Magnum Venus Plastech INNOVATOR MEGAJECT 5000 User Manual

MANUAL

MAGNUM VENUS PLASTECH

INNOVATOR MEGAJECT 3250 (8000) Rev: 05/2011
INNOVATOR MEGAJECT 5000 (8001)

Innovator Megaject

Operations Manual

CORPORATE HEADQUARTERS and MANUFACTURING

5148 113th Ave. N. *Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER / WEST COAST MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel [phone] * Fax [phone]

MVP Plastech UK

Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel:[phone]

Fax: [phone]

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Innovator Megaject

Operations Manual

Table of Contents:

SAFETY WARNINGS

SECTION 1: GETTING STARTED

SECTION 2: CONTROL BOX INSTRUCTIONS

SECTION 3: OPERATING PROCEDURES

SECTION 4: FLUID SECTION MAINTENANCE & REPAIR

SECTION 5: CATALYST PUMP MAINTENANCE & REPAIR

SECTION 6: PATRIOT POWERHEAD

SECTION 7: INJECTION HEAD & MIXER ASSEMBLY

SECTION 8: SP4 SOLVENT PUMP ASSEMBLY

SECTION 9: PARTS DRAWINGS

SECTION 10: REVISON INFORMATION

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SAFETY WARNINGS INSTRUSTIONS:

OPERATING YOUR POLYESTER SYSTEM SAFELY

1. Introduction

Any tool, if used improperly, can be dangerous. Safety is ultimately the responsibility of
those using the tool. In like manner, safe operation of polyester processes is the
responsibility of those who use such processes and those who operate the equipment.
This manual outlines procedures to be followed in conducting polyester operations
safety. This system has been specifically designed for use of Polyester Resin, Gel-Coat,
and Methyl Ethyl Ketone Peroxides (MEKP) applications. Other formulations or blends
considered for use in this equipment is strictly prohibited without the expressed consent
by Magnum Venus Plastech Inc. Magnum Venus Plastech cannot eliminate every
danger nor foresee every circumstance that might cause an injury during equipment
operation. Some risks, such as the high pressure liquid stream that exits the spray tip,
are inherent to the nature of the machine operation and are necessary to the process in
order to manufacture the end-product. For this reason, ALL personnel involved in
polyester operations should read and understand the Safety Manual. It is very important
for the safety of employees involved in the operation that equipment operators,
maintenance and supervisory personnel understand the requirements for safe operation.
Each user should examine his own operation, develop his own safety program and be
assured that his equipment operators follow correct procedures. Magnum Venus
Plastech hopes that this manual is helpful to the user and recommends that the
precautions in this manual be included in any such program. Magnum Venus Plastech
recommends this Safety Manual remain on yo ur 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:

NFPA No.33 Chapter 14, Organic Peroxides and Dual Component Materials

NFPA No.63 Dust Explosion Prevention

NFPA No.70 National Electrical Code

NFPA No.77 Static Electricity

NFPA No.91 Blower and Exhaust System

NFPA No.654 Plastics Industry Dust Hazards

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Type of Fire Extinguishing equipment recommended: Fire Extinguisher – code ABC,
rating number 4a60bc.

Extinguishing Media – Foam, Carbon Dioxide, Dry Chemical, Water Fog.

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

National Fire Protection Association
470 Atlantic Avenue
Boston, MA 02210

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

American Insurance Association
85 John Street
New York, NY 10038

Local codes and authorities also have standards to be followed in the operation of your
spraying equipment. Your insurance carrier will be helpful in answering questions that
arise in your development of safe procedures.

1.2 Personal Safety Equipment

Magnum Venus Plastech recommends the following Personal Safety Equipment for
conducting safe operations of the Polyester Systems:

Magnum Venus Plastech recommends that the user consult the state and local
regulations established for all Safety equipment listed.

2.0 Material Safety

2.1 Hazards Associated with Laminating Operations

The major hazards which should be guarded against in polyester laminating operations
are those associated with:

1. The flammability and explosion dangers of the catalyst normally used – Methyl Ethyl
Ketone Peroxide (MEKP).

2. The flammability dangers of clean-up solvents sometimes used (Magnum Venus
Plastech recommends that clean-up solvents be non-flammable), and of resin diluents
used, such as styrene.

