OptiMix 1 Plural Component Liquid Dispensing System

OptiMix� 1 Plural ComponentLiquid Dispensing System

Customer Product ManualPart 1605263-02

Issued 10/15

NORDSON CORPORATION AMHERST, OHIO USA

For parts and technical support, call the Industrial CoatingSystems Customer Support Center at (800) 433-9319 or

contact your local Nordson representative.

This document is subject to change without notice.Check http://emanuals.nordson.com for the latest version.

Part 1605263-02 � 2015 Nordson Corporation

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 2014. 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

Nordson and the Nordson logo are registered trademarks of NordsonCorporation, and OptiMix is a trademark of the Nordson Corporation.

All other trademarks are the property of their respective owners.

Change Record i

Part 1605263-02� 2015 Nordson Corporation

Change RecordRevision Date Change

02 10/15 Repair part numbers added

Change Recordii


Table of Contents iii


Table of ContentsSafety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulations and Approvals 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personal Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Halogenated Hydrocarbon Solvent Hazards 4. . . . . . . . . . . .Action in the Event of a Malfunction 4. . . . . . . . . . . . . . . . . . . . . .Disposal 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Theory of Operation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit Configuration 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Symbols 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Accessories 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Atomizing Air Regulator 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .USB Interface 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alarm 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remote Control (Optional) 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Transportation, Installation and Assembly 11. . . . . . . . . . . . . . . .Transportation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation Location 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remote Control Connections (Optional) 13. . . . . . . . . . . . . . . .

Controller Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Keypads 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Volumetric Measurement 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flush Parameters 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual Valve Control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hose Filling Parameters (Setup Fill) 20. . . . . . . . . . . . . . . . . . . . . .Material Container Level Monitoring 22. . . . . . . . . . . . . . . . . . . . . .Valve Management 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recipe Management 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Date and Time 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Software Update 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation − Control Module 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Startup 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Menu Structure 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Navigation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control System Symbols 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation Area 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Status Display 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Mode Display 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Spraying Mode (F2) 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flushing Mode (F1) 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Circulation Mode (F3) 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit Stop (F5) 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fill Level Indication 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recipe Selection 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Information Relating to Mixing Ratio and Volume 34. . . . . . . . .Alarms 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Measurement 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .USB Data Log 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Language Selection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alarm History 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Day and Batch Counters 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Information 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation − System 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Startup 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching the Unit On 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up the Control System 40. . . . . . . . . . . . . . . . . . . . . . . . .Flushing Mixing Unit and Spray Gun 41. . . . . . . . . . . . . . . . . . .Filling and Venting the Metering Pumps 41. . . . . . . . . . . . . . . . .Performing a Control Measurement 41. . . . . . . . . . . . . . . . . . . .

Coating 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Spraying Pressure 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Achieving Quality Coating Results 42. . . . . . . . . . . . . . . . . . . . .Flushing 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Release 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutting Down 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temporary Decommissioning 43. . . . . . . . . . . . . . . . . . . . . . . . . .Decommissioning for a Long Period or Permanently 44. . . . . .

Storage 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Waste Disposal 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixing Unit 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hoses and Pipes 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Metering Valves 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flow Meters 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 49. . . . . . . . . . . . . . . . . . . . . . . . . . .System Configurations 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OptiMix 1 System Parts 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base Frame 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Valve, 3MM 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Valve, 6MM 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic Valve, 3MM Stroke Limit 56. . . . . . . . . . . . . . . . . . . .Automatic Valve, 6MM Stroke Limit 58. . . . . . . . . . . . . . . . . . . .Mixing Unit, Complete 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mixing Unit with Injection Tube 62. . . . . . . . . . . . . . . . . . . . . . . .Static Mixer 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Atomizing Air Mounting Kit 64. . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear Meter 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filter Regulator 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Options 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel Kit 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other Options 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents v


Appendix A A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hose Volumes A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Configurations B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Diagrams C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsvi


OptiMix 1 Plural Component Liquid Dispensing Systems 1


OptiMix 1 Plural Component LiquidDispensing Systems

Safety 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.

OptiMix 1 Plural Component Liquid Dispensing Systems2


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.



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 him this card

� Tell him what kind of material you were spraying

MEDICAL ALERT—AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN

Injection in the skin is a serious traumatic injury. It is important to treat 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.



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.



Description The OptiMix 1 is an electronically controlled, meter based, two- orthree-component multiple color metering unit with a freely adjustable mixingratio. Depending on the configuration, the unit can be used in low pressureand high pressure spray applications. The unit allows the handling ofcoating materials of different viscosities in flow rates from a few milliliters upto several liters per minute. For the processing of materials with higherviscosities, the system can be equipped with fluid heaters.

Specifications NOTE: Specifications are typical. Outcome will vary depending on thesystem being used, the material being used, the product being coated,pump output hose specifications, and external environment.

Table 1 OptiMix 1 Specifications

Description Specification

Volumetric Mixing Ratio 0.5:1 to 50:1

Proportioning Tolerance 1%

Controllable Valves Up to 10

Maximum recipe memory 10

Flow Rate Range 100 − 3000 cc/min

Viscosity Range 20 − 5000 cps

Voltage Range 100 − 240 V, 50 − 60 Hz

Controller Voltage 24 VDC

Maximum Air Inlet Pressure 100 psi (7 bar)

Maximum Fluid Pressure, 3 mm Valve 3625 psi (250 bar)

Maximum Fluid Pressure, 6 mm Valve 725 psi (50 bar)

Ambient Operating Temperature Range 41� − 122�F (5� − 50�C)

Maximum Fluid Temperature 176�F (80�C)

Equipment Rating CE

Enclosure Rating IP55

Air Inlet Thread 1/4 in. G (Female)*

Air Outlet Thread 1/4 in. G (Male)*

Fluid Inlet Thread 3/8 in. NPS (Male)*�3/8 in. NPS (Male) adapter can be removed for 3/8 in. G (Male) thread�

Fluid Outlet Thread 3/8 in. NPS (Male)*

Dimensions (L x W x H) 20 in x 20 in x 55 in(500 mm x 500 mm x 1400 mm)

Weight (depending on version) 110 lbs. (50 kg)

*See Other Options on Page 66 for additional thread adapter options.

Specific technical data for your OptiMix 1 can be found on the name plateslocated on the equipment, or in the documentation for the individualcomponents.



Intended Use The OptiMix 1 is intended for processing multiple solvent- or water-basedtwo- or three-component coating materials in industry and trade.

NOTE: Any other use, other than for the purpose for which the OptiMix 1 isintended, requires specific permission from Nordson. Otherwise, thewarranty will be invalid.

NOTE: Intended use also includes compliance with the technicaldocumentation and adherence to the prescribed operating, servicing andmaintenance guidelines.

Theory of Operation In a 2K system, the unit meters and dispenses the B-component (catalyst)within the continuously flowing volume of the A-component (base). Thesystem is based on the measurement of the two volume flows: theB-component (catalyst) flow is adjusted in relation to the measured volumeflow of the A-component (base), according to the mixing ratio set in theselected recipe.

Multiple recipes can be stored in the system controller. Each recipe definesthe active A and B component valves, the desired mixing ratio, and the potlife of the mixture. Up to ten total components can be controlled by theaddition of metering valves. The recipes dictate which of these componentsis to be assigned to each A and B valve.

In a 3K system, three components (A, B and C) are metered and mixedaccording to mixing ratios determined in the programmed recipes. Ameasured amount of the C component is dispensed into the mixed A/B fluidstream.

Recipe parameters and tolerances are stored in the system controller. Flowmeters monitor the system’s output to stay within the mixing ratiotolerances. The controller monitors time lapsed to stay within the pot lifespecified. The unit is switched off and / or an alarm sounds if theparameters are exceeded.

A static mixer is connected directly to the outlet of the integrator in order tomaintain quality. Material can be supplied either by piston pumps,diaphragm pumps, or pressure tanks. Make sure that all components arepumped within a similar pressure range. For example, pressure tankswould not be used with high pressure piston pumps.

Make sure that the B and C components have approximately 7.25 − 14.50psi (0.5 − 1.0 bar) higher air inlet pressure on piston pumps than the Acomponents to facilitate feeding.



Unit Configuration

13

Figure 1 Front and Rear View of the OptiMix 1

1. Control panel with control module2. Meter for the A component side3. Metering valve for A component4. Static mixer5. Spray hose connection

6. Type plate7. Metering valve for B component8. Meter for the B component side9. Pressure regulator for control air

10. Compressed air connection

11. Flushing valve for the Bcomponent side

12. Flushing valve for the Acomponent side

13. Atomizing air pressure gageand regulator



Control Panel The following controls may be found on the control panel:

3

4

Figure 2 Control Panel

1. Control module with touch screen2. USB interface

3. Alarm switch4. Master switch

Control Symbols The controls on the control panel are indicated by the following symbols:

Figure 3 Control Symbols



Accessories

Atomizing Air Regulator When using the OptiMix 1 with an air spray gun or an air-assist airless spraygun, the atomizing air regulator supplies the spray gun with atomizing air.This regulator is standard on all units.

The atomizing air regulator consists of an air pressure regulator with agauge located to the left of the control panel. Air passes through the airregulator and a separate air hose to the atomizer air connection for thespray gun on the front side of the OptiMix 1.

