Nordson EP2 User manual

EP2 Pump System
Customer Product Manual
Document Number1072608-04
Issued 10/21
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.
NORDSON CORPORATION • AMHERST, OHIO • USA

© 2021 Nordson Corporation
1072608-04
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 2004. 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
Safety............................................................................................................................................... 1
Introduction...................................................................................................................................... 1
Qualied Personnel ......................................................................................................................... 1
Intended Use ................................................................................................................................... 1
Regulations and Approvals.............................................................................................................. 1
Personal Safety ............................................................................................................................... 2
High-Pressure Fluids...................................................................................................................... 3
Fire Safety ....................................................................................................................................... 4
Halogenated Hydrocarbon Solvent Hazards.................................................................................. 4
Action in the Event of a Malfunction ................................................................................................ 5
Disposal........................................................................................................................................... 5
Safety Labels................................................................................................................................... 6
Description...................................................................................................................................... 8
Pump Operation .............................................................................................................................. 9
System Operation.......................................................................................................................... 10
Specications ................................................................................................................................ 12
Installation..................................................................................................................................... 13
Oil Change Kit Installation ............................................................................................................. 13
Mounting........................................................................................................................................ 13
Pump Oil Level .............................................................................................................................. 14
Electrical Connections................................................................................................................... 14
Wiring Guidelines ......................................................................................................................... 14
Wiring Diagram............................................................................................................................. 15
Fluid System Installation................................................................................................................ 16
Inlet and Outlet Connections........................................................................................................ 16
Fluid System Installation Guidelines ............................................................................................ 16
Operation....................................................................................................................................... 17
System Startup.............................................................................................................................. 17
Changing Coating Materials/Flushing the System......................................................................... 19
Shutdown....................................................................................................................................... 20
Short-Term Shutdown................................................................................................................... 20
Long-Term Shutdown ................................................................................................................... 20
Pressure Relief Valve Adjustment ................................................................................................. 21
Maintenance.................................................................................................................................. 22
EP2 Pump Oil Change .................................................................................................................. 22
Daily Maintenance Procedures...................................................................................................... 23
Monthly Maintenance Procedures................................................................................................. 24
Annual Maintenance Procedures .................................................................................................. 24
Troubleshooting............................................................................................................................ 25
Repair............................................................................................................................................. 27
Parts............................................................................................................................................... 29
Using the Illustrated Parts List....................................................................................................... 29
EP2 Pump System ........................................................................................................................ 30
Accessory Groups ......................................................................................................................... 32
Panel Assembly............................................................................................................................ 32
Frame and Motor Assembly ......................................................................................................... 32
Options .......................................................................................................................................... 33
Oil Change Kit ............................................................................................................................... 33
PTFE High-Pressure Fluid Hose Assemblies................................................................................ 33
Inline (Supply) Filter....................................................................................................................... 33

i
Change Record
© 2021 Nordson Corporation 1072608-04
Change Record
Revision Date Change
03 9/21 Revised pump versions and congurations.
04 10/21 Updated relief valve.

© 2021 Nordson Corporation
1072608-04
ii Change Record

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EP2 Pump System
© 2021 Nordson Corporation 1072608-04
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specic 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.
Qualied Personnel
Equipment owners are responsible for making sure that Nordson equipment is installed,
operated, and serviced by qualied personnel. Qualied 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:
• using incompatible materials
• making unauthorized modications
• 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 which it is
used. Any approvals obtained for Nordson equipment will be voided if instructions for
installation, operation, and service are not followed.

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Personal Safety
To prevent injury follow these instructions.
• Do not operate or service equipment unless you are qualied.
• Do 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.
• Keep clear of moving equipment. Before adjusting or servicing moving equipment,
shut o󰀨 the power supply and wait until the equipment comes to a complete stop.
Lock out power and secure the equipment to prevent unexpected movement.
• Relieve (bleed o󰀨) hydraulic and pneumatic pressure before adjusting or servicing
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 to the gun handle or other true earth
ground. Do not wear or carry metallic objects such as jewelry or tools.
• If 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
identied and corrected.
• Obtain 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.
• Make sure the spray area is adequately ventilated. To 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.

