FRP SystemOne 1100-1-1 CHOPPER OPERATION MANUAL

MAGNUM VENUS PRODUCTS Operation Manual

Part No. M1100-1-1 Revision 04.10.01 FRP SystemOne

FRP SystemOne Operation Manual

Unit Information Unit # Type Of: Power Cylinder Metering Pump Gun Roving Cutter Fluid Section

Corporate HQ & Mfg. Phone: (727) 573-2955 Fax: (727) 571-3636 Email: [email protected] Web: www.magind.com

Manufacturing Phone: (253) 854-2660 (800) 448-6035 Fax: (253) 854-1666 Email: [email protected] Web: www.venusmagnum.com

© 2001 Magnum Venus Products Manual Part No: M1100-1-1 FRP SystemOne

Table of Contents FRP SystemOne Operation Manual C H A P T E R 1 - QUICK LIST Start Up Installation & Setup C H A P T E R 2 - INSTALLATION AND SET-UP Pre-Operation Checklist Wetting Unit Proper Operating Pressures Installation C H A P T E R

3 - MAINTENANCE

C H A P T E R 4 - PARTS DRAWINGS Cart Assembly Mounting Column Assembly 12’ Boom Assembly Pneumatic Manifold Assembly 3-Gallon Flush Tank Assembly

FRP SystemOne

Chapter

1 FRP SystemOne Quick List Quick List Instructions Start-Up Sheet 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Check & fill solvent system Check & fill resin & catalyst supply Place suction wand in resin supply Prime resin pump Prime catalyst pump and set catalyst percentage Check system for fluid leaks Set air pressure to gun/chopper Install turbulent mixer in mix chamber Select spray tip, flow nozzle or convergence tip Check chopper motor, rubber roller adjustment Attach chute & cover Adjust fan pattern Adjust chop pattern

NOTE: These instructions include resin and catalyst pressurization procedures. To avoid equipment malfunction or possible injury, please follow these instructions. If you have any questions, please contact our Technical Service Department at 800-448-6035.

FRP SystemOne

1

FRP SystemOne Pumping System

Quick List Instructions Installation & Setup

1.

Unpack unit & components

2.

Place unit & stand pipe in base plate or portable cart (or mount to wall with wall brackets) Tighten bolts to secure

3.

Install catalyst jug

4.

Install resin surge chamber & filter assembly

5.

Install manifold air hose to power cylinder

6. Attach hose fittings to resin pump, catalyst pump, air & flush tank 7.

Install boom to mast (if applicable)

8.

Hang hose on boom (if applicable)

9.

Attach pickup hose

10. Place flush tank in holder and attach air hose from manifold 11. Double check all hose fittings

2

FRP SystemOne

Chapter

2 FRP SystemOne Installation & Set-Up Checklist 1. Tighten all hose fittings and fluid connections to make sure they are tight. 2. Check electrical grounds, gun to pump and pump to earth ground. 3. Check all clamp brackets, pump column, slave arm bracket, manifold clamp, etc. To make sure they will not move when unit is in operation. 4. Check the mounting of catalyst pump to make sure clevis pins are secure. 5. Make sure exhaust silencer is secured to the power cylinder of the resin pump. 6. IMPORTANT: Snug up the packing nut at the top of the catalyst pump Approximately ¼ turn. 7. Snug up, tighten, the resin pump packing be inserting two rods into the holes in the oil cup at the top of the resin pump fluid section. Turn clockwise until packing is snug. 8. Tighten the gun valve rod packing nut until it is very snug. IMPORTANT: Activate the gun trigger 10 - 15 times then tighten the packing nut. Repeat this tightening procedure 3 times to make sure the gun valve rod packing is tight. FRP SystemOne

3

Wetting Out Unit Air Supply: 1.

Use minimum ½” air hose supply to the system. Air requirements, 18 CFM 2. Open incoming air supply ball valve. 3. Set regulator labeled gun at 90 to 100 psi. Tighten packing nuts on the gun and trigger the gun 15 to 20 times. Tighten packing nuts again and repeat gun triggering. Priming Solvent: 1.

