Magnum Venus Plastech MicroPro User Manual

MicroPro Operations Manual

Rev. 09/2012

MicroPro Operations Manual

CORPORATE HEADQUARTERS and MANUFACTURING

11692 56th Court * Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER and 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

Rev. 09/2012 Page | 2

Table of Contents

MicroPro Operations Manual

SECTION:

TERMS & CONDITIONS OF SALE

SAFETY & WARNINGS

INTRODUCTION

UNIT SETUP

SETTING PUMP RATIO

Page

4

6

15

19

21

DAILY START-UP & SHUT-DOWN 23

POWERHEAD MANUAL REFERENCE 25

METERING PUMP MANUAL REFERENCE 26

DISPENSE GUN MANUAL REFERENCE 27

PARTS DRAWINGS 28

SLAVE ARM STICKER 51

REVISION INFORMATION 52

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Terms & Conditions of Sale:

• Customs duties, import and export licenses and certificates, if required, and all
local taxes are excluded from this offer. If US state and local taxes are applicable
and not included in equipment invoice, such amount may be invoiced later.

• Delivery dates or shipping schedules are approximate and based upon the most
recent information available at the time of order. Dates may be adjusted upon
receipt of subsequent information or modification of order. Seller will ship prior to
the delivery date if possible, but not without Buyer’s consent on Advanced
Equipment sales.

• All contract dates and timelines begin upon receipt at MVP of customer purchase
order, signed Terms and Conditions of Sale (if applicable), and down payment per
quotation (if applicable).

• If shipments are delayed by the Buyer, or because the Buyer’s account is in
arrears, payments shall become due on the date when the Seller is prepared to
make shipment. Products held by the Seller for the Buyer shall be at the risk and
expense of the Buyer.

• Damages, defects or shortages must be communicated immediately to MVP.
Discrepancy in pricing and/or quantities on invoices must be reported within 30
days of the invoice date. Claims made 30 days or more following the invoice date
will not be honored.

• Permission to return items must be requested and granted in advance. No credit
will be given if items are returned prior to requesting and receiving permission. All
returns are subject to a restocking fee. The standard 15% charges may be
increased or decreased depending on the reason for the return. Special ordered
items may not be returned.

• Seller warrants that the mechanical operation of the goods as specified shall be
free from faults in respect to materials and workmanship for a period of 12 months
for parts from the date of invoice. For systems, 12 months from start-up or, if
earlier, 18 months from the date of the Bills of Lading. The warranty does not cover
general wear and tear or damage due to negligence or improper use. Seller’s
liability under the warranty shall be limited solely to repair or replacement costs,
and has no responsibility for reimbursing repair cost incurred by Buyer in
connection with equipment without first giving written authorization for such
charges. Seller makes no express warranties except those set forth in this
agreement, and disclaims all other warranties, expressed or implied, including
without limitation, implied warranties of non-infringement merchantability and
fitness for a particular purpose. Seller accepts no liability for loss of production,
loss of profits, or other direct or indirect damages. In any claim by the Buyer

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against the Seller in respect of the goods, the liability of the Seller shall be limited
to the value of the goods.

• Many factors beyond Seller’s control contribute to the success of Buyer’s finished
products, such as raw materials used to manufacture the product. Equipment is
warranted to perform to specifications detailed in quotation, but Seller is not liable
for quality or quantity of finished products produced by Buyer.

• The country of origin is the United States of America. Sale, installation and all
rights of the parties are governed by the laws of the state of Florida. Venue with
regard to any litigation shall be in Pinellas County, Florida. The parties agree to
waive all rights to trial by jury as to any and all disputes.

• The goods remain the property of the Seller until full payment is received.

• Sale of equipment is subject to application and issuance of proper US Government

export license and regulations, if applicable.

• Installation of equipment is responsibility of Buyer and Seller, with cost
responsibility and number of days provided as detailed in original customer
Quotation. Seller will provide installation supervision personnel within 30 days of
customer request. If installation is delayed by the Buyer more than six months
from the date of shipment, or if customer facility or material/parts are not prepared
for installation, seller will invoice full installation costs, up to $1,250 a day plus
expenses, for each MVP installation technician on site. Seller has the option to
waive this fee at its discretion.

• Parties shall be excused for delays caused by embargoes, acts of civil or military
authorities, Acts of God, or other circumstances beyond the reasonable control of
the parties. Notification of such delays must be made in writing within ten days of
occurrence.

