VPH-10000 Powerhead Manual
Contents
1. Figure 2 Lift the inner edge of the Diaphragm up and remove J 4 4 from block Coat the Diaphragm bore with lithium grease 4 08465 G N E vm NOTE Avoid putting any scratches in the Valve Blocks To remove the Diaphragm use a small screwdriver and push the center riser on the Diaphragm to one side and slide out Repeat the removal of the Diaphragm from the Upper Valve Block VPH 5001 8 Remove each O ring and replace with new Coat every new O ring with lithium grease 8465 Coat the diaphragm bore and both valve piston bores with lithium grease 8465 before assembling Use a wire brush to clean the valve rod threads of any dry thread lock compound MagnumVenusPlastech Rev 05 2012 Page 17 VPH 10000 Powerhead Manual Valve Block Reassembly NOTE Removable thread lock compound will be required for reassembly If either one of the two Valve Rods unscrewed from the Valve Poppet MPH 5005 during disassembly put one to two drops of removable thread lock compound on threads and assemble 1 Set the Valve Rod assembly into the Lower Valve Block MPH 5001 NOTE Rotate the Valve Rod assembly so the hole in the Valve Poppet aligns with the Pipe Plug PF AP 04 SS bore Insert 7 32 Hex wrench through the pipe plug bore and into the hole in the Valve Poppet to hold Valve Rod assembly in place 2 Slide the Upper Valve Block VPH 5001 into the Lower Valve Block MPH 5001 and align properly Screw the Butt2. O B 008 O Ring MPH 2512 Seal Guide MPH 2528 Spring Figure 7 6 Repeat the Pilot Valve rebuild on the Lower End Cap Ww MagnumVenusPlastech Rev 05 2012 Page 22 VPH 10000 Powerhead Manual Air Cylinder Reassembly 1 Install the Piston Rod Bushing VPH 10011 with new O rings into the Lower End Cap and secure with the Snap Ring 7205 2 26 2 Insert the Piston Rod VPH 10008 through the Piston Rod Bushing VPH 10011 3 Slide the Cylinder VPH 10003 over the Piston VPH 10006 down onto the Lower End Cap O ring O B 178 4 Set the Upper End Cap VPH 10002 onto the Cylinder with the Valve Block flats facing the same direction Screw the Hex Nuts F HN 06F onto the Tie Rods and snug the Hex Nuts 5 Position the O rings on the back of the Pilot Valve assembly 6 Mount the Pilot Valve assembly to the side of the End Caps using the four Cap Screws F CS 04C 40 SS Be sure the Pilot Valve is positioned correctly 7 Install the Muffler VPH 5004 01 to the Pilot Valve using the two Hex Bolts F HB 04C 56 SS 8 Install the Connectors VHP 10009 Retainer VPH 10010 and Quick Pin 7203 8 1 into the Piston Shaft 9 Connect the pilot air hose and regulated air hose to air motor MagnumVenusPlastech Rev 05 2012 Page 23 VPH 10000 Powerhead Manual Parts Drawings VPH 10000 10 POWER HEAD ASSEMBLY 4 STROKE VPH 10000 SK 10 AIRMOTOR SEAL KIT VPH SB XL SHIFT BLOCK FO
3. N 0 0 206 90 O RING 2 PCS MPH 5010 1 2 DIAPHRAM 2 PCS O D 010 90 O RING 2 PCS 0 U 006 O RING 2 PCS O B 011 O RING 4 PCS 0 B 008 O RING 6 4 O B 012 O RING O B 014 O RING 2 PCS 0 B 445 O RING 1 PCS 2 Pes O B 448 O RING O B 178 O RING MagnumVenusPlastech Rev 05 2012 Page 27 VPH 10000 Powerhead Manual gt USE REMOVABLE LOCTITE ON THESE THREADS AT ASSEMBLY MAGNUM VENUS PRODUCTS Shift Block for VPH 5000 7000 10000 VPH SB XL REV 10 14 05 BT2 REV A ADDED REPAIR KIT 06 04 07 BT2 jo MagnumVenusPlastech Rev 05 2012 Page 28 VPH 10000 Powerhead Manual Shift Block fof VPH 5000 7000 10000 PARTS LIST ITEM PARTNO QTY DESCRIPTION REPAIR KITS 1 VPH 5001 1 UPPER VALVE BLOCK PART NO DESCRIPTION 2 MPH 5001 1 LOWER VALVE BLOCK 3 MPH 2517 2 VALVE PISTON MPH SB XL SK SEAL KIT 4 VPH 5005 1 VALVE POPPET 5 MPH 2521 2 VALVE END CAP 6 MPH 5009 2 VALVE EXHAUST 7 019 2 O RING 8 0 U 206 90 2 O RING 9 O B 116 2 ORING 10 O B 026 2 O RING 11 0 D 010 99 2 O RING 12 O B 125 1 O RING 13 O B 008 2 14 O B 014 4 O RING 15 O B 012 2 16 F CS 04C 40 SS 4 SOCKET HEAD CAP SCREW 17 F CS 04C 08 SS 4 SOCKET HEAD CAP SCREW 18 F SS 832 02 SS 4 SET SCREW 19 F BHCS 04C 16 SS 1 BUTTON HEAD CAP SCREW 20 MPH 5010 2 DIAPHRAGM 21 PF AP M4 SS 1 PIPE PLUG 22 MPH 2539 1 PUSH POLY FITTING MALE ELBOW 23 MPH 2538 1 PU
