ITW Gema EASY 2-F Guide

Issued 07/02
Operating Instructions and Spare parts list
EASY 1-F
Powder Coating Equipment
E
0102 II (2) D

22 EASY 1-F / EASY 2-F
Issued 07/02
Mains connectionAux
Gun
1.1 IN
5 ... 10 bar
73...145 PSI
1.4 2.2 2.3
2.1
1.3
1.2 1.5
Input voltage:
Input power:
Degree of protection:
Output:
Corresponding guns:
85 – 264 V
47 – 440 Hz
65 VA
IP 54
10 V 1,2 A
EasySelect
POWDER GUN CONTROL
TYPE EASYTRONIC
CONNECTIONS ON THE REAR OF THE EASYTRONIC CONTROL UNIT
11413 2
3
5
4
6
7
8
10
9
11
12
1EasyTronic control unit
2EasySelect Manual powder gun
3Pneumatic hose with quick-
release connection
4EasyFlow Injector
5Powder hopper cover
6Powder hopper
7Swivel wheel
8Pneumatic wheel
9Fluidizing air unit
10 Mobile frame with hand rail
11 Venting tube (AIRMOVER) with
Ball valve
12 Clamping element
13 Shelf
14 Gun/Hose holder
EASY 1-F ELECTROSTATIC POWER MANUAL EQUIPMENT
1.1 IN Compressed air input
1.2 Conveying air connection
1.3 Supplementary air
connection
1.4 Rinsing air connection
1.5 Fluidizing air connection
2.1 Power supply
(85–264 V)
2.2 Gun connection for the
EasySelect Manual gun.
PG 1 Manual gun cannot be
connected!
2.3 Output for Vibrator (EASY 1-B
only) and Stirrer control
(EASY 1-S only )
Grounding connection

21
EASY 1-F / EASY 2-F
Issued 07/02
Table of Contents
Directions for use
Safety rules for electrostatic Powder coating
Technical Data of the EASY 1-F / EASY 2-F Powder Manual coating Equipment
About these Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EASY 1-F / EASY 2-F Electrostatic Powder Manual Equipment . . . . . . . . . . . . . . . . . . . . . . 2
1. Field of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Scope of delivery for EASY 1-F (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Supplementary material for EASY 2-F (Standard) . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation of the Powder coating equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description of Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EasyTronic Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Preparation for Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
a) Filling the Powder hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
b) Switch the Booth on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
c) Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Daily Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
a) Powder fluidizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
b) Regulating the powder output, and powder cloud . . . . . . . . . . . . . . . . . . . . . . . . 7
Set Total air volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Select Powder output volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Select electrode rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
c) Powder coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
d) Remote control through the Powder gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
e) Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
f) Powder hose rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Colour change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
a) Daily Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
b) Weekly Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
c) When the Powder coating equipment is not used for a number of days: . . . . . . 9
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning the powder hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning the EasySelect Manual powder gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EASY 1-F / EASY 2-F Pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ordering Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EASY 1-F Powder Coating equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powder hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

22 EASY 1-F / EASY 2-F
Issued 07/02

Safety regulations - H V. 2004
Safety regulations for electrostatic manual powder spraying
equipment
1 Safety symbols (Pictograms)
This chapter sets out the fundamental safety regulations that must be followed by the user
and third parties using the powder spraying equipment.
These safety regulations must be read and understood before the powder spraying equipment
is used.
The following warnings for ITW Gema operating instructions are shown here with their
meanings. The general safety precautions must also be followed as well as the regulations in
the operating instructions.
Danger! Danger due to live electricity or moving parts. Possible
consequences: Death or serious injury.
Warning! improper use of the equipment could damage the machine
or cause it to malfunction. Possible consequences: minor
injuries or damage to equipment.
Information! useful tips and other information.
2 Conformity of use
1. The manual powder spraying equipment is built exclusively for the normal
application of powder coating according to current recognized technological and
safety regulations.
2. Any other use is considered as non-conform. The manufacturer is not responsible
for damage resulting from improper use of this equipment; the end-user alone is
responsible. If the manual powder spraying equipment is to be used for other
purposes or other substances outside of our guidelines then ITW Gema AG
should be consulted.
3. Observance of the operating, service and maintenance instructions specified by
the manufacturer is also part of conformity of use. The hand held powder
spraying equipment should only be used, maintained and started up by trained
personnel who are informed about and are familiar with the possible hazards
involved.
4. Unauthorized modifications to powder spraying equipment exempts the
manufacturer from any liability from resulting damage.
5. The relevant accident prevention regulations, as well as other generally
recognized safety regulations, occupational health and structural regulations are
to be observed. (see appendix “Standards”)
6. Furthermore the country-specific safety regulations must be observed.
Explosion protection Type of protection Temperature class
0102 II (2) D IP54 T6 (zone 21)
T4 (zone 22)

