MRS00004EN, V02
Translation of the original operation manual
© Dürr Systems AG 2017
Dürr Systems AG
Application T
echnology
Carl-Benz-Str. 34
74321 Bietigheim-Bissingen
Germany
Phone +49 7142 78-0
Internet: www.durr.com
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 reserved in the event of the
grant of a patent or utility model.
03/2019Atomizer Connection EcoGun - MRS00004EN
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Information about the document
This document describes the correct handling of
the product.
Read the document prior to every activity.
Prepare the document for the application.
Pass on the product only together with the com-
plete documentation.
Always follow safety instructions, handling
instructions and specifications of every kind.
Illustrations can deviate from the technical con-
struction.
Validity range of the document
This document describes the following products:
N91530017
Atomizer link EcoGun AS AUTO pro
Applicable documents
Follow associated drawing, parts list and especially
the following documents in the system documenta-
tion:
MSG00005* - EcoGun AS AUTO pro
MRS00001* - Fluidboard for Paint Robot EcoRP
10 R1100 system
MCU00008* - AUC Control Cabinet for Paint
Robot EcoRP 10 R1100 system
KUKA - Cat track A1- A6 KR 10 R1
100 EX
2G
An asterisk (*) in the document number
replaces the symbol of the language variant.
Pay attention to other relevant documents
on the accompanying CD.
Hotline and Contact
If you have queries or would like technical informa-
tion, please contact your dealer or sales partner.
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TABLE OF CONTENTS
1 Product overview...................................... 5
1.1 Overview
............................................. 5
1.2
Short description................................. 5
2 Safety.......................................................... 5
2.1 Presentation of Notes.......................... 5
2.2 Intended Use....................................... 5
2.3 Residual risks...................................... 5
2.4 Installation schematic.......................... 6
2.5 Staff qualification................................. 6
2.6 Personal protective equipment............ 7
3 Transport, scope of supply and
storage....................................................... 7
3.1 Transport............................................. 7
3.2 Scope of delivery................................. 7
3.3 Unpacking........................................... 7
3.4 Handling of packaging material........... 8
3.5 Storage................................................ 8
4 Assembly................................................... 8
4.1 Safety recommendations..................... 8
4.2 Assembling bracket............................. 9
4.3 Lubricating Hoses.............................. 10
4.4 Putting Hoses in Order...................... 10
4.5 Inserting the Hoses............................ 11
4.6 Assembling Convoluted Hose........... 11
4.7 Lay cables......................................... 12
4.8 Connecting........................................ 12
5 Cleaning and maintenance..................... 12
5.1 Safety recommendations................... 12
5.2
General notes.................................... 14
5.3 Cleaning............................................ 15
5.4 Maintenance...................................... 15
5.4.1 Maintenance schedule................... 15
5.4.2 Replacing Compressed Air Hose... 15
5.4.3 Replacing Material Hose................ 16
6 Faults
........................................................ 16
6.1
Behavior during faults........................ 16
6.2 Defects table..................................... 16
7 Disassembly and Disposal..................... 17
7.1 Safety recommendations................... 17
7.2 Disassembling connections............... 17
7.3 Disassembly...................................... 17
7.4 Disposal ............................................ 18
8 Technical data.......................................... 18
8.1 Dimensions........................................ 18
8.2 Operating conditions......................... 19
8.3 Operating values............................... 19
8.4 Material specification......................... 19
8.5 Operating and auxiliary materials...... 19
9 Replacement parts.................................. 19
9.1 Spare part.......................................... 19
9.2 Order................................................. 19
10 Index......................................................... 20
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1 Product overview
1.1 Overview
Fig. 1: Atomizer link EcoGun AS AUTO pro
1.2 Short description
The atomizer link connects fluid plate, technology
cabinet and the spray gun (hereafter called atom-
izer).
The atomizer link consists of the following compo-
nents:
Support bracket for fastening the atomizer on
the robot
Hose package for supplying the atomizer with
the necessary media
Convoluted hose for guiding supply lines
2 Safety
2.1 Presentation of Notes
The following notes can appear in this instructions
manual.
DANGER!
High risk situation that can lead to serious inju-
ries 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.
Contains additional information and recom-
mendations.
