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Patriot - Testing & Adjusting Manual

Rev. 01/2016

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SAFETY & WARNING INFORMATION

OPERATING YOUR POLYESTER SYSTEM SAFELY

1. Introduction

Any tool, if used improperly, can be dangerous. Safety is ultimately the responsibility of those
using the tool. In like manner, safe operation of polyester processes is the responsibility of those
who use such processes and those who operate the equipment. This manual outlines
procedures to be followed in conducting polyester operations safety. This system has been
specifically designed for use of Polyester Resin, Gel-Coat, and Methyl Ethyl Ketone Peroxides
(MEKP) applications. Other formulations or blends considered for use in this equipment is
strictly prohibited without the expressed consent by Magnum Venus Products Inc. Magnum
Venus Products cannot eliminate every danger nor foresee every circumstance that might
cause an injury during equipment operation. Some risks, such as the high pressure liquid
stream that exits the spray tip, are inherent to the nature of the machine operation and are
necessary to the process in order to manufacture the end-product. For this reason, ALL
personnel involved in polyester operations should read and understand 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
manual is helpful to the user and recommends that the precautions in this manual be included in
any such program.  Magnum Venus Products recommends this Safety Manual remain on your
equipment at all times for your personnel safety.  In addition to the manual, Magnum Venus
Products recommends that the user consult the regulations established under the Occupational
Safety & Health Act (OSHA), particularly the following sections:

1910.94 Pertaining to Ventilation.

1910.106 Pertaining to flammable liquids

1910.107 Pertaining to spray finishing operations, particularly Paragraph (m) Organic Peroxides
and Dual Component Coatings.

Other standards and recognized authorities to consult are the National Fire Protection
Association (NFPA) bulletins as follows:

NFPA No.33 Chapter 14, Organic Peroxides and Dual Component Materials

NFPA No.63 Dust Explosion Prevention

NFPA No.70 National Electrical Code

NFPA No.77 Static Electricity

NFPA No.91 Blower and Exhaust System

NFPA No.654 Plastics Industry Dust Hazards

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Summary of Contents for PATRIOT

Page 1: ...Rev 01 2016 TESTING ADJUSTING THE PATRIOT METERING SYSTEM ...

Page 2: ...age 2 CORPORATE HEADQUARTERS and MANUFACTURING 10535 Hardin Valley Rd Knoxville TN 37932 USA Tel 1 865 686 5670 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: ...tents SECTION Page TERMS CONDITIONS OF SALE 4 SAFETY WARNINGS 7 INTRODUCTION 16 ESTABLISHING A SPRAY FAN 19 SPRAY TESTING 22 POUR TESTING 31 CHARGEABLE ACCUMULATORS 34 EXTERNAL START UP SHUT DOWN 38 INTERNAL START UP SHUT DOWN 45 APPENDIX 52 REVISION INFORMATION 54 ...

Page 4: ... 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 to retu...

Page 5: ...g 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 Buyer Notwi...

Page 6: ...nd 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 manual is he...

Page 7: ...quipment 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 flammability and ...

Page 8: ...cond 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 pressure ...

Page 9: ...ng 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 system pump ...

Page 10: ... 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 fluid system...

Page 11: ...tion 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 used sho...

Page 12: ...plier 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 doctor imm...

Page 13: ...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 components on...

Page 14: ...at 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 EQUIPMENT OP...

Page 15: ...resin meter but are driven through a linkage attached to the resin meter The initiator meter and resin meter have a fixed ratio to each other in that they move together metering a given amount of resin and initiator This leads us to one of the major principles since the initiator meter is attached to and driven by the resin meter you can never get more of one component just less of the other The i...

Page 16: ...ve ball seats sealing the inlet body this forces the material to flow up and out of the pump The piston body ball lifts off its seat and allows material to flow through the piston and out the pump Piston body ball lifts off its seat allowing material to flow out the pump Inlet body ball seats sealing off the pump cylinder forcing material thru the piston body and out the pump PUMP OUTLET DOWN STRO...

Page 17: ... its seat everything above the piston body is pushed out A vacuum is created below the piston body and new material is drawn in Piston body ball seals forcing all the material above the piston out of the pump Inlet valve ball lifts from its seat and new material is drawn into the pump inlet body PUMP INLET PUMP OUTLET UP STROKE ...