For single-base systems, this regulator is manually shut off for flushing. Inmultiple-base systems, the regulator is automatically shut off.

Figure 4 Mounting Kit for Atomizing Air

USB Interface The USB interface is standard on all systems. It enables the operator todownload data stored in the control system onto a USB stick, and to updatethe software for the control system.

The USB interface is located on the control panel to the left of the controlmodule. It is marked with the USB symbol.

Figure 5 USB Interface

Alarm The alarm makes a loud continuous tone when malfunctions are detected.The alarm is standard on all systems.

Using the push button on the control panel, the alarm can be muted. SeeFigure 2.

Remote Control (Optional) The optional remote control allows the use of the OptiMix 1 in workshopsthat come under explosion protection ordinances. This assumes that thecontrol panel, which is not explosion-protected, is installed outside thehazardous area.



Several common operational functions can be run inside Zone 1 hazardousareas using the ATEX-approved remote control, which comes with a 30meter cable. See Table 2.

Green Indicator Light

Yellow Indicator Light

Red Indicator Light

Emergency Stop Button

Figure 6 Remote Control

Table 2 Remote Control Indicator Lights

Button Action When Pressed Indicator Light Flashing Indicator Light On

Green Switches the unit to sprayingmode

Filling mode Spraying mode

Yellow Switches the unit to flushingmode

Flushing active Unit flushed

Red Switches the unit to stop There is a fault present(alarm message)

Unit stopped

EmergencyStop

Shuts down the unit N/A N/A

The remote control is switched on and off using a key switch on the controlpanel. During the changeover from control panel to remote control andback, the control system automatically switches to Stop.

WARNING: If the key remains in the key switch, the operation location canbe changed without the operator’s knowledge. This can create a danger forthe operator. Unplug the key switch after each change, so that only theoperator can change the operation location.

With the remote control activated, the function keys F1 (Flushing mode), F2(Spraying mode) and F3 (Circulation mode) are disabled on the controlpanel. All other functions are still operable.

The F5 function key on the control panel and the red button on the remotecontrol are always active during operation, so that the unit can always beswitched to Stop on both the control panel and on the remote control.



Transportation, Installation and Assembly

Transportation Follow these instructions when transporting the unit:

� Ensure sufficient load bearing capacity of lifting gear and lifting tacklewhen loading the unit. You will find the dimensions and weights of theunit on the machine card.

� The unit must only be lifted by the lifting and lashing points provided forthis purpose.

� Make sure that the fork tines are long enough when using a forklift.Guide the fork tines through the two opposite forklift lifting points on therack.

� When transporting using a fork lift, have the forks as far apart aspossible to minimize the risk of overturning.

� Ensure even load distribution to secure the system against tipping over.

� Do not transport any other objects while lifting or loading the unit.

� Never stand under suspended loads or inside the loading area. Thisposes a life hazard!

� Secure the load on the transport vehicle against slipping and falling off.

If the unit was already operated, please observe the following:

� Disconnect the entire system power supply, even for short transportationdistances.

� Empty the unit before transportation. Fluid residues may escape duringtransportation despite this measure.

� Remove all loose parts from the unit.

� Assemble the parts or fittings dismantled for transport purposes beforestart up and in compliance with the intended use of the system.

Installation LocationNOTE: Set the unit up horizontally on a foundation that is flat, firm, andvibration-free. The unit must not be tipped or on an incline. Ensure that allthe operating elements and safety features are easy to reach.

WARNING: This unit must be installed in an unclassified location. It is notsuitable for a hazardous area location or zone.

Safety measures at the place of installation:

� This unit requires a solid base and sufficient free space for safeoperation.

� Secure the unit at its final location to protect it against unintendedmovement.

� Always keep the working area, especially all walkways and standingareas, clean and tidy. Immediately remove any spilled material andsolvents.



� Always ensure adequate ventilation at the work place to avoid damageto health and material objects.

� Always observe the processing instructions issued by the materialmanufacturers.

� Although there are no legal directives for low-mist airless sprayingmethods, all hazardous solvent vapors and paint particles should beextracted.

� Protect objects adjacent to the spraying object against possible damagecaused by the material mist.

Assembly

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

Electrical Connections The unit is connected to an electric power supply via the included powercable (voltage 100 − 240 V, frequency 50 − 60 Hz, 575 VA).

To provide power to the system, wire the power cable to an electrical panelor to a customer-supplied plug. See Table 3 and Figure 7. Regardless ofthe installation, power should be provided through an external disconnectswitch with lockout capability.

Table 3 Electrical Connections

Wire Color Function

Brown L1 (hot)

Blue L2 (neutral)

Green/Yellow GND (ground)

L1

L2

GND

(BROWN)

(BLUE)

(GRN/YEL)

Figure 7 Electrical Connections



Pneumatic Connections The unit (standard version) is supplied by a central air connection.

NOTE: The compressor capacity must match the air requirements of theunit and the diameters of the air supply hoses must match the connectionsso that an adequate air supply is ensured.

NOTE: Operation with contaminated or moist compressed air causesdamage to the unit’s pneumatic system. Use only dry, dust-free, oil-free air.

For inlet air, connect the air line to the pressure regulator on the back of thesystem. The provided threaded fitting is 1/4 in. G. An optional 1/4 in. G x1/4 in. NPT nipple is available. See Other Options on page 66 for moreinformation.

For spray gun atomizing air, the system is supplied with a 1/4 in. G malenipple on the output of the atomizing air regulator. If a 1/4 in. NPT thread isrequired, remove the supplied nipple and replace it with a 1/4 in. G x 1/4 in.NPT nipple. Refer to Other Options on page 66 for more information.

Tighten all pneumatic connections securely.

Hydraulic Connections Depending on the number of pre-equipped components, the unit must besupplied with at least one base component, one catalyst, and one flushingagent.

For the fluid inlet fittings, each dispense valve is supplied with a male 3/8 in.NPS thread. If a 3/8 in. G thread is required, remove the 3/8 in. NPS x 3/ 8in. G adapter and install a 1/2 in. −20 JIC x 3/8 in. G adapter. See OtherOptions on page 66 for more information.

For the fluid outlet fittings, the system is supplied with a 3/ 8 in. NPS malesconnection. If a 1/ 2 in. −20 JIC connection is required, add an adapter.See Other Options on page 66 for more information.

The static mixer outlet must be connected with one or more guns via anappropriate material hose (note length and rated pressure). The threadsmust be in perfect condition and must seal tightly under pressure.

Remote Control Connections (Optional)

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

The optional remote controller should be installed by a qualified electrician.See Appendix C for complete wiring diagrams.

Route the remote control cable through the empty strain relief located onthe bottom of the control box. Lead the wires and make the terminalconnections as shown in the wiring diagrams. Tighten the strain reliefconnector.



Controller SetupThe parameters for setting up the system controls are stored in the Setupmenu. The system control must be switched to Stop during set up. You willsee an appropriate note if you try to open the Setup menu from anotheroperating mode. See Figure 8.

Figure 8 Setup in Stop Mode Only

Please note that this menu is password protected and therefore onlyaccessible to authorized persons.

Figure 9 Password Prompt

Press the Setup button in the Main menu to open the setup menu.You will then see the password prompt. The first page of the setup menuwill open once the password has been entered. See Figure 9.

NOTE: The default password is 1950.



1

2

3

4

5

6

7

5

8 109

Figure 10 Setup Menu Pages 1 & 2

1. Volumetric measurement2. Set up flushing program3. Set hose volume and mixer type4. Configure filling level monitoring5. Log out from the Setup menu, return to

Main menu

6. Set date and time7. Manual valve control8. Set up valve management9. Set up recipes

10. Change to the Service level

Use the arrow buttons to browse forwards and backwards between the twopages of the menu. See Figure 10.

KeypadsUnlike in the operating area, the menu windows for the setup area includeinput fields in addition to the display and selection fields.

Input fields have a yellow background, with a few exceptions. Press theinput field you wish to edit. The relevant keypad will then be displayed. SeeFigure 11.

Figure 11 Keypad Example

To enter values, press the characters from the character set shown on thekeypad in sequence. Table 4 lists the bottom row keypad functions.



Table 4 Keypad Functions

Button Function

Home Moves the cursor to the leftmost position

End Moves the cursor to the rightmost position

SP Delete the character to the right

BS Delete the character to the left

> > Moves the cursor to the right

< < Moves the cursor to the left

Shift Select the top character shown on the key (capitals)

ENT Confirm input (Enter)

CLR Clear

Volumetric MeasurementAs the output of the metering pumps declines as wear increases, the Kfactors (number of measuring pulses of the volume counter per liter) has tobe recalibrated from time to time by volumetric measurement. In this way,the most precise possible mixing ratio can be ensured over the long term.

To perform a volumetric measurement of a metering pump, it must be filledwith processing material and vented.

1. Make sure that all air pressure regulators for the metering pumps havebeen fully regulated down and only the compressed air shut−off valve onthe metering pump you want to measure is opened.

2. Press the Volumetric Measurement button in the Setupmenu.

3. See Figure 12. From the volumetric measurement menu, select:

� A to measure the metering pump for the A component currentlyselected.

