HVLS-1000 Series Fluid
Section Manual
Rev. 05/2012
HVLS-1000 Series Fluid Section Manual
CORPORATE HEADQUARTERS and MANUFACTURING
11692 56th Court * Clearwater, FL 33760 * Tel 727-573-2955 * Fax 727-571-3636
TECHNOLOGY CENTER and MANUFACTURING
1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666
MVP Plastech UK
Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: +44 (0) 1822 832621
Fax: +44 (0) 1822 833999
www.mvpind.com
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Table of Contents
HVLS-1000 Series Fluid Section Manual
SECTION:
Page
TERMS & CONDITIONS OF SALE 4
SAFETY & WARNINGS 6
INTRODUCTION 15
REQUIREMENTS 17
MAINTENANCE 20
FLUID SECTION DISASSEMBLY 24
FLUID SECTION ASSEMBLY 26
ACCUMULATOR & FILTER 30
TROUBLESHOOTING CHART 32
AIR LOCK IN THE CATALYST PUMP 36
FLUID SECTION INFORMATION 37
PARTS DRAWINGS 38
REVISION INFORMATION 39
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Terms & Conditions of Sale:
• Customs duties, import and export licenses and certificates, if required, and all
local taxes are excluded from this offer. If US state and local taxes are applicable
and not included in equipment invoice, such amount may be invoiced later.
• Delivery dates or shipping schedules are approximate and based upon the most
recent information available at the time of order. Dates may be adjusted upon
receipt of subsequent information or modification of order. Seller will ship prior to
the delivery date if possible, but not without Buyer’s consent on Advanced
Equipment sales.
• All contract dates and timelines begin upon receipt at MVP of customer purchase
order, signed Terms and Conditions of Sale (if applicable), and down payment per
quotation (if applicable).
• If shipments are delayed by the Buyer, or because the Buyer’s account is in
arrears, payments shall become due on the date when the Seller is prepared to
make shipment. Products held by the Seller for the Buyer shall be at the risk and
expense of the Buyer.
• Damages, defects or shortages must be communicated immediately to MVP.
Discrepancy in pricing and/or quantities on invoices must be reported within 30
days of the invoice date. Claims made 30 days or more following the invoice date
will not be honored.
• Permission to return items must be requested and granted in advance. No credit
will be given if items are returned prior to requesting and receiving permission. All
returns are subject to a restocking fee. The standard 15% charges may be
increased or decreased depending on the reason for the return. Special ordered
items may not be returned.
• Seller warrants that the mechanical operation of the goods as specified shall be
free from faults in respect to materials and workmanship for a period of 12 months
for parts from the date of invoice. For systems, 12 months from start-up or, if
earlier, 18 months from the date of the Bills of Lading. The warranty does not cover
general wear and tear or damage due to negligence or improper use. Seller’s
liability under the warranty shall be limited solely to repair or replacement costs,
and has no responsibility for reimbursing repair cost incurred by Buyer in
connection with equipment without first giving written authorization for such
charges. Seller makes no express warranties except those set forth in this
agreement, and disclaims all other warranties, expressed or implied, including
without limitation, implied warranties of non-infringement merchantability and
fitness for a particular purpose. Seller accepts no liability for loss of production,
loss of profits, or other direct or indirect damages. In any claim by the Buyer
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against the Seller in respect of the goods, the liability of the Seller shall be limited
to the value of the goods.
• Many factors beyond Seller’s control contribute to the success of Buyer’s finished
products, such as raw materials used to manufacture the product. Equipment is
warranted to perform to specifications detailed in quotation, but Seller is not liable
for quality or quantity of finished products produced by Buyer.
• The country of origin is the United States of America. Sale, installation and all
rights of the parties are governed by the laws of the state of Florida. Venue with
regard to any litigation shall be in Pinellas County, Florida. The parties agree to
waive all rights to trial by jury as to any and all disputes.
• The goods remain the property of the Seller until full payment is received.
• Sale of equipment is subject to application and issuance of proper US Government
export license and regulations, if applicable.
• Installation of equipment is responsibility of Buyer and Seller, with cost
responsibility and number of days provided as detailed in original customer
Quotation. Seller will provide installation supervision personnel within 30 days of
customer request. If installation is delayed by the Buyer more than six months
from the date of shipment, or if customer facility or material/parts are not prepared
for installation, seller will invoice full installation costs, up to $1,250 a day plus
expenses, for each MVP installation technician on site. Seller has the option to
waive this fee at its discretion.
• Parties shall be excused for delays caused by embargoes, acts of civil or military
authorities, Acts of God, or other circumstances beyond the reasonable control of
the parties. Notification of such delays must be made in writing within ten days of
occurrence.
• Our agreement supersedes any previous agreement and applies in full.
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HVLS-1000 Series Fluid Section Manual
SAFETY & WARNING INFORMATION:
OPERATING YOUR POLYESTER SYSTEM SAFELY
1. Introduction
Any tool, if used improperly, can be dangerous. Safety is ultimately the responsibility of those
using the tool. In like manner, safe operation of polyester processes is the responsibility of those
who use such processes and those who operate the equipment. This manual outlines
procedures to be followed in conducting polyester operations safety. This system has been
specifically designed for use of Polyester Resin, Gel-Coat, and Methyl Ethyl Ketone Peroxides
(MEKP) applications. Other formulations or blends considered for use in this equipment is
strictly prohibited without the expressed consent by Magnum Venus Plastech Inc. Magnum
Venus Plastech cannot eliminate every danger nor foresee every circumstance that might cause
an injury during equipment operation. Some risks, such as the high pressure liquid stream that
exits the spray tip, are inherent to the nature of the machine operation and are necessary to the
process in order to manufacture the end-product. For this reason, ALL personnel involved in
polyester operations should read and understand the Safety Manual. It is very important for the
safety of employees involved in the operation that equipment operators, maintenance and
supervisory personnel understand the requirements for safe operation. Each user should
examine his own operation, develop his own safety program and be assured that his equipment
operators follow correct procedures. Magnum Venus Plastech hopes that this manual is helpful
to the user and recommends that the precautions in this manual be included in any such
program. Magnum Venus Plastech recommends this Safety Manual remain on your equipment
at all times for your personnel safety. In addition to the manual, Magnum Venus Plastech
recommends that the user co nsult the regulations established under the Occupational Safety &
Health Act (OSHA), particularly the following sections:
1910.94 Pertaining to Ventilation.
1910.106 Pertaining to flammable liquids
1910.107 Pertaining to spray finishing operations, particularly Paragraph (m) Organic Peroxides
and Dual Component Coatings.
Other standards and recognized authorities to consult are the National Fire Protection
Association (NFPA) bulletins as follows:
NFPA No.33 Chapter 14, Organic Peroxides and Dual Component Materials
NFPA No.63 Dust Explosion Prevention
NFPA No.70 National Electrical Code
NFPA No.77 Static Electricity
NFPA No.91 Blower and Exhaust System
NFPA No.654 Plastics Industry Dust Hazards
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Type of Fire Extinguishing equipment recommended: Fire Extinguisher – code ABC, rating
number 4a60bc.
Extinguishing Media – Foam, Carbon Dioxide, Dry Chemical, Water Fog.
Copies of the above bulletins are available, at a nominal charge from:
National Fire Protection Association
470 Atlantic Avenue
Boston, MA 02210
Research Report No.11 of the American Insurance Association deal with “Fire, Explosion and
Health Hazards of Organic Peroxides”. It is published by:
American Insurance Association
85 John Street
New York, NY 10038
Local codes and authorities also have standards to be followed in the operation of your spraying
equipment. Your insurance carrier will be helpful in answering questions that arise in your
development of safe procedures.
1.2 Personal Safety Equipment
Magnum Venus Plastech recommends the following Personal Safety Equipment for conducting
safe operations of the Polyester Systems:
Magnum Venus Plastech recommends that the user consult the state and local regulations
established for all Safety equipment listed.
2.0 Material Safety
2.1 Hazards Associated with Laminating Operations
The major hazards which should be guarded against in polyester laminating operations are
those associated with:
1. The flammability and explosion dangers of the catalyst normally used – Methyl Ethyl Ketone
Peroxide (MEKP).
