DÖRR EcoGun AS MAN DC Operation Manual Download

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EcoGun AS MAN DC
Manual Spray Gun with Direct Charging

MSG00023EN, V03

N36190001V

www.durr.com

Operation manual

Summary of Contents for EcoGun AS MAN DC

Page 1: ...EcoGun AS MAN DC Manual Spray Gun with Direct Charging MSG00023EN V03 N36190001V www durr com Operation manual ...

Page 2: ...ctions and specifications of every kind Illustrations can deviate from the tech nical construction Validity range of the document This document describes the following product N36190001V EcoGun AS MAN DC 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 inf...

Page 3: ... 20 8 2 Maintenance schedule 21 9 Faults 21 9 1 Safety recommendations 21 9 2 Defects table 22 9 3 Troubleshooting 26 9 3 1 Replace needle nozzle and seal kit 26 9 3 2 Replace flat jet control 29 9 3 3 Replace material flow con trol 30 9 3 4 Replace valve set 31 9 3 5 Replace handle 31 9 3 6 Replace hook 32 9 3 7 Replacing sealing ring 33 9 3 8 Replace paint pipe for flammable paints 34 9 3 9 Repl...

Page 4: ... is hand held The spray gun is available with three dif ferent paint connections Straight pipe for flammable topcoats and clear coats Spiral pipe for flammable metallic paints Attached non conductive paint hose 5 or 10m long for non flammable paints 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 C...

Page 5: ...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 outsid...

Page 6: ...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...

Page 7: ...ing 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...

Page 8: ... 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 atmo...

Page 9: ... 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 Assembly 11 2019 EcoGun AS MAN DC MSG00023EN 9 56 ...

Page 10: ...n 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...

Page 11: ...ation 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 ð With a correct installation the spray gun is grounded via the controller and the material supply Fig 11 Ground material supply system 2 Ground material supply system Commissioning 11 2019 EcoGu...

Page 12: ...o 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 Commissioning 11 2...

Page 13: ...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 react...

Page 14: ... 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 ...

Page 15: ...r 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 h...

Page 16: ...he hand This hole must ensure exten sive contact of the palm of the hand with the handle of the spray gun 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 ...

Page 17: ...hed 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 ð The 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 deterg...

Page 18: ... 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...

Page 19: ...onal 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 ...

Page 20: ...ble 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 deat...

Page 21: ...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 ...

Page 22: ...cal spray pattern problems Spray pattern Fault identification Spray jet is distorted Spray jet is bent or tapered Spray jet is too thick in the middle Spray jet is split Spray jet is uneven Faults 11 2019 EcoGun AS MAN DC MSG00023EN 22 56 ...

Page 23: ...zzle and seal kit Spray jet is too thick in the middle Material too viscous Change material consistency Horn air pressure too low Decrease the horn air pres sure via the flat jet control Air pressure too low Increase the air pressure via the total air control Spray jet is split Material too thin Change material consistency Horn air pressure too high Decrease the horn air pres sure via the flat jet...

Page 24: ...e sealing ring Paint drops from the work piece Layer of paint is too thick Reduce feed rate or move spray gun more quickly Viscosity is too low Increase viscosity Evaporation rate of the solvent is too low Use solvent with a higher evaporation rate or adjust evaporation rate by using additives Paint leakage on the nozzle 26 Nozzle 26 is soiled or defective Replace nozzle Ä 9 3 1 Replace needle noz...

Page 25: ...controller H V LED lights up even though the gun trigger is released Air leakage on gun or air hose Rectify air leakage Flow switch in the con troller is defective Replace flow switch Ä Applicable documents operating instructions of the controller Flow switch is contami nated with oil water or dirt Replace flow switch Ä Applicable documents operating instructions of the controller Warning tone or ...

Page 26: ...ater on the mainte nance unit Blow out the air ducts Grounded object near the paint supply Ensure minimum distance of 300mm between isolated paint supply and grounded objects Worn out seal kit 24 Replace seal kit Ä 9 3 1 Replace needle nozzle and seal kit 9 3 Troubleshooting 9 3 1 Replace needle nozzle and seal kit Personnel Operator additional qualification high tension technology additional qual...

Page 27: ...ied open end wrench included in the tool kit 6 Release trigger 11 Fig 27 Replace O ring of nozzle 7 Replace O ring 6 if damaged 8 Pull the trigger 11 completely Fig 28 Disassemble electrode needle 9 Turn electrode needle 7 counterclock wise using the fingers and remove it Fig 29 Disassemble seal set 10 Unscrew and remove the seal kit 8 with the supplied socket wrench included in the tool kit For e...

Page 28: ...needle 12 in the housing 17 Move trigger 11 over the housing until the bores are one over the other 18 Insert collar bushings 10 into the bores 19 Insert and tighten screws 9 20 Pull the trigger 11 completely and keep it pulled 21 Insert seal kit 8 Tighten carefully 22 Insert electrode needle 7 Tighten by hand in clockwise direction 23 Insert nozzle 5 Tighten carefully 24 Release trigger 11 25 Ins...

