Nordson OptiMix Customer Product Manual

Low-pressure system

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Low-Pressure

OptiMix

System

Customer Product Manual

Part 303783B

For parts and technical support, call the Industrial Coating

Systems Customer Support Center at (800) 433-9319 or

contact your local Nordson representative.

This document is subject to change without notice.

Check http://emanuals.nordson.com for the latest version.

NORDSON CORPORATION

AMHERST, OHIO

USA

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Page 1 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. This document is subject to change without notice. Check http://emanuals.nordson.com for the latest version. NORDSON CORPORATION AMHERST, OHIO...
Page 2 Amherst, OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1998. 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.
Page 5: Safety
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.
Page 6: Personal Safety
Low-Pressure OptiMix 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.
Page 7: High-Pressure Fluids
Low-Pressure OptiMix System 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.
Page 8: Fire Safety
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. Manual 14-25 303 783B...
Page 9: Halogenated Hydrocarbon Solvent Hazards
“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 If a system or any equipment in a system malfunctions, shut off the...
Page 10: Description
Low-Pressure OptiMix System See Figure 1. The low-pressure OptiMix system is designed for use in air 2. Description spray, air electrostatic, and HVLP applications, both manual and automatic. The high-volume displacement of the base and catalyst pumps keep duty cycles low even at high volume output requirements.
Page 11: Specifications
Low-Pressure OptiMix System Specifications Refer to Table 1 for a list of the specifications necessary to operate the low-pressure OptiMix system. Table 1 Low-Pressure OptiMix System Specifications Fluid-to-Air Pressure Ratio Low Pressure High Pressure Conversion Coating 16:1 13:1 Delivery: Liters per min...
Page 12: Installation
Low-Pressure OptiMix System WARNING: Allow only qualified personnel to perform the 3. Installation following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. See Figure 2. Connect the solvent supply line from the solvent feed to the solvent inlet (3) on the mixing block (4).
Page 13 Low-Pressure OptiMix System 1425002A Fig. 2 System Components 1. Bleed-type master air valve 7. Catalyst pump 12. Air input 2. Mixer manifold 8. Catalyst pump lube cup 13. Resin pump lube cup 3. Solvent inlet 9. Resin pump 14. Slave arm mechanism 4.
Page 14 Low-Pressure OptiMix System 3. Installation (contd.) Table 2 Low-Pressure Ratio Chart Position cc/Cycle 1:1 OptiMix System 2:1 OptiMix System 3:1 OptiMix System Hole Base Pump cc/Cycle Ratio cc/Cycle Ratio cc/Cycle Ratio 9.93 18.3:1 35:1 3.31 54.94:1 14.90 12.2:1 23.33:1 4.968 36.6:1...
Page 16: Operation
Low-Pressure OptiMix System WARNING: Allow only qualified personnel to perform the 4. Operation following tasks. Observe and follow the safety instructions in this document and all other related documentation. Startup When the system has been flushed and the proper ratio has been set, the system is ready to supply the fluid to the spray devices.
Page 17: Full System Flush
Low-Pressure OptiMix 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 and then slowly decrease the pressure back to zero.
Page 18: Flushing System
Refer to the material manufacturer’s recommendation for cleaning solvent. NOTE: It is recommended to leave solvent in the OptiMix after flushing. 1. See Figure 2. Close the bleed-type master air valve (1), and turn the air-regulator knob (11) to zero bar/psi.
Page 19: Quick Flush
Low-Pressure OptiMix System 3. See Figure 4. Turn the manifold handle (7) to the up position. Trigger the spray device and slowly open the regulator until the system begins pumping. 4. Allow the pump to cycle slowly until all the paint is flushed out of the lines.
Page 20: Resin Flush
Low-Pressure OptiMix System Resin Flush To do a resin flush, complete the following steps: 1. Turn off the main air pressure. 2. Bleed off pressure in all paint lines. 3. See Figure 3. Push slave arm pin (2) in to disconnect catalyst pump.
Page 21: Maintenance
This section contains troubleshooting procedures. These procedures cover only the most common problems that you may 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.
Page 22: Hydraulic Section Repair
7. Hydraulic Section Repair following tasks. Observe and follow the safety instructions in this document and all other related documentation. There are two pumps used in the low-pressure OptiMix system; the resin pump and the catalyst pump. Low-Pressure Resin Pump Perform the following steps before servicing the resin pump.
Page 23: Disconnecting The Hydraulic Section From The Air Motor
Low-Pressure OptiMix System Disconnecting the Hydraulic 1. See Figure 5. Remove the machine screws (3) from the lower standoff bolts (8). Remove the lower standoff bolts. Section from the Air Motor 2. Using two in. wrenches positioned on the hydraulic section shaft flats (9), break the connection and unscrew the hydraulic section (2) from the air motor (1).
Page 24: Disassembling The Hydraulic Section
Low-Pressure OptiMix System Disassembling the Hydraulic Section 1. See Figure 6. Put the flats on the top of the pump shaft (1) in a vise and take off the seal (22) and the lower cup spacer (21). 2. Unscrew the nut (15) from the upper check ball housing (20).