2. The flammability dangers of clean-up solvents sometimes used (Magnum Venus Plastech
recommends that clean-up solvents be non-flammable), and of resin diluents used, such as
styrene.
3. The flammability dangers of catalyst diluents, if used. (Magnum Venus Plastech recommends
that catalyst not be diluted.
4. The flammability dangers of the uncured liquid resins used.
5. The combustibility dangers of the cured laminate, accumulations of over spray, and laminate
sandings.
6. The toxicity dangers of all the chemicals used in laminating operations with respect to
ingestion, inhalation and skin and eye hazards.
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2.2 Catalyst (Methyl Ethyl Ketone Peroxide)
MEKP is among the more hazardous materials found in commercial channels. The safe
handling of the “unstable (reactive)” chemicals presents a definite challenge to the plastics
industry. The highly reactive property which makes MEKP valuable to the plastics industry in
producing the curing reaction of polyester resins also produces the hazards which require great
care and caution in its storage, transportation, handling, processing and disposal. MEKP is a
single chemical. Various polymeric forms may exist which are more or less hazardous with
respect to each other. These differences may arise not only from different molecular structures
(all are, nevertheless, called “MEKP”) and from possible trace impurities left from the
manufacture of the chemicals, but may also arise by contamination of MEKP with other
materials in its storage or use. Even a small amount of contamination with acetone, for instance,
may produce an extremely shock-sensitive and explosive compound.
Contamination with promoters or materials containing promoters, such as laminate
sandings, or w ith any readily oxidizing material, such as brass or iron, will cause
exothermic “redox” reactions which can become explosive in nature. Heat applied to
MEKP, or heat build-up from contamination reactions can cause it to reach what is called
its Self-Accelerating Decomposition Temperature (SADT).
Researchers have reported measuring pressure rates-of-rise well in excess of 100,000 psi per
second when certain MEKP’s reach their SADT. (For comparison, the highest pressure rate-ofrise listed in NFPA Bulletin NO.68, “Explosion Venting”, is 12,000 psi per second for an
explosion of 12% acetylene and air. The maximum value listed for a hydrogen explosion is
10,000 psi per second. Some forms of MEKP, if allowed to reach their SADT, will burst even an
open topped container. This suggests that it is not possible to design a relief valve to vent this
order of magnitude of pressure rate-of-rise. The user should be aware that any closed
container, be it a pressure vessel, surge chamber, or pressure accumulator, could explode
under certain conditions. There is no engineering substitute for care by the user in handling
organic peroxide catalysts. If, at any time, the pressure relieve valve on top of the catalyst tank
should vent, the area should be evacuated at once and the fire department called. The venting
could be the first indication of a heat, and therefore, pressure build-up that could eventually lead
to an explosion. Moreover, if a catalyst tank is sufficiently full when the pressure relief valve
vents, some catalyst may spray out, which co uld cause eye injury. For this reason, and many
others, anyone whose job puts them in an area where this vented spray might go, should
always wear full eye protection even when laminating operations are not taking place.
Safety in handling MEKP depends to a great extent on employee education, proper safety
instructions and safe use of the chemicals and equipment. Workers should be thoroughly
informed of the hazards that may result from improper handling of MEKP, especially in regards
to contamination, heat, friction and impact. They should be thoroughly instructed regarding the
proper action to be taken in the storage, use and disposal of MEKP and other hazardous
materials used in the laminating operation. In addition, users should make every effort to:
A. Store MEKP in a cool, dry place in original containers away from direct sunlight and away
from other chemicals.
B. Keep MEKP away from heat, sparks and open flames.
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C. Prevent contamination of MEKP with other materials, including polyester over spray and
sandings, polymerization accelerators and promoters, brass, aluminum and non-stainless
steels.
D. Never add MEKP to anything that is hot, since explosive decomposition may result.
E. Avoid contact with skin, eyes and clothing. Protective equipment should be worn at all times.
During clean-up of spilled MEKP, personal safety equipment, gloves and eye protection must be
worn. Firefighting equipment should be at hand and ready.
F. Avoid spillage, which can heat up to the point of self-ignition.
G. Repair any leaks discovered in the catalyst system immediately, and clean up the leaked
catalyst at once in accordance with the catalyst manufacturer’s instructions.
H. Use only original equipment or equivalent parts from Magnum Venus Plastech in the catalyst
system (i.e.: hoses, fitting, etc.) because a dangerous chemical reaction may result between
substituted parts and MEKP.
I. Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries
should never be returned to the supply tank, such catalyst should be diluted with copious
quantities of clean water and disposed of in accordance with the catalyst manufacturer’s
instructions.
The extent to which the user is successful in accomplishing these ends and any additional
recommendations by the catalyst manufacturer determines largely the safety that will be present
in his operation.
2.3 Clean-Up Solvents and Resin Diluents
WARNING
A hazardous situation may be present in your pressurized fluid system! Hydrocarbon
Solvents can cause an explosion w hen used with aluminum or galvanized components in
a closed (pressurized) fluid system (pump, heaters, filters, valves, spray guns, tanks,
etc.). The explosion could cause serious injury, death and/or substantial property
damage. Cleaning agents, coatings, paints, etc. may contain Halogenated Hydrocarbon
Solvents. Some Magnum Venus Plastech spray equipment includes aluminum or
galvanized components and will be affected by Halogenated Hydrocarbon Solvents.
A. There are three key elements to the Halogenated Hydrocarbon (HHC) solvent hazard.
a. The presence of HHC solvents. 1,1,1 – Trichloroethane and Methylene Chloride are
the most common of these solvents. However, other HHC solvents are suspect if
used; either as part of paint or adhesives formulation, or for clean-up flushing. b.
Aluminum or Galvanized Parts. Most handling equipment contains these elements. In
contact with these metals, HHC solvents could generate a corrosive reaction of a
catalytic nature.
b. Equipment capable of withstanding pressure. When HHC solvent contacts aluminum
or galvanized parts inside a closed container such as a pump, spray gun, or fluid
handling system, the chemical reaction can, over time, result in a build-up of heat and
pressure, which can reach explosive proportions.
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When all three elements are present, the result can be an extremely violent explosion. The
reaction can be sustained with very little aluminum or galvanized metal; any amount of
aluminum is too much.
A. The reaction is unpredictable. Prior use of an HHC solvent without incident (corrosion or
explosion) does NOT mean that such use is safe. These solvents can be dangerous alone (as a
clean-up or flushing agent) or when used as a component or a coating material. There is no
known inhibitor that is effective under all circumstances. Furthermore, the mixing of HHC
solvents with other materials or solvents, such as MEKP, alcohol, and toluene, may render the
inhibitors ineffective.
B. The use of reclaimed solvents is particularly hazardous. Reclaimers may not add any
inhibitors. Also, the possible presence of water in reclaimed solvents could feed the reaction.
C. Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction.
Such coatings can be worn, cracked, scratched, or too thin to prevent contact. There is no
known way to make oxide coatings or to employ aluminum alloys, which will safely prevent the
chemical reaction under all circumstances.
D. Several solvent suppliers have recently begun promoting HHC solvents for use in coating
systems. The increasing use of HHC solvents is increasing the risk. Because of their exemption
from many State Implementation Plans as Volatile Organic Compounds
(VOC’s), their low flammability hazard, and their not being classified as toxic or carcinogenic
substances, HHC solvents are very desirable in many respects.
WARNING: Do not use Halogenated Hydrocarbon solvents in pressurized fluid systems
having aluminum or galvanized wetted parts.
NOTE: Magnum Venus Plastech is aware of NO stabilizers available to prevent
Halogenated Hydrocarbon solvents from reaction under all conditions w ith aluminum
components in closed fluid system. TAKE IMMEDIATE ACTION Halogenated
Hydrocarbon solvents are dangerous w hen used with aluminum components in a closed
fluid system.
A. Consult your material supplier to determine whether your solvent or coating contains
Halogenated Hydrocarbon Solvents.
B. Magnum Venus Plastech recommends that you contact your solvent supplier regarding the
best non-flammable clean-up solvent with the heat toxicity for your application.
C. If, however, you find it necessary to use flammable solvents, they must be kept in approved,
electrically grounded containers.
D. Bulk solvent should be stored in a well-ventilated, separate building, 50 feet away from your
main plant.
