Magnum Venus Plastech Impregnator Roll User Manual

Impregnator Roll

Goods Wet Out Unit

MAGNUM VENUS PLASTECH Part No. 90037-1

Operations Manual

Table of Contents

Impregnator Roll Goods Wet Out Unit

Operations Manual

IMPREGNATOR CONCEPT

TYPES OF REINFORCEMENTS & SPECIALTY MATERIALS
CHAPTER 1 - START UP OPERATIONS

Solvent Material Supply
CHAPTER 2 - PUMP PRIMING

Priming the Resin and Catalyst Pumps
CHAPTER 3 - ACCUMULATOR CHARGING
CHAPTER 4 - BALANCING RESIN AND CATALYST

Resin Distribution System & Loading Reinforcement
CHAPTER 5 - RESIN/GLASS RATIO SETTINGS

CHAPTER 6 - CONTROL FUNCTIONS
Control Panel Functions for All Models

CHAPTER 7 - OPERATING TECHNIQUE
CHAPTER 8 - AIR INCLUSION IN LAMINATE
CHAPTER 9 - SHUT DOWN PROCEDURES

CHAPTER 10 – PARTS DRAWINGS

IMPREGNATOR CONCEPT

The Magnum Venus Roving Impregnator System was designed for rapid, economical wet-out of
reinforcement (fiberglass) with polyester resin. This is achieved in the following manner.

The reinforcement is mounted on mandrel shafts above Impregnator. Material is fed down through the
rubber feed rolls. These rolls are spring loaded and provide a means for spooling material off the
mandrels. Material then passes through a resin bath, which is formed by the end dam at either end of
resin rolls. Precatalyzed resin is supplied by a Magnum Venus H.I.S. dispensing system, through a
resin manifold and into spreader tubes. The spreader tubes deposit resin on both sides of the
reinforcement in amounts required for impregnation. The gap or nip of resin rolls is controlled by
micrometer adjustment, allowing only the proper ratio of resin to glass to pass through the rolls as
reinforcement exits the machine.

TYPES OF REINFORCEMENTS

Various types of reinforcement are being processed with the Magnum Venus Impregnator units. These
range from woven roving to chopped strand mat. There are, however, limitations to what kinds and at
what rates various materials can be impregnated.

Woven Products: As a general rule the more loosely a reinforcement is woven the better it lends itself
to impregnation. A tight weave material will act as a fluid barrier and will not let resin pass through the
glass strands as readily. As a result, it is very difficult to impregnate more than one layer of a tightly
woven material at a time, where as a loose woven reinforcement will allow resin to pass through, and
multiple layers can be impregnated. There is a point in multiplayer impregnating where it becomes
impractical to impregnate; again this depends on type of material and weave.

Chopped Strand Mat: Chopped strand mat materials are difficult to process through the Impregnator
without having some form of wet strength support. This support can be in the form of machine
stitching, additional binder, or by processing a woven product or unidirectional material with the mat.

It is possible to process chopped strand mat without a woven product as a carrier if the following steps
are taken into consideration.

1. A maximum drop distance from machine to mold surface of 7 feet (or less) is maintained.

2. A mat with maximum wet strength is employed.

3. The machine is kept running on a continuous basis.

4. If stops are required, the operator must advance mat through the wet-out bath every 15-30
seconds to keep the mat binder material from dissolving completely and mat from coming apart.

Most all manufacturers of glass reinforcements have chopped strand mat products that can be
processed in the Impregnator. It is a matter of individual preference as to which one is utilized.

SPECIALTY MATERIALS

There are several specialty reinforcing materials on the market that can be used with the Magnum
Venus Plastech Impregnator. Unidirectional is the most often utilized of these specialty reinforcements.

To be successful using unidirectional in the Impregnator, a material that has a cross stitch every few
inches should be used. This will insure good integrity of the material until it is placed in the mold.

You will find that unidirectional materials wet out much more readily than do woven or chopped mat
materials. This is due to the loose strands of glass as opposed to a tight weave or compacted mat

material. As a result you will find the setting on the nip rolls will be slightly less for a unidirectional
material than a woven material of the same thickness.

