1606053-03 - automatic iso-flo hd voltage block...

Automatic Iso-Flo� HDVoltage Block System

Customer Product ManualPart 1606053−03

Issued 3/18

NORDSON CORPORATION • AMHERST, OHIO • USA

Part 1606053−03 � 2018 Nordson Corporation

Table of ContentsSafety 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qualified Personnel 1-1. . . . . . . . . . . . . . . . . . . . . . . .Intended Use 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulations and Approvals 1-1. . . . . . . . . . . . . . . . . .Personal Safety 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Fluids 1-2. . . . . . . . . . . . . . . . . . . .Fire Safety 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Halogenated Hydrocarbon Solvent Hazards 1-4.Action in the Event of a Malfunction 1-4. . . . . . . . . .Disposal 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Labels 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Theory of Operation 2-4. . . . . . . . . . . . . . . . . . . . . . . .

Fluid Delivery 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Interlock Operation 2-8. . . . . . . . . . . . . . . .Reset Valve Operation 2-8. . . . . . . . . . . . . . . . . . . .

Specifications and Operating Requirements 2-10. . . .Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ground Connection 3-1. . . . . . . . . . . . . . . . . . . . . . . .Electrostatic Cable Connection 3-3. . . . . . . . . . . . . . .Hose Connections 3-3. . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Air Input 3-3. . . . . . . . . . . . . . . . . . . . . . .Coating Material Input 3-4. . . . . . . . . . . . . . . . . . . .Coating Material Output 3-4. . . . . . . . . . . . . . . . . .

Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First-Time Startup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Lubrication 4-1. . . . . . . . . . . . . . . . . . . . . . . .Flushing 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Operation 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .Startup 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Short Term Shutdown 4-4. . . . . . . . . . . . . . . . . . . .Long Term Shutdown 4-5. . . . . . . . . . . . . . . . . . . . .

Color Change 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily/Shift Change 4-6. . . . . . . . . . . . . . . . . . . . . . .Weekly 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 5-1. . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fluid System Problems 5-2. . . . . . . . . . . . . . . . . . . . . .

Checking for Blockages 5-2. . . . . . . . . . . . . . . . . . .Control Valve Problems 5-3. . . . . . . . . . . . . . . . . . . . .Hardware Problems 5-4. . . . . . . . . . . . . . . . . . . . . . . .Electrostatic Problems 5-5. . . . . . . . . . . . . . . . . . . . . .

Repair 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left and Right Shuttle Assembly Repair 6-1. . . . . . .Male Coupling Repair 6-3. . . . . . . . . . . . . . . . . . . . . .

Materials Required 6-3. . . . . . . . . . . . . . . . . . . . . . .Male Coupling Disassembly 6-3. . . . . . . . . . . . . . .Male Coupling Assembly 6-4. . . . . . . . . . . . . . . . .

Female Coupling Repair 6-6. . . . . . . . . . . . . . . . . . . . .Materials Required 6-6. . . . . . . . . . . . . . . . . . . . . . .Female Coupling Disassembly 6-6. . . . . . . . . . . .Female Coupling Assembly 6-8. . . . . . . . . . . . . . .

Fluid Hookup Adapter Assembly Repair 6-9. . . . . . .Air Control Valve Assembly Repair 6-9. . . . . . . . . . . .Pump Repair 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials Required 6-10. . . . . . . . . . . . . . . . . . . . . . .Pump Removal 6-10. . . . . . . . . . . . . . . . . . . . . . . . . .Pump Disassembly 6-11. . . . . . . . . . . . . . . . . . . . . .Air Motor Piston Replacement 6-12. . . . . . . . . . . . .Fluid Piston Seal Replacement 6-12. . . . . . . . . . . .Limit Valve Adjustment 6-14. . . . . . . . . . . . . . . . . . .Pump Assembly 6-14. . . . . . . . . . . . . . . . . . . . . . . . .Pump Installation 6-15. . . . . . . . . . . . . . . . . . . . . . . .Pump External Component Replacement 6-16. . .

Parts 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 7-1. . . . . . . . . . . .Main Assembly Parts 7-2. . . . . . . . . . . . . . . . . . . . . . .Component Parts Lists 7-6. . . . . . . . . . . . . . . . . . . . . .

Toggle Valve Assembly 7-6. . . . . . . . . . . . . . . . . . .Left Shuttle Valve Assembly 7-7. . . . . . . . . . . . . . .Shuttle Assemblies (Left and Right) 7-8. . . . . . . .Male Coupling Assembly 7-10. . . . . . . . . . . . . . . . . .Female Coupling Assembly 7-11. . . . . . . . . . . . . . .Fluid Hookup Adapter Assembly 7-12. . . . . . . . . . .Air Control Valve Assembly 7-12. . . . . . . . . . . . . . .Right Shuttle Valve Assembly 7-12. . . . . . . . . . . . . .Pump Assembly 7-14. . . . . . . . . . . . . . . . . . . . . . . .Arc Suppressor Assembly 7-16. . . . . . . . . . . . . . . . .Door Valve Assembly 7-17. . . . . . . . . . . . . . . . . . . . .

Recommended Spare Parts 7-18. . . . . . . . . . . . . . . . . .Adhesives, Sealants, and Lubricants 7-18. . . . . . . . . .Optional Dump Shuttle 7-18. . . . . . . . . . . . . . . . . . . . . .

Contact UsNordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.Address all correspondence to:

Nordson CorporationAttn: Customer Service555 Jackson StreetAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 1997. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

Iso-Flo, Nordson, and the Nordson logo are registered trademarks ofNordson Corporation.

Delrin is a registered trademark of E. I. DuPont de Nemours andCompany.

Loctite is a registered trademark of Loctite Corporation.

Polypack is a registered trademark of Bostik Corporation.

Never Seez is a registered trademark of Bostik Inc.

Viton is a registered trademark of DuPont Dow Elastomers L.L.C.

Change Record i

Part 1606053−03� 2018 Nordson Corporation

Change RecordRevision Date Change

02 6/15 Updated safety labels.

03 3/18 Changes PN 900223 to 1612251.

Change Recordii


Safety 1-1


Section 1Safety

Introduction Read and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, including these instructions, isaccessible to persons operating or servicing equipment.

Qualified Personnel Equipment owners are responsible for making sure that Nordson equipmentis installed, operated, and serviced by qualified personnel. Qualifiedpersonnel are those employees or contractors who are trained to safelyperform their assigned tasks. They are familiar with all relevant safety rulesand regulations and are physically capable of performing their assignedtasks.

Intended Use Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury to personsor damage to property.

Some examples of unintended use of equipment include

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards or interlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximum ratings

Regulations and Approvals Make sure all equipment is rated and approved for the environment in whichit is used. Any approvals obtained for Nordson equipment will be voided ifinstructions for installation, operation, and service are not followed.

Safety1-2


Personal Safety To prevent injury follow these instructions.

� Do not operate or service equipment unless you are qualified.

� Do not operate equipment unless safety guards, doors, or covers areintact and automatic interlocks are operating properly. Do not bypass ordisarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicing movingequipment, shut off the power supply and wait until the equipmentcomes to a complete stop. Lock out power and secure the equipment toprevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjusting orservicing pressurized systems or components. Disconnect, lock out,and tag switches before servicing electrical equipment.

� While operating manual spray guns, make sure you are grounded.Wear electrically conductive gloves or a grounding strap connected tothe gun handle or other true earth ground. Do not wear or carry metallicobjects such as jewelry or tools.

� If you receive even a slight electrical shock, shut down all electrical orelectrostatic equipment immediately. Do not restart the equipment untilthe problem has been identified and corrected.

� Obtain and read Safety Data Sheets (SDS) for all materials used.Follow the manufacturer’s instructions for safe handling and use ofmaterials, and use recommended personal protection devices.

� Make sure the spray area is adequately ventilated.

� To prevent injury, be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated, such as hot surfaces, sharpedges, energized electrical circuits, and moving parts that cannot beenclosed or otherwise guarded for practical reasons.

High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremelyhazardous. Always relieve fluid pressure before adjusting or servicing highpressure equipment. A jet of high-pressure fluid can cut like a knife andcause serious bodily injury, amputation, or death. Fluids penetrating theskin can also cause toxic poisoning.

If you suffer a fluid injection injury, seek medical care immediately. Ifpossible, provide a copy of the SDS for the injected fluid to the health careprovider.

Safety 1-3


The National Spray Equipment Manufacturers Association has created awallet card that you should carry when you are operating high-pressurespray equipment. These cards are supplied with your equipment. Thefollowing is the text of this card:

WARNING: Any injury caused by high pressure liquid can be serious. Ifyou are injured or even suspect an injury:

� Go to an emergency room immediately.

� Tell the doctor that you suspect an injection injury.

� Show them this card

� Tell them 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 theinjury surgically as soon as possible. Do not delay treatment to researchtoxicity. Toxicity is a concern with some exotic coatings injected directly intothe bloodstream.

Consultation with a plastic surgeon or a reconstructive hand surgeon maybe 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 causingmore damage, and many other variables including skin microflora residingin the paint or gun which are blasted into the wound. If the injected paintcontains acrylic latex and titanium dioxide that damage the tissue’sresistance to infection, bacterial growth will flourish. The treatment thatdoctors recommend for an injection injury to the hand includes immediatedecompression of the closed vascular compartments of the hand to releasethe underlying tissue distended by the injected paint, judicious wounddebridement, and immediate antibiotic treatment.

Fire Safety To avoid a fire or explosion, follow these instructions.

� Ground all conductive equipment. Use only grounded air and fluidhoses. Check equipment and workpiece grounding devices regularly.Resistance to ground must not exceed one megohm.

� Shut down all equipment immediately if you notice static sparking orarcing. Do not restart the equipment until the cause has been identifiedand corrected.

� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.

� Do not heat materials to temperatures above those recommended bythe manufacturer. Make sure heat monitoring and limiting devices areworking properly.

Safety1-4


Fire Safety (contd)

� Provide adequate ventilation to prevent dangerous concentrations ofvolatile particles or vapors. Refer to local codes or your material SDSfor guidance.

� Do not disconnect live electrical circuits when working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoff valves, and fireextinguishers are located. If a fire starts in a spray booth, immediatelyshut off the spray system and exhaust fans.

� Shut off electrostatic power and ground the charging system beforeadjusting, cleaning, or repairing electrostatic equipment.

� Clean, maintain, test, and repair equipment according to the instructionsin your equipment documentation.

� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for parts informationand advice.

Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system thatcontains aluminum components. Under pressure, these solvents can reactwith aluminum and explode, causing injury, death, or property damage.Halogenated hydrocarbon solvents contain one or more of the followingelements:

Element Symbol Prefix

Fluorine F “Fluoro-”

Chlorine Cl “Chloro-”

Bromine Br “Bromo-”

Iodine I “Iodo-”

Check your material SDS or contact your material supplier for moreinformation. If you must use halogenated hydrocarbon solvents, contactyour Nordson representative for information about compatible Nordsoncomponents.

Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the systemimmediately and perform the following steps:

� Disconnect and lock out system electrical power. Close hydraulic andpneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction and correct it before restarting thesystem.

Disposal Dispose of equipment and materials used in operation and servicingaccording to local codes.

Safety 1-5


Safety Labels Table 1-1 contains the text of the safety labels on this equipment. Thesafety labels are provided to help you operate and maintain your equipmentsafely. See Figure 1-1 for the location of the safety labels.

Table 1-1 Safety Labels

Item Part Description

1. 130322

Ignition Hazard

This unit is designed to be used with material which does not sustainburning when tested in accordance with ASTM D 4206. (Sustain Burningcharacteristics are above 49 �C/120 °F.)

Consult SDS sent with the material to identify FIRE POINT SUSTAINBURNING characteristics. If this information is not specified, contact thematerial supplier.

Failure to follow this warning and these instructions may result in severepersonal injury or property damage.

2. 226328WARNING: Turn off air and power before opening door and servicing.Defeating the interlock can result in exposure to high voltage or a crushhazard.

1300330B

2

1

Figure 1-1 Safety Label Locations

Safety1-6


Description 2-1


Section 2Description

IntroductionThis manual covers the Nordson automatic Iso-Flo HD voltage-blocksystem. It contains installation, operation, maintenance, troubleshooting,repair procedures, and replacement parts lists. Other components of yourcoating system are covered by separate manuals.

Description This Iso-Flo unit is used in electrostatic coating systems equipped with oneto three automatic spray devices, or one manual spray device.

WARNING: Operating the unit with more than three automatic or onemanual spray device(s) connected to it may be unsafe and in violation ofNational Fire Prevention Association (NFPA) regulations. It also voids thewarranty. If this occurs, Nordson Corporation will not be responsible for theperformance or life of the system.

The Iso-Flo unit electrically isolates the coating-material supply pumps andcontainers from the spray devices. It allows you to electrostatically chargeand spray conductive coating materials without having to provide safetycages around the supply pumps and containers. The Iso-Flo unit provides acontinuous supply of coating material to the spray devices on demand.

You can choose to electrostatically charge the coating material at theIso-Flo unit or at the spray devices. Electrostatic voltage is supplied to theIso-Flo unit by a remote power unit and high-voltage cable. The spraydevices are supplied with electrostatic voltage by a remote power unit andhigh-voltage cable or by an integral power supply (IPS).

The Iso-Flo unit is operated solely by compressed air. The cabinet housestwo pneumatically operated shuttles, two pumps, and a set of controlvalves. The shuttles alternately open and close to keep the pumps suppliedwith coating material while isolating the electrostatically charged materialfrom the rest of the system. Coating material is supplied to the spraydevices by one pump while the other is refilling.

The unit has a safety interlock that grounds the electrostatic voltage at thecabinet if the door is opened or the compressed air supply fails.

Table 2-1 describes the major system components and their functions.Figure 2-1 shows their location in the Iso-Flo cabinet.

Description2-2


Description (contd)

Table 2-1 Iso-Flo System Components and Functions

Item Component Function

1 Reset valve Allows the operator to override the system controls and change theshuttle positions.

2 Door valves Control air flow to the ground switch. Part of the safety interlock.

3 Shuttle valves Control shuttle operation, in response to air signals from the pumplimit switches and the air control assembly.

4 Shuttles Connect the grounded coating material supply to the pumps, or thepumps to the coating material outlet and charged side of thesystem.

5 Couplings Connect to allow coating material to flow to the pumps or coatingmaterial outlet.

6 Ground switch Grounds the electrostatic voltage when door is opened or air supplyfails. Part of the safety interlock, along with the door valves.

7 Coating material inlet Provides a connection to the coating material supply.3/8-in. NPTF threads

8 Air control assembly Controls air flow to the shuttle and limit valves. Consists of threecheck valves, a release valve, and fittings, including a 1/4-in. NPTFbulkhead fitting for connecting the compressed air supply hose.

9 Upper limit valves Controls air flow and shuttle position, depending on pump air pistonposition. Normally open, mechanically actuated by pump air motor.

10 Pumps Supply coating material to the spray device. Pumps areair-powered.

11 Lower limit valves Control air flow and shuttle position, depending on pump air pistonposition. Normally closed, mechanically actuated by pump air motor.

12 Ground stud, strap,clamp

Connects the cabinet to ground.

13 Cable adapter Provides a connection for a Nordson electrostatic cable.

14 Coating material outlet Provides a connection for a fluid hose or regulator. 3/8-in. NPSM threads

15 Sight bowls Catch solvent fluid overflow and allow condition of pump plungerseals to be monitored.

16 Lubrication cups Allow solvent fluid to be added to pump. The solvent fluid lubricatesthe pump plunger seals.

Description 2-3


1300329B

1 2 3 4 5 6 7 8

9

10

11

12

13

14

1516102 5

Figure 2-1 Automatic Iso-Flo HD System Components

Description2-4


Theory of Operation

Fluid Delivery Figures 2-2, 2-3, and 2-4 divide the Iso-Flo unit into sides A and B. The Aside includes the pump, shuttle, and valves on the left side of the cabinet.The B side includes the pump, shuttle, and valves on the right side of thecabinet.

See Figure 2-2. At the start of the cycle, shuttle B is up. Coating material isflowing through the upper couplings and refilling pump B. Pump B isgrounded. Shuttle A is down, and pump A is forcing coating materialthrough the lower couplings and out to the spray device. Pump A and thebottom half of shuttle A are charged with electrostatic voltage.

1300328A

FluidAir

Working air

1

2

2

4

3

A B

Figure 2-2 Iso-Flo Unit Operation (1 of 3)

1. Shuttles2. Couplings

3. Pumps 4. Spray device

Description 2-5


See Figure 2-3. When pump A is almost empty, it opens normally closedlower limit valve A. (The pump air pistons contact the fluid indicators, whichin turn open or close the limit valves.) Lower limit valve A sends air to thesupply pilot of shuttle valve B. Shuttle valve B shifts and sends air to pumpB and shuttle B. Shuttle B shifts down. Coating material now flows fromboth pumps, through the lower couplings on the shuttles, to the spraydevice. Both the pumps and the bottom halves of the shuttles areelectrostatically charged.

1300327A

FluidAir

Working air

A B

1

2

2

34

7

9

58

6


1. Shuttles2. Couplings3. Pumps

4. Spray device5. Air pistons6. Fluid indicators

7. Lower limit valves (N.C.)8. Upper limit valves (N.O.)9. Shuttle valves

Description2-6


Fluid Delivery (contd)

See Figure 2-4. Lower limit valve A also sends air to normally open upperlimit valve B. Upper limit valve B opens when pump B starts to empty. (Aspump B empties the air piston moves down, allowing the upper fluidindicator to retract and upper limit valve B to open.) Air flows to the refillpilot of shuttle valve A. The shuttle valve shuts off the air flow to pump Aand sends air to shuttle A. Shuttle A shifts up and coating material flowsthrough the upper couplings and refills pump A. Pump A is now grounded,while pump B is charged and delivering coating material to the spray device.

This cycle repeats automatically, switching functions from side to side, aslong as the spray device is triggered. When spraying stops, the currentcycle is paused until spraying starts again. The overlap in cycles, whenboth pumps are supplying coating material to the spray device, prevents adrop in coating material pressure during the cycle changeover.

NOTE: The upper shuttle blocks are always grounded. The lower shuttleblocks are always charged (when electrostatic power supplies are on). Thecenter slide blocks, the pumps, and the fluid hoses are alternately groundedor charged depending on the shuttle position. Regulators, hoses, and anyother parts in the charged portion of the fluid path must be located so theydo not come into contact with hardware that is grounded, or alternatelygrounded and charged.

Description 2-7


1300326A

FluidAirWorking air

A B

1

2

2

3

4

7

9

58

6


1. Shuttles2. Couplings3. Pumps

4. Spray device5. Air pistons6. Fluid indicators

7. Lower limit valves (N.C.)8. Upper limit valves (N.O.)9. Shuttle valves

Description2-8


Safety Interlock OperationSee Figure 2-5. The safety interlock consists of two mechanically actuatedpneumatic door valves (1) and a spring-loaded, normally closed groundswitch (2). The top of the switch connects to the grounded upper shuttleblocks (3). The bottom of the switch is wired to the lower shuttle blocks (4),which are connected to the charged side of the system.

As long as the cabinet door remains closed, the door valves allow air to flowto the switch. The air pressure keeps the switch open. Opening the doorcloses the valves and exhausts the air in the lines to the switch. Theinternal spring closes the switch, completing the circuit between thegrounded and the charged sides of the system and grounding theelectrostatic voltage. The same thing happens if the air supply fails.

1300325A

Fluid

Ground wiresWorking air

12

3

4

3

4

Figure 2-5 Interlock Operation

1. Door valves2. Ground switch

3. Upper shuttle blocks 4. Lower shuttle blocks

Reset Valve OperationSee Figure 2-6. The reset valve (1) allows the operator to override thesystem’s automatic controls and manually control the shuttle positions.Pushing the valve toggle to the left moves the left-hand shuttle (9) to the fill(up) position and right-hand shuttle (10) to the supply (down) position.Pushing the toggle to the right reverses the shuttle positions.

With the reset valve toggle pushed to the left, air flows from the reset valvethrough the shuttle valve (3), closing the normally-open pilot valve (4). Thiscuts off the normal flow of control air to the lower limit valves (6).

Description 2-9


At the same time, air flows from the shuttle valve to the left-hand checkvalve (5) to the right-hand upper limit valve (7). The signal then goes fromthe right-hand upper limit valve to the left-hand control valve (8) refill pilot.The left shuttle moves up to the refill position, while the right shuttle movesdown to the supply position.

1300324A

AirWorking air

9

8 8

7

6

4

3

1

6

10

2

5

7

Figure 2-6 Reset Valve Operation

1. Reset valve2. Air control assembly3. Shuttle valve4. Pilot valve

5. Check valves6. Lower limit valves7. Upper limit valves

8. Control valves9. Left shuttle

10. Right shuttle

Description2-10


Specifications and Operating Requirements

Table 2-2 Specifications and Operating Requirements

Item Specifications or Operating Requirements

Cabinet dimensions 1067 x 914 x 235 mm (42 x 36 x 9.25 in.) (H x W x D)

Air input pressure 5.5−8.3 bar (80−120 psi)

Average air flow less than 0.9 liters/sec (2 scfm)

Air quality clean and dry, with 99.99% of 1 micron contaminants removed

Air input fitting 1/4-in. NPTF

Coating material input pressure 5.5−10.3 bar (80−150 psi)

Coating material input fitting 3/8-in. NPTF

Output flow Up to 1.77 liters (60 oz) per minute at 4.1 bar (60 psi) total, 20seconds Zahn 2, ambient temperature

Output pressure 4.1 bar (60 psi) with 7 bar (100 psi) input air pressure

Output fitting 3/8-in. NPSM

Electrostatic voltage 60 kV Input

NotesFilter your coating material to prevent coupling leaks or clogging of smallpassages in the couplings, pumps, and fluid hoses.

