Lily Corporation CD15 Operation manual

1 Ver. 1.6
Product Warranty and Disclaimer 2
Safety Precautions 2
The Resin Supply
Fluid Connections 3
Filling The Supply Tanks 3
Monitoring The Resin Supply 4
Operation
The System and How It Works
Servicing the System
To Begin With 6
Dispensing 6
Shut Down 7-8
Clean - Up 7
Ratio Assurance Check 8-9
Changing Ratio 10
The Fluid Circuit 11
The Fill Sensors 12
Lily Corporation
240 S. Broadway
Aurora, Illinois 60505-4205
United States of America
Ph: 630-892-0860
Fax:[phone]
www.lilycorp.com
Operation and Service Manual
CD15
The Air Supply
Connections & Requirements 5
Troubleshooting
Troubleshooting 40-41
Parts Diagrams 24-39
Parts Diagrams
Lubrication 12
COCO Module 13
Disassembly 13-14
Assembly 15-17
Metering Cylinders 17-18
The Control Circuit

2 Ver. 1.6
EXPRESS WARRANTY AND DISCLAIMER OF IMPLIED WARRANTIES
Lily Corporation unconditionally guarantees its products to be free of defects in material or
workmanship and further warrants that, for a period of three months from date of factory
shipment, its products will meet the performance criteria stated in Lily Corporation’s
publications.
There are no other warranties, expressed or implied, including those of merchantability and
fitness for particular purposes.
Lily Corporation cautions the users of its products that epoxies must be
metered at the correct ratio and thoroughly mixed to achieve their formulated
strength. The user is further cautioned that thorough mixing within a static
mixing device can only occur with uniform flow of the two components.
Transmission of the two components through separate hoses to a remote
mixer may result in uneven flow of the components due to swelling and
contracting of the hoses, or different compressibility of the material
Warning and Safety Precautions
The CD15 can develop fluid pressures in excess of 1000 pounds per square
inch. Everyone within 25 feet should wear eye protection when the system is
energized. Mechanical members are actuated under forces of up to 500 psi.
Maiming injuries can be incurred. Do not energize the system unless all
screens are in place, and fingers, tools, and other objects are outside of the
frame of the machine.
Become thoroughly acquainted with first-aid procedures recommended by your
resin supplier in the event resin enters one’s eyes. If solvents are to be used
for cleaning, personnel should become thoroughly acquainted with their
characteristics. Most solvents are hazardous under all circumstances and
extremely dangerous in non-ventilated areas, or at elevated temperatures.
A thorough understanding of the Operator’s Manual is crucial to the safe
operation of the CD15. Do not attempt to operate this system until thoroughly
familiar with it’s contents. Phone Lily Corporation if clarifications are needed.

3 Ver. 1.6
Resin Supply
Fluid Connections
Use a 7/8” wrench to remove the caps and connect the
hoses. Some fluid may drip from the fittings . It is a
harmless material used to test the equipment following
manufacture, and does not need to be purged from the
system before dispensing. Stow the caps on the
magnetic flange of the channel.
Leave the inlet fluid fittings connected. Their
disconnection and re-connection only leaves
opportunities for costly error.
AB
Connect the fluid hose from the A tank (base resin) at the
lower left hand fitting (base resin inlet) on the front of the
CD15 dispenser. Connect the B tank (catalyst) at the
lower right hand fitting (catalyst inlet) as you view the
dispenser.
Install the Tempest mixer at the dispenser outlet (upper) fittings by
mating and tightening the two ½” compression fittings. Tighten the
fittings uniformly or they will bind and be difficult to assemble. The
fittings can be drawn up with the fingers, and then snugged with a
7/8” wrench. Be certain the component designations ( A & B
marked on the mixer) and the dispenser outlets match.
Filling The Supply Tanks
Epoxies have two components: The base resin, (Part A) is nearly always the majority
component if the ratio is other than 1:1. The catalyst (Part B) (“B” does not stand for base!)
is also known as the hardener. The catalyst is usually thinner than the base. It is of the greatest
importance that the person placing the components into the reservoirs knows—without any
doubt—the difference. If there is any doubt as to which is which, STOP!......until you “know”
1. Rotate the selector valve
pointer 180° from the air inlet
tubing. This will close off
incoming air, and vent the tank.
2. Lift the bale and press
down on the tank lid to free it.
3. Twist and tilt the lid until it
clears the opening. The lid
seal should be attached to the
rim. If not, check to see if it has
dropped into the tank, or stuck
to the underside of the tank lip.
4. After the material has been
added, replace the lid. Lock it
into place by pushing its bale
forward. Rotate the selector
valve pointer back toward the
air supply tubing to energize
the tank.

