Durr EcoGun 648 User manual

II 2 GX
OPERATION MANUAL
EcoG
un
648
automatic spraying gun
This device is inTended for professional use. Before
commissioning The device please read This manual. inThe
case of incorrecT use of The spray gun, serious injury To
The user or damage To The device may occur.

E02-026 GB rev: 01 2014/10
Dürr Systems Czech Republic a.s.
Podolí 1237,
84 01 Ledeč nad Sázavou Czech
Republic
VAT code: CZ 2 2 37 3
EC-DECLARATION OF CONFORMITY
PRODUCT
NAME: low pressure automatic spray gun
TYPE: EcoGun 648
USAGE: automatic coating of liquid paints
COMPLIES WITH
European directives
2006/42/EC; 94/9/EC; 2003/10/EC; 2002/44/EC
USED STANDARDS
EN ISO 12100; EN 13463-1; EN 19 3; EN 1127-1; EN ISO 3746
ATEX
Czech gov. order No. 23/2003 Col. (94/9/EC)
Clan:
II Category: 2 Mark:
II 2 G
Notified body:
Tech. File:
NB 1026 – FTZÚ Ostrava
A135-06
DECLARATION
We are declaring and taking the responsibility that the
properties and parameters of the equipment meet the
safety requirements and the technical requirements and
that the equipment is safe and meets all the above stated
requirements.
Manufacturer has a certification for quality system management
according to: EN ISO 9001:2009.
APPROVED BY
Ing. Jan Hevessy
CEO & Chairman of the board
In Ledeč nad Sázavou
Date: 8.10.2014

3
EcoGun 648
CONTENTS
SAFETY REGULATIONS 4
EQUIPMENT DESCRIPTION 5
USE 6
TECHNICAL PARAMETERS 7
COMMISSIONING 8
ADJUSING THE AUTOMATIC GUN 8
Adjustment 8
Assembly of hoses 8
SERVICING 9
MAINTENANCE AND CLEANING 9
Principles for cleaning and maintenance 9
Important principles for error-free operation 9
OPERATIONAL SAFETY 10
PRODUCT TESTING 10
PACKING OF PRODUCTS 10
DISPOSAL 11
WARRANTY CONDITIONS 11
No warranty is provided 11
COMBINATIONS OF NOZZLE SETS 11
SPECIFICATION OF PARTS 12
Display of parts 13
Accessories included with the device 14
DIMENSIONAL SKETCH 14
DIMENSIONS SKETCH 15

4
EcoGun 648
SAFETY REGULATIONS
Grounding of equipment (for ammable application
materials)
Due to the speed of the ow of the liquid at the high spraying
pressure, then under certain circumstances an electro-static charge
may originate in the equipment. When discharging, this may result
in the occurrence of sparks or ames. Therefore, the devices must
be grounded when spraying ammable materials. For connection of
the grounding, see commissioning.
Using the automatic gun
Never put hands or ngers in front of the gun. During assembly
or dismantling of the nozzle, when cleaning or pausing the work,
be careful and make sure that the gun is always secured against
activation to prevent any consequent injury.
Injury to operators
Injury caused by the application material can be very serious. In
the case of injury, immediately contact a doctor and advise which
material caused the injury.
Protection during use
To maintain and handle the application materials, and when cleaning
the equipment, follow the instructions from the manufacturer’s of
these materials. To protect the skin, respiratory system and eyes, use
protective working items, respirators, protective masks, breathing
devices, protective glasses, protective creams, etc.).
Pressure resistance
Keep the maximum working pressure of the application material
and working values for the compressed air - for recommended values,
see technical parameters.
Connecting hose
Angular adapters enable to connect the control air hose with an
outside diameter of 6.0mm and the sprayed air with the outside
diameter 8.0mm without special clamping elements. The angular
adjustable threading for the connection of the NH hose is tted by
cam tightening nut M14x1.5 for the safe and complete connection of
the hose with the diameter 6.0x4.0mm.
Workplace
For spraying and handling ammable liquids, the respective
standards are valid. Premises and rooms in which the work with
painting substances is carried out must be indicated and marked
with respect to the class of ammability pursuant to valid standards
and regulations.

