High-Pressure Mechanical Two-Component Mixing System

Transcription

1 High-Pressure Mechanical Two-Component Mixing System Customer Product Manual Part A For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) or contact your local Nordson representative. This document is subject to change without notice. Check for the latest version. NORDSON CORPORATION AMHERST, OHIO USA

2 Nordson Corporation welcomes requests for information, comments and inquiries about its products. Address all correspondence to Nordson Corporation 555 Jackson Street Amherst, OH Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks 100 Plus, Blue Box, ChromaFlex, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat, Excel 2000, Flow Sentry, Isocoil, Isocore, Iso-Flo, Nordson, the Nordson logo, PRX, Pro-Flo, RBX, Ready-Coat, Rhino, Select Coat, Select Cure, Shur-Lok, Smart Spray, System Sentry, Thread Coat, Tribomatic, and Versa-Spray are registered trademarks of Nordson Corporation. CPX, CanWorks, Excel 2000, PowderGrid, Pulse Spray, SCF, Versa-Coat, Versa Screen, Package of Values, and Swirl Coat are trademarks of Nordson Corporation. Loctite is a registered trademark of Henkel Loctite Corporation.

3 Table of Contents i Table of Contents 1. Safety... 1 Qualified Personnel... 1 Intended Use... 1 Regulations and Approvals... 1 Personal Safety... 2 High-Pressure Fluids... 3 Fire Safety... 4 Halogenated Hydrocarbon Solvent Hazards... 5 Action in the Event of a Malfunction... 5 Disposal Description Installation... 6 Pump Ratios... 8 Example... 8 High-Pressure Ratio Charts Operation Initial Startup Startup Ratio Check Full System Flush Releasing Pressure Flushing the System Quick Flush Resin Flush Shutdown Maintenance Troubleshooting... 18

4 ii Table of Contents 7. Hydraulic Section Repair Disconnecting the Hydraulic Section from the Unit Disassembling the Fluid Section Assembling the Hydraulic Section Air Motor Repair Signal Valve Service Main Valve Service Pilot Valve Service Parts Using the Illustrated Parts List Service Kits Main Valve Kit Gasket Kit Stroke Signal Valve Repair Kit :1 Pump Service Kit :1 Pump Service Kit :1 Pump Service Kit Five-Inch Piston Seal Kit Pilot Valve Repair Kit Five-Inch Rod Seal Kit Specifications... 37

5 High-Pressure Mechanical Two-Component Mixing System 1 High-Pressure Mechanical Two-Component Mixing System 1. Safety Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to persons operating or servicing equipment. Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks. Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. Some examples of unintended use of equipment include using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts using unapproved auxiliary equipment operating equipment in excess of maximum ratings Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed.

6 2 High-Pressure Mechanical Two-Component Mixing System Personal Safety To prevent injury follow these instructions. Do not operate or service equipment unless you are qualified. Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. Keep clear of moving equipment. Before adjusting or servicing moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment. While operating manual spray guns, make sure you are grounded. Wear electrically conductive gloves or a grounding strap connected to the gun handle or other true earth ground. Do not wear or carry metallic objects such as jewelry or tools. If you receive even a slight electrical shock, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. Obtain and read Material Safety Data Sheets (MSDS) for all materials used. Follow the manufacturer s instructions for safe handling and use of materials, and use recommended personal protection devices. Make sure the spray area is adequately ventilated. To prevent injury, be aware of less-obvious dangers in the workplace that often cannot be completely eliminated, such as hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot be enclosed or otherwise guarded for practical reasons.

7 High-Pressure Mechanical Two-Component Mixing System 3 High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremely hazardous. Always relieve fluid pressure before adjusting or servicing high pressure equipment. A jet of high-pressure fluid can cut like a knife and cause serious bodily injury, amputation, or death. Fluids penetrating the skin can also cause toxic poisoning. If you suffer a fluid injection injury, seek medical care immediately. If possible, provide a copy of the MSDS for the injected fluid to the health care provider. The National Spray Equipment Manufacturers Association has created a wallet card that you should carry when you are operating high-pressure spray equipment. These cards are supplied with your equipment. The following is the text of this card: WARNING: Any injury caused by high pressure liquid can be serious. If you are injured or even suspect an injury: Go to an emergency room immediately. Tell the doctor that you suspect an injection injury. Show him this card. Tell him what kind of material you were spraying. MEDICAL ALERT AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN Injection in the skin is a serious traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or a reconstructive hand surgeon may be advisable. The seriousness of the wound depends on where the injury is on the body, whether the substance hit something on its way in and deflected causing more damage, and many other variables including skin microflora residing in the paint or gun which are blasted into the wound. If the injected paint contains acrylic latex and titanium dioxide that damage the tissue s resistance to infection, bacterial growth will flourish. The treatment that doctors recommend for an injection injury to the hand includes immediate decompression of the closed vascular compartments of the hand to release the underlying tissue distended by the injected paint, judicious wound debridement, and immediate antibiotic treatment.

