MVP Patriot Megaject Innovator II Operation Manual
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MVP Patriot Megaject Innovator II Operation Manual

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Patriot Megaject Innovator II
Operation Manual
Rev: 04/2014

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  • Page 1 Patriot Megaject Innovator II Operation Manual Rev: 04/2014...
  • Page 2 Patriot Megaject Innovator II Operations Manual 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...

  • Page 3: Table Of Contents

    Patriot Megaject Innovator II Operations Manual Table of Contents TERMS & CONDITIONS OF SALE SAFETY & WARNINGS INTRODUCTION CONTROL BOX INSTRUCTIONS CONTROL BOX CONFIGURATION OPERATING PROCEDURES FLUID SECTION MAINTENANCE & REPAIR CATALYST PUMP MAINTENANCE & REPAIR PATRIOT POWERHEAD INJECTION HEAD & MIXER ASSEMBLY...

  • Page 4: Terms & Conditions Of Sale

    Patriot Megaject Innovator II Operations Manual Terms & Conditions of Sale: GSSC, Inc.’s Terms & Conditions of Sale (“Terms & Conditions”) 588284v4 1. ACCEPTANCE: Acceptance of any purchase order from a customer or potential customer (“Buyer”) is subject to credit approval by GSSC, Inc.
  • Page 5 Patriot Megaject Innovator II Operations Manual 15. WARRANTIES: (a) SELLER’S WARRANTIES: Seller warrants that all Goods sold shall mechanically operate as specified and shall be free from faults in respect to materials and workmanship for a period of: (i) for parts, twelve (12) months from the date of invoice, and (ii) for systems, twelve (12) months from start- up, or, if earlier, eighteen (18) months from the date of the bill of lading.

  • Page 6: Safety & Warnings

    Patriot Megaject Innovator II Operations Manual 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.
  • Page 7 Patriot Megaject Innovator II Operations Manual Type of Fire Extinguishing equipment recommended: Fire Extinguisher – code ABC, rating number 4a60bc. Extinguishing Media – Foam, Carbon Dioxide, Dry Chemical, Water Fog. Copies of the above bulletins are available, at a nominal charge from:...
  • Page 8 Patriot Megaject Innovator II Operations Manual 2.2 Catalyst (Methyl Ethyl Ketone Peroxide) MEKP is among the more hazardous materials found in commercial channels. The safe handling of the “unstable (reactive)” chemicals presents a definite challenge to the plastics industry. The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage, transportation, handling, processing and disposal.
  • Page 9 Patriot Megaject Innovator II Operations Manual C. Prevent contamination of MEKP with other materials, including polyester over spray and sandings, polymerization accelerators and promoters, brass, aluminum and non-stainless steels. D. Never add MEKP to anything that is hot, since explosive decomposition may result.
  • Page 10 Patriot Megaject Innovator II Operations Manual When all three elements are present, the result can be an extremely violent explosion. The reaction can be sustained with very little aluminum or galvanized metal; any amount of aluminum is too much. A. The reaction is unpredictable. Prior use of an HHC solvent without incident (corrosion or explosion) does NOT mean that such use is safe.
  • Page 11 Patriot Megaject Innovator II Operations Manual G. Adequate ventilation (as covered in OSHA Section 1910.94 and NFPA No.91) is important wherever solvents are stored or used, to minimize, confine and exhaust the solvent vapors. H. Solvents should be handled in accordance with OSHA Section 1910.106 and 1910.107.
  • Page 12 Patriot Megaject Innovator II Operations Manual 2.7 Toxicity of Chemicals A. Magnum Venus Products recommends that you consult OSHA Sections 1910.94, 1910.106, 1910.107 and NFPA No.33, Chapter 14, and NFPA No.91. B. Contact your chemical supplier(s) and determine the toxicity of the various chemicals used as well as the best methods to prevent injury, irritation and danger to personnel.
  • Page 13 Patriot Megaject Innovator II Operations Manual 3.0 Equipment Safety WARNING Magnum Venus Products suggests that personal safety equipment such as EYE GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be worn when servicing or operating this equipment. Ear protection should be worn when operating a fiberglass chopper to protect against hearing loss since noise levels can be as high as 116 dB (decibels).
  • Page 14 Patriot Megaject Innovator II Operations Manual 3.2 Grounding Grounding an object means providing an adequate path for the flow of the electrical charge from the object to the ground. An adequate path is one that permits charge to flow from the object fast enough that it will not accumulate to the extent that a spark can be formed.

