FRP SystemOne GELCOATER OPERATION MANUAL. MAGNUM VENUS PRODUCTS Operation Manual. Part No. M Revision

Transcription

1 GELCOATER OPERATION MANUAL MAGNUM VENUS PRODUCTS Operation Manual Part No. M Revision

2 Operation Manual Unit Information Unit # Type Of: Power Cylinder Metering Pump Gun Fluid Section

3 Table of Contents Operation Manual CHAPTER Start Up Installation & Setup 1 - QUICK LIST CHAPTER 2 - GETTING STARTED Installation & Setup Pre-Operation Checklist CHAPTER 3 - OPERATION Wetting Unit Proper Operating Pressures Gun Set-Up CHAPTER 4 - MAINTENANCE CHAPTER 5 - PARTS DRAWINGS Unit Assembly Mounting Column Assembly Cart Assembly Pneumatic Manifold Assembly 3-Gallon Flush Tank Assembly Catalyst Jug Assembly Power Cylinder (4.25 ) Assembly Resin Filter Assembly Drum Suction Wand Assembly Surge Chamber Assembly

4 Chapter 1 Quick List Instructions Start-Up Sheet 1. Check & fill solvent system 2. Check & fill resin & catalyst supply 3. Place suction wand in resin supply 4. Prime resin pump 5. Prime catalyst pump and set catalyst percentage 6. Check system for fluid leaks 7. Set air pressure to gun 8. Install turbulent mixer in mix chamber 9. Select & install nozzle 10. Adjust fan pattern NOTE: These instructions include resin and catalyst pressurization procedures. To avoid equipment malfunction or possible injury, please follow these instructions. If you have any questions, please contact our Technical Service Department at

5 Quick List Instructions Installation & Setup 1. Unpack unit & components 2. Place unit & stand pipe in base plate or portable cart (or mount to wall with wall brackets) Tighten bolts to secure 3. Install catalyst jug 4. Install resin surge chamber & filter assembly 5. Install manifold air hose to power cylinder 6. Attach hose fittings to resin pump, catalyst pump, air & flush tank 7. Install boom to mast (if applicable) 8. Hang hose on boom (if applicable) 9. Attach pickup hose 10. Place flush tank in holder and attach air hose from manifold 11. Double check all hose fittings 2

6 Chapter 2 Getting Started Installation 1. Remove unit from crate. With the crate lying flat, open the top panel and remove the components: a. Floor mount assembly b. Gelcoat pump and pump column c. Gun and hose set d. Resin filter and surge chamber assembly e. Suction wand assembly f. Catalyst jug g. Solvent tank h. Catalyst pump i. Air manifold 2. Assemble pump and column to floor mount assembly. a. Slide pump column into floor mount and tighten the two hex bolts in floor mount. 3. Assemble resin filter/surge chamber assembly to pump. a. Check to make sure all Filter/Surge chamber connections are tight. b. Attach the filter/surge chamber assembly to the swivel fitting located at the outlet of the resin pump. c. With the filter/surge chamber assembly vertical. Tighten the fitting with a wrench until it is tight. 3

7 4. Mount catalyst jug bracket. a. Attach the Catalyst jug bracket to the base of the catalyst pump slide drive support. b. Mount the bracket so it extends to the left side of the slide drive support as you stand facing the end of the slide drive. 5. Mount solvent tank retainer bracket. a. Attach the tank bracket to the column approximately 2 to 3 inches from the top of the floor mount frame round tube. b. The bracket should be on the left side of the column as you face the unit. Position the bracket so the tank will sit on the floor mount square tubing. Tighten the flush tank bracket bolts to the column. c. Remove the solvent tank from the carton and place into bracket. 6. Attach catalyst pump. NOTE If SystemOne unit is configured with a catalyst alarm, please refer to the catalyst alarm manual when you reach this stage of set-up. a. Mount the Catalyst pump to the slide drive bracket using the clevis pins and keepers provided. b. The bottom of the catalyst pump is pinned to the lower leg of the slide drive bracket. c. The upper clevis, (piston rod), is pinned to the slide drive using the forward of the long slot in the slide drive. d. Hold the clevis pins in place with the wire keepers by placing them in the holes in the clevis pins. 7. Mount air supply manifold. a. Clamp manifold assembly to the pump column above the power cylinder of the resin pump. b. Regulators and gauges should face to the pump side of the column. c. Clamp yoke tight enough so the assembly does not move around the column. 8. Attach suction wand to gelcoat pump. a. Check all fittings on the wand assembly to make sure they are airtight. b. Attach the wand assembly to the foot valve swivel fitting and tighten. 4

