DÖRR EcoGun AS MAN DC SMP 11 User manual

MSG00028EN, V02
N361900...
www.durr.com
Operation manual
EcoGun AS MAN DC EU/US
Manual Spray Gun with Direct Charging

Information about the document
This document describes the correct han-
dling of the product.
nRead the document prior to every activity.
nPrepare the document for the application.
nPass on the product only together with
the complete documentation.
nAlways follow safety instructions, han-
dling instructions and specifications of
every kind.
nIllustrations can deviate from the tech-
nical construction.
Validity range of the document
This document describes the following
product:
N36190001
EcoGun AS MAN DC SMP
11 EU/US
N36190002
EcoGun AS MAN DC SMP
11 N HT2P 10m EU/US
N36190003
EcoGun AS MAN DC WBP
11 EU/US
N36190004
EcoGun AS MAN DC WBP
11 N HT2P 10m EU/US
N36190005
EcoGun AS MAN DC SBP
11 EU/US
N36190006
EcoGun AS MAN DC SBP
11 N HT2P 10m EU/US
Applicable documents
MHT00005* - EcoHT 80 controller
MHT00006* - EcoHT 80 controller
An asterisk (*) in the document
number replaces the symbol of the
language variant.
Hotline and Contact
If you have queries or would like technical
information, please contact your dealer or
sales partner.
11/2022
EcoGun AS MAN DC EU/US - MSG00028EN2/60

TABLE OF CONTENTS
1 Product overview.......................... 5
1.1 Overview................................ 5
1.2 Short description.................... 5
2 Safety............................................. 6
2.1 Presentation of Notes............. 6
2.2 Intended Use.......................... 6
2.3 Residual risks......................... 7
2.4 Staff qualification.................... 8
2.5 Personal protective equip-
ment....................................... 9
3 Transport, scope of supply and
storage........................................... 9
3.1 Scope of delivery.................... 9
3.2 Handling of
packaging material............... 10
3.3 Storage................................. 10
4 Assembly..................................... 10
4.1 Requirements for the
Installation point................... 10
4.2 Connecting........................... 10
5 Commissioning........................... 13
6 Operation..................................... 16
6.1 Safety recommendations...... 16
6.2 General notes....................... 16
6.3 Selecting air cap................... 16
6.4 Changing the air cap............ 17
6.5 Alignment of the air cap........ 18
6.6 Guiding the spray gun.......... 19
6.7 Purging................................. 19
6.7.1 Safety recommendations... 19
6.7.2 General notes.................... 19
6.7.3 Purging spray gun............. 20
7 Cleaning....................................... 21
7.1 Safety recommendations ..... 21
7.2 Cleaning............................... 22
8 Maintenance................................ 24
8.1 Safety notes......................... 24
8.2 Maintenance schedule......... 25
9 Faults............................................ 25
9.1 Safety recommendations ..... 25
9.2 Defects table........................ 26
9.3 Troubleshooting.................... 30
9.3.1 Replace needle, nozzle
and seal kit........................ 30
9.3.2 Replace flat jet control....... 33
9.3.3 Replace material flow con-
trol..................................... 34
9.3.4 Replace valve set.............. 35
9.3.5 Replace handle................. 35
9.3.6 Replace hook.................... 36
9.3.7 Replacing sealing ring....... 37
9.3.8 Replace paint pipe (for
flammable paints).............. 38
9.3.9 Replace paint hose (for
non-flammable paints)....... 39
9.3.10 Replace cascade............... 40
10 Disassembly and Disposal......... 41
10.1 Safety recommendations.... 41
10.2 Disassembly....................... 42
10.3 Disposal ............................. 42
11 Technical data............................. 43
11.1 Dimensions and weight...... 43
11.2 Connections........................ 43
11.3 Operating conditions........... 43
11.4 Operating values................ 43
11.5 Type plate........................... 43
11.6 Materials used.................... 43
11.7 Operating and auxiliary
materials............................. 44
11.8 Material specification.......... 44
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12 Spare parts, tools and accesso-
ries................................................ 45
12.1 Spare parts......................... 45
12.2 Tools................................... 57
12.3 Accessories........................ 57
12.4 Order.................................. 59
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1 Product overview
1.1 Overview
Fig. 1: Overview
1 Air cap
2 Nozzle
3 Basic housing
4 Hook
5 “H. V.” indicator light
6 Material flow control
7 Housing
8 Connections
9 Paint tube
10 Flat jet control
11 Trigger
12 Electrode
13 Cap nut
1.2 Short description
The spray gun is intended for electrostatic
surface coating. Compressed air and direct
charging support the coating process. The
spray gun is hand-held.