4. Remove the Pipe Plug PF AP 04 SS from the Lower Valve Block MPH 5001 Use a 7 16 socket on either of the two Valve Pistons MPH 2517 and rotate until the hole in the Valve Poppet MPH 5005 aligns with the pipe plug port in the Lower Valve Block 5 Insert a 7 32 Hex Wrench through the pipe plug port and into the hole in the Valve Poppet MPH 5005 See Figure 1 Using a 7 16 socket or wrench unscrew either of the two Valve Pistons MPH 2517 and remove Repeat removal of the second Valve Piston Figure 1 Use a 7 16 socket or wrench on the top of the valve piston and rotate to align the round hole in the poppet with the tapped hole in the block Insert hex wrench into the poppet and unscrew the valve piston from the valve rod Repeat process for second valve piston NOTE The hole diameter in the Valve Poppet is 2685 6 81mm if a 7 32 hex wrench is not available MagnumVenusPlastech Rev 05 2012 Page 16 VPH 10000 Powerhead Manual 6 Remove the Button Head Cap Screw F BHCS 04C 16 SS from the front of the Lower Valve Block MPH 5001 Twist and pull the Upper Valve Block VPH 5001 from the Lower Valve Block MPH 5001 Remove the valve rod assembly from the Valve Block 7 Remove the two Cap Screws F CS 04C 08 SS from each of the two Valve Exhausts MPH 5009 Pull both of the Valve Exhausts from the Valve Blocks Remove the Diaphragm MPH 5010 from the Lower Valve Block MPH 5001 See Figure 2 J
5. SS F FW 04 PF HN 08 08S VPH 10007 F HB 08C 24 GR8 MPH 3262 DONOTOILAIRMOTOR F SW 08 SM Ab hu a aNNNNGAN b NN PN a NOAA NNNNANNNSN lt amp S NIN HH rh zb h e DESCRIPTION ITEM PART NO QTY DESCRIPTION PISTON 65 PF ST 02 BR 1 STREET TEE CYLINDER 66 MPH 2546 01 1 RESET STEM ASSEMBLY PISTON ROD 67 MPH 2545 1 SEAL MUFFLER ASSEMBLY PISTON ROD BUSHING LOWER END CAP UPPER END CAP OPTIONAL PARTS AND ASSEMBLIES SPRING HOUSING ASSY STEM SEAL PARTS LIST O RING ITEM PARTNO QTY DESCRIPTION SEAL GUIDE VPH SB XL 1 SHIFT BLOCK ASSY VALVE STEM PILOT VALVE 68 MPH 2542 1 RESET BUTTON ASSY INLET ROD PILOT VALVE UPPER VALVE BLOCK REPAIR KITS LOWER VALVE BLOCK PART NO DESCRIPTION VALVE PISTON VALVE POPPET VPH 10000 SK SEAL KIT VALVE END CAP VALVE EXHAUST O RING TIE ROD O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING HEX BOLT HEX NUT HEX BOLT CAP SCREW CAP SCREW LOCK WASHER SET SCREW BUTTON HEAD CAP SCREW SPRING SPRING SPRING DIAPHRAGM PIPE PLUG POLY ELBOW POLY TEE 91 4 TUBING ROD CONNECTOR CONNECTOR RETAINER QUICK PIN SNAP RING O RING PIPE PLUG FLAT WASHER ADAPTER TIE ROD HEX BOLT PISTON STOP DO NOT OIL DECAL NOT SHOWN LOCK WASHER MagnumVenusPlastech Rev 05 2012 Page 26 VPH 10000 Powerhead Manual VPH 10000 SK SEAL KIT 10 AIR MOTOR 2 PCS u
6. Spring MPH 2533 into the Spring Housing MPH 2541 with Inlet Rod MPH 2540 facing up MPH 2526 Spring O U 006 O Ring MPH 2540 Inlet Rod e MPH 2533 Spring O B 012 O Ring MPH 2541 Spring Housing H t Figure 5 The MPH 2526 spring will be installed from the bottom of the end cap NOTE Do not install the small Spring MPH 2526 at this time 3 Screw the Inlet Spring Housing MPH 2509 into the Upper End Cap ivo MagnumVenusPlastech Rev 05 2012 Page 21 VPH 10000 Powerhead Manual 4 Remove the Stem Seal MPH 2511 01 from the bottom of the Upper End Cap VPH 10002 Remove the Seal Guide MPH 2512 with the Spring MPH 2528 Replace O ring O B 012 and lightly coat O ring and Stem with SUPERLUBE grease SUPERLUBE Drop the small Spring MPH 2526 into the Stem Seal bore the Spring should center itself onto the end of the Inlet Rod MPH 2540 See Figure 6 Figure 6 Install the Spring MPH 2526 after the Spring Housing MPH 2541 Spring MPH 2533 and Inlet Rod MPH 2514 has been installed in the top of the End Cap 5 Insert the Spring MPH 2528 with the Seal Guide MPH 2512 into the End Cap Set the small end of the Seal Guide MPH 2512 onto the Spring MPH 2528 Set a new O ring O B 008 on top of the Seal guide Screw the Stem Seal 2511 01 with Valve Stem MPH 2513 into the Upper End Cap See Figure 7 1 MPH 2513 Valve Stem MPH 2511 1 Stem Seal V O B 012 O Ring