Page 18: ...m efficiency Note Because conditions and material vary widely we cannot give you specific instructions for every material We do offer guidelines and tests so that you can tune your Magnum Venus Products equipment to meet your needs The basic idea is to use just enough pressure to the power head to establish the spray fan and no more 1 Lay out a strip of material for the test For testing the materi...

Page 19: ...ff until the unit no longer produces a fan Then increase the operating pressure until there is just enough to form a soft looking spray fan 6 If the pressure was not adequate to form a well defined fan pattern increase the main pressure by 5psi and do another short test spray Repeat step 6 until a well defined spray pattern has been obtained then follow step 5 Note Photocopy page Appendix A to mak...

Page 20: ...essure is very low for the material you are using Solutions Increase the operating pressure Increase the material s temperature Use a smaller Nozzle size B Three heavy fingers Horns are beginning to develop but the operating pressure is still very low Solutions Increase operating pressure Increase material s temperature Use smaller nozzle size ...

Page 21: ...erating pressure Increase material s temperature D The pattern is at or near full width There are well defined fingers however there is little or no white frothing air bubbles in the center of the sprayed material Result D is a usable pattern for an experienced operator Solutions Slightly increase operating pressure Slightly increase material s temperature ...

Page 22: ...written notes of the main pressure and the material temperature readings Appendix A F The pattern is too wide and the fingers are poorly defined Heavy misting is seen and smelled and there is significant overspray material laid down beyond the main pattern The heavy white frothing does not disappear within 2 minutes Note This is the most common mistake in running Magnum Venus Products equipment So...

Page 23: ...tive material materials that change color when they are catalyzed make this testing easier and more accurate MVP recommends using a dyed catalyst or a color reactive material 1 Lay a sheet of test material on a flat surface Note The temperature of the surface can affect the reaction time of many chemicals The coldness of a concrete floor can cause changes in cure times 2 Pull the trigger and start...

Page 24: ...ething like figure 3 above 5 Use a tongue depressor to test several areas on the strip top of stroke bottom of stroke and the up and down stroke in several places Repeat testing for material hardening several times to find out if some areas are hardening faster or slower than other areas Note Color reactive materials materials that change color when they harden make this testing very easy and accu...

Page 25: ...ow can also be adapted to pour applications by pouring a saw tooth shaped bead of material Where the top of the saw tooth is the top of the stroke and the valley is the bottom of the stroke Improper cure at the top and bottom of the stroke indicates an accumulator issue either catalyst or resin Result 1 Material delivered at the top and bottom of the stroke is not curing or curing more slowly than...

Page 26: ... accumulator installed Pump pressure is too high lower resin pressure See chapter 5 for accumulator charging procedures NOTE Use caution as there may be some material still in the accumulator a long narrow rod can be inserted up through the filter body to lift the polyball off the seat and allow any remaining material to drain if desired Start Spray Test Direction of gun travel End Spray Test Resu...

Page 27: ...ice and Repair Manual Start Spray Test Direction of gun travel End Spray Test Result 5 Material is delivered with streaks running the length of the test spray Some strips cure normally some not at all other cure at faster or slower rates see figure above This is not a pumping problem it is a mixing problem Indicates a mixing problem and the fan is delivering streams of poorly catalyzed resin and o...

Page 28: ... catalyst followed by material that is properly mixed and cures See below Indicates system is unbalanced at the beginning of the spray Low resin is delivered upon pulling the trigger of the gun followed by low catalyst delivery After a moment or two the system balances and properly mixed material is delivered Probable Cause The catalyst needle on the gun opens before the resin needle Solution Adju...

Page 29: ...e above Indicates The system is unbalanced at the beginning of the spray No catalyst at the beginning of the spray followed by normal mix and spray Probable Cause The resin needle is opening too much before the catalyst needle This means a shot of pure uncatalyzed resin will be delivered until the catalyst needle is opened Solution Adjust the catalyst and resin needles to the proper settings ...

Page 30: ... on the catalyst pump down stroke from the top of the stroke to the bottom is not curing or slow cure see figure above Indicates No catalyst is being delivered on the down stroke Probable Cause Worn or damaged inlet body Worn or damaged inlet body ball Worn or damaged inlet body O ring Solution Replace worn and damaged parts see Service and Repair Manual Start Pour Test Direction of gun travel End...

