Lily Corporation CD85 Operation manual

1 Ver. 1.0
Product Warranty and Disclaimer 2
Safety Precautions 2
The Resin Supply
The Connections ?
Monitoring the Resin Supply ?
Operation
The System and How It Works
Service
To Begin With 3
Dispensing 3
Shut - Down ?
Clean - Up 4
Ratio Assurance Check 5
Changing Ratio 6
The Fluid Circuit ?
COCO Valve Module 7
The Fill Sensors ?
Lubrication 8
COCO Module 8
Metering Cylinders 12
Trouble - Shooting 14
Parts Diagrams 17-24
The Pneumatic Control Circuit 25
Lily Corporation
240 S. Broadway
Aurora, Illinois 60505-4205
United States of America
Ph: 630-892-0860
Fax:[phone]
www.lilycorp.com
CD85

2 Ver. 1.0
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 components due to air content or chemistry.
Warning and Safety Precautions
The CD150 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 CD150. Do not attempt to operate this system until thoroughly familiar with it’s
contents. Phone Lily Corporation if clarifications are needed.

3 Ver. 1.0
Operation
●Purge the air hose from the compressor of water or other contaminants.
●Be sure that the cabinet On/Off switch is in the “Off” position.
●Reduce the dispenser air pressure to zero by turning the regulator counter-clockwise until it stops turning.
●Attach the dispense hoses or valve assembly to the outlet fittings.
●Make sure all cabinet covers are in place.
●Energize the transfer system.
Connect the air supply and switch the dispenser “On”. Slowly increase the air pressure at the dispenser
regulator until the system begins to dispense material. Continue increasing the pressure to approximately 100
psi while looking for fluid or air leaks. Following this test reduce the air pressure to that required for the
application at hand. The dispense pressure may be altered at any time by adjusting the regulator. Once the
pressure setting has been made the unit will continue to dispense at that pressure until the setting is changed.
NOTE: The dispense pressure gauge will only register a reading during a dispense cycle
The regulator at the control panel regulates the air pressure only to the main air cylinder when on its dispense
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 following chart shows the relationship between the
regulated cylinder pressure at various ratios.
RATIO MULTIPLIER
1:1 4.9
2:1 6.6
3:1 7.4
4:1 7.9
5:1 8.1
18:1 9.2
To Begin With
Dispensing
CHECK THIS

4 Ver. 1.0
Because the resin components are not joined together within the dispenser, no clean-up is required. And, most
epoxy resins can be left within the dispenser for quite a while. 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 valve assembly. This is a procedure we also call “burping”. The 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 a 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 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. To burp the unit, simply dispense a few ounces into a waste container
immediately after removing the mixer or manifold. This will flush any base resin which may have entered the
catalyst fitting or valve.
If a manifold or static mixer is mounted directly to the outlet valves of the COCO valve assembly then the
dispenser must be “burped” as mentioned in the previous section.
If static disposable mixers are used then clean-up is a matter of removing the mixer and disposing of it. The
threads at the mounting nozzle for the static should be cleaned with solvent then have grease applied at this
point also. This will prevent the mixer retaining nut from being glued in place.
Operation
Clean Up

5 Ver. 1.0
WARNING! The CD150 contains moving parts which are by definition wearing parts. Critical components are
wearing from the moment the system is energized. 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 being 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 step procedure.
Stage I: To determine if the COCO outlet valve seals are leaking in the direction of normal flow.
1. With air connected to the dispenser, switch the dispenser “OFF”. (This will open the inlet valves
and close the outlet valves)
2. Energize the transfer system.
3. Remove the dispense hoses or static mixer from the outlet valves.
4. Wipe the outlet fittings and place a towel or rag beneath them.
5. Wait at least five minutes and observe the fittings for any indication of leakage.
6. If seepage has occurred, replace the leaking seals. ( This would indicate failure of the outlet valve
seals.)
7. If no seepage has occurred then move on to Stage II
8.
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 it stops.
2. Flip the dispenser switch to the “ON” position. ( This will open the outlet valves and close the inlet
valves)
3. Repeat steps 4 and 5 from Stage I.
4. If seepage has occurred replace the leaking seals. (This would indicate failure of the inlet valve
seals.)
5. If no seepage has occurred move to Stage III.
Stage III: To determine if the COCO inlet seals are leaking in the direction opposite of normal
flow.
1. Tightly cap the outlet fittings
2. De-energize the transfer system.
3. Disconnect the material supply hoses from the dispenser.
4. Turn the dispenser regulator knob clockwise to the maximum pressure available.
5. Wipe the inlet fittings clean and place a towel beneath them.
6. Wait at least five minutes and observe the fittings for any indication of leakage.
7. If seepage has occurred, replace the leaking seals. (This would indicate failure of the inlet seals.)
8. If no seepage has occurred, the ratio assurance check is complete.
Operation
Ratio Assurance Test

