ITW Gema EASY 2-F, EASY 1-F Operating Instructions And Spare Parts List
Operating Instructions and Spare parts list
EASY 1-F
Powder Coating Equipment
E
0102 II (2) D
Issued 07/02
EASY 1-F ELECTROSTATIC POWER MANUAL EQUIPMENT
11413 2
3
12
4
11
10
9
8
5
6
7
1 EasyTronic control unit
2 EasySelect Manual powder gun
3 Pneumatic hose with quick-
release connection
4 EasyFlow Injector
5 Powder hopper cover
6 Powder hopper
7 Swivel wheel
8 Pneumatic wheel
9 Fluidizing air unit
10 Mobile frame with hand rail
11 Venting tube (AIRMOVER) with
Ball valve
12 Clamping element
13 Shelf
14 Gun/Hose holder
CONNECTIONS ON THE REAR OF THE EASYTRONIC CONTROL UNIT
1.1 IN Compressed air input
1.2 Conveying air connection
1.3 Supplementary air
1.3
POWDER GUN CONTROL
Input voltage:
Input power:
Degree of protection:
Output:
Corresponding guns:
1.4 2.2 2.3
TYPE EASYTRONIC
85 – 264 V
47 – 440 Hz
65 VA
IP 54
10 V 1,2 A
EasySelect
Gun
1.2 1.5
Mains connectionAux
5 ... 10 bar
73...145 PSI
1.1 IN
2.1
1.4 Rinsing air connection
1.5 Fluidizing air connection
2.1 Power supply
2.2 Gun connection for the
2.3 Output for Vibrator (EASY 1-B
connection
(85–264 V)
EasySelect Manual gun.
PG 1 Manual gun cannot be
connected!
only) and Stirrer control
(EASY 1-S only )
Grounding connection
Issued 07/02
22
EASY 1-F / EASY 2-F
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
EASY 1-F / EASY 2-F
21
Issued 07/02
Issued 07/02
22
EASY 1-F / EASY 2-F
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
Safety regulations - H
IP54
V. 2004
T6 (zone 21)
T4 (zone 22)
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.
V. 2004
Safety regulations - H
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.
Safety regulations - H
V. 2004
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.
V. 2004
Safety regulations - H
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
BGV A2
BGI764
BGR132
VDMA 24371
General Regulations.
Electrical equipment and material.
Electrostatic coating
Guidelines for the avoidance of the dangers of ignition due to electrostatic
charging (Guideline “Static Electricity”)
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.
5.3 European Standards EN
RL94/9/EG
EN 292-1 EN 292-2
EN 50 014 to EN 50
020 identical DIN VDE
0170/0171
EN 50 050
EN 50 053 Part 2
PR EN 12981
EN 60529 identical
DIN 40050
EN 60 204 identical
DIN VDE 0113
The approximation of the laws of the Member States relating to apparatus
and safety systems for their intended use in potentially explosive
atmospheres
Machine safety
2)
Electrical equipment for locations where there is danger of explosion
Electrical apparatus for potentially explosive atmospheres - Electrostatic
hand-held spraying equipment
2)
Requirements for the selection, installation and use of electrostatic spraying
equipment for flammable materials - Hand-held electrostatic powder spray
2)
guns
Coating plants - Spray booths for application of organic powder
coating material - Safety requirements
IP-Type protection: contact, foreign bodies and water protection for electrical
equipment.
2)
VDE Regulations for the setting up of high-voltage electrical machine tools
and processing machines with nominal voltages up to 1000 V
5.4 VDE (Association of German Engineers) Regulations
Source:
DIN VDE 0100
DIN VDE 0105
Part 1
Part 4
DIN VDE 0147
Part 1
DIN VDE 0165
1)
Carl Heymanns Verlag KG, Luxemburger Strasse 449, 5000 Köln 41, or from the appropriate
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
employers association.
Regulations for setting-up high voltage equipment with nominal voltages up
to 1000 V.
4)
VDE Regulations for the operation of high voltage equipment.
General regulations.
Supplementary definitions for stationary electrical spraying equipment.
Setting up stationary electrostatic spraying equipment
Setting up electrical equipment in locations where there is a danger of
explosion.
4)
1)
3)
3)
4)
4)
Safety regulations - H
V. 2004
Loading...