7. agree to waive all rights to trial by jury as to any and all disputes e The goods remain the property of the Seller until full payment is received e Sale of equipment is subject to application and issuance of proper US Government export license and regulations if applicable e Installation of equipment is responsibility of Buyer and Seller with cost responsibility and number of days provided as detailed in original customer Quotation Seller will provide installation supervision personnel within 30 days of customer request 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 05 2012 5 VPH 10000 Powerhead Manual Gr SAFETY amp WARNING INFORMATION OPERATING YOUR POLYESTER SYSTEM SAFELY AN 1 Introduction Any tool if used improperly can be dangerous Safety is ultimately the
8. gun hanging over or lying inside the mold A catalyst leak in this situation would certainly damage the part possibly the mold and may cause a fire 3 Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom sections and at the hose and fittings Replace if wear or weakness is evident or suspected 4 Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub against any of the hoses at any point If allowed to rub the hose will be cut through causing a hazardous leakage of material which could increase the danger of fire Also the material may spew onto personnel in the area 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 ivo MagnumVenusPlastech Rev 05 2012 Page 11 VPH 10000 Powerhead 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 Plaste
9. 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 any
10. 2 Page 19 VPH 10000 Powerhead Manual Air Cylinder Disassembly 1 Remove the Quick Pin 7203 8 1 from the Piston Rod VPH 10008 Lift the Connector Retainer VPH 10010 up and remove the two Rod Connectors VPH 10009 2 Remove the five 5 Hex nuts F HN 06F from the Tie Rods VPH 5003 3 Pull the Upper End Cap VPH 10002 off the Cylinder VPH 10003 4 Carefully lift the Cylinder VHP 10003 off the Piston and Piston O ring 5 Slide the Piston Rod VPH 10008 up from the Lower End Cap VPH 10002 6 Use a pair of Snap Ring Pliers to remove the Snap Ring 7205 2 26 from the Piston Rod Bushing VPH 10011 7 Remove the Piston Rod Bushing from the Lower End Cap 8 Replace all O rings and coat with lithium grease 8465 Coat the inside of the Cylinder Piston rod and Piston rod bushing with lithium grease 8465 MagnumVenusPlastech Rev 05 2012 Page 20 VPH 10000 Powerhead Manual Pilot Valve Rebuild NOTE The two pilot valves in the upper and lower end caps are the same Start with the pilot valve in the upper end cap 1 Remove the Spring housing MPH 2541 from the Upper end cap VPH 10002 Remove Spring MPH 2533 with Inlet Rod MPH 2540 Turn the End Cap over and a small Spring MPH 2526 will fall out See Figure 5 2 Replace O ring O B 012 on the Spring Housing MPH 2541 and the O ring O U 006 on the Inlet Rod MPH 2540 Coat O rings and Springs with SUPERLUBE grease SUPERLUBE Set
11. ANY TIMES AS NECESSARY DO NOT PERFORM ANY MAINTENANCE OR REPAIRS UNTIL YOU HAVE FOLLOWED THE PRECAUTIONS STATED ABOVE IF YOU AS AN EQUIPMENT OPERATOR OR SUPERVISOR DO NOT FEEL THAT YOU HAVE BEEN ADEQUATELY TRAINED OR INSTRUCTED AND THAT YOU LACK THE TECHNICAL KNOWLEDGE TO OPERATE OR PERFORM MAINTENANCE ON A PIECE OF MAGNUM VENUS PLASTECH EQUIPMENT PLEASE CALL MAGNUM VENUS PLASTECH BEFORE OPERATING OR PERFORMING MAINTENANCE ON THE EQUIPMENT IF YOU HAVE ANY QUESTIONS REGARDING THE ABOVE PRECAUTIONS OR ANY SERVICE OR OPERATION PRECEDURES CALL YOUR MAGNUM VENUS PLASTECH DISTRIBUTOR OR MAGNUM VENUS PLASTECH NOTICE All statements information and data given herein are believed to be accurate and reliable but are presented without guaranty warranty or responsibility of any kind express or implied The user should not assume that all safety measures are indicated or that other measures are not required DANGER Contaminated catalyst may cause Fire or Explosion Before working on the catalyst pump or catalyst accumulator wash hands and tools thoroughly Be sure work area is free of dirt grease or resin Clean catalyst system components with clean water only DANGER Eye skin and respiration 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 hand
