CD250

Operation and Service Manual

Product Warranty and Disclaimer 2

Safety Precautions

The Resin Supply

Fluid Connections 3

The Air Supply

Requirements and Connections
4

Operation
Start-Up / Dispemsing 5

To Pause Dispensing 5

Shutting Down 6

Clean-Up / Maintenance 6

Ratio Assurance Test 7-8

Changing Ratio 9

Servicing the System

Lubrication 10

Ball Valve Seal Replacement 10-13

Metering Piston Seal Replacement 13-15

Lily Corporation Trouble - Shooting 16-17

240 S. Broadway Parts Diagrams

Aurora, Illinois 60505-4205 Assembly Drawings 18-28

United States of America Air Logic Diagram 29

Ph: 630-892-0860
Fax:630-892-5623
www.lilycorp.com

1 Model CD250 Service Manual: Ver1.4

 EXPRESS WARRANTY AND DISCLAIMER OF IMPLIED WARRANTIES

Lily Corporation unconditionally guarantees its products to be free of defects in material or

workmanship and further warrants that, for a period of three months from date of factory
shipment, its products will meet the performance criteria stated in Lily Corporation’s
publications.

There are no other warranties, expressed or implied, including those of merchantability and
fitness for particular purposes.

Warning and Safety Precautions

The CD250 can develop fluid pressures in excess of 1000 pounds per square
inch. Eye protection should be worn when the machine is being operated.
Mechanical members are actuated under extreme forces which can cause
severe injuries. Do not energize the machine unless all covers are in place,
and all hands, tools, and other objects are outside of the frame of the machine.
Become thoroughly acquainted with first-aid procedures recommended by your
resin supplier. If solvents are to be used for cleaning, personnel should
become thoroughly acquainted with their characteristics. Most solvents are
hazardous under all circumstances and extremely dangerous in non-ventilated
areas, or at elevated temperatures.
If the transfer pumps are being supplied by Lily Corporation as part of this
dispensing system, please read the warnings and safety precautions supplied
by the transfer pump manufacturer. This information is included with this
system.
A thorough understanding of the Operator’s Manual is crucial to the safe
operation of the CD250. Do not attempt to operate this system until thoroughly
familiar with it’s contents. For clarifications or questions lease call, email, or fax
Lily Corporation.

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 The Resin Supply
Fluid Connections
Connect the material supply hoses from the transfer pump outlet fittings to the material inlet
fittings at the rear of the dispenser. The material inlet fittings are labeled “A” and “B” and the
transfer pumps are identified as “A” and “B” as well. The fluid fittings are 1” JIC.

TRANSFER PUMP OUTLET CONNECTION MATERIAL INLET CONNECTION

Connect the 2” suction hose to the transfer pump inlet. To the opposite end of the suction
hose attach the 2” ball valve and the female cam-loc fitting. This cam-loc will then be attached
to the cam-loc on the outlet valve on the material tote.

All of the fluid hoses except the 2” suction hose used with this dispenser are high pressure
hydraulic hoses. The ball valves used are rated to 4000 psi. Keep in mind that a colder and
more viscous epoxy resin will require greater transfer pump pressure to supply it to the
dispenser than a warmer or less viscous epoxy resin.

The dispense hoses are attached to the front of the CD250 Dispenser. They are also identified
as “A” and “B”. For the initial setup it doesn’t matter which dispense hose is attached
to the outlet fittings, but once the dispenser has been used, care must be taken to insure
that the hose used for the “A” component is not switched with the hose for the “B” component

MATERIAL OUTLET CONNECTIONS MANUAL DISPENSE

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 The Resin Supply
Fluid Connections, continued
These hoses are 3/4” in diameter and are connected to the dispenser with a female 1” JIC
fitting and the other end is attached to the manual dispense valve with a female 3/4” JIC
fitting.

The dispense valve is a simple, manually operated, pair of ball valves.

Please note: When in use, the dispense valve must be completely “OFF” or completely “ON”.
It must not be used to throttle flow. If it is used to throttle flow, seal wear will be increased and
the valve’s ability to completely shut off flow will be lost.

