Magnum Venus Plastech PCP-1000 User Manual

Rev. 05/2012

PCP-1000 CATALYST PUMP

MANUAL – MID RANGE

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CORPORATE HEADQUARTERS and MANUFACTURING

11692 56thCourt * Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER and MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel [phone] * Fax [phone]

MVP Plastech UK

Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: [phone]

Fax: [phone]

www.mvpind.com

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TABLE OF CONTENTS:

SECTION: Page

TERMS & CONDITIONS OF SALE 4

SAFETY & WARNING INFORMATION 6

INTRODUCTION 15

METERING PUMP DISASSEMBLY 19

METERING PUMP ASSEMBLY 22

PARTS DRAWINGS 25

REVISION INFORMATION 35

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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 late r.

 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 m ay 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

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against the Seller in respect of the goods, the liability of the Seller shall be limited
to the value of the goods.

 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 Occupational 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 laminat e
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 from 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. Firefighting equipment should be at hand and ready.

F. Avoid spillage, which can heat up to the point of self-ignition.

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 output 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 diluents being contaminated through rust particles in drums, poor quality control on the
part of the diluent 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, over ­sprayed 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 situation
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 ent ry 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 continuous 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.

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3.0 Equipment Safety

WARNING

Magnum Venus Plastech suggests that personal safety equipment such as EYE
GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be worn when 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 ANOTHER PERSON. (TREAT THE GUN AS IF IT WERE A
LOADED PISTOL.)

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 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 PCP-1000 Catalyst Pump Manual, provides information you need to
perform simple maintenance and repair on your equipment.

 Step-by-step assembly and disassembly procedures are included for each

component.

Please read the manual carefully. Follow the steps in the order given, otherwise you
may damage the equipment or injure yourself.

DANGER: Always wear proper safety equipment, including eye protection and
gloves when performing service and repair on this equipment.

During Disassembly:

As you disassemble the equipment, lay out the components on a clean surface in the
correct order and direction. This will help you to reassemble them.

This manual covers the following Catalyst Pump Assemblies:

PCP-1000-C-3J Catalyst Pump Assembly
PCP-1000-RV Catalyst Pump Assembly – Relief Valve
PCP-1000-RV-INT Catalyst Pump Assembly – Relief Valve – International
PCP-1000-TMA Catalyst Pump Assembly – Tape Machine
85707-1 Catalyst Pump Assembly (old systems)
85707-3 Catalyst Pump Assembly (old systems)

Note: Some parts and part numbers will be different between the different
Catalyst Pump Assemblies – it is important to have a current parts drawing for
the Pump assembly you are working on.

Tools needed for removal and repair of Catalyst pump.

 8” Adjustable wrench (08467)
 6” Adjustable wrench (08466)
 Flat head screw driver
 5/64” Allen wrench (9301-1-2) or (Allen wrench set 8469)
 Straight scribe (08126)

Note: If flushing the complete catalyst system from catalyst jug to gun is desi red
before working on system, use only distilled water.

Seal kit #: PCP-1000-SK

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Installation & Set-up

CHECKLIST

1. Check all clamp brackets, pump column, slave arm bracket, manifold clamp, etc. to make

sure they will not move when unit is in operation.

2. Check the mounting of catalyst pump to make sure pins are secure.

3. Make sure exhaust silencer is secured to the power cylinder of the resin pump.

IMPORTANT: Snug up the packing nut at the top of the catalyst pump approximately ¼ turn.

4. Pro Gun: Tighten the gun valve rod packing nuts until they are very snug. IMPORTANT:

Activate the gun trigger 10 - 15 times then tighten the packing nuts. Repeat this
tightening procedure 3 times to make sure the gun valve rod packing is tight.

5. Attach Suction Wand to Resin Pump.

a. Check all fittings on the wand assembly to make sure they are airtight.

b. Attach the wand assembly to the foot valve port of the resin pump.

6. Hose connections.

a. Connect the black resin hose from the gun to the outlet fitting on the resin filter.

b. Connect the catalyst hose from the catalyst pump to the inlet of the catalyst manifold.

c. Connect the catalyst hose from the gun to the outlet of the catalyst manifold assembly.

d. Attach the air hose from the gun to the fitting on the air manifold.

e. (internal mix) Attach the yellow poly flush hose from the gun to the outlet fitting of the

solvent tank.

f. (internal mix) Attach the small red air supply hose from the flush regulator to the input

fitting on the solvent tank.

g. Attach the large red air hose from the pump regulator to the power cylinder of the resin

pump.