There are special woven materials available that vary the number of strands that are in the warp or the
weave of the fabric, the purpose being; to put the strength of the material in the direction that is more
beneficial. You will find by utilizing these various types of woven materials you will get much better wet
out, as well as better physical properties, and it will be much easier to place the material in the mold.
Keep in mind that one material is not the right choice for every job and much time and effort can be
saved if the materials are wisely chosen at the start.

CHAPTER 1

H.I.S. PUMPING SYSTEM-START UP AND OPERATION

Your Impregnator system is normally equipped with a Venus High Volume H.I.S. polyester dispensing
unit. This unit is capable of up to 40 lbs. Of resin per minute output; catalyzed from .25 to 1.25% by
volume. To put the dispensing system into operation, follow procedures outlined below.

NOTE: On models where pump is remote from unit, such as the bridge crane model, a second
person will be required to charge the system in an expedient manner.

CAUTION: When working around pressurized H.I.S. system, safety glasses should be worn at
all times.

SOLVENT MATERIAL SUPPLY

1. Check all hose connections. They must be pressure tight, no possible leaks.

2. Fill flush tank approximately ¾ full of the proper solvent. (Methylene chloride preferred).

3. Pressurize tank to 35 to 45 PSI.

4. Flush gun by pushing valve operator button on top of automatic gun block. Solvent flush should
flow freely from mix chamber of gun. If no solvent is forthcoming, check for proper air pressure,
obstructions in solvent line or gun head, or that the in and out hose connections have not been
reversed on pressure tank.

5. When solvent is available at gun head for flushing unit, then and only then, proceed to charge
system with resin.

CHAPTER 2

PRIMING RESIN PUMP

CAUTION: Before attempting to operate resin pump, check all hoses and fittings to insure
system will hold pressure.

1. Fill cup at base of pump shaft 2/3 full with lubricant. Refer to lubrication materials list for proper
lubricant.

2. Fill power head lubricator 2/3 full with lubricant. Refer to lubrication materials list for proper
lubricant.

NOTE: Pump must be assured of a sufficient resin supply at all times.

3. Back Air regulator to power head completely off. Rotate counter clockwise.

4. Open ball valve to power head.

5. Open gun head.

6. With an adequate supply of resin to foot valve of pump, (minimum 7-1/2 PSI) slowly open
regulator to power head of pump. Not more than 10 PSI.

NOTE: Because seals in a new pump may be dry and therefore will not make a good seal, it may
be necessary to wet the seals. This can be accomplished by removing the resin hose,
accumulator, and pipe nipple from pump outlet and pulling a small amount of resin into pump
through pump outlet port. Reassemble nipple, accumulator and resin hose and proceed with
priming operation.

7. As pump begins to move resin through the system, close the gun head. Allow the pump to
continue operating until it stalls out.

8. Close ball valve to power head of pump.

9. Open needles of gun head, allowing resin to drain from hose and accumulator.

NOTE: An appropriate container will be required under gun to contain resin flow.

PRIMING CATALYST PUMP

NOTE: Magnum Venus Plastech recommends the use of a manufacturer tinted catalyst if at all
possible. This will insure the operator a visual check for proper catalyzation.

CAUTION: Safety Cover must be on catalyst accumulator at all times when catalyst pump is
connected to slave arms of resin pump.

1. With catalyst pump positioned in slave arms and lower quick pin in place remove catalyst hose
from catalyst accumulator relief valve body.

2. Loosen packing nut located on top of catalyst pump where pump shaft enters pump. NOTE:
This step is not mandatory if packing nut is plastic.

CAUTION: If stainless steel packing nut is not loosened before hand operating pump, excessive
heat build-up can result in packing area.

