Magnum Venus Plastech ADVANTAGE User Manual

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ADV ANT AGE

Gelcoater System

MAGNUM VENUS PRODUCTS

Operations Manual

Part No. 90065-1

Advantage Gelcoater

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Advantage Gelcoater

Operations Manual

Corporate HQ/Mfg.

5148 1 13th A ve. Clearwater, FL 33760 T el: (727) 573-2955 Fax: (727) 571-3636

Advantage Gelcoater

MVP Technology Center

1862 Ives A ve. Kent, WA 98032 T el.: (253) 854-2660 Fax: (253) 854-1666

E-mail: info@mvpind.com · Web: www .mvpind.com

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T able of Contents

Advantage Gelcoater

Operations Manual

CHAPTER 1 - QUICK REFERENCE Quick List Quick View

CHAPTER 2 - INTRODUCTION The Advantages of the Advantage Major Components Description of Controls T ool Requirements Material Requirements Safety Equipment Requirements

CHAPTER 3 - INST ALLATION AND SET-UP Wall Mount Unit Portable Unit

CHAPTER 4 - DAIL Y INSPECTION

CHAPTER 5 - PRIME FLUSH SYSTEM Fill Flush Tank O-Ring Maintenance Pressurization of Flush T ank Test Flush System

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C H A P T E R 6 - PRIME CA T AL YST SYSTEM Quick List Quick View

CHAPTER 7 - PRIME RESIN SYSTEM

CHAPTER 8 - CONNECT CA T AL YST PUMP

CHAPTER 9 - TESTING & ADJUSTING Spray Patterns Troubleshooting

CHAPTER 10 - SHUTDOWN Short T erm Long T erm

CHAPTER 11 - MAINTENANCE Daily Maintenance Checklist Weekly Maintenance Checklist Monthly Maintenance Checklist Three Month Maintenance Checklist Six Month Maintenance Checklist Annual Maintenance Checklist

CHAPTER 12 - PARTS DRAWINGS

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Chapter

Advantage Gelcoater

Quick Reference

1. Place suction wand in adequate resin supply

2. If multicolor, select which color pump you wish to use

3. Prime resin pump

4. Prime catalyst pump

5. Adjust catalyst %

6. Increase air pressure to resin pump to desired output

7. Check all hoses for fluid or air leaks

8. Fill & check solvent system

9. Set air pressure to gun

10 . Adjust & set air assist

NOTE

This manual contains the information you need to operate, shutdown, and perform simple maintenance and repairs on your Advantage Gelcoater equipment. Please read the manual carefully. Follow the steps for each procedure in the order the steps are given, otherwise you may damage the equipment or cause serious injury to self and others.

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Advantage Gelcoater

T wo Color

Quick View

6, 9, 10

3 4

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Chapter

ADV ANTAGE

Gelcoater

Introduction

The Advantages of the Advantage:

The Magnum Venus Product s Advantage Gelcoat Unit was designed to deliver a smooth uniform layer of gelcoat onto the mold surface with a minimum of overspray and fuming. The internal mix low-pressure airless gun thoroughly combines gelcoat and MEKP catalyst, insuring no contamination of the finished gelcoat. Proper use will eliminate problems such as gelcoat blistering caused by raw catalyst overspray .

Major Components

Y our Advantage Gelcoater consists of the following major components: 22:1 gelcoat pump and accumulator

Catalyst pump and accumulator Internal flushing system Internal mix, airless gun-head, which is used for mixing resin & catalyst.

The metering system provides highly accurate and reliable metering of resin and catalyst.

Description of Controls

Before beginning, familiarize yourself with the control manifold, consisting of the following controls and gauges:

1. The Pump Pressure Gauge and Regulator monitor and control

main air pressure to the resin pump.

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2. The Flush Pressure Gauge and Regulator monitor and control air to the solvent flushing system.

3. The Gun Pressure Gauge and Regulator monitors and controls the air to the gun.

4. (Optional) The Air Assist Gauge and Regulator monitors and controls the air assist nozzle on the gun head.

Air Requirements

Clean, dry compressed air at a minimum of 90 PSI (6.3 kgs per sq. cm.) with a minimum volume of 10 CFM (0.3 cm.) is required to operate the unit, supplied through a ½ inch ID hose (1.25 cm.).

