IVx3 Service Module - 8018
Contents
1. Close the Vacuum Isolation Valve Now wait several minutes to check that the vacuum level on the vacuum gauge does not drop If the vacuum level drops then check the IVx3 Seal and repair as needed INJECT output signal PURGER output signal Valve Mode Control PURGE OFF INJECT Rev 10 2012 Page 19 Vacuum Valve Service Module Manual Actuator Testing 1 10 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 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 steps2. Vacuum Valve Service Module Manual MagnumVenusPlastech Rev 10 2012 Page 30 Vacuum Valve Service Module Manual Revision Information Rev 10 2012 Created Control Box Manual La MagnumVenusPlastech Rev 10 2012 Page 31 Vacuum Valve Service Module Manual Magnunr Venus p 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 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 10 2012 Page 32
3. Clean catalyst system components with clean water only DANGER Eye skin and respiration hazard The Catalyst MEKP may cause blindness skin irritation or breathing difficulty Keep hands away from face Keep food and drink away from work area WARNING Please refer to your catalyst manufacturer s safety information regarding the safe handling and storage of catalyst Wear appropriate safety equipment as recommended MagnumVenusPlastech Rev 10 2012 Page 14 Vacuum Valve Service Module Manual W Introduction This Vacuum Service Module is an air driven unit which allows users of the PPVS PPVS Infusion and AutoCatch to easily check and adjust the switching point of these control valves It also allows for testing for vacuum leaks in the IVx3 IVx2 TAS and TAS 14 Injection valves The Calibration Box s internal vacuum can be adjusted infinitely between atmosphere and minus 800mb 8018 IVx3 SERVICE MODULE has the following features Universal insert for vacuum integrity testing Adjustable vacuum level Vacuum isolation valve Pressure indicator for PPVS testing etc Three position selector valve to control outputs to inject and purge ports Air out port Internal regulator set at 6 bar for control signals and air out port Air leak signal outputs this can be used to test PPVS 1000 etc Some fittings and tubing supplied attached to the box so no additional items required for most tests P po
4. Dry Chemical Water Fog Copies of the above bulletins are available at a nominal charge from AN 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 It is published by American Insurance Association 85 John Street New York NY 10038 Local codes and authorities also have standards to be followed in the operation of your spraying equipment Your insurance carrier will be helpful in answering questions that arise in your development of safe procedures 1 2 Personal Safety Equipment Magnum Venus Plastech recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems Magnum Venus Plastech recommends that the user consult the state and local regulations established for all Safety equipment listed 2 0 Material Safety 2 1 Hazards Associated with Laminating Operations The major hazards which should be guarded against in polyester laminating operations are those associated with 1 The flammability and explosion dangers of the catalyst normally used Methyl Ethyl Ketone Peroxide MEKP 2 The flammability dangers of clean up solvents sometimes used Magnum Venus Plastech recommends that clean up solvents be non flammable and of resin diluents used such as styrene 3 The flammability dangers of catalyst diluents if use
5. observed to stop when the PPVS signals at the chosen switch point 1 Connect the INJECT Output to the PPVS supply port using 4 mm tube 2 Then Tee the PPVS Leak Signal port on the top of the PPVS into the MPG signal using 4 or 6 mm tube 3 Using the Vacuum Level Control adjust the vacuum pressure Up Down The Unit will stop when the PPVS activates the leak port MagnumVenusPlastech Rev 10 2012 Page 23 Vacuum Valve Service Module Manual Testing using the in box leak circuit 1 Connect the PPVS supply signal to the Inject port on the control box 2 Connect one of leak circuit lead signal to the top of the PPVS 6mm push fit using the tube and 6mm 4mm reducer provided 3 Then connect the other leak signal to the indicator 4 Adjust the PPVS when the indicator is on the machine would be running See image below INDICATOR VACUUM LEVEL CONTROL Testing PPVS 1000 for vacuum leak 1 Load the PPVS valve into the Universal Insert Adaptor port 2 Connect the INJECT Output on the control box to the PPVS supply port using 4 mm tube 3 Connect the PPVS signal line to the pneumatic Indicator on the control box 4 Using the Vacuum Level Control adjust the vacuum to the desired level 5 Turn the Vacuum Isolator valve to the Closed position horizontal to lock the vacuum level if the vacuum level moves leaks down the seal in the valve is not holding vacuum aq MagnumVenusPla