3. The flammability dangers of catalyst diluents, if used. (Magnum Venus Plastech
recommends that catalyst not be diluted.

4. The flammability dangers of the uncured liquid resins used.

5. The combustibility dangers of the cured laminate, accumulations of over spray, and
laminate sandings.

6. The toxicity dangers of all the chemicals used in laminating operations with respect to
ingestion, inhalation and skin and eye hazards.

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2.2 Catalyst (Methyl Ethyl Ketone Peroxide)

MEKP is among the more hazardous materials found in commercial channels. The safe
handling of the “unstable (reactive)” chemicals presents a definite challenge to the
plastics industry. The highly reactive property which makes MEKP valuable to the
plastics industry in producing the curing reaction of polyester resins also produces the
hazards which require great care and caution in its storage, transportation, handling,
processing and disposal. MEKP is a single chemical. Various polymeric forms may exist
which are more or less hazardous with respect to each other. These differences may
arise not only from different molecular structures (all are, nevertheless, called “MEKP”)
and from possible trace impurities left from the manufacture of the chemicals, but may
also arise by contamination of MEKP with other materials in its storage or use. Even a
small amount of contamination with acetone, for instance, may produce an extremely
shock-sensitive and explosive compound.

Contamination with promoters or materials containing promoters, such as
laminate sandings, or w ith any readily oxidizing material, such as brass or iron,
will cause exothermic “redox” reactions which can become explosive in nature.
Heat applied to MEKP, or heat build-up from contamination reactions can cause it
to reach what is called its Self-Accelerating Decomposition Temperature (SADT).

Researchers have reported measuring pressure rates-of-rise well in excess of 100,000
psi per second when certain MEKP’s reach their SADT. (For comparison, the highest
pressure rate-of-rise listed in NFPA Bulletin NO.68, “Explosion Venting”, is 12,000 psi
per second for an explosion of 12% acetylene and air. T he 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 form improper handling of MEKP,
especially in regards to contamination, heat, friction and impact. They should be
thoroughly instructed regarding the proper action to be taken in the storage, use and
disposal of MEKP and other hazardous materials used in the laminating operation. In
addition, users should make every effort to:

A. Store MEKP in a cool, dry place in original containers away from direct sunlight and
away from other chemicals.

B. Keep MEKP away from heat, sparks and open flames.

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C. Prevent contamination of MEKP with other materials, including polyester over spray
and sandings, polymerization accelerators and promoters, brass, aluminum and non­stainless steels.

D. Never add MEKP to anything that is hot, since explosive decomposition may result.

E. Avoid contact with skin, eyes and clothing. Protective equipment should be worn at all
times. During clean-up of spilled MEKP, personal safety equipment, gloves and eye
protection must be worn. Fire fighting equipment should be at hand and ready.

F. Avoid spillage, which can heat up to the point of self-ignition.

G. Repair any leaks discovered in the catalyst system immediately, and clean up the
leaked catalyst at once in accordance with the catalyst manufacturer’s instructions.

H. Use only original equipment or equivalent parts from Magnum Venus Plastech in the
catalyst system (i.e.: hoses, fitting, etc.) because a dangerous chemical reaction may
result between substituted parts and MEKP.

I. Catalyst accumulated from the purging of hoses or the measurement of fluid output
deliveries should never be returned to the supply tank, such catalyst should be diluted
with copious quantities of clean water and disposed of in accordance with the catalyst
manufacturer’s instructions.

The extent to which the user is successful in accomplishing these ends and any
additional recommendations by the catalyst manufacturer determines largely the safety
that will be present in his operation.

2.3 Clean-Up Solvents and Resin Diluents

WARNING

A hazardous situation may be present in your pressurized fluid system!
Hydrocarbon Solvents can cause an explosion when used with aluminum or
galvanized components in a closed (pressurized) fluid system (pump, heaters,
filters, valves, spray guns, tanks, etc.). T he explosion could cause serious injury,
death and/or substantial property damage. Cleaning agents, coatings, paints, etc.
may contain Halogenated Hydrocarbon Solvents. Some Magnum Venus Plastech
spray equipment includes aluminum or galvanized components and will be
affected by Halogenated Hydrocarbon Solvents.