2.

Open solvent tank lid and fill tank ¾ full. Install lid on tank and close the relief valve located on the top of the lid. Set flush tank pressure at 50 to 60 psi. Push the flush valve on the side of the gun block to test solvent flush.

Priming Catalyst to Gun: 1.

Tighten the catalyst packing nut ¼ turn.

2.

Fill the two gallon catalyst jug ¾ full, purge the air out of the catalyst feed line by slightly tilting the catalyst jug. Lock the gun in the open position. Remove the pivot pin from the catalyst slide arm linkage. Use the slide arm to hand prime catalyst out to the gun until a steady stream is achieved. Do not reinstall pivot pin at this time.

3.

Priming Resin to Gun: 1. 2.

Insert the resin suction wand into a 55-gallon drum or resin. Tighten the resin pump packing nut until tight. Fill packing nut cavity ¾ full with suitable oil. 3. With gun locked in the open position, slowly increase resin pump regulator pressure until pump is running at a slow but steady rate. Allow pump to run until a fairly steady stream of resin is being dispensed. Close the gun and flush the gun head. 4. Increase resin pump pressure to 100 psi. Allow the unit to set under static load for 15 to 30 minutes to seat the resin packing set. 5. Clamp or tape the resin return hose coming from the bottom of the in-line resin filter to the resin pickup wand, into the resin drum. Turn the resin pump regulator to zero. Slowly open the ball valve at the bottom of the resin filter to drain the fluid pressure.

4

FRP SystemOne

Charging the Resin Surge Chamber: 1. 2.

Open ball valve below inline resin filter. To charge the resin surge chamber, use the air hose with the female quick disconnect (charging hose) and insert over the male quick disconnect at the top of the resin surge chamber. Push down on female quick disconnect for 5 to 10 seconds and disengage. 3. Close ball valve below in-line resin filter. Pressurizing Fluids: 1. 2.

Slowly increase resin pump regulator, 50 psi would be a good starting point. Pull the pivot pin using the slide arm. Use slow up and down motion to pressurize the catalyst pump for several strokes or until

firm. 3. Pin the pivot pin into the slide arm. Gun Set-Up: 1. Install turbulent mixer into mix chamber and install tip. For longer turbulent mixer life, do not over tighten the nozzle cap. 2. Test the spray pattern, make pump pressure adjustment for required resin outputs. 3. Thread either one or two strands of glass into chopper motor. Use chopper motor pivot to adjust glass entry into resin fan. Center the glass into the resin fan using the eccentric stud.

Start-Up Instructions 1. Removing Unit From Crate. With the crate laying flat. Open the top panel and remove the components as needed. a. b. c. d. e. f. g. h.

Cart Pump and Column Assembly. Boom, Hose, and Gun Assembly. Resin Filter/Surge Chamber Assembly. Suction Wand Assembly. Component Box. Catalyst Jug. Solvent Tank.

FRP SystemOne

5

2. Assemble Cart. a. Attach Handle to Cart. 3. Assemble Pump and Column Assembly to cart. a. Insert Column into column support hole in top of cart. b. Orient the column until pump faces the front of the cart. c. Tighten the lock screws to retain pump/column assemble to cart. Lock screws are located under cart on the front side. 4. Assemble Boom, Hoses, and Gun Assembly to pump column. a. With the boom folded, hose coiled, and gun attached as the assembly comes out the crate. Lift the boom up and insert the base pivot over the column. b. With the boom installed on column. Remove the ties holding the two sections of boom together. c. Remove the ties that hold the gun and hoses in the coil. Take care not to drop the gun. d. Remove the boom spring from the diagonal angle support at the base of the boom. e. Swivel the boom back over the rear of the cart (barrel location area). Unfold the boom sections so both inner and outer sections are straight over back of cart. f. With the boom sections stretched out to their full reach. Attach one end of the boom extension spring to the support chain attached at the boom knuckle. g. While lifting the outer section of the boom upward, attach the other end of the extension spring to the link welded to the top of the outer boom. NOTE If Outer section of boom and gun hang to close the floor. Lift the outer section of the boom again and attach the extension spring to a new location on the support chain. Shortening the chain will raise the outer section of the boom.