6 Ver. 1.0
Operation
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. However, with any other ratio, the catalyst metering piston will be of a smaller
diameter. Ratio is therefore changed by exchanging one catalyst metering assembly for another. A metering
assembly consists of a metering cylinder, a metering piston, and the seals, etc. component to them. Metering
assemblies for alternate ratios are available from Lily. A few simple steps are required to change ratio:
4. Dispense a full shot or cycle. When the system re-sets, the
metering pistons will remain within their metering cylinders
because the material is no longer pressurized by the transfer
pumps.
6. Use a strap wrench to turn the catalyst metering assembly
counter-clockwise until it is free. Do not attempt to remove
the assembly with any other tool than a strap wrench, as the
chamber may be damaged by any uneven grasping force.
7. Use the seal pick to remove the base manifold o-ring.
Clean the pocket thoroughly and install a new o-ring in the
proper groove.
6. Important! Lubricate the threads of the replacement
metering assembly with an anti-seize compound or silicone
lubricant. Thread the assembly into the manifold by turning it
clockwise until it is seated. Do not over-tighten. As the
chamber bottoms out in the manifold you will feel a definite
stop. Do not tighten further.
Changing Ratio
1. Reduce the Dispenser Pressure to Zero.
3. Reduce the Transfer Pump pressures to zero.
2. Switch the Dispenser to “On”.
5. Remove the large side panels for access to the metering
assemblies.
7. Replace the side panels.

7 Ver. 1.0
3
EE
A B A
F
DD
G
C
C
EE
DD
F
AB A
CC
G
A thorough understanding of the CD150 operation will take the guess work out of trouble shooting, and
provide a better appreciation of conditions which may adversely affect its performance.
The resin components are pressurized within vessels (A) or by pumps. Pressurized, the components flow
through open inlet valves (B) to enter their respective metering cylinders (C).
The metering pistons (D) are extended by the resin pressure until they bear against the main air cylinder end
cap (E).
After both metering pistons are fully extended, the inlet valves (B) close, and the outlet valves (F) open.
The resin components then exit under the pressure exerted by the main air cylinder (E) descending against the
metering pistons (D).
The components merge at a mixer (G). When the dispense stroke is completed, the outlet valves (F) close, the
inlet valves (B) open to allow the metering cylinders to refill, as the main air cylinder ascends.
THE SYSTEM AND HOW IT WORKS
The Fluid Circuit

8 Ver. 1.0
SERVICING THE SYSTEM
If the CD125 is properly maintained, service will involve little more than routine replacement of dynamic seals
exposed to material being dispensed. The frequency of seal replacement will depend upon the material
dispensed. Thousands of gallons of non-abrasive resin with good lubricity may be dispensed with little, if any,
service; while the use of an abrasive – and usually inexpensive – material is likely to necessitate frequent seal
replacement. Costly damage to metering cylinders and their pistons may also result from the use of an abrasive
product.
If the air supply is properly maintained, the system will deliver literally millions of trouble-
free cycles. However, in the real world, that is not always possible. Therefore, periodic (twice
a year) lubrication of the air circuitry is recommended. To do so, deenergize the system and
remove the right cover. Free the four way air fitting (P-189) fixed to the bulkhead fitting (S-
009) by pressing the collar of the elbow down. Also disconnect the 1/4” tubing next to the
four way air fitting. Squeeze a generous dose of Lily Lube (P-315) into the rigid leg of the
four-way fitting and the 1/4” tube. Reconnect the fitting and tube. No other lubrication is
needed. Never use WD-40 or similar
When a ratio assurance check reveals a need for seal replacement at the Coco module, it is not necessary to
replace all of the seals within the module. Rather, replace only those seals metering the same component.
Resin components differ dramatically in terms of their abrasiveness, so the wear of the seal managing one
component is seldom an indication that the seals on the opposite side are similarily worn.
It is good practice to replace the coupler shaft seals (S-328) when replacing the ball seals. They are exposed
to the same product, so the wear is comparable. Besides, the seals are exposed during the course of replacing
theball seals, and therefore easily replaced in the course of ball seal replacement.
When servicing the coco module, refer to the exploded parts view on page #30 as well as the illustrated steps
below.
Disassembly
Turn the dispenser switch off. Vent the fluid tanks, and disconnect the air supply to the dispenser. Remove all
three screens. Grasp the metering pistons and press them down into their cylinders. This will purge the
cylinders of material, which will flow back into the tanks. Disconnect the material supply hoses at the Coco
inlet fittings, and remove the mixer at the outlet fittings. Then, follow the steps below:
1. Using a 7/8” wrench,
remove the inlet and
outlet hose from their
respective fittings at the
COCO valve.
2. Remove the air lines
from the COCO
actuator.
Lubrication
The COCO Module

