Magnum Venus Plastech V6SC User Manual

ThermoJect model V6SC

Section

Description

Page

1.0

Machine Overview

1.1

Health & Safety General Overview

2.0

Instrumentation and Control Familiarisation

3.0

Getting started-Priming Fluid Sections

4.0

Machine Operation

5.0

Shut down

6.0

Routine Maintenance

7.0

Maintenance

8.0

Resin Pump

9.0

10.0

Injection Head & Mixer Assembly

11.0

Optional Solvent Pump

12.0

13.0

Machine Doctor

14.0

15.0

Machine Air Circuit

Commissioning and instruction manual

Issue 1 05/09

CONTENTS

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1.0 To enable understanding of machine controls please read the

Data Logging Screen
Screen Data mouse

Data Logger power

Pneumatic Instrument
Panel

Lift Off cover
Lift handles

Main machine cover
fixing screws at rear

Rear fluid
connections

In put air connection

Locking Wheels

following descriptions referenced to the general machine view

1.1 Health & Safety - General over view of important health and safety

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.

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issues relating to this machine

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 main cover 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

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, solvent or heating water 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 . All metal parts including the entire
Stainless steel chassis, facia and cover may be cleaned with solvent cleaners

Cleaning fluid section IMPORTANT RECOMMMENDATION

MVP Ltd. Have conducted several test and found the safest and most effective cleaner for
the pump and resin fluid pipe internal surface to be Acrastrip UK agents Chymera Ltd
Kenilworth, CV8 1PN. Tel. [phone], e mail [e-mail]
This is introduced into the pump inlet pipe whist at working temperature and pumped through
and recirculated from both the tank recirculation pipe end and resin inject outlet in turn. After
an initial recirculation of this cleaning fluid the pump is run without any cleaner being
introduced at the inlet in order to purge most of the contaminated cleaner and residue resin
mix.

After this initial cleaning operation clean uncontaminated cleaner is again pumped through
to rinse the system and can be left in the machine pump fluid sections during shut down.
Before the next production fill the machine is brought back up to temperature whereupon the
cleaning fluid is pumped out.

A fresh cleaning fluid batch may be again be recirculated throughout and finally pump mout
whereupon compressed air is connected to the pump inlet and forced through the system in
order to dry out any remaining residue.

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Incoming air pressure E Stop. Isolates all
Normal 6.5 -7.0 bar air pressure supply Injection resin pressure
to machine.
Pre Determining Counter
Pump air pressure (speed) able to set automatic fill quantity

Recirculation PUMP Test sample
Pump Speed Resin Inject pressure ON STOP Valve OPEN

Regulator Setting regulator
Injection
ON

At this stage the new production resin batch may be primed and made ready for machin e
production use.

2.0 Instrumentation and control familiarisation

The ThermoJect instrumentation and control is entirely pneumatic operated.
The following describes each facia indication and control feature and normal setting

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1 2 3
To switch Air supply ON to machine.

1. Connect 10mm air supply to Filter reg ( rear RH lower )

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

3. Pull reset out at rear ( this will stay out until shop air loss or E stop Operated)

3.0 Getting started

Air pressure to machine will now be indicated on LH instrument panel gauge and should
read at least 6.5 bar. Do not operate machine lower than 5.0 bar inlet air pressure.

Fluid sec\tion Connections

1/ connect 10 mm feed and return hot water supply to fittings on rear machine lower rail.

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Hot water flow and return 10mm push
fittings

NOTE It is important that the flow
polarity is observed

2/ Secure and connect the blue heated pump inlet hose to the heated resin day tank.
3/ Connect the recirculation black hose and sample valve with fitting to the heated Day tank

Top recirculation fitting.
4/ Route and connect the outlet hose with MPG and electronic pressure sensor to resin

injection point.
Pre heating system .

It is recommended that the machine fluid system is preheated to near working
temperature prior to filling with heated resin. Proceed therefore to recirculate hot
water throughout the machine hot water temperature control fluid section for 5
minutes.

Once preheated, commence to prime the resin fluid sections by operating ( push in)
the fascia recirculation push button. Note at any time the red pump stop button can
be operated to cancel this command.

It is important to run the machine as slow as possible to begin with to prevent pump
cavitation. A pump speed regulator setting of between 1 and 2 bar should be
sufficient

It is highly recommended that the single component resin is recirculated for at least
20 minutes to be sure the entire resin fluid section is thermally soaked and is all up to
temperature (circa 80C)

During this initial priming stage it is important to pour a small amount of single
component resin in to the pump top seal cup to act as a pump shaft lubricant.

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Proceed to extract a small quantity of heated resin at the test valve outlet. No more

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.

Counter reset

Count set

Note the PDC Counter may have 5 digits per count register.
Each digit represents nominal 100 cc resin displaced per
pump stroke.

than 150 cl is required . Stop the machine and remove the outer cover. Pour
sufficient heated resin carefully into the top of the pump gold block recess. Replace
machine cover and continue to recirculate.