h. With the outer section of the boom supported by the spring and chain. Fold the outer section of the boom parallel to the inner section. 5. Assemble Resin Filter/Surge Chamber Assembly to Pump. a. Check to make sure all Filter/Surge Chamber connections are tight. 6

FRP SystemOne

r

b. Attach the Filter/Surge Chamber Assembly to the swivel fitting located at the outlet of the resin pump. c. With the Filter/Surge Chamber Assembly vertical. Tighten the fitting with a wrench until it is tight enough to prevent fluid leaks and to support the assembly in an up right position. 6. Mount Catalyst Jug Bracket. a. Attach the Catalyst Jug Bracket to the base of the catalyst pump slide drive support. b. Mount the bracket so it extends to the left side of the slide drive support as you stand facing the end of the slide drive. 7. Mount Solvent Tank Retainer Bracket. a. Attach the Tank Bracket to the column approximately 5 inches from the top of the cart. b. The bracket arm should be on the backside of the column as you face the pump, extending to the left side of the cart. c. Tighten the bolts holding the yoke clamp to the bracket until the bracket is firmly clamped to the column. d. Remove the Solvent Tank from the carton and place into bracket. 8. Attach Catalyst Pump. a. Mount the Catalyst Pump to the slide drive bracket using the clevis pins and keepers provided. b. The bottom of the catalyst pump is pinned to the lower leg of the slide drive bracket. c. The upper clevis, (piston rod), is pinned to the slide drive using the hole forward of the long slot in the slide drive. d. Hold the clevis pins in place with the wire keepers by placing them in the holes in the clevis pins. 9. Mount Air Supply Manifold. a. Clamp Manifold Assembly to the pump column above the power cylinder of the resin pump. b. Regulators and gauges should face to the pump side of the column. c. Clamp yoke tight enough so the assembly does not move around the column.

FRP SystemOne

7

10. Attach Suction Wand to Resin Pump. a. Check all fittings on the wand assembly to make sure they are airtight. b. Attach the wand assembly to the foot valve port of the resin pump. 11. Hose connections. a. Connect the black resin hose from the gun to the outlet fitting on the resin filter b. Connect the catalyst hose from the gun to the outlet of the catalyst pump assembly. c. Attach the red air hose from the gun to the fitting on the regulator labeled gun. d. Attach the yellow poly flush hose from the gun to the outlet fitting of the solvent tank. e. Attach the small red air supply hose from the flush regulator to the input fitting on the solvent tank. f. Attach the large red air hose from the pump regulator to the power cylinder of the resin pump. g. Attach the ground wire from the gun to the electrical grounding lug on the pump power head. h. Remove the catalyst poly tubes from the component box. i. Cut the ½ inch dia. poly line, with the clamps, to 26 inches long. Clamp one end to the outlet of the catalyst jug and the other end to the inlet of the catalyst pump. Make sure clamps are airtight. j. Connect the 3/8-inch poly line to the relief valve on the catalyst pump assembly and insert the other end into the hole in the top of the catalyst jug. 12. Mount Exhaust Silencer to power head of resin pump. a. Remove the exhaust deflector from the power head of the resin pump, (4 screws). Screw silencer into the pipe threads of the exhaust port.

NOTE If icing of silencer becomes a problem. Remove the silencer and replace the exhaust deflector. Noise level will be higher with silencer removed.