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High-Pressure Fluids
High-pressure uids, unless they are safely contained, are extremely hazardous. Always
relieve uid pressure before adjusting or servicing high pressure equipment. A jet of
high-pressure uid can cut like a knife and cause serious bodily injury, amputation, or
death. Fluids penetrating the skin can also cause toxic poisoning.
If you su󰀨er a uid injection injury, seek medical care immediately. If possible, provide a
copy of the SDS for the injected uid to the health care provider.
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:
• Go to an emergency room immediately.
• Tell the doctor that you suspect an injection injury.
• Show them this card
• Tell them what kind of material you were spraying
MEDICAL ALERT — AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN
Injection in the skin is a serious traumatic injury. It is important to treat 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 deected causing more damage, and many
other variables including skin microora 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 ourish. 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.

4EP2 Pump System
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Fire Safety
To avoid a re or explosion, follow these instructions.
• Ground all conductive equipment. Use only grounded air and uid hoses. 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 or arcing. Do not
restart the equipment until the cause has been identied and corrected.
• Do not smoke, weld, grind, or use open ames where ammable materials are being
used or stored. Do not heat materials to temperatures above those recommended
by the manufacturer. Make sure heat monitoring and limiting devices are working
properly.
• Provide adequate ventilation to prevent dangerous concentrations of volatile particles
or vapors. Refer to local codes or your material SDS for guidance.
• Do not disconnect live electrical circuits when working with ammable materials. Shut
o󰀨 power at a disconnect switch rst to prevent sparking.
• Know where emergency stop buttons, shuto󰀨 valves, and re extinguishers are
located. If a re starts in a spray booth, immediately shut o󰀨 the spray system and
exhaust fans.
• Shut o󰀨 electrostatic power and ground the charging system before adjusting,
cleaning, or repairing electrostatic equipment.
• Clean, maintain, test, and repair equipment according to the instructions in your
equipment documentation.
• Use 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 Prex
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.

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EP2 Pump System
© 2021 Nordson Corporation 1072608-04
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut o󰀨 the system immediately
and perform the following steps:
• Disconnect and lock out system electrical power. Close hydraulic and pneumatic
shuto󰀨 valves and relieve pressures.
• Identify 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.

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Safety Labels
Table 1 contains the part number and description for each safety label on this equipment.
Safety labels are provided to help you operate and maintain your equipment safely.
See Figure 1 for the location of safety labels.
Table 1 Safety Labels
Item Part Label Description
1 - - - - - - WARNING: Disconnect main power supply before removing this panel.
2 - - - - - -
WARNING: Read instruction manual and observe all warnings.
WARNING: High pressure device eye protection required.
WARNING: INJECTION 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 case of penetration, adequate medical aid must be immediately
obtained.
WARNING: COMPONENT RUPTURE
To avoid rupture or injury do not operate this pump at a pressure higher
than the maximum working pressure.
WARNING: FIRE
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 re.
3 242867 WARNING: Risk of electrical shock
4 - - - - - - WARNING: Rotating shafts. Do not operate without shroud.
5 - - - - - -
WARNING: HOT SURFACE
Operation of the pump causes surface to get hot. To avoid personnel
injury, do not touch surface during or after operation.

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EP2 Pump System
© 2021 Nordson Corporation 1072608-04
1
2
3
4
3
5
Figure 1 Safety Label Location

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© 2021 Nordson Corporation
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Description
See Figure 2. The Nordson EP2 Pump System is an electrically powered, positive-
displacement, constant-delivery uid system. It consists of a
• panel with load switch and uid system components.
• EP2 three-piston dual-diaphragm rotary pump driven by a constant-speed (1725 RPM)
electric motor and gear reducer.
The system has a 380−420 V, 3 phase (Wye), 50/60 Hz, 1.5 kw electric motor.
NOTE:See Figure 3 for system version with frame only.
NOTE:Refer to the EP2 Three-Piston Pump manual for pump repair and parts lists.
1
2
3
4
5
6
7
9
8
11
12
10
13
14
15
Figure 2 EP2 Pump System with Panel and Frame
1. Ground clamp
2. Load switch
3. Pressure relief valve
4. Pressure gauge (system)
5. Fluid output
6. Two-way ball valve (priming valve)
7. Three-way ball valve
8. Fluid return (to supply)
9. Return from spray system (panel
rear)
10. Drain rod
11. Fluid inlet (from supply)
12. Pump
13. Coupling and shroud
14. Gear reducer
15. Motor