8 9. Make hose connections. a. Connect the black resin hose from the gun to the outlet fitting on the resin filter. b. Connect the catalyst hose from the gun to the outlet of the catalyst pump assembly. c. Attach the red air hose from the gun to the fitting on the regulator labeled gun. d. Attach the yellow poly flush hose from the gun to the outlet fitting of the solvent tank. e. Attach the small red air supply hose from the flush regulator to the input fitting on the flush tank. f. Attach the red air hose from the pump regulator to the power cylinder or the gelcoat pump. g. Attach the ground wire from the gun to the electrical grounding lug on the pump power head. h. Remove the catalyst poly tubes from the component box. Cut the ½ inch diameter poly line with the clamps to 26 inches long. Clamp one end to the outlet of the catalyst jug and the other end to the inlet of the catalyst pump. Make sure the clamps are airtight. i. Connect the 3/8-inch poly line to the relief valve on the catalyst relief valve and insert the other end into the hole in the top of the catalyst jug. j. Connect the green hose from side of the gun handle to the blue valve on air manifold. 10. Mount exhaust muffler to the power head of the gelcoat pump. a. Remove the exhaust deflector from the power head of the gelcoat pump, (4 screws). Screw silencer into the pipe threads of the exhaust port. 5

9 Operation Wetting Out Unit Air supply: 1. Use minimum ½ air hose supply to the system. Air requirements, 9 to 10 CFM 2. Open incoming air supply ball valve. 3. Set regulator labeled gun at 90 to 100 psi. Tighten packing nuts on the gun and trigger the gun 15 to 20 times. Snug packing nuts again and repeat gun triggering. Priming Solvent: 1. Open solvent tank lid and fill ¾ full. Install lid on tank and close the relief valve located on the top of the lid. Set flush tank pressure at 50 to 60 psi. 2. Push the flush valve on the side of the gun block to test solvent flush. Priming Catalyst to Gun: 1. Tighten the catalyst packing nut ¼ turn. Chapter 3 2. Fill the two gallon catalyst jug ¾ full, purge the air out of the catalyst feed line by slightly tilting the catalyst jug. 6

10 3. Lock the gun in the open position. Remove the pivot pin from the catalyst slide arm linkage. Use the slide arm to hand prime catalyst out to the gun until a steady stream is achieved. Do not reinstall pivot pin at this time. Priming Resin to Gun: NOTE The resin pump was tested using oil. It may require up to 1/2 gallon of gelcoat to be run through the unit to purge any remaining oil from the system. 1. Insert the gelcoat suction wand into container of gelcoat. 2. Tighten the gelcoat pump packing nut until snug only. Fill packing nut cavity ¾ full with suitable oil. 3. With the gun locked in the open position, slowly increase pump regulator pressure until pump is running at a slow but steady rate. Allow pump to run until a fairly steady stream of gelcoat is being dispensed. Close the gun and flush the gun head. 4. Increase gelcoat pump pressure to 100 psi. Allow the unit to set under static load for 15 to 30 minutes to seat the resin packing set. 5. Clamp or tape the resin return hose coming from the bottom of the in-line resin filter to the resin pickup wand and into the drum. Turn the resin pump regulator to zero. Slowly open the ball valve at the bottom of the resin filter to drain the fluid pressure. Charging the Resin Surge Chamber: 1. Open the ball valve below inline resin filter. 2. To charge the resin surge chamber, use the air hose with the female quick disconnect (charging hose) and insert over the male quick disconnect at the top of the resin surge chamber. Push down on female quick disconnect for 5 to 10 seconds and disengage. 3. Close ball valve below in-line filter. 7

11 Pressurizing Fluids: NOTE On the air manifold, the blue valve is the safety override. The small brass button next to the valve is the priming button. The SystemOne Unit is standard with a safety override valve. This valve opens and closes the air supply to the resin pump air motor. The valve will be opened when the gun trigger is opened or when the priming button is pushed down. NOTE Remove catalyst quick pin before pressurizing gelcoat pump. 1. Push down on the priming button and slowly increase gelcoat pump regulator, 40 to 50 psi would be a starting point. 2. Using the slide drive arm, use slow up and down motion to pressurize the catalyst pump. There should be a uniform gain in resistance between up and down strokes. 3. Pin the pivot pin into the slide arm. Set catalyst percentage. Gun Set-Up: 1. Install turbulent mixer into mix chamber. Insert static mixer and spray tip onto the air assist housing. Screw air-assist unto the gun mix housing. For longer turbulent mixer life, do not over tighten the air assist nozzle housing. Attach short air assist house from needle valve on side of gun handle to air-assist head. 2. Test spray pattern, make gelcoat pump pressure adjustment until a fairly uniform pattern is achieved. Slowly open the air-assist needle valve located on the side of the gun handle until a soft uniform pattern is achieved. 8

