EST 651 User manual

II 2 GX
OPERATION MANUAL
EST 651
High-Pressure
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.

E01-027 GB rev: 4 2013/9
®
EST + a.s.
Podolí 1237
584 01 Ledeč nad Sázavou
CZEC REPUBLIC
VAT code: CZ 25 25 37 35
EC-DECLARATION OF CONFORMITY
PRODUCT
NAME: high-pressure automatic spray gun
TYPE: EST 655, EST 657 MIX, EST 651, EST 656, ventil
vysokotlaký EST 651VV and their modifications
VARIANTS: —
USAGE: automatic paint spraying
COMPLIES WITH
European directives
2006/42/EC; 94/9/EC; 2003/10/EC; 2002/44/EC
STANDARDS USED
EN ISO 12100; EN 1953; EN 1127-1; EN 13 463-1; 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 – FTZ , Ostrava, CZ
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: ČSN EN ISO 9001:2009.
APPROVED BY
Jaroslav Starosta, Production Manager
In Ledeč nad Sázavou
Date: 2013-09-02

3
EST 651
TABLE OF CONTENTS
SAFETY REGULATIONS 4
EQUIPMENT DESCRIPTION 5
TECHNICAL PARAMETERS 6
USE 7
COMMISSIONING 7
OPERATION 8
MAINTENANCE AND CLEANING 10
SAFETY OF OPERATION 12
TESTING OF PRODUCTS 12
PACKING OF PRODUCTS 12
DISPOSAL 12
WARRANTY TERMS 12
TROUBLESHOOTING 13
SPECIFICATION OF COMPONENTS - EST 651 14
DIAGRAM OF COMPONENTS OF THE GUN EST 651 15
DISPLAY OF COMPONENTS 16
DIMENSIONAL SKETCH 17

4
EST 651
SAFETY REGULATIONS
Earthing of the Equipment
Due to ow rate of the liquid at the high spraying pressure the
electro-static charge may be developed on the spraying gun under
certain circumstances. It may result in sparks of ames due to
discharging. To prevent this phenomena the spraying device must be
earthed. In addition the conductive connection (potential equalizing
cable) must be installed between the high-pressure device and the
gun during processing of the materials with the ignition point below
210 °C (NITRO etc.).
Resistance to Pressure
All elements forming part of the high-pressure section of the
automatic spraying gun comply by their operating pressure with the
maximum pressure specied by the technical parameters.
Manipulation with High-Pressure Valve
The high-pressure gun operates with very high pressures.
Therefore never put your hand and/or ngers before the gun and
never focus the gun to the body. During assembly or disassembly of
the nozzle, resp. during cleaning or during any interruption of the
work proceed very carefully and secure the gun to prevent accidental
start (disconnection of the control air). This is to prevent accidental
start of the gun and possible subsequent injury.
Injury of Operator
The injury caused by the high-pressure liquid may be very serious.
In case of injury immediately seek the doctor and notify him/her on
type of material causing the injury.
Personal Protection at Work
During spraying and handling with the application materials, as
well as during cleaning of the equipment adhere to instructions of
manufacturers of the materials; use suitable personal protective
equipments (clothes, gloves, respirators, protection masks, resp.
breathing devices, protecting creams etc.) to protect the skin and
respiration tracts.
Although very small amount of fog is generated during the high-
pressure spraying, the spraying procedure cannot be considered for
the fog-free one. Even if the air contains very low number of the
particles, it is necessary to exhaust the solvent vapours, which are
especially dangerous.
Equipment Cleaning
During cleaning of the equipment with the ammable liquids it is
necessary to prevent the back-spraying into the closed vessel, as the
liquid stream can produce the explosive mixture of the gas and air.