Page 31: ...r slow cure see figure above Indicates No catalyst is being delivered on the up stroke Probable Cause Worn or damaged catalyst piston seal Damaged catalyst pump cylinder Worn or damaged piston body ball Damaged piston body ball seat Solution Replace worn and damaged parts see Service and Repair Manual Start Pour Test Direction of gun travel End Pour Test B B B B T T T ...

Page 32: ...Material delivered at the top and bottom of the stroke is hot curing very rapidly Also thin areas of material might be noticeable compared to the volume delivered in the middle of the stroke see figure above Indicates Low resin at the top T and bottom B of the pump stroke Probable Cause There is no or improper accumulator effect in the resin system Solution Resin accumulator full of hard material ...

Page 33: ...ing the charging procedure to confirm an even cure Charging Procedures Line Charge 1 Shut off air to the resin pump by either turning regulator to zero or turning the pump control valve to the off position 2 Lock the gun in the on position over an appropriate container or open the ball valve at the bottom of the resin filter if one is installed Note For catalyst charging lock the gun in the open p...

Page 34: ...y existing charge by inserting a blunt object allen wrench into the top of the charging valve 11 Attach charging pump to the resin accumulator by connecting the black charging hose to the charging valve on top of the resin accumulator Note Do not over tighten charging pump hose 12 Pull the charging pump handle all the way out connect air hose to male quick disconnect on charging pump Note not pull...

Page 35: ...n pump by either turning regulator to zero or turning the pump control valve to off position 18 Lock the gun in the on position over an appropriate container or open the ball valve at the bottom of the resin filter Note For catalyst charging lock the gun in the open position over an appropriate container or open the recirculation dump valve on the manifold 19 Relieve any existing charge by inserti...

Page 36: ... 5psi increments as required to fine tune the accumulator charge 24 Disconnect charging hose from the resin accumulator Check the top of the accumulator for air leaks by applying a light fluid water to the top of the accumulator valve body If air leaks remove and repair charging valve 25 Close the gun and flush into appropriate container or close the resin return valve at the bottom of the filter ...

Page 37: ...rt up Shut down PRE START CHECKLIST External Mix System FIRST TIME START UP CHECK LIST External Mix System SET UP FOR CHARGEABLE External Mix System SPRAY FAN SETUP External Mix System DAILY START UP External Mix System DAILY SHUT DOWN CHECKLIST External Mix Systems ...

Page 38: ...h 5 Incoming air valve is in the OPEN position 6 Air supply is ON 7 Remove nozzle cap catalyst tip and nozzle 8 Check for oil in the pump reservoir fill 1 3 full 9 Check that there is Catalyst in the Catalyst Bottle 10 Check that the Catalyst Bottle Cap and Screen are in place 11 Place the Resin Pick up wand in the resin supply container 12 Place the end of the Resin Return Hose in the resin conta...

Page 39: ... pump with the slave arm drive observe for catalyst exiting the Gun Leave the pivot pin out 6 Make sure the ball valve below the surge chamber is closed 7 Using the regulator on the manifold slowly turn up the pump air pressure until the pump moves slowly and evenly 8 Allow the resin pump to cycle until only resin exits the Gun 9 Turn the air to the pump down to zero 10 Disengage the gun trigger l...

Page 40: ...ive observe catalyst returning to the catalyst jug pump until the stream is air free 7 Close recirculation valve on Catalyst Manifold 8 Manually pump the catalyst pump with Slave Arm drive bring catalyst pressure to operating pressure about 100 psi 9 Make sure to close the Ball Valve at the bottom of the resin filter 10 Slowly turn up the pump air pressure to the operating pressure 30 50 psi If a ...

Page 41: ...pattern onto a wide paper test strip Observe the pattern Too wide with no defined horns highly atomized spray fan turn down the pump pressure Too narrow but with well defined horns turn up the pump pressure Good width with small defined horns optimized for low emission spraying Use air assist adjustment to refine the fan If more material is needed us a larger Spray Tip do not increase pump pressur...

Page 42: ...the catalyst drive observe catalyst returning to the catalyst jug pump until the stream is air free 7 Close recirculation valve on Catalyst Manifold 8 Manually pump the catalyst pump with the Slave Arm drive bring catalyst pressure to operating pressure 100psi 9 Check resin pump pressure if needed slowly turn up the pump air pressure to the operating pressure 30 50 psi If a safety over ride valve ...

