DÖRR EcoBell2 SL EC User manual

www.durr.com
EcoBell2 SL EC
Rotating Atomizer with External
Charging
Operating Manual
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ORIGINAL OPERATING MANUAL
Document No.: MRA00001EN
Version:: 07
As of:: 01/2020
Approved: 05.12.2014
Manufacturer
Dürr Systems AG
Application Technology
Carl-Benz-Str. 34
D-74321 Bietigheim-Bissingen
Germany
Tel: [phone]
Transmitting and duplication of this document as well as utilization and communication of its
contents are not allowed unless expressly granted. Offenders will be held liable for the payment
of damages. All rights reserved in the event of the grant of a patent, utility model or design.
=== Ende derL istefür Textmarke Copyright ===
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Operating Manual
© Dürr Systems AG
EcoBell2 SL EC
- Rotating Atomizer with External Charging
Document No.: MRA00001EN
Version:: 07 •As of:: 01/2020
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TABLE OF CONTENTS
1Introduction............................................................................................ 9
1.1 Information about the document .............................................................. 9
1.2 Symbols in the document......................................................................... 9
1.3 Intended use.......................................................................................... 10
1.4 Avoiding foreseeable misuses............................................................... 12
1.5 Material numbers................................................................................... 12
1.6 Device combination................................................................................ 12
1.6.1 Dürr components needed for the use of the atomizer as 2G device...............12
1.6.2 Dürr components needed for the use of the atomizer as 3G device...............12
1.6.3 Available device combinations ........................................................................13
1.6.3.1 EcoBell2 SL EC...............................................................................................13
1.6.3.2 EcoBell2 SL EC with “EcoAUC” control system .............................................13
1.6.3.3 Total system EcoRP 10 R1100.......................................................................13
2Safety.................................................................................................... 13
2.1 Danger zones......................................................................................... 14
2.2 Safety requirements............................................................................... 16
2.3 ATEX marking........................................................................................ 16
2.4 Residual risks......................................................................................... 18
2.4.1 Parameters ......................................................................................................18
2.4.2 Operation.........................................................................................................18
2.4.3 Maintenance and repair...................................................................................18
2.5 Conduct in the event of a hazardous situation....................................... 19
2.6 Responsibility of the operator................................................................. 19
2.7 Personnel Requirements ....................................................................... 21
2.7.1 Cleaning Staff ..................................................................................................21
2.7.2 Assembly personnel ........................................................................................21
2.7.3 Electrical personnel .........................................................................................22
2.7.4 Paint personnel................................................................................................22
2.8 Personal protective equipment............................................................... 22
2.9 Danger of damage to property............................................................... 25
2.10 Environmental protection....................................................................... 25
2.11 Emergency shutdown ............................................................................ 25
3Transport and storage......................................................................... 26
3.1 Delivery.................................................................................................. 26
3.2 Storage.................................................................................................. 26
3.2.1 Storage of electrode rings and atomizer body.................................................26
4Operating principle.............................................................................. 27
4.1 Brief description..................................................................................... 27

