Magnum Venus Plastech MKIV Revision 1-2 User Manual

Megaject MKIV

Manufacturing Technology Centre,

Chilsworthy Beam,

Gunnislake,Cornwall,PL18 9AT, UK

Tel: [phone] Fax: [phone]

e-mail: [e-mail]

http://www.plastech.co.uk

Instruction Manual

Revision 1_2

Machine Serial Number: KO30141

Megaject MK IV Issue 1_2 25/11/2003 Page 1 of 31

Contents

1. Megaject MK IV Overview

Introduction
Injection Head
Machine Front Guard
Catalyst System
Solvent Tank

2. Operating Controls

3. Commissioning and Set-up Procedures

4. Filling/Refilling Solvent Tank

5. Setting Catalyst Percentage

6. Recirculating & Repriming

Recirculating
Repriming

7. Injecting & Flushing

Before Injection
Injection
Flushing

8. Optimising Output

9. Shutdown Instructions

10. Maintenance

Maintenance Schedule
Replacing Resin Pump Seals
Replacing Catalyst Pump Seals
Servicing Injection Head
Mixer Tubes
Resin & Catalyst Pipework
Catalyst Overpressure Valve
Machine Air Circuit
Solvent Pump

11. Appendices

Mould Pressure Guard
CATAL catalyst monitoring system
Resin Heaters

Revision History

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Catalyst Bottle
(behind)

Control
Cabinet

Pick up pipe

Injection
Head

Main Air
Cylinder

Catalyst Pump
Solvent Tank

Front
Guard

Catalyst Over­pressure valve

Megaject Mk IV Overview

Introduction

This manual covers the operating and maintenance instructions of your particular model and
also includes details of options which may not be present on your machine. This will be
indicated at the relevant points.

This chapter shows the main machine components.

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Injection Head

1. Resin recirculation valve. Swaps the resin stream between the injection and

the recirculation position. (90° movement)

2. Catalyst recirculation valve. Swaps the catalyst stream between the injection

and recirculation positions. (180° movement)

Note: Recirculation valves must be turned to their full extent for correct
operation i.e. 90° for resin and 180° for catalyst

3. Thumb Start Switch. Used to start machine for injection. Will only operate

when recirculation valves are in the injection position.

4. Autosprue Connector (for use with Autosprue option only)

5. Resin and Catalyst Interlock Switches. Check that both resin and catalyst

recirculation valves are in the inject position.

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Machine Front Guard

1. Pump Front Guard. The linkage between the resin pump, catalyst pump and

the catalyst ratio arm is guarded to prevent any injury from moving machine
parts during the operation of the machine. The guard locking screw holds the
front guard in position. Removal of the guard will stop the machine.

Catalyst System

1. Catalyst Pump. Operated by the main resin pump. Catalyst ratio is indicated on

the ratio arms. On Megaject PF machines for use with phenolic resins (000­067/68), two 316 stainless steel slave pumps are provided, with the catalyst ratio
determined by adding the two ratios.

2. Catalyst Overpressure Valve. If during the operation of the machine, the

catalyst system becomes blocked for any reason causing the catalyst to exceed a
pre-set pressure, the catalyst overpressure valve will activate and stop the
machine. Refer to Megaject Doctor for fault finding.

3. Catalyst Container. Catalyst store with feed and return pipes attached.

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Solvent Pump NEW SP3

Note. With the introduction of the new Stainless Steel SP3 Solvent Pump System on
models supplied from January 2003 it is possible to upgrade previous machine models
with this unit. It is a simpler design over the former SP2 system and has greater
cleaning efficiency as there is greater throughput of air to the pump and thus to the
mixing head.

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SP3 Assembly

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Operating Controls

Note: Some options may not appear on your machine

1. Incoming Air Pressure Gauge.

Indicates incoming air pressure to the machine.

2. Counters.

i) standard counter

Records the number of pump strokes of the machine. Each digit represents 100
cc’s (0.1 litres) of resin displaced.

ii) Pre-Determined Counter (PDC)

The pre-determining counter contains two readouts. The upper readout displays
the machine output count during injection. The lower readout displays the preset
count entered by the operator. Each digit represents 100 cc's (0.1 litres) of resin
displaced.

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To preset the counter, push white arrow lever on counter down and whilst
holding down - set the predetermined amount of strokes required with the
individual digit buttons and then release the white arrow lever. (Range 0-99.9
litres)

3. Recirculation Switch.

Turn to right to run the machine in recirculation mode (‘on’). Turn to left to stop
machine running in recirculation mode. (‘off’)

4. Pump Speed Pressure Gauge

Measures air pressure being sent to the resin pump air motor.

5. Pump Speed Pressure Regulator

Adjusts air pressure fed to the resin pump air motor, with reading shown on pump
speed pressure gauge.

6. Start Button (PDC machines only)

Begins machine operation. Will only operate when resin and catalyst recirculation
valves are in the inject position.

7. Air Purge Switch. (pull to operate)

Air purges excess resin\solvent from the injection head. Operates until pushed back
to stop.

OPTION: MPG Control Unit (automatically controls pump speed –

see Appendices)

8. MPG Preset Level Gauge

Indicates the maximum injection pressure selected by the operator

9. MPG Preset Regulator

Adjusts maximum injection pressure, with reading shown on MPG preset level

gauge.

10. Pump Signal gauge

Indicates pressure signal being sent to resin pump auto regulator. The lower

the pressure, the slower the pump speed.

11. Solvent Flush Button.

Activates the machine solvent flush cycle for approximately 30 seconds.

12. Mould Vacuum Level Gauge

Indicates level of vacuum achieved by the internal vacuum generator. With perfect
sealing of vacuum cavity, levels of -0.8 to -0.9 bar can be achieved.

13. Mould Vacuum On/Off.

Switches vacuum on/off. (Switch down for ON). Vacuum connection point is located
on rear of cabinet.

14. Mould Vacuum Isolator.

Isolates the vacuum generator from the remainder of the machine enabling air tight
vacuums to be held and read with the vacuum generator switched on or off. ( Switch
horizontal for isolate.)

15. Emergency Stop Button.

Removes all air pressure from the machine and deactivates the pull ‘on’ switch.

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16. Machine Pull ‘On’ Switch

Activates the machine. Deactivates in the event of either the emergency stop button
being pressed or if air supply falls below 1 bar.

OPTION: CATAL Catalyst Flow Monitor (see Appendices)

17. Analogue Flow Meter

Indicates level of catalyst flow in recirculation and injection modes

18. Green ‘ON’ LED

Indicates when the CATAL unit is operating. This will only occur when power

is supplied and the main pump is in motion.

19. Low\High Range Switch.

Adjusts scale resolution for differing catalyst flow rates.

20. Alarm Set Level

Adjusts the catalyst flow level at which an alarm will sound.

(on back of cabinet)

External power supply socket. (+/- 9V)

Remote LED large/small repeater socket (repeaters optional)

Whistle - not shown

Sounds when machine requires flushing (1 minute after end of injection). Operating solvent
flush button cancels whistle and resets timer.

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