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MAGNUM VENUS PLASTECH Part No. 90037-1

Operations Manual

Impregnator Roll Goods Wet Out Unit

Table of Contents

Impregnator Roll Goods Wet Out Unit Operations Manual

IMPREGNATOR CONCEPT

TYPES OF REINFORCEMENTS & SPECIALTY MATERIALS CHAPTER 1 - START UP OPERATIONS Solvent Material Supply CHAPTER 2 - PUMP PRIMING

Priming the Resin and Catalyst Pumps CHAPTER 3 - ACCUMULATOR CHARGING CHAPTER 4 - BALANCING RESIN AND CATALYST

Resin Distribution System & Loading Reinforcement CHAPTER 5 - RESIN/GLASS RATIO SETTINGS

CHAPTER 6 - CONTROL FUNCTIONS

Control Panel Functions for All Models CHAPTER 7 - OPERATING TECHNIQUE

CHAPTER 8 - AIR INCLUSION IN LAMINATE

CHAPTER 9 - SHUT DOWN PROCEDURES CHAPTER 10 – PARTS DRAWINGS

IMPREGNATOR CONCEPT The Magnum Venus Roving Impregnator System was designed for rapid, economical wet-out of reinforcement (fiberglass) with polyester resin. This is achieved in the following manner. The reinforcement is mounted on mandrel shafts above Impregnator. Material is fed down through the rubber feed rolls. These rolls are spring loaded and provide a means for spooling material off the mandrels. Material then passes through a resin bath, which is formed by the end dam at either end of resin rolls. Precatalyzed resin is supplied by a Magnum Venus H.I.S. dispensing system, through a resin manifold and into spreader tubes. The spreader tubes deposit resin on both sides of the reinforcement in amounts required for impregnation. The gap or nip of resin rolls is controlled by micrometer adjustment, allowing only the proper ratio of resin to glass to pass through the rolls as reinforcement exits the machine.

TYPES OF REINFORCEMENTS Various types of reinforcement are being processed with the Magnum Venus Impregnator units. These range from woven roving to chopped strand mat. There are, however, limitations to what kinds and at what rates various materials can be impregnated. Woven Products: As a general rule the more loosely a reinforcement is woven the better it lends itself to impregnation. A tight weave material will act as a fluid barrier and will not let resin pass through the glass strands as readily. As a result, it is very difficult to impregnate more than one layer of a tightly woven material at a time, where as a loose woven reinforcement will allow resin to pass through, and multiple layers can be impregnated. There is a point in multiplayer impregnating where it becomes impractical to impregnate; again this depends on type of material and weave. Chopped Strand Mat: Chopped strand mat materials are difficult to process through the Impregnator without having some form of wet strength support. This support can be in the form of machine stitching, additional binder, or by processing a woven product or unidirectional material with the mat. It is possible to process chopped strand mat without a woven product as a carrier if the following steps are taken into consideration.

1. A maximum drop distance from machine to mold surface of 7 feet (or less) is maintained.

2. A mat with maximum wet strength is employed.

3. The machine is kept running on a continuous basis.

4. If stops are required, the operator must advance mat through the wet-out bath every 15-30

seconds to keep the mat binder material from dissolving completely and mat from coming apart.

Most all manufacturers of glass reinforcements have chopped strand mat products that can be processed in the Impregnator. It is a matter of individual preference as to which one is utilized.

SPECIALTY MATERIALS There are several specialty reinforcing materials on the market that can be used with the Magnum Venus Plastech Impregnator. Unidirectional is the most often utilized of these specialty reinforcements. To be successful using unidirectional in the Impregnator, a material that has a cross stitch every few inches should be used. This will insure good integrity of the material until it is placed in the mold. You will find that unidirectional materials wet out much more readily than do woven or chopped mat materials. This is due to the loose strands of glass as opposed to a tight weave or compacted mat

material. As a result you will find the setting on the nip rolls will be slightly less for a unidirectional material than a woven material of the same thickness. There are special woven materials available that vary the number of strands that are in the warp or the weave of the fabric, the purpose being; to put the strength of the material in the direction that is more beneficial. You will find by utilizing these various types of woven materials you will get much better wet out, as well as better physical properties, and it will be much easier to place the material in the mold. Keep in mind that one material is not the right choice for every job and much time and effort can be saved if the materials are wisely chosen at the start.

CHAPTER 1 H.I.S. PUMPING SYSTEM-START UP AND OPERATION Your Impregnator system is normally equipped with a Venus High Volume H.I.S. polyester dispensing unit. This unit is capable of up to 40 lbs. Of resin per minute output; catalyzed from .25 to 1.25% by volume. To put the dispensing system into operation, follow procedures outlined below. NOTE: On models where pump is remote from unit, such as the bridge crane model, a second person will be required to charge the system in an expedient manner. CAUTION: When working around pressurized H.I.S. system, safety glasses should be worn at all times. SOLVENT MATERIAL SUPPLY

1. Check all hose connections. They must be pressure tight, no possible leaks.

2. Fill flush tank approximately ¾ full of the proper solvent. (Methylene chloride preferred).

3. Pressurize tank to 35 to 45 PSI.

4. Flush gun by pushing valve operator button on top of automatic gun block. Solvent flush should flow freely from mix chamber of gun. If no solvent is forthcoming, check for proper air pressure, obstructions in solvent line or gun head, or that the in and out hose connections have not been reversed on pressure tank.

5. When solvent is available at gun head for flushing unit, then and only then, proceed to charge system with resin.

CHAPTER 2 PRIMING RESIN PUMP CAUTION: Before attempting to operate resin pump, check all hoses and fittings to insure system will hold pressure.

1. Fill cup at base of pump shaft 2/3 full with lubricant. Refer to lubrication materials list for proper lubricant.

2. Fill power head lubricator 2/3 full with lubricant. Refer to lubrication materials list for proper lubricant.

NOTE: Pump must be assured of a sufficient resin supply at all times.

3. Back Air regulator to power head completely off. Rotate counter clockwise.

4. Open ball valve to power head.

5. Open gun head.

6. With an adequate supply of resin to foot valve of pump, (minimum 7-1/2 PSI) slowly open regulator to power head of pump. Not more than 10 PSI.

NOTE: Because seals in a new pump may be dry and therefore will not make a good seal, it may be necessary to wet the seals. This can be accomplished by removing the resin hose, accumulator, and pipe nipple from pump outlet and pulling a small amount of resin into pump through pump outlet port. Reassemble nipple, accumulator and resin hose and proceed with priming operation.

7. As pump begins to move resin through the system, close the gun head. Allow the pump to continue operating until it stalls out.

8. Close ball valve to power head of pump. 9. Open needles of gun head, allowing resin to drain from hose and accumulator.

NOTE: An appropriate container will be required under gun to contain resin flow. PRIMING CATALYST PUMP NOTE: Magnum Venus Plastech recommends the use of a manufacturer tinted catalyst if at all possible. This will insure the operator a visual check for proper catalyzation. CAUTION: Safety Cover must be on catalyst accumulator at all times when catalyst pump is connected to slave arms of resin pump.

1. With catalyst pump positioned in slave arms and lower quick pin in place remove catalyst hose from catalyst accumulator relief valve body.

2. Loosen packing nut located on top of catalyst pump where pump shaft enters pump. NOTE: This step is not mandatory if packing nut is plastic.

CAUTION: If stainless steel packing nut is not loosened before hand operating pump, excessive heat build-up can result in packing area.

3. Connect large suction hose to inlet tube fitting of pump. Secure with hose clamp on plastic sleeve supplied.

4. Connect small return tube to relief valve tube fitting on bottom of catalyst accumulator.

5. Place MEKP Catalyst container on floor below catalyst pump. MEKP must be lower than pump.

6. With upper quick pin removed and packing nut loose, if applicable, operate catalyst pump by hand using the priming knob only. Catalyst should start to move up suction tube to pump.

NOTE: It may be necessary to wet seal surfaces of the pump to start fluid moving. This can be accomplished by elevating the catalyst jug above inlet body of the pump and letting a small amount of catalyst run down the tube to the inlet of pump, then make one or two strokes with the pump.

7. Return catalyst jug to the floor and continue pumping until catalyst has reached a point in the suction tube 1 to 2 inches from the inlet of the pump. Stop pumping action and place MEKP container in jug bracket at side of resin pump.

8. Position suction tubes so they form an arc between jug and pump. The crown of the arc should be higher than the catalyst jug and inlet of pump.