V. 2004
Safety regulations - H
3 Safety Technical Information
3.1 General information
The powder spraying equipment from ITW Gema is safe to operate and is built according to
the latest technological specifications. This equipment can be dangerous if it is not used for
its specified purpose. It should also be noted that because of this there exists:
- A danger to life and limb of the user or third party.
- A danger of damage to the equipment and other machinery belonging to the user.
- A hazard to the efficient operation of the equipment.
1. The powder spraying equipment should only be started up and used once
the operating instructions have been carefully studied.
2. Before every Start-up check the equipment for operational safety (regular
servicing is essential)!
3. Safety regulations BGI 764 and VDE regulations DIN VDE 0147, Part 1, must
be observed for safe operation.
4. Safety precautions specified by local legislation must be observed.
5. The plug must be disconnected before the machine is opened for repair.
6. Only original ITW-Gema replacement parts should be used, because the
explosion protection will also be preserved that way. Damage caused by
other parts is not covered by guarantee.
7. If ITW-Gema powder spraying equipment is used in conjunction with
machinery from other manufacturers then their safety regulations must also
be taken into account.
8. Caution must be exercised when working with a powder/air mixture! A
powder/air mixture in the right concentration is flammable! No smoking
during powder coating.
9. As a general rule for all powder spraying installations, persons with
pacemakers should never enter high voltage areas or areas with
electromagnetic fields. Persons with pacemakers should not enter areas with
powder spraying installations!
Warning! We emphasize that the customer themselves is
responsible for safe operation of equipment. ITW-Gema
is in no way responsible for any resulting damages.
3.2 Safety conscious working
Each person responsible for the assembly, start-up, operation, service and repair of powder
spraying equipment must have read and understood the operating instructions and the
“Safety” chapter. The operator must ensure that the user has had the appropriate training
for powder spraying equipment and is aware of the possible sources of danger.
The control devices for the spray guns must only be set up and used inside of the zone 22,
and the spray guns should be used in the zone 21.

Safety regulations - H V. 2004
3.3 Individual safety regulations for the operating firm and/or operating
personnel
1. Any operating method which will negatively influence the technical safety of
the powder spraying equipment is to be avoided.
2. The operator is under obligation to check the powder spraying equipment at
least once a month for signs of external damage, defects or changes
(including the operating characteristics) which could influence safety and to
report them immediately.
3. The operator is obliged to check that the powder spraying equipment is only
operated when in satisfactory condition.
4. As far as is necessary, the operating firm must ensure that the operating
personnel wear protective clothing (e.g. facemasks).
5. The operating firm must guarantee cleanliness and an overview of the
workplace with suitable instructions and checks in and around the powder
spraying equipment.
3.4 Notes on special types of hazard
3.4.1 Power
High voltage equipment must not be opened - the plug must first be taken out – otherwise
there is the danger of electric shock.
3.4.2 Powder
Powder/air mixtures can be ignited by sparks. There must be sufficient ventilation in the
powder coating booth. Powder lying on the floor around the powder spraying device is a
potentially dangerous source of slipping.
3.4.3 Static charges
Static charges can have the following consequences: Charges from people, electric shocks,
sparking. Charges from objects must be avoided – see Earthing
3.4.4 Earthing
All electricity conducting parts and machinery found in the workplace (according to DIN VDE
0745, Part 102) must be earthed 1.5 m either side and 2.5 m around each booth opening.
The earthing resistance of each piece of machinery must amount to 1 MΩ. The resistance
must be tested on a regular basis. The condition of the machinery surroundings as well as
the suspension gear must ensure that the machinery remains earthed. If the earthing of the
machinery includes the suspension arrangements then these this must constantly be kept
clean in order to keep the necessary conductivity. The appropriate measuring devices must
be kept ready in the workplace in order to carry out the testing.
3.4.5 Compressed air
When there are to be longer pauses or stand-still times between working then the powder
spraying equipment should be drained of compressed air. There is a danger of injury when
pneumatic hoses are damaged and from the uncontrolled release and improper use of
compressed air.
3.5 Prohibition of unauthorized conversions and modifications to equipment
All unauthorized conversions and modifications to powder spraying equipment are forbidden
for safety reasons.
The powder spraying equipment should not be used if damaged, the faulty part must be
immediately replaced or repaired. Only original ITW-Gema replacement parts should be
used. Damage caused by other parts is not covered by guarantee.
Repairs must only be carried out by specialists or in ITW-Gema workshops. Unauthorized
modifications can lead to personal injury and damage to machinery. The ITW Gema AG
guarantee would no longer be valid.