2.2 Intended Use
Use
The atomizer link supplies the atomizer with low
viscosity to medium viscosity fluid coating mate-
rials, their approved detergents and compressed
air in industrial plants.
Operate the atomizer link only within the approved
technical data Ä
8 “Technical data”.
The atomizer link may be used under the following
conditions:
In explosive areas of Ex zones 1 and 2
With flammable fluid coating materials of the
explosion group IIA and their approved purging
agents
With non-inflammable fluid coating materials
and their approved purging agents
Misuse
If used improperly, it can cause serious injuries.
Examples of wrong use are:
Use in explosive areas Ex zone 0
Use of unapproved materials
Unauthorized modifications
2.3 Residual risks
Changed Hose Lengths
Hose and cable lengths are matched for the
process. Changes to the hose lengths can cause
electrostatic discharges and trigger explosions or
fire. Serious injuries or death can be the conse-
quence.
Do not extend hoses.
Do not shorten hoses.
Escaping material and compressed air
When working on the product, spurted material
and leaking compressed air can cause severe
damage to the eyes.
Before working on the product:
Wear eye protection.
Product overview
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Before working on the system:
Rinse the system.
Disconnect the system from compressed air
and material supply system.
Secure the system against being switched on
again.
Depressurize the lines.
Mains disconnecting device on the technology
cabinet is switched of
f and secured against
reconnection.
Noise
If pressurized pneumatic lines under pressure
come off loose, it creates loud noises. This might
damage the hearing.
Before carrying out any work:
Switch off the mains disconnecting device on
the technology cabinet. Secure against recon-
nection.
Depressurize the lines.
Wear ear protection.
Danger from harmful or irritant substances
Coming in contact with hazardous substances can
result in serious injury or death.
Follow safety data sheets.
Wear specified protective equipment.
2.4 Installation schematic
Fig. 2: Installation plan
2.5 Staff qualification
WARNING!
Inadequate qualification
Wrong estimation of dangers can cause serious
injury or death.
– Only sufficiently qualified persons may exe-
cute all work.
– Some work requires additional qualification.
Additional qualifications of specialized per-
sonnel are marked with a “+”.
This document is intended for qualified personnel
in the industry.
Cleaning staff
The cleaning staf
f receives regular instructions
from the operator about the following contents:
Using the product
Handling cleaning tools
Handling cleaning agents
Technical Measures for occupational safety and
health
Mechanic
The mechanic is trained specifically for the field of
work in which he works.
Furthermore, he has the following knowledge:
Guidelines, Standards and Rules of Engi-
neering
Local conditions
Technical Measures for occupational safety and
health
The mechanic is responsible for the following activ-
ities on equipment and components:
Assembly
Waiting
Maintenance
Disassembly
+ additional qualification explosion protection
In addition to the knowledge of the various spe-
cialist fields, the mechanic has knowledge of regu-
lations and safety measures when working in
potentially explosive areas.
Safety
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+ additional qualification high tension tech-
nology
In addition to the knowledge of the various spe-
cialist fields, the mechanic has knowledge of the
following specialist fields
Painting process
High voltage engineering for electrostatic
coating
Dürr Systems
offers special product training for
Ä
“Hotline and Contact”.
2.6 Personal protective equipment
When working in explosive areas, the protective
clothing, including gloves, must meet the require-
ments of DIN EN 1149-5. Footwear must meet the
requirements of EN ISO 20344 and EN IEC
61340-4-3. The volume resistivity must not exceed
100MΩ.
Wear the specified personal protective equipment
when working. Provide the following personal pro-
tective equipment:
Anti-Static Safety Boots
Protect feet from crushing, falling items
and slipping on slippery ground.
Moreover, anti-static safety boots reduce
electrostatic charge by discharging the
electrostatic charges. Safety boots must
comply with the requirements of
EN 61340-5-1. The measured volume
resistivity must not exceed 100MΩ.
Eye protection
Protects eyes from dust, paint drops and
particles.
Protective gloves
Protect the hands from:
mechanical forces
Thermal forces
Chemical effects
Protective workwear
Tight fitting workwear with low tear
strength, tight sleeves and no hanging
parts.
Respirator mask
Protects from hazardous gases, vapors,
dust and similar materials and media.
3 Transport, scope of supply and
storage
3.1 Transport
Requirements:
Hoses are cleaned Ä
5.3
“Cleaning”.
