Magnum Venus Plastech DP-1000 User Manual

DP-1000 (EPO3)

Operations Manual

MAGNUM VENUS PRODUCTS Part No. 90000-3

Operations Manual

DISCLAIMER:
The information in this document is presented in good faith and is based on the best available data. Because
chemistry of materials, operation al demands, and other conditions vary from one plant to another, and from
one time to another; Magnum Venus Products cannot give specific instructions for adjusting and operating your
equipment. We do give guidelines and urge customers to perform the operations and products tests described
in this manual and all other pertinent documents.

Update: Back Pressure Regulator

Magnum Venus Products has introduced a new optional component for the EPO3 Dual Pump Meter/ Mix Unit.
This new component is called the Back Pressure Regulator. (MVP part number 05801). This update sheet
discusses the purpose and operation of the Back Pressure Regulator.

What does it do?

The Back Pressure Regulator controls fluid pressure during recirculation mode. The Back Pressure Regulator
is a simple way to maintain the desired fluid pressure between operating and recirculating modes.

Do you need a Back Pressure Regulator?

You should install the MVP Back Pressure Regulator if you are having difficulties balancing fluid pressures
after turning off recirculation.

How do you use it?
The Back Pressure Regulator is used when the equipment is switched to the recirculation mode. Turn the

regulator clockwise to increase fluid pressure and counterclockwise to decrease fluid pressure until the
hardener fluid pressure is the same as during operation mode. Once you have set the Back Pressure
Regulator you do not need to adjust it again unless you change materials or desired ratios.

Table of Contents

DP-1000 (EPO-3)

Operations Manual

Safety Labels
INTRODUCTION

The EPO3 Dual Pump Meter/ Mix Unit

INSTALL THE NEW UNIT
Uncrate Unit
Tool List
Install Material Containers
Remove Unit Metal Cover
Turn Front Panel Controls Off
Front Panel Controls
Unit Side Panels
Install Electrical Wire
Install Hoses
Attach Air Lines

PRIME THE UNIT
Special Conditions: Sensitive Materials
Check Hose Fittings
Fill Solvent Tank
Disassemble Gun-Head
Pressurize Solvent Tank
Flush Gun
Recheck Hoses Fittings
Set Pump To Maximum Stroke Length
Recirculate Material

SET MATERIAL RATIOS
Find Mixing Ratio
Choose Pump Size
Set Pump to Ratio
Test For Proper Settings
Replace Unit Metal Cover

PRESSURE ADJUSTMENT

Select Injectors
Assemble Gun-Head
Recirculate Material Again

Recheck Pressure
Correct Pressure Drift
Change To Operating Mode
Test Spray Patterns

THE ACCUMULATORS

Remove Fluid and Air Pressure

Charge Accumulators with Charging Pump

Test For Proper Mix
RESIN INJECTION

Requirements
Testing RTM Mix

SHUTDOWN PROCEDURES

Short-Term Procedure
Long-Term Procedure

WEEKLY MAINTENANCE

Maintenance Procedures
APPENDIX A: OPTIONAL EQUIPMENT

Air Assist Nozzle
Chopper
Digital Resin Meter
Nitrogen Accumulator Charging System
APPENDIX B: SPRAY NOZZLE LIST

DANGER:
Only Qualified Electricians Should Install Electrical System!

WARNING:
Air Pressure Should Not Exceed 120 psi!

WARNING:
Wear Eye Protection When Working With Solvent!

WARNING:
Do Not Disable Pressure Relief Valve on Solvent Tank!

WARNING:
If Pump Runs Rapidly Shut Off Main Pressure Immediately!

DANGER:
Nitrogen Bottles Should Be chained Securely!

WARNING:
Never Allow Pump Pressure to Exceed 1200 psi Or Heaters May Rupture!

DANGER:
Never Operate Unit Without Accumulator Safety Cover!

WARNING:
Never Remove Accumulator Safety Cover Before All Air And Fluid Pressure Has Been
Relieved!

WARNING:
Charging Pump Handle Can Extend Rapidly When Air Pressure Is Connected!

DANGER:
Never Leave Flammable Solvents Under Pressure Overnight!

DANGER:
Never Remove Accumulator Safety Cover When Pressure Is Present in the Variable-Stroke
Pump Accumulator!

