Magnum Venus Plastech INNOVATOR II CONTROL UNIT User Manual

INSTALATION/OPERATIONS MANUAL INNOVATOR II

INNOVATOR II CONTROL UNIT

Installation & Operations Manual

Model numbers:
INNOVATOR II

MAGNUM VENUS PLASTECH REV 1.40
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INSTALATION/OPERATIONS MANUAL INNOVATOR II

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INSTALATION/OPERATIONS MANUAL INNOVATOR II

TABLE OF CONTENTS

CHAPTER 1-Safety and Warning Information ..................................................................................................................................... 5

Operating Your Polyester System Safely ............................................................................................................................................... 5

1.0 Introduction ................................................................................................................................................................................ 5

1.2 Personal Safety Equipment ........................................................................................................................................................ 5

2.0 Material Safety ........................................................................................................................................................................... 5

2.1 Hazards Associated with Laminating Operations ....................................................................................................................... 5

2.2 Catalyst (Methyl Ethyl Ketone Peroxide) .................................................................................................................................... 6

2.3 Clean-Up Solvents and Resin Diluents ........................................................................................................................................ 7

2.4 Catalyst Diluents ......................................................................................................................................................................... 7

2.5 Cured Laminate, Overspray and Laminate Sandings Accumulation ........................................................................................... 7

2.7 Toxicity of Chemicals .................................................................................................................................................................. 7

2.8 Treatment of Chemical Injuries .................................................................................................................................................. 8

3.0 Equipment Safety ....................................................................................................................................................................... 8

3.1 Emergency Stop Procedures....................................................................................................................................................... 8

3.2 Grounding ................................................................................................................................................................................... 8

CHAPTER 2-Introduction .................................................................................................................................................................... 9

CHAPTER 3-Installation .................................................................................................................................................................... 11

Component Assemblies ....................................................................................................................................................................... 11

Connecting the system to air source ................................................................................................................................................... 11

CHAPTER 4-Overview of Controls .................................................................................................................................................... 14

Overview of controls ........................................................................................................................................................................... 14

Machine operations ............................................................................................................................................................................ 15

Emergency Stop .............................................................................................................................................................................. 16

Catalyst over-pressure protection .................................................................................................................................................. 16

RGA (Resin Gel Alarm) .................................................................................................................................................................... 17

Flush ............................................................................................................................................................................................... 17

Mold Pressure Guard (MPG) .......................................................................................................................................................... 18

Injection mode ............................................................................................................................................................................... 19

Recirculation mode ........................................................................................................................................................................ 19

Guard Interlocks ............................................................................................................................................................................. 20

Control box user connections .............................................................................................................................................................. 21

Side of control box ......................................................................................................................................................................... 21

Rear of control box ......................................................................................................................................................................... 22

CHAPTER 5-Control box configuration (Internal controls) ................................................................................................................ 23

RGA adjustment .................................................................................................................................................................................. 24

Flush timer adjustment ....................................................................................................................................................................... 26

MPG adjustment ................................................................................................................................................................................. 26

Catalyst over pressure adjustment ..................................................................................................................................................... 27

Internal push buttons and valve operations ....................................................................................................................................... 28

CHAPTER 6-Injection Sequence........................................................................................................................................................ 33

CHAPTER 7-Maintainence ................................................................................................................................................................ 35

IMPORTANT NOTE: ............................................................................................................................................................................ 35

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CHAPTER 8-Troubleshooting............................................................................................................................................................ 37

Innovator 2012 Pro Gun schematic ....................................................................................................................................................... 7

Innovator 2012 Megaject schematic ..................................................................................................................................................... 9

Innovator 2012 Accessories ................................................................................................................................................................ 11

Innovator 2012 Remote pendant ........................................................................................................................................................ 13

CHAPTER 8-Revsion History ............................................................................................................................................................... 1

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CHAPTER 1-Safety and Warning Information

Operating Your Polyester System Safely

1.0 Introduction

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment. The
contents of this guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to
change the specification of the product or its performance, or the contents of the guide, without notice. All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any
means, electrical or mechanical including photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher.