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l2 SL EC - Rotating Atomizer with External Charging
Document No.: MRA00001EN
Version:: 07 •As of:: 01/2020
4.2 Overview................................................................................................ 27
4.3 Functionality........................................................................................... 28
4.4 Assemblies............................................................................................. 30
4.4.1 Bell disk............................................................................................................30
4.4.2 Turbine.............................................................................................................32
4.4.2.1 Shaft detent .....................................................................................................33
4.4.2.2 Shaping air.......................................................................................................34
4.4.2.3 Rotational SpeedControl..................................................................................35
4.4.3 Valve block ......................................................................................................35
4.4.3.1 Main valve needle............................................................................................36
4.4.3.2 Valve for quick rinsing the bell disk .................................................................36
4.4.3.3 Recirculation for 1K paints...............................................................................37
4.4.4 Color tube ........................................................................................................37
4.4.5 Atomizer body and sleeve ...............................................................................38
4.4.5.1 The shaping air................................................................................................38
4.4.6 External charging.............................................................................................39
4.4.6.1 Function...........................................................................................................39
4.4.7 Clamping device (Jig)......................................................................................40
4.5 Connections........................................................................................... 41
4.5.1 Interfaces.........................................................................................................41
4.5.2 Flange assembly..............................................................................................42
4.5.2.1 Cable for potential equalization .......................................................................42
4.5.2.2 High voltage line ..............................................................................................43
4.6 Accessories and Related Parts.............................................................. 43
4.6.1 Accessories .....................................................................................................43
4.6.1.1 Case for checking high voltage shutdown.......................................................45
4.6.1.2 Atomizer attachment 60 ° (elbow) ...................................................................45
4.6.1.3 Atomizer pickup...............................................................................................45
4.6.1.4 Clamp for atomizer mount ...............................................................................45
4.6.1.5 Manual grounding rod......................................................................................45
4.6.1.6 Assembly bracket for atomizer ........................................................................45
4.6.1.7 Thread cleaner.................................................................................................45
4.6.1.8 Assembly aid for the atomizer body ................................................................46
4.6.1.9 Tool for disassembly of the atomizer body......................................................46
4.6.1.10 External mixer..................................................................................................46
4.6.1.11 Cable for potential equalization .......................................................................46
4.6.1.12 Tool set............................................................................................................46
4.6.2 Related Parts...................................................................................................46
4.6.2.1 High tension supply .........................................................................................46
4.6.2.2 R/O converter ..................................................................................................47
4.7 Tools...................................................................................................... 47
4.7.1 Tool kit .............................................................................................................47
4.7.2 Functionality of tools........................................................................................51

Operating Manual
© Dürr Systems AG
EcoBell2 SL EC
- Rotating Atomizer with External Charging
Document No.: MRA00001EN
Version:: 07 •As of:: 01/2020
5 / 156
4.7.3 Use of tools in Ex zones..................................................................................51
4.7.3.1 Area of applicability..........................................................................................52
4.7.3.2 Restricted use of tools in Ex zones .................................................................52
5Installation and assembly ................................................................... 54
5.1 Installation illustration............................................................................. 54
5.2 Assembly ............................................................................................... 54
5.2.1 Requirements for the installation point ............................................................55
5.2.2 Prerequisites for installation.............................................................................55
5.2.3 Flange assembly..............................................................................................55
5.2.3.1 Assemble the atomizer....................................................................................55
5.2.3.2 Cable and hose routing....................................................................................57
5.2.4 Fasten electrode ring.......................................................................................59
5.2.5 Attach the atomizer to the flange package......................................................63
5.2.6 Attaching the bell disk......................................................................................64
5.2.7 Attach type plate..............................................................................................65
5.2.8 Final checks.....................................................................................................65
5.2.8.1 Atomizer...........................................................................................................65
5.2.8.2 Pneumatic supply ............................................................................................66
5.2.8.3 Media Lines .....................................................................................................66
6Operation.............................................................................................. 67
6.1 Safety notes for operation...................................................................... 67
6.1.1 Danger due to explosive atmosphere..............................................................67
6.1.2 Danger due to high voltage .............................................................................67
6.1.3 Material may leak uncontrollably at high speed. .............................................67
6.1.4 Danger due to harmful or irritant materials......................................................68
6.1.5 Danger due to rotating bell disk.......................................................................68
6.2 General Notes on Operation.................................................................. 68
6.2.1 Valves..............................................................................................................69
6.2.2 Noises..............................................................................................................69
6.2.3 Vibrations.........................................................................................................69
6.2.4 Cleanliness ......................................................................................................69
6.2.5 Hoses...............................................................................................................69
6.2.6 Grounding and High Voltage ...........................................................................69
6.2.7 Spray Pattern...................................................................................................70
6.3 Operating Parameters............................................................................ 70
6.3.1 Painting data....................................................................................................71
6.3.2 High voltage.....................................................................................................72
6.3.3 Compressed air ...............................................................................................73
6.4 Starting Operations................................................................................ 73
6.4.1 Commissioning notes ......................................................................................73
6.4.2 Commissioning................................................................................................75