• Our agreement supersedes any previous agreement and applies in full.

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SAFETY & WARNING INFORMATION:

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 your equipment
at all times for your personnel safety. In addition to the manual, Magnum Venus Plastech
recommends that the user consult the regulations established under the Occupational Safety &
Health Act (OSHA), particularly the following sections:

1910.94 Pertaining to Ventilation.

1910.106 Pertaining to flammable liquids

1910.107 Pertaining to spray finishing operations, particularly Paragraph (m) Organic Peroxides
and Dual Component Coatings.

Other standards and recognized authorities to consult are the National Fire Protection
Association (NFPA) bulletins as follows:

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

Researchers have reported measuring pressure rates-of-rise well in excess of 100,000 psi per
second when certain MEKP’s reach their SADT. (For comparison, the highest pressure rate-of­rise listed in NFPA Bulletin NO.68, “Explosion Venting”, is 12,000 psi per second for an
explosion of 12% acetylene and air. The maximum value listed for a hydrogen explosion is
10,000 psi per second. Some forms of MEKP, if allowed to reach their SADT, will burst even an
open topped container. This suggests that it is not possible to design a relief valve to vent this
order of magnitude of pressure rate-of-rise. The user should be aware that any closed
container, be it a pressure vessel, surge chamber, or pressure accumulator, could explode
under certain conditions. There is no engineering substitute for care by the user in handling
organic peroxide catalysts. If, at any time, the pressure relieve valve on top of the catalyst tank
should vent, the area should be evacuated at once and the fire department called. The venting
could be the first indication of a heat, and therefore, pressure build-up that could eventually lead
to an explosion. Moreover, if a catalyst tank is sufficiently full when the pressure relief valve
vents, some catalyst may spray out, which could cause eye injury. For this reason, and many
others, anyone whose job puts them in an area where this vented spray might go, should
always wear full eye protection even when laminating operations are not taking place.

Safety in handling MEKP depends to a great extent on employee education, proper safety
instructions and safe use of the chemicals and equipment. Workers should be thoroughly
informed of the hazards that may result from improper handling of MEKP, especially in regards
to contamination, heat, friction and impact. They should be thoroughly instructed regarding the
proper action to be taken in the storage, use and disposal of MEKP and other hazardous
materials used in the laminating operation. In addition, users should make every effort to:

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 non-stainless
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. Firefighting 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.). The explosion could cause serious injury, death and/or substantial property
damage. Cleaning agents, coatings, paints, etc. may contain Halogenated Hydrocarbon
Solvents. Some Magnum Venus Plastech spray equipment includes aluminum or
galvanized components and will be affected by Halogenated Hydrocarbon Solvents.

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

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,
contact your catalyst supplier and follow his instructions explicitly. Preferable, the supplier
should premix the catalyst to prevent possible “on the job” contamination while mixing.

WARNING

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

2.5 Cured Laminate, Overspray and Laminate Sandings Accumulation

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, over­sprayed 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 consult 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 your skin and eyes and as if
they are poison to your body. For this reason, Magnum Venus Plastech recommends the use of
protective clothing and eye wear in using polyester systems. However, users should be
prepared in the event of such an injury. Precautions include:

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 suggests that personal safety equipment such as EYE
GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be worn when servicing or
operating this equipment. Ear protection should be worn when operating a fiberglass
chopper to protect against hearing loss since noise levels can be as high as 116 dB
(decibels). This equipment should only be operated or serviced by technically trained
personnel!

WARNING

Never place fingers, hands, or any body part near or directly in front of the spray gun
fluid tip. The force of the liquid as it exits the spray tip can cause serious injury by
shooting liquid through the skin. NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR
POINT THE GUN AT OR NEAR ANOTHER PERSON. (TREAT THE GUN AS IF IT WERE A
LOADED PISTOL.)

3.1 Emergency Stop Procedures

The following steps should be followed in order to stop the machinery in an emergency situation

1. The ball valve located where the air enters the power head of the resin pump, should be
moved to the “OFF” or closed position. To do this, simply rotate the lever on the ball valve
90 degrees. Doing this will cause all the system air to bleed out of the system in a matter of
a few seconds, making the system incapable of operating

NOTE: Step 2 is a precautionary step and should be followed whenever the above
mentioned ball valve is activated to the stop mode. Failure to do so, can damage the
regulators and components on reactivating to the “ON” position.

