Magnum Venus Plastech CB-5000-PRX User Manual

RTM Control Box Operations

Manual

CB-5000-PRX

MAGNUM VENUS PLASTECH

RTM Control Box Operations Manual Rev: 2/08

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TABLE OF CONTENTS:

1. Introduction

2. RTM Control Box Programming

3. Making Control Box Connections

4. Start up & Shut down Procedures

5. Trouble Shooting

6. Component Drawings

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1

CHAPTER

Introduction:

The CB-5000-PRX RTM Control Box is a modular system used to manually control the RTM
process. The CB-5000-PRX RTM Control Box includes a Digital Resin Meter. Using an optical
sensor, pulses are sent to the meter as the pump moves and then when a preset number
(amount of resin) is reached the gun & pump are turned off. It can be used with a basic
Primax pumping system or added to an existing RTM system. Then as the RTM process
demands more control, components can be added and manually controlled at the CB-5000­PRX Control Box.

The CB-5000-PRX gives the option to control the following components:

 Pump pressure
 Solvent Flush pressure
 Gun ON
 Gun OFF
 Solvent Purge / Flush
 Air Purge / Flush
 RTM Valve ON (injection port)
 RTM Valve OFF (injection port)
 Vacuum Assist Valve ON
 Vacuum Assist Valve OFF
 Digital Resin Meter (meters an

accurate amount of resin)

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2

CHAPTER

RTM Control Box Programming:

Quick Start

1. Turn power to the Control Box on

2. To set the Preset (number of counts) press or key once. Use the key to
increase that column to the desired number. Use the key to select the desired

column; you must set each of the columns, one’s, ten’s, and hundred’s separately.

3. When finished entering the desired number into the Preset press the key once to
store the number.

Note: Pressing the key will reset the counter to zero.

Calibration & Setup:

The Meter will take counts from a sensor assembly attached to the pump assembly. The
sensor assembly will send the meter a given number of counts per stroke depending on the
sensor assembly installed. The more counts per stroke provided to the meter the more
accurate it will be.

There are a couple of methods of calibrating the Preset for your part.
Set the counter at the maximum setting or very high for the first operation. Once you have

filled your part with the desired amount of material note the number on the display. This
number becomes your Preset. Enter the number into your Preset, when the counts reach that
number the pump will shut off and the display will reset to zero.

Another method to determine your Preset is to

1. Test sample resin by cycling the resin pump 10 full up and down strokes and note the
number that appears on the display.

2. Weigh the resin sample that was discharged from the pump.

3. Divide the desired amount (weight) of resin required to produce the part by the amount
(weight) of the resin sample discharged in the step above (step #2)

A (desired weight)

B (resin sample weight)

4. Multiply the number noted in step #1 by C the number derived in step #3. This becomes
your Preset, enter this number into your Preset, when the counts reach that number the
pump will shut off and the display will reset to zero.

= C

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Front Panel Description:

The front panel bezel material is flame and scratch resistant, textured plastic with clear viewing
window that meets NEMA 4X/IP65 requirements, when properly installed. Continuous
exposure to direct sunlight might accelerate the aging process of the plastic material used in
the bezel. The bezel should be cleaned only with a soft cloth and neutral soap product. Do
NOT use solvents.

There are up to seven annunciators available in the lower display that illuminate to inform the
operator of the counter and output status. See Figure 10, Front Panel, for a description of the
annunciators.

Four front panel keys are used to access different modes and parameters. The following is a
description of each key.

Do not use tools of any kind (screwdrivers, pens, pencils, etc.) to operate the keypad of this
unit.

Keypad Functions:

This key is a user programmable key. When the key is pressed, the unit performs the
appropriate function as programmed. The RST printing on this key is used as a quick
reference for the operator if the function key is selected for a reset function.

This key is used to access programming, enter changes to data values, and scroll

through the available parameters in any mode.

This key selects the next available mode option during programming. When
programming a numerical value in digit entry mode, this key is used to increment the selected
digit position. When in auto scrolling entry mode, it increments the value. When in the
operating mode, this key is pressed to allow changing of the data value viewed in the
secondary display.

When programming a numerical value in digit entry mode, this key accesses the value
and selects the digit to the right. When in auto scrolling entry mode, it decrements the value.
When in the operating mode, this key is pressed to allow changing of the data value viewed in
the secondary display.

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Programming Numeric Data Values:

The presets, prescaler, and output time values may be accessible when the unit is in the
normal operating mode (not programming mode), providing that the Program Disable input is

not activated. Pressing the key will sequence the secondary display through the available
presets, prescaler, and output time values.

