Magnum Venus Plastech MVE-1400-X-1 User Manual

UltraMAX MULTI – COLOR

GELCOATER OPERATION MANUAL

MVE-1400-X-1

MVG-1400-X-1

Rev. 03/2013

UltraMax Multi-Color Gelcoater Manual

CORPORATE HEADQUARTERS and MANUFACTURING

11692 56th Court * Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER and MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel [phone] * Fax [phone]

MVP Plastech UK

Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: [phone]

Fax: [phone]

www.mvpind.com

Rev. 03/2013 Page | 2

UltraMax Multi-Color Gelcoater Manual

TABLE OF CONTENTS:

SECTION:

Page

TERMS & CONDITIONS OF SALE 4

SAFETY & WARNING INFORMATION 7

INTRODUCTION 16

GETTING STARTED 17

CHANGING BETWEEN COLORS 19

PRIMING THE UNITS 21

DAILY STRAT-UP & SHUT-DOWN PROCEDURES 25

MAINTENANCE 28

COMPONENT MANUALS 30

PARTS DRAWINGS 31

REVISION INFORMATION 49

Rev. 03/2013 Page | 3

UltraMax Multi-Color Gelcoater Manual

Terms & Conditions of Sale:

1.

ACCEPTANCE: Acceptance of any purchase order from a customer or potential customer (“Buyer”) is subject to credit approval by

GSSC, Inc. (“Seller”), acceptance of the purchase order by Seller and, when applicable, any manufacturer, vendor, or other third party that
provides goods to Seller for resale to Buyer (“Vendor”). If Seller, in its sole discretion, determines that Buyer's credit becomes unsatisfactory
or it has reasonable grounds for insecurity, Seller reserves the right, upon notice to Buyer, to demand adequate assurance of due
performance from Buyer and/or terminate any purchase order with no liability to Seller. BY REQUESTING A QUOTE FROM SELLER,
ACCEPTING AN INVOICE FROM SELLER, OR PRESENTING A PURCHASE ORDER TO SELLER, BUYER CONFIRMS THAT THESE
TERMS & CONDITIONS SHALL GOVERN ALL PURCHASES OF PRODUCTS OR MATERIALS PROVIDED TO BUYER BY SELLER
(“GOODS”). GOODS SOLD BY SELLER ARE EXPRESSLY SUBJECT TO THE TERMS AND CONDITIONS SE T FORTH HEREIN
AND ANY DIFFERENT OR ADDITIONAL TERMS OR CONDITIONS SET FORTH IN A PURCHASE ORDER OR SIMILAR
COMM UNICA TION RECEIVED FROM BUYER A RE OBJECTED TO A ND SHAL L NOT BE BIND ING UP ON S ELLER
UNL ES S SPECIFICALLY AGREED TO IN WRITING BY AN AUTHORIZED CORPORATE OFFICER OF SELLER.NO SELLER
EMPLOYEE OR AGENT HAS THE AUTHORITY TO MODIFY THESE TERMS & CONDITIONS VERBALLY. SELLER OBJECTS TO AND
REJECTS ANY TERMS BETWEEN BUYER AND ANY OTHER PARTY, AND NO SUCH TERMS, INCLUDING BUT NOT LIMITED TO ANY
GOVERNMENT REGULATIONS OR “FLOWDOWN” TERMS, SHALL BE A PART OF OR INCORPORATED INTO ANY PURCHASE ORDER
FROM BUYER TO SELLER, UNLESS AGREED TO IN WRITING BY AN AUTHORIZED REPRESENTATIVE OF SELLER.

2.

PRICES AND TAXES: Buyer agrees to pay the prices quoted by Seller or listed on any related invoice, and is responsible for additional

applicable shipping and handling charges, taxes, duties, and charges for import and export licenses and certificates. All prices quoted by
Seller are subject to change without notice. Seller will generally collect applicable taxes along with the purchase price unless Buyer submits
a valid tax exemption certificate, and indicates which Goods are covered by it. Prices on special-order Goods may be subject to change
before shipment. In order to be corrected any discrepancies in pricing and/or quantities on invoices must be reported by Buyer within thirty
(30) days of the invoice date.

3.

PAYMENT: Payment terms are 30 days net from the invoice date or upon such other terms approved by Seller in writing. Retainage shall not

apply, and Buyer shall not hold back any retainage from Seller, even if retainage is part of any contract between Buyer and any other party.
Payment is not contingent on Buyer’s ability to collect or obtain funds from any other party. Credit card sales are billed at the time of purchase.
Buyer expressly represents it is solvent at the time it places any purchase order with Seller. Seller, in its sole discretion, may determine that Buyer’s
financial condition requires full or partial payment prior to manufacture or shipment. If Buyer fails to make any payment when due, Seller reserves
the right to suspend performance. Buyer agrees to pay a charge on all amounts past due at the rate of 1 ½% per month (18% per year) or the
maximum lawful rate, whichever is less. In the event of non-payment, Buyer agrees to pay Seller’s reasonable attorney fees and court costs, if any,
incurred by Seller to collect payment, and all applicable interest charges. Seller may apply payments to any outstanding invoices unless
Buyer provides specific payment direction.

4.

TITLE AND RISK OF LOSS OR DAMAGE: As to Goods delivered directly by Seller, title passes upon delivery at the place Buyer

receives possession; and, thereafter, all risk of loss or damage shall be on Buyer. All other sales are F.O.B., point of shipment, and Buyer
takes title and assumes responsibility for risk of loss or damage at the point of shipment for such sales. Claims for Goods damaged in transit
are Buyer’s sole responsibility when not delivered directly by Seller.

5.

QUOTATIONS: All quotations expire thirty (30) days 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 return items must be requested and granted in advance. No credit will be given if items are

returned prior to requesting and receiving permission. Subject to the foregoing, Seller shall accept returns of Goods for any reason for a
period of thirty (30) days following shipment for exchange or refund of the purchase price; provided, that such Goods must be unused and are
subject to a 15% restocking charge, which may be increased or decreased, in the Seller’s sole discretion, depending on the reason for such return.
Any Goods which were special ordered by Buyer are may not be returned, and any such Goods which are returned are subject to a
restocking/cancellation fee of 100% of the cost of the Goods. Goods shall be deemed accepted by Buyer (and cannot thereafter be
returned), if Buyer fails to object to the Goods within thirty (30) days after the Goods are received by Buyer.

8.

CANCELLATION: The Buyer may cancel any purchase order prior to shipment of the Goods by mutual agreement of the parties

and upon payment to Seller of reasonable and proper cancellation charges.

9.

TERMINATION: Seller may terminate the whole or any part of any purchase order if there is a material breach of these Terms & Conditions. In

the event of any such breach, the Seller will provide Buyer with written notice of the nature of the breach and the Seller’s intention to terminate for
default. In the event Buyer does not cure such failure within ten (10) days of such notice, Seller may, by written notice, terminate the purchase
order; provided, that Buyer shall continue its performance to the extent not terminated.

10.