2. Turn all system regulators to the “OFF” position (counter-clockwise) position

NOTE: Verify that the Catalyst relief line, located on the catalyst manifold, and the resin
return line, located on the resin filter, are secured relieving catalyst and resin fluid
pressure.

3. Catalyst pressure in the catalyst pump can be eliminated by rotating the ball valve on the
catalyst manifold 90 degrees to the “open” or “on” position.

Note: The “open” or “on” position is when the ball valve handle is parallel (in line) with
the ball valve body. The “closed” or “off” position is when the ball valve handle is
perpendicular (across) the ball valve body.

4. Resin pressure in the resin pump can be eliminated by rotating the ball valve on the resin
filter 90 degrees to the “open” or “on” position. Place a container under the ball valve to
catch any resin that is ejected out of the valve.

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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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Introduction:

The MicroPro proportioner uses an air driven Powerhead to drive the metering system,
which delivers a consistent mix / meter at low flow rates. The system can be configured
in ratios from 1:1 to 3.7:1, 1.84:1 to 5.85:1 and 4.15:1 to 13:1 using a combination of
metering pumps.

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 MicroPro proportioner consists of a combination of two of the following metering
pumps and other components:

 1:1 Classic Pro Gun Repair Manual

 MPR-PH-3250 3.25” Powerhead Assembly – MicroPro 10:1

or

 MPR-PH-5000 5” Powerhead Assembly – MicroPro

 VHPC-1200 Metering Pump

Depending on unit configuration on of the following:

 VHPC-2200 Metering Pump
 VHPC-3200 Metering Pump
 VHPC-4200 Metering Pump

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Below is a Ratio Chart showing the possible ratios with the different metering pumps:

Material Ratio Range

Powerhead Fixed Fluid Section Var. Fluid Section Power Ratio Output

High Low

MP-5-12-12

VHPC-1200 VHPC-1200 19:1 1:1 4.6:1 .53-.87 GPM

MP-5-12-22

MP-5-12-32

MP-5-12-42

MP-5-22-22

MP-5-22-32

MP-4.25-22-42

MP-4.25-32-32

MP-3.25-32-42

MP-3.25-42-42

VHPC-1200 VHPC-2200 21:1 1.3:1 5.8:1 .51-.78 GPM

VHPC-1200 VHPC-3200 26:1 2.2:1 10.4:1 .48-.63 GPM

VHPC-1200 VHPC-4200 32:1 5:1 21.5:1 .46- .52 GPM

VHPC-2200 VHPC-2200 21:1 1:1 4.6:1 .42-.69 GPM

VHPC-2200 VHPC-3200 31:1 1.8:1 8.25:1 .39-.54 GPM

VHPC-2200 VHPC-4200 27:1 4:1 18.6:1 .36- .43 GPM

VHPC-3200 VHPC-3200 31:1 1:1 4.6:1 .23-.38 GPM

VHPC-3200 VHPC-4200 25:1 2.2:1 10.4:1 .21-.28 GPM

VHPC-4200 VHPC-4200 40:1 1:1 4.6:1 .10-.17 GPM

Output Min. - Max. in GPM (gallons per minute)

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MicroPro Operations Manual

Air Manifold Controls:

Familiarize yourself with the Air Manifold controls, which consist of the following
regulators and gauges:



MAIN AIR INLET VALVE – this is where the air supply to the unit is connected.
The valve turns On / Off the air supply to the unit.



PUMP PRESSURE GAUGE & REGULATOR – this is the regulator used to
control the air pressure for the Powerhead.



AIR PURGE GAUGE & REGUALTOR – this gauge & regulator are used to set the
pressure used to air purge the gun, mix chamber and mixer.



SOLVENT TANK GAUGE & REGULATOR – this gauge & regulator are used to
set the solvent flush pressure.



PRIMING BUTTON – the priming button is used to operate the pump without the
gun being open. The priming button sends an air signal to the safety over ride
valve to operate the air motor and pump while the gun remains closed.

Rev. 09/2012 Page | 17

Fluid Pressure – Material Manifolds:



FLUID PRESSURE GAUGE – This displays the fluid pressure for each of the two
components. These are located at the material manifold for each material.



MATERIAL PRESSURE RELIEF VALVE – the valve is used to relieve the
material fluid pressure back to the source container.



