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

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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.

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

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

8. Ensure both resin and catalyst recirculation valves are in the recirculation position. Turn

recirculation switch ‘on’. Recirculate until a bubble free fluid flow is observed at both the
resin and catalyst containers and pump output is even on both strokes. If air in the
catalyst system persists turn the recirculation switch ‘off’ and repeat procedure 6

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

when priming is complete.

9. Turn resin and catalyst recirculation valves to inject position.

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

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

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

12. The injection head must be flushed. Return resin and catalyst 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.

13. 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 and/or
catalyst 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.

Megaject MK V Issue 1_6 Page 14 of 41

Filling/Refilling Solvent Tank

Sufficient solvent levels are essential for the correct flushing of the machine. The solvent level
must not be allowed to fall below 5 litres as this may cause inefficient flushing.

Safety Note: Solvents are flammable. Care must be taken when handling solvents. Avoid
naked flames and sparks. Do not smoke in any area containing solvents.

When refilling solvent tank ensure earth clip is connected to dispensing container

Procedure

1. Remove small white filler cap from solvent tank. Refill tank to approx. 4/5 full.

Solvent level must always be high enough to cover top of pump chamber inside
the tank.

2. Replace cap

Megaject MK V Issue 1_6 Page 15 of 41

Setting Mix Ratios

Megaject catalyst levels can be adjusted by movement of the secondary pump along the ratio
arms connected to the main resin pump.

Safety Note: Before altering mix ratio, ensure that the resin and catalyst recirculation valves
are in the recirculation position. REMOVE air/power supply to the machine. Any guards
removed MUST be replaced before operation.

Procedure

1. Remove end guard

2. Turn handwheels simultaneously until secondary pump is in required position as

indicated on ratio arm. Ensure top and bottom readings are identical.

3. Recirculate machine to ensure pump is correctly primed

4. If required, carry out a timed gel test, injecting approx 200 cc’s of resin into a

cup.

Ratio Arm Configuration

Megaject MK V Issue 1_6 Page 16 of 41

Recirculating & Repriming

Recirculating

Recirculation of the machine should be carried out on a regular basis to ensure resin and
catalyst flows are even, free of air bubbles (observed through recirculation returns) and to
prevent sedimentation of any fillers/additives in the resin system.

Recirculation should be carried out at the start of each shift or if new material has been
added to either the resin or catalyst containers.

Procedure

1. Ensure both recirculation valves are in the recirculate position.

2. Adjust pump pressure regulator until the pump pressure gauge reads approx. 2 bar.

If MPG is fitted, adjust MPG preset level to approx. 1 bar.

3. Turn the recirculation switch to the ‘on’ position.

4. Allow machine to recirculate for required period. Ensure recirculating materials are

free of air bubbles and even on both pump strokes.

5. Turn recirculation switch to ‘off’ position.

Repriming

To be carried out when the operator wishes to change the resin/catalyst in a machine which
has already been commissioned.

Procedure

1. Remove pick up filter from fluid. Recirculate machine to empty fluid lines

2. To clean the lines and pump, place pick pipe in solvent container and recirculate

until clean solvent is observed at the recirculation pipe.

3. Place the recirculation pipe in a waste container. Place pick up pipe in new fluid.

Recirculate machine until all solvent is discharged and new fluid is observed at the
recirculation pipe.

4. Place recirculation pipe in fluid container with pick up pipe.

5. Continue recirculating until material is free of all air bubbles.

Note: If the new material is of a similar chemical type to the existing material, then it may
not be necessary to clean the system with solvent before loading the new material.

Megaject MK V Issue 1_6 Page 17 of 41

Injecting and Flushing

This procedure should be followed each time an injection or series of injections are carried
out.

Before Injection

Procedure

1. Check the pull ‘ON’ valve is on and the incoming air pressure gauge reads at least 6 bar.

2. Check recirculation switch is ‘off’.

3. Ensure there is sufficient resin, catalyst and solvent.

4. Check secondary pump is set to required ratio.

5. Adjust the pump pressure regulator to the required setting. (Suggested initial setting – 1

bar)

Note: If MPG system is fitted, adjust the MPG preset regulator until the required maximum
injection pressure is indicated on the MPG preset level gauge. (Suggested initial setting – 2
bar)

6. (PDC machines only) Set predetermined count to required count number. Press counter

reset button to set output count to zero.