DANGER:
Failure To Clean Pressure Relief Valve System Can Result in Rupture of Accumulators, Hoses,
Or Heaters

INTRODUCTION

The EP03 Dual Pump Meter/ Mix Unit
The EPO3 unit is a medium –to high-volume metering and mixing system capable of metering two

components at rations from 1:1 through 8:1, depending upon pump selection and pump settings.
The unit is capable of supplying a smooth, continuous flow of fully-mixed, reactive thermosetting
materials. A static mixing element used at the gun produces full mixing of most medium viscosity
epoxies, polyesters, and other thermosetting resins. Viscosity is reduced by using in-line heating
units which can increase fluid temperatures by as much as 50 per recirculation cycle.

Metering ratios are adjusted by re-positioning the upper-pivot point of the hardener pump. This
makes possible extremely fine adjustment of ratio settings.

Continuous flow from the gun is supplied with the use of two pressure-charged air accumulators
located at each pump outlet. These accumulators operate in a fashion similar to hydraulic power
accumulators that dampen momentary pressure hesitations which can occur during pump
reversal.

Proper operation of the EP03 is achieved by a balancing of fluid pressures during the initial gun
use. Factors affecting this pressure balancing function are: viscosity of the material, size of the
injector orifice in the gun ( the size of the orifice regulates back pressures) , temperature settings
(which affects viscosity), and accumulator charge. Once control of these variables is achieved,
you will have fully mixed material at the initial triggering of the gun.

Whenever you stop operation of the EP03 for more than 10 minutes, you must place the machine
in the recirculation mode. This ensures that fully heated material is always present in the pumps
and in the hoses leading to the gun. The recirculation mode prevents and initial shot of cold
material which may occur as the material cools in the unit.

Maintaining proper pressure balance during the change from recirculation to operation mode is
very important in achieving proper mixing immediately upon triggering of the gun. We advise you
to concentrate on this aspect of operation during your initial training on the EPO3 unit.

The EPO3 unit can operate in several different configurations depending on accessories and
options. This unit can be used to spray certain materials, pour and cast, or perform RTM (Resin
Transfer Molding).

You can also attach a fiberglass chopper to the gun-head for addition of reinforcing fibers to the
material. Other options, such as digital timers, can be added as well. The EPO 3 can be used in
conjunctions with MVP’s high-production automated machinery such as Reciprocators,
Impregnators, and Winders. See your MVP catalog for complete descriptions of these systems.

Before you install the EPO3, you must consider the design of your material storage and handling
system. If you are working from five-gallon containers, you can easily use the pickup wands and
return hoses supplied with the system.

If you are working from 55-gallon barrels, you may consider installing these barrels in a horizontal
position with fittings attached to pickup material from the large bung hole and return material to the
small bung hole (with proper venting of the container.

Larger quantities require installation of material containers with material heating supplied for
viscosity control. If your material is under 1,000 centipoise at room temperature, you can operate
without bulk material heating.

CHAPTER 2

INSTALL THE UNIT

Uncrate Unit

Uncrate the unit and set on level floor surface at least 3 feet from the nearest wall to allow easy access.

Tool List

When preparing the EPO3 for use, it is important to have all of the tools, spare parts, and the supplies
available before beginning operation. The following tools (not shipped with the unit) must be available
when using the EPO3.

 Protective gloves approved for use with all materials to be handled.

 Eyeglasses approved by local safety and health agencies.

 Respiration equipment approved by material supplier and safety and health agencies.

 Cleaning solvents approved by material supplier and safety and health agencies.

 Suitable solvent containers with safety lids approved as proper for flammable conditions.

 Full set of open-ended wrenches (3/8”) through 1-½”)

 Set of crescent wrenches (6”, 10”, and 12”).

 Assortment of flat-ended screwdrivers from 1/8” through 3/8” blade size.

 One medium-weight hammer.

 Pliers.

 Swivel socket wrenches (3/8”, and ½”)

 6” table vice.

 14” pipe wrench.

 Strap wrench.

 Machinist’s scribe form removing O-rings.

 Balance-beam scale.

 Four material containers (two types: 5 gallon material holding and 1 quart pre-weighed for ratio

calculation).

