MVP Patriot Megaject Innovator II Operation Manual Download Page 15

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Patriot Megaject Innovator II Operations Manual

Rev. 04/2014

Page | 15

Introduction:

The Patriot Megaject Innovator uses the Patriot pumping system for accurate metering.

This manual provides information needed to properly operate and perform simple
maintenance and repair on this equipment.



Step-by-step operations procedures are provided.



This manual includes Installation, Start-up and Shut-Down instructions.



Step-by-step assembly and disassembly procedures are included for each
component.

Please read this manual carefully. Follow the steps in the order given, otherwise you
may damage the equipment or injure yourself.

Component Assemblies:

The Patriot Megaject Innovator consists of a number of components

– these

components will have their own detailed manuals and drawings. For complete repair
and maintenance instruction please reference these manual.



Patriot Powerhead Manual

– PAT-PH-3250



Patriot 1-1/4 Fluid Section Manual

– PAT-LS-12270-RTM



Patriot Metering Pump Manual

– PAT-CP-0550



Innovator II Manual (Control Box)

– INV-CB-100

Megaject Injection Head (ASSY-0427)

Summary of Contents for Patriot Megaject Innovator II

Page 1: ...Patriot Megaject Innovator II Operation Manual Rev 04 2014 ...

Page 2: ... 2014 Page 2 CORPORATE HEADQUARTERS and MANUFACTURING 200A Perimeter Park Road Knoxville TN 37922 USA Tel 1 865 321 8809 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 E mail info mvpind com www mvpind com ...

Page 3: ...Y WARNINGS 6 INTRODUCTION 15 CONTROL BOX INSTRUCTIONS 19 CONTROL BOX CONFIGURATION 28 OPERATING PROCEDURES 33 FLUID SECTION MAINTENANCE REPAIR 38 CATALYST PUMP MAINTENANCE REPAIR 39 PATRIOT POWERHEAD 40 INJECTION HEAD MIXER ASSEMBLY 41 SP4 FLUSH ASSEMBLY 50 TROUBLESHOOTING 52 PARTS DRAWINGS 54 REVISION INFORMATION 77 ...

Page 4: ... 30 days from the date of the quotation unless otherwise noted on the quotation This time limit applies even if Buyer uses the quotation to submit a job or project bid to any other party 6 ASSIGNMENT The Buyer s rights and responsibilities under any purchase order or these Terms Conditions shall not be assigned by Buyer without the express written consent of the Seller 7 RETURN OF GOODS Permission...

Page 5: ... writing by Seller Buyer and not Seller is responsible for compliance with all United States export control rules and regulations Buyer shall not name Seller as shipper or exporter of record in connection with the export of any Goods purchased from Seller 19 INSTALLATION Installation of the Goods is the responsibility of Buyer unless otherwise indicated in the quotation or invoice provided to Buye...

Page 6: ...nderstand the Safety Manual It is very important for the safety of employees involved in the operation that equipment operators maintenance and supervisory personnel understand the requirements for safe operation Each user should examine his own operation develop his own safety program and be assured that his equipment operators follow correct procedures Magnum Venus Products hopes that this manua...

Page 7: ...Safety Equipment for conducting safe operations of the Polyester Systems Magnum Venus Products recommends that the user consult the state and local regulations established for all Safety equipment listed 2 0 Material Safety 2 1 Hazards Associated with Laminating Operations The major hazards which should be guarded against in polyester laminating operations are those associated with 1 The flammabil...

Page 8: ...i per second for an explosion of 12 acetylene and air The maximum value listed for a hydrogen explosion is 10 000 psi per second Some forms of MEKP if allowed to reach their SADT will burst even an open topped container This suggests that it is not possible to design a relief valve to vent this order of magnitude of pressure rate of rise The user should be aware that any closed container be it a p...

Page 9: ...mplishing these ends and any additional recommendations by the catalyst manufacturer determines largely the safety that will be present in his operation 2 3 Clean Up Solvents and Resin Diluents WARNING A hazardous situation may be present in your pressurized fluid system Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed pressurized fluid syste...

Page 10: ...r use in coating systems The increasing use of HHC solvents is increasing the risk Because of their exemption from many State Implementation Plans as Volatile Organic Compounds VOC s their low flammability hazard and their not being classified as toxic or carcinogenic substances HHC solvents are very desirable in many respects WARNING Do not use Halogenated Hydrocarbon solvents in pressurized flui...