V. 2004
Safety regulations - H
4 Safety requirements for electrostatic powder coating
1. This equipment is dangerous if the instructions in this operating manual are not followed.
2. All electrostatic conductive parts and in particular the machinery, within 5m of the coating
equipment must be earthed.
3. The floor of the coating area must conduct electricity (normal concrete is generally
conductive).
4. The operating personnel must wear electricity conducting footwear (e.g. leather soles).
5. The operating personnel should hold the gun with bare hands. If gloves are worn, these
must also conduct electricity.
6. The supplied earthing cable (green/ yellow) must be connected to the earthing screw of the
electrostatic powder spraying hand appliance. The earthing cable must have a good metallic
connection with the coating booth, the recovery unit and the conveyor chain and with the
suspension arrangement of the objects.
7. The electricity and powder supply to the hand guns must be set up so that they are fully
protected against heat and chemical damage.
8. The powder coating device may only be switched on, once the booth has been started up. If
the booth cuts out then the powder coating device must be switched off.
9. The earthing of all electricity conducting devices (e.g. hooks, conveyor chains) must be
checked on a weekly basis. The earthing resistance must amount to ≤ 1 MΩ.
10. The control device must be switched off if the hand gun is cleaned or the nozzle is changed.
The control device is also to be switched off when filling powder, so that ex atmosphere is
not produced unnecessarily.
11. When working with cleaning agents there may be a risk of hazardous fumes. The
manufactures information must be observed when using such cleaning agents.
12. The manufacturers instructions and the applicable environmental requirements must be
observed when disposing of powder lacquer and cleaning agents.
13. If any part of the spray gun is damaged (broken parts, tears) or missing then it should not be
used.
14. For your own safety, only use accessories and attachments listed in the operating
instructions. The use of other parts can lead to risk of injury. Only original ITW-Gema
replacement parts should be used.
15. Repairs must only be carried out by specialists and under no circumstances should they be
carried out in the operating area. All unauthorized conversions and modifications may lead to
injury or damage to machinery. The former protection must not be reduced.
16. Conditions leading to dangerous levels of dust concentration in the powder spraying booths
or in the powder spraying areas must be avoided. There must be sufficient technical
ventilation available, to prevent a dust concentration of more than 50% of the lower
explosion limit (UEG) (UEG = max. permissible powder/air concentration) If the UEG is not
known then a value of 20 g/m
3
should be used.