  • Page 15: Introduction

    Patriot Megaject Innovator II Operations Manual 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.
  • Page 16 Patriot Megaject Innovator II Operations Manual Unit Overview: CONTROL INJECTION GUN CATALYST JUG CATALYST OPV (OVERPRESSURE VALVE) STATIC MIXER MPG BLOCK POWERHEAD MIXER OUTLET SLAVE ARM CATALYST PUMP RESIN PUMP Fig. 1 Rev. 04/2014 Page | 16...
  • Page 17 Patriot Megaject Innovator II Operations Manual CATALYST JUG & RECIRCULATION SIGHT-GLASS AIR FILTER (CONNECT MAIN AIR HERE) FLUSH TANK Fig. 2 RAV (RESIN AUTO VALVE) FLUSH VALVE CAV (CATALYST AUTO VALVE) CATALYST OPV (OVERPRESSURE VALVE) Fig. 3 Rev. 04/2014 Page | 17...
  • Page 18 Patriot Megaject Innovator II Operations Manual Getting Started: Unpack unit Attach Pickup Hoses to the inlet of the pump Note: Be sure the Flush Tank connections are correct or the Equipment will be damaged. It is important not to fill the Flush Tank more than 3/4 full or solvent can get in the air system and cause damage.

  • Page 19: Control Box Instructions

    Patriot Megaject Innovator II Operations Manual CONTROL BOX INSTUCTIONS: Overview of controls: The Innovator control panel is shown in figure 4. Controls have been grouped based upon function, to make the system as user friendly as possible. Reference the “Innovator II Manual” for complete details on the Innovator II Control Box.
  • Page 20 Patriot Megaject Innovator II Operations Manual GEL ALARM INDICATOR STROKE CATAYLST O/P COUNTER INDICATOR FLUSH BUTTON EMERGENCY STOP BUTTON MOLD PRESSURE PUMP PRESSURE GUARD GAUGE GAUGE PUMP PRESSURE MOLD PRESSURE REGULATOR GUARD REGULATOR RECIRCULATION BUTTON INJECTION BUTTON STOP BUTTON Fig. 4...
  • Page 21 Patriot Megaject Innovator II Operations Manual Machine operations: Before the system can be used the air isolation sleeve-valve must be moved to the “ON” position and the E-Stop must be released. When air is initially supplied, all controls should automatically reset to their non-operational state.
  • Page 22 Patriot Megaject Innovator II Operations Manual RGA (Resin Gel Alarm): The machine features a RGA (Resin Gel Alarm) system, designed to alert the operator to the risk of catalyzed resin curing in the machine or mold during an injection or prior the machine being flushed and cleaned.
  • Page 23 Patriot Megaject Innovator II Operations Manual Flush: Press the flush button to clean the injection head. The operator cannot initiate a flush when the machine is in injection mode, therefore accidental flushing of the system into a mold during an injection is not possible.
  • Page 24 Patriot Megaject Innovator II Operations Manual Injection mode: Before an injection is started, ensure all external connections to the mold etc. are correctly made. Also ensure that resin and catalyst lines are correctly primed and that the required levels of materials are available. Ensure the level of fluid in the flush tank is sufficient to clean the machine after the injection.
  • Page 25 Patriot Megaject Innovator II Operations Manual Recirculation mode: Prior to and during operation in recirculation mode, use the pump pressure regulator and gauge to suitably adjust the air pressure supply to the pump and control the pump speed. Press the recirculate button to start the machine, the pump will run and resin and catalyst will be pumped around the system and returned to source.
  • Page 26 Patriot Megaject Innovator II Operations Manual Control box user connections: Side of control box - see Fig. 6 Signal connections are also supplied to the side of the control enclosure and are illustrated in figure 4. The connections are as follows: ...
  • Page 27 Patriot Megaject Innovator II Operations Manual Rear of control box: PUMP SUPPLY SLEEVE VALVE CHARGING HOSE Fig. 7 Rev. 04/2014 Page | 27...