Page 29: ... Static Safety Boots Requirements The spray gun is disassembled Ä 10 2 Disassembly Disassembly Fig 32 Disassemble valve 1 Open valve 1 2 Unscrew and remove the valve 1 with the supplied open end wrench included in the tool kit Fig 33 Replace O ring of valve 3 Replace O ring 2 Assembly 4 Lightly grease new O ring 2 5 Insert and tighten valve 1 Faults 11 2019 EcoGun AS MAN DC MSG00023EN 29 56 ...

Page 30: ...ty Boots Requirements The spray gun is disassembled Ä 10 2 Disassembly Disassembly Fig 34 Disassemble adjusting screw 1 Unscrew and remove the adjusting screw 1 with the supplied open end wrench included in the tool kit Fig 35 Replace O ring of the adjusting screw 2 Replace O ring 2 Assembly 3 Lightly grease new O ring 2 4 Insert and tighten adjusting screw 1 Faults 11 2019 EcoGun AS MAN DC MSG000...

Page 31: ... spring 2 using pliers 2 Remove valve set 1 Assembly 3 Insert valve set 1 4 Insert compression spring 2 5 Assemble material flow control Ä 9 3 3 Replace material flow control 9 3 5 Replace handle Personnel Operator additional qualification high tension technology additional qualification explosion pro tection Protective equipment Protective workwear Anti Static Safety Boots Disassembly Fig 37 Repl...

Page 32: ...cation high tension technology additional qualification explosion pro tection Protective equipment Protective workwear Anti Static Safety Boots Requirements The spray gun is disassembled Ä 10 2 Disassembly Disassembly Fig 39 Replace hook 1 Loosen and remove screw 2 using a hexagon socket wrench 2 Push hook 1 from the base body Assembly 3 Push hook 1 onto the base body 4 Insert and tighten screw 2 ...

Page 33: ...nd seal kit Disassembly Fig 40 Disassemble cover 1 Remove cover 1 Fig 41 Assemble sealing ring 2 Remove sealing ring 2 Assembly 3 Insert sealing ring 2 4 Fit cover 1 5 Press against the cover 1 such as by using a screwdriver in order to press the sealing ring 2 in NOTICE If the sealing ring is pressed into the housing without the cover the sealing ring may become damaged 6 Assemble trigger Ä 9 3 1...

Page 34: ...ve equipment Protective workwear Anti Static Safety Boots Requirements The spray gun is disassembled Ä 10 2 Disassembly Disassembly Fig 42 Disassemble cover 1 Loosen cover 1 with open end wrench SW22 Fig 43 Loosen nuts 2 Loosen the nuts 2 4 with the supplied open end wrench included in the tool kit 3 Remove paint pipe 3 Faults 11 2019 EcoGun AS MAN DC MSG00023EN 34 56 ...

Page 35: ...paints Personnel Operator additional qualification high tension technology additional qualification explosion pro tection Protective equipment Protective workwear Anti Static Safety Boots Disassembly Fig 45 Disassemble cover 1 Loosen cover 1 with open end wrench SW22 Fig 46 Loosen nylon screw 2 Loosen nylon screw 2 Faults 11 2019 EcoGun AS MAN DC MSG00023EN 35 56 ...

Page 36: ...gh tension technology additional qualification explosion pro tection Protective equipment Protective workwear Anti Static Safety Boots Requirements The spray gun is disassembled Ä 10 2 Disassembly Disassembly Fig 48 Loosening Screws 1 Loosen the nut 2 with the supplied open end wrench included in the tool kit 2 Loosen three screws 1 Fig 49 Disconnect cascade connection 3 Carefully pull housing 6 a...

Page 37: ...e 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 due to escaping material and compressed air Escaping compressed material can cause serious injury Be...

Page 38: ...eatens the environment and prevents re use and recycling Always dispose of components in accordance with their characteristic Ä 11 6 Materials used Collect leaked out operating and auxil iary materials completely Dispose of operating and auxiliary materials according to the disposal provisions in force In case of doubt refer to the local dis posal authorities 11 Technical data 11 1 Dimensions and ...

Page 39: ...ormation Manufacturer 11 6 Materials used Component Material Connections Stainless steel Screws bolts Stainless steel Materials in contact with material Stainless steel PBT PE POM PA 11 7 Operating and auxiliary materials Material Material number Grease tube Syntheso GLEP 1 100g for seals and threads W32020010 11 8 Material specification Suitable Material Non flammable fluid coating materials and ...

Page 40: ...and accessories 12 1 Replacement parts Fig 52 Exploded view Item Denomination Quan tity Material number 1 Plug 1 M48010274 2 Hex screw 2 M41010031 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 40 56 ...

Page 41: ...M05020112 4 Hook 1 M19060021 5 Hex screw 1 M41010030 6 Adjusting screw color 1 M41040155 7 Valve 1 M54990029 8 Trigger 1 M69040007 9 Pipe set straight 1 N36960221 Fig 53 Exploded view Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 41 56 ...

