User manual EcoGun 248 - Dürr Systems Czech Republic as
Contents
1. 6 bar Operating air pressure recommended 2 5 3 5 bar Maximum pressure of applied material 6 bar Air CONSUIMPUOMN svi 130 410 NI min Power range of sprayed coating material g min Spraying distance uscar iinciiaes 150 190mm Air quality Max deW DOING reus a Max oil content ras acia tienes 1 mg m Max size of solid partici n 5 um Max tempera CUS ganci 40 C Gun weight standard i 521g Connecting sizes Alf SUDDIY iii G 1 4 Supply of coating material vivsssicinnia di G 3 8 Environment classification Ex Il 2 GX It depends on size of nozzle assembly and type of coating material COMMISSIONING Before commissioning the gun must be cleaned from preservative substances by suitable degreasing agent flush the gun with solvent suitable for the coating material to be applied The gun is factory adjusted and prime sprayed quality test Pressure air is to be supplied through following hose up to 10 meters nominal inner diameter 8 mm over 10 meters nominal inner diameter 9 5 mm OPTIONS FOR COATING MATERIAL SUPPLY EcoGun 249 model spraying gun features following supply options Lower supply Fluid connector AM 38 fitting G 3 8 DIRECT CONNECTION OF AIR QUICK COUPLINGS TO THE GUN The gun design enables connection of air quick couplings to the gun The air input fitting may house the quick coupling mandrel2. Clean the holes in the nozzle assembly very carefully as this is the most important part affecting the spraying quality During cleaning of the gun front part keep the gun with nozzle directing downward thus the entry of solvent with residues of the coating material to gun air channels is prevented as well as subsequent damage to the gun function after each cleaning connect the gun to the pressure air supply and blow out the ai channels by actuation of lever WU O Connect pressured air Pas NEEDED after cleaning grease the level bushing 27 operational part of the control screw 21 and threads of control screws with suitable grease MOLYKOTE Cu 7439 The gun is washed in appropriate solvent corresponding to type of sprayed coating material Pihe gun can be washed in the gun washing machine However never immerse the gun to solvent and prevent long term stay of gun in the solvent vapour area 13 EcoGun 249 IMPORTANT PRINCIPLES FOR HIGH QUALITY FUNCTION Proper choice of the assembly nozzle acc to type of the coating material and size of the object if you have any special requirements please contact the sales technical depts of the manufacturer Properly treated air for spraying free of dirt water and oil perfectly filtered Filtered coating material of correct viscosity and free of dirt follow and adhere to the instructions of the manufacturers of particular coating materials Properly prepared cle
3. e g type SFIW 13 from RECTUS The manufacturer recommends to use brand quick couplings with low pressure loss and long operating life The quick couplings may be used to the air inlet only during application of water based coating materials which do not require electro static drop in ADJUSTING OF GUN The gun does not require any adjustment when basic maintenance requirements are followed Each gun is factory adjusted and prime spayed Upon disassembly and reassembly due to replacement of the nozzle assembly or worn components it is necessary to inspect adjustment of following elements EcoGun 249 EcoGun 249 10 ADVANCE TIMING ADJUSTMENT Start of air before opening of coating material outlet Reproduction of D rr Systems Czech Republic component quality ensuresthattheadvancetimingispermanently setduring common replacement of the nozzle set and d not require any adjustment Needle gland is tightened semi automatically with possible manual tightening OPERATION Important prerequisite of the high quality proper function is proper maintenance The gun is designed in such manner that the require ments may be easily adhered to The nozzle assemblies are made from stainless steel AISI 304 and they are delivered as spare parts as complete nozzle with needle To achieve high quality spraying it is necessary to take care of cle anness of the nozzle assembly prevention of nozzle neck damage cleanness and integrity of v