The Air Supply

Requirements
The volume of dispensed resin is determined by air pressure. An inadequate supply of air will
result in sluggish performance. A 175 cfm air compressor is the MINIMUM required for the
proper operation of the CD250 Dispenser. The minimum air pressure required is 60psi. The
maximum air pressure to the CD250 dispenser should not exceed 150 psi. For the air
requirements of the transfer pumps, refer to the manufacturers operators manual.

AIR SUPPLY FROM CD250 TO

TRANSFER PUMP CONNECTION TRANSFER PUMPS

The air supply must be clean and dry. Built into the
CD250 Dispenser is a moisture separator and a
coalescing micro filter. The water separator is an auto
draining unit. It will drain the fluid accumulated through a
hole in the bottom of the machine. The micro filter has an
indicator located on the top of the filter housing to
indicate when it needs to be serviced.

Always blow out air hoses before connecting them toremove

any accumulated moisture and debris, preventing it from AIR FILTRATION
entering the dispenser. The air connections used on the
CD250 Dispenser are the Chicago claw style fittings.

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 Operation
Start-Up / Dispensing

1. Connect all fluid hoses as noted earlier. Make sure that the manual dispense valve is in
the closed position ( handle pulled back ).
2. Make certain that all regulators are adjusted to” ZERO”.
3. Make sure the CD250 is turned “OFF”.
4. Make all air connections as noted earlier.
5. Adjust both regulators at the transfer pumps to approximately 30 – 40 psi for the initial
start-up. These pressures can be adjusted later, once the equipment is primed and
ready for production dispensing.
6. With a 5 gal. “waste” bucket available, open the manual dispense valve, (no mixer attached to
the valve at this time) and direct flow into the waste bucket.
7. Turn the CD250 “ON”. At this time the machine will start to operate, being powered by the
transfer pumps. The goal is to prime the equipment and purge the air and testing fluids from the
new fluid lines. If the flow of material is too fast, turn down the pressure on the transfer pumps.

8. Once the air and testing fluid is purged from the fluid lines and the resin is running clean,
switch the machine “OFF” and allow it to return to the “PARK” position by leaving the
manual dispense valve “OPEN” until flow stops. The manual dispense valve can now be
“CLOSED”. The dispenser is now primed and ready for use.

9. Attach the static mixer to the manual dispense valve. Adding a small amount of
grease to the threads of the retaining nut will make removing it later easier.

10. Once the unit is in position for dispensing, make sure the manual dispense valve is in the
closed position and switch the dispenser”ON”. hold the static mixer over a waste bucket and open
the until material starts to flow from the mixer then close the valve. The system is now ready to
apply material to the deck.

11. As you become more comfortable with the dispenser, you can increase flow by increasing the
air pressure to the dispenser and transfer pumps. Do not use the dispense valve to throttle or
adjust the flow rate, use the air pressure regulators!

To Pause Dispensing

1. To pause dispensing for a few minutes simply close the manual dispense valve. Keep in
mind that the material in the static mixer will start to cure if the pause is too long.

2. You can also turn the CD250 “OFF” by using the switch on the front of the machine. If you
turn the machine “OFF”, leave the manual dispense valve “OPEN” until the machine makes a final
dispense cycle and returns to the “PARK” position. Then close the manual dispense valve.

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 Operation
Shutting Down

1. When stopping for a material change, end of shift, end of day, etc., you will use a different
procedure than if just pausing for a few minutes.

2. Adjust the regulator for the CD250 Dispenser to “0” psi.

3. Turn the CD250 “OFF” by using the switch on the front of the machine. When the switch is
“OFF”, the CD250 will make a final dispense cycle and return to the “PARK” position.

4. Once the CD250 has “PARKED”, close the manual dispense valve. At this time the static
mixer should be removed and disposed of and the threads of the dispense valve cleaned
and lubricated.