8 4 High-Pressure Mechanical Two-Component Mixing System Fire Safety To avoid a fire or explosion, follow these instructions. Ground all conductive equipment in the spray area. Use only grounded air and fluid hoses. Check equipment and workpiece grounding devices regularly. Resistance to ground must not exceed one megohm. Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Do not heat materials to temperatures above those recommended by the manufacturer. Make sure heat monitoring and limiting devices are working properly. Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material MSDS for guidance. Do not disconnect live electrical circuits while working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shutoff valves, and fire extinguishers are located. If a fire starts in a spray booth, immediately shut off the spray system and exhaust fans. Shut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice.

9 High-Pressure Mechanical Two-Component Mixing System 5 Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system that contains aluminum components. Under pressure, these solvents can react with aluminum and explode, causing injury, death, or property damage. Halogenated hydrocarbon solvents contain one or more of the following elements: Element Symbol Prefix Fluorine F Fluoro- Chlorine Cl Chloro- Bromine Br Bromo- Iodine I Iodo- Check your material MSDS or contact your material supplier for more information. If you must use halogenated hydrocarbon solvents, contact your Nordson representative for information about compatible Nordson components. Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the system. Disposal Dispose of equipment and materials used in operation and servicing according to local codes.

10 6 High-Pressure Mechanical Two-Component Mixing System 2. Description The high-pressure mechanical two-component mixing system is used for a wide variety of finishing and coating applications. The system precisely mixes and pumps two-component materials. Three ratio ranges are available: 1 : : 1 2 : : 1 3 : : 1 The High-Pressure Two-Component Mixing System is designed for airless, airless electrostatic, and air assist airless dispensing systems. Three separate catalyst pump systems are available, one for each ratio range. 3. Installation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. This section describes the installation of the high-pressure mechanical two-component mixing system. 1. See Figure 1. Connect the solvent supply line from the solvent feed to the solvent inlet (12). 2. Connect the fluid line from the catalyst supply to the catalyst pump inlet (9). 3. Connect the fluid line from the resin supply to the resin pump inlet (7). 4. Connect the main air to the air input (2) on the mixer manifold (3). 5. Connect the static mixer to the material outlet (4). 6. Fill the catalyst pump lube cup (11) and the resin pump lube cup (5) with solvent chamber fluid. NOTE: Use material transfer pumps or siphon feed to supply material to the high-pressure mechanical two-component mixing system. Gravity fed material is not reliable in this type of application.

11 High-Pressure Mechanical Two-Component Mixing System OPEN e A Fig. 1 High-Pressure Mechanical Two-Component Mixing System 1. Air regulator knob 6. Resin pump 2. Air input 7. Resin pump inlet 3. Mixer manifold 8. Air motor 4. Material outlet for static mixer 9. Catalyst pump inlet 5. Resin pump lube cup 10. Catalyst pump 11. Catalyst pump lube cup 12. Solvent inlet 13. Mixing block 14. Bleed type master air valve 15. Ratio test sampling tubes

12 8 High-Pressure Mechanical Two-Component Mixing System Pump Ratios Positioning the fluid sections to a different stroke length varies the volumetric displacement of the two materials. Example The initial ratio set-up is 1:1, when both fluid section settings are identical. The numbers 1 through 9 across the top and along the side of the chart refer to the positioning holes on the pump linkage. The intersection point on the chart, shows the ratio by volume. Each fluid section combination has a similar chart detailing the ratio range. To set the catalyst pump to the desired ratio, refer to Tables 1, 2 and See Figure 2. Remove the pin from the slave arm (2) on the catalyst pump (5), and move it to the desired pin setting (1). 2. Remove pins from the fixed arm (4), and move it to the desired pin setting. NOTE: The slave arm (2) and the fixed arm (4) must have the same pin setting. 3. Repeat steps 1 and 2 for the resin pump (3). 4. Connect the spray device to the static mixer.