Actual output will vary depending on your system configuration. Output isaffected by variables such as the size and length of the fluid hoses to thespray devices.

While the system will operate at the minimum pressures listed in Table 2-2,use the highest available air and fluid input pressures to obtain optimumperformance. Do not exceed the maximum pressures given in the table.Contact your Nordson representative for information and assistance.

Installation 3-1


Section 3Installation

WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

MountingMount the Iso-Flo cabinet as close to the spray device as possible. This willallow you to use short hoses, which will minimize flow restriction andcolor-change time.

Secure the cabinet to the wall or free-standing panel at a convenientworking height, and allow enough clearance to open the door and servicethe unit. Four holes are provided in the back of the cabinet for fasteners.

Refer to Specifications and Operating Requirements on page 2-10 forcabinet dimensions.

Ground Connection See Figure 3-1.

1. Attach the ground clamp (11) on the end of the ground cable to a trueearth ground. The ground can be a properly installed metal electricalconduit, water pipe, or a metal rod driven deeply into the earth.

2. Make sure the cable is securely connected to the ground stud (8). Usean ohmmeter to check the ground continuity.

NOTE: The braided wire cable can be attached to the ground stud (6) ontop of the cabinet, instead of the stud on the side.

Installation3-2


Ground Connection (contd)

1300323B

31 5

11

8

10

1415

12

2 47

6

9

13

Figure 3-1 Installation

1. Fluid supply hose

2. Fluid inlet fitting (3/8-in. NPTF)3. Air supply hose

4. Air inlet fitting (1/4-in. NPTF)5. Fluid outlet hose

6. Ground stud7. Grommeted hole8. Ground stud9. Electrostatic cable

10. Cable adapter

11. Ground clamp12. Fluid pressure regulator

13. Fluid outlet fitting (3/8-in. NPSM)14. Cable extension15. Knurled nuts

Installation 3-3


Electrostatic Cable ConnectionIf you are charging the coating material at the Iso-Flo unit, use thisprocedure to connect the electrostatic cable to the unit.

See Figure 3-1.

1. Connect the electrostatic cable (9) to the power supply, according to theinstructions in the power supply manual.

2. Insert the cable extension (14) through the cable adapter (10). Theadapter is labeled CABLE.

3. Thread the brass nut on the cable onto the adapter and tighten itsecurely.

4. Route the cable extension to one of the knurled nuts (15) securing theshuttle to the V-shaped panel insert.

5. Loosen the knurled nut and secure the lug on the end of the extensionto the stud. Tighten the nut hand-tight.

Hose ConnectionsThis procedure covers air input and coating material input and outputconnections.

See Figure 3-1.

WARNING: To prevent electrical shock and retain agency approvals, onlyuse recommended hoses in your system. Contact your Nordsonrepresentative for information and part numbers.

Operating Air InputConnect the air supply hose (3) to the 1/4-in. NPTF air inlet fitting (4) on thetop of the cabinet labeled COMPRESSED AIR. The hose should havemetal fittings on each end. Continuity must exist between the fittings, andthe hose must be grounded.

NOTE: The air supply must be clean and dry. Moisture in the air canground out the electrostatic voltage.

The Iso-Flo unit’s pneumatic components require periodic lubrication. Useone of the following options to lubricate the pneumatic system:

� Install a small air line lubricator at the air inlet fitting before installing theair supply hose. Set the lubricator to the lowest possible flow rate(1−3 drops per hour of operation).

� Manually add 5−10 drops of lightweight valve oil directly into the air inletfitting once each week.

Installation3-4


Coating Material InputConnect the fluid supply hose (1) to the 3/8-in. NPTF fluid inlet fitting (2) onthe top of the cabinet labeled PAINT INLET. The hose should have metalfittings at each end. Continuity must exist between the fittings, and the hosemust be grounded.

Coating Material OutputInsert the fluid outlet hose (5) through the grommeted hole (7) in the top ofthe cabinet labeled PAINT OUTLET. Connect the hose to the 3/8-in. NPSMfluid outlet fitting (13). Use a hose that has protective, double, or reinforcedinsulation.

NOTE: You can install a fluid pressure regulator (12) on this fitting andconnect the hose to the regulator. If you do so, keep the regulator, extrafittings, and output hose as far as possible from the right-hand pump andhoses. The regulator can also be installed in the line to the spray device, orto the device.

Operation 4-1


Section 4Operation


First-Time StartupUse these procedures to prepare a new Iso-Flo unit for production.

WARNING: Persons and equipment in the vicinity of high-voltageelectrostatic systems can accumulate a dangerous static charge unless theyare grounded. Refer to the Safety section for information on grounding.Failure to observe this warning could result in fire, explosion, personalinjury, or even death.

See Figure 4-1 for the location of the components mentioned in theseprocedures.

Pump Lubrication1. Prepare a batch of Nordson type Q-solvent (for waterborne materials)

according to the instructions on the shipping container.

2. The lubrication cup is located on the front of each pump. Unscrew theplug on the top of the lubrication cup and add 1/2 ounce of properlydiluted Q-solvent to each cup.

NOTE: Fill the lubrication cups to the bottom of the vent hole. This willequal the 1/2 ounce of properly diluted Q-solvent that is needed.

Operation4-2


FlushingFlushing will remove oils, metal filings, and other contaminants left from themanufacturing and installation process, and purge air from the system.Always use a cleaning solution compatible with the coating material you willbe using.

1. Supply compressed air and a compatible cleaning solution to the Iso-Flounit. Do not turn on the electrostatic voltage.

2. Trigger the spray device and let the Iso-Flo unit cycle for a few minutesuntil all traces of air have been expelled from the system.

3. Supply coating material to the Iso-Flo unit.

4. Trigger the spray device.

5. Turn the RESET valve toggle (10) to the left and hold it there for a fewseconds, then do the same to the right. Repeat this process until alltraces of cleaning solution are expelled and undiluted coating material isspraying from the spray device.

NOTE: Toggling the pumps on and off allows only a few ounces of coatingmaterial to enter the pump during the refill cycle and minimizes waste.

Operation 4-3


1300322B

RESET10

8

92

3

1

7

4

1

4

6

5

Fig. 4-1 Operation and Maintenance

1. Male coupling2. Slide rods3. Cylinder shaft4. Female coupling

5. Fluid pressure regulator(optional)

6. Center slide block7. Dummy coupling

8. Sight bowl9. Lubrication cup

10. RESET valve toggle

Operation4-4


Daily OperationWARNING: Persons and equipment in the vicinity of high-voltageelectrostatic systems can accumulate a dangerous static charge unless theyare grounded. Refer to the Safety section for information on grounding.Failure to observe this warning could result in fire, explosion, personalinjury, or even death.


Startup1. If using an air lubricator, check the reservoir level and fill it if it is low.

2. Supply compressed air and coating material to the unit.

3. Make sure air and coating material input pressures are set correctly foryour application. Refer to the Description section for maximum andminimum operating pressures. For optimum performance, use thehighest available pressures up to the maximum.

4. Set the desired output pressure at an optional fluid pressureregulator (5). The regulator can be installed at the fluid outlet fitting, inthe line to the spray device, or at the spray device.

5. Turn on the electrostatic power supply or spray-device control system.

6. Trigger the spray device and start spraying.

NOTE: Shut off the electrostatic power supply during breaks in production.Leave the air supply on to keep the shuttles closed and prevent coatingmaterial from drying on the couplings.

Short Term Shutdown1. Shut off the electrostatic power supply.

2. Shut off the compressed air and coating material supply.

3. Trigger the spray device to relieve air and fluid pressure.

4. Open the cabinet door and manually move the shuttle center slideblocks (6) to separate the couplings (1, 4).

5. Clean the couplings with a clean cloth soaked in a compatible cleaningsolution.

6. Close the cabinet door.

Operation 4-5


Long Term Shutdown1. Turn off the electrostatic power supply.

2. Flush the system with a compatible cleaning solution. Refer to Flushingon page 4-2.

3. Shut off the cleaning-solution supply.

4. Allow the Iso-Flo unit to cycle until it expels the cleaning solution. Whenit stops, push and hold the reset valve toggle (10) in each direction for afew seconds to expel any remaining traces of solution.

5. Shut off the compressed air supply.

6. Open the cabinet door.

7. Manually move the shuttle center slide blocks (6) to separate thecouplings (1, 4). Clean the couplings with a clean cloth soaked in acompatible cleaning solution.

8. Close the cabinet door.

Color ChangeNOTE: To reduce the amount of wasted material and time needed to makethe color change, shut off the coating material supply before the end of theproduction run. To calculate the time needed to use up the material in theunit, divide 40 ounces by the spray-device flow rate.

1. Empty the Iso-Flo unit by spraying into the booth or by opening a dumpvalve in the fluid line to the spray device.

2. Supply a compatible cleaning solution to the unit.

3. Trigger the spray device and let the unit cycle for a few minutes until thecleaning solution is free of all traces of the old coating material.

4. Supply new coating material to the unit.

5. Trigger the spray device.

6. Push the reset valve toggle to the left and hold it there for a fewseconds, then do the same to the right. Repeat this procedure until alltraces of cleaning solution are expelled and undiluted coating material isspraying from the spray device.

7. Start spraying the new material.

Operation4-6


MaintenanceThe Iso-Flo unit requires little maintenance except cleaning and lubrication.


Daily/Shift Change1. Shut off the electrostatic power supply.

2. Shut off the compressed air and coating material supply.

3. Trigger the spray device to relieve air and fluid pressure.

4. The lubrication cups (9) are located on the front of the pumps. Unscrewthe plug on the top of the lubrication cup and add 1/2 ounce of properlydiluted Q-solvent (for waterborne materials) to the cup, if needed.

NOTE: Fill the lubrication cup to the bottom of its vent hole. This willequal the 1/2 ounce of properly diluted Q-solvent that is needed.

5. Check the sight bowls (8). Excess solvent drains into them. Empty thebowls if necessary.

NOTE: The solvent normally turns the color of the coating materials beingused. If the drainage into the sight bowls exceeds the amount of solventbeing added, the pump seals are wearing and leaking slightly. This isnormal after several months of use. An excessive amount of coatingmaterial in the solvent, or constant leakage from the bowls into the cabinet,indicates worn or damaged pump seals. If this occurs, rebuild the pumps.

