H.I.S. SYSTEMS INSTRUCTION MANUAL

Transcription

1 H.I.S. SYSTEMS INSTRUCTION MANUAL MAGNUM VENUS PRODUCTS H.I.S. INSTRUCTIONS MANUAL H.I.S. Instruction Manual

2 TABLE OF CONTENTS Preface Flow Diagram Safety Installation Portable Chopper Installation Wall Mount Installation Central System Installation Flat Base Plate Unit Installation Casting Unit Installation Operation Data (Air) Standard Materials Other Materials and Ancillary Components Start-up Procedure Priming Procedure (Resin) Priming Procedure (Catalyst) Fan Pattern Test Procedure Recharging Accumulators Chopper Set-Up Shut-down Procedure Reassembling Resin Accumulator & Filter Yearly Maintenance Schedule Gun Assembly Instructions ( 80 Model) Gun Head Assembly Instructions ( 75 Model) Chopper Assembly Instructions ( 80 Model) Chopper Assembly Instructions ( 75 Model) Catalyst Pump Assembly Instructions (P21) Resin Pump Assembly Instructions P41 & P51 Pump Resin Pump Slave Arm Assembly Resin Pump Accumulators and Filter Assy. Instructions H.I.S. Instruction Manual

3 PREFACE The Magnum Venus Products Hydraulic Injection Spray (HIS) System is the ultimate in spray-up equipment. However, like any machine, it will operate only as long as the operator maintains it and will perform according to the Operator s skill. With proper utilization of this equipment it will pay for itself within six months of normal production usage. This manual has been prepared to aid everyone in the operation/maintenance of this equipment. This patented system has been marketed and regularly used since During this time, continuing developments and engineering improvements have been made to perfect the equipment and to meet current industry requirements. The diagrams and text should cover all facets of operation and maintenance that may arise. The trouble shooting section is not intended to cover all problems that could exist, but to start the Operator thinking in an organized manner to determine what the problem is and how to rectify it. The HIS system is complex only in the number of components. However, once each part is understood as to its function, it becomes a simple mechanical system easily understood by the Operator. A little time spent studying the flow diagram (on the next page) and the parts drawing package (included with this manual), in order to relate the function with the actual part, will remove any mystery of the HIS system. The Operator s Manual is to aid in better understanding the functions of each element and it s correlation to others in a properly functioning system. We include two manuals with each unit; one for the office and one for the shop operator. Thus, there is no reason the operator or shop mechanic should not be familiar with the unit and able to service it when required. Thank you for buying Magnum Venus Products equipment H.I.S. Instruction Manual

4 THE BASICS OF MAGNUM VENUS PRODUCTS H.I.S. SYSTEMS FLOW DIAGRAM H.I.S. Instruction Manual

5 THINK SAFETY STOP! Before attempting to perform maintenance on the Magnum Venus Products system: 1. Protective clothing should be worn at all times. 2. Safety glasses should be worn at all times 3. Maintenance should not be performed unless others are in attendance to render assistance in case of an emergency. 4. Should any parts of the body come in contact with MEKP, the area should be washed immediately with large amounts of clean water. SHOULD EYES OR INTERNAL PARTS OF BODY COME IN CONTACT WITH MEKP, CONTACT A PHYSICIAN IMMEDIATELY. CAUTION! Before attempting to disassemble any portion of catalyst or resin system: 1. The air supply to powerhead of pump should be turned off. 2. The fluid pressure in the system should be relieved by triggering gun and allowing fluid to drain into proper receptacle. 3. The air charge on both resin and catalyst accumulators should be released through charging valves on top of accumulators. 4. Air to solvent tank should be turned off and the pressure relieved from tank (Only after flushing gun clean of all resin and catalyst). 5. If pressure is trapped in system by a fluid block (plugged filter, set-up gun, etc.) remove pressure by disconnecting resin line prior to suspected blockage H.I.S. Instruction Manual

6 A LARGE RAG OR SHOP TOWEL SHOULD BE HELD TIGHTLY AROUND WRENCH AND FITTING AS FITTING IS REMOVED. REMOVE FITTING SLOWLY, ALLOWING FLUID PRESSURE TO ESCAPE INTO RAG OR TOWEL. INSTALLATION Your Magnum Venus HIS equipment has been shipped to you as fully assembled as possible while reducing bulk and shipping costs and creating protection for your purchase. All HIS units consist of similar basic components, thus we will detail only the most common installation: the portable chopper unit. The parts drawing included for your system will allow you to follow the portion of the component installation pertaining to the system you have purchased. PORTABLE CHOPPER INSTALLATION: CAUTION: care must be taken at all times to assure stability of equipment; and pumping unit completely installed before boom is fully extended. Special adaptations to boom may require adding ballast to the cart. After removing components from shipping crate, lay portable cart on its side with the large coupling side against floor. Screw boom support column into this coupling until it bottoms out. Turn column counter-clockwise ¼ turn or until king pin bracket (bearing bracket) lies with its side to floor. Secure boom to column with bolts provided (in column). Adjust king pin on boom to align with column and tighten bolts securely. Install spring on boom following printed instructions on tag on boom chain. Screw pump column, with mounted pump, into coupling located on opposite side of cart platform from column and boom. Turn pump column so pump mounting brackets face the handle bracket on cart platform, lock mounting column in position by jamming the lock ring on column against the coupling on cart platform. Turn boom column into coupling, secure in place by turning lock ring on column tight against coupling. Install catalyst jug bracket (flat bar against pump mounting bracket) using fasteners and nuts on let side of the pump mounting bracket when facing the pump H.I.S. Instruction Manual