Note: Check all hose fittings and fluid connections to make sure they are tight.

h. Attach the ground wire from the gun to the electrical grounding lug on the pump mounting

bracket.

Note: Check electrical ground to ensure it is installed from the pump mounting bracket to
an earth ground.

i. Remove the catalyst poly tubes from the component box.

j. Cut the ½ inch diameter poly line, with the clamps, to 26 inches long. Clamp one end to

the outlet of the catalyst jug and the other end to the inlet of the catalyst pump. Make
sure clamps are airtight.

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 17

k. Connect the ¼-inch poly line to the relief valve on the catalyst manifold assembly and

insert the other end into the hole in the top of the catalyst jug.

l. Connect the ¼-inch poly line to the catalyst recirculation valve on the catalyst manifold,

and insert the other end into the hole in the top of the catalyst jug.

7. Check all components and hoses for damage.

8. Check and tighten all fittings.

9. Check resin filter – apply red grease to the filter cap threads and o-ring reinstall. Do not

over tighten.

10. Check resin surge chamber – apply red grease to o-ring and nipple threads and reinstall

surge chamber hand tight.

Maintenance

 At least every six months, completely disassemble and inspect the catalyst pump

assembly. Replace the S.S. balls, O-Rings, springs, piston seal and packing
assembly.

 Snug / tighten the Metering pump packing nut approximately 1/8 – 1/4 turn

clockwise to prevent leakage. Repeat this procedure when necessary to
prevent material from leaking. Do not over tighten as this will reduce the
life of the packing set and may cause damage to the pump.

Troubleshooting

 The catalyst system should be checked if you are experiencing an uneven cure

or slow gel time.

 For a complete troubleshooting guide, please refer to the manual “Testing &

Adjusting Your MVP Pumping System” containing important testing procedures
that should be performed every time the catalyst pump is serviced.

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 18

Remove Catalyst Pump Assembly:

CAUTION: There are four (4) small stainless steel balls in the catalyst pump assembly. If
a ball drops to the floor, it will be damaged. (Even if it appears undamaged, it will contain
dents and scratches that will create problems.) Damaged balls must be replaced or the
pump will not work properly.

WARNING: Be sure hands, tools and work area are clean and free of resin, dirt or grease
before attempting to disassemble the components of the catalyst pump assembly.

DANGER: To prevent injury, never perform service and repair on the catalyst system
until system pressure has been relieved.

DANGER: If material is plugging the system, some parts of the system may still contain
fluids under high pressure, even after following normal procedures to relieve pressure.

1. Turn Pump Pressure regulator to zero (0) psi.

2. Relieve fluid pressure by opening recirculation valve on the catalyst manifold. For

system without a catalyst manifold hold the gun over an appropriate container and pull
the trigger.

3. Drain any remaining catalyst from the catalyst jug.

WARNING: Follow catalyst manufacturer’s recommendations regarding handling,
storage or disposal of catalyst.

WARNING: To prevent injury, hold a large rag or shop towel around the wrench and
fitting as you remove the fitting. Remove fitting slowly to allow fluid pressure to escape
into the rag or towel.

4. Read the warning above, then disconnect hose lines and cover them so they do not leak.

5. Remove the catalyst pump assembly from the slave arms by removing the priming knob

(50100-1), and upper and lower quick pins (52106-3).

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 19

Catalyst Pump Disassembly:

Remove Outlet Body from Inlet Body

1. Place the pump in a smooth-jawed vise by clamping on the flat edges of the inlet body.

2. Unscrew the outlet body (15824-3) from the inlet body (4104-7-1) by using two opposing

wrenches to loosen the lock nut (4101-1-1) above the inlet body.

NOTE: The O-Ring (O-S-014) between the outlet body and the inlet body will need to be
replaced during reassembly.

3. Remove the inlet body assembly from the vise, being careful not to drop the S.S. ball

(9101-1-14).

Disassemble Outlet Body

1. Unscrew the outlet check valve assembly (52108-1) from the catalyst pump’s outlet

body. Not all systems will have this check valve assembly installed; some systems will
have the outlet fitting or the relief valve adapter.

2. Unscrew the bearing block assembly (50210-3) from the piston rod (85788-1).

NOTE: Do not remove the Bearing (9202-1-1) from the bearing block assembly unless it
is worn or damaged.

3. Unscrew the packing nut (50590-1) from the outlet body.

4. Push the piston rod (85788-1) out of the outlet body. Be careful not to damage the outlet

body.

CAUTION: Be very careful not to scratch the inside of the outlet body with the rod.

