Magnum Venus Plastech INNOVATOR PRO 5000 User Manual

MANUAL

MAGNUM VENUS PLASTECH

INNOVATOR PRO 3250 (8002) Rev: 05/2011
INNOVATOR PRO 5000 (8003)

Innovator Pro

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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Table of Contents:

Innovator Pro

Operations Manual

SAFETY WARNINGS

SECTION 1: INTRODUCTION

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: RECIRCULATION GUN ASSEMBLY

SECTION 9: SP4 FLUSH ASSEMBLY

SECTION 10: PARTS DRAWINGS

SECTION 11: 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 no n­stainless 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 powerhead 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 Pro

Introduction

Introduction:

The Pro Innovator 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 Pro Innovator 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.

 Auto Pro Gun Repair Manual – PRTM-DG-3000-A (Injection Gun)
 1:1 Classic Pro Gun Repair Manual – PRTM-RG-1000-AUK (Recirculation gun)

Innovator Pro 3250: (8002)

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

Innovator Pro 5000: (8003)

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

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Unit Overview:

HEAD

PUMP

RECIRCULATION

GUN

INJECTION

GUN

FLUSH
VALVE

STATIC

MIXER

MPG

BLOCK

MIXER

OUTLET

CONTROL

BOX

CATALYST

JUG

POWER

FILTER TANK

RESIN

PRESSURE

RELIEF VALVE

RESIN
PUMP

SLAVE ARM

GUARD

CATALYST

SHELL

GUARD

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CATALYST

FILTER TANK

RECIRCULATION

SIGHT-GLASS

AIR FILTER

(CONNECT MAINS

AIR HERE)

FLUSH

TANK

CATALYST

OVER-PRESSURE

VALVE

ACCUMULATOR

CHARGE

HOSE

RESIN ACCUMULATOR

RELIEF VALVE

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CATALYST ACCUMULATOR

MANIFOLD ASSEMBLY

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SLAVE

DRIVE

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Getting Stated:

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 Catalyst

Manifold.

8. Connect the Relief Valve and Pressure Dump Valve Tubes on the Catalyst

Manifold to the Catalyst Jug. Close the Pressure Dump Valve on the Catalyst
Manifold.

9. Attach Pickup Hoses to the inlet of the pump

10. 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

AIR

each side to open lid.

Innovator Pro

CONTROL BOX INSTRUCTIONS

Connecting the control box 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 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.

ON

OFF

Remove bolt from

Figure 1 – Air Isolation Valve

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 2. The lid is hinged and can then be lifted upwards.

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Figure 2 – Lid Securing Bolts

Innovator Pro Manual

Locate the control circuit air pressure regulator (see figure 10) 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 Pro control panel is shown in figure 3. Controls have been
grouped based upon function, to make the system as user friendly as possible.

• Emergency Stop – Press this button in the event of an emergency to

place the system into a safe state. Twist and pull to release and allow
machine operation.

• 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.

• Prime – Press and hold this button to operate in prime mode.

• 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, recirculate 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 pre-determining counter will count on each pump

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

• Flush Button – Activates the flush cycle through the SP4 flush pump.

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Innovator Pro Manual

• RGA Indicator – Indicates red when the RGA (Resin Gel Alarm) is active,

a whistle will also sound.

Figure 3 – Control Panel

Machine Operation:

Before the system can be used the slide-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 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 or recirculating, the E-Stop is equivalent
to pressing the stop button.

NOTE: Residual pressures may remain in the fluid sections of the system,
even though the E-Stop has been activated.

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Innovator Pro Manual

NOTE: The control circuits will remain pressurized when the E-Stop is
activated. Use the isolation valve on the rear of the control box to shut off
the air supply to the machine if required. After isolation, residual air
pressure may remain in parts of the control circuit.

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

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 (see the
“Control Box Configuration” section).

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.

Flush Timer Adjustment - The flush timer duration can be increased or

decreased by adjusting the flush timer restrictor. This controls the rate of airflow
out of the timer circuit reservoir, and the speed that the pressure falls in order to
actuate the automatic flush stop valve.

To set the timer, simply adjust the restrictor and then time the flush cycle.
Continue this procedure until the desired flush time is obtained. Times of over 60
seconds are achievable with this circuit.

See the “Control Box Configuration” section to identify the location of the flush
timer restrictor in the control box.

NOTE: If the restrictor is fully wound in, air flow will be blocked and the
timer will not operate. This can be used to disable the automatic timer if
required.