CAUTION: The suction tubes must be held in this position at all times insuring that the air bubble in suction tube does not get drawn into catalyst pump. Air in catalyst pump can cause improper catalyzation. NOTE: The bubble may be as long as 8 inches and still function properly. With time, bubble will grow longer as catalyst gases off. The bubble gives a visual indication that catalyst pump is taking in material. With each up stroke of pump, the bubble will move forward toward pump. With each down stroke, bubble will return to its original position. Mark the position of the bubble by placing the black rings at each end of the bubble.

9. With jug and suction tubes in position and catalyst to the inlet of the catalyst pump, tilt catalyst pump toward resin pump so that the outlet of the pump becomes the highest point in the system. Operate pump by hand until fluid is emitted from outlet on both strokes of the pump.

NOTE: Be certain that all air is removed from catalyst pump to prevent air lock of pump. Air lock of pump will result in improper catalyzation.

10. When all air has been purged from pump, connect the catalyst hose to the accumulator. CAUTION: check all hoses and connections to insure a pressure tight seal.

11. With hose connected to pump and gun, make sure ball valve to power head of resin pump is closed. Open needles of gun head.

12. Operate catalyst pump by hand until an even, steady flow of material emerges from gun. NOTE: A suitable container will be required under gun.

13. Close needles of gun and flush solvent through mix chamber to clean out resin and catalyst.

CHAPTER 3 CATALYST ACCUMULATOR CHARGING NOTE: It is possible to damage the catalyst injector if resin side of system is pressurized first. To insure against such damage the catalyst side of the system should always be pressurized before the resin side.

1. With both the regulator and ball valve controlling air flow to resin pump power head in the off position, open needles of the gun head.

2. Because of the pressure required to force catalyst out to the gun head the accumulator may be full of catalyst. Allow this fluid to drain from accumulator through the open gun until the floating ball in the catalyst accumulator is seated on bottom of the accumulator.

NOTE: To speed up this operation, it may be necessary to install charging pump on catalyst accumulator and connect supply air (approximately 100 PSI) to the charging pump to assist in purging accumulator. CAUTION: charging pump “T” handle must be in full up position before connecting to air supply. Failure to have handle up may result in damage to pump and/or injury to operator. NOTE: Care must be taken not to move the catalyst accumulator valve body when installing or removing charging pump. Catalyst accumulator parts are not much more than hand tight and any movement could result in seal failure.

3. When poly ball is seated on bottom of accumulator and accumulator is completely empty of fluid, charge the accumulator to 4 times the operating pressure of the resin pump power head. (The resin accumulator is charged at the same PSI).

NOTE: A 50-60 PSI operating pressure to power head of resin pump will be enough to supply resin to nip rolls for most applications.

4. The catalyst accumulator has a very small volume and only 2-4 strokes of charging pump will be required to fully charge it. When accumulator is charged remove pump from accumulator.

NOTE: Charging Pump Gauge will read supply pressure with the “T” handle up and accumulator pressure with “T” handle down.

5. After removing charging pump, check charging valve of accumulator for a pressure seal by placing soapy water or other appropriate fluid over valve opening. If no air bubbles appear install seal cap.

NOTE: If air leaks from charging valve, accumulator will not hold a charge and source of the leak must be found and eliminated before proceeding.

6. Purge charging pump of catalyst fumes before attempting to charge resin accumulator. Stroke the pump several times to purge interior of pump.

RESIN ACCUMULATOR CHARGING NOTE: Resin accumulator must be completely void of fluid before attempting to charge system.

1. Purge catalyst fumes from charging pump by stroking pump several times before connecting

charging pump to valve body at top of resin accumulator.

CAUTION: Raise charging pump “T” handle to full up position before connecting air supply to charging pump. Failure to do so may result in damage to the pump and/or injury to the operator.

NOTE: Resin pour tubes and manifold block must be removed from gun head pour nozzle before attempting to charge resin side of system.

2. Connect air supply to charging pump. Air supply should be approximately 100 P.S.I. 3. With regulator and ball valve to resin pump power head in the off positions, open needles of

gun.

NOTE: A suitable container will be required under gun. 4. Allow fluid to drain from resin accumulator before charging.

NOTE: It may be necessary to assist the draining operation with the charging pump. Operate the charging pump until fluid no longer flows from the gun head. If this assist method is used it will be necessary to remove charging pump from accumulator after fluid has stopped flowing and relieve the pressure from the accumulator by forcing air valve open with a small, flat end rod in the same manner as you would let air out of tire inner tube.

This is necessary because 95% of the time an overcharged condition will have occurred while purging accumulator. 5. Proceed to charge resin accumulator to 4 times the amount that the power head of resin pump

will be operated at. In most cases 50-60 PSI power head operation will supply an adequate amount of resin to nip of rolls.

NOTE: Charging pump gauge will read line pressure with the “T” handle up and accumulator pressure with handle down.

NOTE: The resin accumulator must be completely void of fluid to insure an adequate charge. An improper charge will result in surging, uneven flow of resin, and poor catalyzation.

6. Remove air supply from charging pump and charging pump from accumulator.

7. After removing charging pump, check charging valve of accumulator for a pressure seal by

placing soapy water or other appropriate fluid over valve opening. If no air bubbles appear install seal cap.

NOTE: If air leaks from charging valve, accumulator will not hold a charge and the source of the leak must be found and eliminated before proceeding.

8. Close needles of gun and flush gun head.

9. Close the regulator to power head of the resin pump. Open the ball valve to power head.

10. Slowly open the regulator to power head. As resin fills the system, slowly increase PSI until desired operating pressure is reached and pump stalls out.

11. Install Turbulent Mixer and nozzle cap on gun head. With a container under gun to catch material, operate the pump until all air is purged from resin hose.

NOTE: Apply lubricant to threads of nozzle before installation to prevent galling of the threads. See lubrication materials list for proper lubricant.

NOTE: After air has been purged from the hose, the resin flow should be steady and even; no pulsation or surge when pump changes direction. If excessive pulsation is noted the charging operation must be repeated until desired results are obtained. An inadequate accumulator charge will result in poor resin/ catalyst mix and improper cure of the laminate.

12. When desired charge is obtained, there should be an even flow of material from the gun head

and a fairly uniform mix of catalyst and resin, provided the turbulent mixer is in place. Additional mix will take place as material moves through the pour tube manifold, etc.

CHAPTER 4 BALANCING RESIN AND CATALYST

1. Place a suitable container, one that will hold 2 gallons or more, under gun head.

2. With turbulent mixer and nozzle in place, open ball valve to power head of resin pump slowly.

When ball valve is open, slowly turn regulator to the power head to desired PSI (50-60 PSI for most applications).

The pump will stall out when fluid pressure is equal to the air pressure applied to power head.

NOTE: There is a 10:1 ratio between air pressure applied to pump and the fluid pressure that results due to the mechanical advantage in piston sizes.

3. With a container under gun and safety glasses on, trigger gun and allow the system to operate

for approximately 10-15 strokes. As system operates note the flow of material. It should be steady and even, no pulsation when resin pump changes direction. If colored catalyst is used, a fairly uniform mix should be coming from gun, provided turbulent mixer is in place.

4. After 10-15 strokes of the resin pump, release the trigger button, and pump will stall out when fluid and air pressure equalize.

5. Flush gun to clean gun mix chamber.

6. Observe the poly ball and fluid level in catalyst accumulator. They should be no higher than 2-1/2 to 3 inches from the top or bottom of accumulator. A perfect charge will place the poly ball and fluid level in the center of accumulator. When accumulators are properly charged and material is balanced and available at gun head, the pour tube system can be installed.

RESIN DISTRIBUTION SYSTEM (POUR TUBES)

NOTE: All connections for the pour tube system are “O” ring sealed. A liberal application of lubricant, preferably MVP Grease, is recommended before installation. All connections and seals in the resin distribution system are designed for hand assembly and disassembly. Care should be exercised to insure all joints, threads, and seals are well lubricated. To install resin distribution system, assemble as outlined below.

1. If the turbulent mixer and nozzle have not been previously installed, lubricate the nozzle threads

and “O” ring with MVP Grease and install.

NOTE: Threads may gall and damage nozzle cap if not lubricated.

2. Lubricate “O” rings in the manifold block and check to see if the static mixer is in place and all plugs are pressure tight.

3. Install pour tube manifold onto the gun nozzle. The pour tube manifold must be perpendicular to the gun and roll plate.