6. DIAS II MagnumVenusPlastech Rev 10 2012 Page 15 Vacuum Valve Service Module Manual W Overview 8mm 10mm Main Air Inlet Hi p HE i f HE 977 a f F If Te gt 2 La A vA ae a Deer g 2 9 EI a A 5s SOS SESE te anann ele T non Universal Insert Adapter Plug the Valve being tested adjusted in this location Vacuum Gauge indicates vacuum level as set by the Vacuum Level Control Vacuum Isolation Valve locks the vacuum on the valve to test for leaks Indicator pneumatic indicator connects to the control valve output to indicate when the valve activates pm MagnumVenusPlastech Optional Air Outlet 4mm connection Signal Valve sends an air signal to the Injection valve to activate Can be used to activate the IVx3 in either Purge or Inject mode Vacuum Level Control adjusts sets the vacuum pressure Rev 10 2012 Page 16 Vacuum Valve Service Module Manual Test Fittings Tubing 38 A247 E 4 5 Veg v Air Leak Signal Controls Overview 9 2 PURGE Output Signal Port INJECT Output Signal Port PURGE OFF INJECT When connected to a valve it switches the valve mode If the valve is placed in the off state no signals are sent When in purge mode an air signal
7. Valve Service Module 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 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 fi
8. 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 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 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 the
9. 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 With the Fluid section of the valve removed Put the IVX3 into the Inject position and then squirt some soapy water around the Bottom Bush 6983 to check for air leaks With the Fluid section installed Put the IVX3 into the Inject position and then Squirt some soapy water around the Isolation Channel as shown in the image below Isolation Channel E 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 Bush is in good condition d Actuator shaft is not damaged scored etc CPF MagnumVenusPlastech Rev 10 2012 Page 20 Vacuum Valve Service Module Manual 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 clo
10. IVx3 SERVICE MODULE MANUAL 8018 i 77 _ e INDICATOR E O UNIVERSAL INSERT ADAPTER VAC UUM GAUGE INDICATOR VACUUM VACUUM oL ISOLATION LEVEL CONTR VALVE PURGE MagnumVenusPlastech Rev 10 2012 Vacuum Valve Service Module 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 P MagnumVenusPlastech Rev 10 2012 Page 2 Vacuum Valve Service Module Manual TABLE OF CONTENTS SECTION TERMS amp CONDITIONS OF SALE SAFETY amp WARNING INFORMATION INTRODUCTION OVERVIEW IVx3 INJECTION TEST PROCEDURES PPVS 1000 TEST PROCEDURES PPVS INFUSION TEST PROCEDURES TAS TEST PROCEDURES INSIDE THE CONTROL BOX PARTS DRAWINGS REVISION INFORMATION o Qu MagnumVenusPlastech Rev 10 2012 Page 15 16 19 23 25 26 27 28 31 Page 3 Vacuum Valve Service Module 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 in
11. ay 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 Repair any leaks discovered in the catalyst system immediately and clean up the leaked catalyst at once in accordance with the catalyst manufacturer s instructions H Use only original equipment or equivalent parts from Magnum Venus Plastech in the catalyst system i e hoses fitting etc because a dangerous chemical reaction may result between substituted parts and MEKP Catalyst accumulated from the purging of hoses or the measurement of fluid output A should never be returned to the supply tank such catalyst should be diluted with copious quantities of clean water and disposed of 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 syst
12. ble Materials Check with local codes and authorities for other specific standards that might apply to your application NEVER USE HARD MATERIALS SUCH AS WIRE PINS ETC TO CLEAR A PLUGGED GUN HARD MATERIALS CAN CAUSE PERMANENT DAMAGE DAB WITH A BRISTLE BRUSH BLOW BACKWARDS WITH AIR UNTIL CLEAR WHILE WEARING A PROTECTIVE EYE SHIELD REPEAT AS MANY TIMES AS NECESSARY DO NOT PERFORM ANY MAINTENANCE OR REPAIRS UNTIL YOU HAVE FOLLOWED THE PRECAUTIONS STATED ABOVE IF YOU AS AN EQUIPMENT OPERATOR OR SUPERVISOR DO NOT FEEL THAT YOU HAVE BEEN ADEQUATELY TRAINED 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 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
13. cluded 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 ship prior to the delivery date if possible but not without Buyer s consent on Advanced Equipment sales All contract dates and timelines begin upon receipt at MVP of customer purchase order signed Terms and Conditions of Sale if applicable and down payment per quotation if applicable If shipments are delayed by the Buyer or because the Buyer s account is in arrears payments shall become due on the date when the Seller is prepared to make shipment Products held by the Seller for the Buyer shall be at the risk and expense of the Buyer Damages defects or shortages must be communicated immediately to MVP Discrepancy in pricing and or quantities on invoices must be reported within 30 days of the invoice date Claims made 30 days or more following the invoice date will not be honored Permission to return items must be requested and granted in advance No credit will be given if items are returned prior to requesting and receiving permission All returns are subject to a restocking fee The standard 15 charges may be increased or decreased depending on the reason for the return Special ordered items may not be returned Seller warrants that the m
