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MAGNUM VENUS PRODUCTS Part No. 90079-1

Operations Manual

High Volume Modular System

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Table of Contents

High Volume Modular System Manual CHAPTER 1 - OPERATIONAL DATA CHAPTER 2 - MATERIALS Resin Catalyst Glass-Fiber Roving Solvent Air CHAPTER 3 - START-UP, RUNNING AND SHUT-DOWN PROCEDURE Start-Up Priming Procedure (Resin) Priming Procedure (Catalyst) Shut-down Procedure Removing Materials from System CHAPTER 4 - PARTS DRAWINGS

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CHAPTER 1

OPERATIONAL DATA

In order to function at maximum performance level, the High Volume Modular system requires an air source capable of providing 35 CFM of clean, dry air, at 100 PSI. The air supply hose to the unit must be kept as short as practical and be no less than ½” inner diameter to assure an adequate air supply. Clean, dry air is essential to give the best service life of the power head and chopper motor. Consult your local representative or Magnum Venus Products directly for air requirements if you feel your operation may need more detailed information.

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CHAPTER 2 MATERIALS

Selection of proper materials and the use of them can make the difference between success and failure, with this or any other equipment. Your local distributor can assist in proper selection for the best results. The following generalities should be followed. RESIN should be formulated for gun use with proper promoters for MEKP. Also, with Thixotropic characteristics and relatively low viscosity for fast impregnating. Resin should be stored at about 70 to 75 degrees Fahrenheit (21 – 30 degrees C) before using. Resin at 85 degrees F (30 deg. C) will allow the equipment to perform better, minimize the variations and control problems, speed up impregnation, and improve quality of products. Solid additives which are introduced into resin for any purpose (such as flame retardation or thixotropic properties) invariably increase the wear factor on internal moving parts in the resin pump. More frequent replacement of these parts must be considered as part of the cost of using such additives. It may be necessary to use special parts in the system such as carbide needles and seats or heat-treated pump cylinders with modifications of the piston area to help lengthen the life of the parts. CATALYST should be Methyl Ethyl Keytone Peroxide of strength to give proper gel times for products made with percentages of ¾ to 3% on standard equipment. This range is ½ to 1 ¼ % on high volume units. A factory-tinted catalyst, for visual control purposes, is recommended. This can be obtained from the peroxide manufacturer. Failure of the equipment (unless other problems) is generally the result of trying to add tinting materials. Never use solvents to clean the catalyst system as it forms unstable peroxides. Use only clear water. GLASS FIBER ROVING should be made for spray-up roving cutters and with a soft, non-static treatment. The Magnum Venus Hydraulic systems do not have a high pressure air blast that causes the fibers to tumble and float all over, as with air aspirated guns, hence the softer the treatment, the better the glass pattern. If treatment is too hard, fibers lay in clumps, the pattern is narrow and it is difficult to attain uniformity and good impregnation. SOLVENT The High Volume Modular unit is composed of parts and material lines compatible to Acetone and solvent replacements . NOTE: Certain reclaimed solvents could affect systems in such a way as to nullify the warranty. AIR must be clean and dry. Moisture or oils in air supply may damage various components of this system as they would any other machinery.

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CHAPTER 3 START-UP, RUNNING AND SHUT DOWN PROCEDURE

The Magnum Venus Products High Volume Modular System is the ultimate in spray-up equipment. This instruction manual, the Trouble-Shooting guide and the Parts Drawing Package should be read thoroughly and used as a reference when working with your Magnum Venus System. We have tried to note when differences occur, but suggest you contact Magnum Venus Products or it’s nearest representative if performance of your particular Magnum Venus Products system is not satisfactory following these instructions.

START-UP

These steps should be followed when unit is new, recently repaired, or has no material in system:

1. Read and become familiar with Manual, Trouble-shooting Guide and drawings for your particular unit, and all other operational aids provided with unit.