SAFETY RELIEF VALVE – the safety relief valve will automatically open to
prevent excessive fluid pressure. The safety relief valve is set to open at a preset
pressure and returns the material to the source container.

Material Manifold:

MicroPro Operations Manual

Material Accumulator

Fluid Pressure Gauge

Safety Relief Valve

Material Pressure Relief Valve

Rev. 09/2012 Page | 18

MicroPro Operations Manual

Unit Setup:

WARNING

Please observe all warnings before performing any maintenance

Follow the pressure relief procedures in this manual.

Use proper safety gear, gloves and safety glasses.

Clean all tools to be used for repair of grease or other material that can react with the

material being pumped.

1. Turn all the regulators to zero (all the way counter clock wise) before connecting
the main air supply and make sure the main air inlet valve is closed.

2. Connect air supply to system which requires 90 - 100 psi supply (6-7bar) 5 CFM
of clean dry air. Open the main air inlet valve in one fast stroke.

Note: the main air supply inlet valve is a safety ball valve and must be all the way
closed or all the way open. When the ball valve is closed the air pressure
remaining in the air manifold and air system will be released.

3. Check for air leaks and repair as necessary.

4. Fill solvent container (no more then 2/3 full) with desired solvent, non-flammable
solvents are recommended. Pressurize container from 40 to 60 psi (3-4 bar)
with air regulator located on the flush tank. Check for solvent leaks and repair as
needed.

5. The Air Purge regulator should also be set at 40 to 60 psi (3-4 bar). This
regulator sets the air pressure used to air purge the gun and mixer.

6. Located on the hose set by the gun is a 3-way ball valve. Rotate the ball valve
handle to the flush position which is the direction pointing to the yellow tubing.
Test solvent flush by pushing flush buttons located on either side of the gun
block. Rotate the ball valve handle to the direction of the clear tubing; push the
flush buttons to air purge the mixer housing. Always rotate the ball valve handle
to the neutral position (center) when flushing/air purge is complete.

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MicroPro Operations Manual

Priming Metering Pumps:

1. Install ratio block onto gun head to keep the A&B materials separate for priming.
This will allow for no material waste for priming and ratio checks.

2. Set both pumps for longest pump stroke for priming. If either tank or pump
completely runs out of A or B materials, never re-prime fluid section with static
mixer attached. This could result in material cross over inside the gun.

3. Using the throat seal oil (TLS-ISO) provided with the system, pour oil into the
packing nut reservoirs, (see drawing VHPC-2200, item 3, part number VHPC­2207 packing nut) ¾ full of TSL-ISO oil (TLS-ISO-800). This will protect materials
from drying on the piston rod which affects the life of the piston rod packings.

4. Fill both A & B containers with materials. Always keep the ISO tank lid on the
tank and slightly snug tighten to avoid moisture contamination and or crystals
from forming. Crystallized ISO will plug the fluid filter and will affect metering of
the system.

5. Be sure the pump pressure regulator is set to zero.

6. Have two clean containers available to catch the materials as they are dispensed
from the ratio block. Position the gun so that the ratio block separates the two
materials into the containers to prevent cross contamination.

7. With ratio block attached to gun head, pull the trigger on the gun and adjust the
pump pressure (clock wise) to begin cycling the pumping system. Once a steady
flow of both A & B materials, note if any fluid pressures for both materials. Very
little fluid pressure is required for ratio checks but the fluid gauge needle should
come off its stop even if an exact reading is not obtainable.

8. When using the ratio block, the two materials have not come into contact and no
solvent flush should be required at this time.

9. A ratio check or a gel test can be performed at this time

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MicroPro Operations Manual

Setting Pump Ratio:

The resin pump (part A) (Poly) normally is fixed at the longest pump stroke length and is
not used for adjusting the ratio changes.

The hardener pump (part B) (ISO) is used to set the proper ratio by loosening the cap
screw (F-CS-05C-08 Socket cap screw) and sliding the Upper & Lower Slide Clevis (top
and bottom of the metering pump) in the slotted track to the desired setting, the
retighten cap screw. The indicator stickers on the top and bottom of the slotted track
are used for a reference indicator when setting ratios.

During the priming of the fluid sections if both fluids read pressure, proceed with setting
ratios. If one of the fluid sections shows no pressure because of a very low viscosity
material, a restriction is needed to create fluid pressure. By adding a smaller diameter
hose onto the ratio block to restrict the flow is normally all that is needed to increase the
fluid pressure.