4. ALVE SET IDENT NUMBER 907 964 Position NAME IDENTIFICATION NO UANTITY 13 Sealing U1 135 016 1 15 Pin 907 722 2 37 Seal roller 135 002 1 39 Assembly mandrel 806 403 NEEDLE SEALING SET IDENT NUMBER 906 765 Position NAME IDENTIFICATION NO UANTITY 9 Gland 70 806 674 1 10 Spring guide 806 675 1 11 Gland spring 804 290 1 12 Gland screw 806 466 1 7 y Of o2 21 EcoGun 249 TROUBLESHOOTING FAULT The gun does not spray or spray intermittently CAUSE AIR RELEASED FROM NOZZLE Empty vessel for coating material Loose nozzle in gun body Damaged gland in gun body Nozzle hole clogged Coating material amount control closed No AIR FROM JET REMEDY Add coating material supply Properly tighten the nozzle Replace the gland Clean Set control Closed air supply Closed air supply control Open supply Open air control on gun Resulting spray curved or clubbed Dirt in annular section of jet and nozzle Damaged jet hole or nozzle neck Dirt in wing or auxiliary holes Improperly tightened jet Remove dirt do not damage jet Replace for a new one Clean do not damage the holes Properly tighten the jet Resulting spray features little colour in the middle Low flatness of resulting spray To much air to wings High air pressure for spraying Low viscosity of coating mat
5. D U P a OPERATION MANUAL EcoGun 249 air spray gun Ex Il 2 GX THESE SPRAY GUNS HAVE BEEN ENGINEERED FOR PROFESSIONAL USE READ AND UNDERSTAND THIS OPERATION MANUAL BEFORE OPERATING DOING ANY SERVICE OR MAINTENANCE PROCEDURE INCORRECT USE MAY RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE SPRAY GUN CE D rr Systems Czech Republic a s Podoli 1237 584 01 Lede nad S zavou CZECH REPUBLIC VAT code CZ 25 25 37 35 EC DECLARATION OF CONFORMITY PRODUCT NAME Low pressure manual spray gun TYPE EcoGun 119 EcoGun 249 and their modifications VARIANTS USAGE Liquid paint coating COMPLIES WITH European directives 2006 42 EC 94 9 EC 2003 10 EC 2002 44 EC STANDARDS USED EN ISO 5349 1 EN ISO 12100 EN 13463 1 EN ISO 13732 EN 1953 A1 EN 1127 1 EN ISO 3746 ATEX 94 9 EC Clan II Category 2 Mark Ex 11 2G X Notified body NB 1026 FTZ Ostrava CZ Tech File 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 EN ISO 9001 2009 APPROVED BY Ing Jan Hevessy CEO amp Chairman of the In Lede nad S zavo Date 12 9 2014 E01 042 GB rev 01 2014 9 CO
6. NTENTS SAFETY REGULATIONS Vibrations and noise Work with gun Personal protection during work EQUIPMENT USE AND DESCRIPTION EcoGun 249 spraying gun Air path used material Coating material path used material Advantages of new gun TECHNICAL PARAMETERS COMMISSIONING Options for coating material supply Direct connection of air quick couplings to the gun ADJUSTING OF GUN Advance timing adjustment OPERATION Control of coating mataerial amount Control of spray shape Control of air supply to gun Replacement of nozzle assembly Replacement of needle gland Replacement of air valve sealing MAINTENANCE AND CLEANING Cleaning and maintenance principles Important principles for high quality function Other optional accessory OPERATION SAFETY PRODUCT TESTING PRODUCT PACKING DISPOSAL WARRANTY TERMS The warranty is not provided COMBINATIONS OF NOZZLE ASSEMBLIES O00 00 000 N nn UI AAA EcoGun 249 EcoGun 249 SPECIFICATION OF COMPONENTS Figures of components Accessory delivered with device Needle sealing set ident number 906 668 Air valve set ident number 906 552 TROUBLESHOOTING SAFETY REGULATIONS Appropriate standards apply to spraying and handling with flammable liquids Areas and rooms where coating materials are handled with shall be identified and adapted regarding the flammability of the coating materials in compliance with applicable standards and regulations In case the spraying guns are used and
7. aned and maintained spraying gun Adhere to the recommended air pressure for atomising Y Y Y Y Y AARIANTS OF NH suPPLY TYPE Car No SET CONTENT Hose set 8 6 fig 1 907 436 Hose is not part of delivery Hose set 6 4 fig 2 907 437 Hose is not part of delivery pic 1 pic 2 co Lo OTHER OPTIONAL ACCESSORY Pressure control with separator Air contaminant separator Hose quick couplings Hoses Compressor Personal protection equipments 14 EcoGun 249 OPERATION SAFETY The product complies with regulations ad standards related to the products of such nature All employees authorised with operation and maintenance of the equipment shall be provably acquainted with safety and health regulations for work in paint shops and with the spraying gun operating and maintenance manual The operators shall perform training of the personnel and provide them with specified personal protecting equipments Training resp more detailed information can provide the equipment supplier upon request RELATED STANDARDS EN ISO 12100 EN ISO 13732 1 EN 894 EN ISO 4414 EN 1037 A1 EN 1070 EN 1127 1 EN 13463 1 EN 60079 0 EN 60721 3 7 A1 EN ISO 11204 PRODUCT TESTING Each piece of equipments is subject to factory functional and pressure testing PRODUCT PACKING Depends on individual parts of the delivery DISPOSAL On expiration of the components resp gun operation life
