Circulating and Non-Circulating Color Change Manifoldsemanuals.nordson.com/finishing/files/Cont-Liq/107999c.pdf · Circulating and Non-Circulating Color Change Manifolds Customer

Circulating andNon-Circulating Color

Change Manifolds

Customer Product ManualPart 107 999C

NORDSON CORPORATION � AMHERST, OHIO � USA

� 1999 Nordson CorporationAll rights reserved

107 999CIssued 11/99

Manual 6-24

Nordson Corporation welcomes requests for information, comments and inquiries about its products. Generalinformation about Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service

555 Jackson StreetAmherst, OH 44001

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1990. No part ofthis 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

Blue Box, Can Works, Century, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat, Excel2000, Flow Sentry, FoamMix, Horizon, Hot Shot, Isocoil, Isocore, Iso-Flo, MEG, Nordson, the Nordson logo,

Package of Values, PowderGrid, Pro-Flo, PRX, RBX, Ready Coat, Rhino, SCF, Select Coat, Select Cure, Shur-Lok,Smart-Coat, System Sentry, Tribomatic, Versa-Coat, Versa-Screen, and Versa-Spray

are registered trademarks of Nordson Corporation.

Accu-Jet, Auto-Flo, CanNeck, Clean Coat, CPX, EasyClean, Ink-Dot, OptiMix, PowderGrid, Pulse-Spray, SureCoat, Swirlcoat and Walcom are trademarks of Nordson Corporation.

Viton is a registered trademark of E.I. DuPont de Nemours & Co.

Table of Contents i


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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 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-Circulating (Dead-Ended) Manifold 6. . . . . . . . . . . . . . . . . . . . . .

Circulating Manifold 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upgrading 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-Circulating (Dead-Ended) Manifold 7. . . . . . . . . . . . . . . . . . .

Circulating Manifold 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Color Change Manifolds 10. . . . . . . . . . . . . . . . . . . . . . . . . .

Installing a Non-Circulating Manifold 10. . . . . . . . . . . . . . . . . . . . .

Installing a Circulating Manifold 11. . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Color Modules 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Color Modules on Non-Circulating Manifolds 13. . . . . .

Installing Color Modules on Circulating Manifolds 14. . . . . . . . . .

4. Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Pressures 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii


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Non-Circulating Manifold 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Color Change 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circulating Manifold 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Color Change 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Repair 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-Circulating Manifold 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circulating Manifold 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Parts 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Color Change Manifolds 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-Circulating Manifold 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circulating Manifold 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Color Modules 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-Circulating Color Module 28. . . . . . . . . . . . . . . . . . . . . . . . . . .

Circulating Color Module 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve with Check 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Kits 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Seat Kits 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Plugs 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Conversion Kit 36. . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston with Seals Kit 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circulating and Non-Circulating Color Change Manifolds 1


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Circulating and Non-Circulating Color ChangeManifolds

Read and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, including these instructions, isaccessible to persons operating or servicing equipment.

Equipment owners are responsible for making sure that Nordsonequipment is installed, operated, and serviced by qualified personnel.Qualified personnel are those employees or contractors who are trainedto safely perform their assigned tasks. They are familiar with all relevantsafety rules and regulations and are physically capable of performingtheir assigned tasks.

Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury topersons 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

Make sure all equipment is rated and approved for the environment inwhich it is used. Any approvals obtained for Nordson equipment will bevoided if instructions for installation, operation, and service are notfollowed.

1. Safety

Qualified Personnel

Intended Use

Regulations and Approvals

Circulating and Non-Circulating Color Change Manifolds2


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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 areintact and automatic interlocks are operating properly. Do not bypassor disarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicingmoving equipment, shut off the power supply and wait until theequipment comes to a complete stop. Lock out power and secure theequipment to prevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjustingor servicing pressurized systems or components. Disconnect, lockout, 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 tothe gun handle or other true earth ground. Do not wear or carrymetallic objects such as jewelry or tools.

� If you receive even a slight electrical shock, shut down all electrical orelectrostatic equipment immediately. Do not restart the equipmentuntil the problem has been identified and corrected.

� Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling anduse 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 workplacethat often cannot be completely eliminated, such as hot surfaces,sharp edges, energized electrical circuits, and moving parts thatcannot be enclosed or otherwise guarded for practical reasons.

Personal Safety



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High-Pressure Fluids

High-pressure fluids, unless they are safely contained, are extremelyhazardous. Always relieve fluid pressure before adjusting or servicinghigh pressure equipment. A jet of high-pressure fluid can cut like a knifeand cause serious bodily injury, amputation, or death. Fluids penetratingthe skin can also cause toxic poisoning.