4. Rotate manifold block into position parallel to roll plate, and pull down until the block rests on the angle bracket.

5. Lubricate “O” rings on the pour tube plugs and install into pour tubes.

6. Install pour tubes into manifold block.

NOTE: For an unbalanced laminate, such as woven roving and mat, it may be necessary to have more holes in one pour tube than in the other. Care should be taken to install the pour tubes on the correct side if an unbalanced laminate is employed.

7. When pour tubes are in position over the nip rolls, rotate the pour tubes until the holes will direct

the resin down into nip of rolls and not onto reinforcement materials. When pour tubes are installed and in the correct position, the reinforcement material can be loaded and positioned onto Impregnator.

LOADING REINFORCEMENT Reinforcements of various types and combinations can be wet-out with the Impregnator. Refer to the section on reinforcement types. There are machine limitations noted in that section.

NOTE: When setting up the material, care must be taken to align the reinforcement in such a manner that it enters Impregnator at the proper location. The reinforcement should be centered equal distance from the ends of the rolls. This location must be repeated every time a new roll of material is loaded onto the machine. Through experience the simplest way to maintain location and repeatability is by use of shaft set collars.

Following steps outlined below will simplify the material loading process.

1. Place roving mandrels on the bearing blocks provided on machine. Center the mandrel on the bearing blocks so an equal length of mandrel protrudes past the bearing blocks on either end.

2. Place two set collars on one end of the mandrel, one on each side of the bearing block. Lock set collars into position with set screws.

NOTE: Set collars should be loose enough to sides of bearing lock so that mandrel turns freely.

3. Place proper size roving cone on the mandrel with the tapered end toward the center.

4. Remove mandrel from the bearing blocks and insert through core of the reinforcement. Place another roving cone on the mandrel and set cones into roving core.

5. Replace mandrel, with reinforcement mounted, back onto the bearing blocks.

6. Center material between the bearing blocks so there is an equal space at each end between material and bearing block. Check to make sure the cones are into the core and will not work loose.

7. Lock the cones to the mandrel shaft with set screws.

NOTE: When removing the paper core from the mandrel shaft to lead a new roll of material into place, unlock cone on opposite end from the set collars and insert mandrel shaft into new roll of material from that end, and replace cone, locking it into position. The new roll will be in the same location as the previous roll.

The above procedure holds true for units that have a roving cassette. Positioning of material is the same when mounting on a cassette.

Models with roving cassette will require the cassette to be lifted into position on Impregnator after reinforcement is mounted on cassette. 8. When material is in position on Impregnator, feed reinforcement down through the feed and

resin rolls. (Use remote roll or creep control valve to operate rollsuntil approximately 12 inches hangs below the resin rolls. Open feed rolls, and remove and wrinkles that may be between resin and feed rolls.

NOTE: With chopped strand mat and similar materials there is a hard side and a soft or fluffy side. When running such materials with a carrier such as woven roving, the soft side should always be toward the carrier, not toward the resin roll.

9. Adjust end dams up to the edges of the material. Care must be taken to insure proper

placement of the end dams. If they are too narrow it will cause the material to fold over and allow too much resin to pass through; too wide and excess resin will drop through resin rolls at the edges of the material When adjusting end dams for chopped strand mat the dams should be as close to the edges of the mat as possible and still allow the material to pass through without folding or wrinkling at edges. For woven roving and other materials that have a frayed edge, end dams should be set so the dam is as close to the outside strands as possible and the fray is folded up as it passes through resin rolls. When running two dissimilar materials such as chopped mat and woven roving, end dams must be as close to edges of the materials as possible. It may be necessary to compromise on setting end dams because of different types of edges on the two materials.

CHAPTER 5 RESIN/GLASS RATIO SETTINGS

The resin content is controlled by micrometer adjustment dials on the vertical roll plate supports. By opening or closing the adjustment dials, resin content can be varied to +/- 2% Through experience, it has been found that a 40-48% glass content works best for optimum performance of the Impregnator. Less than 40% glass, the laminate is very resin rich and dripping below Impregnator is a problem. More than 48% and the glass content is so high it does not wet-out well and additional effort is required for secondary hand rolling, etc. Due to various conditions; temperatures, viscosity, reinforcements employed, etc., it is impractical to give an exact setting to control resin content. Therefore, an approximation must be made and material burn out tests performed to get an exact resin roll setting. To obtain a very close approximation the operator should first measure the total reinforcement thickness (measured dry) and add to this dimension .025 to .035 to obtain proper roll setting. Example: Woven roving thickness = .030 Chopped mat thickness = .025 Added clearance = .030 Total = .085

A .085 gap setting of the rolls would be the starting point to determine glass/ resin ratio. A burn out test will be required to get extra data on glass content.

NOTE: Different materials- reinforcements and resin may look very different when wet-out by the Impregnator compared to what you are used to seeing. For example: a woven roving all appear to be much higher in resin content than it actually is. On the other hand, a heavy mat, (1-1/2 – 2 oz), will appear much dryer than it is. A combination mat and roving will appear dry on the mat side and wet on the roving side. Through experience, an operator will be able to tell when he is close to the proper setting on the rolls when he first starts and can adjust accordingly. By keeping a record of the burn-out tests of your various laminates the operator can change roll settings by checking records. NOTE: Burn-out tests should be conducted when a precise glass to resin ratio must be maintained. Burn-out tests will give exact data for setting nip of resin rolls. To perform a burn-out test: 1. Cut a sample of cured laminate and weigh it accurately. 2. Burn all resin from the laminate by use of a torch, oven or other suitable method. 3. Weigh the glass that is left after burning away the resin, again being very accurate. 4. By comparing the before and after weight you can obtain a very close glass to resin ratio.

The following steps should be taken when the machine is first set-up, and when there is any doubt as to the accuracy of the roll settings. 1. Close rolls completely by turning the micrometer knobs counter clockwise until they are

completely free, just spinning on the shaft with no load on the knob. 2. Looking up from below the resin rolls, check to see if rolls are completely together; no gap or

light appears between rolls at any point.

3. With a feeler gauge set for .030 turn both micrometer dial knobs clockwise until the gap, measured with the feeler gauge, is .030 across the full width of rolls.

4. Loosen set screw in the micrometer dial and rotate dial until the 30 is at the indication marks on the frame. Lock dial in place with set scew.

Turning dial in either direction will now change the gap setting of rolls to correspond with dial indication.

NOTE: Each indication mark on the dial has a value of .001. Two complete revolutions are required for a .100 gap of rolls. (.001 inch = .025 mm).

CHAPTER 6 CONTROL PANEL FUNCTIONS

PORTABLE AND FLOOR MOUNTED MODELS 1. Forward and Reversing Valve: Controls direction of rotation of Impregnator rolls. 2. On-Off Valve-Resin Pour: Controls resin flow from pump. Up position, to run pump; down

position, to stop pump.

3. Speed Control Regulator: Governs speed at which material will travel through machine.

4. Pressure Regulator: Solvent Pressure Pot.

5. Pressure Gauge: Solvent Pressure Pot. CAUTION: Do not operate flush tank pressure above 60 PSI.

6. Feed Roll – Open: Opens feed rolls to remove wrinkle from between feed and resin rolls. 7. Re-Set Control: When rolls are shut off by the bump bars, (panic stop bars) this button must be

pushed to re-activate pneumatic circuit to the roll drive. CAUTION: If forward and reversing valve is left on after panic bars have stopped machine, machine will start when re-set control button is pushed.

8. Solvent Flush Control: When button is pushed, solvent is flushed through gun head.

BRIDGE CRANE AND GANTRY MODEL CONTROL PANEL 1. Direction Control Stick: Pushing control stick in the direction you wish to travel will activate one

or more motors which will result in a modulated speed in the direction desired. The farther the stick is pushed from the center position, the faster machine travels; up to twenty feet per minute. Let go of stick and motion will stop and stick will return to center position.

2. Roll-Turret Control Stick: This, too, is a modulated speed control. Push stick forward and rolls will turn to feed reinforcement through. Pull back and operation will reverse. Let go of stick and motion will stop and stick will return to center position. Push the stick left or right and Impregnator will rotate in the desired direction, up to 360º rotation. Let go of the control stick, motion will stop and stick will return to center position.

NOTE: Do not reverse the impregnating rolls with a wet laminate in rolls. Damage to rubber feed rolls could result if exposed to resins or solvents.

3. Resin Pour Control: Holding button on the top of the roll-turret control stick down will activate the automatic gun circuit and catalyzed resin will flow to the resin roll bath.