CHANGE IN BUYER’S FINANCIAL CONDITION: Seller reserves the right to cancel any order or to require full or partial

payment in advance without liability to Seller in the event of: (i) insolvency of the Buyer; (ii) the filing of voluntary petition in
bankruptcy by Buyer; (iii) the appointment of a Receiver or Trustee for the Buyer; (iv) the execution by Buye r of an assignment for
benefit o f creditors; or (v) pas t due payment on previous s hipments to Buyer by Seller. Seller reserves the right to cancel Buyers
credit at any time for any reason.

11.

INTERPRETATION RESPONSIBILITY; PRODUCT USE AND SAFETY: Seller does not guarantee that the Goods it sells conform to

any plans and specifications or intended use. When plans and specifications are involved, Buyer is solely responsible for verifying Seller’s
interpretations of such plans and specifications, and it is Buyer’s sole responsibility to assure that Seller’s Goods will be acceptable for any
specific job. When Seller offers substitute Goods on any proposal, Buyer is solely responsible for confirming their acceptability.

12.

DELIVERY: Shipping dates given in advance of actual shipment are approximate and not guaranteed. All contract dates and timelines

begin upon receipt by Seller of a purchase order, Buyer’s acceptance of these Terms & Conditions, and the payment of any required down
payment.

Rev. 03/2013 Page | 4

UltraMax Multi-Color Gelcoater Manual

13.

EXCUSABLE DELAYS: Seller shall have no liability if its performance is delayed or prevented by causes beyond its reasonable control,

including, without limitation, acts of nature, labor disputes, government priorities, transportation delays, insolvency or other inability to
perform by any Vendor, or any other commercial impracticability. In the event of any such delay, the date of delivery or performance shall
be extended for a period equal to the time lost by reason of delay. If Goods are held or stored beyond the delivery date for the convenience
of Buyer, such Goods shall be so stored at the risk and expense of Buyer.

14.

CLAIMS: Claims for any nonconforming Goods must be made by Buyer, in writing, within ten (10) days of Buyer’s receipt of such Goods

and must state with particularity all material facts concerning the claim then known to Buyer. Failure by Buyer to give notice within such ten
(10) day period shall constitute an unqualified acceptance of such Goods by Buyer, and a waiver of any right to reject or revoke acceptance
of such Goods.

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. Seller also warrants that the Goods shall,
upon payment in full by Buyer for the Goods, be free and clear of any security interests or liens. Buyer’s exclusive remedy for breach of such
warranties shall be limited to repair or replacement costs or termination of any security interests or liens, and Seller shall have no
responsibility for reimbursing repair costs incurred by Byer in connection with Goods without first giving written authorization for such
charges. In any claims by the Buyer against the Seller in respect of the Goods, the liability of the Seller shall be limited to the value of the
Goods. This warranty applies only to Goods properly used and maintained and does not apply to any Goods which are misused,
neglect or accident, or which has been installed, operated, repaired, altered or modified other than in accordance with instructions or
written authorization by Seller. This warranty does not apply to any Goods not manufactured by Seller, and Buyer's sole warranty
with respect to such Goods shall be that of the Seller’s Vendor, if any.
(b) VENDOR’S WARRANTIES: Seller shall assign to Buyer any Vendor warranties and/or remedies provided to Seller by its Vendor.
(c) INTELLECTUAL PROPERTY INFRINGEMENT: SELLER DISCLAIMS ANY AND ALL WARRANTIES AND/OR INDEMNIFICATIONS
AGAINST INFRINGEMENT OF ANY INTELLECTUAL PROPERTY RIGHTS OF ANY NATURE. SELLER SHALL, IF GIVEN PROMPT
NOTICE BY BUYER OF ANY CLAIM OF INTELLECTUAL PROPERTY INFRINGEMENT WITH RESPECT TO ANY GOODS SOLD
HEREUNDER, REQUEST THE APPLICABLE VENDOR TO GRANT FOR THE BUYER SUCH WARRANTY OR INDEMNITY RIGHTS AS
SUCH VENDOR MAY CUSTOMARILY GIVE WITH RESPECT TO SUCH GOODS.
(d) LIMITATIONS: THERE ARE NO OTHER WARRANTIES WRITTEN OR ORAL, EXPRESS, IMPLIED OR BY STATUTE. SELLER
SPECIFICALLY DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NO
REPAIR OF GOODS OR OTHER COSTS ARE ASSUMED BY SELLER UNLESS AGREED TO, IN ADVANCE, IN WRITING.

16.

LIMITATIONS OF LIABILITY: UNLESS APPLICABLE LAW OTHERWISE REQUIRES, SELLER’S AND ANY VENDOR’S TOTAL

LIABILITY TO BUYER, BUYER’S CUSTOMERS OR TO ANY OTHER PERSON, RELATING TO ANY PURCHASES GOVERNED BY
THESE TERMS & CONDITIONS, FROM THE USE OF THE GOODS FURNISHED OR FROM ANY ADVICE, INFORMATION OR
ASSISTANCE PROVIDED BY SELLER (BY ANY METHOD, INCLUDING A WEB SITE), IS LIMITED TO THE PRICE OF THE GOODS
GIVING RISE TO THE CLAIM. NEITHER SELLER NOR ITS VENDORS SHALL BE LIABLE FOR ANY SPECIAL, INCIDENTAL, DIRECT,
CONSEQUENTIAL OR PENAL DAMAGES, INCLUDING, BUT NOT LIMITED TO BACKCHARGES, LABOR COSTS, COSTS OF
REMOVAL, REPLACEMENT, TESTING OR INSTALLATION, LOSS OF EFFICIENCY, LOSS OF PROFITS OR REVENUES, LOSS OF USE
OF THE GOODS OR ANY ASSOCIATED GOODS, DAMAGE TO ASSOCIATED GOODS, LATENESS OR DELAYS IN DELIVERY,
UNAVAILABILITY OF GOODS, COST OF CAPITAL, COST OF SUBSTITUTE GOODS, FACILITIES OR SERVICES, DOWNTIME, OR
CLAIMS FROM BUYER’S CUSTOMERS OR OTHER PARTIES. IF SELLER FURNISHES BUYER WITH ADVICE OR OTHER
ASSISTANCE WHICH CONCERNS ANY GOODS SUPPLIED HEREUNDER, OR ANY SYSTEM OR EQUIPMENT IN WHICH ANY SUCH
GOODS MAY BE INSTALLED, AND WHICH IS NOT REQUIRED PURSUANT TO THESE TERMS & CONDITIONS, THE FURNISHING OF
SUCH ADVICE OR ASSISTANCE WILL NOT SUBJECT SELLER TO ANY LIABILITY, WHETHER BASED ON CONTRACT, WARRANTY,
TORT (INCLUDING NEGLIGENCE) OR OTHER GROUNDS.

17.

BUYER’S USE OF GOODS: Many factors beyond Seller’s control contribute to the success of the Buyer’s finished products, such as raw

materials used to manufacture the products. Seller is not liability for the quality or quantity of finished products produced by Buyer with the use of
the Goods.

18.

