AMCOL 3063 User manual

AMCOL CORPORATION
3063 BILLET AND DUMMY
BLOCK SPRAY SYSTEMS
Operator’s Manual

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 1
File ID: 3063-OM05
Approved for Use
LSB: AA-0025
LSD: 9/28/2021
FDR: PS04
Contents
1 Introduction .....................................................................................................................................2
2 Included Components....................................................................................................................3
3 Installation.........................................................................................................................................4
PRIOR TO GETTING STARTED............................................................................................................4
Installation .........................................................................................................................................4
4 Operation .........................................................................................................................................6
System Operating Cycle.................................................................................................................6
Liquid Air Purge.................................................................................................................................7
5 Recommended Settings.................................................................................................................8
6 Maintenance ...................................................................................................................................9
Recommended Spares...................................................................................................................9
Preventative and Predictive Maintenance ...............................................................................12
Daily .............................................................................................................................................12
Quarterly......................................................................................................................................12
Yearly ...........................................................................................................................................12
7 System Troubleshooting ................................................................................................................13
No Liquid .........................................................................................................................................13
Too Much Liquid.............................................................................................................................14
Too Little Liquid or Poor Coating ..................................................................................................14
Fluid Runs On or Is Not Atomized During Part or All of the Spray Cycle..................................14
PA201 Refractometer ....................................................................................................................15
8 System Schematics........................................................................................................................16
9 Drawings .........................................................................................................................................17
AMCOL Corporation
21435 Dequindre, Hazel Park, MI 48030
248-414-5700
fax: [phone]
www.amcolcorp.com

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 2
1 Introduction
This manual features instructions regarding the installation, operation, and maintenance of
the AMCOL model 3063 Billet and Dummy Block Spray Systems. For more information on the
system and its components, please refer to the AMCOL model 3063 Billet and Dummy Block
Spray Systems Technical Description.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 3
2 Included Components
Standard components included with every standard 3063 system:
1. Valve package with 2 open valves for PLC interface.
2. Liquid reservoir with liquid air purge and recirculation capability.
3. Rotating spray head with overspray cover.
4. Fixed position mounting assembly.
5. Fire resistant hose assemblies.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 4
3 Installation
PRIOR TO GETTING STARTED
• WARNING! DO NOT DISASSEMBLE, REPAIR, OR REPLACE COMPONENTS OR SUBASSEMBLIES OF