Tool Requirements

When using the Advantage Gelcoater, you should have all the following tools, spare parts and supplies available before beginning operation or repair:

One small hammer One 6” adjustable wrench One 12” adjustable wrench One 7/16” open-end wrench Two 14” pipe wrenches V enus-Gusmer Wet-Mil Gauge Eight lag bolts (1/2” x 3”; 1 cm x 8 cm) (Wall Mount Unit) One pint of medium weight lithium grease Flat-tip screwdriver with 1/4” tip width Gelcoater Unit T ool Kit (shipped with unit) Optional Porosity Kit (Part Number: 09983)

Material Requirements

Y ou should have the following materials available before installing or operating your Advant age Gelcoater:

Gelcoat resin (5 gallons or 19 liters) Recommended solvent

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Empty buckets and containers for cleanup Clean rags and paint brushes for equipment cleaning Wax paper or cardboard for test spraying

Safety Equipment Requirements

Y ou should have available all safety clothing and equipment recommended by your materials manufacturers and federal, state, and local industrial safety agencies. Safety equipment you will need to work on your Magnum Venus Product s equipment includes safety gloves and eye protection.

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Chapter

ADV ANTAGE

Gelcoater

Installation & Set-Up

Uncrate Gelcoater . Uncrate the Advant age Gelcoater and set it on a level floor surface at

least 3 feet (90 cm) from the nearest wall to allow easy access.

Wall Mount Unit Installation

Fasten Brackets to the wall approximately 36 inches above the floor .

NOTE

Use appropriate fastening devices for the type of wall the gelcoater will be mounted on.

Bolt the Advantage Gelcoater frame onto the bracket with the bolts provided as shown in Figure 1.

Portable Unit Installation

Unit is shipped assembled except for Catalyst Pump and Jug System

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Figure 1: W all Mount Unit Figure 2: Portable Unit

T urn Controls Off

Make sure all control regulators are turned to “0”.

Install Hoses

Uncoil all hoses and inspect for kinks and damage. Hoses are shipped attached to gun & pump except for catalyst

hose and flush hose. These need to be attached at the pump and tank only . They are attached to gun.

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Figure 3: Cat. Hose & Flush Hose to Gun Head

Attach the other end of the flush hose to the flush tank fitting marked “OUT” (see Figure 4).

Figure 4: Attach Flush Hose to Flush Tank

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Attach an airline between the air regulator and the fitting (marked “IN”) on the flush tank (see Figure 5).

NOTE

Do not turn on the air supply at this time. You will be instructed when to do so.

Figure 5: Air Supply Hose to Flush Tank

Install Main Air Line Install the main airline (minimum 1/2” diameter) between the Advantage

Gelcoater and an air compressor capable of at least 10 cfm (0.3 cm.). Install Catalyst Jug

W ARNING

Never grease any part of the catalyst system. Use only clean water for cleaning.

Place catalyst jug into catalyst jug bracket. Attach catalyst feed line (1/2” poly tube with clamps) from the barbed

nipple on the bottom of the catalyst jug to the catalyst pump inlet fitting

(See Figures 6 & 7).

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NOTE

Attach catalyst feed line so there are no sharp bends or kinks in the line and the line is in a downward angle from the jug to the catalyst pump.

Figure 6: Att ach Feed Line from Catalyst Jug

Figure 7: Attach Feed Line to Catalyst Pump

Advantage Gelcoater

NOTE

Make sure all clamps are tight to prevent leaks.

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Attach the return line (3/8” tube) to the catalyst pump relief valve body (see Figure 8)

Insert the other end of the return line into the 3/8” hole on the jug near the cap.

Figure 8: Attach Cat. Return Line to Catalyst Pump

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Chapter

ADV ANTAGE

Gelcoater

Daily Inspection

Always wear approved eye protection when working near pressurized equipment.

Follow all warning and suggestions regarding the use of respirators, clothing, and appropriate safety procedures recommended by manufacturers of your materials.

BEFORE CONTINUING, be sure all regulators on the manifold are completely off.

CAUTION

WARNING

Check Material Supplies Check bulk supplies of gelcoat resin, catalyst, and solvent. If any supplies

are low, do not start operations until supplies are adequate. Fill the catalyst jug at least 1/3 full of clean catalyst (see Figure 9).

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CAUTION

After filling the catalyst jug, reinstall cap on jug. Otherwise, catalyst may be contaminated.

Figure 9: Fill Catalyst Jug

Place the gelcoat resin container in position on or near the Advantage Gelcoater . Y ou need at least 2 gallons (7.5 liters) of gelcoat resin to begin operations.