5
EcoGun 648
If spray guns are used and operated in other countries, local
standards and regulations apply.
EQUIPMENT DESCRIPTION
»The EcoGun 648 automatic spray gun is designed for the application
of liquids by pressure supply (painting substances, glues, etc.).
The gun can be divided into three functional parts:
»The jet system consists of a nozzle, stainless jet with insert and
closing needle. The nozzle system creates a spraying image. The
needle and the nozzle are manually sealed to ensure complete
tightness when closing the output of the applied material. There is
special insert on the nozzle that enables complete tightness of the
nozzle with a lower tightening force.
»The front part of the mechanical part of the gun consists of a
stainless distribution cube of the applied material with the
tightening of the needle against the escape of pressure supplied
material. The outlet of the material is tted with a G1/8“ cap.
The outlet enables to easily clean the connection channel or for
the circulation of material and enables to connect two applied
materials. The circulation of the NH is not included in the delivery.
»The applied material is supplied from the source (transport
pump, pressure reservoir or central distribution of the
material) under pressure into the gun.
»The rear part of the mechanical part of the gun consists of a
Duralumin body with a pneumatic cylinder for opening (closing)
the nozzle system with any regulation of the lift of the needle for
setting the lift, regulation of wing air for setting the form of the
stream (round, oval), variable holder with the hole for clamping
to the manipulator with a diameter of 10 mm. The opening of the
outlet of the applied materials and the spraying air is ensured by
the pneumatic cylinder with the piston in the body of the gun.
»The spraying air (A) is regulated by the regulator of the
compressed air and closed (opened by the lift of the gun
piston).
»The control air (C) is separately controlled by a three-way
electromagnetic valve. The gun is controlled by the supply of
control air in front of the piston. Closing is by discharging the
air in front of the piston into the atmosphere.
»the piston into the atmosphere.
»The wing air (K) is controlled by mechanical regulation of
CAUTION
All workers assigned to operation and maintenance of the device must be
provably acquainted with the safety regulations and with the device operation
and maintenance manual!

6
EcoGun 648
setting the form of the stream (at or round). After mounting
the threading for the automatic supply of the wing air with
angular coupling (not included in the delivery), it is possible
to be separately remotely controlled by means of a two-way
electromagnetic valve.
USE
The EcoGun 648 automatic spray gun is designed for the surface
treatment of products by air spraying. The nozzle system is designed
for the pressure supply of applied material and is recommended for
the spraying of coating substances (hereinafter referred to as NH),
while it can also be used for spraying other materials, which by their
composition, do not damage the material of the spraying gun. As
the route of the NH is stainless, including the nozzle system, the
gun can be used for all applied materials. The gun is constructed for
remote control with separate air inlets for the control of the gun and
for spraying. It is possible to directly control the volume of material
on the gun and the form of the stream (at or round).
For fully automated operation, automated guns can be completed
by equipment for automatic control and programming the width of
the spray. In this case, all the benets of the automatic spray gun
will be put to full use.

7
EcoGun 648
TECHNICAL PARAMETERS
The consumption of air for spraying is ..........150-700 l.min-1
Performance (according to the nozzle system) 50-1200 g.min-1
Range of spraying air .......................................max. 6 bar
Recommended control pressure of air .......................4 bar
Quality of air (spraying):
– max. dew point ....................................................+3°C
– max. content of oil ...........................................1 mg/m3
– max. size of solid particles .....................................5 μm
– max. temperaturea .............................................+40°C
Quality of air (control):
– max. dew point ....................................................+3°C
– max. content of oil ........................................ 25 mg/m3
– max. size of solid particles ................................... 40 μm
– max. temperature ...............................................+40°C
Frequency of switching (according to the electromagnetic valve)
...............................................................max. 200 min-1
Pressure of NH (according to density) .................max. 6 bar
Pressure resistance ................................................10 bar
Weight of the gun, including the holder .................... 900 g
Ambient temperature ........................................ 5 až 40°C
Sizes of nozzle system ................................ 08P; 10P; 12P
Noise .........................................................max.98 dB(A)
Classication of environment
Connecting dimensions .................see: „Assembly of hoses“
Noise level
The noise level depends on the size of the nozzle system and the
value of the input pressure. The noise of this gun varies between 96
– 98 dB(A). The permitted noise level according to the Collection of
Laws No. 272/2011 is 85 dB(A) and, therefore protective work items
must be worn to protect the ears.
II 2 GX