Page 42: ...6 Compression spring 1 M68010285 17 Valve set air 1 N36960226 18 Sealing ring 1 M08010561 19 Housing set 1 N36960212 20 Handle set 1 N36960216 21 Cover 1 M59012347 22 Sealing ring 1 M08010560 23 Basic housing 1 M16120034 24 Seal set 1 N36960206 25 Electrode needle set 1 N36960209 26 Needle set 1 N36960210 27 Cap nut complete 1 M30090045 Replacement parts tools and accessories 11 2019 EcoGun AS MAN...

Page 43: ...nation Quan tity Material number 28 Hex screw 2 M41010033 Fig 55 Replacement parts basic housing Basic housing Item Denomination Quan tity Material number 29 Hex screw 1 M41010033 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 43 56 ...

Page 44: ...nation Quan tity Material number 30 O Ring 2 M08030956 31 Spring 1 M68010291 Fig 57 Replacement part valve Valve Item Denomination Quan tity Material number 32 O Ring 1 M08030952 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 44 56 ...

Page 45: ...or Item Denomination Quan tity Material number 33 O Ring 1 M08030954 Fig 59 Replacement parts nozzle color Nozzle color Item Denomination Quan tity Material number 34 O Ring 1 M08030959 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 45 56 ...

Page 46: ...0562 Handle Fig 61 Replacement parts handle Handle N36960216 for flammable topcoats clear coats and metallic coaths Item Denomination Quan tity Material number 36 Hex screw 2 M41010033 37 O Ring 1 M08030953 38 O Ring 1 M08030955 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 46 56 ...

Page 47: ... paints Item Denomination Quan tity Material number 36 Hex screw 2 M41010033 37 O Ring 1 M08030953 38 O Ring 1 M08030955 39 Hex screw 2 M41010034 40 Stop 1 M47060304 41 Handle end A 1 N36960232 42 Hose support bracket 1 M12210192 43 Collar 1 M05020113 44 Hex screw 1 M41010032 45 Nylon screw 1 M41300119 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 47 56 ...

Page 48: ...pcoats and clear coats Item Denomination Quan tity Material number 46 Seal 1 M08280116 47 Connection 1 M01010241 48 Cover 1 M59012350 49 Pipe straight 1 M34010665 50 Plug sleeve 1 M20050004 51 Nut 1 M30180068 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 48 56 ...

Page 49: ...over 1 M59012350 50 Plug sleeve 1 M20050004 51 Nut 1 M30180068 52 Pipe spiral 1 M34010666 Fig 65 Replacement parts paint hose Paint hose W40130240 5m and W40130241 10m for non flammable paints Item Denomination Quan tity Material number 46 Seal 1 M08280116 53 Connection 1 M01010240 54 Cover 1 M59012349 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 49 56 ...

Page 50: ...r 1 Open end wrench 1 W09020020 2 Cleaning brush 1 W20020008 3 Box wrench 1 W11020037 12 3 Accessories Denomination Material number Extension cable plug connection 10m E09070247 Extension cable plug connection 20m E09070248 Cleaning set 21 parts N36960038 Maintenance kit EcoGun AS MAN DC EC N36960248 Replacement parts tools and accessories 11 2019 EcoGun AS MAN DC MSG00023EN 50 56 ...

Page 51: ...4 Order 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 Risk of injury from unsuitable replace ment parts Parts of third party suppliers may not...

Page 52: ...onnections Air connection 38 Material connection 38 Contact 2 D Defects Table 22 Dimensions 38 Disassembly 38 Discharge energy 39 Disposal 38 Handling packaging material 7 F Flat jet control Replacement 29 H Handle replacement 31 Hook replacement 32 Hotline 2 I Information about the document 2 Installation point 8 Intended use 5 L Labelling according to CSA 5 Lubricant 39 M Maintenance schedule 21...

Page 53: ...ostatic discharge 7 Purge 17 Q Qualification 6 Qualification of the personnel 6 R Replacement Cascade 36 Flat jet control 29 Handle 31 Hook 32 Material flow control 30 Needle and nozzle 26 Paint hose 35 Paint tube 34 Valve set 31 Replacement parts list 40 Replacement parts set Air caps 50 Representation Notes 4 Residual risks 6 S Safety Notes 4 Residual risks 6 Scope of Supply 7 Scope of the docum...

Page 54: ... Material specification 39 Operating conditions 38 Technical Data Connections 38 Tools Tool kit 50 Training 7 Type plate 39 V Valve set replacement 31 W Weight 38 Work area 8 Wrong use 5 11 2019 EcoGun AS MAN DC MSG00023EN 54 56 ...

Page 55: ...11 2019 EcoGun AS MAN DC MSG00023EN 55 56 ...

Page 56: ... Germany www durr com Phone 49 7142 78 0 The reproduction and distribution of this document use and communication of its contents are not permitted without express written approval Offenders will be liable for damages All rights in the event of a patent grant or design registration are reserved Dürr Systems AG 2018 www durr com ...

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