5
EST 651
Workplace
Relevant standards apply to spraying and handling with the
ammable liquids. Regarding the ammability class of the coating
materials the areas and rooms, where the coating materials are
used, must be marked and modied in compliance with applicable
standards and regulations.
When the guns are used and operated in other countries, the
local standards and regulations apply.
EQUIPMENT DESCRIPTION
The automatic high-pressure spraying gun EST 651 is designed
to application of the liquids by pressure supply. The gun consists
from two functional parts:
»Front part of the gun mechanical sections consists from stainless
coating substance (hereinafter referred to as NH) distribution
box with needle sealing to prevent leak of the pressure supplied
NH. The connecting angle-adjustable tting for the NH is tted
with the M14x1.5 thread. The second inlet of the NH is blinded
by the G1/8“ plug; when the plug is replaced with the NH
circulation line (not part of the supply), the NH circulation is
enabled (used for heavier NH etc.).
»The back part of the gun mechanical section consists from the
Duralumin body with pneumatic cylinder for opening (closing) of
the needle valve. The valve is opened by supply of the pressure
control air 5 bars before the piston by the 6 mm diameter hose.
Outlet of the pressure NH is closed by release of the air before
the piston to the atmosphere. The control air is separately
controlled by means of the three-way electro-magnetic valve.
In addition, the gun is tted with the holder with 10 mm hole for
xing to the handling device.
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
EST 651
TECHNICAL PARAMETERS
Maximum gun power (acc. to the nozzle used) . 30 ÷ 250 l/h
Max. NH operating pressure.................................. 300 bar
Recommended control air pressure ............................5 bar
(Control) Air quality:
– Max. due point .....................................................+3°C
– Max. oil content............................................. 25 mg/m3
– Max. size of solid particles.................................... 40 μm
NH connecting thread size .................................. M 14x1,5
Control air connecting size (insertion coupling) ...................
.......................................... to connect the ø 6.0x4.0 hose
Max. gun control rate........................... 3-times per second
Gun weight (without nozzle) ....................................563 g
Connecting threads in the gun body .........................G 1/8“
Noise level.........................................................75 dB(A)
Ambient temperature................................ +5°C až +40°C
Environment classication
Noise Level
The noise level depends on the nozzle system size and on the inlet
pressure value. The noise level of the gun reaches up to 75 dB(A).
Acc. to the act no. 272/2011 Coll., the maximum allowed noise level
is 85 dB(A).
II 2 GX

7
EST 651
USE
The automatic high-pressure spraying gun EST 651 is intended
to surface treatment of the products by the high-pressure spraying
of commonly used NH, even the water-born materials. During the
work procedure, the sprayed material is atomized under the high-
pressure up to 300 bars. It can be used even for spraying of other
materials, which do not damage the spraying gun materials by their
composition. The gun is designed to remote control by the pressure
air controlled by the three-way electro-magnetic valve. It can be used
for all spraying devices of the VYZA type so-far produced in EST+ a.
s., which do not exceed the HN max. operating pressure. When other
high-pressure devices are to be used, the operation of the automatic
gun must be consulted in the manufacturing plant in advance. The
gun is intended for equipment of the automatic production lines and
enables also interruption of the spraying regarding the shape of the
sprayed object and the production line cycle. Combination of the high
pressure of the NH and the special high-pressure nozzle results in
even layer of the applied NH with minimum y-out of small particles
to the environment. The nozzle suitable for the particular application
must be selected on basis of previous tests and recommendation of
the manufacturer.
COMMISSIONING
Before commissioning of the gun, the preservation grease must be
removed from the surface by suitable degreaser. Internal section
must be ushed out by the pressure solvent connected to the inlet
angle-adjustable tting for the NH and opening of the needle valve
with subsequent injection of the pressure control air 5 bar.
Upon cleaning the gun is tted with suitable high-pressure nozzle or
with the holder tted with the rotating nozzle. The nozzle is tted
directly to the cup nut with protecting cover, which forms part of
the gun; the rotating nozzle is xed to the holder, which is installed
directly to the gun upon screwing of the cup nut with protecting
cover.
The assembled gun is xed to the manipulator through the holder,
connected to the pressure control air 5 bar through the three-way
electromagnetic valve of ow ca 150 l/min. and the NH supply from
the high-pressure device; then tighten the cut nut on the NH angle-
adjustable tting. The hose must be electro-static conductive for
transport of the ammable liquids. In case of handling with the NH of
quicker sedimentation rate, which requires circulation, the circulation
high-pressure hose can be connected by unscrewing the plug in the
gun front section and tting of the NH circulation line (not part of the
supply). The general connection is done acc. to the wiring diagram.