3. Connect large suction hose to inlet tube fitting of pump. Secure with hose clamp on plastic
sleeve supplied.

4. Connect small return tube to relief valve tube fitting on bottom of catalyst accumulator.

5. Place MEKP Catalyst container on floor below catalyst pump. MEKP must be lower than pump.

6. With upper quick pin removed and packing nut loose, if applicable, operate catalyst pump by
hand using the priming knob only. Catalyst should start to move up suction tube to pump.

NOTE: It may be necessary to wet seal surfaces of the pump to start fluid moving. This can be
accomplished by elevating the catalyst jug above inlet body of the pump and letting a small
amount of catalyst run down the tube to the inlet of pump, then make one or two strokes with
the pump.

7. Return catalyst jug to the floor and continue pumping until catalyst has reached a point in the
suction tube 1 to 2 inches from the inlet of the pump. Stop pumping action and place MEKP
container in jug bracket at side of resin pump.

8. Position suction tubes so they form an arc between jug and pump. The crown of the arc should
be higher than the catalyst jug and inlet of pump.

CAUTION: The suction tubes must be held in this position at all times insuring that the air
bubble in suction tube does not get drawn into catalyst pump. Air in catalyst pump can cause
improper catalyzation.

NOTE: The bubble may be as long as 8 inches and still function properly. With time, bubble will
grow longer as catalyst gases off. The bubble gives a visual indication that catalyst pump is
taking in material. With each up stroke of pump, the bubble will move forward toward pump.
With each down stroke, bubble will return to its original position. Mark the position of the
bubble by placing the black rings at each end of the bubble.

9. With jug and suction tubes in position and catalyst to the inlet of the catalyst pump, tilt catalyst
pump toward resin pump so that the outlet of the pump becomes the highest point in the
system. Operate pump by hand until fluid is emitted from outlet on both strokes of the pump.

NOTE: Be certain that all air is removed from catalyst pump to prevent air lock of pump. Air
lock of pump will result in improper catalyzation.

10. When all air has been purged from pump, connect the catalyst hose to the accumulator.

CAUTION: check all hoses and connections to insure a pressure tight seal.

11. With hose connected to pump and gun, make sure ball valve to power head of resin pump is
closed. Open needles of gun head.

12. Operate catalyst pump by hand until an even, steady flow of material emerges from gun.

NOTE: A suitable container will be required under gun.

13. Close needles of gun and flush solvent through mix chamber to clean out resin and catalyst.

CHAPTER 3

CATALYST ACCUMULATOR CHARGING

NOTE: It is possible to damage the catalyst injector if resin side of system is pressurized first.
To insure against such damage the catalyst side of the system should always be pressurized
before the resin side.

1. With both the regulator and ball valve controlling air flow to resin pump power head in the off
position, open needles of the gun head.

2. Because of the pressure required to force catalyst out to the gun head the accumulator may be
full of catalyst. Allow this fluid to drain from accumulator through the open gun until the floating
ball in the catalyst accumulator is seated on bottom of the accumulator.

NOTE: To speed up this operation, it may be necessary to install charging pump on catalyst
accumulator and connect supply air (approximately 100 PSI) to the charging pump to assist in
purging accumulator.

CAUTION: charging pump “T” handle must be in full up position before connecting to air
supply. Failure to have handle up may result in damage to pump and/or injury to operator.

NOTE: Care must be taken not to move the catalyst accumulator valve body when installing or
removing charging pump. Catalyst accumulator parts are not much more than hand tight and
any movement could result in seal failure.

3. When poly ball is seated on bottom of accumulator and accumulator is completely empty of
fluid, charge the accumulator to 4 times the operating pressure of the resin pump power head.
(The resin accumulator is charged at the same PSI).

NOTE: A 50-60 PSI operating pressure to power head of resin pump will be enough to supply
resin to nip rolls for most applications.

4. The catalyst accumulator has a very small volume and only 2-4 strokes of charging pump will be
required to fully charge it. When accumulator is charged remove pump from accumulator.

NOTE: Charging Pump Gauge will read supply pressure with the “T” handle up and
accumulator pressure with “T” handle down.