The spray gun is available with three dif-
ferent paint connections:
nStraight pipe: for flammable topcoats and
clear coats
nSpiral pipe: for flammable metallic paints
nAttached, non-conductive paint hose (5 or
10m long): for non-flammable paints
The following factors influence the spray jet
and therefore the result:
nAlignment of the air cap Ä 6.5 “Alignment
of the air cap”
nMaterial quantity Ä 5 “Commissioning”
nSpray width Ä 5 “Commissioning”
Product overview
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2 Safety
2.1 Presentation of Notes
The following notes can appear in this
instruction:
DANGER!
High risk situation that can lead to serious
injuries or death.
WARNING!
Medium risk situation that can lead to
serious injuries or death.
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.
Additional information and recom-
mendations.
2.2 Intended Use
Use
The spray gun EcoGun AS MAN DC EU/US
is used exclusively for hand guided electro-
static coating of surfaces with non-flammable
and flammable paints. The coating process
must be conducted in a painting booth with
suitable technical ventilation.
The spray gun EcoGun AS MAN DC EU/US
may only be operated in the industrial area
and within the approved technical data Ä 11
“Technical data”.
The EcoGun AS MAN DC EU/US spray gun
is approved for the follwing use:
n2G (EU)
nClass I Division 1 (USA)
Permitted device combination
The spray gun must only be combined with
the following components:
Controller Connection
cable
EcoHT 80 controller
(100 - 120 V)
E80020003
10 m
E09070245
EcoHT 80 Controller EU
(100 - 120 V)
E80020005
EcoHT 80 Controller EU
(200 - 240 V)
E80020006
Misuse
If used incorrectly, it can cause serious inju-
ries or death.
Safety
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Examples of wrong use are:
nAiming the spray gun at humans or ani-
mals
nUse outside of an spray booth
nUse without mechanical ventilation
nAtomization of fluid nitrogen
nUse of unapproved materials
nCombination of the spray gun with com-
ponents that are not approved by Dürr
Systems for operation.
nUnauthorized modifications
nUse in explosive dust atmospheres or in
atmospheres with flammable fibers and
fluff
nUse in other groups of substances,
except D
nUse of the spray gun without knowing the
operating instructions
EX labelling for EU
II 2G 0.24 mJ
EX labelling for USA
Class I, Div 1, Group D; Tamb + 0 °C to +
40 °C
2.3 Residual risks
High voltage
High voltage can be present on components
and cables. Electric shocks and discharges
can cause serious injuries and death.
nGround the spray gun.
nGround the work piece.
nConnect any conducting objects and paint
containers in the paint booth to the
ground.
nRemove not required objects such as
tools from the paint booth.
nWear antistatic safety boots during opera-
tion.
nWear antistatic protective gloves during
operation.
nDo not touch the electrode during opera-
tion.
Explosion
Sparks, open flames and hot surfaces can
cause explosions in explosive atmospheres.
Serious injury and death could be the conse-
quence.
nBefore carrying out any work, make sure
that there is no explosive atmosphere.
nDo not use sources of ignition and open
light.
nDo not smoke.
nGround the spray gun.
nGround the work piece.
nOnly use conductive lines.
Safety
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Flammable coating materials and their deter-
gents and cleaning agents can cause a fire
or an explosion.
nEnsure that the flashpoint of the cleaning
agent is at least 15K above the ambient
temperature or clean the spray gun at the
cleaning areas with active technical ven-
tilation, in painting booths, according to
EN 16985.
nNote explosion group of the fluid.
nFollow the safety data sheet.
nEnsure that forced ventilation and fire
protection equipment are in operation.
nDo not use sources of ignition and open
light.
nDo not smoke.
nGround the spray gun.
Danger from harmful or irritant sub-
stances
Serious injuries or death can result if you
come into contact with dangerous fluids or
steam.
nthe spray gun Check regularly for
leakage. Observe local regulations and
maintenance schedule.
nEnsure that the forced ventilation is
operational.
nFollow the relevant safety data sheets.
nWear specified protective equipment.
Escaping material
Material escaping under pressure can cause
serious injuries.
Before working on the product:
nDisconnect the system, in which the
product is installed, from compressed air
and material supply.
nSecure system personalized from being
switched on again.
nDepressurize the lines.
Noise
The sound pressure level during operation
may cause severe hearing damage.
nWear ear protection.
nDo not spend more time then necessary
in the work area.