If you suffer a fluid injection injury, seek medical care immediately. Ifpossible, provide a copy of the MSDS for the injected fluid to the healthcare provider.

The National Spray Equipment Manufacturers Association has created awallet card that you should carry when you are operating high-pressurespray equipment. These cards are supplied with your equipment. Thefollowing is the text of this card:

WARNING: Any injury caused by high pressure liquid can beserious. 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 treatthe injury surgically as soon as possible. Do not delay treatment toresearch toxicity. Toxicity is a concern with some exotic coatings injecteddirectly into the bloodstream.

Consultation with a plastic surgeon or a reconstructive hand surgeon maybe advisable.

The seriousness of the wound depends on where the injury is on thebody, whether the substance hit something on its way in and deflectedcausing more damage, and many other variables including skinmicroflora residing in the paint or gun which are blasted into the wound.If the injected paint contains acrylic latex and titanium dioxide thatdamage the tissue’s resistance to infection, bacterial growth will flourish.The treatment that doctors recommend for an injection injury to the handincludes immediate decompression of the closed vascular compartmentsof the hand to release the underlying tissue distended by the injectedpaint, judicious wound debridement, and immediate antibiotic treatment.



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To avoid a fire or explosion, follow these instructions.

� Ground all conductive equipment in the spray area. Use onlygrounded air and fluid hoses. Check equipment and workpiecegrounding devices regularly. Resistance to ground must not exceedone megohm.

� Shut down all equipment immediately if you notice static sparking orarcing. Do not restart the equipment until the cause has beenidentified and corrected.

� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.

� Do not heat materials to temperatures above those recommended bythe manufacturer. Make sure heat monitoring and limiting devices areworking properly.

� Provide adequate ventilation to prevent dangerous concentrations ofvolatile particles or vapors. Refer to local codes or your materialMSDS for guidance.

� Do not disconnect live electrical circuits while working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoff valves, and fireextinguishers 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 beforeadjusting, cleaning, or repairing electrostatic equipment.

� Clean, maintain, test, and repair equipment according to theinstructions in your equipment documentation.

� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for partsinformation and advice.

Fire Safety



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Halogenated Hydrocarbon Solvent Hazards

Do not use halogenated hydrocarbon solvents in a pressurized systemthat contains aluminum components. Under pressure, these solventscan react with aluminum and explode, causing injury, death, or propertydamage. Halogenated hydrocarbon solvents contain one or more of thefollowing 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 moreinformation. If you must use halogenated hydrocarbon solvents, contactyour Nordson representative for information about compatible Nordsoncomponents.

If a system or any equipment in a system malfunctions, shut off thesystem immediately and perform the following steps:

� Disconnect and lock out system electrical power. Close hydraulic andpneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction and correct it before restartingthe system.

Dispose of equipment and materials used in operation and servicingaccording to local codes.

The color change manifold provides quick color changes with minimumcoating loss. The manifold is available in circulating and non-circulatingmodels. The manifold is modular, making it expandable and easy tomaintain. The manifold valves are air-actuated, allowing the colorchange manifold to be mounted in a hazardous area with no ignition risk.

Action in the Event of aMalfunction

Disposal

2. Description



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See Figure 1. The basic non-circulating (dead-ended) color changemanifold consists of four identical valves mounted on a manifoldblock (1). Coating material may be circulated through the valves andmanifold, but is dead-ended to the spray devices. Two of these valvesare used for coating material (4, 5), one is used for solvent (3), and onemay be used to air-push old coating material and/or solvent from thesystem (2). The air-push option is useful in lowering solvent waste andemissions. If the air-push option is not used, this valve may be used todispense an additional coating.

0624001A

1

5

4

3

2

Fig. 1 Non-Circulating Manifold

1. Manifold block2. Air push valve3. Solvent valve

4. Coating valve (color #2)5. Coating valve (color #1)

See Figure 2. The basic circulating color change manifold consists ofnine identical valves. Two sets of three valves are used for coatingmaterial (4, 5). One valve is used for solvent (3). One valve is used todump coating material and/or solvent (6). The remaining valve may beused to air-push coating material and/or solvent from the system (2). Thetwo valves opposite the coating valves allow the coating material to becirculated through a closed-loop hydraulic circuit, through the paint lines,heaters, and back to the supply, allowing the paint to be heated as itcirculates. Two valves allow for return from the guns on a circulatingsystem. The remaining valve serves as a dump valve (6) to clear paintfrom the lines before a color change.