EXPORTS: If Goods are sold for export, Seller’s standard terms & condition for export sales, if any, shall also apply. Acceptance of export

orders is not valid unless confirmed in writing 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. Notwithstanding the foregoing, however, Seller will provide installation supervision personnel within thirty (30) days of Buyer’s request. If
an installation for which the Seller is to participate is delayed by the Buyer more than six (6) months after the date of shipment of the Goods, or if
Buyer’s facility, materials, or parts are not prepared for installation for such period of time, Seller shall be entitled to invoice the Buyer for the
anticipated installation costs, up to $1,250 per day plus expenses, for each of Seller’s installations technicians which are on site.

20.

ANTI-MONEY LAUNDERING RESTRICTIONS: Seller rejects questionable purchase orders and payments: Except for pre-approved

credit arrangements, Seller rejects third-party payments, cashiers' checks, money orders and bank drafts. Seller accepts only checks
imprinted with Buyer’s name; wire transfers originated in Buyer's account; letters of credit with Buyer as account party; and credit or debit
cards in Buyer’s name. All payments must be by single instrument in the amount of the invoice, less credits, from banks acceptable to
Seller.

21.

GOVERNING LAW: These Terms & Conditions and all disputes related to it shall be governed by the laws of the State of Florida, United

States of America, without giving effect to its conflict of law rules.

Rev. 03/2013 Page | 5

UltraMax Multi-Color Gelcoater Manual

22.

JURISDICTION AND VENUE: The parties hereby irrevocably submit to the jurisdiction of the state courts of the State of Florida

and to the jurisdiction of the United States District Court for the Middle District of Florida, for the purpose of any suit, action, or other
proceeding related to, arising out of or based upon these Terms & Conditions or in a ny way related to, arising out of or involving sale
of Goods hereunder; waive and agree not to assert by way of motion, as a defense, or otherwise, in any such s uit, action, or
proceeding, any claim that it is not subject personally to the jurisdiction of the above-named courts, that its property is exempt or
immune from attachment or execution, that the suit, action, or proceeding is brought in any inconvenient forum, that the venue of the
suit, action, or proceeding is improper, or that these Terms & Conditions or the subject matter hereof may not be enforced i n or by
such court; and waive and agree not to seek any review by any court of any other jurisdiction which may be called upon to grant an
enforce ment of the judgment of any such Florida state or federal court. The parties hereby consent to service of process by
registered mail at the address to which notice is to be given. The exclusive venue for any proceeding under these Terms &
Conditions shall be solely in any state court in Pinellas County, Florida, or the Federal District Court fo r the Middle District of Florida,
Tampa Division, sitting in Tampa, Florida. Buyer acknowledges that the prices for Goods offered hereunder are in part dependent
on Buyer’s consent to jurisdiction in Florida and exclusive venue in Pinellas County, Florida or the Federal District Court for the
Middle District of Florida, Tampa Division, sitting in Tampa, Florida, and without Buyer’s consent to this jurisdiction a nd venue
provision the prices for the Goods may be higher.

23.

GENERAL: Any representatio n, affirmation of fact and course of dealing, promise or condition i n connection therewith or usage

of trade not contained herein, shall not be binding on either party. If any provision hereo f shall be unenforceable, invalid or void for
any reason, such provision shall be automatically voided and shall not be part of these Terms & Conditions and the enforceability or
validity of the remaining provisions of these Terms & Conditions shall not be affected thereby.

TO THE EXTENT NOT CONTRARY TO APPLICABLE LAW, THE FOLLOWING SHALL APPLY:

24.

Buyer waives any available homestead exemption as well as any and all requirements or rights with regard to notice, demand,
presentment, or protest and appoint any employee or attorney of Seller to appear in any co urt of competent jurisdiction for the
purpose of confessing judgment for all amounts due Seller pursuant to these terms and conditions.

25.

Buyer hereby waives all rights to notice, judicial hearing or prior court order in connection with Seller’s obtaining any prejudgment
remedy in connection with said transactions or extensions of same. Buyer also waives any and all objec tion which Buyer might
otherwise be able to assert now or in the future to the exercise or use by Seller of any right of setoff, repossession or self-help as
may presently exist under statute, including the Uniform Commercial Code and common law.

IMPORTANT NOTICE: THIS INSTRUMENT PERMITS SELLER TO OBTAIN AND USE YOUR INDIVIDUAL CREDIT HISTORY FOR
CREDIT EVALUATION PURPOSES. THIS INSTRUMENT FURTHER CONTAINS A CONFESSION OF JUDGMENT PROVISION AND
OTHER WAIVERS, WHICH CONSTITUTES A WAIVER OF IMPORTANT RIGHTS YOU MAY HAVE, AND IF YOU DO NOT PAY ON TIME,
ALLOWS SELLER TO OBTAIN A JUDGMENT AGAINST YOU WITHOUT FURTHER NOTICE OR YOUR PRIOR KNOWLEDGE. BY
ACCEPTING THESE TERMS YOU GIVE UP YOUR RIGHT TO NOTICE AND TRIAL. THE POWERS OF THE COURT CAN BE USED TO
COLLECT THE AMOUNT DUE REGARDLESS OF ANY CLAIMS YOU MAY HAVE WHETHER FOR RETURNED OR FAULTY GOODS,
FAILURE BY SELLER TO COMPLY WITH THESE TERMS & CONDITIONS, OR ANY OTHER CAUSE.

Rev. 03/2013 Page | 6

UltraMax Multi-Color Gelcoater 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. 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 Plastech Inc. Magnum
Venus Plastech 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 Plastech 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 Plastech recommends this Safety Manual remain on your equipment
at all times for your personnel safety. In addition to the manual, Magnum Venus Plastech
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

Type of Fire Extinguishing equipment recommended: Fire Extinguisher – code ABC, rating
number 4a60bc.

Rev. 03/2013 Page | 7

UltraMax Multi-Color Gelcoater Manual

Extinguishing Media – Foam, Carbon Dioxide, Dry Chemical, Water Fog.

Copies of the above bulletins are available, at a nominal charge from:

National Fire Protection Association
470 Atlantic Avenue
Boston, MA 02210

Research Report No.11 of the American Insurance Association deal with “Fire, Explosion and
Health Hazards of Organic Peroxides”. It is published by:

American Insurance Association
85 John Street
New York, NY 10038

Local codes and authorities also have standards to be followed in the operation of your spraying
equipment. Your insurance carrier will be helpf ul in answering questions that arise in your
development of safe procedures.

1.2 Personal Safety Equipment

Magnum Venus Plastech recommends the following Personal Safety Equipment for conducting
safe operations of the Polyester Systems:

Magnum Venus Plastech 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 explosion dangers of the catalyst normally used – Methyl Ethyl Ketone
Peroxide (MEKP).

2. The flammability dangers of clean-up solvents sometimes used (Magnum Venus Plastech
recommends that clean-up solvents be non-flammable), and of resin diluents used, such as
styrene.

3. The flammability dangers of catalyst diluents, if used. (Magnum Venus Plastech recommends
that catalyst not be diluted.

4. The flammability dangers of the uncured liquid resins used.

5. The combustibility dangers of the cured laminate, accumulations of over spray, and laminate
sandings.

6. The toxicity dangers of all the chemicals used in laminating operatio ns with respect to
ingestion, inhalation and skin and eye hazards.