4 Ver. 1.6
Resin Supply
Warning: Corrosive damage to system components can occur if a resin component has a
PH of greater than 10 or less than 1.
Monitoring The Resin Supply
If either resin container is depleted, the CD15 will dispense the remaining component. Air is a
fluid, and the system cannot tell the difference. In the case of crack injection, the result may
be very costly, as it is unlikely that the error can be fully corrected. Therefore,
Do not allow the supply tanks to run out of material
When the dispenser is supplied by pressure vessels, it is not possible to
see how much resin remains in the tanks. However, the resin supply can
be monitored by using the counter on the control panel. The counter
registers the number of cycles the dispenser makes.
Resin
Ratio
Cycles
Per
Gallon
1:1 40
2:1 54
3:1 61
3.5:1 63
4:1 65
To use the counter to monitor resin consumption, go to the chart to
determine how many cycles occur in dispensing a single gallon of
combined components at the ratio you are using. For examples, if you
are dispensing at a 2:1 ratio, one gallon of material (the combined
components) will be consumed with every 54 cycles. If you are
dispensing at a 3.5:1 ratio, one gallon of material will be consumed
with every 63 cycles.
Next, decide how many gallons can be
safely dispensed without depleting either
component. If, for example, the ratio is 2:1,
and you have placed 4 gallons in the base
tank and 2 gallons in the catalyst tank for a
total of six gallons, 4 gallons of the
combined components can be safely
consumed. This will leave a reserve of two
gallons.
Now set the counter to zero by depressing the bar beneath the window. Mark the number 216 (4
gallons of resin @ 54 cycles per gallon = 216 cycles) in numbers on the top of the machine. Use a a
Magic Marker or other conspicuous method to remind you to pay attention to the gauge reading.
Until the count approaches 216, you do not have to worry about the supply.
It is recommended that a minimum of 2 gallons be reserved as a margin. This is especially important
at ratios other than 1:1. For instance, if the ratio is 4:1, a two gallon reserve leaves less than one half
gallon in the catalyst tank! If you are using a ratio that is not listed on the chart, ask Lily Technical
Service for the number of dispense cycles at the ratio you are using.

5 Ver. 1.6
The Air Supply
The air connections are the ‘press to connect’ variety. The connection
is made by firmly inserting the tube end into the fitting. It is released by
pulling the fitting collar firmly back against the fitting body while pulling
the tube from the fitting.
An excess of tubing is provided with
this assembly. Trim the assembly to fit
your installation.
Connections & Requirements
S-161
S-654

6 Ver. 1.6
The Air Supply - HT15 Mounted
The air connections are the ‘press to connect’ variety. The connection
is made by firmly inserting the tube end into the fitting. It is released by
pulling the fitting collar firmly back against the fitting body while pulling
the tube from the fitting.
An excess of tubing is provided with
this assembly. Trim the assembly to fit
your installation.
Connections & Requirements
Air Compressor
Connection
Bulkhead Connection at
Handtruck
Connection to CD15
Air Lines to Pressure
Vessels

7 Ver. 1.6
Operation
●Purge the air hose from the compressor of water or other contaminants.
●Switch the dispenser cabinet off.
●Point the selector valve handles on the material tanks toward the tubing.
●Fix a mixer or manifold and fluid valve at the material outlet fittings.
●Reduce the dispenser air pressure to zero by turning the regulator counter
clockwise until its spring is relaxed.
●Make certain water for eye-wash is at hand, and that those nearby are wearing
goggles and protective gear as recommended by the resin supplier.
●Take steps I and II under Clean-up on Page 7.
To Begin With
Dispensing
Connect the air supply, and switch the air on. Increase the air pressure at the dispenser
regulator until the system begins to dispense. Slowly increase the pressure to the maximum
while observing for fluid or air leaks. This practice will identify any damaged tubing, seals, or
fittings before the system is moved on site. Following the high pressure check, reduce the
pressure to that selected for the application at hand. The dispense pressure may be altered
at any time by adjusting the regulator. Once the pressure setting has been selected, the unit
will continue to dispense at that pressure until the setting is changed. Note: The dispenser
pressure gauge will only register a reading during a dispense cycle.
A stem within a gage slot tracks the vertical travel of the dispense air
cylinder. This enables the operator to monitor the dispense rate of the
unit, and to determine when it has stalled due to the refusal of a crack
to accept additional resin.
The regulator at the control panel regulates the air pressure only to the
main air cylinder when on its dispense (downward) stroke. The
pressure it exerts on the metering pistons determines the pressure at
which the resin exits the dispenser. However, the air cylinder pressure
is never the same as that of the resin pressure. The resin pressure will
vary with the ratio for which the dispenser is set. The chart at the left
lists the relationship between the regulated cylinder pressure and the
resin pressure at various ratios.
Ratio Factor
1:1 4
2:1 5.4
2.5:1 5.7
3:1 6
3.5:1 6.2

