Nordson cp User manual

CP Pump
Customer Product Manual
Part 104373−04
Issued 2/17
NORDSON CORPORATION AMHERST, OHIO USA
Check http://emanuals.nordson.com/finishing for the latest version.
This document is subject to change without notice.
For parts and technical support, call the Industrial Coating Systems
Customer Support Center at [phone]

Part 104373−04 E2017 Nordson Corporation
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 1989. No part of this document may be
photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained
in this publication is subject to change without notice.
Trademarks
Nordson and the Nordson logo are registered trademarks of Nordson
Corporation.
All other trademarks are the property of their respective owners.

Table of Contents i
Part 104373−03
E2015 Nordson Corporation
Table of Contents
Safety 1-1..................................................
Introduction 1-1.............................................
Qualified Personnel 1-1......................................
Intended Use 1-1............................................
Regulations and Approvals 1-1................................
Personal Safety 1-2..........................................
High-Pressure Fluids 1-2...................................
Fire Safety 1-3..............................................
Halogenated Hydrocarbon Solvent Hazards 1-4...............
Action in the Event of a Malfunction 1-4........................
Disposal 1-4................................................
Safety Labels 1-5............................................
Description 2-1.............................................
Introduction 2-1..............................................
Specifications 2-1............................................
General 2-1...............................................
Fluid Pressures 2-2........................................
Fluid Hoses 2-2...........................................
Air Pressure and Consumption 2-3...........................
Sound Levels 2-3..........................................
Pump Components 2-3.......................................
Air Motor 2-3.............................................
Hydraulic Section 2-3......................................
Theory of Operation 2-4......................................
Installation 3-1..............................................
Mounting and Grounding 3-1..................................
Pneumatic Connections 3-2...................................
Fluid Connections 3-2........................................
Siphon Connections 3-2....................................
Siphon Rod and Strainer 3-2.............................
Pressure Feed Connection 3-2............................
Optional Circulation Kit Installation 3-3.......................
Fluid Hose Connections 3-4.................................

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Part 104373−03 E2015 Nordson Corporation
Operation 4-1...............................................
Preparation 4-1..............................................
Solvent Chamber Fluid and Vitalizer Oil 4-1...................
Solvent Flush 4-2............................................
Daily Startup 4-3.............................................
Daily Shutdown 4-3..........................................
Maintenance 4-4.............................................
Daily 4-4.................................................
Weekly 4-4...............................................
Troubleshooting 5-1.........................................
Repair 6-1..................................................
Introduction 6-1.............................................
Cover Removal 6-2..........................................
Hydraulic Section Repair 6-3..................................
Packing Gland Replacement 6-3............................
Packing Gland Rebuild 6-5.................................
Plunger Replacement 6-6...................................
Siphon Ball Check Valve Rebuild 6-6.........................
High-Pressure Ball Check Valve Rebuild 6-7..................
Air Valve Replacement 6-9...................................
Air Valve Rebuild 6-10.........................................
Air Motor Rebuild 6-11.........................................
Air Motor Disassembly 6-11..................................
Air Motor Assembly 6-12....................................
Air Preparation System 6-13....................................
Air Tubing Diagram and Tube Chart 6-14.........................