12. ORATE HEADQUARTERS and MANUFACTURING 11692 56 Court Clearwater FL 33760 Tel 727 573 2955 Fax 727 571 3636 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 MVP Plastech UK Chilsworthy Beam Gunnislake Cornwall PL18 9AT UK Tel 44 0 1822 832621 Fax 44 0 1822 833999 www mvpind com Assemblies Covered in this Manual VPH 10000 10 PowerSlide Powerhead 4 Stroke Rev 05 2012 MagnumVenusPlastech Rev 05 2012 Page 32
13. R VPH 5000 7000 amp 10000 MPH SB XL SK SEAL KIT VALVE BLOCK Ww MagnumVenusPlastech Rev 05 2012 Page 24 VPH 10000 Powerhead Manual NOTE A LIGHT COAT OF SUPER O LUBE IS RECOMMENDED ON THE UPPER AND LOWER PILOT VALVES L USE REMOVABLE LOCTITE ON THESE THREADS AT ASSEMBLY MAGNUM VENUS PLASTECH Assembly 10 Power Head 4 Stroke VPH 10000 REV ITEMS 51 WAS 01417 11 09 07 BT2 J ITEMS 5 WAS INCORRECT ITEM 64 WAS F SW 06 ADDED ITEMS 65 66 67 amp 68 01 28 09 BT2 K FIXEDITEM65 03 10 09 BT2 L ADDED SUPER LUBE NOTE FOR PILOT VALVES 05 25 11 BT2 ivo MagnumVenusPlastech Rev 05 2012 Page 25 VPH 10000 Powerhead Manual Assembly 10 Power Head 4 Stroke VPH 10000 35 36 37 38 39 40 41 42 43 44 45 47 48 49 50 51 53 55 57 58 59 61 62 63 64 PARTS LIST QTY PART NO VPH 10006 VPH 10003 VPH 10008 VPH 5004 01 VPH 10011 VPH 10001 VPH 10002 MPH 2541 MPH 2511 01 O B 127 MPH 2512 MPH 2513 MPH 2540 VPH 5001 MPH 5001 MPH 2517 VPH 5005 MPH 2521 MPH 5009 O B 019 VPH 5003 O U 206 90 O B 116 O B 026 O D 010 90 O B 125 O B 008 O B 014 O B 012 O U 006 O B 124 O B 448 O B 178 O B 445 F HB 04C 56 SS F HN 06F F HB 12F 24 GR5 F CS 04C 40 SS F CS 04C 08 SS F SW 04 SS F SS 832 02 SS F BHCS 04C 16 SS MPH 2526 MPH 2528 MPH 2533 MPH 5010 PF AP 04 SS MPH 2539 MPH 2538 MS 2052 1 VPH 10009 VPH 10010 7203 8 1 7205 2 26 O B 011 PF AP 02
14. SH POLY FITTING MALE TEE 24 MS 2052 1 561 Q1 4x6 3 4 TUBING 25 O B 011 2 26 PF AP 02 SS 2 PIPEPLUG 27 PF RB 08 06 1 PIPE BUSHING 28 PF HN 06 06S 1 HEX NUT 29 MPH 3262 2 PISTON STOP 30 PF ST 02 BR 1 TEE FITTING 31 MPH 2546 01 41 VALVE STEM ASSY 32 MPH 2545 1 SEAL OPTIONAL PARTS AND ASSEMBLIES PARTS LIST ITEM PARTNO QTY DESCRIPTION ER MPH 2542 1 RESET BUTTON ASSY MagnumVenusPlastech Rev 05 2012 Page 29 VPH 10000 Powerhead Manual MPH SB XL SK SEAL KIT 5 MOTOR 2 PCS 0 B 008 O RING 5 pre FA Vo 2 PCS O B 011 O RING 2 PCS O D 010 90 O RING 2 PCS O B 012 O RING 2 PCS NS N MPH 5010 1 2 DIAPHRAM 4 PCS 0 B 014 O RING 2 PCS 0 B 116 O RING PC B O Q O S 019 O RING 2 PCS O B 026 O RING 1 PCS O B 125 O RING MagnumVenusPlastech Rev 05 2012 Page 30 VPH 10000 Powerhead Manual Revision Information Rev 02 2010 Created the Manual Rev 02 2010 A Added Safety amp Warning information added the procedures for mounting the Pilot Valve to the powerhead Rev 06 2011 Included the note for the SUPERLUBE grease on the Upper and Lower Pilot Valves Updated the drawings in the manual Rev 05 2012 Updated the Logo MVP Address and the manual format added the Terms and Conditions section Ww MagnumVenusPlastech Rev 05 2012 Page 31 VPH 10000 Powerhead Manual Magnunr Venus Plastech MAGNUM VENUS PLASTECH M CORP
15. VPH 10000 Powerhead Manual 10 00 Diameter MagnumVenusPlastech Rev 05 2012 VPH 10000 Powerhead Manual MagnumVenusPlastech CORPORATE HEADQUARTERS and MANUFACTURING 11692 56 Court Clearwater FL 33760 Tel 727 573 2955 Fax 727 571 3636 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 MVP Plastech UK Chilsworthy Beam Gunnislake Cornwall PL18 9AT UK Tel 44 0 1822 832621 Fax 44 0 1822 833999 www mvpind com MagnumVenusPlastech Rev 05 2012 Page 2 VPH 10000 Powerhead Manual TABLE OF CONTENTS SECTION Page TERMS amp CONDITIONS OF SALE 4 SAFETY amp WARNING INFORMATION 6 INTRODUCTION 15 VALVE BLOCK DISASSEMBLY 16 VALVE BLOCK REASSEMBLY 18 AIR CYLINDER DISASSEMBLY 20 PILOT VALVE REBUILD 21 AIR CYLINDER REASSEMBLY 23 PARTS DRAWINGS 24 REVISION INFORMATION 31 ec G2 MagnumVenusPlastech Rev 05 2012 3 VPH 10000 Powerhead 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 Sell