13 High-Pressure Mechanical Two-Component Mixing System A Fig. 2 Pump Ratios 1. Pin setting 2. Slave arm 3. Resin pump 4. Fixed arm 5. Catalyst pump

14 10 High-Pressure Mechanical Two-Component Mixing System High-Pressure Ratio Charts The following tables list the ratio ranges between the resin pumps, and the catalyst pumps. Table 1 1:1 Initial Set-Up. Ratio Range 1:1 to 2.8:1 Stroke mm mm mm mm mm mm mm mm mm Resin Pin Setting Catalyst Pin Setting Stroke 1:1 1.13:1 1.24:1 1.47:1 1.55:1 1.7:1 1.9:1 2.2:1 2.8: mm 1.13:1 1:1 1.1:1 1.3:1 1.37:1 1.5:1 1.7:1 1.96:1 2.49: mm 1.24:1 1.1:1 1:1 1.19:1 1.25:1 1.39:1 1.56:1 1.78:1 2.27: mm 1.47:1 1.3:1 1.19:1 1:1 1.05:1 1.17:1 1.3:1 1.49:1 1.9: mm 1.55:1 1.37:1 1.25:1 1.05:1 1:1 1.11:1 1.25:1 1.43:1 1.8: mm 1.7:1 1.5:1 1.39:1 1.17:1 1.11:1 1:1 1.12:1 1.28:1 1.6: mm 1.9:1 1.7:1 1.56:1 1.3:1 1.25:1 1.12:1 1:1 1.14:1 1.45: mm 2.2:1 1.96:1 1.78:1 1.49:1 1.43:1 1.28:1 1.14:1 1:1 1.27: mm 2.8:1 2.49:1 2.27:1 1.9:1 1.8:1 1.6:1 1.45:1 1.27:1 1: mm Stroke 78.7 mm 69.9 mm Table 2 2:1 Initial Set-Up. Ratio Range 2:1 to 5.6: mm mm mm mm mm mm mm Resin Pin Setting Catalyst Pin Setting Stroke 2:1 2.26:1 2.48:1 2.94:1 3.1:1 3.4:1 3.8:1 4.4:1 5.6: mm 2.26:1 2:1 2.2:1 2.6:1 2.74:1 3:1 3.4:1 3.92:1 4.98: mm 2.48:1 2.2:1 2:1 2.38:1 2.5:1 2.78:1 3.12:1 3.56:1 4.54: mm 2.94:1 2.6:1 2.38:1 2:1 2.1:1 2.34:1 2.6:1 2.98:1 3.8: mm 3.1:1 2.74:1 2.5:1 2.1:1 2:1 2.22:1 2.5:1 2.86:1 3.6: mm 3.4:1 3.0:1 2.78:1 2.34:1 2.22:1 2:1 2.24:1 2.56:1 3.2: mm 3.8:1 3.4:1 3.12:1 2.6:1 2.5:1 2.24:1 2:1 2.28:1 2.9: mm 4.4:1 3.92:1 3.56:1 2.98:1 2.86:1 2.56:1 2.28:1 2:1 2.54: mm 5.6:1 4.98:1 4.54:1 3.8:1 3.6:1 3.2:1 2.9:1 2.54:1 2: mm

15 High-Pressure Mechanical Two-Component Mixing System 11 Table 3 3:1 Initial Set-Up. Ratio Range 3:1 to 8.4:1 Stroke mm mm mm mm mm mm mm mm mm Resin Pin Setting Catalyst Pin Setting Stroke 3:1 3.39:1 3.72:1 4.41:1 4.65:1 5.1:1 5.7:1 6.6:1 8.4: mm 3.39:1 3:1 3.3:1 3.9:1 4.11:1 4.5:1 5.1:1 5.88:1 7.47: mm 3.72:1 3.3:1 3:1 3.57:1 3.75:1 4.17:1 4.68:1 5.34:1 6.81: mm 4.41:1 3.9:1 3.57:1 3:1 3.15:1 3.51:1 3.9:1 4.47:1 5.7: mm 4.65:1 4.11:1 3.75:1 3.15:1 3:1 3.33:1 3.75:1 4.29:1 5.4: mm 5.1:1 4.5:1 4.17:1 3.51:1 3.33:1 3:1 3.36:1 3.84:1 4.8: mm 5.7:1 5.1:1 4.68:1 3.9:1 3.75:1 3.36:1 3:1 3.42:1 4.35: mm 6.6:1 5.88:1 5.34:1 4.47:1 4.29:1 3.84:1 3.42:1 3:1 3.81: mm 8.4:1 7.47:1 6.81:1 5.7:1 5.4:1 4.8:1 4.35:1 3.81:1 3:1 9 28mm

16 12 High-Pressure Mechanical Two-Component Mixing System 4. Operation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. This section includes operation procedures for the high-pressure mechanical two-component mixing system. Initial Startup Flush unit with solvent compatible with the material to be mixed. NOTE: The main air pressure should not be set above 6.89 bar (100 psi). Startup See Figure 3. Fluid flow is controlled by the manifold handle (7). Refer to Table 4 for a description of the manifold handle positions. Position Up Down Middle Table 4 Manifold handle positions Result ON-resin and catalyst material is supplied to the spray device. ON-resin and catalyst material is dispensed through the ratio test sampling tubes. OFF-material flow is stopped. 1. Place a container under the ratio test sampling tubes (8), and turn the manifold handle (7) to the down position. 2. Slowly increase the air pressure until the system begins to stroke and smooth flow of resin and catalyst is present. 3. Return the mix manifold handle to the middle position. 4. Perform a ratio check.