CAUTION

If the gelcoat resin runs out during operation, the pump will runaway and damage may occur.

NOTE

Runaway/The speed of the pump increases immediately and damage to the pumping system can occur.

Be sure you have enough solvent to fill the flush tank at least half full (at least 1-1/2 gallons). Do not fill the flush tank yet; this procedure is described later in this manual.

Check Hoses Check hoses for abrasions, kinks, and cuts.

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Inspect hose fittings and seals for leaks. Make sure all hose connections are tight. Check Fittings and Assemblies Check the resin accumulator to be sure threads are hand-tight. Check pick-up wand fittings to be sure fittings are tight (use 14” pipe

wrenches)(strap wrench preferred). Lubricate Resin Pump Fill the pump body reservoir at the base of the pump shaft 2/3 full of SAE

30-weight motor oil (must be non-detergent. Tighten Gun Packing Before Priming.

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Figure 10: Lubricate the Resin Pump

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Chapter

ADV ANTAGE

Gelcoater

Prime Flush System

Turn Controls Off Be sure the FLUSH regulator is closed (see Figure 13).

T o close the regulator , turn the regulator counterclockwise.

Be sure the air is OFF and connect the main air supply to the unit. (See Figure 14)

NOTE

Please see new Manifold configuration in Drawing section (p/n MA-ADV-1).

Figure 13: Close Flush Regulator

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Figure 14: Connect Main Air Supply

Fill Flush Tank

Release any pressure in the flush tank by gently pulling upwards on the lever attached to the pressure relief valve (see Figure 15).

Open the lid by pulling up the hatch lock, turning the hatch sideways, and lifting the hatch out of the tank (see Figure 16).

NOTE

Do not drop the flush tank hatch into the tank.

Check the flush tank for dirt or debris. Wipe with a clean rag if necessary .

Fill the tank with clean solvent. Reinstall the tank hatch.

Be sure the pressure relief valve is completely closed and the lever is in a horizontal position.

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CAUTION

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Figure 16: Lift the Hatch LockFigure 15: Release Flush T ank Pressure

O-Ring Maintenance

The flush tank’s O-ring expands and distorts if wetted by the solvent. Orings also distort (much more slowly) when exposed to solvent vapors. Distorted O-rings will not hold an airtight seal and must be replaced. However , the distorted O-ring can be reused. Simply put the O-ring in a well-ventilated area to dry out. When it returns to its original shape, it may be used on the flush tank hatch again. We have supplied a second O-ring so you do not have to wait for the original ring to recover .

Pressurize Flush Tank

Turn on air supply to the unit. Air supplied to unit should be 90 to 100 PSI (6.7 to 7 kg/sq. cm).

Open the FLUSH regulator (clockwise) but do not exceed 50-70 psi for ProGuns.

NOTE

If the O-ring on the flush tank hatch is leaking, you will hear a hissing noise as you pressurize the flush system. If the O-ring is leaking, remove the hatch and reinstall with the second O-ring. See the note regarding O-rings.

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CAUTION

Do not overpressurize the flush system.

NOTE

Be sure the gun trigger is not pulled back or locked back.

CAUTION

When working with machinery that uses pressurized fluids, wear approved protection for your eyes.

Test Flush System

T est the flush system by manually flushing the gun into an appropriate empty container (see Figure 17). To flush the gun, perform the following steps:

Hold an appropriate container under the gun-head. Wearing appropriate safety gear (gloves, goggles, clothes etc.) place

one finger over the nozzle port. Push button on the left side of the gun for 5 - 7 seconds. Solvent pours from the mix chamber on the gun-head. Be sure the flush tank pressure does not exceed 50-70 psi for ProGuns.

NOTE

Store the solvent in an approved container with the lid in place to prevent evaporation.

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Figure 17: Flush the Gun

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Chapter

ADVANT AGE

Gelcoater

Prime Catalyst System

Before Priming

CAUTION

The flush system must be primed and operating before you put any gelcoat resin or catalyst into the pumps or material will “set-up” in the equipment, requiring extensive repair .

CAUTION

IMPORT ANT : Always prime the resin side first, followed by the catalyst side. If this procedure is reversed, the catalyst may go to the resin side and gel.

Check catalyst supplies for quality and quantity . Check hose fittings again for tightness. Hold the gun-head over an empty container . Pull gun trigger back and lock trigger by shifting trigger to the side (see

Figure 18). Disconnect Catalyst Pump Pull out the top quick pin connecting the catalyst pump to the slave arm

(see Figure 19). Pull the piston rod block up until the quick pinhole is above the slave arm.

