ADVANTAGE Gelcoater System MAGNUM VENUS PRODUCTS Operations Manual Part No.
Advantage Gelcoater Operations Manual Corporate HQ/Mfg. MVP Technology Center 5148 113th Ave. Clearwater, FL 33760 Tel: (727) 573-2955 Fax: (727) 571-3636 1862 Ives Ave. Kent, WA 98032 Tel.: (253) 854-2660 Fax: (253) 854-1666 E-mail: info@mvpind.com · Web: www.mvpind.
Table of Contents Advantage Gelcoater Operations Manual C H A P T E R Quick List Quick View 1 - QUICK REFERENCE C H A P T E R 2 - INTRODUCTION The Advantages of the Advantage Major Components Description of Controls Tool Requirements Material Requirements Safety Equipment Requirements C H A P T E R Wall Mount Unit Portable Unit 3 - INSTALLATION AND SET-UP C H A P T E R 4 - DAILY INSPECTION C H A P T E R 5 - PRIME FLUSH SYSTEM Fill Flush Tank O-Ring Maintenance Pressurization of Flush Tank Test Flush S
C H A P T E R Quick List Quick View 6 - PRIME CATALYST SYSTEM C H A P T E R 7 - PRIME RESIN SYSTEM C H A P T E R 8 - CONNECT CATALYST PUMP C H A P T E R Spray Patterns Troubleshooting 9 - TESTING & ADJUSTING C H A P T E R Short Term Long Term 10 - SHUTDOWN C H A P T E R 11 - MAINTENANCE Daily Maintenance Checklist Weekly Maintenance Checklist Monthly Maintenance Checklist Three Month Maintenance Checklist Six Month Maintenance Checklist Annual Maintenance Checklist C H A P T E R Advantage Gelcoat
Chapter 1 Advantage Gelcoater Quick Reference 1. Place suction wand in adequate resin supply 2. If multicolor, select which color pump you wish to use 3. Prime resin pump 4. Prime catalyst pump 5. Adjust catalyst % 6. Increase air pressure to resin pump to desired output 7. Check all hoses for fluid or air leaks 8. Fill & check solvent system 9. Set air pressure to gun 10.
Advantage Gelcoater Two Color Quick View 6, 9, 10 2 2 3 4 5 1 1 8 7 Advantage Gelcoater 2
Chapter 2 ADVANTAGE Gelcoater Introduction The Advantages of the Advantage: The Magnum Venus Products Advantage Gelcoat Unit was designed to deliver a smooth uniform layer of gelcoat onto the mold surface with a minimum of overspray and fuming. The internal mix low-pressure airless gun thoroughly combines gelcoat and MEKP catalyst, insuring no contamination of the finished gelcoat. Proper use will eliminate problems such as gelcoat blistering caused by raw catalyst overspray.
2. The Flush Pressure Gauge and Regulator monitor and control air to the solvent flushing system. 3. The Gun Pressure Gauge and Regulator monitors and controls the air to the gun. 4. (Optional) The Air Assist Gauge and Regulator monitors and controls the air assist nozzle on the gun head. Air Requirements Clean, dry compressed air at a minimum of 90 PSI (6.3 kgs per sq. cm.) with a minimum volume of 10 CFM (0.3 cm.) is required to operate the unit, supplied through a ½ inch ID hose (1.25 cm.).
Empty buckets and containers for cleanup Clean rags and paint brushes for equipment cleaning Wax paper or cardboard for test spraying Safety Equipment Requirements You should have available all safety clothing and equipment recommended by your materials manufacturers and federal, state, and local industrial safety agencies. Safety equipment you will need to work on your Magnum Venus Products equipment includes safety gloves and eye protection.
Chapter 3 ADVANTAGE Gelcoater Installation & Set-Up Uncrate Gelcoater. Uncrate the Advantage Gelcoater and set it on a level floor surface at least 3 feet (90 cm) from the nearest wall to allow easy access. Wall Mount Unit Installation Fasten Brackets to the wall approximately 36 inches above the floor. NOTE Use appropriate fastening devices for the type of wall the gelcoater will be mounted on. Bolt the Advantage Gelcoater frame onto the bracket with the bolts provided as shown in Figure 1.
Figure 1: Wall Mount Unit Figure 2: Portable Unit Turn Controls Off Make sure all control regulators are turned to “0”. Install Hoses Uncoil all hoses and inspect for kinks and damage. Hoses are shipped attached to gun & pump except for catalyst hose and flush hose. These need to be attached at the pump and tank only. They are attached to gun.