8
EcoGun 648
COMMISSIONING
Before commissioning, the gun must be cleaned from preservation
substances using a suitable de-greasing detergent. Connect the hose
for control and spraying air. Connect the NH hose; tighten the cap
nut on the adjusting angular threading for NH.
The control air is closed through the three-way electromagnetic valve
with a ow of 150 l/min. The spraying air is closed by the lift of the
piston. Set the form of the NH stream by regulation of wing air. Set
the required lift of the needle by regulation (regulation of lift, micro
regulation S, micro regulation B).
The following distinguishing is principally used (indication on the
body of the gun):
- inlet indicated „C“ for the supply of control air
- inlet indicated „A“ for the supply of spraying air
- inlet indicated „K“ for the supply or regulation of the wing air
The overall connection is according to the connection diagram.
ADJUSING THE AUTOMATIC GUN
If keeping to the basic requirements for maintenance, the gun
will not need any adjustment during operation.
During dismantling and assembling due to replacing the nozzle
system or worn parts, it is necessary to check the adjustment of the
following parts:
Adjustment
»seal on the needle - the construction is based on the automatic
sealing set. If the seal stops sealing, then the sealing set must
be replaced.
Assembly of hoses
»Connect the NH hose with the diameter 6.0x4.0 into the
adjustable angular thread with metal reinforcement of the
end of the hose, tighten the cap nut for safe connection of
the hose. For the transport of ammable liquids, the hose
ATTENTION
The equipment is grounded in the case of the use of application materials with
a ash point under 21° C (NITRO etc.) and substances of the 2nd class of risk,
pre-heated to their ash point. Grounding is through the gun holder after tting
the washer with the diameter of 8.4 ČSN 021744 under the nut of the holder.
Use a metal conductor for grounding, the best is steel wire with a diameter of 5
mm, or copper wire with a minimum cross section of 4 mm.

9
EcoGun 648
must be electro-statically conductive. For the connection
of this hose, use clamping unit M14x1.5 (not included in
the delivery). Connect the hose for the control air with the
diameter 6.0x4.0mm and the spraying air with the diameter
8.0x6.0mm.
SERVICING
Important preconditions for the high quality function of the gun
are the adjustment and the respective maintenance of the gun,
particularly cleanliness and cleaning after use.
To achieve high-quality spraying, it is necessary to ensure the
cleanliness of the jet system (particularly the semi-ring part between
the nozzle and the neck of the nozzle).
The regulation of the volume of the outow of the liquid from
the nozzle can be resolved by the restriction of the lift of the needle
(we recommend using it only when it is not possible to reduce the
pressure of the transported liquid).
MAINTENANCE AND CLEANING
PrinciPles for cleAning And mAintenAnce
1. Do not leave the dried application substance on the gun.
Always clean using the respective solvent recommended by
the manufacturer of the material.
2. Do not use metal items to clean the holes in the nozzle
system.
3. When necessary, lubricate the thread of the cap nut on the air
nozzle and the needle in the groove in the rear part of the gun
with a few drops of oil.
imPortAnt PrinciPles for error-free oPerAtion
1. Clean all of the nozzle system.
2. Correctly treat the air for spraying (without dirt, water and
oil).
3. Filtered application material must have the correct viscosity -
follow the regulations of the producers of materials.
ATTENTION
When regulating the output in the nozzle there is greater wearing of parts.
Do not immerse the gun in solvent, the life of the sealing will be permanently
reduced.

10
EcoGun 648
4. Follow the recommended air pressures for spraying.
If the equipment is used for the application of oils, varnishes,
expoxydes, two-component substances and materials with similar
properties, only solvents recommended by the producers of these
substances must be used.
After work, the equipment should be regularly cleaned. We
recommend to prepare a regular cleaning program for cleaning and
maintenance (tightening of seals), to ensure the reliable function
and service life of the device.
OPERATIONAL SAFETY
The product complies with the regulations and standards related
to products of this type.
All employees authorized to operate and maintain equipment
must be familiarized in a proven manner with the health and safety
regulations for working in paint shops and the user and maintenance
manuals for the high-pressure valve.
The operator must train the operators and provide employees
with the stated personal protective aids. Training or provision of
wider information can be obtained from the equipment supplier.
PRODUCT TESTING
»Functional and pressure tests are conducted on each product in
the manufacturing plant.
PACKING OF PRODUCTS
»According to individual parts for delivery.
ATTENTION
Never put ngers or hands into the stream of the spraying liquids as this can
cause severe injuries.
In the case of injury by the sprayed material, immediately contact a doctor
and advise the type of liquid that affected the skin.
Do not dismantle any part of the gun if the equipment is under pressure!
APPLICABLE STANDARDS
EN ISO 12100, EN ISO 13732-1, EN 894-1+A1, EN ISO 4414, EN 1037+A1,
EN 1070, EN 1127-1, EN 13463-1,
EN 60079-0, EN 60721-3-7, EN ISO 11204,

11
EcoGun 648
DISPOSAL
»After termination of the service life of the parts or the sprayer,
then after cleaning, the product can be put into sorted waste.
»Packaging materials of products (catalogue number 200101, see
Regulation of the Ministry of the Environment No. 381/2001 Coll.)
are liquidated as mixed communal waste. Put the used paper
package into separate waste collection.
WARRANTY CONDITIONS
»See the Service Manual
nowArrAnty is Provided
»In the case of mechanical damage or incorrect handling of the
product.
»In the case of damage, wearing or failure caused by incorrect or
inadequate maintenance, abrasion, corrosion or the use of unstable
parts or materials.
»In the case of unpermitted and unprofessional intervention into the
device.
»The warranty does not apply to parts of a consumer nature, for
example, sealing elements, springs, needle, the stop valve and jet
where the wear depends on the abrasive properties of the applied
substance, pressure and other circumstances.
COMBINATIONS OF NOZZLE SETS
Air cAP nozzle Assembly
tyPe identificAtion number tyPe identificAtion number
pl 907 204
08P 907 505
10P 907 506
12P 907 507
pc 906 646
16UA 908 062
18UA 908 063
20UA 908 064
22UA 908 065
hm 906 677 10UA 908 060
12UA 908 061
The nozzle set consists of the nozzle, needle and the insert with the
nut.