16. air 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 I Catalyst accumulated from the purging of hoses or the measurement of fluid output delverie AN should never be returned to the supply tank such catalyst should be diluted with copious quantities of clean water and disposed of in accordance with the catalyst manufacturer s instructions The extent to which the user is successful in accomplishing these ends and any additional recommendations by the catalyst manufacturer determines largely the safety that will be present in his operation 2 3 Clean Up Solvents and Resin Diluents WARNING A hazardous situation may be present in your pressurized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed pressurized fluid system pump heaters filters valves spray guns tanks etc The explosion could cause serious injury death and or 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 Ha
17. always wear full eye protection even when laminating operations are not taking place Safety in handling MEKP depends to a great extent on employee education proper safety instructions and safe use of the chemicals and equipment Workers should be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regards to contamination heat friction and impact They should be thoroughly instructed regarding the proper action to be taken in the storage use and disposal of MEKP and other hazardous materials used in the laminating operation In addition users should make every effort to A Store MEKP in a cool dry place in original containers away from direct sunlight and away from other chemicals B Keep MEKP away from heat sparks and open flames C Prevent contamination of MEKP with other materials including polyester over spray and sandings polymerization accelerators and promoters brass aluminum and non stainless steels Ww MagnumVenusPlastech Rev 05 2012 Page 8 VPH 10000 Powerhead 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 Firefighting equipment should be at hand and ready F Avoid spillage which can heat up to the point of self ignition G Rep
18. ch recommends the use of protective clothing and eye wear in using polyester systems However users should be prepared in the event of such an injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Besure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals have WARNING AN 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 opera
19. e the mixing of HHC solvents with other materials or solvents such as MEKP alcohol and toluene may render the inhibitors ineffective B The use of reclaimed solvents is particularly hazardous Reclaimers may not add any inhibitors Also the possible presence of water in reclaimed solvents could feed the reaction C Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction Such coatings can be worn cracked scratched or too thin to prevent contact There is no known way to make oxide coatings or to employ aluminum alloys which will safely prevent the chemical reaction under all circumstances D Several solvent suppliers have recently begun promoting HHC solvents for use in coating systems The increasing use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans as Volatile Organic Compounds VOC s their low flammability hazard and their not being classified as toxic or carcinogenic AN substances HHC solvents are very desirable in 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 TAKE IMMEDIATE ACTION Halogenated Hydrocarbon solvents are dangerous when used with alumi
