DÖRR EcoGun AS MAN EC User manual

EcoGun AS MAN EC
Manual Spray Gun with External Charging
MSG00022EN, V03
N36180001V
www.durr.com
Operation manual

Information about the document
This document describes the correct han-
dling of the product.
Read the document prior to every activity.
Prepare the document for the application.
Pass on the product only together with
the complete documentation.
Always follow safety instructions, han-
dling instructions and specifications of
every kind.
Illustrations can deviate from the tech-
nical construction.
Validity range of the document
This document describes the following
product:
N36180001V
EcoGun AS MAN EC
Applicable documents
MHT00005* - 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.
11/2019EcoGun AS MAN EC - MSG00022EN2/52

TABLE OF CONTENTS
1 Product overview.......................... 4
1.1 Overview................................ 4
1.2 Short description.................... 4
2 Safety............................................. 4
2.1 Presentation of Notes............ 4
2.2 Intended Use.......................... 5
2.3 Residual risks......................... 5
2.4 Staff qualification.................... 6
2.5 Personal protective equip-
ment....................................... 7
3 Transport, scope of supply and
storage........................................... 7
3.1 Scope of delivery................... 7
3.2 Handling of
packaging material................. 7
3.3 Storage.................................. 7
4 Assembly....................................... 7
4.1 Requirements for the
Installation point..................... 7
4.2 Connecting............................. 8
5 Commissioning........................... 10
6 Operation..................................... 13
6.1 Safety recommendations..... 13
6.2 General notes...................... 13
6.3 Selecting air cap.................. 13
6.4 Changing the air cap............ 14
6.5 Alignment of the air cap....... 15
6.6 Guiding the spray gun.......... 15
6.7 Rinsing................................. 16
6.7.1 Safety recommendations.. 16
6.7.2 Rinsing spray gun............. 16
7 Cleaning....................................... 17
7.1 Safety recommendations .... 17
7.2 Cleaning............................... 19
8 Maintenance................................ 20
8.1 Safety notes......................... 20
8.2 Maintenance schedule......... 21
9 Faults........................................... 21
9.1 Safety recommendations .... 21
9.2 Defects table........................ 22
9.3 Troubleshooting................... 25
9.3.1 Replace needle, nozzle
and seal kit........................ 25
9.3.2 Replace flat jet control...... 28
9.3.3 Replace material flow con-
trol..................................... 29
9.3.4 Replace handle................. 30
9.3.5 Replace valve set.............. 31
9.3.6 Replace hook.................... 31
9.3.7 Replacing sealing ring....... 32
9.3.8 Replace paint pipe............ 33
9.3.9 Replace cascade.............. 34
9.3.10 Replace electrode.............. 35
10 Disassembly and Disposal........ 35
10.1 Safety recommendations... 35
10.2 Disassembly....................... 36
10.3 Disposal ............................ 36
11 Technical data............................. 36
11.1 Dimensions and weight...... 36
11.2 Connections....................... 37
11.3 Operating conditions.......... 37
11.4 Operating values................ 37
11.5 Type plate........................... 37
11.6 Materials used.................... 37
11.7 Operating and auxiliary
materials............................. 37
11.8 Material specification.......... 37
12 Replacement parts, tools and
accessories................................. 38
12.1 Replacement parts............. 38
12.2 Tools................................... 47
12.3 Accessories........................ 47
12.4 Order.................................. 48
13 Index............................................ 49
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1 Product overview
1.1 Overview
Fig. 1: Overview
1 Cap nut
2 Air cap
3 Nozzle
4 Electrode
5 Basic housing
6 Hook
7 H. V. indicator light
8 Material flow control
9 Housing
10 Connections
11 Paint tube
12 Flat jet control
13 Trigger
1.2 Short description
The spray gun is intended for electrostatic
surface coating with non-flammable paints.
Compressed air and external charging sup-
port the coating process. The spray gun is
hand-held.
The following factors influence the spray jet
and therefore the result:
Alignment of the air cap Ä 6.5 “Alignment
of the air cap”
Material quantity Ä 5 “Commissioning”
Spray width Ä 5 “Commissioning”
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.
