Magnum Venus Plastech ADVANTAGE User Manual
ADV ANT AGE
Gelcoater System
MAGNUM VENUS PRODUCTS
Operations Manual
Part No. 90065-1
Advantage Gelcoater
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
©2001 Magnum Venus Product s Manual Part No: 90065-1
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
1
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
Advantage Gelcoater
T wo Color
Quick View
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6, 9, 10
2
3
4
5
1
8
7
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Chapter
2
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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Advantage Gelcoater
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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4
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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Advantage Gelcoater
Chapter
3
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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Advantage Gelcoater
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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Advantage Gelcoater
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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Advantage Gelcoater
Chapter
4
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
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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Advantage Gelcoater
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
5
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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Advantage Gelcoater
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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Advantage Gelcoater
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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Advantage Gelcoater
Chapter
6
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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