Non-Circulating (Dead-Ended)Manifold

Circulating Manifold



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0624002A

1

6

5

4

2

3

Fig. 2 Circulating Manifold

1. Manifold block2. Air push valve3. Solvent valve

4. Coating valves (color #2)5. Coating valves (color #1)6. Dump valve

Because of the manifold’s modular design, additional color valve modulesmay be added to the end of an existing manifold in either a circulating ornon-circulating system. There is no limit to the number of color moduleswhich may be added.

The following paragraphs explain the theory of operation for thecirculating and non-circulating color change manifolds.

Non-Circulating (Dead-Ended) Manifold

See Figure 3. Pressurized coating material is connected to the materialsupply elbow (1) on the paint valve. When air is applied, an air pistonwithin the paint valve is lifted. The rising piston lifts the needle from theseat, allowing coating material to exit the valve, enter the manifold (3),and pass out to the spray device. The spray device may then betriggered and coating material may be applied to the substrate.

Upgrading

Theory of Operation



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Non-Circulating (Dead-Ended) Manifold (contd)

When air is removed, the needle is pushed back into the seat, stoppingthe coating material flow into the manifold. In the standard configurationof the valve, a material return elbow (2) is installed on the opposite sideof the valve. This configuration allows the pressurized coating material tocirculate through the valve and return to the supply. In a heated system,this allows heated coating material to circulate in a closed loop throughthe valve body for better temperature control. The material return elbowmay be removed and replaced with a pipe plug, making the coatingsupply system dead-ended.

0624003A

12

Standby Active

1 2

33

Fig. 3 Non-Circulating Manifold Schematic

1. Material supply elbow 2. Material return elbow 3. Manifold


See Figure 4. Pressurized coating material is connected to the materialsupply elbow (1) on valve A. When air is applied to valve A, an air pistonwithin the valve is lifted. The rising piston lifts the needle from the seat,allowing paint to exit the valve, enter the material supply manifold (2),and pass out to circulating spray devices. The spray devices may thenbe triggered and paint may be applied to the substrate.



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Some of the coating material passes through the spray devices and tothe substrate, and some circulates through the spray device and returnsto the material return manifold (3) where it is stopped by the closedvalve C. When air is applied to valve C, the circulating coating materialpasses through the valve and returns to the supply through the materialreturn elbow (4). This completes the active circuit, meaning that whenboth valves A and C are opened, the coating material is activelycirculating through the guns.

While one color in the manifold is active, the second color is standing by.In the standby mode, valve A is closed and valve B is open, allowing thecoating material to circulate in a closed-loop system from the supply,heaters, filter, etc. and return to the pump. This allows additional colorsto circulate in preparation for a color change, providing control of paintingquality.

0624004A

Standby Active

4

2

3

1

4

2

3

1

Fig. 4 Circulating Manifold Schematic

1. Material supply elbow2. Material supply manifold

3. Material return manifold 4. Material return elbow



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WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

WARNING: Relieve system pressure before performing thefollowing tasks. Failure to observe this warning could result inserious injury or death.

This section explains installation procedures for the circulating andnon-circulating color change manifolds and optional components.

Use the following procedures to install the color change manifold.

Installing a Non-Circulating Manifold

1. Mount the non-circulating color change manifold as close to the spraydevices as practical. Use the supplied 3/8-in. hardware.

2. See Figure 5. Connect 1/4-in. OD air tubing to the air elbow (4) oneach valve.

3. Connect a 37� 1/2-20 JIC fluid line to each of the material supplyelbows (2).

4. Install a 1/4-in. NPTM fluid fitting on the manifold end plate (3).

5. Connect a fluid line from the fluid fitting on the manifold end plate tothe spray devices.

NOTE: The following steps are not mandatory. Follow these steps onlyif required for your application.

Follow either of these guidelines to customize the non-circulating colorchange manifold to suit your application.

� Remove the fluid return elbow from each valve and install a pipe plug.This will dead end the fluid input at the valve.

� Connect an air line to the air push supply elbow (1). This will allow airto push the old color out of the system before a color change.

3. Installation

Installing Color ChangeManifolds



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0624005A

Color #2

Color # 1

Air push

Solvent

2

41

3

Fig. 5 Installing a Non-Circulating Manifold

1. Air push supply elbow2. Material supply elbows

3. Manifold end plate4. Air elbow

Installing a Circulating Manifold

1. Mount the circulating color change manifold as close to the spraydevices as practical. Use the supplied 3/8-in. hardware.