Injection

Procedure

1. Place the injection nozzle into the mould injection port and hold.

2. Turn both recirculation valves to injection position.

3. Standard machine

press and hold thumb start button ­machine will inject until thumb start button is released.

OR

4. PDC machine

either:
i) press green start button ­machine will inject until predetermined count is reached.

or

ii) press and hold thumb start button ­machine will inject until thumb start button is released.

Megaject MK V Issue 1_6 Page 18 of 41

Note: Pump pressure and MPG preset level (if fitted) can be adjusted during injection to

optimise the injection speed. DO NOT exceed the maximum safe injection
pressure for the selected mould.

5. Turn both recirculation valves to recirculation position.

6. Remove injection nozzle from mould

7. Place sprue plug in mould injection port.

Flushing

Procedure

1. Hold injection nozzle in waste container

2. Pull air purge button until excess resin is expelled.

3. Push solvent flush button. After approximately 30 seconds this button will reset. The

solvent flush button may be used a second time if necessary.

Note: If two or more injections are to be carried out consecutively, it may not be

necessary to flush the mixing head between shots. Approximately 1 minute after
the end of an injection, the whistle will sound indicating that the machine must be
flushed. Operating the solvent flush or continuing with the injection will cancel the
alarm.

Injection & Flushing when using an Autosprue™

When carrying out an injection through an Autosprue™, it is essential that the both the
Autosprue™ resin and signal pipes are connected to the injection head before starting
injection. The Autosprue™ MUST REMAIN CONNECTED to the injection head for the
flushing cycle. Only when flushing is complete may the Autosprue™ be disconnected.

Refer to Autosprue™ instructions for further details.

Megaject MK V Issue 1_6 Page 19 of 41

Optimising output

Maximum output rate is dependant on various factors when pumping resin systems. The
following factors should be taken into account in order to achieve maximum mixed output.

1. Supply of air to the machine.

An air supply of sufficient pressure and volume flow rate must be supplied to the machine. To
check supply is sufficient, ensure that incoming air flow is at least 1200 litres/min at 8 bar

2. Resin viscosity.

High viscosity resins will reduce the potential output of any metering machine for a given
power input. Viscosity of the resin can be decreased by a) increasing the temperature. b)
Reducing filler loadings. c) Using viscosity modifiers

3. Pipe work restriction from pump to mixing head.

Fitting larger bore output hoses, or reducing the hose length can improve output of the
machine. This is an important criteria if long hoses (> 4 metres) or higher viscosity resins are
used.

4. Fillers

When using fillers, it is essential that the filler is well mixed and not allowed to settle out over
a period of time. A tank agitator may be used. Alternatively regularly recirculate the resin.
This may however reduce pump seal life. Filler particle sizes of 5m or less should be used. If
filter blockage is occurring, a larger mesh size should be used. Contact Magnum Venus
Plastech for further details.

Megaject MK V Issue 1_6 Page 20 of 41

Shutdown Instructions

Procedure

1. At the end of the day/shift switch off the machine air and leave the resin and catalyst

recirculation valves in the recirculation position.

2. The resin pump piston shaft should be parked at the bottom of its stroke. This ensures

any smears of resin on the pump shaft do not dry out causing excess seal wear

3. For shutdown periods, if any doubts exist about the stability of the resin system, it should

be reprimed with an unfilled, unaccelerated resin system. Once the system is full of
unaccelerated resin, pump approx 300cc’s (3 counts) of resin through the injection head
then flush. Do not leave the Megaject either empty or with a cleaning solvent in the resin
system. Under normal circumstances, catalyst may be left in the system for extended
periods.

4. If filled resin systems have been used filler may sediment at the bottom of the pump and

pipework. Under these circumstances a higher pump pressure may be required to start
the pump recirculating. If filler has formed a sediment around the bottom inlet ball valve
of the pump it may momentarily stick. In such circumstances continue to pump on

recirculation for 3 minutes which should ‘unstick’ the valve. The resulting flow will quickly

wash away sediment, allowing the pump to operate correctly. Should the problem
continue, the bottom resin pump ball valve must be serviced. (refer to service
instructions).