Page 11: ...ncentration of catalyst and therefore will react quicker with over spray and the leak 2 5 Cured Laminate Overspray and Laminate Sandings Accumulation A Remove all accumulations of overspray FRP sandings etc from the building as they occur If this waste is allowed to build up spillage of catalyst is more likely to start a fire in addition the fire would burn hotter and longer B Floor coverings if u...

Page 12: ...ical supplier on what to do in the event the chemical gets onto your skin or into the eyes or is swallowed 2 Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person 3 Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals have WARNING Contact your do...

Page 13: ... closed position To do this simply rotate the lever on the ball valve 90 degrees Doing this will cause all the system air to bleed out of the system in a matter of a few seconds making the system incapable of operating NOTE Step 2 is a precautionary step and should be followed whenever the above mentioned ball valve is activated to the stop mode Failure to do so can damage the regulators and compo...

Page 14: ...dards that might apply to your application NEVER USE HARD MATERIALS SUCH AS WIRE PINS ETC TO CLEAR A PLUGGED GUN HARD MATERIALS CAN CAUSE PERMANENT DAMAGE DAB WITH A BRISTLE BRUSH BLOW BACKWARDS WITH AIR UNTIL CLEAR WHILE WEARING A PROTECTIVE EYE SHIELD REPEAT AS MANY TIMES AS NECESSARY DO NOT PERFORM ANY MAINTENANCE OR REPAIRS UNTIL YOU HAVE FOLLOWED THE PRECAUTIONS STATED ABOVE IF YOU AS AN EQUI...

Page 15: ... and disassembly procedures are included for each component Please read this manual carefully Follow the steps in the order given otherwise you may damage the equipment or injure yourself Component Assemblies The Patriot Megaject Innovator consists of a number of components these components will have their own detailed manuals and drawings For complete repair and maintenance instruction please ref...

Page 16: ...novator II Operations Manual Rev 04 2014 Page 16 Unit Overview Fig 1 CONTROL BOX CATALYST JUG INJECTION GUN MPG BLOCK SLAVE ARM STATIC MIXER MIXER OUTLET POWERHEAD RESIN PUMP CATALYST PUMP CATALYST OPV OVERPRESSURE VALVE ...

Page 17: ...r II Operations Manual Rev 04 2014 Page 17 FLUSH TANK CATALYST JUG RECIRCULATION SIGHT GLASS AIR FILTER CONNECT MAIN AIR HERE FLUSH VALVE CAV CATALYST AUTO VALVE CATALYST OPV OVERPRESSURE VALVE RAV RESIN AUTO VALVE Fig 2 Fig 3 ...

Page 18: ...8465 and Red Grease 6706 2 1 Connecting the system to air source The machine is supplied with inline filter and should be connected to an un lubricated air supply Ensure the maximum inlet air pressure marked on the filter is not exceeded 1Mpa 10 bar 145PSI A sleeve valve is provided on the rear of the enclosure so that air may be isolated from the control box Air should be removed from the machine...

Page 19: ... pressure being supplied to the pump Regulator Adjust this to control the air pressure being supplied to the pump and set the pump speed Flush Alarms CAT OP VALVE Indicator will turn red if overpressure state exists RGA ALARM Indicator will turn red if gel alarm timer has expired Pushbutton Press this button to operate the flush cycle Mold Pressure Guard Preset level gauge Control signal air press...

Page 20: ...UMP PRESSURE REGULATOR PUMP PRESSURE GAUGE STROKE COUNTER GEL ALARM INDICATOR CATAYLST O P INDICATOR FLUSH BUTTON MOLD PRESSURE GUARD GAUGE MOLD PRESSURE GUARD REGULATOR INJECTION BUTTON RESET BUTTON CURRENT COUNT DISPLAY PRESET COUNT DISPLAY DIGIT LOCKOUT DIGIT MODIFIERS RECIRCULATION BUTTON STOP BUTTON ...

Page 21: ...tton To de activate the E Stop twist and pull to release Catalyst Over Pressure protection The machine features catalyst over pressure protection In addition to the industry standard inclusion of a pressure relief valve in the catalyst circuit the control circuit will detect the over pressure condition and stop the pump from running In injection or recirculation modes this is equivalent to pressin...