E. You should allow only enough solvent for one day’s use in your laminating area.
F. “NO SMOKING” signs must be posted and observed in all areas of storage or where solvents
and other flammable materials are used.
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G. Adequate ventilation (as covered in OSHA Section 1910.94 and NFPA No.91) is important
wherever solvents are stored or used, to minimize, confine and exhaust the solvent vapors.
H. Solvents should be handled in accordance with OSHA Section 1910.106 and 1910.107.
2.4 Catalyst Diluents
Magnum Venus Plastech spray-up and gel-coat systems currently produced are designed so
that catalyst diluents are not required. Magnum Venus Plastech, therefore, recommends that
diluents not be used. This avoids the possible contamination which could lead to an explosion
due to the handling and mixing of MEKP and diluents. In addition, it eliminates any problems
from the diluents being contaminated through rust particles in drums, poor quality control on the
part of the diluents suppliers, or any other reason. If, however, diluents are absolutely required,
contact your catalyst supplier and follow his instructions explicitly. Preferable, the supplier
should premix the catalyst to prevent possible “on the job” contamination while mixing.
WARNING
If diluents are not used, it should be remembered that catalyst spillage, gun, hose and
packing leaks are potentially more hazardous, since each drop contains a higher
concentration of catalyst, and therefore will react quicker with over spray and the leak.
2.5 Cured Laminate, Overspray and Laminate Sandings Accumulation
A. Remove all accumulations of overspray, FRP sandings, etc. from the building as they occur.
If this waste is allowed to build up, spillage of catalyst is more likely to start a fire, in addition, the
fire would burn hotter and longer.
B. Floor coverings, if used, should be non-combustible.
C. Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product, oversprayed chop or resin, FRP sandings or any other material with MEKP.
To prevent this spillage and leakage, you should:
1. Maintain your Magnum Venus Plastech System. Check the gun several times daily for
catalyst and resin packing or valve leaks. REPAIR ALL LEAKS IMMEDIATELY.
2. Never leave the gun hanging over, or lying inside the mold. A catalyst leak in this situation
would certainly damage the part, possibly the mold, and may cause a fire.
3. Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom
sections and at the hose and fittings. Replace if wear or weakness is evident or suspected.
4. Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub
against any of the hoses at any point. If allowed to rub, the hose will be cut through, causing a
hazardous leakage of material which could increase the danger of fire. Also, the material may
spew onto personnel in the area.
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2.7 Toxicity of Chemicals
A. Magnum Venus Plastech recommends that you consult OSHA Sections 1910.94, 1910.106,
1910.107 and NFPA No.33, Chapter 14, and NFPA No.91.
B. Contact your chemical supplier(s) and determine the toxicity of the various chemicals used as
well as the best methods to prevent injury, irritation and danger to personnel.
C. Also determine the best methods of first aid treatment for each chemical used in your plant.
2.8 Treatment of Chemical Injuries
Great care should be used in handling the chemicals (resins, catalyst and solvents) used in
polyester systems. Such chemicals should be treated as if they hurt your skin and eyes and as if
they are poison to your body. For this reason, Magnum Venus Plastech recommends the use of
protective clothing and eye wear in using polyester systems. However, users should be
prepared in the event of such an injury. Precautions include:
1. Know precisely what chemicals you are using and obtain information from your chemical
supplier on what to do in the event the chemical gets onto your skin or into the eyes, or is
swallowed.
2. Keep this information together and easily available so that it may be used by those
administering first aid or treating the injured person.
3. Be sure the information from your chemical supplier includes instructions on how to treat any
toxic effects the chemicals have.
WARNING
Contact your doctor immediately in the event of any injury and give him the information
you have collected. If your information includes first aid instructions, administer first aid
immediately while you are contacting your doctor.
Fast treatment of the outer skin and eyes that contact such chemicals generally includes
immediate and thorough washing of the exposed skin and immediate and continuous flushing of
the eyes with lots of clean water for at least 15 minutes or more. These general instructions of
first aid treatment, however, may be incorrect for some chemicals; that is why yo u must know
the chemicals and treatment before an accident occurs. Treatment for swallowing a chemical
frequently depends upon the nature of the chemical.
NOTE: Refer to your System User Manual for complete and detailed operating
instructions and service information.
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3.0 Equipment Safety
WARNING
Magnum Venus Plastech suggests that personal safety equipment such as EYE
GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be w orn w hen servicing or
operating this equipment. Ear protection should be w orn when operating a fiberglass
chopper to protect against hearing loss since noise levels can be as high as 116 dB
(decibels). This equipment should only be operated or serviced by technically trained
personnel!
WARNING
Never place fingers, hands, or any body part near or directly in front of the spray gun
fluid tip. The force of the liquid as it exits the spray tip can cause serious injury by
shooting liquid through the skin. NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR
POINT THE GUN AT OR NEAR ANOTHER PERSON. (TREAT T HE GUN AS IF IT WERE A
LOADED PISTOL.)
3.1 Emergency Stop Procedures
The following steps should be followed in order to stop the machinery in an emergency situation
1. The ball valve located where the air enters the power head of the resin pump, should be
moved to the “OFF” or closed position. To do this, simply rotate the lever on the ball valve
90 degrees. Doing this will cause all the system air to bleed out of the system in a matter of
a few seconds, making the system incapable of operating
NOTE: Step 2 is a precautionary step and should be followed whenever the above
mentioned ball valve is activated to the stop mode. Failure to do so, can damage the
regulators and components on reactivating to the “ON” position.
2. Turn all system regulators to the “OFF” position (counter-clockwise) position
NOTE: Verify that the Catalyst relief line, located on the catalyst manifold, and the resin
return line, located on the resin filter, are secured relieving catalyst and resin fluid
pressure.
3. Catalyst pressure in the catalyst pump can be eliminated by rotating the ball valve on the
catalyst manifold 90 degrees to the “open” or “on” position.
Note: The “open” or “on” position is when the ball valve handle is parallel (in line) with
the ball valve body. The “closed” or “off” position is when the ball valve handle is
perpendicular (across) the ball valve body.
4. Resin pressure in the resin pump can be eliminated by rotating the ball valve on the resin
filter 90 degrees to the “open” or “on” position. Place a container under the ball valve to
catch any resin that is ejected out of the valve.
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3.2 Grounding
Grounding an object means providing an adequate path for the flow of the electrical charge from
the object to the ground. An adequate path is one that permits charge to flow from the object
fast enough that it will not accumulate to the extent that a spark can be formed. It is not possible
to define exactly what will be an adequate path under all conditions since it depends on many
variables. In any event, the grounding means should have the lowest possible electrical
resistance. Grounding straps should be installed on all loose conductive objects in the spraying
area. This includes material containers and equipment. Magnum Venus Plastech recommends
grounding straps be made of AWG No.18 stranded wire as a minimum and the larger wire be
used where possible. NFPA Bulletin No77 states that the electrical resistance of such a
leakage path may be as low as 1 meg ohm (10 ohms) but that resistance as high as 10,000
meg ohms will produce an adequate leakage path in some cases. Whenever flammable or
combustible liquids are transferred from one container to another, or from one container to the
equipment, both containers or container and equipment shall be effectively bonded and
grounded to dissipate static electricity. For further information, see National Fire Protection
Association ( NFPA) 77, titled “Recommended Practice on Static Electrical”. Refer especially to
section 7-7 titled “Spray Application of Flammable and Combustible Materials”. Check with local
codes and authorities for other specific standards that might apply to your application. NEVER
USE HARD MATERIALS SUCH AS WIRE, PINS, ETC., TO CLEAR A PLUGGED GUN. HARD
MATERIALS CAN CAUSE PERMANENT DAMAGE. DAB WITH A BRISTLE BRUSH, BLOW
BACKWARDS WITH AIR UNTIL CLEAR WHILE WEARING A PROTECTIVE EYE SHIELD.