To set the ratio, an accurate scale or volumetric beakers are needed.

1. Pull the trigger on the gun, allowing for the A&B materials to begin to flow out of
the ratio block. Slide two pre-weighed containers under the resin streams. Allow
no less then 10 pump reversals before removing the containers. Release the
trigger on the gun. Subtract container weights to find ratio. Some material
manufactures may only give a volumetric ratio rather then weight. If this is the
case and setting the ratio by weight measurement is preferred then the Specific
Gravity of each material is needed to convert weight to volume in cc’s.

Example:

The Poly resin (A) weight is 500 grams and has a Specific gravity of 1.09 which
requires dividing the sample weight by Specific gravity (500/1.09=458.71 cc’s).
Repeat using the Specific gravity and dividing by ISO hardener (B) to weight to
convert to cc’s.

2. To adjust the ratio, loosen the cap screw to adjust the pump stroke length on the
ISO hardener (B) fluid section (shorter – lower slave arm number).

3. Tighten cap screw before checking ratio again. Make notes of each setting that
the ratios were taken from on the indicator sticker until desired ratio is set.

Once the material ratio has been set flush the ratio block by pushing in the flush valves
and selecting between solvent/air purge with 3-way ball valve.

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MicroPro Operations Manual

NOTE: It is recommended to make notes of all settings during ratio checks
including pump pressures and material temperatures. At the start of each work
week, a ratio check should be performed. This is even more important when
using fillers mixed into the Poly resin to assure filler settling has not taken place
in the Poly resin filter and or pump.

Dispensing Material:

4. Install mix chamber, spring and ball checks. It is sometimes easier to install mix
block first then remove the plugs on the of the front mix block to install the ball
and springs (see drawing CPD-6100 if needed). Attach the static mixer to mix
chamber.

5. Pull the trigger on the Gun; dispense material into a waste bucket. Make note of
the fluid pressures for both A & B materials then release the trigger on the gun
and flush the gun and mixer out. The fluid pressures do not have to match but it
is preferred that there is not a huge difference - 300 psi on the resin (A) and 150
psi on the hardener (B) would be acceptable in most cases. In some cases, the
pump may run so slow that it is difficult to read an exact pressure. As long as
both pressure gauge needles come off of their stops is all that is needed for
proper ball seating when gravity feeding.

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MicroPro Operations Manual

Start-Up & Shut-Down:

DAILY SHUT-DOWN:

1. For shut-down, the fluid pump shafts should be in the bottom of the stroke to
avoid any material from drying on the shafts. Not following this procedure will
have a great effect on piston rod seal life. Release the trigger on the gun to
Stop the pump just before the pumps reach the bottom reversal.

2. Flush both A & B side of the mix chamber into a waste container and air purge dry.

3. Remove mixer from mix housing. Inspect the static mixer that it has been
completely cleaned of metered materials.

4. Remove Mix housing, spring and balls and inspect for any set-up materials.
Depending on the resin systems used it may not be necessary to remove mix
housing for shut-down every day however the static mixer should always be
removed for daily shut-down.

5. Turn off the Main Air Inlet valve

6. Remove the flush tank pressure by lifting the relief valve ring.

7. Open the fluid Pressure Relief valves on the material manifolds to release fluid
pressure and then close.

DAILY START-UP:

1. Inspect material levels to begin production - resin, hardener and solvent.

2. Close the relief valve on top of the solvent tank.

3. Open the Main Air Inlet supply to system.

4. Install mix housing, spring and balls into mix housing.

5. Set the desired pump ratio and check as necessary.

6. Press the Priming button while adjusting the pump air pressure control to the
desired setting. Pull the trigger on the gun and allow several pump strokes into a
waste container.

7. Install mixer and prepare moulds / work area for operation.

8. The unit is ready to operate – it is important to perform a periodic ratio check and
material gel test this can done at this time.

Rev. 09/2012 Page | 23

MAINTENANCE:

1. The water trap should be inspected daily, drain water from trap as needed.

2. Inspect pump piston shafts from material build-up and clean as needed.

3. Inline filters should be checked weekly and cleaned as needed

4. Replace the return and relief valve tubing on the material manifold as needed to
prevent blockage.

SOLVENT FLUSHING FOR LONG TERM SHUT-DOWN:

1. Depending how much material is in the tanks and if you want to save it. Place a
container for each material under each port of the ratio block of the gun.

