Hypaject MK III
Operating Instruction Manual
Plastech Thermoset Tectonics Serial Number: KO24063
Unit 1, Delaware Industrial Estate Date: 19th November 2002
Gunnislake
Cornwall
PL18 9AR
Tel: +44 (0) 1822 832621
Fax: +44 (0) 1822 833999
E-mail: rtm@plastech.co.uk
Contents:-
1.0 Introduction.
2.0 Hypaject familiarisation and control functions
2.1 Basic operating concept.
2.2 Main Unit overview
2.3 Control Panel
2.4 General Notes
3.0 Commissioning Notes.
4.0 Hypaject Operation
4.1 Resin Loading Procedure
4.2 Procedure for set-up and use of High Temp Glass Faced Tool
4.3 Injection Procedure
4.4 Hypaject cleaning and shut down.
5.0 Maintenance
5.1 Resin Homogeniser
5.2 Resin load and resin injection valves
6.0 APPENDIX A - Additional instructions
6.1 OMRON E5CK Temperature controllers
Hypaject MK III Instructions Issue 07: April 2001-04-23 2
1.0 Introduction.
This manual covers the operation and maintenance of the Hypaject MK III resin injection
machine. Some options may not be present on your individual machine. The machine is
primarily designed for the injection of pre-mixed and single component resin systems. It may
be used to inject a wide variety of thermoset resin systems including polyesters, vinyl esters,
phenolics, multi component epoxies and single component epoxies such as Hexcel’s RTM6
and 3M’s PR500. If you require further information on the adaptability of the Hypaject MK III,
please contact Plastech TT
2.0 Hypaject familiarisation and control functions
This chapter introduces the user to the controls and components required for use of the
Hypaject MKIII.
2.1 Basic operating concept.
The Hypaject is a non-mixing pressure dispensing RTM unit offering universal application
for injecting mixtures of any liquid resin/catalysts into an RTM mould. The maximum volume,
which can be injected without interruption, is 6 litres.
In operation the units main holding tank (Homogeniser) is filled with the desired amount of
resin matrix utilising an internally generated vacuum source. The resin is then actively
degassed using the homogeniser vacuum. Once the resin has degassed, the homogeniser
is pressurised and the resin injected into the RTM mould using a diaphragm valve for
control. The Hypaject MKIII includes the additional options of up to five separate resin
heating zones with digital display for both the weight and pressure of resin during use.
Hypaject MK III Instructions Issue 07: April 2001-04-23 3
2.2 Main Unit overview (example)
4 3 5 2 6
1
The machine consists of the following components
1. Instrumentation and control panel
2. Heated Homogensier
3. Hand operated load valve
4. Resin heated outlet pipe work.
5. Resin Load Plate.
6. Inlet load pipe
Hypaject MK III Instructions Issue 07: April 2001-04-23 4
2.3 Control panel
2.3.2 Desktop Mounted Control Cabinet
1. Homogeniser Vacuum Gauge
Measures the vacuum level in the homogeniser when under vacuum
2. Homogeniser Pressure Gauge
Measures the pressure in the homogeniser when pressurised
3. Homogeniser Vacuum/Off /Pressure switch
Switches the homogeniser between operating under vacuum and operating under pressure.
Releases vacuum or pressure in Off position
4. Homogeniser Pressure Regulator
Adjusts homogeniser pressure. Push in to lock regulator
5. Autosprue Open/Close
Sends the open/close signal to the Autosprue control valve.
6. Injection & Load Valves Open/Close
Opens the diaphragm valves between the homogeniser and the mould injection hose and
the homogeniser and the resin load pipe.
7. Mould vacuum level indicator (option)
Indicates mould vacuum output level
Hypaject MK III Instructions Issue 07: April 2001-04-23 5
8. Mould Vacuum On/Off Switch (option)
Switch down for ON, up for OFF
9. Mould Vacuum Isolator (option)
The mould vacuum isolation valve is placed horizontal to close and vertically to open.
Vacuum may be drawn via the self-swaging 6mm connector located on the rear of the
control cabinet.