2. See Figure 6. Connect 1/4-in. OD air tubing to the air elbows (4) oneach valve.

3. Connect a 37� 1/2-20 JIC fluid line to each of the material supplyelbows (2).

4. Install a 1/4-in. NPTM fluid fitting on the upper and lower manifold endplates (5).

5. Connect a fluid line from the 1/4-in. NPTM fluid fitting on the uppermanifold end plate to the spray devices.



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Installing a Circulating Manifold (contd)

6. Connect a fluid line from the spray devices to the 1/4-in. NPTM fluidfitting on the lower manifold end plate.

NOTE: The following steps are not mandatory. Follow these steps onlyif required for your application.

Follow either of these guidelines to customize the circulating colorchange manifold to suit your application.

� Connect an air line to the air push supply elbow (1). This will allow airto push the old color out of the system before a color change.

� Place the fluid line leading from the dump valves (3) into a suitablewaste container.

0624006A

2

Air push

Solvent

3

4

4

1

Color #1

5

Color #2

Fig. 6 Installing a Circulating Manifold

1. Air push supply elbow2. Material supply elbows3. Dump valves

4. Air elbows5. Manifold end plates



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WARNING: System or material pressurized. Relieve systempressure. Failure to observe this warning could result inequipment damage, personal injury, or death.

Use the following procedures to install additional color modules ontocirculating and non-circulating color change manifolds.

Installing Color Modules on Non-Circulating Manifolds

1. See Figure 7. Remove the manifold end plate (3) and O-ring from themanifold (1).

2. Insert the stacking screws (4) through the holes in the manifold endplate, through the color module (2) and tighten the screws into themanifold.

0624007A

1

3

2

4

Fig. 7 Installing Color Modules on Non-Circulating Manifolds

1. Manifold2. Color module

3. Manifold end plate 4. Stacking screws

Installing Color Modules



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Installing Color Modules on Circulating Manifolds

1. See Figure 8. Remove the manifold end plates (3) and O-rings onthe upper and lower manifolds (1).

2. Insert the stacking screws (4) through the holes in the manifold endplates, through the color module (2), and tighten the screws into theupper and lower manifolds.

0624008A

1

4

3

2

Fig. 8 Installing Color Modules on Circulating Manifolds

1. Manifold2. Color module

3. Manifold end plate 4. Stacking screws



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Use the following procedures to operate the color change manifold.

Refer to Table 1 for operating specifications for the circulating andnon-circulating color change manifolds.

Table 1 Operating Pressures

Parameter Specification

Actuating Air 2.76−4.83 bar (40−70 psi)

Air Push 0.34−6.9 bar (5−100 psi)

Maximum Fluid Input 103.4 bar (1500 psi)

NOTE: A high-pressure spring kit is available if higher fluid pressures(103.4−206.8 bar (1500−3000 psi)) are required. Refer to Valve Kits inthe Parts section.

4. Operation

Operating Pressures



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Use the following procedures to operate the non-circulating color changemanifold.

Startup1. Pump coating material to the color change manifold.2. Pump solvent to the color change manifold.3. Apply actuating air pressure to the desired color valve.4. Trigger the spray device to dispense coating material.

Color Change1. Remove actuating air from the active color valve.2. Flush the system using one of the following guidelines.

� Apply actuating air pressure to the solvent valve to flush the oldcoating material out of the system.

� Apply actuating air to the air push valve to flush the solvent fromthe system.

3. Apply actuating air pressure to the next color valve.4. Trigger the spray device to dispense coating material.

Shutdown1. Remove actuating air from the coating valve.2. Flush the system using the solvent valve or air push option.

Non-Circulating Manifold



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Use the following procedures to operate the circulating color changemanifold.

Startup1. Pump coating material to the color change manifold.2. Pump solvent to the color change manifold.3. Apply actuating air pressure to the desired color valve.4. Apply actuating air pressure to the first circulation valve.5. Trigger the spray device to dispense coating material.

Color Change

1. Remove actuating air from the active color valve and circulationvalve.

2. Flush the system using one of the following guidelines.

� Apply actuating air pressure to the solvent valve to flush the oldcoating material out of the system.

� Apply actuating air to the air push valve to flush the solvent fromthe system.