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Please see new Resin Pump/ Slave Arm Configuration in Drawing Section (p/n 85710-1)

Figure 18: Lock Gun Trigger Figure 19: Pull Out Top Quick Pin

Lean the top of the catalyst pump toward the resin pump to allow trapped air to escape (see Figure 20).

Turn the recirculation valve to the recirculation mode, towards fitting and tube that go to catalyst jug.

Hand-Prime Catalyst Pump. SLOWL Y and GENTL Y hand-prime the catalyst pump by moving the

piston rod block up and down (see Figure 21). Gently pump material into the system until material flows steadily into

catalyst jug on both strokes (up and down) of the catalyst pump indicating there is no more air in the pump.

Place recirculation valve into pump mode, toward blue catalyst hose. Gently pump material into the system until material flows steadily from the

gun head on both strokes (up and down) of the catalyst pump indicating there is no more air in the line.

Lean the catalyst pump away from the resin pump. Trap the catalyst pump-bearing block between the quick pin and the slave

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Figure 20: Lean the Catalyst Pump Toward the Resin Pump

arm bearing (see Figure 22).

T o monitor cat alyst flow , use the float in the catalyst jug’s sight tube. The float rises and falls with each cycle of the catalyst pump.

Gun trigger must be closed before flushing.

Unlock the gun trigger .

Figure 21: Hand Prime the Catalyst Pump

NOTE

Place an appropriate empty container under the gun-head. Press the flush button on the side of the gun to flush the gun head.

CAUTION

If the container is not empty, solvent will splash out of the container when you flush the system.

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Figure 22: Trap the Catalyst Pump Bearing Block

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Chapter

ADV ANTAGE

Gelcoater

Prime Resin System

Before Priming

CAUTION

The flush system must be primed and operating before you put any gelcoat resin or catalyst into the pumps or material will “set-up” in the equipment, requiring extensive repair .

Check resin supplies for quality and quantity . Check resin hose fittings again for tightness. Be sure PUMP PRESSURE regulator gauge reads 0 PSI. Hold the gun-head over any empty container . Pull gun trigger back and lock trigger by using the trigger lock.

NOTE

Before priming resin system, be sure the catalyst pump is disconnected to shut off the catalyst flow .

Make sure the catalyst pump is disconnected. (Catalyst pump is leaned away from the resin pump and is trapped between the quick pin and the slave arm bearing.)

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Begin Priming Place the resin wand into the gelcoat resin container (see Figure 23). Slowly turn the PUMP PRESSURE regulator (on the manifold) clockwise

until the pump begins moving. When the pump begins moving, stop turning the regulator.

CAUTION

While being operated, the pump must have a sufficient supply of resin. If the resin runs out, the pump will speed up and cavitate, and damage can occur.

Let the pump run until resin is flowing out of the gun-head. The resin should be flowing in a steady stream, with no air in the stream.

Turn the PUMP PRESSURE regulator on the manifold counterclockwise until the regulator is completely off.

Figure 23: Place the Resin Wand into Resin Cont ainer

Charge Resin Accumulator

When charging accumulators, the pump pressure should be off and the gun locked open.

NOTE

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Remove cap from charging valve on top of resin accumulator. Attach charging hose (located on manifold) to the charging valve on top of

the resin accumulator. (See figures 24 & 25) Open air valve on manifold for approximately 2 to 3 seconds (resin/

gelcoat moves slowly on a re-charge - this may not be enough time).

NOTE

This charge of air will force any resin from the accumulator into the hose set and open gun. The poly ball inside the accumulator will be forced against the seat at the bottom of the accumulator. If air comes from the gun head - check to make sure poly-ball in accumulator is seating properly .

Shut off air valve and remove-charging hose from top of accumulator and replace the charging valve cap (should check for leaky valve before replacing cap).

Figure 24: Photo of Charging Valve on Top of the Resin

Figure 25: Photo of Air Valve on Manifold

Accumulator

Unlock the gun trigger . Place an appropriate empty container under the gun-head.

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Push the flush button on the side of the gun to flush the gun. Release the button when clean solvent flows from the gun-head. Discard resin waste in an approved manner.

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Chapter

ADV ANTAGE

Gelcoater

Connect Catalyst Pump

Connect Catalyst Pump Pull out the lower quick pin that attaches the bottom of the catalyst pump

to the bottom slave arm.