6. If using an air lubricator, check the reservoir level and fill it if it is low.

7. Manually move the shuttle center slide blocks (6) to separate thecouplings (1, 4). Clean the couplings with a clean cloth soaked in acompatible cleaning solution.

Weekly1. Perform the daily maintenance procedures.

2. Lubricate the female couplings (4), dummy couplings (7), slide rods (2),and cylinder shafts (3) as follows:

a. Use a one-inch stiff brush with the bristles trimmed to 1/2-in. long tobrush O-ring grease into the heavy springs surrounding the femaleand dummy couplings. Work the grease through the springs ontothe coupler shafts.

b. Wipe any coating material residue or old grease off the slide rodsand coat them with a thin film of O-ring grease.

c. Coat the cylinder shafts with a thin film of O-ring grease.

3. If your Iso-Flo unit is not equipped with an air lubricator, remove the airsupply line and add 5−10 drops of lightweight valve oil into the air inletfitting at the top of the unit.

Troubleshooting 5-1


Section 5Troubleshooting


Introduction This section contains troubleshooting procedures. These procedures coveronly the most common problems that you may encounter. If you cannotsolve the problem with the information given here, contact your localNordson representative for help.

Problems are listed in Tables 5-1 through 5-4.

Table 5-1 Fluid System Problems

No. Problem Page

1. No coating material 5-2

2. Coating material supply erratic 5-2

3. System blocked 5-2

Table 5-2 Control Valve Problems

No. Problem Page

1. Unit stuck—Right shuttle up, left shuttle down 5-4

2. Unit stuck—Both shuttles down 5-4

3. Unit stuck—Both shuttles up 5-4

Table 5-3 Hardware Problems

No. Problem Page

1. Pump will not move 5-5

2. Couplings will not close 5-5

3. Shuttle will not move 5-5

4. Pump sight bowl overflows 5-5

5. Coating material leaking 5-5

Table 5-4 Electrostatic Problems

No. Problem Page

1. No electrostatic voltage 5-6

2. Poor wrap 5-6

Troubleshooting5-2


Fluid System ProblemsWARNING: Relieve air and fluid pressure before disconnecting hoses orother components. High pressure fluids are an injection hazard. Failure toobserve this warning could result in personal injury or death.

WARNING: Turn off electrostatic voltage before performing any diagnosticsor repair work. Failure to observe this warning could result in personalinjury or death.

Problem Possible Cause Corrective Action

1. No coating material Fluid pressure regulator set at zero Adjust the fluid pressure.

System blocked Refer to Problem 3.

Unit not cycling Refer to Control Valve Problems.

2. Coating materialsupply erratic

Coating material supply pressuretoo low

Increase the coating material supplypressure to 5.5 bar (80 psi) minimum(10.3 bar or 150 psi maximum).

Air pressure too low Increase the air pressure to 5.5 bar(80 psi) minimum (8.3 bar or 120 psimaximum).

Faulty fluid pressure regulator Replace the regulator.

Coating material has cured oncouplings

Clean the couplings.

3. System blocked Coating material filter plugged Clean or replace the filter element.

Fluid supply hose plugged Flush or replace the hose.

Fluid hose to spray device plugged Flush or replace the hose.

Couplings plugged Clean or replace the couplings.Disassemble the male half first.

Spray device nozzle or fluid tipplugged

Clean or replace the nozzle or fluidtip.

Spray device passagewaysplugged

Clean or replace the spray device.

Troubleshooting 5-3


Checking for BlockagesTo check for blockages in the fluid system, start at the spray device andwork against the direction of flow, toward the supply, as follows:

1. Relieve fluid pressure by shutting off the system compressed air supplyand triggering the spray device, or opening a drain valve. Set the fluidpressure to zero.

2. Disconnect the fluid hose from the spray device, and place the hose endin a waste container. Secure the hose end to prevent unwantedmovement.

3. Turn on the system air supply and restart the system. Increase fluidpressure slowly. If no fluid flows from the hose, the blockage is not atthe spray device, but further back in the system.

4. Repeat steps 1 through 3, disconnecting each fluid hose in turn, untilfluid flows freely. The last hose or component that no fluid flowed fromis blocked.

Troubleshooting5-4


Control Valve ProblemsWARNING: Shut off electrostatic voltage before performing the followingtasks. Failure to observe this warning could result in personal injury fromelectrical shock.

Before making the corrections listed below, disconnect the air tubing fromthe limit valve outlet ports (straight fittings).

NOTE: Corrective actions must be done in the sequence given in this chart.For example, in Problem 1, you cannot adjust the upper limit valve on theright pump until you adjust the lower limit valve on the left pump.


1. Unit stuck—Rightshuttle up, left shuttledown

Lower limit valve on left pump notadjusted properly

Screw the valve into the block untilair flows from the valve outlet port.

NOTE: If unit is stuck withleft shuttle up and rightshuttle down, switch sidesin causes and corrections.

Upper limit valve on right pump notadjusted properly

Screw the valve into the block untilair stops flowing from the valve outletport.

Lower limit valve on right pump notadjusted properly

Screw the valve out of the block untilair stops flowing from the valve outletport.

2. Unit stuck—Bothshuttles down

Lower limit valve on left pump notadjusted properly



Screw the valve out of the block untilair flows from the valve outlet port.

Lower limit valve on right pump notadjusted properly


3. Unit stuck—Bothshuttles up


Screw the valve into the block untilair stops flowing from the valve outletport.

Lower limit valve on left valve notadjusted properly

Screw the valve out of the block untilair stops flowing from the valve outletport.

Troubleshooting 5-5


Hardware Problems


1. Pump will not move Air motor seized Rebuild the air motor.

Plunger seized Rebuild the fluid side of pump.

Limit valves not adjusted properly Refer to Control Valve Problems.

Fluid indicator associated with limitvalve defective

Replace the fluid indicator. Refer tothe procedures in the Repair section.

2. Couplings will notclose

Air pressure too low Increase the air pressure to 5.5 bar(80 psi) minimum (8.3 bar or 120 psimaximum).

Shaft in female half of coupling dry Lubricate the couplings. Refer to theWeekly maintenance procedures inthe Operation section.

Coupling damaged Rebuild or replace the couplings.Refer to the procedures in the Repairsection.

3. Shuttle will not move Cylinder leaking air at packing nut Replace the cylinder.

Shuttle rods loose or unscrewed Tighten the rod nuts and rods.

Shuttle control valve defective Replace the valve.

4. Pump sight bowloverflows

Too much solvent added tolubrication cup

Add 1/2 ounce (about 1 teaspoon) perweek.

Pump plunger seals worn Rebuild the fluid side of pump.

Pump cylinder worn or scored Replace the cylinder.

5. Coating materialleaking

Couplings worn or damaged Rebuild or replace the couplings.

Hose fitting loose Tighten the fittings.

Hose damaged Replace the hose. Route the hose toavoid damage.

Voltage burning pin holes in hose Replace the hose. Route the hose toavoid damage.

Troubleshooting5-6


Electrostatic Problems


1. No electrostaticvoltage

Electrostatic power supply off Turn power supply on.

Faulty electrostatic cable Replace the electrostatic cable.

Cabinet door open (voltage isgrounded)

Close the cabinet door.

Door valves not opening whendoor is closed

Adjust the door valve position.

Faulty ground switch Replace the ground switch.

Short in spray device Check for a short; repair or replacethe spray device.

Short in fluid hose to spray device Separate the hoses from groundedhardware.

Moisture in compressed air Check the air dryer; install one ifnecessary.

Conductive film on plastic cabinetliner panels

Wash the liner panels with acetone.

2. Poor wrap No or low electrostatic voltage Turn the power supply on. If voltagecan not be increased, refer to yourpower supply and spray devicemanuals.

Voltage too high Use 60 kV or less for waterbornecoating materials.

Repair 6-1


Section 6Repair


IntroductionThis section provides repair information for your Iso-Flo unit, includingstep-by-step instructions for repairing the male and female couplings,pumps, and flow sensor, and information on lubricants, adhesives, andsealants required to repair other unit assemblies.

WARNING: Shut off electrostatic voltage and ground the system, and shutoff and relieve air and fluid pressure before performing any maintenance orrepair work on the system. Failure to observe this warning could result inserious personal injury.

Left and Right Shuttle Assembly Repair See Figure 6-1 when rebuilding the shuttle assemblies. Apply lubricants,adhesives, and sealants as noted. The shuttle blocks are not replaceable.If they are damaged or worn you must replace the entire assembly.

Refer to Male Coupling Repair and Female Coupling Repair to rebuild themale and female couplings.

Repair6-2


Left and Right Shuttle Assembly Repair (contd)

1300314A

2

9

1

3

4

4

6

12

11

10

20

8

11

10

21

8

22

23

24

25

5

14

15

16

17

18

19

10

Apply pipe adhesive/sealantpart 900481 (Loctite High TempSS567) to threads beforeinstalling.

Thread cylinder rod into slideblock 36.3 mm (1.43 in.) thenapply one drop of threadlockingadhesive part 900439 (LoctiteHigh Temp 271) to threads.

Apply Never Seez lubricant part900344 to threads of cylinderhousing before threading intotop block.

Apply O-ring lubricant part1612251 (Parker O-Lube) toexternal O-rings beforeinstalling.

Apply O-ring lubricant part1612251 (Parker O-Lube)to shaft of dummy couplingbefore rebuilding.

13Tighten lower nylon nuts to6.7−9 N�M (60−80 inch-lbs)then apply one drop ofthreadlocking adhesive part900464 (Loctite Removable242) to nut threads.

7

Figure 6-1 Left and Right Shuttle Assembly Repair

1. Branch tee2. Cylinder3. Male elbow4. Nylon nut5. Dummy plug6. Retaining ring7. Nylon bearing8. Male coupling9. Shuttle rods

10. Male elbow11. Female coupling12. Pipe plug13. Dummy coupling14. O-ring15. Shaft16. Spring17. Collar

18. Washer19. Screw20. Male connector21. Screws22. Top block23. Slide block24. Adapter block25. Bottom block

Repair 6-3


Male Coupling Repair

Materials RequiredBefore you rebuild the male coupling, have the following materials ready:

� Male and female coupling repair kit or male coupling repair kit

� O-ring lubricant (Parker O-Lube or equivalent)

Refer to Male Coupling Assembly on page 7-10 and Adhesives, Sealants,and Lubricants on page 7-18 for kit and lubricant part numbers and orderinginformation.

Male Coupling DisassemblySee Figure 6-2.

CAUTION: To prevent torque damage to the shuttle mechanism, use yourfree hand to prevent the shuttle block from twisting when loosening thecoupling.

1. Unscrew the male coupling and remove it from the shuttle block. Usean open end wrench or a Nordson pump wrench and turncounterclockwise.