3. Apply actuating air pressure to the dump valve.

4. Apply actuating air pressure to the next color valve.

5. Apply actuating air pressure to the next circulation valve.

6. Trigger the spray device to dispense coating material.

Shutdown

1. Remove actuating air pressure from the coating valve and circulationvalve.

2. Flush the system using the solvent valve or air push option.




107 999CIssued 11/99

Manual 6-24


Follow these guidelines periodically to maintain the circulating andnon-circulating color change manifolds.

1. Flush the color change manifold with solvent.

2. Check all fluid and air connections.

3. Check fluid hoses for damage. Replace any damaged hosesimmediately.

4. Provide clean, dry air to all valves. Excessive moisture orcontamination in the air will affect valve performance.


WARNING: Relieve all pneumatic and fluid pressure beforeperforming the following tasks. Failure to observe this warningcould result in serious injury or death.

Use the following procedures to disassemble and assemble thecirculating and non-circulating color change manifolds. Afterdisassembly, inspect all parts for wear and replace them as necessary.

NOTE: Flush all valves and manifolds with solvent before disassembly.

5. Maintenance

6. Repair



107 999CIssued 11/99

Manual 6-24

Use the following procedures to disassemble and assemble thenon-circulating color change manifold.

Disassembly

1. See Figure 9. Tag and disconnect all fluid and pneumatic lines fromthe valves (2).

2. Remove the four screws (5) securing each valve to the manifold (1).

3. Remove the two screws (5) securing the manifold end plate (7) to themanifold. Remove the end plate and O-ring (6) from the manifold.

4. If necessary, disassemble the valves. Refer to Valves—Disassemblyin this section.

Assembly

1. If necessary, assemble the valves. Refer to Valves—Assembly in thissection.

2. See Figure 9. Install the O-ring (6) into the manifold (1). Secure themanifold end plate (7) to the manifold using the two screws (5).

3. Secure each valve (2) to the manifold using the four screws (5).

4. Connect all fluid and pneumatic lines to the valves as described in theInstallation section.

Use the following procedures to disassemble and assemble thecirculating color change manifold.

Disassembly

1. See Figure 10. Tag and disconnect all fluid and pneumatic lines fromthe valves (1).

2. Remove the screws (3) and lock washers (4) securing the valves andupper connecting blocks (10).

3. Separate the dump block (8), upper connecting blocks (10), and fourO-rings (9) from the valves mounted on the upper manifold (12).

4. Remove the screws (11) and lock washers (4) securing the dumpvalves to the lower manifold (18).





107 999CIssued 11/99

Manual 6-24

Disassembly (contd)

5. Separate the lower connecting blocks (15) and O-rings (9) from thelower manifold.

6. Remove the check valve cartridges (16) and O-rings (17) from thelower manifold.

7. Remove the screws (5) to remove the lower manifold end plate (19)and O-ring (13) from the lower manifold.

8. Remove the screws (5) to remove the upper manifold end plate (14)and O-ring (13) from the upper manifold.

9. Remove the four screws (5) to remove each valve from the uppermanifold, middle connecting blocks, or dump block.

10. If necessary, disassemble the valves. Refer to Valves— Disassemblyin this section.

Assembly

1. If necessary, assemble the valves. Refer to Valves—Assembly in thissection.

2. See Figure 10. Secure each valve (1) to the upper manifold (12),middle connecting blocks (7), and dump block (8).

3. Secure the upper manifold end plate (14) and O-ring (13) to the uppermanifold using the two screws (5).

4. Secure the lower manifold end plate (19) and O-ring (13) to the lowermanifold (18) using the two screws (5).

5. Install the check valve cartridges (16) and O-rings (17) into the lowermanifold.

6. Secure the dump valves, lower connecting blocks (15) andO-rings (9) to the lower manifold using the screws (11) and lockwashers (4).

7. Secure the upper valves (mounted on the dump block (8) and andmiddle connecting blocks (7)), upper connecting blocks (10), andO-rings (9) to the upper manifold using the screws (3) and lockwashers (4).

8. Connect all pneumatic and fluid lines to the valves as described in theInstallation section.



107 999CIssued 11/99

Manual 6-24

Use the following procedures to disassemble and assemble the valves.

Disassembly

1. Remove the valve from the manifold. Refer to the disassemblyinstructions for your circulating or non-circulating color changemanifold.

2. See Figure 13. Remove the screws (1), lock washers (2), aircylinder (3), and air cylinder gasket (4) from the valve body (13).