8. binations of DS 2 Nozzle Set Nozzle Sets 1 3 Body EcoGun 119 Not supplied 4 O ring 33 3 x 1 6 105 081 1 5 O ring 105 173 6 Air Fitting 808 378 1 7 Air Supply Control 908 374 1 8 O ring 105 031 1 9 Gland 70 806 674 1 10 Spring Quide 806 675 1 11 Gland Spring 804 290 1 12 Gland Screw 806 466 1 13 Sealing U1 135 016 1 14 Piston Seat 135 017 1 15 Spindle 907 722 1 16 Spindle Spring 124 082 1 17 Bushing L 808 095 1 18 Pressing Spring 124 089 1 19 Bearing L 808 097 1 20 End Stop Screw 808 096 1 21 Control Screw 808 380 1 22 Sealing 806 948 1 23 Control Bushing 808 379 1 24 Control Wheel 806 464 1 25 Ring Set 906 439 1 26 Screw 114 247 1 27 Trigger pin 808 377 1 28 Ring 3 2 117 017 1 29 Trigger 806 510 1 30 Fluid connector AM 38 808 425 1 31 Reinforcement bushing 129 041 1 32 Clamping ring SF 806 882 1 33 Cap nut G 3 8 807 433 1 34 Reinforcement bushing 129 014 1 35 Clamping ring SF 129 012 1 36 Cap nut G 3 8 807 433 1 37 Sealing of the roller 135 002 1 38 Locking nut 807 709 1 18 EcoGun 249 FIGURES OF COMPONENTS 19 EcoGun 249 ACCESSORY DELIVERED WITH DEVICE Position NAME IDENTIFICATION NO UANTITY 40 Allen key size 7 152 019 1 41 Universal wrench 806 697 1 42 Assembly wrench 806 698 1 43 Cleaning brush 139 100 1 44 Gun hook 904 599 1 45 Sealing 807 708 1 46 Insert 128 670 1 47 Assembly rod 907 520 1 25 Ring set 906 439 1 20 EcoGun 249 AIR V
9. erial Low amount of air to wings Low air pressure for spraying High viscosity Set proper amount by control of spray width Decrease the air pressure Adjust viscosity acc to manufacturer instructions Set higher amount by control of spray width Increase pressure Properly adjust and measure with viscosimeter 22 EcoGun 249 23 WARRANTY CARD TITLE AND TYPE OF PRODUCT PRODUCTION NUMBER EcoGun 249 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 D rr Systems Czech Republic 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 Partsandmaterialsofregularoperating consumption statedinthe documentation supplied with the product and parts whose life span is adequate to application conditions Defects arisen by ine
10. ery precise holes in the air jet Upon replacing or cleaning of the nozzle it shall be properly tightened to make it tight Recommended torque on the nozzle is 10 Nm The gun is factory adjusted and prime sprayed quality test D A KR Sea CONTROL OF COATING MATAERIAL AMOUNT This regulation restricts the lift of the needle which throttles the flow of material in the nozzle By loosening the locking nut 38 and subsequently turning the stop screw 20 the lift of the needle and the volume the material is changed After reaching the lift of the locking nut 38 tighten it again We recommend using this method only temporarily A more suitable manner is to select a smaller nozzle set or reducing the pressure of the sprayed air if it will not reduce the quality of the spraying Fully tightening of the stop bolt will prevent the lift of the needle and any undesired spraying during handling CONTROL OF SPRAY SHAPE Air runs out of the wing holes in the air jet and the air widens the beam shape Its amount is controlled by turning of the control wheel Left side turning increases supplied air amount and enlarges the beam EcoGun 249 CONTROL OF AIR SUPPLY TO GUN This control 7 is located on the gun butt and enables throttling the air supply amount to gun and thus the operator can decrease the air amount for spraying resp completely stop the supply without any handling on the air control in distribution l
11. ines REPLACEMENT OF NOZZLE ASSEMBLY After dismantling the stop bolt 20 and the securing nut 38 remove the spring of the needle 18 with the bearing of the needle 19 and the needle 2 For easier handling press the lever which will suppress the needle from the rear part of the gun Remove the nozzle from the front part of the gun by unscrewing 1 Dismantle the nozzle from the gun by the attached wrench 41 Before assembly of a new nozzle set it is recommended to clean the assembly areas Attach the new nozzle and fully tighten The recommended tightening moment on the nozzle is 10 Nm Behind the gun insert the needle with spring and bearing and replace the locking nut bolt stop and nozzle REPLACEMENT OF NEEDLE GLAND Upon any leakage it is necessary to re tighten the gland 9 by the gland S screw 12 by clockwise rotation of the screw to condition where the gland is again tight In case the gland screw cannot rotate and the gland still leaks the gland shall be replaced for a new one Unscrew the gland screw 12 and remove the old gland 12 assembly Before installation o new gland clean the gland area Insert new gland 9 spring guide 10 and gland spring 11 from the needle sealing set Tighten the gland screw to ensure proper tightness of the gland REPLACEMENT OF AIR VALVE SEALING Disassembly pic a Disassemble the end stop screw 20 and locking nut 38 with spring 18 bearing 19 and