Rev. 03/2013 Page | 8

UltraMax Multi-Color Gelcoater 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. MEKP is a
single chemical. Various polymeric forms may exist which are more or less hazardous with
respect to each other. These differences may arise not only from different molecular structures
(all are, nevertheless, called “MEKP”) and from possible trace impurities left from the
manufacture of the chemicals, but may also arise by contaminatio n of MEKP with other
materials in its storage or use. Even a small amount of contamination with acetone, for instance,
may produce an extremely shock-sensitive and explosive compound.

Contamination with promoters or materials containing promoters, such as laminate
sandings, or with any readily oxidizing material, such as brass or iron, will cause
exothermic “redox” reactions which can become explosive in nature. Heat applied to
MEKP, or heat build-up from contamination reactions can cause it to reach what is called
its Self-Accelerating Decomposition Temperature (SADT).

Researchers have reported measuring pressure rates-of-rise well in excess of 100,000 psi per
second when certain MEKP’s reach their SADT. (For comparison, the highest pressure rate-of­rise listed in NFPA Bulletin NO.68, “Explosion Venting”, is 12,000 psi per second 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 vessel, surge chamber, or pressure accumulator, could explode
under certain conditions. There is no engineering substitute for care by the user in handling
organic peroxide catalysts. If, at any time, the pressure relieve valve on top of the catalyst tank
should vent, the area should be evacuated at once and the fire department called. The venting
could be the first indication of a heat, and therefore, pressure build-up that could eventually lead
to an explosion. Moreover, if a catalyst tank is sufficiently full when the pressure relief valve
vents, some catalyst may spray out, which could cause eye injury. For this reason, and many
others, anyone whose job puts them in an area where this vented spray might go, should
always wear full eye protection even when laminating operations are not taking place.

Safety in handling MEKP depends to a great extent on employee education, proper safety
instructions and safe use of the chemicals and equipment. Workers should be thoroughly
informed of the hazards that may result form improper handling of MEKP, especially in regards
to contamination, heat, friction and impact. They should be thoroughly instructed regarding the
proper action to be taken in the storage, use and disposal of MEKP and other hazardous
materials used in the laminating operation. In addition, users should make every effort to:

A. Store MEKP in a cool, dry place in original containers away from direct sunlight and away
from other chemicals.

B. Keep MEKP away from heat, sparks and open flames.

C. Prevent contamination of MEKP with other materials, including polyester over spray and
sandings, polymerization accelerators and promoters, brass, aluminum and non-stainless
steels.

Rev. 03/2013 Page | 9

UltraMax Multi-Color Gelcoater Manual

D. Never add MEKP to anything that is hot, since explosive decomposition may result.

E. Avoid contact with skin, eyes and clothing. Protective equipment should be worn at all times.
During clean-up of spilled MEKP, personal safety equipment, gloves and eye protection must be
worn. Fire fighting equipment should be at hand and ready.

F. Avoid spillage, which can heat up to the point of self-ignition.

G. Repair any leaks discovered in the catalyst system immediately, and clean up the leaked
catalyst at once in accordance with the catalyst manufacturer’s instructions.

H. Use only original equipment or equivalent parts from Magnum Venus Plastech in the catalyst
system (i.e.: hoses, fitting, etc.) because a dangerous chemical reaction may result between
substituted parts and MEKP.

I. Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries
should never be returned to the supply tank, such catalyst should be diluted with copious
quantities of clean water and disposed of in accordance with the catalyst manufacturer’s
instructions.

The extent to which the user is successful in accomplishing 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, heaters, filters, valves, spray guns, tanks,
etc.). T he explosion could cause serious injury, death and/or substantial property
damage. Cleaning agents, coatings, paints, etc. may contain Halogenated Hydrocarbon
Solvents. Some Magnum Venus Plastech spray equipment includes aluminum or
galvanized components and will be affected by Halogenated Hydrocarbon Solvents.

A. There are three key elements to the Halogenated Hydrocarbon (HHC) solvent hazard.

a. The presence of HHC solvents. 1,1,1 – Trichloroethane and Methylene Chloride are the

most common of these solvents. However, other HHC solvents are suspect if used;
either as part of paint or adhesives formulation, or for clean-up flushing. b.
Aluminum or Galvanized Parts. Most handling equipment contains these elements. In
contact with these metals, HHC solvents could generate a corrosive reaction of a
catalytic nature.

b. Equipment capable of withstanding pressure. When HHC solvent contact aluminum or

galvanized parts inside a closed container such as a pump, spray gun, or fluid handling
system, the chemical reaction can, over time, result in a build-up of heat and pressure,
which can reach explosive proportions.

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.

Rev. 03/2013 Page | 10

UltraMax Multi-Color Gelcoater Manual

A. The reaction is unpredictable. Prior use of an HHC solvent without incident (corrosion or
explosion) does NOT mean that such use is safe. These solvents can be dangerous alone (as a
clean-up or flushing agent) or when used as a component or a coating material. There is no
known inhibitor that is effective under all circumstances. Furthermore, the mixing of HHC
solvents with other materials or solvents, such as MEKP, alcohol, and toluene, may render the
inhibitors ineffective.

B. The use of reclaimed solvents is particularly hazardous. Reclaimers may not add any
inhibitors. Also, the possible presence of water in reclaimed solvents could feed the reaction.

C. Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction.
Such coatings can be worn, cracked, scratched, or too thin to prevent contact. There is no
known way to make oxide coatings or to employ aluminum alloys, which will safely prevent the
chemical reaction under all circumstances.

D. Several solvent suppliers have recently begun promoting HHC solvents for use in 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 systems
having aluminum or galvanized wetted parts.

NOTE: Magnum Venus Plastech is aware of NO stabilizers available to prevent
Halogenated Hydrocarbon solvents from reaction under all conditions w ith aluminum
components in closed fluid system. TAKE IMMEDIATE ACTION Halogenated
Hydrocarbon solvents are dangerous when used with aluminum components in a closed
fluid system.

A. Consult your material supplier to determine whether your solvent or coating contains
Halogenated Hydrocarbon Solvents.

B. Magnum Venus Plastech recommends that you contact your solvent supplier regarding the
best non-flammable clean-up solvent with the heat toxicity for your applicatio n.

C. If, however, you find it necessary to use flammable solvents, they must be kept in approved,
electrically grounded containers.

D. Bulk solvent should be stored in a well-ventilated, separate building, 50 feet away from your
main plant.

E. You should allow only enough solvent for one day’s use in your laminating area.

F. “NO SMOKING” signs must be posted and observed in all areas of storage or where solvents
and other flammable materials are used.

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.

Rev. 03/2013 Page | 11

UltraMax Multi-Color Gelcoater Manual

2.4 Catalyst Diluents

Magnum Venus Plastech spray-up and gel-coat systems currently produced are designed so
that catalyst diluents are not required. Magnum Venus Plastech, therefore, recommends that
diluents not be used. This avoids the possible contamination which could lead to an explosion
due to the handling and mixing of MEKP and diluents. In addition, it eliminates any problems
from the diluent being contaminated through rust particles in drums, poor quality control on the
part of the diluents suppliers, or any other reason. If, however, diluents are absolutely required,
contact your catalyst supplier and follow his instructions explicitly. Preferable, the supplier
should premix the catalyst to prevent possible “on the job” contaminatio n while mixing.

