Magnum Venus Plastech MKIV Revision 1-6 User Manual

Megaject MKV

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_6

Machine Serial Number:

SAFETY MESSAGE
All fittings, components, seals and hoses are selected and

fitted specifically to this machine to ensure that they are
compatible with the fluid materials to be used, therefore on
no account should any Magnum Venus Plastech (MVP),
factory fitted parts be replaced by non MVP components.
This is especially relevant to the catalyst fluid section. ­Stainless steel or plastic fittings MUST NOT be replaced
during a machine service with non-compatible fittings made
from inappropriate materials (such as brass), as contact
between an organic peroxide catalyst and fittings of a non
compatible material can cause a violent reaction and
explosion.

Megaject MK V Issue 1_6 Page 1 of 41

Contents

1. Megaject MK V Overview

Introduction
Injection Head
Machine Front Guard
Catalyst System
Solvent Tank

2. Operating Controls

3. Commissioning and Set-up Procedures

Epoxy
Polyester

4. Filling/Refilling Solvent Tank

5. Setting Mix Ratios

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 (polyester option only)
Optional 20cc Pump
Optional 50cc Pump
Servicing Injection Head (Epoxy)
Servicing Injection Head (Polyester)
Optional Auto Catalyst Valve for phonolic
Optional RAV Resin Auto Valve
Mixer Tubes
Resin & Catalyst Pipework
Catalyst Overpressure Valve (polyester option only)
Machine Air Circuit
Solvent Pump

11. Appendices

Mould Pressure Guard
CATAL catalyst monitoring system (polyester option only)
Resin Heaters

Revision History

Megaject MK V Issue 1_6 Page 2 of 41

Megaject Mk V Overview

Control

Pipe Umbilical

Injection
Head

Solvent
Pump

Main Guards
Solvent

earth strap

Resin Pumps

Emergency Stop

Resin recirc
hoses (Pick up
pipes not

Introduction

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

This chapter shows the main machine components.

Megaject MK V Issue 1_6 Page 3 of 41

1

1
3

4
5

Injection Head

1. Resin recirculation valves. Swap the resin streams between the injection and

the recirculation position. (90° movement)

2. Catalyst recirculation valve – not shown (Polyester option only). 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.

Megaject MK V Issue 1_6 Page 4 of 41

Recirculation Valve Positions

Megaject MK V Issue 1_6 Page 5 of 41

Machine Guards

1. Main Pump Guards. The moving mechanical parts of the machine are guarded

to prevent any injury from moving machine parts during the operation of the
machine. GUARDS MUST BE IN POSITION DURING MACHINE OPERATION. The
end guard may be opened for ratio adjustment using a suitable allen key.

Catalyst System (Polyester option only)

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

the ratio arms.

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.

Megaject MK V Issue 1_6 Page 6 of 41

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.

Megaject MK V Issue 1_6 Page 7 of 41

SP3 Assembly

Megaject MK V Issue 1_6 Page 8 of 41

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.

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)

Megaject MK V Issue 1_6 Page 9 of 41

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.

Megaject MK V Issue 1_6 Page 10 of 41

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.

Megaject MK V Issue 1_6 Page 11 of 41

Commissioning & Set Up Procedures

CAUTION

Overalls and eye protection must be worn at all times during operation of the
machine.

CAUTION

Do not adjust the catalyst overpressure valve. If in any doubt about operation or
adjustment of any part of this machine please contact Magnum Venus Magnum
Venus Plastech Ltd

IMPORTANT NOTE

The resin pump upper collars must be filled with Magnum Venus Plastech Pump
Lubricant (supplied) to clean and lubricate pump seals. Fill to approximately half full.

An oiler/lubricator must NOT be used in the air supply to the machine. Air must be
filtered and dry at 6-8 bar (85-115 psi).

The Megaject MK V is tested and secured against leaks prior to despatch. It is
essential that the inlet tube connected to the resin pick up pipe and filter remain tight
and sealed at all times to prevent air ingress into the resin system.

