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Pro Rider Operations Manual

Rev. 08/2016

Page | 15

Introduction:

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

Major Components:

The Pro Rider Gel Coater consists of the following major components:



Resin Pump Fluid section and Air Motor



Shift Block Assembly



Catalyst Pump Assembly



Gun Assembly

Description of Controls for Spray unit:

Familiarize yourself with the Air Manifold controls, which consist of the following
regulators and gauges:



PUMP PRESSURE gauge and regulator. This controls the main air pressure to
the resin pump Air Motor.



ATOMIZING-AIR gauge and regulator. This controls the air pressure to the
catalyst nozzle on the gun. This is normally set to 18

– 25psi (1 -1.5 bar)



RESIN DUMP VALVE

– This is located on the Filter Body. This is used to

relieve gel coat pressure.

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Содержание CB-5000-PRV

Страница 1: ...Pro Rider Gel Coater Operations Manual Rev 08 2016 ...

Страница 2: ...e 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 ...

Страница 3: ...LE 4 SAFETY WARNINGS 6 INTRODUCTION 15 GETTING STARTED 16 PRIMING the UNIT 18 DAILY START UP SHUT DOWN 20 TROUBLE SHOOTING GUIDE 21 AIR LOCK IN THE CATALYST PUMP 28 PUMP REPAIR PROCEDURES 30 CATALYST PUMP REPAIR PROCEDURES 31 GEL COAT GUN REPAIR PROCEDURES 32 PARTS DRAWINGS 33 REVISION INFORMATION 45 ...

Страница 4: ...rom 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 return...

Страница 5: ...y 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 Notwiths...

Страница 6: ...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 helpf...

Страница 7: ...ipment 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 ex...

Страница 8: ...nd 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 ve...

Страница 9: ...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 hea...

Страница 10: ...oating 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 systems ...

Страница 11: ...n 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 should...

Страница 12: ...ier 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 immed...

Страница 13: ...sition 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 r...

Страница 14: ... 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 OPER...

Страница 15: ...pment or injure yourself Major Components The Pro Rider Gel Coater consists of the following major components Resin Pump Fluid section and Air Motor Shift Block Assembly Catalyst Pump Assembly Gun Assembly Description of Controls for Spray unit Familiarize yourself with the Air Manifold controls which consist of the following regulators and gauges PUMP PRESSURE gauge and regulator This controls th...

Страница 16: ...ion Throughout this manual directions are given for lubricating various parts of the Pro Pump There are three types of lubricant used If the part contacts resin use MVP Red Grease 6706 2 1 If the part is located where it will contact air use Lubriplate 08465 Throat Seal Oil TSL 3200 used in the oil reservoir of the pump Other Supplies Solvent for cleaning A small Chip Paint Brush for cleaning Smal...

Страница 17: ... jug outlet to the Catalyst pump Inlet 6 Connect the Catalyst hose to the Catalyst Pump outlet 7 Install Gel coat Filter Surge Chamber assembly 8 Attach the Gel coat hose to the Outlet of the Filter assembly 9 Install Air Manifold connect Air Hose to Powerhead Air Supply to the Shift Block 10 Attach hose fittings catalyst atomizing hose and gun air supply 11 Attach Pickup Hoses to the Inlet of the...

Страница 18: ...he drum pail 3 Remove the Catalyst Tip and Spray Tip from the front of the gel coat gun 4 Position the gun over an appropriate container and with the gun trigger locked in the open position slowly increase pump regulator pressure until pump is running at a slow but steady rate Allow pump to run until a steady stream of gel coat is being dispensed 5 Close the gun and brush the front of the gun head...

Страница 19: ...alyst pump are set to the same percentage on the slave arm to prevent damage to the catalyst pump Gun Set Up Spray Note Use a little red grease on the o rings and threads before installing the spray tip catalyst tip and retainer 1 Install the Gel Coat Spray Tip into the front of the gun block 2 Install the Catalyst Tip over the Spray Tip Use caution not to damage the o rings on the front of the gu...

Страница 20: ...connecting arm when it is unpinned from the slave arms this will help prevent damage to the catalyst pump 5 Replace the Pin into the Slave arm and catalyst pump bearing block 6 Check atomizing air pressure adjust as necessary It should be set to 18 25psi 1 1 5 bar 7 Lubricate the spray tip o rings stud o rings and gun front threads 8 Install nozzle catalyst tip and retaining ring onto the front of...

Страница 21: ...alve CV 2000 not working correctly Check and Repair the Catalyst Check Valve CV 2000 No cure or slow over all cure Catalyst pump set at too low or too high of a percentage Move catalyst pump to a higher setting closer to the gel coat pump Be sure to attach the catalyst pump in a vertical position Catalyst supply below outlet fitting on jug Fill catalyst jug 1 3 full Quick pin not attached to pump ...

