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Turbo Autosprue -TAS
Low Pressure - Nylon Hose # 5855
Also available as:
Heavy Duty - High Pressure Hose # 5856
High Temperature # 5856HT
TAS Spares Kit # 5858
Procedure for set-up and use
The Turbo Autosprue™ is designed to interface between RTM or LRTM moulds and a Magnum Venus
Plastech meter mix machine, or any other automatic unit for dispensing mixed resin.
Turbo Autosprue Instructions Issue_ 11 17/12/08 Magnum Venus Plastech Ltd - Reg No 3978164 Page 1 of 6
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Connecting the TAS to the mould:
Ensuring that the two nose o rings are in place (just the one o ring on older models), wipe some silicone
grease over the o rings to help protect them from wear.
With the spring clip in position on the Locksert connect the Turbo Autosprue™ (TAS) to the mould by
simply pushing the TAS firmly into the Locksert until a positive click is heard as the spring clip locates,
and locks the TAS in the insert.
Once locked in position the TAS nose will be flush with the base of the Locksert and the mould face.
To check that the TAS is correctly locked in place, pull firmly whilst rotating the TAS body.
To remove the TAS from the Locksert simply turn the spring clip through 90º and gently pull on the TAS
body to release the TAS.
Operation:
With the TAS firmly locked into the mould Locksert connect the machine nozzle to the quick release
input connector. Connect the red 4mm start pipe to the 4mm air fitting on the side of the TAS body.
Place the 10mm nylon drain pipe in a vented waste container ensuring that it is firmly fastened in the
container to avoid the pipe becoming dislodged during flushing with solvent and air.
When the machine starts the TAS valve will open and allow free passage of resin mix into the mould. On
completion of the injection the machine will close the TAS and flush the mix-head, injection pipe and the
internal fluid path of the TAS and then deliver the waste solvent to the vented waste container.
The TAS is suitable for use in all orientations - vertical, upside down and horizontal, and exhaustive tests
have proven that the TAS operates and flushes efficiently with a long service life in all positions with all
commonly used thermoset resin systems, whether filled or unfilled.
All tests have been conducted using one of Magnum Venus Plastech’s injection machines fitted with the
SP3 non-pressurised solvent pump system. In conditions of low air pressure (below 5.0 bar) efficient flush
and cleaning may not occur, leaving build up and traces of catalysed resin within the valve, feed pipe and
drain pipe. Ensure therefore that all flushing systems are maintained correctly and operated at the
recommended supply pressure range of 6 - 7 bar.
SAFETY NOTE:
Ensure that relevant Personal Protective Equipment, especially eye protection, is worn when testing or servicing the
Turbo Autosprue.
Note:
NEVER - Operate TAS without sufficient cleaning/flushing solvent flow.
ENSURE – The correct cleaning/flushing solvent pressure of at least 6 bar
IMMEDIATELY - Renew nose outer red silicon seal (3265) if damaged
DO NOT - Unlock or attempt to remove TAS from the mould:
1. During the injection or flushing operation.
2. Until the resin in the mould has cured.
ONLY USE - Genuine spare parts from Magnum Venus Plastech.
RENEW – Locksert clip if damaged or contaminated.
Turbo Autosprue Instructions Issue_ 11 17/12/08 Magnum Venus Plastech Ltd - Reg No 3978164 Page 2 of 6
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Maintenance:
(Refer to drawing 22414 below)
The Turbo Autosprue™ is designed to operate for several hundred injection cycles without any need for
maintenance. After lengthy service (700-1200 cycles) we recommend that the following maintenance
checks are carried out.
1. TESTING THE SEALS.
Operate the valve between open and closed and check that the valve nose seal moves back and forward
by 7- 8mm. If the movement of the nose seal is observed to be sluggish proceed to check, and if
necessary replace, the main piston seal and / or the shaft seals.
2. CHANGING THE NOSE SEAL.
With the TAS closed (no open signal) operate the machine’s flush cycle.
After 12 seconds and with the air-dry flush cycle still operating block the drain pipe outlet. This will
pressurise the valve’s fluid section and enable the observation of any air leakage out through the main
nose seal # 5837.
Should any air leakage be present under these conditions replace the nose seal # 5837.
The integrity of the nose seal # 5837 is determined entirely by the tightness of the nose screw # 5832 as
it compresses the nose seal against the washer # 6095 and the base of the shaft.
CORRECT TIGHTENING of the nose screw will seal the nose.
OVER TIGHTENING of the nose screw will seal the nose BUT prevent the nose seal moving back
and forth between the seal surface of the nose # 5852 and the seal surface of the body # 5831.
UNDER TIGHTENING of the nose screw will not seal the nose and it may leak solvent and air into the
mould cavity and/or leak resin through to the flush outlet whilst injecting.