REPEAT AS MANY TIMES AS NECESSARY. DO NOT PERFORM ANY MAINTENANCE OR
REPAIRS UNTIL YOU HAVE FOLLOWED THE PRECAUTIONS STATED ABOVE. IF YOU, AS
AN EQUIPMENT OPERATOR OR SUPERVISOR, DO NOT FEEL THAT YOU HAVE BEEN
ADEQUATELY TRAINED OR INSTRUCTED AND THAT YOU LACK THE TECHNICAL
KNOWLEDGE TO OPERATE OR PERFORM MAINTENANCE ON A PIECE OF MAGNUM
VENUS PLASTECH EQUIPMENT, PLEASE CALL MAGNUM VENUS PLASTECH BEFORE
OPERATING OR PERFORMING MAINTENANCE ON THE EQUIPMENT. IF YOU HAVE ANY
QUESTIONS REGARDING THE ABOVE PRECAUTIONS OR ANY SERVICE OR OPERATION
PRECEDURES, CALL YOUR MAGNUM VENUS PLASTECH DISTRIBUTOR OR MAGNUM
VENUS PLASTECH.
NOTICE: All statements, information and data given herein are believed to be accurate
and reliable but are presented without guaranty, warranty or responsibility of any kind
express or implied. The user should not assume that all safety measures are indicated
or that other measures are not required.
DANGER: Contaminated catalyst may cause Fire or Explosion. Before working on the
catalyst pump or catalyst accumulator, wash hands and tools thoroughly. Be sure work
area is free of dirt, grease or resin. Clean catalyst system components with clean water
only.
DANGER: Eye, skin and respiration hazard. The Catalyst, MEKP, may cause blindness,
skin irritation or breathing difficulty. Keep hands away from face. Keep food and drink
away from work area.
WARNING: Please refer to your catalyst manufacturer’s safety information regarding the
safe handling and storage of catalyst. Wear appropriate safety equipment as
recommended.
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Introduction:
This manual, the HVLS-1000 FLUID SECTION MANUAL, provides information you need to
perform simple maintenance and repair on your equipment.
Step-by-step assembly and disassembly procedures are included for each component.
A troubleshooting guide helps you diagnose and perform common repair situations.
A comprehensive maintenance schedule provides a detailed list for performing daily,
weekly, monthly, three-month and annual maintenance.
Please read the manual carefully. Follow the steps in the order given, otherwise you may
damage the equipment or injure yourself.
DANGER: Always wear proper safety equipment, including eye protection and gloves
when performing service and repair on this equipment.
This manual covers the following pump assemblies:
HVLS-1000 High Volume Fluid Section Assembly
HVLS-1000-DHV High Volume Fluid Section Assembly – Duo Units
HVLS-1000-HD High Volume Fluid Section Assembly – Heavy Duty
MCPA-HVLS High Volume Fluid Section Assembly – Multi Color units
HVLS-1040-CK High Volume Fluid Section Conversion Kit – Magnapak
VPHV-0600 High Volume 6:1 Pump Assembly
VPHV-1200 High Volume 12:1 Pump Assembly
VPHV-1200-HD High Volume 12:1 Pump Assembly – Heavy Duty
During Disassembly:
As you disassemble the equipment, lay out the components in the correct order and direction.
This will help you to reassemble them.
Note: the order of the piston cup, piston cup spacer ring, piston cup backup ring and
compression ring and the directions they face. These directions are critical to proper
functioning of this equipment.
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Lubrication:
Throughout this manual, directions are given for lubricating various parts of the Fluid Section.
There are three types of lubricant used:
If the part contacts resin, use MVP Red Grease (6706-2-1).
If the part is located where it will contact air, use Lubriplate® (08465).
Throat Seal Oil (TSL-3200) used in the oil reservoir of the pump.
DANGER: FIRE AND EXPLOSION HAZARD. Never use any lubrication on the
components of the catalyst system. Contact your catalyst manufacturer for additional
material handing information.
Major Components:
Resin Pump Fluid section.
Description of Controls for Spray unit:
Familiarize yourself with the manifold controls, which consist of the following regulators and
gauges:
PUMP PRESSURE gauge and regulator. These control main air pressure to the
resin pump.
ATOMIZING-AIR gauge and regulator. This controls the air pressure to the catalyst
nozzle on the gun.
PRIMING BUTTON this control is to operate the pump with triggering the gun.
Hazard Information:
Please note the following safety and informational designations used throughout this manual:
DANGER: Indicates hazards or unsafe practices that are likely to result in severe
personal injury or death.
WARNING: Indicates hazards or unsafe practices which could result in severe personal
injury or extensive equipment damage.
CAUTION: Indicates hazards or unsafe practices which could result in minor injury or
damage to equipment.
NOTE: Indicates additional information including explanations of certain procedures or
helpful suggestions. Notes do not contain safety information.
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HVLS-1000 Series Fluid Section Manual
Requirements:
Air Requirements:
Clean, dry compressed air must be available at up to 90 psi (6.3 kg/cm2) and a minimum volume
of 14 CFM (0.4 m3). Air must be provided through an air hose with a diameter of 0.5 inch (1.3
cm) or greater.
Tool and Supplies Requirements:
When performing service and repair on the Fluid Section, you should have the following tools,
spare parts and supplies available before beginning.
NOTE: Items followed by a * may be purchased from Magnum Venus Plastech.
One table vise
Loctite™ 243 (removable) or equivalent thread lock compound
One small hammer
Needle-nose pliers
Solvent or emulsifier for cleaning
One clean work table
Set of hex wrenches * (08469)
One 5/8-inch wrench * (08474)
One 9/16-inch wrench * (08476)
One 5/16-inch wrench * (08477)
Empty buckets for cleaning
Clean ¼-inch plastic dowel or rod
One 8-inch adjustable wrench * (08467)
One 12-inch adjustable wrench * (08468)
One 7/16-inch open-end wrench
One ½-inch socket wrench
One 7/16-inch socket wrench * (08472)
Wooden sticks or tongue depressors (for testing)
Labels and pens (for marking pneumatic lines)
Clean rags and paint brushes for cleaning equipment
One tube of medium-weight lithium grease (such as Lubriplate® lubricant * (08465))
Large (approximately 3 feet by 10 feet or 1 meter by 3 meters) strips of paper for
performing spray tests.
One pin wrench * (45031-1) (comes with catalyst jug)
One scribe * (08126)
Red Grease * (6706-2-1 1oz can) (6706-2-16 16oz can) (6706-2-32 32oz can)
Seal Kit * -
HVLS-1000-SK Seal Kit – High Volume Fluid Section
HVLS-10SK-4U-1T Seal Kit – four HVLS-1010-U Packings
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HVLS-1000 Series Fluid Section Manual
NOTE: Lubriplate® is a registered trademark of the Lubriplate division of Fiske Brothers
Refining Company.
NOTE: Loctite™ is a trademark of the Loctite Corporation.
NOTE: Teflon® is a registered trademark of E.I. DuPont de Nemours and Co.
IMPORTANT WARRANTY INFORMATION
Please note that components used on this equipment are made of specially developed, highstrength material.
Only authentic Magnum Venus Plastech replacement parts are acceptable for
use with this equipment.
Use of unacceptable replacement parts will void our liability and warranty of this
equipment.
Please contact your Magnum Venus Plastech distributor for more information.
Installation & Set-up:
1. Check all clamp brackets, pump column, slave arm bracket, manifold clamp, etc. to make
sure they will not move when unit is in operation.
2. Check the mounting of catalyst pump to make sure clevis pins are secure.
3. Make sure exhaust silencer is secured to the power cylinder of the resin pump.
IMPORTANT: Snug up the packing nut at the top of the catalyst pump approximately ¼
turn.
4. Snug up, tighten, the resin pump packing by 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. Note: Do
not over tighten.
5. Pro Gun: Tighten the gun valve rod packing nuts until they are very snug. IMPORTANT:
Activate the gun trigger 10 - 15 times then tighten the packing nuts. Repeat this
tightening procedure 3 times to make sure the gun valve rod packing is tight.
6. Attach Suction Wand to Resin Pump.
a. Check all fittings on the wand assembly to make sure they are airtight.
b. Attach the wand assembly to the foot valve port of the resin pump.
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HVLS-1000 Series Fluid Section Manual
7. Hose connections.
a. Connect the black resin hose from the gun to the outlet fitting on the resin filter.
b. Connect the catalyst hose from the catalyst pump to the inlet of the catalyst manifold.
c. Connect the catalyst hose from the gun to the outlet of the catalyst manifold assembly.
d. Attach the red air hose from the gun to the fitting on the regulator labeled gun.
e. Attach the yellow poly flush hose from the gun to the outlet fitting of the solvent tank.
f. Attach the small red air supply hose from the flush regulator to the input fitting on the
solvent tank.
g. Attach the large red air hose from the pump regulator to the power cylinder of the resin
pump.