Figure 3: Cat. Hose & Flush Hose to Gun Head Attach the other end of the flush hose to the flush tank fitting marked “OUT” (see Figure 4).
Attach an airline between the air regulator and the fitting (marked “IN”) on the flush tank (see Figure 5). NOTE Do not turn on the air supply at this time. You will be instructed when to do so. Figure 5: Air Supply Hose to Flush Tank Install Main Air Line Install the main airline (minimum 1/2” diameter) between the Advantage Gelcoater and an air compressor capable of at least 10 cfm (0.3 cm.). Install Catalyst Jug WARNING Never grease any part of the catalyst system. Use only clean water for cleaning.
r NOTE Attach catalyst feed line so there are no sharp bends or kinks in the line and the line is in a downward angle from the jug to the catalyst pump. Figure 6: Attach Feed Line from Catalyst Jug Figure 7: Attach Feed Line to Catalyst Pump NOTE Make sure all clamps are tight to prevent leaks.
Attach the return line (3/8” tube) to the catalyst pump relief valve body (see Figure 8) Insert the other end of the return line into the 3/8” hole on the jug near the cap. Figure 8: Attach Cat.
Chapter 4 ADVANTAGE Gelcoater Daily Inspection CAUTION Always wear approved eye protection when working near pressurized equipment. WARNING Follow all warning and suggestions regarding the use of respirators, clothing, and appropriate safety procedures recommended by manufacturers of your materials. WARNING BEFORE CONTINUING, be sure all regulators on the manifold are completely off. Check Material Supplies Check bulk supplies of gelcoat resin, catalyst, and solvent.
CAUTION After filling the catalyst jug, reinstall cap on jug. Otherwise, catalyst may be contaminated. Figure 9: Fill Catalyst Jug Place the gelcoat resin container in position on or near the Advantage Gelcoater. You need at least 2 gallons (7.5 liters) of gelcoat resin to begin operations. CAUTION If the gelcoat resin runs out during operation, the pump will runaway and damage may occur. NOTE Runaway/The speed of the pump increases immediately and damage to the pumping system can occur.
Inspect hose fittings and seals for leaks. Make sure all hose connections are tight. Check Fittings and Assemblies Check the resin accumulator to be sure threads are hand-tight. Check pick-up wand fittings to be sure fittings are tight (use 14” pipe wrenches)(strap wrench preferred). Lubricate Resin Pump Fill the pump body reservoir at the base of the pump shaft 2/3 full of SAE 30-weight motor oil (must be non-detergent. Tighten Gun Packing Before Priming.
Chapter 5 ADVANTAGE Gelcoater Prime Flush System Turn Controls Off Be sure the FLUSH regulator is closed (see Figure 13). NOTE To close the regulator, turn the regulator counterclockwise. Be sure the air is OFF and connect the main air supply to the unit. (See Figure 14) Please see new Manifold configuration in Drawing section (p/n MA-ADV-1).
Figure 14: Connect Main Air Supply Fill Flush Tank Release any pressure in the flush tank by gently pulling upwards on the lever attached to the pressure relief valve (see Figure 15). Open the lid by pulling up the hatch lock, turning the hatch sideways, and lifting the hatch out of the tank (see Figure 16). NOTE Do not drop the flush tank hatch into the tank. Check the flush tank for dirt or debris. Wipe with a clean rag if necessary. Fill the tank with clean solvent. Reinstall the tank hatch.
Figure 15: Release Flush Tank Pressure Figure 16: Lift the Hatch Lock O-Ring Maintenance The flush tank’s O-ring expands and distorts if wetted by the solvent. Orings also distort (much more slowly) when exposed to solvent vapors. Distorted O-rings will not hold an airtight seal and must be replaced. However, the distorted O-ring can be reused. Simply put the O-ring in a well-ventilated area to dry out. When it returns to its original shape, it may be used on the flush tank hatch again.
CAUTION Do not overpressurize the flush system. NOTE Be sure the gun trigger is not pulled back or locked back. CAUTION When working with machinery that uses pressurized fluids, wear approved protection for your eyes. Test Flush System Test the flush system by manually flushing the gun into an appropriate empty container (see Figure 17). To flush the gun, perform the following steps: Hold an appropriate container under the gun-head. Wearing appropriate safety gear (gloves, goggles, clothes etc.