2.4 Staff qualification
WARNING!
Inadequate qualification
Wrong estimation of dangers can cause
serious injury or death.
nOnly sufficiently qualified persons may
execute all work.
nSome work requires additional qualifi-
cation. Additional qualifications of spe-
cialized personnel are marked with a
“+”.
This document is intended for qualified per-
sonnel in industry and craftmanship.
Operator
The operator is trained specifically for the
field of work in which he works.
Furthermore, the operator possesses the fol-
lowing knowledge:
nTechnical Measures for occupational
safety and health
The operator is responsible for the following
work:
nOperate and monitor the system/ product.
nIntroduce measures in the event of faults.
nClean system/ product.
+ additional qualification explosion pro-
tection
In addition to the knowledge of the various
specialist fields, the mechanic has knowl-
edge of regulations and safety measures
when working in potentially explosive areas.
Safety
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+ additional qualification high tension
technology
In addition to the knowledge of the various
specialist fields, the mechanic has knowl-
edge of the following specialist fields
nPainting process
nHigh voltage engineering for electrostatic
coating
Dürr Systems offers special product training
for Ä “Hotline and Contact”.
2.5 Personal protective equipment
When working in explosive areas, the protec-
tive clothing, including gloves, must meet the
requirements of EN 1149-5. Footwear must
meet the requirements of ISO 20344 and
IEC 61340-4-3. The volume resistivity must
not exceed 100MΩ.
When working in explosive areas, the pro-
tective clothing, including gloves, must meet
the requirements of explosion protection.
Footwear must meet the requirements of
ISO 20344 and IEC 61340-4-3. The volume
resistivity must not exceed 100MΩ.
Wear the specified personal protective
equipment when working. Provide the fol-
lowing personal protective equipment:
Anti-Static Safety Boots
Protect feet from crushing, falling
items and slipping on slippery
ground.
Moreover, anti-static safety boots
reduce electrostatic charge by dis-
charging the electrostatic charges.
Eye protection
Protects eyes from dust, paint drops
and particles.
Protective gloves
Protect the hands from:
nmechanical forces
nThermal forces
nChemical effects
Protective workwear
Tight fitting workwear with low
tear strength, tight sleeves and no
hanging parts.
Respiratory protection device
The respiratory protection device
protects from hazardous gases,
vapors, dust and similar materials
and media. The version of the res-
piratory protection device must be
suitable for the media used as well
as their usage.
Use ear protection
Protects from auditory damage due
to noise.
3 Transport, scope of supply
and storage
3.1 Scope of delivery
Following components are included in the
scope of supply:
nSpray gun without air cap
nTool kit
nIn addition at N36180002, N36180004,
N36180006:
– Controller
– Hoses and cables
nAccessories:
– Air cap
Inspect delivery on receipt for completeness
and integrity.
Report defects immediately Ä “Hotline and
Contact”.
Transport, scope of supply and storage
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3.2 Handling of packaging material
ENVIRONMENT!
Incorrect disposal
Incorrectly disposed packaging material
can damage environment.
nDispose of material no longer required
in an environment-friendly manner.
nObserve local disposal specifications.
3.3 Storage
Storage provisions:
nDo not store outdoors.
nthe spray gun only store when in a clean
and dry condition.
nStore in a dust-free place.
nDo not expose to aggressive media.
nProtect from solar radiation.
nAvoid mechanical vibrations.
nTemperature: 0°C to 40°C
nRelative humidity: 40% to 80%
4 Assembly
4.1 Requirements for the
Installation point
nThe compressed air supply to the spray
gun must be interrupted and secured
against reconnection.
nThe compressed air supply must be
adjustable.
nLines, seals and screw connections must
be designed to conform to the require-
ments of the spray gun Ä 11 “Technical
data”.
nThe workplace must have a mechanical
ventilation.
nA hook or a lug must be provided for
hanging the spray gun.
Working environment and grounding
The flooring of the working area must be
anti-static acc. to EN 50050-1, measurement
after EN 1081. The antistatic flooring pre-
vents electrostatic charges from building up.
Dangerous flashovers are prevented.
4.2 Connecting
Personnel:
nOperator
n + additional qualification high tension
technology
n + additional qualification explosion pro-
tection
Protective equipment:
nProtective workwear
nAnti-Static Safety Boots
1. WARNING!
Sources of ignition may cause explo-
sions!
Ensure a non-explosive atmosphere.
Assembly
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Fig. 2: Connect compressed air supply
2. Bolt compressed air supply (3) to the
compressed air controller (2) of the elec-
trostatic controller (1).
