WAGNER PEM-X1 Installation instructions

0102 II 2D 2mJ

P_01660

Manual Powder Spray Gun

PEM-X1

Version 09/2012

Translation of the Original

Operating Manual

PEM-X1

OPERATING MANUAL

VERSION 09/2012 ORDER NUMBER DOC 2326020

Contents

1 GENERAL INFORMATION 6

1.1 Preface 6

1.2 Warnings, Notes and Symbols in these Instructions 6

1.3 Languages 7

1.4 Abbreviations 7

2 CORRECT USE 8

2.1 Device Type 8

2.2 Correct Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Safety Parameters 8

2.5 Processing Materials 9

2.6 Reasonably Foreseeable Misuse 9

2.7 Residual Risks 9

3 IDENTIFICATION 10

3.1 Explosion Protection Identication 10

3.2 Permissible Device Combinations 10

4 GENERAL SAFETY INSTRUCTIONS 11

4.1 Safety Instructions for the Operator 11

4.1.1 Electrical Devices and Operating Equipment 11

4.1.2 Personnel Qualications 11

4.1.3 A Safe Work Environment 11

4.2 Safety Instructions for Sta 12

4.2.1 Safe Handling of WAGNER Powder Spray Devices 12

4.2.2 Grounding the Device 12

4.2.3 Material Hoses 12

4.2.4 Cleaning 13

4.2.5 Handling Powder Paints 13

4.3 Information about Harmless Discharges 14

4.4 Protective and Monitoring Equipment 15

5 DESCRIPTION 16

5.1 Design of the Spray Gun 16

5.2 Functioning of the Spray Gun 16

5.3 Technical Data 17

5.3.1 Dimensions 18

5.4 Permitted Accessories 19

5.5 Scope of Delivery 19

6 ASSEMBLY AND COMMISSIONING 20

6.1 Qualication of the Assembly/Commissioning Sta 20

6.2 Storage Conditions 20

6.3 Installation Conditions 20

6.4 Preparing the Spray Gun 21

6.4.1 Selection of the Suitable Nozzle System 21

6.5 Connecting the Spray Gun 23

6.6 Grounding 25

6.6.1 Grounding the Powder Coating System 26

PEM-X1

OPERATING MANUAL

VERSION 09/2012 ORDER NUMBER DOC 2326020

7 OPERATION 27

7.1 Qualication of the Operating Sta 27

7.2 Safety Instructions 27

7.3 Optimizing the Powder Cloud for Coating 28

7.3.1 Recommended Settings for Total Air Volume 28

7.4 Switching o the Spray Gun 29

7.5 Adjustment of Powder Quantity 30

7.6 "Double Click" Recipe (High Dynamic Remote) 31

7.7 Reproducible Setting of the Nozzle Position 32

8 CLEANING AND MAINTENANCE 33

8.1 Cleaning 33

8.1.1 Cleaning Sta 33

8.1.2 Safety Instructions 33

8.1.3 Cleaning Procedures 34

8.2 Maintenance 35

8.2.1 Maintenance Sta 35

8.2.2 Safety Instructions 35

8.2.3 Maintenance Procedures 36

8.2.4 Replacing the Spray Gun 37

8.3 Removing the Flat Spray Nozzle 38

8.4 Fitting the Flat Spray Nozzle 39

8.5 Removing the Round Spray Nozzle 40

8.6 Fitting the Round Spray Nozzle 41

8.7 Replacing the Protective Wedge 42

8.8 Changing from Flat Spray Nozzle to Round Spray Nozzle 44

8.9 Mounting the Corona-Star 46

8.10 Replacing the Suspension Hook 47

9 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010 48

9.1 Overview of Inspections 49

10 DISASSEMBLY AND DISPOSAL 52

10.1 Disassembly 52

10.2 Disposal 52

11 TROUBLESHOOTING AND RECTIFICATION 53

12 ACCESSORIES 55

12.1 Flat Spray Nozzle 55

12.2 Deector Cone 55

12.3 Electrode Holder 55

12.4 Hose Take-Up 56

12.5 Retrot Set Corona-Star 56

12.6 Wedge Tool 56

12.7 Nozzle Extension X1 VL 150/300 57

12.8 Powder Hose 57

12.9 Wall Mount 58

12.10 Powder Measuring Adapter 59

Contents

PEM-X1

OPERATING MANUAL

VERSION 09/2012 ORDER NUMBER DOC 2326020

13 SPARE PARTS 60

13.1 How to order Spare Parts? 60

13.2 PEM-X1 Corona Manual Spray Gun 61

13.3 Electrode Holder X1 R 62

14 DECLARATION OF WARRANTY AND CONFORMITY 63

14.1 Important Notes on Product Liability 63

14.2 Warranty Claim 63

14.3 Declaration of Conformity 64

14.4 EC Type Examination Certicate 65

14.5 FM Approval 68

PEM-X1

OPERATING MANUAL

VERSION 09/2012 ORDER NUMBER DOC 2326020

1 GENERAL INFORMATION

The operating manual contains information about safely operating, maintaining, cleaning

and repairing the device.

The operating manual is part of the device and must be available to the operating and

service sta.

The operating and service sta should be instructed according to the safety instructions.

The device may only be operated in compliance with this operating manual.

This equipment can be dangerous if it is not operated according to the denitions in this

operating manual.