WARNING

If diluents are not used, it should be remembered that catalyst spillage, gun, hose and
packing leaks are potentially more hazardous, since each drop contains a higher
concentration 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 be non-combustible.

C. Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product, over­sprayed chop or resin, FRP sandings or any other material with MEKP.

To prevent this spillage and leakage, you should:

1. Maintain your Magnum Venus Plastech System. Check the gun several times daily for
catalyst and resin packing or valve leaks. REPAIR ALL LEAKS IMMEDIATELY.

2. Never leave the gun hanging over, or lying inside the mold. A catalyst leak in this situatio n
would certainly damage the part, possibly the mold, and may cause a fire.

3. Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom
sections and at the hose and fittings. Replace if wear or weakness is evident or suspected.

4. Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub
against any of the hoses at any point. If allowed to rub, the hose will be cut through, causing a
hazardous leakage of material which could increase the danger of fire. Also, the material may
spew o nto personnel in the area.

2.7 Toxicity of Chemicals

A. Magnum Venus Plastech 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.

C. Also determine the best methods of first aid treatment for each chemical used in your plant.

Rev. 03/2013 Page | 12

UltraMax Multi-Color Gelcoater Manual

2.8 Treatment of Chemical Injuries

Great care should be used in handling the chemicals (resins, catalyst and solvents) used in
polyester systems. Such chemicals should be treated as if they hurt your skin and eyes and as if
they are poison to your body. For this reason, Magnum Venus Plastech recommends the use of
protective clothing and eye wear in using polyester systems. However, users should be
prepared in the event of such an injury. Precautions include:

1. Know precisely what chemicals you are using and obtain information from your chemical
supplier 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 immediately in the event of any injury and give him the information
you have collected. If your information includes first aid instructions, administer first aid
immediately while you are contacting your doctor.

Fast treatment of the outer skin and eyes that contact such chemicals generally includes
immediate and thorough washing of the exposed skin and immediate and continuous flushing of
the eyes with lots of clean water for at least 15 minutes or more. These general instructions of
first aid treatment, however, may be incorrect for some chemicals; that is why you must know
the chemicals and treatment before an accident occurs. Treatment for swallowing a chemical
frequently depends upon the nature of the chemical.

NOTE: Refer to your System User Manual for complete and detailed operating
instructions and service information.

Rev. 03/2013 Page | 13

UltraMax Multi-Color Gelcoater Manual

3.0 Equipment Safety

WARNING

Magnum Venus Plastech suggest that personal safety equipment such as EYE
GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be worn w hen 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). This equipment should only be operated or serviced by technically trained
personnel!

WARNING

Never place fingers, hands, or any body part near or directly in front of the spray gun
fluid tip. The force of the liquid as it exits the spray tip can cause serious injury by
shooting liquid through the skin. NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR
POINT THE GUN AT OR NEAR ANOTHER PERSON. (TREAT THE GUN AS IF IT WERE A
LOADED PISTOL.)

3.1 Emergency Stop Procedures

The following steps should be followed in order to stop the machinery in an emergency situatio n

1. The ball valve located where the air enters the Powerhead of the resin pump, should be
moved to the “OFF” or closed 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 reactivating to the “ON” position.

2. Turn all system regulators to the “OFF” position (counter-clockwise) position

NOTE: Verify that the Catalyst relief line, located on the catalyst manifold, and the resin
return line, located on the resin filter, are secured relieving catalyst and resin fluid
pressure.

3. Catalyst pressure in the catalyst pump can be eliminated by rotating the ball valve on the
catalyst manifold 90 degrees to the “open” or “on” position.

Note: The “open” or “on” position is when the ball valve handle is parallel (in line) with
the ball valve body. The “closed” or “off” position is when the ball valve handle is
perpendicular (across) the ball valve body.

4. Resin pressure in the resin pump can be eliminated by rotating the ball valve on the resin
filter 90 degrees to the “open” or “on” position. Place a container under the ball valve to
catch any resin that is ejected out of the valve.

Rev. 03/2013 Page | 14

UltraMax Multi-Color Gelcoater 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 a charge to flow from the object
fast enough that it will not accumulate to the extent that a spark can be formed. It is not possible
to define exactly what will be an adequate path under all conditions since it depends o n many
variables. In any event, the grounding means should have the lowest possible electrical
resistance. Grounding straps should be installed on all loose conductive objects in the spraying
area. This includes material containers and equipment. Magnum Venus Plastech recommends
grounding straps be made of AWG No.18 stranded wire as a minimum and the larger wire be
used where possible. NFPA Bulletin No77 states that the electrical resistance of such a
leakage path may be as low as 1 meg ohm (10 ohms) but that resistance as high as 10,000
meg ohms will produce an adequate leakage path in some cases. Whenever flammable or
combustible liquids are transferred from one container to another, or from one container to the
equipment, both containers or container and equipment shall be effectively bonded and
grounded to dissipate static electricity. For further information, see National Fire Protection
Association ( NFPA) 77, titled “Recommended Practice on Static Electrical”. Refer especially to
section 7-7 titled “Spray Application of Flammable and Combustible Materials”. Check with local
codes and authorities for other specific standards that 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 OPERATOR OR SUPERVISOR, DO NOT FEEL THAT YOU HAVE BEEN
ADEQUATELY TRAINED OR INSTRUCTED AND THAT YOU LACK THE TECHNICAL
KNOWLEDGE TO OPERATE OR PERFORM MAINTENANCE ON A PIECE OF MAGNUM
VENUS PLASTECH EQUIPMENT, PLEASE CALL MAGNUM VENUS PLASTECH BEFORE
OPERATING OR PERFORMING MAINTENANCE ON THE EQUIPMENT. IF YOU HAVE ANY
QUESTIONS REGARDING THE ABOVE PRECAUTIONS OR ANY SERVICE OR OPERATION
PRECEDURES, CALL YOUR MAGNUM VENUS PLASTECH DISTRIBUTOR OR MAGNUM
VENUS PLASTECH.

NOTICE: All statements, information and data given herein are believed to be accurate
and reliable but are presented without guaranty, warranty or responsibility of any kind
express or implied. The user should not assume that all safety measures are indicated
or that other measures are not required.

DANGER: Contaminated catalyst may cause Fire or Explosion. Before working on the
catalyst pump or catalyst accumulator, wash hands and tools thoroughly. Be sure work
area is free of dirt, grease or resin. Clean catalyst system components with clean water
only.

DANGER: Eye, skin and respiration hazard. The Catalyst, MEKP, may cause
blindness, skin irritation or breathing difficulty. Keep hands away from face.
Keep food and drink away from work area.

WARNING: Please refer to your catalyst manufacturer’s safety information
regarding the safe handling and storage of catalyst. Wear appropriate safety
equipment as recommended.

Rev. 03/2013 Page | 15

UltraMax Multi-Color Gelcoater Manual

Introduction:

This manual will cover the first time priming, daily start up and shut-down plus
operations of the UltraMax Multi-Color Gel Coat unit. It also contains repair sections for
the components that make up your Multi-Color Gel Coat unit.