7 Fasten the roving shelf to column with the flat of the pan up (screws provided in the column). Fasten large ring roving guides to column (screw provided). Remove nuts from handle and insert T bar of handle into brackets on cart platform and secure. On pump wing of cart platform, fasten flush tank bracket. Mount manifold assembly on pump column manifold mounting bracket per instruction tag on bracket. If optional weight control unit is purchased; remove scale from Component Box 1; set pan into pan guide bracket on column hook scale onto hook on upper end of pan. Place cap screw through guide on bearing bracket and scale and secure with nut. Pan should move up and down freely. Any drag can be removed with slight bending of guide. Remove resin accumulator and filter assembly from component box. Disassemble tank, screen and spring from filter and remove accumulator body form filter body. (Do not drop poly ball when removing accumulator body). Screw filter body onto flow control body of resin pump. NOTE: high volume units do not use flow control or filter in this area. Accumulator attaches to Tee. Tighten this connection and position filter body so reassembled accumulator is up and parallel to pump column. Reassemble screen, spring and tank on filter (hand tight). Turn elbow and nipple on outlet side of filter so nipple is facing back of boom. Turn elbow clockwise to achieve this positioning and simultaneously tighten elbow into filter outlet port. Remove catalyst pump and accumulator from component box. Remove all protective paper, taking care to replace safety cover on accumulator. Pull the two quick pins from slave arm of resin pump. After removing the priming knob with a suitable screwdriver. Slide the bearing block up between sides of upper slave am and lower inlet body bearing in and down between sides of lower slave arm. Push one quick pin through a hole in lower slave arm, through bearing in inlet body and hole on side opposite slave arm. Select the corresponding hole in upper slave arm and insert second quick pin in the same manner. Reattach the priming knob. Supply hose and catalyst hose fitting should be on the left side of slave arm when facing resin pump. Hoses can now be attached to the gun and/or chopper as follows: 1. If flush hose is ¼: diameter natural tubing, attach to gun head by inserting through hole in handle and trigger into flush port; pull back on tubing to make sure it is locked in place. Figure 4 shows correct procedure for installing Model 80 gun flush hose on guns purchased after May 18, Figures 5 and 6 show procedure to convert flush hose installation on Model 80 guns purchased prior to May 18, Figure 6 does require some machining if conversion is desired and H.I.S. Instruction Manual

8 Magnum Venus Products recommends gun handle be sent to Magnum Venus Products or contact Magnum Venus Products for machining instructions. GUN HANDLE FLUSH TUBE GUN BLOCK GUN TRIGGER 1. Cut tube square with a sharp razor knife, remove any burs. 2. Feed the flush tube through the hole in the handle and then through the hole in the trigger. 3. Push the flush tube into the ferrule of the flush fitting and tighten the nut. FLUSH HOSE INSTALLATION DETAIL lv NO LONGER SOLD IN THIS CONFIGURATION POLY TUBE POLY NUT FERRULE CONNECTOR BUSHING O-RING FITTING BODY SEAL GUN BLOCK FLUSH HOSE AND FITTING CONFIGURATIONS DETAIL V H.I.S. Instruction Manual

9 FILE OR MACHINE THIS SURFACE FLAT REMOVE DRAFT ANGLE FROM BACK SIDE OF GUN HEAD FLANGE. (FILE OR MACHINE FLAT) REMOVE.062 (1/16) INCH FROM BOTTOM OF THE GUN FLANGE TO ALLOW CLEARANCE FOR FLUSH FITTING. The re-work shown here is required to convert old handles to fit current flush fitting. FLUSH HOSE FITTING CHANGE HANDLE CHANDES DETAIL Vl 2. If flush hose in ¼ diameter white hose, attach to center elbow on gun head. Tighten fittings at this time. 3. Blue catalyst hose with red rubber shield attaches to catalyst hose nipple on left side of gun head (catalyst side is marked). Tighten firmly. 4. Black resin hose attaches to right side of gun head. Tighten firmly. 5. Attach Red air hose to threaded fitting on back of gun handle. It may be necessary to twist air hose circularly, left or right, before tightening to place gun and chopper in line with boom. Fasten chopper cable hanging from boom end using bolt common to chopper base plate and gun handle. Attach nipple of pick-up hose into 90-degree elbow at tip of standpipe and tighten elbow with a large wrench. Attach flush tank bracket to cart platform and place flush tank in. Attach nipple on end or ¼ red air hose from air control valve on manifold to the fitting marked in on flush tank and tighten. Oiler screws into the air inlet on resin pump cylinder head, with arrow on top of oiler pointing to pump. Attach ½ red air hose from manifold to nipple on side of oiler and tighten fitting. From back of boom, route red air hose through top ring of pump column and fasten tight to nipple on upper right hand regulator of manifold block (Chopper only). Pass solvent hose down through both rings on column and fasten to nipple marked out on flush tank and tighten. Run the black resin hose through top two rings on pump H.I.S. Instruction Manual