2. Pull the trigger on the gun and adjust the pump pressure control so the pumps
are moving slowly and evenly.

3. When the majority of the material is out of both tanks and air is spiting from the
ports of the ratio block release the trigger on the gun.

4. Remove lids from feed containers; pour 1 to 2 liters of solvent into containers.
Clean container walls using a brush.

5. Place the gun over a waste container and pull the trigger on the gun. Then adjust
the pump pressure to purge the dirty solvent into a waste container through the
front of the gun.

6. Repeat steps #4 - 5 with clean solvent in each of the two containers until it
comes out of the gun clean, then run pump until solvent flow has stopped.
When the fluid sections are at the bottom of the stroke release the trigger on the
gun.

7. Inspect throat seal oil at the top of the pump, clean and add as needed.

8. Replace the return and relief valve tubing on the material manifold as needed to
prevent blockage.

MicroPro Operations Manual

Rev. 09/2012 Page | 24

MicroPro Operations Manual

Powerhead Manual:

Depending on the pump ratios the MicroPro will have either the 3.25” Powerhead (MPR­PH-3250) or 5” Powerhead (MPR-PH-5000) installed.

For detailed repair instructions for the 5” Powerhead see the manual “MPH_UPPH_VPH
– 5000 Series Manual”

For detailed repair instructions for the 3.25” Powerhead see the manual “MPH_VPH –
3250 Series Manual”

Rev. 09/2012 Page | 25

MicroPro Operations Manual

Metering Pump Manual:

Depending on the metering pump combination installed on this unit you will see the
following:

• See Manual “VHPC-1200 Metering Pump Manual”

Plus possibly one of the following:

• See Manual “VHPC-2200 Metering Pump Manual”

• See Manual “VHPC-3200 Metering Pump Manual”

• See Manual “VHPC-4200 Metering Pump Manual”

Rev. 09/2012 Page | 26

MicroPro Operations Manual

Dispense Gun Manual:

The MicroPro comes standard with the 1:1 Classic Pro gun for the Dispense Gun. For a
detailed description of the repair procedures please see the following manual

• See Manual “1:1 Classic Pro Gun Manual”

Rev. 09/2012 Page | 27

MicroPro Operations Manual

Parts Drawings:

Drawing Number Description

MPR-MDA-3250 3.25” PUMP AND DRIVE ASSEMBLY
MPR-MDA-5000 5” PUMP AND DRIVE ASSEMBLY
MPR-PH-3250 3.25” POWERHEAD ASSEMBLY
MPR-PH-5000 5” POWERHEAD ASSEMBLY
CPD-6100 PRO GUN BLOCK – DUO 1:1
CPD-6000 PRO GUN ASSEMBLY – DUO 1:1
MPR-PD-4000 DRIVE LINKAGE ASSEMBLY
MLM-BF-1000 BASE FRAME ASSEMBLY
MLM-BRKT-MM-200 MANIFOLD BRACKET
MLM-MM-1 MATERIAL MANIFOLD RIGHT
MLM-MM-2 MATERIAL MANIFOLD LEFT

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16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

REFERENCE
ONLY
25263-101

Slave Arm Stickers:

Rev. 09/2012 Page | 51

MicroPro Operations Manual

Revision Information:

Revision Description

Rev: 08/2010 Document was created

Rev: 09/2012 Updated the manual format and Address. Added

the Terms & Conditions of Sale section to the
manual. Included the VHPC-1200 metering pump
option and ratio chart into this manual. Updated the
drawings.

Rev. 09/2012 Page | 52

MicroPro Operations Manual

MAGNUM VENUS PLASTECH

CORPORATE HEADQUARTERS and MANUFACTURING

11692 56th Court * Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER and 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:

 1:1 CLASSIC PRO GUN REPAIR MANUAL

 MPH_UPPH_VPH – 5000 SERIES MANUAL

or

 MPH_VPH – 3250 SERIES MANUAL

 VHPC-1200 METERING PUMP MANUAL

and possibly one of the following

 VHPC-2200 METERING PUMP MANUAL
 VHPC-3200 METERING PUMP MANUAL
 VHPC-4200 METERING PUMP MANUAL

Rev. 09/2012 Page | 53