4. Feed Rolls-Open Button: Holding button down on top of Direction Control Stick, will open the rubber feed rolls. This feature is used to remove wrinkles that may form between feed rolls and resin roll. By opening the feed rolls; the weight of the laminate and driving force of the resin rolls will pull the material tight.

5. Panic Stop Bars: The function of the control is to give a measure of safety to the operator when

working around the Impregnator rolls with roll guards up. Any slight pressure on either bar (3 pounds or less) will instantly stop the rolls from turning.

6. Roll Re-Set Control: When rolls are stopped by activating the panic stop bar the reset control

button must be pushed to re-activate the rolls pneumatic circuit. CAUTION: If the roll control is left on after panic bar has stopped rolls, they will start turning the instant the re-set button is pushed.

7. Elevator Down: Control function; man lift travels down.

8. Elevator Up: control function; man lift travels up.

9. Hoist Down: Control function; material hoist cables move down.

10. Hoist up: Control function; material hoist cables move up. NOTE: Both the material hoist and man lift are driven by 1 H.P., vane type air motors. Any over load will cause motor to stall out. When the over load is removed the motor will operate with no resulting damage to motor.

11. Elevator Remote Control: These controls are located on the elevator frame and are designed to be removed and clipped onto a sweep or squeegee handle for the convenience of the operator’s helper.

12. Remote Speed Control-Drive Rolls: Rotating the control in a clockwise rotation will increase

speed on Impregnator rolls when operating with the remote or creep control.

13. Remote Roll or Creep Control Valve: Push the handle down and the material will feed through the Impregnator. Reverse handle up and the rolls will turn in the opposite direction, retracting the material.

NOTE: Do not reverse impregnating rolls with a wet laminate in rolls. Damage to rubber feed rolls could result if prolonged exposure to uncured laminate occurs.

NOTE: The remote roll control valve handle must be in the off position (center detent) when operating roll-turret control stick. If remote control valve is not off, accurate control of the rolls with the stick will be lost.

14. Solvent Flush Control: Pushing and holding the flush button in flushes solvent through the gun

head, etc. Regulators are used to control various pressures required in the system are labeled on the panel. The 2 switches control the solvent tank pressure and the system pilot pressure. Turn solvent pressure switch to off and no air will flow to solvent tank. Turn pilot pressure switch to off and control functions on the valve panel will not operate.

CAUTION: Before attempting to operate the MVP Impregnator you should thoroughly familiarize yourself with the controls; their cause and effect. Failure to do so could result in damage to the unit and/or injury to operator. An unfamiliar operator should drive unit around until he becomes comfortable and feels at ease handling the machine before attempting to process laminate with the unit.

Any individual who can drive a car can be trained to operate the MVP Bridge or Gantry Impregnator units. To be a successful and proficient operator, however, the individual must be well coordinated, very conscientious and alert at all times. There are various functions the operator must monitor at all times. Therefore, his attention must be devoted to the machine.

It has been found, through practice, an operator will become proficient in about 5-10 days, depending on the individual. The sooner an individual becomes familiar with the controls and learns to relax, the sooner he will be able to devote his time to the lay-down technique of applying the laminate.

CHAPTER 7 OPERATING TECHNIQUE

The feed rates of various MVP Impregnator models vary from 5-20 feet, per minute, depending on the model and configuration of the mold or part being laminated. Laminate thickness also is a controlling factor in lay down rates. It has been our experience that the more mobile and versatile the unit is, the less labor involved in actual lay down and working out of the laminate required. For example: A bridge crane or gantry supported unit can process laminate in a given time and with less labor than a floor mounted or cart mounted portable unit because the laminate can be placed directly in the mold. The mobile units have been designed with a variety of mold shapes and configurations in mind. The controls are such that a good operator can speed-up or slow down his rate of travel to coincide with laminate lay down rate enabling precise placement of the lamination curved shapes and surfaces. With proper choice of reinforcement; taking drape of materials, size of radii corners, etc., into consideration, a considerable labor savings can be gained by eliminating secondary hand work. The floor mounted and dolly mounted models were designed primarily for large, for surfaces or very simple parts. Their primary function is to impregnate large quantities of FRP in the shortest possible time, thereby saving a large amount of labor. When amounted over a carousel track or conveyor, many parts or molds can be processed in a short time. More secondary operations such as hand rolling, squeegeeing or use of an MVP vibrating Roll-out system may be required because of the inability to place the laminate precisely in the mold. The lay-down technique employed becomes very important in determining the quality of the laminate and amount of labor involved in working the air out of the laminate. The configuration of part will be a governing factor in deciding which technique to use. For large flat areas or areas that have no compound curves, the best method has proven to be to control the rate of travel and rate of laminate feed so a wave, or roll effect is developed. This roll, or wave, will then push the majority of the air that is trapped under the laminate as it is layed down in front of the roll. A sweep or squeegee can be employed to help work the air out (much like applying wall paper) when using this technique. A second method which works well with surfaces that are irregular, such as ribbed sections, is to stretch and pull the laminate slightly. This technique should be employed anytime a vertical and horizontal surface must be covered in the same pass. Again a sweep or squeegee or some other tool can be employed to keep the laminate from bridging a radius. The most common mistake a new operator will make is the entrapment of air under the laminate as it is laid down. As a result, until the new operator develops a proven method and the skills required to operate the Impregnator unit without first having to plan each move ahead, secondary operations to remove air will be required; people with laminating rollers or squeegees working air out of the laminate. As the operator becomes more familiar with the machine and operating it becomes a reflex action, less and less secondary work will be required because less air will be trapped under the laminate.

CHAPTER 8 AIR INCLUSION IN LAMINATE

Contrary to first impressions, the Impregnator does not squeeze resin into the reinforcement. If the nip of the resin rolls is set in such a manner that they actually squeeze the glass, any resin in the material would be forced out just like the old washing machine clothes wringers, and the laminate would be very dry and high in glass content. In actual practice, the nip of the resin rolls is slightly wider than the reinforcement is thick. As the glass material passes through the resin bath it is wet-out and as it goes through the nip of the rolls the proper amount of catalyzed resin is allowed to pass through with it, governed by how wide the roll setting is. It becomes apparent, when the Impregnator method is analyzed, that if a given laminate is processed through the unit, a slow rate will allow more time for wet-out and better impregnation. The same laminate run at a faster rate will have more air inclusion because the material does not have time to wet-out completely before passing through the nip of the rolls. The thickness of reinforcement and/or the tightness of the weave becomes the governing factor in the rate at which it can be processed. The tighter the weave or thicker the laminate, the slower the rate will have to be. When processing woven roving, complete air removal is next to impossible if a reasonable production rate, with minimum secondary work, is expected. This is because of the air entrapment where the weave and the warp cross. Because of the double thickness of material at these intersections and the small air pocket that is formed, a vacuum bag process would be required to make the laminate 100% void free. Very few products require this type of quality laminate and therefore a compromise is in order; allowing minimum number of small air voids which in turn will allow a more rapid rate of impregnation. The problem with woven roving is compounded by going to a heavier material and/or a tighter weave. A tightly woven material sets up a fluid barrier that will not allow resin to pass through the strands of glass and wet them out. Keeping this problem in mind when designing reinforcement requirements for a particular product, will save much labor and allow a much faster rate of production with the Impregnator unit. Processing chopped strand mat, and like materials, also prevents some impregnating problems. The heavier a mat material is, the slower it must be processed. Additional binder in the mat, giving it added wet strength, (which is needed for processing mat without a carrier) will also require a slower production rate. The heavy binder acts as a fluid barrier and a slow rate is required to give the material time to wet-out as it passes through the resin bath. A certain amount of air inclusion can be tolerated when high production rates are required if the proper air removal method is employed on the secondary operation. The unique design of the thin finned laminating roller allows air to escape up and through the fins of the roller as the reinforcement is pushed down into the resin. When using other types of laminating roller, the air is pushed forward, in front of the roller, and must be worked to the edge of the laminate before it can escape. To use of the squeegee: This method of air removal works well for woven materials. The pressure action of the squeegee, as it passes over the laminate, pushes the trapped air up and out of the laminate. This type of air removal does not work with reinforcement materials that do not have the integrity to hold together after they are wet-out, such as chopped strand mat. For top quality laminates, such as corrosion applications or laminates laid on a gel-coated surface, air removal is a must. The impregnation rate must be slow enough to allow the glass to be thoroughly wetted and the operator to trap a minimum amount of air between laminate and

the mold surface when applying material. Only then can secondary operations be held to a minimum. There will always be a certain amount of air removal required when a top quality laminate is needed. How much will depend on your product specifications. It has been our experience that each customer has had some difficulty developing a technique that meets his requirements. Approaching the problems with an open mind and a willingness to try various ideas and methods is necessary to develop a viable, economical, productive operation. As the operator and support people progress and become more efficient and gain a better understanding of the Impregnator unit; how it works, what it is designed to do, and what they are capable of doing with it, the majority of problems encountered at the start will solve themselves or cease to exist. Remember, Magnum Venus Plastech has provided you with a tool; one unique to the industry. For what, and how, you use that tool is entirely at your discretion. We at Magnum Venus Plastech will work with you and your people in any way feasible to help you utilize this tool to make your operation of the Impregnator profitable.