2. Check all fittings for proper connection. 3. Fill resin pump cavity (center section) approximately 1/3 full using Throat

Seal/Lubricant (TSL-XX). 4. Turn all regulators counter-clockwise so gauges will read 0 (zero) when air is

connected to system. 5. Open catalyst Recirculation valve on the Catalyst Manifold. 6. Pull bottom quick pin from Pivot Link Assembly (part number UPS-3104-01). NOTE: This will allow resin pump to stroke but prevent catalyst pump from pumping during start-up procedure. It should be general procedure to never have the catalyst pump connected except when spraying a laminate. 7. Attach air source to manifold fitting. Open main air inlet ball valve. NOTE: ½” diameter (minimum) air hose should be used for maximum efficiency. 8. Remove top from flush tank and fill with clean suitable solvent. Replace tank top. 9. Slowly bring flush regulator up to 40 PSI (turn clockwise). NOTE: Flush tank pressure should never be higher than 60 PSI. 10. Open flush air control valve. 11. Remove nozzle, nozzle cap, turbulent mixer and mix chamber from gun. 12. Push solvent button on gun until solvent exits gun nozzle. 13. Open gun by pulling gun trigger. Aim gun into suitable container and keep gun open

during priming procedure.

PRIMING PROCEDURE (RESIN)

NOTE: The High Volume system should be connected to a Bulk Feed Resin System. MVP Recommends a 2” Y-filter and ball valve on the Resin Inlet.

1. Open resin pump air valve and slowly turn resin pump regulator clockwise until resin pump is stroking slow, even strokes (approximately 1 to 10 PSI). On systems with

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air supply override valves you must press and hold the priming button before the pump will move.

NOTE: as resin enters pump you may have to increase PSI slightly in order to maintain even pump stroke. Observe gun to make sure resin is exiting evenly with no air inclusion.

2. Shut off air to resin pump by either turning regulator to zero or turning pump air control valve to off position.

3. Close gun and flush into appropriate container for approximately 2 seconds. NOTE: Flush by pushing solvent button on side of gun. 4. Repeat opening of gun and aim into appropriate container for catalyst priming. Keep

gun open during priming procedure.

PRIMING PROCEDURE (CATALYST)

1. Slowly fill 2-gallon catalyst jug with MEKP (never dilute catalyst for Magnum Venus

system). NOTE: See catalyst manufacturer for proper MEKP formulation for your particular operation. 2. Check to make sure catalyst recirculation valve is open. Open if needed. 3. Remove quick pin from pivot link assembly. 4. Loosen catalyst packing nut slightly to hand prime. 5. Slowly with steady, even strokes, hand pump catalyst pump using rail assembly.

Stop hand priming when steady stream of catalyst exits gun. Close gun and flush for approximately 2 seconds.

6. Reinstall quick pin into pivot link assembly. 7. Close catalyst recirculation valve on the catalyst manifold. 8. Retighten packing nut. Snug tight only. 9. Slowly open resin pump air valve and slowly turn pump regulator to 15-20 PSI.

Resin and catalyst pump will stroke until system is full. On systems with air supply override valves you must press and hold the priming button before the pump will move. Check all fittings for leaks.

10. System is ready for use. NOTE: Always remember to turn off regulator and slowly open gun trigger to bleed system fluid pressure before any disassembly or repair takes place.

SHUTDOWN PROCEDURE

1. Turn resin pump and chopper regulators to zero. Turn resin pump air valve to off position.

2. Open catalyst recirculation valve on the catalyst manifold. 3. Pull quick pin from pivot link assembly. 4. Remove nozzle, nozzle cap, turbulent mixer and mix housing and injector assembly

from gun head. Clean parts and set aside. Inspect for wear. 5. Aim gun into container and pull trigger until flow of material becomes small trickle.

Release trigger. 6. Push flush button to flush gun head. 7. Check water trap. 8. Check pump packings for leaks. Resin leaking into oil reservoir in center section

cavity indicates packings need tightening or replacement.