10 column and secure to nipple on outlet side of filter body and wrench tighten. The blue catalyst hose follows the same course as resin and attaches to the hose nipple on the catalyst pump accumulator. Recheck all fittings for tightness and move fully extended boom from extreme left to right to insure hoses are free moving and not being crimped or pulled tight there should be no sharp bends or kinks. Attach charging pump bracket (it is taped for shipping to charging pump itself) to center section according to instructions on tag. To install 2-gallon catalyst jug system, attach feed line (1/2 tube with black fittings and clamps) to barbed nipple on inlet body of catalyst pump. Attach opposite end to barbed fitting on catalyst jug. Return line (3/8 tube, no fittings) is attached to barbed nipple on catalyst accumulator relief valve body and other end inserts in 3/8 hole in top of jug. Clamps on feed line must be tightened. To install 5-gallon or 1-gallon catalyst jug system, push free end of suction tube (with black rings) into barbed nipple on inlet body of catalyst pump and tighten clamp firmly. Attach other tube to barbed nipple on relief valve body of catalyst accumulator with a firm push. Opposite ends, with suction filter, go into catalyst jug. Tighten jug cap securely. Recheck all fasteners and connections to make sure all are secure. The unit is now assembled for pre-operative check. Wall Mounted Chopper Unit Installation Wall mounted Chopper unit with boom, for wand pick-up or central supply systems are basically assembled in the same manner as portable units. Additional installation information is as follows: Locate a wall which will support approximately 200 pounds of additional weight. If desired, a neat installation (when possible) is a 4 x 4 x ¾ plywood sheet fastened to wall studs with components of the HIS unit mounted to the sheet. (See detail VII and VIII). The center of the plywood sheet should be mounted in front of a wall stud and anchored secure with lag screws. The bottom of the sheet should be mounted parallel to and 9 up from the floor. Additional lag screws should be installed through the plywood sheet and into other structural wood in wall to assure sheet will be strongly attached. (Central systems may be installed higher off the floor but should not be too high to make working on units impractical while standing on the floor. See Central System Installation, Page 12 and Detail VIII.) On a vertical plumb line (detail VII), 24 from either side of mounting sheet and 10 above lower edge of sheet, screw a lag screw through bottom hole of pump mounting bracket and into plywood. Locate upper hole in mounting bracket on the plumb line and using another lag screw, fasten bracket to sheet. Properly secured, the lag screws will be H.I.S. Instruction Manual

11 common to mounting bracket, plywood sheet and wall stud; a proper installation when lag screws are tight. At a location 39 from bottom of plywood and 1 ¼ to the right of plumb line, screw a lag screw through bottom hole in the manifold and spacer tube provided, and into plywood. Position the manifold parallel to plumb line and screw the other ¼ x 4 lag screw through manifold and spacer and into plywood. Tighten both lag screws until flush with surface of manifold. Measure 10 ½ in from right hand edge (right hand as you face sheet) of plywood 1 ½ up from bottom of sheet, position the lowest attachment hole of the flush tank bracket and secure to plywood. Mount resin pump on bracket. Attach catalyst jug bracket. Securely tighten. FOR DIRECT WALL MOUNTING OR ON WALL MOUNTING BOARD - BE SURE PUMP IS MOUNTED SECURELY TO LOAD SUPPORTING BUILDING MEMBER. HONOR 9" FLOOR REFERENCE DISTANCE FOR PICK UP WAND DRUM USE. UNIT MAY BE RAISED TO 22" FROM FLOOR REFERENCE FOR BULK SUPPLY CENTRAL SYSTEM. STUD / BUILDING SUPPORT MEMBER STUD / BUILDING SUPPORT MEMBER WALL BOARD 1-1/2" MANIFOLD SPACER (2) AIR MANIFOLD 4' x 4' x 3/4" PLYWOOD PUMP MOUNT BRACKET PUMP CATALYST JUG BRACKET ALTERNATE PUMP MOUNT BRACKET USED ON NEWER SYSTEMS FLUSH TANK BRACKET DETAIL Vll H.I.S. Instruction Manual

12 DETAIL Vlll The Boom can now be mounted in vicinity of resin pump mounting location. See Detail IX. Whichever boom size is used, the following criteria must be met: the height of the boom outer section should be 6 6 from floor at the inner, outer, boom joint. The hoses from back of boom must reach their attachment points on pumps, manifold and solvent tank without undue tensioning. Mounting location must have sufficient support to withstand the leverage when forces are applied to end of the fully extended boom H.I.S. Instruction Manual

13 WALL MOUNT CEILING MOUNT 6'-6" HEAD CLEARANCE DETAIL IX Note: The king pin must be vertically plumb for proper operation of boom. The balance of installation is similar to portable unit (see previous pages). DETAIL X H.I.S. Instruction Manual

14 Central System Installation Pumping system installation is similar to wall mount, however the resin pump received will have a threaded foot valve with inline filter and a 1 street ell to receive a 1 plumbing. (High volume units are equipped with 2 plumbing.) The installation from pump to resin supply line should include a nipple from the ell, union coupling, nipple and shut-off valve between pump and supply line in the order specified. This will allow repairs at the station without shutting down the bulk supply system. (Plumbing described is not included with the unit.) It will also include a 5-gallon catalyst jug which can be mounted to the left of the resin pump (facing pump) at a location on edge of plywood sheet, 12 from the bottom. Secure jug bracket to plywood with lag screws (see detail VIII). A typical HIS Central (bulk) System is shown in detail X for your convenience. Additional accessory items for central or bulk systems may be found in your Magnum Venus Products catalog. Installation of Units on Flat Base Saturators, Hydrajector, Hand-Held Casting Units all have similar installation procedures as the Chopper units with the exception of the boom, column support and portable cart. As they are virtually t assembled, the same procedures with the component and hose line installation can be followed. With Hydrajectors and Casting Units, there will be a static blender in Component Box 1 which is attached to the gun s outbound flow port. Airlift mounted pumping units (Hydrajector and Casting Units) are designed to lower and raise pumps from drums to eliminate even the minute possibility of air pick-up in these critical applications. Assure overhead area is clear to allow lift to rise to its full height. When first raising lift (manifold hose with quick disconnect is used) check all hoses to assure they are free. To raise lift, connect to quick disconnect and apply approximately 60 psi air. When pump is lifted to full height, align bung in drum with pump foot valve. To lower, disconnect fitting. A few trial runs will give you smooth control (see Detail XI). The MVP HIS Gelcoater is virtually the same system with the exception of long accumulators and a carbide spray tip. The long accumulators (also used on High Volume units) provide even greater amounts of material available to assure constant delivery in this very critical application. The carbide tip gives longer life under abrasive gel coats while providing an orifice of greater precision creating a better fan with gel coat in which it is more difficult to break the particles and achieve good spray. A heated Gelcoat unit will contain a heater, plus bracket which will be tagged with mounting instructions. Full operating instructions, trouble shooting and parts drawings will be included with your heater. Read thoroughly prior to operating heater H.I.S. Instruction Manual