Page 22: ...ressure in the injection line The operator may increase the injection pressure to make the pump stroke and therefore reset the alarm and complete the injection The RGA is de activated so that it stops monitoring pump strokes and cancels any active visual audible alarms by either flushing the machine or pressing the RGA reset button The RGA reset button is accessed on the side of the control panel ...

Page 23: ...ty mechanism to prevent the line pressure from exceeding the maximum working pressure of the injection line to the mold The MPG block is supplied with 2 air lines One air line supplies air from the MPG pressure regulator on the control panel The other is connected to an internal circuit on the control box When fluid pressure at the injection head exceeds the MPG preset level shown on the MPG press...

Page 24: ...setting When the injection line pressure reduces below the MPG set pressure the machine will continue to inject Adjust the predetermining counter to set the number of required pump strokes for the injection See figure 5 for an overview of the predetermining stroke counter To change the preset count press and hold the white button with arrow decal while pressing one of the black buttons under the p...

Page 25: ...t be entered when the machine is injecting or flushing To stop the machine press the stop button NOTE The catalyst over pressure valve is active during recirculation Guard Interlocks If the machine is fitted with a slave arm guard that does not require a tool to open the guard will be fitted with an interlock to stop the pump running when it is opened In this case if the guard is open or not corre...

Page 26: ... cycle is initiated PPVS SIGNAL This is the return signal from the PPVS when used Once this port Receives a signal it will start the pump system If the PPVS blocks the signal the pump will stop and the Pro gun will close If using the Megaject version the dispense head will stay open NOTE There must be a signal present on the PPVS signal for the machine to inject If no PPVS is to be used then the s...

Page 27: ...Patriot Megaject Innovator II Operations Manual Rev 04 2014 Page 27 Rear of control box Fig 7 PUMP SUPPLY CHARGING HOSE SLEEVE VALVE ...

Page 28: ...any components in the control box are labeled to aid identification and therefore locating items that may require adjustment should be relatively straight forward with the aid of a circuit diagram The internals of a typical Innovator control box are shown in figures 8 Some components have been marked for illustrative purposes however it must be emphasized that the appropriate air circuit should al...

Page 29: ...whistle can be adjusted by the user The pneumatic RGA control is located bottom center on the flow control ban Fig 9 The mechanical timer is shown in figure 10 Turn the knob to adjust the timer to the required time between 20 300 seconds The dial shows seconds divided by 10 therefore to set the timer to 100 seconds adjust the dial to 10 Fig 9 Fig 10 RGA TIMER TIMER ADJUSTMENT ...

Page 30: ...timer restrictor This controls the rate of airflow out of the timer circuit reservoir and the speed that the pressure falls in order to actuate the automatic flush stop valve To set the timer simply adjust the restrictor and then time the flush cycle Continue this procedure until the desired flush time is obtained Times of over 60 seconds are achievable with this circuit NOTE If the restrictor is ...

Page 31: ...rols how quickly the pressure builds within the circuit and therefore the time and speed in which the pump restarts The slower the flow of air through the restrictor the longer the pump will take to restart NOTE If this restrictor is fully wound in air flow will be blocked and the pump will not start Conversely if too higher flow of air is supplied to the circuit safe and correct operation of the ...

Page 32: ...t falls and the pump stops When the circuit is once again sealed the restrictor controls how quickly the pressure builds within the circuit and therefore the time and speed in which the pump restarts The slower the flow of air through the restrictor the longer the pump will take to restart NOTE If this restrictor is fully wound in air flow will be blocked and the pump will not start Conversely if ...

Page 33: ...Page 33 Operating Procedures 1 Pre Start Check List for Patriot Megaject Innovator 2 First Time Start Up for Patriot Megaject Innovator 3 Daily Start Up for Patriot Megaject Innovator 4 Daily Shut Down for Patriot Megaject Innovator The Check Lists are following ...

Page 34: ...ll catalyst resin fitting to be sure they are tight 6 Fill pump packing nut 1 3 full with PAT LS OIL 7 Fill the Catalyst Jug at least 1 2 full of catalyst 8 Secure the Pick up wand to the pump inlet 9 Place the Resin Pick up wand in the resin supply container 10 Place the end of the Resin Return Hose in the resin container 11 Fill the Solvent Flush Tank 3 4 full 12 Place the appropriate container ...

