DÖRR EcoGun AS AUTO Mini RS User manual

EcoGun AS AUTO Mini RS
Automatic Air Spray Gun
MSG00007EN, V03
N36210007V
www.durr.com
Operation manual

Information about the document
This document facilitates safe handling of
the product.
Read the document before beginning any
work.
The document must be kept readily
accessible and close to the place of use
for use in the future.
The document must be included if the
product is transferred.
Always follow specifications such as
instructions for use and safety tips.
Images are there to help general under-
standing and can differ from the actual
product.
Validity range of the document
This document describes the following
product:
N36210007V
EcoGun AS AUTO Mini
RS
Hotline and Contact
If you have queries or would like technical
information, please contact your dealer or
sales partner.
11/2016
EcoGun AS AUTO Mini RS - MSG00007EN2/28

TABLE OF CONTENTS
1 Product overview.......................... 4
1.1 Overview................................ 4
1.2 Short description.................... 4
2 Safety............................................. 4
2.1 Explanation of symbols.......... 4
2.2 Intended Use.......................... 5
2.3 Residual risks......................... 5
2.4 Staff qualification.................... 6
2.5 Personal protective equip-
ment....................................... 6
3 Transport, scope of supply and
storage........................................... 6
3.1 Scope of delivery................... 6
3.2 Handling of
packaging material................. 6
3.3 Storage.................................. 7
4 Assembly....................................... 7
4.1 Requirements for the
Installation point..................... 7
4.2 Assembly............................... 7
5 Commissioning............................. 8
6 Operation....................................... 9
6.1 Safety recommendations....... 9
6.2 Rinsing................................... 9
6.2.1 Safety recommendations.... 9
6.2.2 General notes..................... 9
6.2.3 Rinsing.............................. 10
7 Cleaning and maintenance........ 10
7.1 Safety recommendations..... 10
7.2 Cleaning............................... 11
7.3 Maintenance........................ 12
7.3.1 Maintenance schedule...... 12
8 Faults........................................... 13
8.1 Defects table........................ 13
8.2 Troubleshooting................... 14
8.2.1 Replace needle and
nozzle................................ 14
8.2.2 Replace needle seal......... 16
8.2.3 Set delay time................... 17
9 Disassembly and Disposal........ 18
9.1 Safety recommendations..... 18
9.2 Disassembly......................... 19
9.3 Disposal .............................. 19
10 Technical data............................. 19
10.1 Dimensions and weight...... 19
10.2 Connections....................... 19
10.3 Operating conditions.......... 20
10.4 Emissions........................... 20
10.5 Operating values................ 20
10.6 Compressed air quality...... 20
10.7 Type plate.......................... 20
10.8 Operating and auxiliary
materials............................ 20
10.9 Materials used.................... 20
10.10 Material specification.......... 21
11 Replacement parts, tools and
accessories................................. 21
11.1 Replacement parts............. 21
11.2 Accessories........................ 26
11.3 Order.................................. 26
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1 Product overview
1.1 Overview
Fig. 1: Product overview
1 Material connection
2 Atomizer air connection
3 Control air connection
4 Material flow control
5 Screw cap
6 Nozzle
7 Fastening bore
8 Housing
1.2 Short description
The atomizer is using compressed air to coat
surfaces. The coating material is fed through
lines.
The following factors influence the spray jet
and the result:
Atomizer air pressure
The higher the atomizer pressure, the
higher the atomizing and the finer the
spray jet
Control air pressure
Opens the needle and controls the mate-
rial flow.
Material pressure
The higher the material pressure, the
higher the material flow
Control air pressures and the atomizer pres-
sure are controlled externally via valves.
The material flow can also be regulated via
the regulator on the atomizer, if it is not con-
trolled externally.
2 Safety
2.1 Explanation of symbols
The following notes can appear in this
instructions manual.
DANGER!
High risk situation that can lead to serious
injuries or death.
WARNING!
Medium risk situation that can lead to
serious injuries or death.
Product overview
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CAUTION!
Low risk situations that can lead to minor
injuries.
NOTICE!
Situations that can lead to material
damage.
ENVIRONMENT!
Situations that can lead to environmental
damage.
Contains additional information
and recommendations.
2.2 Intended Use
Use
The EcoGun AS AUTO Mini RS spray gun is
intended for use in application stations only.
The EcoGun AS AUTO Mini RS spray gun is
solely intended for automatic coating of sur-
faces in one of the following operating
methods:
as independent, not hand guided, device
as part of a fully automated paint booth
as part of a paint robot
The material feed can be effected via the
pressure line or under gravitation (flow
beaker).