20. er will ship prior to the delivery date if possible but not without Buyer s consent on Advanced Equipment sales All contract dates and timelines begin upon receipt at MVP of customer purchase order signed Terms and Conditions of Sale if applicable and down payment per quotation if applicable If shipments are delayed by the Buyer or because the Buyer s account is in arrears payments shall become due on the date when the Seller is prepared to make shipment Products held by the Seller for the Buyer shall be at the risk and expense of the Buyer Damages defects or shortages must be communicated immediately to MVP Discrepancy in pricing and or quantities on invoices must be reported within 30 days of the invoice date Claims made 30 days or more following the invoice date will not be honored Permission to return items must be requested and granted in advance No credit will be given if items are returned prior to requesting and receiving permission All returns are subject to a restocking fee The standard 15 charges may be increased or decreased depending on the reason for the retum 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 warrant
21. g of MEKP and diluents In addition it eliminates any problems from the diluent 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
22. ling and storage of catalyst Wear appropriate safety equipment as recommended ivo MagnumVenusPlastech Rev 05 2012 Page 14 VPH 10000 Powerhead Manual Introduction This manual covers the 10 diameter by 4 stroke length Powerhead VPH 10000 The reassembly will require the use of removable Loctite amp or equivalent thread lock compound Lithium grease Lubriplate 08465 and SUPERLUBE o ring lubricant NOTE Before starting any service work release fluid and air pressure from system Remove the two air lines from the air motor The Powerhead assembly does not have to be completely removed from the system for service work Please read the manual carefully Follow 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 This will help you to reassemble them MagnumVenusPlastech Rev 05 2012 Page 15 VPH 10000 Powerhead Manual Valve Block Disassembly 1 Remove the two Hex Head Screws F HB 04C 56 SS from the front of the Muffler and remove the Muffler 2 Remove the four Socket Head Cap Screws F CS 04C 40 SS from the Valve Block 3 Unscrew the Poly Fitting Nut from the male elbow MPH 2539 located on the side of the Valve Block Remove the two End Caps MPH 2521 from the Valve Block 4
23. logenated Hydrocarbon Solvents A There are three key elements to the Halogenated Hydrocarbon HHC solvent hazard a The presence of HHC solvents 1 1 1 Trichloroethane and Methylene Chloride are the most common of these solvents However other HHC solvents are suspect if used either as part of paint or adhesives formulation or for clean up flushing b Aluminum or Galvanized Parts Most handling equipment contains these elements In contact with these metals HHC solvents could generate a corrosive reaction of a catalytic nature b Equipment capable of withstanding pressure When HHC solvent 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 ivo MagnumVenusPlastech Rev 05 2012 Page 9 VPH 10000 Powerhead 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 Furthermor
24. num components in a closed fluid system A Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocarbon Solvents B Magnum Venus Plastech recommends that you contact your solvent supplier regarding the best non flammable clean up solvent with the heat toxicity for your application C If however you find it necessary to use flammable solvents they must be kept in approved electrically grounded containers D Bulk solvent should be stored in a well ventilated separate building 50 feet away from your main plant E You should allow only enough solvent for one day s use in your laminating area F NO SMOKING signs must be posted and observed in all areas of storage or where solvents and other flammable materials are used 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 ivo MagnumVenusPlastech Rev 05 2012 Page 10 VPH 10000 Powerhead 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 mixin