Prime – The Prime button is used to activate the pump with out the unit being in

Recirculation or Injection mode – with both the recirculation and injection guns
closed (prime fluid pressure). Prior to and during operation in prime mode, use
the pump pressure regulator and gauge to suitably adjust the air pressure supply
to the pump.

To operate the machine in prime mode, press and hold the prime button. The
pump will run with both the injection and recirculate guns closed.

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Recirculation Mode – Prior to and during operation in recirculate mode, use the
pump pressure regulator and gauge to suitably adjust the air pressure supply to
the pump.

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

To stop the machine, press the stop button.

The operator cannot start the machine in recirculate mode when the machine is
injecting, the stop button must be pressed first.

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 and run
in recirculation mode, the fluid lines leading to the inject gun will not be
primed. 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 catalyzing by performing
cup tests prior to using the machine to inject a mould.

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.

Set the MPG set-pressure to the required pressure. Once the injection has
begun, the pump will stop running and the injection gun will close when the fluid
pressure at the injection head exceeds this pressure. When the injection line
pressure reduces below the MPG set-pressure, the machine will continue to
inject after a pre-configured delay. This delay can be adjusted within the control
box and is also used for PV sensor/remote hold functionality.

Adjust the predetermining counter to set the number of required pump strokes for
the injection. See figure 4 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.

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.

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Press the inject button to start the machine in inject. The machine can not be
started in inject mode if it is operating in recirculation or flush modes. The injection
gun 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.

Count reset button

Stroke count

Preset count

Press and hold when
adjusting the Preset counter

Use these black buttons for
adjusting the Preset counter

Figure 4 – Predetermining Counter

If a PPVS sensor is being used the pump will stop and the inject gun will close
when the mould pressure reaches set-point. When the mould pressure drops to
an acceptable level, the inject gun will open and the pump will run once again
after a user configurable delay. This delay has been included to prevent rapid
cycling of the inject gun and pump (“hunting”) under closed-loop control.

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 5. 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.

NOTE: The MPG control is active only in injection mode and it is correct to
hear air leaking from the MPG block when the MPG is operational.

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Innovator Pro Manual

Figure 5 – Mould Pressure Guard (MPG) Block

MPG Adjustment – The characteristics of the MPG control circuit can be

modified by adjusting the MPG restrictor. This component controls the rate at
which air is supplied to the pump speed control circuit. When the MPG or PPVS
devices leak air, the pressure in the circuit falls and the control circuit stops the
pump and closes the inject gun.

When the circuit is once again sealed, the restrictor controls how quickly the
pressure builds within the circuit and therefore the time delay before the inject
gun opens and the pump restarts.

The lower the flow of air through the restrictor, the longer the pump will take to restart.

See the “Control Box Configuration” section to identify the location of MPG
restrictor in the control box.

NOTE: If this restrictor is fully wound-in, air flow will be blocked and the
pump will not start. Conversely, if too higher flow of air is supplied to the
circuit, safe and correct operation of the machine cannot be guaranteed.

This delay can be further increased if required, by the addition of an air reservoir
to the circuit. Contact MVP for further information.

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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 to 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.

RGA Adjustment – The time between strokes permitted to pass before the RGA
alarms and the volume of the alarm whistle can be adjusted by the user.

The pneumatic RGA is located in the lid of the control box, behind the
predetermining counter. The mechanical timer is shown in figure 6. Turn the knob
to adjust the timer to the required time, between 20 – 300 seconds. The dial
shows seconds divided by 10, therefore to set the timer to 100 seconds, adjust
the dial to 10.

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The RGA alarm whistle volume can be changed by adjusting the flow controller
that is in line with the whistle.

Figure 6 – RGA Mechanical Timer

Guard Interlocks – CE Units only – 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, prime or recirculation modes. Opening the guard while the
pump is operating will have the same effect as pressing the stop button.

Catalyst Over-Pressure protection – The machine features catalyst
overpressure protection. In addition to the industry standard inclusion of a
pressure relief valve in the catalyst circuit, the control circuit will detect the over­pressure condition and stop the pump from running. In injection, prime 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 injection gun will close and the TAS signal will exhaust.

A visual indicator is provided on the side of the control box (see figure 8), 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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Innovator Pro Manual

Control Box User Connections - Rear:

The rear of the control box features the following user connections shown in figure 7:

• 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 in recirculation or injection modes. It can be used to control items
such as resin heaters.