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 consult 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:

Copies of the above bulletins are available, at a nominal charge from:

Research Report No.11 of the American Insurance Association deal with “Fire, Explosion and Health Hazards of Organic Peroxides”. It is published by:

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.

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
Type of Fire Extinguishing equipment recommended: Fire Extinguisher – code ABC, rating number 4a60bc.
Extinguishing Media – Foam, Carbon Dioxide, Dry Chemical, Water Fog.

National Fire Protection Association
470 Atlantic Avenue
Boston, MA 02210

American Insurance Association
85 John Street
New York, NY 10038

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

Major hazards which should be guarded against in polyester/epoxy/urethane laminating operations are those associated with:

Flammability and explosion dangers of the catalyst/activators/hardeners normally used

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.

Flammability dangers of catalyst diluents, if used. (Magnum Venus Plastech recommends that catalyst not be diluted)

Flammability dangers of the uncured liquid resins.

Combustibility dangers of the cured laminate, accumulations of over spray, and laminate sandings.

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 with 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-of-rise 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 could 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:

Store MEKP in a cool, dry place in original containers away from direct sunlight and away from other chemicals.
Keep MEKP away from heat, sparks and open flames.
Prevent contamination of MEKP with other materials, including polyester over spray and sandings, polymerization accelerators and promoters, brass, aluminum and non-stainless steels.
Never add MEKP to anything that is hot, since explosive decomposition may result.
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.
Avoid spillage, which can heat up to the point of self-ignition.
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.
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.
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.

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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 when 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.

There are three key elements to the Halogenated Hydrocarbon (HHC) solvent hazard:

 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.

 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.

 Equipment capable of withstanding pressure. When HHC solvent contact 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.

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.

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 with aluminum components in closed

fluid system. TAKE IMMEDIATE ACTION… Halogenated Hydrocarbon solvents are dangerous when used with aluminum components in a closed fluid system.

Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocarbon Solvents.
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.
If you find it necessary to use flammable solvents, they must be kept in approved, electrically grounded containers.
Bulk solvent should be stored in a well-ventilated, separate building, 50 feet away from your main plant.
You should allow only enough solvent for one day’s use in your laminating area.
“NO SMOKING” signs must be posted and observed in all areas of storage or where solvents and other flammable materials are used.
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.
Solvents should be handled in accordance with OSHA Section 1910.106 and 1910.107.



 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.

 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.
 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.

 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.

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 dilettante. In addition, it eliminates any problems from the dilettante 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

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.

Floor coverings, if used, should be non-combustible.
Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product, over-sprayed chop or resin, FRP sandings or any other material with MEKP.
To prevent this spillage and leakage, you should:

 Maintain your Magnum Venus Plastech System. Check the gun several times daily for catalyst and resin packing or valve leaks. REPAIR ALL LEAKS IMMEDIATELY.
 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.
 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.
 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

2.7 Toxicity of Chemicals

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.

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.

a hazardous leakage of material which could increase the danger of fire. Also, the material may spew onto personnel in the area.

Also determine the best methods of first aid treatment for each chemical used in your plant.

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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:

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 you 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.

3.0 Equipment Safety

WARNING

Magnum Venus Plastech suggest that personal safety equipment such as EYE GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be worn when servicing or operating this
equipment. Ear protection should be worn 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

 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.

 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person.
 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals have.

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 THE 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.

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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CHAPTER 2-Introduction

The Innovator Injection system is a multipurpose injection system that can be utilized with LRTM, disposable vacuum
bags and reusable silicone bagging systems. Provided with the correct options/accessories the Innovator can
accommodate and automate many processes that are now done by hand. Being completely air driven, the system can be
set up anywhere in the shop that is convenient to the parts. Also by being mobile the unit can be moved from part to part
instead of having to move heavy molds to the injection machine.

Thru a series of pneumatic interlocks and controls, the Innovator has virtually eliminated the possibility of operator error
and allows personnel to monitor other aspects of the injection other than the pump system while manufacturing a part.

The system utilized the RAD (Rapid Access Design) concept that all other MVP machines use. This decreases
maintenance downtime and lost production hours.

This manual covers the installation, operation and maintaining of the Innovator 2012.

Note: this manual will reference other MVP manuals for certain components of the Innovator 2012 throughout.