12
EcoGun 648
SPECIFICATION OF PARTS
Position nAme identificAtion number QuAntity
1 Body NH EcoGun 648 not included as a spare part —
2 Air body not included as a spare part —
3 Air cap according to the table of
combinations —
4 Nozzle set according to the table of
combinations —
5"O“ ring 33 x 1,6 105 081 1
6"O“ ring 10 x 1 105 156 1
7"O“ ring 4 x 1 105 008 2
8"O“ ring 5 x 1 105 165 1
9 Bolt M 4 x 20 114 142 4
10 Sealing set 648 907 485 1
11 Seal 7 832 577 1
12 "O“ ring 11 x 1.8 105 028 1
13 Piston 805 037 1
14 Piston bearing 805 097 1
15 Spring 124 023 1
16 Spring 124 007 1
17 Micro regulation B 907 488 1
18 Micro regulation S 907 498 1
19 Regulation of lift 907 491 1
20 AUPI holder 907 493 1
21 Angular coupling 131 017 1
22 Angular coupling 131 018 1
24 Cap G 1/8“ 807 497 1
25 Sealing 807 380 2
26 Threading NH 648 807 517 1
27 Angular threading -
adjustable 180 708 1
28 Bolt M 3.5 x 8 114 247 2
29 Set of rings 906 439 1
30 Regulation wheel 114 247 2
31 Regulation pocket 804 426 2
32 Sealing 804 424 2
33 Regulation bolt 806 694 2

13
EcoGun 648
disPlAy of PArts
DSCZ
28
30
31 32
33
29
18
17
25 26 27
25
24
21
22
20
9
9
10
3
5
4
6
28
30
31 32
33
29
11
12
13
14
15
16
19
2
1
7
8

14
EcoGun 648
Accessories included with the device
Position nAme identificAtion number QuAntity
40 Universal wrench 806 697 1
41 Allen wrench 5 152 021 1
42 Allen wrench 3 152 011 1
43 Assembly wrench 906 699 1
44 Test brush 139 100 1
29 Set of rings 906 439 1
DIMENSIONAL SKETCH
Legend:
1. Source of pressure medium (transport pump, pressure storage tank or
central distribution of material)
2. Source of compressed air (distribution of compressed air)
3. Electromagnetic valve 3/2 (for control air) - min. ow 150 l.min-1
4. Air pressure regulator
43 42 41 40 44
29
4
3
2
1
AP
R
R O
NH
EcoGun 648

15
EcoGun 648
DIMENSIONS SKETCH
DSCZDSCZ
DSCZ
10
22
40
82,5
1111
56
40
2,5
167
157,5
69
182

© 2014 Dürr Systems Czech Republic a.s. ., Ledeč nad Sázavou
Dürr Systems Czech Republic a.s.
Podolí 1237 | 584 01 Ledeč nad Sázavou | Czech Republic
Tel.: [phone] | Fax: [phone] | E-mail: [e-mail]
www.durr.com
www.durr-cz.cz
N02.036 GB
rev: 02
2014/10
WARRANTY CARD
TiTle and Type of producT producTion numBer
ouTpuT check producTion daTe dispaTch
sTamp and signaTure daTe of sale
Warranty Servicing Activity
Responsibility for potential defects is driven by Czech Civil Code No. 89/2012.
The warranty period for the products of the Dürr Systems Czech Republic
company is 36 months from the date of agreed sale supply, if not agreed
otherwise in the business contract. The warranty period is extended in case of
an acknowledged complaint by the time of arguable shutdown of the equipment,
generally by the time between the reporting of the defect and its due removal.
In case of application of an acknowledgeable defect, whose removal would
signicantly exceed the agreed deadline, the interested party can ask for free
lending of spare equipment for the necessary time.
The warranty does not apply to:
»Parts and materials of regular operating consumption stated in the documentation
supplied with the product and parts, whose life span is adequate to application
conditions;
»Defects arisen by inexpert use and maintenance of the product in conict with
the recommendations stated in the operating and maintenance manual;
»Defects arisen for reason of own modications of the equipment and use
of materials and parts that were not approved by the manufacturer for the
operation of the equipment.
EcoGun 648