  • Page 28: Control Box Configuration

    Patriot Megaject Innovator II Operations Manual CONTROL BOX CONFIGURATION: The user can adjust the Flush timer duration, the MPG response time and RGA stroke timer and Alarm volume. The procedures for doing this are described in the following sub-sections. Use the air circuit for your machine controls to identify the location of the components that require adjustment.
  • Page 29 Patriot Megaject Innovator II Operations Manual RGA adjustment: The time between strokes permitted to pass before the RGA alarms and the volume of the alarm whistle can be adjusted by the user. The pneumatic RGA control is located bottom center on the flow control ban (Fig. 9).
  • Page 30 Patriot Megaject Innovator II Operations Manual Figure 11 – Whistle Volume: (FCO1) The RGA alarm whistle volume can be changed by adjusting the flow controller that is in line with the whistle. WHISTEL VOLUME Fig. 11 Flush Timer adjustment: The flush timer duration can be increased or decreased by adjusting the flush timer restrictor.
  • Page 31 This flow control is set at factory and should not be adjusted. The response of the pump can further be slowed if required, by the addition of an air reservoir to the circuit. Contact MVP for further information MPG ADJUSTMENT Fig. 13 Rev.
  • Page 32 Patriot Megaject Innovator II Operations Manual Catalyst Over Pressure Adjustment: The characteristics of the CAT O/P control circuit can be modified by adjusting the CAT O/P restrictor. This component controls the rate at which air is supplied to the bleed control circuit.

  • Page 33: Operating Procedures

    Patriot Megaject Innovator II Operations Manual 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: Rev.
  • Page 34 Patriot Megaject Innovator II Operations Manual PRE-START CHECKLIST PATRIOT MEGAJECT INNOVATOR ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN, AND MUST BE TICKED OFF AS COMPLETED. TICK WHEN ACTIVIT ACTIVITY COMPLETED Y NO. Priority Put on Respirator as specified for spray painting, Protective Clothing, Eye Protection, and PVC Gloves Have all Tools and materials available for pre-start checks.
  • Page 35 Patriot Megaject Innovator II Operations Manual FIRST TIME START-UP CHECK LIST PATRIOT MEGAJECT INNOVATOR ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN, AND MUST BE TICKED OFF AS COMPLETED. THIS SEQUENCE FOLLOWS ON FROM “PRE-START CHECKLIST PATRIOT MEGAJECT INNOVATOR” ACTIVIT...
  • Page 36 Patriot Megaject Innovator II Operations Manual DAILY START-UP PATRIOT MEGAJECT INNOVATOR ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN, AND MUST BE TICKED OFF AS COMPLETED. THIS SEQUENCE FOLLOWS ON FROM “FIRST TIME START-UP CHECKLIST” ACTIVITY TICK WHEN ACTIVITY COMPLETED...
  • Page 37 Patriot Megaject Innovator II Operations Manual DAILY SHUT DOWN CHECKLIST PATRIOT MEGAJECT INNOVATOR ACTIVITIES MUST BE DONE IN THE SEQUENCE SHOWN, AND MUST BE TICKED OFF AS COMPLETED. THIS SEQUENCE FOLLOWS ON FROM “DAILY START UP CHECKLIST” ACTIVITY TICK WHEN...

  • Page 38: Fluid Section Maintenance & Repair

    Patriot Megaject Innovator II Operations Manual 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: Catalyst Pump Maintenance & Repair

    Patriot Megaject Innovator II Operations Manual Catalyst Pump Maintenance: The standard 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”.

  • Page 40: Patriot Powerhead

    Patriot Megaject Innovator II Operations Manual 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: Injection Head & Mixer Assembly

