Magnum Venus Plastech High Volume User Manual

High Volume

Modular System

MAGNUM VENUS PRODUCTS Part No. 90079-1

Operations Manual

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Table of Contents

High Volume Modular System Manual

CHAPTER 1 - OPERATIONAL DATA
CHAPTER 2 - MATERIALS

Resin
Catalyst
Glass-Fiber Roving
Solvent
Air

CHAPTER 3 - START-UP, RUNNING AND SHUT-DOWN PROCEDURE
Start-Up
Priming Procedure (Resin)
Priming Procedure (Catalyst)
Shut-down Procedure
Removing Materials from System

CHAPTER 4 - PARTS DRAWINGS

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CHAPTER 1
OPERATIONAL DATA

In order to function at maximum performance level, the High Volume Modular system requires
an air source capable of providing 35 CFM of clean, dry air, at 100 PSI. The air supply hose to
the unit must be kept as short as practical and be no less than ½” inner diameter to assure an
adequate air supply. Clean, dry air is essential to give the best service life of the power head
and chopper motor. Consult your local representative or Magnum Venus Products directly for
air requirements if you feel your operation may need more detailed information.

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CHAPTER 2
MATERIALS

Selection of proper materials and the use of them can make the difference between success
and failure, with this or any other equipment. Your local distributor can assist in proper
selection for the best results. The following generalities should be followed.

RESIN should be formulated for gun use with proper promoters for MEKP. Also, with
Thixotropic characteristics and relatively low viscosity for fast impregnating. Resin should be
stored at about 70 to 75 degrees Fahrenheit (21 – 30 degrees C) before using. Resin at 85
degrees F (30 deg. C) will allow the equipment to perform better, minimize the variations and
control problems, speed up impregnation, and improve quality of products. Solid additives
which are introduced into resin for any purpose (such as flame retardation or thixotropic
properties) invariably increase the wear factor on internal moving parts in the resin pump.
More frequent replacement of these parts must be considered as part of the cost of using such
additives. It may be necessary to use special parts in the system such as carbide needles and
seats or heat-treated pump cylinders with modifications of the piston area to help lengthen the
life of the parts.

CATALYST should be Methyl Ethyl Keytone Peroxide of strength to give proper gel times for
products made with percentages of ¾ to 3% on standard equipment. This range is ½ to 1 ¼ %
on high volume units. A factory-tinted catalyst, for visual control purposes, is recommended.
This can be obtained from the peroxide manufacturer. Failure of the equipment (unless other
problems) is generally the result of trying to add tinting materials. Never use solvents to

clean the catalyst system as it forms unstable peroxides. Use only clear water.
GLASS FIBER ROVING should be made for spray-up roving cutters and with a soft, non-static

treatment. The Magnum Venus Hydraulic systems do not have a high pressure air blast that
causes the fibers to tumble and float all over, as with air aspirated guns, hence the softer the
treatment, the better the glass pattern. If treatment is too hard, fibers lay in clumps, the pattern
is narrow and it is difficult to attain uniformity and good impregnation.

SOLVENT The High Volume Modular unit is composed of parts and material lines compatible
to Acetone and solvent replacements . NOTE: Certain reclaimed solvents could affect

systems in such a way as to nullify the warranty.
AIR must be clean and dry. Moisture or oils in air supply may damage various components of

this system as they would any other machinery.

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CHAPTER 3

START-UP, RUNNING AND SHUT DOWN PROCEDURE

The Magnum Venus Products High Volume Modular System is the ultimate in spray-up
equipment. This instruction manual, the Trouble-Shooting guide and the Parts Drawing
Package should be read thoroughly and used as a reference when working with your Magnum
Venus System. We have tried to note when differences occur, but suggest you contact

Magnum Venus Products or it’s nearest representative if performance of your particular

Magnum Venus Products system is not satisfactory following these instructions.

START-UP

These steps should be followed when unit is new, recently repaired, or has no material in
system:

1. Read and become familiar with Manual, Trouble-shooting Guide and drawings for
your particular unit, and all other operational aids provided with unit.

2. Check all fittings for proper connection.

3. Fill resin pump cavity (center section) approximately 1/3 full using Throat
Seal/Lubricant (TSL-XX).

4. Turn all regulators counter-clockwise so gauges will read 0 (zero) when air is
connected to system.

5. Open catalyst Recirculation valve on the Catalyst Manifold.

6. Pull bottom quick pin from Pivot Link Assembly (part number UPS-3104-01).

NOTE: This will allow resin pump to stroke but prevent catalyst pump from pumping
during start-up procedure. It should be general procedure to never have the catalyst
pump connected except when spraying a laminate.