8

FRP SystemOne

Chapter

3 FRP SystemOne Maintenance Schedule 4-Hour Oil Chopper Air Motor For every four hours of operation, the chopper air motor should be oiled. Push down on the quick disconnect, pull back on the clip, pull it off the bar fitting and add one or two drops of oil for every four hours of operation. Daily Relief Valve Check We start to get accumulating a lot of catalyst in the hose. We want to drain that off and see how much catalyst that we accumulate in the relief valve hose, daily. If it’s excessive, we want to replace the ball in the relief valve. Daily Water Trap Check Water traps should be drained daily. Just push the bottom button and drain any water that may have collected in line. Weekly Power Head Lubrication Turn the pump regulator down to zero. Loosen the air hose fitting and add 10 to 15 drops of 90-weight non-detergent gear oil. Weekly Fluid Section Packing Nut Check Check the fluid section for any resin coming up through the packings into the cavity. If you see any resin, tighten the packing nut. Add oil if needed. Weekly Catalyst Packing Nut Check Look for any catalyst bleeding up through the packings. If you see any leakage, tighten the packing nut an eighth of a turn.

FRP SystemOne

9

Weekly Gun Maintenance Weekly maintenance on the gun includes tightening the resin and the catalyst packing nuts. 1.

Turn the pump pressure down to zero. Open up the ball valve to relieve the fluid pressure on the resin and to release the fluid pressure on the catalyst we’ll pull the trigger on the gun.

2.

To seat the packings, tighten both the catalyst and the resin packing nuts and quickly trigger the gun 10 to 15 times in rapid succession. Repeat the process. It is very important to trigger the gun quickly. Surge Chamber Maintenance For weekly cleaning of the surge chamber and filter turn the pump regulator pressure down to zero. 1.

To relieve the fluid pressure in the resin system, open the ball valve below the resin filter.

2. To bleed the charge in the accumulator, insert the small diameter rod in the charging valve on the top of the resin accumulator and bleed the charge off. Be sure to cover the rod with a rag. 3.

To remove the resin filter, move the return hose out of our way. Push the core out of the resin screen. Clean the screen and the core and the inside of the bottle.

4. Unscrew the resin accumulator. Clean the accumulator and filter. Clean the threads and white ball. 5.

Inspect the oil ring and replace if cut or distorted.

6. Reinstall the core into the screen. Then reinstall the screen core into the filter bottle. It’s very important that we use Venus white grease on the aluminum threads before re-installing. Do not over tighten. 7.

Reinstall the resin return hose to the ball valve below the filter. Twist until there is a snug fit. Inspect the “O” ring. Replace if necessary.

8.

Place white grease on the “O” ring and on the threads. The seat area must be clean for the polyball to seat properly when charging the resin accumulator. Inspect the oil ring for any splits or cuts. Replace if necessary.

10

FRP SystemOne

9.

Place polyball on seat.

10. The surge chamber is now ready for reinstalling. Insert the “O” ring seal in the bottom of the accumulator and lightly twist the accumulator until it is snug.

FRP SystemOne

11

Chapter

4 FRP SystemOne Parts Drawings

12

FRP SystemOne

MAGNUM VENUS PRODUCTS

FRP SystemOne

13

14

FRP SystemOne

MAGNUM VENUS PRODUCTS

FRP SystemOne

15

16

FRP SystemOne

MAGNUM VENUS PRODUCTS

FRP SystemOne

17

18

FRP SystemOne

MAGNUM VENUS PRODUCTS

FRP SystemOne

19

20

FRP SystemOne

MAGNUM VENUS PRODUCTS

FRP SystemOne

21

22

FRP SystemOne

FRP SystemOne

12

FRP SystemOne

Corporate HQ & Mfg. Phone: (727) 573-2955 Fax: (727) 571-3636 Email: [email protected] Web: www.magind.com

Manufacturing Phone: (253) 854-2660 (800) 448-6035 Fax: (253) 854-1666 Email: [email protected] Web: www.venusmagnum.com

© 2001 Magnum Venus Products Manual Part No: M1100-1-1

FRP SystemOne