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

a. The presence of HHC solvents. 1,1,1 – Trichloroethane and Methylene

Chloride are the most common of these solvents. However, other HHC
solvents are suspect if used; either as part of paint or adhesives formulation, or
for clean-up flushing. b. Aluminum or Galvanized Parts. Most handling
equipment contains these elements. In contact with these metals, HHC
solvents could generate a corrosive reaction of a catalytic nature.

b. Equipment capable of withstanding pressure. When HHC solvent 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.

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When all three elements are present, the result can be an extremely violent explosion.
The reaction can be sustained with very little aluminum or galvanized metal; any amount
of aluminum is too much.

A. The reaction is unpredictable. Prior use of an HHC solvent without incident (corrosion
or explosion) does NOT mean that such use is safe. These solvents can be dangerous
alone (as a clean-up or flushing agent) or when used as a component or a coating
material. There is no known inhibitor that is effective under all circumstances.
Furthermore, the mixing of HHC solvents with other materials or solvents, such as
MEKP, alcohol, and toluene, may render the inhibitors ineffective.

B. The use of reclaimed solvents is particularly hazardous. Reclaimers may not add any
inhibitors. Also, the possible presence of water in reclaimed solvents could feed the
reaction.

C. Anodized or other oxide coatings cannot be relied upon to prevent the explosive
reaction. Such coatings can be worn, cracked, scratched, or too thin to prevent contact.
There is no known way to make oxide coatings or to employ aluminum alloys, which will
safely prevent the chemical reaction under all circumstances.

D. Several solvent suppliers have recently begun promoting HHC solvents for use in
coating systems. The increasing use of HHC solvents is increasing the risk. Because of
their exemption from many State Implementation Plans as Volatile Organic Compounds

(VOC’s), their low flammability hazard, and their not being classified as toxic or
carcinogenic substances, HHC solvents are very desirable in many respects.

WARNING: Do not use Halogenated Hydrocarbon solvents in pressurized fluid
systems having aluminum or galvanized wetted parts.

NOTE: Magnum Venus Plastech is aware of NO stabilizers available to prevent
Halogenated Hydrocarbon solvents from reaction under all conditions w ith
aluminum components in closed fluid system. TAKE IMMEDIATE ACTION…
Halogenated Hydrocarbon solvents are dangerous w hen used with aluminum
components in a closed fluid system.

A. Consult your material supplier to determine whether your solvent or coating contains
Halogenated Hydrocarbon Solvents.

B. Magnum Venus Plastech recommends that you contact your solvent supplier
regarding the best non-flammable clean-up solvent with the heat toxicity for your
application.

C. If, however, you find it necessary to use flammable solvents, they must be kept in
approved, electrically grounded containers.

D. Bulk solvent should be stored in a well-ventilated, separate building, 50 feet away
from your main plant.

E. You should allow only enough solvent for one day’s use in your laminating area.

F. “NO SMOKING” signs must be posted and observed in all areas of storage or where
solvents and other flammable materials are used.

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G. Adequate ventilation (as covered in OSHA Section 1910.94 and NFPA No.91) is
important wherever solvents are stored or used, to minimize, confine and exhaust the
solvent vapors.

H. Solvents should be handled in accordance with OSHA Section 1910.106 and

1910.107.

2.4 Catalyst Diluents

Magnum Venus Plastech spray-up and gel-coat systems currently produced are
designed so that catalyst diluents are not required. Magnum Venus Plastech, therefore,
recommends that diluents not be used. This avoids the possible contamination which
could lead to an explosion due to the handling and mixing of MEKP and diluents. In
addition, it eliminates any problems from the diluents being contaminated through rust
particles in drums, poor quality control on the part of the diluents suppliers, or any other
reason. If, however, diluents are absolutely required, co ntact your catalyst supplier and
follow his instructions explicitly. Preferable, the supplier should premix the catalyst to
prevent possible “on the job” contamination while mixing.

