Nordson 331151C Reference guide

Low-Pressure
Color Change Manifold
Customer Product Manual
Part 331151C
Issued 10/03
NORDSON CORPORATION AMHERST, OHIO USA
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 331151C E2003 Nordson Corporation
tents
Table of Contents
Safety 1......................................
Qualified Personnel 1.......................
Intended Use 1.............................
Regulations and Approvals 1.................
Personal Safety 2...........................
High-Pressure Fluids 2....................
Fire Safety 3...............................
Halogenated Hydrocarbon Solvent Hazards 4
Action in the Event of a Malfunction 4..........
Disposal 4.................................
Description 5.................................
Color Change Plates 6.......................
Color Change Manifold Components 6.........
Options 7...................................
Theory of Operation 8.........................
Installation 9.................................
Fluid Lines 9................................
Air Supply Lines 10...........................
Adding Colors 10.............................
Adding a Divider Plate 10......................
Operation 11..................................
Startup 11...................................
Change Colors 11............................
Shutdown 11.................................
Maintenance 11...............................
Repair 12.....................................
Color Change Manifold Disassembly 12.........
Color Change Manifold Assembly 13............
Microvalve Repair 14.........................
Removal 14...............................
Disassembly 15............................
Assembly 16..............................
Installation 16.............................
Troubleshooting 16............................
Parts 18.......................................
Using the Illustrated Parts List 18..............
Color Change Manifold 19.....................
Female Plate Assembly 20....................
Male Plate Assembly 20......................
Circulating Plate Assembly 21.................
Non-Circulating Plate Assembly 22.............
Microvalve Assembly 22......................
Kits 23......................................
Buna-N, Hot Paint Manifold Air Fitting Kit 23...
Mounting Bar Kits 24.......................
Recommended Spare Parts 25.................
Optional Parts 26............................
Divider Plate Assembly 26..................
Zalak Microvalve O-ring Kit 27...............
Zalak Manifold Air Fitting Kit 27..............
Specifications 28...............................
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 1999. No part of this 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
Nordson and the Nordson logo are registered trademarks of Nordson
Corporation.
Loctite is a registered trademark of Loctite Corporation.
Zalak is a registered trademark of E.I. DuPont de Nemours and Company.

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Low-Pressure Color Change Manifold
Safety
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to persons operating or servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.

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Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
SKeep clear of moving equipment. Before adjusting or servicing moving
equipment, shut off the power supply and wait until the equipment
comes to a complete stop. Lock out power and secure the equipment to
prevent unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SWhile operating manual spray guns, make sure you are grounded.
Wear electrically conductive gloves or a grounding strap connected to
the gun handle or other true earth ground. Do not wear or carry metallic
objects such as jewelry or tools.
SIf you receive even a slight electrical shock, shut down all electrical or
electrostatic equipment immediately. Do not restart the equipment until
the problem has been identified and corrected.
SObtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
SMake sure the spray area is adequately ventilated.
STo prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
High-Pressure Fluids
High-pressure fluids, unless they are safely contained, are extremely
hazardous. Always relieve fluid pressure before adjusting or servicing high
pressure equipment. A jet of high-pressure fluid can cut like a knife and
cause serious bodily injury, amputation, or death. Fluids penetrating the
skin can also cause toxic poisoning.
If you suffer a fluid injection injury, seek medical care immediately. If
possible, provide a copy of the MSDS for the injected fluid to the health care
provider.

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The National Spray Equipment Manufacturers Association has created a
wallet card that you should carry when you are operating high-pressure
spray equipment. These cards are supplied with your equipment. The
following is the text of this card:
WARNING: Any injury caused by high pressure liquid can be serious. If
you are injured or even suspect an injury:
SGo to an emergency room immediately.
STell the doctor that you suspect an injection injury.
SShow him this card
STell 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 treat the
injury surgically as soon as possible. Do not delay treatment to research
toxicity. Toxicity is a concern with some exotic coatings injected directly into
the bloodstream.
Consultation with a plastic surgeon or a reconstructive hand surgeon may
be advisable.
The seriousness of the wound depends on where the injury is on the body,
whether the substance hit something on its way in and deflected causing
more damage, and many other variables including skin microflora residing in
the paint or gun which are blasted into the wound. If the injected paint
contains acrylic latex and titanium dioxide that damage the tissue’s
resistance to infection, bacterial growth will flourish. The treatment that
doctors recommend for an injection injury to the hand includes immediate
decompression of the closed vascular compartments of the hand to release
the underlying tissue distended by the injected paint, judicious wound
debridement, and immediate antibiotic treatment.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SGround all conductive equipment. Use only grounded air and fluid
hoses. Check equipment and workpiece grounding devices regularly.
Resistance to ground must not exceed one megohm.
SShut down all equipment immediately if you notice static sparking or
arcing. Do not restart the equipment until the cause has been identified
and corrected.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SDo not heat materials to temperatures above those recommended by
the manufacturer. Make sure heat monitoring and limiting devices are
working properly.