2. Unscrew the coupling tip (1) from the male adapter (9).

3. Remove the ball (5) and large spring (6).

4. Using a pick or small screwdriver, remove the O-ring (4), flat washer (3),and tungsten O-ring (2) from the coupling tip. Do not mar the insidesurfaces of the tip.

5. Push on the head of the pin (7) to compress the small spring (8) andrelieve the tension on the retaining ring (13).

6. Remove the retaining ring, stainless steel flat washer (12), and nylonwasher (11) from the end of the pin.

7. Remove the pin and small spring from the adapter.

8. Discard all parts except the coupling tip (1), pin (7), and adapter (9).Discarded parts are included in the coupling repair kits listed in Parts.

Repair6-4


Male Coupling Assembly See Figure 6-2.

NOTE: Lubricate all O-rings with O-ring grease before installing them.

1. Install the the new tungsten O-ring (2) into the coupling tip (1).

2. Install the new flat washer (3) into the coupling tip, with the roundededge toward the tungsten O-ring.

3. Install the new O-ring (4) into the groove inside the coupling tip. Set thecoupling tip aside.

4. Slip the new small spring (8) over the pin (7). Insert the pin and springassembly into the adapter (9), flat end of the pin first.

5. Push on the head of the pin to compress the spring and force the flatend of the pin out the end of the adapter.

6. Gently push the new nylon washer (11), flat side first, over the end of thepin. After the washer is started on the pin, use thumb pressure to forceit against the pin shoulder.

7. Install the new flat washer (12) on the pin. Lock the nylon washer andflat washer in place with the new E-clip retaining ring (13).

8. Grasp the end of the pin and pull it gently to make sure it moves freelyagainst the spring pressure.

9. Install the new large spring (6) over the pin and spring assembly.

10. Drop the new stainless steel ball (5) into the coupling tip and thread thecoupling tip onto the male adapter. Tighten the coupling tip hand tight.

11. Measure the gap between the coupling tip and the top of the wrenchflats on the adapter. This gap should be less than 3 mm (1/8 in.) If thegap is greater than 3 mm (1/8 in.), the coupling tip is not seated in thecounterbore. Unscrew the coupling tip and reposition the flat washer (3)before using wrenches to finish tightening the assembly.

12. Tighten the coupling tip to approximately 14−20 N�m (10−15 ft-lb).

13. Lubricate the new O-ring (10) and install it in the groove in the end of theadapter.

14. Check the coupling operation by inserting a smooth rounded rod into thetip of the male coupling to unseat the ball. Further insertion of the rodshould start pushing the end of the pin out of the adapter.

CAUTION: To prevent torque damage to the shuttle mechanism, use yourfree hand to prevent the shuttle block from twisting when tightening thecoupling.

15. Thread the adapter clockwise into the shuttle block. Tighten the adapterto 14−20 N�m (10−15 ft-lb).

Repair 6-5


1 3 4 5 6 7 8 9 10 11 12 132

121

2

3 4 9

11

1076 8

5

13

Apply O-ring lubricantpart 1612251 (ParkerO-Lube) to all O-ringsbefore installing.

Torque to 14−20 N�m(10−15 ft-lb) wheninstalling on adapter.

Torque to 14−20 N�m(10−15 ft-lb) wheninstalling on shuttle.

Must be less than 3 mm(1/8 in.)

Install with roundededge toward item 2O-ring.

1300315A

Figure 6-2 Male Coupling Repair

1. Coupling tip2. Tungsten O-ring3. Flat washer4. O-ring5. Ball

6. Large spring7. Pin8. Small spring9. Adapter

10. O-ring11. Nylon washer12. Stainless steel flat washer13. E-clip retaining ring

Note: Item numbers are the same as item numbers in the Male Coupling Assembly parts list on page 7-10.

Repair6-6


Female Coupling Repair

Materials RequiredBefore you rebuild the female coupling, have the following materials ready:

� Male and female coupling repair kit or female coupling repair kit


� Threadlocking adhesive (Loctite Removable 242 or equivalent)

Refer to Female Coupling Assembly on page 7-11 and Adhesives, Sealants,and Lubricants on page 7-18 for kit and lubricant part numbers and orderinginformation.

Female Coupling Disassembly See Figure 6-3.

CAUTION: To prevent torque damage to the shuttle mechanism, use yourfree hand to prevent the shuttle block from twisting when loosening thecoupling.

1. Unscrew the female coupling and remove it from the shuttle block. Usean open end wrench or a Nordson pump wrench and turncounterclockwise.

2. Pry the retaining ring (13) out of the threaded end of the body (9).

3. Remove the retaining ring, small spring (12), and ball (11).

CAUTION: Do not damage the insert (3). Any damage to this carefullymachined part will require replacing the entire coupling.

4. Insert a no. 6 spanner wrench into the holes on the head of the post (2).Place a wrench on the body flats to prevent it from turning. Unscrew thepost from the body.

NOTE: If the post is frozen in place, compress the large spring until thepost protrudes far enough out of the insert (3) to grasp it with locking pliersand unscrew it.

5. Slide the body out of the sleeve (6) and remove the large spring (7).

6. Remove the O-rings (8, 10) from the body.

7. Unscrew the collar (1) from the sleeve, using the wrench flats on eachside.

8. Remove the PTFE O-ring (4), insert (3), O-ring (2), and post from thecollar.

9. Discard all parts except the collar (1), insert (3), post (5), sleeve (6), andbody (9). Discarded parts are included in the coupling repair kits listedin Parts.

Repair 6-7


1300316A

1 2 3 4 5 6 7 8 9 10 11 12 13

1

12

11

10

9876

5

4

3

2

13

Apply O-ring lubricant toO-ring groove and shaftbefore assembling.

Apply threadlockingadhesive part 900464(Loctite Removable 242)to threads beforeassembling.

Torque to 14−20 N�m(10−15 ft-lb) wheninstalling on shuttle.

Apply O-ring lubricant toall O-rings beforeinstalling.

O-ring lubricant: Nordson1612251 (Parker O-Lube)

Figure 6-3 Female Coupling Repair

1. Collar2. O-ring3. Insert4. PTFE O-ring5. Post

6. Sleeve7. Large spring8. O-ring9. Body

10. O-ring11. Ball12. Small spring13. Internal retaining ring

Note: Item numbers are the same as item numbers in the Female Coupling Assembly parts list on page 7-11.

Repair6-8


Female Coupling AssemblyNOTE: Lubricate all O-rings with O-ring grease before installing them.

1. Lubricate the O-ring grooves and shaft of the body (9).

2. Lubricate new O-rings (8, 10) and install them on the body.

3. Install a new PTFE O-ring (4) on the post (5):

a. Lubricate a tapered pin with O-ring grease.

b. Carefully push the PTFE O-ring onto the tapered pin, expanding theO-ring just enough so it will fit over the threaded end of the post. Ifyou expand it too much you could crack it.

c. Remove the PTFE O-ring from the tapered pin and install it over thethreaded end of the post.

4. Lubricate a new O-ring (2) and install it in the collar (1).

5. Install the insert (3) in the collar.

6. Insert the head of the post through the hole in the insert. Gently pushthe PTFE O-ring into the counterbored seat in the insert. Be careful notto cut the outside diameter of the O-ring on the edge of the counterbore.

7. Screw the sleeve (6) into the collar to firmly seat the PTFE O-ring in thecounterbore.

8. Apply threadlocking adhesive to the threads on the post. Use theadhesive sparingly to avoid clogging the small holes in the body.

9. Slide the new large spring (7) over the sleeve and insert the body intothe sleeve.

10. Push down on the collar to compress the spring and screw the post intothe body. Tighten the post with a no. 6 spanner wrench.

11. Install a new ball (11) and spring (12) into the threaded end of the body.

12. Install the new retaining ring (13) in the body, making sure that it isinstalled squarely and that the tangs are all within the shallow recessprovided.

13. Inspect the assembly, especially the insert sealing lip, inside the collarand surrounding the head of the post. Make sure the surface is smoothand free from nicks or burrs.

14. Push down on the collar to check the movement of the sleeve over thebody. Compressing the large spring should cause the head of the postto protrude about 8 mm (5/16 in.) from its seated position.

CAUTION: To prevent torque damage to the shuttle mechanism, use yourfree hand to prevent the shuttle block from twisting when tightening thecoupling.

15. Thread the female coupling clockwise into the shuttle block. Tighten to14−20 N�m (10−15 ft-lb).

Repair 6-9


Fluid Hookup Adapter Assembly Repair

1300317A

2

35

4

1 1

Apply pipe adhesive/sealant part900481 (Loctite High Temp SS567)to threads before installing.

If you remove the nipple item 14from item 5 bulkhead fitting, applypipe adhesive/sealant part 900481(Loctite High Temp SS567) tonipple threads before re-installing.

14

Figure 6-4 Fluid Hookup Adapter Assembly Repair

1. Male elbows2. Male branch tee

3. Lock washer4. Jam nut

5. Bulkhead fitting14. Double male nipple

Note: Item numbers are the same as item numbers in the Fluid Hookup Adapter Assembly parts list on page 7-12, exceptfor item 14, which is listed in the Main Assembly Parts list on page 7-2.

Repair6-10


Air Control Valve Assembly Repair

1300318A

IN EX

H

CY

L

2

1

34

56

7

7

8 7

8

1211

13

10

9

10

910

7

Side View Front View

Apply pipe adhesive/sealant part 900481(Loctite High TempSS567) to threadsbefore installing.

Figure 6-5 Air Control Valve Assembly Repair

1. Bulkhead adapter2. Brass nipple3. Cross4. Street elbow5. Branch tee

6. Male elbow7. Male elbow8. Check valve9. Street tee

10. Nipple11. Branch tee12. 3-way air-piloted valve13. Hex nipple

Note: Item numbers are the same as item numbers in the Air Control Valve Assembly parts list on page 7-12.

Pump RepairIf you are rebuilding the fluid side of the pumps, flush the system with acompatible cleaning solution and expel as much cleaning solution from thepumps as possible by toggling the reset valve. Refer to Flushing onpage 4-2 for instructions.

Materials RequiredBefore you rebuild the pump, have the following materials ready:

� Pump repair kit


� Pipe thread adhesive/sealant (Loctite High Temp SS 567 or equivalent)

� Threadlocking adhesive (Loctite Removable 242 or equivalent)

The repair kit includes air and fluid cylinder O-rings, air piston, lower airpiston nut O-ring, and fluid piston seal. Order separately any other partsrequired.

Repair 6-11


Refer to Pump Assembly on page 7-14 and Adhesives, Sealants, andLubricants on page 7-18 for kit, lubricant, and adhesive part numbers andordering information.

NOTE: The pump heads, shaft, and fluid piston are not replaceable. If theyare damaged, you must replace the pump with a new one.