15 1862 IVES AVENUE KENT, WASHING TO N (253) FAX (253) Info@venusmagnum.com DETAIL XI Casting Unit Installation Unit will be shipped in a refrigerator like carton with upright support column already attached. Square tube L is inserted in support column allowing four (4) height adjustments. Selected adjustment must be secured with bolt and nut provided. Square tube with gun mounting bracket is inserted into back side of L, adjusted to desired length and secured with thumbscrew. If optional timer is ordered, it will be in its own component box and will have the mounting bracket for the automatic head attached to it. Bracket, with timer, is now attached to gun support arm. Automatic head, from Component Box 1 is in turn attached to mounting bracket. When no timer is involved, the angle gun head mounting bracket will be with other fabricated parts. Holes on extreme right side will allow attachment to gun support arm. The automatic gun head is then mounted. Foot pedal triggering with attachment hoses to gun head will be in Component Box 1 with hoses and head parts marked with corresponding numbers for attachment. Balance of system is installed in same basic manner as the portable units H.I.S. Instruction Manual

16 Operational Data In order to function at maximum performance level, the standard HIS system requires an air source capable of providing 25 CFM of clean, dry air at 100 psi. The High Volume HIS system requires 35 CFM at 100 psi. The air supply hose to the unit must be kept as short as practical and be no less than ½ Inner Diameter to assure adequate air supply. Clean, dry air is essential to give the best service life of the powerhead and chopper motor. Consult your local representative or MVP directly for air requirements if you feel your operation may need more detailed information. Materials Selection of proper materials and the use of them, can make the difference between success and failure, with this or any other equipment. Your local distributor can assist in proper selection for the best results. The following generalities should be followed: Resin: should be formulated for gun use with proper promoters for MEKP. Also with Thixotropic characteristics and relatively low viscosity for fast impregnating. Resin should be stored at about 70 to 85 degrees F before using. Resin at 85 degrees F will allow the equipment to perform better, minimize the variations and control problems, speed up impregnation, and improve quality of products. Solid additives which are introduced into resin for any purpose (such as flame retardation or thixotropic properties) will invariably increase the wear factor on internal moving parts of the resin pump. More frequent replacement of these parts must be considered as part of the cost of using such additives. It may be necessary to use special parts in the system such as carbide needles and seats or hard chromed pump cylinders with modifications of the piston are to help lengthen the life of the parts. Catalyst: should be Methyl Ethyl Keytone Peroxide of strength to give proper gel times for products made with percentages of ¾ to 3% on standard equipment. This range is ½ to 1 ¼% on High Volume units. A factory tinted catalyst, for visual control purposes, is recommended. This can be obtained from the peroxide manufacturer. Failure of the equipment (unless other problems are present) is generally the result of trying to add tinting materials. NOTE: NEVER USE SOLVENTS TO CLEAN THE CATALYST SYSTEM AS IT FORMS UNSTABLE PEROXIDES. USE CLEAR WATER. Glass fiber Roving: should be made for spray-up roving cutters and with a soft nonstatic treatment. The MVP Hydraulic Systems do not have a high pressure air blast that cause the fibers to tumble and float all over as with aspirated guns, hence the softer the treatment, the better the glass pattern. If treatment is too hard, fibers lay in clumps, the pattern is narrow and it is difficult to attain uniformity and good impregnation H.I.S. Instruction Manual

17 Solvent: Methylene Chloride, with no flash point, is recommended due to the high safety factor it gives your shop. However, the HIS unit is composed of parts and material lines compatible to Acetone as well. Certain reclaimed solvents could affect system which may nullify Warranty. Air: must be clean and dry. Moisture or oils in air supply may damage various components of this system as they would any other machinery. Other Materials: MVP offers slave pumps with a variety of adaptations which, added to our systems, allow positive metering and dispensing of materials such as; liquid wax, BPO dispersions, pigments, Cumene, Furane and others. Components can consist of double slave arms to hold several pumps allowing more than one material to be dispensed, mid and high range slave arm pumps for pumping these materials in the same or a higher percentage than the normal ¾ to 3 percent. Since we presently cannot handle all manufacturers formulas of these materials and the pumping of different materials may require more equipment changes than mentioned, it is imperative that you consult your MVP representative or MVP direct before attempting to pump other materials. CAUTION: NEVER pump any material other than MEKP through an MVP MEKP slave arm pump. Start-Up, Running and Shut-Down Procedure The MVP HIS system is the ultimate in spray-up equipment. This instruction manual, the Trouble-Shooting Guide and the parts drawing package should be read thoroughly and used as a reference when working with your MVP system. We suggest you contact MVP or its nearest representative if the performance of your HIS system is not satisfactory after following these instructions. Start-Up These steps should be followed when the unit is new, recently repaired or has no material in the system: 1. Read and become familiar with Manual, Trouble-Shooting Guide and drawings for your particular unit. Read and become familiar with all other operational aides provided with the unit. 2. Check all fittings for proper connection. 3. Fill oiler to designated mark on oiler using light weight oil provided with unit or available from MVP when supply has been depleted. 4. Fill resin pump cavity (center section) approximately 1/3 full using TSL oil (throat seal lube). 5. Turn all regulators counter-clockwise so gauges will read zero (0) when air is connected to the system. 6. Pull top quick pin from catalyst pump slave arm H.I.S. Instruction Manual