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Fire Safety (contd)
SProvide adequate ventilation to prevent dangerous concentrations of
volatile particles or vapors. Refer to local codes or your material MSDS
for guidance.
SDo not disconnect live electrical circuits when working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
SShut off electrostatic power and ground the charging system before
adjusting, cleaning, or repairing electrostatic equipment.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
Halogenated Hydrocarbon Solvent Hazards
Do not use halogenated hydrocarbon solvents in a pressurized system that
contains aluminum components. Under pressure, these solvents can react
with aluminum and explode, causing injury, death, or property damage.
Halogenated hydrocarbon solvents contain one or more of the following
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 more
information. If you must use halogenated hydrocarbon solvents, contact
your Nordson representative for information about compatible Nordson
components.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
SDisconnect and lock out system electrical power. Close hydraulic and
pneumatic shutoff valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting the
system.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

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Description
See Figure 1. The low-pressure color change manifold allows you to make
quick color changes with minimum material coating loss.
The modular construction of the color change manifold allows you to
increase or decrease the number of colors simply by adding or removing
plates.
Manifolds can be configured for the application by assembling four or more
of the following plates:
SMale end plate
SFemale end plate
SCirculating valve plate
SNon−circulating valve plate
SDivider plate
2
5
4
1
3
6
7
7
Figure 1 Color Change Manifold
1. Fluid outlet fitting
2. Fluid return fittings
3. Fluid inlet fittings
4. Air fittings
5. Non-circulating valve plate
6. Circulating valve plate
7. End plates

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Color Change Plates
Figure 2 identifies the two types of valve plates. The paint type you use
determines which color change plate is used.
SUse a circulating valve plate for paints that need to be agitated or
heated. When the microvalve is closed, the paint continues to circulate.
SUse a non-circulating valve plate for paint that does not need to be
heated or agitated. When the microvalve is closed, the paint is stopped
at the valve.
Circulating Non-circulating
11
10 7
9 8
1 3 4 62 5
7
8
9
10
234 5
11
Figure 2 Circulating and Non-Circulating Valve Plates
1. Return outlet
2. Air supply for valve 1
3. Paint inlet to valve 1
4. Paint inlet to valve 2
5. Air supply for valve 2
6. Circulation-to-pump
7. Microvalve 2
8. Weep hole for valve 2
9. Weep hole for valve 1
10. Microvalve 1
11. Fluid outlet
Color Change Manifold Components
See Figure 3 for the components in a typical color change manifold.
Each color change manifold consists of a male (6) and female end plate (1),
and combinations of circulating (3) and non-circulating (7) valve plates. The
circulating plate has two valves and can be used for two colors. The
non-circulating plate also has two valves, which can be used for color, air, or
solvent.

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1
3
6
7
45
8
8
2
2
9
Figure 3 Typical Color Change Manifold
1. Female end plate
2. Mounting holes
3. Circulating valve plate
4. Fluid inlets to valves
5. Return outlet
6. Male end plate
7. Non-circulating valve plate
8. Body clips
9. Air pilot fittings
Options
Flowmeter The flowmeter is an option that allows you to measure the fluid flow out of the
color changer.
NOTE: If you require a flowmeter, contact your Nordson representative.
Zalak O-rings Your paint or solvent may be incompatible with the standard O-rings provided
with your color change manifold. You may need to replace them with Zalak
O-rings. Contact your Nordson Corporation representative to determine if you
need Zalak O-rings.
Divider Plate See Figure 4. The divider plate assembly may be placed between any
combination of circulating and non-circulating valve plates. It is used to divide
the color change manifold into two separate color change manifolds. It is
typically used for two component material, with resin on one side and the
catalyst on the other side.

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3
1
5
2
4
Figure 4 Divider Plate Assembly
1. Female end plate
2. Circulating and non-circulating
valve plates
3. Divider plate
4. Circulating and non-circulating
valve plates
5. Male end plate
Theory of Operation
See Figure 5. A different color paint is supplied to valves 1 and 2. A remote
pneumatic solenoid valve opens and closes the microvalves with air
pressure. Only one microvalve is open at a time. The paint flows through
the open microvalve to the applicator.
SThe microvalves are normally closed (air open, spring return). The paint
arriving at closed microvalve 2 cannot flow past the valve seat to the
fluid outlet so it circulates through the plate out the return and back to
the pump.
SWhen air is applied to microvalve 1, the piston compresses the spring
and pulls the poppet with it. This allows the material to flow past the
seat to the fluid outlet and to the applicator.
SIf the valve seals fail, paint leaks out of the weep holes, alerting the
operator that the microvalve plate requires service.