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PAT-CCP-LS-0590-SS
User Manual
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Magnum Venus Plastech PAT-CCP-LS-0590-SS User Manual

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PATRIOT CHOP CHECK
FLUID SECTION
MANUAL
PAT-CCP-LS-0590 & PAT-CCP-LS-0590-SS
Rev. 02/2012
CORPORATE HEADQUARTERS and MANUFACTURING
11692 56th Court * Clearwater, FL 33760 * Tel 727-573-2955 * Fax 727-571-3636
TECHNOLOGY CENTER and MANUFACTURING
1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666
MVP Plastech UK
Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: +44 (0) 1822 832621
Fax: +44 (0) 1822 833999
www.mvpind.com
Rev. 02/2012 Page | 2
Table of Contents:
SECTION:
Page
TERMS & CONDITIONS OF SALE 4
SAFETY & WARNING INFORMATION 6
INTRODUCTION 15
FLUID SECTION REMOVAL 17
FLUID SECTION DISASSEMBLY 19
FLUID SECTION ASSEMBLY 21
FLUID SECTION INFORMATION 25
PARTS DRAWINGS 27
REVISION INFORMATION 41
Rev. 02/2012 Page | 3
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 against the Seller in respect of the goods, the liability of the Seller shall be limited to the value of the goods.
Rev. 02/2012 Page | 4
• 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 Occupatio nal 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
Type of Fire Extinguishing equipment recommended: Fire Extinguisher – code ABC, rating number 4a60bc.
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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 form improper handling of MEKP, especially in regards to contamination, heat, friction and impact. They should be thoroughly instructed regarding the proper action to be taken in the storage, use and disposal of MEKP and other hazardous materials used in the laminating operation. In addition, users should make every effort to:
A. Store MEKP in a cool, dry place in original containers away from direct sunlight and away from other chemicals.
B. Keep MEKP away from heat, sparks and open flames.
C. Prevent contamination of MEKP with other materials, including polyester over spray and sandings, polymerization accelerators and promoters, brass, aluminum and non-stainless steels.
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D. Never add MEKP to anything that is hot, since explosive decomposition may result.
E. Avoid contact with skin, eyes and clothing. Protective equipment should be worn at all times. During clean-up of spilled MEKP, personal safety equipment, gloves and eye protection must be worn. Fire fighting equipment should be at hand and ready.
F. Avoid spillage, which can heat up to the point of self-ignitio n.
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 o utput 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 contact aluminum or
galvanized parts inside a closed container such as a pump, spray gun, or fluid handling system, the chemical reaction can, over time, result in a build-up of heat and pressure, which can reach explosive proportions.
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.
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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.
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.
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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 diluent 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 situatio n 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.
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.
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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 continuo us 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.
3.0 Equipment Safety
WARNING
Magnum Venus Plastech suggest that personal safety equipment such as EYE GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be worn w hen 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 ANOT HER PERSON. (TREAT THE GUN AS IF IT WERE A LOADED PISTOL.)
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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 a 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:
This manual, the Patriot Chop Check Manual, provides information you need to perform simple maintenance and repair on your equipment.
• Step-by-step assembly and disassembly procedures are included.
Please read the manual carefully. Follow the steps in the order given, otherwise you may damage the equipment or injure yourself. Be prepared by having a clean work area, tools and current parts drawing available.
DANGER: Always wear proper safety equipment, including eye protection and gloves when performing service and repair on this equipment. When removing Pump Fluid Section, Hoses and Resin Surge Chamber, be sure to bleed off fluid pressure from the system before disconnecting. Release Surge Chamber charge before removing Surge Chamber. System may be under pressure and cause injury.
This manual covers the following Fluid Section assembly:
• PAT-CCP-LS-0590 Patriot Chop Check Fluid Section
• PAT-CCP-LS-0590-SS Stainless Steel Chop Check Fluid Section
This manual covers the following Pump assembly:
• PAT-CCP-PA-1300-SS Stainless Steel Chop Check Pump Assembly
• PAT-CCP-PA-2300 Patriot Chop Check Pump Assembly
Note: The Fluid Section can be rebuilt in place or easily removed and taken to a workbench. Flushing the fluid section with suitable cleaning agent can make the rebuild process much easier.
During Disassembly . . .
As you disassemble the equipment, lay out the components in the correct order and direction. This will help you to reassemble them.