    Patriot Megaject Innovator II Operations Manual 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.
  • Page 42 Patriot Megaject Innovator II Operations Manual Injection Head Assembly (ASSY-0427) (see figure 15) Injection Head Assembly (ASSY-0427) – 22423_07 Assy-0424 RAV Assembly See drawing 83022_XX 7701-6-3 6758 Assy-0425 CAV Assembly Assy-0447 CAV Assembly See drawing 83018_XX See drawing 83013_XX Fig. 15 Rev.
  • Page 43 Patriot Megaject Innovator II Operations Manual Catalyst Auto Valve Assembly – CAV (see figure 16 & 17) Assy-0425 CAV Assembly See drawing 83018_XX for correct part numbers. 6150 6150 Fig. 16 CAV Servicing Notes: (see figure 16 & 17) The catalyst auto valve needs little servicing as all components are suitable for both...
  • Page 44 Patriot Megaject Innovator II Operations Manual B. Recirculation A. Injection Illustration of Catalyst Auto valve cross section showing catalyst flow and correct position of air actuator for A. injection flow B. recirculation flow Fig. 17 Rev. 04/2014 Page | 44...
  • Page 45 Patriot Megaject Innovator II Operations Manual RAV – Instructions for use and Maintenance: (see figure 18) Fig. 18 To replace the Main Seal (5873), remove Hex Head Screw (5832), Seal (5837) and Washer (6059). Replace Seal (5837) with the recess against the screw head.
  • Page 46 Patriot Megaject Innovator II Operations Manual To replace Shaft Seal (6004), remove Main Seal (5837). Disconnect Signal Pressure. Unscrew to remove Cylinder Top (6167). Caution the top is under spring pressure. Remove Spring (5825) and Limiter (5835). Pull Piston Shaft (5827) upwards.
  • Page 47 Patriot Megaject Innovator II Operations Manual Head Mixer and Mould Pressure Guard (MPG) (See fig. 19 & 20) Assy-0423 MPG Assembly (Dwg. 82009) (see fig. 20) 0619 Fig. 19 Rev. 04/2014 Page | 47...
  • Page 48 Patriot Megaject Innovator II Operations Manual Mixer Tubes: (see figure 19) Mixer tubes will only require replacement if partial or full gelation/sedimentation has occurred 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.
  • Page 49 Patriot Megaject Innovator II Operations Manual Automatic Flush Valve Assembly 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: Sp4 Flush Assembly

    Patriot Megaject Innovator II Operations Manual SP4 Solvent Pump: SP4 Solvent Pump Assembly – The SP4 performs a 200cc solvent purge followed by an air purge to thoroughly clean and purge the injection head and mixer. It is contained in a 3 gallon Stainless Steel flush tank. During the flush cycle only the SP4 solvent pump will be pressurized to force out the solvent contained inside and then purges with air for the reminder of the flush cycle.
  • Page 51 Patriot Megaject Innovator II Operations Manual On the inside of the flush tank the there are two (2) connections to the flush pump.  The pump inlet air tube connects to the inlet side of the SP4 solvent pump through the inlet fitting.

  • Page 52: Troubleshooting

    Patriot Megaject Innovator II Operations Manual Troubleshooting: Will not start inject or has stopped during injection sequence  Check incoming air supply  Apply correct pressure and CFM to unit.  Stop button has been pushed  Remote stop button pushed ...
  • Page 53 Patriot Megaject Innovator II Operations Manual  Catalyst Overpressure circuit is engaged (check indicator on panel)  Check for blockage in catalyst delivery lines.  Check FC #04 for proper adjustment.  Check for air leaks on Catalyst Overpressure valve and connection 1B-7(21).

  • Page 54: Parts Drawings

    Patriot Megaject Innovator II Operations Manual Parts Drawings: PAT-LS-12270-RTM RTM INNOVATOR FLUID SECTION ASSY PAT-SD-3100 PATRIOT SLAVE DRIVE ASSEMBLY SEAL KIT – RTM (SSB) PAT-LS-12270-R-SK PAT-CP-0550 CATALYST PUMP ASSEMBLY SEAL KIT – PATRIOT CATALYST PUMP PAT-CP-0550-SK PAT-CP-INV INNOVATOR CATALYST JUG 3-1/4”...
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  • Page 59 Patriot Megaject Innovator II Operations Manual PAT-LS-12270-R-SK PATRIOT SEAL KIT - RTM Rev. 04/2014 Page | 59...
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  • Page 77: Revision Information

    Patriot Megaject Innovator II Operations Manual Revision Information: Revision: Description: Rev: 04/2014 Document was created / updated to reflect the new Innovator II Control Box (INV-CB-100) and configuration. Rev. 04/2014 Page | 77...
  • Page 78 Patriot Megaject Innovator II Operations Manual 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...

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