Page 35: ...ontrol panel 4 Slowly increase the pump regulator so that the pump strokes slowly and evenly 5 Allow the pump to recirculate until the flow of Resin and Catalyst back to there respective containers is free of bubbles 6 Press the Stop button to take the unit out of recirculation mode 7 Test the catalyst and resin to the Injection head Place a suitable container under the injection head and press th...

Page 36: ...nd adjust as necessary 8 Set the desired number of counts on the Counter Display 9 Press the Stop button to take the unit out of recirculation mode 10 It is always a good idea to do a gel test each morning and balance the fluid pressures So place the appropriate container under the injection head and press the Inject button and pump 2 or 3 strokes Then press the Stop button 11 Press the Reset butt...

Page 37: ...Clothing Eye Protection and PVC Gloves 1 Close TAS Turbo Autosprue or pinch injection hose to close the mould 2 Press the Reset button on the Counter to reset the counter 3 Flush the injection head and hose or TAS Turbo Autosprue 4 Disconnect the injection hose or TAS from the injection head 5 Turn off the main air slide valve at the back of the unit ABNORMAL CONDITIONS OBSERVED AND CORRECTED Abno...

Page 38: ... Fluid Section Maintenance The standard Megaject Innovator uses the Patriot 1 1 4 Fluid Section Assembly PAT LS 12270 RTM for detailed instructions for Repair Maintenance of this fluid section please reference the manual Patriot 1 1 4 Fluid Section Manual PAT LS 12270 ...

Page 39: ...d Megaject Innovator uses the Patriot Catalyst Pump Assembly PAT CP 0550 for detailed instructions for Repair Maintenance of this Catalyst Pump please reference the manual Patriot Catalyst Pump Manual PAT CP 0550 SLIDE DRIVE STICKERS 2 2 5 1 5 1 PAT RS 1227 055 75 FLIUD SECTION PAT LS 12270 and PAT CP 0550 ...

Page 40: ...2014 Page 40 Powerhead Maintenance The standard Megaject Innovator uses the Patriot 3 1 4 Powerhead Assembly PAT PH 3250 for detailed instructions for Repair Maintenance of this fluid section please reference the manual Patriot Powerhead Manual PAT PH 3250 ...

Page 41: ... Page 41 Injection Gun Mixer Following in this section are the instructions for the items listed below 1 Auto Head Assembly 2 Catalyst Auto Valve Assembly CAV 3 Resin Auto Valve Assembly RAV 4 Head Mixer Mould Pressure Guard MPG 5 Automatic Flush Valve Assembly ...

Page 42: ...2014 Page 42 Fig 15 Injection Head Assembly ASSY 0427 see figure 15 Injection Head Assembly ASSY 0427 22423_07 Assy 0425 CAV Assembly See drawing 83018_XX Assy 0424 RAV Assembly See drawing 83022_XX Assy 0447 CAV Assembly See drawing 83013_XX 6758 7701 6 3 ...

Page 43: ...surement using callipers after service and before using the machine in production Take care not to damage or scratch the spool internal body 6369 when O ring 3316 needs replacing The valve should only need servicing if air or catalyst is noted to weep from between the air cylinder 6078 and Stainless steel body 6067 In this case the O ring 3316 should be renewed If catalyst appears to weep back to ...

Page 44: ...I Operations Manual Rev 04 2014 Page 44 Illustration of Catalyst Auto valve cross section showing catalyst flow and correct position of air actuator for A injection flow And B recirculation flow A Injection B Recirculation Fig 17 ...

Page 45: ...r only Do not over tighten Hex Head Screw Note Seal 5837 would normally be replaced by removing Nose Block 5852 first However it can be accessed replaced by unscrewing the Screw 5832 without removing the Nose Block 5852 If the shaft turns whilst removing Screw apply signal air pressure to open connector 6080 this aids locking the shaft against rotation It is essential that screw is not over tighte...