CHAPTER 9 SHUT DOWN CLEANING PROCEDURE

By establishing a set routine the shut down and clean-up procedure can be kept to a minimum. With a well established policy and experienced personnel the clean-up procedure can be accomplished in as little as five minutes for shut downs under one hour, such as lunch breaks. For end of shift shut down, or overnight, a more thorough cleaning is required, but this can be accomplished in 15 to 20 minutes, with practice. A good policy is to have a designated area set aside for cleaning the unit; a cleaning station if you will. All the necessary solvents, tools, and safety features such as eye washes, showers, etc., can be located near this area. There are a few tools that will hasten the cleaning chores that are not furnished by Magnum Venus Plastech. These items are expendable and are readily obtained at a good hardware supplier. These items follow:

1. Bottle Brush- one with a wire handle and bristles at least ¾ inches in diameter. (Brush materials must be compatible with resin & solvents).

NOTE: A long rod (48 inches long or so) should be attached to one brush. The brush with long rod is used for cleaning the pour tubes.

2. Flexible hose or lengths of ¾” diameter pipe with union to drain resin trap pan.

3. 8” crescent wrench for removing gun plugs, etc.

4. Small screw driver with 3/16” wide blade. (Preferably with a wooden handle).

5. A set of allen wrenches for removal of set screws.

6. A small container for cleaning and storing small parts as the unit is disassembled.

7. A large, long washing tray for solvent when washing pour tubes, manifold block and resin dams.

(There may be other items that the clean-up crew will find handy but those listed above are a necessity if the job is to be carried out with any speed). When the machine is in place at the cleaning station, and the necessary tools and materials are handy, the following procedure can be followed when cleaning the unit:

NOTE: Two men should be used to clean the machine.

CAUTION: The rolls must always be operated in reverse when cleaning the machine. Hands and fingers should never be placed on underside of rolls at any time. CAUTION: SAFETY GLASSES SHOULD BE WORN at all times by personnel involved in cleaning Impregnator.

1. Remove glass material from the Impregnator by cutting above the rubber feed rolls. Run the

loose material through the Impregnator and dump the excess resin through the rolls. Stop the rolls from turning.

2. Place the resin trap pan in place under the rolls and connect hose or drain pipe to the bottom of the pan for draining the clean-up solvent. Place a container of at least 5 gallons capacity under the drain pipe or hose to catch used solvent.

3. Close nip of the rolls by turning the micrometer adjustment knobs counterclockwise to zero.

4. Move the end dams to the extreme edges of the resin rolls.

5. Start the rolls turning in reverse rotation.

6. Flush solvent through the gun head and pour tube assembly by pressing the air valve push button located on top of gun head cylinder block.

7. Allow solvent to fill the nip of the rolls. Wipe the resin rolls with your hands or with a shop towel

while the rolls are turning in reverse rotation. CAUTION: Never allow fingers or hands to come into contact with the underside of the rolls. Safety glasses and protective clothing should be worn at all times when cleaning Impregnator.

8. After the rolls are resin free, stop rolls and remove end dams and clean them thoroughly. Always stop rolls before removing end dams.

9. Remove the pour tubes by raising the end of the tube with the extension plug up, out of the bracket and pull tube out of manifold block. Care should be taken not to damage the “O” ring seals in the manifold block.

CAUTION: The pour tubes may have solvent left in them from the flush operation.

10. Remove the pour tube manifold block by swinging it out clockwise and pulling down. Care should be taken not to damage the “O” ring seal on the gun nozzle.

11. On some models the manifold block is equipped with a static mixer. Care must be taken to insure all catalyzed resin is flushed out of the mixer.

12. Clean all pour tube assembly parts thoroughly with clean solvent.

NOTE: The bottle brush, with the long rod attached to the handle, should be soaked in solvent and pushed-pulled through the pour tubes to remove all traces of resin.

13. Remove the nozzle from the gun head. Clean the nozzle and turbulent mixer with clean solvent.

Do not soak the turbulent mixer in solvent for any length of time. The mixer will absorb the solvent and swell and will not fit into gun head until sitting 24 hours to allow swelling to go down.

14. The rubber feed rolls should be cleaned by removing all foreign matter with your hands. NOTE: Do not soak or saturate the rubber feed rolls with solvent. Any prolonged contact with solvent will damage rubber.

CAUTION: Never allow fingers or hand to come into contact with the underside of the rolls while the machine is in operation.

15. Start rolls turning in reverse rotation. Starting from the middle and working to each end, spray

the resin rolls with solvent spray to remove all traces of resin from the rolls.

CAUTION: Safety glasses and protective clothing should be worn at all times when cleaning the Impregnator.

16. Stop Operation; re-assemble the nozzle and turbulent mixer, re-assemble the pour tube

assembly with the gun head and turn into place on machine. The Impregnator is now ready to resume operation.

NOTE: When re-assembling parts noted in Step 16, all threads and “O” rings seals should be well lubricated. See lubrication materials list.

If Impregnator unit is to be down for an extended period (2 hours or more) perform the following procedure between steps 11 and 12.

a. Remove the bottom gun plug from the resin side (side plug if high volume unit). Hold hand over the mix chamber of the gun and flush solvent through the plug port. Clean plug thoroughly.

b. Remove the side gun head plug from the catalyst side and blot out any excess catalyst from the open port with clean cloth. Wash plug with clean water and replace.

CAUTION: All parts that contact raw catalyst should be cleaned with clean water only and thoroughly dried before returning to service.

c. Turn air valve to power head of resin pump to off position.

d. Turn air valve to solvent pressure pot to off position and open relief valve on pressure pot.

e. Turn air regulator supplying air to gun trigger air valve to off position. Turn counter clockwise

until gauge reads zero.

The above steps “a” through “e” are safety precautions to prevent operation of material dispensing system accidentally.

EXTENDED SHUT DOWN OR STORAGE Should you wish to shut unit down for a prolonged period, 30 days or more, (15 days or more in the case of the resin pump), the following procedure should be followed to insure all systems will be operational when you wish to reactivate Impregnator.

1. All pressure should be bled from the pumping system.

2. The resin pump should have solvent cycled through until all trace of resin, etc., is removed. The solvent should then be drained from pump, gun and hoses, and a light-weight oil cycled through the pump only and then drained out.

3. Water should be cycled through catalyst pump, gun and hose until all trace of catalyst is

removed. Water should then be drained form pump and gun and they should be blown with clean, dry air.

4. Clean gun head to remove all traces of resin and catalyst; inside and out.

5. Coat all exposed pump shafts and needle shafts with lubricant to protect from shop dust etc.

NOTE: Use no oils or lubricants on catalyst pump.

6. Lubricate all bearings, shafts, and working surfaces, such as roving mandrels, with lubriplate.

See lubrication materials list.

7. Impregnator resin rolls, roll plates, and side support plates, should be coated with “pop-out” or other good mold release. See lubrication materials list.

8. All gear reducers, air motors, bearings, etc., should be serviced. See lubrication and

maintenance guide.

9. All air valves and operator buttons should be lubricated internally. See lubrication guide, and lubrication materials list.

NOTE: Step nine can be achieved by squirting oil into inlet ports of valves and then operating valves.

10. The machine should be moved as far away from the main shop area as possible and covered

with drop cloths to prevent glass dust, etc., from getting into bearings and on other machined surfaces. Taking the above precautions before a prolonged storage may prevent a major overhaul of pumping system and pneumatic functions prior to putting Impregnator back into operation.

LUBRICATION AND MAINTENANCE SCHEDULE At the end of every shift, after machine has been cleaned:

a. Coat all surfaces below resin rolls with “pop-out”. See lubrication materials lists.

b. Lubricate all bearings below carriage with lubriplate or equivalent.

c. Coat gun needle shafts with lubricant.

d. Coat gun nozzle threads and all “O” ring seals in the pour tube assembly with special MVP grease. See lubrication materials list.