The use is only permitted within the specified
technical data. Ä 10 “Technical data”
The spray gun is approved for use in explo-
sive areas of Ex zones 1 and 2.
Wrong Use
Wrong use of the spray gun entails a risk of
death.
Do not aim the spray gun at people or
animals.
Do not atomize liquid nitrogen.
Combine the spray gun only with compo-
nents approved by Dürr Systems for
operation.
Only use approved materials. Observe
the safety data sheets.
Do not attempt to make conversions or
changes on your own.
Do not use spray gun in areas with Ex
zone 0.
EX labeling
II 2G T6 X
II - Device group II: all areas except
mining
2G - Device category 2 for gas
T6 - Temperature class T6: Surface tem-
perature, max. 85 °C
X - Specific conditions for safe operation
The following conditions must be observed
for safe operation:
Ground spray gun and work piece.
Only use conductive lines.
Ensure that static electricity can be dis-
charged.
2.3 Residual risks
Explosion
Sparks, open flames and hot surfaces can
cause explosions in explosive atmospheres.
Serious injuries and death can be the conse-
quence.
Perform all maintenance away from
explosive atmospheres.
Do not use any sources of ignition and no
open light.
Do not smoke.
Ground the product.
Ground the work piece.
Only use conductive lines.
Flammable materials can cause a fire or an
explosion.
Ensure that the flashpoint of the cleaning
agent is at least 5 K above the ambient
temperature.
Pay attention to the explosion group of
the material, cleaning agent and rinsing
agent.
Safety
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Ensure that forced ventilation and fire
protection equipment are in operation.
Do not use any sources of ignition and no
open light.
Do not smoke.
Follow safety data sheets.
Danger from harmful or irritant sub-
stances
Contact with hazardous liquids or vapors,
can result in serious injury or death.
Ensure that the forced ventilation is
operational.
Observe the safety data sheets.
Wear specified protective equipment.
Pressure
Material can escape with high pressure and
penetrate the body. Death or serious injuries
may result.
Before working on the product:
Disconnect the system with the product
from compressed air and material supply.
Secure the system against being
switched on again.
Relieve the lines.
Movable components
There is a risk of death if components or
equipment in the vicinity move unexpectedly.
Switch off and lock out all system compo-
nents against being switched on again
before working on the product.
Noise
The noise during normal operation may
cause severe hearing damage.
Wear hearing protection.
Do not spend more time then necessary
in the work area.
Hot surfaces
During normal operation the surfaces of
components can get extremely hot. Burn
injuries can happen on contact.
Before carrying out any work:
Check the temperature.
Do not touch hot surfaces.
Let components cool down.
Wear protective gloves.
2.4 Staff qualification
Dürr Systems offers special product training
Ä “Hotline and Contact”.
2.5 Personal protective equipment
Wear the required personal protective equip-
ment when working. Provide the following
personal protective equipment:
3 Transport, scope of supply
and storage
3.1 Scope of delivery
The spray gun is included in the scope of
supply.
Inspect delivery on receipt for completeness
and integrity.
Report defects immediately Ä “Hotline and
Contact”.
3.2 Handling of packaging material
ENVIRONMENT!
Environmental damage due to wrong
disposal
Wrongly disposed packaging material
may not be re-used or recycled. It harms
the environment.
– Dispose of material no longer
required in an environment-friendly
manner.
– Observe local disposal specifica-
tions.
Transport, scope of supply and storage
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3.3 Storage
Requirements for the warehouse:
Do not store outdoors.
Store in a dry and dust-free place.
Do not expose to aggressive media.
Protect from solar radiation.
Avoid mechanical vibrations.
Temperature: 10 °C to 40 °C
Relative humidity: 35 % to 90%
4 Assembly
4.1 Requirements for the
Installation point.
It must be possible to disconnect the
compressed air supply and material feed
to the spray gun and secure it against
reconnection.
Lines, seals and screw connections must
be designed to conform to the spray gun
requirements Ä 10.5 “Operating values”.
A fastening device capable of securing
the spray gun is required.
The control air supply must be adjustable.
4.2 Assembly
Protective equipment:
Protective workwear
Protective gloves
Observe the following at assembly:
Diameter of the fastening bore: 6.4 mm
Nominal diameters:
Control air and atomizer air: Ø6 mm
push-in connector (M5 thread)
Material connection: Ø6 mm push-in
connector (G1/8” thread)
1. WARNING!
Sources of ignition may cause explo-
sions!
Ensure a non-explosive atmosphere.
Fig. 2: Assembly
2. Slide the atomizer with the fastening bore
(1) onto the fastening device and secure
it.