CAUTION

When lower quick pin is out, do not let the piston rod bottom out in the catalyst pump or the inlet body ball will be damaged and must be replaced.

Line up the bottom bearing block of the catalyst pump with the hole in the bottom slave arm that matches the catalyst percent number you want.

Use a quick pin to attach the catalyst pump to the bottom slave arm (See Figure 26).

Line up the hole in the upper bearing block with the matching hole in the upper slave arm (see Figure 27).

Use a quick pin to attach the upper bearing block to the upper slave arm. Attach mix housing onto front of gun block.

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Figure 26: Attach Catalyst to the Slave Arm

NOTE

The upper and lower catalyst pump mounts must be in upper and lower holes with the same number or the pump will be damaged (see Figure 27).

Figure 27: Line Up the Holes

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Chapter

ADV ANTAGE

Gelcoater

Testing & Adjusting

T o achieve the proper spray patterns, gun nozzles must be selected and tested and matched to the appropriate pump pressure.

Before T esting and Adjusting Lay out large sheets of cardboard or wax paper for spraying.

NOTE

Sheets should be at least 5-ft. (150 cm) long and 3 ft. (91.44cm) wide.

Have an appropriate empty container to flush the gun into. Gelcoat temperature should be at recommended temperature by gelcoat

supplier. Select Nozzle St art with nozzle (400067C) as an average nozzle size #31 121.

NOTE

Refer to Nozzle Chart.

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Air Assist Nozzle - 419 #30419 Install Nozzle Assembly Insert turbulent mixer into the mix chamber. Insert static mixer into nozzle extension body . Attach nozzle extension body to gun mix chamber .

NOTE

Use lithium grease on mix chamber and all nozzle extension body threads.

CAUTION

T o avoid cont amination of the laminate, do not apply grease to any part that will contact the interior of the gunhead.

Attach selected nozzle onto the extension body . Insert the nozzle into the retainer (see Figure 29). Tighten nozzle retainer onto the nozzle extension body .

NOTE

While tightening nozzle retainer onto nozzle extension body, hold nozzle in the appropriate position to get desired spray pattern.

Figure 28: Apply Grease to Nozzle Retainer

Figure 29: Insert Nozzle in Retainer

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Set Pressure Turn PUMP PRESSURE regulator slowly until gauge reads 35 PSI. Spray Test Pattern Hold the gun about 18 - 20 in. (45 - 50 cm) high over the paper . Pull the

trigger , and spray one three-foot pass. While spraying, check the spray pattern to make sure there are only slight

“fingers” or “tails” (heavy streams of material). Also check for misting or fuming.

Increase air assist pressure in 5 PSI increments until “finger” disappears. Optimum operating air assist pressure is 35 - 45 psi, depending upon the viscosity of the materials.

NOTE

Figure 30 shows examples of fingers. Figure 31 illustrates a good spray pattern.

Figure 30: Spray Pattern with Fingers

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Figure 31: Good Spray Pattern

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Check the troubleshooting chart below to correct any problems.

Troubleshooting Chart

If You See: Then:

“Fingers” Check Gelcoat temperature to ensure it falls

within the manufacturers recommended tempera ture window. Typically , this will be between 60°F and 80°F . Increase Resin Pump and Air Assist operating pressure in 5-PSI increments until “fingers” disappear.

Misting or Fuming Reduce Resin Pump operating pressure in 5-PSI

increments until clean, even, smooth fan pattern results.

Fan T oo Wide Select smaller nozzle angle. Refer to the nozzle

chart provided in this manual.

Not Enough V olume Select larger nozzle orifice. Never use pump

pressure to increase flow or fuming will result

CAUTION

Too much pump pressure or air-assist pressure to the gun-head will cause porosity in the gelcoat laminate.

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Chapter

ADVANT AGE Gelcoater Shutdown

Short-Term Shutdown

Cleaning the gun head is required if you are stopping production or there will be long pauses in operations for lunch, part cure or any reason.

NOTE

This section discusses short-term shutdown. Follow these procedures whenever the gun will be idle for at least the standard gel time of your materials. If the gun will be idle for longer than one week, perform Long-T erm Shutdown.

Drain Moisture Filter

CAUTION

Always wear approved eye protection when working near pressurized equipment.

Drain moisture filter by holding a small, empty container under the filter and turning the filter valve beneath the filter until water drains out (See Figure 32).

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After draining the filter , close the filter valve.