NOTE: Directive (d) should be performed every time pour tube assembly is broken down. Failure to do so will cause galling of the threads and damage to the “O” ring seals.

SPEED REDUCER LUBRICATION Browning worm gear speed reducer high temperature lubricant # GL32HT or equivalent is recommended. See lubrication materials list. Using correct amount of oil is important. Too little or too much oil can cause overheating and rapid wear of gears, bearings, and seals. The approximate amounts of oil required are given on the lubrication name plate attached to the reducer housing. Service life and gear efficiency are affected by oxidation or contamination of the lubricating oil. Improved performance is obtained by periodic lubrication. AFTER AN INITIAL TWO WEEK OPERATING PERIOD, drain the oil while warm. Flush the gear case with light weight (5w or 10w), mineral oil and refill to proper level with fresh, recommended oil. FOR NORMAL OPERATING CONDITIONS, LUBRICATE AGAIN AFTER ONE MONTH AND THEREAFER AT FOUR MONTH INTERVALS. If unit is operated in abnormally high ambient temperatures or unusual contaminating atmospheres, or longer than 8 hours per day, lubricate more frequently.

NOTE: All gear reducers are filled with lubricant at the factory. A LUBRICATION CHECK OF ALL REDUCERS SHOULD BE PERFORMED BEFORE OPERATING. This is necessary to insure that no lubricant was lost in shipment.

BALL BEARING UNIT LUBRICATION All bearing units are lubricated at factory and are ready for use (except for unusually severe applications). Lubricated for life bearings have no grease fittings and require no additional lubrication while in use. Re-lube bearing housings have a lubrication fitting mounted on the housing and should be lubricated when used in wet or dirty applications.

NOTE: Bearings subjected to solvents while cleaning Impregnator should be lubricated after machine is cleaned. Failure to do so may result in damage to the bearing or contamination by catalyzed resin which will freeze baring unit up and render machine inoperable.

Experience will determine the best interval for each specific application. When lubricating bearings, add grease slowly while shaft is rotating. When grease begins to come out of seals, bearing will contain the correct amount of lubricant. See lubrication materials list.

DRIVE CHAIN LUBRICATION All drive chains are Number 40, ½” pitch, single strand, standard roller chain. Lubrication will reduce noise of the chain drive. Roller chain should be kept in good condition by proper lubrication and occasional cleaning. Lubricate manually with oil applied periodically with brush or spout can.

NOTE: Chain drives are located at bridge drive assembly, carriage drive assembly, turret drive assembly, and under gear cover on left end of Impregnator. The large spur gears that drive feed rolls should be lubricated at same time as the drive chain.

PNEUMATIC SYSTEM LUBRICATION

The pneumatic system is provided with an in-line lubrication device. This lubricator should be kept ¾ full of Air Motor Oil. For prolonged storage of unit, air valves and motors should be lubricated with Air Motor Oil through inlet ports and operated two or three times prior to shut-down. See lubrication materials list.

H.I.S SYSTEM LUBRICATION

Resin Pump: The MVP pump, supplied with your Impregnator unit, has an in-line lubricator on the power head of pump. This oiler should be kept not more than ¾ full at all times with a light-weight machine oil, S.A.E. 10 or preferably, Air Motor Oil. The proper amount should be approximately 5-10 drops per minute. The lubricant or solvent cup at bottom of the pump casting, (surrounding the piston shaft), should be kept at least ½ full of light weight machine oil, S.A.E. 30 or automatic transmission fluid. See lubrication materials list. The only other lubrication requirements of the resin pump are lubrication of all threads and seals in the fluid portion of the pump with MVP Grease, upon assembly. Air motor threads and seals should be lubricated with lubriplate upon assembly. See lubrication materials list.

H.I.S. GUN There are two (2) areas on the gun that require lubrication.

1. Threads of the nozzle cap should be well lubricated with MVP Grease.

2. Exposed portions of needle shafts should be coated with lubricant after cleaning the machine.

All thread and seal areas of gun should be well lubricated with lubriplate upon assembly of gun head. With the exception of any parts that come into contact with catalyst.

NOTE: Do not apply lubricant to any parts that come into contact with catalyst. Clean with water only.

To insure against mechanical failure a regularly scheduled maintenance program should be set and followed. The frequency lubrication, etc., is carried out will depend largely on your use of the machine. Infrequent use (once or twice a week) is just as hard on the equipment, if not harder, than running it 24 hours a day. The reason being; valves become sticky from lack of use, pump seals become hard, moisture and contamination settle in airlines and motors, etc. Keeping the Impregnator unit clean and in good mechanical repair will mean a minimum of down time and will insure unit will be ready for production when you are.

LUBRICATION MATERIALS LIST

* Denotes Preferred Lubricant

1. Speed Reducer Lubricant *Browning # GL32HT Mobil Super Cyl. 600W Chevron Gear Compound #160 Texaco, Inc. #650T Cylinder Oil

2. Flange Block Bearing Lubricant

*Lubriplate #630-AA Humble Lidok #2 Texaco Multifak #2

3. Chain and Gear Lubricant *Lubriplate #630-AA Humble Lidok #2 Texaco Multifak #2

4. Air Motor and Valve Lubricant *Air Motor Oil (MVP) S.A.E. 10 non-detergent Mobil #AFT 220

5. Resin Pump Shaft Lubricant (Solvent Cup) *S.A.E. 30 non-detergent Mobil #AFT 200 Fluid

6. Nozzle Threads, Needle Shaft, Packings, etc. *MVP Grease Vaseline Petroleum Jelly Lubriplate 630-AA

NOTE: Use MVP Grease on threads that are subjected to resin. This sealant is water soluble and holds up to styrene better than most petroleum lubricants.

There are other lubricants available that can be used for the various applications. If one other than those listed is used, it should be of equivalent properties or better.

CHAPTER 10 PARTS DRAWINGS

414

41

26

16

24

19

39

4020

47

43

18

24

16

42

62

27

23

23

39

47

2520

40

25

42

48

51

49

50

36

36

1

35

38

33

3

32

55

6

34

35

5

10

30

8

46

13

31

44

45

7

12

2

34

9

28

30

22

28

45

3731

46

8

44

13

30

12

11

30

9

15

30

29

56

28

14

29

30

42

28

56

19

57

58

58

21

21

Assembly - 7" Power Head 4" Stroke

MAGNUM VENUS PRODUCTS

REV.