� B to measure the metering pump for the B component currentlyselected.



Figure 12 Component Selection for Volumetric Measurement

4. Adjust the air inlet pressure for the metering pumps up to 43.5 − 50.8 psi(3.0−3.5 bar).

5. When prompted by the control system, spray a specified quantity ofmaterial via the spray gun into a measuring cup and acknowledge thisstep by pressing the forward arrow (�). See Figure 13.

Figure 13 Control System Prompt

6. Close and secure the spray gun again once the filling process isfinished.

7. Set the air inlet pressure for the metering pumps to zero.

8. Wait a few minutes to allow the entrained air to escape from the materialin the measuring cup (particularly with more viscous materials).

9. Enter the material quantity poured as the measured volume. You canenter the measured volume in cubic centimeters (ccm) or U.S. fluidounces (fl. oz.). See Figure 14.

Figure 14 Measured Volume and K Factor



NOTE: Accurate work in these steps will lead to more precise mixing ratios.

10. Press the Calculate button to have the new K factor determined by thecontrol system.

11. Save the new settings.

Exit the menu by pressing the Finished button.

Flush ParametersBy defining flush parameters, you can set a flushing program with up toeight sequential steps that are performed automatically.

The flushing volumes and the sequence of steps should be compatible withthe material supplier specifications and set accordingly. Certaincomponents could be incompatible. Adjustments can be made at any time.

Press the Flushing Program button in the Setup menu to openthe flush parameters input window, seen in Figure 15.

Figure 15 Flush Parameters Screen

You define the flush parameters step by step. To do this, first enter thevolume or duration of the step concerned in seconds or cubic centimeters.Clicking the button after the input field switches the unit between seconds(sec) and cubic centimeters (ccm).

NOTE: If the unit is not equipped with flow rate measuring cells or a flushpump with shaft encoder or stroke sensor, the flushing volume can not bedetected. In this case, only a time target can be specified for each step ofthe flushing program.

Press the Setup button to open the action selection.

Use the buttons in this menu to determine what action is to be executed inthe step concerned. See Figure 16.

The Air and Break actions can only be activated in the low pressure pump ifa valve for air flushing is present.



Figure 16 Action Selection

Once you have defined all the steps in the flush program, you must specifyhow many times this sequence is to be repeated.

Manual Valve Control

Press the Manual Valve Control button in the Setup menu toopen the manual valve control window, shown if Figure 17.

The various valves involved in the function check can be controlled from thisscreen by pressing the relevant button. The button for the valve currentlyopen has a green background. Only one valve can be opened at a time.An open valve is automatically closed when another valve is selected. Thisprevents material from penetrating another valve, which could triggermalfunctions.

Figure 17 Manual Valve Control

Table 5 Valve Functions

Label Function

Main valve Shut-off valve for the compressed air inlet

V1 − V10 Metering valves 1−10

Flush A Flushing valve for A component side

Flush B Flushing valve for B component side

Flush air Air flushing valve

Pressure Valve for switching between flushing pressure and spraying pressure



Atomizer Atomizer air valve

Spray gun Spray gun valve

When checking function, always open the valve first and then fill it by slowlybuilding up the pressure. This allows potential leaks to be detected quicklyand prevents pressure surges.

The flush valves should always be used at the start and end of the functioncheck on a material valve to prevent a chemical reaction between anypossible material component residues.

Hose Filling Parameters (Setup Fill)

Press the Hose Volume and Mixer Type button in the Setupmenu to open the first input window for entering the filling parameters. SeeFigure 18.

Figure 18 Filling Parameters Part 1

Enter the following parameters:

� Spray hose volume. “Fill” will be shown on the display until this volumeof material has left the spray gun after the start of spraying operation.This is to prevent material that is mixed incorrectly or not mixed at allfrom being applied.

NOTE: A formula for calculating hose volume and a table of volumes forcommon hoses can be found on page A-1.

� Volume for pot life reset − The minimum volume that must have left thespray gun after an interruption in spray operation without flushing beforepot life monitoring is reset. The complete volume of the line systemmust be taken into account (static mixer + hose + safety margin).Otherwise, the full volume of old material will not be expelled.

� Mix ratio limit when filling − The mixing tolerance, beyond which thesystem should switch off automatically during filling.

� Volume flushing pump double stroke − The output of the flushing pump.You will find this value on the flushing pump type plate.

� Delay of atomizer air sensor − The period that should pass before theatomizer air sensor is activated. The Atomizer Air Malfunction faultmessage will be displayed if the A component does not flow within thedelay period when the air flow is present.



Three option buttons follow the input fields (enabled options have a greenbackground).

1. External mixer − This option should be switched On if you are using anexternal mixer, and Off if you are using a mixer on a rack.

The system control must be adjusted to the mixer type used. As inCirculation mode, the metering valves must be closed if the mixer is onthe rack (Circulation on the “short route” from the mixing unit back to thematerial container), and must be open for an external mixer (Circulationon the “long route” from the mixer unit through the hose package back tothe material container).

2. Flush atomizer air − Switch the atomizer air Off when the gun isconnected to the trigger device, otherwise the cleaning agent isatomized and escapes into the environment.

3. Atomizer air sensor − The atomizer air sensor monitors the air flow ofthe atomizer air in spraying mode.

Use the arrow button to switch to the second setup fill window. See Figure 19.

Figure 19 Filling Parameters Part 2

Enter the following parameters:

� Delay start of flushing via spray gun − Period of time available to theuser to place the gun into the gun triggering device after a pot life alarm.The following conditions must be met for the operation of the triggeringdevice: the trigger device option button must be displaying Auto, andthe spray gun must be inserted in the triggering device.

� Factor A of flushing valve − K factor for the A component flushing valve.The K factor for the flushing valves cannot be determined by volumetricmeasurement. You must therefore either take the information from thetechnical specifications for the measuring cell or take the K factor of ametering valve determined already by volumetric measurement. Seepage 16 for more information.

� Factor B of flushing valve − K factor for the B component flushing valve(See Factor for A flushing valve).

� Flush pump VOC share − Enter the solvent component of the flushingagent as a percentage (%). The volume contributes to the VOC counterand is added there. See Page 38 for more information.



Four option buttons follow the input fields:

1. Volume unit: Set to l for liters as the volume unit or gal. for U.S. gallonsas volume unit.

2. Select stroke sensor flushing pump: Set to On if the flushing volume isto be determined by the stroke sensor on the flushing pump. Set to Offif the flushing volume is to be determined by the gear flow meters.

3. Gun trigger device: Set to Auto if the spray gun is to be flushedautomatically by the trigger device. Set to Manual if no trigger device isfitted or if the automatic function is not to be used.

4. Fill spray gun: Set to Auto if the spray gun is to be filled with materialfor spraying automatically as soon as the spray gun is plugged into thetrigger device. Spraying mode is selected and the Trigger device optionbutton is set to Auto. Set to Manual if no trigger device is fitted or if itsautomatic function is not to be used.

Material Container Level MonitoringContainer level monitoring makes it possible to guarantee a constant supplyof material and hence to prevent the system from being shut down if thematerial containers run dry. The minimum and maximum filling levels of thematerial containers must be stored in the control system for the monitoringfunction to work.

NOTE: Filling level monitoring is a purely computational process. It doesnot replace measurement by level sensors.

Press the Filling Level Monitoring button in the Setup menu toopen the input window for maximum and minimum filling levels. See Figure 20.

Figure 20 Fill Level Monitoring Input Windows

The system control monitors the fill levels of up to 10 material containers.The display is distributed across a number of windows. Use the arrowbuttons to browse forwards and backwards between the various menuwindows. The volume unit preset in the system control is displayedbetween the arrow buttons, as liters (l.) or U.S. gallons (gal.).

The Actual line shows the current fill levels of the containers concerned.



Enter for all material containers (all input in liters):

� Min: The minimum filling level at which a message should appear in thedisplay. In volumetric measurement mode, the unit is automaticallyswitched off at this level.

� Cont: The size of the container you are using.

� Press the Set button after entering the minimum filling level andcontainer size to save your input for each of the containers.

Valve ManagementThe control system can manage up to 10 valve/pump combinations. Avalve/pump combination includes a metering valve and a metering pump.The data for the valve/pump combinations used in the unit is recorded inValve Management.

Press the Valve Management button in the Setup menu to openthe valve management input window, shown in Figure 21.

Figure 21 Valve Management Screen

In Valve Management, you can enter:

� Current valve: Number of the valve/pump combination. This can beselected using the Valve − and Valve + buttons.

� Impulses per liter: The output of the metering pump is calculated fromthe electrical pulses of the volume counter or shaft encoder using thenumber of pulses per liter (K factor). This factor is determined from themetering pump output. The K factor has to be recalibrated from time totime by volumetric measurement as the output of a metering pumpdeclines with increasing wear in operation. See page 16 for moreinformation.

� VOC share: Proportion of solvent in the materials used as a percentage(VOC = Volatile Organic Compounds).

� Double stroke error: Minimum duration of an error−free double stroke,at below which a corresponding alarm is to be output (approx. 700 ms).

Press the Save button to save your input.



Recipe ManagementNOTE: The data for the valve/pump combination in use on the unit must berecorded in Valve management before you can set up recipes.