Figure 17: Flush the Gun 19 Advantage Gelcoater
Chapter 6 ADVANTAGE Gelcoater Prime Catalyst System Before Priming CAUTION The flush system must be primed and operating before you put any gelcoat resin or catalyst into the pumps or material will “set-up” in the equipment, requiring extensive repair. CAUTION IMPORTANT: Always prime the resin side first, followed by the catalyst side. If this procedure is reversed, the catalyst may go to the resin side and gel. Check catalyst supplies for quality and quantity. Check hose fittings again for tightness.
Please see new Resin Pump/ Slave Arm Configuration in Drawing Section (p/n 85710-1) Figure 18: Lock Gun Trigger Figure 19: Pull Out Top Quick Pin Lean the top of the catalyst pump toward the resin pump to allow trapped air to escape (see Figure 20). Turn the recirculation valve to the recirculation mode, towards fitting and tube that go to catalyst jug. Hand-Prime Catalyst Pump. SLOWLY and GENTLY hand-prime the catalyst pump by moving the piston rod block up and down (see Figure 21).
Figure 20: Lean the Catalyst Pump Toward the Resin Pump Figure 21: Hand Prime the Catalyst Pump arm bearing (see Figure 22). NOTE To monitor catalyst flow, use the float in the catalyst jug’s sight tube. The float rises and falls with each cycle of the catalyst pump. NOTE Gun trigger must be closed before flushing. Unlock the gun trigger. Place an appropriate empty container under the gun-head. Press the flush button on the side of the gun to flush the gun head.
Figure 22: Trap the Catalyst Pump Bearing Block 23 Advantage Gelcoater
Chapter 7 ADVANTAGE Gelcoater Prime Resin System Before Priming CAUTION The flush system must be primed and operating before you put any gelcoat resin or catalyst into the pumps or material will “set-up” in the equipment, requiring extensive repair. Check resin supplies for quality and quantity. Check resin hose fittings again for tightness. Be sure PUMP PRESSURE regulator gauge reads 0 PSI. Hold the gun-head over any empty container. Pull gun trigger back and lock trigger by using the trigger lock.
Begin Priming Place the resin wand into the gelcoat resin container (see Figure 23). Slowly turn the PUMP PRESSURE regulator (on the manifold) clockwise until the pump begins moving. When the pump begins moving, stop turning the regulator. CAUTION While being operated, the pump must have a sufficient supply of resin. If the resin runs out, the pump will speed up and cavitate, and damage can occur. Let the pump run until resin is flowing out of the gun-head.
Remove cap from charging valve on top of resin accumulator. Attach charging hose (located on manifold) to the charging valve on top of the resin accumulator. (See figures 24 & 25) Open air valve on manifold for approximately 2 to 3 seconds (resin/ gelcoat moves slowly on a re-charge - this may not be enough time). NOTE This charge of air will force any resin from the accumulator into the hose set and open gun.
Push the flush button on the side of the gun to flush the gun. Release the button when clean solvent flows from the gun-head. Discard resin waste in an approved manner.
Chapter 8 ADVANTAGE Gelcoater Connect Catalyst Pump Connect Catalyst Pump Pull out the lower quick pin that attaches the bottom of the catalyst pump to the bottom slave arm. CAUTION When lower quick pin is out, do not let the piston rod bottom out in the catalyst pump or the inlet body ball will be damaged and must be replaced. Line up the bottom bearing block of the catalyst pump with the hole in the bottom slave arm that matches the catalyst percent number you want.
Figure 26: Attach Catalyst to the Slave Arm NOTE The upper and lower catalyst pump mounts must be in upper and lower holes with the same number or the pump will be damaged (see Figure 27).
Chapter 9 ADVANTAGE Gelcoater Testing & Adjusting To achieve the proper spray patterns, gun nozzles must be selected and tested and matched to the appropriate pump pressure. Before Testing and Adjusting Lay out large sheets of cardboard or wax paper for spraying. NOTE Sheets should be at least 5-ft. (150 cm) long and 3 ft. (91.44cm) wide. Have an appropriate empty container to flush the gun into. Gelcoat temperature should be at recommended temperature by gelcoat supplier.