12 Chapter 4 Maintenance Schedule Daily Maintenance 1. Drain water trap. 2. Daily shutdown should include, remove air-assist tip and static mixers from housing and clean. Remove turbulent mixer and mix chamber from gun and clean. Lightly dampen a rag with solvent and wipe down gun head, handle and actuator. Do not soak gun in solvent. Weekly Maintenance Gelcoat Pump Packing Set Check gelcoat pump piston rod oil reservoir, inspect for gelcoat bypassing packing set. 1. Turn pump regulator to zero. Open ball valve at gelcoat filter to release gelcoat pressure. 2. Insert a rod or Philips screwdriver into one of the holes in the gelcoat-packing nut. Snug the packing nut. Do not over tighten. Power Cylinder Turn pump regulator to zero. Loosen the air hose fitting and add 10 to 15 drops of 90-weight non-detergent gear oil. 9

13 Gun Gun maintenance: Turn the pump regulator pressure to zero. Open up the ball valve at filter to relieve gelcoat fluid pressure. Open gun to relieve catalyst fluid pressure. Snug Pro gun packing nuts (light snug on catalyst packing nut) and trigger the gun on and off to seat the resin and catalyst seals. Repeat a second time. Filter & Accumulator 1. Turn gelcoat pump regulator to zero. Open ball valve at the gelcoat filter to relieve gelcoat fluid pressure. To bleed the charge in the accumulator, insert the small diameter rod in the charging valve on the top of the resin accumulator (check valve) and depress to bleed the charge off. Be sure to cover the rod with a rag. 2. To remove the gelcoat filter, remove the return hose from the ball valve. Un-screw the resin filter, clean the filter screen and core. Use Venus-Gusmer white grease on the filter housing threads. 3. Un-screw the gelcoat accumulator. Clean the accumulator, poly ball and thread on the nipple. Coat nipple, o-ring and poly ball with white grease. Inspect o-ring, replace as needed. Catalyst Pump 1. Inspect catalyst pump packing nut for leaking coming up through the packing set. Tighten the packing nut no more than one eighth of a turn at a time as needed. Wipe catalyst pump piston rod off with a clean dry towel. Six Month Maintenance Flush Tank 1. Release fluid pressure from flush tank and drain out solvent. Use a clean towel to wipe the inside of the tank clean. Wipe out any solid debris. Inspect flush tank o-ring, replace as needed. Hose Set 1. Inspect hose set for any kinks or wear, replace hoses as needed. The flush should be replaced once a year. Catalyst Jug & Feed Hose 1. Drain catalyst from jug, wash the jug out with distilled water and drain. Repeat a second time. Replace feed and return hose as needed. 10

14 IT IS ADVISED THAT THE FOLLOWING COMPONENTS BE REBUILT AFTER 6-MONTHS OF USE IN A 8-HOUR, 5-DAY A WEEK SHOP. Catalyst Pump 1. Minimum rebuild should include all o-rings, balls, piston seal and packing set. Gelcoat Pump 1. Minimum rebuild should include, packing set, piston cups and cylinder o-rings, Gun 1. Minimum rebuild should include all seals and o-rings. 11

15 Chapter 5 Parts Drawings 12

16 MAGNUM VENUS PRODUCTS 13

17 14

18 MAGNUM VENUS PRODUCTS 15

19 16

20 MAGNUM VENUS PRODUCTS 17

21 18

22 MAGNUM VENUS PRODUCTS 19

23 20

24 MAGNUM VENUS PRODUCTS 21

25 22

26 MAGNUM VENUS PRODUCTS 23

27 24

28 MAGNUM VENUS PRODUCTS 25

29 26

30 MAGNUM VENUS PRODUCTS 27

31 28

32 MAGNUM VENUS PRODUCTS 29

33 30

34 MAGNUM VENUS PRODUCTS 31

35 32

36

37

38

39

40 MVP Magnum Phone: (727) Fax: (727) Web: MVP Venus Phone: (253) (800) Fax: (253) Web: Magnum Venus Proeducts Manual Part No: M