Figure 7 – Rear User Connections

The accumulator charge hose connection is also situated at the rear of the control
box.

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Control Box User Connections - Side:

Signal connections and an indicator are located on the side of the control
enclosure, as illustrated in figure 8. They are as follows:

• Catalyst Overpressure Indicator – When this turns
red, it indicates there is a catalyst over-pressure state.

• 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.

• Signal Connector (PPVS) – 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
machine pump will stop running and the inject gun will
close. When the signal is blocked the machine will
begin to run again after a user configurable delay. DO
NOT SUPPLY AIR TO THIS CONNECTION.

• Remote Stop – Connect a remote stop signal here.
This function works similarly to the stop button on the
control panel.

Figure 8 – Control Box Side

Connections

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Control Box Configuration:

The user can adjust the flush timer duration, the MPG response time and RGA
stroke timer and alarm volume. Use the air circuit for your machine controls to
identify the location of the components that require adjustment. A copy of the air
circuit is supplied with each machine and can be located inside the control box.

Many components in the control box are labeled to aid identification and
therefore locating items that may require adjustment should be relatively straight
forward with the aid of a circuit diagram.

The internals of a typical Pro Innovator control box are shown in figures 9 & 10.

Some components have been marked for illustrative purposes; however it must
be emphasized that the appropriate air circuit should always be used as the
definitive reference.

RGA - Subassembly

PDC – Pre Determined counter

Pump Regulator
Sub-assembly

OR (Shuttle) Valve

Figure 9 – Box Lid Internals

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E-Stop Sub-assembly

Innovator Pro Manual

RGA -Timer

Valve Plate Sub-assembly

AND Valve

Control Circuit Pressure Regulator

Flow Controller (Restrictor)

Air Circuit Drawing

Figure 10 – Box Base Internals

NOTE: ALWAYS ENSURE THAT THE TUBE LOOMS THAT ARE RUN FROM
THE BASE OF THE BOX TO THE LID, ARE NOT KINKED AND THAT THEY
ARE POSITIONED CORRECTLY TO THE SIDES OF THE ENCLOSURE
WHEN THE LID IS CLOSED.

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SECTION

Innovator Pro

OPERATING PROCEDURES

1. Pre-Start Check List for Innovator Pro

2. First Time Start-Up for Innovator Pro

3. Daily Start-Up for Innovator Pro

4. Daily Shut Down for Innovator Pro

The Check Lists are following:

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PRE-START CHECKLIST - INNOVATOR PRO

ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN, AND MUST BE TICKED
OFF AS COMPLETED.

ACTIVITY

Priority

1
2
3
4
5
6
7

8

9

10

11

12

13
14
15
16
17
18

ACTIVITY

Put on Respirator as specified for spray painting,
Protective Clothing, Eye Protection, and PVC Gloves

Have all Tools and materials available for pre-start checks.
Connect the 6mm air line to the to the air supply.
Slide the air valve on the back of the cabinet to OPEN position.
Twist & Pump E-Stop to allow machine operation
Check all catalyst & resin fitting to be sure they are tight
Fill resin pump packing nut 1/3 full with PAT-LS-OIL.
Press the Injection Button and check that the Injection Gun

valve rotates open – press the Stop button.
Using the “T” Bit and handle tighten the both packing nuts on
the Injection Gun block.
Repeat step 7 several times then repeat step 8 – do this three
time to set the packing in the gun block.
Press the Recirculate Button and check that the Recirculation
gun valve has rotated open – press the Stop Button
Using the “T” Bit and handle tighten the both packing nuts on
the Recirculation Gun block.
Repeat step 10 several times then repeat step 11 – do this three
time to set the packing in the recirculation gun block.
Fill the Catalyst Jug at least 1/2 full of catalyst.

Secure the Pick-up wand to the pump inlet
Place the Resin Pick-up wand in the resin supply container.
Place the end of the Resin Return Hose in the resin container.
Fill the Solvent Flush Tank at least 3/4 full.
Place the appropriate container under the Injection Head and

Test the Flush system by pressing the Flush Button.