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Tools required:
• Red Grease (6706-2-1 1 oz) (6706-2-16 16 oz) (6706-2-32 32 oz)
• PAT-LS-OIL (PAT-LS-OIL-1GL 1Gallon) (PAT-LS-OIL-5GL 5 Gallon)
• Loctite™ 243 (removable) or equivalent Removable Thread Locking Compound
• 5/16-inch Hex Wrench
• Hex Wrench Set (08469)
• 8-inch Adjustable Wrench (08467)
• 12-inch Adjustable Wrench (08468)
• 1/2-inch Wrench or 1/2" x 9/16” Combination Wrench (08476)
• 9/16-inch Wrench (08476) or 1/2” x 9/16” Combination Wrench (08476)
• Repair Kit: PAT-CCP-LS-0590-RK
IMPORTANT WARRANTY INFORMATION
Please note that components used on this equipment are made of specially developed, high-strength material.
Only authentic Magnum Venus Plastech replacement parts are acceptable for use with this equipment.
Use of unacceptable replacement parts will void our liability and warranty of this equipment.
Please contact your Magnum Venus Plastech distributor for more information.
Lubrication:
Throughout this manual, directions are given for lubricating various parts of the Fluid Section. These are the typical lubricants used:
If the part contacts resin, use MVP Red Grease (6706-2-1).
If the part is located where it will contact air, use Lubriplate® (08465).
Throat Seal Oil (TSL-3200) used in the oil reservoir of the pump.
Throat Seal Oil for use with ISO (TSL-ISO-800) 8 oz.
Grease for use with ISO (GR-ISO-100) 1 oz.
DANGER: FIRE AND EXPLOSION HAZARD. Never use any lubrication on the components of the catalyst system. Contact your catalyst manufacturer for additional material handing information.
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Fluid Section Removal:
1. Remove the Ram and Pump from the material.
2. Place a piece of plastic or paper under the Ram and Pump to catch any dripping
material.
3. Put the pump into the lowest position of the down stroke.
4. Shift the Ram Control valve into the down position; allow pump and Ram to travel
to the lowest position.
5. Disconnect the resin hose from the side of the Pump fluid section.
Warning: Be sure to remove fluid pressure from the system before disconnecting resin hose, tie rods or surge chamber. System may be under pressure and can cause injury.
6. Remove the E-Ring (F-ER-1.00-HD), lift up the Sleeve (PAT-PA-9109) and remove
the two Connectors (APP-9096).
7. Remove the four Hex Nuts (F-HN-06C) and Lock Washers (F-SW-06) holding the
fluid section to the Adapter Tie Rods (PAT-CCP-0522).
8. Shift the Ram Control valve into the Ram up position, move the ram up until the
Adapter Shaft (PAT-CCP-0521) clears the Transition Plate (PAT-CCP-0503) this will allow the pump fluid section to be removed.
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Fluid Section Disassembly:
NOTE: As you disassemble, lay the parts out on a towel or rag in the order you take them apart. This will help you remember how they go back together. Inspect each part for wear or damage and note parts that require replacement.
NOTE: The procedures for disassembly of the Stainless Steel version and standard steel version will be the same. For part numbers see the correct drawing in the Parts Drawing section of this manual.
1. If not already done, move the pump to the bottom of the down stroke.
2. Unscrew the four Hex Nuts (F-HN-06C) from the end of the Tie Rods (PAT-CCP-
0520).
3. Pull the Inlet Bell Flange (PAT-CCP-0537) off the Tie Rods (PAT-CCP-0520).
4. Remove Hex Bolt (F-HB-04F-08) from the bottom of the Priming Rod. If the
Priming Rod spins put a wrench on the wrench flats of the Priming Rod just above the Priming Piston (PAT-CCP-0523).
5. Remove the Backup Washers (PAT-CCP-0528), Relief Washer (PAT-CCP-0525)
and the Priming Piston (PAT-CCP-0523) from the Priming Rod.
6. Unscrew the Tie Rods (PAT-CCP-0520) out of the Outlet Body.
7. Pull the Cylinder out of the Outlet Body and off the Piston. This will also force the
Intake Valve off the end of the Priming Rod.
8. Remove Lower Seat from out of the end of the Cylinder.
9. Remove the loose Intake Valve, Spacer and Valve Stop (PAT-CCP-0530) out of
the end of the Cylinder.
10. Remove the Piston Bushing (PAT-CCP-0513) and Piston Seal Assembly (PAT-
CCP-0514) out of the other end of the Cylinder.
11. Unscrew the Intake Valve Packing Nut (PAT-CCP-0532) from the Intake Valve
12. Remove both of the Foot Valve Seals (PAT-CCP-0536) from inside the Intake
Valve
13. If necessary remove the Intake Bushing (PAT-CCP-0533) from inside the Valve
Nut (PAT-CCP-0532).
14. Pull the Fluid Rod and Piston assembly out of the Outlet Body and Rod Seal
assemblies (PAT-CCP-0516) – set a side for now.
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15. Remove the Packing Nut (PAT-CCP-0504) from the top of the Outlet Body.