We recommend the use of Acetone as the primary choice of cleaning solvent. If a
different solvent system is to be used please contact Magnum Venus Plastech for
details of changes required.

Note: If the machine is to be fed directly from a resin tank it may not be possible to use

the resin pick up pipe and filter supplied. A suitable in-line filtering system is
available from Magnum Venus Plastech TT

Disclaimer: Magnum Venus Plastech do not accept responsibility for the performance of

Megaject machines when using non recommended materials. For further

information contact Magnum Venus Plastech TT.

Procedure (Epoxy)

1. Connect earth lead from solvent tank to suitable earth point. Ensure recirculation

switch is off. Connect 10mm air line (supplied) to workshop air supply. Pull the ON
switch down to the ON position. Observe incoming air pressure gauge reads a
minimum 6 bar at all times.

2. Place resin pick up pipes and resin recirculation pipes in resin container. Securely

anchor both pipes.

3. Fill solvent tank following ‘Filling/Refilling Solvent Tank’ procedure.

4. Adjust pump output regulator to read 2 bar on the pump pressure gauge.

5. If MPG system is fitted, adjust preset regulator until preset level gauge reads 2

bar.

Megaject MK V Issue 1_6 Page 12 of 41

6. Ensure both resin recirculation valves are in the recirculation position. Turn

recirculation switch ‘on’. Recirculate until a bubble free fluid flow is observed at
the resin containers and pump output is even on both strokes.

Note: The recirculation switch should be used for recirculation only and must be turned

‘off’ when priming is complete.

7. Turn resin valves to inject position.

8. Using either the start button (Predetermined counter machines only) or the thumb

start switch, pump 300cc’s (3 counts) into a waste container.

9. Pump 200 cc’s (2 counts) into a cup. DO NOT STIR.

10. The injection head must be flushed. Return resin recirculation valves to recirculate

position. Place injection nozzle in a waste container. Operate the air purge button
to expel waste resin. Press the solvent flush button. This will reset after
approximately 30 seconds. Operate the air purge button to dry out the head and
mixer tube.

11. Check that resin in cup gels evenly and fully. If not, return to procedure 6.

Note: We strongly recommend that after injection, the recirculation valves are always

placed back into the recirculation position. This ensures that small amounts of
resin do not leak forward into the head chambers. Major movement of the pipes
and/or day and night workshop temperature variations could cause slight weeping
into the head if the machine is idle and the recirculation valves are not left in the
recirculation position.

Procedure (Polyester)

1. Connect earth lead from solvent tank to a suitable earth point. Ensure recirculation switch

is off. Connect 10mm air line (supplied) to workshop air supply. Pull the ON switch down
to the ON position. Observe incoming air pressure gauge reads a minimum 6 bar at all
times.

2. Place resin pick up pipe and resin recirculation pipe in resin container. Securely anchor

both pipes.

3. Using the funnel provided, fill catalyst container to approx 3/4 full. For polyester resin

systems we recommend Acetyl Acetone Peroxide (AAP) catalyst (e.g. Luperox 224).

Note: The use of MEKP is not recommended for RTM as product de-mould time is
significantly longer than with AAP. MEKP may also cause ‘gassing’ in the catalyst system
resulting in inaccurate catalyst flow and potential ‘wet spots’ in the moulded part.

4. Fill solvent tank following ‘Filling/Refilling Solvent Tank’ procedure.

5. Remove front guard and catalyst slave pump from the backplate. (DO NOT remove any

catalyst pump pipework.) Operate pump by hand until even resistance is felt on both
strokes and the lines are free of air. If difficulty is encountered removing all air invert
pump and continue operating by hand. Replace pump at required percentage and refit
guard.

6. Adjust pump output regulator to read 2 bar on the pump pressure gauge.

Megaject MK V Issue 1_6 Page 13 of 41