17 High-Pressure Mechanical Two-Component Mixing System 13 Ratio Check See Figure 3. The system must be in operating condition. Both resin and catalyst pumps should be purged through the mixer manifold. Perform the following steps during production. 1. Perform a Quick Flush. Refer to Quick Flush. 2. Place a container under the ratio test sampling tubes (8), and turn the manifold handle down. NOTE: There will be residual pressure left in the system. 3. Place a graduated beaker under each ratio test sampling tube and slowly increase the pressure until the pump gradually begins to stroke. 4. Fill the graduated beaker to the desired levels. 5. Slowly decrease the pressure back to 0 bar (0 psi). 6. Check the fluid levels in the graduated beakers and make catalyst pump adjustments if necessary. 7. Turn the manifold handle (7) back to the up position, and increase the system air back to operating pressure. 8. Trigger the spray device into the container until the mixed material is present. The system is now ready for painting. Full System Flush Flush new or rebuilt pumps before putting them into service. Flushing removes dirt, grease, and machining chips that may be left inside the pump after assembly and installation. A full system flush is required for color changes, for system maintenance procedures or for daily shutdown. NOTE: When changing coating materials or colors, flush the pump to remove all traces of the old material before introducing a new material into the system. WARNING: System or material pressurized. Relieve pressure. Failure to observe may result in serious injuries.

18 14 High-Pressure Mechanical Two-Component Mixing System Releasing Pressure 1. See Figure 3. Turn the main air supply off. 2. Trigger the spray device. 3. Place a container under the ratio test sampling tubes (8). 4. Turn manifold handle (7) to down position. 5. Close the ratio test sampling tubes by turning the manifold handle to the middle position. Flushing the System NOTE: For cleaning solvent types, refer to the material manufacturer s recommendation. 1. See Figure 1. Introduce solvent through the catalyst and resin pump inlets (9, 7). 2. Close the bleed-type master air valve (14). 3. Turn the air regulator knob (1) to 0 bar (0 psi). 4. Open the bleed-type master air valve. 5. See Figure 3. Turn the manifold handle to the up position. 6. Trigger the spray device and slowly open the regulator until the system begins pumping. 7. Allow the pump to cycle slowly until all the paint is flushed out of the lines, and release the trigger. NOTE: The pump will stall against the pressure. 8. See Figure 1. Turn the air regulator knob (1) to 0 bar (0 psi). 9. Trigger the spray device to relieve line pressure.

19 High-Pressure Mechanical Two-Component Mixing System See Figure 3. Turn the manifold handle (7) to the down position. 11. Slowly open the air regulator until the system starts pumping solvent through the ratio test sampling tubes (8). 12. Use a container to catch the solvent as it flows out through the ratio test sampling tubes. 13. Turn the air regulator knob to 0 bar (0 psi), and turn the manifold handle to the middle position. The system is now flushed. NOTE: It is recommended to leave some solvent in the system after flushing e A Fig. 3 Mixer Manifold 1. Resin fluid line 2. Mixing block 3. Catalyst solvent needle valve 4. Resin solvent needle valve 5. Solvent inlet 6. Catalyst fluid line 7. Manifold handle 8. Ratio test sampling tubes

20 16 High-Pressure Mechanical Two-Component Mixing System Quick Flush Perform quick flush to shut the system down for a short period of time, or after every shift to avoid catalyst material from blocking the spray device. Flush the system often enough to prevent fluid from reacting or curing in the mixer, hoses and spray devices. Contact your material manufacturer for the effective pot life of the material you are using. To do a quick flush, follow these steps: 1. See Figure 3. Make sure that the manifold handle (7) is in the middle position. 2. Slowly open the solvent needle valve (3) on the catalyst side of the manifold. Apply proper solvent pressure to push mixed material out. 3. Trigger the spray device until clear solvent is present. 4. Close the solvent needle valve on the catalyst side of the manifold. 5. Slowly open the solvent needle valve (4) on the resin side of the manifold. Apply proper solvent pressure to push mixed material out. 6. Trigger the spray device until resin is flushed out of the mixing block (2). 7. Close the resin solvent needle valve. 8. Trigger the spray device to relieve pressure. NOTE: Make sure solvent needle valves are closed completely to avoid unwanted solvent from flowing into catalyzed material. Resin Flush To perform a resin flush, complete the following steps: 1. Turn off air pressure to the system. 2. Bleed off pressure in all paint lines. 3. See Figure 2. Remove upper and lower pin to disconnect catalyst pump. 4. See Figure 3. Slowly open the catalyst side solvent needle valve (3). Apply proper solvent pressure to push out the mixed material. 5. Flush the resin pump by introducing solvent. Run resin pump until clean solvent appears at the spray device tip. The catalyst pump is disabled during this process.