3. Using two wrenches, remove the lock nut (5) and seal nut (8).

4. Remove the screws (22) securing the valve adapter (16) to the valvebody.

5. Pull the O-ring (21) from the valve adapter.

6. Remove the retaining ring (20), spring guide (19), spring (18), andball (17) from the valve adapter.

7. Remove the packing cartridge (14) with attached ball tip (15) from theair cylinder end of the valve body.

NOTE: The ball tip and seat are a matched set. If one of them needsto be replaced, replace them both.

8. Check the ball tip and seat for wear or scoring. Replace them asnecessary.

9. Check the packing cartridge and O-rings for wear. Replace them asnecessary.

Valves



107 999CIssued 11/99

Manual 6-24

Assembly

NOTE: If the valve will be used as a dump valve, remove the ball (17),spring (18), spring guide (19), and retaining ring (20) from the valveadapter before installing the valve on the dump block.

1. See Figure 13. Coat the packing cartridge (14) with a small amountof non-detergent grease. Install the packing cartridge into the valvebody (13) from the air cylinder end.

2. Secure the valve adapter (16) to the valve body using the fourscrews (22). Tighten the screws evenly to compress the packingcartridge spring.

3. Insert the seal nut (8) and O-ring (9) into the piston disk (10).

4. Screw the piston lock nut assembly (7) into the packing cartridgeclockwise until the assembly comes to rest against the valve body.

5. Turn the piston lock nut assembly counter-clockwise 11/4 turns untilthere is an approximately 0.045 in. gap between the piston and valvebody.

6. While holding the piston lock nut assembly, lock the assembly inplace with the lock nut (5) and thread locking compound.

7. Secure the air cylinder (3) and air cylinder gasket (4) to the valvebody using the screws (1) and lock washers (2).



107 999CIssued 11/99

Manual 6-24

To order parts, call the Nordson Customer Service Center or your localNordson representative. Use this five-column parts list, and theaccompanying illustration, to describe and locate parts correctly.

Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the partnumber applies to all parts in the illustration.

The six-digit number in the Part column is the Nordson Corporation partnumber. A series of dashes in this column (- - - - - -) means the partcannot be ordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.

Item Part Description Quantity Note

— 000 000 Assembly 1

1 000 000 � Subassembly 2 A

2 000 000 � � 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 thepart number is a bulk item ordered in quantities or if the quantity perassembly 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. Specialattention should be given to notes.

7. Parts

Using the Illustrated PartsList



107 999CIssued 11/99

Manual 6-24

Use the following lists to order replacement parts for the circulating andnon-circulating color change manifolds.


See Figure 9.

Item Part Part Description Quantity Note

— 248 269 Manifold, non-circulating, hydraulic 1

— 143 222 Manifold, assembly, 4 port, stainlesssteel

1

1 248 261 143 224 � Manifold, upper 1

2 - - - - - - - - - - - - � Valve, with check 4 A

3 972 176 972 177 � Elbow, male, 37, 1/2-20 x 1/4 8

4 973 571 973 415 � Plug, pipe, socket, standard, 1/4 4

5 981 233 981 233 � Screw, socket, 1/4-20 x 1.000 in. 18

6 940 160 940 160 � O-ring, hotpaint, 0.625 x 0.750 x0.063 in.

1

7 248 251 143 225 � Plate, upper manifold end 1

8 248 271 248 271 � Bracket, mounting 1

9 981 240 981 240 � Screw, hex, 1/4-28 x 0.750 in., cap 1

NS 152 999 901 911 � Wrench 2

NOTE A: Refer to Valve with Check for a list of the saleable parts included in this assembly.

NS: Not Shown

Color Change Manifolds



107 999CIssued 11/99

Manual 6-24

0624009A

7

2

8

9

3

4

516

Fig. 9 Non-Circulating Manifold Parts



107 999CIssued 11/99

Manual 6-24


See Figure 10.