Note: Check all hose fittings and fluid connections to make sure they are tight.
h. Attach the ground wire from the gun to the electrical grounding lug on the pump
mounting bracket.
Note: Check electrical ground to ensure it is installed from the pump mounting bracket to
an earth ground.
i. Remove the catalyst poly tubes from the component box.
j. Cut the ½ inch diameter poly line, with the clamps, to 26 inches long. Clamp one end to
the outlet of the catalyst jug and the other end to the inlet of the catalyst pump. Make
sure clamps are airtight.
k. Connect the ¼-inch poly line to the relief valve on the catalyst manifold assembly and
insert the other end into the hole in the top of the catalyst jug.
l. Connect the ¼-inch poly line to the catalyst recirculation valve on the catalyst manifold, and insert
the other end into the hole in the top of the catalyst jug.
9. Check all components for damage.
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HVLS-1000 Series Fluid Section Manual
Maintenance:
DANGER: Contaminated catalyst may cause FIRE or EXPLOSION. Before working on
the catalyst pump or catalyst accumulator, wash hands and tools thoroughly. Be sure
work area is free of dirt, grease or resin. Clean catalyst system components with clean
water only.
DANGER: FLUIDS UNDER HIGH PRESSURE. Before performing any service and repair
on this equipment, be sure to relieve air and fluid pressure.
DANGER: Always wear appropriate eye protection when working with this equipment.
WARNING: When removing hoses, place a rag over the hose before loosening it.
Performing proper maintenance at the recommended time intervals maximizes your
equipment’s productivity and efficiency. This section describes recommended maintenance
procedures to be performed daily, weekly, monthly, every three months, twice per year and
once per year.
Please follow the maintenance schedules recommended in this manual. This schedule is based
on a one-shift, 5-day work week, using standard general purpose resin. An idle unit left with
resin in it requires more frequent parts replacement.
DAILY MAINTENANCE CHECKLIST:
PART PROCEDURE
Air Filter (“Water Trap”) Drain the air filter by holding a container under the filter
and turning the valve at the bottom.
Hoses Check for kinks or leaks.
Fluid Section Check the oil reservoir and add oil if needed.
Nozzle Cap Coat nozzle cap and threads with Red Grease.
Materials Check and fill catalyst jug and gel coat / resin. Never
run out
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HVLS-1000 Series Fluid Section Manual
WEEKLY MAINTENANCE CHECKLIST:
PART PROCEDURE
Air Filter (“Water Trap”) Drain
Hoses Check for kinks or leaks.
Gauges and Regulators Check for damage and proper operation.
Accumulator Remove and clean inside. Danger: Never attempt to
remove an accumulator until you have relieved
pressure. See Chapter 6: Accumulator & Filter.
Fluid Section Check the oil reservoir and add oil if needed. If
necessary, clean and dry the silencers. Check the
pickup hose and wand for leaks and damage. Check
for packing leaks.
Air Lines Check for leaks, wear and kinks. Replace if necessary.
MONTHLY MAINTENANCE CHECKLIST:
PART PROCEDURE
Air Filter (“Water Trap”) Drain.
Hoses Check for kinks or leaks.
Gauges and Regulators Check for damage and proper operation.
Accumulator Remove and clean inside. Danger: Never attempt to
remove an accumulator until you have relieved
pressure. See Chapter 6: Accumulator & Filter.
Fluid Section Check the oil reservoir and add oil if needed. If
necessary, clean and dry the silencers. Check the
pickup hose and wand for leaks and damage. Check
for packing leaks.
Catalyst Jug Check and clean tubes and filter screens if necessary.
Danger: Fire and explosion hazard. Never allow
solvent or grease to contact any part of the catalyst
system.
Air Lines Check for leaks, wear and kinks. Replace if necessary.
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HVLS-1000 Series Fluid Section Manual
SIX MONTH MAINTENANCE CHECKLIST:
PART PROCEDURE
Air Filter (“Water Trap”) Drain.
Hoses Check for kinks or leaks.
Gauges and Regulators Check for damage and proper operation.
Accumulator Remove and clean inside. Replace the O-Rings.
Danger: Never attempt to remove an accumulator
until you have relieved pressure. See Chapter 6:
Accumulator & Filter.
Fluid Section Replace the oil in the oil reservoir. If necessary, clean
and dry the silencers. Check piston rod, cylinder head,
piston and trip sleeve for wear and damage, replace as
needed. Replace O-Rings, cups, and packing set.
Check the pickup hose and wand for leaks and
damage. Check for packing leaks. Check piston rod
and pump cylinder for wear, replace as needed.
Replace the packing set, piston cups and O-Rings.
Catalyst Jug Check and clean tubes and filter screens if necessary.
Danger: Fire and explosion hazard. Never allow
solvent or grease to contact any part of the catalyst
system.
Air Lines Check for leaks, wear and kinks. Replace if necessary.
Catalyst Pump Replace all soft parts of the catalyst pump. Be sure to:
check bushings and pump cylinder and replace S.S.
balls, O-Rings, springs, piston seal and packing set.
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HVLS-1000 Series Fluid Section Manual
ANNUAL MAINTENANCE CHECKLIST:
PART PROCEDURE
Air Filter (“Water Trap”) Drain. Repair any leaks or damage.
Gauges and Regulators Check for damage and proper operation.
Accumulator Remove and clean inside. Replace the O-Rings.
Danger: Never attempt to remove an accumulator
until you have relieved pressure. See Chapter 6
Accumulator & Filter.
Fluid Section Replace the oil in the oil reservoir. Clean and dry the
silencers. Check piston rod, trip sleeve, cylinder head
and piston for wear or damage, replace as required.
Replace the O-Rings, piston cups and packing set.
Rebuild lower assembly.
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HVLS-1000 Series Fluid Section Manual
Disassembly of Fluid Section:
NOTE: Flushing the pump fluid section with solvent will make it easier to clean and
rebuild.
CAUTION: There are two (2) hard chrome balls in the Fluid Section assembly. If a ball
drops to the floor, it will be damaged. (Even if it appears undamaged, it will contain
dents and scratches that will create problems.) Damaged balls must be replaced or the
pump will not work properly.
NOTE: When disassembling the Fluid Section, replace any O-Rings that you expose.
Maintenance:
1. For a complete maintenance schedule, please refer to Chapter 3: Maintenance.
Troubleshooting:
1. For a complete troubleshooting schedule, please refer to Chapter 7: Troubleshooting
Chart.
Parts Drawings:
1. To perform service and repair on the Fluid Section, please follow the procedures below.
Please refer to a current parts drawing for the Fluid Section you are working on for part
numbers.
Turn Off Pressure:
1. Be sure all fluid pressure and air pressure is relieved from the system before performing
any work.
DANGER: To avoid serious injury or equipment damage, do not proceed unless the
system has been completely depressurized.
Remove Catalyst Pump:
1. Be sure the catalyst pump has been removed from the catalyst drive.
Note: some of the part numbers below will be different depending on which fluid section
you are working on – refer to a current parts drawing for the assembly you are working
on.
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HVLS-1000 Series Fluid Section Manual
To remove the Fluid Section from the Unit:
1. Remove the E-Ring, lift up the Sleeve and remove the two Connectors.
2. Remove the Quick Pin and slide the Rail Assembly out of the Piston Rod Adapter.
Fluid Section Disassembly Procedures:
1. Remove the four (4) Hex Nuts (F-HN-08C) from the Pump Cylinder Tie Rods
(86540-1).
2. Slide the Foot Valve Collar (86420-1), Foot Valve 1 (86370-) and Cylinder (86400-1)
down off the Piston Rod (HVLS-1004); discard the two O-Rings (01611). Remove
the Ball Stop (04309-1) and Ball Guide (HVLS-1007). Remove and discard the 15/8” Chrome Ball (03604). Clean and inspect ball seat area of Foot Valve (86370-1).