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ell2 SL EC - Rotating Atomizer with External Charging
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6.4.3 Testing the paint flow control (volumetric measurement)................................75
6.5 Purging .................................................................................................. 78
6.5.1 Purging sequence............................................................................................78
6.5.2 Detergent.........................................................................................................78
6.6 Checks during operation........................................................................ 79
7Cleaning and maintenance.................................................................. 80
7.1 Safety Instructions ................................................................................. 80
7.1.1 Cleaning...........................................................................................................81
7.1.2 Servicing and maintenance .............................................................................82
7.2 Cleaning agents..................................................................................... 83
7.2.1 Recommended cleaning agents......................................................................84
7.3 Cleaning and maintenance plan............................................................. 85
7.4 Cleaning................................................................................................. 87
7.4.1 Cleaning procedure A......................................................................................88
7.4.1.1 Pre-cleaning with non-flammable detergent....................................................88
7.4.1.2 Main cleaning with n-propanol or iso-propanol................................................88
7.4.1.3 Drying the atomizer..........................................................................................88
7.4.2 Cleaning procedure B......................................................................................88
7.4.2.1 Cleaning with non-flammable detergent..........................................................88
7.4.2.2 Drying the atomizer..........................................................................................88
7.4.3 Scope of cleaning............................................................................................89
7.4.3.1 Atomizer body..................................................................................................90
7.4.3.2 Shaping air ring................................................................................................90
7.4.3.3 Electrode fingers..............................................................................................91
7.4.3.4 Bell disk............................................................................................................92
7.4.3.5 Drying the atomizer..........................................................................................93
7.4.3.6 Final work ........................................................................................................93
7.5 Maintenance work.................................................................................. 94
7.5.1 Assembling the bell disk..................................................................................95
7.5.1.1 Unscrewing the bell disk from the shaft...........................................................95
7.5.1.2 Checking the distributor disk ...........................................................................96
7.5.1.3 Screwing the bell disk onto the shaft...............................................................99
7.5.1.4 Final check.....................................................................................................102
7.5.2 Installing and dismantling the nozzle.............................................................102
7.5.2.1 Dismantling the nozzle...................................................................................102
7.5.2.2 Installing the nozzle .......................................................................................103
7.5.3 Replacing the electrodes...............................................................................103
7.5.3.1 Removing the electrodes...............................................................................104
7.5.3.2 Installing the electrodes.................................................................................104
7.5.4 Dismounting and mounting atomizer body....................................................104
7.5.4.1 Dismantling the atomizer body ......................................................................104
7.5.4.2 Install atomizer housing.................................................................................106

Operating Manual
© Dürr Systems AG
EcoBell2 SL EC
- Rotating Atomizer with External Charging
Document No.: MRA00001EN
Version:: 07 •As of:: 01/2020
7 / 156
7.5.5 Cleaning the shaping air ring.........................................................................108
7.5.6 Replacing the contact ring.............................................................................109
7.5.6.1 Dismantling the contact ring ..........................................................................109
7.5.6.2 Installing the contact ring...............................................................................109
7.6 Final work after maintenance activity................................................... 110
8Faults .................................................................................................. 111
8.1 Safety provisions.................................................................................. 111
8.2 Fault Indicator...................................................................................... 112
8.3 Behavior during faults.......................................................................... 113
8.4 Troubleshooting................................................................................... 113
9.1 Mounting the valve block ..................................................................... 117
9.1.1 Dismantling the valve block...........................................................................117
9.1.2 Mounting the valve block...............................................................................118
9.2 Mounting the turbine............................................................................ 119
9.2.1 Dismantling the turbine..................................................................................119
9.2.2 Installation of the turbine................................................................................120
9.2.3 Checking the position of the nozzle...............................................................121
9.3 Installation of the light conductor.......................................................... 122
9.3.1 Removing the light conductor........................................................................122
9.3.2 Cleaning the light conductor..........................................................................124
9.3.3 Testing the light conductor.............................................................................124
9.3.4 Installing the light conductor..........................................................................124
9.4 Mounting of the shaft detent................................................................. 124
9.4.1 Dismantling of the shaft detent......................................................................125
9.4.2 Installation of the shaft detent........................................................................125
9.5 Installing the main needle valve........................................................... 126
9.5.1 Removing the main needle valve ..................................................................126
9.5.2 Installing the main needle valve ....................................................................127
9.6 Working on paint pipe.......................................................................... 128
9.6.1 Removing paint pipe......................................................................................128
9.6.2 Checks on removed paint pipe......................................................................128
9.6.3 Disassembling the paint pipe.........................................................................128
9.6.4 Assembling the paint pipe..............................................................................129
9.6.4.1 Paint tube with recirculation...........................................................................129
9.6.4.2 Paint tube with recirculation...........................................................................130
9.6.5 Mounting the paint pipe .................................................................................134
9.7 Assemble valve.................................................................................... 135
9.7.1 Removing the valve.......................................................................................135
9.7.2 Assembling valve...........................................................................................136
9.8 Replacing the hose at the flange assembly ......................................... 137
9.9 Resistance test .................................................................................... 138
9.10 Final work after fault removal............................................................... 138