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EP2 Pump System
© 2021 Nordson Corporation 1072608-04
1
2
3
4
5
6
7
Figure 3 EP2 Pump Assembly with Frame Only (Shown with Shroud Removed)
1. Motor
2. Gear reducer
3. Coupling
4. Guard
5. Pump
6. Oil ll cap
7. Shroud
Pump Operation
See Figure 4. Coating material can be supplied by a pressure-feed, gravity feed, or
siphon system. The coating material enters the pump through the uid inlet (3) and a one-
way inlet check valve (4) into the pump housing.
As the pump shaft turns, it rotates a wobble plate. The high spot on the wobble plate
pushes on the three spring-loaded, oil-lled pistons. The pistons force the diaphragms to
bow out, compressing coating material and forcing it through the outlet check valves and
out of the pump.
After the high spot of the wobble plate passes the pistons, the piston springs force the
pistons back and the piston rells with oil. The diaphragm exes in, drawing coating
material into the pump housing through the inlet check valves.
1
2
3
4
Figure 4 EP2 Three-Piston Pump Operation
1. Dual-diaphragm cartridge
2. Outlet check valve
3. Fluid inlet 4. Inlet check valve

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System Operation
See Figure 5. Coating material enters the pump inlet through a low-pressure gravity or
siphon feed system. The pressurized coating material passes through the manifold and
then is either routed to the spray system through the outlet tting or, if the two-way ball
valve is opened, through the drain rod to a waste container.
Fluid returning from the spray system ows through the return tting on the rear side of
the panel, through the 3-way ball valve, back pressure regulator, and back to the supply.
The three-way ball valve can also route the return uid ow to the drain rod.
The back pressure regulator maintains the desired uid pressure within the spray system
during normal operation. Depending on the application, it may be removed from the panel
and installed in a di󰀨erent location in the spray system.
The pressure relief valve protects the pump and system components from excessive
pressure.
• It is set for lacquer coating systems to open at 89.6−91.4 bar (1300−1325 psi). This is
the factory setting.
• For CleanSpray systems, it must be set to open at 51.7−55.2 bar (750−800 psi). Refer
to Pressure Relief Valve Adjustment on page 21.

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EP2 Pump System Hydraulic
Pressure Gauge
Manifold
Spray System
3-Way
Ball Valve
2-Way
Ball Valve
Back Pressure
Regulator
Drain
Rod
Dump
Pressure
Relief
Valve
Pump
M
Supply
2-Way 3-Way 2-Way 3-Way 2-Way 3-Way
Normal Operation Flushing Priming
Valve Handle Positions
Figure 5 EP2 Pump System Hydraulic Diagram

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Specications
These specications are for standard systems. Engineered systems specications may
be di󰀨erent.
Category Specication
Output Fluid Pressure 83 bar (1200 psi) maximum
Output Volume (nominal) 7.6 lpm (2.0 gpm) @ 400 rpm
Pressure Feed 3.5 bar (50 psi) maximum
Siphon Feed Vacuum 0.238 bar (7 in. Hg) maximum
Inlet and Outlet Port Sizes Inlet: 3/4 in. NPT
Outlet: 1/2 in. NPT
Pump Oil Capacity 1.04 liter (1.1 qt) (use only Nordson EP2 pump oil)
Electrical 380−420 volt, 3 phase (Wye), 50/60 Hz
Motor Speed 1725 rpm
Drive Capacity 2.0 hp
System Weight 68 kg (150 lb)
Dimensions Height, top of panel to base bottom: 28.46 in. (722.88 mm)
Width, including motor: 40.74 in. (1034.80 mm)
Width, panel: 31 in. (787.4 mm)
Depth, base and panel: 13.25 in. (336.55 mm)
Refer to Figure 6 for base dimensions and mounting dimensions.
Sound Level Summary Fluid Pressure: 83 bar (1200 psi)
Sound Level (dB A): 67
Sound Level (dB C): 68

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Installation
WARNING:Allow only qualied personnel to perform the following tasks. Follow the
safety instructions in this document and all other related documentation.
Oil Change Kit Installation
The pump is shipped lled with oil. If you ordered an optional oil change kit, part 179490,
install the quick-disconnect tting included in the kit on the oil drain tube on the left side of
the pump.
To do this without losing oil from the pump and making a mess, turn the system on its
side with the oil drain tube up, unscrew the drain cap from the tube and install the quick-
disconnect tting on the tube.
Mounting
See Figure 6 for mounting base dimensions. Mount the pump system on a sturdy, at
surface, such as a work bench or metal table.
33.5 in.
(850.9 mm)
32.0 in.
(812.8 mm)
9.0 in.
(228.6 mm)
10.5 in.
(266.7 mm)
0.535 in. Mounting Hole
4 Places
35.0 in.
(889.0 mm)
29.25 in.
(742.95 mm)
1.75 in.
(44.45 mm)
2.375 in.
(60.325 mm)
3/8-16UNC-2B
4 Places
Figure 6 Mounting Base Dimensions