12. ing materials which are intended to application by spraying and whose chemical composition does not disturb the spraying gun components Recommended distance of nozzle mouth to the sprayed surface spraying distance depends on side of nozzle assembly and type of coating material it ranges from 150 to 190 mm Semi automatic needle seal ensures maximum period of maintenance free and reliable operation of the seal Mechanical re tightening of the needle seal enables increased intervalbetween service repairs The system jointsadvantages of automatic and mechanical design of the needle seal re tightening Options EcoGun 249 Option EcoGun 249 with air cap LP is equipped with nozzle setups No O8LP 10LP or 12LP Is designed especialy for high quality sur face finish in the automotive industry Option EcoGun 249 with air cap LC is equipped with nozzle setups No 14LX 16LX 18LX 20LX or 22LX Is designed for the application of a wide range of applies materials by air spraying in the industry car varnishing workshops plastic industry wood processing kera mic industry particularly for the application of base paints where an increased output of the sprayer is necessary EcoGun 249 SPRAYING GUN This type of the gun can handle following types of the coating ma terials Solvent based synthetic nitro acetone polyurethane epoxy and acrylic primers fillers and finish varnishes Water based acrylic silicate silicone and po
13. it may be disposed to the sorted waste material upon cleaning The packing materials of the product cat no 200101 see Decree of the Environment Protection Ministry no 381 2001 Coll shall be disposed as mixed municipal waste Used paper packing dispose to the separate waste material WARRANTY TERMS see service manual 15 EcoGun 249 16 THE WARRANTY IS NOT PROVIDED Y Y Y For mechanical damage of rough handling with the product For damage wearing or fault caused by improper or non adequate maintenance abrasion corrosion or use of non original spare parts components and materials For non allowed or non professional intervention on the device The warranty does not apply to easily worn components such as sealing elements springs and nozzle with needle at which the wearing depends on abrasive properties of the applied materials pressure and other circumstances EcoGun 249 COMBINATIONS OF NOZZLE ASSEMBLIES AIR JET NOZZLE ASSEMBLY TYPE IDENTIFICATION NO TYPE IDENT No O8LP 908 438 LP 908 435 10LP 908 439 12LP 908 440 14LX 908 454 16LX 908 455 LC 908 450 18LX 908 456 20LX 908 457 22LX 908 458 Nozzle set consists of nozzle with distribution plug and needle 17 EcoGun 249 SPECIFICATION OF COMPONENTS Position NAME IDENTIFICATION No UANTITY 1 Air Cap Specified in table 1 Com
14. lvents and thinners may cause chemical burn During nozzle assembly disassembly cleaning or each interruption of work proceed very carefully and ensure locking of the gun to prevent eventual starting Thus you may prevent the injury Before any repair the gun shall be disconnected from the pressure air and applied material CAUTION All persons authorised to operation ad maintenance of the equipment must be E provably acquainted with the safety regulations and with the operation and maintenance manual for the equipment EcoGun 249 PERSONAL PROTECTION DURING WORK During spraying and handling with the application materials and during cleaning of the equipment follow instructions and recommendation of manufacturers of particular materials Use suitable work protection aids to protect skin respiratory tract and eyes clothes gloves respirators protecting masks resp breathing apparatuses goggles protection creams etc EQUIPMENT USE AND DESCRIPTION EcoGun 249 air spraying gun is a gun with lower pressure supply of the material The gun features complete stain less path for applied material Atomising system with decreased pressure of atomising air at the gun jet mouth similar to RP system The gun features very good grip and balance in hand as well as easy less wearisome handling Assembly threads of connecting elements are glued with suitable sealing compound LOCTITE 542 The spraying gun can handle all types of coat