9 Ver. 1.0
SERVICING THE SYSTEM
DISASSEMBLY cont”d
3. Use a 7/8” wrench
to loosen the fittings
at the COCO spacer
block. Do the same for
the “A” and “B” sides.
4. Remove the COCO /
Actuator assembly from
the machine
5. With a 3/16” Allen
wrench, remove the bolt
securing the spacer
block to the frame
module.
6. With a small pair of
snap-ring pliers remove
the internal snap ring
that secures the coupler
shaft in the ball valve
housing.
7. Remove the coupler
shaft along with it’s
bushing and set aside.
12. With a seal pick,
remove the coupler shaft
seal. Take care not to
scratch the bore.
Cleaning Clean the components thoroughly, but do not use steel bristle brushes or instruments likely to scratch or
gouge. Most solvents and cleaning agents can be used without damage to the stainless steel parts.
Inspection Carefully inspect each part. If possible, use a magnifier and light. Pay special attention to the balls and the
valve sockets. If there is any blemish, replace the part. Flat and spring washers do not need to be replaced unless
damaged.
5. With a 3/16” Allen
wrench, remove the four
bolts that hold the ball
valve body to the spacer
block.
7. Remove the O-Ring
(S-509) and the concave
spring washer (S-330).

10 Ver. 1.0
8. Remove the
remaining washer
(S-329).
11. Use the seal pick
to gently remove the ball
valve seal from its
seat. Take care not
to scratch the housing.
14. Using the seal pick
remove the flat washer
Assembly
1. Fit the seal
spring (S-330) into
the pocket with its
concave side toward
the ball.12. Remove the
lower
2. Place the washer (S-
329) over the spring.
Nudge it to be certain
that both it and the
spring are fully seated.
3. Insert the seal
perpendicular to the
bore until it is
within the pocket.
Then, twist it flat so
that the spring side
of the seal is facing
down.
4. Nudge it into place
with the fingers, and
then press it firmly into
the bottom of the
pocket with the setting
tool (M-806 ) from the
seal kit.
12. Now the ball can be
removed from the
housing. Inspect the ball
looking for wear or
scratches in the surface.
Replace if needed.
13. Use the seal pick to
remove the lower seal
from it’s seat. Take care
not to scratch the seat.
15. Finally, use the seal
pick to remove the
concave spring washer
from the bottom of the
ball valve housing.

11 Ver. 1.0
SERVICING THE SYSTEM
11. Carefully insert the
coupler shaft (M-581),
bronze bushing (M-
802) and washer (P-
469) into the housing.
12. Install the
retaining ring (P-
505). Note that one
side of the ring has
slightly rounded
edges, while the
other side has a sharp
square edge. The
sharp edge of the
snap ring must face
away from the ball.
10. Insert the seal
(S-328) into the
coupler shaft bore. To
avoid damage to the
seal edges, start it
perpendicular to the
bore, and then flatten it
into place with the
spring toward the ball.
5. Slide the ball into
the pocket with the
detent (slot) facing
the coupler pocket.
Use the tang of the
coupler shaft (M-
581) to squarely
align the ball slot.
6. Install the exterior
seal (S-332) with the
spring groove facing
away from the ball.
7. Install the flat
washer over the seal,
and apply silicone
lube to hold it in
place. Install the
spring, concave side
to the ball!!
8. Press a new o-ring
into the groove around
the outside of the spring
and washer. Use silicone
lube to hold it in place.
9. Attach the valve
body to the spacer block.
Take care not to
distort the o ring seal.
Snug, but do not tighten,
the bolts until after the
coupler shaft is installed.
9. Install the concave
spring washer with the
concave side towards the
ball!
10. Bolt the valve
assembly back to the
frame. Be sure that the
ball valves are oriented
properly.