8 Ver. 1.6
Operation
Shut Down
Because the resin components are not joined within the dispenser, no clean-up of the
dispenser is required. And, most epoxy resins can be left within a system indefinitely.
However, there is a very important step to be taken at shut-down if (a), a low viscosity resin
is being used, and (b), a mixer or manifold is fixed directly to the outlet fittings of the Coco
module. The procedure is called “burping”. Burping is necessary because the base and
catalyst components of most low viscosity resins have a much different specific gravity. Like
vinegar and oil in salad dressing, one is heavier than the other, and quickly sinks to the
bottom. Until they are mixed, the base component tends to sink beneath the catalyst. When
the components hover together within a mixer fixed to the outlet valves, it is possible within a
very few minutes for the base component to settle and pond out beneath the catalyst. With
sufficient time, it may enter the catalyst outlet valve with costly results as it hardens
overnight.
Clean Up
Use the Gusto Purge Assembly (Page #30) to clean the mixer, tubing, FF-2 valves, and other items
exposed to catalyzed resin. Complete steps 1 and 2 below to charge the Gusto tank before starting
injection. It is a precaution which allows clean-up in the event the air supply is lost due to compressor
failure. For with the Gusto tank fully charged with air, there is sufficient energy within the tank to
clean up at least the major components.
1. Vent the Gusto tank by rotating the selector valve so that it points away from
the adapter block, and towards the bronze filter. Remove the lid and pour about
one-half gallon of Acetone or Methyl Ethyl Ketone (MEK) solvent into the tank.
Do not use petroleum based solvents such as toluol, xylol, mineral spirits or
naptha, as they will destroy the Gusto lid seal. Do not fill the tank, as this will
reduce the volume of air available for an emergency clean-up.
2. Replace the lid and secure it with its bale. Rotate the selector valve 90
degrees so that it is closed to the inlet and outlet. Connect the air supply and
pressurize the tank at the maximum pressure available. Set the tank aside until
time to clean-up.
3. Next “burp” the CD15. To do this simply dispense a few ounces of material into
a waste container immediately after removing the mixer from the dispenser. This
will flush any base resin that may have entered the catalyst fitting or valve.
4. Immediately after burping the dispenser and disconnecting the mixer, cap the
dispenser outlet fittings with the caps secured at the magnetic bracket, Then
secure the mixer to the manifold at the Gusto tank. Disconnect the air supply from
the dispenser, and connect it at the Gusto air inlet. Close the FF-2 valve, and
then rotate the selector valve to point to the mixer.

9 Ver. 1.6
Operation
5. Allow the pressure in the volume tank on the compressor to catch up before introducing
the solvent bursts. With the maximum pressure and volume available, open the fluid outlet
valve. Quickly shake the Gusto tank to splash small solvent bursts into the air stream. Space
the bursts about 5 seconds apart. If a low viscosity resin is being used, 5 or 6 bursts are
usually sufficient to clean the mixer and tubing. However, if a thick material must be purged,
more bursts will be required. Keep the bursts as small as possible, for large dosages of
solvent choke the air stream velocity, reducing the scouring effect. Continue until the
exhausted solvent is free of resin.
6. To clean the interior of the FF-2 valves, lay the Gusto tank on its side so
that solvent floods the outlet fitting. Then, quickly rotate the valves a few
times under the full solvent flow.
Clean Up
Ratio Assurance Test
WARNING!The CD15 contains moving parts which are by definition wearing parts. Critical
components are wearing from the moment you energize the system. It is absolutely essential
that this wear be anticipated and monitored to assure proper ratio dispensing. Key personnel
must become familiar with the following procedure for monitoring the wear of metering seals,
for if it does not become routine, improperly metered material will result.
The frequency with which the performance of the seals should be checked varies with the
abrasiveness of the fillers within the product being dispensed, as well as the volume of resin
dispensed. Normally, once each week of operation is sufficient to detect any ratio error
before it becomes significant. However, if the results are critical, monitoring should be more
intense. The ratio check is a three stage procedure.
Stage I: To determine if the outlet valve seals are leaking in the direction of normal flow.
1. Switch the dispenser “off”. [This will open the inlet valves, and close the outlet valves.]
2. Remove the mixer from the dispenser.
3. Wipe the outlet fittings, and place a paper towel beneath them.
4. Wait at least five minutes, and then observe the towel for any evidence of leakage from
the fittings. If no seepage has occurred, move to stage II.
If seepage, regardless of how minute, has occurred, replace the leaking seals. If seepage,
regardless of how minute, has occurred, replace the leaking seals.

10 Ver. 1.6
Stage II: To determine if the Coco inlet valve seals are leaking in the direction of normal
flow.
1. Turn the pressure regulator counterclockwise until no pressure is registered on the gauge.
2. Flip the dispenser switch “on”. [This will open the outlet valves and close the inlet valves.]
3. Repeat steps 4 and 5 from Stage I.
If seepage, regardless of how minute, has occurred, replace the leaking seals.
Stage III: To determine if the Coco inlet valves are leaking in the direction opposite normal
flow.
1. Tightly cap the outlet fittings
2. Turn the switch “on”. [This will open the outlet valves and close the inlet valves.]
3. Rotate the directional valves to vent the pressure vessels.
4. Disconnect the material supply hoses at the dispenser.
5. Turn the dispenser pressure regulator knob clockwise to the maximum pressure available.
6. Wipe the inlet fittings, and place a paper towel beneath them.
7. Wait at least five minutes, and then observe the towel for any evidence of leakage from
the fittings.
If seepage occurs, regardless of how minute, has occurred, replace the leaking seals.
Ratio Assurance Test
Operation