Install Material Containers

Install material containers next to the unit, preferably with some method of heating material. Recirculation
through unit heaters can also be used for preheating small quantities of materials.

Remove Unit metal Cover

Remove unit’s metal cover during setup procedures.
Turn Front Panel Controls Off

Make sure the unit is not connected to power and that all MAIN PANEL controls are turned off and the
regulators are turned to “0” (zero) (see Figure 1).

(Figure 1. Front Panel Controls)

Turn off all front panel switches.
Turn all regulators to “0” (zero) or fully counterclockwise.
Turn off MAIN PRESSURE to unit. Check that heater indicator on the front panel is OFF (do not activate
heaters).

Front Panel Controls

Each control on the front panel is described in the following:
The HEAT indicator, on the left and right sides of the control panel, shows when the heaters are ON or
OFF. When the HEAT is on the lens turns green.
TEMP gauges indicate what the temperature is for the materials in the hoses.
MAIN PRESSURE switch turns on the pump that applies pressure to the materials.
MAIN PRESSURE gauge indicates how much pressure is being applied to the materials.
MAIN PRESSURE regulator allows you to vary the pressure applied to the materials.
FLUSH PRESSURE switchturns on the flushing system in the unit.
FLUSH PRESSURE gauge indicates pressure when the unit is being flushed.
FLUSH PRESSURE regulator varies the solvent system pressure.
RECIRCULATION PRESSURE switch allows the materials to be cycled through the unit without being
output from the gun-head. The gun trigger is in the middle position during recirculation mode.
RECIRCULATION PRESSURE gauge indicates what the pressure is when the unit is in recirculation
mode.
RECIRCULATION PRESSURE regulator varies the recirculation pressure.
PRE-HEAT button is pushed and held in for the period of time it takes for the heater block to warm up.
BLOCK HEAT switches allow you to select LOW, OFF, or HIGH temperature for the block heaters.
LINE HEAT switches allow you to select LOW, OFF, or HIGH temperature for the line heaters.

Unit Side Panels
The location of the connections and hoses for the INLET and OUTLET PANELS are shown in
Figures 2 and 3.

Inlet Panel

POWER SUPPLY connection
RESIN RETURN HOSE
RESIN SUPPLY
HARDENER PUMP RELIEF valve
(“PUMP H”).
HARDENER RETURN HOSE
HARDENER SUPPLY
AIR INLET

Outlet Panel
RESIN HEATER
RESIN
RESIN RETURN
HARDENER HEATER
HARDENER
HARDENER RETURN
AIR SUPPLY
AIR SIGNAL RETURN
SOLVENT

(Figure 2. Inlet Panel)

(Figure 3. Outlet Panel)

Install Electrical Wire

DANGER: Only Qualified Electricians Should Install Electrical System!
Install electrical wire (220 single phase, 25 amp) through manifold panel at lower side of machine (see

Figure 4). If flammable materials are to be processed, explosion –proof wiring must be used.
To install the unit hoses, perform the following steps:

Unpack all hoses and inspect for kinks or damage.
Install green pickup hoses and black recirculation hoses to INLET PANEL on left side of the right panel.
Install high-pressure relief hose to lower fitting at the same panel. Place hoses in correct material
containers.

Be extremely careful to match the proper recirculation hose with the correct pickup wand or material will be
contaminated. The high-pressure relief hose should be placed in a separate container.

(Figure 4. Power Supply Connection)

Install gun hoses at OUTLET PANEL with black supply hoses and recirculation hoses attached at left side
of right panel according to fitting sizes (see Figure 3). Be extremely careful to attach the resin and
hardener recirculation hoses to the proper fitting or material cross-over can occur. Use colored tape to
color-code hoses according to material.
Place pickup wands into barrels or attach green hoses to bottom fitting on bulk containers. Place
recirculation hoses into proper containers, being careful not to mix hoses and move materials between
containers. Colored tape should be applied to the hoses to ensure material is not accidentally crossed
over.

Attach Air Lines

WARNING: Air Pressure Should Not Exceed 120 psi!
Install air line (at least ½” diameter) to unit and air compressor capable of at least 40 cfm. Attach air lines

to right side of INLET hose panel.