8
EST 651
CAUTION
Relevant standards apply to spraying and handling with the ammable liquids.
Regarding the ammability class of the coating materials the areas and rooms,
where the coating materials are used, must be marked and modied in compliance
with applicable standards and regulations. The gun earthing is implemented via
the high-pressure hose from the equipment, however with application materials
of the ignition point below 21°C (NITRO etc.) or with materials, which are heated
to values exceeding the ignition temperature due to operational reasons, an
additional earthing is recommended by the potential equalizing cable (use the
metal conductor, optimally the steel rope of ø 5 mm, resp. copper wire min. 4
mm2).
OPERATION
1. The fault-free operation of the gun depends on preparation
of NH. Devote maximum care to mixing, treating to optimum
viscosity and ltration of the NH. Use of the proper solvent is
crucial for dilution of the NH and cleaning of the gun.
2. Select the nozzle type acc. to the shape and dimension of
the object, the NH type and viscosity (suitable nozzle can be
recommended by OTS of the manufacturing plant).
3. The optimum NH operation pressure is selected on basis of the
test spraying by the selected nozzle (onto the white paper), see
the high-pressure device operation manual. Selection of proper
operating pressure is crucial to the operation life of the gun,
and particularly the high-pressure nozzles. Do not exceed the
indispensable pressure!
4. If the nozzle hole is clogged, wash it in clean solvent and remove
the contaminants causing the clogging by the air jet. Cleaning of
the rotating nozzles is much simpler: remove the contaminants
by rotation and ushing and put the nozzle back to operation by
turning back. During cleaning or any manipulation do not turn
the gun against yourself or any other person, lock the supply of
the NH and pressure control air.
5. On long-term interruption of the work or when other type of
the NH us used, clean the gun internal section by pumping the
solvent applicable to the sprayed NH into the high-pressure
section instead of the NH. After approx. 5 minutes, when the
solvent dissolves the residual NH, ush the gun by pulses and
observe the solvent colour. When the solvent without traces of
formerly used starts to outlet, the gun is clean and ready for
other use.
6. Even on short-term interruption of the work, immerse the gun
neck, as well as the used nozzles, to the vessel with solvent.

9
EST 651
7. Daily on completion of works clean the gun and ush it acc. to
procedure specied in paragraph 5.
NH Filtration
Standard spraying gun is not tted with the NH lter, for proper
function is thus necessary to ensure perfect ltering of the application
material before inlet to the gun (e.g. F50 lter with the same
replaceable lter cartridge). Size of the lter cartridge in relation to
the nozzle equivalent size is specied in this reference table.
NOZZLE
EQUIVALENT SIZE
IN 0.1MM
FILTER SIEVE SIZE
MESH
USE
from 16 200 (74 µm) pickle, glazing, clear
lacquer, articial-resin
lacquer
25 - 30 100 (149 µm) primer, effect lacquer,
llers, marking paint
from 40 60 (250 µm) dispersion, latex,
acrylic paint,
polyurethane paint
Daily clean the lter and cartridges as needed, particularly on change
to other NH. Do not let the contaminated lter cartridge dry-up after
removal from the lter, as the NH residuals cannot be removed. The
cartridge must be immersed into proper solvent immediately after
removal from the lter.
The NH lter, which is installed directly to the angle-adjustable NH
tting on the gun, is optionally available. This lter is tted with the
MASCHEN sieve 200, 100 or 50. It is also possible to select the NH
tting thread size between M14x1.5 or G1/4“.