WARNING

If diluents are not used, it should be remembered that catalyst spillage, gun, hose
and packing leaks are potentially more hazardous, since each drop contains a
higher concentration of catalyst, and therefore will react quicker with over spray
and the leak.

2.5 Cured Laminate, Overspray and Laminate Sandings Accumulation

A. Remove all accumulations of overspray, FRP sandings, etc. from the building as they
occur. If this waste is allowed to build up, spillage of catalyst is more likely to start a fire,
in addition, the fire would burn hotter and longer.

B. Floor coverings, if used, should be non-combustible.

C. Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product,
over-sprayed chop or resin, FRP sandings or any other material with MEKP.

To prevent this spillage and leakage, you should:

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

2. Never leave the gun hanging over, or lying inside the mold. A catalyst leak in this
situation would certainly damage the part, possibly the mold, and may cause a fire.

3. Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the
boom sections and at the hose and fittings. Replace if wear or weakness is evident or
suspected.

4. Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT
rub against any of the hoses at any point. If allowed to rub, the hose will be cut through,
causing a hazardous leakage of material which could increase the danger of fire. Also,
the material may spew onto personnel in the area.

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2.7 Toxicity of Chemicals

A. Magnum Venus Plastech recommends that you co nsult OSHA Sections 1910.94,

1910.106, 1910.107 and NFPA No.33, Chapter 14, and NFPA No.91.

B. Contact your chemical supplier(s) and determine the toxicity of the various chemicals
used as well as the best methods to prevent injury, irritation and danger to personnel.

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

2.8 Treatment of Chemical Injuries

Great care should be used in handling the chemicals (resins, catalyst and solvents) used
in polyester systems. Such chemicals should be treated as if they hurt yo ur skin and
eyes and as if they are poison to your body. For this reason, Magnum Venus Plastech
recommends the use of protective clothing and eye wear in using polyester systems.
However, users should be prepared in the event of such an injury. Precautions include:

1. Know precisely what chemicals you are using and obtain information from your
chemical supplier on what to do in the event the chemical gets onto your skin or into
the eyes, or is swallowed.

2. Keep this information together and easily available so that it may be used by those
administering first aid or treating the injured person.

3. Be sure the information from your chemical supplier includes instructions on how to
treat any toxic effects the chemicals have.

WARNING

Contact your doctor immediately in the event of any injury and give him the
information you have collected. If your information includes first aid instructions,
administer first aid immediately while you are contacting your doctor.

Fast treatment of the outer skin and eyes that contact such chemicals generally includes
immediate and thorough washing of the exposed skin and immediate and continuous
flushing of the eyes with lots of clean water for at least 15 minutes or more. These
general instructions of first aid treatment, however, may be incorrect for some chemicals;
that is why 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.

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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 w orn when
operating a fiberglass chopper to protect against hearing loss since noise levels
can be as high as 116 dB (decibels). T his equipment should only be operated or
serviced by technically trained personnel!

WARNING

Never place fingers, hands, or any body part near or directly in front of the spray
gun fluid tip. T he 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 T HE 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.