21 High-Pressure Mechanical Two-Component Mixing System Repeat step 5 with new resin. 7. When new resin is purged, turn off the air pressure, reconnect the slave arm pins and begin spraying. 8. Trigger the device until the catalyzed paint is present at the spray device tip. Shutdown To shut down the unit, perform the following steps: 1. See Figure 3. Move the manifold handle (7) into the middle position. 2. Perform a full system flush. Refer to Full System Flush in this section. 3. Maintain pressure on the resin and catalyst pumps. 4. Stop the resin pump with the shaft in the up position. Turn the air off to avoid injury. 5. See Figure 1. Empty the resin pump lube cup (5). Clean and refill the cup with solvent chamber fluid. 6. Cycle the pumps so that they can be left in the down position during the shutdown period. CAUTION: If the pump is stopped in the up position, any residue on the shaft can air dry and harden. The abrasive buildup can attack the upper seal. 5. Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Perform the following maintenance steps on a regular basis to prevent early wear out and damage to seals. 1. Change the solvent chamber fluid regularly to keep it free from contaminants. 2. Grease the slave arm mechanism regularly.

22 18 High-Pressure Mechanical Two-Component Mixing System 6. Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. This section contains troubleshooting procedures. These procedures cover only the most common problems that you encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help. Problem Possible Cause Corrective Action 1. Loss of fluid flow Material source is empty Refill tank. 2. Coating material comes out of oven, not fully cured. 3. Coating material does not pass manufacturer s quality tests for hardness, gloss, adhesive qualities etc. Line is leaking Manifold handle is in middle position Catalyzed material in line Loss of air pressure Not enough catalyst Too much catalyst Check all lines, replace if damaged. Put manifold handle in proper position. Check lines and static mixer. Replace line if fully catalyzed or do a quick flush. Check main compressor. Make sure all air filters on main air compressor are clean. Make sure air signal valves on air motor are clear of debris. Remove air motor cap on piston. Inspect piston for damage or worn seals. Make sure the slave arm is in proper position to operate catalyst pump. Check the ratio chart to make sure the pump is in the right position for the desired ratio. Check ratio. Refill catalyst source tank if empty. Check the throat seal on the catalyst pump. If lube continuously overflows with material, replace seal. Check the ratio chart and make sure the catalyst pump is in the proper position. Check ratio. Check the throat seal on the resin pump. If lube material continuously overflows, replace seal.

23 High-Pressure Mechanical Two-Component Mixing System Hydraulic Section Repair WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. This section covers the procedures necessary to clean and service the hydraulic sections and the air motor. Two pumps are used in the high-pressure mechanical two-component mixing system, the resin pump and the catalyst pump. Before servicing the two pumps, perform the following procedures: 1. Relieve fluid pressure. 2. Turn the main air supply off. 3. Pull the trigger on the spray device and bleed the pressure from all lines.

24 20 High-Pressure Mechanical Two-Component Mixing System Disconnecting the Hydraulic Section from the Unit 1. Detach all feed assemblies. 2. See Figure 4. Remove the pins (1) to remove the hydraulic section. 3. Remove the inlet feed pump fitting (3) 4. Remove the outlet fitting (2) Fig. 4 Catalyst and Resin Pump 1. Pin 2. Outlet fitting 3. Inlet feed pump fitting 1 4. Lower ball check housing 5. Bolts A

25 High-Pressure Mechanical Two-Component Mixing System 21 Disassembling the Fluid Section Three pumps with different ratios are available for the high-pressure mechanical two-component mixing system: 1:1 Pump fluid section 2:1 Pump fluid section 3:1 Pump fluid section The following procedures describe the disassembly for the 1:1 pump fluid section. 1. See Figures 5, 6, and 7. Remove the tie rods (17), securing the ball check housing (18). 2. Tap the ball check housing assembly off the hydraulic section assembly. 3. Remove the roll pin (19) from the ball check housing. 4. Soak the ball (20) and ball check housing in solvent. Replace the O-ring (21). 5. Pull off the lube cup (3), and remove the lube cup O-ring (26). 6. Remove the four cap screws (5), the lockwashers that secure the lube cap adapter (7), and remove the upper part of the pump assembly. 7. Remove the ball (14) and seal (8) from the transfer seat housing (13). 8. Remove the airless pump head (10) from the pump cylinder (12). 9. Clean and hone the pump cylinder. Use a 2-in. honing tool and a hand or bench drill: a. Put a small amount of oil in the cylinder and push the hone tool completely into the cylinder before turning on the drill. b. Move the hone tool rapidly in and out of the cylinder (10 15 smooth, continuous strokes), making sure only the first row of beads of the hone are exposed during the procedure. c. Turn the cylinder and repeat the procedure on the other end. d. After completion, inspect the cylinder. You should see a cross diamond hatch pattern.