Alignment is not important.
Assembly
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3. WARNING!
Statically charges components may
cause explosions during operation!
Ground the atomizer through the fas-
tening bore, if the fastening device itself
is non-conductive and is not grounded.
Ensure housing contract.
Resistance between housing and
grounding terminal ≤ 1 MΩ.
Fig. 3: Connect
4. The atomizer does not work
when the lines are not con-
nected correctly.
Connect lines. Ensure correct assign-
ment.
1- Material
2 - Atomizer air
3 - Control air
5 Commissioning
Protective equipment:
Use ear protection
Eye protection
Respiratory protection device
Protective workwear
Protective gloves
Depending on the design of the application
system, two technicians must be present to
execute the commissioning.
Technician 1: Operates the controls
Technician 2: Checks on the atomizer.
1. Actuate the atomizer without material via
the control unit or the visualizer.
2. Check the switching behavior.
Does the needle open and close as
required?
Are all types of air supply connected?
3. Rinse atomizer Ä 6.2 “Rinsing”.
4. Connect material. Create a trial spray
pattern on a test work piece.
Setting the spray pattern
Protective equipment:
Use ear protection
Eye protection
Respiratory protection device
Protective workwear
Protective gloves
You can adjust the material quantity to ach-
ieve the required spray pattern.
Commissioning
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You can vary the size of the
spray pattern by adjusting the
distance between the atomizer
and the work piece.
Fig. 4: Setting the spray pattern
1. Use valves in the control cabinet or on
the material flow control (1) to adjust the
material flow.
Open the material flow control
on the atomizer when control-
ling via the control cabinet.
2. Use valves in control cabinet to adjust the
atomizer air.
6 Operation
6.1 Safety recommendations
WARNING!
Danger of explosion due to chemical
reactions
Material, halogenated hydrocarbon-based
rinsing agent or cleaning agent can
chemically react with aluminum compo-
nents of the product. Chemical reactions
can cause explosions. Serious injuries
and death can be the consequence.
– Only use rinsing agents and
cleaning agents that do not contain
any halogenated hydrocarbons.
NOTICE!
Material damage due to dried material
residues
If material residues dry in the product,
that can harm components.
– Rinse product immediately after
each use.
6.2 Rinsing
6.2.1 Safety recommendations
NOTICE!
Material damage due to unsuitable
rinsing agent
If the rinsing agent reacts chemically with
the components or the material, compo-
nents get damaged.
– Use only the rinsing agents that are
compatible with the components and
the material.
– Refer to safety data sheet of mate-
rial manufacturer.
6.2.2 General notes
When rinsing, use fluid to remove inner
soiling from components.
Operation
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6.2.3 Rinsing
Protective equipment:
Use ear protection
Eye protection
Respiratory protection device
Protective workwear
Protective gloves
The spray gun must be rinsed:
After end of work
Before every change of material
Prior to cleaning
Prior to dismantling
Before a long time of non-use
Before placing in storage
Additional rinsing intervals
depend on the material used.
1. Rinse the spray gun with an appropriate
rinsing agent until the rinsing agent runs
clean without any material residue.
7 Cleaning and maintenance
7.1 Safety recommendations
WARNING!
Danger of fire and explosion
Flammable materials can cause a fire or
an explosion.
– Ensure that the flashpoint of the
cleaning agent is at least 5 K above
the ambient temperature.
– Pay attention to the explosion group
of the material, cleaning and rinsing
agent.
– Ensure that technical ventilation and
fire protection equipment are in
operation.
– Do not use any sources of ignition
and no open light.
– Do not smoke.
– Observe the safety data sheets.
WARNING!
Risk of injury from unsuitable replace-
ment parts in explosive areas.
Replacement parts not compliant with
the specifications of the ATEX guide-
lines can cause explosions in an explo-
sive atmosphere. Serious injuries and
death can be the consequence.
– Use exclusively original replacement
parts.
WARNING!
Danger from harmful or irritant sub-
stances
If you come in contact with hazardous liq-
uids or vapors, serious injury or death
can be the consequence.
– Ensure the technical ventilation is
operational.
– Observe the safety data sheets.
– Wear specified protective clothing.
WARNING!
Risk of injury due to escaping material
and compressed air
Material can escape with high pressure
and penetrate the body. The injury can
look like a harmless cut wound. Death or
serious injuries may result.
– If there are injuries, seek medical
attention immediately.
Before working on the product:
– Disconnect the system with the
product from compressed air and
material supply.
– Secure the system against recon-
nection.
– Relieve the lines.
Cleaning and maintenance
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