NOTE

Moisture should be drained from the unit daily to prevent moisture buildup.

Please see new Resin Pump (p/n 85710-1) and Resin Filter (p/n 85753-3) in Drawing Section.

Figure 32: Drain the Filter

Clean Gun Head

NOTE

Cleaning the gun head is required if you are stopping production or there will be long pauses in operations for lunch, part cure, or any reason.

Push the flush button on the left side of the gun to flush the gun into an appropriate container .

Remove nozzle and nozzle retainer from nozzle extension body . Remove the nozzle extension body from gun head. Using the turbulent mixer puller , remove the turbulent mixer from mix

chamber. Insert the 1/4” steel rod (provided in the Gelcoater Unit Tool Kit) into the

front of nozzle extension body and press out the static mixer . Rinse the nozzle assembly parts and the static mixer in a container of

solvent.

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Soak the nozzle assembly parts in a closed container of solvent.

NOTE

When using solvent for cleaning or flushing, be sure to store the used solvent in a manufacturer-approved container with a tight-fitting lid for storage while waiting to run the used solvent through your recycling equipment. Solvents evaporate quickly .

WARNING

Solvents such as acetone are extremely flammable.

Visually inspect the open ports of the gun block for signs of gelled material after flushing.

Remove Fluid Pressure Follow all warnings and suggestions regarding the use of respirator ,

clothing, and appropriate safety procedures recommended by manufacturers of your material.

Turn PUMP PRESSURE regulator knob counterclockwise until the pressure gauge reads “0”.

Position gun-head over suitable container and pull gun trigger and lock open to drain fluid pressure from system.

Flush the gun into an appropriate container . Relieve charge from accumulator by inserting a 1/16” rod into charging

valve on top of resin accumulator . (See figure 33)

WARNING

Draining the air charge from accumulators MUST NOT be done unless resin fluid pressure is relieved from pumping system.

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Figure 33: Relieving Pressure from Accumulator

Place a container under the resin pump filter and slowly unscrew the filter tank from the filter body (see Figure 34).

NOTE

If the filter is difficult to unscrew by hand, use a cloth strap wrench or a chain wrench to prevent damage to the filter.

Clean the filter tank, spring, screen and filter core in solvent. Allow the parts to air dry .

NOTE

Clean your filter once a week and when changing colors for a multi-color operation.

Slowly begin to unscrew the resin accumulator.

DANGER DANGER DANGER DANGER DANGER

NOTE

STOP! If accumulator is hard to unscrew by hand, accumulator may still be charged. Gently push a rod up into the resin filter body and gently push up on the poly ball. This relieves the charge from the accumulator. Once the charge is relieved, unscrew the accumulator .

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WARNING

Never unscrew the resin accumulator while it is still charged. You may be seriously injured.

When you have unscrewed the resin accumulator, disassemble it and clean the parts with solvent. Allow the parts to air dry .

Figure 34: Unscrew Filter Tank

Disable Catalyst Pump Remove the quick pin from the top of the catalyst pump and upper slave

arm. Tilt the cat alyst pump away from the resin pump until the catalyst pump is

resting against the vertical connecting post. Trap the catalyst’ s upper bearing block between the vertical connecting

post and the quick pin. Shutdown Flush System Turn the FLUSH regulator knob on the manifold until the gauge reads “0”. Close air supply valve to the flush system. Relieve the pressure in the solvent tank by gently pulling on the

pressure relief valve’s ring. Cover Unit Cover the Advantage Gelcoater with clean plastic sheeting to protect the

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system. Y ou have now completed the steps necessary to shut down your

equipment.

Long-Term Shutdown

NOTE

Follow these long-term shutdown procedures whenever the gun will be idle for at least one week, or longer than the storage pot life of your materials. These procedures should also be followed if you are shipping your unit. If the gun will be idle for longer than twenty minutes and less than one week, perform Short-T erm Shutdown.

NOTE

Solvent flush of system should precede cleaning of gun, accumulator , etc. After disconnecting and cleaning catalyst system.

Drain Moisture Filter

CAUTION

Always wear approved eye protection when working near pressurized equipment.

Drain the moisture filter by holding a small empty container under the filter and turning the filter valve beneath the filter until water drains out (see Figure 35).

After draining the filter , close the filter valve. Place the resin wand into approximately 2 gallons (9 liters) of solvent, and

clean the wand assembly thoroughly .

NOTE

Moisture should be drained from the unit daily to prevent moisture buildup.