Press the Recipe button in the Setup menu to open the recipemanagement input window, shown in Figure 22.

Enter the following data to set up a recipe:

� Current recipe: The recipe number can be selected using the Recipe –and Recipe + buttons. You can create up to 10 different recipes.

� Designation: Recipe name.

Figure 22 Recipe Management Screen

� Valve A: Number of the valve/pump combination through which the Acomponent used in the recipe will be delivered.

� Valve B: Number of the valve/pump combination through which the Bcomponent used in the recipe will be delivered.

� Mixture A : B: Desired volumetric mixing ratio between the A and Bcomponent. If the mixing ratio is defined by weights, you have toconvert the weights into volumes. Use the formulas: Volume = Weight DensityWeight = Volume x Density

� Pot life: Pot life is the period in which the mixed material can beprocessed from the time of it being mixed until the material increasinglycures.

� Controller tolerance: Permissible deviation from the desired mixingratio. The tolerance range is factory set to 3%. If the deviation isgreater than the pre-set tolerance, the controller intervenes to correct it.

� Shutdown: In the event that the deviation from the desired mixing ratiois greater than the tolerance, we define an error limit and a time periodthat the error limit must continue before the controller triggers an alarmmessage and shuts down the unit automatically. The error limit forautomatic shutdown is factory set to 5%, and the fault duration isfactory set to 5 seconds. With these settings, the unit is switched offautomatically when the mixing error exceeds 5 % and lasts longer than5 seconds. See Figure 23.



Figure 23 Example of the Behavior of the System Control and Automatic Shutdown with Factory Settings

Use the Yes/No button in the Enable row to specify whether the recipe is tobe released for use in recipe selection.

Press the Save button to save your input.

Date and Time

Press the Date and Time button in the Setup menu to open theinput window for setting the date and time.

Here you can set the date (day, month, year) and the time (hour, minute,second) using the + and − buttons for each of these.

Examples:

� Press the D+ button three times to adjust the date from 14 to 17.

� Press the D− button once to adjust the date from 14 to 13.

Software UpdateTo update the control system software, insert a USB stick carrying the newversion of the software into the USB port on the control panel and press theUSB Software Update button in the Set Date/Time input window. Seepage 25.



Operation − Control Module

1

2

Figure 24 Control Elements on the Control Module

See Figure 24. All control functions may be selected from the touchscreenwith the function keys F1 through F5 (1) and the buttons displayed in thevarious menu windows (2). The F6 function key, if present, has nofunctionality.

The control system is divided into two areas – the operating area accessibleto all, and the password-protected settings area.

Startup

Figure 25 Overview Screen

When the unit is switched on, the touchscreen first displays a Welcomescreen. After a few seconds, it continues automatically to the Overviewscreen. See Figure 25. The overview is the basic display in the controlsystem.



Menu Structure

Figure 26 Menu Structure



NavigationThe individual menu windows can be selected using the correspondingbuttons in the Overview screen, the Main menu, or the Settings menu. Inaddition, the following standard functions are available for navigation withinthe menu structure:

Home: Return to the basic display (Overview)

Level Up: Switch to the next higher menu level

Continue: Scroll forward on the same menu level

Back: Scroll back on the same menu level

Control System SymbolsThe buttons in the control system are indicated by the following symbols:

Table 6 OptiMix 1 Symbols

Symbol Description Symbol Description

Alarm Manual valve control

Alarm history Pot life

Control measurement Recipe management

Counter Recipe selection

Date and time Reset fill level

Details relating to mixing ratio and volume

Service

Fill level alarm Setup

Continued…




Home USB

Fill level parameter Setup fill

Information Valve management

Language selection Volumetric measurement

Main menu

Operation AreaAll operating functions can be run using the function keys F1 − F5, thebuttons on the Overview screen, and those of the Main menu.

Overview Function Keys

14

16

1

15

1718

2 3 4

5

6

7

8

9 10 11 1312

Figure 27 Overview Screen Function Keys

1. Number of the menu window2. Name of recipe currently selected3. Status display4. Operating mode display5. Displays the nominal mixing ratio

according to the recipe selected6. Displays the pot life configured in the

recipe7. Progress bar for spray hose filling8. Progress bar for pot life expired9. Displays the level in the material

containers for A (blue bar) and B (redbar) components

10. Reset fill levels11. Switch to recipe selection12. Displays mixing ratio and

volume information13. Switch to main menu14. Switch to flushing mode15. Switch to spray mode16. Switch to circulation mode17. Reset key for acknowledging

alarm messages18. Switch to stop mode



Main Menu

2 3 41

5

6

8

7

Figure 28 Main Menu Function Keys

1. Displays current alarm message2. Run control measurement3. USB data log4. Language selection

5. Displays alarm history6. Switch to setup menu7. Displays day and batch

counter8. Displays system software

versions

Status DisplayThe control system uses the status display to indicate selected operatingstates. It is shown in the title bar of all menu windows. The following iconsmay be seen here:

Table 7 Status Display Symbols


Alarm message Pot life has expired

The unit is being flushed A material container hasreached its minimum level

If more than one operating state is simultaneously present, the relevantstatus displays will flash in a cycle.

Operating Mode DisplayThe operating mode currently selected is indicated in all menu windows bythe icon to the far right of the title bar. The following icons may be seenhere:



Table 8 Operating Mode Symbols


Filling Circulating

Flushing Stop

Spraying Mode (F2)Press the function key F2 to switch the control system to spraying mode.

The metering valves and the air supply to the metering pumps are open inspraying mode. The two components of the material to be used arepumped through the mixing block and the static mixer to the spray gun andmixed together as they pass through the static mixer. The touchscreendisplays the Overview during spraying operation.

NOTE: Observe the operating mode display. When the spraying operationhas started, the operating mode initially displays Filling, then changes toSpraying as soon as the spray hose is filled with material. Once thisoccurs, the unit is ready for operation.

An interruption of the spraying mode during which the unit is not flushed willactivate pot life monitoring. This can be seen by the black progress bar onthe Overview screen. Pot life is the period in which the mixed material canbe processed from the time of it being mixed until the material increasinglycures.

Pot life monitoring is intended to prevent the mixed material from curinginside the unit. You will see an appropriate alarm message when the pot lifehas expired. If this alarm is present, immediately flush the unit or continuespraying.

Flushing Mode (F1)Press the function key F1 to switch the control system to flushing mode,shown in Figure 29.

Figure 29 Flushing Mode Display

The metering valves are closed in flushing mode. The air supply to the airmotors at the metering pumps is interrupted. The flushing agent is pumpedthrough the flushing valves and the static mixer to the spray gun.



The flushing mode flushes any mixed material out of the unit before it curesduring an interruption in spraying operations.

Circulation Mode (F3)In circulation mode, the metering pumps transport the materials to besprayed out of their respective containers, and then back into theircontainers, with no mixing occurring. The purpose of circulation is to fill theunit with material to be sprayed, to vent the unit, and to warm the material tobe sprayed uniformly when material heaters are in use.

For the circulation operation, the control system is only relevant if the unit isequipped with an external mixing unit. When working with a mixing unit ona rack, open the return ball valves at the mixing unit to switch the unit intothe circulation operation.

For units with an external mixing unit, press the function key F3 to switchthe control system to circulation mode. See Figure 30.

Figure 30 Circulate Display Screen

The touchscreen shows the component selection and the current statusduring circulation operation monitored by the system control. Select thecomponent(s) to be circulated through the unit using the A and B buttons.

You can select the two components individually or together. Thecomponents selected are indicated by a green marker on the screen.

The Active icon with the green background is shown when circulation isrunning.

Unit Stop (F5)Press the function key F5 to switch the control system to Stop. Themetering valves and the air supply to the metering pumps are closed whenthe system is stopped. The touch screen displays the Overview screen,and the operating mode display shows Stop.

Fill Level IndicationContainer monitoring makes it possible to guarantee a constant supply ofmaterial, preventing unnecessary shutdowns. This assumes that thematerial containers are changed or completely filled on every update andthat the filling levels are reset to the maximum level.



Press the Fill Level button on the Overview screen to reset thefilling levels to the maximum level. The first Set Fill Level window will thenbe opened (material containers for valves V1−V3). See Figure 31.

Figure 31 Fill Level Indication of Valves, Screens 1 & 2

The system control monitors the fill levels of up to 10 material containers,with three valve displays per window. Use the arrow buttons to browseforwards and backwards between the various windows. The volume unitpreset in the system control is displayed between these arrow buttons.

The fill levels are shown as a value in liters or gallons and graphically asbars. The level bars of the components used in the current recipe are blue(A) and red (B), and any other components are shown in black. Set thefilling level back to the maximum level using the Set button when a materialcontainer has been changed or completely filled.

Recipe SelectionUp to 10 different mixing settings can be stored as recipes and recalled inrecipe selection.

Press the Recipe Selection button on the Overview screen toopen recipe selection. You will see a confirmation prompt asking if you wishto change the recipe. If you confirm with yes, you then are asked whetheryou wish to flush before changing the recipe. See Figure 32.

Figure 32 Recipe Selection Confirmation Screens 1 & 2



NOTE: You must launch the flushing program and flush the unit for eachchange of recipe to prevent reactions between materials.