THIS SYSTEM WITHOUT FIRST DEENERGIZING THE SYSTEM AIR SOURCE WITH LOCK AND TAG; THIS
CAN BE TESTED BY VISUALLY INSPECTING THE PRIMARY AIR GAUGE (A) ON THE VALVE PACKAGE
TO BE AT 0 PSI AND MANUALLY ATTEMPTING TO ACTUATE EITHER THREE-WAY AIR VALVE ON THE
VALVE PACKAGE.
• WARNING! BE SURE THAT THE PRESS IS PROPERLY GUARDED IN ORDER TO AVOID INADVERTENT OR
UNINTENDED ACCESS TO THE SPRAY HEAD BY UNTRAINED PERSONNEL. REFERENCE ANSI B11.17 OR
SIMILAR PRESS GUARDING STANDARD.
• WARNING! BE SURE TO MOUNT THE RESERVOIR AND VALVE PACKAGE OUTSIDE OF THE GUARDED
AREA, AS THEY WILL HAVE TO BE ACCESSED DURING NORMAL PRESS OPERATION.
• WARNING! DO NOT ATTEMPT TO ADJUST OR MODIFY NOZZLES, WHICH WILL BE WITHIN THE
GUARDED AREA, WITHOUT DEENERGIZING THE PRESS WITH LOCK AND TAG.
• WARNING! THE SYSTEM IS NOT DESIGNED OR CAPABLE OF DISPENSING FLAMMABLE OR
COMBUSTIBLE LIQUIDS.
• WARNING! USE PROPER EYE PROTECTION WITH SIDE SHIELDS WHEN IN THE AREA OF OPERATION.
DURING TESTING AND SUBSEQUENT SYSTEM REPAIR, IT IS STRONGLY RECOMMENDED TO USE FULL-
FACE SHIELD PROTECTION.
• WARNING! THE SPRAY ASSEMBLY INVOLVES A CHAIN DRIVEN ROTATION NOZZLE THAT MAY
UNEXPECTEDLY ACTUATE. DO NOT ACCESS THIS AREA WITHOUT FIRST DEENERGIZING THE COMPLETE
SYSTEM AS NOTED ABOVE.
Installation
1. Remove complete system from the pallet and manually operate outside of the press
area. This can be completed by connecting all components according to the hose
connections as indicated in the photos on the following page. Once these hoses are
connected, connect plant air to the valve package and manually actuate the air valves
according to the system operating cycle. During manual operation, confirm that these
components are set accordingly and that the spray volume and pattern is acceptable. If
the settings specific to your operation are other than those recommended by AMCOL, they
should be recorded and controlled for later access and training.
2. With the press in normal operation and while standing outside of the press guarding,
observe potential areas for installation of the spray head, reservoir, and valve package. The
nozzles will have to fit without being hit by moving components of the press. The valve
package will have to be outside the press guarding and ideally within sight of the operator
and spray nozzle, but out of the general traffic area.
3. Deenergize, lock, and tag the press, then place the spray head nozzle in the expected
position (with no hoses attached) to properly assess the exact placement of this assembly.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 5
Exit the lock and tag area and reactivate the press with the nozzle in position in order to
determine that the nozzle is in a position to avoid damage during normal press operation.
The rotating assembly should be centered to a billet or block 4” from the billet face or
dummy block. Once the exact location is determined, mark the location or permanently
install using the mounting holes.
4. Mount the valve package using the four mounting holes on the back plate.
5. Connect a lightly lubricated ½” air line to the air inlet of the valve package. Be sure that
this air source is properly locked and tagged prior to beginning your installation. Do not
energize until all hoses have been properly installed and attached.
6. Reconnect hoses as supplied with the system. Numbers on each hose are included to
indicate the correct connection.
Hose 1 –Plant air from valve package to reservoir air inlet manifold
Hose 2 –Liquid from reservoir to liquid safety switch on valve package
Hose 3 –Liquid (U) from 025 Atomizer returning to reservoir return port
Hose 4 –Regulated air to atomizing air (A) on 025 Atomizer
Hose 5 –Liquid (L) from valve package to atomizer on the overspray cover
Hose 6 –Air from lubricator on valve package to air motor on overspray cover
Hose 7 –Air from valve package to air pilot (P)
7. Fill air motor lubricator with an ISO 32 VG oil (such as 6401 Monolec® R&O Compressor Oil
from Lubrication Engineers).
8. Energize the air source and manually operate the valve package as outlined in the
system operating cycle.
9. Assuming the system is now operational, and the system settings are acceptable,
deenergize the air to the valve package and finalize the PLC connection of the Norgren
three-way valves located on the valve package to the press PLC with the sequencing
timing. See Section 4 Recommended Settings.
10. Reenergize the air source to the valve package, and the spray system should be
operational in automatic mode.
5