Fig. 3: Ground electrostatic controller
3. Screw on grounding cable (5) to the
grounding bolt (4) of the electrostatic con-
troller (1). Connect with the grounding
point at the installation site.
Fig. 4: Connect connection cable
4. Screw on connection cable (6) to the
output (7) of the electrostatic controller
(1).
Fig. 5: Connect connection cable
5. Bolt connection cable (6) to the input (9)
of the spray gun (8).
6. To prevent it from becoming loose, fasten
connection cable (6) using the fastening
bracket (10). Make sure that the cap nut
of the connection cable (6) is positioned
on the fastening bracket (10) with a flat
side.
Assembly
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Fig. 6: Connect compressed air hose
7. Screw on compressed air hose (11) to
the compressed air connection (12) of the
spray gun (8).
Fig. 7: Connect compressed air hose
8. Screw on compressed air hose (11) to the
“AIR OUT” connection (13) of the electro-
static controller (1).
Fig. 8: Connecting material supply
9. Connect material supply (15) to the paint
pipe (14).
Assembly
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Bundle connection cable
Fig. 9: Bundle connection cable
Adhere to the following conditions in order to
avoid affecting the strength and live of the
connection cable:
nDo not bundle the connection cable up
to a distance of approx. 70cm from the
spray gun.
nBundle the connection cable with suffi-
cient extra length to avoid it being pulled
or overly bent during movements. Bundle
the connection cable with a tie made of
resin or plastic material.
nBundle connection cable loosely every
5cm.
nDo not glue plastic tape and metal ties
around the connection cable.
5 Commissioning
Ground spray gun and surroundings
Ground spray gun and the surroundings to
ensure safe operation and good painting
results.
Personnel:
nOperator
n + additional qualification high tension
technology
n + additional qualification explosion pro-
tection
Protective equipment:
nAnti-Static Safety Boots
nProtective workwear
nEye protection
nRespiratory protection device
nUse ear protection
Fig. 10: Ground spray gun
1. Ground the spray gun.
ðWith a correct installation, the spray
gun is grounded via the controller and
the material supply.
Commissioning
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Fig. 11: Ground material supply system
2. Ground material supply system.
Fig. 12: Ground operator
3. Ground operator.
Fig. 13: Ground work piece
4. Ground the work piece.
Commissioning
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Perform functional check of high voltage
Personnel:
nOperator
n + additional qualification high tension
technology
n + additional qualification explosion pro-
tection
Protective equipment:
nAnti-Static Safety Boots
nProtective workwear
nEye protection
nRespiratory protection device
nUse ear protection
Requirements:
nThe connection cable, the compressed
air hose and the material supply were
assembled Ä 4.2 “Connecting”.
Fig. 14: Open ball valve
1. Open ball valve (1).
Fig. 15: Switch on electrostatic controller
2. Switch on the electrostatic controller (2).
Fig. 16: “H. V.” indicator light
3. Pull the trigger of the spray gun.
ðThe “H. V.” indicator light (3) on the
electrostatic controller lights up green.
The “H. V.” indicator light on the spray
gun lights up red.
4. Switch off the electrostatic controller (2).
Commissioning
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Setting the spray pattern
Fig. 17: Setting the material flow
1. Set the material quantity by turning the
material flow control (1).
nRight turn: Reduce material quantity.
nLeft turn: Increase material quantity.
Fig. 18: Set spray width
2. Set the spray width by turning the flat jet
setting (2).
nRight turn: Minimize spray width.
nLeft turn: Maximize spray width.
6 Operation
6.1 Safety recommendations
WARNING!
Danger of explosion due to chemical
reactions
Material, halogenated hydrocarbon-based
rinsing agent or cleaning agent can chem-
ically react with aluminum components of
the product. Chemical reactions can cause
explosions. Serious injury and death could
be the consequence.
nOnly use purging agents and cleaning
agents that do not contain any halo-
genated hydrocarbons.
NOTICE!
Material damage due to dried material
residues
If material residues dry in the product, that
can harm components.
nPurge product immediately after each
use.
6.2 General notes
1. Perform the following checks during oper-
ation:
nCheck O-rings for correct seating and
tightness.
nCheck air car for cleanliness.
nCheck nozzle for cleanliness.
6.3 Selecting air cap
The spray gun is suitable for different appli-
cations. The selection of the air cap deter-
mines the area of application.