THE UNIT IS NOW READY TO BE STARTED UP. GO TO – “FIRST TIME START-UP
INNOVATOR PRO”

ABNORMAL CONDITIONS OBSERVED AND CORRECTED

Abnormal Condition

aaaa when

corrected

OPERATORS NAME _____________________________DATE: _____________

TICK WHEN
COMPLETED

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SIGN OFF WHEN PRE-START CHECKS ARE COMPLETED: ____________________________

FIRST TIME START-UP CHECK LIST

INNOVATOR PRO

ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN, AND MUST BE TICKED
OFF AS COMPLETED. THIS SEQUENCE FOLLOWS ON FROM “PRE-START
CHECKLIST INNOVATOR PRO”

ACTIVITY

ACTIVITY

NO.

Priority

1
2
3

4

5

6
7

8
9

10

Put on Respirator as specified for spray painting, Protective
Clothing, Eye Protection, and PVC Gloves

Turn the pump regulator to zero
Adjust the catalyst percentage required with the slide arm Knob.
With all the material containers properly filled. Press the

Recirculation Button on the control panel.
Slowly increase the pump regulator so that the pump strokes
slowly and evenly.
Allow the pump to recirculate until the flow of Resin and Catalyst
back to there respective containers is free of bubbles.
Press the Stop button to take the unit out of recirculation mode

Test the catalyst and resin to the Injection head – Place a
suitable container under the injection head and press the Inject
button. After 4 or 5 strokes press the Stop button.
Check that the material properly cures

Properly dispose of the catalyst and resin.
Flush the Injection head as necessary into the appropriate

container.

ABNORMAL CONDITIONS OBSERVED AND CORRECTED

Abnormal Condition

OPERATORS NAME

________________________________

SIGN OFF WHEN START UP CHECKS ARE COMPLETED:

DATE:

____________

_______________________

TICK WHEN
COMPLETED

aaaa when

corrected

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ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN, AND MUST BE TICKED OFF AS
COMPLETED. THIS SEQUENCE FOLLOWS ON FROM “FIRST TIME START-UP CHECKLIST”

ACTIVITY

NO.

Priority

1
2
3
4

5
6
7
8
9

10

11
12
13

14

15

MAGNUM VENUS PLASTECH

DAILY START-UP
INNOVATOR PRO

ACTIVITY

Put on Respirator as specified for spray painting, Protective Clothing,
Eye Protection, and PVC Gloves

Check all hoses for damage.
Check all material supplies and fill or replace as needed.
Open main air supply slide valve on the back of the control box.
Press the recirculation button and allow the unit to recirculate for at least 20

strokes or until no bubbles are seen returning to the catalyst jug from the
recirculation tube.

Check that the catalyst percentage is set properly
Check resin pump pressure and adjust as necessary.
Check the MPG set pressure and adjust as necessary.
Set the desired number of counts on the Counter Display.
Press the Stop button to take the unit out of recirculation mode.
It is always a good idea to do a gel test each morning and balance the fluid

pressures. So place the appropriate container under the injection head and
press the Inject button and pump 2 or 3 strokes. Then press the Stop
button.
Press the Reset button on the Counter to reset the counter to zero.

Flush the injection head as necessary.
The unit is ready to inject a part – connect the injection hose to the injection

head and press the Inject button. If using a TAS (Turbo Autosprue), PPVS
or other options properly connect the control line to the control box.
When the injection is complete press the Reset button on the counter and
connect to the next part or flush.
Flush the injection head as necessary.

ABNORMAL CONDITIONS OBSERVED AND CORRECTED

Abnormal Condition

OPERATORS NAME

SIGN OFF WHEN START UP CHECKS ARE COMPLETED:

_______________________________

__________________________

36

DATE:

_____________

Innovator Pro Manual

TICK WHEN
COMPLETED

aaaa when
corrected

DAILY SHUT DOWN CHECKLIST

INNOVATOR PRO

ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN, AND MUST BE TICKED
OFF AS COMPLETED. THIS SEQUENCE FOLLOWS ON FROM “DAILY START UP
CHECKLIST”

ACTIVITY

NO.

Priority

1

2
3
4
5

Abnormal Condition

OPERATORS NAME

SIGN OFF WHEN SHUT DOWN CHECKS ARE COMPLETED:

MAGNUM VENUS PLASTECH

ACTIVITY

Put on Respirator as specified for spray painting, Protective
Clothing, Eye Protection, and PVC Gloves

Press the Stop button to Close the injection head, TAS (Turbo
Autosprue) or pinch injection hose to close the mould
Press the Reset button on the Counter to reset the counter.

Flush the injection head and hose or TAS (Turbo Autosprue)
Disconnect the injection hose or TAS from the injection head.
Turn off the main air slide valve at the back of the unit.