To change a numeric data value it must be visible on the secondary display. Pressing the
or key will allow changing of the value. The two methods for changing numeric data values

are "digit entry" and "auto scrolling".

Digit Entry:

If the data entry method has been set to "digit entry", the least significant digit will blink.
Pressing the key multiple times will select other digits. Pressing the will increment the
selected digit. The data value will be entered when the key is pushed, or the old value will

be retained if no key activity is detected for 10 seconds.

Short-Cut - Decrementing Value

To decrement a digit value, press and hold the key and then press the key. This will
decrement the selected digit to zero if held.

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SHIFT VALVE SUPPLY

SOLVENT TANK PRES.

VACUUM VALVE OFF

VACUUM VALVE ON

AIR PURGE

SOLVENT PURGE

RTM VALVE ON

RTM VALVE OFF

GUN ON

GUN OFF

CHAPTER

Making Control Box Connections:

To make the connections disassemble the connector plug attached to the side of the control
box. Use 1/4 inch poly tube, MVP number 01417 and Hose Clamp 7701-2-1 to make
connections between the connector plug and component. Connections are made by sliding
the Hose Clamp onto the correct poly tube pushing the poly tube onto the correct barb fitting
and thread the Hose Clamp over the poly tube and barb fitting. It is a good idea to mark both
ends of each piece of tubing to aid in trouble shooting and plumbing.

The CB-5000 is a modular system and for this manual it will show how to make all
connections. If the connection to the Vacuum valve, RTM valve or the Gun are not going to be
used you must plug the “OFF” signals. This can be done by attaching a short piece of poly
tube to correct port and folding it over (kink) then tape it to itself, or plugging it with something.
The “ON” signals or other components will only blow air if they are pushed, but can be plugged
as desired by following the process mentioned above.

Below is a diagram of the signal connections for the CB-5000-PRX RTM Control Box.

It is best to organize and plan the routing of the tubing as it is installed to make the installation
easier and look better. Use plastic ties or tape to pair similar tubing and control the tubing
bundle.

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Plug Disassembly:

1. Remove the four screws holding the outer shell of the plug together.

2. Remove the inner guard from the plug shell. Remember to put the tubing thru the inner
guard before connecting it to the barb fitting.

Shift Valve Supply:

3. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #1 barb fitting. (see diagram
above)

4. Push the other end of the poly tube into the push fitting located on the bottom side of
the air motor valve.

Solvent Tank Pressure:

5. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #2 barb fitting. (see diagram
above)

6. Attach the other end of the poly tube to the Flush Tank on the side marked as “AIR”.

Vacuum Assist Valve:

7. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #3 barb fitting (Vacuum
Valve “OFF” signal). (see diagram above)

8. Push the other end into the push fitting located at the top of the Vacuum Assist Valve.
(see drawing below)

9. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #4 barb fitting (Vacuum
Valve “ON” signal). (see diagram above)

10. Push the other end into the push fitting located on the bottom of the air cylinder of the
Vacuum Assist Valve, just below the “OFF” signal. (see drawing below)

Air Purge:

11. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #5 barb fitting (Air Purge).
(see diagram above)

12. Push the other end into the push fitting located at the top of air purge portion of the RTM
Flush Valve mounted on the gun. (see drawing below)

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Solvent Purge:

13. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #6 barb fitting (Solvent
Purge). (see diagram above)

14. Push the other end into the push fitting located at the top of solvent purge portion of the
RTM Flush Valve mounted on the gun. (see drawing below)

RTM Valve / Injection Port:

15. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #7 barb fitting (RTM Valve
“ON”). (see diagram above)

16. Push the other end into the push fitting located on the bottom of the air cylinder of the
RTM Valve, just below the “OFF” signal. (see drawing below)

17. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #8 barb fitting (Vacuum
Valve “OFF”). (see diagram above)

18. Push the other end into the push fitting located at the top of the RTM Valve. (see
drawing below)

Gun Control:

19. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #9 barb fitting (Gun “ON”
signal). (see diagram above)

20. Attach the other end into the fitting located at the front of the Pro Gun. (see drawing
below)

21. Mark both ends of the poly tube appropriately and put one end thru the inner guard and
slide the hose clamp onto the tube and then attach it to the #10 barb fitting (Gun “OFF”
signal). (see diagram above)

22. Attach the other end into the fitting located at the back of the Pro Gun. (see drawing
below)

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VACCUM VALVE FLUSH ASSY.