5. Use a clean ¼-inch (0.6 cm) dowel or rod to push the packing assembly (4102-5-01) and

upper guide (4102-4-1) out of the top of the outlet body (15824-3).

NOTE: Some older catalyst pumps may have the spring disc set (04313-1) in the outlet
body – install upgrade kit (04313-3).

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 20

PISTON ROD

SPRING

SS BALL

PISTON BODY

PISTON SEAL

LOWER GUIDE

SEAL RETAINER

Piston Rod Disassembly

Remove the following components from the piston rod:

a. Seal Retainer (4102-9-1)

b. Piston Guide (4102-8-1)

c. Piston Seal (7304-1-1)

d. Piston Body (4102-7-1) being careful not to drop the

S.S. ball

e. The S.S. Ball (9201-1-5) inside the piston body.

6. If the spring (4101-3-1) in the end of the piston rod is

damaged, remove it.

7. Roll the piston rod on a flat surface to check that the piston rod is not bent. If the piston

rod is bent, it must be replaced.

CAUTION: To prevent equipment damage, be sure to use only genuine Magnum
Venus Plastech replacement parts. Using unauthorized parts may lead to
equipment damage and personal injury.

Disassemble Outlet Check Valve Assembly

 Not all systems will have this outlet check valve assembly installed;

some systems will have the outlet fitting or the relief valve adapter.

1. Unscrew the retainer (4101-17-1) with a hex wrench while the retainer side of the check

valve is facing upward.

2. Remove the spring (4101-16-1) and S.S. ball (9201-1-7) from the check valve and

inspect them. Clean or replace the spring or ball if necessary.

NOTE: The two O-Rings on the check valve will need to be replaced during reassembly.

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 21

Disassemble Inlet Body

1. Remove the S.S. ball (9201-1-14) from the inlet body (4101-7-1).

CAUTION: Be careful not to drop the S.S. ball. If the ball is dropped, it must be replaced.

2. From the inlet body, remove the tube fitting (4101-8-1).

For systems with inlet Check Valve CV-2000 installed:

A. Remove the Check Valve (CV-2000) for the inlet body (4101-7-1).

B. Remove o-ring (O-S-013) and replace with new o-ring.

C. Remove the Inlet Tube Fitting from the check valve. Remove and discard the O-Ring

(O-S-013) replace with new o-ring depending on the inlet fitting.

D. Remove the seat housing (CV-2001) from the spring housing (CV-2002).

E. Remove and clean spring (CV-2004) and piston (CV-2003) with warm water.

F. Remove and clean o-ring O-S-011 with warm water, replace as necessary.

G. Clean seat housing and spring housing with warm water and inspect for damage.

H. Install the spring into piston and piston into the spring housing.

I. Install a new o-ring (O-S-011) into the seat housing and thread seat housing onto spring

housing.

J. Install the tube fitting into the outlet side of the check valve.

K. Install the rebuilt check valve (CV-2000) onto the outlet body.

NOTE: Once disassembly is complete all parts should be flushed in distilled water and
inspected for damage and replaced if necessary.

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 22

PISTON SEAL

SEAL RETAINER

LOWER GUIDE

PISTON BODY

Catalyst Pump Assembly:

Assemble Outlet Check Valve Assembly

 Not all systems will have this outlet check valve assembly installed;

some systems will have the outlet fitting or the relief valve adapter.

DANGER: Fire and Explosion hazard. Use only clean water to wet the S.S. ball. Fire or
explosion may occur if the catalyst system is contaminated.

WARNING: Follow all materials handling and storage suggestions from your catalyst
manufacturer.

1. Wet the S.S. ball (9201-1-7) and the ball seat with clean water, and gently roll the ball

into the check valve body (4101-15-1).

2. Insert the spring (4101-16-1) on top of the S.S. ball in the check valve body.

3. Screw the retainer into the check valve.

4. Be sure the jam nut (4101-18-1) is screwed onto the check valve.

Assemble Outlet Body

WARNING: Follow all materials handling and storage suggestions from your catalyst
manufacturer.

1. On the piston body (4102-7-1), install the piston seal (7304-

1-1). Be sure the spring in the piston seal faces toward the
piston body (top of the pump).

2. Install the piston guide (4102-8-1) onto the piston body just

below the piston seal.

3. Screw the seal retainer (4102-9-1) onto the piston body.

NOTE: Bottom out the seal retainer on the threads, but not over-tighten. The seal should
still be able to move slightly.

4. Clean the piston seal with clean water.

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 23

PACKING NUT

UPPER GUIDE

PACKING SET (5 pc.)