5. After a shutdown period, it is expedient to ensure the resin and catalyst systems are fully

primed. See commissioning instructions for details.

Megaject MK V Issue 1_6 Page 21 of 41

Maintenance

The Megaject RTM Machine range has proved to be extremely reliable in service. To
maximise service life, it is important to keep the machine free from dirt and contamination
and follow correct procedures for use and maintenance as instructed in this manual.

Spares Ordering

To order spare parts for your machine, please indicate the relevant drawing ident number for
the part required.

Important Note: Read this section before attempting any maintenance of your
machine.

1. Eye Protection and protective clothing and gloves MUST be worn for all maintenance

operations.

2. Before carrying out any maintenance on this equipment, Remove air supply from machine.

3. Be aware that small residual pressures may exist in fluid lines even when the machine is

isolated from the air supply. Take care when removing fittings.

4. We recommend that if any work is to be carried out on the fluid sections (i.e. resin,

catalyst or solvent) that they are pumped empty prior to maintenance.

Maintenence Schedule.

(based on experience with standard recommended materials)

Every 1 tonne of resin pumped

1. Check general cleanliness of machine and ensure there are no leaks.

2. Check resin pump lubricant level

3. Clean resin filters. (Remove, clean with acetone, dry and replace).

4. Remove mixer shroud and check cleanliness of mixer tube.

Every 5 tonnes of resin pumped

1. Split injection mixing head. Examine internals for gelled resin or foreign objects. It

is not necessary to dismantle head Non Return Valves if the head appears to be in
good condition.

2. If MPG block is fitted, remove 4 M5 cap screws and examine parts. It is not

necessary to remove MPG diaphragm.

Every 100 tonnes of resin pumped

1. Replace main resin pump seals

2. Replace mixer tube and mixer tube O ring.

3. Empty solvent tank, clean tank and filter.

Megaject MK V Issue 1_6 Page 22 of 41

Replacing Resin Pump Seals

Important Safety Note

air supply to the machine disconnected and due caution must be observed when opening all
fluid and pneumatic connections by using personal protection against possible internal
residual pressures.

The following sections describe seal and internal fluid section maintenance procedures
accompanied by assembly and parts drawings. Resin pump

All maintenance work on the machine must be carried out with the

Megaject MK V Issue 1_6 Page 23 of 41

Resin pump service.

In order to service internal resin pump seals first pump out any resin from internals by placing

system on recirculation. It is also advisable to clean internals with solvent after resin removal
before service. Do this by re-circulating 5 litres solvent through resin pump and finally pumping
the solvent out of system.
Isolate machine from air supply

4.3.2 Piston Seal (0555) and Shaft seal (0549)

To access Piston seal (part 0555) remove 4 x M8 securing bolts (Part 0559). Slide Pump cylinder

(0548) and lower gold block assembly (0558) from piston.

The piston seal may now be removed by unscrewing seal retainer nut (0556). Replace seal

observing that the seal lip must face UP and valve ball (0554) is placed back into cage (0551)

NOTE If the shaft seal (0549) is to be replaced proceed further without re-assembling the Piston and

seal

The piston is re assembled in reverse order to the above. Observe that medium strength
thread lock should be used on piston bolt (0342)

To replace the shaft seal (0549) it is necessary to remove the top block (0546) from the machine.

To do this first remove the four M8 retaining bolts accessed from the underside of top block.. This
will allow the top block to be drawn down shaft away from the four square air motor pillars.

Using circlip pliers remove large circlip (0544). Remove washer (0545). Remove old seal (0549)

and discard. Install new seal and re assemble pump in reverse order. Note- O ring top and
bottom seals (0547) may be replaced during these service operations if found to be damaged.

