Magnum Venus Plastech FRP-1100-1-1 User Manual

FRP SystemOne

1100-1-1 CHOPPER OPERATION MANUAL

MAGNUM VENUS PRODUCTS

Operation Manual

Part No. M1 100-1-1

Revision 04.10.01

FRP SystemOne

Unit #

Type Of:

FRP SystemOne

Operation Manual

Unit Information

Power Cylinder
Metering Pump
Gun
Roving Cutter
Fluid Section

Corporate HQ & Mfg.

Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www .magind.com

Manufacturing

Phone: [phone] [phone]
Fax: [phone]
Email: [e-mail]
Web: www .venusmagnum.com

FRP SystemOne

© 2001 Magnum Venus Product s Manual Part No: M1100-1-1

T able of Contents

FRP SystemOne

Operation Manual

CHAPTER 1 - QUICK LIST
Start Up
Installation & Setup

CHAPTER 2 - INST ALLATION AND SET-UP
Pre-Operation Checklist
Wetting Unit
Proper Operating Pressures
Installation

CHAPTER 3 - MAINTENANCE

CHAPTER 4 - PARTS DRAWINGS
Cart Assembly
Mounting Column Assembly
12’ Boom Assembly
Pneumatic Manifold Assembly
3-Gallon Flush T ank Assembly

FRP SystemOne

Chapter

1

FRP SystemOne Quick List

Quick List Instructions

Start-Up Sheet

1. Check & fill solvent system

2. Check & fill resin & catalyst supply

3. Place suction wand in resin supply

4. Prime resin pump

5. Prime catalyst pump and set catalyst percentage

6. Check system for fluid leaks

7. Set air pressure to gun/chopper

8. Install turbulent mixer in mix chamber

9. Select spray tip, flow nozzle or convergence tip

10. Check chopper motor, rubber roller adjustment
1 1. Attach chute & cover

12. Adjust fan pattern

13. Adjust chop pattern

NOTE: These instructions include resin and catalyst pressurization procedures.
T o avoid equipment malfunction or possible injury , please follow these
instructions. If you have any questions, please contact our Technical Service
Department at 800-448-6035.

FRP SystemOne

1

FRP

System

One

Pumping System

Quick List Instructions

Installation & Setup

1. Unpack unit &
components

2. Place unit & stand pipe in
base plate or portable cart (or
mount to wall with wall brackets)
Tighten bolts to secure

3. Install catalyst jug

4. Install resin surge chamber &
filter assembly

5. Install manifold air hose to power
cylinder

6. Attach hose fittings to resin

pump, catalyst pump, air &

flush tank

7. Install boom to mast
(if applicable)

8. Hang hose on boom
(if applicable)

9. Attach pickup hose

10 . Place flush tank in holder and

attach air hose from manifold

1 1. Double check all hose fittings

2

FRP SystemOne

Chapter

2

FRP SystemOne

Installation & Set-Up

Checklist

1. Tighten all hose fittings and fluid connections to make sure they are
tight.

2. Check electrical grounds, gun to pump and pump to earth ground.

3. Check all clamp brackets, pump column, slave arm bracket, manifold
clamp, etc. T o make sure they will not move when unit is in operation.

4. Check the mounting of catalyst pump to make sure clevis pins are
secure.

5. Make sure exhaust silencer is secured to the power cylinder of the
resin pump.

6. IMPORTANT: Snug up the p acking nut at the top of the catalyst

pump Approximately ¼ turn.

7. Snug up, tighten, the resin pump packing be inserting two rods into
the holes in the oil cup at the top of the resin pump fluid section. Turn
clockwise until packing is snug.

8. Tighten the gun valve rod packing nut until it is very snug.

IMPORT ANT: Activate the gun trigger 10 - 15 times then tighten
the packing nut. Repeat this tightening procedure 3 times to make

sure the gun valve rod packing is tight.

FRP SystemOne

3

Wetting Out Unit

Air Supply:

1. Use minimum ½” air hose supply to the system. Air requirements,
18 CFM

2. Open incoming air supply ball valve.

3. Set regulator labeled gun at 90 to 100 psi. T ighten packing nuts on
the gun and trigger the gun 15 to 20 times. Tighten p acking nuts

again and repeat gun triggering.

Priming Solvent:

1. Open solvent tank lid and fill tank ¾ full. Install lid on tank and
close the relief valve located on the top of the lid. Set flush tank
pressure at 50 to 60 psi.