3. Loosen Packing Nut (HVLS-1003) and slide the Piston Rod (HVLS-1004) out of the
bottom of the Outlet Body (HVLS-1001).
4. Unscrew the Piston Nut (86530-1) from the Piston Body (86390-1). Remove the two
Piston Cups (02181-1), Piston Cup Backup (68310-3) and Piston Cup Spacer
(86520-3) from the Piston Body (86390-1). Discard the two Piston Cups (02181-1).
5. Unscrew the Piston Body (86390-1) from the Piston Adapter (86510-1). Remove the
1-5/8” Chrome Ball (03604) and the Piston Ball Spring (04072-1) Discard the 1-5/8”
Chrome Ball (03604)
6. Remove the Packing Nut (HVLS-1003) from the Outlet Body (HVLS-1001). Use a
1/4” wooden dowel to push the Packing Set Assembly (02158-4) out the top of the
Outlet Body (HVLS-1001). Discard the packing set. Clean and inspect the Guide
Bearing (HVLS-1006), Female Compression Ring (67110-1), Male Compression
Ring (87090-1), Wave Spring (HVLS-1009), and Spring Support Ring (HVLS-1005).
7.
Clean and inspect all parts that will be reused, replace as needed.
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HVLS-1000 Series Fluid Section Manual
Assembly of Fluid Section:
Note: some of the part numbers below will be different depending on which fluid
section you are working on – refer to a current parts drawing for the assembly
you are working on.
1. Use MVP Red Grease (6706-2-1) to fill in the female side of each of the four
Packing in the Packing Set Assembly (02158-4) and the Female Packing Ring
(67110-1). Wipe a light coat of Red Grease on the 1-5/8” Chrome Ball (03604).
Smear Red Grease on the inner radius on both Piston Cups (02181-4). Coat the
threads on the Packing Nut (HVLS-1003) with the Red Grease.
2. Insert the Spring Support Ring (HVLS-1005) into the Outlet Body (HVLS-1001),
followed by the ten Wave Springs (HVLS-1009). Place the Packing set Assembly
(02158-4) on top of the Male Packing Ring (87090-1). Set the Female Packing Ring
(67110-1) on top of the Packing Set Assembly (02158-4).
3. Place the entire assembly into the Outlet Body (HVLS-1001) with the female side of
the Packing Set facing down. Set the Guide Bearing (HVLS-1006) into the Outlet
Body (HVLS-1001). Screw the Packing Nut (HVLS-1003) into the Outlet Body
(HVLS-1001) only two to three threads.
NOTE: Do not tighten the Packing Nut at this time.
4. Place the new O-Ring (O-V-030) onto the Piston Adapter (86510-1) and thread into
the Piston Rod.
Packing Nut
Guide Bearing
Female Compression Ring
Packing Set
Male Compression Ring
Wave Spring Set - 10
Spring Support Ring
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HVLS-1000 Series Fluid Section Manual
5. Slide one (1) Piston Cup (02181-1) onto the Piston Body (86390-1) with the open
side of the Piston Cup facing up. Slide the Piston Cup Back-Up Ring (68310-3)
groove side up against the Piston Cup. Install the second Piston Cup (02181-1)
open side down against the Piston Cup Back-up Ring (68310-3). Slide the Spacer
Ring (86520-3) against the second Piston Cup (02181-1). Coat the threads of the
Piston Nut (86530-1), and screw it onto the Piston Body (86390-1).
6. Place 1-5/8” Chrome Ball (03604) into the Piston Body (86390-1). Set the Piston Ball
Spring (04072-1) into the Piston Body with the small end of the spring against the 15/8” Chrome Ball (03604).
NOTE: Do not drop, dent, or scratch the 1-5/8” Chrome Ball (03604).
7. Coat the threads of the Piston Body (86390-1), and screw it onto the Adapter
(86510-1). Tighten the Piston Nut (86530-1) and the Piston Body (86390-1) wrench
tight.
8. Slide the Piston Rod (HVLS-1004) up through the Outlet Body (HVLS-1001) and
tighten the Packing Nut (HVLS-1003) enough to hold the Piston Rod in place.
9. Install 1-5/8” Chrome Ball (03604), then the Foot Valve Guide (HVLS-1007) into the
Foot Valve (86370-1). Compress the Ball Stop (04309-1) and insert it into the Foot
Valve (86370-1) groove.
10. Slide O-Ring (O-V-234) onto the cylinder ends and lubricate with Red Grease.
Position one end of the Cylinder (86400-1) into the Foot Valve (86370-1).
11. Use lithium grease on the Pump Cylinder Tie Rod (86540-1) threads and screw into
Outlet Body (HVLS-1001) if they were removed.
12. Slide the Cylinder (86400-1) with Foot Valve (86370-1) over the Piston Rod
Assembly and start the Hex Nuts (F-HN-08C) onto the Pump Cylinder Tie Rods
(86540-1). Tighten uniformly until wrench tight.
13. Use a 1/4” metal rod, or Phillips screwdriver to tighten the Packing Nut (HVLS-1003).
Note: the Packing Nut only needs to be tightened snug enough to put pressure on
the Packing Set Assembly. The Packing Nut should only be adjusted when there
is NO fluid pressure load in the fluid section.
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HVLS-1000 Series Fluid Section Manual
Optional Packing & Packing Sets:
02158-4 Packing Set - Standard
HVLS-1040 CUP SEAL – MAGNAPAK – use with special packing nut & bushing
HVLS-1010-U PACKING, PER EACH - UHMW
Optional Piston Cups / Cup Seals:
HVLS-1022-U Piston Cup Seal – UHMW
Magnapak Fluid Sections: (see HVLS-1040-CK)
The Magnapak fluid sections replace the packing set and piston cups with a different setup.
Most of the procedures will be the same as above procedure except as shown below.
1. Lightly grease the Cup Seals (HVLS-1040) with Red Grease (6706-2-1).
2. Install the two Cup Seals (HVLS-1040) into the top of the Outlet Body.
3. Pack the Bushing (HVLS-1032) with Red Grease (6706-2-1) and install into the Outlet Body
on top of the Cup Seals.
4. Lightly grease the threads of the Retaining Nut (HVLS-1031) and thread into the top of the
Outlet Body snug.
Note: Only use PAT-LS-OIL or Gun Oil (6706-3-XX) to lubricate the Magnapak Seal
set in the Retaining Nut.
o PAT-LS-OIL 8 Ounces
o PAT-LS-OIL-1GL 1 Gallon
o PAT-LS-OIL-5GL 5 Gallons
o 6706-3-1 1 Ounce Bottle – Pro Gun Oil
o 6706-3-8 8 Ounce Bottle – Pro Gun Oil
o 6706-3-16 16 Ounce Bottle – Pro Gun Oil
o 6706-3-32 32 Ounce Bottle – Pro Gun Oil
Retaining Nut
Bushing
Cup Seal
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HVLS-1000 Series Fluid Section Manual
To Reinstall onto Unit:
Note: the following instruction will vary depending on the Fluid Section you are working
on.
1. Position the Sleeve over the Power Cylinder Piston Shaft. Bring the Power Cylinder Piston
Shaft down onto the top of the Piston Rod Adapter. Insert the two Connectors and lower the
Sleeve. Install the Ring in machined groove.
2. Slide the Rail Assembly around the Piston Rod Adapter and insert the Quick Pin.
3. Fill the packing nut cavity 1/2 to 2/3 full with TSL (Throat Seal Oil).
o TSL-800 1/2 PINT
o TSL-3200 1 QUART
o TSL-1280 1 GALLON
or
o PAT-LS-OIL 8 ounces
o PAT-LS-OIL-1GL 1 Gallon
o PAT-LS-OIL-5GL 5 Gallons
Set The Packing Set:
1. Prime the Fluid Section with fluid.
2. Close the gun-head.
3. SLOWLY increase the pump pressure to 60 - 80 psi. It will be necessary to push and
hold the priming button if one is installed on this unit.
4. Keep the pump stalled for 5 to 15 minutes to allow the packing set to set.
5. Perform the above procedures for both the up and down strokes.
Note: If the pump is slowly moving while it should be stalled it indicates that the there is
a leak past the ball or seals (up stroke)
6. Decrease the pump pressure to the desired operating pressure. Now you are ready to
connect, prime and pressurize the catalyst pump for operation.
