012 Page 34 IVx3 Injection Valve Manual MAGNUM VENUS PLASTECH LTD TITLE IVX3 PART NUM 8010 REV A DRAWN BY STEPHEN WARDEN SHEET 1 2 DATE 09 03 2012 MagnumVenusPlastech Rev 03 2012 Page 35 IVx3 Injection Valve Manual PARTS LIST PART NUMBER DESCRIPTION ASSY 0483 IVX3 VALVE ONLY 0645 ELBOW MALE STUD SWIVEL 4MM M5 2575 10MM 3 8 BSP QF MS 0462 AUTOSPRUE FEMALE RESIN CONNECT 1 5M 0206 TUBING NYLON 4 2 5 BLUE 2 4231 ANTI KINK TUBE NUT 10 8 MAGNUM VENUS PLASTECH LTD TITLE IVX3 PART NUM 8010 REV A DRAWN BY STEPHEN WARDEN SHEET 2 2 DATE 09 03 2012 MagnumVenusPlastech Rev 03 2012 Page 36 IVx3 Injection Valve Manual USE LOCTITE 243 BLUE OR EQUIVALENT EQUIVALENT d USE LOCTITE 638 GREEN OR MAGNUM VENUS PLASTECH LTD TITLE IVX3 ACTUATOR PART NUM ASSY 0473 REV A DRAWN BY STEPHEN WARDEN SHEET 1 2 DATE 16 03 2012 MagnumVenusPlastech Rev 03 2012 Pag
37. ship prior to the delivery date if possible but not without Buyer s consent on Advanced Equipment sales All contract dates and timelines begin upon receipt at MVP of customer purchase order signed Terms and Conditions of Sale if applicable and down payment per quotation if applicable If shipments are delayed by the Buyer or because the Buyer s account is in arrears payments shall become due on the date when the Seller is prepared to make shipment Products held by the Seller for the Buyer shall be at the risk and expense of the Buyer Damages defects or shortages must be communicated immediately to MVP Discrepancy in pricing and or quantities on invoices must be reported within 30 days of the invoice date Claims made 30 days or more following the invoice date will not be honored Permission to return items must be requested and granted in advance No credit will be given if items are returned prior to requesting and receiving permission All returns are subject to a restocking fee The standard 1596 charges may be increased or decreased depending on the reason for the return Special ordered items may not be returned Seller warrants that the mechanical operation of the goods as specified shall be free from faults in respect to materials and workmanship for a period of 12 months for parts from the date of invoice For systems 12 months from start up or if earlier 18 months from the date of the Bills of Lading The warranty does
38. signal port Inject signal port Resin Solvent Outlet Resin Solvent Inlet Resin Injection Port Valve Pressure Ratings e Actuator air pressure 6 bar 87 PSI 7 bar 102 PSI e Maximum fluid pressure resin ports 7 bar 102 PSI NOTE Use clean filtered non lubricated air to supply the signal ports of the actuator MagnumVenusPlastech Rev 03 2012 Page 17 IVx3 Injection Valve Manual IVX3 with PPVS INFUSION Valve connecting the IVX3 Injection valve to the PPVS INFUSION will allow for automatic Open Close control of the IVX3 valve based on the vacuum level Connect the output signal of the PPVS to the Inject Signal port on the IVX3 valve Connect the Purge Signal port to a purge valve or flush signal The control circuit must ensure that the Inject Signal and Purge Signal ports CANNOT be pressurized at the same time as this could cause damage to the mold valve and or part Connect the Resin supply Inlet and Outlet as noted above The PPVS INFUSION should normally be positioned around 80mm from the IVX3 Injection valve however this may vary depending on the application Control boxes are available for this configuration please contact MVP for further information NOTE For some applications particularly where high flow rates are required great care must be taken when closing a valve while an injection is in progress The user must ensure that safe guards are in place to prevent the sudden
39. tor Assembly the Fluid Valve must first be removed IVX3 Spares Kit 8011 IVX3 Tool Kit 8012 Flat Tip Screw Driver for 7056 SUPERLUBE or MOLYKOTE 111 grease Remove the Fluid Valve Follow the instructions given in Chapter 5 to remove the fluid valve Actuator Disassembly 1 Carefully remove the four 4 Machine Screws 7056 from the top of the Cylinder Lid 6980 Note the Cylinder Lid will have force on it from the Upper Spring 7041 Remove the Cylinder Lid 6980 off the Actuator Cylinder 6981 Remove the Upper Spring 7041 from inside the Actuator Install a new O ring 7044 lubricated with MOLYKOTE 111 or SUPERLUBE grease into the Top Bush 6982 Remove and replace the O ring 7045 on the Cylinder Lid 6980 To remove the Internal Cylinder Body module firmly hold the Actuator Cylinder 6981 and press on the end of the Lower Shaft 6977 extending from the bottom of the Actuator Install two new Pneumatic Seals 7039 on the INT Cylinder Body and lightly coat with MOLYKOTE 111 or SUPERLUBE grease Unscrew the Int Cylinder Cap 6975 from the Int Cylinder Body 6974 using the IVX3 Tools A amp B Note the Cylinder Cap will have a force applied to it from the Lower Spring 7040 MagnumVenusPlastech Rev 03 2012 Page 26 IVx3 Injection Valve Manual 9 Pull the Actuator Piston Assembly shown below from the Int Cylinder Body 6974 Int Cylinder Cap Int Cylinder Body IVX3 Tool A a
40. 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 form improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users should make every effort to A Store MEKP in a cool dry place in original containers away from direct sunlight and away from other chemicals B Keep MEKP away from heat sparks and open flames C Prevent contamination of MEKP with other materials including polyester over spray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels MagnumVenusPlastech Rev 03 2012 Page 8 IVx3 Injection Valve Manual 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 Fire fighting equipment should be at hand and ready F Avoid spillage which can heat up to the point of self ignition G Repair
41. y such program Magnum Venus Plastech recommends this Safety Manual remain on your equipment at all times for your personnel safety In addition to the manual Magnum Venus Plastech recommends that the user consult the regulations established under the Occupational Safety amp Health Act OSHA particularly the following sections 1910 94 Pertaining to Ventilation 1910 106 Pertaining to flammable liquids 1910 107 Pertaining to spray finishing operations particularly Paragraph m Organic Peroxides and Dual Component Coatings Other standards and recognized authorities to consult are the National Fire Protection Association NFPA bulletins as follows NFPA No 33 Chapter 14 Organic Peroxides and Dual Component Materials NFPA No 63 Dust Explosion Prevention NFPA No 70 National Electrical Code NFPA No 77 Static Electricity NFPA No 91 Blower and Exhaust System NFPA No 654 Plastics Industry Dust Hazards Type of Fire Extinguishing equipment recommended Fire Extinguisher code rating number 4a60bc MagnumVenusPlastech Rev 03 2012 Page 6 IVx3 Injection Valve Manual Extinguishing Media Foam Carbon Dioxide Dry Chemical Water Fog Copies of the above bulletins are available at a nominal charge from 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
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