25. on Head Cap Screw F BHCS 04C 16 SS into the Lower Valve Block 3 Use one or two drops of removable thread lock compound in the female threads of the Valve Pistons MPH 2517 See Figure 3 Shake off any excess thread lock compound and screw onto either Valve Rod end Repeat for process for the second Valve Piston and remove Hex wrench from Valve Block Ke Ki NG n Figure 3 Use only one or two drops of thread lock compound in valve piston threads 4 Use either Teflon tape or Pipe compound on the Pipe Plug PF AP 04 SS threads and screw into the Lower Valve Block 5 Insert the Diaphragms MPH 5010 into the Upper and Lower Valve Blocks with the outside leading edge of the Diaphragms facing out Push the Diaphragms all the way down into the Valve Block bore Ww MagnumVenusPlastech Rev 05 2012 Page 18 VPH 10000 Powerhead Manual 6 Install the Valve Exhausts MPH 5009 onto the Upper and Lower Valve Blocks One side of the Valve Exhausts has three holes one of the holes must line up with the machined holes in the Upper and Lower Valve Block See Figure 4 7 Install the two Socket Head Cap Screws FCS 04C 08 SS into each of the two Valve Exhausts and snug tight A e Figure 4 Do not block the hole in the valve block when installing the valve exhaust 8 Install Valve End Caps MPH 2521 into the Upper and Lower Valve Blocks and lightly snug tight Ww MagnumVenusPlastech Rev 05 201
26. pect to ingestion inhalation and skin and eye hazards ivo MagnumVenusPlastech Rev 05 2012 Page 7 VPH 10000 Powerhead Manual 2 2 Catalyst Methyl Ethyl Ketone Peroxide MEKP is among the more hazardous materials found in commercial channels The safe handling of the unstable reactive chemicals presents a definite challenge to the plastics industry The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage transportation handling processing and disposal MEKP is a single chemical Various polymeric forms may exist which are more or less hazardous with respect to each other These differences may arise not only from different molecular structures all are nevertheless called MEKP and from possible trace impurities left from the manufacture of the chemicals but may also arise by contamination of MEKP with other materials in its storage or use Even a small amount of contamination with acetone for instance may produce an extremely shock sensitive and explosive compound Contamination with promoters or materials containing promoters such as laminate AN 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 i
27. s 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 res
28. 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 ABC rating number 4a60bc ivo MagnumVenusPlastech Rev 05 2012 Page 6 VPH 10000 Powerhead Manual Extinguishing Media Foam Carbon Dioxide Dry Chemical Water Fog Copies of the above bulletins are available at a nominal charge from T 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 i
29. t to reach what is called its Self Accelerating Decomposition Temperature SADT Researchers have reported measuring pressure rates of rise well in excess of 100 000 psi per second when certain MEKP s reach their SADT For comparison the highest pressure rate of rise listed in NFPA Bulletin NO 68 Explosion Venting is 12 000 psi per second for an explosion of 1296 acetylene and air The maximum value listed for a hydrogen explosion is 10 000 psi per second Some forms of MEKP if allowed to reach their SADT will burst even an open topped container This suggests that it is not possible to design a relief valve to vent this order of magnitude of pressure rate of rise The user should be aware that any closed container be it a pressure vessel surge chamber or pressure accumulator could explode under certain conditions There is no engineering substitute for care by the user in handling organic peroxide catalysts If at any time the pressure relieve valve on top of the catalyst tank should vent the area should be evacuated at once and the fire department called The venting could be the first indication of a heat and therefore pressure build up that could eventually lead to an explosion Moreover if a catalyst tank is sufficiently full when the 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