— 248 266 Manifold, circulating, hydraulic 1

— 164 512 Manifold, circulating, hydraulic, stainlesssteel

1



3 981 913 981 913 � Screw, socket, 10-32 x 1.750 in. 8

4 983 120 983 120 � Washer, lock, e, split, #10 14

5 981 233 981 233 � Screw, socket, 1/4-20 x 1.000 in. 40

6 972 176 972 177 � Elbow, male, 37, 1/2-20 x 1/4 NPT 6

7 248 258 164 520 � Block, middle connecting 2

8 248 250 164 514 � Block, dump 1

9 940 162 940 162 � O-ring, PTFE, 0.625 x 0.759 x 0.006 7

10 248 252 164 517 � Block, upper connecting 2

11 981 737 981 737 � Screw, socket, 10-32 x 2.000 in. 6

12 248 261 143 224 � Manifold, upper 1


2

14 248 251 143 225 � Plate, upper manifold end 1

15 248 255 164 515 � Block, lower connecting 3

16 248 267 248 267 � Valve, cartridge, check 3


6

18 248 257 164 519 � Manifold, lower 1

19 248 253 164 516 � Plate, lower manifold end 1

20 248 254 248 254 � Plate, mounting 1

21 983 160 983 160 � Washer, lock, e, split, 3/8 2

22 981 402 981 402 � Screw, hex, 3/8-16 x 1.00 in., cap 2

NS 900 236 900 236 � Sealant, paste, PTFE 1

NS 152 999 152 999 � Wrench 1


NS: Not Shown



107 999CIssued 11/99

Manual 6-24

0624010A

101

1

9

20

18

22

215

19

1713

16

15

11

4

6

32

4

7

5

14

12

8

9

1

1

5

135

9

Fig. 10 Circulating Manifold Parts



107 999CIssued 11/99

Manual 6-24

Color modules are used to add additional color valves to an existingmanifold. Use the following lists to order replacement parts for circulatingand non-circulating color modules.

Non-Circulating Color Module

See Figure 11.


— 248 270 Module, non-circulating manifold 1

— 164 537 Module, non-circulating manifold,stainless steel

1

1 - - - - - - - - - - - - � Valve with check 1 A

2 972 176 972 177 � Elbow, male, 37, 1/2-20 x 1/4 NPT 1


4 981 233 981 233 � Screw, socket, 1/4-20 x 1.000 in. 4

5 248 256 164 518 � Module, upper manifold 1


1

7 248 260 248 260 � Screw, stacking, 0.250-20 x 3.25 in. 2


NS 152 999 152 999 � Wrench 1


NS: Not Shown

Color Modules



107 999CIssued 11/99

Manual 6-24

7

0624011A

2

4

3

5

1

6

Fig. 11 Non-Circulating Color Module Parts



107 999CIssued 11/99

Manual 6-24

Circulating Color Module

See Figure 12.


— 248 265 Module, color, circulating 1

— 164 513 Module, color, circulating, stainless steel 1


2 973 571 973 415 � Plug, pipe, socket, extra short, 1/4 2

3 983 120 983 120 � Washer, lock, e, split, #10 6

4 981 913 981 913 � Screw, socket, 10-32 x 1.750 in. 4

5 981 233 981 233 � Screw, socket, 1/4-20 x 1.000 in. 12

6 940 162 940 162 � O-ring, PTFE, 0.625 x 0.759 x 0.063in.

3

7 248 252 164 517 � Block, upper connecting 1

8 248 258 164 520 � Block, middle connecting 1

9 972 176 972 177 � Elbow, male, 37, 1/2-20 x 1/4 2

10 981 737 981 737 � Screw, stacking, 10-32 x 2.000 in. 2

11 248 256 164 518 � Module, upper manifold 1


2

13 248 255 164 515 � Block, lower connecting 1

14 248 260 248 260 � Screw, stacking, 0.250-20 x 3.25 in. 4


2

16 248 267 248 267 � Valve, cartridge check 1

17 248 259 164 521 � Module, lower manifold 1


NS 152 999 152 999 � Wrench 1


NS: Not Shown



107 999CIssued 11/99

Manual 6-24

3

1

11

17

5

1

6

7

4

9

5

1

6

15

16

12

14

13

10

3

6

8

2

12

14

0624012A

Fig. 12 Circulating Color Module Parts



107 999CIssued 11/99

Manual 6-24

See Figure 13. Use the following list to order replacement parts for thevalves.


— 248 262 Valve, with check 1

— 131 831 Valve, with check, stainless steel 1

— - - - - - - � Valve, with check 1

— - - - - - - � Valve, with check, stainless steel 1

1 981 140 981 140 � � Screw, fillister, 10-32 x 1.00 4

2 983 120 983 120 � � Washer, lock, e, split, #10 4

3 248 333 248 333 � � Cylinder, air 1

4 153 031 153 031 � � Gasket, gun, H20 1 A

5 984 539 984 539 � � Nut, lock, 10-32, upper 1 A

6 900 424 900 424 � � Compound, thread lock, VC-3 1

7 - - - - - - - - - - - - � � Piston, lock nut assembly 1 A

8 240 274 240 274 � � � Nut, seal lock 1 A

9 940 090 940 090 � � � O-ring, Viton, 0.208 ID x 0.070 in. 1 A

10 - - - - - - - - - - - - � � � Disc, piston 1 A

11 940 155 940 155 � � O-ring, hot paint, 0.563 x 0.688 x0.063 in.