Hoses are disassembled Ä
7.3 “Disassembly”.
1.
Hose ends worn out.
2.
Roll up hoses for transporting. Respect the
bend radius Ä 8.1 “Dimensions”.
3.2 Scope of delivery
Convoluted hose
Preassembled support bracket
Material hose.
Compressed air hoses
Petroleum jelly 40 g
Inspect delivery on receipt for completeness
and integrity.
Report defects immediately
.
Ä “Hotline and
Contact”
Complete parts list in the electronic system docu-
mentation Ä “Applicable documents”.
3.3 Unpacking
DANGER!
Danger of explosion from electrostatic
charges on plastic film and foils
The foil can discharge at the time of unpacking.
Discharge can cause explosion in explosive
areas. Serious injury and death could be the con-
sequence.
– Unpack product outside Ex zones.
1.
Unpack components.
2.
Dispose of packing material.
3.
Remove Velcro tapes on the rolled up convo-
luted hoses.
ð
Do not throw away. Velcro tapes are still
needed.
Transport, scope of supply and storage
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3.4 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.
3.5 Storage
When storing, consider the following points:
Do not store outdoors.
Store in a dry and dust-free place.
Do not expose to aggressive media.
Protect from sunlight and UV radiation.
Maintain bend radii and avoid mechanical
stresses.
Close all openings when storing after disas-
sembly.
Temperature: 10°C to 40°C
Relative humidity: 35% to 90%
Maximum storage period: 2 years from the date
of manufacture
4 Assembly
4.1 Safety recommendations
DANGER!
Damaged material hoses
Material can escape from damaged material
hoses and give rise to explosive atmosphere.
Electrostatic discharges or other sources of igni-
tion can trigger an explosion. Serious injuries or
death can be the consequence.
– Observe the minimum bend radius.
– Do not place hose lines over sharp edges.
– Do not step on the hose lines.
– Replace damaged hoses.
DANGER!
Changed Hose Lengths
Hose and cable lengths are matched for the
process. Changes to the hose lengths can cause
electrostatic discharges and trigger explosions or
fire. Serious injuries or death can be the conse-
quence.
– Do not extend hoses.
– Do not shorten hoses.
WARNING!
Bursting Material Hoses
Material can escape from damaged material
hoses or the material hoses can burst. This can
cause serious injuries.
– Observe the minimum bend radius.
– Do not place hose lines over sharp edges.
– Do not step on the hose lines.
– Replace damaged hoses.
WARNING!
Escaping material
Escaping compressed material can cause
serious injury.
Before carrying out any work:
– Switch of
f material supply system. Secure
against reconnection.
– Depressurize the lines.
– Switch off the mains disconnecting device on
the technology cabinet. Secure against recon-
nection.
Before carrying out any work:
– Wear the specified personal protective equip-
ment.
WARNING!
Use of wrong hose types
The use of unapproved hose types can cause
damage to personal injury and property damage.
– The hose materials are process-dependent.
– Only use approved hose types.
WARNING!
Ignition due to electrostatic discharge
If the hose pipes are not grounded, they can
cause serious injury or death.
– Ground hose pipes through the system, in
which they are installed.
– Ensure that electrostatic charges are dis-
charged.
Assembly
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WARNING!
Danger due to damaged components
Operating the product with damaged compo-
nents can result in serious injury or death.
– Check components at specified intervals for
damage.
– If you detect unusual operating sounds or any
other noticeable aspects, put the product out
of service.
– Contact the manufacturer Ä “Hotline and
Contact”.
– Replace damaged components promptly.
WARNING!
Danger of crushing from robot movements
Robots move at high speeds and high power. If
the robot catches hold of persons, it can cause
life-threatening injury or death.
– Make sure that no people are in the danger
zone of the robot during operation.
– Before carrying out any work:
Moving robots in maintenance position
Switch off the mains disconnecting device
on the technology cabinet.
Secure against reconnection.
4.2 Assembling bracket
WARNING!
Danger of crushing from robot movements
Robots move at high speeds and high power. If
the robot catches hold of persons, it can cause
life-threatening injury or death.
– Make sure that no people are in the danger
zone of the robot during operation.
– Before carrying out any work:
Moving robots in maintenance position
Switch off the mains disconnecting device
on the technology cabinet.