Safety regulations - H V. 2004
5 A summary of the rules and regulations
The following is a list of relevant rules and regulations which are to be observed:
5.1 Guidelines and Regulations, German professional association
BGV A1 General Regulations.
BGV A2 Electrical equipment and material.
BGI764 Electrostatic coating
BGR132 Guidelines for the avoidance of the dangers of ignition due to electrostatic
charging (Guideline “Static Electricity”)
VDMA 24371 Guidelines for electrostatic coating with synthetic powder
1)
- Part 1 General requirements.
- Part 2 Examples of use.
5.2 Leaflets
ZH 1/310 Leaflet on the use of tools in locations where there is danger of explosion.
1)
5.3 European Standards EN
RL94/9/EG The approximation of the laws of the Member States relating to apparatus
and safety systems for their intended use in potentially explosive
atmospheres
EN 292-1 EN 292-2 Machine safety
2)
EN 50 014 to EN 50
020 identical DIN VDE
0170/0171
Electrical equipment for locations where there is danger of explosion
3)
EN 50 050 Electrical apparatus for potentially explosive atmospheres - Electrostatic
hand-held spraying equipment
2)
EN 50 053 Part 2 Requirements for the selection, installation and use of electrostatic spraying
equipment for flammable materials - Hand-held electrostatic powder spray
guns
2)
PR EN 12981 Coating plants - Spray booths for application of organic powder
coating material - Safety requirements
EN 60529 identical
DIN 40050
IP-Type protection: contact, foreign bodies and water protection for electrical
equipment.
2)
EN 60 204 identical
DIN VDE 0113
VDE Regulations for the setting up of high-voltage electrical machine tools
and processing machines with nominal voltages up to 1000 V
3)
5.4 VDE (Association of German Engineers) Regulations
DIN VDE 0100 Regulations for setting-up high voltage equipment with nominal voltages up
to 1000 V.
4)
DIN VDE 0105
Part 1
Part 4
VDE Regulations for the operation of high voltage equipment.
4)
General regulations.
Supplementary definitions for stationary electrical spraying equipment.
DIN VDE 0147
Part 1
Setting up stationary electrostatic spraying equipment
4)
DIN VDE 0165 Setting up electrical equipment in locations where there is a danger of
explosion.
4)
Source:
1)
Carl Heymanns Verlag KG, Luxemburger Strasse 449, 5000 Köln 41, or from the appropriate
employers association.
2)
Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30
3)
Generalsecretariat, Rue Bréderode 2, B-1000 Brüssel, or the appropriate national committee.
4)
VDE Verlag GmbH, , Bismarckstrasse 33, 1000 Berlin 12

24 EASY 1-F / EASY 2-F
Issued 07/02
TECHNICAL DATA OF THE EASY 1-F / EASY 2-F POWDER MANUAL COATING EQUIPMENT
Type EASY 1-F EASY 2-F
Electrical data
Input voltage: 85 – 264 V
Frequency: 47 – 440 Hz
Connected load: 65 VA 130 VA
Rated output voltage (to powder gun): max. 12 VSmax. 12 VS
Rated output current (to powder gun): max. 1 A max. 1 A
Type of protection: IP 54
Temperature range: 10 °C to +40 °C (+50 °F to 104 °F)
Approval:
Pneumatic data
Main compressed air input: G 1/4" (Female)
Max. Input pressure: 10 bar
Min. Input pressure: 6 bar
Max. Water vapour content of the compressed air: 1.3 g/m3
Max. Oil vapour content of the compressed air: 0.1 mg/kg
(Oil/Water)
Max. Compressed air consumption
Powder hose - ø 11 mm: 14 m3/h 21 m3/h
Dimensions
Width: 608 mm 692 mm
Depth: 823 mm 823 mm
Height: 1195 mm 1195 mm
Weight: 42 kg 51 kg
Volume: 50 l (approx. 25 kg) 50 l (approx. 25 kg)
The Easy 1-F / Easy 2-F Manual coating equipment can only be used
with the EasySelect Manual Powder Gun!
IMPORTANT

1
EASY 1-F / EASY 2-F
Issued 07/02
ABOUT THESE OPERATING INSTRUCTIONS
These operating instructions contain all the important information which
is required to operate the EASY powder coating equipment. It will guide
you safely through the installation stage, give you information to convert
your EASY 1 system to an EASY 2 system, also notes and tips for the
optimum use of your new powder coating system.
The information about the functioning of the individual system compo-
nents - EasyTronic powder gun control, EasySelect Manual powder gun
or EasyFlow powder injector will be found in the respective accompany-
ing documentation.

2EASY 1-F / EASY 2-F
Issued 07/02
EASY 1-F / EASY 2-F ELECTROSTATIC POWDER MANUAL EQUIPMENT
1. Field of Application
The EASY 1-F / EASY 2-F Electrostatic Powder Manual equipment with
the EasySelect Manual powder gun is ideally suited for manual coating
of objects in small series.
2. Scope of delivery for EASY 1-F (Standard)
An EasyTronic control unit (1) in a metal housing with a Mains connec-
tion cable.
A mobile trolley (10) with a shelf (13) and a holder (14) for guns and
hoses.
A powder hopper (6)with cover and venting tube with ball valve (11).
A pressure reducing valve for the fluidizing air (9), mounted on the
trolley.
A plug-in EasyFlow injector (4)
An EasySelect Manual powder gun (2)with electric cable, powder hose,
rinsing air hose and standard nozzle set (see EasySelect Manual powder
gun operating instructions).
Pneumatic hoses (3) for conveying air (red), supplementary air (black),
and pneumatic hose for fluidizing air (black)
3. Supplementary material for EASY 2-F (Standard)
- An EasyTronic control unit, control unit housing, complete with gun
holder, special Mains connecting cable and connecting material
- A plug-in EasyFlow injector, a suction tube, Lock nut, and a
pneumatic kit
- An EasySelect Manual powder gun with electric cable, powder
hose, rinsing air hose and standard nozzle set
- Pneumatic hoses for conveying air (red), supplementary air
(black), and a pneumatic connection with a double air connection
adapter from the pressure reducing valve to the control unit.