Product overview
11/2019EcoGun AS MAN EC - MSG00022EN4/52

CAUTION!
Low risk situations that can lead to minor
injuries.
NOTICE!
Situations that can lead to material
damage.
Additional information and recom-
mendations.
2.2 Intended Use
Use
The spray gun EcoGun AS MAN EC is used
exclusively for hand guided electrostatic
coating of surfaces with non-flammable
paints. The coating process must be con-
ducted in a painting booth with suitable tech-
nical ventilation.
The spray gun EcoGun AS MAN EC may
only be operated in the industrial area and
within the approved technical data Ä 11
“Technical data”.
The EcoGun AS MAN EC spray gun is
approved for use in Class I Division 1.
Permitted device combination
The spray gun must only be combined with
the following components:
Controller Connection cable
EcoHT 80 controller
(100 - 120V)
E80020003
Connection cable,
10m
E09070245
EcoHT 80 controller
(200 - 240V)
E80020004
Misuse
If used incorrectly, it can cause serious inju-
ries or death.
Examples of wrong use are:
Aiming the spray gun at humans or ani-
mals
Use outside of an spray booth
Use without mechanical ventilation
Atomization of fluid nitrogen
Use of unapproved materials
Combination of the spray gun with com-
ponents that are not approved by Dürr
Systems for operation.
Unauthorized modifications
Use in explosive dust atmospheres or in
atmospheres with flammable fibers and
fluff
Use in other groups of substances,
except D
Use of the spray gun without knowing the
operating instructions
Labelling according to CSA
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.
Ground the spray gun.
Ground the work piece.
Connect any conducting objects and
paint containers in the paint booth to the
ground.
Remove not required objects such as
tools from the paint booth.
Wear antistatic safety boots during opera-
tion.
Wear antistatic protective gloves during
operation.
Do not touch the electrode during opera-
tion.
Safety
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Explosion
Sparks, open flames and hot surfaces can
cause explosions in explosive atmospheres.
Serious injury and death could be the conse-
quence.
Before carrying out any work, make sure
that there is no explosive atmosphere.
Do not use sources of ignition and open
light.
Do not smoke.
Ground the spray gun.
Ground the work piece.
Only use conductive lines.
Flammable coating materials and their deter-
gents and cleaning agents can cause a fire
or an explosion.
Ensure that the flashpoint of the fluid is at
least 15 K above the ambient tempera-
ture.
Note explosion group of the fluid.
Follow the safety data sheet.
Ensure that forced ventilation and fire
protection equipment are in operation.
Do not use sources of ignition and open
light.
Do not smoke.
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.
Follow safety data sheets.
Wear specified protective equipment.
Escaping material
Material escaping under pressure can cause
serious injuries.
Before working on the product:
Disconnect the system, in which the
product is installed, from compressed air
and material supply.
Depressurize the lines.
Secure the system against being
switched on again.
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.
2.4 Staff qualification
WARNING!
Inadequate qualification
Wrong estimation of dangers can cause
serious injury or death.
– Only sufficiently qualified persons may
execute all work.
– Some 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:
Technical Measures for occupational
safety and health
The operator is responsible for the following
work:
Operate and monitor the system/ product.
Introduce measures in the event of faults.
Clean 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
Painting process
High 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 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:
3 Transport, scope of supply
and storage
3.1 Scope of delivery
Following components are included in the
scope of supply:
Spray gun
Tool kit
Inspect delivery on receipt for completeness
and integrity.
Report defects immediately Ä “Hotline and
Contact”.
3.2 Handling of packaging material
ENVIRONMENT!
Incorrect disposal
Incorrectly disposed packaging material
can damage environment.
– Dispose of material no longer required
in an environment-friendly manner.
– Observe local disposal specifications.
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: 0°C to 40°C
Relative humidity: 40% to 80%
4 Assembly
4.1 Requirements for the
Installation point.
The compressed air supply to the spray
gun must be interrupted and secured
against reconnection.
The compressed air supply must be
adjustable.
Lines, seals and screw connections must
be designed to conform to the require-
ments of the spray gun Ä 11 “Technical
data”.
The workplace must have a mechanical
ventilation.