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oBell2 SL EC - Rotating Atomizer with External Charging
Document No.: MRA00001EN
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10 Dismantling and Disposal................................................................. 139
10.1 Switching off the atomizer.................................................................... 139
10.2 Separating the atomizer from the flange package................................ 140
10.3 Dismantling of the atomizer.................................................................. 140
10.4 Disposal of the atomizer ...................................................................... 141
11 Technical Data.................................................................................... 142
11.1 Replacement parts............................................................................... 144
11.1.1 Ordering.........................................................................................................144
11.1.2 Replacement parts list...................................................................................144
12 Contacts and Hotline......................................................................... 152
13 Appendix ............................................................................................ 152
13.1 Check list for commissioning - External charging G500....................... 152

Operating Manual
© Dürr Systems AG
EcoBell2 SL EC
- Rotating Atomizer with External Charging
Introduction
Document No.: MRA00001EN
Version:: 07 •As of:: 01/2020
9 / 156
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1 Introduction
1.1 Information about the document
This instruction manual contains the necessary information for the
safe operation, maintenance and repair of the product.
Please keep this manual handy at all times at the place of activity of
the product for the staff. When passing on the product to a third party
this instructional manual must also be handed over.
Activities described in this operation/instruction manual must be
performed only by qualified staff.
Activities which have not been described in this instruction manual
must be performed only by the manufacturer.
Every person who uses this product must have read and understood
these operating instructions.
Dürr Systems disclaims all liability for damages arising from the fact
that the instructions were not followed!
For further questions please contact our service- or replacement
department or the representative of Dürr Systems (refer to chapter 11
"Contacts & Hotline").
Technical changes that cause variations of the specifications and
illustrations in this instruction manual are subject to
modification.
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1.2 Symbols in the document
Potential risks are pointed out in the document with the help of
symbols and signal words.
D A N G E R
Risk of fatal injuries
The safety phrase "Danger" marked in red represents a high risk the
consequence of which could be either death or serious injury.

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EcoBell2 SL EC
- Rotating Atomizer with External Charging
Introduction
Document No.: MRA00001EN
Version:: 07 •As of:: 01/2020
W A R N I N G
Risk of serious injuries
The safety phrase "Warning" marked in orange represents a medium
risk the consequence of which could be either death or serious injury.
C A U T I O N
Risk of minor injuries
The safety phrase "Caution" marked in yellow represents a low risk
the consequence of which could be either minor or moderate injury.
A T T E N T I O N
Risk of damage to property and production disruption
The safety phrase "Attention" marked in blue represents a risk the
consequence of which could be either damage to property and or an
interruption in production.
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1.3 Intended use
During electrostatic coating, the rotating atomizer, “atomizer” in short,
allows atomization of a fluid coating material into droplets by
mechanical forces. High voltage up to 100 kV generates an
electrostatic field. The electrostatic field charges the paint droplets. A
grounded work piece attracts the charged droplets. Air flows support
the process. A tapering spray cloud condenses on the work piece.
The EcoBell2 SL EC atomizer with external charging may only be
operated with proven non-flammable fluid coating materials. The
associated approved and permitted detergents and cleaning agents
must also be non-flammable:
- Water based 1K paint (single component paint)
(corresponding to EN 50348 Appendix A a)
- Pre-mixed water based 2K paint (two-component paint)
(corresponding to EN 50348 Appendix A a)
The atomizer is intended for use in industrial application stations
within a painting booth (also spray booths). Application stations and
painting booths are subject to local, national and international
specifications for machine safety and explosion protection.