Before any resin injection takes place observe the recirculation flow of resin back into
the holding tank to confirm no air is present in the flow at slow or higher speeds.

4.0 Machine Operation

4.1. Injection operation start and stop.

Recirculation.

It is recommended that when the machine is not injecting and especially prior to injection use
recirculation is switched on to keep all the fluid sections and resin at constant temperature. A
slow recirculation speed should be used meaning that the pump speed should be no more
than 0.5 to 1.0 l/min. (5-10 pump strokes per minute) To start recirculation press the
recirculation start button. To stop push the red stop button once.

Test sample

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A resin sample at temperature may be taken during SLOW recirculation mode. Place or
hold a container under the test valve outlet and operate the test toggle switch to open and
close as needed. CAUTION Never leave the test switch unattended in the open position

Injection

To inject resin first confirm that the recirculation flow is correct and no cavitation of the pump

at speed is noted. If cavitation takes place the pump will be heard to “jump” on the down

stroke characterised by uneven flow and short metering delivery compared to the output on
the UP pump stroke. This condition MUST be eliminated before any injection commences.

Usual causes of pump cavitation are-
a/ Resin viscosity too high for pump speed setting
b/ Insufficient temperature of resin leading to higher resin viscosity
c/ Pump speed setting above the maximum recommended for single component resins
( pump speed should not exceed 7 litres /min)

Ensure resin connection to the mould is secure and full vacuum security is achieved.
Ensure hose to mould from ThermoJect outlet hose is at working temperature (Circa 80C)
Press counter reset button to zero top register and set the pre determined count (PDC)

register to a desired value. If the PDC is not to be used to automatically stop the injection set
the pre determined count to highest number i.e. 99999

Set an initial pump speed of approximately 3 bar and press green injection button.

Remember at any point during injection the injection valve may be closed by pressing STOP
Red pushbutton.

Restart is achieved by pressing green injection button .
Speed of injection may be adjusted as required either up or down regulation of the pump

speed regulator as indicated on the pump speed (pressure) gauge.
IMPORTANT NOTE . Should the pump not respond to increased speed regulation then the

mould injection pressure (MPG) must be increased . The MPG will always override the pump
speed control be limiting it, should the down stream line pressure achieve the MPG pressure
setting.

5.0 Shut down

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

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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 recommended pump lube fluid. This should be checked at least twice a week during
normal daily production use. See separate section 9.0 on internal part maintenance.

6.3 Optional 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

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.

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8.0 100 cc water heated Resin Pump

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10.2 Auto Resin Valve assembly - RAV

Caution Note. For safety reasons - Always ensure that the Resin Auto valve above is
locked into position with the two securing lock M5 screws 4081

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10.3 Head Mixer and Mould pressure Guard (MPG)

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11.0 Optional Solvent pump NEW SP3

Note. With the introduction of the new Stainless Steel SP3 Solvent pump system on models
supplied from January 2003 it is possible to upgrade previous machine models with this unit.
It is a simpler design over the former SP2 system and has greater cleaning efficiency as
there is greater throughput of air to the pump and thus to the mixing head. A heated solvent
tank version is also available.

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11.1 SP3 assembly

13.0 Machine Doctor

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Fault
symptom

Possible cause

Remedies

Machine fails to
start on
recirculation or
injection
command

1. Air supply too low

Ensure air supply at least 6 bar
(90psi)

2. Pump speed set too
low

Set at least to 1 bar and above

3. MPG set too low

Set MPG pressure higher

ON injection
command
( when green
button is
pressed)

Check Resin valve has moved to
open position. Observe Metal pin at
pneumatic actuator has moved out..
Approx 8 mm for Resin valve. If not
then increase shop air pressure or
service the valve at fault.

5. PDC Counter not
reset correctly or set at
zero

Press reset firmly or set at least a
count of 5

6. Resin head valve
blocked .This condition
could happen if the
machine has been left
with resin in the system
for extended times
without use.

Internally clean and if necessary
renew internal parts.

Caution NOTE. Always replace the
resin valve locking M5 screws
securely after servicing the Resin
auto valve.

Resin flow has
bubbles or
appears erratic

1. Air leaks in the resin
feed intake system.

1.Check all joints for leaks in intake
pipe work and fittings on the resin
pickup fluid section

Flush does not
clean efficiently
or appears
weak

1.Low air supply
pressure

Ensure supply pressure between 6
to 8 bar (90 – 120 psi)

2.solvent valve assy
blocked or broken

Check assy 58742-PLAS internal
seat and spring

This table provides typical fault conditions their possible causes and remedies

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Resin pump top
seal leaking
beyond pump
lube zone

1. worn top seal

Renew seal

2. Top seal worn quickly
due to non lube renewal

Observe recommended pump lube
renewal

3.resin pump left for
extended times in UP
position causing shaft to
become dry

Observe recommended service
notes on pump parking position

Machine air circuit

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Issue record

Issue 01 dated 03/05/09 arh
– First write . Yet to be upgraded with air circuit and additional notes

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