2. Push the flush valve on the side of the gun block to test solvent
flush.

Priming Catalyst to Gun:

1. Tighten the catalyst packing nut ¼ turn.

2. Fill the two gallon catalyst jug ¾ full, purge the air out of the
catalyst feed line by slightly tilting the catalyst jug.

3. Lock the gun in the open position. Remove the pivot pin from
the catalyst slide arm linkage. Use the slide arm to hand prime
catalyst out to the gun until a steady stream is achieved. Do not

reinstall pivot pin at this time.

Priming Resin to Gun:

1. Insert the resin suction wand into a 55-gallon drum or resin.

2. Tighten the resin pump packing nut until tight. Fill packing nut
cavity ¾ full with suitable oil.

3. With gun locked in the open position, slowly increase resin pump

regulator pressure until pump is running at a slow but steady rate.
Allow pump to run until a fairly steady stream of resin is being
dispensed. Close the gun and flush the gun head.

4. Increase resin pump pressure to 100 psi. Allow the unit to set
under static load for 15 to 30 minutes to seat the resin packing set.

5. Clamp or tape the resin return hose coming from the bottom of the
in-line resin filter to the resin pickup wand, into the resin drum. Turn
the resin pump regulator to zero. Slowly open the ball valve at the

bottom of the resin filter to drain the fluid pressure.

4

FRP SystemOne

Charging the Resin Surge Chamber:

1. Open ball valve below inline resin filter.

2. T o charge the resin surge chamber , use the air hose with the
female quick disconnect (charging hose) and insert over the male

quick disconnect at the top of the resin surge chamber . Push down
on female quick disconnect for 5 to 10 seconds and disengage.

3. Close ball valve below in-line resin filter.

Pressurizing Fluids:

1. Slowly increase resin pump regulator , 50 psi would be a good
starting point.

2. Pull the pivot pin using the slide arm. Use slow up and down
motion to pressurize the catalyst pump for several strokes or until

firm.

3. Pin the pivot pin into the slide arm.

Gun Set-Up:

1. Install turbulent mixer into mix chamber and install tip. For

longer turbulent mixer life, do not over tighten the nozzle cap.

2. T est the spray pattern, make pump pressure adjustment for
required resin outputs.

3. Thread either one or two strands of glass into chopper motor. Use
chopper motor pivot to adjust glass entry into resin fan. Center the
glass into the resin fan using the eccentric stud.

Start-Up Instructions

1. Removing Unit From Crate.

With the crate laying flat. Open the top panel and remove the
components as needed.

a. Cart
b. Pump and Column Assembly .
c. Boom, Hose, and Gun Assembly .
d. Resin Filter/Surge Chamber Assembly .
e. Suction Wand Assembly .
f. Component Box.
g. Catalyst Jug.
h . Solvent T ank.

FRP SystemOne

5

2. Assemble Cart.

a. Attach Handle to Cart.

3. Assemble Pump and Column Assembly to cart.
a. Insert Column into column support hole in top of cart.

b. Orient the column until pump faces the front of the cart.
c. Tighten the lock screws to retain pump/column assemble to cart.

Lock screws are located under cart on the front side.

4. Assemble Boom, Hoses, and Gun Assembly to pump column.
a. With the boom folded, hose coiled, and gun attached as the

assembly comes out the crate. Lift the boom up and insert the
base pivot over the column.

b. With the boom installed on column. Remove the ties holding the

two sections of boom together .

c. Remove the ties that hold the gun and hoses in the coil. T ake care

not to drop the gun.

d. Remove the boom spring from the diagonal angle support at the

base of the boom.

e. Swivel the boom back over the rear of the cart (barrel location

area). Unfold the boom sections so both inner and outer sections
are straight over back of cart.

f. With the boom sections stretched out to their full reach. Attach

one end of the boom extension spring to the support chain at­tached at the boom knuckle.

g. While lifting the outer section of the boom upward, attach the other

end of the extension spring to the link welded to the top of the
outer boom.

NOTE

If Outer section of boom and gun hang to close the floor . Lift
the outer section of the boom again and attach the extension
spring to a new location on the support chain. Shortening the
chain will raise the outer section of the boom.

h . With the outer section of the boom supported by the spring and

chain. Fold the outer section of the boom parallel to the inner
section.

5. Assemble Resin Filter/Surge Chamber Assembly to Pump.

a. Check to make sure all Filter/Surge Chamber connections are

tight.

6

FRP SystemOne