OUTLET BODY

PISTON ROD

5. Clean the S.S. ball (9201-1-5) and the ball seat with clean water, and gently roll the ball

into the piston body.

DANGER: Fire and Explosion hazard. Use only clean water to we the S.S. ball. Fire or
explosion may occur if the catalyst system is contaminated.

6. If the spring was removed from the piston rod, replace it with a new one.

7. Screw the piston body over the spring onto the piston rod.

8. Slide the piston body assembly into the outlet body, being

careful not to cut the piston seal.

WARNING: Do not scratch the inside of the outlet body.

9. Slide the packing assembly (4102-5-01) onto the piston rod.

Be sure the wide packing goes on last.

10. Slide the upper guide (4102-4-1) onto the piston rod on top of

the packing set.

11. Install the packing nut (50590-1) onto the piston rod and screw

into the outlet body. Tighten it hand-tight, but do not over-tighten.

NOTE: If the packing leaks, turn the nut one-quarter turn. Do not allow the packing nut to
bottom out on the outlet body.

12. Put medium-strength Loctite®on the threads of the piston rod, then screw the bearing

block assembly (50210-3) onto the top of the piston rod using two wrenches.

13. If your system has the outlet check valve, connect the outlet check valve assembly

(4101-01-01) to the outlet body (15824-3).

14. The arrow on the outlet check valve should point away from the outlet body.

Assemble Inlet Body

DANGER: Fire & Explosion Hazard. Use only clean water to wet the O-Ring and S.S. ball.
Fire or explosion may occur if the catalyst system is contaminated.

1. Wet the S.S. ball (9201-1-14) with water. Gently roll the ball into the inlet body.

2. For systems that do not have the CV-2000 Inlet Check Valve - wet the new O-Ring (O-S-

013) with clean water and slide it onto the tube fitting (4101-8-1).

3. Screw the tube fitting into the inlet body (4101-7-1).

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 24

Connect Outlet Body to Inlet Body

1. Be sure the lock nut (4101-1-1) is screwed onto the outlet body (15824-3).

2. Wet the new O-Ring (O-S-014) with clean water and place it on the outlet body.

CAUTION: Be sure the O-Ring is not on the threads of the outlet body.

3. Screw the outlet body into the inlet body, when the inlet body makes

contact with the outlet body unscrew the outlet body part of a turn so that
the inlet and outlet ports are offset one flat on hex. (See figure to the right)

4. Tighten the lock nut to the outlet body (15824-3).

Connect Catalyst Pump Assembly

NOTE: If you are continuing to service the rest of the Pumping system, do not connect
the catalyst pump assembly until after you have serviced the pump and accumulator. If
you have finished servicing the pump and want to connect the catalyst pump assembly,
follow the procedures below.

1. Reattach the catalyst pump assembly to the slave arms with the upper quick pin

assembly (52106-3).

CAUTION: Be sure the quick pins are in the same hole on both the upper and lower slave
arms.

2. Reattach the priming knob (50100-1) to the top of the bearing block assembly (50210-3).

3. Cut ½ inch (1.3 cm) off the end of the inlet hose that attaches to the inlet body’s tube

fitting (4104-8-1).

4. Connect the inlet hose between the catalyst jug and the pump.

5. Connect the remaining hoses.

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 25

Parts Drawings:

PCP-1000-X Catalyst Pump Assembly – Internal & External
PCP-1000-RV-INT Catalyst Pump Assembly – International
PCP-1000-TMA Catalyst Pump Assembly – Tape Machine
85707-X Catalyst Pump Assembly
PCP-1000-SK Catalyst Pump Seal Kit

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 26

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 27

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 28

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 29

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 30

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 31

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 32

MAGNUM VENUS PRODUCTS

10

28

26

38

12

8

4

34

9

44

14

35

15

16

42

13

33

5

33

33

11

46

47

2

24

27

46

329

17

18

19

32

20

49

36

33

41

30

8

23

50

51

85707-1 PRO CAT PUMP ASSY

85707-3 PRO CAT PUMP ASSY

WITH RECIRC

85707-1

MID RANGE PRO CAT PUMP ASSY

22

REV. C - REPLACED BURST DISC ASSY WITH 4101-10-1 CAP, & RELIEF VALVE WITH RV-100-1500 7/31/02 JEM

REV. D - ITEM 50. WAS 55900-1 09/08/05 BT2

33

52

53

54

55

56

57

REV. E - DELETED ITEMS 6, 7, 45, ADDED CV-2000 AND ALL ITS COMPONENTS 12/22/05 BT2
REV. F - ITEM 55 WAS O-S-011 03/10/06 BT2

37

25

1

21

85707-3

MID RANGE PRO CAT PUMP ASSY WITH RECIRC

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 33

DESCRIPTION

PART NO.