30. t will be an adequate path under all conditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed on all loose conductive objects in the spraying area This includes material containers and equipment Magnum Venus Plastech recommends grounding straps be made of AWG No 18 stranded wire as a minimum and the larger wire be used where possible NFPA Bulletin No77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm 10 ohms but that resistance as high as 10 000 meg ohms will produce an adequate leakage path in some cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and grounded to dissipate static electricity For further information see National Fire Protection Association NFPA 77 titled Recommended Practice on Static Electrical Refer especially to section 7 7 titled Spray Application of Flammable and Combustible Materials Check with local codes and authorities for other specific standards that 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 M
31. ting instructions and service information Ww MagnumVenusPlastech Rev 05 2012 Page 12 VPH 10000 Powerhead Manual 3 0 Equipment Safety WARNING Magnum Venus Plastech suggests that personal safety equipment such as EYE GOGGLES GLOVES EAR PROTECTION and RESPIRATORS be worn when servicing or operating this equipment Ear protection should be worn when operating a fiberglass chopper to protect against hearing loss since noise levels can be as high as 116 dB decibels This equipment should only be operated or serviced by technically trained personnel WARNING Never place fingers hands or any body part near or directly in front of the spray gun fluid tip The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON TREAT THE GUN AS IF IT WERE A LOADED PISTOL 3 1 Emergency Stop Procedures The following steps should be followed in order to stop the machinery in an emergency situation 1 The ball valve located where the air enters the power head of the resin pump should be moved to the OFF or closed position To do this simply rotate the lever on the 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 15 a precautionary step and should be followed whenever the above men
32. tioned ball valve is activated to the stop mode Failure to do so can damage the regulators and components on reactivating to the ON position 2 Turn all system regulators to the OFF position counter clockwise position NOTE Verify that the Catalyst relief line located on the catalyst manifold and the resin return line located on the resin filter are secured relieving catalyst and resin fluid pressure 3 Catalyst pressure in the catalyst pump can be eliminated by rotating the ball valve on the catalyst manifold 90 degrees to the open or 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 AN 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 ivo MagnumVenusPlastech Rev 05 2012 Page 13 VPH 10000 Powerhead 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 a 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 wha
33. y does not cover general wear and tear or damage due to negligence or improper use Seller s liability under the warranty shall be limited solely to repair or replacement costs and has no responsibility for reimbursing repair cost incurred by Buyer in connection with equipment without first giving written authorization for such charges Seller makes no express warranties except those set forth in this agreement and disclaims all other warranties expressed or implied including without limitation implied warranties of non infringement merchantability and fitness for a particular purpose Seller accepts no liability for loss of production loss of profits or other direct or indirect damages In any claim by the Buyer MagnumVenusPlastech Rev 05 2012 Page 4 VPH 10000 Powerhead 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
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