A hook or a lug must be provided for
hanging the spray gun.
Transport, scope of supply and storage
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Working environment and grounding
The flooring of the working area must be
anti-static according to DIN EN
50050-1:2014-03, measurement according
to DIN EN 1081:1998-04. The antistatic
flooring prevents electrostatic charges from
building up. Dangerous flashovers are pre-
vented.
4.2 Connecting
Personnel:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Protective workwear
Anti-Static Safety Boots
1. WARNING!
Sources of ignition may cause explo-
sions!
Ensure a non-explosive atmosphere.
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).
Assembly
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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.
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:
Do not bundle the connection cable up to
a distance of approx. 70cm from the
spray gun.
Bundle 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.
Bundle connection cable loosely every
5cm.
Do 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:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Anti-Static Safety Boots
Protective workwear
Eye protection
Respiratory protection device
Use 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:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Anti-Static Safety Boots
Protective workwear
Eye protection
Respiratory protection device
Use ear protection
Requirements:
The 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).
Right turn: Reduce material quantity.
Left turn: Increase material quantity.
Fig. 18: Set spray width
2. Set the spray width by turning the flat jet
setting (2).
Right turn: Minimize spray width.
Left 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 chemi-
cally react with aluminum components 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 halo-
genated 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 General notes
1. Perform the following checks during oper-
ation:
Check O-rings for correct seating and
tightness.
Check air car for cleanliness.
Check 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:
Spray pattern width 30 - 170mm
Flow 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:
Spray pattern width 90 - 300mm
Flow 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:
Spray pattern width 230 - 350mm
Flow rate 230 - 400mL/min
6.4 Changing the air cap
Personnel:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Protective workwear
Anti-Static Safety Boots
Requirements:
The 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).
3. Remove air cap (4).
Assemble air cap
4. CAUTION!
Risk of injury from pointed electrode
Fit air cap (4).
Operation
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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:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Protective workwear
Anti-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.
6.6 Guiding the spray gun
Personnel:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Anti-Static Safety Boots
Protective workwear
Eye protection
Respiratory protection device
Use ear protection
Protective 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.
– Use antistatic protective gloves.
– If 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.
Operation
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Requirements:
The spray gun has been put into opera-
tion Ä 5 “Commissioning”.
The electrostatic controller is switched
on.
Fig. 22: Guide the spray gun
1. Guide spray gun as follows:
Guide spray gun at 90 degrees to the
surface.
Maintain a distance of 15 to max.
25cm to the surface.
The distance can vary for effect
coatings.
6.7 Rinsing
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.
– Use only the rinsing agents that are
compatible with the components and
the material.
– Refer to safety data sheet of material
manufacturer.
6.7.2 Rinsing 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.
– Keep spray gun horizontal or directed
downwards during the rinsing process.
Rinse the spray gun in the following cases:
After end of operation
Before every change of material
Prior to cleaning
Prior to dismantling
Before a long time of non-use
Before placing in storage
Operation
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Rinsing intervals depend on the
material used.
Personnel:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Protective workwear
Respiratory protection device
Eye protection
Use ear protection
Protective gloves
Anti-Static Safety Boots
Requirements:
Technical ventilation is in operation.
Material pressure is switched off.
A 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. Rinse 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.
7 Cleaning
7.1 Safety recommendations
DANGER!
High voltage
High voltage can be present on compo-
nents and cables. There is a risk of death
due to electric shocks and discharges.
Before carrying out any work:
– Switch off electrostatic controller.
– Discharge electrode by means of a
grounding rod. In this, pull the trigger
completely.
– Verify no current is present.
WARNING!
Danger of fire and explosion
Flammable coating materials and their
detergents and cleaning agents can cause
a fire or an explosion.
– Ensure that the flashpoint of the fluid is
at least 15 K above the ambient tem-
perature.
– Note explosion group of the fluid.
– Follow safety data sheets.
– Ensure that forced ventilation and fire
protection equipment are in operation.
– Do not use sources of ignition and
open light.
– Do not smoke.
Cleaning
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WARNING!
Danger to health from harmful or irri-
tant substances
Contact with hazardous liquids or vapors,
can result in serious injury or death.