ITEM

COMMON ASSEMBLY PARTS LIST

QTY

MID RANGE PRO CAT PUMP ASSY WITH RECIRC 85707-3

1/4" POLY TUBE NATURAL

01417

1

4'

MACHINE SCREW

2

02849-16

1

CYLINDER OUTLET BODY

3

15824-3

1

LOCK NUT

4

4101-1-1

1

CHECK VALVE BODY

5

4101-15-1

1

JAM NUT

8

4101-18-1

2

PISTON ROD SPRING

9

4101-3-1

1

INLET BODY

10

4101-7-1

1

INLET TUBE FITTING

11

4101-8-1

1

UPPER GUIDE

12

4102-4-1 1

ASSY - PACKING SET

13

4102-5-01 1

PISTON BODY

14

4102-7-1

1

PISTON GUIDE

15

4102-8-1

1

O-RING

18

O-T-019 1

CATALYST SURGE CHAMBER BODY

19

4104-3-1 1

SURGE RELIEF VALVE BODY

20

4104-4-1

1

RELIEF VALVE ASSY

21

RV-1000-1500

1

RETURN TUBE

22

01417

3 FT

GAUGE ADAPT0R

23

4104-8-1

1

FITTING - CAT HOSE TO 1/8" NPT

24

4104-9-1

1

ASSY - TUBE FITTING

25

4108-1-01

1

SEAL RETAINER

16

4102-9-1

1

SURGE CHAMBER CAP

17

4104-10-1

1

41

8702-1-1

1

3000 PSI/KPA SS GAUGE

28

50590-1 1

PACKING NUT

50210-3

1

BUSHING BLOCK SPA

49

26

50100-1 1

PRIMING KNOB CAT PUMP

27

50210-1

1

BUSHING BLOCK -PISTON ROD END

29

6701-24-EN

1

PUMP SEAL WARNING DECAL

30

6701-6-1

1

2-1/4 DIA CLEAR STICKER

33

O-S-013

5

O-RING

34

O-S-014

1

O RING

35

7304-1-1

1

PISTON SEAL

36

7701-3-20

1

1/8-NPT SS HEX NIPPLE

37

8407-6-1

1

BALL VALVE

38

85788-1

1

PISTON ROD

MID RANGE PRO CAT PUMP ASSY 85707-1

MID RANGE PRO CAT PUMP ASSY WITH RECIRC 85707-3

PART NO.

ITEM

QTY

DESCRIPTION

MID RANGE PRO CAT PUMP ASSY 85707-1

55910-1

PART NO.

ITEM

50

1

QTY

ELBOW - CAT HOSE TO GUN

DESCRIPTION

FITTING - CAT HOSE TO GUN

1

51

55800-1

32

O-S-3-908

1

O-RING

42

9201-1-14

1

7/16 DIA SS BALL

44

9201-1-5

1

5/32 DIA SS BALL

46

9202-1-1

2

SPHERICAL BEARING

54

CV-2003

1

PISTON

56

CV-2001

1

SEAT HOUSING

55

O-S-011A

1

O-RING

53

CV-2004

1

SPRING

52

CV-2002 1

SPRING HOUSING

57

CV-2000

1

CHECK VALVE

ASSOCIATED PARTS AND ASSEMBLIES

INLET BODY SPA

4101-7-01

47

1

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 34

Revision Information:

Rev. 04/2011 Updated document drawings and format. The Revision

information chapter was added.

Rev. 05/2012 Updated the Logo, MVP Address and the manual format,

added the Terms and Conditions section. Removed the
Accumulator section and drawings and separated the
assembly and disassembly procedures.

PCP-1000 Catalyst Pump Manual

Rev. 05/2012 Page | 36

MAGNUM VENUS PLASTECH

CORPORATE HEADQUARTERS and MANUFACTURING

11692 56thCourt * Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER and MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel [phone] * Fax [phone]

MVP Plastech UK

Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: [phone]

Fax: [phone]

www.mvpind.com

Rev. 05/2012

Assemblies Covered in this Manual:
PCP-1000-C-3J Catalyst Pump Assembly
PCP-1000-RV Catalyst Pump Assembly – Relief Valve
PCP-1000-RV-INT Catalyst Pump Assembly – Relief Valve – International
PCP-1000-TMA Catalyst Pump Assembly – Tape Machine
85707-1 Catalyst Pump Assembly (old systems)
85707-3 Catalyst Pump Assembly (old systems)