12 Ver. 1.0
SERVICING THE SYSTEM
The frequency of service will depend upon the abrasive content of the material being dispensed, and to a lesser
degree, the abrasive atmosphere common to many construction sites. The need for metering assembly service is
recognized by leakage between the metering piston and its cylinder, sluggish extension of the piston, or by
seisure of the piston within the cylinder.
To remove a metering assembly for service, turn the dispenser switch off, disconnect the air supply at the
dispenser, and follow the steps below:
2. Loosen and
remove the metering
cylinder by rotating
it counterclockwise.
Do not use a pipe
wrench! Use a strap
wrench.
5. Now the piston
can be removed
from the metering
cylinder.
7. Seal spacer
removed.
8. Layout showing
the piston seals,
spacer, end cap,
retaining screw and
piston.
6. To replace the
piston seals, remove
the screw in the cap
retaining the seal.
Then remove the cap,
the seal, spacer, and
the second seal.
4. Unscrew the
metering piston
retaining nut and
remove.
3. Remove the
piston pad, springs,
and piston pad
holder from the
metering piston. Be
careful not to loose
the springs.
The Metering Cylinders
2. Remove the
shoulder screww
holding the piston
pad in place. Be
careful not to loose
the springs located
beneath the white
plastic pad.

13 Ver. 1.0
SERVICING THE SYSTEM
9. Be sure to install the
seals with the metal
springs facing out,
towards the piston seal
retainer.
10. Install the piston seal
retainer and retaining
nut.
11. Slide the metering
piston back into the
metering cylinder, small
end first.
12. Once the metering
piston has been slid back
into the metering cylinder
then the retaining nut can
be slid over the piston
and tightened.
11. Install the piston pad
holder then the springs
and piston pad. The
springs will locate in the
small recesses machined
into the pad and pad
retainer. Use a small
amount of grease to help
hold the springs in place
during assembly.
12. Install a new o-ring in
the base manifold and
then install the metering
cylinder. Use a strap
wrench only and tighten
until the cylinder bottoms
out (stops turning).
Tightening any further is
not necessary.

14 Ver. 1.0
TROUBLE SHOOTING
Spurts of air, or air
bubbles in the material........... Check the material level. Some air may enter the resin as it cavitates just before it is
depleted. This is especially true of viscous material.
Air bubbles in the resin ..........Check the resin tank for an air leak into the stem at its interior fitting.
Incorrect ratio ....................... Conduct ratio assurance check to confirm valve performance. (Page #10)
Check compressibility of viscous components due to air content.
Sluggish flow ...........................Disconnect the outlet fittings and observe the resin flow from the outlet ports. If the flow
is unrestricted, replace the mixer or other restriction in the exterior plumbing.
If the material is viscous (thick) due to chemistry or temperature, heat the material to
100°F. Anticipate a shorter working life!
Leakage of resin at
material piston ........................Replace the piston seal(s). (Page #’s 18, 19).
Leakage of resin between
flippers and valve bodies ........Replace the COCO stem seals. (Page #14).
Metering piston fails
to extend, or extends
slowly ....................................... Disconnect the material inlet hose at the dispenser and check the flow. If the flow is
restricted, check for an obstruction in the material supply line, or insufficient delivery
from the pressure vessel or transfer pump.
If the material supply is adequate, remove the Metering Assembly, and check for freedom
of piston movement within the cylinder. If the piston is seized or binding, service the
assembly. (Page #’s 18, 19).
With the piston fully extended, turn the switch off and wipe the piston with soap and
water or a solvent. Lubricate as well.
Material contains abrasive fillers, or is too thick.
System begins to dispense,
but cannot complete a
dispense cycle .......................... Obstruction in material outlet lines or metering cylinder.
System is unresponsive ...........Check the air supply.
System does not make
dispense stroke. Audible
air leak at sensor ports. .......... Metering pistons not sealing off sensor ports due to worn or damaged pads. Replace the
pads. (Page #18, step 8)
Insufficient material pressure to firmly impinge the pads against the cap.
Coco module is sluggish or
stalls. .........................................Material contains too much abrasive filler.Change materials.
Low air supply pressure.
Misaligned inlet valve bodies. See Step 16 on page 17.
Main air cylinder return
(ascent) is sluggish. ..................Defective Rapid Exhaust valve (P-336).

