Nordson OptiMix Reference guide

Low-Pressure
OptiMixtSystem
Customer Product Manual
Part 303783B
NORDSON CORPORATION DAMHERST, OHIO DUSA
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.

E1999 Nordson Corporation
All rights reserved
303 783B
Issued 5/99
Manual 14-25
Nordson Corporation welcomes requests for information, comments and inquiries about its products.
Address all correspondence to
Nordson Corporation
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1998. 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
100 Plus, Blue Box, ChromaFlex, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat,
Excel 2000, Flow Sentry, Isocoil, Isocore, Iso-Flo, Nordson, the Nordson logo, PRX, Pro-Flo, RBX, Ready-Coat,
Rhino, Select Coat, Select Cure, Shur-Lok, Smart Spray, System Sentry, Thread Coat, Tribomatic, and Versa-Spray
are registered trademarks of Nordson Corporation.
CPX, CanWorks, Excel 2000, OptiMix, PowderGrid, Pulse Spray, SCF, Versa-Coat, Versa Screen, Package of
Values, and Swirl Coat are trademarks of Nordson Corporation.
Loctite is a registered trademark of Henkel Loctite Corporation.

Table of Contents i
E1999 Nordson Corporation
All rights reserved 303 783B
Issued 5/99
Manual 14-25
Table of Contents
1. Safety 1.....................................................
Qualified Personnel 1.......................................
Intended Use 1.............................................
Regulations and Approvals 1.................................
Personal Safety 2...........................................
High-Pressure Fluids 3....................................
Fire Safety 4...............................................
Halogenated Hydrocarbon Solvent Hazards 5................
Action in the Event of a Malfunction 5.........................
Disposal 5.................................................
2. Description 6.................................................
Specifications 7............................................
3. Installation 8.................................................
4. Operation 12.................................................
Startup 12.................................................
Checking the Ratio 12.......................................
Full System Flush 13........................................
Relieving Pressure 13....................................
Flushing System 14......................................
Quick Flush 15.............................................
Resin Flush 16.............................................
Shutdown 16...............................................
5. Maintenance 17...............................................
6. Troubleshooting 17............................................

Table of Contents
ii
E1999 Nordson Corporation
All rights reserved
303 783B
Issued 5/99
Manual 14-25
7. Hydraulic Section Repair 18....................................
Low-Pressure Resin Pump 18................................
Disconnecting the Hydraulic Section from the Air Motor 19.......
Disassembling the Hydraulic Section 20.....................
Honing the Cylinder 20....................................
Rebuilding the Foot Valve Housing 22.......................
Rebuilding the Upper Ball Check Assembly 22...............
Connecting the Hydraulic Section to the Air Motor 23.........
Low-Pressure Catalyst Pump 24..............................
Disconnecting the Hydraulic Section from the Unit 24.........
Disassembling the Hydraulic Section 25.....................
Honing the Cylinder 25....................................
Assembling the Hydraulic Section 26.......................
1:1 Fluid Section Pump 27.................................
2:1 Fluid Section Pump 28.................................
3:1 Fluid Section Pump 29.................................
Repairing the Air Motor 30...................................
Servicing Signal Valves 31................................
Servicing the Main Valve 32...............................
Servicing the Pilot Valve 34................................
8. Parts 36.....................................................
Material Pump Rebuild Kit 37................................
Pilot Valve Rebuild Kit 37....................................
1:1 Fluid Section Rebuild Kit 37..............................
2:1 Fluid Section Rebuild Kit 38..............................
3:1 Fluid Section Rebuild Kit 38..............................
Main Valve Rebuild Kit 38....................................
Gasket Kit 39..............................................
Signal Valve Rebuild Kit 39..................................
Piston Seal Rebuild Kit 40...................................
Manifold Rebuild Kit 40......................................

Low-Pressure OptiMix System 1
E1999 Nordson Corporation
All rights reserved 303 783B
Issued 5/99
Manual 14-25
Low-Pressure OptiMix System
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.
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.
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
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.
1. Safety
Qualified Personnel
Intended Use
Regulations and Approvals

Low-Pressure OptiMix System
2
E1999 Nordson Corporation
All rights reserved
303 783B
Issued 5/99
Manual 14-25
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.
Personal Safety

Low-Pressure OptiMix System 3
E1999 Nordson Corporation
All rights reserved 303 783B
Issued 5/99
Manual 14-25
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.
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.

Low-Pressure OptiMix System
4
E1999 Nordson Corporation
All rights reserved
303 783B
Issued 5/99
Manual 14-25
To avoid a fire or explosion, follow these instructions.
SGround all conductive equipment in the spray area. 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.
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 while 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.
Fire Safety

Low-Pressure OptiMix System 5
E1999 Nordson Corporation
All rights reserved 303 783B
Issued 5/99
Manual 14-25
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.
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.
Dispose of equipment and materials used in operation and servicing
according to local codes.
Action in the Event of a
Malfunction
Disposal

Low-Pressure OptiMix System
6
E1999 Nordson Corporation
All rights reserved
303 783B
Issued 5/99
Manual 14-25
See Figure 1. The low-pressure OptiMix system is designed for use in air
spray, air electrostatic, and HVLP applications, both manual and
automatic. The high-volume displacement of the base and catalyst
pumps keep duty cycles low even at high volume output requirements.
This low-pressure system offers a choice of three ratio ranges; 2:1 to
18:1, 4:1 to 35:1, and 6:1 to 55:1. There are three separate catalyst
pump systems, one for each ratio range.
1425001A
Fig. 1 Low-Pressure OptiMix System Assembly
2
. Description