There are several configurations of the UltraMax Multi-Color Gel Coater – External Mix
(MVE-1400-X-1(-INT) or MVE-1400-X-1(-INT)) which uses the ATG-3500 Gel Coat gun
and Internal Mix (MVG-1400-X-1(-INT)). Where X is the number of colors (fluid
sections) mounted on the unit. The units can be configured with 2, 3, 4, 5 and 6 colors
or expanded to a total of 6 colors by adding additional colors (fluid sections) (MCPA­2500-1). The –INT is for international units that ship outside of the USA.

The major components (Gun, Fluid Section, Powerhead, Catalyst Pump) referenced in
this manual will vary depending on the configuration of your unit.

MVE – External Mix: “ATG-3500 Gel Coat Repair & Maintenance Manual”.

MVG – Internal Mix: “Classic Pro Gun Repair Manual”

XXX-1400-X-1:

• MPH_VPH-4250 Series Manual – VPH-4250

• VLS-2400 Fluid Section Manual – MCPA-2500 (MCPA-2500-1)

• VHPC-2000 Metering Pump – VHPC-2000 (catalyst pump)

Optional Items:

• MagnaPac Fluid Section – MCPA-2500-MP (MCPA-2500-1-MP)

• 5” Powerhead & Track Assembly – MCTA-5000

• VLS-4600 Fluid Section – MCPA-4600

• High Volume Fluid Section – MCPA-HVLS

Most of the operations procedures will be the same for all of the configurations but will
be noted where there are different procedures.

Magnum Venus Plastech spray equipment provides one of the most efficient methods of
quickly applying material to a surface or mold. To make the most of our low-pressure
metering systems airless, internal mix or external mix guns, the operator must
understand how to adjust the system for maximum efficiency.

One of the most important concepts is to use just enough pressure to the power head to
establish a good spray fan, and no more. Then use the Air Assist to fine tune or do final
adjustment to the spray pattern.

Rev. 03/2013 Page | 16

UltraMax Multi-Color Gelcoater Manual

Getting Started:

1. Unpack unit & components

2. Assemble frame work as needed (note drawing 1101-03-01)

NOTE: If UltraMAX Multi-Color Gelcoater unit is configured with a mobile option
kit, please refer to the kit’s installation instructions for set-up.

3. Install the Carriage Assembly to the pump module assembly

4. Install catalyst jug

5. Install gelcoat filter & surge chamber assembly

6. Install air manifold and manifold air hose to powerhead

7. Attach hose fittings to gelcoat pump, catalyst pump and gun air

8. Attach pickup hoses to the inlet of the pump

9. Internal Mix: Place flush tank in holder and attach air hose from manifold.

Connect yellow flush tube from gun to flush tank.

10. Double check all hose fittings and connections are tight

NOTE: If UltraMAX Multi-Color Gelcoater unit is configured with heaters, please
refer to the installation instructions when you reach this stage of set-up.

NOTE: If UltraMAX Multi-Color Gelcoater unit is configured with heater and or a
heater selector switch, please refer to the drawing when you reach this stage of
set-up.

NOTE: If UltraMAX Multi-Color Gelcoater unit is configured with a catalyst alarm,
please refer to the catalyst alarm manual when you reach this stage of set-up.

Rev. 03/2013 Page | 17

UltraMax Multi-Color Gelcoater Manual

Air supply:

1. Use minimum ½” air hose supply to the system. Air requirements: 18 CFM (510

L/Min.) at 90 -100psi (6 – 7bar)

2. Open incoming air supply ball valve all the way.

Note: the main air supply ball valve is a safety ball valve and must be all the way
closed or all the way open. When the ball valve is closed the air pressure
remaining in the air manifold and air system will be released.

3. Check that the system air is set at 90 to 100 psi.

Rev. 03/2013 Page | 18

UltraMax Multi-Color Gelcoater Manual

Changing Between Colors:

1. Trigger the gun or use the priming button to move the pump so that it is at the

bottom of the stroke (lowest position).

2. Prepare the gun:

External Mix – brush gel coat spray tip and catalyst tip with solvent.
Internal Mix – flush mix chamber with solvent.

3. Turn the air motor regulator knob counter clock wise (CCW) to lower the air

pressure to zero.

4. Open the ball valve at the bottom of resin filter housing. Place the appropriate

container under the ball valve if a return hose is not installed. This will relieve

resin pressure to the supply drum or container.

Note: it is important in order to release fluid pressure in the hose that is no longer
in use.

5. Release the pressure in the gel coat accumulator by pushing a small dull rod (Allen

wrench) into the top of the accumulator charging valve.

6. Rotate the ball valve on the catalyst manifold to the open position. This will

relieve catalyst pressure to the supply jug as the air motor is operated up
and down to release or connect to a gel coat color pump.

7. Close the ball valve at the quick disconnect end of the resin hose assembly.

8. Disconnect the current resin hose assembly (or color) from the gun assembly and

clean the quick disconnect fittings with solvent.

Note: it is important to keep the quick disconnect fittings clean so that the O-ring
in the female quick disconnect does not become damaged and leak

9. Connect the new gel coat hose assembly (or color) to the gun assembly and open

the ball valve at the quick disconnect end of the gel coat hose.

10. Push up on the Sleeve holding the coupling Half Shells in place and remove the

coupling Half Shells from the Rod Ends.

Rev. 03/2013 Page | 19

UltraMax Multi-Color Gelcoater Manual

11. Loosen the Clamp Bolt assemblies (2) by turning counter clock wise (CCW).

12. Slide the Carriage assembly to the approximate center of the desired fluid section

and align the shafts. The air motor shaft or fluid section shaft may need to be
moved up or down to allow proper alignment.

13. When the shafts are properly aligned and touching end to end, push the Sleeve up

and install the two coupling Half Shell connectors.

14. Tighten the Clamp Bolts (2), by turning the knobs clock wise (CW).

15. Charge the gel coat accumulator if applicable to the system.

16. Close the ball valve at the bottom of the gel coat filter body.

17. While pressing the pump prime button, adjust the pump regulator to the desired air

pressure.

18. Close the ball valve on the catalyst manifold. Using the catalyst drive hand prime

the catalyst pump pressure and replace the pivot pin into the slide drive assembly.

Adjust the spray pattern as desired. See the “Testing and Adjusting manual” for details.

Rev. 03/2013 Page | 20

UltraMax Multi-Color Gelcoater Manual

Priming the Unit:

Priming Solvent: (Internal Mix Systems Only)

1. Open solvent tank lid and fill 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 (3.5 – 4 bar).

2. Check for leaks and fix as necessary.

3. Push the flush valve on the side of the gun block to test solvent flush.

Select Gel Coat Pump Color:

1. Connect the Carriage Assembly to the desired Gel Coat fluid section / Color (see

“Changing Between Colors” above).

2. Connect the accompanying gel coat hose assembly to the gun and open the ball

valve at the quick disconnect end.

Priming Catalyst to Gun:

1. Gun preparations:

Internal Mix: (Pro Gun) Tighten packing nuts on the gun and trigger the gun 10 to 15

times. Snug packing nuts again and repeat gun triggering, repeat this process three
or four times. Remove nozzle and mixer from the mix chamber.