Tools needed:

� Side cutters

� Small, thin-blade, flat screwdriver

� 12- and 15-inch or larger adjustable wrenches

� Vise

� 1/4-inch hex wrench

NOTE: If you are replacing any external valves or fittings on the pump,refer to Pump External Component Replacement (Figure 6-8) in thismanual.

Pump RemovalSee Figure 6-6.

1. Number all air tubing (4) and fluid hoses (3) and their correspondingfittings. Disconnect the tubing and hoses.

2. Remove the two screws and sealing washers (2) from the bottom of thepump support bulkhead.

3. Remove the pump (1) from the Iso-Flo cabinet.

Repair6-12


1300373A

1

4

32

DO NOT FILL CUPADD ONLY 1/2 oz.

TYPE “Q” SOLVENTWEEKLY

Figure 6-6 Pump Removal and Installation

1. Pump2. Screws and washers

3. Fluid hoses4. Air tubing

Pump Disassembly See Figure 6-7.

1. Use a 1/4-inch hex wrench to remove the four socket-head screws (2A)from the top of the air motor head (24).

2. Remove the air motor head.

3. Pull up on the air motor cylinder (14), tilting and twisting it to pull it off theair piston (16).

NOTE: If you are only replacing the air motor piston, you do not need toperform the rest of the steps in this procedure.

4. Use the hex wrench to remove the center head screws (2B).

5. Remove the center head (25) and piston and shaft assembly.

6. Pull the fluid cylinder (19) off the fluid piston (27) and base head (28).

Repair 6-13


Air Motor Piston ReplacementSee Figure 6-7.

1. Hold the lower jam nut (17) with a 15-inch adjustable wrench. Removethe upper jam nut (15) with a 12-inch adjustable wrench.

2. Remove the air piston from the shaft (26).

3. Screw the lower jam nut down the shaft until it stops.

NOTE: If you must replace the spacer (22), unscrew the lower jam nut fromthe shaft.

4. Remove the O-ring (23) from the lower jam nut. Lubricate a new O-ringand install it in the jam nut groove.

5. Center the new air piston on top of the lower jam nut.

6. Thread the upper jam nut onto the shaft until it stops. Place a wrenchon the shaft flats to prevent it from turning. Tighten the upper jam nut onthe shaft until snug.

7. Slide the air piston up until it fits into the boss on the upper jam nut.

8. Hold up the air piston and screw the lower jam nut upwards by handuntil it contacts the piston. Tighten the lower jam nut.

9. Inspect the inside wall of the air cylinder. If scratched, replace it with anew one.

Fluid Piston Seal Replacement

CAUTION: Do not scratch the fluid piston seal groove. Any scratches willcause the pump to leak.

See Figure 6-7.

NOTE: The shaft (26) and fluid piston (27) are not serviceable. If they aredamaged, you must replace the pump.

1. Carefully slide a thin flat-bladed screwdriver under the fluid pistonseal (20).

2. Pry the seal out of the groove enough to cut it with side cutters.

3. Clean the seal groove and make sure there are no scratches in thegroove surfaces.

4. Center the seal on the piston, making sure the seal lip faces the bottomof the piston.

5. Push the seal over the piston with your palms until it fits into the groove.Be careful not to damage the seal lip.

6. Clean the inside of the fluid cylinder with a compatible solvent such asalcohol. Make sure the inside wall of the cylinder is smooth and free ofnicks and burrs. Replace the cylinder if damaged.

7. Apply a thin layer of O-ring lubricant to the inside wall of the fluidcylinder.

Repair6-14


1300320B

20

11

21

23

22

21

21

19

17

16

15

14

1213

24

25

26

27

28

Apply O-ring lubricant to all O-ringsbefore installing.

Apply O-ring lubricant to inside wall andtop and bottom lips before installing.

Apply O-ring lubricant to piston sealand bottom of piston before installing.

If fluid piston is removed from shaft, apply2−3 drops of threadlocking adhesive part900464 (Loctite Removable 242) to shaftthreads before re-assembling.

O-ring lubricant: Nordson part1612251 (Parker O-Lube orequivalent)

9

18

2A

2B

Top View

If replacing limit valves or indicators, referto Limit Valve Adjustment procedure.

Figure 6-7 Pump Repair

2. Screws9. Limit valve (MJVO-3)

11. Balls12. Fluid indicators13. O-rings14. Air cylinder15. Upper jam nut

16. Air piston17. Lower jam nut18. Limit valve (MJV-3)19. Fluid cylinder20. Fluid piston seal21. Square O-rings22. Spacer

23. O-ring24. Air motor head25. Center head26. Shaft27. Fluid piston28. Base head

Note: Item numbers are the same as item numbers in the Pump Assembly parts list on page 7-14.

Repair 6-15


Limit Valve AdjustmentSee Figure 6-7.

Perform this procedure if you replace either limit valve (9 or 18) or the fluidindicators (12). If these components are not installed and adjustedcorrectly, the Iso-Flo unit will not cycle properly.

1. Apply O-ring lubricant to the O-ring (13) and install it on the fluidindicator (12).

2. Thread the fluid indicator all the way into the head.

3. Install the valve ball (11) into the valve port in the head.

4. Thread the limit valve (9 and 18) into the valve port hand-tight. Connectair tubing to the elbow fitting (input port) on the valve.

5. Apply 5.5 bar (80 psi) air pressure to the limit valve.

6. Press down on the fluid indicator stem until the top of the stem is18.5 mm (0.73 inches) above the head face.

7. Screw the limit valve into the port until it cracks (refer to Table 6-1).Then screw the valve into the port a minimum of one-half turn to notmore than 1.5 turns more, until the outlet fitting points straight up.

8. Lock the valve in place with the lock nut and washer.

9. Release the fluid indicator stem. The indicator should reseat and closeor open the limit valve.

Table 6-1 Limit Valve Crack Definition

Item Valve Output at Crack

9 MJVO-3, normally open 0 psi (closes, with 80 psi input)

18 MJV-3, normally closed > 50 psi (opens, with 80 psi input)

Pump AssemblySee Figure 6-7.

1. Remove the square O-rings (21) from the air motor head (24), centerhead (25), and base head (28). Apply O-ring lubricant to the newsquare O-rings and install them in the grooves in the heads. Make surethe O-rings are not twisted in the grooves.

2. Apply a thin layer of O-ring lubricant to the inside wall of the fluidcylinder.

NOTE: One end of the fluid cylinder (19) has a chamfer on its insidediameter. Install the fluid cylinder so that the chamfered end is against thecenter head (25).

3. Install the fluid cylinder into the O-ring groove on the base head, thenguide the fluid piston into the cylinder. Make sure the top lip of thecylinder fits into the O-ring groove in the bottom of the center head.

Repair6-16


4. Install the four socket-head screws (2B) through the center head asfollows:

CAUTION: Do not overtighten screws. Excessive torque will damage thecylinder. Use a hex wrench less than 100 mm (4 in.) long.

a. Use a crisscross pattern to install the screws (3) until the screwheads contact the air motor head.

b. Using a crisscross pattern, tighten each screw to 3.4 N�m (30 in.-lb).

c. Using a crisscross pattern, tighten each screw to 6.8 N�m (60 in.-lb).

d. Using a crisscross pattern, tighten each screw to 9 N�m (80 in.-lb).

5. Apply a 1/16-in. thick coat of O-ring lubricant to the outside diameter ofthe piston seal. Apply a thin coat of O-ring grease to the rest of the sealand the entire bottom face of the piston. Liberally coat the entire innersurface of the cylinder with O-ring lubricant.

6. Install the air motor cylinder by tilting it over the air motor piston.Gradually tip the cylinder until it is vertical and the piston is completelyinside the cylinder.

7. Push the air motor cylinder down and fit the lower cylinder lip into theO-ring groove in the center head.

8. Install the air motor head on the air cylinder. Make sure the top lip of thecylinder fits into the O-ring groove in the air motor head.

9. Install the four socket-head screws (17-A) through the air motor headand tighten them using the procedure in step 3.

Pump InstallationSee Figure 6-6.

1. Install the pump (1) on the pump support bulkhead and secure it with thescrews and washers (2).

2. Connect the air tubing (4) and fluid hoses (3) to their correspondingfittings.

Repair 6-17


Pump External Component Replacement

1300321B

3

54

6

Apply pipe adhesive/sealant part 900481(Loctite High TempSS567) to threadsbefore installing.

8

10

9

18

1

8

10

7



Figure 6-8 Pump External Component Replacement

1. Male elbow3. Oil cup4. Male elbow5. Male elbow

6. Sight glass7. Brass nipple8. Brass pipe elbow

9. Limit valve MJVO-310. Male connectors18. Limit valve MJV-3

Note: Item numbers are the same as item numbers in the Pump Assembly parts list on page 7-14.

Repair6-18


Parts 7-1


Section 7Parts

Introduction To order parts, call the Nordson Customer Service Center or your localNordson representative. Use this five-column parts list, and theaccompanying illustration, to describe and locate parts correctly.

Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the part numberapplies to all parts in the illustration.

The number in the Part column is the Nordson Corporation part number. Aseries of dashes in this column (- - - - - -) means the part cannot be orderedseparately.

The Description column gives the part name, as well as its dimensions andother characteristics when appropriate. Indentions show the relationshipsbetween assemblies, subassemblies, and parts.

� If you order the assembly, items 1 and 2 will be included.

� If you order item 1, item 2 will be included.

� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if the partnumber is a bulk item ordered in quantities or if the quantity per assemblydepends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list. Notescontain important information about usage and ordering. Special attentionshould be given to notes.

Item Part Description Quantity Note— 0000000 Assembly 11 000000 � Subassembly 2 A2 000000 � � Part 1

Parts7-2


Main Assembly Parts See Figure 7-1.

NOTE: Parts that do not have a part number are not serviceable parts. Toreplace or repair them refer to their parts breakdown or order the assemblyor kit to which they belong.

Item Part Description Quantity Note— 224245 ISO-FLO, HD, continuous 11 - - - - - - � VALVE, HD continuous, toggle, assembly 1 A2 900517 � TUBING, spiral cut 0.92 ft B3 - - - - - - � VALVE, assembly, left HD continuous shuttle 1 A4 226665 � SHUTTLE, HD continuous Iso-Flo, left 1 A5 - - - - - - � ADAPTER, fluid hook up, assembly 2 A6 226666 � SHUTTLE, HD continuous Iso-Flo, right 1 A7 - - - - - - � VALVE, air control, assembly 1 A8 - - - - - - � VALVE, assembly, right HD continuous shuttle 1 A9 226110 � GROMMET, 7/8-in. ID x 1/16 x 1 5/8-in. OD 110 222977 � PUMP, heavy duty, Iso-Flo 2 A11 246153 � ADAPTER, cable 112 984705 � NUT, hex head, M16 x 2 x 5.5-mm thick 113 240976 � CLAMP, ground, with wire 114 973207 � NIPPLE, double male, 3/8 x 3/8 in.,

stainless steel1

15 982921 � SCREW, hex head, 5/16-18 x 0.75 in., zinc, G5 416 226106 � WASHER, sealing, 0.434 x 3/4-in. OD 417 900557 � TUBING, nylon, 0.375 x 0.050 in. 10.2 ft B18 226105 � SPRING, compression, 0.500 in. x 0.054 in.

x 206

19 984120 � NUT, hex, machine, #10-32, steel, zinc 1620 983123 � WASHER, flat, 0.219 x 0.500 x 0.049 in., zinc 1221 231191 � SPACER, 0.37 x 0.19 x 0.50 in., brass 422 982754 � SCREW, truss head, #10-32 x 1.25 in., steel,

zinc8

NOTE A: Refer to applicable assembly parts list or kit list in this manual for parts breakdown.