VPH-7000

L

L

17

L

L

L

17

59

USE REMOVABLE LOCTITE ON THESE THREADS AT ASSEMBLYLTM

61

60

37

11

62

26

F = ITEM 8 WAS MPH-2509, ITME 13 WAS MPH-2514 2/7/03 JEM

357

65

66

63

G = ADDED ITEMS FOR MPH-2542 RESET ASSY 3/25/03 JEM

63

H = REMOVED APP-9096, APP-9109, & APP-9102 FROM ASSY 6/10/03 JEM

2 VPH-7001 1 CYLINDER - 7" PUMP X 4" STROKE

3 VPH-4259 1 PISTON ROD

4 VPH-5004-01 1 MUFFLER ASSY - 4" STROKE PUMP

5 VPH-4254 1 PISTON ROD BUSHING

6 MPH-7002 1 LOWER ENDCAP - 7" PUMP

7 MPH-7001 1 UPPER ENDCAP - 7" PUMP

8 MPH-2541 2 INLET SPRING HOUSING - PILOT VALVE

9 MPH-2511-01 2 ASSY - STEM SEAL

10 O-B-121 1 O-RING

11 MPH-2512 2 SEAL GUIDE

12 MPH-2513 2 VALVE STEM - PILOT VALVE

13 MPH-2540 2 INLET ROD - PILOT VALVE

14 VPH-5001 1 UPPER VALVE BLOCK - 4" STROKE PUMP

15 MPH-5001 1 LOWER VALVE BLOCK

16 MPH-2517 2 VALVE PISTON

17 MPH-2519 2 VALVE ROD - 4" STROKE PUMP

18 MPH-5008 1 VALVE POPPET

19 MPH-2521 2 VALVE END CAP

20 MPH-5009 2 VALVE EXHAUST

21 O-B-019 2 O-RING

22 VPH-5003 5 TIE ROD 4" STROKE PUMP

23 O-U-206-90 2 O-RING

24 O-B-116 2 O-RING

25 O-B-026 2 O-RING

26 O-D-010-90 2 O-RING

27 O-B-125 1 O-RING

28 O-B-008 4 O-RING

29 O-B-O14 4 O-RING

30 O-B-012 6 O-RING

31 O-B-006 2 O-RING

32 O-B-118 1 O-RING

33 O-B-439 1 O-RING

34 O-B-167 2 O-RING

35 O-B-431 2 O-RING

36 F-HB-04C-56-SS 2 HEX HEAD CAP SCREW

37 F-HN-06F 10 HEX NUT

38 F-HBFT-08C-20-GR5 1 HEX HEAD CAP SCREW

39 F-CS-04C-40-SS 4 SOCKET HEAD CAP SCREW

40 F-CS-04C-08-SS 4 SOCKET HEAD CAP SCREW

41 F-SW-04-SS 2 LOCK WASHER

42 F-SS-832-02-SS 4 CUP POINT SET SCREW

43 F-BHCS-04C-16-SS 1 BUTTON HEAD CAP SCREW

44 MPH-2526 2 SPRING



47 MPH-5010 2 DIAPHRAM

48 PF-AP-04-SS 1 PIPE PLUG

49 MPH-2539 1 PUSH POLY FITTING - MALE ELBOW

50 MPH-2538 1 PUSH POLY FITTING - MALE TEE

51 01417 .56ft Ø1/4 x 6-3/4 POLY TUBING - NATURAL

55 MPH-3261 1 SNAP - RING

56 O-B-011 2 O-RING

57 PF-AP-02-SS 2 PIPE PLUG

58 F-FW-04 2 FLAT WASHER

MPH-7000-SK

REPAIR KITSPART NO.

* SEAL KIT

DESCRIPTION

* COMPONENTS INCLUDED WITH SEAL KIT.

*

*

*************

DESCRIPTIONPART NO.ITEM

PARTS LIST

QTY

Assembly - 7" Power Head 4" Stroke VPH-7000

FIGURE 1-1

1 MPH-7004 1 PISTON - 7" PUMP

59 PF-HN-08-08S 1 ADAPTER

62 MPH-3262 2 PISTON STOP

60 2104-4-1 4 TIE ROD

61 F-HB-06C-24-GR8 4 GR 8 HEX BOLT

PARTS LIST

ITEM PART NO. QTY DESCRIPTION

63 00276 1 TEE FITTING

64 MPH-2546-01 1 VALVE STEM ASSY

65 MPH-2545 1 SEAL

66 MPH-2542 1 RESET BUTTON ASSY

OPTIONAL PARTS AND ASSEMBLIES

PARTS LIST

ITEM PART NO. QTY DESCRIPTION

Modular HV Fluid Section Assy


REV. A = ITEM 21 WAS 68310-1, ITEM 27 WAS 86520-1 5/2/03 JEM

HVLS-1000

2

1

3

12

5

6

7

8

10 (REQ)

10

9

9

9

9

25

24

11

11

17

16

15

23

29

29

29

29

4

26

15

22

14

21

27

14

28

20

13

30

1919

19

18

B = ADDED OPTIONSL ITEMS AND SEAL KIT 7/3/03 JEM

86530-128 PISTON NUT1

86520-327 SPACER RING1

86510-126 PISTON ADAPTER1

86420-125 FOOT VALVE COLLAR1

86400-124 CYLINDER1

86390-1

23

PISTON BODY1

68310-3

22

BACK UP RING1

67110-1

21

FEMALE PACKING RING1

7101-2-12

20

HEX CAP SCREW4

3101-8-1

19

PISTON ROD ADAPTER1

04309-1

18

BALL STOP1

04072-1

17

PISTON BALL SPRING1

03604

16

BALL202181-1

15

PISTON CUP2

02158-4

14

PACKING SET1

01621

13

O-RING1

01611

12

O-RING2

00714

11

ELBOW1

7201-6-8

10

HEX NUT4HVLS-1009

9

WAVE SPRING 108

HVLS-10077 BALL GUIDE1

HVLS-10066 GUIDE BEARING1

HVLS-10055 SPRING SUPPORT RING1

HVLS-10044 DISPLACEMENT ROD1

HVLS-10033 PACKING NUT1

HVLS-10022 PUMP MOUNT PLATE1

HVLS-10011 OUTLET BODY1


PARTS LIST

QTY

Modular HV Fluid Section Assy HVLS-1000

TIE ROD86540-129 4

MALE PACKING RING187090-1

86370-1 1 FOOT VALVE BODY

30

21A 68310-1 1 HARDENED BACK-UP RING


PART NO.ITEM DESCRIPTIONQTY

HVLS-1000-SK SEAL KIT

DESCRIPTION

REPAIR KITS

PART NO.

****

* ITEMS INCLUDED IN SEAL KIT

24A 86401-1 1 HARDENED CYLINDER

27A 86520-1 1 HARDENED SPACER RING

HV Sat Manifold Assy Less Charging Hose - G13 Gun 87015-3

1

16 9 2 6

613

3

12

5411

19

7

6 24

6

17

12

20

148

15

2

9

10

21

9

8

14

22

REV. D = ADDED 87015-3 ASSEMBLY TO DRAWING (9-10-02) LWS

21

23

AIR IN

18


HV Saturator Manifold Assy - G13 Gun 87015-1

OMIT CHARGING HOSE & PLUG

PORT ON 87015-3 ASSEMBLY

17 7701-1-1 FITTING ELBOW

HEX NIPPLE FITTING

FEMALE QUICK DISCONNECT

FILTER W/ METAL BOWL

18

19

20

21

12

14

15

17

16

8

9

11

8405-1-1

8405-2-1

8404-1-1

8702-2-1

6504-1-05

1

1

1

2

REGULATOR

REGULATOR

160 PSI GAUGE

1/4" x 5' AIR HOSE

27701-3-7

7701-4-3

7701-3-12

7702-2-2

7701-7-1

2

1

1

1

7701-3-2

PF-HN-04-04S

7701-3-5

3

2

1

COUPLING FITTING

BALL VALVE

PLUG

BUSHING FITTING

ADAPTOR FITTING

ADAPTOR FITTING

HEX NIPPLE FITTING

HV Saturator Manifold Assy - G13 Gun 87015-1

2

3

4

5

6

1

ITEM

2

6504-17-03.3

7701-3-1

7101-1-16

7201-6-4 2

2

1

4

PARTS LIST

PART NO.

MA-2001-1 1

QTY

1/2" x 39" AIR HOSE

HEX HEAD BOLT

HEX NUT

DESCRIPTION

MANIFOLD BLOCK

BALL VALVE

BALL VALVE

09350

0581910

13 1

1

PUMP GAUGE DECAL6701-7-EN22 1

FLUSH GAUGE DECAL6701-9-EN23 1

0081724 1 1/4 x 2" PIPE NIPPLE

HEX NUT27201-6-45

1/4 x 2" PIPE NIPPLE

FLUSH GAUGE DECAL

PUMP GAUGE DECAL

BALL VALVE

BALL VALVE

HEX NIPPLE FITTING

ADAPTOR FITTING

ADAPTOR FITTING

BUSHING FITTING

PLUG

BALL VALVE

COUPLING FITTING

160 PSI GAUGE

REGULATOR

REGULATOR

FILTER W/ METAL BOWL

HEX NIPPLE FITTING

FITTING ELBOW

17701-3-1215

00817

6701-9-EN

6701-7-EN

7702-2-2

8702-2-1

8404-1-1

8405-2-1

8405-1-1

24

23

22

21

17

20

19

18

1

1

1

2

1

1

1

1

05819

09350

7701-3-1

7701-3-5

PF-HN-04-04S

7701-3-2

7701-4-3

7701-3-7

7701-1-1

10

13

11

14

12

8

9

6

7

1

1

3

2

1

1

1

4

1

MANIFOLD BLOCK

DESCRIPTION

HEX HEAD BOLT

1/2" x 39" AIR HOSE

HV Sat Manifold Assy Less Charging Hose - G13 Gun 87015-3

1/4" x 5' AIR HOSE

MA-2001-1

PART NO.