3
EASY 1-F / EASY 2-F
Issued 07/02
Figure 1
CONNECTION INSTRUCTIONS
The Manual Powder equipment is partially assembled in the factory.
Only certain cables and hoses must be connected by the customer (see
separate Assembly Instructions).
1. Connect the hose for the compressed air supply from com-
pressed air circuit directly to the main air connection - 1.1 IN on
the rear of the control unit (female thread: 1/4" B.S.P.).
The compressed air must be free from oil and water.
2. Connect the black hose for the fluidizing air to the corresponding
output (1.5) on the rear of the control unit and to the pressure
reducing valve (9) on the trolley.
3. Fit the grounding connection cable on the control unit with the
grounding screw, and the 5
m long grounding cable with
the clamping clip on the
booth or on the hanger
device.
4. Connect the gun cable with
the 7 pole plug on the rear of
the control unit on the
socket - 2.2 (Gun).
The PG 1 Manual powder gun
cannot be connected!
5. Connect the hose for rinsing
air on the rinsing air output -
1.4 and on the powder gun.
6. Plug the injector in, and
connect the powder hose on
the injector and on the
powder gun.
7. Connect the red hose for
conveying air to the corre-
sponding output - 1.2 on the
rear of the control unit and to
the injector.
8. Connect the black hose for
supplementary air to the
corresponding output - 1.3
on the rear of the control unit
and to the injector.
9. Fit one end of the venting
hose onto the venting tube
(11) of the cover, and place
the other end in the opening
of the booth.
Atmospheric pressure must be present in the powder hopper
during operation!
10. Connect the Mains cable to the socket -2.1.
NOTICE
NOTICE
NOTICE
Mains connectionAux
Gun
1.1 IN
5 ... 10 bar
73...145 PSI
1.4 2.2 2.3
2.1
1.3
1.2 1.5
Input voltage:
Input power:
Degree of protection:
Output:
Corresponding guns:
85 – 264 V
47 – 440 Hz
65 VA
IP 54
10 V 1,2 A
EasySelect
POWDER GUN CONTROL
TYPE EASYTRONIC

4EASY 1-F / EASY 2-F
Issued 07/02
2
1
DESCRIPTION OF FUNCTION
Main compressed
air connection
The arrows always show the direction of flow
Figure 2
The fluidized powder in the powder hopper is sucked into the injector by
means of the conveying air (1- red hose). The powder/air mixture
reaches the powder gun through the powder hose (2). The powder is
electrostatically charged at the nozzle of the gun. In addition, an electro-
static field is created between the gun nozzle and the grounded object.
The charged, and sprayed powder adheres to the surface of the object.
The powder is fluidized by air forced through a porous plastic plate from
below. The powder acquires, thereby, fluid-like characteristics.
The conveying air, supplementary air, and rinsing air are set on the
control unit, and the fluidizing air is set on the fluidizing unit on the
trolley. The functioning of the injector is described in the EasyFlow
injector operating instructions.