5. After removing charging pump, check charging valve of accumulator for a pressure seal by
placing soapy water or other appropriate fluid over valve opening. If no air bubbles appear
install seal cap.

NOTE: If air leaks from charging valve, accumulator will not hold a charge and source of the
leak must be found and eliminated before proceeding.

6. Purge charging pump of catalyst fumes before attempting to charge resin accumulator. Stroke
the pump several times to purge interior of pump.

RESIN ACCUMULATOR CHARGING

NOTE: Resin accumulator must be completely void of fluid before attempting to charge system.

1. Purge catalyst fumes from charging pump by stroking pump several times before connecting
charging pump to valve body at top of resin accumulator.

CAUTION: Raise charging pump “T” handle to full up position before connecting air supply to
charging pump. Failure to do so may result in damage to the pump and/or injury to the
operator.

NOTE: Resin pour tubes and manifold block must be removed from gun head pour nozzle
before attempting to charge resin side of system.

2. Connect air supply to charging pump. Air supply should be approximately 100 P.S.I.

3. With regulator and ball valve to resin pump power head in the off positions, open needles of
gun.

NOTE: A suitable container will be required under gun.

4. Allow fluid to drain from resin accumulator before charging.

NOTE: It may be necessary to assist the draining operation with the charging pump. Operate
the charging pump until fluid no longer flows from the gun head. If this assist method is used it
will be necessary to remove charging pump from accumulator after fluid has stopped flowing
and relieve the pressure from the accumulator by forcing air valve open with a small, flat end
rod in the same manner as you would let air out of tire inner tube.

This is necessary because 95% of the time an overcharged condition will have occurred while
purging accumulator.

5. Proceed to charge resin accumulator to 4 times the amount that the power head of resin pump
will be operated at.

In most cases 50-60 PSI power head operation will supply an adequate amount of resin to nip of
rolls.

NOTE: Charging pump gauge will read line pressure with the “T” handle up and accumulator
pressure with handle down.

NOTE: The resin accumulator must be completely void of fluid to insure an adequate charge.
An improper charge will result in surging, uneven flow of resin, and poor catalyzation.

6. Remove air supply from charging pump and charging pump from accumulator.

7. After removing charging pump, check charging valve of accumulator for a pressure seal by
placing soapy water or other appropriate fluid over valve opening. If no air bubbles appear
install seal cap.

NOTE: If air leaks from charging valve, accumulator will not hold a charge and the source of the
leak must be found and eliminated before proceeding.

8. Close needles of gun and flush gun head.

9. Close the regulator to power head of the resin pump. Open the ball valve to power head.

10. Slowly open the regulator to power head. As resin fills the system, slowly increase PSI until
desired operating pressure is reached and pump stalls out.

11. Install Turbulent Mixer and nozzle cap on gun head. With a container under gun to catch
material, operate the pump until all air is purged from resin hose.

NOTE: Apply lubricant to threads of nozzle before installation to prevent galling of the threads.
See lubrication materials list for proper lubricant.

NOTE: After air has been purged from the hose, the resin flow should be steady and even; no
pulsation or surge when pump changes direction. If excessive pulsation is noted the charging
operation must be repeated until desired results are obtained. An inadequate accumulator
charge will result in poor resin/ catalyst mix and improper cure of the laminate.

12. When desired charge is obtained, there should be an even flow of material from the gun head
and a fairly uniform mix of catalyst and resin, provided the turbulent mixer is in place. Additional
mix will take place as material moves through the pour tube manifold, etc.

CHAPTER 4

BALANCING RESIN AND CATALYST

1. Place a suitable container, one that will hold 2 gallons or more, under gun head.

2. With turbulent mixer and nozzle in place, open ball valve to power head of resin pump slowly.
When ball valve is open, slowly turn regulator to the power head to desired PSI (50-60 PSI for
most applications).

The pump will stall out when fluid pressure is equal to the air pressure applied to power head.

NOTE: There is a 10:1 ratio between air pressure applied to pump and the fluid pressure that
results due to the mechanical advantage in piston sizes.