7101-1-16

6504-17-03.3

6504-1-05

ITEM

4

3

1

2

QTY

2

1

1

1

PARTS LIST

6

11

8

9

5

14

131

3

10

10

12

15

2

4

6

SOLVENT

FC1S1 - 3 GAL FLUSH TANK ASSY


REV. D 2/6/01

6101-01-01

D6101-01-1

8 8703-5-1 1 FLUSH TANK RELIEF VALVE

9 7301-16-381 2 O-RING (1 SPARE)

ASSOCIATED PARTS AND ASSEMBLIES

PART NO. DESCRIPTIONITEM QTY

1 8703-2-1 1 3 GAL FLUSH TANK W/ ACCESSORIES

5 6101-02-01 1 LID ASSEMBLY - FC1S1

FIGURE 1-1

16 D6101-01-1 1 FC1S1 3 GAL FLUSH TANK ASSY DRAWING


PARTS LIST

QTY

FC1S1 3 Gal Flush Tank Assy 6101-01-01

2 8703-3-1 1 3 GAL FLUSH TANK INLET TUBE3 8703-4-1 1 3 GAL FLUSH TANK OUTLET TUBE

4 8703-1-1 1 FLUSH TANK CHECK VALVE6 55210-1 2 HOSE FITTING

10 7301-13-109 2 O-RING

11 7701-6-10 1 STRAIGHT POLY FITTING

13 6701-13-EN 1 AIR DECAL

14 6701-14-EN 1 SOLVENT DECAL

12 6701-12-EN 1 PRESSURE RELIEF INSTRUCTION

15 95172-EN 1 DECAL - MAGNUM VENUS PRODUCTS


A = CHECK VALVE ASSY WAS OMITTED FROM DWG, VHPC-4200 & VHPC-4200-RV 8/14/02 JEMREV.

2

3

5

6

7

8

9

8

11

12

13

14

15

16

17

1

18

17 10

4

Assy - C42 Catalyst Pump VHPC-4200-C-3J

19

21

22

23

17

11

20

24

ASSY - C42 CATALYST PUMP VHPC-4200-C-3J

Note:

figure 1-1one flat on hex as shown inOffset intake and outlet ports

FIGURE 1-1

VHPC-4200-SK

PART NO.

COMMON ASSY PARTS LIST

DESCRIPTIONPART NO.ITEM QTY

DESCRIPTION

SEAL KIT

REPAIR KITS

INLET TUBE FITTING

PACKING SET ASSY

PISTON ROD SLEEVE

PISTON ROD SPRING10

18

16

17

13

14

15

12

11

7

9

8

6

5

2

4

3

104013-1

6701-24-EN

O-S-013

4101-8-1

51050-1

1

1

3

1

9201-1-7

02014

50530-1

03072

50440-1

1

1

1

2

1

INLET BODY

O-RING

SEAL RETAINER

PISTON SEAL

PISTON BODY

7/32" SS BALL

9/16" SS BALL

7301-9-016

50820-1

50940-1

50730-1

02022-5

1

1

2

1

1

50360-1

50591-3

50630-1

1

1

1

CYLINDER

O-RING

LOCK NUT

OUTLET BODY

PISTON ROD

PACKING NUT

PUMP SEAL WARNING DECAL (NOT SHOWN)

CLEVIS1VHPC-420119

9202-1-11 1 SPHERICAL BEARING

JAM NUT

SPRING RETAINER

CHECK VALVE BODY

COMPRESSION SPRING

4101-18-1

4101-17-1

4101-15-1

4101-16-1

24

20

23

22

21 1

1

2

1

25

VHPC-1001-3J 1 OUTLET FITTING


Ultra - Proportioner SystemREV.

UPS-3100

2

RESINFLUIDSECTION(REF)

4

7

10

11

12

14

15

17

18

19

20

20

21

22

26

24

25

25

27

28

28

29

29

30

31

32

33

34

35

35

35

36

3736

38

2316

A = DELETED ITEM 1 (UPS-3101) DECAL, SHOULD BE ON UNIT LEVEL 10/30/02 JEM

B = ITEM 37 WAS F-BHCS-1024-06 11/18/02 JEM

C = ITEM 30 WAS F-LN-04C LOCK NUT 6/3/023 JEM


PART NO.ITEM DESCRIPTIONQTY

PARTS LIST

Ultra - Proportioner System UPS-3100

PART NO.ITEM QTY DESCRIPTION

2 UPS-3102 1 MOUNT BAR

4 UPS-3103-01 1 CLEVIS BLOCK ASSY

7 UPS-3104-01 1 PIVOT LINK ASSY

14 UPS-3108 1 SPACER

11 UPS-3106-01 1 RH SIDE RAIL ASSY

17 UPS-3110 1 BACK END PIECE

15 UPS-3109-01 1 FRONT END PIECE ASSY

12 UPS-3106-02 1 LH SIDE RAIL ASSY

10 UPS-3105 1 CATALYST STUD BOLT

24 7203-1-1 1 HAIRPIN COTTER

23 9202-1-1 1 SPHERICAL BEARING

22 DUAL-2012 1 ADJUSTMENT KNOB

21 UPS-3114 1 TOP PLATE

20 UPS-3113 1 ADJUSTMENT SCREW

19 UPS-3112 1 ADJUSTMENT NUT

18 UPS-3111-01 1 PIN ASSY

25 APS-1016 2 QUICK PIN

26 UPS-3115 1 HAIRPIN COTTER

27 F-SB-08-20 1 SHOULDER BOLT

28 APS-1015 2 EXTERNAL SNAP RING

29 F-LN-06C 2 NYLOCK NUT

30 F-HN-04C 1 HEX NUT

31 F-CS-1024-06 1 SOCKET HEAD CAP SCREW

32 7101-2-12 2 HEX CAP SCREW

33 02885-12 1 SPRING PIN

34 F-CS-04C-32 1 SOCKET HEAD CAP SCREW

35 F-BHCS-04C-12 8 BUTTON HEAD CAP SCREW

36 F-BHCS-04C-06 2 BUTTON HEAD CAP SCREW

37 01218-4 1 BUTTON HEAD CAP SCREW

38 F-CS-06C-40 2 SOCKET HEAD CAP SCREW

16 7203-8-1 1 QUICK PIN

Catalyst Jug Assy W / Recirc - W/O Sight Tube


REV. A = ADDED CJ-2000-4-RS TO DWG 10/09/02 JEM

CJ-2000-4-R

1

2

16

7

9

8

4

310

11

12

13

17

14

1A

11A

22

21

20

19

18

CJ-2000-4-RSCatalyst Jug Assy W / Recirc - W / Sight Tube

24

23

16


PARTS LIST

QTY

Catalyst Jug Assy W / Recirc W/Sight Tube CJ-2000-4-RS

FILTER SCREEN NUT3 4105-10-1 1

60 MESH SS SCREEN4 4105-7-1 1

1/4 POLY TUBE7 01417 5FT

CONTAMINATES CAUTION DECAL8 6701-4-EN 1

DAILY/ MONTHLY INSTR DECAL9 6701-15-EN 1

O-RING10 7301-9-016 1

CAT JUG TUBE FITTING11A 4105-12-1 1

1/2" SUCTION HOSE CLAMP12 7701-2-2 1

1/2" POLY TUBE13 01419 3FT

CAT JUG SUCTION HOSE DECAL14 6701-16-EN 1

CAT JUG NUT PIN WRENCH (NOT SHOWN)15 4105-8-1 1

DESCRIPTIONPART NO.ITEM QTY

ASSOCIATED PARTS AND ASSEMBLIES

1/2" x 4' FEED LINE4105-2-0117 1

Catalyst Jug Assy W / Recirc W/O Sight Tube CJ-2000-4-RCommon Assembly Parts For:

Catalyst Jug Assy W / Recirc W/O Sight Tube CJ-2000-4-R

PARTS LIST

2 GAL CAT JUG W/ CAP

100 MESH 2 GAL CAT JUG SCREEN8801-1-1002 1

4105-11-03

PART NO.ITEM

1

DESCRIPTIONQTY

1

Catalyst Jug Assy W / Recirc W/Sight Tube CJ-2000-4-RS

PARTS LIST

2 GAL CAT JUG W/ CAP4105-11-02

PART NO.ITEM

1A

DESCRIPTIONQTY

1

CAT JUG TUBE FITTING59371-111 1

1/4" x 14" SIGHT TUBE4105-4-118 1

4105-9-119 SIGHT TUBE FLOAT1

4105-5-120 SPLIT BUSHING1

O-S-01021 O-RING1

4105-1-122 TUBE FITTING BODY1

4105-12-0123 1 OUTLET FITTING

4105-1-0124 1 TUBE FITTING

4105-6-1 100 MESH SS SCREEN116

Corporate Headquarters/Manufacturing 5148 113

th Ave.

Clearwater, FL 33760 USA Ph: (727) 573-2955 Fax: (727) 571-3636

MVP Technology Center 1862 Ives Ave. Kent, WA 98032 USA Ph: (253) 854-2660 Fax: (253) 854-1666

E-mail: [email protected] · Web: www.mvpind.com

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