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Parts 7-1...................................................
Introduction 7-1.............................................
Using the Illustrated Parts List 7-1...........................
Parts Lists Table of Contents 7-2..............................
Quick Reference Lists 7-3....................................
Pump Part Numbers 7-3...................................
Replacement Assemblies and Service Kits 7-3................
Recommended Spare Parts 7-4.............................
On-line Maintenance 7-4.................................
Off-line Maintenance 7-4.................................
Options 7-5.................................................
Circulation Kits 7-5........................................
Solvent Chamber Feed Kit 7-5..............................
PTFE High-Pressure Fluid Hoses 7-5........................
Rubber Air Hoses 7-5......................................
Common Parts 7-6..........................................
Air Valve Parts 7-10...........................................
Air Motor Parts 7-12...........................................
Common Hydraulic Section Parts 7-14...........................
Version-Specific Parts for Hydraulic Section 7-16...............
General Finishing Pump (130697) 7-16.....................
Solventborne and Waterborne Pumps (249351, 112246) 7-16..
EPR Pump (170494) 7-16.................................
Abrasive Resistant Waterborne Pump (1004016) 7-17........
Accessory Groups 7-17........................................
General Finishing and Solventborne Accessory Group 7-17......
Waterborne and Abrasive-Resistant Waterborne
Accessory Group 7-18......................................
Solventborne EPR Accessory Group 7-18.....................
Air Preparation Systems 7-19...................................
Wilkerson Air Preparation System 7-19........................
SMC Air Preparation System 7-20............................
Service Kits 7-21..............................................
Air Valve Service Kit 7-21....................................
Air Motor Service Kit 7-21....................................
Packing Gland Service Kits 7-21.............................
Solventborne and Waterborne Packing Gland Service Kit 7-22.
Solvent EPR Packing Gland Service Kit 7-22................
Abrasive-Resistant Packing Gland Service Kit 7-22...........
Hydraulic Seal Kits 7-23....................................
Hydraulic Seal Kit for Waterborne,
Solventborne, and Abrasive-Resistant Pumps 7-23...........
Hydraulic Seal Kit for Solventborne EPR Pumps 7-23........
High-Pressure Ball Check Valve Service Kits 7-24..............
High-Pressure Ball Check Service Kit for
General Finishing, Solventborne, and Waterborne Pumps 7-24
High-Pressure Ball Check Service Kit for
Solventborne EPR Pumps 7-24............................
High-Pressure Ball Check Service Kit for
Abrasive-Resistant Waterborne Pumps 7-25................
Siphon Ball Check Valve Service Kits 7-25....................
Siphon Ball Check Service Kit for General Finishing,
Solventborne, Waterborne, and Abrasive-Resistant Pumps 7-25
Siphon Ball Check Service Kit for
Solventborne EPR Pumps 7-26............................

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Part 104373−03 E2015 Nordson Corporation

Change Record i
Part 104373−04
E2017 Nordson Corporation
Change Record
Revision Date Change
03 10/15 Removed O-rings from siphon ball check valve service kit.
04 2/17 Updated certification.

Change Record
ii
Part 104373−04 E2017 Nordson Corporation

Safety 1-1
Part 104373−04
E2017 Nordson Corporation
Section 1
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to persons operating or servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.

Safety
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Part 104373−04 E2017 Nordson Corporation
Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
SKeep clear of moving equipment. Before adjusting or servicing moving
equipment, shut off the power supply and wait until the equipment
comes to a complete stop. Lock out power and secure the equipment to
prevent unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SWhile operating manual spray guns, make sure you are grounded.
Wear electrically conductive gloves or a grounding strap connected to
the gun handle or other true earth ground. Do not wear or carry metallic
objects such as jewelry or tools.
SIf you receive even a slight electrical shock, shut down all electrical or
electrostatic equipment immediately. Do not restart the equipment until
the problem has been identified and corrected.
SObtain and read Safety Data Sheets (SDS) for all materials used.
Follow the manufacturer’s instructions for safe handling and use of
materials, and use recommended personal protection devices.
SMake sure the spray area is adequately ventilated.
STo prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
High-Pressure Fluids
High-pressure fluids, unless they are safely contained, are extremely
hazardous. Always relieve fluid pressure before adjusting or servicing high
pressure equipment. A jet of high-pressure fluid can cut like a knife and
cause serious bodily injury, amputation, or death. Fluids penetrating the
skin can also cause toxic poisoning.
If you suffer a fluid injection injury, seek medical care immediately. If
possible, provide a copy of the SDS for the injected fluid to the health care
provider.