Secure against reconnection.
Personnel:
Mechanic
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
Requirements:
Hand axis is in null position.
Material supply system is switched off and
secured against reconnection.
Mains disconnecting device on the technology
cabinet is switched of
f and secured against
reconnection.
Fig. 3: Assembling Sleeve
Molykote D
1.
Lubricate screws (4) M5 x 10.
2.
Screw-on sleeve (3) into the bores (2) of the
flange plate (1) using four screws (3).
Fig. 4: Assembling bracket (example)
Molykote D
3.
Fit cylindrical pin (2) into the hand axis (1).
4.
Fit flange plate (3) on the cylindrical pin (2).
5.
Lubricate seven screws (5) M5 x 10.
6.
Bolt down flange plate (3) crosswise using
screws (5).
7.
Fit cylindrical pin (4) into the flange plate (3).
Assembly
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8.
Fit flange plate (6) on the flange plate (3).
9.
Fit flange plate (8) on the flange plate (6).
10.
Lubricate screws (7) M6 x 16.
11.
Screw-on flange plates (6) and (8) into the
flange plate (3) using four screws (7).
4.3 Lubricating Hoses
Personnel:
Mechanic
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
Materials:
W32120005 - Petroleum jelly 40 g
Due to the robot movement, hoses rub
against each other and on the inside of the
convoluted hose. These contact areas are
denominated as torsion sections. A constant
film of lubrication is required along the tor-
sion sections.
1.
Place hoses next to each other on a clean and
flat surface.
Fig. 5: Torsion Section (Example)
2.
Spread petroleum jelly evenly on 2 m along the
torsion section (1).
ð
Also apply petroleum jelly between
hoses.
Fig. 6: Lubricating Hoses (Example)
4.4 Putting Hoses in Order
Personnel:
Mechanic
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
NOTICE!
Distorted Hoses and Lines
If distorted and twisted hoses and cables are
installed, the hoses and cables can be damaged
due to robot movement. That could result in
property damage and production disruptions.
– Put Hoses and cables in order before
assembly.
Hoses are lubricated.
1.
Place hoses next to each other on a clean and
flat surface.
2.
Bundle and order hoses.
Hoses must not be contorted or twisted with
each other.
Assembly
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Fig. 7: Fixing Hose Package (Example)
3.
Fix ordered hose package at a distance of 1m
with a Velcro tape (1).
Remove Velcro tapes (1) when inserting
into the convoluted hose.
Fig. 8: Binding Hose Ends (Example)
4.
Bind hose ends together with adhesive tape.
Optionally fasten a pull wire to the hose
ends. Using the pull wire makes it easier
to pull in the hose package into the con-
voluted hose.
4.5 Inserting the Hoses
Personnel:
Mechanic
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
Requirements:
Convoluted hose is disassembled from the
robot.
Follow “Cat track A1- A6” operating instructions
Ä “Applicable documents”.
A pull wire facilitates pulling in the hose
package.
1.
Push cord through the sleeve of the support
bracket.
2.
Push cord into the convoluted hose.
3.
Push hoses up to the first Velcro tape in the
convoluted hose. Remove Velcro tape.
4.
Push hoses up to the next V
elcro tape in the
convoluted hose.
5.
Remove next Velcro tape.
6.
Repeat the process until the hose projects out
of the convoluted hose by about 30 cm.
7.
Mount convoluted hose on the robot by means
of the hose clips.
Follow “Cat track A1- A6” operating instructions
Ä
“Applicable documents”.
4.6 Assembling Convoluted Hose
WARNING!
Danger of crushing from robot movements
Robots move at high speeds and high power. If
the robot catches hold of persons, it can cause
life-threatening injury or death.
– Make sure that no people are in the danger
zone of the robot during operation.
– Before carrying out any work:
Moving robots in maintenance position
Switch off the mains disconnecting device
on the technology cabinet.
Secure against reconnection.
Assembly
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WARNING!
Hovering Load
The robot arm can sink uncontrolled. Serious
injuries or death can be the consequence.
Do not walk underneath robot arm.
Before working on the robot:
– Pause robot.
– Shut down the power supply. Secure against
reconnection.
– Check holding brake on arm 1.
– If necessary, secure robot arm.