ABNORMAL CONDITIONS OBSERVED AND CORRECTED

__________________________________

__________________________

37

DATE:

_______________

Innovator Pro Manual

aaaa when
corrected

TICK WHEN
COMPLETED

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Innovator Pro Manual

SECTION

Innovator Pro

FLUID SECTION MAINTENANCE

Innovator Pro 3250: (8002)

The Innovator Pro uses the Patriot 1-1/4” Fluid Section Assembly (PAT-LS­12270-P) – for detailed instructions for Repair & Maintenance of this fluid section
please reference the manual “Patriot 1-1/4” Fluid Section Manual – PAT-LS-

12270”.

Innovator Pro 5000: (8003)

The Innovator Pro uses the Patriot 1-3/4” Fluid Section Assembly (PAT-LS­24050-P) – for detailed instructions for Repair & Maintenance of this fluid section
please reference the manual “Patriot 1-3/4” Fluid Section Manual – PAT-LS-

24050”.

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SECTION

Innovator Pro

CATALYST PUMP MAINTENANCE

Innovator Pro 3250: (8002)

The Innovator Pro uses the Patriot Catalyst Pump Assembly (PAT-CP-0550) –
for detailed instructions for Repair & Maintenance of this Catalyst Pump please
reference the manual “Patriot Catalyst Pump Manual PAT-CP-0550”.

SLIDE DRIVE STICKERS:

2%2.5% 1.5% 1%

FLIUD SECTION PAT-LS-12270 and PAT-CP-0550

.75%

PAT-RS-1227-055

Innovator Pro 5000: (8003)

The Innovator Pro uses the Patriot Catalyst Pump Assembly (PAT-CP-0980) –
for detailed instructions for Repair & Maintenance of this Catalyst Pump please
reference the manual “Patriot Catalyst Pump Manual PAT-CP-0980”.

SLIDE DRIVE STICKERS:

FLIUD SECTION PAT-LS-24050 and PAT-CP-0980

2%2.25% 1.5% 1%

.75%

PAT-RS-2405-098

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Innovator Pro Manual

SECTION

Innovator Pro

POWERHEAD MAINTENANCE

Innovator Pro 3250: (8002)

The Innovator Pro uses the Patriot 3-1/4” Powerhead Assembly (PAT-PH-3250) –
for detailed instructions for Repair & Maintenance of this fluid section please
reference the manual “Patriot Powerhead Manual PAT-PH-3250”.

Innovator Pro 5000: (8003)

The Innovator Pro uses the Patriot 5” Powerhead Assembly (PAT-PH-5000) – for
detailed instructions for Repair & Maintenance of this fluid section please reference
the manual “Patriot Powerhead Manual PAT-PH-5000”.

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SECTION

Innovator Pro

INJECTION GUN & MIXER ASSEMLBY

The Innovator Pro uses the Classic Auto Pro Gun Assembly (PRTM-DG-3000-A) –
for detailed instructions for Repair & Maintenance of the Auto Pro Gun please
reference the manual “Auto Pro Gun Repair Manual”.

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SECTION

Innovator Pro

RECIRCULATION GUN ASSEMBLY

The Innovator Pro uses the 1:1 Classic Auto Pro Gun Assembly (PRTM-RG-1000­AUK) – for detailed instructions for Repair & Maintenance of the Auto Pro Gun
please reference the manual “1:1 Classic Pro Gun Repair Manual”.

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SECTION

Yellow outlet tube

conn

ects

I

nlet air tube loops up and

Innovator Pro

SP4 SOLVENT ASSEMBLY

SP4 Solvent Pump Assembly – The SP4 performs a 200cc solvent purge
followed by an air purge to thoroughly clean and purge the injection head and
mixer. It is contained in a 3 gallon Stainless Steel flush tank. During the flush
cycle only the SP4 solvent pump will be pressurized to force out the solvent
contained inside and then purges with air for the reminder of the flush cycle.

The SP4 is activated by pressing the Flush button on the control panel and will
operate for 30 to 60 seconds. The duration of the flush / purge cycle can be
adjusted as previously noted in the Section 2 – Control Box configuration.

Connecting the SP4 – Connect the yellow outlet tube from the outlet side of the
solvent pump through the outlet fitting to the flush neck on the flush valve of the
injection gun.