5. Adjust the air pressure to the transfer pumps to zero.

6. Disconnect the air supply from the machine.

7. The machine and transfer pumps can be left in this state until the next start-up.

Clean-Up / Maintenance

Since the two components of the resin do not come together until in the disposable mixer, there is no
machine clean up. However, there are some small maintenance items that should be done at the
end of each shift or day.

First, wipe down the metering pistons with solvent,

removing
any buildup of material that might be present. Then,
lightly
coat with a silicone grease. This will keep material
from sticking to the pistons.

Then, inspect piston pads for wear. Replace if

necessary.

Now, wipe down the air cylinder rod as well as the two guide
rods.
Access to this area of the machine is achieved by removing the
bottom panels. Loosen the 6 bolts holding the panel in place, lift
the panel up then out.

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 Operation

Check the fluid level in the packing cups of the transfer

pumps and add Throat Seal Liquid as needed.

Ratio Assurance Test

WARNING! The CD250 contains moving parts – wearing parts. Therefore, critical components
are wearing from the moment the system is energized. It is absolutely essential that this wear
be anticipated and monitored. Operating personnel must become familiar with the following
procedure for monitoring the wear of metering seals. If monitoring does not become routine,
an improperly proportioned product will result.

A check once each week of operation is usually sufficient to detect seal wear before it
becomes a problem. The frequency required will vary with the product being dispensed, as
well as the volume of material being dispensed. If the application is especially critical, then
the monitoring should be more frequent.

1. Make sure that the “ON/OFF” valve on the dispenser is in the “OFF” position.
2. Turn all of the pressure regulators on the machine down to zero.
3. Disconnect the dispense hoses and allow the accumulated resin within the fittings to
drain.
4. Connect your air supply to the dispenser.
5. Slowly increase the air pressure to the transfer pumps to 80 PSI.
6. Observe the outlet fittings for one minute, for any signs of leakage. Any leakage at this
point means the ball valves will need to be rebuilt by replacing the ball valve seals.
If there is no leakage, proceed to the next step.
7. Reduce the pressure to the transfer pumps to “Zero”.
8. Switch the Isolation Valve to the “Closed” position. (Isolation Valve is located inside the
cabinet on the lower left side. Mounted on top of the Guide Rod Support.)
9. Move the dispenser “On/Off” valve to the “On” position.
10. While holding a waste bucket under the outlet fittings, slowly increase the air pressure
to the transfer pumps to 80 psi. Material will be dispensed while the air cylinder
completes a dispense cycle.

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 Operation
Ratio Assurance Procedure cont’d.

11. Once this dispense cycle is complete, wipe the dispense fittings clean, allow
accumulated resin within the fittings to drain, and observe the fittings for one minute. If
any leakage is visible, the ball valves will need to be rebuilt by replacing the ball valve
seals. If there is no leakage, this means the ball valve seals are good and the
dispenser is “on ratio”.
12. Reduce the pressure to the transfer pumps to “Zero”.
13. While holding a waste bucket under the outlet fittings, switch the Isolation Valve to the
“Open” position.
14. Move the dispenser “ON/OFF” valve to the “OFF” position.
15. Slowly increase the air pressure to the Dispenser and it will make another dispense
cycle and “PARK”.
16. Turn all of the pressure regulators back to “Zero” and disconnect your air supply.
17. Re-connect the dispense hoses and replace any covers.

Caution: The above procedure is the only one that assures ratio accuracy. Random
volumetric comparisons taken at low pressures or high flow rates do not reveal the
condition of the seals. Only an extended and significant fluid pressure can
accurately reflect their condition.

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

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 SERVICING THE SYSTEM
Lubrication
For information on the lubrication requirements for the transfer pumps, please refer to the
manufacturer’s owner’s manuals. If the transfer pumps are supplied by Lily Corporation then
these manuals will be included with the CD250 Operators Manual.

To lubricate the pneumatic circuit od the CD250, remove the top cabinet cover. On the left
front of the machine is a manifold that is feeding air to the pneumatic control circuits in the
dispenser. Disconnect the 3/8” diameter tube and squeeze a 1” stream of silicone lube into
the tube. No other lubrication is needed.