Personnel:
Mechanic
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
Anti-Static Safety Boots
Requirements:
Material supply system is switched off and
secured against reconnection.
Material-carrying lines are depressurized.
Mains disconnecting device on the technology
cabinet is switched off and secured against
reconnection.
Support bracket is assembled.
Fig. 9: Assembling Convoluted Hose
1.
Fasten convoluted hose (2) on the robot by
means of the hose clips (1).
Follow operating instructions of the cat
track Ä
“Applicable documents”.
4.7 Lay cables.
The convoluted hose with the interfaces ends at
the foot of the robot:
To the fluidboard:
Material hose
(Coating material and detergent)
To the technology cabinet:
Compressed air hoses
(Control air and/or horn air)
Routing of the hoses depends on the provided
facilities. Route hoses from the robot to the assem-
blies in a professional manner
. Follow diagram and
labels.
4.8 Connecting
Requirements:
Material supply is switched off and secured
against reconnection.
Material-carrying lines are depressurized.
Mains disconnecting device on the technology
cabinet is switched of
f and secured against
reconnection.
Connecting the atomizer links to the atom-
izer, fluid plate and technology cabinet is
described in separate operating instructions
of the components Ä “Applicable docu-
ments”
.
5 Cleaning and maintenance
5.1 Safety recommendations
DANGER!
Risk of death due to explosions
The product is installed in potentially explosive
atmospheres. Disregarding the safety regulations
of there areas may cause death due to explo-
sion.
– Switch off the mains disconnecting device on
the technology cabinet. Secure against recon-
nection.
– Before entering, ensure that the atmosphere
is not explosive.
– Observe all general safety instructions for
handling the total system.
Cleaning and maintenance
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DANGER!
Unsuitable cleaning agents and cleaning
tools
Using the unsuitable cleaning agents can create
a potentially explosive mixture. Tools can be
potential ignition sources.
– Do not use sparking tools, e.g. steel brushes.
– Use a special wooden tool to clean notches
and grooves.
– Do not use any thinner spray guns.
– Do not rub of
f with dry cloth (electrostatic
charge)
– Ensure that:
The flashpoint of the cleaning agent is at
least 5K above the ambient temperature.
Technical ventilation is operational.
WARNING!
Danger of crushing from robot movements
Robots move at high speeds and high power. If
the robot catches hold of persons, it can cause
life-threatening injury or death.
– Make sure that no people are in the danger
zone of the robot during operation.
– Before carrying out any work:
Moving robots in maintenance position
Switch off the mains disconnecting device
on the technology cabinet.
Secure against reconnection.
WARNING!
Escaping material
Escaping compressed material can cause
serious injury.
Before carrying out any work:
– Switch of
f material supply system. Secure
against reconnection.
– Depressurize the lines.
– Switch off the mains disconnecting device on
the technology cabinet. Secure against recon-
nection.
Before carrying out any work:
– Wear the specified personal protective equip-
ment.
WARNING!
Noise
If pressurized pneumatic lines under pressure
come off loose, it creates loud noises. This might
damage the hearing.
Before carrying out any work:
– Switch of
f the mains disconnecting device on
the technology cabinet. Secure against recon-
nection.
– Depressurize the lines.
– Wear ear protection.
WARNING!
Danger due to Chemical Reactions
Cleaning agent can react chemically with the
hoses. Poisonous vapors can arise. Contact with
hazardous vapors can result in serious injury or
death.
– Ensure that the forced ventilation is opera-
tional.
– Only use cleaning agents that are compatible.
– Follow the safety data sheet of the cleaning
agents.
– Wear suitable protective equipment.
NOTICE!
Material damage due to unsuitable rinsing
agent
If the rinsing agent reacts chemically with the
components or the material, components get
damaged.
– Use only the rinsing agents that are compat-
ible with the components and the material.
– Refer to safety data sheet of material manu-
facturer.
NOTICE!
Unsuitable Cleaning Tools
Unsuitable cleaning tools can cause damage.
– Only use cloths, soft brushes and paint-
brushes.
– Do not use abrasive cleaning tools.
– Do not use compressed air for cleaning.
– Do not use any thinner spray guns.
– Do not use high pressure for cleaning agents.
