As soon as a problem is noticed, immediately remove the disposable plastic mixer nozzle and try dispensing material. This may prevent or purge material cross-over if it has not already hardened. After the static mixer is removed, THEN check the following:
Is the mixer nozzle plugged? (material set up)
Is there sufficient air supply?
Is there sufficient material supply?
Is the air regulator set at desired pressure?
Do a ratio check at the dispense valve:
Check to see if there is flow from both pumps.
Check to see if the pump outlet valve is cutting off material and also that it is not sucking air in the return stroke.
Check phasing. Is one material flowing before the other?
Measure volume output of each material.
Check the rod metering pressure seal to make sure it is working properly.
Procedure for checking pressure seals and check valves:
Remove material hose from one side of applicator.
Reduce air pressure at regulator to 15 psi.
Hold hose over waste container.
Depress silver button on applicator with finger. DO NOT MOVE LEVER.
Pump will now move forward and pressure will rise on the side with hose still connected. Material will flow from the hose that is disconnected.
The pump will stall against pressure if the pressure seal is properly holding. *NOTE: Some materials may have air in them, which will allow pump to continue moving. If after 2 or 3 strokes pump does not stall against pressure and hold for 5-10 seconds, the pressure seal must be replaced.
To check the opposite side, reverse the hoses and repeat steps 3 thru 6.
Verify that outlet check valves are sealing. Observe check valves at the end of steps 6 and 7 above before opening the ball valves. The pressure should remain near its peak point for a half-minute or so.
*NOTE: If ratio and the seals and check valves test okay, the problem is in the line or applicator, and not in the meter.
If ratio check is not correct, the problem is in the meter.
Check level of materials in containers, making sure level is always over 1/3 filled.
Clean off applicator dispense head after removing plastic mixer nozzle. Trigger applicator into waste container to verify smooth, air free flow of both materials. Wipe head clean and coat head with compatible lubricant.
Place new plastic mixer nozzle on applicator block and secure with retainer nut. NOTE: For some high pressure and high flow rate systems, a mixer retaining housing may be required to avoid cracking plastic mixers.
Turn off main air supply or disconnect it.
Remove plastic mixer nozzle.
Trigger applicator to relieve any pressure in lines or system.
Clean head of applicator and coat with compatible lubricant.
Tips & Precautions
Keep the instruction manual.
Never permit either material tank to get below approximately 1/3 full.
A common problem is cross-over (one material crossing over into the other material’s manifold and/or hose). Damage and cost from cross-over is NOT covered under AST Corporation Warranty. Cross-over can be avoided by carefully following instructions.
If the gauges display pressures that “peg” the needle, immediately remove power from machine.
Do not install a disposable mixer nozzle to the dispense manifold until positive air-free flow is achieved from both outlets of the applicator block tip.
Air can be trapped in hoses during filling of an empty system. To avoid trapping air, arrange the hoses to obtain a continuous gradual upward slope of the hose from the pump outlet to the applicator while the system is pumping at low speed. Point the dispense assembly upward to let the material push the air out.
Questions?? Call us! If you’re with the machine, we can walk you through the procedure for start-up and shut-down. Ask for Technical Assistance at (763) 592-2060.
Check air supply for clean air.
Ratio check: This can be done at either the pump outlet or at the applicator head. On a daily basis it should be done to the applicator head.
Remove the retainer cap or mixer nozzle
Trigger applicator; two separate beads of material will appear. Compare for correct volume ratio.
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