Durr EcoGun 651 Operation Manual

This device is intended for professional use. Before commissioning the device please read this manual. In the case of incorrect use of the spray gun, serious injury to the user or damage to the device may occur.

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

Due to flow 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 flames 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 21°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 specified 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 fingers 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 flammable 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.

flammable liquids. Regarding the flammability class of the coating materials the areas and rooms, where the coating materials are used, must be marked and modified 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 EcoGun 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 fitting for the NH is fitted 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 fitted with the holder with 10 mm hole for fixing 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!

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 classification 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

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 Dürr Systems Czech Republic 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 fly-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 flushed out by the pressure solvent connected to the inlet angle-adjustable fitting for the NH and opening of the needle valve with subsequent injection of the pressure control air 5 bar. Upon cleaning the gun is fitted with suitable high-pressure nozzle or with the holder fitted with the rotating nozzle. The nozzle is fitted directly to the cup nut with protecting cover, which forms part of the gun; the rotating nozzle is fixed to the holder, which is installed directly to the gun upon screwing of the cup nut with protecting cover. The assembled gun is fixed to the manipulator through the holder, connected to the pressure control air 5 bar through the three-way electromagnetic valve of flow ca 150 l/min. and the NH supply from the high-pressure device; then tighten the cut nut on the NH angle- adjustable fitting. The hose must be electro-static conductive for transport of the flammable 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 fitting of the NH circulation line (not part of the supply). The general connection is done acc. to the wiring diagram.

Regarding the flammability class of the coating materials the areas and rooms, where the coating materials are used, must be marked and modified 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 filtration 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 flushing 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, flush 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.

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

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 difficult and it can result in damage of smooth surface of the part and thus more difficult 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 specified 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 specified 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 qualified maintenance staff. 6. Keep the gun and other accessory in perfect cleanness, as it is crucial 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 fingers 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!

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 fit the workers with specified 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,

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 Insufficient spraying power »» Low pressure of sprayed material »» Increase the pressure on the pump »» Clogged filter cartridge in the pump high- pressure filter »» Clean, resp. replace the filter 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

Position Name Identification No. Quantity 1 NH body 651 Not supplied as spare part — 2 Air body 651 — 3 Rotating nozzle Acc. to nozzle table — 4 Nozzle — 5 Sealing 7 832 577 1 6 O-ring 11x1.8 105 028 1 7 Piston 651 807 404 1 8 Opening 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 fitting 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 orifice 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 16 17 20 13 13 1 2 5 6 7 8 25 23 26 24 9 10 11 12 29 4 27 3 16 18 19 28 14 21 22

2. Electro-Magnetic Valve for Control Air 3/2 3. Air Pressure Regulator

Dürr Systems Czech Republic a.s.,| Podolí 1237 | 584 01 Ledeč nad Sázavou | Czech Republic Tel.: +420 569 726 094 | Fax: +420 569 726 096 | E-mail: [email protected] w w w . d u r r . c o m w w w . d u r r - c z . c z N02.035 GB rev: 03 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 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 significantly 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 conflict with the recommendations stated in the operating and maintenance manual; »» Defects arisen for reason of own modifications of the equipment and use of materials and parts that were not approved by the manufacturer for the operation of the equipment. EcoGun 651