7. Attach air source to manifold fitting. Open main air inlet ball valve.

NOTE: ½” diameter (minimum) air hose should be used for maximum efficiency.

8. Remove top from flush tank and fill with clean suitable solvent. Replace tank top.

9. Slowly bring flush regulator up to 40 PSI (turn clockwise).

NOTE: Flush tank pressure should never be higher than 60 PSI.

10. Open flush air control valve.

11. Remove nozzle, nozzle cap, turbulent mixer and mix chamber from gun.

12. Push solvent button on gun until solvent exits gun nozzle.

13. Open gun by pulling gun trigger. Aim gun into suitable container and keep gun open
during priming procedure.

PRIMING PROCEDURE (RESIN)

NOTE: The High Volume system should be connected to a Bulk Feed Resin System. MVP

Recommends a 2” Y-filter and ball valve on the Resin Inlet.

1. Open resin pump air valve and slowly turn resin pump regulator clockwise until resin
pump is stroking slow, even strokes (approximately 1 to 10 PSI). On systems with

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air supply override valves you must press and hold the priming button before the
pump will move.

NOTE: as resin enters pump you may have to increase PSI slightly in order to maintain
even pump stroke. Observe gun to make sure resin is exiting evenly with no air
inclusion.

2. Shut off air to resin pump by either turning regulator to zero or turning pump air
control valve to off position.

3. Close gun and flush into appropriate container for approximately 2 seconds.

NOTE: Flush by pushing solvent button on side of gun.

4. Repeat opening of gun and aim into appropriate container for catalyst priming. Keep
gun open during priming procedure.

PRIMING PROCEDURE (CATALYST)

1. Slowly fill 2-gallon catalyst jug with MEKP (never dilute catalyst for Magnum Venus
system).

NOTE: See catalyst manufacturer for proper MEKP formulation for your particular
operation.

2. Check to make sure catalyst recirculation valve is open. Open if needed.

3. Remove quick pin from pivot link assembly.

4. Loosen catalyst packing nut slightly to hand prime.

5. Slowly with steady, even strokes, hand pump catalyst pump using rail assembly.
Stop hand priming when steady stream of catalyst exits gun. Close gun and flush
for approximately 2 seconds.

6. Reinstall quick pin into pivot link assembly.

7. Close catalyst recirculation valve on the catalyst manifold.

8. Retighten packing nut. Snug tight only.

9. Slowly open resin pump air valve and slowly turn pump regulator to 15-20 PSI.
Resin and catalyst pump will stroke until system is full. On systems with air supply
override valves you must press and hold the priming button before the pump will
move. Check all fittings for leaks.

10. System is ready for use.

NOTE: Always remember to turn off regulator and slowly open gun trigger to bleed
system fluid pressure before any disassembly or repair takes place.

SHUTDOWN PROCEDURE

1. Turn resin pump and chopper regulators to zero. Turn resin pump air valve to off
position.

2. Open catalyst recirculation valve on the catalyst manifold.

3. Pull quick pin from pivot link assembly.

4. Remove nozzle, nozzle cap, turbulent mixer and mix housing and injector assembly
from gun head. Clean parts and set aside. Inspect for wear.

5. Aim gun into container and pull trigger until flow of material becomes small trickle.
Release trigger.

6. Push flush button to flush gun head.

7. Check water trap.

8. Check pump packings for leaks. Resin leaking into oil reservoir in center section
cavity indicates packings need tightening or replacement.

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9. Turn main air valve off.

10. Relieve flush tank pressure until all air has exhausted from flush tank.

REMOVING MATERIALS FROM SYSTEM

NOTE: Remove fluid pressure before performing maintenance or disassembly.

1. Disconnect resin pump from bulk resin system and allow to drain. Place inlet in
solvent or fill bulk system with solvent.

2. Aim gun into container and open gun by pulling trigger. Keep trigger open.

3. Open resin pump air valve and turn regulator until pump begins to stroke even, slow
strokes.

4. When clean solvent exits gun, shut off regulator.

5. Place container under resin pump accumulator and slowly unscrew the accumulator.

6. Clean resin accumulator with solvent.

7. Reinstall accumulator.

8. Resin system can now be broken down for maintenance. Refer to Manual, Trouble­shooting Guide and Parts Drawings for proper maintenance. Refer to page 30 of
Trouble Shooting Guide for filled system procedure and pages13 & 14 for long
period shutdown procedure.

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CHAPTER 6

PARTS DRAWINGS

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