If the unit has not yet been flushed, press the Yes button to launch theflushing program.

If the system has already flushed, press the No button to go to recipeselection.

You can select one of the preset recipes using the Recipe − and Recipe +buttons. The number of the recipe currently selected is shown between thetwo buttons.

The subsequent rows in the menu window show the data stored for therecipe in Recipe Management . See Figure 33. See Page 24 for moreinformation.

Figure 33 Recipe Selection

Information Relating to Mixing Ratio and Volume

Press the Mixing Ratio button on the Overview screen to accessinformation relating to mixing ratio and volume, as shown in Figure 34.

This window shows the target and actual mixing ratio of components A andB, and the actual volumes of counters A and B.

Figure 34 Mixing Ratio and Volume Screen

AlarmsIf certain malfunctions occur during operation, an appropriate alarmmessage is displayed and stored in the alarm history. See Figure 35.



In the case of metering faults, the actual mixing ratio will also be displayed.

You can acknowledge alarm messages and clear them from the display bypressing function key F4.

Figure 35 Alarm Screen

Recall an alarm message you have cleared without acknowledgingit by pressing the Alarm button in the Main menu.

See the Troubleshooting section beginning on Page 47 for an overview ofpossible alarm messages with instructions for troubleshooting andcorrecting malfunctions.

Control MeasurementIn a control measurement, a predefined measured volume of component Aand the corresponding volume according to the mixing ratio of component Bare fed separately and dispensed through the spray gun into measuringcups.

The purpose of the control measurement is to check the mixing ratio foraccuracy, and to check the metering pumps and metering valves for correctoperation.

NOTE: To perform a control measurement, the unit must be filled withprocessing material and must be vented.

1. Make sure that all air pressure regulators for the metering pumps havebeen fully regulated down, and the compressed air shut-off valves areopened on the metering pumps that deliver the materials used in thecurrent recipe.

2. Press the Control Measurement button in the Main menu.See Figure 36.

3. Press the A+B button on the component selection screen displayed.

4. Adjust the air inlet pressure for the metering pumps up to 3.0−3.5 bar.

5. Unlock and operate the spray gun.

The unit delivers the A component first. After approximately 10 seconds,the B component is delivered.



The fill volumes accumulate on the display during the control measurement.

6. Close and secure the spray gun once the filling process is complete.

7. Set the air inlet pressure for the metering pumps to zero.

Figure 36 Control Measurement Screens

8. Allow a few minutes for any trapped air to escape from the material inthe measuring cups, particularly when working with highly viscousmaterials.

9. Check whether the volumes indicated on the screen match the actualquantities, and whether the quantities of the two components are correctfor the mixing ratio specified in the recipe.

If this is not the case, a volumetric measurement must be performed for theA− and B−component metering pumps used in the current recipe. SeePage 16 for more information.

USB Data LogData stored in the system control unit, such as volumes, alarm messages,and so forth, can be downloaded to a USB drive from the USB data log.

To run a USB data log, plug a USB drive into the USB port on thecontrol panel and press the USB button in the Main menu. The USBDatalog screen is shown in Figure 37.

Depending on the amount of data, the USB data log can take up to 40minutes to transfer.

Figure 37 USB Data Log Screen



Language Selection

Press the Language button in the Main menu to open thelanguage selection screen. The language designated for the control systemmenus can be configured in the language selection screens. Press theappropriate flag icon to select a language. See Figures 38 and 39.

Figure 38 Language Selection Screens, East and North

Figure 39 Language Selection Screen, West and South

Alarm History

Press the Alarm History button in the Main menu to display thealarm history screen, shown in Figure 40.

The alarm history saves up to 200 alarm messages with the date and timerecorded. Once this storage limit is reached, the oldest alarm message isdeleted from the alarm history each time a new message is added.

Faults can be diagnosed and traced using the alarm history.



Figure 40 Alarm History

Use the scroll bar to navigate through the alarm history.

Day and Batch Counters

The day and batch counters record the volume that has passedthrough the various valves per day and batch. Press the Counter button inthe Main menu to display the day counter screens, shown in Figure 41.

Figure 41 Day Counter Screens

The day and batch counters can be reset to 0 using the Reset buttons.

The VOC column shows the consumptions of volatile organic compounds(VOC). This is also reset to 0 when a day or batch counter is reset.

Use the arrow buttons to browse forwards and backwards between themenu windows.



Information

Press the Information button in the Main menu to open theinformation screen. See Figure 42.

This window displays the software versions of the display and theprogrammable logic controller (PLC).

Figure 42 Information Screen



Operation − SystemThe following is required as a minimum for correct operation of the unit:

� a material supply for the A-side (standard component),

� a material supply for the B-side (hardener),

� a flushing agent supply with a solvent suitable for the A- andB-components.

� Two suitable collecting vessels for excess material are required. Thesecontainers are to be supplied by the end user.

Before starting work, check to see that all the safety features are presentand fully functional and that all connections are secure.

WARNING: If material pumps run dry, the generated friction heat can causea fire or an explosion.

� Always make sure that the material drums do not run dry duringoperation. If this occurs, stop the corresponding pump immediately andstart feeding material.

StartupNOTE: Observe the technical notes of the respective materialmanufacturer.

During commissioning, check that the unit or its individual components areleak-proof by slowly building up pressure.

Overview of the work sequence for startup:

� Switch on the unit

� Set up the control system (only during initial commissioning)

� Flush mixing unit and spray gun

� Fill and vent the metering pumps

� Perform a control measurement

Switching the Unit OnSwitch the unit on using the master switch on the control panel.

When the unit is switched on, the touchscreen first displays the Welcomescreen. After a few seconds, it continues automatically to the Overviewscreen.

The Overview is the basic display in system control.

Setting Up the Control SystemDuring initial startup, the parameters for the control system must beadjusted. See Page 14 for detailed information.



Flushing Mixing Unit and Spray GunNOTE: The flushing pump should always be ready for use while the unit isbeing used so that all components coming into contact with the mixedmaterial can be flushed within the pot life specified.

1. Place the suction pipe of the flushing pump into the flushing agent drum.

2. Make sure that the air pressure regulator for the flushing pump has beenregulated completely back.

3. Open the compressed air shut-off valve on the flushing pump.

4. Set the pressure regulator of the flushing pump to 3−6 bar (43.5 − 87.0psi), depending on the length of the material hoses.

5. Press the F1 function key on the control module to switch the controlsystem to flushing mode.

6. Hold the spray gun into a collection container.

7. Unlock the spray gun and hold the trigger down until the flushingprogram has completed.

8. Close and secure the spray gun.

Filling and Venting the Metering Pumps1. Fill the metering pumps of A- and B-component with material to be

applied and vent them.

NOTE: Observe and follow the notes in the separate operating manuals forthe metering pumps.

Performing a Control MeasurementYou must perform a control measurement at each commissioning in order toensure that the mixing ratios specified in the recipes are met.

1. Select the recipe you wish to work with from the Overview window inthe control system.

2. Perform a control measurement as described on Page 35.

CoatingPrior to coating, the unit must be put into operation.

1. Press the F2 function key on the control module to switch the controlsystem to spraying mode.

2. Adjust the air pressure regulators on the metering pumps to a low airinlet pressure.

3. Spray the flushing agent residues in the system into a collecting vesseluntil clean material flows out.

4. Adjust the air pressure regulator on the metering pumps to the optimalspraying pressure.

The unit is now ready for operation.



Adjusting Spraying PressureObserve the following information when adjusting the spraying pressure:

� Optimal spraying pressure is indicated by a uniform application ofmaterial with fading peripheral zones.

� Operate the unit with an air pressure only as high as necessary toachieve a good atomization at the recommended spraying distance ofapproximately 30 − 40 cm (11.8 − 15.7 in).

� Setting spraying pressure too high causes increased materialconsumption and paint mist.

� Spraying at pressure set too low results in the appearance of stripes anddifferences in the coating thickness.

NOTE: The metering pumps for the B-side components must haveapproximately 10% higher air inlet pressure than those for the A-sidecomponents in order to feed the hardener.

Achieving Quality Coating Results� Hold the spray gun at a right angle (90�) to the area being coated. If the

spray gun is no held at a right angle, the coating becomes irregular.

� Move the spray gun with your arm and not with your wrist, maintaining aconsistent distance from the area being coated.

� Put the spray gun into motion before pulling the trigger to avoidexcessively thick application of material at the beginning of the sprayingprocess.

� Release the trigger before stopping the movement.

� Replace the spray nozzles often, as worn nozzles can cause highermaterial consumption and have a negative effect on the quality ofcoating.

FlushingWhen interrupting work, flush all components that came into contact withthe mixed material within the pot life specified by the manufacturer.

Material heaters fitted on the system must be switched off and the systemallowed to cool down before flushing. The system will be cooled down morequickly by circulating the material.

WARNING: Explosive vapors may be generated as the flushing agentevaporates which may ignite near heat sources.

1. Close and lock the spray gun.

2. Press the F1 function key on the control module to switch the controlsystem to flushing mode.

3. Open the spray gun and spray into an empty collecting vessel until theflushing program has finished.

4. Close and lock the spray gun.



The section between the mixing unit and the spray gun is cleaned duringthe flushing procedure. Any material remaining in the section between thematerial inlet and the mixing unit may remain in the unit, as it has not beenmixed yet.