10. Resin container Up/Down (Option)
Raises, lowers or holds the resin container
Homogeniser Top Band Heater – Zone 2 (option)
11. Temperature controller. (See attached OMRON E5CK instruction sheets). Use Up/Down
keys to adjust heater temperature.
12. Heater ON/OFF switch
13. Circuit test button. Press to test fault circuit. Fault light will illuminate
14. Fault/Reset button. Indicates if fault present or heater over temperature. Press to re-set.
Homogeniser Bottom Band Heater – Zone 3 (option)
Controls as above
Heated Outlet Hose – Zone 1 (option)
Controls as above
Heated Melt Plate – Zone 4 (option)
Controls as above
Heated Load Hose – Zone 5 (option)
Controls as above
15. Internal Thermocouple readout. (option)
Indicates temperature sensed by thermocouple probe inside homogeniser
16. Homogeniser Pressure Readout (option)
ADW 15 unit indicating homogeniser pressure/vacuum (psi). 0-10v analogue output module
is incorporated as standard.
17. Homogeniser Weight Readout
ADW 15 unit indicating homogeniser weight (kg). 0-10v analogue output module is
incorporated as standard
18. Tare Button
Tares homogeniser weight.
19. Emergency Stop.
Cuts all electrical and pneumatic supplies. Pull up to restart.
Hypaject MK III Instructions Issue 07: April 2001-04-23 6
20 Load Platform Up/Down
Turn left to lower resin platform, right to raise resin platform and centre to hold resin
platform in position.
Desktop Cabinet Rear
1. Homogeniser thermocouple connector. (option)
Provides input from homogeniser thermocouple to homogeniser temperature readout unit.
2. Mould Vacuum Connection
6mm quick fit connector for mould vacuum output. (option)
3. External Pressure Source. (option)
6mm connection port for external machine pressure source (max 10 bar). Allows alternative
gasses to be used. e.g. Argon
4. External Vacuum Source. (option)
6mm quick fit connector enables external vacuum sources to be connected. Allows greater
homogeniser vacuum levels to be achieved.
5. External/internal Pressure Source Selector (option)
180 degree operation. Enables selection of internal or external pressure source. Turn
towards external connection port to enable external source.
6. External/Internal Vacuum Source Selector (option)
Hypaject MK III Instructions Issue 07: April 2001-04-23 7
180 degree operation. Enables selection of internal or external vacuum source. Turn
towards external vacuum source connection port to enable external source.
7. Incoming Air
Connection for main air supply. Max 10 bar clean dry non lubricated.
8. Mains Isolator
Isolates all incoming electrical supply.
Zones 1-5 contain electrical supply connector with thermocouple input connector. Additional
thermocouple and panel connector are provided for data acquisition purposes.
2.4 General Notes
Machines with heating options.
The control cabinet is cooled by a fan which runs whenever the main isolator is on. The
Mains isolator should be locked off and the supply to the panel disconnected if any work is
carried out within the panel or on the Hypaject heater zones.
The control panel should always be kept locked. The overall condition of the panel, heaters
and heater cables should be checked periodically for damage. Any damage should be
rectified immediately.
Temperature Controllers
The temperature controllers are pre-set before shipment. To adjust settings, please follow
the enclosed temperature controller manual. (See appendix A)
Over-temperature cut-out
If the temperature of any heating zone reaches the over-temperature level the overtemperature cut-out will operate for that zone which illuminates the relevant red indicator on
the panel disabling output to the heater. The alarm state will indicate until the temperature
has fallen below the over-temperature level. The alarm must be reset by pressing the
appropriate reset button.
Thermocouple break
If a control thermocouple breaks or is disconnected for any zone the temperature controllers
will display ' - - -' and the relevant red fault indicator and cut-out circuit is activated as
indicated above.
Control fuse failure
Each Zone contains a separate control fuse. If any individual temperature controller fails to
operate, then the control fuse must be checked.
Lamp/cut out test
The circuits should be regularly tested. Operate each test button in turn. These test the
fuse failure and over-temperature lamps. With the panel isolator on, press each test button
in turn. The red over-temperature lamps will illuminate. Press the appropriate reset button
to reset
Earth connections
For safety reasons this machine must be earthed to a suitable earthing point.