Safety 1-3
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The National Spray Equipment Manufacturers Association has created a
wallet card that you should carry when you are operating high-pressure
spray equipment. These cards are supplied with your equipment. The
following is the text of this card:
WARNING: Any injury caused by high pressure liquid can be serious. If
you are injured or even suspect an injury:
SGo to an emergency room immediately.
STell the doctor that you suspect an injection injury.
SShow him this card
STell him what kind of material you were spraying
MEDICAL ALERT—AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN
Injection in the skin is a serious traumatic injury. It is important to treat the
injury surgically as soon as possible. Do not delay treatment to research
toxicity. Toxicity is a concern with some exotic coatings injected directly into
the bloodstream.
Consultation with a plastic surgeon or a reconstructive hand surgeon may
be advisable.
The seriousness of the wound depends on where the injury is on the body,
whether the substance hit something on its way in and deflected causing
more damage, and many other variables including skin microflora residing
in the paint or gun which are blasted into the wound. If the injected paint
contains acrylic latex and titanium dioxide that damage the tissue’s
resistance to infection, bacterial growth will flourish. The treatment that
doctors recommend for an injection injury to the hand includes immediate
decompression of the closed vascular compartments of the hand to release
the underlying tissue distended by the injected paint, judicious wound
debridement, and immediate antibiotic treatment.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SGround all conductive equipment. Use only grounded air and fluid
hoses. Check equipment and workpiece grounding devices regularly.
Resistance to ground must not exceed one megohm.
SShut down all equipment immediately if you notice static sparking or
arcing. Do not restart the equipment until the cause has been identified
and corrected.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SDo not heat materials to temperatures above those recommended by
the manufacturer. Make sure heat monitoring and limiting devices are
working properly.

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Part 104373−04 E2017 Nordson Corporation
Fire Safety (contd)
SProvide adequate ventilation to prevent dangerous concentrations of
volatile particles or vapors. Refer to local codes or your material SDS
for guidance.
SDo not disconnect live electrical circuits when working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
SShut off electrostatic power and ground the charging system before
adjusting, cleaning, or repairing electrostatic equipment.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
Halogenated Hydrocarbon Solvent Hazards
Do not use halogenated hydrocarbon solvents in a pressurized system that
contains aluminum components. Under pressure, these solvents can react
with aluminum and explode, causing injury, death, or property damage.
Halogenated hydrocarbon solvents contain one or more of the following
elements:
Element Symbol Prefix
Fluorine F “Fluoro-”
Chlorine Cl “Chloro-”
Bromine Br “Bromo-”
Iodine I “Iodo-”
Check your material SDS or contact your material supplier for more
information. If you must use halogenated hydrocarbon solvents, contact
your Nordson representative for information about compatible Nordson
components.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
SDisconnect and lock out system electrical power. Close hydraulic and
pneumatic shutoff valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting the
system.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

Safety 1-5
Part 104373−04
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Safety Labels
See Figure 1-1 for the location of the safety labels. Figure 1-2 displays the
main safety label (1). Table 1-1 describes the remaining safety labels (2, 3).
Figure 1-3 displays the ATEX patent label.
Safety labels are provided to help you operate and maintain your
equipment.
2
1
3 3
Figure 1-1 Safety Label Locations
DHIGH PRESSURE DEVICE
Read instruction manual before operation and observe all warnings.
DINJECTION HAZARD
Airless spray painting equipment can cause serious injury if the spray
penetrates the skin. Do not point the gun at anyone or any part of the body. In
cases of penetration, adequate medical aid must be immediately obtained.
DCOMPONENT RUPTURE
This system is capable of producing 104 BAR (1500 PSI) pressure. To avoid
rupture and injury, do not operate this pump at a pressure higher than the rated
maximum working pressure of any component in the system (including but not
limited to spray guns, hoses, hose connections, and heaters).
DFIRE
Static voltage is developed by airless spraying. The pump, associated system,
and object being sprayed must be grounded to prevent static discharge sparks
which could start a fire.
DSERVICING
Before servicing, cleaning, or removal of any part, set trigger lock on gun, and
always shut off power source; then carefully release pressure in fluid portions
of the system.
MODEL
PART NO.
RATIO
SERIAL NO.
NORDSON CORPORATION AMHERST, OH 44001
Figure 1-2 Main Safety Label

Safety
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Safety Labels (contd)
Table 1-1 Safety Labels
Item Part Description
2. −
WARNING: Air motor section contains spring loaded pistons. Refer to
manual for disassembly instructions.
3. −
General warning, caution, risk of danger.
Figure 1-3 ATEX Patent Label