10
EST 651
MAINTENANCE AND CLEANING
1. Pressure air free of water, oil and mechanical impurities must be
used for the gun control.
2. Do not let the NH dry-up in the gun and/or surface. Removal of
the dry-up HN is difcult and it can result in damage of smooth
surface of the part and thus more difcult next cleaning (NH is
easy collected on the damaged surface). Cleaning must be done
by washing with proper solvent, not by immersion into the gun,
as it can adversely affect function and operation life of the gun.
3. When the high-pressure nozzle hole is clogged, do not clean it
by any metal objects, such as wires, pins, use instead special
cleaning wires, or clean the device acc. to instructions specied
in section „Operation“, point 4.
4. When the NH with rough pigments is sprayed, it is necessary to
check the sealing of the closing needle at least once in the shift;
the leak results in discharge of the NH from the hole between
front and back section of the gun body. When the NH leaks
from the hole, the gun must be disassembled and the sealing
module, resp. worn needle must be replaced.
»The replacing is performed as follows: Unscrew the body with
carbide seat (15). Unscrew the stop nut (10) from the back
section and remove the spring (7). With the supplied key
unscrew the closing needle (14), secure the opening needle (6)
by the key in the back section. Remove the opening needle
with the piston backward. Disassemble the 4 screws (11) and
separate the front section from the back one. Press the sealing
module (12) out by means of the supplied key. Upon cleaning of
the sealing module area the disassembly is completed. Visually
check the needle for damage in the contact area with the sealing
elements of the sealing modules, resp. replace the needle for
the new one. Assembly of the new sealing modules requires
skills and care to prevent cutting of both sealing O-rings of
the modules. Apply the machine oil to the module and press it
carefully completely into the gun body. Apply the machine oil
onto the needle with piston, insert it carefully from the back
side to both sealing modules - do not apply force. Assemble the
other parts in reverse order specied in the previous section.
5. Disassembly of the individual gun parts, even if it is easy, shall
not be performed often and needlessly. The assembly works can
be done with common maintenance tools and supplied special
key. Replacing of spare parts of the gun must be assigned
exclusively to the qualied maintenance staff.
6. Keep the gun and other accessory in perfect cleanness, as it is
crucial for fault-free operation.

11
EST 651
Important Rules for Fault-free Operation
»Cleanness of whole automatic gun and high-pressure nozzle.
»Properly treated control air (free of contaminants, water and oil).
»Filtered application material of proper viscosity - adhere to
instructions of manufacturers of the materials.
»Do not exceed necessary pressure for the NH atomizing in vain,
otherwise the operation life of the gun parts may be decreased.
»If the device was used for application of two-component substances
and materials of similar properties, only solvents recommended
by manufacturers of these substances can be used. Cleaning must
be performed always before expiration of the material pot life.
»On completion of work, the device should be regularly cleaned.
Compilation of regular cleaning and maintenance schedule is
recommended to ensure reliable function and life of the device.
CAUTION
Never put your ngers and/or hand to the spraying beam. The liquid pressure
can cause very severe injury with permanent damage of the skin.
Do not disassemble any part of the piston, when the device is pressurized!

12
EST 651
SAFETY OF OPERATION
The product complies with the regulations and standards applicable
to the product of this type.
All workers assigned to operation and maintenance of the device
must be provably acquainted with the safety and health protecting
regulations for work in painting shops and with the high-pressure
valve operation and maintenance manual.
The operating company must ensure training of the operators
and t the workers with specied personal protecting equipments.
Training, resp. supply of additional details, can be requested from
the device supplier.
TESTING OF PRODUCTS
»Each gun is subject to factory functional and pressure testing
PACKING OF PRODUCTS
»According to individual parts for delivery.
DISPOSAL
»After termination of the service life of the parts or the sprayer,
after cleaning the sprayer can be put into sorted waste.
»Packaging materials for the product (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 a separate waste collection.
WARRANTY TERMS
»See Service Manual
No warranty 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.
RELATED 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,