Air Assist Nozzle - 419 #30419 Install Nozzle Assembly Insert turbulent mixer into the mix chamber. Insert static mixer into nozzle extension body. Attach nozzle extension body to gun mix chamber. NOTE Use lithium grease on mix chamber and all nozzle extension body threads. CAUTION To avoid contamination of the laminate, do not apply grease to any part that will contact the interior of the gunhead. Attach selected nozzle onto the extension body. Insert the nozzle into the retainer (see Figure 29).
Set Pressure Turn PUMP PRESSURE regulator slowly until gauge reads 35 PSI. Spray Test Pattern Hold the gun about 18 - 20 in. (45 - 50 cm) high over the paper. Pull the trigger, and spray one three-foot pass. While spraying, check the spray pattern to make sure there are only slight “fingers” or “tails” (heavy streams of material). Also check for misting or fuming. Increase air assist pressure in 5 PSI increments until “finger” disappears.
Check the troubleshooting chart below to correct any problems. Troubleshooting Chart If You See: Then: “Fingers” Check Gelcoat temperature to ensure it falls within the manufacturers recommended tempera ture window. Typically, this will be between 60°F and 80°F. Increase Resin Pump and Air Assist operating pressure in 5-PSI increments until “fingers” disappear. Misting or Fuming Reduce Resin Pump operating pressure in 5-PSI increments until clean, even, smooth fan pattern results.
Chapter 10 ADVANTAGE Gelcoater Shutdown Short-Term Shutdown NOTE Cleaning the gun head is required if you are stopping production or there will be long pauses in operations for lunch, part cure or any reason. NOTE This section discusses short-term shutdown. Follow these procedures whenever the gun will be idle for at least the standard gel time of your materials. If the gun will be idle for longer than one week, perform Long-Term Shutdown.
After draining the filter, close the filter valve. NOTE Moisture should be drained from the unit daily to prevent moisture buildup. Please see new Resin Pump (p/n 85710-1) and Resin Filter (p/n 85753-3) in Drawing Section. Figure 32: Drain the Filter Clean Gun Head NOTE Cleaning the gun head is required if you are stopping production or there will be long pauses in operations for lunch, part cure, or any reason.
Soak the nozzle assembly parts in a closed container of solvent. NOTE When using solvent for cleaning or flushing, be sure to store the used solvent in a manufacturer-approved container with a tight-fitting lid for storage while waiting to run the used solvent through your recycling equipment. Solvents evaporate quickly. WARNING Solvents such as acetone are extremely flammable. Visually inspect the open ports of the gun block for signs of gelled material after flushing.
Figure 33: Relieving Pressure from Accumulator Place a container under the resin pump filter and slowly unscrew the filter tank from the filter body (see Figure 34). NOTE If the filter is difficult to unscrew by hand, use a cloth strap wrench or a chain wrench to prevent damage to the filter. Clean the filter tank, spring, screen and filter core in solvent. Allow the parts to air dry. NOTE Clean your filter once a week and when changing colors for a multi-color operation.
WARNING Never unscrew the resin accumulator while it is still charged. You may be seriously injured. When you have unscrewed the resin accumulator, disassemble it and clean the parts with solvent. Allow the parts to air dry. Figure 34: Unscrew Filter Tank Disable Catalyst Pump Remove the quick pin from the top of the catalyst pump and upper slave arm. Tilt the catalyst pump away from the resin pump until the catalyst pump is resting against the vertical connecting post.
system. You have now completed the steps necessary to shut down your equipment. Long-Term Shutdown NOTE Follow these long-term shutdown procedures whenever the gun will be idle for at least one week, or longer than the storage pot life of your materials. These procedures should also be followed if you are shipping your unit. If the gun will be idle for longer than twenty minutes and less than one week, perform Short-Term Shutdown.
Figure 35: Draining the Filter Clean Gun Head Push the button on the left side of the gun to flush the gun into an appropriate container. Remove nozzle and nozzle retainer from nozzle extension body. Remove the nozzle extension body from gun head. Using the turbulent mixer puller, remove the turbulent mixer from mix chamber. Insert the 1/4” steel rod (provided in the Gelcoater Unit Tool Kit) into the front nozzle extension body and press out the static mixer.
WARNING Solvents such as acetone are extremely flammable. Visually inspect the open ports of the gun block for signs of gelled material after flushing. Remove Fluid Pressure Follow all warnings and suggestions regarding the use of respirator, clothing, and appropriate safety procedures recommended by manufacturers of your material. Turn PUMP PRESSURE regulator knob counterclockwise until the pressure gauge reads “0”.