Страница 22: ...nder high pressure Catalyst will be sprayed from the hose fitting when the fitting is loosened Follow safety instructions read the Safety Warning section in the beginning of this manual Relieve pressure from the system Replace the catalyst hose with new one Gel coat too cold Consult your materials supplier for proper temperature Maintain a draft free environment of about 70 degrees F An auxiliary ...

Страница 23: ...ilter Wide Fan Air pressure too high Lower pressure then increase pressure to the desired fan Nozzle too small or too wide Change nozzle Round fan Orifice in nozzle worn clogged or damaged Push fine wire through orifice from back side Use fingernail to clean material form V shaped notch in front Soak hardened material in solvent If notch is rough or worn replace nozzle Air assist pressure too high...

Страница 24: ...rew at shift block broken Replace the broken cartridge valve or socket cap screw See Chapter 6 Pro Pump Pro pump or hose plugged Danger To prevent injury always relieve fluid pressure before attempting to remove components Disassemble and clean Pro pump Replace any worn parts Replace hose as required Air not connected Check that air hose is connected at manifold and regulator is at 20 psi or more ...

Страница 25: ...he Turbulent Mixer Distribution Ring partly clogged Remove the mix chamber and clean the distribution ring Mix Housing damaged Replace as needed Fingers heavy lines in the spray fan Gel Coat too cold Increase gel coat temperature Use Inline resin heater Pump air pressure too low Slowly increase the pump pressure in 5psi 1 2 bar increments and check spray fan Air Assist pressure is too low Slowly I...

Страница 26: ... worn or cut Replace O rings Catalyst leaks from week hole on catalyst side of gun O rings on catalyst valve worn or cut Replace O rings No catalyst is coming from gun Catalyst air piston is not actuating Check for clogged catalyst air passages small holes underneath back cylinder Note There is more than one passageway from holes Plugged catalyst restrictor Hex head screw with orifice located in f...

Страница 27: ...ev 08 2016 Page 27 Material is leaking from weep hole on material side of gun Loose diffuser seat Adjust until snug Then turn 1 4 to 1 2 turn more Don t over tighten Worn needle packing Replace packing and adjust as indicated above ...

Страница 28: ...alyst pump by locking the gun open over an empty bucket Leave the gun in this position WARNING Relieve pressure from the catalyst pump before continuing 2 Remove the catalyst hose from the nipple on the catalyst pump WARNING When removing hose place a rag over the hose and fitting before loosening it 3 Remove the quick pin from the catalyst bearing block and upper slave arm 4 Tilt the pump toward ...

Страница 29: ... air bubble can be quickly removed if the PRO RECIRC option is installed on this equipment Simply open the recirculation valve and hand prime catalyst back to the catalyst jug until there is a bubble free flow then return the recirculation valve back to flow out the gun ...

Страница 30: ...ations Manual Rev 08 2016 Page 30 Pump Repair Procedures The Pro Rider Gel Coat system uses the VPRO 45220 NPR Pump assembly for repair and maintenance instructions reference the manual VPRO 45220 Series Pump Manual ...

Страница 31: ...anual Rev 08 2016 Page 31 Catalyst Pump Repair The Pro Rider Gel Coat system uses the PCP 2000 RV PR Catalyst Pump assembly for repair and maintenance instructions reference the manual PCP 2000 Catalyst Pump Manual Low Range ...

Страница 32: ...Manual Rev 08 2016 Page 32 Gel Coat Gun Repair The Pro Rider Gel Coat system comes standard the ATG 3500 Gel Coat Assembly for repair and maintenance instructions reference the manual ATG 3500 Repair and Maintenance Manual ...

Страница 33: ...s Manual Rev 08 2016 Page 33 Parts Drawings PRO RIDER 22 1 PRO RIDER GEL COATER MA NPR ATG PRO RIDER AIR MANIFOLD ATG GUN NPR 1054 ASY CATALYST CONTAINER FF NPR 100 PRO RIDER FILTER ASSEMBLY MA NPR AIR MANIFOLD PRO RIDER ...

Страница 34: ...Pro Rider Operations Manual Rev 08 2016 Page 34 This page is left intentionally ...

Страница 35: ...O RIDER PUMP PRO RIDER REV 11 03 05 BT2 22 21 19 100 500 1000 17 5 6 7 9 15 23 1 8 16 18 20 PART OF ITEM 1 PART OF ITEM 1 24 25 26 REV A ADDED ITEMS 24 25 AND 26 04 24 06 BT2 13 REV B ITEM 2 WAS ATG 3500 ITEM 4 WAS MA NPR ITEM 13 WAS MPM 2052 1 ITEM 14 WAS MS 2052 1 09 31 06 BT2 ...