18 7. Slide catalyst pump to back of slave arm and re-insert quick pin into slave arm hole just in front of catalyst pump bearing block. It should be general procedure never to have the catalyst pump connected except when actually spraying a laminate. Note: This will allow resin pump to stroke but prevent catalyst pump from moving during start-up procedure. 8. Attach air source to manifold fitting. Note ½ diameter (minimum) air hose should be used for maximum efficiency. See Detail XIII. RESIN PUMP AIR SHUT OFF VALVE RESIN PUMP AIR REGULATOR CHOPPER REGULATOR MAIN AIR SHUT OFF VALVE FLUSH REGULATOR FLUSH AIR CONTROL VALVE WATER TRAP DETAIL XIII 9. Remove top from flush tank and fill with clean suitable solvent. Replace tank top. (Acetone or Methylene Chloride preferred). 10. Slowly bring flush regulator up to 40 psi (turn clockwise). Note: Flush Tank pressure should never be higher than 60 psi. 11. Slowly open flush air control valve. 12. Remove nozzle, nozzle cap, turbulent mixer and front resin plug from gun. 13. Push forward on gun trigger until solvent exits gun nozzle. Release trigger and check entire flush system for leaks. To relieve pressure, turn flush air control valve to off position and lift up on wire ring of relief valve located on top of flush tank. Note: Release pressure from system before any corrective action takes place. 14. Make sure portable cart is properly assembled and supported using ballast where necessary for other than standard units. 15. Place resin supply onto portable cart and insert resin wand into resin container. Resin supply should be thoroughly mixed before being used. Central bulk resin systems should have a filter between the resin supply and pump to prevent clogging H.I.S. Instruction Manual

19 In the case where you own the long tube MVP Pump, the air lift connected to the pump will raise the pump for placing pump in resin. Connect air line from manifold to quick connect on air lift. After pump has been lifted align pump with hole in drum, disconnect air line from air lift, pump will descend into resin. 16. Slowly open gun needles by pulling gun trigger. Aim gun into suitable container and keep gun open during priming procedure. Resin Pump Priming Procedure 17. Open resin pump air valve and slowly turn resin pump regulator clockwise until resin pump is stroking slow, even strokes (approximately 1 to 10 psi). Observe gun to make sure resin is exiting nozzle evenly with no air inclusion. 18. Shut off air to resin pump by either turning regulator to zero or turning pump air control valve to off position. Note: Keep gun needles in open position. 19. Attach charging pump to resin accumulator by connecting black hose on end of charging pump to top of resin accumulator. Read labels on accumulator and charging pump. Note: Do not over tighten charging pump hose to accumulator. This will prevent swivel fitting on charging pump hose from turning. 20. With charging pump handle in up position, connect air hose from manifold to male quick disconnect on charging pump. 21. Place charging pump into slot of charging pump bracket. Pump charging pump handle with steady even strokes until gauge on charging pump reads approximately 280 psi (spray test figure only). Note: Charging pump bracket is attached to charging pump during shipping and should be attached to resin pump per instruction card attached to bracket. Note: Gauge will only show reading on down stroke, thus needle is bouncing during pumping action. 22. Disconnect air hose from charging pump and remove charging pump from resin accumulator. Check top of accumulator for air leak by applying a light fluid (such as water) to top of accumulator valve body. Note: If leaking occurs, refer to the Trouble-Shooting Guide for corrective action. 23. Close gun and flush into appropriate container for approximately 2 seconds H.I.S. Instruction Manual

20 Note: Flush by pushing forward on trigger. 24. Repeat opening of gun and aim into appropriate container for catalyst priming. Keep gun open during priming procedure. Catalyst Pump Priming Procedure 25. Slowly fill 2 gallon catalyst jug with MEKP (never dilute catalyst for MVP system). Note: See catalyst manufacturer for proper MEKP formulation for your particular operation. 26. Remove top quick pin from upper slave arm. 27. Loosen catalyst packing nut slightly to hand prime. 28. Slowly, with steady, even strokes, hand-pump catalyst pump using priming knob. Stop priming when steady stream of catalyst exits gun with no air inclusion. Note: Always dispose of catalyst per manufacturer s recommended procedure. 29. Repeat same charging procedure on catalyst accumulator that was done on resin accumulator. Read labels on catalyst accumulator and safety cover. Since inside of catalyst accumulator is made of glass, never remove safety cover while catalyst is in system. Note: If air is heard exiting gun during charging of catalyst accumulator, this indicates either poly ball or glass tube O-ring is not seating properly. Refer to Trouble-Shooting Guide for reassembly. Remember to always relieve system and accumulator pressure before any trouble-shooting is performed (see Recharging Accumulators in this manual, below). 30. Close gun and flush for approximately 2 seconds. 31. Connect catalyst pump to slave arm using quick pin. Note: Always have quick pins in same percentage holes on upper and lower slave arm or damage to catalyst pump may result. 32. Retighten packing nut. Do not over tighten. 33. Slowly open resin pump air valve and slowly turn pump regulator to 40 psi. Resin and catalyst pump will stroke until system is full. Check all fittings for leaks. Note: Always remember to turn off regulator and slowly open gun trigger to bleed system before any disassembly or repair takes place H.I.S. Instruction Manual