Description 2-1
Part 104373−03
E2015 Nordson Corporation
Section 2
Description
Introduction
The Nordson Constant Pressure (CP) pump is an air powered, positive
displacement, demand-type, reciprocating dual piston pump.
Table 2-1 CP Pump Versions
Part Number
and Type Description
130697
General Finishing
Used with solventborne coating materials. TFE/
leather packings, Buna-N O-rings.
112246
Solventborne
Used with solventborne coating materials. Spring-
loaded PTFE U-cup packings, Buna-N O-rings.
170494
Solventborne EPR
Used with high-ketone (such as MEK) solvent-borne
coating materials. Spring-loaded PTFE U-cup pack-
ings, Ethylene/Prophylene/Rubber O-rings.
249351
Waterborne
Used with waterborne coating materials. Spring-
loaded PTFE U-cup packings, Buna-N O-rings.
1004016
Abrasive-Resistant
Waterborne
Used with abrasive waterborne coating materials.
Polyurethane U-cup packings, Buna-N O-rings, and
carbide high-pressure ball check seats.
The fluid output pressure to air input pressure ratio of the pump is 18.5:1,
producing 104 bar (1500 psi) of fluid pressure with 5.5 bar (80 psi) air
pressure, and a flow rate of 3.8 lpm (1.0 gpm) at 60 strokes/minute.
The pump is mounted vertically on a stand or wall. It can be supplied with
coating material through a siphon hose and strainer, or a pressure feed
system. Optional circulation valve kits are available for circulating systems.
Refer to the Parts section for ordering information.
Specifications
General
Height: 635 mm (25 in.)
Width: 483 mm (19 in.)
Depth: 330 mm (13 in.)
Weight: 48 kg (105 lbs)
Solvent chamber capacity: 480 ml (16 oz)

Description
2-2
Part 104373−03 E2015 Nordson Corporation
Fluid Pressures
Pump ratio: 18.5:1
Maximum fluid output pressure: 104 bar (1500 psi)
Maximum fluid delivery: 3.8 l/min. (1.0 gal/min.)
at 60 strokes/min.
Maximum feed pressure: 1.4 bar (20 psi)
Figure 2-1 is a chart showing air input pressure to hydraulic output pressure
ratios.
1200180A
0 200 400 600 800 1000 1200 1400 1600
20
40
60
80
Hydraulic pressure (psi)
Air pressure (psi)
Figure 2-1 Air Pressure-to-Fluid Pressure Ratios
Fluid Hoses
All hoses must be Nordson or equivalent PTFE hoses with electrical
continuity between the fittings, capable of withstanding 207 bar (3000 psi)
pressure. Do not use pipe in the high pressure circuit.
Air supply hose: 1/2-in. ID minimum
Hydraulic fluid hose: 1/4-in. ID reinforced PTFE
Alternate tubing: 3/8-in. OD x 0.035 in. wall
seamless stainless steel
Siphon hose 1/2-in. ID nylon
Drain-off hose 3/8-in. ID nylon

Description 2-3
Part 104373−03
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Air Pressure and Consumption
Input air pressure (maximum): 5.5 bar (80 psi)
Table 2-2 Air Consumption
Air Pressure
Strokes Per Minute
20 40 60
1.4 bar
(20 psi)
0.059 m3/min
(2.12 cfm)
0.119 m3/min
(4.24 cfm)
0.178 m3/min
(6.36 cfm)
2.7 bar
(40 psi)
0.092 m3/min
(3.32 cfm)
0.186 m3/min
(6.64 cfm)
0.279 m3/min
(9.96 cfm)
4.1 bar
(60 psi)
0.124 m3/min
(4.44 cfm)
0.249 m3/min
(8.88 cfm)
0.373 m3/min
(13.32 cfm)
5.5 bar
(80 psi)
0.16 m3/min
(5.72 cfm)
0.32 m3/min
(11.44 cfm)
0.48 m3/min
(17.16 cfm)
Sound Levels
Sound levels created by the CP pump are shown in decibels.
Table 2-3 Sound Levels
Air Pressure Sound Level (dB A) Sound Level (dB C)
7 bar (100 psi) 85 83
4.13 bar (60 psi) 82 81
Pump Components
Air Motor
See Figure 2-2. The air motor consists of two cylinders (4) containing two
spring-return pistons. A modular air preparation system consisting of an air
filter (12), regulator (6), and lubricator (5) conditions the compressed air
used to control and operate the air motor.
The accumulator (1) stores and releases working air to smooth the flow of
air to the cylinders and help prevent pressure fluctuations (wink) at the
spray device. Pump operation is controlled by the roller valves (11), the
double pilot valve (14), and the air valve (2).
Hydraulic Section
The hydraulic section consists of two separate hydraulic housings (9), a
siphon manifold (10), and a solvent chamber (7). Fluid enters the pump
through the siphon manifold and exits through the outlet manifold (8). The
solvent chamber holds solvent chamber fluid, which lubricates the hydraulic
plungers and reduces wear on the packings.

