Lily Corporation CD250 Operation manual

1 Model CD250 Service Manual: Ver1.5
Product Warranty and Disclaimer
Safety Precautions
The Resin Supply
Fluid Connections
Operation
Servicing the System
Start-Up / Dispensing
To Pause Dispensing
Shutting Down
Clean-Up / Maintenance
Ratio Assurance Test
Changing Ratio
Lubrication
Ball Valve Seal Replacement
Metering Piston Seal Replacement
Trouble - Shooting
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
CD250
The Air Supply
Requirements and Connections
2
3
5
5
6
6
7-8
9
4
18-28
29
Parts Diagrams
Assembly Drawings
Air Logic Diagram
10
10-13
13-15
16-17

2 Model CD250 Service Manual: Ver1.5
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.
Warning and Safety Precautions
The CD250 can develop fluid pressures in excess of 1000 pounds per square
inch. Eye protection should be worn when the machine is being operated.
Mechanical members are actuated under extreme forces which can cause
severe injuries. Do not energize the machine unless all covers are in place,
and all hands, tools, and other objects are outside of the frame of the machine.
Become thoroughly acquainted with first-aid procedures recommended by your
resin supplier. 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.
If the transfer pumps are being supplied by Lily Corporation as part of this
dispensing system, please read the warnings and safety precautions supplied
by the transfer pump manufacturer. This information is included with this
system.
A thorough understanding of the Operator’s Manual is crucial to the safe
operation of the CD250. Do not attempt to operate this system until thoroughly
familiar with it’s contents. For clarifications or questions lease call, email, or fax
Lily Corporation.

3 Model CD250 Service Manual: Ver1.5
The Resin Supply
Fluid Connections
Connect the material supply hoses from the transfer pump outlet fittings to the material inlet
fittings at the rear of the dispenser. The material inlet fittings are labeled “A” and “B” and the
transfer pumps are identified as “A” and “B” as well. The fluid fittings are 1” JIC.
Connect the 2” suction hose to the transfer pump inlet. To the opposite end of the suction
hose attach the 2” ball valve and the female cam-loc fitting. This cam-loc will then be attached
to the cam-loc on the outlet valve on the material tote.
All of the fluid hoses except the 2” suction hose used with this dispenser are high pressure
hydraulic hoses. The ball valves used are rated to 4000 psi. Keep in mind that a colder and
more viscous epoxy resin will require greater transfer pump pressure to supply it to the
dispenser than a warmer or less viscous epoxy resin.
The dispense hoses are attached to the front of the CD250 Dispenser. They are also identified
as “A” and “B”. For the initial setup it doesn’t matter which dispense hose is attached
to the outlet fittings, but once the dispenser has been used, care must be taken to insure
that the hose used for the “A” component is not switched with the hose for the “B” component
TRANSFER PUMP OUTLET CONNECTION MATERIAL INLET CONNECTION
MATERIAL OUTLET CONNECTIONS MANUAL DISPENSE

4 Model CD250 Service Manual: Ver1.5
The Resin Supply
Fluid Connections, continued
These hoses are 3/4” in diameter and are connected to the dispenser with a female 1” JIC
fitting and the other end is attached to the manual dispense valve with a female 3/4” JIC
fitting.
The dispense valve is a simple, manually operated, pair of ball valves.
Please note: When in use, the dispense valve must be completely “OFF” or completely “ON”.
It must not be used to throttle flow. If it is used to throttle flow, seal wear will be increased and
the valve’s ability to completely shut off flow will be lost.
The air supply must be clean and dry. Built into the
CD250 Dispenser is a moisture separator and a
coalescing micro filter. The water separator is an auto
draining unit. It will drain the fluid accumulated through a
hole in the bottom of the machine. The micro filter has an
indicator located on the top of the filter housing to
indicate when it needs to be serviced.
The Air Supply
Requirements
The volume of dispensed resin is determined by air pressure. An inadequate supply of air will
result in sluggish performance. A 175 cfm air compressor is the MINIMUM required for the
proper operation of the CD250 Dispenser. The minimum air pressure required is 60psi. The
maximum air pressure to the CD250 dispenser should not exceed 150 psi. For the air
requirements of the transfer pumps, refer to the manufacturers operators manual.
Always blow out air hoses before connecting them toremove
any accumulated moisture and debris, preventing it from
entering the dispenser. The air connections used on the
CD250 Dispenser are the Chicago claw style fittings.
TRANSFER PUMP CONNECTION
AIR SUPPLY FROM CD250 TO
TRANSFER PUMPS
AIR FILTRATION