Страница 36: ...ASSY 7 PCP 2000 RV 1 CATALYST PUMP 6 NPR 1054 ASY 1 CATALYST JUG ASSY 14 HA 0224 25 1 ATOMIZING AIR HOSE 15 F HB 04C 16 GR5 2 HEX BOLT 17 F HB 05C 16 GR5 2 HEX BOLT 16 F LN 04C 2 LOCK NUT 12 HC 0224 25 1 CATALYST HOSE 13 HA 0344 25 1 AIR REFINEMENT HOSE 11 HAW 0344 5 1 RESIN WHIP 10 HAW 0444M 20 1 RESIN HOSE 18 F HB 05C 12 3 HEX BOLT 19 F SW 05 5 LOCK WASHER 23 NPR 1002 1 HANDLE 22 NPR 1001 1 PAIL...

Страница 37: ...Pro Rider Operations Manual Rev 08 2016 Page 37 Air Manifold for Pro Rider MAGNUM VENUS PRODUCTS REV 09 01 06 BT2 MA NPR ATG 9 5 3 4 13 8 17 10 18 REV A DELETED ITEM 20 M AGD 1044 09 12 06 BT2 ...

Страница 38: ...LO NUT 2 PF ME 06 04 1 MALE ELBOW 4 PF SE 02 2 STREET ELBOW 3 PR 1035 2 AIR GAUGE 7 PF AP 04 1 ALLEN PLUG 8 PF SW 02M 04F 1 SWIVEL 6 PF AP 02 1 ALLEN PLUG 5 PR 1030 2 REGULATOR 13 BOS 3009 2 SPACER WASHER 14 PR 1020 1 MOUNTING PLATE 16 PF MT 04 1 MALE TEE 15 F HB 04C 28 2 HEX BOLT 11 PR 1019 1 AIR MANIFOLD 12 PR 1032 1 SLIDE VALVE 10 F LN 04C 2 LOCK NUT 9 PF ME 04 2 MALE ELBOW 19 PF SE 04 1 STREET...

Страница 39: ...Pro Rider Operations Manual Rev 08 2016 Page 39 CATALYST JUG FOR PRO RIDER MAGNUM VENUS PRODUCTS REV 06 28 05 BT2 NPR 1054 ASY 3 3 ...

Страница 40: ...Pro Rider Operations Manual Rev 08 2016 Page 40 DESCRIPTION PART NO ITEM PARTS LIST QTY CATALYST JUG NPR 1054 ASY 2 MS 1017 1 FILTER 1 PR 1054 1 BOTTLE AND CAP 3 MS 2052 1 5 5 FT TUBING ...

Страница 41: ... Operations Manual Rev 08 2016 Page 41 Fluid Filter for Pro Rider MAGNUM VENUS PRODUCTS REV A ITEM 7 WAS QTY OF 2 ITEM 10 WAS PF RB 08 06 DELETED ITEM 11 PF SE 06 AND ITEM 12 PF HN 08L 10 31 05 BT2 FF NPR 100 3 ...

Страница 42: ... QTY Fluid Filter Pro Rider FF NPR 100 2 FF 5002 1 FILTER CAP 1 PF AP 04 1 PLUG 3 O V 022 1 O RING 4 FF 5099 100 1 FILTER SCREEN 5 PF HN 08 04 2 HEX NIPPLE 6 FF 5001 1 FILTER BODY 7 PF SE 08 2 STREET ELBOW 8 BV 44 HP 1 BALL VALVE 9 PF HN 04 04S 1 HEX NIPPLE 10 PF HN 08 06 1 HEX NIPPLE ...

Страница 43: ...Pro Rider Operations Manual Rev 08 2016 Page 43 Air Manifold for Pro Rider MAGNUM VENUS PRODUCTS REV 06 29 05 BT2 MA NPR 9 5 3 4 13 8 17 10 18 ...

Страница 44: ...W 4 PF SE 02 2 STREET ELBOW 3 PR 1035 2 AIR GAUGE 7 PF AP 04 1 ALLEN PLUG 8 7701 6 14 1 POLY FITTING 6 PF AP 02 1 ALLEN PLUG 5 PR 1030 2 REGULATOR 13 BOS 3009 2 SPACER WASHER 14 PR 1020 1 MOUNTING PLATE 16 PF MT 04 1 MALE TEE 15 F HB 04C 28 2 HEX BOLT 11 PR 1019 1 AIR MANIFOLD 12 PR 1032 1 SLIDE VALVE 10 F LN 04C 2 LOCK NUT 9 PF ME 04 2 MALE ELBOW 19 PF SE 04 1 STREET ELBOW 20 M AGD 1044 1 CONTROL...

Страница 45: ...pdated the manual format and Address Added the Terms Conditions of Sale section to the manual Updated the drawing Rev 10 2014 Updated the Address name and the Terms Conditions of Sale section Removed references to Plastech Removed references to the EMG 1000 gun Rev 08 2016 Updated the Logo and Parts Drawings section ...

Страница 46: ...6 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 Included with this operations manual are the following component manuals VPRO 45220 PRO PUMP MAINTENANCE AND REPAIR MANUAL PCP 2000 PRO LOW RANGE CATALYST PUMP MANUAL ATG 3500 REPAIR AND MAINTENANCE MANUAL ...

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