Magnum Venus Plastech PATRIOT SSB User Manual

Patriot SSB Auto

Commissioning and instruction and maintenance manual

Issue 05

CONTENTS

Section Description Page

1.0 Machine Overview 2

1.1 Health & Safety General Overview 3

2.0 Instrumentation and Control Familiarisation 4-7

3.0 Priming SSB Fluid Sections 7-9

4.0 Machine Operation 9-11

5.0 Shut down 11

6.0 Routine Maintenance 11

7.0 Maintenance 12

8.0 Patriot Resin Pump 16

9.0 Catalyst Pump, CAV,OP valve and ratio system 22

10.0 Injection Head & Mixer Assembly 32

11.0 Solvent Pump 33

11.2 Solvent automatic head valve 34

12.0 RGA Resin Gel Alarm 36

13.0 SSB Auto Machine Doctor 38

14.0 Additional Machine Connections 41

15.0 Machine Air Circuit 42
Revision history 43

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1.0 To enable understanding of machine controls please read the

following descriptions referenced to the general machine view

Resin automatic valve

Solvent automatic
valve

Catalyst automatic
valve

Pump speed regulator
Pump Start/Stop

recirculation
Static Mixer

Mould Pressure
injection hose pressure
Guard

Mixer outlet point

Catalyst Bottle 5L
Mount

Patriot Resin Pump

Solvent tank 20L
Mount

Optional Drum Trolley
fixing points

Optional PV
Sensor
system

Pump Speed air
pressure

Emergency stop/
Power ON/OFF

Mix resin pressure
Counter
Reset (Side mounted)
Mix Resin Pressure

Regulator
Solvent/Air Flush
Pump Start /Stop
Resin Gel Alarm (RGA)

MotoCat Ratio Control

Internal Lever enables
unlock of fluid section
for easy maintenance

Ratio arm Cover

Catalyst pump

Lockable Castor
wheels

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1.1 Health & Safety - General over view of important health and safety
issues relating to this machine

The following instruction manual contains a number of references to controls and
procedures that will ensure safe operation of the machinery. The machines are designed
to process substances that are hazardous to health and therefore it is vital that any
materials that are introduced to the machinery have valid MSDS (material safety data
sheets) in place and that machine operators and maintenance staff are fully informed and
trained in the use of the materials and of the potential hazards.

Users are also advised to ensure that these operator instructions are correctly and
adequately made available to machine operators and maintenance staff.

Machine Guard

The Machine guard, which is supplied with this machine, must be correctly fitted at all
times during operation. Also during servicing, maintenance staff must ensure due care is
taken if it is found necessary to conduct any operational tests whilst the machine guard is
removed.

Residual Pressure

Due care should be exercised by maintenance staff to protect against any residual
pressures that may be present in the machine as discussed in the maintenance sections

Organic Peroxides

Particular note should be taken that materials utilised for the various fluid parts of the
machine are specifically selected and designed for use with Organic Peroxides and resins
The nature of organic peroxide catalysts can be reactive with certain metals and plastics.
It is therefore imperative that when renewing parts during maintenance, only genuine
MVP Ltd component parts and spare parts be fitted to the machine.

Leaks & Seals

Any leaks that become evident either compressed air or fluid from machine piping or
fittings must be investigated and corrected as soon as they become evident. Any fluid
leaks or spillages of resin, catalyst or solvent must be immediately cleaned from machine
parts or surrounding area. Cleaning materials used must be safely disposed of in
accordance with recommendations as described on the appropriate MSDS

Safety Notices

All safety use recommendation and warning labels displayed upon the machine cover and
chassis must be maintained clean and visible to the operator.

Cleaning external surfaces

Do not use solvent based cleaners on the counter or the Resin Gel Alarm (RGA) system.
All metal parts including the entire Stainless steel chassis and facia may be cleaned with
solvent cleaners.

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2.0 Instrumentation and control familiarisation

To switch Air supply
ON to machine.

E Stop Button

Reset Button

1. Release E
stop - Turn
counter
clockwise to
allow spring
up action

2. Press Blue
reset button
on side

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To set resin outlet line

install 9 vdc

→

+

ess

Counter reset

Count set

Note the PDC Counter can
only be adjusted when PDC
white button is continuously
pressed whilst pressing each
counter button to select
predetermined count number.

Note. If counter is set to zero
then it is NOT possible to pr
green start

Adjust air pressure
to pump motor to at
least 1 bar (15 psi)

To recirculate the
operate this control
to ON ( turn
clockwise ¼ turn)

To inject Press this
button IN

To adjust Catalyst
ratio turn to right to
increase ratio. Turn
to left to decrease
ratio

pressure limit, adjust
to at least 0.5 bar
(7 psi)

To flush head, Pull
OUT for at least 30
seconds.