B: Order in one foot increments.

Continued...

Parts 7-3


1300313B

1 2 3 4 5 6 7 8 9

10

1112

13

14

5

1516

1718

19202122

41

31

19313239404344

Figure 7-1 Main Assembly Parts (1 of 2)

Parts7-4


Main Assembly Parts (contd)

See Figures 7-1 and 7-2.

Item Part Description Quantity Note23 982719 � SCREW, round head, 1/4-20 x 3 in., slotted,

brass8

24 226116 � NUT, knurled, finger, 1/4-20, brass 825 984210 � NUT, hex, jam, 1/4-20, steel, zinc 1626 226114 � BRACKET, angle, 0.250-in. hole 127 309596 � SERVICE KIT, suppressor, arc 1 A28 981462 � SCREW, hex head, 1/4-20 x 1 in., zinc, G5 129 984217 � NUT, hex, lock, 1/4-20 UNC-2B 130 229535 � CLAMP, 1/2-in. EMT 131 983124 � WASHER, lock, internal, #10, steel, zinc 1032 981131 � SCREW, hex head, #10-32 x 0.625 in., zinc 233 981461 � SCREW, hex head, 1/4-20 x 0.750 in., zinc, G5 234 - - - - - - � BRACKET, foot mounting, 12344 135 244649 � BRACKET, mounting, 11917-1 236 983120 � WASHER, lock, split, #10, steel, nickel 437 981160 � SCREW, pan head, #10-32 x 0.50 in., slotted,

zinc4

38 - - - - - - � VALVE, door, upper, HD continuous 2 A39 - - - - - - � TERMINAL, ringtong, insulated, 16-14 640 - - - - - - � WIRE, vinyl, 14 AWG, red 3.5 ft B41 900556 � TUBING, nylon, 0.250 x 0.035 in. 52 ft B42 983140 � WASHER, lock, 3, split, 1/4-in. steel, nickel 843 931149 � WIRE, vinyl, 18 AWG, green with yellow 4.17 ft B44 933071 � TERMINAL, ringtong, insulated, 22-18, 10 2NS 244854 � FLUID, type Q concentrate, 1 quart 1

NOTE A: Refer to applicable assembly parts list or kit list in this manual for parts breakdown.

B: Order in one-foot increments.

NS: Not Shown

Parts 7-5


1300312A

25

23

24

26

27

23

24

25 2827

29

30

20

19

39 3940 40

19203637

38

35 33

25

34

31

32

19

42

Figure 7-2 Main Assembly Parts—Details (2 of 2)

Parts7-6


Component Parts ListsNOTE: Refer to the Main Assembly Parts list and illustrations for locationsof components.

Toggle Valve AssemblySee Figure 7-3. This part is item 1 in the Main Assembly Parts list.

Item Part Description Quantity Note— - - - - - - VALVE, HD continuous, toggle, assembly 11 972119 � ELBOW, male, 1/4-in. tube x 1/8-in. NPT 22 226107 � VALVE, toggle, TV-4MP 13 972716 � CONNECTOR, male, 1/4-in. tube x 1/8-in. NPT 1

1300311A

1

2

1

3

Figure 7-3 Toggle Valve Assembly

Parts 7-7


Left Shuttle Valve AssemblySee Figure 7-4. This part is item 3 in the Main Assembly Parts list.

Item Part Description Quantity Note— 226663 VALVE, assembly, left HD continuous shuttle 11 973615 � TEE, branch, 1/4-in. tube x 1/8-in. NPT, plastic 12 125211 � VALVE, air operated, MPA-3P 13 148936 � VALVE, air, MJV-4D 14 973278 � TEE, male run, 1/4-in. tube x 1/8-in. NPT 15 230993 � VALVE, pilot, MPA-5P 16 972119 � ELBOW, male, 1/4-in. tube x 1/8-in. NPT 17 972716 � CONNECTOR, male, 1/4-in. tube x 1/8-in. NPT 2

1300310A

2

7

3 65

4

1

MJV−4DMPA−3P

Figure 7-4 Left Shuttle Valve Assembly

Parts7-8


Shuttle Assemblies (Left and Right)See Figure 7-5. These parts are items 4 and 6 in the Main Assembly Partslist. Refer to Repair in this manual for repair procedures.

Item Part Description Quantity Note— - - - - - - SHUTTLE, HD continuous Iso-Flo, left 1— - - - - - - SHUTTLE, HD continuous Iso-Flo, right 11 971268 � TEE, branch, 1/4-in. tube x 1/4-in. NPT, plastic 12 148456 � CYLINDER, O-ring piston, single rod 13 971266 � ELBOW, male, 1/4-in. tube x 1/4-in. NPT 14 984177 � NUT, nylon, 1/2-13 45 - - - - - - � PLUG, dummy, assembly 1

NS 945017 � � O-RING, hotpaint, 3/8-in. tube 16 986334 � RING, retaining, internal, 100, inverted 27 901381 � BEARING, nylon, 0.755 x 1.004 x 1.00 in. 28 246483 � COUPLING, male 2 A9 147049 � ROD, shuttle, 21.5-in. long 210 972913 � ELBOW, male, 3/8-in. tube x 1/4-in. NPT,

stainless steel3

11 246484 � COUPLING, female 2 A12 703191 � PLUG, pipe, socket, flush, stainless steel,

1/4-in. NPT1

13 - - - - - - � COUPLING, dummy coupler 114 945017 � � O-RING, hotpaint, 3/8-in. tube 115 - - - - - - � � SHAFT, dummy coupler 116 130340 � � SPRING, compression, 1.500 x 1.095-in. OD

x 0.120 in.1

17 - - - - - - � � COLLAR, dummy, brass 118 983050 � � WASHER, flat, 0.344 x 0.625 x 0.063 in., zinc 119 981457 � � SCREW, low head, socket, 5/16-18 x

0.750 in., black1

20 972910 � CONNECTOR, male, 3/8-in. tube x 3/8-in. NPT,stainless steel

1

21 981233 � SCREW, socket head, 1/4-20 x 1.00 in., zinc 422 - - - - - - � BLOCK, top, shuttle, continuous 123 - - - - - - � BLOCK, slide, shuttle, continuous 124 - - - - - - � BLOCK, adapter, shuttle, continuous 125 - - - - - - � BLOCK, HD shuttle 1

NOTE A: Refer to Male Coupling Assembly and Female Coupling Assembly in this manual for parts breakdown.

NS: Not Shown

Parts 7-9


1300309A

2

9

1

3

4

4

6

13

12

11

10

20

8

11

10

21

8

7

22

23

24

25

5

14

15

16

17

18

19

10

Figure 7-5 Shuttle Assemblies (Left and Right)

Parts7-10


Male Coupling AssemblySee Figure 7-6. This part is item 8 in the Shuttle Assemblies Parts list.Refer to Repair in this manual for repair procedures.

Item Part Description Quantity Note— 246483 COUPLING, male 11 - - - - - - � TIP, coupling 1 A2 942020 � O-RING, 0.250 x 0.500 in., tungsten 1 B3 130343 � WASHER, flat, 0.625 in. x 0.349 in. 1 B4 940150 � O-RING, hotpaint, 0.563 x 0.688 x 0.063 in. 1 B5 900046 � BALL, 302/316 stainless steel, 0.343-in.

diameter, 1001 B

6 - - - - - - � SPRING, compression, 1.250 x 0.360 x0.040 in.

1 A

7 139389 � PIN, valve, safety 1 B8 987070 � SPRING, compression, 0.750 x 0.240-in. OD x

0.026 in.1 B

9 - - - - - - � ADAPTER, male 1 A10 945017 � O-RING, hotpaint, 3/8-in. tube 1 B11 983260 � WASHER, 0.312 x 0.151 x 0.062 in., nylon 1 B12 983026 � WASHER, flat, 0.312 in. x 0.156-in. MS,

stainless steel1 B

13 986116 � RETAINING ring, external, 15, Reering 1 BNOTE A: These parts are not serviceable. To replace order a new male coupling.

B: Noted parts are included in the Male and Female Coupling Repair Kit part 139401, and in the MaleCoupling Repair Kit, part 234441. Use either kit to repair the male coupling.

AR: As Required

1300292A

1 3 4 5 6 7 8 9 10 11 12 132

Figure 7-6 Male Coupling

Parts 7-11


Female Coupling AssemblySee Figure 7-7. This part is item 11 in the Shuttle Assemblies Parts list.Refer to Repair in this manual for repair procedures.

Item Part Description Quantity Note— 246484 COUPLING, female 11 - - - - - - � COLLAR, coupling 1 A2 941120 � O-RING, hotpaint, 0.500 x 0.688 x 0.094 in. 1 B3 - - - - - - � INSERT, collar, coupling 1 A4 940305 � O-RING, -106, PTFE, 0.174 x 0.103 in. 1 B5 - - - - - - � POST, coupling 1 B6 - - - - - - � SLEEVE, coupling 1 A7 130340 � SPRING, compression, 1.500 x 1.095-in. OD x

0.120 in.1 B

8 941110 � O-RING, hotpaint, 0.438 x 0.625 x 0.094 in. 1 B9 246586 � BODY, post, coupling 110 945017 � O-RING, hotpaint, 3/8-in. tube 1 B11 900046 � BALL, 302/316 stainless steel, 0.343-in.

diameter, 1001 B

12 130324 � SPRING, compression, 0.750 x 0.360-in. OD x0.026 in.

1 B

13 986304 � RING, retaining, internal, 43, push on 1 BNOTE A: These parts are not serviceable. To replace order a new female coupling.

B: Noted parts are available in the Male and Female Coupling Repair Kit, part 139401, and the FemaleCoupling Repair Kit, part 234440. Use either kit to repair the female coupling.

1300293A

1 2 3 4 5 6 7 8 9 10 11 12 13

Figure 7-7 Female Coupling

Parts7-12


Fluid Hookup Adapter AssemblySee Figure 7-8. This part is item 5 in the Main Assembly Parts list. Refer toRepair in this manual for repair procedures.