External Mix: Remove the catalyst and spray tip from the front of the gun.

2. Tighten the catalyst packing nut – 1/8 to 1/4 of a turn to snug packing.

3. Fill the two gallon catalyst jug ¾ full, purge the air out of the catalyst feed line by

slightly tilting the catalyst jug.

4. Open the recirculation valve on the catalyst manifold.

5. Remove the pivot pin for catalyst drive linkage. Using the catalyst drive hand prime

catalyst back to the jug through the recirculation valve. Do this till there is no air in
the tube.

6. Close the recirculation valve on the catalyst manifold.

7. Lock or hold the gun in the open position over an appropriate container. Remove

the pivot pin from the catalyst drive linkage. Use the catalyst drive to hand prime
catalyst out to the gun until a steady stream is achieved. Do not reinstall pivot pin

at this time / open the catalyst recirculation valve at the catalyst manifold to
prevent over pressurizing the catalyst system.

Rev. 03/2013 Page | 21

UltraMax Multi-Color Gelcoater Manual

Priming Gel Coat to Gun:

NOTE: The resin pump was tested using oil. It may require up to 1/2 gallon (1 – 2
liters) of gel coat to be run through the unit to purge any remaining oil from the
system.

1. Fill the Packing Nut cavity ¾ full with TSL oil or suitable oil.

2. Insert the gel coat suction wand into container of gel coat. Clamp or tape the resin

return hose coming from the bottom of the in-line filter to the resin pickup wand and
into the drum.

3. With the gun 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.

4. Close the gun:

Internal Mix: Flush the mix chamber clean.
External Mix: Brush the front of the gun head clean with solvent.

5. Slowly increase gel coat pump pressure to 100 psi (7 bar). Allow the unit to set

under static load for 15 to 30 minutes to seat the resin packing set.

6. Turn the pump regulator to zero. Slowly open the ball valve at the bottom of the

resin filter to drain the fluid pressure.

Note: the above procedures will need to be performed for each fluid section/color.

Charging the Gel Coat Surge Chamber: (If applicable)

1. Open the ball valve below inline resin filter.

2. 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 filter.

Rev. 03/2013 Page | 22

UltraMax Multi-Color Gelcoater Manual

Pressurizing Fluids:

NOTE: On the air manifold, the blue valve is the safety override. The small brass
button next to the valve is the priming button.

The Gel coater Unit is standard with a safety override valve. This valve automatically
opens and closes the air supply to the pump air motor. The safety valve will be opened
when the gun trigger is opened or when the priming button is pushed.

NOTE: Remove catalyst pivot pin before pressurizing gel coat to the pump. Do
not reinstall pivot pin at this time / open the catalyst recirculation valve at the
catalyst manifold to prevent over pressurizing the catalyst system.

1. Push on the priming button and slowly increase the gel coat pump regulator: 40

to 50 psi would be a starting point.

2. Using the catalyst drive arm, use slow up and down motion to pressurize the

catalyst pump.

External Mix: Prime a little pressure – there is no gauge on this system.
Internal Mix: Prime to 200psi to 400psi. There should be a gain in pressure on

both the up and down strokes – watch the catalyst pressure gauge.

3. Pin the catalyst drive into the pivot arm. Set desired catalyst percentage.

Gun Set-Up Internal Mix:

Note: Use a little red grease on the O-rings and threads before installing the spray
tip, catalyst tip and retainer.

1. Install turbulent mixer into mix chamber. Insert static mixer and spray tip onto the

air assist housing. Screw air-assist onto the gun mix housing. For longer
turbulent mixer life, do not over tighten the air assist nozzle housing.

2. Attach air assist tube from needle valve on side of gun handle to air-assist head.

3. Spray test pattern; make gel coat pump pressure adjustment until a fairly uniform

pattern is achieved. There should be slight horns on either side of the spray fan.
Slowly open the air-assist needle valve located on the side of the gun handle
until a soft uniform pattern is achieved.

Rev. 03/2013 Page | 23

UltraMax Multi-Color Gelcoater Manual

Gun Set-Up External Mix:

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 gun block.

3. Install the retainer to secure Catalyst Tip and Spray Tip in place.

4. Spray test pattern; make gel coat pump pressure adjustment until a fairly uniform

pattern is achieved. There should be slight horns on either side of the spray fan.
Slowly open the air-assist needle valve located on the side of the gun handle until
a soft uniform pattern is achieved.

Rev. 03/2013 Page | 24

UltraMax Multi-Color Gelcoater Manual

Daily Procedures:

External Mix Daily Start-Up:

1. Check all hoses for damage.

2. Check all material supplies and fill or replace as needed.

3. Open recirculation valve on Catalyst Manifold

4. Open main inlet air valve on the manifold.

5. Remove the Pivot Pin from the catalyst drive.

6. Manually pump the catalyst pump with 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 pump pressure, if adjustment is needed press and hold the priming button

while adjusting air pressure - slowly turn up the pump air pressure to the
operating pressure.

10. Replace the Pivot Pin into the catalyst pump drive.

11. Check atomizing air pressure, adjust as necessary.

12. Lubricate the nozzle O-rings, stud O-rings and gun front threads

13. Install nozzle, catalyst tip and retaining ring onto the front of the gun.

Rev. 03/2013 Page | 25

UltraMax Multi-Color Gelcoater Manual

Internal Mix Daily Start-Up:

1. Check all hoses for damage.

2. Check all material supplies and fill or replace as needed.

3. Close the flush tank relief valve

4. Open recirculation valve on Catalyst Manifold

5. Open main inlet air valve on the manifold.

6. Remove the Pivot Pin from the catalyst drive.

7. Manually pump the catalyst pump with the catalyst drive, observe 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. Check pump pressure, if adjustment is needed press and hold the priming button

while adjusting air pressure - slowly turn up the pump air pressure to the
operating pressure.

11. Replace the Pivot Pin into the catalyst pump drive.

12. Insert the Distribution Ring into the Mix Chamber locating rim.

13. Place mix housing Seal into the Mix Chamber locating rim.

14. Insert the Catalyst Injector and injector seal into the aperture in the Distribution

Ring. The spring goes into the gun block.

15. Place Mix Chamber and Catalyst Injector onto the front of the Pro Gun, secure it

with the 2 screws.

16. Apply a small amount of Red Grease to the threads of the Mix Chamber.

17. Install mixer, seal and air assist assembly onto the mix chamber.

Rev. 03/2013 Page | 26

UltraMax Multi-Color Gelcoater Manual

External Mix Daily Shut-Down:

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.

Internal Mix Daily Shut-Down:

1. Flush the Mix Housing and air assist with solvent.

2. Wipe the face of the Air Assist nozzle after flushing.

3. Turn off the main air ball valve at the air manifold.

4. Release the solvent flush tank pressure.

5. Disassemble the Air Assist and clean it with solvent.

6. Remove the Mix Housing and clean.

7. Wipe the Gun Block face with a clean rag.

8. Hang the gun with the gun block exit holes facing downwards.

Rev. 03/2013 Page | 27

UltraMax Multi-Color Gelcoater Manual

Maintenance Schedule:

Daily Maintenance:

1. Drain water trap.

2. Daily shutdown should include: remove air-assist tip and static mixers from

housing and clean; remove turbulent mixer and mix chamber from gun and clean;
lightly dampen a rag with solvent and wipe down gun head, handle and actuator.
Do not soak gun in solvent.