16. Remove the Rod Bushing (PAT-CCP-0505) and Rod Seal assemblies (PAT-CCP-
0516) from the top of the Outlet Body.
PISTON and PISTON VALVE DISASSEMBLY:
Note: Clean and inspect all parts for wear and damage. Replace damaged parts and all parts provided in the repair and seal kits.
1. Unscrew the Piston Valve and Priming Rod from the Piston. Use caution, the
piston ball may fall out and become damaged. If the ball falls onto a hard surface it may become scratched or get a flat spot on it.
2. Remove the Piston Ball, Ball Guide, Ball Spring (PAT-LS-1010) and Ball Stop
(PAT-CCP-0511) from inside the Piston.
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Fluid Section Assembly:
NOTE: The procedures for assembly of the Stainless Steel version and standard steel version will be the same except for Seals in the Intake Valve. For part numbers see the correct drawing in the Parts Drawing section of this manual.
PISTON and PISTON VALVE ASSEMBLY:
1. Install the Ball Stop (PAT-CCP-0511) into the bottom of the Piston.
2. Install the Spring (PAT-LS-1010) into the Piston narrow end forward.
3. Insert the Ball Guide into the Piston over the Spring. (see below for proper
orientation)
Note: The relief (round) end of the ball guide goes against the spring into the piston.
4. Install a new O-ring (O-E-022) onto the Piston Valve.
5. Apply a light coat of the appropriate grease to Piston Ball and place it into the
Piston on top of the Spring (PAT-LS-1010).
6. Thread the Piston Valve into the end of the Piston and tighten. Set aside for now.
Ball Guide
Spring (PAT-LS-1010)
Piston Valve
Priming Rod
PUMP ASSEMBLY:
7. Apply a light coat of the appropriate grease to the Rod Seal Assemblies (PAT-
CCP-0516). Now install them into the top of the Outlet Body. The open side (side with o-ring) goes down inside.
8. Install the Rod Bushing (PAT-CCP-0505) into the Packing Nut (PAT-CCP-0504).
O-Ring (O-E-022)
Piston Ball
Ball Stop (PAT-CCP-0511)
Piston
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9. Thread the Packing Nut (PAT-CCP-0504) into the top of the Outlet Body.
Packing Nut (PAT-CCP-0504)
Rod Bushing (PAT-CCP-0505)
Outlet Body
Rod Seal Assembly (PAT-CCP-0516)
10. Apply a light coat of the appropriate grease to the Backup Ring (PAT-CCP-0515)
then install into the top end of the Cylinder.
11. Apply a light coat of the appropriate grease to the Piston Seal Assembly (PAT-
CCP-0514) then install it into the top end of the Cylinder on top of the Backup Ring, o-ring facing up.
12. Install the Piston Bushing (PAT-CCP-0513) into the top of the Cylinder.
13. Apply a light coat of the appropriate grease onto O-ring (O-E-140) and install onto
the end of the Cylinder.
Piston Bushing (PAT-CCP-0513)
Backup Ring (PAT-CCP-0515)
O-Ring (O-E-140)
Piston Seal Assembly (PAT-CCP-0514)
Cylinder
14. Install the Cylinder into the Outlet Body.
15. Apply a light coat of the appropriate grease onto the Fluid Rod assembly, now
carefully push the Fluid Rod Assembly into the Cylinder, Piston Seal and Rod Seal Assemblies (PAT-CCP-0516) from the bottom and then up through the Packing Nut (PAT-CCP-0504).
Rev. 02/2012 Page | 22
16. Install the Valve Stop (PAT-CCP-0530) over the Priming Rod into the end of the
Cylinder.
17. Install the Spacer into the end of the Cylinder on top of the Valve Stop.
Spacer
O-Ring (O-E-032)
Spacer
Cylinder
Valve Stop (PAT-CCP-530)
Intake Valve Assy.
18. Apply a light coat of the appropriate grease to the two Foot Valve Seals (PAT-
CCP-0536) and install them into the Intake Valve o-ring side facing up.
Intake Bushing (PAT-CCP-533)
Valve Nut (PAT-CCP-532)
Foot Valve Seals (PAT-CCP-536)
Intake Valve
19. Install the Intake Bushing (PAT-CCP-0533) into the Valve Nut (PAT-CCP-0532).
20. Thread the Valve Nut (PAT-CCP-0532) into the Intake Valve.
21. Apply a light coat of the appropriate grease to the Priming Rod and in a threading
motion slide the Intake Valve assembly onto the Priming Rod.
22. Apply a light coat of the appropriate grease to a new O-ring (O-E-032) then install
onto the Lower Seat.
23. Install the Lower Seat into the end of the Cylinder the small chamfer side (seat)
should face in towards the Intake Valve.
Rev. 02/2012 Page | 23
24. Install the Priming Seal (PAT-CCP-0524) onto the Priming Piston (PAT-CCP-
0523).