5
EASY 1-F / EASY 2-F
Issued 07/02
The operating panel of the EasyTronic control unit consists of 4 main
areas: Diagnosis LEDs, Displays, "+/–" Keys, and Function keys.
1. The Diagnosis LEDs 1 – 8 serve to show the status of the equip-
ment, and equipment faults. Detailed information is found in
Chapter "Troubleshooting guide".
2. There are two Displays with whose help the following values are
displayed:
•Powder output (Setting range 0 – 100 %) Powder output in %
always refers to the max. possible output volume to the total
air volume setting.
•Total air volume (Setting range 1.6 – 6.0 Nm3/h)
3. The Keys "+" and "–" are for setting the powder output, and the
total air volume used.
If the Key is pressed once, the value is increased or decreases,
respectively, by one step. If the Key is pressed continuously, the
setting change rapidly.
4. The Function keys have the following functions:
•Electrode rinsing air for flat jet nozzles
•Electrode rinsing air for round jet nozzles
When a Key is pressed once, the corresponding function is
activated, and the corresponding LED illuminates.
If a Key with an illuminated LED is pressed for longer than 1
second, the function is deactivated.
ITW Gema recommends leaving the electrode rinsing air
switched on, but can, however, remain switched off with
application with very small amounts of powder.
•Application keys: With these keys the electrostatic (High-
voltage, and current) are automatically set so that the setting
for the selected application is the optimum.
– Settings for flat parts
– Settings for complicated parts with depressions
– Settings for coating parts already coated
The High-voltage and current can be deactivated when the
appropriate key is pressed for more than 1 second when the
LED illuminates
The EasyTronic control unit is switched on and off with a Push button.
If the equipment is switched on, the yellow lamp is illuminated.
When the equipment is first switched on the preselected factory settings
displayed:
60% 4.0 Nm3/h
Flat jet rinsing Complicated parts
After switching the equipment off (also when the equipment is discon-
nected from the Mains) the actual settings are retained.
EASYTRONIC CONTROL UNIT
Figure 3

6EASY 1-F / EASY 2-F
Issued 07/02
PREPARATION FOR START UP
1. Open the powder hopper filling cover.
2. Set the Airmover (if present) by turning the air valve
3. Fill with maximum 25 kg (50 l) powder or the powder must reach
to a maximum of 5-10 cm below the handles of the powder
hopper, otherwise the fluidized powder can escape from the cover.
4. Close the filling cover of the powder hopper again.
b) Switch the Booth on
Switch the powder coating booth on according to the operating
instructions.
c) Function Check
1. Press the main switch on the control unit. The yellow control lamp
in the switch illuminates.
The equipment carries out the calibration automatically. An in-
crease in sound can be heard inside the control unit. Both displays
show 888. The equipment is ready for operation after not more
than 20 seconds and switches to the factory settings.
2. Take the powder gun in the hand and point at a grounded object
in the booth, distance approx. 20 cm.
3. Press the gun trigger.
The LED No. 8 illuminates. The High-voltage is switched on and
powder is conveyed.
If all tests are positive, the control unit, and the powder gun are ready for
operation. If one of the functions is not operating as expected, check
this in the "Troubleshooting Guide", on pages 11 and 12.
a) Filling the Powder hopper

7
EASY 1-F / EASY 2-F
Issued 07/02
DAILY START UP
a) Powder fluidizing
The fluidizing of the powder is dependent on the type of powder, the
humidity of the air and the ambient temperature. The fluidizing functions
with the switching on of the control unit.
Proceed as follows:
1. Set the Airmover (if fitted) by turning the air valve
2. Open the filling cover of the powder hopper
3. Slowly increase the fluidizing air on the fluidizing air pressure
gauge (9)
The powder should only “boil” lightly, but evenly. If necessary, stir
the powder with a stick.
4. Fix the position of the pressure reducing valve by pressing the
knob down
5. Close the filling cover again
6. Switch the Airmover off
b) Regulating the Powder output, and Powder cloud
The powder output is dependent on the powder, and the setting of the
total air volume.
1. Switch on the control unit
2. Set the total air volume (For further information see the EasyFlow
Operating Instructions)
The total air volume is dependent on the powder hose length, the
number of turns of the hose, the hose diameter, and the object to
be coated.
The value set for the total air volume can be left as it is, as long as
the same powder hose is used. If the hose length and/or the hose
diameter are changed, then the total air volume must be reset.
3. Select the powder output volume according to the desired coating
thickness.
The selection takes place with the aid of the Keys + and – either
on the control unit or on the rear of the powder gun.
To start, a standard setting of 60% is recommended. The total air
volume is maintained constant automatically.
4. Check the fluidizing of the powder
5. Point the powder gun into the booth and press the powder gun
trigger
6. Select the correct electrode rinsing
When using flat jet nozzles:
- Press the Key with the corresponding symbol . The LED of the
corresponding Key illuminates.
When using round jet nozzles with air rinsed deflector plates:
- Press the Key with the corresponding symbol . The LED of the
corresponding Key illuminates.
(continued)
Set Total air volume
Select Powder output
volume
Select electrode
rinsing