Ensure pump assembly is evenly retightened with M8 tie bolts (0559)

When Pump is reinstalled in machine, renew pump seal lubricant in top seal block (0546)

Megaject MK V Issue 1_6 Page 24 of 41

Replacing Catalyst Pump Seals (Polyester option only)

See drawings 22042

Procedure

1. Remove catalyst pump from ratio arms. Disconnect inlet and outlet hoses at

swivel fittings

2. Unscrew bottom and top blocks from outer tube. Examine bottom block ball

bearing for pitting/damage. Replace if necessary.

3. Slide pump bore out of top block and remove from piston shaft

4. Replace pump bore outer tube O rings and lubricate using silicone grease.

5. Unscrew piston seal body from shaft. Examine piston ball and spring. Replace if

necessary.

6. Unscrew piston seal retainer. Remove and replace piston seal.

7. Remove top block from piston shaft. Unscrew top seal block from top block.

Remove shaft seals from top seal block and replace.

8. Remove felt washers and replace.

9. Reassembly is a reversal of the above procedure. When refitting the piston seal

retainer (part 0531) clean threads thoroughly. Place a small amount of Loctite
243 threadlock on the threads and screw in finger tight only.

Megaject MK V Issue 1_6 Page 25 of 41

20cc Pump Piston Seal

To access the pump piston seal or any other pump internal parts proceed as follows.
Pump out catalyst from system and then remove catalyst feed pipe and filter

assembly from catalyst bottle. Remove pump guard
Remove 4 M8 bolts (0559) from the lower catalyst block (1865) from pump body.

The pump cylinder (1867) is now exposed.
Remove this by withdrawing down to expose the pump shaft and piston assembly.

Remove the Piston retainer/lower seal retainer 1870 to allow removal of back bush
1873 and the piston seal (3644).

Replace with new seal. Observe the correct” lip up” orientation of the seal as detailed
on drawing.
Reassembled in the reverse order

10.2 Catalyst pump Piston shaft seal
Do not attempt to remove the top piston rod clevis (4278) from the shaft as this is

permanently thread locked together.
The top seal (3363) can be removed and replaced by following the above description

to remove the pump and disassembly. The piston assembly 1869 must be removed
so that the piston rod can be withdrawn upwards through the top seal housing (1866)
and removed to access piston rod seal (3363). Remove circlip 2882 and retainer
washer 1874 and old seal 3363.
Ensure new seal 3363 is evenly pushed into the top housing with the seal lip entering
first. Reassemble in reverse order.

Note when replacing piston assembly ensure M8 stud 4087 remains as factory set in
Thread sealed position as indicated in above assembly parts drawing.

When using ball spring the stud 4087 should be thread locked in position to
dimension 23.5mm when spring used or dimension 17mm when no spring is used."

Megaject MK V Issue 1_6 Page 26 of 41

Megaject MK V Issue 1_6 Page 27 of 41

50CC Pump

DRAWING 22301 50 CC pump assy

WORDS HERE

Megaject MK V Issue 1_6 Page 28 of 41

Servicing Injection Head (Epoxy)

See drawing 22018

Note: During maintenance ensure resin and catalyst recirculation valves are in the

recirculate position. Avoid any cross contact of resins and/or catalyst.

Procedure

1. Remove air signal and solvent lines from the head. Using a 5mm allen key,

remove head block bolts. Split head into two sections. Remove head block O ring.
To remove NRV 3, (polyester option only) first remove spring retaining pin at top
of valve. Screw M10 bolt partially into the valve and pull to remove from head.

2. NRV 7’s may be unscrewed.

3. To remove NRV 4, (polyester option only) undo catalyst pipe swage fittings.

Unscrew 3 way ball valve from NRV 4. Unscrew NRV 4 from bottom head block.

4. Inspect all head block and NRV galleries. If hardened resin is evident, remove or

replace parts as necessary.

5. To disassemble all NRV’s, remove spring retaining pin. PTFE cone can be

replaced by removing spring from seat retainer.

6. When using a new PTFE cone, grind into NRV seat using thumb pressure only to

ensure a good seal. On reassembly a suitable hook must be used to stretch the
spring sufficiently to enable the retaining pin to be replaced.

7. Reassembly is a reversal of above procedures. Inspect head block O ring and

replace if necessary using a small amount of silicon grease to lubricate.