Cleaning and maintenance
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5.2 General notes
For some types of work on the atomizer link, the
robot must be in maintenance position. For those
respective jobs, please refer to the maintenance
position.
Fig. 10: Maintenance position
Fixation
For working on assembled atomizers, secure the
hand axis of the robot against twisting by means of
the fixation.
Personnel:
Mechanic
+ additional qualification high tension tech-
nology
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
Requirements:
Robot is in the maintenance position.
Material supply system is switched off and
secured against reconnection.
Material-carrying lines are depressurized.
Mains disconnecting device on the technology
cabinet is switched off and secured against
reconnection.
Fig. 11: Mounting the Fixation
1.
Fit the fixation (1) with the holes (2) on the pins
(3).
2.
Bolt captive knurled screws (4) into the bores.
ð
Hand axis of the robot is fixed.
3.
Loosen knurled screws (4) after working on the
atomizer
. Remove fixation (1).
Fig. 12: Adjusting screw of the fixation
Screw (5) and (6) are set before dispatch.
Do not release screw connections.
NOTICE!
Damage to the Robot
Putting the robot with mounted fixing into opera-
tion may lead to damage and production down-
times.
Before commissioning:
– Remove fixation.
Cleaning and maintenance
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5.3 Cleaning
Personnel:
Cleaning staff
Protective equipment:
Eye protection
Respirator mask
Protective workwear
Protective gloves
Anti-Static Safety Boots
In addition, also follow the separate oper-
ating instructions of the energy supply
Ä
“Applicable documents”.
Requirements:
Material-carrying lines are purged.
Material supply system is switched off and
secured against reconnection.
Material-carrying lines are depressurized.
Mains disconnecting device on the technology
cabinet is switched of
f and secured against
reconnection.
1.
Moisten a piece of cloth or a soft brush with
cleaning agent.
2.
Damp wipe surfaces.
5.4 Maintenance
5.4.1 Maintenance schedule
Interval Maintenance work
Semi-annually
Check that screw connections are seated tightly, re-tighten if necessary.
Annually
Replacing material hoses:
Ä
5.4.3 “Replacing Material Hose”
Replacing compressed air hoses:
Ä
5.4.2 “Replacing Compressed Air Hose”
5.4.2 Replacing Compressed Air Hose
Personnel:
Mechanic
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
Requirements:
Material supply system is switched off and
secured against reconnection.
Material-carrying lines are depressurized.
Mains disconnecting device on the technology
cabinet is switched off and secured against
reconnection.
Compressed air hose is disconnected from the
atomizer.
Observe separate operating instructions
Ä
“Applicable documents”.
1.
Cut off hose connection.
2.
Fix new compressed air hose on the trimmed
hose using adhesive tape.
3.
Pull out old compressed air hose from the con-
voluted hose at the foot of the robot.
New compressed air hose is drawn in.
4.
Connect hose connection of the new com-
pressed air hose to the atomizer
.
Follow label and diagram.
Cleaning and maintenance
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5.4.3 Replacing Material Hose
Personnel:
Mechanic
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective gloves
Requirements:
Material-carrying lines are purged.
Material supply system is switched off and
secured against reconnection.
Material-carrying lines are depressurized.
Mains disconnecting device on the technology
cabinet is switched off and secured against
reconnection.
Material hose is disconnected from the atom-
izer.
Observe separate operating instructions.
1.
Cut of
f hose connection.
2.
Fix new material hose on the trimmed hose
using adhesive tape.
3.
Pull out old material hose from the convoluted
hose at the foot of the robot.
New material hose is drawn in.
Follow label and diagram.
4.
Connect hose connection of the new material
hose to the atomizer
.
6 Faults
6.1 Behavior during faults
If faults occur:
Purge material-bearing conduits.
Disconnect the material feed and secure
against being switched on again.
Depressurize material-bearing conduits.
Switch off the mains disconnecting device on
the technology cabinet and secure it against
restarting.
Verify that no current is present.
Follow the defects table to correct the fault.
Before beginning troubleshooting:
Ensure a non-explosive atmosphere.
If it is not possible to rectify the fault
Ä “Hot-
line and Contact”.
6.2 Defects table
Fault description Cause Remedy
Material hose has burst. Wear
Replace material hose.
Ä
5.4.3 “Replacing Material Hose”
Compressed air hose has burst or is deformed. Wear
Replace compressed air hose.