8EASY 1-F / EASY 2-F
Issued 07/02
c) Powder coating
Make sure that all electrically conductive parts within 5 m of the
coating booth are grounded!
1. Take the powder gun in hand and point it into the coating booth,
however, do not point it at the object to be coated yet
2. Select the application settings
Press the corresponding application key on the control
unit. The LED of the corresponding Key illuminates.
3. Press the powder gun trigger
4. Coat the object(s)
e) Switching off
1. Release the powder gun trigger
2. Switch off the control unit
The settings for High-voltage, rinsing air, and powder output are
retained.
f) Powder hose rinsing
After longer stillstand periods the powder hose should be cleaned of
powder. Proceed as follows:
1. Remove the powder hose from the hose connection on the injector
2. Point the powder gun into the booth
3. Blow the hoses through manually with a compressed air gun
4. Replace the powder hose on the hose connection of the injector
again.
7. Adjust the powder cloud to a test object
When using flat jet nozzles:
- Unscrew the threaded sleeve approximately 45°, so that the flat jet
nozzle (or extension) can be turned slightly
- Turn the flat jet nozzle to the desired axial position
- Tighten the threaded sleeve again
When using round jet nozzles with air rinsed deflector plates
- Exchange the deflector plate (ø 16, 24, and 32 mm supplied with the
powder gun)
d) Remote control through the Powder gun
With the aid of the Keys + and – on the rear of the powder gun different
functions can be remotely controlled:
1. Select the application settings
Press the Keys +and –on the powder gun simultaneously
Check by observing the LED display on the powder gun:
Red = Flat parts
Green = Complicated parts
Red/Green (alternating) = Spraying over
2. Change the powder output
Press the Key +or –on the powder gun. The powder output is
correspondingly increased or decreased.
CAUTION

9
EASY 1-F / EASY 2-F
Issued 07/02
COLOUR CHANGE
1. Empty the powder hopper and clean (see page 10)
2. Blow out the powder hose with compressed air
Powder hoses are easily cleaned by taking a cube of foam pack-
ing material and blowing it through the hose with compressed air.
Use our specially designed compressed air gun (Order No.
346 055).
The foam cubes can be ordered in sheets of 100 pieces (Order
No. 241 717).
3. Dismantle the powder gun and clean (see EasySelect Manual
powder gun operating instructions).
4. Clean the injector (see EasyFlow Injector operating instructions).
5. Prepare the coating equipment for start-up with new powder (see
"Filling the powder hopper" page 6).
MAINTENANCE SCHEDULE
Regular and conscientious maintenance increases the operating life of
the unit and ensures a longer constant coating quality!
a) Daily Maintenance:
1a Clean the injector, see EasyFlow Injector operating instructions
2a Clean the powder gun, see EasySelect Manual powder gun
operating instructions.
3a Clean the Manual powder gun powder hose, see Colour change,
Point 2.
b) Weekly Maintenance:
1b Clean the powder hopper, injector and powder gun.
Only fill the powder hopper shortly before restarting operation
2b Check the grounding connection between the control unit and the
coating booth, the object hanger device or the chain conveyor
c) When the Powder coating equipment is not used for a number of days:
1c Remove the Mains plug
2c Clean the coating equipment, see Point 1b
3c Turn off the main compressed air supply

10 EASY 1-F / EASY 2-F
Issued 07/02
CLEANING
Cleaning the powder hopper
CAUTION
NOTICE
1. Disconnect the fluidizing air supply
2. Remove the injector
3. Remove the cover, blow out with compressed air and clean with a
clean dry brush and cloth
4. Clean the suction tube, and injector
5. Empty the remaining powder into a container
6. Vacuum the hopper and, above all, the floor of the hopper
7. Clean the hopper with a cloth
8. Reassemble the powder hopper
Refill the powder hopper shortly before reusing! Never clean the
powder hopper with solvents or water!
Cleaning the EasySelect Manual powder gun
Frequent cleaning of the powder gun ensures the quality of the coating.
Switched off the control unit before cleaning the powder gun. The
compressed air used for cleaning must be free from oil and water.
Daily:
1. Blow off the exterior of the powder gun, and wiping clean etc.
Weekly:
2. Remove the powder hose from the connection.
3. Remove the nozzle from the powder gun and clean.
4. Remove the powder gun from the connection and blow through
with compressed air in the direction of flow.
5. Clean the powder gun tube with the spiral brush supplied.
6. Blow the powder gun through with compressed air again.
7. Clean the powder hose.
8. Assemble the powder gun and reconnect.