3. Clean the resin hose assembly’s quick disconnects

Weekly Maintenance:

Track Assembly

1. Clean and lubricate the track wheels and track rail with red grease.

2. Check, Clean and lubricate the intermediate pump shaft and mount plate bushing.

Gel coat Pump Packing Set

Check gel coat pump piston rod oil reservoir, inspect for gel coat bypassing packing set.

1. Turn pump regulator to zero. Open ball valve at gel coat filter to release gel coat

pressure.

2. Insert a rod or Philips screwdriver into one of the holes in the gel coat-packing

nut. Snug the packing nut 1/8th to 1/4 of a turn. Do not over tighten.

Gun maintenance:

1. Turn the pump regulator pressure to zero.

2. Open up the ball valve at the filter to relieve gel coat fluid pressure.

3. Open catalyst recirculation valve at the catalyst manifold to relieve catalyst fluid

pressure.

4. Snug Pro gun packing nuts (light snug on catalyst packing nut) and trigger the

gun on and off to seat the resin and catalyst seals.

5. Repeat a second time.

6. Close the catalyst recirculation valve at the catalyst manifold.

Rev. 03/2013 Page | 28

UltraMax Multi-Color Gelcoater Manual

Filter & Accumulator

1. Turn gel coat pump regulator to zero. Open ball valve at the gel coat filter to

relieve gel coat fluid pressure. To bleed the charge in the accumulator, insert the
small diameter rod in the charging valve on the top of the resin accumulator (check
valve) and depress to bleed the charge off. Be sure to cover the rod with a rag.

2. To remove the gel coat filter, remove the return hose from the ball valve.

Unscrew the resin filter; clean the filter screen. Use MVP red grease on the filter
housing threads.

3. Unscrew the gelcoat accumulator. Clean the accumulator, poly ball and thread

on the nipple. Coat nipple, O-ring and poly ball with red grease. Inspect O-ring ­replace as needed.

Catalyst Pump

Inspect catalyst pump packing nut for catalyst leaking up through the packing set.
Tighten the packing nut no more than 1/8 of a turn at a time as needed. Wipe
catalyst pump piston rod off with a clean dry towel.

Six Month Maintenance

Flush Tank

Release fluid pressure from flush tank and drain out solvent. Use a clean towel to
wipe the inside of the tank clean. Wipe out any solid debris. Inspect flush tank O­ring, replace as needed.

Hose Set

Inspect hose set for any kinks or wear, replace hoses as needed. The flush hose
should be replaced once a year.

Catalyst Jug & Feed Hose

Drain catalyst from jug; wash the jug out with distilled water and drain. Repeat a
second time. Replace feed and return hose as needed.

IT IS ADVISED THAT THE FOLLOWING COMPONENTS BE REBUILT AFTER 6­MONTHS OF USE IN AN 8-HOUR, 5-DAY A WEEK ENVIRONMENT.

Catalyst Pump

Minimum rebuild should include all O-rings, balls, piston seal and packing set.

Gelcoat Pump

Minimum rebuild should include, packing set, piston cups and cylinder O-rings,

Gun

Minimum rebuild should include all seals and O-rings.

:

Rev. 03/2013 Page | 29

UltraMax Multi-Color Gelcoater Manual

Component Manuals:

Fluid Section Manual:

XXX-1400-X-1 uses the MCPA-2500 Fluid Section – standard output:

• See Manual “VLS-2400 Fluid Section Manual”

Optional:

MCPA-4600 Fluid Section:

• See Manual “VLS-4600 Fluid Section Manual”

MCPA-HVLS Fluid Section:

• See Manual “HVLS-1000 Fluid Section Manual”

Catalyst Pump Manual:

XXX-1400-X-1 uses the VHPC-2000 Catalyst Pump:

• See Manual “VHPC-2000 Metering Pump”

Powerhead Manual:

XXX-1400-X-1 uses the VPH-4250 4.25” Powerhead – MCTA-4250 Standard:

• See Manual “MPH / VPH- 4250 Series Manual”

Optional: MCTA-5000 uses the VPH-5000 5” Powerhead:

• See Manual “MPH / UPPH / VPH- 5000 Series Manual”

Gun Manual:

MVG-1400-X-1 uses the CPG-1000-S (-INT) Classic Pro Gelcoat Gun:

• See Manual “Classic Pro Gun Manual – CPC / CPG/ CPP / CPW”

MVE-1400-X-1 uses the ATG-3500 (-INT) Gelcoat Gun:

• See Manual “ATG Gelcoat Gun Manual”

Rev. 03/2013 Page | 30

UltraMax Multi-Color Gelcoater Manual

Parts Drawings:

MVE-1400-X-1 Ultramax Multi-Color Unit Assembly – External Mix Gun
MVG-1400-X-1-INT Ultramax Multi-Color Unit Assy – Internal Mix Gun - International
MCPA-2500-1 Additional Pump Assembly Kit
MCPA-2500-1-MP Additional Pump Assembly Kit – MagnaPac Seals
MCTA-4250 4.25” Powerhead & Track Assembly
MCTA-4250-CK 4.25” Powerhead & Track Assembly Conversion Kit
MCTA-5000 5” Powerhead & Track Assembly
1101-03-01 Multi-Color Gelcoat Frame Assembly

Rev. 03/2013 Page | 31

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 32

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 33

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 34

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 35

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 36

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 37

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 38

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 39

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 40

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 41

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 42

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 43

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 44

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 45

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 46

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 47

UltraMax Multi-Color Gelcoater Manual

Rev. 03/2013 Page | 48

UltraMax Multi-Color Gelcoater Manual

Revision Information:

Revision: Description:

Rev. 02/2013 Updated the drawings and the “Terms and Conditions”

section. Updated the document format, logo, and
address and added the revision information section.

Rev. 03/2013 Updated the drawing MVG-1400-X-1-INT and added

additional manuals on the last page.

Rev. 03/2013 Page | 49

UltraMax Multi-Color Gelcoater Manual

MAGNUM VENUS PLASTECH

CORPORATE HEADQUARTERS and MANUFACTURING

11692 56th Court * Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER and MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel [phone] * Fax [phone]

MVP Plastech UK

Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: [phone]

Fax: [phone]

www.mvpind.com

Included with this operations manual are the following component manuals:



VLS-2400 FLUID SECTION MANUAL



MPH, VPH-4250 SERIES MANUAL



VHPC-2000 METERING PUMP MANAUL



CLASSIC PRO GUN MANUAL – CPC, CPG, CPP, CPW

OR



ATG GELCOAT GUN MANUAL

– ATG-3500 GELCOAT GUN

– MCPA-2500 FLUID SECTION

– 4.25” POWERSLIDE POWERHEAD

– VHPC-2000 METERING PUMP

- CPG-1000 PRO GUN

Rev. 03/2013 Page | 50