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Pump Oil Level
CAUTION:To prevent damage to the pump, do not allow the oil to drop below the
recommended level. Use only Nordson EP2 pump oil, part 1049265. Do not use EP1
pump oil, as it will damage the pump.
See Figure 3. Unscrew the oil ll cap (7) and check the pump oil level . The oil level
should be within 6 mm (1/4 in.) from the top.
Electrical Connections
WARNING:Electrical installation and wiring must be done by a qualied electrician, and
must conform to all applicable regulations and codes.
WARNING:Disconnect and lock out power before connecting electrical wiring to the
load switch box. Ground the pump base, load switch box (US versions) and all system
components, including supply and waste containers, to prevent static discharges that
could cause a re or explosion.
Wiring Guidelines
Motor: 380−420 volt, 3 phase (Wye), 50/60 Hz
• Use electrical wiring sized and rated for use with the motor. All electrical installations
must conform to local regulations and codes.
• Use approved, properly sized, liquid-tight conduit connectors or strain reliefs to bring
wiring into the load switch box.
• Refer to the wiring diagrams in this manual for proper voltage conguration and wiring
connections.
NOTE:The pump can rotate in either a clockwise or counterclockwise direction, so
phase wiring order is not critical.
• Connect the pump base ground clamp to a true earth ground.
WARNING:The load switch must be grounded. Failure to ground the load switch will
create an electrical hazard that could result in severe shock and personal injury.

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Wiring Diagram
CUSTOMER-SUPPLIED
POWDER CORD
♦ USE LIQUID-TIGHT CONDUIT
CONNECTORS AND CONDUIT
LOAD SWITCH
WIRING DETAIL
PE
L1 L2 L3
T1 T2 T3 PE
MOTOR JUNCTION BOX
WIRING DETAIL
T1 T2 T3 GND
T6 T4 T5
ATTACH WIRE TO CHASSIS GROUND
INSIDE JUNCTION BOX
380 - 420 VOLT, 3 PHASE (WYE) 50/60 HZ
AC WIRING
Figure 7 Wiring Diagram

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Fluid System Installation
Inlet and Outlet Connections
See Figure 8. Use pipe thread adhesive/sealant (Nordson part 900431) on all tting
threads.
1. Pump Inlet: 7/8−14 JIC (use siphon hose supplied with system)
2. Outlet to Spray System: 3/4−16 JIC
3. Return to Fluid Supply: 3/4−16 JIC
4. Return from Spray System: 1/2−20 JIC
4
2
3
1
Figure 8 Fluid Connections (Top View)
Fluid System Installation Guidelines
• All tubing and ttings must be stainless steel. Liberally coat tting threads with pipe
joint adhesive to eliminate air and uid leaks. Tighten ttings securely.
• Use exible hose to connect the spray system and supply to the pump system. The
exible hose dampens vibrations.
• For both siphon and pressure-feed systems, use the specially designed 1/2 in. ID, 1.5
m (5 ft) siphon hose supplied with the system to connect the coating material supply to
the pump inlet. For 3 gpm engineered systems, 3/4 in. ID hoses are used.
• The capacity of the supply line must be greater than 2 gpm. Restrictions will cause
cavitation, resulting in abnormal wear of the gearbox section in the pump head, and
damage to the diaphragm cartridges. Pressure uctuations in the spray system are a
sign of pump cavitation.
• For pressure feed systems, install an inline strainer/lter on the siphon side of the
pump with a 350 micron element. The lter should be as close to the EP2 pump as
possible but with a hose at least 1.5 m (5 ft) long between the lter and the pump.
• For troubleshooting supply line problems, a manifold with vacuum gauge is available.
Connect the manifold to the siphon hose. Refer to Specications on page 12 for
maximum allowable vacuum pressure in the supply line.
WARNING:The system pressure relief valve opens if the uid pressure exceeds the
valve setting to protect the system and the operators from excessive pressure. Do not
bypass this valve. Doing so could result in damage to the pump and possible personal
injury. For lacquer coating systems the valve is typically set to open at 89.6−91.4 bar
(1300−1325 psi). For Cleanspray systems the valve is set to open at 51.7−55.2 bar
(750−800 psi). Refer to Pressure Relief Valve Adjustment on page 21.