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HVLS-1000 Series Fluid Section Manual
Accumulator & Filter:
Maintenance:
The accumulator & filter should be disassembled and cleaned approximately once per week
(more often if the weather is hot).
Troubleshooting:
If you must keep increasing pressure to maintain an adequate spray fan, the filter may be
clogged with debris. If the spray is pulsing, the accumulator is probably blocked. When dealing
with system blockages, follow the safety instructions below.
DANGER: Before disassembling accumulator, relieve fluid pressure and air pressure. If
material is plugging the system, some parts of the system may still contain fluids under
high pressure, even after you have followed normal procedures to relieve the pressure.
WARNING: To prevent injury, hold a large rag or shop towel around the wrench and
fitting as you remove the fitting. Remove the fitting slowly to allow fluid pressure to
escape into the rag or towel.
WARNING: Always wear appropriate eye protection and other protective clothing when
performing service and repair on the accumulator & filter.
Parts Drawings:
To service the accumulator, please follow the procedures below, using drawing FF-5000-XX
Accumulator & Filter Assembly.
Relieve Air and Pump Pressure:
1. Turn pump pressure off.
2. Hold the gun over an appropriate empty container and lock the gun in an open position.
3. Disconnect air from the system.
4. Place an empty container under the filter/accumulator; slowly open the ball valve at the
bottom of the filter cap.
DANGER: Never attempt to remove, repair or clean an accumulator until you have
relieved pressure.
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HVLS-1000 Series Fluid Section Manual
Remove and Disassemble Filter:
1. Unscrew the filter cap (FF-5002) from the filter body (FF-5001).
NOTE: The components of the resin accumulator and filter should not be over tightened.
NOTE: Typically the High Volume units do not have screens in the filter body.
2. Inspect the interior of the filter body and clean with solvent.
3. Check the O-Ring (O-V-022) on the filter cap for wear or damage. Replace if necessary.
NOTE: If resin is leaking down the side of the filter cap, the O-Ring (O-V-022) is worn and
should be replaced.
Assemble and Install Filter Body:
1. Lubricate the threads of the filter cap (FF-5002) and o-ring (O-V-022) with red grease
(6706-2-1).
2. Screw the filter cap into the filter body (FF-5001).
Remove Accumulator Bottle:
DANGER: Before disassembling accumulator, relieve fluid pressure and air pressure. If
material is plugging the system, some parts of the system may still contain fluids under
high pressure, even after you have followed normal procedures to relieve the pressure.
1. Unscrew the surge chamber from the nipple
2. Inspect the interior of the accumulator bottle. Clean with solvent and blow dry with air if
needed.
Install Accumulator Bottle:
1. Screw the nipple and surge chamber into the top of the filter body (FF-5001).
2. Check for leaks
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HVLS-1000 Series Fluid Section Manual
Slow cure during upstroke
Slow cure during down stroke
No cure or slow over
-
all cure
Troubleshooting Chart:
DIAGNOSING PROBLEMS:
The most common problems with the equipment are diagnosed by analyzing the cured part.
NOTE: Many problems are the direct result of a failure to maintain the equipment according
to the maintenance schedules given. Please follow your maintenance chart.
PROBLEM CAUSE SOLUTION
S.S. Ball in catalyst pump piston
body not seating
Clean ball and inspect seat.
Replace ball, piston seal or piston
body if questionable.
S.S. Ball in catalyst pump inlet
body not seating.
Catalyst Check Valve (CV-2000)
not working correctly.
Catalyst pump set at too low or
too high of a percentage.
Catalyst supply below outlet
fitting on jug.
Catalyst drive not engaged or
connected
Catalyst leak. Check all fittings. The catalyst
Catalyst relief valve on catalyst
pump is leaking.
Catalyst suction screen in
catalyst jug clogged.
Air lock in catalyst pump.
Catalyst pump piston seal worn
or damaged
Clean ball and inspect seat.
Replace ball or have seat
repaired if questionable.
Check and Repair the Catalyst
Check Valve (CV-2000).
Move catalyst pump to a higher
setting (closer to the gel coat
pump). Be sure to attach the
catalyst pump in a vertical
position.
Fill catalyst jug 1/3 full.
Install quick pin. Be sure to
attach the catalyst pump
vertically.
system must be fluid tight.
Relieve pressure from pump.
Clean and repair the Relief Valve
Clean catalyst suction screen and
ensure that catalyst supply is not
contaminated.
Remove air lock. See Appendix:
Air Lock in the Catalyst Pump.
Replace piston seal. During
reassembly, be sure spring in
seal faces top of pump
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HVLS-1000 Series Fluid Section Manual
PROBLEM
CAUSE
SOLUTION
Low output on upstroke of
No fan, constant low output, or
pump
fast cure
Catalyst pump outlet body
damaged.
Replace catalyst pump outlet
body and piston seal. During
reassembly, be sure spring in seal
faces top of pump. Prevent by
connecting catalyst pump
vertically.
Catalyst pump check valve
blocked or stuck.
Catalyst hose plugged.
Danger: In the next steps you
will be dealing with fluids under
high pressure. Follow safety
instructions read the Safety &
Warning section in the beginning
of this manual.
Disassemble check valve and
remove blockage.
Relieve pressure from the system.
Replace the catalyst hose with
new one.
Resin or gel coat too cold. Consult your materials supplier for
proper temperature. Maintain a
draft-free environment of about 70
degrees F. An auxiliary heat
source may be required to reduce
gel time.
Piston cups, piston ball, or pump
cylinder worn.
Inspect the piston cups, piston
ball, and pump cylinder. Clean
and replace any damaged
components.
Screen of pump pick-up wand
blocked.
Gun Block plugged or seal
rotated
Resin hose plugged.
Danger: To prevent injury, always
relieve fluid pressure before
attempting to remove
components.
Unscrew screen from hose and
clean.
Repair or replace the gun block –
remove blockage.
Flush hose with solvent. If
material is hard, replace hose.
Pick-up wand assembly leaking. Tighten assembly fittings.
Resin filter clogged. Disassemble and clean the resin
filter. See Chapter 6: Accumulator
& Filter.
Material too cold or air pressure
low.
Heat material or increase pump
pressure
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PROBLEM
CAUSE
SOLUTION
Narrow Fan
Round fan
Excessive Misting
Pump jumps on upstroke
Pump dives on down stroke
Low output on upstroke
Wide Fan
Heavy pulsation
Material too cold, nozzle too large
or air pressure low.
Resin filter clogged. Disassemble and clean the resin
Air pressure too high. Lower pressure then increase
Nozzle too small or too wide. Change nozzle.
Orifice in nozzle worn, clogged,
or damaged.
Air-assist pressure too high. Decrease air-assist pressure.
Air pressure too high. Reduce air pressure to gel coat
Resin accumulator plugged.
Danger: To prevent injury,
always relieve fluid pressure
before attempting to remove
components.
Piston ball worn or not seating
properly.
Foot valve, spring retainer, or foot
valve ball damaged or dirty.
Pick-up wand assembly not tight. Tighten or seal joints of pick-up
Air in material. Agitate material to remove air.
Piston cups, piston ball, or pump
cylinder worn.
Heat Material, use smaller
nozzle, or as a last resort
increase pump pressure.
filter.
pressure to the desired fan.
Push fine wire through orifice
from back side. Use fingernail to
clean material form “V” shaped
notch in front. Soak hardened
material in solvent. If notch is
rough or worn, replace nozzle.
pump.
Disassemble accumulator and
clean.
Replace piston ball and piston
cups. Be sure to lubricate ball
and cups thoroughly with Red
Grease.
Clean or replace foot valve,
spring retainer and foot valve
ball. Be sure to lubricate ball
thoroughly with Red Grease.
wand.
Inspect the piston cups, piston
ball, and pump cylinder. Clean
and replace any damaged
components.
Rev. 05/2012 Page | 34
PROBLEM
CAUSE
SOLUTION
Pump does not run
Material in oil reservoir
N
o Gel coat
or Resin
delivery on down stroke
Hose leaks at fittings
HVLS-1000 Series Fluid Section Manual
Packing nut too tight Loosen the packing nut and tighten
just a little more then hand tight.