26 22 High-Pressure Mechanical Two-Component Mixing System Assembling the Hydraulic Section Apply lithium grease on all O-rings and external threads. Use blue removable Loctite on the internal and external threads of the lower valve cup housing. 1. See Figure 5. Replace all O-rings and seals, and clean and inspect all parts. 2. Install the foot valve seat (22), the O-ring (21), the ball (20), and the ball check housing (18) with the roll pin into the pump base (23). 3. Slide the shaft (11) through the airless pump head (10), and screw the transfer seat housing (13) into the pump cylinder (12). 4. Push the seal (8) onto the bottom of the transfer seat housing. 5. Place the ball (14), the piston guide (15), and the transfer seat seal (16) into the transfer seat housing. 6. Place the O-rings (4) over the upper and lower end of the pump cylinder (12). 7. Install the pump cylinder on the airless pump head. Make sure the correct end points toward the pump head. 8. Install the lube cup adapter (7) on the pump head, using the four cap screws (5). 9. Install the ball check housing (18) on the pump base (23), and reconnect it to the lower end of the pump cylinder. 10. Install the lube cup O-ring (26), and push the lube cup (3) on to the lube cup adapter. 11. Install the nipple (2) on the shaft (11), and install the pump shaft adapter (1). 12. Install the tie rods (17), and secure them with the lock washer (23) and nut (24). 13. See Figure 4. Mount the pump, using the two pins (1) to connect the pump to the unit, and reconnect the inlet and outlet hoses.

27 High-Pressure Mechanical Two-Component Mixing System Fig. 5 1:1 Pump Fluid Section 1. Pump shaft adapter 2. Nipple 3. Lube cup 4. O-ring 5. Cap screw 6. Lock washer 7. Lube cup adapter 8. Seal 9. Washer 10. Airless pump head 11. Shaft 12. Pump cylinder 13. Transfer seat housing 14. Ball 15. Piston guide 16. Transfer seat seal 17. Tie rod 18. Ball check housing Roll pin 20. Ball 21. O-ring 22. Foot valve seat 23. Pump base 24. Lock washer 25. Nut 26. Lube cup O-ring A

28 24 High-Pressure Mechanical Two-Component Mixing System A Fig. 6 2:1 Pump Fluid Section 1. Pump shaft adapter 2. Nipple 3. Lube cup 4. O-ring 5. Cap screw 6. Lock washer 7. Lube cup adapter 8. Upper seal 9. Washer 10. Airless pump head 11. Shaft 12. Pump cylinder 13. Transfer seat housing 14. Ball 15. Piston guide 16. Transfer seat seal 17. Tie rod 18. Ball check housing 19. Roll pin 20. Ball 21. O-ring 22. Foot valve seat 23. Pump base 24. Lock washer 25. Nut 26. Lube cup O-ring 27. Lower seal

29 High-Pressure Mechanical Two-Component Mixing System Fig. 7 3:1 Pump Fluid Section 1. Pump shaft adapter 2. Nipple 3. Lube cup 4. O-ring 5. Cap screw 6. Lock washer 7. Lube cup adapter 8. Upper seal 9. Washer 10. Airless pump head 11. Shaft 12. Pump cylinder 13. Transfer seat housing 14. Ball 15. Piston guide 16. Transfer seat seal 17. Tie rod 18. Ball check housing 19. Roll pin 20. Ball 21. O-ring 22. Foot valve seat 23. Pump base 24. Lock washer 25. Nut 26. Lube cup O-ring A

30 26 High-Pressure Mechanical Two-Component Mixing System 8. Air Motor Repair Water, oil, and compressed air are the primary causes for motor maintenance. If the air motor is not cycling properly, inspect and clean the signal and the pilot valve. Before disassembling these valves, perform the following steps: 1. See Figure 8. Depress the override button (2) at the top of the pilot valve (1). This will manually move the spool and redirect the air so that the air motor will shift and change direction. This possibly moves any contamination and the pump will cycle normally. 2. Increase the air pressure to the pump and force out the contamination. If the air motor is still not cycling normally after attempting both of these steps, the signal valve (3), and the pilot valve (1) should be serviced A Fig. 8 Air Motor 1. Pilot valve 2. Override button 3. Signal valve

