DÖRR EcoGun AS AUTO pro HD User manual
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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:
N36210013V
EcoGun AS AUTO pro HD
Hotline and Contact
If you have queries or would like technical
information, please contact your dealer or
sales partner.
02/2020EcoGun AS AUTO pro HD - MSG00009EN2/44
TABLE OF CONTENTS
1 Product overview.......................... 4
1.1 Overview................................ 4
1.2 Short description.................... 5
2 Safety............................................. 5
2.1 Presentation of Notes............ 5
2.2 Intended Use.......................... 6
2.3 Staff qualification.................... 6
2.4 Personal protective equip-
ment....................................... 7
2.5 Residual risks......................... 7
3 Transport, scope of supply and
storage........................................... 8
3.1 Scope of delivery................... 8
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 Rinsing................................. 13
6.3.1 Safety recommendations.. 13
6.3.2 Rinsing.............................. 14
7 Cleaning....................................... 14
7.1 Safety recommendations .... 14
7.2 Cleaning............................... 15
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........................ 19
9.3 Troubleshooting................... 22
9.3.1 Replace needle and
nozzle................................ 22
9.3.2 Replace needle seal......... 24
9.3.3 Set delay time................... 25
9.3.4 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................................... 38
12.3 Accessories........................ 38
12.4 Order.................................. 41
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1 Product overview
1.1 Overview
Fig. 1: Product overview
1 Atomizer air control (R)
2 Horn air control (F)
3 Material flow control
4 Control air connection (C)
5 Spraying air connection (A)
6 Cap nut
7 Air cap
8 Material connection
9 Fastening bore
10 Housing
11 Leakage bore
Fig. 2: Air caps overview for various nozzle sets
1 Air cap for round jet nozzle (Rd.)
2 Air cap for rotary jet nozzle (Dr.)
3 Air cap for flat jet
Product overview
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1.2 Short description
The spray gun is intended for surface
coating. Compressed air is used to apply
material. The coating material is fed through
lines. The operation can be done with paint
circulation or tap line.
Use a suitable nozzle set, depending on the
requirement.
Flat jet nozzle set: Generates round and
flat spray patterns (spray pattern width up
to 35 cm).
Round jet nozzle set: Generates round
spray patterns, marking painting and
painting with a directed fine jet. Suitable
for narrow surfaces (up to about 4 cm)
with very low over-spray component e.g.
for glass industry, over-painting of weld
and solder seams.
Rotary jet nozzle set: Generates round
spray pattern. Applies materials with a
very high viscosity (e.g. glue) with high
spraying air requirement. Coated parts
with difficult-to-access shapes and
recesses, for which the dense misting
creates a cover.
The following factors influence the spray jet
and therefore the result:
Alignment of the air cap (only if using a
flat jet nozzle set)
The alignment of the air cap determines
the alignment of the spray jet.
Atomizer air pressure
The higher the atomizer air pressure, the
higher the atomizing and the finer the
spray jet.
Horn air pressure (only if using a flat jet
nozzle set)
The higher the horn air pressure, the
more oval is the spray jet.
Control air pressure
Opens the needle and controls the mate-
rial outflow.
Material pressure
The higher the material pressure, the
higher the material flow.
Control air pressure is controlled externally
via valves.
If the horn air pressure and atomizer air
pressure are not controlled externally, they
can be adjusted on the horn air control (F)
and the atomizer air control (R). The
spraying air pressure (A) is controlled exter-
nally via valves.
You can also regulate the material flow via
the material flow control, if it is not controlled
externally Ä 5 “Commissioning”.
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.
Safety
02/2020 EcoGun AS AUTO pro HD - MSG00009EN 5/44
2.2 Intended Use
Use
The EcoGun AS AUTO pro HD spray gun is
solely intended for automatic coating of sur-
faces by one of the following operating
methods:
As independent, not hand guided device
As part of a semi- or fully automated paint
booth
As part of a paint robot
The material feed can be effected optionally
via the pressure line or under gravitation
(flow beaker).
The product is only intended for use in
industry and craftmanship.
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 and 2.
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
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
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:
Ground spray gun and work piece.
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”.
Safety
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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.
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 escaping under pressure can cause
serious injuries.
Before working on the product:
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.
Safety
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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”.
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.
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.
Transport, scope of supply and storage
02/2020EcoGun AS AUTO pro HD - MSG00009EN8/44
Fig. 3: Assembly
2. Push spray gun with the fastening bore
(1) on the support bracket.
Alignment is arbitrary. Distance 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. 4: 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 con-
nections for paint circulation mode.
For tap line mode, connect line to a
material connection. Close the other
material connection with the locking
screw Ä 12.3 “Accessories” supplied
as accessory.
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 4.2 “Assembly”.
Fig. 5: 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. Close the other
material connection with the locking
screw Ä 12.3 “Accessories” supplied
as accessory.
Assembly
02/2020EcoGun AS AUTO pro HD - MSG00009EN10/44
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