14. d 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 respect to ingestion inhalation and skin and eye hazards MagnumVenusPlastech Rev 10 2012 Page 7 Vacuum Valve Service Module 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
15. e Module Manual Testing the TAS urvo auto sprue Testing TAS for vacuum leak l 2 3 Load the TAS valve into the Universal Insert Adaptor port Connect the INJECT Output on the control box to the TAS supply port using 4 mm tube Operate the switch on the Service Module and put the valve in the INJECT position Ensure the actuator shaft assembly moves freely through its full range of travel and that the top of the shaft is visible Put the switch on the Service Module into 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 8096 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 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 Once a suitable vacuum level is reached close the isolation valve on the Service Module to isolate the vacuum source Adjust the vacuum level to zero Off Ideally the level on the vacuum gauge should remain stationary and the vacuum should be maintained Open the vacuum Isolation valve to remove the vacuum NOTE It is important that the valve does not leak in production air could be drawn into the part during the curing cycle Pressure Testing t
16. echanical 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 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 10 2012 Page 4 Vacuum Valve Service Module Manual against the Seller in respect of the goods the liability of the Seller shall be limited to the value of the goods e 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 quali
17. edes any previous agreement and applies in full MagnumVenusPlastech Rev 10 2012 5 Vacuum Valve Service Module Manual SAFETY amp WARNING INFORMATION OPERATING YOUR POLYESTER SYSTEM SAFELY AN 1 Introduction Any tool if used improperly can be dangerous Safety is ultimately the responsibility of those using the tool In like manner safe operation of polyester processes is the responsibility of those who use such processes and those who operate the equipment This manual outlines procedures to be followed in conducting polyester operations safety This system has been specifically designed for use of Polyester Resin Gel Coat and Methyl Ethyl Ketone Peroxides MEKP applications Other formulations or blends considered for use in this equipment is strictly prohibited without the expressed consent by Magnum Venus Plastech Inc Magnum Venus Plastech cannot eliminate every danger nor foresee every circumstance that might cause an injury during equipment operation Some risks such as the high pressure liquid stream that exits the spray tip are inherent to the nature of the machine operation and are necessary to the process in order to manufacture the end product For this reason ALL personnel involved in polyester operations should read and understand the Safety Manual It is very important for the safety of employees involved in the operation that equipment operators maintenance and supervisory personnel understand the req
18. em 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 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 n 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 10 2012 9 Vacuum Valve Service Module Ma
19. he TAS 1 2 For TAS testing use the fittings to block the Flush Purge line Connect the Resin Inlet to the pressure output on the Service Module 6 7 bar 87 100 PSI Connect Inject signal from selector to the TAS signal When the valve is closed use soapy water around nose body to check for leaks Point nose away from yourself and others and then open close a number of times to check the actuator exhausting air and then repeat the leak test and cycling a number of times to ensure the valve is ok MagnumVenusPlastech Rev 10 2012 Page 26 Vacuum Valve Service Module Manual INSIDE THE BOX B Leak Circuit Flow Control Vacuum Isolation Valve y L PL 7 Lut NE A pit 150 rw E m Universal Insert Port Vacuum Level Regulator MagnumVenusPlastech Rev 10 2012 Page 27 Vacuum Valve Service Module Manual Parts Drawings 83005 01 Pneumatic Diagram 8018 La MagnumVenusPlastech Rev 10 2012 Page 28 Vacuum Valve Service Module Manual MAINS AIR INLET 6989 6995 UNIVERSAL INSERT ADAPTOR INDICATOR A N E e NIL IZ w Yen LEAK SIGNAL 1 V LEAK SIGNAL 2 EXTERNAL AIR SUPPLY 0903 INJECT DRAWING NAME IVX3 SERVICE MODULE 8018 REVISION NOTES DRAWING NUMBER MAGNUM VENUS PLASTECH LTD 2012 MagnumVenusPlastech Rev 10 2012 Page 29