Disconnect the catalyst pump from the upper slave arm. > Pull out the top quick pin in the upper slave arm. > Pull up the piston rod priming knob and lean the top of the catalyst pump toward the resin pump as far as it will go. Empty any remaining catalyst from the catalyst jug. Fill the catalyst jug with clean distilled water. Slowly and gently pump the distilled water through the system by moving the catalyst pump-priming knob up and down by hand.
Remove the resin wand from the resin and allow the wand to drain into an appropriate container. Lock gun open. Slowly bring pressure up on resin pump. Slowly pump extra resin from system. Release gun trigger. Place an appropriate container under the gun head. Lock the gun trigger back. Place wand in container of flush. Turn the PUMP PRESSURE regulator knob clockwise until the pump begins to stroke (even, slow strokes).
Figure 38: Remove Filter Tank NOTE If the filter is difficult to unscrew by hand, use a strap wrench or a chain wrench to prevent damage to the filter. Clean the filter tank, spring, screen and filter core in solvent. Reassemble accumulator and filter assembly. Unlock the gun trigger. Push flush button located on side of gun to flush gun block. Shutdown Flush System Turn the FLUSH regulator knob on the manifold until the gauge reads “0”. Close air supply valve to the flush system.
Chapter 11 ADVANTAGE Gelcoater Maintenance Performing proper maintenance at the recommended time intervals maximizes your equipment’s productivity and efficiency. This section describes recommended maintenance procedures to be performed daily, weekly, monthly, every three months, twice a year, and once a year. Please follow the maintenance schedules recommended in this section. CAUTION Wear appropriate safety equipment when performing maintenance procedures on your equipment.
Daily Maintenance Checklist Part: Procedure: Moisture Filter Drain Hoses Check for kinks or leaks Gun Check gun packing - tighten as necessary Gun Check weep holes on top of gun block OR check gun block for leaks.
Weekly Maintenance Checklist This schedule is based on a one shift, 5-day work week, using standard GRP resin (an idle unit left with resin in it may require more frequent part replacing.) Part: Procedure: Gauges and Regulators Check for wear, damage, and proper operation Resin Accumulator Remove and clean inside Resin Filter Wash and inspect filter screen for damage Power Head Clean silencer with solvent and blow dry Resin Pump Lower Assembly Check pickup hose and wand for leaks or damage.
Monthly Maintenance Checklist Part: Procedure: Gauges and Regulators Check for wear, damage, and proper operation Resin Accumulator Remove and clean inside Resin Filter Wash and inspect filter screen for damage Power Head Clean silencer with solvent and blow dry Resin Pump Lower Assembly Check pickup hose and wand for leaks or damage. Check inside the center section for packing leaks. Flush Tank Clean any residue and rinse with solvent. Air Lines Check for leaks, wear, and kinks.
Three-Month Maintenance Checklist Part: Procedure: Gauges and Regulators Check for wear, damage, and proper operation Resin Accumulator Remove and clean inside. Replace: spring, ss ball, o-ring in charging valve Resin Filter Wash and inspect filter screen for damage Power Head Clean silencer with solvent and blow dry Resin Pump Lower Assembly Check the pickup hose and wand for leaks or damage.
Six Month Maintenance Checklist Part: Procedure: Gauges and Regulators Check for wear, damage, and proper operation Resin Accumulator Remove and clean inside. Replace: spring, ss ball, o-ring in charging valve Resin Filter Wash and inspect filter screen for damage Power Head Clean silencer with solvent and blow dry Resin Pump Lower Assembly Check the pickup hose and wand for leaks or damage.
Annual Preventative Maintenance Checklist Part: Procedure: Gauges and Regulators Check for wear, damage, and proper operation Resin Accumulator Remove and clean inside. Replace: spring, ss ball, o-ring in charging valve Resin Filter Wash and inspect filter screen for damage Power Head Clean silencer with solvent and blow dry. Replace o-rings, gaskets, springs and balls. Resin Pump Lower Assembly Check the pickup hose and wand for leaks or damage.
Chapter 12 ADVANTAGE Parts Drawings Advantage Gelcoater
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Corporate HQ/Mfg. MVP Technology Center 5148 113th Ave. Clearwater, FL 33760 Tel: (727) 573-2955 Fax: (727) 571-3636 1862 Ives Ave. Kent, WA 98032 Tel.: (253) 854-2660 Fax: (253) 854-1666 E-mail: info@mvpind.com · Web: www.mvpind.