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Figure 35: Draining the Filter

Clean Gun Head Push the button on the left side of the gun to flush the gun into an appro-

priate container . Remove nozzle and nozzle retainer from nozzle extension body . Remove the nozzle extension body from gun head. Using the turbulent mixer puller , remove the turbulent mixer from mix

chamber. Insert the 1/4” steel rod (provided in the Gelcoater Unit Tool Kit) into the

front nozzle extension body and press out the static mixer . Rinse the nozzle assembly parts and the static mixer in a closed

container of solvent. Soak the nozzle assembly parts in a closed container of solvent. Remove mix chamber

Solvent flush of system should precede cleaning of gun, accumulator , etc. Af ter disconnecting and cleaning catalyst system.

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NOTE

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WARNING

Solvents such as acetone are extremely flammable.

Visually inspect the open ports of the gun block for signs of gelled material after flushing.

Remove Fluid Pressure Follow all warnings and suggestions regarding the use of respirator ,

clothing, and appropriate safety procedures recommended by manufacturers of your material.

Turn PUMP PRESSURE regulator knob counterclockwise until the pressure gauge reads “0”.

Position gun-head over suitable container and pull gun trigger and lock open to drain fluid pressure from system.

Flush gun block into appropriate container . Relieve charge from accumulator by inserting a 1/16” rod into charging

valve on top of resin accumulator . (See figure 36)

WARNING

Draining the air charge from accumulators MUST NOT be done unless resin fluid pressure is relieved from pumping system

Figure 36: Relieving Pressure from Accumulator

Clean Catalyst System

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Disconnect the catalyst pump from the upper slave arm.

> Pull out the top quick pin in the upper slave arm. > Pull up the piston rod priming knob and lean the top of the

catalyst pump toward the resin pump as far as it will go. Empty any remaining catalyst from the catalyst jug. Fill the catalyst jug with clean distilled water . Slowly and gently pump the distilled water through the system by moving

the catalyst pump-priming knob up and down by hand. Continue hand pumping until a stream of clean water flows from the gun

on both the upstroke and downstroke. Empty the water from the catalyst jug and continue hand pumping until

water no longer exits the gun. Blow, clean compressed air into the cat alyst jug lines to remove

moisture. Disable the catalyst pump by trapping the upper bearing block of

catalyst pump between the vertical post and the quick pin.

Figure 37: Disable Catalyst Pump

Flush Resin System

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NOTE

Make sure the catalyst pump is still disabled and pressures are off.

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Remove the resin wand from the resin and allow the wand to drain into an appropriate container .

Lock gun open. Slowly bring pressure up on resin pump. Slowly pump extra resin from system. Release gun trigger.

Place an appropriate container under the gun head. Lock the gun trigger back.

Place wand in container of flush. Turn the PUMP PRESSURE regulator knob clockwise until the pump

begins to stroke (even, slow strokes). When clean solvent flows from the gun head, close the PUMP

PRESSURE regulator knob by turning it counterclockwise until the PUMP PRESSURE gauge reads “0”.

Make sure air charge is relieved from the accumulator by inserting a 1/16” rod into charging valve on top of the resin accumulator.

DANGER DANGER DANGER DANGER DANGER

NOTE

STOP! If accumulator is hard to unscrew by hand, accumulator may still be charged. Gently push a rod up into the resin filter body and gently push up on the poly ball. This relieves the charge from the accumulator . Once the charge is relieved, unscrew the accumulator .

WARNING

Never unscrew the resin accumulator while it is still charged. You may be seriously injured.

Slowly begin to unscrew and remove the resin accumulator . Clean the resin accumulator with solvent. Place a container under the resin filter and slowly unscrew the filter tank

from the filter body (see Figure 38).

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Figure 38: Remove Filter Tank

NOTE

If the filter is difficult to unscrew by hand, use a strap wrench or a chain wrench to prevent damage to the filter .

Clean the filter tank, spring, screen and filter core in solvent. Reassemble accumulator and filter assembly . Unlock the gun trigger . Push flush button located on side of gun to flush gun block. Shutdown Flush System Turn the FLUSH regulator knob on the manifold until the gauge reads “0”. Close air supply valve to the flush system. Relieve the pressure in the solvent tank by gently pulling up on the pres-

sure relief valve lever. Cover Unit Cover the Advantage Gelcoater with clean plastic sheeting to protect the

system.

CAUTION

Always wear approved eye protection when working near pressurized equipment.