If the system is equipped with automatic gun triggering, the displacementfunction can be used as an alternative to the flushing program, minimizingthe consumption of solvent and material.

Pressure Release 1. Regulate the compressed air pressure regulators for the metering

pumps and the flushing pump fully back.

2. Close the compressed air shut-off valves at the air inlets of the meteringpumps and the flushing pump.

3. Depressurize the metering pumps using the filters or return devices.

NOTE: Observe and follow the instructions in the operation manuals for themetering pumps.

4. Trigger the spray gun for a moment to relieve the material pressure.

Shutting DownThe work flow for decommissioning depends on whether you want to takethe unit out of service temporarily, for a long period of time, or permanently.

Temporary DecommissioningFor a temporary decommissioning, flush the unit, perform a pressurerelease, and switch the unit off.

1. Flush the unit.

2. Regulate the compressed air pressure regulators for the meteringpumps and the flushing pump fully back.



5. Press the F5 function key on the control module to switch the controlsystem to Stop.

6. Switch the unit off at the master switch on the control panel.

7. Trigger the spray gun for a moment to relieve the flushing pressure, sothat the entire unit has been relieved.



Decommissioning for a Long Period or PermanentlyWhen decommissioning for a long period or permanently, clean the unitcompletely, perform a pressure release, switch off the unit, disconnect thecompressed air supply, and unplug the electrical power supply.

1. Flush the unit.

2. Flush each of the metering pumps with an appropriate solvent using themanual valve control menu.

3. Regulate the compressed air pressure regulators for the meteringpumps and the flushing pump fully back.



6. Press the F5 function key on the control module to switch the controlsystem to Stop.

7. Switch the unit off at the master switch on the control panel.

8. Trigger the spray gun for a moment to relieve the flushing pressure, sothat the entire unit has been relieved.

9. Dismantle all hose connections to the mixer unit and lock them off.

10. Apply a neutral preservation oil to the valves to avoid problems onrecommissioning caused by solidified parts.

11. Disconnect the electrical and pneumatic feed lines.

Storage� Pay attention to ambient conditions when putting the unit into storage.

Store in a dry place.

� Protect the control unit from heat and moisture.

� Avoid severe temperature fluctuations during storage. If necessary,allow the unit to adjust to the new environment over several hoursbefore re-commissioning.

� The mixing unit is resistant to external influences, but it should be filledwith preservation oil over long periods of storage to protect the sealpacking and to ensure problem-free recommissioning.

� Decommission the metering pumps as described in the pump’soperating manual.

Waste DisposalAt the end of use, shut down and dismantle the unit and dispose of it inaccordance with all legal regulations.

1. Perform all work steps necessary for permanent decommissioning.

2. Clean the unit thoroughly of all material residues.

3. Dismantle the unit and separate all materials. Dispose of metal togetherwith scrap metal; plastic parts can be disposed of as domestic wastewhere allowed.



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

WARNING: Maintenance and repair work on electrical components mustonly be carried out by trained electricians.

Before maintenance and repair work:

1. Cut off the compressed air supply.

2. Disconnect the power supply.

3. Depressurize the unit completely.

WARNING: Despite releasing the pressure, material congestion oragglomeration of material may mean that there are residual pressures stillpresent. These may suddenly release during disassembly work and canresult in serious injuries.

NOTE: When disconnecting material hoses, cover the screw fitting with acloth to catch any escaping material sprays.

After completing maintenance and repair work, check the function of all thesafety features. Check that the unit is functioning correctly.

Mixing UnitOn completion of coating work, the unit must always run through a fullflushing process to avoid curing of the mixed material within the unit.Alternatively, the displacement function can be used, if available, tominimize the consumption of solvent and material.

The mixing unit should be protected against spray mist. If necessary, cleanthe area with solvent. The unit must be de-energized, as the measuringsensors in the standard version are not explosion protected.

Hoses and PipesThere is no need for special cleaning of the hoses or pipes if the flushingcycles are carried out correctly. However, if reactions occur within thesystem, it is advisable to replace the affected components to prevent solidsfrom dissolving over time and entering the system, which could lead toblockages and a loss of quality.

Control PanelThe control panel should only be cleaned using mild detergents.

Clean the touch screen using only appropriate agents such as plastic or PCcleaner. Never use a solvent on the screen. Semi-adhering clear protectivefilms can be applied for added protection against dirt and foreign materials.



Metering ValvesThe metering valves should be taken apart and cleaned at regular intervals,and seals should be replaced as needed. Keep the valve oilers full ofsolvent chamber fluid. Refer to Other Options on page 66 for solventchamber fluid part number.

If a metering valve is not used over a long period of time, it is advisable todismantle the paint supply unit and to flush the valve. Otherwise, solids cansettle inside the valve.

Replace the seals if valves stop functioning correctly, or if air or materialleaks. Since the catalyst valves are operated much more frequently, regularinspection and servicing of these valves is advisable.

Flow MetersFlow meters must be serviced and maintained according to the instructionsin the operating manuals for the corresponding measuring systems in use.Flow meters are normally maintenance-free. However, the following appliesif it should become necessary to clean blocked meters :

� Flow meters with ball bearings should only be serviced by authorizedpersonnel. Depressurize the unit and close the ball valves beforeassembly. Watch for exiting fluids when dismantling the meters. Placea container underneath them to prevent spillage.

� The flow meters are precision equipment and contain small parts suchas seals and gear wheels. Do not use pointed objects to loosen orclean parts of the meters. Do not over-tighten the lock screws, andalways tighten crossways.



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

These troubleshooting procedures cover only the most common problems.If you cannot solve a problem with the information given here, contact yourlocal Nordson representative for help.

Problem Possible Cause Corrective Action

1. Dosing error alarm The mixing ratio differs from theset value. The actual mixing ratiois displayed.

Check to see that there is enoughmaterial in the containers.

Check to see if the mixing unit isclogged. Switch the system toflushing operation and check whetherflushing agent is delivered to both theA- and the B-component side inalternating flushing. If the flushingagent for one of the components isnot being pumped, this side of themixing unit is clogged and should becleaned.

Check to see if the metering valve ofthe B component is permanentlyopened and is no longer cycling, or iscycling slowly and irregularly beforethe system shuts down. If so, thestroke limiter for the metering valveshould be adjusted.

Check that the return ball valves onthe mixing unit are fully closed.

Check that the ball valves in thesuction system are open, if present.

NOTE: The unit must be flushed toremove the incorrectly mixed materialfrom the unit before sprayingoperations can be resumed.

2. Pot life expired alarm Pot life is expired. Flush the unit.

3. Fill level comp A orFill level comp Balarm

The fill level in the materialcontainer for the A or B componentused in the current recipe hasfallen below the minimum volumeconfigured in container monitoring.

Add material to the materialcontainers.

Continued...



Corrective ActionPossible CauseProblem

4. Atomize air sensoralarm

The atomizer air sensor registersair flow in the atomizer air while nomaterial flow is detected by theflow rate measuring cell.

Check and clean the flow ratemeasuring cell.

5. PLC low battery alarm The back-up battery of theprogrammable logic controller(PLC) is empty.

Save all important data and replacethe battery.

6. Remote controlemergency stop

The emergency stop button at theremote control was triggered.

Check why the button was triggered.If safe operation is ensured,acknowledge the alarm and unlockthe emergency stop button.



Parts To order parts, call the Nordson Industrial Coating Systems CustomerSupport Center at (800) 433-9319 or contact your local Nordsonrepresentative.

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

System Configurations Appendix B, Page B-1 lists the various configurations available for OptiMix 12K and 3K systems. For more information, contact your Nordsonrepresentative.



OptiMix 1 System Parts

Base Frame See Table 9 for parts list.

Figure 43 OptiMix 1 Base Frame



Table 9 Base Frame Parts List

Item Part Description Quantity Note— −−−−−− OptiMix 1 base frame

1 −−−−−− � Screw 2

2 −−−−−− � Spacer 2

3 −−−−−− � Washer 8

4 −−−−−− � Nut 6

5 −−−−−− � Circuit diagram bag 1

6 −−−−−− � Screw 2

7 −−−−−− � Frame 1

8 −−−−−− � Screw 2

9 −−−−−− � Square plug 2

10 −−−−−− � Machine feet 4

11 −−−−−− � Washer 8

12 −−−−−− � Nut 4

13 −−−−−− � Pug−type fitting 1

14 1605330 � Filter regulator 1 A15 −−−−−− � Air connection nipple 1

16 1605363 � Adapter, male, 1/4 BSPT x 1/4 NPT, brass,OPTIONAL

1

17 −−−−−− � Elbow 1

18 −−−−−− � T−piece 1

19 −−−−−− � Plug−type fitting 2

20 −−−−−− � Screw 2

21 −−−−−− � Washer 2

22 −−−−−− � Nut 1

23 −−−−−− � Holder 1

24 −−−−−− � Holder coupling 2

NS −−−−−− � L−piece 1

NS 1073943 � Tubing, 4mm, nylon, clear 1NS 1085033 � Tubing, 10mm, nylon, blue 1

NOTE A: See page 65 for filter regulator repair parts.