13
EST 651
»The warranty is not applicable for parts of a consumer nature, for
example, sealing elements, springs, jet with needle, stop valve and
the jet for which wearing depends on the abrasive properties of the
applied substance, pressure and other circumstances.
TROUBLESHOOTING
FAULT CAUSE REMEDY
Insufcient spraying
power
»Low pressure of
sprayed material
»Increase the pressure on the
pump
»Clogged lter cartridge
in the pump high-
pressure lter
»Clean, resp. replace the lter
cartridge
»Partially clogged
cartridge
»Clean, resp. replace the
cartridge
»Very small nozzle »Use larger nozzle
Bad spraying pattern
»Large nozzle »Select smaller nozzle
»Low pressure of
sprayed material
»Increase the material pressure
at the pump
»Low viscosity of
sprayed material
»Dilute the applied material
acc. to manufacturer's
instructions
Leak of the pressure NH
from sealing module
»Damaged sealing
module or needle
»Replace the sealing module
and needle for the new ones
Leak of pressure air
from sealing module
- spraying head
improperly opens
or closes at higher
pressure
»Damaged sealing
module or needle
»Replace the sealing module
and needle for the new ones

14
EST 651
SPECIFICATION OF COMPONENTS - EST 651
POSITION NAME IDENTIFICATION NO. QUANTITY
1NH body 651 Not supplied as spare
part
—
2Air body 651 —
3Rotating nozzle Acc. to nozzle table —
4Nozzle —
5Sealing 7 832 577 1
6 O-ring 11x1.8 105 028 1
7 Piston 651 807 404 1
8Opening needle 651 907 406 1
9 Spring 813 656 1
10 Stop element MIX 805 083 1
11 Stop body 807 504 1
12 Stop nut 807 405 1
13 Screw M 4x20 114 142 4
14 O-ring 11x1.8 105 150 1
15 Sealing module 656 907 367 1
16 Sealing 807 380 2
17 Plug G 1/8“ 807 497 1
18 Fitting G 1/8“; M 14x1.5 807 379 1
19 Angle-adjustable tting 129 026 1
20 Angular coupling 131 017 1
21 Holder 807 494 1
22 NH circulation line 907 508 1
23 Closing needle S 906 896 1
24 Closing needle B 906 985 1
25 Body 1,5 S 907 511 1
26 Body 2,5 B 907 714 1
27 Sealing 135 008 1
28 Nozzle holder Exit 301 001 1
29 Fixing nut with protecting orice 134 003 1
ACCESSORIES SUPPLIED wITH DEVICE
Universal key 806 697 1
Assembly key 906 699 1
Allen wrench 3 152 011 1
Allen wrench 5 152 021 1
Test-tube brush 139 100 1

15
EST 651
DIAGRAM OF COMPONENTS OF THE GUN EST 651
15
16 17
20
13
13
1
2
567
8
25
23
26
24
9
10 11
12
29
427
3
16
18
19
28
14
21
22

16
EST 651
DISPLAY OF COMPONENTS
96
162
2,5
81
40
82,5
29
10
40
161
80
2,5

17
EST 651
DIMENSIONAL SKETCH
1. High-Pressure Gun EST 651
2. Electro-Magnetic Valve for Control Air 3/2
3. Air Pressure Regulator
3
1
2
AP
R
NH
inlet - paint inlet
- compressed air
C

18
EST 651

19
EST 651

© 2013 EST + a.s., Ledeč nad Sázavou
EST + a.s. | Podolí 1237 | 584 01 Ledeč nad Sázavou | Czech Republic
Tel.: [phone] | Fax: [phone] | E-mail: [email protected]
www.estplus.cz
N02.035 GB
rev: 01
2014/4
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 EST + a.s. 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.
EST 651