Hypaject MK III Instructions Issue 07: April 2001-04-23 8
CAUTION: -
Do Not allow air supply to be switched off whilst Homogeniser remains pressurised. The
loading and injection valves may open and allow resin discharge from both inlet and outlet
points when homogeniser is under high pressure.
Hypaject MK III Instructions Issue 07: April 2001-04-23 9
3.0 Commissioning Notes.
CAUTION
Wear suitable protective clothing , approved eye protection goggles and
chemically resistant gloves at all times when operating the Hypaject with solvents
and resin systems.
Before connecting air and electrical power to Hypaject place unit in the desired working
location, lock wheels and connect resin output pipe to mould.
1. Check the homogeniser vacuum/pressure switch is switched to pressure
2. Check the load valve and injection valve are closed.
3. Check homogeniser pressure regulator (4) is turned down to zero fully anticlockwise
4. Connect air supply to Hypaject.
Electrical (heated machines only)
1. Check heater output switches are “Off”. Plug electrical supply into 240v mains and
switch mains isolator to 'on'
2. Set desired temperatures on all temperature controllers.
3. Place desired resin container on platform under loading pipe.
4. Turn on heater output switches and allow temperatures to rise to those set.
Hypaject MK III Instructions Issue 07: April 2001-04-23 10
4.0 Hypaject Operation
4.1 Resin Loading Procedure
1. Turn homogeniser pressure regulator fully anticlockwise to zero.
2. Ensure inject valve is closed.
3. Switch homogeniser vacuum/pressure switch to ‘vacuum’ . Allow vacuum to rise to
maximum (Approximately 0.8/0.9 bar negative) as indicated on vacuum gauge.
4. Open hand operated diaphragm valve (turn anticlockwise) and load required quantity of
resin into Homogeniser. Close hand operated diaphragm valve when complete
(clockwise)
Caution
Do not load more than Homogeniser capacity will allow. (6000cc’s)
Note
It is suggested that a period of up to 5 minutes is allowed to elapse whilst the loaded
volume of resin is given further time to degas and to reach the pre set Homogeniser
zone temperature.
5. Turn vacuum/pressure switch to pressure
Hypaject MK III Instructions Issue 07: April 2001-04-23 11
4.2 Procedure for set-up and use of High Temp Glass Faced Tool
1. Select the mould cavity thickness required and place the correct shims on the mould
clamps. With no shims in place the mould has a cavity of 1mm.
2. Seals.The mould is fitted with a double ‘Dynamic Seal’. This seal is inflated with
compressed air and will allow sealing at the varying cavity thicknesses. The seal is
controlled via the control box mounted onto the back of the mould. The control box
includes a pressure on/off switch and pressure gauge. Do not attempt to inflate the seal
above 4 Bar.
The Pressure switch must be turned to the off position before the M24 Mould
clamp bolts are loosened.
The seal must not be inflated with the mould open or unclamped.
Dynamic Seal Safety.
The air supply to the control box is routed through a roller switch mounted onto one of
the mould clamps. This switch is actuated by the M24 bolt when the mould is closed and
is a safety mechanism only.
It should not be used as the method of controlling/inflating the seal.
When changing the cavity thickness the spring loaded roller switch actuator should
checked to ensure that it strikes the roller at the correct point e.g. when the mould is in
the closed position.
Always check that the seals are inflated prior to injection.
3. Make sure the reinforcement being used can be compressed to the mould cavity
thickness selected.
4. Carefully load reinforcement material into cavity, ensuring the fibre does not pass over
the inner seal.
5. Close the mould and tighten the M24 clamps.
6. Switch both dynamic seals to pressure and inflate the inner and outer Dynamic seals.
7. If using vacuum to assist injection this can now be tested to ensure the cavity is vacuum
tight.
Two corner vent points are provided.
If operating the mould at temperatures above 60C, 6mm PTFE pipe must be used for
venting the mould cavity. 6mm nylon pipe can be used if working at lower temperatures.