Ä
5.4.2 “Replacing Compressed Air Hose”
Convoluted hose is broken. Wear
Replacing convoluted hose:
Disconnect connections.
Disassembling Convoluted Hose
Disassemble hose package.
Insert new hose package.
Assembling Convoluted Hose
Connect hose package.
Damage to the support bracket Collision
Replace support bracket.
Faults
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7 Disassembly and Disposal
7.1 Safety recommendations
DANGER!
Explosive atmosphere
The product is installed in potentially explosive
atmospheres. Disregarding the safety regulations
of there areas may cause death due to explo-
sion.
– Stop the system before carrying out any work.
– Disconnect the system from compressed air
and material supply system.
– Secure the system against being switched on
again.
– Relieve the lines.
– Check for an explosive atmosphere prior to
entering into a potentially explosive area.
– Observe all general safety instructions for
handling the total system.
WARNING!
Escaping material
Escaping compressed material can cause
serious injury.
Before carrying out any work:
– Switch of
f material supply system. Secure
against reconnection.
– Depressurize the lines.
– Switch off the mains disconnecting device on
the technology cabinet. Secure against recon-
nection.
Before carrying out any work:
– Wear the specified personal protective equip-
ment.
WARNING!
Danger of crushing from robot movements
Robots move at high speeds and high power. If
the robot catches hold of persons, it can cause
life-threatening injury or death.
– Make sure that no people are in the danger
zone of the robot during operation.
– Before carrying out any work:
Moving robots in maintenance position
Switch off the mains disconnecting device
on the technology cabinet.
Secure against reconnection.
WARNING!
Noise
If pressurized pneumatic lines under pressure
come off loose, it creates loud noises. This might
damage the hearing.
Before carrying out any work:
– Switch of
f the mains disconnecting device on
the technology cabinet. Secure against recon-
nection.
– Depressurize the lines.
– Wear ear protection.
7.2 Disassembling connections
Requirements:
Robot is in the maintenance position.
Material-carrying lines are purged.
Material supply system is switched off and
secured against reconnection.
Mains disconnecting device on the technology
cabinet is switched off. Secured against recon-
nection.
Atomizer has been disassembled.
Disconnecting the connections from atom-
izer, fluid plate and technology cabinet is
described in separate operating instructions
Ä
“Applicable documents”.
7.3 Disassembly
WARNING!
Danger of crushing from robot movements
Robots move at high speeds and high power. If
the robot catches hold of persons, it can cause
life-threatening injury or death.
– Make sure that no people are in the danger
zone of the robot during operation.
– Before carrying out any work:
Moving robots in maintenance position
Switch off the mains disconnecting device
on the technology cabinet.
Secure against reconnection.
Disassembly and Disposal
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WARNING!
Hovering Load
The robot arm can sink uncontrolled. Serious
injuries or death can be the consequence.
Do not walk underneath robot arm.
Before working on the robot:
– Pause robot.
– Shut down the power supply. Secure against
reconnection.
– Check holding brake on arm 1.
– If necessary, secure robot arm.
Personnel:
Mechanic
+ additional qualification high tension tech-
nology
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
Requirements:
Material-carrying lines are purged.
Material supply system is switched off and
secured against reconnection.
Material-carrying lines are depressurized.
Mains disconnecting device on the technology
cabinet is switched off and secured against
reconnection.
Connections are separated Ä
7.2 “Disassem-
bling connections”.
Fig. 13: Disassembling Convoluted Hose
1.
Loosen clamps (1) on the robot.
Follow operating instructions of the cat
track Ä
“Applicable documents”.
2.
Remove convoluted hose (2) from the robot.
7.4 Disposal
ENVIRONMENT!
Incorrect disposal
Improper waste disposal threatens the environ-
ment and prevents re-use and recycling.
– Always dispose of components in accordance
with their characteristic.
– Collect leaked out operating and auxiliary
materials completely.
– Dispose of operating and auxiliary materials
according to the disposal provisions in force.
– In case of doubt, refer to the local disposal
authorities.