21 Fan Pattern Test Procedure 34. Attach resin gun plug, turbulent mixer, nozzle and nozzle cap to gun. Numbers on nozzle will indicate fan angle and orifice size. Refer to nozzle catalog for correct nozzle for your particular application. 35. Turn resin pump regulator down to zero then back to 20 psi. 36. Spray one slow, even pass onto test sheet. Observe spray pattern. If fan is very narrow with heavy fingers on inside and outside of pattern, increase resin pump regulator 5 psi and repeat spray test pattern. If fan is misting or fuming and a heavy, white froth appears in resin that does not dissipate, regulator pressure is too high for nozzle and resin being used. Recharging Accumulators 1. Turn resin pump regulator down to read zero pressure or turn air pressure valve to off position. Note: remember to note psi settings for proper spray fan. 2. Aim gun into proper container and slowly open trigger until spray fan becomes slow drip. Close gun, flush and reopen gun. 3. Release charge from resin accumulator. Note Charge is released by inserting a 1/16 rod into hole on top of accumulators. 4. Release charge from catalyst accumulator. 5. Recharge both accumulators as previously described. Correct charge is determined by amount of psi it took to achieve the spray pattern and by the type of MVP pumping system. Refer to manual, trouble-shooting guide or as noted: HIS 11:1 Pump HIS 7:1 Pump HIS 4:1 Pump Charge both accumulators 7 times the operating pressure of the resin pump. Charge both accumulators 5 times the operating pressure of The resin pump. Charge both accumulators 3 times the operating pressure of the resin pump. HIS 10:1 HV Pump Charge both accumulators 7 times the operating pressure of the resin pump. HIS 5:1 HV Pump Charge both accumulators 4 times the operating pressure of the resin pump H.I.S. Instruction Manual

22 Example: If you determined that 40 psi is the correct pressure for the fan pattern, charge both accumulators to 280 psi (7 x 40 = 280). This example would be for an HIS 11:1 pump. Note: In extreme cases unusual materials will dictate that resin and catalyst accumulators will need different charging pressures to achieve even flow of materials. If the standard, even changing pressure does not apply to you, contact MVP or the nearest MVP representative for proper charging. Remember, this is a rarity and standard procedure described above should usually be followed. 6. Close gun and flush. 7. Spray on test sheet. Observe fan for correct spray. 8. Observe accumulators and spray fan (pulsation) for proper charge. CAUTION: Safety cover should never be removed when fluid is in the system. Chopper Set-Up 1. Place glass on shelf or weight scale (option). If no weight scale is used, 1 box is placed on shelf and 1 box on edge of portable cart base. 2. Thread glass through ceramic coated guides. MVP always recommends 2 strands of glass whenever possible for the following reasons; (1) Better glass pattern is achieved with 2 strands. (2) Less fuzz build-up. (3) Less wear and tear on the chopper unit (chopper runs slower with 2 strands to achieve same output as one strand). Thread glass through brake adjustment guides to prevent strands from over-running chopper after gun has been shut off. Note: Brake guides may have to be bent slightly forward or backward to achieve proper settings. 3. Make sure chopper is adjusted properly. See Trouble-Shooting Guide for further information. 4. Loosen nut for chopper alignment. 5. Position chopper as close to center of gun nozzle as possible. 6. Move chopper up or down so glass will enter spray fan approximately 11/2 to 2 in front of gun nozzle. Tighten chopper nut. 7. Turn chopper regulator to approximately 1/3 higher psi than resin pump pressure. Note: This is only a starting point. Test shots of glass and weighing will determine correct output and psi to achieve output. 8. Make a test pass on a flat surface. Observe pattern. If glass is entering fan to left or right of spray fan, chopper is not centered on spray fan H.I.S. Instruction Manual

23 If chopper is set too close to spray fan, too much glass will be falling off both sides of spray fan. If chopper is set too high to spray fan, glass will be lumped in the middle of the spray fan. Correct Setting: (1) Glass entering center of spray fan (2) Glass spreading evenly across spray fan (3) No glass or very minimal amount of glass falling off sides of spray fan. Remember to flush after every spray by pushing forward on gun trigger for approximately 2 to 3 seconds. Repeat 1 to 2 times. 9. Oil chopper motor by removing chopper throttle valve and inserting 2 to 3 drops of chopper motor oil. Note: Chopper motor should be oiled for every 4 hours of operation. Shut-down Procedure for rebuilding or repair 1. Place pickup wand into a container with appropriate amount of solvent. 2. Turn resin pump and chopper regulators to zero. Turn resin pump air valve to off position. 3. Pull top quick pin attaching catalyst pump to upper slave arm and move catalyst pump to back of slave arm. Re-insert pin in slave arm hole just in front of catalyst pump bearing block. 4. Aim gun into open container and slowly open gun by pulling trigger. Keep trigger open. 5. Open resin pump air valve and turn regulator until pump begins to stroke slow, even strokes. 6. When solvent exits gun nozzle, shut off regulator. 7. Place container under resin pump filter and slowly unscrew filter tank from filter body. 8. Clean filter tank, filter screen and filter core in solvent. Note: Filter will need cleaning on a regular basis depending on material used. Filter screen will show degree of contaminates to judge cleaning period. (You do not have to completely flush resin system to clean filter, but follow proper bleeding procedure before removing filter.) 9. Remove charge from resin accumulator by inserting 11/16 rod into hole on top of accumulator. Keep rod pushed in hole until all air is exhausted from accumulator. 10. Slowly unscrew accumulator. STOP: Is accumulator hard to unscrew by hand? This may indicate that a charge still exists in accumulator and cannot be discharged from the top of the accumulator. If this happens, push rod up into filter body. Rod will hit poly ball and by pushing up gently on poly ball, air charge will be relieved H.I.S. Instruction Manual

24 Note: Always wear safety glasses and protective clothing. 11. After accumulator is removed from filter body, clean accumulator in solvent. Accumulator should be cleaned weekly to prevent resin gelation. Resin system can now be broken down for maintenance. Refer to Trouble-Shooting Guide and parts drawings for proper maintenance. Refer to Trouble-Shooting Guide for filled system procedure and for long period shut-down. Daily start-up and shutdown procedure described here is also included in the Trouble-Shooting Guide. Reassembly of resin accumulator and resin filter 1. Grease accumulator nipple threads and O-ring. Check O-ring for damage or wear. Replace if necessary. 2. Place poly ball on top of nipple. 3. Screw accumulator body onto nipple. Hand tighten only. 4. Grease threads of filter tank. 5. Place filter core into filter screen. Note: pin on core must enter filter screen first. 6. Place screen and core into tank. Note: pin end of core and screen goes into tank first. Core and screen will rest against spring in bottom of filter tank. 7. Screw filter tank, core and screen into bottom of filter body. Hand tighten only. 8. To remove catalyst from system, use only clean water. Wash all parts thoroughly and blow dry. Note: Catalyst has a much longer shelf life than resin and therefore does not need to be removed from the system as often. See Catalyst manufacturer for shelf life H.I.S. Instruction Manual