The pipe is retained by the brass fitting and ‘olive’ situated at each vent point. The vent
pipes must be routed to the vacuum supply via a suitable vacuum ‘catch-pot’ to prevent
excess resin from entering the vacuum pump.
Small amounts of fibre (surface tissue) positioned across the first resin seal at the final
point of fill will also act as a vent and allow injection without the use of the disposable
vent pipes. If this technique is to be used, the operator must observe carefully and
ensure that the mould is not ‘over injected’. If using this technique vacuum can be
applied via the fitting situated between the two Dynamic seals, and the two cavity vents
can be blocked. This technique avoids the requirement for disposable vent pipes and a
resin ‘catch-pot’.
8. Before starting the injection, make sure the mould and machine are at the correct
temperature. Injecting before the correct temperature can cause the mould cavity to
expand and result in cavitation.
Hypaject MK III Instructions Issue 07: April 2001-04-23 12
9. Inject as per section 4.3
10. When the injection is complete, do not close the inject valve until the vacuum on the tool
has been switched off and allowed to decay. It is very important to finish the injection
with a slight positive pressure on the cavity.
11. Turn off pressure to the Dynamic Seal.
Note : When operating at temperatures above 100°C it may be necessary to remove the
pressure from the inner seal at the end of the injection. Tests have shown that at higher
temperatures, it is possible for small air bubbles to leak through the seal and create voids in
the laminate edge.
Never turn this seal off during the injection stage. When using standard
thermosetting resins at lower temperatures the inner seal should be left inflated
throughout the cycle.
12. Allow the part to cure according to the resin manufacturers recommendations.
13. It is very important that the mould temperature is constant and that it does not drop
throughout the injection and curing periods.
14. NOTE: Use of Pre-Heating Plate. When using injection resin that requires pre-heating
to a specific activation temperature (such as 3M- PR500) the back plate assembly can
be used. The back plate is located onto the back of the mould surface using the 6 X
M10 bolts provided with the Autosprue position at the opposite end to the injection point
into the mould. The Autosprue is clamped into position using the same clamping
mechanism. In this configuration the resin is forced through the pre-heat channel prior to
entry into the fibre pack, thus bringing it up to the same temperature as the mould
surface. The surfaces of the back plate and the back surface of the mould must be
maintained with the same release agent as the rest of the mould (see Mould Release
Agent Specification Sheet)
Hypaject MK III Instructions Issue 07: April 2001-04-23 13
4.3 Injection Procedure
CAUTION !
DO NOT OPEN THE LOAD VALVE WHEN THE HOMOGENISER IS
UNDER PRESSURE.
Procedure
1. Connect injection hose to mould or Autosprue. (see Autosprue connection drawing)
2. Using the homogeniser pressure regulator set the homogeniser pressure to the desired
value.
3. Open Autosprue (if fitted)
4. Open inject valve.
5. Observe the rate of injection. Adjust the injection pressure as required. Do Not close
Autosprue during injection without first closing the injection valve.
6. Once the mould is full turn injection valve switch “off” to stop flow of resin into the mould.
(if vacuum assisted injection is being used, slowly remove vacuum before closing
injection valve to ensure completion of injection at positive pressure).
7. Close Autosprue. (if fitted)
Hypaject MK III Instructions Issue 07: April 2001-04-23 14
4.4 Hypaject Cleaning and Shut Down.
Caution! Always ensure homogeniser pressure is zero before opening
load valve!
A) For Single Component Materials
Without Autosprue
1. Turn homogeniser pressure to zero and allow sufficient time for pressure to decay.
2. Remove injection hose from mould.
3. Switch homogeniser to vacuum.
4. Open inject valve and allow all resin in injection hose to be drawn into the homogeniser.
5. Place waste container under load pipe. Close inject valve. Switch homogeniser to
pressure. Ensure pressure is set to zero.
6. Open load valve and allow resin to flow into waste container.
7. Close load valve. Switch homogeniser to vacuum.
8. Place injection hose in container of flushing epoxy (i.e. epoxy which has not been
accelerated or catalysed and is liquid at room temperature).