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3.2 Grounding

Grounding an object means providing an adequate path for the flow of the electrical
charge from the object to the ground. An adequate path is one that permits charge to
flow from the object fast enough that it will not accumulate to the extent that a spark can
be formed. It is not possible to define exactly what will be an adequate path under all
conditions since it depends on many variables. In any event, the grounding means
should have the lowest possible electrical resistance. Grounding straps should be
installed on all loose conductive objects in the spraying area. This includes material
containers and equipment. Magnum Venus Plastech recommends grounding straps be
made of AWG No.18 stranded wire as a minimum and the larger wire be used where
possible. NFPA Bulletin No77 states that the electrical resistance of such a leakage
path may be as low as 1 meg ohm (10 ohms) but that resistance as high as 10,000 meg
ohms will produce an adequate leakage path in some cases. Whenever flammable or
combustible liquids are transferred from one container to another, or from one container
to the equipment, both containers or container and equipment shall be effectively
bonded and grounded to dissipate static electricity. For further information, see
National Fire Protection Association ( NFPA) 77, titled “Recommended Practice on
Static Electrical”. Refer especially to section 7-7 titled “Spray Application of Flammable
and Combustible Materials”. Check with local codes and authorities for other specific
standards that might apply to your application. NEVER USE HARD MATERIALS SUCH
AS WIRE, PINS, ETC., TO CLEAR A PLUGGED GUN. HARD MATERIALS CAN
CAUSE PERMANENT DAMAGE. DAB WITH A BRISTLE BRUSH, BLOW
BACKWARDS WITH AIR UNTIL CLEAR WHILE WEARING A PROTECTIVE EYE
SHIELD. REPEAT AS MANY TIMES AS NECESSARY. DO NOT PERFORM ANY
MAINTENANCE OR REPAIRS UNTIL YOU HAVE FOLLOWED THE PRECAUTIONS
STATED ABOVE. IF YOU, AS AN EQUIPMENT OPERATOR OR SUPERVISOR, DO
NOT FEEL THAT YOU HAVE BEEN ADEQUATELY TRAINED OR INSTRUCTED AND
THAT YOU LACK THE TECHNICAL KNOWLEDGE TO OPERATE OR PERFORM
MAINTENANCE ON A PIECE OF MAGNUM VENUS PLASTECH EQUIPMENT,
PLEASE CALL MAGNUM VENUS PLASTECH BEFORE OPERATING OR
PERFORMING MAINTENANCE ON THE EQUIPMENT. IF YOU HAVE ANY
QUESTIONS REGARDING THE ABOVE PRECAUTIONS OR ANY SERVICE OR
OPERATION PRECEDURES, CALL YOUR MAGNUM VENUS PLASTECH
DISTRIBUTOR OR MAGNUM VENUS PLASTECH.

NOTICE: All statements, information and data given herein are believed to be
accurate and reliable but are presented without guaranty, warranty or
responsibility of any kind express or implied. The user should not assume that all
safety measures are indicated or that other measures are not required.

DANGER: Contaminated catalyst may cause Fire or Explosion. Before working
on the catalyst pump or catalyst accumulator, wash hands and tools thoroughly.
Be sure work area is free of dirt, grease or resin. Clean catalyst system
components with clean water only.

DANGER: Eye, skin and respiration hazard. The Catalyst, MEKP, may cause
blindness, skin irritation or breathing difficulty. Keep hands away from face.
Keep food and drink away from work area.

WARNING: Please refer to your catalyst manufacturer’s safety information
regarding the safe handling and storage of catalyst. Wear appropriate safety
equipment as recommended.

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SECTION

Innovator Megaject

GETTING STARTED

The Innovator Megaject uses the Patriot pumping system for accurate metering.

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
you may damage the equipment or injure yourself.

Component Assemblies:

The Innovator Megaject consists of a number of components – these
components will have their own detailed manuals and drawings. For complete
repair and maintenance instruction please reference these manual.

 Megaject Dispense Head

Innovator Megaject 3250: (8000)

 Patriot Powerhead Manual – PAT-PH-3250
 Patriot 1-1/4 Fluid Section Manual – PAT-LS-12270-PE
 Patriot Metering Pump Manual – PAT-CP-0550

Innovator Megaject 5000: (8001)

 Patriot Powerhead Manual – PAT-PH-5000
 Patriot 1-3/4 Fluid Section Manual – PAT-LS-24050-PE
 Patriot Metering Pump Manual – PAT-CP-0980

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1. Unpack unit & components

2. Install the Catalyst pump onto the Slave Drive assembly.

3. Mount the Catalyst Jug Bracket

4. Install Catalyst Jug into the Catalyst Jug Bracket

5. 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.

6. Install the Catalyst leak control tube from the top of the Catalyst Pump to the

port in the Catalyst Jug.

7. Connect the Catalyst Hose from the Catalyst Pump outlet to the Injection

head.

8. Attach Pickup Hoses to the inlet of the pump

9. Place Flush Tank in holder and attach air hose. Connect yellow Flush Tube

from Injection Head to Flush Tank.