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 6
4 Operation
System Operating Cycle
1. System Idle and Ready to Spray –System Air Pressure (B) is steady at 60 PSI and the
double diaphragm pump is cycling one time every 2 seconds.
2. Energize Air Timing Valve (C) –The Atomizing Air Pressure (E) will immediately go to 40 PSI
and hold steady. The System Air Pressure (B) will remain virtually unchanged at 60 PSI. The
spray head will begin rotating and the air (no liquid) will be coming out of the spray tips. If
there is any liquid during this part of the spray cycle, there are issues with the valve
sequencing or valve closure at the end of the prior cycle.
3. Energize Liquid Timing Valve (D) –The Air Pilot Pressure Monitor (H) will immediately match
the System Air Pressure (B). The Liquid Safety Switch and pilot on 025 Atomizer are both
open, thus allowing liquid through the flow restrictor, into the air stream in the atomizer,
through the spinner head and spray tubes, and out of the spray tips.
4. Deenergize Liquid Timing Valve (D) –The Air Pilot Pressure Monitor (H) will immediately go
to 0 PSI. The Liquid Safety Switch and 025 Atomizer are now closed.
5. Liquid Cleanout of Spray Head –Liquid in the 025 Atomizer, spinner head, spray tubes,
and spray tips is now cleaned out completely, prior to ending the spray cycle. This part of
the spray cycle takes 2 seconds when the system and its components are operating
properly.
6. Deenergize Air Timing Valve (C) –The Atomizing Air Pressure (E) will immediately go to 0
PSI, and the rotating head will immediately stop. There should be no liquid dripping from the
spray tips.
7. System Idle and Ready to Spray –Only the double diaphragm pump is pulsating at a rate
of one cycle every 2 seconds.
This process is repeated during each spray cycle. Sample ladder logic using Connected
Components Workbench with an Allen Bradley Micro810 PLC can be seen below.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 7
Liquid Air Purge
The Liquid Air Purge is an accessory that allows for manually actuated pumping of the liquid
from the reservoir, through the valve package, to the 025 Atomizer, and back to the liquid
reservoir. The purpose of this function is to remove any air pockets from any point in the
liquid line. To complete the process:
1. Close the Air Pilot Line using the Air Pilot Shutoff (F).
2. Manually actuate the Liquid Timing Valve (D). The Air Pilot Pressure Monitor should read 0
PSI.
3. Close the Fluid Recirculation Ball Valve (J).
4. Open the Air Purge Return Valve (K) on the liquid reservoir.
5. Open the reservoir top to observe the fluid as it is returned from the 025 Atomizer.
6. Manually actuate the Liquid Timing Valve (D) while observing the liquid as it is returned
back to the reservoir. The liquid flow may become sporadic or inconsistent. Continue this
procedure until flow is continuous and consistent. Liquid should shut off immediately when
the Liquid Timing Valve (D) is deactivated.
7. Close the Liquid Air Purge Valve (K) located on the liquid reservoir.
8. Open the Fluid Recirculation Ball Valve (J) to <10% open as indicated in the
recommended system settings.
9. Reopen the Air Pilot Shutoff (F) before operating.
The same process can be used to troubleshoot all three valves associated with the Liquid
Spray Timing.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 8
5 Recommended Settings
Item ID
Description
Recommended Settings
A
System Shutoff
Open during normal operation –Close to perform repairs. Has lock and tag eyelet.
B
System Air
Pressure
60 PSI. This is the valve package inlet pressure. It can be set with no valves energized.
C
Air Timing Valve
(ATV)
Energize for at least 0.5 seconds before energizing the Liquid Timing Valve (D), and
leave energized until 2.0 seconds after deenergizing the LTV. Actuating this valve
sends air through the atomizer to the spray tips. It will also send air to the motor used to
drive the spinner.
D
Liquid Timing
Valve (LTV)
At least 0.5 seconds after energizing the Air Timing Valve (C), energize the liquid timing
valve for 0.75 seconds or more. Limit the time to 3 rotations of the spinner. This valve is
used to open the liquid safety switch on the valve package and the air pilot located
on the 025 Atomizer.
E
Atomizing Air
Pressure
40 PSI. This is the air pressure used to atomize and propel fluid at the spray tips on the
spinner head.
F
Air Pilot Shutoff
Open during normal operation. Closed only when completing Liquid Air Purge
procedure (see section 4).
G
Air Motor
Lubricator
1.0. This setting is used to define flow rate of an oil lubricant (ISO 32 VG Oil such as 6401
Monolec® R&O Compressor Oil from Lubrication Engineers or similar) to the air motor,
which requires only minimal oil in the air to avoid seizing of the motor.
H
Air Pilot Pressure
Monitor
Set using System Air Pressure (B). This gauge is for monitoring and troubleshooting only.
In the event that this gauge is reading something other than the System Air Pressure, or
that it is moving slowly during the Liquid Timing (D) sequence, there is a system
malfunction.
I
Pump Shutoff
Open during normal operation. Allows for quick shut off of reservoir pump in the event
of an emergency involving a leaking valve, hose, or strainer.
J
Fluid
Recirculation Ball
Valve
<10% Open (30 cycles per minute). This valve adjusts the recirculation flow back to the
reservoir and pressure to the nozzle. As this valve is opened, the flow rate to the
reservoir increases, while the liquid pressure to the nozzle is reduced.
K
Air Purge Return
Valve
Closed during normal operation. This valve is used to purge the liquid line of any air
that may enter as a result of changing on cleaning the filter, or repairing/replacing
any liquid connections.
L
Pump Inlet
Pressure
45 PSI. Increase pressure to increase liquid volume. This will increase pump flow and
outlet pressure. Liquid pressure at the 025 Atomizer must be at or above the Atomizing
Air Pressure (E) in order to avoid back pressure inconsistencies.
M
Air Motor Speed
Control
3.0 turns from closed. This adjustment is used to set a specific rotational speed of the
spinner nozzle using air flow rate to the air/gear motor. Set by adjusting tight in the
clockwise direction and then rotating in a counterclockwise (opening) direction.
N
025 Atomizer with
Flow Restrictor
Not adjustable. Air and liquid are mixed within the 025 Atomizer body (red) which also
has an internal air pilot. Liquid output is determined based on the size of a machined
port vs pressure (standard injector is 3A).
H