NS: Not Shown



Automatic Valve, 3MMSee Table 10 for parts list.

1

Figure 44 Automatic Valve, 3MM



Table 10 Automatic Valve, 3mm Parts List

Item Part Description Quantity Note— 1605283 Valve, OptiMix, 3mm1 1608087 � Fitting, elbow, 4mm tube 22 −−−−−− � Cover 2

3 −−−−−− � Spring 2 B

4 −−−−−− � Nut 4

5 −−−−−− � O−ring 2 A, B

6 −−−−−− � Piston plate 2

7 −−−−−− � O−ring 2 A, B

8 −−−−−− � Retaining ring 2 A, B

9 −−−−−− � Lip seal 2 A, B

10 −−−−−− � Bushing 2 B

11 −−−−−− � O−ring 4 A, B

12 1608088 � Screw, valve HSG 813 −−−−−− � Housing 2

14 1608089 � Plug, valve HSG 215 −−−−−− � Valve needle 2 B

16 1605373 � O−ring, valve 4 A, B17 −−−−−− � Sleeve 2

18 −−−−−− � Saddle ring 2

19 −−−−−− � Packing ring 6 A, B

20 −−−−−− � Counter ring 2

21 −−−−−− � Disc spring 12 B

22 1608090 � Screw, valve MTG 423 1605288 � Housing, valve CPL, 3mm 124 1608091 � Fitting, oiler 2NS 1605284 � Kit, seal, valve, 3mm 1 BNS 1605285 � Kit, repair, valve, 3mm 1

NOTE A: Included in seal kit 1605284

B: Included in repair kit 1605285

NS: Not ShownIllustration Note F: Apply O-ring lubricant 900223

r: Apply removable thread lock adhesive 900464

T: Apply solvent chamber fluid 1602006



Automatic Valve, 6MMSee Table 11 for parts list.

1

Figure 45 Automatic Valve, 6MM



Table 11 Automatic Valve, 6mm Parts List

Item Part Description Quantity Note— 1605294 Valve, OptiMix, 6mm1 1608087 � Fitting, elbow, 4mm tube 12 −−−−−− � Cover 1

3 −−−−−− � Spring 1 B

4 −−−−−− � Nut 1


6 −−−−−− � O−ring 1 A, B


8 −−−−−− � Lip seal 1 A, B

9 −−−−−− � Bushing 1 B

10 −−−−−− � O−ring 2 A, B

11 −−−−−− � O−ring 1 A, B

12 1608088 � Screw, valve HSG 813 1608089 � Plug, valve HSG 114 −−−−−− � Housing 1 B

15 1608091 � Fitting, oiler 116 −−−−−− � Valve needle 1





22 −−−−−− � Disc spring 6 B

23 1608090 � Screw, valve MTG 424 1605293 � Housing, valve CPL, 6mm 125 −−−−−− � O−ring 1 A, B

26 −−−−−− � Plug 1

27 −−−−−− � Cover 1

NS 1605295 � Kit, seal, valve, 6mm 1 BNS 1605296 � Kit, repair, valve, 6mm 1








Automatic Valve, 3MM Stroke LimitSee Table 12 for parts list.

1

Figure 46 Automatic Valve, 3MM, Stroke Limit



Table 12 Automatic Valve, 3mm, Stroke Limit Parts List

Item Part Description Quantity Note— 1605289 Valve, OptiMix, 3mm, stroke limit1 1608087 � Fitting, elbow, 4mm tube 22 −−−−−− � Screw 1

3 −−−−−− � Nut 1

4 −−−−−− � Cover 1

5 −−−−−− � Spring 2 B

6 −−−−−− � Nut 4


8 −−−−−− � O−ring 2 A, B


10 −−−−−− � O−ring 2 A, B

11 −−−−−− � Lip seal 2 A, B

12 −−−−−− � Bushing 2 B

13 −−−−−− � O−ring 4 A, B


16 1608089 � Plug, valve HSG 217 1608090 � Screw, valve MTG 418 1605288 � Housing, valve CPL, 3mm 119 −−−−−− � Valve needle 2 B





25 −−−−−− � Disc spring 12 B

26 1608091 � Fitting, oiler 227 −−−−−− � Cover 1

NS 1605284 � Kit, seal, valve, 3mm 1 BNS 1605285 � Kit, repair, valve, 3mm 1








Automatic Valve, 6MM Stroke LimitSee Table 13 for parts list.

1

Figure 47 Automatic Valve, 6MM, Stroke



Table 13 Automatic Valve, 6mm, Stroke Limit Parts List

Item Part Description Quantity Note— 1605290 Valve, OptiMix, 6mm, stroke limit1 1608087 � Fitting, elbow, 4mm tube 22 −−−−−− � Screw 1

3 −−−−−− � Nut 1

4 −−−−−− � Cover 1

5 −−−−−− � Spring 2 B

6 −−−−−− � Nut 2


8 −−−−−− � O−ring 2 A, B


10 −−−−−− � Lip seal 2 A, B

11 −−−−−− � Bushing 2 B

12 −−−−−− � O−ring 4 A, B

13 −−−−−− � O−ring 2 A, B


16 1608089 � Plug, valve HSG 217 −−−−−− � Valve needle 2 B





23 −−−−−− � Disc spring 12 B

24 1608090 � Screw, valve MTG 425 1605293 � Housing, valve CPL, 6mm 126 1608091 � Fitting, oiler 227 −−−−−− � Cover 1

NS 1605291 � Kit, seal, valve, 6mm, stroke limit 1 BNS 1605292 � Kit, repair, valve, 6mm, stroke limit 1








Mixing Unit, CompleteSee Table 14 for parts list.

19

Figure 48 Mixing Unit, Complete



Table 14 Mixing Unit, Complete, Parts List

Item Part Description Quantity Note— Mixing unit1 1608092 � Screw, cover plate 82 1608093 � Cover, valve body 23 1608094 � Plug, manifold 24 1605373 � O−ring, valve, OptiMix 65 1605289 � Valve, OptiMix, 3mm stroke limit 1 A, B5 1605290 � Valve, OptiMix, 6mm stroke limit 1 A, B6 1608096 � Bushing, manifold 27 1608097 � Radiator key coupling 18 1608098 � Male adapter, 3/8-in. NPS 29 1608099 � Male adapter, 1/4-in. NPS 210 −−−−−− � Connecting plate 2

11 1605328 � Gear meter 2 D12 1608100 � Screw, connecting plate 613 1605374 � Valve, check, OptiMix 214 1605299 � Unit, mixing, injection tube 1 A15 1608101 � Plug, fluid port 416 1605283 � Valve, OptiMix, 3mm 1 A, C16 1605294 � Valve, OptiMix, 6mm 1 A, C17 1608102 � Fitting, extension 418 1608103 � Fitting, elbow, oiler 419 1608104 � Connector, gear meter cable 1NS 1608105 � Cable, gear meter 3 meters X

NOTE A: See separate part illustrations and part lists provided in this manual.

B: The 3mm or 6mm valve with stroke limit can be used for this valve.

C: The 3mm or 6mm valve can be used for this valve.

D: The gear meter seal kit is part number 1605338.

X: The mixing unit includes one cable that is 3 meters long.

NS: Not ShownIllustration Note b: Apply removable thread lock adhesive 900464




Mixing Unit with Injection TubeSee Table 15 for parts list.

Figure 49 Mixing Unit with Injection Tube

Table 15 Mixing Unit with Injection Tube Parts List

Item Part Description Quantity Note— 1605299 Unit, mixing, injection tube, OptiMix1 −−−−−− � Retaining ring 1

2 1605301 � Screw, mixing, injection tube 13 −−−−−− � Housing 1

4 −−−−−− � O−ring 1 A

5 −−−−−− � Lip seal 1 A

6 −−−−−− � Washer 1

7 −−−−−− � Housing 1

8 1605302 � Screw, mixing, injection tube 19 −−−−−− � Injection tube 1

10 −−−−−− � Threaded pin 1

11 −−−−−− � Gasket 1 A

12 −−−−−− � Housing 1

NS 1605300 � Kit, repair, mixing, injection tube 1NOTE A: Included in repair kit 1605300

NS: Not Shown

Illustration Note b: Apply removable thread lock adhesive 900464

F: Apply O-ring lubricant 900223

M: Apply hydraulic pipe thread sealant / adhesive 900481




Static MixerSee Table 16 for parts list.

Figure 50 Static Mixer

Table 16 Static Mixer Parts List

Item Part Description Quantity Note— 1605303 Mixer, static, OptiMix1 1605304 � Gasket, mixer, static 22 1605362 � Element, mix, mixer, static 23 −−−−−− � Housing 2

4 1605305 � Gasket, mixer, static 15 −−−−−− � Male adapter 1

Illustration Note M: Apply hydraulic pipe thread sealant / adhesive 900481




Atomizing Air Mounting KitSee Table 17 for parts list.