To achieve the correct tightening of the nose screw we recommend the following actions:
Assemble the nose seal # 5837 with the back-up washer # 6059 and the nose seal screw # 5832 as
shown using a small amount of BLUE LOCTITE 243 on the end of the screw. Screw into the shaft end #
5828 until it is finger tight and meets some resistance.
At this point proceed to turn the screw a further ¼ to ½ turn ensuring that the shaft # 5828 does not turn
at the same time. - To prevent the shaft from turning, apply 6 – 7 bar air pressure to the 4mm air fitting #
0645 on the side of the main body. This will open the valve and hold the shaft tight.
Immediately reassemble the valve and connect to the machine, and with the TAS out of the mould
operate the flush cycle and observe that there is no leak of solvent, or air from the sealed nose.
To test the integrity of the nose seal, further pressure can be applied to the TAS by blocking the TAS
drain pipe whilst the machine is flushing, this action will place the nose seal under full shop air pressure.
NOTE: The flush line should only be blocked in this manner once the solvent has flushed through and the
valve is only purging with air pressure.
If any leakage is observed at the nose during this test, immediately tighten screw # 5832 by a further ¼
turn, or more until the leak is sealed. This will increase the diameter of the nose seal # 5837 a further
fraction of a millimetre and effectively seal the nose in both the closed and open conditions.
3. CHANGING THE PISTON SEAL & SHAFT SEALS.
The 2 main shaft seals # 6004 should be replaced every 2,000 cycles or sooner if required. Any resin
found to be migrating into the upper air cylinder indicates the need for the immediate renewal of seals #
6004.
These are accessed by first removing the nose seal # 5837, then unscrew the cylinder top (but be aware
of the force of the internal spring). The Spring, Limiter and Piston assembly is then withdrawn from the
open cylinder end by pulling on the end of the brass shaft.
For further details of Turbo Autosprues required to operate at temperatures higher than 120ºC,or for use
at higher pressures, Contact your local Magnum Venus Plastech distributor.
Turbo Autosprue Instructions Issue_ 11 17/12/08 Magnum Venus Plastech Ltd - Reg No 3978164 Page 3 of 6
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Plastech TT Ltd © 2004. Design Rights - Plastech TT Ltd 2003. World Patents Pending. Autosprue™
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Problem Solving:
TAS valve sticking
1. The heavy, and very sticky silicon grease (especially at low temperatures) that is used to lubricate
the air cylinder can if applied too liberally, form a seal between the base of the cylinder and the
underside of the piston. During times of rest the grease can form a perfect, but unwanted seal as
it is compressed by the spring.
o To solve the problem, remove all traces of over greasing especially on the underside of
o NOTE: The PTFE bush # 5835 was modified in Dec 2006 to eliminate this occurrence.
2. Another reason for the TAS valve to stick closed is the excessive use of the White Loctite sealant
that is used when inserting the PTFE bush # 5835. If too much Loctite is used and the top of the
bush is not wiped completely clean before inserting the piston assembly it can over time, set and
adhere the piston to the cylinder base.
o To solve the problem, remove the piston and rod assembly and clean off any traces of
3. If the valve is still difficult to open, then check that:
o At least 7 bar pressure is available to power the valve.
o That the TAS valve been flushed correctly.
Damaged TAS Nose
1. It is most important not to damage the sealing surface of the 10mm hole in the TAS nose.
Damage usually occurs when the valve has been gelled up and mechanical attempts have been
made to rectify the problem.
o To solve the problem clean the gelled up nose surface with solvent and a cloth, or
o NOTE: Any scratch, or pitting damage on the precision 10mm nose bore will result in a
the aluminium piston and cleaning any grease from the bottom of the internal air cylinder.
The only grease needed is a very light smear on the vertical walls of the cylinder and a
very light smear on the two red o rings before replacing the piston assembly back into the
cylinder. Any additional grease will lead to re-appearance of the occasional problem of
sticking closed.
Loctite sealant or silicon grease. A light machine oil smeared over the cylinder wall will
suffice on re-assembly, as an alternative to the heavy duty silicon grease, however a
small smear of silicon grease is still required between the two shaft o rings # 6004.
alternatively, leave the nose in acetone for several hours to soften the residue before
attempting to clean the internal surface of the nose. On no account should any hard
metal scrape, or a 10mm drill bit, be used to clean this surface.
leaking nose seal and eventual damage to the nose seal itself. In the event that this nose
seal surface is observed to be damaged as described then it is necessary to replace with
a new nose # 5852.
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Installing the TAS in a metal mould
When you have a metal mould with the insert dimensions built in you can fix the Turbo Autosprue
in position either as shown above or below. Always bear in mind not to block the pin that
comes up in operation
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