Item Part Description Quantity Note— - - - - - - ADAPTER, fluid hook up 1 A1 972912 � ELBOW, male, 3/8 in. tube x 3/8-in. NPT,

stainless steel2

2 973197 � TEE, male branch, auto, 3/8-in. NPT, stainlesssteel

1

3 983073 � WASHER, lock, internal, 7/8 in. steel, zinc 14 984259 � NUT, hex, jam, 7/8-14, steel, zinc 15 232901 � BODY, bulkhead fitting, stainless steel 1

NOTE A: All part quantities shown are for one adapter. Two adapters are used in one Iso-Flo unit.

Air Control Valve AssemblySee Figure 7-9. This part is item 7 in the Main Assembly Parts list. Refer toRepair in this manual for repair procedures.

Item Part Description Quantity Note— - - - - - - VALVE, air control, assembly 11 973968 � ADAPTER, bulkhead, 1/4-in. NPT 12 973027 � NIPPLE, brass, schedule 40, 1/4-in. NPT x

0.87 in.1

3 973223 � CROSS, pipe, 1/4-in. NPT, brass 14 973157 � ELBOW, pipe, street, 1/4-in. NPT, brass 15 971268 � TEE, branch, 1/4-in. tube x 1/4-in. NPT, plastic 16 971266 � ELBOW, male, 1/4-in. tube x 1/4-in. NPT 17 972119 � ELBOW, male, 1/4-in. tube x 1/8-in. NPT 68 164560 � VALVE, check, MJSV-1, 1/8-in. NPT, brass 39 973259 � TEE, pipe, street, 1/8-in. NPT x 1/8-in. NPT 210 973000 � NIPPLE, steel, schedule 40, 1/8-in. NPT x

0.75 in.3

11 973615 � TEE, branch, 1/4-in. tube x 1/8-in. NPT, plastic 112 170743 � VALVE, air piloted, 3-way, N/O 113 973469 � NIPPLE, hex, 1/4-in. NPT x 1/8-in. NPT x

0.687 in., brass1

Right Shuttle Valve AssemblySee Figure 7-10. This part is item 8 in the Main Assembly Parts list.

Item Part Description Quantity Note— 226662 VALVE, assembly, right HD continuous shuttle 11 972119 � ELBOW, male, 1/4-in. tube x 1/8-in. NPT 22 125211 � VALVE, air operated, MPA-3P 23 148936 � VALVE, air, MJV-4D 14 973615 � TEE, branch, 1/4-in. tube x 1/8-in. NPT, plastic 15 972716 � CONNECTOR, male, 1/4-in. tube x 1/8-in. NPT 2

Parts 7-13


1300308A

2

35

4

1 1

Figure 7-8 Fluid Hookup Adapter Assembly

1300307A

IN

EX

H

CY

L

2

1

34

56

7

7

8 7

8

1211

13

10

9

10

910

7

Side View Front View

Figure 7-9 Air Control Valve Assembly

1300306A

2

5

3 42

1

1

MPA−3P MPA−3P

IN

A B

MJV-4D

Figure 7-10 Right Shuttle Valve Assembly

Parts7-14


Pump Assembly See Figure 7-11. This part is item 10 in the Main Assembly Parts list. Referto Repair in this manual for repair procedures.

Item Part Description Quantity Note— 222977 PUMP, heavy duty, Iso-Flo 1 A1 971266 � ELBOW, male, 0.25-in. tube x 0.25-in. NPT 12 981508 � SCREW, socket head, 5/16-18 x 6.5 in., black 83 1026151 � HOUSING, cup, solvent, Iso-Flo 1

NS 336846 � PLUG, pipe, 3/4-in. NPT, HDPE, regulator 1NS 973141 � ELBOW, male, pipe, hydraulic, 1/4 in., stainless

steel1

4 972913 � ELBOW, male, 3/8-in. tube x 1/4-in. NPT,stainless steel

1

5 972912 � ELBOW, male, 3/8-in. tube x 3/8-in. NPT,stainless steel

1

6 161552 � BOWL, sight glass, Iso-Flo 17 973027 � NIPPLE, brass, schedule 40, 1/4-in. NPT x

0.87 in.1

8 973125 � ELBOW, pipe, 1/8-in. NPT, brass 29 901385 � VALVE, air operated, MJVO-3 110 972716 � CONNECTOR male, 1/4-in. tube x 1/8-in. NPT 411 900047 � BALL, 302/316 stainless steel,

0.375-in. diameter, 1002

12 223528 � INDICATOR, fluid, HD pump limit 213 940130 � � O-RING, hot paint, 0.438 x 0.563 x 0.063 in. 114 236609 � CYLINDER, air, translucent 115 323718 � NUT, jam, piston, upper 116 323717 � PISTON, air 1 B17 323716 � NUT, jam, piston, lower 118 901378 � VALVE, air operated, MJV-3 119 336830 � CYLINDER, fluid, stainless steel, Iso-Flo 120 223195 � SEAL, Polypack, polymite with Viton 1 B21 940470 � O-RING, Buna-N, square, 4.500 x 4.625 in. 4 B22 240325 � SPACER, 0.688 x 1.500 x 0.386 in., aluminum 123 940190 � O-RING, hot paint, 0.813 x 0.938 x 0.063 in. 1 B24 - - - - - - � HEAD, air motor, HD pump, Iso-Flo 1 C25 - - - - - - � HEAD, center, HD pump, Iso-Flo 1 C26 - - - - - - � SHAFT, HD pump, Iso-Flo 1 C27 - - - - - - � PISTON, HD pump, Iso-Flo 1 C28 - - - - - - � HEAD, base, HD pump, Iso-Flo 1 C

NOTE A: All pump parts quantities shown are for one pump. Two pumps are used in one Iso-Flo unit.

B: Noted parts are included in Pump Repair Kit, part 223723.

C: These parts are not serviceable. To replace order a new pump.

Parts 7-15


1300305B

20

1 A

A View A−A

2

3

2

54

6

8

109 11

21

23

22

21

21

19

18

17

16

15

14

1213

7

10

24

25

26

27

28



Figure 7-11 Pump Assembly

Parts7-16


Arc Suppressor AssemblySee Figure 7-12. This part is item 27 in the Main Assembly Parts list.

Item Part Description Quantity Note— 309596 SERVICE KIT, suppressor, arc 1 A— - - - - - - � SUPPRESSOR, arc, manual Iso-Flo 1 A1 973000 � � NIPPLE, steel, schedule 40, 1/8-in. NPT x

0.75 in.1

2 972119 � � ELBOW, male, 1/4-in. tube x 1/8-in. NPT 13 900556 � � TUBING, nylon, 0.250 x 0.035 in. 0.67 ft B4 901378 � � VALVE, air operated, MJV-3 15 125211 � � VALVE, air operated, MPA-3P 16 973278 � � TEE, male run, 1/4-in. tube x 1/8-in. NPT 1

NOTE A: The arc suppressor cannot be disassembled without damage. Only the external parts can be replaced.To replace the arc suppressor, order the Arc Suppressor Service Kit, part 309596.

B: Order in increments of one foot.

1300304A

2

3

6

1

4 5

Figure 7-12 Arc Suppressor Assembly

Parts 7-17


Door Valve AssemblySee Figure 7-13. This part is item 38 in the Main Assembly Parts list.

Item Part Description Quantity Note— - - - - - - VALVE, door, upper, HD continuous 1 A1 901378 � VALVE, air operated, MJV-3 12 972716 � CONNECTOR, male, 1/4-in. tube x 1/8-in. NPT 13 972119 � ELBOW, male, 1/4-in. tube x 1/8-in. NPT 1

NOTE A: All door valve parts quantities shown are for one valve. Two door valves are used in one Iso-Flo unit.

1300303A

1

2

3

MJV−3

IN

OUT

Figure 7-13 Door Valve Assembly

Parts7-18


Recommended Spare PartsKeep the following parts in inventory to avoid unplanned downtime.Quantities listed support a single unit. Adjust order quantities based on thenumber of units in service.

Part Description Quantity222977 PUMP, heavy duty, Iso-Flo 1309596 SERVICE KIT, suppressor, arc 1226107 VALVE, toggle, TV-4MP 1148936 VALVE, air, MJV-4D 1125211 VALVE, air operated, MPA-3P 1230993 VALVE, pilot, MPA-5P 1901378 VALVE, air operated, MJV-3 1901385 VALVE, air operated, MJVO−3 1148456 CYLINDER, O-ring piston, single rod 1223723 KIT, HD pump repair, Iso-Flo 1246483 COUPLING, male 1246484 COUPLING, female 1139401 SERVICE KIT, coupling, male and female 1297980 CABLE, HD, electrostatic, 8M 1244854 FLUID, type Q concentrate 1

Adhesives, Sealants, and LubricantsUse these adhesives, sealants, and lubricants when repairing your unit.Refer to Repair in this manual for application instructions.

Part Description Note900481 ADHESIVE, pipe/thread/hydraulic sealant (Loctite High Temp SS567 for stainless

steel threads)

900439 ADHESIVE, threadlocking (Loctite High Temp 271)900464 ADHESIVE, threadlocking (Loctite Removable 242)900344 LUBRICANT, Never Seez, 8 oz can1612251 LUBRICANT, O-ring, Parker (Parker O-Lube), 2 oz.

Optional Dump ShuttlePart Description Note

235613 KIT, HD dump shuttle, automatic

DECLARATION of CONFORMITY

Product: Trilogy

Models: Trilogy Automatic Waterborne, HD Automatic ISO−FLO, EPS6

Description: Trilogy Automatic liquid waterborne applicator used with the HD automatic ISO−FLO voltageblock system and EPS6 Power Supply.

Applicable Directives:Machinery Directive 2006/142/ECEMC Directive 2004/108/EECATEX Directive 94/9/EC

Standards Used for Compliance:EN12100 (2003) EN50348 (2002) EN61000-6-3 (2007)EN60204 (2006) EN50059 (1990) EN61000-6-2 (2005)

FM7260 (1996) EN55011 (2009)

Type of protection:Ex II 2 G, 93.24 mJ, Ambient temperature: 0 �C to +40 �C

Principles:This product has been manufactured according to good engineering practice.The product specified conforms to the directive and standards described above.

Certificates:INERIS 05ATEX0068X, Verneuil en Halatte, FRANCE

ATEX Surveillance:1180 (Baseefa) Buxton, Derbyshire, UK

Date: 15 December 2015

Marco CicconeManager Engineering Development

Nordson Authorized Representative in the EUContact: Operations Manager

Industrial Coating SystemsNordson Deutschland GmbHHeinrich−Hertz−StraBe 42−44D−40699 Erkrath

Nordson Corporation � Westlake, Ohio DOC13014A04

1606053-03 - automatic iso-flo hd voltage block...

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