3. With a container under gun and safety glasses on, trigger gun and allow the system to operate
for approximately 10-15 strokes. As system operates note the flow of material. It should be
steady and even, no pulsation when resin pump changes direction. If colored catalyst is used, a
fairly uniform mix should be coming from gun, provided turbulent mixer is in place.

4. After 10-15 strokes of the resin pump, release the trigger button, and pump will stall out when
fluid and air pressure equalize.

5. Flush gun to clean gun mix chamber.

6. Observe the poly ball and fluid level in catalyst accumulator. They should be no higher than 2­1/2 to 3 inches from the top or bottom of accumulator. A perfect charge will place the poly ball
and fluid level in the center of accumulator.

When accumulators are properly charged and material is balanced and available at gun head,
the pour tube system can be installed.

RESIN DISTRIBUTION SYSTEM (POUR TUBES)

NOTE: All connections for the pour tube system are “O” ring sealed. A liberal application of

lubricant, preferably MVP Grease, is recommended before installation. All connections and
seals in the resin distribution system are designed for hand assembly and disassembly. Care
should be exercised to insure all joints, threads, and seals are well lubricated. To install resin
distribution system, assemble as outlined below.

1. If the turbulent mixer and nozzle have not been previously installed, lubricate the nozzle threads
and “O” ring with MVP Grease and install.

NOTE: Threads may gall and damage nozzle cap if not lubricated.

2. Lubricate “O” rings in the manifold block and check to see if the static mixer is in place and all
plugs are pressure tight.

3. Install pour tube manifold onto the gun nozzle. The pour tube manifold must be perpendicular
to the gun and roll plate.

4. Rotate manifold block into position parallel to roll plate, and pull down until the block rests on the
angle bracket.

5. Lubricate “O” rings on the pour tube plugs and install into pour tubes.

6. Install pour tubes into manifold block.

NOTE: For an unbalanced laminate, such as woven roving and mat, it may be necessary to
have more holes in one pour tube than in the other. Care should be taken to install the pour
tubes on the correct side if an unbalanced laminate is employed.

7. When pour tubes are in position over the nip rolls, rotate the pour tubes until the holes will direct
the resin down into nip of rolls and not onto reinforcement materials. When pour tubes are
installed and in the correct position, the reinforcement material can be loaded and positioned
onto Impregnator.

LOADING REINFORCEMENT

Reinforcements of various types and combinations can be wet-out with the Impregnator. Refer
to the section on reinforcement types. There are machine limitations noted in that section.

NOTE: When setting up the material, care must be taken to align the reinforcement in such a
manner that it enters Impregnator at the proper location. The reinforcement should be centered
equal distance from the ends of the rolls. This location must be repeated every time a new roll
of material is loaded onto the machine. Through experience the simplest way to maintain
location and repeatability is by use of shaft set collars.

Following steps outlined below will simplify the material loading process.

1. Place roving mandrels on the bearing blocks provided on machine. Center the mandrel on the
bearing blocks so an equal length of mandrel protrudes past the bearing blocks on either end.

2. Place two set collars on one end of the mandrel, one on each side of the bearing block. Lock
set collars into position with set screws.

NOTE: Set collars should be loose enough to sides of bearing lock so that mandrel turns freely.

3. Place proper size roving cone on the mandrel with the tapered end toward the center.

4. Remove mandrel from the bearing blocks and insert through core of the reinforcement. Place
another roving cone on the mandrel and set cones into roving core.

5. Replace mandrel, with reinforcement mounted, back onto the bearing blocks.

6. Center material between the bearing blocks so there is an equal space at each end between
material and bearing block. Check to make sure the cones are into the core and will not work
loose.

7. Lock the cones to the mandrel shaft with set screws.

NOTE: When removing the paper core from the mandrel shaft to lead a new roll of material into
place, unlock cone on opposite end from the set collars and insert mandrel shaft into new roll of
material from that end, and replace cone, locking it into position. The new roll will be in the
same location as the previous roll.