25 Yearly Maintenance Schedule (Average) This schedule is based on one 8-hour shift, 5 day work week, using standard G.P. resin (an idle unit left with resin in it may require more frequent part changes). When using gelcoats or filled materials, figures and wear factors should be approximately 50% more on the resin side of the system unless abrasive kits are used in both gun head and resin pump. When replacing any parts, follow instructions in Trouble Shooting Manual for the particular component. Catalyst Feed Jug Assembly: Daily: Check feed & return for leaks Monthly: Check and clean tubes & filter screens 3 Month Intervals: Clean catalyst jug Catalyst Hose: Daily: Yearly: Flush Line: Daily: Yearly: Check for leaks and/or cracks in outer lining. Replace hose Clean and inspect for wear and/or leaks. Replace hose. Chopper: Daily: Weekly: Oil air motor every 4 hours of running. Adjust rubber roll and idler. Replace blades Replace rubber roll. Clean Silencer 3 Month Intervals: Replace bearings & washer Check air tube for wear 6 Month Intervals: Replace bearing, vanes & seals in air motor Manifold Assembly: Daily: Drain water trap Weekly: Check gauges and regulators for wear Resin Accumulator: Weekly: Wash and clean inside 3 Month Intervals: Replace Spring, Stainless Steel Ball & O-rings Resin Filter: Weekly: Wash and clean filter screen weekly or whenever changing from one material to another. Adjust screen mesh size according to material being used. Resin Pump Powerhead: Weekly: Check Oiler Clean silencers (wash in solvent and blow dry with air) H.I.S. Instruction Manual

26 6 Month Intervals: Replace O-rings, Gaskets, Springs & Balls Check piston, sleeve and valve spool for wear Resin Pump Lower Assembly: Weekly: Check inside center section for packing leaks and pick-up hose and wand assembly for leaks. 6 Month Intervals: Replace packings, Piston cups, springs, balls & o-rings Check piston rod and pump cylinder for wear Flush Tank: Weekly: clean tank 6 Month Intervals: Replace relief valve assembly Air Lines: Weekly: check for leaks and wear, replace as needed. Gun Head: Monthly: Replace Nozzle (unless carbide), Injector & Turbulent Mixer 3 Month Intervals: Replace packings, seats, turbulent mixer, o-rings, springs, needles & stainless steel ball Catalyst Pump & Accumulator: 6 Month Intervals: Replace stainless steel balls, o-rings, springs, piston seal & packings Check all bushings and pump cylinder for wear Charging Pump: 6 Month Intervals: replace springs, balls, seats & o-rings Heaters: 6 Month Intervals: Replace springs, balls, seats & o-rings Resin Hose: Yearly: Replace yearly or earlier if cracks begin to occur on outside of line or if any excessive stiffening of hose is noted. Pick-up Wand/Siphon Hose: Yearly: Replace hose H.I.S. Instruction Manual

27 Gun Assembly Instructions The gun assembly procedure, as described, is the factory recommended method. MVP will not be responsible for any damage to unit if the recommended procedure is not followed. Components are first assembled to form subassembly units. The subassemblies are in turn assembled to complete gun assembly. This procedure simplifies the assembly process. This assembly applies for all HIS 80 gun systems (Chopper, Gelcoat, Casting, Saturator or Hydrajector). The exploded drawings should be used in conjunction with these instructions. CAUTION: Do not lubricate any part of this assembly that comes into contact with MEKP. Gun Head Subassembly ( 80 Model) 1. With gun head place in vise (nozzle end up), drop flush seat into nozzle opening. Very gently tap seat down until it bottoms out in nozzle chamber. Do not distort seat. Use appropriate wooden dowel. See instruction sheet on page 32 item Insert flush seat retainer into nozzle opening of gun head. Use ST63 ( ) flush retainer puller (in repair kit) to insert retainer. Drive retainer firmly down against flush seat; make sure side holes in retainer align with side holes in gun head. Unscrew puller after retainer is installed. 3. Place ST70 ( ) rod in vise with approximately 2 of rod sticking above vise. Drop flush needle (threaded end first) through nozzle opening on gun head. Holding threaded end of flush needle, place needle and gun head down on top of ST70 ( ) tool in vise. 4. Using ST27 ( ) packing tool in tool kit, push flush retainer onto threaded need of flush needle and down into flush chamber of gun head until retainer bottoms out. 5. Slide one set of packing over flush needle and push down in place using ST27 ( ) packing tool (see instruction below). Note: Install packing one piece at a time; 5 pieces of packing = 1 set. Packing installation tool ( ) Gun Block Packing Set (5 pc. Set) Needle NEEDLE PACKING INSTALLATION DIAGRAM H.I.S. Instruction Manual