9. Open inject valve and allow a sufficient quantity of flushing epoxy to be loaded through
the injection hose ensuring that the injection hose remains full at the end.
10. Close inject valve. Open load valve and allow a small amount of flushing epoxy to flow
through the load pipe to waste.
11. With the flushing epoxy inside the homogeniser, turn off all temperature outputs and
allow the whole machine to cool to ambient temperature.
12. Once at room temperature, open the load valve and allow all flushing epoxy to drain into
the waste container.
WARNING! BEFORE FLUSHING MACHINE WITH SOLVENT ENSURE THAT
ALL HEATED ZONES ARE AT AMBIENT TEMPERATURE!
13. Place injection hose into a container of solvent. Switch homogeniser to vacuum.
14. Open inject valve and allow a sufficient quantity of solvent to be loaded through the
injection hose.
15. Close inject valve. Allow solvent to circulate inside homogeniser under vacuum for 2-3
minutes.
16. Ensure homogeniser pressure is set to zero. Switch homogeniser to pressure. Open
load valve and allow solvent to drain from homogeniser into waste container.
17. Repeat steps 13-16 if necessary.
With Autosprue
1. Turn homogeniser pressure to zero and allow sufficient time for pressure to decay.
2. Ensure Autosprue is closed. Switch homogeniser to vacuum.
3. Open inject valve and allow all resin in injection hose and Autosprue to be drawn into the
homogeniser.
4. Place waste container under load pipe. Close inject valve. Switch homogeniser to
pressure.
5. Open load valve and allow resin to flow into waste container.
6. Close load valve. Switch homogeniser to vacuum.
7. Place Autosprue waste hose in container of flushing epoxy (i.e. epoxy which has not
been accelerated or catalysed and is liquid at room temperature).
8. Open inject valve and allow a sufficient quantity of flushing epoxy to be loaded through
the Autosprue and injection hose ensuring that the Autosprue and injection hose remain
full at the end. (Autosprue must remain closed throughout)
9. Close inject valve. Open load valve and allow a small amount of flushing epoxy to flow
through the load pipe to waste.
Hypaject MK III Instructions Issue 07: April 2001-04-23 15
10. With the flushing epoxy inside the homogeniser, turn off all temperature outputs and
allow the whole machine to cool to ambient temperature.
11. Once at room temperature, open the load valve and allow all flushing epoxy to drain into
the waste container.
WARNING! BEFORE FLUSHING MACHINE WITH SOLVENT ENSURE THAT
ALL HEATED ZONES (INCLUDING AUTOSPRUE) ARE AT AMBIENT
TEMPERATURE!
12. Place Autosprue waste hose into a container of solvent. Switch homogeniser to vacuum.
13. Open inject valve and allow a sufficient quantity of solvent to be loaded through the
Autosprue and injection hose.
14. Close inject valve. Allow solvent to circulate inside homogeniser under vacuum for 2-3
minutes.
15. Ensure homogeniser pressure is set to zero. Switch homogeniser to pressure. Open
load valve and allow solvent to drain from homogeniser into waste container.
16. Repeat steps 12-15 if necessary.
B) For two component resin systems. (liquid at room temperature)
Without Autosprue
WARNING! BEFORE FLUSHING MACHINE WITH SOLVENT ENSURE THAT
ALL HEATED ZONES ARE AT AMBIENT TEMPERATURE!
1. Turn homogeniser pressure to zero and allow sufficient time for pressure to decay.
2. Disconnect injection hose from mould.
3. Switch homogeniser to vacuum.
4. Open inject valve and allow all resin in injection hose to be drawn into the homogeniser.
5. Place waste container under load pipe. Close inject valve. Ensure homogeniser
pressure is set to zero. Switch homogeniser to pressure.
6. Open load valve and allow resin to flow into waste container.
7. Close load valve. Switch homogeniser to vacuum.
8. Place injection hose into a container of solvent. Switch homogeniser to vacuum.
9. Open inject valve and allow a sufficient quantity of solvent to be loaded through the
injection hose.