Figure 51 Atomizing Air Mounting Kit

Table 17 Atomizing Air Mounting Kit Parts List

Item Part Description Quantity Note— 1605315 Kit, mounting, atomizing air, OptiMix1 1605363 � Male adapter (Optional) 1 A2 −−−−−− � Plug 1

3 −−−−−− � Plug, L−type fitting 1

4 1605316 � Hose, compressed air, atomizing air, OptiMix 15 −−−−−− � Plug, L−type fitting 1

6 −−−−−− � Gasket 1

7 −−−−−− � Nut 1

8 −−−−−− � Pipe fitting 1

9 1605317 � Regulator, air pressure, atomizing, OptiMix 110 1605318 � Guage, pressure, atomizing, OptiMix 1

NOTE A: Order optional P/N 1605363 to connect to 1/4 in. NPT. See page 66 for other optional fittings.

NS: Not Shown

Illustration Note r: Apply solvent chamber fluid 1602006



Gear Meter

Item Part Description Quantity Note— 1605328 Meter, gear, OptiMix

1605338 � Kit, seal, gear meter 1— 1608106 Kit, gear meter repair A

NOTE A: Repair kit includes gears, bushings, and all seals

Filter Regulator

Item Part Description Quantity Note— 1605330 Filter, regulator, OptiMix

1605335 � Kit repair, filter, regulator 11605336 � Filter element, regulator 11605337 � Holder, condensation, regulator filter 1

Options

Wheel KitSee Table 18 for parts list.

Figure 52 Wheel Kit



Table 18 Wheel Kit Parts List

Item Part Description Quantity Note— 1605322 Kit, wheel, OptiMix1 1605323 � Caster, swivel roller with stop 22 1605324 � Caster, fixed roller 23 −−−−−− � Washer 16

4 −−−−−− � Screw 16

Other Options

Item Part Description Quantity Note1605327 Controller, remote, OptiMix1605326 Kit, mounting, external valve1605339 Adapter, threaded, SWI, 1/2−20JIC x 3/8 BSPP A1605340 Adapter, threaded, SWI, 1/2−20JIC x 3/8 NPS B1605363 Adapter, male, 1/4 BSPT x 1/4 NPT, brass C900223 O−ring lubricant900464 Removable thread lock adhesive1602006 Fluid, solvent chamber, 0.5 liter900481 Adhesive, pipe/thread/hydraulic sealant

NOTE A: Used to adapt fluid inlet to 1/2 in.−20 JIC

B: Used to adapt fluid outlet to 1/2 in.−20 JIC

C: Used to adapt air inlet to 1/4 in. NPT

AR: As Required

NS: Not Shown

Hose Volumes A-1


Appendix AHose Volumes

See Table A-1 for standard hose volumes. Hose volume is calculated usingthe following formula:

Vol = Hose volumeDi = Inside diameter of the hoseL = Hose length

Table A-1 Hose VolumesDiameter

(mm)Diameter

(in)Length

(m)Length

(ft)Volume(ccm)

Volume(cu in)

4 0.16 5.00 16.40 63.00 3.84

4 0.16 7.50 24.61 94.00 5.74

4 0.16 10.00 32.81 126.00 7.69

4 0.16 12.50 41.01 157.00 9.58

4 0.16 15.00 49.21 188.00 11.47

4 0.16 20.00 65.62 251.00 15.32

4 0.16 25.00 82.02 314.00 19.16

4 0.16 30.00 98.42 377.00 23.01

4 0.16 40.00 131.23 503.00 30.69

4 0.16 50.00 164.04 628.00 38.32

5 0.20 5.00 16.40 98.00 5.98

5 0.20 7.50 24.61 147.00 8.97

5 0.20 10.00 32.81 196.00 11.96

5 0.20 12.50 41.01 245.00 14.95

5 0.20 15.00 49.21 295.00 18.00

5 0.20 20.00 65.62 393.00 23.98

5 0.20 25.00 82.02 491.00 29.96

5 0.20 30.00 98.42 589.00 35.94

5 0.20 40.00 131.23 785.00 47.90

5 0.20 50.00 164.04 982.00 59.93

6 0.24 5.00 16.40 141.00 8.60

6 0.24 7.50 24.61 212.00 12.94

6 0.24 10.00 32.81 283.00 17.27

6 0.24 12.50 41.01 353.00 21.54

6 0.24 15.00 49.21 424.00 25.87

6 0.24 20.00 65.62 565.00 34.48

6 0.24 25.00 82.02 707.00 43.14

6 0.24 30.00 98.42 848.00 51.75

6 0.24 40.00 131.23 1131.00 69.02

Continued…

Hose VolumesA-2


Diameter(mm)

Diameter(in)

Length(m)

Length(ft)

Volume(ccm)

Volume(cu in)

6 0.24 50.00 164.04 1414.00 86.29

8 0.31 5.00 16.40 251.00 15.32

8 0.31 7.50 24.61 377.00 23.01

8 0.31 10.00 32.81 503.00 30.69

8 0.31 12.50 41.01 628.00 38.32

8 0.31 15.00 49.21 754.00 46.01

8 0.31 20.00 65.62 1005.00 61.33

8 0.31 25.00 82.02 1257.00 76.71

8 0.31 30.00 98.42 1508.00 92.02

8 0.31 40.00 131.23 2011.00 122.72

8 0.31 50.00 164.04 2513.00 153.35

10 0.39 5.00 16.40 393.00 23.98

10 0.39 7.50 24.61 589.00 35.94

10 0.39 10.00 32.81 785.00 47.90

10 0.39 12.50 41.01 982.00 59.93

10 0.39 15.00 49.21 1178.00 71.89

10 0.39 20.00 65.62 1571.00 95.87

10 0.39 25.00 82.02 1963.00 119.79

10 0.39 30.00 98.42 2356.00 143.77

10 0.39 40.00 131.23 3142.00 191.74

10 0.39 50.00 164.04 3927.00 239.64

12 0.47 5.00 16.40 565.00 34.48

12 0.47 7.50 24.61 848.00 51.75

12 0.47 10.00 32.81 1131.00 69.02

12 0.47 12.50 41.01 1414.00 86.29

12 0.47 15.00 49.21 1696.00 103.50

12 0.47 20.00 65.62 2262.00 138.04

12 0.47 25.00 82.02 2827.00 172.51

12 0.47 30.00 98.42 3393.00 207.05

12 0.47 40.00 131.23 4524.00 276.07

12 0.47 50.00 164.04 5655.00 345.09

16 0.63 5.00 16.40 1005.00 61.33

16 0.63 7.50 24.61 1508.00 92.02

16 0.63 10.00 32.81 2011.00 122.72

16 0.63 12.50 41.01 2513.00 153.35

16 0.63 15.00 49.21 3016.00 184.05

16 0.63 20.00 65.62 4021.00 245.38

16 0.63 25.00 82.02 5027.00 306.77

16 0.63 30.00 98.42 6032.00 368.10

16 0.63 40.00 131.23 8042.00 490.75

16 0.63 50.00 164.04 10053.00 613.47

20 0.79 5.00 16.40 1571.00 95.87

20 0.79 7.50 24.61 2356.00 143.77

20 0.79 10.00 32.81 3142.00 191.74

20 0.79 12.50 41.01 3927.00 239.64

20 0.79 15.00 49.21 4712.00 287.54

20 0.79 20.00 65.62 6283.00 383.41

20 0.79 25.00 82.02 7854.00 479.28

20 0.79 30.00 98.42 9425.00 575.15

20 0.79 40.00 131.23 12566.00 766.82

20 0.79 50.00 164.04 15708.00 958.56

System Configurations B-1


Appendix BSystem Configurations

Figure B-1 OptiMix 1 System Configurations

System ConfigurationsB-2


Wiring Diagrams C-1


Appendix CWiring Diagrams

Appendix C Index Table C-1 Index

Subject PageCable Color Codes C-1

Supply C-3

CPU / PLC C-4

Input C-5

Counter 0-1 C-6

Valves C-7 - C9

Remote Control EX C-10 - C-11

Robot Connection C-12 - C-13

Wiring Color Code Chart Table C-2 Cable Color Codes

Cable Description Color CodeMain Power Black

Neutral Light Blue

Earth Green / Yellow

AC / Control Voltage AC Phase: Red

Neutral: Red

Control Voltage DC L+: Dark Blue

L-: Dark Blue

External Voltage Orange

Measuring Voltage White

Wiring DiagramsC-2C-2


OptiMix 1 Plural Component Liquid Dispensing System C−3


Figure C−1



Figure C−2



Figure C−3



Figure C−4



Figure C−5



Figure C−6



Figure C−7

OptiMix 1 Plural Component Liquid Dispensing SystemC−10


Figure C−8



Figure C−9



Figure C−10



Figure C−11

DECLARATION of Incorporation Product: Plural Component Liquid Dispensing System Models: OptiMix 1 Description: This machine electronically controls mixing and proportioning process for two-component and three-component coatings. Applicable Directives: 2006/42/EC - Machinery Directive Standards Used for Compliance: EN/ISO12100 (2010) EN60204-1 (2006)

___________________ Date: 04March 2014 Mike Hansinger Manager Engineering Development Industrial Coating Systems Nordson Authorized Representative in the EU Person authorized to compile the relevant technical documentation. Contact: Operations Manager Industrial Coating Systems Nordson Deutschland GmbH Heinrich-Hertz-StraBe 42-44 D-40699 Erkrath

Nordson Corporation W estlake, Ohio DOC13032

OptiMix 1 Plural Component Liquid Dispensing System

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