DÖRR EcoGun AA AUTO User manual
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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:
N36230001V
EcoGun AA AUTO
Hotline and Contact
If you have queries or would like technical
information, please contact your dealer or
sales partner.
02/2020EcoGun AA AUTO - MSG00008EN2/48
TABLE OF CONTENTS
1 Product overview.......................... 4
1.1 Overview................................ 4
1.2 Short description.................... 4
2 Safety............................................. 5
2.1 Presentation of Notes............ 5
2.2 Intended Use.......................... 5
2.3 Staff qualification.................... 6
2.4 Personal protective equip-
ment....................................... 6
2.5 Residual risks......................... 6
3 Transport, scope of supply and
storage........................................... 7
3.1 Scope of delivery................... 7
3.2 Handling of
packaging material................. 8
3.3 Storage.................................. 8
4 Assembly....................................... 8
4.1 Requirements for the
Installation point..................... 8
4.2 Assembly............................... 8
4.3 Setting the spray jet............. 11
5 Commissioning........................... 11
6 Operation..................................... 13
6.1 Safety recommendations..... 13
6.2 General notes...................... 13
6.3 Selecting air cap.................. 13
6.4 Rinsing................................. 14
6.4.1 Safety recommendations.. 14
6.4.2 Rinsing.............................. 14
7 Cleaning....................................... 14
7.1 Safety recommendations .... 14
7.2 Cleaning............................... 16
8 Maintenance................................ 17
8.1 Safety notes......................... 17
8.2 Maintenance schedule......... 18
8.3 Lubrication........................... 18
9 Faults........................................... 18
9.1 Safety recommendations .... 18
9.2 Defects table........................ 20
9.3 Troubleshooting................... 22
9.3.1 Replace nozzle................. 22
9.3.2 Replace needle and
seals.................................. 23
9.3.3 Replace needle spring
and plunger spring............ 24
9.3.4 Set delay time................... 25
9.3.5 Replace piston seals......... 26
10 Disassembly and Disposal........ 27
10.1 Safety recommendations... 27
10.2 Disassembly....................... 27
10.3 Disposal ............................ 28
11 Technical data............................. 28
11.1 Dimensions and weight...... 28
11.2 Connections....................... 28
11.3 Operating conditions.......... 28
11.4 Emissions........................... 28
11.5 Operating values................ 29
11.6 Type plate........................... 29
11.7 Materials used.................... 29
11.8 Operating and auxiliary
materials............................. 29
11.9 Material specification.......... 29
12 Replacement parts, tools and
accessories................................. 30
12.1 Replacement parts............. 30
12.2 Tools................................... 43
12.3 Accessories........................ 43
12.4 Order.................................. 45
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1 Product overview
1.1 Overview
Fig. 1: Product overview
1 Connecting piece
2 Atomizer air control (R)
3 Horn air control (F)
4 End cap
5 Control air connection (C)
6 Spraying air connection (A)
7 Cap nut with seal
8 Air cap
9 Material connection (M)
10 Fastening bore
11 Housing
12 Leakage bore
1.2 Short description
The spray gun is intended for surface
coating in high pressure area. Compressed
air is used to apply material. The atomized
coating material is fed through high pressure
lines. The operation can be done with paint
circulation or tap line.
Use a nozzle with a suitable diameter,
depending on the requirement.
The following factors influence the spray jet
and therefore the result
Alignment of the air cap
The alignment of the air cap determines
the alignment of the spray jet.
Atomizer air pressure
The higher the atomizer air pressure, the
finer is the atomization and the smaller is
the spray pattern.
Horn air pressure
The higher the horn air pressure, the
softer the spray jet pattern edges
become.
Control air pressure
Opens the needle and controls the mate-
rial outflow.
Material pressure
The higher the material pressure, the
higher the material flow and thus the finer
the atomization. The lower the material
pressure, the higher is the efficiency and
the smaller is the overspray generated.
Nozzle
Product overview
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The higher the bore diameter, the more
the material flowing out. The greater the
angle, the broader is the spray pattern.
Control air pressure is controlled externally
via valves.
The spraying air pressure (A) is controlled
externally via valves. The horn air pressure
and atomizer air pressure can be adjusted
on the spray gun by means of the horn air
pressure (F) and the atomizer air control (R).
The material pressure is controlled externally
via valves.
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.
CAUTION!
Low risk situations that can lead to minor
injuries.
NOTICE!
Situations that can lead to material
damage.
ENVIRONMENT!
Situations that can lead to environmental
damage.
Additional information and recom-
mendations.
2.2 Intended Use
Use
The EcoGun AA AUTO spray gun is only
intended for use in industry and craftman-
ship.
The EcoGun AA AUTO spray gun is solely
intended for automatic coating of surfaces by
one of the following operating methods:
As independent, not hand guided device
As part of a fully automated paint booth
As part of a paint robot
The material is fed through a high pressure
line.
The use is only permitted within the specified
technical data Ä 11 “Technical data”.
The spray gun is approved for use in explo-
sive areas of Ex zones 1.
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.
Atomization of fluid nitrogen
Use of unapproved materials
Use of hose lines that are unsuited to the
material and operating pressure used.
Combination of the spray gun with com-
ponents that are not approved by Dürr
Systems for operation.
Unauthorized modifications
Use in explosive areas Ex zone 0
EX labeling
II 2G T6 X
Safety
02/2020 EcoGun AA AUTO - MSG00008EN 5/48
II - Device group II: all areas except
mining
2G - Device category 2 for gas
T6 - Temperature class T6: Surface tem-
perature, max. 85°C
X - Specific conditions for safe operation
The following conditions must be observed
for safe operation:
The spray gun and the work piece must
be grounded.