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9. Turn main air valve off. 10. Relieve flush tank pressure until all air has exhausted from flush tank.

REMOVING MATERIALS FROM SYSTEM

NOTE: Remove fluid pressure before performing maintenance or disassembly.

1. Disconnect resin pump from bulk resin system and allow to drain. Place inlet in solvent or fill bulk system with solvent.

2. Aim gun into container and open gun by pulling trigger. Keep trigger open. 3. Open resin pump air valve and turn regulator until pump begins to stroke even, slow

strokes. 4. When clean solvent exits gun, shut off regulator. 5. Place container under resin pump accumulator and slowly unscrew the accumulator. 6. Clean resin accumulator with solvent. 7. Reinstall accumulator. 8. Resin system can now be broken down for maintenance. Refer to Manual, Trouble-

shooting Guide and Parts Drawings for proper maintenance. Refer to page 30 of Trouble Shooting Guide for filled system procedure and pages13 & 14 for long period shutdown procedure.

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CHAPTER 6

PARTS DRAWINGS

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1

35

38

33

3

32

55

6

34

35

5

10

30

8

46

13

31

44

45

7

12

2

34

9

28

30

22

28

45

3731

46

8

44

13

30

12

11

30

9

15

30

29

56

28

14

29

30

42

28

56

19

57

58

58

21

21

L

59

USE REMOVABLE LOCTITE ON THESE THREADS AT ASSEMBLYLTM

61

60

37

11

62

26

357

65

66

63

G = ADDED ITEMS FOR MPH-2542 RESET ASSY 3/25/03 JEM

63

H = REMOVED APP-9096, APP-9109, & APP-9102 FROM ASSY 6/10/03 JEM

L

L

23

18

23

J = ITEM 18 WAS 3 PIECES, (2) MPH-2519, & MPH2408 11/24/03 JEM

L

L

SHOWS ORIENTATION OF ITEM 11, (MPH-2512), SEAL GUIDE.

Assembly - 7" Power Head 4" Stroke

MAGNUM VENUS PRODUCTS

REV.

VPH-7000

414

41

26

16

24

19

39

4020

47

43

24

16

42

62

27

39

47

2520

40

25

42

48

51

49

50

36

36

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56 O-B-011 2 O-RING

57 PF-AP-02-SS 2 PIPE PLUG

58 F-FW-04 2 FLAT WASHER

MPH-7000-SK

REPAIR KITSPART NO.

* SEAL KIT

DESCRIPTION

* COMPONENTS INCLUDED WITH SEAL KIT.