Air Motor is stuck Push the Reset button the bottom of
the air motor valve.
Fluid section or hose plugged.
Danger: To prevent injury,
always relieve fluid pressure
before attempting to remove
components.
Air not connected. Check that air hose is connected at
Air restricted. Straighten any kinks in air hoses.
Gun blocked or Seal rotated Repair gun block or replace
Gun is not opening Check and repair gun triggering
Packing worn. Replace packing set in lower part of
Piston rod worn or scored. Replace piston rod.
Packing Nut too loose Tighten the Packing Nut a little more
Foot valve, spring retainer, or
foot valve ball damaged or
dirty.
Fitting loose Tighten fitting. Check all fittings for
Fitting or nipple damaged. Replace damaged parts.
Crimped hose If the hose has been sharply bent, the
Disassemble and clean Fluid section.
Replace any worn parts. Replace hose
as required.
manifold, and regulator is at 20 psi or
more.
the pump.
then hand tight.
Clean or replace foot valve, spring
retainer, and foot valve ball. Be sure to
lubricate ball thoroughly with Red
Grease.
leaks before operating.
plastic liner may be ruptured. Remove
and replace hose.
Rev. 05/2012 Page | 35
HVLS-1000 Series Fluid Section Manual
Air Lock in the Catalyst pump:
DANGER: Fluids Under High Pressure. Before performing any service and repair on this
equipment, be sure to relieve air and fluid pressure.
DANGER: Always wear appropriate eye protection when working with this equipment.
WARNING: When removing hoses, place a rag over the hose before loosening it.
What is an Air Lock?
An air lock is an air bubble in the catalyst pump that blocks catalyst. The piston body moves
inside the bubble of air instead of pumping catalyst.
If you have determined that there is an air lock in your catalyst pump, follow the procedures in
this section.
1. Relieve line pressure from the catalyst pump by locking the gun open over an empty
bucket. Leave the gun in this position.
WARNING: Relieve pressure from the catalyst pump before continuing.
2. Remove the catalyst hose from the nipple on the catalyst accumulator.
WARNING: When removing hose, place a rag over the hose and fitting before loosening
it.
3. Remove the quick pin from the catalyst bearing block and upper slave arm.
4. Tilt the pump back toward the resin pump to release the bubble.
NOTE: If the bubble does not appear in the inlet tube, remove the lower quick pin and
turn the pump upside-down.
5. Slowly hand-pump the catalyst into a suitable container until catalyst spurts from the
nipple an equal amount on both the upstroke and down stroke.
6. Reconnect the catalyst hose to the nipple.
7. Hand-pump the catalyst pump until catalyst comes out through the gun.
8. Install the pump and quick pin into the slave arm.
9. Close the gun
Rev. 05/2012 Page | 36
HVLS-1000 Series Fluid Section Manual
Fluid Section
Pump Area (Sq. in)
Stroke Length
Displacement (in
3
) / Stroke
Air
Filler loading:
UPS
-
3117
UPS
-
3118
UPS
-
3119
UPS
-3120
Fluid Section Information:
HVLS-1000 Fluid Section is a part of a modular system that can fit a multiple of applications and a
multiple of configurations by changing a minimum of components. The HVLS-1000 is designed to
deliver power, versatility and rugged construction for long lasting use. This fluid section features
Rapid Access Design (RAD) for easy access and maintenance.
Output Capabilities: Up to 8 – 50 lbs / min. (3.6 – 22.7 kg / min.), using GP resin of average
viscosity. As a general rule in the standard 12:1 configuration it will pump a GP resin of 2200cps to
2500cps maximum.
HVLS-1000-HD 2.83 (18.26 sq. cm) 4” (101.6 mm) 11.3 (185.17 cc) (.185 liter)
Air Consumption: 14cfm (.4 m3 / min)
configuration you can fill up to 35% - 40%, in a 25:1 pump configuration up to 50% - 55%. Higher
percentages can be achieved by using low viscosity resins specially designed for fillers. It is always a
good idea to use resins that are designed for fillers as they will help keep the fillers in suspension.
Using fillers will increase pump wear and maintenance.
Catalyst Pump Percentage Chart Power Head to Fluid Pump Ratio
As a general rule using a GP resin and ATH or Calcium Carbonate in a 12:1 pump
Catalyst pump
VHPC-1000
VHPC-4200
VHPC-3200
VHPC-2200
VHPC-1200
VHPC-4200 Catalyst Pump &
HVLS-1000 Fluid Section
2.3
2
1.5
1
.75
.5
HVLS-1000(HD)
.25% - 1.3%
.5% - 2.3%
1% - 5%
2 - 8
2 - 10
1.3
1.2
1
.75
.5
.25
VHPC-1000 Catalyst Pump &
HVLS-1000 Fluid Section
Power Head
Diameter (in.)
VPH-4250 4 to 1
VPH-5000 6 to 1
VPH-7000-HD 12 to 1 14cfm (.4 m3/ min.)
VPH-10000 25 to 1
VHPC-3200 Catalyst Pump &
HVLS-1000 Fluid Section
HVLS-1000(HD)
High Volume
5
4.5
4
3.5
3
2.5
2
1.5
1
Consumption
2.5
2.2 5
2
1.7 5
1.5
1.2 5
1
.75
.5
VHPC-3200 Catalyst Pump &
2 - HVLS-1000 Fluid Section
Rev. 05/2012 Page | 37
HVLS-1000 Series Fluid Section Manual
Parts Drawings:
HVLS-1000 HIGH VOLUME FLUID SECTION ASSEMBLY
HVLS-1000-DHV HV FLUID SECTION ASSEMBLY – DUO UNITS
HVLS-1000-HD FLUID SECTION ASSEMBLY – HEAVY DUTY
MCPA-HVLS HV FLUID SECTION ASSEMBLY – MULTI COLOR
HVLS-1040-CK HV FLUID SECTION ASSEMBLY – MAGNAPAK
HVLS-1000-1 HV FLUID SECTION & FILTER ASSEMBLY
HVLS-1000-1-HD HV FLUID SECTION & FILTER ASSEMBLY
HVLS-2000-1-DHV COMPLETE HV LOWER SECTION – DUO
VPHV-0600 HV 6:1 PUMP ASSEMBLY
VPHV-1200 HV 12:1 PUMP ASSEMBLY
VPHV-1200-HD HV 12:1 PUMP ASSEMBLY – HEAVY DUTY
HVLS-1000-SK REPAIR KIT – HIGH VOLUME FLUID SECTION
Rev. 05/2012 Page | 38
HVLS-1000 Series Fluid Section Manual
Revision Information:
Rev: 04/2011 Updated manual format, added revision information
chapter, added Accumulator chapter, added Air Lock
chapter, added Trouble shooting chapter, updated
drawings, updated back cover with MVP information,
numbered pages and added footer.
Rev: 05/2012 Updated the manual format, Address, Logo. Added an
optional Piston Cup / Piston Cup Seal section. Included
optional metering pump ratios and references. Added the
Terms & Conditions of Sale section to the manual.
Included the VPHV pump assembly drawings.
Rev. 05/2012 Page | 39
HVLS-1000 Series Fluid Section Manual
Assemblies Covered in this Manual:
MAGNUM VENUS PLASTECH
CORPORATE HEADQUARTERS and MANUFACTURING
11692 56th Court * Clearwater, FL 33760 * Tel 727-573-2955 * Fax 727-571-3636
TECHNOLOGY CENTER and MANUFACTURING
1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666
MVP Plastech UK
Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: +44 (0) 1822 832621
Fax: +44 (0) 1822 833999
www.mvpind.com
HVLS-1000 High Volume Fluid Section Assembly
HVLS-1000-DHV High Volume Fluid Section Assembly – Duo Units
HVLS-1000-HD High Volume Fluid Section Assembly – Heavy Duty
MCPA-HVLS High Volume Fluid Section Assembly – Multi Color units
HVLS-1040-CK High Volume Fluid Section Conversion Kit – Magnapak
VPHV-0600 High Volume 6:1 Pump Assembly
VPHV-1200 High Volume 12:1 Pump Assembly
VPHV-1200-HD High Volume 12:1 Pump Assembly – Heavy Duty
Rev. 05/2012
Rev. 05/2012 Page | 40
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