Page 25 Low-Pressure OptiMix System 1425008A Fig. 6 Resin Pump Fluid Section 1. Pump shaft 11. Cap screw 21. Lower cup spacer 2. Nipple 12. O-ring 22. Seal 3. Lube cup 13. Lower cylinder 23. Lower cup retaining nut 4. O-ring 14. Lower cylinder retaining ring 24.
Page 26: Rebuilding The Foot Valve Housing
Low-Pressure OptiMix System Rebuilding the Foot Valve Housing NOTE: Use 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. Replace all O-rings and seals.
Page 27: Connecting The Hydraulic Section To The Air Motor
Low-Pressure OptiMix System 7. Put a light coat of lithium grease on the piston seal (5) and push it into the lower cylinder (13). 8. Position the upper pump housing (8) over the pump shaft (1) and place it into the lower cylinder (13). Take care not to damage the O-ring (12), push the lower cylinder (13) into the upper pump housing (8).
Page 28: Low-Pressure Catalyst Pump
Low-Pressure OptiMix System Low-Pressure Catalyst Pump 1. Relieve fluid pressure by pulling the trigger on the spray device. 2. Turn off the main air supply. 3. See Figure 2. Disconnect slave arm (17) from catalyst pump (9). 1425006A Fig. 7 Catalyst Pump 1.
Page 29: Disassembling The Hydraulic Section
Low-Pressure OptiMix System Disassembling the Hydraulic Section See Figures 8, 9, and 10 at the end of this section. 1. Remove the 4 tie rods (18) holding the lower ball check housing (19). 2. Tap the ball check housing assembly off the hydraulic section assembly.
Page 30: Assembling The Hydraulic Section
Low-Pressure OptiMix System Assembling the Hydraulic Section 1. Use all new software parts, O-rings, and seals. NOTE: Use 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.
Page 31: 1:1 Fluid Section Pump
Low-Pressure OptiMix System 1:1 Fluid Section Pump 1425009B Fig. 8 1:1 Fluid Section Pump 1. Pump shaft adapter 10. Washer 19. Ball check housing 2. Nipple 11. Airless pump head 20. Roll pin 3. Lube cup 12. Shaft 21. Ball 4.
Page 32: 2:1 Fluid Section Pump
Low-Pressure OptiMix System 2:1 Fluid Section Pump 1425011B Fig. 9 2:1 Fluid Section Pump 1. Pump shaft adapter 10. Washer 19. Ball check housing 2. Nipple 11. Airless pump head 20. Roll pin 3. Lube cup 12. Shaft 21. Ball 4.
Page 33: 3:1 Fluid Section Pump
Low-Pressure OptiMix System 3:1 Fluid Section Pump 1425010B Fig. 10 3:1 Fluid Section Pump 1. Pump shaft adapter 10. Washer 19. Ball check housing 2. Nipple 11. Airless pump head 20. Roll pin 3. Lube cup 12. Shaft 21. Ball 4.
Page 34: Repairing The Air Motor
Low-Pressure OptiMix System Repairing the Air Motor Water, oil, and compressed air are the primary causes of most maintenance. If the air motor is not cycling properly, inspect and clean the signal and the pilot valve. Before disassembling these valves, perform these two operations.
Page 35: Servicing Signal Valves
Low-Pressure OptiMix System Servicing Signal Valves There are two signal valves that may occasionally need servicing. The signal valve must be removed for servicing. 1. See Figure 12. Pull off the air tube (4). 2. Remove the set screw (7) at the top or bottom of the housing (5). Pull the signal valve (6) out of the housing.
Page 36: Servicing The Main Valve
Low-Pressure OptiMix System Servicing the Main Valve NOTE: The main valve does not need to be serviced unless serious problems are found with the signal and pilot valves. 1. See Figure 12. Remove the four screws (24) and the gasket (21) between the main valve and the pump housing.
Page 37 Low-Pressure OptiMix System 1425013A Fig. 12 Air Motor Assemblies 1. Screw 9. Stem 17. Spool 2. Pilot valve 10. Check valve housing 18. O-rings 3. Gasket 11. O-ring 19. Cylinder 4. Tigon air tube 12. O-ring 20. O-rings 5. Signal valve housing 13.
Page 38: Servicing The Pilot Valve
Low-Pressure OptiMix System Servicing the Pilot Valve 1. See Figure 12. 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 13. Remove the inside teardrop-shaped gaskets (3) from the top and bottom of the spool caps (1).
Page 39 Low-Pressure OptiMix System 1425003A Fig. 13 Pilot Valve 1. Spool cap 3. Gasket 5. Housing 2. O-ring 4. Spool 303 783B Manual 14-25 E 1999 Nordson Corporation All rights reserved Issued 5/99...
Page 40: Parts
Low-Pressure OptiMix System To order parts, call the Nordson Customer Service Center or your local 8. Parts Nordson representative. Part Description 303 751 System, two component, low pressure, 1:1 303 752 System, two component, low pressure, 2:1 303 753 System, two component, low pressure, 3:1...
Page 41: Material Pump Rebuild Kit
Low-Pressure OptiMix System Material Pump Rebuild Kit See Figure 6. Item Part Description Quantity Note — 303 765 Service kit, material pump - - - - - - S O-ring - - - - - - S Seal, piston - - - - - -...
Page 42: 2:1 Fluid Section Rebuild Kit
Low-Pressure OptiMix System 2:1 Fluid Section Rebuild Kit See Figure 9. Item Part Description Quantity Note — 238 833 Service kit, 2:1 pump - - - - - - S O-ring - - - - - - S Seal, upper...
Page 43: Gasket Kit
Low-Pressure OptiMix System Gasket Kit See Figure 14. Item Part Description Quantity Note — 303 771 Kit, gasket - - - - - - S Gasket - - - - - - S O-ring - - - - - -...
Page 44: Piston Seal Rebuild Kit
Low-Pressure OptiMix System Piston Seal Rebuild Kit See Figure 14. Item Part Description Quantity Note — 303 774 Service kit, 3 in. piston seal - - - - - - S Wiper, piston rod - - - - - -...

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