The above procedure holds true for units that have a roving cassette. Positioning of material is
the same when mounting on a cassette.

Models with roving cassette will require the cassette to be lifted into position on Impregnator after
reinforcement is mounted on cassette.

8. When material is in position on Impregnator, feed reinforcement down through the feed and
resin rolls. (Use remote roll or creep control valve to operate rollsuntil approximately 12 inches
hangs below the resin rolls. Open feed rolls, and remove and wrinkles that may be between
resin and feed rolls.

NOTE: With chopped strand mat and similar materials there is a hard side and a soft or fluffy
side. When running such materials with a carrier such as woven roving, the soft side should
always be toward the carrier, not toward the resin roll.

9. Adjust end dams up to the edges of the material. Care must be taken to insure proper
placement of the end dams. If they are too narrow it will cause the material to fold over and
allow too much resin to pass through; too wide and excess resin will drop through resin rolls at
the edges of the material

When adjusting end dams for chopped strand mat the dams should be as close to the edges of
the mat as possible and still allow the material to pass through without folding or wrinkling at
edges.

For woven roving and other materials that have a frayed edge, end dams should be set so the
dam is as close to the outside strands as possible and the fray is folded up as it passes through
resin rolls.

When running two dissimilar materials such as chopped mat and woven roving, end dams must
be as close to edges of the materials as possible. It may be necessary to compromise on
setting end dams because of different types of edges on the two materials.

CHAPTER 5

RESIN/GLASS RATIO SETTINGS

The resin content is controlled by micrometer adjustment dials on the vertical roll plate supports.
By opening or closing the adjustment dials, resin content can be varied to +/- 2%

Through experience, it has been found that a 40-48% glass content works best for optimum
performance of the Impregnator. Less than 40% glass, the laminate is very resin rich and
dripping below Impregnator is a problem. More than 48% and the glass content is so high it
does not wet-out well and additional effort is required for secondary hand rolling, etc.

Due to various conditions; temperatures, viscosity, reinforcements employed, etc., it is
impractical to give an exact setting to control resin content. Therefore, an approximation must
be made and material burn out tests performed to get an exact resin roll setting. To obtain a
very close approximation the operator should first measure the total reinforcement thickness
(measured dry) and add to this dimension .025 to .035 to obtain proper roll setting.

Example: Woven roving thickness = .030
Chopped mat thickness = .025
Added clearance = .030
Total = .085

A .085 gap setting of the rolls would be the starting point to determine glass/ resin ratio. A burn out
test will be required to get extra data on glass content.

NOTE: Different materials- reinforcements and resin may look very different when wet-out by
the Impregnator compared to what you are used to seeing. For example: a woven roving all
appear to be much higher in resin content than it actually is. On the other hand, a heavy mat,
(1-1/2 – 2 oz), will appear much dryer than it is. A combination mat and roving will appear dry
on the mat side and wet on the roving side. Through experience, an operator will be able to tell
when he is close to the proper setting on the rolls when he first starts and can adjust
accordingly. By keeping a record of the burn-out tests of your various laminates the operator
can change roll settings by checking records.

NOTE: Burn-out tests should be conducted when a precise glass to resin ratio must be
maintained. Burn-out tests will give exact data for setting nip of resin rolls. To perform a burn­out test:

1. Cut a sample of cured laminate and weigh it accurately.

2. Burn all resin from the laminate by use of a torch, oven or other suitable method.

3. Weigh the glass that is left after burning away the resin, again being very accurate.

4. By comparing the before and after weight you can obtain a very close glass to resin ratio.

The following steps should be taken when the machine is first set-up, and when there is any doubt
as to the accuracy of the roll settings.

1. Close rolls completely by turning the micrometer knobs counter clockwise until they are
completely free, just spinning on the shaft with no load on the knob.

2. Looking up from below the resin rolls, check to see if rolls are completely together; no gap or
light appears between rolls at any point.

3. With a feeler gauge set for .030 turn both micrometer dial knobs clockwise until the gap,
measured with the feeler gauge, is .030 across the full width of rolls.