Resin Gel Alarm. To
activate –
battery. See

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during recirculation. It should be adjusted

downwards) during pump movement.

Catalyst
flow

The Catalyst Bottle mounted at the rear
of the machine is fitted with a glass tube
to allow observation of catalyst flow

to remain visible by tightening in position

Above is a typical view of the catalyst
flowing down the glass tube during
re-circulation. This flow should be
seen for each stroke (upwards or

Before proceeding to connect air supply to the machine ensure for safety reasons the
following steps are taken. Refer also to image files in Last section of this manual

• Emergency Stop/ ON/OFF button is pushed down and locked - Machine OFF.

• Solvent/Air flush switch is off (Pushed in)

• Pump Start/Stop recirculation Control is switched to OFF as marked (90º turn)

• PDC counter is set to zero 0000 counts and reset is pressed once firmly

• Catalyst Ratio arm guard is screwed into position.

2.1 Connect shop air supply to machine located at rear top of machine chassis (8mm
Push fit connector) Yellow 8mm pipe supplied

2.2 Switch on air by partially rotating anticlockwise RED Emergency Stop/ON/OFF button.
This will enable it to turn the air ON by spring UP action.

2.3 Press blue pushbutton marked “RESET”

2.4 Check machine pump operation by first clockwise increasing the Pump speed
regulator control to preset to 2 bar shown on Pump speed Pressure gauge.

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2.5 Check Mix resin pressure regulator is preset at 1 bar shown on Mix resin pressure
gauge by clockwise increasing Mix resin regulator control.

2.6 Rotate to recirculation switch Pump control clockwise (90º)

2.7 The pump will now operate.

2.8. Turn Pump recirculation switch counter clockwise to OFF position

3.0 Priming SSB fluid sections. Catalyst, Resin, Solvent and pump
Lubrication.

NOTE - For safety reasons it is essential when carrying out any manual activity on the
lower guarded machine pump section that the machine is switched OFF.

3.1 Switch Machine OFF and for security isolate air by depressing E stop red button which
will lock down in OFF position

3.2 Fill Solvent cleaning tank with at least 5 litres of Acetone (see caution note below)
Maximum 20 litres. Use smaller white filler cap opening to do this. Replace cap (Do not fill
solvent tank through the large RED cap.)

Caution Note- DO NOT FILL the cleaning tank with solvent when the machine is fitted
with the SP3-NSH non solvent water based cleaner system tank. Use only water based
cleaner in these circumstances. E.g. RST-5 and HtwoO proprietary liquid cleaning
systems
The SP3 NSH tank is marked as such and is distinguished by external electrical heater
attached.

3.3 To enable access to fill the Catalyst bottle, first the black plastic catalyst feed pipe
bottle top union must be loosened to release the grip on the catalyst feed pipe. With this
done, unscrew the white bottle cap and fill bottle with the appropriate catalyst for
Polyester resin to be used. Replace cap and finger tighten the catalyst feed pipe once the
filter end is immersed and is touching the bottom of the catalyst bottle.

3.4 Place resin pickup pipe into suitable drum of pre accelerated polyester resin. Secure
pipe so that as resin container becomes empty (Lighter) the resin feed pipe does not pull
the container over causing a spillage. Also place resin recirculation pipe end securely

into resin container.

3.6 Set Catalyst ratio to Maximum Ratio by switching the MotoCat control to move the
Catalyst pump to the rear max. ratio. Note the motor will automatically stop when this
point has been reached.

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3.7 Operate recirculation to ON position and observe Catalyst and Resin pipes prime with
their materials. Continue until recirculation both resin and catalyst recirculation pipes
indicate flow back into the resin tank and the Catalyst bottle to ensure full priming of all
fluid sections.

NOTE.
If the catalyst does not prime easily it is possible to loosen the catalyst pipe union at the
head catalyst inlet. (See Catalyst Auto Valve drawing 22422-8 pipe union part number

0153). By loosening this union the down stream air can easily escape during initial priming
of the pump. Once the catalyst fluid has reached the pump, stop priming and re tighten
this union 0153 before continuing thus preventing Catalyst spillage

This initial priming method is only used for initial priming of a new machine from empty. It
is NOT necessary to use this method again once the machine has been in use.

3.8. Stop pump and prepare to prime head block and mixer for the first time.

3.9 IMPORTANT. Attach the 1 metre priming Pipe securely with quick release connection
to Mixer outlet point. Secure the other end in a waste container. Alternatively the Turbo
Autosprue (TAS) may be connected but so that it does not open during this initial priming
exercise simply do not connect the 4 mm TAS red signal line. However do secure the
clear 10mm drain pipe safely to a waste container.

3.10. Set pre determining counter to at least 10 counts and press counter reset button

3.11 Press inject green button. The pump will start and then stop after the predetermined
volume of resin mix has been dispensed into the container.