– Ensure that the forced ventilation is
operational.
– Follow safety data sheets.
– Wear specified protective clothing.
WARNING!
Danger of explosion due to chemical
reactions
Material, halogenated hydrocarbon-based
rinsing agent or cleaning agent can chemi-
cally react with aluminum components 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 halo-
genated hydrocarbons.
NOTICE!
Damage due to unsuitable cleaning
tools
Unsuitable cleaning tools can damage the
product.
– Only use cloths, soft brushes and
paintbrushes.
– Do not use abrasive cleaning tools.
– Do not poke blocked nozzles with met-
allic objects.
– Do not use compressed air for
cleaning.
– Do not use any thinner spray guns.
– Do not use high pressure for cleaning
agents.
NOTICE!
Unsuitable cleaning agents
Unsuitable cleaning agents can damage
the product.
– Only use cleaning agents approved by
the material manufacturer.
– Follow safety data sheets.
– Place heavily soiled components in a
cleaning bath.
– Only place those parts in the
cleaning bath, which are suitable for
the cleaning bath.
– Use only electrically conductive
containers.
– Ground the container.
– Do not use ultrasound baths.
Use alcohols (isopropanol, butanol) for
non-flammable coating materials.
Remove dried non-flammable coating
materials using a material manufacturer-
approved organic thinner.
When cleaning with flammable detergent,
do not spray into a closed container. An
explosive gas-air mixture can form inside
closed containers.
Cleaning
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7.2 Cleaning
Personnel:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Use ear protection
Eye protection
Respiratory protection device
Protective workwear
Protective gloves
Anti-Static Safety Boots
1. Purge spray gun Ä 6.7 “Rinsing”.
2. Remove material residues with a cloth or
a soft brush.
3. Clean the spray gun carefully and dry it
with a soft cloth.
Clean air cap and nozzle
Personnel:
Operator
+ additional qualification high tension
technology
+ additional qualification explosion pro-
tection
Protective equipment:
Protective workwear
Protective gloves
Anti-Static Safety Boots
For a thorough cleaning, air cap and nozzle
must be disassembled.
Disassembly
Fig. 23: Ground electrode
1. Discharge electrode (1) using a
grounding rod (2). In this, pull the trigger
completely.
Fig. 24: Replace air cap
2. Loosen cap nut (3).
3. Remove air cap (4).
4. Pull trigger.
ðThe needle is pulled backwards so
that it will not be damaged during dis-
assembly of the nozzle (5).
5. Unscrew and remove the nozzle (5) with
the supplied open-end wrench (included
in the tool kit).
Cleaning
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6. Release trigger lever.
7. Clean air cap (4) using cleaning agent
and cleaning brush.
8. Dry cleaned air cap (4) using compressed
air (at max. 2bar).
9. Clean the nozzle (5) in the cleaning bath
using a soft brush.
Assembly
10. Insert and tighten nozzle (5).
Tightening torque: 10Nm
11. Fit air cap (4).
12. Hand-tighten cap nut (3).
8 Maintenance
8.1 Safety notes
DANGER!
High voltage
High voltage can be present on compo-
nents and cables. There is a risk of death
due to electric shocks and discharges.
Before carrying out any work:
– Switch off electrostatic controller.
– Discharge electrode by means of a
grounding rod. In this, pull the trigger
completely.
– Verify no current is present.
WARNING!
Risk of injury from unsuitable replace-
ment parts in explosive areas.
Replacement parts not compliant with the
explosion protection specifications can
cause explosions in an explosive atmos-
phere. Serious injuries and death can be
the consequence.
– Use exclusively original replacement
parts.
WARNING!
Danger to health from harmful or irri-
tant substances
Contact with hazardous liquids or vapors,
can result in serious injury or death.
– Ensure that the forced ventilation is
operational.
– Follow safety data sheets.
– Wear specified protective clothing.
WARNING!
Risk of injury due to escaping material
and compressed air
Escaping compressed material can cause
serious injury.
Before carrying out any work:
– Disconnect the system, in which the
spray gun is installed, from com-
pressed air and material supply.
– Secure the system against being
switched on again.
– Depressurize the lines.
Maintenance
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