Never use WD-40,3 in 1 Oil, Marvel Mystery Oil, or any other petroleum based products.

Ball Valve Seal Replacement

Note: Start this procedure with the CD250 Dispenser in the “Park” position. Then remove the
fluid lines from the 4-way ball valve.

Remove the 4 mounting bolts securing the ball valve to the

mounting bracket.

Remove the bolts mounting the bracket to the main frame

assembly.

Loosen the set screws that secure the coupler to the ball
valve actuator shaft.

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 SERVICING THE SYSTEM
Ball Valve Seal Replacement

Remove the 4-way ball valve from the actuator.

Note the position of the ball valve stop plate.

Remove the coupler from the ball valve body by

loosening the set screws on the outside of the
body. Then remove the socket head capscrew
securing the coupler to the ball valve shaft. This
capscrew is located inside the coupler.
Remove the stop plate.

Remove the 4 bolts securing the ball valve together.

Gently rotate the top portion of the ball valve body an

inch or so, then, using a small pry bar, carefully pry up
on the top portion of the ball valve body until it
becomes free from the main body. Now lift this top
portion of off the main body.

There are two seals associated with this part. One of

the seals is an o-ring with a Teflon backup on the
outer sealing area. The other is an o-ring with a Teflon
backup on the ID of the part. Remove and repalce
these two seals with the seals supplied in the seal kit
with the CD250.

Remove the fluid fittings from the main valve body.

Make notes as to the location of the different fittings.

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 SERVICING THE SYSTEM
Ball Valve Seal Replacement

Now remove the main fittings from the ball valve body,
These will require a 1 5/16” wrench and the ball valve will
need to be held firmly in a vice.

Be careful when removing these main fittings as seals

from the ball valve may be removed with the fitting itself.

With the main fittings removed, the ball (trunion) itself can
now be removed from the main ball valve body by pulling
it up and out of the main valve body. Now, the remaining
ball valve seals can be removed.

Trunion

In the bottom of the main ball valve body you’ll find

another O-ring seal and Teflon backup as well as another
bushing. Using the seal pick supplied with the CD250
remove the old O-ring and replace it with a new one.
Inspect the bushing for any unusual wear.

After a thorough cleaning and inspection, the ball valve can be re-assembled. Using silicone
grease, lube the O-ring and bushing in the bottom of the main ball valve body and insert the
ball (trunion).

Use silicone grease on the seals between the ball and the main fittings then, insert the main
fittings into the main ball valve body.

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 SERVICING THE SYSTEM
Ball Valve Seal Replacement

Lubricate the O-ring seals and bushing on the upper ball valve body and install the upper ball
valve body onto the main ball valve body. Be sure that the upper ball valve body is
installed with the stop set screw in the same location as it was when the ball valve was
disassembled.

Install the 4 bolts that secure the ball valve together.

Replace the fluid fittings in their original location.

Re-install the coupler onto the ball valve shaft.

Re-install the ball valve onto the actuator shaft.

Re-install the ball valve bracket to the main frame.

Re-install the 4 bolts securing the ball valve body to the support bracket.

Once the ball valve has been secured to the mounting bracket, tighten the set screws
securing the coupler to the actuator shaft.

Re-connect the fluid lines to the ball valve.

Replace any removed panels.

Perform another ratio assurance check.

Metering Piston Seal Replacement

Remove the lower panels from the CD250 Dispenser.

Make sure the dispenser is turned “OFF” and that all regulators are turned down to “ZERO”.
To remove the metering assemblies it is important that the metering pistons are pushed
completely into their cylinders.

Connect an air supply to the dispenser.

Turn the dispenser ”ON”.

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 SERVICING THE SYSTEM
Metering Piston Seal Replacement

Open the dispense valve at this time and direct it into a waste bucket.

Manually plug the “bleed” holes on the left side of the air cylinder end cap. This will cause the
ball valves to “switch”.

Turn the dispenser air pressure up until the air cylinder moves about half way between the
metering cylinders then reduce it to “ZERO”.