3.12 The RGA Resin Gel Alarm will sound within n30 seconds (see separate section on
RGA at the end of this section 3.)

3.13 Operate (Pull) solvent Air flush control. Allow machine head and mixer to flush clean
and dry out with air flow for about 35 seconds. Return solvent /air flush control to off
position. (PUSH IN)

b/ The machine design has build in safety preventing inadvertent operation of the flush if
the operator attempts to flush during injection. The flush control will only be active when
the machine is NOT injecting

The machine is now fully primed and ready for first mix and gel test before production
operation.

3.14 Resin Mix gel time test

It is important that the mixed resin reactivity (gel time) needs to be checked before
injecting a mould. It is wise therefore to make a test mixture from the machine mix head in

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order to determine this gel time exactly at the ambient temperature and for selected
catalyst ratio.

To carry out a mix and gel test set the desired catalyst ratio and then simply follow the
same procedure from stages 3.9 to 3.13 above but direct the mixed resin safely into a gel
test container. Once the resin mix sample has been dispensed and the machine has
stopped, place the resin outlet pipe securely into the waste container before flushing the
head and pipe.

3.15 General notes on gel time.

a/ It is wise to set and confirm gel times at least 30% longer than mould fill time
b/ Remember that UP resin will gel twice as fast for a 10°C increase in resin temperature.
c/ Be aware that cool resin is significantly more viscous than when at normal room
temperature. In these circumstances allow more time to fill the mould and thus more time
for gel time is needed to ensure mould fill without pre gel condition.
d/ As a guide, MVP’s experience has shown a general UP low viscosity resin suitable for
injection has given the following general specifications on gel time
Using 6% strength Cobalt Naphthalate ( 6% CN) as the primary accelerator and AAP
catalyst

0.1% CN = 1 hour gel time with 1% AAP catalyst

0.2% CN = 20-30 minutes gel time at 1 % AAP catalyst

0.3% CN = 15-25 minutes gel time at 1% AAP catalyst
A typical 20 minute gel time would be formulated with 0.2% CN with 2 % AAP catalyst

ratio setting.
These figures are given as a guide and must be checked for your chosen UP resin

system. Some resins are supplied already accelerated however users often add more CN
accelerator to speed u the resin gel time if found too slow.

4.0 Machine Operation

4.1 RTM or Light RTM operation

4.2 Adjust Catalyst ratio to required setting

4.3 Attach Mould to Mixer output point using 10 mm nylon pipe or via Autosprue® or
Turbo Autosprue brass quick connect. IMPORTANT –Ensure this is locked into position.

Notes a/ Additional lengths of 10mm pipe are available from MVP Ltd.

b/ The TAS 4mm red signal pipe is connected to the SSB chassis connection on
the left hand side 4mm central connector marked Autosprue signal.

Note- do not mistakenly connect to the lower 4 mm chassis connector as this
is a remote start optional connection and if connected to the Turbo AS it will
actually start the machine.

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These are marked and located on the LH side of the chassis next to the Mixer
output point. see diagram illustration at end of this manual referring to additional
connections.

Note – The 6 mm Autosprue connection at this location is no longer required
for the latest Turbo Autosprue (TAS) and should remain plugged. However
this point can be utilised by the user as an air gun pressure connection point
or to the Vacuminder.

4.4. Injection operation start and stop
Injection is carried out by setting the Pre determining counter (PDC) lower number set to

the expected volume of resin required. Each digit count represents a volume of resin
approximately equal to 38 cc. To determine exactly the volume collect 10 strokes of resin
accurately from the recirculation resin hose end and observe how much it weighs or
volume for the 10 strokes. If 10 strokes measure 380 ml (0.38 Litres) then each stroke
(numeric count on the counter will give a volume of 38cc. .
Be aware that a count of ten should only be made once the mixed resin has filled the
mixer and pipe

Once the predetermined counter has been set and the PDC counter top LH reset button
has been pressed firmly and the outlet pipes are connected to the mould simply press in
the green start injection button. The machine will now open both the head resin valve and
catalyst valve and internally provide the machine control with a confirmation signal to
start. The machine will dispense/inject the PDC volume of catalysed resin. Speed of
injection can be adjusted by the pump speed regulator. Upon reaching the PDC set count
the machine will stop automatically and the head valves and Autosprue will close safely.

4.5. Once the machines stops, the Resin gel alarm (RGA) will sound after 30 seconds (if
flush is not operated) to warn that the head needs to be flushed. Operate the Flush pull
switch for a minimum of 30 seconds. As soon as this switch is activated to flush the alarm
(if sounding) will cease but the red flashing warning will only extinguish after 30 seconds
confirming that sufficient air drying time has elapsed.