15. lyurethane substances and other application materials of similar properties Work environment IE 72 acc to CSN EN 60721 3 7 AIR PATH USED MATERIAL Gun body Al alloy with Ni surface layer Sealing elements POM PE PTFE Parts Stainless steel brass COATING MATERIAL PATH USED MATERIAL Gun body Lined stainless steel AISI 304 Sealing elements PTFE Parts Stainless steel AISI 304 ADVANTAGES OF NEW GUN Progressive design and ergonomic shape of the gun body guarantee very good grip Extremely light gun of weight only 521 g and in standard variant only 544 g High transfer efficiency exceeding legislative requirements related to the environment New atomising system with decreased atomising output pressure at the jet mouth high atomisation fineness and beam distribution quality New series of modernized nozzle assemblies New ergonomic control elements of completely totally new design Normally supplied nozzle assemblies featuring perfect tightness Special gun body surface treatment guarantees perfect cleanability Gun body sealing system made from very resistant materials guarantees resistance against cleaning in washing machines New PTFE sealing elements Semi automatic gland increasing operation life High resistance against solvents High inspection level of each product Y Y Y Y Y Y Y Y Y Y Y Y Y EcoGun 249 EcoGun 249 TECHNICAL PARAMETERS Maximum allowed input air overpressure
16. needle 2 Use wrench 41 to disassemble the control bushing 17 with spring 16 from the gun Press lever to insert the pin 15 to the gun and then remove it Insert to the gun assembly key 42 insert the mandrel assembly 38 from the air valve set insert needle to the mandrel and press lever to press out the seal roller 13 from the gun Seal will remain on the key assembly 42 which then pull out from the gun pic b 11 EcoGun 249 Use the assembly mandrel to press out the sealing from removed control bushing Insert the mandrel 39 to the control bushing and screw in the end stop screw 20 to press the sealing U1 13 out of the control bushing pic a pic b Assembly Insert the new sealing 37 from the air valve set to the assembly wrench 42 and tap it to the gun body Similarly insert the sealing U1 13 into disassembled control bushing Insert new pin 15 from the set to body screw in the spring with control bushing to the body insert needle and screw in the end stop screw with spring and spring bearing We recommend to leave repairs to the authorised service cent re see service manual 12 EcoGun 249 MAINTENANCE AND CLEANING CLEANING AND MAINTENANCE PRINCIPLES Preventdrying of the coating material in the gun or on the surface its removal when dried is difficult and may result in damage of smooth surface CAUTION Do not use any metal items for cleaning
17. operated in other countries then relevant national standards and regulations apply Electrostatic charge electricity can occur under certain circumstances due to flow of air and liquids During discharge it may result in sparking and or flaming To prevent such situation it is necessary to use hoses with guaranteed electrostatic drop in particularly for coating materials with ignition point below 21 C nitro acetone coating materials etc and some coating materials of 2nd flammability class preheated to higher temperature it is necessary to ensure certified hoses with such identification CAUTION Do not use the basic variants of the guns for solvents from chlorohydrocarbon family as e g 1 1 1 trichlorethan and metylchloride may cause chemical reaction with aluminium and with galvanized resp zinc coated parts and thus create explosive mixture with eventual explosion effect 3 VIBRATIONS AND NOISE The vibration level transferred to hands does not exceed maximum allowed value acc to NV 272 2011 Coll The noise level depends on size of nozzle system and on input pressure value which ranges from 80 to 90dB A Allowed permitted nose level acc to act no 272 2011 Coll is 85dB A and thus it is necessary to use hearing protection equipments WORK WITH GUN The spraying gun operates with air pressure up to 6 bar air pressure recommended 2 5 3 5 bar Do not focus the gun to yourself other persons or animals So
18. xpert 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 2014 Durr Systems Czech Republic a s Lede nad S zavou www durr cz cz Durr Systems Czech Republic a s Podol 1237 584 01 Lede nad S zavou CZECH REPUBLIC Tel 420 569 726 094 Fax 420 569 726 096 E mail info cz durr com N01 058 GB rev 01 2014 9
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