Page 46: ...without scratching grooves in shaft and replace or replace Shaft 5828 complete with Seals fitted Shaft 5828 may be unscrewed form Shaft 5827 by firmly gripping both close to piston 5830 Reassemble using a small amount of thread lock compound on threads and PTFE sealer paste on Shaft end next to piston base hole 5830 Do not grip and turn shaft beneath O ring seal grooves Caution For safety reasons ...

Page 47: ...Patriot Megaject Innovator II Operations Manual Rev 04 2014 Page 47 Fig 19 Head Mixer and Mould Pressure Guard MPG See fig 19 20 Assy 0423 MPG Assembly Dwg 82009 see fig 20 0619 ...

Page 48: ...rred in the injection head They cannot be repaired and must be replaced To replace first remove Mould Pressure Guard MPG signal pipes and remove mixer shroud from head Remove mixer tube from inside shroud Lightly grease new mixer tube shroud threads with silicon grease ensure shroud internal O ring 0749 is in position and replace in mixer shroud Re attach to mixer head and reconnect MPG pipes ...

Page 49: ...ssembly 58742 1 see fig 21 The Automatic Solvent Flush Valve may be serviced NOTE however the important use of thread lock compound between parts 3 and 8 These two parts need to be disassembled if the main solvent seal 19 needs renewing so ensure that a thread lock compound is used when reassembling ...

Page 50: ...lvent contained inside and then purges with air for the reminder of the flush cycle The SP4 is activated by pressing the Flush button on the control panel and will operate for 30 to 60 seconds The duration of the flush purge cycle can be adjusted as previously noted in the Control Box Configuration section Fig 12 Connecting the SP4 Connect the yellow outlet tube from the outlet side of the solvent...

Page 51: ...n mix head extends down through the outlet side fitting and connects to the outlet of the solvent pump Note it is important that the solvent level in the tank be at no less then 1 3 full or so that there is 25mm 1 of solvent above the SP4 solvent pump This will allow the SP4 solvent pump to properly refill with solvent after each use Maintenance The SP4 Solvent Pump is basically maintenance free h...

Page 52: ...signal Should be on Check V15 output 05 for signal Should be on Stop sequence has been imitated Internal Stop sequence circuit check Check 16 for signal Should be off Remote stop button has malfunctioned Check 15 for signal Should be off CE NORM guard valve has malfunctioned Check 37 for signal Should be off Stop pushbutton PB06 has malfunctioned Check 39 for signal Should be off Pulse valve S01 h...

Page 53: ...with pulses from powerhead Cat OP circuit does not stop pump FC 04 not adjusted properly Adjust flow control Remove 21 from Catalyst Overpressure valve start pump slowly turn in FC 04 until pump stops MPG will not stop pump on overpressure Reduce MPG pressure from panel FC 04 not adjusted properly Adjust flow control Remove 26 from MPG valve start pump slowly turn in FC 06 until pump stops Gel Ala...

Page 54: ... 0550 CATALYST PUMP ASSEMBLY PAT CP 0550 SK SEAL KIT PATRIOT CATALYST PUMP PAT CP INV INNOVATOR CATALYST JUG PAT PH 3250 3 1 4 PATRIOT POWERHEAD 2 STROKE ASSEMBLY PAT PH 3250 SK SEAL KIT 3 1 4 PATRIOT POWERHEAD 82004_01 SP4 PUMP ASSEMBLY 82009_01 MPG VALVE ASSEMBLY 22021_06 CATALYST OVERPRESSURE VALVE ASSEMBLY 83018_01 CAV CATALYST AUTO VALVE 83022_01 RAV RESIN AUTO VALVE ASSY 0424 INV CB 100 P PN...

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Page 77: ...aject Innovator II Operations Manual Rev 04 2014 Page 77 Revision Information Revision Description Rev 04 2014 Document was created updated to reflect the new Innovator II Control Box INV CB 100 and configuration ...

Page 78: ...TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave Kent WA 98032 Tel 253 854 2660 Fax 253 854 1666 E mail info mvpind com www mvpind com Included with this operations manual are the following component manuals PATRIOT POWERHEAD MANUAL PAT PH 3250 PATRIOT 1 1 4 FLUID SECTION MANUAL PAT LS 12270 PATRIOT CATALYST PUMP MANUAL PAT CP 0550 INNOVATOR II MANUAL INV CB 100 Control Box ...

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