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 9
6 Maintenance
Recommended Spares
Description
Part Number
Quantity
025 Atomizer with #3A Fixed
Orifice and Fittings
3063A-025C*
1 each
Repair Kit 025 Nozzle - O-Ring
15261
1 each
Fixed Orifice Assembly #3A
025-3A
1 each
3A Clean Out Tool, 0.0145"
(0.3683mm)
2841A84*
1 each
Fixed Orifice O-Ring Kit
025-3A-OK*
5 each
Spinner Nozzle with Triple Seal
025-SNTS
1 each
P/H Fire Res. Hose (1/4”)
821FR-4-BLK**
50 feet
P/H Fire Res. Hose (3/8”)
821FR-6-BLK**
5 feet
Rebuild Kit for 66605J-34B
Diaphragm Pump (1)
637140-4B
1 each

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 10
Check Balls, ¾” PTFE, for
66605J-34B DP (1)
93100-4
4 each
3 Way Poppet Valve with
Coil
Special per
Voltage
1 each
Solenoid for Poppet
Special per
Voltage
2 each
140 PSI Pressure Gauge (1/8”
Back Mount)
18-013-212
1 each
160 PSI Pressure Gauge (1/4”
Back Mount)
18-013-209
1 each
Gear Motor Extension for
Chain Drive with Screws
12-GME-C-AC*
1 each
Clear Bowl for 1/2” Inline
Strainer with Gasket
9875K11-AC*
2 each
80 Mesh Replacement
Screen for T-Strainer (SS)
9875K82
1 each

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 11
1/2" Polypropylene Pump
with PTFE Check Balls (1)
66605J-34B-AC
1 each
Liquid Safety Switch
01285-PRKR
1 each
ISO 32 VG Oil (such as 6401
Monolec® R&O Compressor
Oil from Lubrication
Engineers)
N/A*
1 gallon
* Strongly recommended
** May be purchased locally
(1) Note: PTFE replaces Santoprene™