28 6. Secure packing by installing packing screw over flush needle and attaching to gun head. This packing screw is the adjustment for stopping solvent leaks and/or allowing the flush needle to open and close smoothly. 7. Insert the flush needle spring over flush needle and into packing screw. (Lubricate spring before installing). 8. Attach spring retainer to threaded end of flush needle. Hold retainer in a vise (hex part only) and use a screwdriver in slot on front of flush needle to compress spring and turn the needle. Screw needle into spring retainer until needle is one thread below the exit surface of spring retainer. 9. Position the resin and catalyst needle seat into each hole in back of gun head. (Catalyst side is marked; other is resin). Gently tap in place using a wooden dowel the same diameter as seat. Do not distort seat. 10. Insert resin and catalyst needles into each hole on top of seat. 11. Slip the retainers over the needles and position in gun head. Use ST27 ( ) tool to install. Make sure large hole end of retainer goes onto needle first and that side hole in retainers are aligned with material supply port holes located in gun. If not aligned properly, material flow through gun will be severely restricted. 12. Insert remaining 2 sets of packing over needles (1set each). Install one piece at a time. See instruction on page Secure packing sets by sliding packing screws over needle and attaching them to gun head. Do not over tighten. The packing screw is used to stop material leaks and/or to allow needles to open and close smoothly. Note: To remove needle assemblies see instructions below H.I.S. Instruction Manual

29 ( ) ( ) H.I.S. Instruction Manual

30 H.I.S. Instruction Manual

31 14. Turn lock nuts onto resin and catalyst needles (bevel side of lock nut towards gun). Screw approximately 2/3 of the way down onto the needle threads. 15. Attach needle guides to the resin and catalyst needle. 16. Insert injector into side hole of catalyst chamber (gun head is marked). Screw injector into gun head until o-ring on injector bottoms out. Caution: Do not over tighten. To remove injector when damaged or worn, see instructions below. This instruction sheet also describes how to remove gelled material from gun chamber. INJECTOR INSTALLATION AND REMOVAL To Remove Catalyst Injector Nozzle Remove side plug, front plugs, spring and check ball. Install Drill Bushing ( ) into gun block (figure 1 above). Install #4 drill (00002) into drill chuck and drill injector out (figure 1 above). Remove drill and drill bushing from gun head, clean threads with 1/4-28 tap (00001) see figure 2 above. To Clean Gelled Resin from Mix Chamber Install Drill Bushing ( ) into gun head. Install 1/8 (.125) diameter drill ( ) in drill chuck (figure 3). Drill full 2-3/8 inches H.I.S. Instruction Manual

32 Caution: Damage could result if drill is forced deeper than 2-3/8 inches. Remove drill & drill bushing. Clean gun head thoroughly. Use a 1/4-28 tap to clean the thread then install new injector and reassemble gun head. Note: For proper injector installation, port on flush seal retainer must be in line with port. 17. Place plug seal onto plug and screw into side hole of catalyst chamber. Note: Serrated surface of plug seal toward gun. 18. Place stainless steel ball into front of catalyst chamber 19. Place spring on top of ball in catalyst chamber. 20. Place plug seal onto plug and screw into front hole of catalyst chamber. This will hold ball and spring into place. FLAT PUNCH H.I.S. Instruction Manual

33 21. Place plug seal onto plug and screw into front hole of resin chamber and side hole of resin chamber if gun is G03 model. 22. Place o-ring on resin nipple (pipe end) and screw into hole in back of resin chamber. 23. Place o-ring onto catalyst hose nipple (pipe end) and screw into hole in back of catalyst chamber. Caution: Do not lubricate catalyst chamber parts. 24. Place turbulent mixer into nozzle opening of gun head. 25. Place nozzle into nozzle cap and screw onto nozzle opening of gun head. Handle Subassembly ( 80 Model) 1. Install air valve assembly into center hole of handle. (Chopper, safety valve override and units with air operated heaters) 2. Insert springs on the two spring screws. Thread spring screws into holes in gun handle (one on each side of air poppet assembly). Lubricate springs. 3. Screw tube fittings into handle (chopper and Gelcoat handle only). Final Assembly ( 80 Model) 1. Align ends of the two needle guides on gun head assembly with openings in spring screws on handle assembly. 2. Pass threaded part, on back of gun head, through center hole in square bracket on handle; keyed head must fit into handle. 3. Screw by attaching nut onto the gun head and tighten it against the square handle bracket. Note: To install trigger, it is necessary to screw needle guides into spring screws until the nut on the guide is 5/16 from the forward surface of the spring screws. Then screw locknuts against spring screw. 4. Position the trigger with the ears in front of the locknuts. 5. Attach trigger to handle with the stud and screw. Note: To make final trigger adjustment, see Detail XV (page 33) or refer to the Trouble Shooting Guide on trigger adjustment. The resin needle must move at the same time or slightly before the catalyst needle. Never catalyst needle first. 6. To attach chopper to gun assembly, see chopper gun assembly procedure. 7. Attach resin hose to resin nipple and catalyst hose to catalyst hose nipple (catalyst side is marked). 8. To attach flush hose to gun, see instructions on page H.I.S. Instruction Manual

34 Gun Head Assembly ( 75 Model) The 75 model gun head is assembled in the same manner as the 80 model instructions, with the exception of steps 22 and 23. After you have completed step 21 in the instructions, follow the below steps and return to step 24 to complete your assembly: 1. Position two of the three provided o-rings on the nipples (pipe threaded end). 2. Screw the nipples into the gun head (o-ring end first). One in the center hole on the flat portion of the head, one in the outboard hole opposite the side of the gun head marked catalyst. Tighten. 3. Attach the elbows (2 each) to the nipples. The resin elbow locates over the right corner of the gun head; the port facing toward the needles. The flush locates over the opposite corner on the catalyst side. 4. Thread the locknut onto the adaptor. 5. Install the third 9/16 o-ring onto the interrupted thread area on the adaptor, and install adaptor into the gun head. 6. Secure by tightening the locknut against the gun head when the o-ring has seated in the gun head and the port in the adaptor is facing the corner of the head. 7. Install the catalyst hose nipple in the adaptor. MVP recommends Teflon tape here to prevent catalyst leak. Tighten snug H.I.S. Instruction Manual