Remove the air supply from the dispenser. Do not turn the machine “OFF” before you remove
the air supply.

Manually push the metering piston back into it’s bore. Depending on which side of the
machine you’re working on, epoxy resin will be pushed out through the dispense valve into
the waste bucket or out of the “inlet” fitting at the back of the machine. Position a waste
bucket here to catch resin as well.

Using the strap wrench supplied with the CD250 Dispenser, remove the catalyst metering
assemblies. Material will drain from the hoses feeding the metering cylinder manifolds. This is
expected and rags or towels should be on hand for clean up. Do not attempt to remove the
metering assemblies with any tool other than a strap wrench as irreparable damage can be
done to the metering cylinder.

Use the seal pick from the seal kit to remove the O-ring from the bottom of the base manifold.
Clean the opening in the bottom of the base manifold then lubricate a new O-ring and install
it.

Once the metering assembly has been removed from the base manifold, push the piston from
the cylinder bore.

Clean the piston and cylinder bore thoroughly. Examine the cylinder. If its bore is scratched or
pitted, it should be replaced.

If the piston is scratched or marred, polish the surface with

Scotch-brite or similar until no burr remains to damage the
metering cylinder.

Replace the seal with its spring groove facing away from the
metering piston.

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 SERVICING THE SYSTEM
Metering Piston Seal Replacement

Inspect the piston pad. If it is torn or worn, replace it.

Lubricate the piston and its cylinder with silicone

lubricant and insert the pad end of the piston into the
threaded end of the cylinder.

Lubricate the threads of the replacement metering assembly with an anti-seize compound or
silicone lubricant. Carefully thread the replacement metering assembly into the metering
cylinder manifold until it is seated. Do not over-tighten! When the metering assembly bottoms
out in the base manifold you will feel a definite stop. Do not try to tighten beyond the firm
stop.

The lower access panels can now be replaced.

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 TROUBLE SHOOTING

Spurts of air, or air bubbles in the material

Check the material level. Even though some material remains, the pump may draw air
through the resin as it cavitates just before it is depleted.

Off ratio
Perform ratio assurance check to confirm ball valve performance.

Sluggish flow
To start with, look for an obstruction in the static mixer. Replace the mixer if needed. If flow
is still sluggish, disconnect the outlet fittings and observe the resin flow from the outlet
ports. If flow is now unrestricted, look for an obstruction in the exterior plumbing.
Verify that the air supply and air pressure is adequate.
Also keep in mind that the viscosity of the resin will affect performance.

Resin leakage at material piston

Replace the piston seals.

Metering piston fails to extend, or extends slowly

Disconnect the material inlet hose at the dispenser and check the flow from the transfer
pump. If the flow is restricted, check for an obstruction in the material supply line, or
insufficient
delivery from the transfer pump. If the material is adequate, remove the metering
assembly and check for freedom of movement within the cylinder. If the piston is seized
or binding, service the assembly. If the transfer pump is not delivering as it should, refer
to the trouble shooting guide that came with the transfer pump. With the piston fully
extended, wipe the piston with solvent and then lubricate well. Material being dispensed is
too viscous.

System begins to dispense, but cannot complete a dispense cycle

Obstruction in material outlet lines, clogged static mixer.

System is unresponsive, does not make a dispense stroke, audible air leak at sensor
ports
Metering pistons not sealing off sensor ports due to worn or damaged piston pads, replace
the pads. Insufficient material pressure to press the pads firmly against the sensor ports.

Main air cylinder fails to return following a complete dispense stroke

Defective rapid exhaust valve.

Unit switches before metering piston is fully extended.

Bleed holes in end cap plugged. Remove foreign material.

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 TROUBLE SHOOTING

Switch to “OFF” does not return the main air cylinder to the “PARK” position
Dispense valve closed, the dispense valve needs to be open for the main air cylinder to
return to the “PARK” position. Defective “OR” valve.

If you cannot correct the problem,

contact Lily Corporation with an exact description of how the various components are
responding.
If possible, phone with the unit, air, tools, and resin information at hand.

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