Specialty units are available with Innovator style controls, please contact your local sales representative for these
systems.

Although similar in controls and pump assemblies, each unit uses a different mixing head(s) for customer convenience.

The Innovator injection system utilizes the Patriot pumping system for accurate mixing and metering and this manual
provides information needed to properly operate and perform simple maintenance and repair on this equipment.

 Step-by-step operations procedures are provided.
 This manual includes Installation, Start-up and Shut-Down instructions.
 Step-by-step assembly and disassembly procedures are included for each component.

Please read this manual carefully. Follow the steps in the order given, otherwise damage or injury could possibly be done
to equipment or personnel.

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CHAPTER 3-Installation

Component Assemblies

The Innovator 2012 consists of a number of components these components will have their own detailed manuals and
drawings. For complete repair and maintenance instruction please reference the following manuals. All units come with
complete documentation but always check for updates at www.mvpind.com.

Assembly

 Unpack unit, components.
 Install the Catalyst pump onto the Slave Drive assembly.
 Mount the Catalyst Jug Bracket
 Install Catalyst Jug into the Catalyst Jug Bracket
 Attach Catalyst Feed tube between the Catalyst Jug outlet and Catalyst pump Inlet ,trim the Feed tube as

necessary to keep it always flowing up to the Catalyst Jug outlet.

 Install the Catalyst leak control tube from the top of the Catalyst Pump to the port in the Catalyst Jug
 Connect the Catalyst Hose from the Catalyst Pump outlet to the Injection head.
 Connect the Catalyst Overpressure drain from the overpressure valve to the Catalyst Jug.
 Attach Pickup Hoses to the inlet of the pump
 Place Flush Tank in holder and attach air hose. Connect yellow Flush Tube from Injection Head to Flush

Tank.

 Check all fluid and poly hose connections for loose fittings.

CAUTION: Connections at the flush tank must be correct or there the flush system will be damaged in the control box.
Refer to the IN/OUT inscribed on the tank. The yellow poly tube must be connected to the OUT and then connected to
the flush valve on the dispense head.
Filling the flush tank above ¾ full is also not advisable.

Connecting the system to air source

The machine is supplied with inline filter and should be connected to an un-lubricated air supply. Ensure the maximum
inlet air pressure marked on the filter is not exceeded (1Mpa = 10 bar = 145PSI).

A sleeve valve, is provided on the rear of the enclosure so that air may be isolated from the control box. Air should be
removed from the machine when it is not in use by sliding the isolation valve sleeve away from the control box.

NOTE: Upon air supply loss, either by the sleeve valve or loss of mains pressure, once the supply is re-energized

all controls will revert to an “OFF” state. This is a safety feature so that none of the valves, or components will
energize unexpectedly and create an unsafe situation.

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CHAPTER 4-Overview of Controls

Overview of controls

The Innovator control panel is shown in figure 4.10. Controls have been grouped based upon function, to make the
system as user friendly as possible.

A brief overview of controls is as follows:

Emergency Stop

 Push button Press this button in the event of an emergency to place the system in a

safe state. Twist and pull to release and allow machine operation.

Pump pressure

 Pressure gauge This is the air pressure being supplied to the pump.

 Regulator Adjust this to control the air pressure being supplied to the pump and set

the pump speed.

Flush/Alarms

 CAT/OP Indicator will turn red if overpressure state exists.

 RGA ALARM Indicator will turn red if gel alarm timer has expired.

 Pushbutton Press this button to operate the flush cycle.

Mold Pressure Guard

 Preset level gauge Control signal air pressure being supplied to Mold Pressure Guard

(MPG) control.

 Regulator Use this to adjust the MPG control signal air pressure.

Start/Stop Controls

 Inject Press to start the machine in inject mode.

 Recirculate Press to start the machine in recirculation mode.

 Stop Press to stop the machine in injection, recirculation or flush modes.

Stroke Counter Set a predetermined stroke count for the machine to stop at.