8 Technical data
8.1 Dimensions
N91530017 - Atomizer link EcoGun AS AUTO pro
Denomination Material number
∅
internal
∅
external
Length Material Minimum
bend radius
Paint hose W40030534 4 6 5 m PFA 64 mm
Control air hose W40030001 4 6 10 m PA 30 mm
Horn air hose W40030002 6 8 10 m PA 40 mm
Atomizer air hose W40030002 6 8 10 m PA 40 mm
Technical data
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8.2 Operating conditions
Detail Value
Booth temperature 23° C ±
3 K
Relative humidity 65 % ±
5
8.3 Operating values
Pressure
N91530017 - Atomizer link
EcoGun AS AUTO pro
Detail Value
Material pressure, min. 0bar
Material pressure, max. 4bar
Control air, min. 3.5bar
Control air, max. 6bar
Horn air, min. 0bar
Horn air, max. 8bar
Atomizer air, min. 0bar
Atomizer air, max. 8bar
Compressed air quality
Purity classes ISO 8573-1:2010 1:4:1
Limitations for purity class 4 (pressure dew
point max.):
≤ -3°C at 7bar absolute
≤ +1°C at 9bar absolute
≤ +3°C at 11bar absolute
8.4 Material specification
Suitable Material:
Non-flammable fluid coating materials and their
approved detergents
Non-flammable fluid coating materials and their
approved detergents
Paints hardening due to UV radiation
Media of the explosion group IIA
Media with a viscosity up to 300mPas
8.5 Operating and auxiliary materials
Denomination Material number
Technical petroleum
jelly 40 g
W32120005
Molykote D -
9 Replacement parts
9.1 Spare part
Atomizer link N91530017
Denomination Material number
Atomizer attachment N34850038
Connection set
EcoGun AS AUTO pro
N36960192
Hose 4x6 blue PA W40030001
Hose 6X8 blue PA W40030002
Paint hose W40030534
Hose guard W40020099
9.2 Order
WARNING!
Risk of injury from unsuitable replacement
parts
Parts of third party suppliers may not bear the
loads. Serious injuries and death can result.
– Only use original replacement parts.
Ordering replacement parts, tools and accessories
as well as information on products that are listed
without order number. Ä
“Hotline and Contact”
Replacement parts
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10 INDEX
A
Advanced training ........................ 7
Assembly
Arranging hoses ......................10
Assembling bracket .................... 9
Assembling Convoluted Hose ............11
Compressed air hose .................. 15
Connect ............................ 12
Inserting hoses ....................... 11
Lay cables .......................... 12
Lubricating Hoses .................... 10
Safety notes .......................... 8
B
Brief description ......................... 5
C
Cleaning .............................. 15
Compressed air hose
Assembly ........................... 15
Compressed air quality ................... 19
Contact ................................ 3
Convoluted hose
assembly ........................... 11
disassembly ......................... 17
D
Disassembly ........................... 17
Disassembling Convoluted Hose ......... 17
Disconnecting Connections ............. 17
Disposal .............................. 18
Handling packaging material ............. 8
F
Faults ................................ 16
H
Hotline .................................3
I
Information about the document ............. 3
Installation plan .......................... 6
Intended use ............................ 5
M
Maintenance
Maintenance position .................. 14
Maintenance schedule ................. 15
Material hose
replacement ......................... 16
Material number ......................... 3
Material specification .....................19
Misuse ................................ 5
N
Notes
Representation ........................5
O
Operating and Auxiliary Materials ........... 19
Order .................................19
Other relevant support documents ........... 3
Overview ...............................5
P
Packaging
Handling packaging material ............. 8
remove ..............................7
Personal protective equipment .............. 7
Power values
Pressure ........................... 19
Pressure
Control air .......................... 19
Control pressure pneumatic cylinder ...... 19
Operating pressure ................... 19
Product Overview
Brief description ....................... 5
Overview ............................ 5
Protective equipment ..................... 7
Electrostatic discharge .................. 7
Q
Qualification ............................ 6
Qualification of the personnel ............... 6
R
Replacement parts ...................... 19
Representation
Notes ............................... 5
Residual risks ........................... 5
Robot
Maintenance position .................. 14
S
Safety
Installation plan ....................... 6
Intended use ......................... 5
Misuse .............................. 5
Notes ............................... 5
Residual risks .........................5
Scope of Supply ......................... 7
Scope of the document .................... 3
Service ................................ 3
Storage ................................ 8
Support bracket
assembly ............................ 9
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