Description
2-4
Part 104373−03 E2015 Nordson Corporation
Pump Components (contd)
14 1
13
12
11
2
3
4
5
6
7
8
9
10
Air Motor
Hydraulic
Section
c
15
Figure 2-2 Pump Components
1. Accumulator
2. Air valve
3. Muffler
4. Cylinder
5. Lubricator
6. Pump control regulator
7. Solvent chamber
8. Outlet manifold
9. Hydraulic housing
10. Siphon manifold
11. Roller valve
12. Air filter
13. Air input fitting
14. Double pilot valve
15. Pilot air regulator
Theory of Operation
See Figures 2-3 and 2-4.
Supply air enters the pump at the shutoff valve. The air is filtered and
passes into a manifold block, where pilot air flows through Lines 1, 4, and 5
to the roller valves and double pilot valve. Working air is regulated and
lubricated before flowing into the accumulator, air valve, and cylinders.
When the pump is started, the position of the air valve spool determines
which piston/plunger begins its downward (pressure) stroke first.

Description 2-5
Part 104373−03
E2015 Nordson Corporation
NOTE: The air valve is an open-center type valve. If the valve spool stops
in the center of the valve block when the pump is turned off, the pump will
not restart because the spool will direct working air into both cylinders. To
start the pump, press the manual override button on the double pilot valve.
This directs pilot air to one side of the air valve and shifts the valve spool
out of the center position.
The air valve directs working air into the left cylinder. The working air forces
the left piston/plunger down. The siphon ball check valve closes and the
coating material in the left hydraulic housing is pressurized and forced out of
the housing, through the high-pressure ball check valve, outlet manifold,
and fluid lines to the spray devices.
The right piston/plunger is forced up by the return spring. The air above the
piston flows out of the cylinder, through the air valve, and into the right
muffler. The right plunger draws new coating material into the siphon
housing, through the siphon ball check valve, and into the right hydraulic
housing. The high-pressure ball check remains closed, retaining the
material in the housing.
Just before the left plunger reaches the bottom of its stroke, the chamfered
land on the piston shaft depresses the roller valve lever on that side of the
pump and actuates the valve.
1
3
2
5
Mufflers
4
Pump Control
Regulator
Pilot Air
Regulator Lubricator
Accumulator
FilterShutoff
Valve
Double Pilot
Valve
Air Valve
Air Cylinders
Roller
Valves
Figure 2-3 Pump Pneumatic Schematic

Description
2-6
Part 104373−03 E2015 Nordson Corporation
Theory of Operation (contd)
Pilot air flows through Line 4, the roller valve, Line 3, and into the double
pilot valve, shifting the valve spool and directing the pilot air entering the
double pilot valve through Line 1 to the air valve, forcing the air valve spool
to shift. The air valve directs working air to the right cylinder.
NOTE: Pilot air pressure is factory set to 4.1 bar (60 psi). Do not change
this pressure.
The strokes of the piston/plungers overlap. This keeps the fluid pressure in
the delivery lines to the guns constant and reduces wink or spray pattern
fading at the gun.
Fluid
Air
2
1
3
4
5
6
8
9
10
11 12
7
To Spray
Device
From Fluid Supply
Figure 2-4 Pump Operation
1. Air valve
2. Muffler
3. Piston
4. Cylinder
5. Solvent chamber
6. Plunger
7. Packing gland
8. Hydraulic housing
9. Siphon ball check valve
10. Siphon manifold
11. High-pressure ball check valve
12. Outlet manifold