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EMERGENCY STOP

BUTTON

PUMP PRESSURE

REGULATOR

PUMP PRESSURE GAUGE

STROKE

COUNTER

GEL ALARM

INDICATOR

CATAYLST O/P

INDICATOR

FLUSH BUTTON

MOLD PRESSURE

GUARD GAUGE

MOLD PRESSURE

GUARD REGULATOR

RESET BUTTON

CURRENT COUNT DISPLAY

PRESET COUNT DISPLAY

DIGIT LOCKOUT

DIGIT MODIFIERS

INJECTION BUTTON

STOP BUTTON

RECIRCULATION BUTTON

INSTALATION/OPERATIONS MANUAL INNOVATOR II

FIG 4.10

FIG 4.15

Machine operations

Before the system can be used the air isolation sleeve-valve must be moved to the “ON” position and the E-Stop must be
released. When air is initially supplied, all controls should automatically reset to their non-operational state.

NOTE: Residual pressures may remain in the system even though the E-Stop has been activated and the air
supply has been removed from the machine.

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INSTALATION/OPERATIONS MANUAL INNOVATOR II

The various controls and operational modes are described in the following sub-sections.

Emergency Stop

When the E-Stop has been activated, the machine will enter a safe state. If the machine is injecting, recirculating or
flushing, the E-Stop is equivalent to pressing the stop button.

To de-activate the E-Stop, twist and pull to release.

Catalyst over-pressure protection

The machine features catalyst over-pressure protection. In addition to the industry standard inclusion of a pressure relief
valve in the catalyst circuit, the control circuit will detect the over-pressure condition and stop the pump from running. In
injection or recirculation modes, this is equivalent to pressing the stop button.

For example, if during an injection the catalyst system is over-pressurized, the injection will stop, the TAS/Pro gun will
close and the system will shut down.

A visual indicator (fig 4.10) is provided on the face of the control box, which will change from black to red in the event of a
catalyst over-pressure condition. To reset the over-pressure control circuit, the catalyst pressure must be relieved and the
reason for the condition must be remedied before the machine can be operated in injection or recirculation modes.

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INSTALATION/OPERATIONS MANUAL INNOVATOR II

RGA (Resin Gel Alarm)

The machine features a RGA (Resin Gel Alarm) system, designed to alert the operator to the risk of catalyzed resin curing
in the machine or mold during an injection or prior the machine being flushed and cleaned.

When the inject button is pressed and the machine starts in injection mode, the RGA becomes active. It monitors the time
between pump strokes during an injection and if the user adjustable preset time is exceeded, an audible alarm will sound
and the visual RGA indicator (FIG 4.10) on the control panel will change from black to red.

The alarm is reset when the pump stroke changes direction in injection mode, however in this case the RGA will continue
to monitor the pump strokes and will alarm again if the preset time between pump strokes is once again exceeded.

An example of this would be if the machine stalled during an injection due to a higher than normal back-pressure in the
injection line. The operator may increase the injection pressure to make the pump stroke and therefore reset the alarm
and complete the injection.

The RGA is de-activated, so that it stops monitoring pump strokes and cancels any active visual/audible alarms, by either
flushing the machine or pressing the RGA reset button.

The RGA reset button is accessed on the side of the control panel and can be pressed by inserting a small screwdriver or
equivalent through the hole marked RGA reset. This is not intended to be used in normal operation and is provided as a
means to silence the alarm, if the pump cannot run and the machine cannot be flushed.

A user configurable pneumatic timer, which can be adjusted between 20-300 seconds (0.3 – 5 minutes) is located in the
control box. In addition, a factory set timer of between 30-60 seconds is included in the RGA circuit to limit the switching
rate of the circuit. These two timers need to time-out in sequence in order for the alarm to trigger. In practice if the
mechanical timer is set to 5 minutes, if the duration of a pump stroke was to exceed around 5.5 – 6 minutes during an
injection, the alarm would trigger.

Flush

Press the flush button to clean the injection head. The operator cannot initiate a flush when the machine is in injection
mode, therefore accidental flushing of the system into a mold during an injection is not possible.

The flush system has an automatic timer function that will stop the flush cycle automatically. The default duration of the
flush is set between 30-60 seconds during manufacture; however this can be adjusted by the user if required.

The flush cycle can be stopped at any time by pressing the stop button. Flush cycle cannot be entered while injecting.

CAUTION: Before the flush button is pressed, ensure that the outlet from the mixing head is directed to a suitable
waste container.

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