Note: Be sure the Flush Tank connections are correct or the Equipment will
be damaged. It is important not to fill the Flush Tank more then 3/4 full or
solvent can get in the air system and cause damage.

Double check all hose fittings and connections are tight

The repair and maintenance of several components will require the use of
removable Loctite® 243 or equivalent thread lock compound, Lithium grease
(Lubriplate 08465) and Red Grease (6706-2-1).

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SECTION

Innovator Megaject

CONTROL BOX INSTRUCTIONS

Connecting the system to an air supply

The machine is supplied with a 5 micron filter and should be connected to an un­lubricated air supply. Ensure the maximum inlet air pressure marked on the filter
is not exceeded (1Mpa = 10 bar = 145PSI).

A pressure regulator for the air circuit is mounted inside the control box. This
should be adjusted so that the controls are supplied with a pressure of
approximately 6 bar (87 PSI=0.6MPa). The regulator will be set to 6 bar at the
factory prior to shipping.

A sleeve valve, shown in figure 1.1 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.

Remove bolt from each side

to open lid.

Figure 1.1 – Air isolation valve Figure 1.2 – Lid securing bolts

In order to check that the control circuit air pressure is set correctly; open the lid
of the control box to access the regulator (with fitted gauge) by removing the two
lid securing bolts. A single bolt is positioned on each side of the control box; this
is illustrated in figure 1.2. The lid is hinged and can then be lifted upwards.

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Locate the control circuit air pressure regulator (see section 5) and ensure that it
is adjusted to 6 bar (0.6 MPa) (ensure the slide valve is in the “ON” position). The
gauge is marked in Mega Pascal’s (MPa), where 1MPa = 10 bar = 145PSI.
Therefore the gauge should read 0.6.

NOTE: Exceeding the upper pressure or use of lubricated air could cause
permanent damage to the controls.

NOTE: When the isolation valve (sleeve valve) is in the off position, it is
possible that residual air pressures may still remain in the system.

Overview of controls

The Innovator control panel is shown in figure 2.1. Controls have been grouped
based upon function, to make the system as user friendly as possible.

Figure 2.1 – Innovator control panel

A brief overview of controls is as follows:

• Emergency Stop – 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.

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• Pump pressure

o Pressure gauge - This is the air pressure being supplied to the pump.
o Regulator – Adjust this to control the air pressure being supplied to

the pump and set the pump speed.

• Flush

o Press this button to operate the flush cycle.

• Start/Stop Controls

o Inject – Press to start the machine in inject mode.
o Recirculate – Press to start the machine in recirculation mode.
o Stop – Press to stop the machine in inject, recirculation or flush modes.

• Mould Pressure Guard

o Preset level gauge – Control signal air pressure being supplied to

Mould Pressure Guard (MPG) control.

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

• Stroke Count – The predetermining counter will count on each pump

stroke when the machine is in injection mode. The user can enter the
desired shot-count so that the machine stops automatically.

• RGA (Resin Gel Alarm) Indicator – If the RGA alarms, to alert the user

to the risk of resin curing in the machine, an audible alarm will sound and
this indicator will change from black to red.

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.

The various controls and operational modes are described in the following sub­sections.

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.

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.

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

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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 mould 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.

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

Mould Pressure Guard (MPG)

The machine features a Mould Pressure Guard (MPG), which is used to control
the maximum allowable pressure at the mixing head. This can be utilized to
provide line pressure control during an injection, or as a safety mechanism to
prevent the line pressure from exceeding the maximum working pressure of the
injection line to the mould.

The MPG block is shown in figure 3.1. The blue air-line supplies air from the
MPG pressure regulator on the control panel. When fluid pressure at the injection
head exceeds the MPG preset level, shown on the MPG pressure gauge, the
internal diaphragm moves and leaks air from the red air line connected to the
control circuit. This causes the machine to slow and stop.

Figure 3.1 – Mould Pressure Guard (MPG) block

NOTE: The MPG control is active on both injection and recirculation modes. It
is correct to hear air leaking from the MPG block when the MPG is operational.