AIR/FLUSH FOR VACUUM ASSIST VALVE

VACUUM ASSIST LINE

Inner/Part Seal

Outer Mold Seal

RTM-LT-CK

TO WASTE TANK/BUCKET

MAS-1000

Mold Half

MAS-1001

VACCUM VALVE - OFF SIGNAL (#3)

VACCUME VALVE - ON SIGNAL (#4)

Vacuum Clamp

RTM-3000

Auto Pro Gun

RTM VALVE - ON SIGNAL (#7)

RTM VALVE - OFF SIGNAL (#8)

MAS-1000

TO WASTE TANK / BUCKET

MAS-1001

Auto Pro Gun

Gun “ON” Signal (#9)

Gun “OFF” Signal (#10)

RTM Flush Assembly

Use caution to connect the correct signal
line to the corresponding purge material

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CONNECTOR PLUG & INNER
GUARD

PIN OUT/ PLUMBING DECAL

REGULATED AIR SUPPLY TO
AIR MOTOR

SENSOR (APS-1025) ATTACHES
TO CSD-1000-UPS and CSD-1000­APS, LOCATED ON THE PUMP
BASE PLATE – USE SENSOR E­SEN-102 FOR PATRIOT UNITS.

SENSOR CABLE (APS-1024)
USED WITH APS & UPS UNITS

MAIN AIR SUPPLY TO THE CB­5000-PRX RTM CONTROL BOX

Miscellaneous Connections:

1. Screw the Sensor (APS-1025) in to the Sensor Mount (CSD-1005-M12) on the side of the

pump base plate (see drawing CSD-1000-UPS sensor assembly – UPS Drive in the
drawing section).

2. Connect the main air supply to the control box supply ball valve. The air supplied to the

control box should be clean and dry. (minimum 8 CFM @ 100psi)

3. Connect the regulated pump air supply to the air motor inlet.

4. Plug the power cord into an appropriate power supply. (110-220 volts AC)

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CHAPTER

Start up and Shut down procedures:

RTM LITE SYSTEM DAILY START UP:

1. Check all hoses for damage.

2. Check all material supplies and fill or replace as needed.

3. Open main inlet air valve on the air manifold.

4. Turn on power to the Control Box.

5. Open recirculation valve on Catalyst Manifold

6. Remove the Pivot Pin from the UPS catalyst pump drive.

7. Manually pump the catalyst pump with the UPS drive, observe catalyst returning to the
catalyst jug, pump until the stream is air free.

8. Check pump air regulator and gauge if needed use the regulator on the manifold, slowly
turn up the pump air pressure to the operating pressure, normally 25 – 40psi. If a safety
over ride valve is installed press and hold the priming button while adjusting air pressure.

Note: If the Pump pressure is too high the mold can be damaged. The pressure
compensating valve (PCV-2000) is recommended to help prevent excessive mold
pressures.

9. Close recirculation valve on Catalyst Manifold.

10. Manually pump the catalyst pump with the UPS drive, bring catalyst pressure to operating
pressure 100 – 200psi.

11. Replace the Pivot Pin into the UPS catalyst pump drive.

12. Adjust the catalyst percentage as required.

13. Set the Preset number / amount of material into the Resin Meter.

14. Reset counter in preparation for injection.

15. Insert the Distribution Ring into the Mix Chamber locating rim.

16. Place mix housing Seal into the Mix Chamber locating rim.

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17. Insert the Catalyst Injector and injector seal into the aperture in the Distribution Ring. The
spring goes into the gun block.

18. Place Mix Chamber and Catalyst Injector onto the front of the Pro Gun, secure it with the
2 screws.

19. Flush the assembled mix chamber with solvent.

20. Apply a little red grease (6706-2-1) to the threads of the mix chamber.

21. Install the RTM-LT-CK onto the mix chamber.

DAILY SHUT-DOWN:

1. Disconnect the gun from the injection port.

2. Flush the gun with solvent.

3. Remove RTM-LT-CK assembly from the mix chamber.

4. Turn off the main inlet air ball valve at the manifold.

5. Turn off power to the Control Box.

6. Release the solvent flush tank pressure, by lifting pressure relief valve.

7. Release Catalyst pressure by opening the recirculation valve on the catalyst manifold.

8. Remove the Mix Housing and clean it.

9. Wipe the gun block face with a clean rag.

10. Hang the gun with the gun block exit holes facing down.

Emergency Stop:
If the emergency stop button is pushed during operation the gun and pump will stop. To

restart pull out the emergency stop button and push the gun “ON” button.
It may take a split second for the pump to stop traveling and a count might be registered on

the counter. So beware you will want to monitor the amount of material injected into the mold
and correct for this situation. This condition could also occur if the gun is turned off during the
injection process.