*

*

*************

59 PF-HN-08-08S 1 ADAPTER

62 MPH-3262 2 PISTON STOP

60 2104-4-1 4 TIE ROD

61 F-HB-06C-24-GR8 4 GR 8 HEX BOLT

PARTS LIST

ITEM PART NO. QTY DESCRIPTION

63 00276 1 TEE FITTING

64 MPH-2546-01 1 VALVE STEM ASSY

65 MPH-2545 1 SEAL

66 MPH-2542 1 RESET BUTTON ASSY

OPTIONAL PARTS AND ASSEMBLIES

PARTS LIST

ITEM PART NO. QTY DESCRIPTION

DESCRIPTIONPART NO.ITEM

PARTS LIST

QTY

Assembly - 7" Power Head 4" Stroke VPH-7000

FIGURE 1-1

1 MPH-7004 1 PISTON - 7" PUMP

2 VPH-7001 1 CYLINDER - 7" PUMP X 4" STROKE

3 VPH-4259 1 PISTON ROD

4 VPH-5004-01 1 MUFFLER ASSY - 4" STROKE PUMP

5 VPH-4254 1 PISTON ROD BUSHING

6 MPH-7002 1 LOWER ENDCAP - 7" PUMP

7 MPH-7001 1 UPPER ENDCAP - 7" PUMP

8 MPH-2541 2 INLET SPRING HOUSING - PILOT VALVE

9 MPH-2511-01 2 ASSY - STEM SEAL

10 O-B-121 1 O-RING

11 MPH-2512 2 SEAL GUIDE

12 MPH-2513 2 VALVE STEM - PILOT VALVE

13 MPH-2540 2 INLET ROD - PILOT VALVE

14 VPH-5001 1 UPPER VALVE BLOCK - 4" STROKE PUMP

15 MPH-5001 1 LOWER VALVE BLOCK

16 MPH-2517 2 VALVE PISTON

18 MPH-5005 1 VALVE POPPET

19 MPH-2521 2 VALVE END CAP

20 MPH-5009 2 VALVE EXHAUST

21 O-B-019 2 O-RING

22 VPH-5003 5 TIE ROD 4" STROKE PUMP

23 O-U-206-90 2 O-RING

24 O-B-116 2 O-RING

25 O-B-026 2 O-RING

26 O-D-010-90 2 O-RING

27 O-B-125 1 O-RING

28 O-B-008 4 O-RING

29 O-B-O14 4 O-RING

30 O-B-012 6 O-RING

31 O-U-006 2 O-RING

32 O-B-118 1 O-RING

33 O-B-439 1 O-RING

34 O-B-167 2 O-RING

35 O-B-431 2 O-RING

36 F-HB-04C-56-SS 2 HEX HEAD CAP SCREW

37 F-HN-06F 10 HEX NUT

38 F-HBFT-08C-20-GR5 1 HEX HEAD CAP SCREW

39 F-CS-04C-40-SS 4 SOCKET HEAD CAP SCREW

40 F-CS-04C-08-SS 4 SOCKET HEAD CAP SCREW

41 F-SW-04-SS 2 LOCK WASHER

42 F-SS-832-02-SS 4 CUP POINT SET SCREW

43 F-BHCS-04C-16-SS 1 BUTTON HEAD CAP SCREW

44 MPH-2526 2 SPRING



47 MPH-5010 2 DIAPHRAM

48 PF-AP-04-SS 1 PIPE PLUG

49 MPH-2539 1 PUSH POLY FITTING - MALE ELBOW

50 MPH-2538 1 PUSH POLY FITTING - MALE TEE

51 01417 .56ft Ø1/4 x 6-3/4 POLY TUBING - NATURAL

55 MPH-3261 1 SNAP - RING

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Modular HV Fluid Section Assy


REV. A = ITEM 21 WAS 68310-1, ITEM 27 WAS 86520-1 5/2/03 JEM

HVLS-1000

2

1

3

12

5

6

7

8

10 (REQ)

10

9

9

9

9

25

24

11

11

17

16

15

23

29

29

29

29

4

26

15

22

14

21

27

14

28

20

13

30

1919

19

18

B = ADDED OPTIONSL ITEMS AND SEAL KIT 7/3/03 JEM

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86530-128 PISTON NUT1

86520-327 SPACER RING1

86510-126 PISTON ADAPTER1

86420-125 FOOT VALVE COLLAR1

86400-124 CYLINDER1

86390-1

23

PISTON BODY1

68310-3

22

BACK UP RING1

67110-1

21

FEMALE PACKING RING1

7101-2-12

20

HEX CAP SCREW4

3101-8-1

19

PISTON ROD ADAPTER1

04309-1

18

BALL STOP1

04072-1

17

PISTON BALL SPRING1

03604

16

BALL202181-1

15

PISTON CUP2

02158-4

14

PACKING SET1

01621

13

O-RING1

01611

12

O-RING2

00714

11

ELBOW1

7201-6-8

10

HEX NUT4HVLS-1009

9

WAVE SPRING 108

HVLS-10077 BALL GUIDE1

HVLS-10066 GUIDE BEARING1

HVLS-10055 SPRING SUPPORT RING1

HVLS-10044 DISPLACEMENT ROD1

HVLS-10033 PACKING NUT1

HVLS-10022 PUMP MOUNT PLATE1

HVLS-10011 OUTLET BODY1

DESCRIPTIONPART NO.ITEM

PARTS LIST

QTY

Modular HV Fluid Section Assy HVLS-1000

TIE ROD86540-129 4

MALE PACKING RING187090-1

86370-1 1 FOOT VALVE BODY

30

21A 68310-1 1 HARDENED BACK-UP RING


PART NO.ITEM DESCRIPTIONQTY

HVLS-1000-SK SEAL KIT

DESCRIPTION

REPAIR KITS

PART NO.