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 12
Preventative and Predictive Maintenance
Daily
•Observe fluid level and fill as necessary.
•Check fluid dilution using Misco PA201 Digital Refractometer (information regarding the
Misco PA201 can be found on pg. 15). Correct dilution as necessary.
•Observe all air pressure settings and gauges to be consistent as per the liquid and air
timing sequence. Use these gauges to confirm that all air valves are properly opening and
closing. System air should never significantly change as each valve opens and closes.
•Observe ½” Inline Strainer for sediment and solids. Clean or replace strainer (80 Mesh
Replacement Screen) if required. Identify root cause.
•Observe spray alignment, quality, and quantity. Make any adjustments or repairs as
necessary.
•Observe the Air Motor Lubricator. Fill as necessary with an ISO 32 VG Oil (such as 6401
Monolec® R&O Compressor Oil from Lubrication Engineers).
Quarterly
•Completely empty reservoir. Wash with water. Refill.
•Change Clear Bowl and Gasket for ½” Inline Strainer.
•Inspect Check Balls, ¾” PTFE, for 66605J-34B Diaphragm Pump.
Yearly
•Replace 025 atomizer with #3A Fixed Orifice and Fittings and Spinner Nozzle with Triple
Seal assembly.
•Replace all air regulator pressure gauges.
•Replace all liquid and air hoses.
•Rebuild or replace double diaphragm pump.
•Replace Air Motor Assembly with Gear Reducer and Roller Chain.
•Disassemble, inspect, and repair or replace the three-way air operated solenoid valves
on valve package.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 13
7 System Troubleshooting
Check in order as listed.
No Liquid
•Reservoir is empty or low. Pump will be pulsating very fast with this condition.
•System Air Pressure (B) is too low during spray cycle. Adjust to 60 PSI. Be sure to observe
the gauge before and during the spray cycle. The gauge pressure should not in any way be
affected by the air consumed by the diaphragm pump during the spray cycle; if this
occurs, the main air supply is somehow limited and does not offer enough flow for proper
operation of the system. Troubleshoot main air supply.
•Fluid Recirculation Ball Valve (J) on reservoir not restricted, or Air Purge Return Valve (K) is
open. Fluid pressure will be too low to overcome the Atomizing Air Pressure (E). Adjust.
•Air has inadvertently entered the liquid line. Complete air purge of the liquid line (see
section 5).
•Safety Switch is not opening. This can be tested by closing Air Pilot Shutoff (F), closing Fluid
Recirculation Ball Valve (J), opening Air Purge Return Valve (K), and manually actuating
Liquid Timing Valve (D). Fluid will circulate freely and continuously back to the reservoir.
•025 Atomizer (N) is not opening, or 3A Flow Restrictor is
clogged. This can be tested by loosening the 3A Flow
Restrictor by one complete turn in order to bypass the flow
restrictor (reminder: this is not an adjustable knob). Be sure to
place a barrier (such as a cardboard sheet) in front of the
spray head during this testing in order to contain the spray.
Manually actuate the spray cycle and observe for fluid. If
the 025 Atomizer is properly opening, a copious amount of
fluid will be coming out of the spray tips. Remove the 3A
and clean using a 0.015 drill bit or brush. Use a light oil on the
O-ring to facilitate reinstallation.
•Air pump on reservoir is malfunctioning. Open Fluid Recirculation Ball Valve (J) and allow
pump to operate. There should be a steady pulsating flow of liquid with no leaking of air or
liquid from the pump itself. Refer to pump manual (Model 66605J-34B Aro Ingersol Rand) for
repair and troubleshooting.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 14
Too Much Liquid
•Liquid safety switch and 025 Atomizer (N) are actuated for too long. Shorten Liquid Air
Valve (D) timing.
•Pump pressure on reservoir (L) too high. Set to 45 PSI.
•Flow Restrictor has been bypassed due to a leaky, damaged, or missing O-ring, or from
chemical erosion of the 025 Atomizer. Replace or repair as needed.
Too Little Liquid or Poor Coating
•46 ILX EJECTEZE concentration is too dilute.
•Opposite of Too Much Liquid (as referenced above).
•Hose, filter, nozzle, or flow restrictor partially clogged.
•Location of rotating head is too far away. Locate spray cover 4” from the face of the
billet or block.
•Rotating head is not centered to the billet or block, or not appropriately sized for billet.
Fluid Runs on or Is Not Atomized During Part or All of the Spray Cycle
•Air Timing Valve (C) is not correct. Must be open during the complete spray cycle. A
visual inspection of the Spray Pressure Regulator gauge (E) allows for a visual inspection of
the timing sequence.
•Liquid Timing Valve (D) cycle is too long. Start after Air Timing Valve and close 2 seconds
prior to the end of the Air Timing Valve sequence.
•Liquid Timing Valve is malfunctioning. Troubleshoot by first observing the Air Pilot Pressure
Monitor (H) to ensure pressure goes up and down quickly with the actuation of the Liquid
Timing Valve.
•Liquid Safety Switch is malfunctioning. Follow the Liquid Air Purge as directed in section 5.
After manual actuation has ended, the pump should be quickly shut down.
•025 Atomizer (N) is not properly closing. Disassemble, clean, or replace.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 15
PA201 Refractometer
The PA201 Refractometer, manufactured by
Misco, is a handheld testing instrument used to
check and monitor dilution ratios of liquid
concentrates that are mixed with water. It is
operated by placing a drop or two of fluid in the
titanium bowl, then pressing the activation button.
A microprocessor will then deliver a nearly
instantaneous digital readout on an LCD display.
This numerical reading can be correlated to a specific dilution for a given product using a
cross reference chart or logarithmic formula.
Calibration is automatic and does not require the use of special calibration solutions or
tools. See the Misco PA201 Refractometer reference manual for additional information.
The Misco PA201 Refractometer is based on the Brix scale reading system. There are many
different types and makes of Refractometers that can be used as a substitute. Be sure that
whatever system is used is reliable and easy to operate.
For optimal performance, AMCOL Recommends:
46 ILX EJECTEZE
Release Agent for Non-ferrous Extrusion
Proven technology, refined over decades.

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 16
8 System Schematics
3063B-BSF
3063A-BSR

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 17
9 Drawings (all drawings are shown for 3063A-BSR)
Spray Head*
3063A-025SP-10
Atomizer*
3063A-025C

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 18
Air Motor Assembly*
14-AMA-GR
Spinner Assembly*
13-SNTS-HS-C

3063 BILLET AND DUMMY BLOCK SPRAY SYSTEMS
Operator’s Manual
PAGE | 19
Reservoir*
3063A-NP30