20. ice Module 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 what will be an adequate path under all conditions since it depends on many variables In any event the grounding means should have the lowest possible electrical resistance Grounding straps should be installed on all loose conductive objects in the spraying area This includes material containers and equipment Magnum Venus Plastech recommends grounding straps be made of AWG No 18 stranded wire as a minimum and the larger wire be used where possible NFPA Bulletin No77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm 10 ohms but that resistance as high as 10 000 meg ohms will produce an adequate leakage path in some cases Whenever flammable or combustible liquids are transferred from one container to another or from one container to the equipment both containers or container and equipment shall be effectively bonded and grounded to dissipate static electricity For further information see National Fire Protection Association NFPA 77 titled Recommended Practice on Static Electrical Refer especially to section 7 7 titled Spray Application of Flammable and Combusti
21. is sent to the 4mm Purge port When switched to inject mode an air signal is sent to the 4mm Inject port MagnumVenusPlastech Rev 10 2012 Page 17 Vacuum Valve Service Module Manual Vacuum Gauge Vacuum Level Control Regulator used to adjust the vacuum pressure VACUUM LEVEL CONTROL Used to adjust the vacuum pressure level By adjusting the vacuum regulator the vacuum level will be indicated on the vacuum gauge Open Position Closed Position VACUUM ISOLATION VALVE Locks or insolates the vacuum pressure on the valve in the Universal Insert Adapter port The Open position applies the set vacuum on the valve in the universal adapter port The Closed position locks the set valve on the valve in the universal adapter port P MVP MagnumVenusPlastech Rev 10 2012 Page 18 Vacuum Valve Service Module Manual IVx3 TEST PROCEDURES Main Air Inlet Connect a clean and dry air supply to the 8mm 10mm Main Air Inlet This should be at 6 bar 90 psi constant air supply The Control box has an internal regulator set to 6 bar to prevent damage to the PPVS or other valves 8mm 10mm Main Air Inlet v Lid UU dd Fre MagnumVenusPlastech Connect air supply to Main Air Inlet Connect the corresponding IVx3 valve port to the proper port on the control box using 4 mm tube see figure With the IVx3 in the OFF mode adjust the Vacuum level control to maximum level
22. nual A The reaction is unpredictable Prior use of an HHC solvent without incident corrosion or explosion does NOT mean that such use is safe These solvents can be dangerous alone as a clean up or flushing agent or when used as a component or a coating material There is no known inhibitor that is effective under all circumstances Furthermore the mixing of HHC solvents with other materials or solvents such as MEKP alcohol and toluene may render the inhibitors ineffective B The use of reclaimed solvents is particularly hazardous Reclaimers may not add any inhibitors Also the possible presence of water in reclaimed solvents could feed the reaction C Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction ouch 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 pres
23. ower 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 mentioned ball valve is activated to the stop mode Failure to do so can damage the regulators and components on reactivating to the ON position 2 Turn all system regulators to the OFF position counter clockwise position NOTE Verify that the Catalyst relief line located on the catalyst manifold and the resin return line located on the resin filter are secured relieving catalyst and resin fluid pressure 3 Catalyst pressure in the catalyst pump can be eliminated by rotating the ball valve on the catalyst manifold 90 degrees to the open or on position Note The open or on position is when the ball valve handle is parallel in line with the ball valve body The closed or off position is when the ball valve handle is perpendicular across the ball valve body 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 10 2012 Page 13 Vacuum Valve Serv
24. re 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 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 MagnumVenusPlas
25. refore pressure build up that could eventually lead to an explosion Moreover if a catalyst tank is sufficiently full when the pressure relief valve vents some catalyst may spray out which could cause eye injury For this reason and many others anyone whose job puts them in an area where this vented spray might go should always wear full eye protection even when laminating operations are not taking place oafety 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 MagnumVenusPlastech Rev 10 2012 8 Vacuum Valve Service Module Manual D Never add MEKP to anything that is hot since explosive decomposition m
26. sed 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 See image below IVx3 Purge Outlet to Indicator IVx3 Resin Inlet to Optional air source a z 0 51 a Q fi z 7 f pressure is seen at indicator gauge the valve is leaking between the resin Inlet and Purge outlet 8 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 MagnumVenusPlastech Rev 10 2012 Page 21 Vacuum Valve Service Module Manual 9 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 10 Apply soapy water to the fluid section where the Lower Valve Body 6986 and Upper Valve Body 6985 join and check for leaks 11 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 12 Point the IVX3 away from yourself and operate to the Inject position air