8. After reconnection of hoses and pipes, machine must be recirculated to expel air.

Note: We highly recommend catalyst and resin pipes are not removed from the recirculation

valves as leakage is inevitable.

Megaject MK V Issue 1_6 Page 29 of 41

Servicing Injection Head (Polyester)

See drawing 22015

Note: During maintenance ensure resin and catalyst recirculation valves are in the

recirculate position. Avoid any cross contact of resin and catalyst.

Procedure

9. Remove air signal and solvent lines from the head. Using a 5mm allen key,

remove head block bolts. Split head into two sections. Remove head block O ring.
To remove NRV 3, first remove spring retaining pin at top of valve. Screw M8 bolt
partially into the valve and pull to remove from head.

10. NRV 2 may be unscrewed from the side port.

11. To remove NRV 1 unscrew from resin recirculation valve swivel fitting and then

remove from top head block.

12. To remove NRV 4, undo catalyst pipe swage fittings. Unscrew 3 way ball valve

from NRV 4. Unscrew NRV 4 from bottom head block.

13. Inspect all head block and NRV galleries. If hardened resin is evident, remove or

replace parts as necessary.

14. To disassemble all NRV’s, remove spring retaining pin. PTFE cone can be

replaced by removing spring from seat retainer.

15. When using a new PTFE cone, grind into NRV seat using thumb pressure only to

ensure a good seal. On reassembly a suitable hook must be used to stretch the
spring sufficiently to enable the retaining pin to be replaced.

16. Reassembly is a reversal of above procedures. Inspect head block O ring and

replace if necessary using a small amount of silicon grease to lubricate.

17. After reconnection of hoses and pipes, machine must be recirculated to expel air.

Note: We highly recommend catalyst and resin pipes are not removed from the recirculation

valves as leakage is inevitable.

Megaject MK V Issue 1_6 Page 30 of 41

Optional Auto Catalyst Valve for Phenolic

To remove Resin
valve/actuator
Assembly, unscrew
swivel joint here (Note –

small amount of resin will
leak)

To split head
blocks (0728 and 0727)
Remove 2 x M6

NRV 2
NRV1

Procedure

1. Remove automatic catalyst recirculation valve and NRV 4 by loosening 2x M6 cap
heads (6331) (illustrated and shown in pro head drawing below) and rotate S clamp
(4112). Pull whole assembly from head.

2. Remove top head block bolts. Split head into two sections. Remove head block O

Megaject MK V Issue 1_6 Page 31 of 41

ring.(0742) To remove NRV 3 (0042), first remove spring retaining pin ()503)
Screw M8 bolt partially into the valve body (0493) and pull body to remove it from
head. Block (0727)

3. NRV 2 may be unscrewed from the side port after removing 6 mm clear pipe at

union (0665)

4. To remove NRV 1 unscrew resin recirculation valve swivel fitting and then

remove from top head block. It is not necessary to remove resin pipes. Note, a
few drops of resin will leak out so be prepared with rag. When replacing this
fitting, eliminate traces of resin in fitting with solvent then grease threads before
re assembly

5. Inspect all head block and NRV galleries. If catalysed resin is evident, remove or

replace parts as necessary.

6. To disassemble all NRV’s, remove spring retaining pin. PTFE cone (0489) can be

replaced by removing spring from seat retainer (0490).

7. When using a new PTFE cone, press and turn into NRV seat using thumb

pressure only to ensure a good seal. On re-assembly a suitable hook must be
used to stretch the spring sufficiently to enable the retaining pin to be replaced.

8. Re-assembly is a reversal of above procedures. Inspect head block O ring

(0742), NRV 3 O ring (0747) and NRV 4 O ring (0693). Replace using a small
amount of silicon grease to lubricate.

9. After re-assembly head must be flushed to check all seals are tight and head

galleries are clean.