Connect the red 4mm tube to the fitting on the inlet side of the quick exhaust.
Connect the 1/4" pump inlet air tube to the other side of the inlet quick exhaust.

down through the inlet fitting
and connects to the inlet of

the solvent pump

1/4” Pump inlet air tube

from injection gun flush

valve to the outlet of the

SP4 solvent pump.

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Red 4mm flush signal line

Flush Tank

Innovator Pro Manual

On the inside of the flush tank the there are two (2) connections to the flush pump.

• The pump inlet air tube connects to the inlet side of the SP4 solvent pump
through the inlet fitting.

• The Yellow flush tube from the injection gun / mix head extends down
through the outlet side fitting and connects to the outlet of the solvent pump.

Note: it is important that the solvent level in the tank be at no less then 1/3
full or so that there is 25mm (1”) of solvent above the SP4 solvent pump.
This will allow the SP4 solvent pump to properly refill with solvent after
each use.

Maintenance – The SP4 Solvent Pump is basically maintenance free however it

might be necessary to replace the O-ring (0464) on the Pump Foot Valve (4481).

It is important to keep the inside of the flush tank clean and free of dirt, debris
and glass fiber as these can prevent the Pump Foot valve from sealing properly.

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PARTS DRAWINGS

1: Patriot Fluid Section Parts Drawings:

PAT-LS-12270-P INNOVATOR PRO FLUID SECTION
PAT-SD-3100 PATRIOT SLAVE DRIVE ASSEMBLY
PAT-LS-12270-R-SK FLUID SECTIOIN – SEAL KIT

2: Patriot Catalyst Pump – PAT-CP-0550 Drawings:

PAT-CP-0550 CATALYST PUMP ASSEMBLY
PAT-CP-0550-SK SEAL KIT - CATALYST PUMP ASSEMBLY

3: Patriot 3-1/4” Powerhead Parts Drawings:

PAT-PH-3250 3-1/4” PATRIOT POWERHEAD ASSEMBLY
PAT-PH-3250-SK SEAL KIT – 3-1/4” PATRIOT POWERHEAD
PAT-PH-5000 5” PATRIOT POWERHEAD ASSEMBLY
PAT-PH-5000-SK SEAL KIT – 5” PATRIOT POWERHEAD

4: SP4 Solvent Pump Parts Drawings:

82006-01 SP4 FLUSH TANK OUTLET ASSEMBLY
82004-01 SP4 PUMP ASSEMBLY
82005-01 SP4 FLUSH TANK INLET ASSEMBLY
82007-01 SP4 FLUSH TANK ASSEMBLY

83001-01 PRO INNOVATOR AIR CIRCUIT

4: Injection Head Parts Drawings:

82009-01 MPG VALVE ASSEMBLY
PRTM-DG-3000-A DISPENSE GUN ASSEMBLY

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PAT-LS-12270-R-SK PATRIOT SEAL KIT - RTM

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REVISION INFORMATION:

Revision: Description:

REV: 05/2010

REV: 08/2010

REV: 09/2010 Updated - Control Box Instructions, SP4

REV: 02/2011 Updated – Air Circuit drawing and other drawings.

Rev: 05/2011 Updated the manual to include the both version of

Document was created

Updated document – added SP4 Information and
drawings, Control box information

information and Injection Gun.

The MPG Valve drawing was added to the drawing
section. The Recirculation gun reference was
changed to PRTM-RG-1000-A. Added the 15:1 Ratio

- Powerhead option.

the Innovator Pro units (Innovator Pro 3250 (8002)
& Innovator Pro 5000 (8003)). The manual now
includes the PAT-LS-24050 fluid section and PAT­CP-0980 catalyst pump. Added the procedures to
set the Gun Packing in the Pre-Start Checklist.

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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]

www.mvpind.com

Included with this operations manual are the following component manuals:

 AUTO PRO GUN REPAIR MANUAL
 1:1 CLASSIC PRO GUN MANUAL

Innovator Pro 3250: (8002)

 PATRIOT POWERHEAD MANUAL PAT-PH-3250
 PATRIOT 1-1/4” FLUID SECTION MANUAL – PAT-LS-12270
 PATRIOT CATALYST PUMP MANUAL PAT-CP-0550

Innovator Pro 5000: (8003)

 PATRIOT POWERHEAD MANUAL PAT-PH-5000
 PATRIOT 1-3/4” FLUID SECTION MANUAL – PAT-LS-24050
 PATRIOT CATALYST PUMP MANUAL PAT-CP-0980

REV: 05/2011

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