Note if the flush control is pushed in, to stop flushing sooner than 30 seconds the RGA
alarm will sound once more warning that not sufficient time has been allowed for the
recommended air dry out time. If this happens simply operate the flush pull switch once
again and only push back in to stop after 30 seconds has elapsed which is confirmed by
the RGA red flashing light ceasing and the RGA going back into sleep mode (No lights
and no alarm.)
Note if a count of resin is set greater than required it is necessary to stop the machine
manually. To stop the machine under this circumstance simply hit the E stop followed by
unlocking the E stop and pressing the blue reset button. .For security reasons the
machine systems will not allow flush if the green start button is depressed ON. Only the

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count reaching the pre determined count or hitting E Stop and resetting the machine to
ON will allow flush to take place.

Finally if a count on the PDC was set too little and more resin is required to fill the mould
simply press the PDC rest button followed by pressing the green start button once again.
As this selects the original count set, the machine will now continue to pump until the full
reset count is achieved. Stop the machine as described above in these circumstances
and record the number of extra counts the mould needed. This will allow a more accurate
count to be set for the next injection cycle on the same mould.

5.0 Shut down

5.1 Operate the pump to the down stroke limit by using of the recirculation switch. This
ensures that the resin pump piston shaft remains unexposed to air during shutdown and
thus lengthens the life of the shaft seal.

5.2 Turn off machine air supply by pushing the emergency stop button to OFF locked
position.

6.0 Routine Maintenance

General.
Ensure working parts of machine are kept clean. Also ensure all controls and indicators
remain clean. The gauges are glass faced and can be cleaned with solvent however all
other plastic controls should be cleaned with non solvent based cleaners. Remove all
spillages from machine. Immediately correct any air leaks or seepage of any fluid from
machine.

6.1 Resin pump. During normal use the resin pump lubrication cup needs to be topped up
with pump lube. This should be checked at least once a week during normal daily
production use. See separate sheet on internal part maintenance in section 9.0

6.2 Catalyst pump and feed and recirculation pipes. The catalyst pump needs no regular
maintenance however any seepage producing catalyst spillage from the machine from
catalyst pump top seal indicates catalyst pump top seal replacement. See separate sheet
on internal part maintenance in section 10.0.

Please note seepage of catalyst NOT producing leakage onto the workshop floor
from this point on the catalyst pump is acceptable.

Visually check security and condition of catalyst feed pipe from Catalyst bottle and smaller
recirculation pipe and all associated fittings. If any show signs of wear, seepage or
damage, replace with new parts immediately. Ensure Catalyst feed pipe is routed from
catalyst bottle to pump lower fitting around the right hand outside of the machine chassis

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The catalyst inlet filter located within the catalyst bottle should be removed and cleaned in
solvent and water at least every 4 months.

The Catalyst bottle internals must remain clean. If catalyst appears to be discoloured or
any form of sediment is observed within the catalyst bottle remove and clean as
necessary and dry out before replacing with fresh catalyst and placing back into service.
Use only water through the catalyst system if cleaning is necessary. Do not use or pump
solvent based cleaners in the catalyst fluid section

6.3 Solvent Pump system. The Solvent tank requires no routine maintenance however if
dirt particles as sediment accumulate within solvent tank base remove and clean and refill
with fresh solvent.

The remaining solvent system should only be routinely maintained by weekly checks to
locate any leaks or damaged pipes which should be repaired immediately.

See separate sheet on internal part maintenance in section 12.0

6.4 Mixing head assembly. The Resin mix pressure sensor (Mould Pressure Guard ­MPG) has an internal diaphragm which should be renewed periodically. A renewal rate
after every 10,000 Kg mix usage is recommended. See sections 11.0 and 11.1

7.0 Maintenance

Important Safety Note All maintenance work on the machine must be carried out with the

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 residue pressures.

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

Maintenance feature for ease of access.

It is now possible to remove the entire Patriot fluid section once the air pipes and fluid
pipes have been disconnected. There are NO bolts holding this section in the machine.
Instead the unit is locked into position with an over centre lever lock.

It is a simple and rapid procedure to remove the pump and is recommended if any main
maintenance operations are to be carried out on this section.
Proceed as follows.

1. Lift catalyst and resin intake wands above fluid levels and recirculate to empty both fluid
section.

2. Remove pump guard and the resin outlet and catalyst outlet pipes. Take care to mob
up slight fluid seepage from these unions as they will still have a small residue of fluid

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1

2

3

4

5

1

2

Remove guard Disconnect resin outlet Disconnect Catalyst
inlet and outlet

3. Disconnect 5 pneumatic pipe connection at rear of pump air motor and 2 at front on
MotoCat .

Disconnect 5 pipes to pump air motor ↑

Disconnect 2 red MotoCat feed pipes

→

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