5 Model CD250 Service Manual: Ver1.5
Operation
1. Connect all fluid hoses as noted earlier. Make sure that the manual dispense valve is in
the closed position ( handle pulled back ).
2. Make certain that all regulators are adjusted to” ZERO”.
3. Make sure the CD250 is turned “OFF”.
4. Make all air connections as noted earlier.
5. Adjust both regulators at the transfer pumps to approximately 30 – 40 psi for the initial
start-up. These pressures can be adjusted later, once the equipment is primed and
ready for production dispensing.
6. With a 5 gal. “waste” bucket available, open the manual dispense valve, (no mixer attached to
the valve at this time) and direct flow into the waste bucket.
7. Turn the CD250 “ON”. At this time the machine will start to operate, being powered by the
transfer pumps. The goal is to prime the equipment and purge the air and testing fluids from the
new fluid lines. If the flow of material is too fast, turn down the pressure on the transfer pumps.
8. Once the air and testing fluid is purged from the fluid lines and the resin is running clean,
switch the machine “OFF” and allow it to return to the “PARK” position by leaving the
manual dispense valve “OPEN” until flow stops. The manual dispense valve can now be
“CLOSED”. The dispenser is now primed and ready for use.
9. Attach the static mixer to the manual dispense valve. Adding a small amount of
grease to the threads of the retaining nut will make removing it later easier.
10.Once the unit is in position for dispensing, make sure the manual dispense valve is in the
closed position and switch the dispenser”ON”. hold the static mixer over a waste bucket and open
the until material starts to flow from the mixer then close the valve. The system is now ready to
apply material to the deck.
11.As you become more comfortable with the dispenser, you can increase flow by increasing the
air pressure to the dispenser and transfer pumps. Do not use the dispense valve to throttle or
adjust the flow rate, use the air pressure regulators!
1. To pause dispensing for a few minutes simply close the manual dispense valve. Keep in
mind that the material in the static mixer will start to cure if the pause is too long.
2. You can also turn the CD250 “OFF” by using the switch on the front of the machine. If you
turn the machine “OFF”, leave the manual dispense valve “OPEN” until the machine makes a final
dispense cycle and returns to the “PARK” position. Then close the manual dispense valve.
To Pause Dispensing
Start-Up / Dispensing

6 Model CD250 Service Manual: Ver1.5
1. When stopping for a material change, end of shift, end of day, etc., you will use a different
procedure than if just pausing for a few minutes.
2. Adjust the regulator for the CD250 Dispenser to “0” psi.
3. Turn the CD250 “OFF” by using the switch on the front of the machine. When the switch is
“OFF”, the CD250 will make a final dispense cycle and return to the “PARK” position.
4. Once the CD250 has “PARKED”, close the manual dispense valve. At this time the static
mixer should be removed and disposed of and the threads of the dispense valve cleaned
and lubricated.
5. Adjust the air pressure to the transfer pumps to zero.
6. Disconnect the air supply from the machine.
7. The machine and transfer pumps can be left in this state until the next start-up.
Since the two components of the resin do not come together until in the disposable mixer, there is no
machine clean up. However, there are some small maintenance items that should be done at the
end of each shift or day.
First, wipe down the metering pistons with solvent,
removing
any buildup of material that might be present. Then,
lightly
coat with a silicone grease. This will keep material
from sticking to the pistons.
Then, inspect piston pads for wear. Replace if
necessary.
Now, wipe down the air cylinder rod as well as the two guide
rods.
Access to this area of the machine is achieved by removing the
bottom panels. Loosen the 6 bolts holding the panel in place, lift
the panel up then out.
Operation
Shutting Down
Clean-Up / Maintenance

7 Model CD250 Service Manual: Ver1.5
WARNING! The CD250 contains moving parts – wearing parts. Therefore, critical components
are wearing from the moment the system is energized. It is absolutely essential that this wear
be anticipated and monitored. Operating personnel must become familiar with the following
procedure for monitoring the wear of metering seals. If monitoring does not become routine,
an improperly proportioned product will result.
A check once each week of operation is usually sufficient to detect seal wear before it
becomes a problem. The frequency required will vary with the product being dispensed, as
well as the volume of material being dispensed. If the application is especially critical, then
the monitoring should be more frequent.
1. Make sure that the “ON/OFF” valve on the dispenser is in the “OFF” position.
2. Turn all of the pressure regulators on the machine down to zero.
3. Disconnect the dispense hoses and allow the accumulated resin within the fittings to
drain.
4. Connect your air supply to the dispenser.
5. Slowly increase the air pressure to the transfer pumps to 80 PSI.
6. Observe the outlet fittings for one minute, for any signs of leakage. Any leakage at this
point means the ball valves will need to be rebuilt by replacing the ball valve seals.
If there is no leakage, proceed to the next step.
7. Reduce the pressure to the transfer pumps to “Zero”.
8. Switch the Isolation Valve to the “Closed” position. (Isolation Valve is located inside the
cabinet on the lower left side. Mounted on top of the Guide Rod Support.)
9. Move the dispenser “On/Off” valve to the “On” position.
10. While holding a waste bucket under the outlet fittings, slowly increase the air pressure
to the transfer pumps to 80 psi. Material will be dispensed while the air cylinder
completes a dispense cycle.
Operation
Check the fluid level in the packing cups of the transfer
pumps and add Throat Seal Liquid as needed.
Ratio Assurance Test