Page 43: ...ator as specified for spray painting Protective Clothing Eye Protection and PVC Gloves 1 Wipe the face of the nozzle and catalyst tip with solvent 2 Turn off the main air ball valve at the air manifold 3 Remove the nozzle and catalyst tip and clean with solvent 4 Wipe the gun face clean with a rag or brush and solvent 5 Hang the gun with the gun block exit holes facing downwards ABNORMAL CONDITION...

Page 44: ...rt up Shut down PRE START CHECKLIST Internal Mix System FIRST TIME START UP CHECK LIST Internal Mix System SET UP FOR CHARGEABLE Internal Mix System SPRAY FAN SETUP Internal Mix System DAILY START UP Internal Mix System DAILY SHUT DOWN CHECKLIST Internal Mix Systems ...

Page 45: ...Pro Gun if applicable 8 Remove nozzle cap nozzle and mixer 9 Check for oil in the pump reservoir fill 1 3 full 10 Check that there is Catalyst in the Catalyst Bottle 11 Check that the Catalyst Bottle Cap and Screen are in place 12 Place the Resin Pick up wand in the resin supply container 13 Place the end of the Resin Return Hose in the resin container 14 Fill the Solvent Flush Tank 15 At the Mani...

Page 46: ...lator on the manifold slowly turn up the pump air pressure until the pump moves slowly and evenly 8 Allow the resin pump to cycle until only resin exits the Gun block 9 Turn the air to the pump down to zero 10 Disengage the gun trigger leave it in the CLOSED position 11 Flush the Gun block with acetone wipe the gun block face clean 12 Adjust the catalyst percentage required with the slide arm Knob...

Page 47: ...catalyst returning to the catalyst jug pump until the stream is air free 8 Close recirculation valve on Catalyst Manifold 9 Manually pump the catalyst pump with the Slave Arm drive bring catalyst pressure to operating pressure 100 200 psi 10 Slowly open the ball valve at the bottom of the resin filter 11 Charge the Resin Accumulator by holding the charging hose fitting on the charging valve at the...

Page 48: ...ern onto a wide paper test strip Observe the pattern Too wide with poorly defined horns turn down the pump pressure Too narrow but with well defined horns turn up the pump pressure Good width with well defined horns optimized for low emission spraying If more material is needed us a larger Spray Tip do not increase pump pressure to increase the amount of material Use a larger or smaller fan angle ...

Page 49: ...p with the Slave Arm drive bring catalyst pressure to operating pressure 100 200 psi 9 Check resin pump pressure if needed slowly turn up the pump air pressure to the operating pressure 30 50 psi If a safety over ride valve is installed press and hold the priming button while adjusting air pressure 10 Replace the Pivot Pin into the catalyst pump drive 11 Insert the Distribution Ring into the Mix C...

Page 50: ...ting Protective Clothing Eye Protection and PVC Gloves 1 Flush the gun with solvent 2 Wipe the face of the nozzle after flushing 3 Turn off the main air ball valve at the air manifold 4 Release the solvent flush tank pressure 5 Remove the nozzle and clean it with solvent 6 Remove the Mix Housing and clean it 7 Wipe the gun block face with a clean rag 8 Hang the gun with the gun block exit holes fa...

Page 51: ...Patriot Testing Adjusting Manual Rev 01 2016 Page 51 Appendix Test Notes use the form below for recording the information from the Spray or Pour test ...

Page 52: ...____________ This material was successfully applied under the following conditions Winter Spring Summer Fall Air temperature of the factory ________ degrees Relative humidity of the factory _______ Other conditions ______________________________________________________________________ ______________________________________________________________________ ___________________________________________...

Page 53: ...l format and Address We added the Terms Conditions of Sale and Revision Information sections to this manual Added the Start up and Shut down sections Rev 08 2014 Updated the manual format Address name and the Terms Conditions of Sale Removed references to Plastech Rev 01 2016 Updated the Address and Logo ...

Page 54: ...age 54 CORPORATE HEADQUARTERS and MANUFACTURING 10535 Hardin Valley Rd Knoxville TN 37932 USA Tel 1 865 686 5670 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 ...

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