Megaject MK V Issue 1_6 Page 32 of 41

Megaject MK V Issue 1_6 Page 33 of 41

Optional RAV Resin Auto Valve

Caution Note. For safety reasons - Always ensure that the Resin Auto Valve
( shown above) is locked into the head top position using the two M5 securing
lock screws #4081

Megaject MK V Issue 1_6 Page 34 of 41

Mixer Tubes

See drawing 22020

Mixer tubes will only require replacement if partial or full gellation/sedimentation has
occurred in the injection head. They cannot be repaired and must be replaced.

To replace, remove mixer shroud from head. (If MPG option is fitted, signal pipes
must be removed first.) Remove mixer tube from shroud. Lightly grease new mixer
tube/shroud threads with silicon grease, ensure O ring is in position and replace in
mixer shroud.

Re-attach to mixer head and reconnect MPG pipes. (Blue pipe nearest to mixer tube)

Resin and Catalyst Pipework

See drawing 22022/22028

If air is being drawn into the system, check integrity of all joints and connections
shown.

Joints should be tight and sealed correctly using a proprietary thread sealant. Do not
use sealant on cone and seat type joints.

Megaject MK V Issue 1_6 Page 35 of 41

Catalyst Overpressure Valve (Polyester option only)

See drawing 22021

Under normal operational circumstances the catalyst overpressure valve is
maintenance free.

If catalyst leaks constantly from fitting (4), O rings (2) must be replaced

Important Note: It is essential that the internal spring tension is not disturbed in the event
of servicing this unit.

Procedure

To renew front O rings

1. Disconnect red signal pipe and clear overflow pipe. Unscrew whole assembly from catalyst

pump using 19 AF spanner on the forward stainless steel body taking care of any small
residual pressurised catalyst as thread seal is broken. DO NOT disturb the spring tension
end cap (0671).

2. Hold brass body (1035) and unscrew stainless steel body (1032). Pull shaft (1034), and

collar (1033) from body, replace O rings (0750) and reassemble. Ensure shaft is reinserted
with rounded end into the body.

3. Reassemble observing order illustrated in dwg. 22021. Ensure bodies (1032) and (1035)

are correctly screwed together using PTFE tape or similar thread sealant.

4. Reattach valve to catalyst pump using thread sealant.

5. Reprime catalyst system to remove any air from the system.

Machine Air Circuit

In case of problems, follow enclosed schematic diagrams to check the machine air circuits.
This circuit is specific to your machine. When contacting Magnum Venus Plastech, please
quote machine serial number. (see front cover)

Megaject MK V Issue 1_6 Page 36 of 41

Solvent Pump

See drawing 22036

Warning: Before commencing any work on the solvent system, ensure that the working

area is free from any sources of ignition.

To Test:

Turn on air supply to machine. Place injection nozzle in a waste container. Press solvent flush
button. Check solvent output from injection nozzle. Check inside tank during the flush cycle.
If air bubbles appear from the bottom of the solvent pump, either the foot valve or the
threaded joints in the solvent pump will require servicing.

To service solvent pump foot valve:

Procedure

1. Remove air supply from machine.

2. Remove 6mm blue air supply pipe. Mark position of 6mm clear solvent feed pipe

with tape. Unscrew fitting and remove pipe from top of solvent pump complete
with fitting cap and PTFE olive

3. Unscrew M8 cap screw holding tank to machine frame and remove tank.

4. Unscrew red solvent cap. Remove whole pump assembly. Solvent will drain from

the pump assembly as it is lifted. To completely empty solvent pump, turn upside
down and allow remaining solvent to pour out of solvent pipe fitting.

5. Secure pump body and unscrew solvent pump foot valve.

6. Examine filter for blockage and replace as necessary.

7. Using correct size drift, remove roll pin from foot valve.

8. Remove foot valve plunger. Replace O ring. Ensure correct size and grade O ring

is used.

9. Re-assemble foot valve using PTFE tape and/or silicone sealant on threads.

10. Replace pump assembly in tank and refit to machine frame.

11. Refit air supply and solvent feed pipes. Ensure that solvent feed pipe is pushed

through the fitting to the marked position and fitting olive is in the correct
position before tightening. Do not overtighten.