2 A

12 972 119 972 119 � � Elbow, male, 1/4 tube x 1/8 NPT 1

13 248 167 � � Body, valve 1

13 131 833 � � Body, valve, stainless steel 1

14 153 152 � � Cartridge, packing 1

14 153 090 � � Cartridge, packing, stainless steel 1

NOTE A: These parts are available in the piston with seals kit, part 106 230.

Continued on next page

Valve with Check



107 999CIssued 11/99

Manual 6-24

Item NoteQuantityDescriptionPartPart

— - - - - - - - - - - - - � � Seat, valve 1 B

15 - - - - - - - - - - - - � � � Tip, ball 1

16 - - - - - - - - - - - - � � � Adapter, valve 1

17 900 011 900 011 � � � Ball, carbide, 0.250, 25 1

18 240 093 240 093 � � � Spring, comp, 0.395 x 0.180 ODx 0.024 in.

1

19 240 092 � � � Guide, spring 1

19 131 839 � � � Guide, spring, stainless steel 1

20 986 605 � � � Ring, retaining, internal, 50, basic 1

20 986 115 � � � Ring, retaining, internal, 50, basic 1


1 A

22 981 893 981 893 � � Screw, socket, 10-32 x 0.500 4

NS 152 999 152 999 � � Wrench 2

NOTE A: These parts are available in the piston with seals kit, part 106 230.

B: The valve seat and its parts are available in the valve seat service kits, parts 240 137 and 164 538.

NS: Not Shown



107 999CIssued 11/99

Manual 6-24

0624013A

1

2

3

4

8

910

14

11

13

16

12

22

15

21

56

7

11

20

19

18

17

Fig. 13 Valve with Check Parts

Valve with Check (contd)



107 999CIssued 11/99

Manual 6-24

The following kits are available for the circulating and non-circulatingcolor change manifolds.

Valve Seat Kits

See Figure 13.


— 240 137 Service kit, seat, valve 1

— 164 538 Service kit, seat, valve, stainless steel 1

11 940 155 940 155 � O-ring, hot paint, 0.536 x 0.688 x0.063 in.

2

— - - - - - - � Seat, valve 1

— - - - - - - � Seat, valve, stainless steel 1

15 240 090 240 090 � � Ball tip 1

16 - - - - - - - - - - - - � � Adapter, valve 1

17 900 011 900 011 � � � Ball, carbide, 0.250, 25 1

18 240 093 240 093 � � Spring, compression, 0.395 x 0.180x 0.024 in.

1

19 240 092 131 839 � � Guide, spring 1

20 986 605 986 115 � � Retaining ring, internal, 50, basic 1


1

Manifold Plugs

Use the following manifold plugs to plug an unused station on acirculating or non-circulating color change manifold.

Part Description Note

240 098 Plug, manifold

940 150 � O-ring, hot paint, 0.563 x 0.688 x 0.063 in.

164 539 Plug, manifold, stainless steel

940 150 � O-ring, hot paint, 0.563 x 0.688 x 0.063 in.

Valve Kits



107 999CIssued 11/99

Manual 6-24

High-Pressure Conversion Kit

See Figure 13. This conversion kit increases the operating pressurerange to 206.8 bar (3000 psi).


— 248 941 Conversion kit, A7A, high pressure 1

3 - - - - - - � Cylinder, air 1

4 153 031 � Gasket, gun, H20 1

5 984 120 � Nut, hex, machined, #10-32 1

8 - - - - - - � Nut, seal lock 1

9 940 090 � O-ring, Viton, 0.208 x 0.070 in. 1

NS 247 206 � Spring, compression, 0.750 x 0.720 x 0.063 in. 1

NS: Not Shown

Piston with Seals Kit

See Figure 13.


— 106 230 Service kit, piston with seals, A7A 1

4 153 031 � Gasket, gun, H20 1

— - - - - - - � Piston assembly, H20 1

5 984 539 � � Nut, lock, 10-32, upper 1

7 - - - - - - � � Piston, lock nut, assembly 1

8 240 274 � � � Nut, seal lock 1

9 940 090 � � � O-ring, Viton, 0.208 x 0.070 in. 1

10 - - - - - - � � � Disc, piston 1

11 940 157 � O-ring, Viton, black, 0.562 x 0.688 in. 2

21 940 174 � O-ring, Viton, black, 0.688 x 0.813 in. 2

Documents

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