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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 mixing head will return to the recirculate position and the
TAS signal will exhaust.

A visual indicator (see section 4) is provided on the side 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.

Recirculation mode

Prior to and during operation in recirculation mode, use the pump pressure
regulator and gauge to suitably adjust the air pressure supply to the pump and
control the pump speed.

Press the recirculate button to start the machine, the pump will run and resin and
catalyst will be pumped around the system and returned to source.

Recirculation mode can not be entered when the machine is injecting.

To stop the machine, press the stop button.

NOTE: The MPG, PPVS and catalyst over-pressure controls are active
during recirculation.

Injection mode

Before an injection is started, ensure all external connections to the mould etc.
are correctly made. Also ensure that resin and catalyst lines are correctly primed
and that the required levels of materials are available. Ensure the level of fluid in
the flush tank is sufficient to clean the machine after the injection.

NOTE: When the system is initially primed with resin and catalyst, ensure
the machine is run in inject mode and resin is collected in a suitable
container from the mixing head and that air is purged etc. Once this has
been done, ensure the resin is correctly catalyzed by performing cup tests
prior to using the machine to inject a mould.

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Prior to and during operation in injection mode, use the pump pressure regulator
and gauge to suitably adjust the air pressure supply to the pump and control the
pump speed.

Set the MPG set-pressure to the required pressure. Once the injection has
begun, the pump will stop running when the fluid pressure at the injection head
exceeds this setting. When the injection line pressure reduces below the MPG
set-pressure, the machine will continue to inject.

Adjust the predetermining counter to set the number of required pump strokes for
the injection. See figure 3.2 for an overview of the predetermining stroke counter.
To change the preset count, press and hold the white button with arrow decal
while pressing one of the black buttons under the preset count corresponding
with the digit to be modified.

Count reset button

Stroke count

Preset count

Press and hold when
adjusting preset count

Use these black buttons to
adjust preset count

Figure 3.2 – Predetermining counter

NOTE: The machine cannot be started in inject mode, if a previous injection
has stopped automatically when the shot count has been reached and the
stroke count has not been reset. Press the reset button on the predetermining
counter to reset the count and allow the machine to be started.

Press the inject button to start the machine in inject mode. The machine can not be
started in inject mode if it is operating in recirculation or flush modes. The injection
head will open, the TAS signal will pressurize and the pump will run. To stop the
machine and leave inject mode, press the stop button. If the predetermining counter
reaches the user set shot count, the machine will stop automatically.

If a PPVS sensor is being used the pump will stop when the mould pressure reaches
set-point. When the mould pressure drops to an acceptable level, the pump will run
once again.

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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 mould 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-settable preset time is exceeded, an audible alarm will
sound and the visual RGA indicator 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 hidden on the back 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.

Guard Interlocks

If the machine is fitted with a slave arm guard that does not require a tool to open,
the guard will be fitted with an interlock to stop the pump running when it is opened.

In this case, if the guard is open, or not correctly closed, the machine will not
operate in injection or recirculation modes. Opening the guard while the pump is
operating will have the same effect as pressing the stop button.

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Control box user connections:

The rear of the control box, shown in figure 4.1, features the following connections:

• 4 air supplies – These can be used to supply machine options.

• Pump run signal – This signal is pressurized when the pump receives a

run signal. It can be used to control items such as resin heaters.

Figure 4.1 – Rear of control box

Signal connections are also supplied to the side of the control enclosure and are
illustrated in figure 4.2. The connections are as follows:

• Turbo Autosprue (TAS) – Use this to connect a TAS (or similar) valve to the

machine. The pilot signal will become pressurized when inject mode is active.

• PPVS Connector – Connect a pneumatic PV sensor (PPVS) here to

automatically control the system during an injection. The user can also
connect a “hold” or “pause” signal to the machine if required. When this
signal is leaked in injection mode, the machines pump will stop running.
When the signal is blocked, or no connection is made the pump will run.

• Stop – Connect a remote stop signal here. This function works similarly to

the stop button on the control panel and will stop the machine in inject or
recirculation modes when air is applied.

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