8 Model CD250 Service Manual: Ver1.5
Operation
11. Once this dispense cycle is complete, wipe the dispense fittings clean, allow
accumulated resin within the fittings to drain, and observe the fittings for one minute. If
any leakage is visible, the ball valves will need to be rebuilt by replacing the ball valve
seals. If there is no leakage, this means the ball valve seals are good and the
dispenser is “on ratio”.
12. Reduce the pressure to the transfer pumps to “Zero”.
13. While holding a waste bucket under the outlet fittings, switch the Isolation Valve to the
“Open” position.
14. Move the dispenser “ON/OFF” valve to the “OFF” position.
15. Slowly increase the air pressure to the Dispenser and it will make another dispense
cycle and “PARK”.
16. Turn all of the pressure regulators back to “Zero” and disconnect your air supply.
17. Re-connect the dispense hoses and replace any covers.
Caution: The above procedure is the only one that assures ratio accuracy. Random
volumetric comparisons taken at low pressures or high flow rates do not reveal the
condition of the seals. Only an extended and significant fluid pressure can
accurately reflect their condition.
Ratio Assurance Procedure cont’d.

9 Model CD250 Service Manual: Ver1.5
Changing Ratio
Ratio is determined by the relative diameters of the catalyst and base pistons. If the ratio is
1:1, both metering pistons will be the same diameter. However, at any other ratio, the catalyst
metering piston will be smaller than the base metering piston. Ratio is changed by replacing
the two catalyst metering assemblies with the appropriate assemblies. The metering
assembly consists of the metering cylinder, metering piston, seal, piston pad, and seal
retainer. Metering assemblies for a variety of ratios are available from Lily Corporation.
1. Remove the lower panels from the CD250 Dispenser.
2. Make sure the dispenser is turned “OFF” and that all regulators are turned down to
“ZERO”.
To remove the metering assemblies it is important that the metering pistons are pushed
completely into their cylinders. The following steps are to insure that this is the case.
3. Disconnect the catalyst inlet fluid hose.
4. Open the dispense valve and direct it into a waste bucket.
5. Turn the CD250 Dispenser “ON”.
6. Manually plug the “vent” holes on the left side of the main air
cylinder end cap. This will cause the ball valves to “switch”.
7. Turn up the air pressure to the dispenser until the air cylinder
starts to move. Turn the regulator back down to “ZERO” once
the air cylinder travels about half way between the metering
cylinders.
8. Remove the air supply from the dispenser. Do not turn the
machine “OFF” before you remove the air supply.
9. Using the strap wrench supplied with the CD250 Dispenser, re
move the catalyst metering assemblies. Material will drain
from the base manifolds. This is expected and rags or towels
should be on hand for clean up. Do not attempt to remove
the metering assemblies with any other tool than a strap
wrench as irreparable damage can be done to the metering
cylinder.
10. Use the seal pick from the seal kit to remove the O-ring from
the inside of the base manifold. Clean the opening in the
bottom of the metering cylinder manifold then lubricate a new
O-ring and install it.
11. Lubricate the threads of the replacement metering assembly
with an anti-seize compound or silicone lubricant. Carefully
thread the replacement metering assembly into the base
manifold until it is seated. Do not over tighten! When the metering assembly bottoms
out in the base manifold you will feel a definite stop. Do not try to tighten beyond the
firm stop.
12. The lower access panels can now be replaced.
Operation
Vent Holes

10 Model CD250 Service Manual: Ver1.5
SERVICING THE SYSTEM
Lubrication
For information on the lubrication requirements for the transfer pumps, please refer to the
manufacturer’s owner’s manuals. If the transfer pumps are supplied by Lily Corporation then
these manuals will be included with the CD250 Operators Manual.
To lubricate the pneumatic circuit od the CD250, remove the top cabinet cover. On the left
front of the machine is a manifold that is feeding air to the pneumatic control circuits in the
dispenser. Disconnect the 3/8” diameter tube and squeeze a 1” stream of silicone lube into
the tube. No other lubrication is needed.
Never use WD-40,3 in 1 Oil, Marvel Mystery Oil, or any other petroleum based products.
Ball Valve Seal Replacement
Note: Start this procedure with the CD250 Dispenser in the “Park” position. Then remove the
fluid lines from the 4-way ball valve.
Remove the 4 mounting bolts securing the ball valve to the
mounting bracket.
Remove the bolts mounting the bracket to the main frame
assembly.
Loosen the set screws that secure the coupler to the ball
valve actuator shaft.