31 High-Pressure Mechanical Two-Component Mixing System 27 Signal Valve Service See Figure 9. The signal valves (6) may need occasional service. Signal valves must be removed for servicing. 1. Disconnect the air tubes (4). 2. Remove the set screw (7) from either the top or bottom of the signal valve housing (5). Pull the signal valve (6) out of the housing. 3. Remove the check valve from the signal valve (6): a. Remove the O-rings (11, 12) from the check valve housing (10). b. Remove the ball (13) and diaphragm (8) from the stem (9). c. Thoroughly clean the check valve assembly parts. NOTE: Do not use an aggressive solvent or cleaning solution. 4. Make sure all air ports in the signal valve (6) and the air motor housing are free of any material buildup. 5. Remove any contamination with a probe. 6. Rinse the air tubing (4) before re-attaching. 7. Inspect the ball, diaphragm, and O-rings. Replace if worn or damaged. NOTE: Do not use lubricants on the check valve parts. 8. Assemble the check valve. a. Push the diaphragm on to the stem. b. Push the stem into the check valve housing. c. Attach the ball (13) to the stem (9). d. Install the O-rings on the check valve housing (10). e. Install the check valve into the signal valve housing (5). 9. Replace the set screw (7) on the top and bottom of the signal valve housing.

32 28 High-Pressure Mechanical Two-Component Mixing System Main Valve Service The main valve does not need to be serviced, unless serious problems are found with the signal and pilot valves. 1. See Figure 9. Remove the four screws (24), and the gasket (21) between the main valve (14) and the pump housing. 2. Remove the screws (15) and the main valve cap (16). 3. Remove the O-rings (19, 20) and the seal (22) from the main valve. 4. Remove the cylinder from the main valve housing (23). Be sure to replace the O-rings that are positioned with the cylinder. 5. Remove the spool assembly (18) from the cylinder. 6. Wipe off the spool assembly (18), gasket (21), seal (22) and the inside of the main valve housing (23). 7. Apply a light coat of lithium grease to the spool assembly and reassemble the valve.

33 High-Pressure Mechanical Two-Component Mixing System A Fig. 9 Air Motor Assembly 1. Screw 2. Pilot valve 3. Gasket 4. Air tubes 5. Signal valve housing 6. Signal valve 7. Set screw 8. Diaphragm 9. Stem 10. Check valve housing 11. O-ring 12. O-ring 13. Ball 14. Main valve 15. Screw 16. Main valve cap 17. Gasket 18. Spool assembly 19. O-ring 20. O-rings 21. Gasket 22. Seal 23. Main valve housing 24. Screw 25. O-ring 26. O-ring 27. O-rings

34 30 High-Pressure Mechanical Two-Component Mixing System Pilot Valve Service 1. See Figure 9. Remove the screws (1), securing the pilot valve (2) to the main valve (14). 2. Remove the gasket (3) between the two valves. 3. See Figure 10. Remove the gaskets (3) from the spool caps (1). Take note of the position of these gaskets when removing. The point of the gasket should be pointing to where the hose is attached to the valve. 4. Remove the O-rings (2). 5. Remove the spool assembly (4). 6. Wipe off the gasket (3) with a clean towel. CAUTION: Do not use an aggressive solvent or cleaning fluid. Failure to observe may result in equipment damage. 7. Clean the inside of the housing (5). 8. Inspect the parts for wear and damage. 9. Reassemble the pilot valve. Use very little lubrication on the spool. Use a small amount of lithium grease over each PTFE O-ring (2).

35 High-Pressure Mechanical Two-Component Mixing System A Fig. 10 Pilot Valve 1. Spool cap 2. O-ring 3. Gasket 4. Spool assembly 5. Housing

36 32 High-Pressure Mechanical Two-Component Mixing System 9. Parts To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use this five-column parts list, and the accompanying illustration, to describe and locate parts correctly. Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code NS (not shown) indicates that a listed part is not illustrated. A dash ( ) is used when the part number applies to all parts in the illustration. The six-digit number in the Part column is the Nordson Corporation part number. A series of dashes in this column ( ) means the part cannot be ordered separately. The Description column gives the part name, as well as its dimensions and other characteristics when appropriate. Indentions show the relationships between assemblies, subassemblies, and parts. Item Part Description Quantity Note Assembly Subassembly 2 A Part 1 If you order the assembly, items 1 and 2 will be included. If you order item 1, item 2 will be included. If you order item 2, you will receive item 2 only. The number in the Quantity column is the quantity required per unit, assembly, or subassembly. The code AR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity per assembly depends on the product version or model. Letters in the Note column refer to notes at the end of each parts list. Notes contain important information about usage and ordering. Special attention should be given to notes.