****

* ITEMS INCLUDED IN SEAL KIT

24A 86401-1 1 HARDENED CYLINDER

27A 86520-1 1 HARDENED SPACER RING

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A = CHECK VALVE ASSY WAS OMITTED FROM DWG, VHPC-4200 & VHPC-4200-RV 8/14/02 JEMREV.

2

3

5

6

7

8

9

8

11

12

13

14

15

16

17

1

18

17 10

4

Assy - C42 Catalyst Pump VHPC-4200-C-3J

19

21

22

23

17

11

20

24

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ASSY - C42 CATALYST PUMP VHPC-4200-C-3J

Note:

figure 1-1one flat on hex as shown inOffset intake and outlet ports

FIGURE 1-1

VHPC-4200-SK

PART NO.

COMMON ASSY PARTS LIST

DESCRIPTIONPART NO.ITEM QTY

DESCRIPTION

SEAL KIT

REPAIR KITS

INLET TUBE FITTING

PACKING SET ASSY

PISTON ROD SLEEVE

PISTON ROD SPRING10

18

16

17

13

14

15

12

11

7

9

8

6

5

2

4

3

104013-1

6701-24-EN

O-S-013

4101-8-1

51050-1

1

1

3

1

9201-1-7

02014

50530-1

03072

50440-1

1

1

1

2

1

INLET BODY

O-RING

SEAL RETAINER

PISTON SEAL

PISTON BODY

7/32" SS BALL

9/16" SS BALL

7301-9-016

50820-1

50940-1

50730-1

02022-5

1

1

2

1

1

50360-1

50591-3

50630-1

1

1

1

CYLINDER

O-RING

LOCK NUT

OUTLET BODY

PISTON ROD

PACKING NUT

PUMP SEAL WARNING DECAL (NOT SHOWN)

CLEVIS1VHPC-420119

9202-1-11 1 SPHERICAL BEARING

JAM NUT

SPRING RETAINER

CHECK VALVE BODY

COMPRESSION SPRING

4101-18-1

4101-17-1

4101-15-1

4101-16-1

24

20

23

22

21 1

1

2

1

25

VHPC-1001-3J 1 OUTLET FITTING

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Ultra - Proportioner SystemREV.

UPS-3100

2

RESINFLUIDSECTION(REF)