25. Install the Priming Piston (PAT-CCP-0523) onto the end of the Priming Rod.
26. Install onto Hex Bolt (F-HB-04F-08) a Backup Washer (PAT-CCP-0528) then the
Relief Washer (PAT-CCP-0525) then the last Backup Washer (PAT-CCP-0528)
27. Thread the Hex Bolt (F-HB-04F-08) into the end of the Priming Rod.
Hex Bolt (F-HB-04F-08)
Backup Washer
Priming Seal (PAT-CCP-0524)
Relief Washer (PAT-CCP-0525)
Priming Piston (PAT-CCP-0523)
Priming Rod
28. Thread the four Tie Rods (PAT-CCP-0520) into the Outlet Body.
29. Apply a light coat of the appropriate grease to a new O-ring (O-E-032) then install
onto the Bell Frame (PAT-CCP- 0537).
30. Install the Inlet Bell Frame (PAT-CCP-0537) onto the end of the Tie Rods (PAT-
CCP-0520) over the Priming Piston. It is preferable to install the Bell Frame so that the fitting ports are perpendicular to the pump outlet.
31. Thread the four Hex Nuts (F-HN-06C) onto the end of the Tie Rods to secure the
Bell Frame and pump assembly.
Rev. 02/2012 Page | 24
Power Head
PAT
-
CCP
-LS-
0590
1:1
PAT
-
CCP
-LS-
059
0-SS Diameter (in.)
Putty
Adhesive
Displacement (in3) /
Fluid Section
PAT
-CP-
0550
FLUID SECTION INFORMATION:
PAT-PH-3250 13 to 1 13 to 1
PAT-PH-4250 23 to 1 23 to 1
PAT-PH-7000 31 to 1
These ratios do not take in account of static or dynamic friction as well as the weight of the moving components. It is assumed that there is no fluid bypass around the piston cups or ball and seat.
• PUMP ASSEMBLIES
PAT-PA-CCP-1300 13:1 PUMP ASSEMBLY PAT-PH-3250 & PAT-CCP-LS-0590 PAT-PA-CCP-2300 23:1 PUMP ASSEMBLY PAT-PH-4250 & PAT-CCP-LS-0590 PAT-PA-CCP-1300-SS 13:1 PUMP ASSEMBLY PAT-PH-3250 & PAT-CCP-LS-0590-SS
• Pump Displacement Information
Fluid Section Stroke Length
PAT-CCP-LS-0590 2” (50.8 mm) 0.589 (9.6 cc) 1.178 (19.30 cc)
Stroke
/ Cycle
• Catalyst Pump Information
Catalyst Pump
PAT-CP-0245 .75% – 2.25 %
PAT-CCP-LS-0590
1.3% - 5.2%
• Slave Arm Stickers
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Parts Drawings:
PAT-CCP-LS-0590 PATRIOT CHOP CHECK FLUID SECTION PAT-CCP-LS-0590-SS STAINLESS STEEL FLUID SECTION PAT-CCP-2300 PATRIOT CHOP CHECK PUMP ASSEMBLY PAT-CCP-PA-2300 PATRIOT CHOP CHECK PUMP ASSEMBLY PAT-CCP-PA-1300-SS STAINLESS STEEL PUMP ASSEMBLY PAT-CCP-LS-0590-RK REPAIR KIT – CHOP CHECK PUMP
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Revision Information:
Revision Description
Rev. 11/2008
Rev. 12/2010
Rev. 02/2012 Updated the Logo, MVP Address and the manual format
Added revision sheet, updated details and note for ball guide page 12. We updated the parts drawings chapter.
Updated the drawings and the Manual format. Updated the MVP logo.
and added the Terms and Conditions section. Revised this manual to include the Stainless Steel version of the fluid section PAT-CCP-LS-0590-SS
Rev. 02/2012 Page | 41
Assemblies Covered in this Manual:
MAGNUM VENUS PLASTECH
CORPORATE HEADQUARTERS and MANUFACTURING
11692 56th Court * Clearwater, FL 33760 * Tel 727-573-2955 * Fax 727-571-3636
TECHNOLOGY CENTER and MANUFACTURING
1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666
MVP Plastech UK
Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: +44 (0) 1822 832621
Fax: +44 (0) 1822 833999
www.mvpind.com
• PAT-CCP-LS-0590 Patriot Chop Check Fluid Section
• PAT-CCP-LS-0590-SS Stainless Steel Chop Check Fluid Section
• PAT-CCP-PA-1300-SS Stainless Steel Chop Check Pump Assembly
• PAT-CCP-PA-2300 Patriot Chop Check Pump Assembly
Rev. 02/2012
Rev. 02/2012 Page | 42
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