Only use conductive lines.
Ensure that static electricity can be dis-
charged.
2.3 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.
Dürr Systems offers special product training
for Ä “Hotline and Contact”.
2.4 Personal protective equipment
Wear the required personal protective equip-
ment when working. Provide the following
personal protective equipment:
2.5 Residual risks
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.
Safety
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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.
Ground the spray gun.
Danger from harmful or irritant sub-
stances
Serious injuries or death can result if you
come into contact with dangerous fluids or
steam.
Spray gun Check regularly for leakage.
Observe local regulations and mainte-
nance schedule.
Ensure that the forced ventilation is
operational.
Follow the safety data sheet.
Wear specified protective equipment.
Escaping material
Material leaking under high pressure can
penetrate the body. Even if the injury looks
like a harmless cut wound, the penetrating
material leads to amputation, serious injuries
can cause death.
Do not try to seal leakages using body
parts, gloves or towels.
If there are injuries, seek medical atten-
tion immediately.
Before working on the product:
Purge the system, in which the product is
installed.
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.
Movable components
There is a risk of death if components or
equipment in the vicinity move unexpectedly.
Switch off and lock out all system compo-
nents against being switched on again
before working on the product.
Noise
The sound pressure level during operation
may cause severe hearing damage.
Wear ear protection.
Do not spend more time then necessary
in the work area.
Hot surfaces
During normal operation the surfaces of
components can get extremely hot. Contact
with it can cause burns.
Before carrying out any work:
Check the temperature.
Do not touch hot surfaces.
Let components cool down.
Wear protective gloves.
3 Transport, scope of supply
and storage
3.1 Scope of delivery
The scope of supply includes the following
components:
Spray gun
Tool kit Ä 12.1 “Replacement parts”
Inspect delivery on receipt for completeness
and integrity.
Report defects immediately Ä “Hotline and
Contact”.
Transport, scope of supply and storage
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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
Storage provisions:
Do not store outdoors.
Store Spray gun only when dry.
Store in a dust-free place.
Do not expose to aggressive media.
Protect from solar radiation.
Avoid mechanical vibrations.
Temperature: 10°C to 40°C
Relative humidity: 35% to 90%
4 Assembly
4.1 Requirements for the
Installation point.
The control air supply and the material
feed to the spray gun must be interrupted
and secured against reconnection.
Lines, seals and screw connections must
be designed to conform to the require-
ments of the spray gun Ä 11.5 “Operating
values”.
A support bracket capable of securing the
spray gun is required.
The control air supply must be adjustable.
The control air supply must have venting.
The material must be fed through a filter
to avoid clogging of the nozzle.
4.2 Assembly
Stationary assembly
Personnel:
Operator
+ additional qualification explosion pro-
tection
Protective equipment:
Protective workwear
Protective gloves
Observe the following at assembly:
Diameter of the fastening bore: 10mm
Nominal diameters: Ä 11.2 “Connections”
1. WARNING!
Sources of ignition may cause explo-
sions!
Ensure a non-explosive atmosphere.
Assembly
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Fig. 2: Assembly
2. Push spray gun with the fastening bore
(1) on the support bracket.
Alignment is not important. Dis-
tance to the work piece: 15 to
25cm
3. WARNING!
Statically charges components may
cause explosions during operation!
Ground the spray gun through the fas-
tening bore or material connection lines, if
the support bracket itself is non-conduc-
tive or is not grounded. Ensure housing
contact.
Resistance between housing and
grounding terminal ≤ 1MΩ.
Fig. 3: Connect
4. The spray gun does not work
when the lines are not connected
correctly.
Connect lines. Ensure correct assign-
ment.
1- Material (M)
2 - Spraying air (A)
3 - Control air (C)
Connect lines to both material
connections for paint circulation
mode.
For tap line mode, connect line to
a material connection. Leave the
other material connection closed
by means of the sealing screw.
Assembly
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Robot assembly
Personnel:
Operator
+ additional qualification explosion pro-
tection
Protective equipment:
Protective workwear
Protective gloves
For a robot assembly, the corresponding
robot version of the spray gun must be used
or the spray gun must be reconstructed with
the components of the optional robot kit
Ä 12.3 “Accessories” for robot version. The
regular inserts are exchanged here against
connecting pieces.
The reconstruction and the connection of the
robot version of the spray gun are described
below.
1. WARNING!
Sources of ignition may cause explo-
sions!
WARNING!
Statically charges components may
cause explosions during operation!
Attach spray gun on the support bracket
as for the stationary assembly and
ground it properly Ä “Stationary
assembly”.
Fig. 4: Assembling robot accessories
2. Lock spraying air connection (A) with the
blind plugs of the robot kits (4).
3. Replace regulating inserts of the atomizer
air control (R) and the horn air control (F)
by the regulating inserts and the screw-in
plug connections of the robot kits (1 and
2).
4. The spray gun does not work
when the lines are not connected
correctly.
Connect lines. Ensure correct assign-
ment.
1- Atomizer air (R)
2 - Horn air (F)
3 - Material (M)
4 - Unused
5 - Control air (C)
Connect lines to both material con-
nections for paint circulation mode.
For tap line mode, connect line to a
material connection. Leave the other
material connection closed by
means of the sealing screw.
Assembly
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Table of contents
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