37 High-Pressure Mechanical Two-Component Mixing System Service Kits Individual components for the high-pressure mechanical two-component mixing system are grouped in service kits. Part Description Quantity System, two comp, high pressure, 1:1 catalyst System, two comp, high pressure, 2:1 catalyst System, two comp, high pressure, 3:1 catalyst Pump, 3:1, fluid section Pump, 2:1, fluid section Pump, 1:1, fluid section Service kit, 1:1 pump Service kit, 2:1 pump Service kit, 3:1 pump Service kit, 5-in. piston seal Service kit, 5-in. rod seal Service kit, stroke, signal valve Kit, gasket Service kit, main valve Service kit, pilot valve Solvent needle valve Kit, rebuild manifold Valve 3-way Manifold, high pressure, assembly Static mixer Check valve 1

38 34 High-Pressure Mechanical Two-Component Mixing System Main Valve Kit See Figure 9. Item Part Description Quantity Note Service kit, main valve Spool assembly Seal O-ring O-ring 2 Gasket Kit See Figure 7. Item Part Description Quantity Note Kit, gasket Gasket Gasket Gasket O-ring 2 Stroke Signal Valve Repair Kit See Figure 9. Item Part Description Quantity Note Service kit, stroke signal valve Diaphragm Stem O-ring O-ring Ball O-ring O-ring 2

39 High-Pressure Mechanical Two-Component Mixing System 35 1:1 Pump Service Kit See Figure 5. Item Part Description Quantity Note Service kit, 1:1 pump O-ring Seal O-ring Piston, guide 1 2:1 Pump Service Kit See Figure 6. Item Part Description Quantity Note Service kit, 2:1 pump O-ring Seal, upper Piston, guide O-ring Seal, lower 1 3:1 Pump Service Kit See Figure 7. Item Part Description Quantity Note Service kit, 3:1 pump O-ring Seal O-ring Piston, guide 1

40 36 High-Pressure Mechanical Two-Component Mixing System Five-Inch Piston Seal Kit See Figure 9. Item Part Description Quantity Note Service kit, 5-in. piston seal Seal Wear strip O-ring 2 Pilot Valve Repair Kit See Figure 10. Item Part Description Quantity Note Service kit, pilot valve O-ring Gasket Spool assembly 1 Five-Inch Rod Seal Kit See Figure 9. Item Part Description Quantity Note Service kit, 5-in. rod seal Piston rod wiper Rod seal O-ring 1

41 High-Pressure Mechanical Two-Component Mixing System Specifications Choose the proper fluid to air pressure ratio to achieve the required fluid pressure at the lowest pump cycling rate within a realistic air pressure range of bar (15 80 psi). Midrange ratios (16:1) are desirable where fluid pressures of bar ( psi) are required. Table 5 Fluid-to-Air Pressure Ratio Fluid-to-Air Pressure Ratio Low Pressure High Pressure Conversion Coating 4:1 16:1 4:1 13:1 Delivery in l/min (gal/min) for resin pump only. Ratio required will be determined to calculate maximum unit delivery. 15 cycles (1 cycle = 2 strokes) 30 cycles (1 cycle = 2 strokes) 60 cycles (1 cycle = 2 strokes) 0.72 (2.725) 1.44 (5.450) 2.88 (10.901) (1.192) (2.385) (4.769) 0.72 (2.725) 1.44 (5.450) 2.88 (10.901) (1.192) (2.385) (4.769) Fluid outlet connection 1 / 4 in. NPS (f) 1 / 2-20 JIC (f) 1 / 4 in. NPS (f) 1 / 2-20 JIC (f) Cycles per liters (gallon) for resin 5.52 (20.8) 12.7 (47.6) 5.52 (20.8) 12.7 (47.6) pump only. Ratio required will be determined to calculate maximum unit delivery. Liters (gallons) per cycle for resin pump only. Ratio required will be determined to calculate maximum (0.048) (0.021) (0.048) (0.021) unit delivery. Fluid pressure range. Capability is based on a normal operating air pressure range of 1.05 to 5.6 kg/cm 2 (15 to 80 psi) (60 320) ( ) (60 320) ( ) Minimum ID air line size 9.5 ( 3 / 8 ) 9.5 ( 3 / 8 ) 9.5 ( 3 / 8 ) 9.5 ( 3 / 8 ) recommended in mm (in.) Air motor: Diameter in mm (in.) 82.6 (3 1 / 4 ) (5 1 / 4 ) 82.6 (3 1 / 4 ) 82.6 (3 1 / 4 ) Overall dimensions L x D x H in mm (in.) 615 x 615 x 1179 (24 x 24 x46) 821 x 385 x 1179 (32 x 15 x 46) 615 x 615 x 1179 (24 x 24 x 46) 615 x 615 x 1179 (24 x 24 x 46) Normal operating air pressure (15 80) in kg/cm 2 (psi) Maximum air pressure 7.0 (100) recommended in kg/cm 2 (psi) High-pressure hoses ID in mm (in.) 6.4 or 9.5 ( 1 / 4 or 3 / 8 ) Air inlet connection in mm (in.) 9.5 ( 3 / 8 ) NPT (f) Ratio range 2:1 55:1 1:1 8.4:1 0.5% 4.5% 1% 10%

42 38 High-Pressure Mechanical Two-Component Mixing System