4

7

10

11

12

14

15

17

18

19

20

20

21

22

26

24

25

25

27

28

28

29

29

30

31

32

33

34

35

35

35

36

3736

38

23

16

B = ITEM 37 WAS F-BHCS-1024-06 11/18/02 JEM

C = ITEM 30 WAS F-LN-04C LOCK NUT 6/3/023 JEM

39

D = REPLACED 7203-8-1 QUICK PIN WITH NUT AND BOLT 10/28/03 JEM

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PART NO.ITEM DESCRIPTIONQTY

PARTS LIST

Ultra - Proportioner System UPS-3100

PART NO.ITEM QTY DESCRIPTION

2 UPS-3102 1 MOUNT BAR

4 UPS-3103-01 1 CLEVIS BLOCK ASSY

7 UPS-3104-01 1 PIVOT LINK ASSY

14 UPS-3108 1 SPACER

11 UPS-3106-01 1 RH SIDE RAIL ASSY

17 UPS-3110 1 BACK END PIECE

15 UPS-3109-01 1 FRONT END PIECE ASSY

12 UPS-3106-02 1 LH SIDE RAIL ASSY

10 UPS-3105 1 CATALYST STUD BOLT

24 7203-1-1 1 HAIRPIN COTTER

23 9202-1-1 1 SPHERICAL BEARING

22 DUAL-2012 1 ADJUSTMENT KNOB

21 UPS-3114 1 TOP PLATE

20 UPS-3113 1 ADJUSTMENT SCREW

19 UPS-3112 1 ADJUSTMENT NUT

18 UPS-3111-01 1 PIN ASSY

25 APS-1016 2 QUICK PIN

26 UPS-3115 1 HAIRPIN COTTER

27 F-SB-08-20 1 SHOULDER BOLT

28 APS-1015 2 EXTERNAL SNAP RING

29 F-LN-06C 2 NYLOCK NUT

30 F-HN-04C 1 HEX NUT

31 F-CS-1024-06 1 SOCKET HEAD CAP SCREW

32 7101-2-12 2 HEX CAP SCREW

33 02885-12 1 SPRING PIN

34 F-CS-04C-32 1 SOCKET HEAD CAP SCREW

35 F-BHCS-04C-12 8 BUTTON HEAD CAP SCREW

36 F-BHCS-04C-06 2 BUTTON HEAD CAP SCREW

37 01218-4 1 BUTTON HEAD CAP SCREW

38 F-CS-06C-40 2 SOCKET HEAD CAP SCREW

16 F-AB-04F-19 1 AIRCRAFT BOLT

39 F-LN-04F 1 LOCK NUT

24 UPS-3101 1 RESIN DECAL

25 UPS-3116 1 GELCOAT DECAL26 UPS-3117 1 HV DECAL

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HV CHOPPER MANIFOLD ASSY 87014-1

1

2

3

4

5

6

8 9

8

9

10

11

12

12 12

12

13

13

22

22

15

23

16

24

24

17

18

21

26

14

14

REV. A = UPDATED FORM, ADDED ITEM 1, REMOVED ONE ITEM 17

AIR IN

12

14

16

16

7

19

20

25

27

24

B = REMOVED ON ITEM 14 1/28/05 JEM

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23 8405-2-1 1 MINI REGULATOR

22 8405-1-1 2 REGULATOR

21 8404-1-1 1 FILTER

17 7701-3-12 1 NIPPLE

14 PF-HN-04-04S 2 ADAPTER

12 7701-3-1 5 HEX NIPPLE

4 6302-1-1 1 MANIFOLD BLOCK

3 09350 1 BALL VALVLE

1 00817 1 PIPE NIPPLE

8 7101-1-16 2 HEX CAP SCREW

7 6504-17-03.3 1 AIR HOSE ASSY

6 6504-16-04 1 AIR HOSE ASSY

5 6504-1-05 1 AIR HOSE ASSY

19 7701-7-1 1 FEMALE QUICK CONNECT

20 7702-2-2 1 BALL VALVE

13 7701-3-2 2 BUSHING

16 7701-3-7 3 ADAPTER

18 7701-4-3 1 PLUG

15 7701-3-5 1 BUSHING

24 8702-2-1 3 PRESSURE GAUGE

10 7701-1-1 1 ELBOW

PARTS LIST

HV CHOPPER MANIFOLD ASSY 87014-1

9 7201-6-4 2 HEX NUT

2 05819 1 BALL VALVE

11 7701-1-9 1 ELBOW

25 6701-7-EN 1 PUMP GAUGE DECAL

26 6701-8-EN 1 GUN GAUGE DECAL

27 6701-9-EN 1 FLUSH GAUGE DECAL

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E-mail: [email protected] Web: www.mvpind.com

Corporate Headquarters/Manufacturing 5148 113

th Ave.

Clearwater, FL 33760 USA Ph: (727) 573-2955 Fax: (727) 571-3636

Manufacturing/Sales 1862 Ives Ave. Kent, WA 98032 USA Ph: (253) 854-2660 Fax: (253) 854-1666

high volume modular system - magnum venus products - · the magnum venus products high volume...

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