Operation
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Air cap HN 400
The air cap HN 400 is used for small and
narrow applications:
nSpray pattern width 30 - 170mm
nFlow rate 50 - 160mL/min
Air cap HN 600
The air cap HN 600 is the standard type.
It achieves a great degree of efficiency with
fine atomizing:
nSpray pattern width 90 - 300mm
nFlow rate 150 - 280mL/min
Air cap HN 800
The air cap HN 800 is a highly atomizing
model for applications with higher viscosity
or higher flow rates:
nSpray pattern width 230 - 350mm
nFlow rate 230 - 400mL/min
6.4 Changing the air cap
Personnel:
nOperator
n + additional qualification high tension
technology
n + additional qualification explosion pro-
tection
Protective equipment:
nProtective workwear
nAnti-Static Safety Boots
Requirements:
nThe electrostatic controller is switched off.
Remove air cap
Fig. 19: Ground electrode
1. Discharge electrode (1) using a
grounding rod (2). In this, pull the trigger
completely.
Fig. 20: Replace air cap
2. Loosen cap nut (3).
Operation
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3. Remove air cap (4).
Assemble air cap
4. CAUTION!
Risk of injury from pointed electrode
Fit air cap (4).
5. Align air cap (4) as required Ä 6.5 “Align-
ment of the air cap”.
6. Tighten cap nut (3) by hand.
6.5 Alignment of the air cap
Personnel:
nOperator
n + additional qualification high tension
technology
n + additional qualification explosion pro-
tection
Protective equipment:
nProtective workwear
nAnti-Static Safety Boots
The position of the air cap determines the
alignment of the spray pattern.
Fig. 21: Align air cap
1. Lightly loosen the cap nut (2).
2. Turn the air cap (1) as required for the
desired spray pattern.
3. Tighten cap nut (2) by hand.
Operation
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6.6 Guiding the spray gun
Personnel:
nOperator
n + additional qualification high tension
technology
n + additional qualification explosion pro-
tection
Protective equipment:
nAnti-Static Safety Boots
nProtective workwear
nEye protection
nRespiratory protection device
nUse ear protection
nProtective gloves
WARNING!
Spark discharging in explosive atmos-
phere
Spark discharging in explosive atmos-
phere can cause explosions. Serious
injury and death could be the conse-
quence.
nUse antistatic protective gloves.
nIf no conductive protective gloves are
available, the glove guiding the spray
gun must have a hole in the palm of
the hand. This hole must ensure exten-
sive contact of the palm of the hand
with the handle of the spray gun.
Requirements:
nThe spray gun has been put into opera-
tion Ä 5 “Commissioning”.
nThe electrostatic controller is switched on.
Fig. 22: Guide the spray gun
1. Guide spray gun as follows:
nGuide spray gun at 90 degrees to the
surface.
nMaintain a distance of 15 to max.
25cm to the surface.
The distance can vary for effect
coatings.
6.7 Purging
6.7.1 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.
nUse only the rinsing agents that are
compatible with the components and
the material.
nRefer to safety data sheet of material
manufacturer.
6.7.2 General notes
When purging, use fluid to remove inner
soiling from components.
Operation
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6.7.3 Purging spray gun
NOTICE!
Clogged air channels
If the material or rinsing agent reaches into
the air channels, air channels can clog up.
This can result in faulty painting results.
nKeep spray gun horizontal or directed
downwards during the purging process.
Purge the spray gun in the following cases:
nAfter end of operation
nBefore every change of material
nPrior to cleaning
nPrior to dismantling
nBefore a long time of non-use
nBefore placing in storage
Purging intervals depend on the
material used.
Personnel:
nOperator
n + additional qualification high tension
technology
n + additional qualification explosion pro-
tection
Protective equipment:
nProtective workwear
nRespiratory protection device
nEye protection
nUse ear protection
nProtective gloves
nAnti-Static Safety Boots
Requirements:
nTechnical ventilation is in operation.
nMaterial pressure is switched off.
nA collecting tray for material and deter-
gent is available.
1. Switch off electrostatic controller.
2. Set air pressure at the compressed air
controller to 0bar.
3. Disconnect spray gun from the material
supply.
4. Pull trigger.
ðThe residual paint is blown out of the
spray gun.
Collect residual paint in the collecting
tray.
5. Connect detergent supply.
6. Purge the spray gun with an appropriate
detergent until the detergent runs clean
without any material residue.
ðCollect detergent in the collecting tray.
7. Ensure proper disposal of the exiting
material and rinsing agent.
8. Depressurize detergent supply.
9. Disconnect detergent supply.
Operation
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