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Chapter

ADV ANTAGE

Gelcoater

Maintenance

Performing proper maintenance at the recommended time intervals maximizes your equipment’s productivity and efficiency . This section describes recommended maintenance procedures to be performed daily , weekly , monthly , every three months, twice a year, and once a year . Please follow the maintenance schedules recommended in this section.

Wear appropriate safety equipment when performing maintenance procedures on your equipment.

This schedule is based on a one shift, 5-day work week, using standard GP resin (an idle unit left with resin in it may require more frequent part replacing).

CAUTION

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Daily Maintenance Checklist

Part: Procedure:

Moisture Filter Drain Hoses Check for kinks or leaks G u n Check gun packing - tighten

as necessary

G u n Check weep holes on top of

gun block OR check gun block for leaks.

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Weekly Maintenance Checklist

This schedule is based on a one shift, 5-day work week, using standard GRP resin (an idle unit left with resin in it may require more frequent part replacing.)

Part: Procedure:

Gauges and Regulators Check for wear, damage, and

proper operation Resin Accumulator Remove and clean inside Resin Filter Wash and inspect filter screen for

damage Power Head Clean silencer with solvent and

blow dry Resin Pump Lower Assembly Check pickup hose and wand for

leaks or damage. Check inside

the center section for packing

leaks. Flush T ank Clean any residue and rinse with

solvent. Air Lines Check for leaks, wear , and kinks.

Replace line as needed

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Monthly Maintenance Checklist

Part: Procedure:

Gauges and Regulators Check for wear, damage, and

proper operation Resin Accumulator Remove and clean inside Resin Filter Wash and inspect filter screen for

damage Power Head Clean silencer with solvent and

blow dry Resin Pump Lower Assembly Check pickup hose and wand for

leaks or damage. Check inside

the center section for packing

leaks. Flush T ank Clean any residue and rinse with

solvent. Air Lines Check for leaks, wear, and kinks.

Replace line as needed

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Three-Month Maintenance Checklist

Part: Procedure:

Gauges and Regulators Check for wear, damage, and proper

operation

Resin Accumulator Remove and clean inside. Replace:

spring, ss ball, o-ring in charging valve

Resin Filter Wash and inspect filter screen for

damage

Power Head Clean silencer with solvent and blow

dry

Resin Pump Lower Assembly Check the pickup hose and wand for

leaks or damage. Check inside the center section for packing leaks

Flush T ank Clean any residue and rinse with

solvent

Air Lines Check for leaks, wear, and kinks.

Replace lines as needed. Gun Head Replace seals and o-rings Catalyst Pump Check all bushings for wear and

damage. Check the pump cylinder for

wear . Replace ss balls, o-rings,

springs, piston seal and packings

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Six Month Maintenance Checklist

Part: Procedure:

Gauges and Regulators Check for wear, damage, and proper

operation

Resin Accumulator Remove and clean inside. Replace:

spring, ss ball, o-ring in charging valve

Resin Filter Wash and inspect filter screen for

damage

Power Head Clean silencer with solvent and blow

dry

Resin Pump Lower Assembly Check the pickup hose and wand for

leaks or damage. Check inside the center section for packing leaks

Flush T ank Clean any residue and rinse with

solvent

Air Lines Check for leaks, wear, and kinks.

Replace lines as needed. Gun Head Replace seals and o-rings Catalyst Pump Check all bushings for wear and

damage. Check the pump cylinder for

wear . Replace ss balls, o-rings,

springs, piston seal and packings

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Annual Preventative Maintenance Checklist

Part: Procedure:

Gauges and Regulators Check for wear, damage, and proper

operation

Resin Accumulator Remove and clean inside. Replace:

spring, ss ball, o-ring in charging valve

Resin Filter Wash and inspect filter screen for

damage

Power Head Clean silencer with solvent and blow

dry . Replace o-rings, gaskets, springs and balls.

Resin Pump Lower Assembly Check the pickup hose and wand for

leaks or damage. Check inside the center section for packing leaks

Flush T ank Clean any residue and rinse with

solvent

Air Lines Check for leaks, wear, and kinks.

Replace lines as needed. Gun Head Replace seals and o-rings Catalyst Hoses Replace seals and o-rings Flush Lines Replace Hoses Resin Hoses Replace Hoses Pick-up Wand Hoses Replace Hoses Catalyst Pump Check all bushings for wear and

damage. Check the pump cylinder for

wear . Replace ss balls, o-rings,

springs, piston seal and packings

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