10. Close inject valve. Allow solvent to circulate inside homogeniser under vacuum for 2-3
minutes.
11. Ensure homogeniser pressure is set to zero. Switch homogeniser to pressure. Open
load valve and allow solvent to drain from homogeniser into waste container.
12. Repeat steps 8-11 if necessary.
With Autosprue
WARNING! BEFORE FLUSHING MACHINE WITH SOLVENT ENSURE THAT
ALL HEATED ZONES (INCLUDING AUTOSPRUE) ARE AT AMBIENT
TEMPERATURE!
1. Turn homogeniser pressure to zero and allow sufficient time for pressure to decay.
Ensure Autosprue is closed.
2. Switch homogeniser to vacuum.
3. Open inject valve and allow all resin in injection hose and Autosprue to be drawn into the
homogeniser.
Hypaject MK III Instructions Issue 07: April 2001-04-23 16
4. Place waste container under load pipe. Close inject valve. Ensure homogeniser
pressure is set to zero. Switch homogeniser to pressure.
5. Open load valve and allow resin to flow into waste container.
6. Close load valve. Switch homogeniser to vacuum.
7. Place Autosprue waste hose into a container of solvent. Switch homogeniser to vacuum.
8. Open inject valve and allow a sufficient quantity of solvent to be loaded through the
injection hose.
9. Close inject valve. Allow solvent to circulate inside homogeniser under vacuum for 2-3
minutes.
10. Ensure homogeniser pressure is set to zero. Switch homogeniser to pressure. Open
load valve and allow solvent to drain from homogeniser into waste container.
11. Repeat steps 7-10 if necessary.
Hypaject MK III Instructions Issue 07: April 2001-04-23 17
5.0 Maintenance
CAUTION :- Wear suitable protective clothing , approved eye protection
goggles and chemically resistant gloves at all times when carrying out any
maintenance on the Hypaject as solvents and resin systems may still be
present within the units internal parts
Disconnect electrical and pneumatic supplies before commencing any maintenance.
As the Hypaject has no basically no “moving” parts it requires very little maintenance.
The following should be checked at least every 12 weeks of constant use.
5.1 Resin Homogeniser
The Homogeniser internals can be accessed by removing the two Victaulic clamp ring bolts.
Carefully prise the clamp split ring clamp apart whilst ensuring lower Homogeniser body is
supported. The Victaulic seal will now be visible and can be removed as the lower body is
carefully lowered.
The Homogeniser internals can be inspected at this stage and cleaned as required.
Reassemble in reverse order.
1. Homogeniser main body(top) 5. Victaulic clamp bolt (x 2)
2. Homogeniser body (lower ) 6. Main body heater element (x 2)
3. Victaulic seal clamp (two part) 7. Lower body heater element
4. HT Victaulic seal 8. Resin Inlet /Outlet fittings (BSP)
Hypaject MK III Instructions Issue 07: April 2001-04-23 18
5.2 Resin load and resin injection valves
To access the valve main diaphragm seals simply remove the 4 seat fixing screws item 12.
Lift actuator body assembly off valve seat . Diaphragm seal (3) may be removed by
unscrewing from actuator shaft. When replacing new seal ensure items 5 and 6 are
correctly assembled onto seal prior to reinstallation. Reassemble in reverse order tightening
screws 12, evenly and firmly to squeeze seal between seat and spacer items 2 and 4.
1. Valve actuator body 5. Support washer 9. Adjuster locking cap
2. Valve seat 6. Diaphragm support 10.Actuator screws x4
3. Valve diaphragm 7. Actuator position indicator 11 6mm air fittings x2
4. Heat spacer 8. Actuator limit adjuster 12 Seat fixing screws x4
The Electrical cabinet has an electric cooling fan white filter located on the left hand lower
side which should be replaced when darkened with dust.
Hypaject MK III Instructions Issue 07: April 2001-04-23 19
Comment [ARH1]:
6.0 APPENDIX A - Instructions for non Plastech equipment
6.1 OMRON E5CK series temperature controllers
Hypaject MK III Instructions Issue 07: April 2001-04-23 20
Loading...