Megaject MK V Issue 1_6 Page 37 of 41

Appendices

Mould Pressure Guard (MPG)

A fluid pump driven by a piston type air motor will deliver an amplified injection pressure.
For example; a standard machine uses an 11:1 air motor/pump ratio. This could result in the
actual pump pressure being amplified eleven times, thus 3 bar could become 33 bar when
the mould cavity becomes hydraulically full.

The MPG is designed to control the Megaject pump speed, and thus injection pressure, to
prevent injection pressure exceeding an adjustable preset limit.

Operation

Set the maximum injection pressure on the MPG preset level gauge using the MPG
regulator. (Suggested initial setting – 2 bar)

If the resin pressure is below the preset pressure, then the automatic regulator will
remain fully open allowing full mains pressure to the resin pump regulator.

If the resin pressure exceeds the preset level, the ‘MPG signal pressure’ will reduce

proportionally closing the automatic regulator and limit air pressure to the resin pump
regulator. This slows or stops the resin pump, reducing resin pressure until it
matches the preset level. During operation, a small leak of air will occur from the
MPG sensor block. This is normal.

The MPG preset level may be adjusted during an injection to achieve optimum pump
output speed at the safest injection pressure.

Several factors will affect the optimum setting of the MPG regulator, e.g. fibre volume
fraction, mould size and rigidity, resin viscosity, required resin delivery rate etc.

Megaject MK V Issue 1_6 Page 38 of 41

CATAL Catalyst Monitoring System

The CATAL catalyst monitoring system provides a visual/audible indication of catalyst flow during
injection and recirculation

Operation

Connect the Catal Power Supply to the Megaject. The connection is via the 5 pin DIN
socket located on the back of the Megaject control cabinet.

The Catal power supply is rated at 110 or 240v input, +/- 9V output. If you have the
incorrectly rated unit for your supply, please contact Magnum Venus Plastech TT.

The catalyst flow monitor will operate only whilst the machine is pumping

Catalyst flow is indicated on the analogue gauge.

The sensor has been factory set to catalyst flow ranges typical in normal RTM
application i.e. 5kg/minute resin mix at 2% cat. ratio. When the flow range switch is
switched to ‘LOW FLOW’ position the system will indicate a catalyst flow as low as
6ml/minute (e.g. resin mix output of 1kg/minute at 0.5% catalyst). If indicating

towards the maximum level move the range switch to ‘HIGH FLOW’ . If meter

reading reaches top of meter, the sensor element may be moved upwards to
accommodate the higher flow. (see diagram overleaf).

It is not necessary to keep readjusting the sensor element. It is simply a coarse
adjustment setting depending on your normal output levels.

The operator can observe the flow rate of catalyst over a wide range of pump speeds
and percentage settings. The audible alarm can be set by turning the alarm setting

control clockwise from zero to a point just below the ‘running level’ (e.g. giving an

alarm when the catalyst flow drops below this setting).

Megaject MK V Issue 1_6 Page 39 of 41

Resin Heaters

Important Note

It is essential that resin heaters are not left turned on with stationary resin in the system.
Uncatalysed resin will eventually cure at elevated temperatures and block the heater
channels..

Whilst the resin heater is on, the machine MUST be either recirculating or injecting.

At the end of a shift, turn off the resin heater and continue to recirculate the machine until
the resin has cooled to room temperature. It is then safe to turn off the machine.

Megaject MK V Issue 1_6 Page 40 of 41

Revision History

Manual

Date

Revision

Code

Revised Content

MKV

23/2/00

1_0

New Manual

MKV Doctor

23/2/00

1_0

New Manual

MKV

1/10/01

1_1

Guard interlock note removed and head position illustration added

MKV

21/1/09

1_5

Safety Message added to page 1

MkV

12/2/09

1_6

Added further detail on the pump seal and RAV

Drawing Number

Revision

22041

4

22042

10

22302

1

22305

3

22303

4

22304

3

22015

13

22018

2

22020

12

22021

4

22028

6

22036

9

22039

3

Air Circuit

S/N

Revision codes appear on the front page of the manual.
e.g. Sprint1_0

Sprint = Machine Name
1 = major revision 1
0 = minor revision 0

Drawings included in this manual

Megaject MK V Issue 1_6 Page 41 of 41