27. should vent out of the resin Inject port Close the valve 13 Operate the IVX3 between the Closed Inject Purge Closed positions a number of times and ensure the 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 MagnumVenusPlastech Rev 10 2012 Page 22 Vacuum Valve Service Module Manual p PPVS 1000 TEST PROCEDURES Testing and Adjusting PPVS 1000 vacuum setting EEUU WWW 1 Option 1 connect the INJECT Output on the control box to the PPVS supply port using 4 mm tube 2 Connect the PPVS signal line to the pneumatic Indicator on the control box 3 Using the Vacuum Level Control adjust the vacuum level Up Down to determine the vacuum pressure that the valve activates amp deactivates at The indicator will signal red when the valve is active 4 To Adjust Change the vacuum pressure at which the valve activates use the 2 5 mm Allen Key provided Turn the adjustment screw Clockwise Cr to switch closer to atmosphere nearer to zero and Anticlockwise to switch down to 300mb higher vacuum pressure Option 2 Test with Unit connected for SSB or Innovator units the 4mm pipe may be left connected as designed and a 6mm pipe connected between the Leak Signal on top of 77 the PPVS and the machine s MPG The amp machine can then be put on re circulation and
28. st 15 minutes or more These general instructions of first aid treatment however may be incorrect for some chemicals that is why you must know the chemicals and treatment before an accident occurs Treatment for swallowing a chemical frequently depends upon the nature of the chemical NOTE Refer to your System User Manual for complete and detailed operating instructions and service information MagnumVenusPlastech Rev 10 2012 Page 12 Vacuum Valve Service Module 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 p
29. stech Rev 10 2012 Page 24 Vacuum Valve Service Module Manual QJ PPVS INFUSION TEST PROCEDURES Ys PPVS Infusion Adjustment n m 1 Connect the INJECT Output on the control box to the PPVS supply port using 4 mm tube 2 Connect the PPVS signal line to the pneumatic Indicator on the control box 3 Using the Vacuum Level Control adjust the vacuum level Up Down to determine the vacuum pressure that the valve activates amp deactivates at The indicator will signal red when the valve is active 4 To Adjust Change the vacuum pressure at which the valve activates use the 2 5 mm Allen Key provided Turn the adjustment screw Clockwise LNN to switch closer to atmosphere nearer to zero and Anticlockwise to switch VACUUM GAUGE down to 300mb higher vacuum pressure INDICATOR Testing PPVS Infusion for vacuum leak VACUU LEVEL CONTROL b 1 Load the PPVS valve into the Universal Insert Mm ae Adaptor port 2 Connect the INJECT Output on the control box to the PPVS supply port using 4 mm tube 3 Connect the PPVS signal line to the pneumatic Indicator on the control box 4 Using the Vacuum Level Control adjust the vacuum to the desired level 5 Turn the Vacuum Isolator valve to the Closed position horizontal to lock the vacuum level if the vacuum level moves leaks down the seal in the valve is not holding vacuum MagnumVenusPlastech Rev 10 2012 Page 25 Vacuum Valve Servic
30. surized 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 aluminum components in a closed fluid system A Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocarbon Solvents B Magnum Venus Plastech recommends that you contact your solvent supplier regarding the best non flammable clean up solvent with the heat toxicity for your application C If however you find it necessary to use flammable solvents they must be kept in approved electrically grounded containers D Bulk solvent should be stored in a well ventilated separate building 50 feet away from your main plant E You should allow only enough solvent for one day s use in your laminating area F NO SMOKING signs must be posted and observed in all areas of storage or where solvents and other flammable materials are used 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 10 2012 Page 10 Vacuum
31. tech Rev 10 2012 Page 11 Vacuum Valve Service Module 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 of protective clothing and eye wear in using polyester systems However users should be prepared in the event of such an injury Precautions include 1 Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals have WARNING 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 lea
32. ty or quantity of finished products produced by Buyer e he 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 agree to waive all rights to trial by jury as to any and all disputes e 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 supers
33. uirements 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 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 MagnumVenusPlastech Rev 10 2012 Page 6 Vacuum Valve Service Module Manual Extinguishing Media Foam Carbon Dioxide
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