15 Ver. 1.0
TROUBLE SHOOTING
Coco module is sluggish,
stalls, or binds ..........................Material contains too much abrasive filler.Change materials.
Low air supply pressure.
Misalignment in assembly of inlet valve bodies. (Page #17)
Main air cylinder fails to
return following full dispense
stroke.........................................Malfunctioning sensor valve in upper end cap. Service the valve, replace the air filter
element, and check on cleanliness of air supply.
“Or” element (A-849) not functioning. Verify by turning the switch off. If cylinder then
returns, replace the “Or” element.
Switch to “off” does not
return main air cylinder. .........Twin valve (A-201) not shifting. Service the valve, replace the air filter element, and
check on cleanliness of air supply.
If you cannot correct the problem,
contact Lily Corporation with an exact description of how the various components are responding.
If possible, phone with the unit, air, tools, and resin information at hand.

16 Ver. 1.0
Parts Diagrams
"OR"
ON/OFF
MAIN
AIR
CYLINDER
COCO
AIR
CYL.
INNER
DIRECTIONAL
VALVE
OUTER
DIRECTIONAL
VALVE
REGULATOR
STROKE
SENSOR
P
S
ORIFICE END OF STROKE
SENSOR
PULSE
RELAY
CD85 PROTOTYPE
WIRING DIAGRAM
(ACME PAVING)
UNREGULATED
AIR

17 Ver. 1.0
Parts Diagrams
Parts List
DESCRIPTION
P ARTITEM
CD85 FRAME BASE
M-75211
CD85 FRONT P ANELM-77813 CD85 REAR P ANEL
M-75314
CD85 SIDE P ANELM-7102
5
CD85 MAIN LID
M-70816
6
5
3
1
5
4

Parts List
DESCRIPTIONP ART NUMBERQTYITEM
CD85 REAR END CAPM-72711 CD85 A/C SLEEVEM-600112 CD85 A/C PISTON
M-73113
CD85 A/C ROD
M73614
CD85 PUSHER BAR
M-73716
CD85 GUIDE BUSHING
M-7382
7
CD85 BUSHING RET AINER
M-730119
CD85 END CAP BUSHINGM-729118 CD85 FRONT END CAPM-728117 PLAIN WASHER 3/8"P-11988 3/8" HEX NUTP-472
4
9
3/8-16 X 1 1 HEX HEAD BOL T GRADE 8S-693
410
STROKE SENSOR
P-022111
NUT - 3/4-10 GRADE 8S-044
112
3/8-16 X 3/4 SHCS SSS-356
413
3/8-16 X 2 1/4 SHCSS-164
114
PLAIN WASHER 3/4"P-453115 5/16-24 X 1.5 SHCSS-120216 A/C SEAL - 5" PISTONP-758217 SEAL - U-CUP 1.25" DIA.S-722
120
SEAL - O-RINGS-720
121
SEAL - WIPER 1.25" DIA.S-721
122
CD85 FRONT A/C END CAP
M-728123
11
9
8
1
12
3
3
2
4
13
14
6
7
16
8
17
20
21
23
Parts Diagrams

Parts Diagrams
Parts List
DESCRIPTIONP ART NUMBERQTYITEM
CD85 BASE MANIFOLDM-75711 CD85 2:1 METERING CYLINDERM-78822 CD85 2:1 METERING CYLINDER CAP
M-78723
CD85 2:1 METERING PISTONM-78924 CD85 PISTON P AD HOLDERM-78525 CD85 MANIFOLD SUPPORTM-78429 CD85 PISTON P ADM-771210 Hex Flange Screw - Regular Thread - Inch
NEW P ART412
PISTON END CAPM-60222214 PISTON SEAL 2:1 CD65/75/85P-310T415 CD65/75/85 DBL SEAL SP ACERM-791216 1/4-20 X .5 SHCS SSS-99217
9
12 12
2
2
17
16
4
4
15
15
3
5
10
1

20 Ver. 1.0
Parts Diagrams
Parts List
DESCRIPTION
PART NUMBER
QTY
ITEM
CD85 MOUNTING BLOCK FOR HOPPER & TRANSFER PUMP
M-772 FOR 1.5 TUBE
21
CD85 SUCTION TUBEA-75112 10.5 GALLON ROUND SS HOPPERS-52213 1 1/2 NPT HOPER BALL VALVEP-76614
1.5 X 2 NPT PIPE NIPPLE15 1.5 X 4 NPT PIPE NIPPLE16
Split Flange Clamp -24
449-74446-2447
Regular Helical Spring Lock Washers(Inch Series)
ASME B18.21.1 - 1/288
Hexagon Socket Head Cap ScrewANSI B18.3 - 1/2 - 13 UNC -
1 1/2 HS HCS
89
3
5 4 6
1
1
7
8
2