1.1 PREFACE

1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this operating manual highlight particular dangers to users and

device and state measures for avoiding the hazard. These warning instructions fall into the

following categories:

Danger - immediate risk of danger.

Non-observance will result in death, serious injury

and serious material damage.

Warning - possible imminent danger.

Non-observance may result in death, serious injury

and serious damage to property.

Caution - a possibly hazardous situation.

Non-observance may result in minor injury.

Note - provides information about particular characteristics and how to proceed.

Notice - a possibly hazardous situation.

Non-observance may result in damage to property.

This information warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

DANGER

This information warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

WARNING

This information warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

CAUTION

This information warns you of a hazard!

Possible consequences of not observing the warning instructions. The signal word

indicates the hazard level.

The measures for preventing the hazard and its consequences.

NOTICE

PEM-X1

OPERATING MANUAL

VERSION 09/2012 ORDER NUMBER DOC 2326020

1.3 LANGUAGES

1.4 ABBREVIATIONS

The this operating manual is available in the following languages:

German 2326019 English 2326020

French 2326021 Italian 2326022

Spanish 2326023

Piece

Item

Marking in the spare parts lists

Number

Spare part

PEM-X1

OPERATING MANUAL

VERSION 09/2012 ORDER NUMBER DOC 2326020

2 CORRECT USE

2.1 DEVICE TYPE

Powder spray guns for manual coating of grounded work pieces

2.2 CORRECT USE

The PEM-X1 manual powder spray gun is designed for the electrostatic coating of work

pieces with organic powders. Any other form of use is considered not intended use.

Wagner disclaims liability for any damage resulting from not intended use.

The spray gun may only be used in spray areas equipped in accordance with EN 50177 or

under equivalent ventilation conditions.

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

This type A-P electrostatic powder spray gun is suitable for processing industrial powder

paints for coating electrically conductive objects and can be used in potentially explosive

atmospheres (zone 22). (See chapter 3.1 "Explosion Protection Identication").

2.4 SAFETY PARAMETERS

The powder hand gun is only suited to the application of powder paint.

J. Wagner AG forbids any other use!

The powder spray gun may only be operated under the following conditions if:

the operating sta have previously been trained on the basis of this operating manual,

the safety regulations listed in this operating manual are observed,

the operating, maintenance and repair information in this operating manual is

observed,

the statutory requirements and accident prevention regulations standard in the

country of use are observed.

The manual powder spray gun may only be operated if all parameters are set and all

measurements/safety checks are carried out correctly.

PEM-X1

OPERATING MANUAL

VERSION 09/2012 ORDER NUMBER DOC 2326020

2.5 PROCESSING MATERIALS

Types of powder which can be charged electrostatically

Metallic powder

2.6 REASONABLY FORESEEABLE MISUSE

2.7 RESIDUAL RISKS

Residual risks are risks which cannot be excluded even in the event of correct use.

If necessary, warning and prohibition signs at the relevant points of risk indicate residual

risks.

The following is prohibited:

Coating work pieces which are not grounded

Unauthorized conversions and modications to spray guns

Processing liquid or similar coating materials

Using defective components, spare parts or accessories other than those described

in chapter 12 of this operating manual.

The forms of misuse listed below may result in health issues and/or damage to property:

Use of damp powder paint

Incorrectly set values for powder discharge

Incorrectly set electrostatic values

Use of defective components and accessories

Use for foodstus

Use in the pharmaceutical sector

Use with not permissible control units

Residual risk Source Consequences Specic measures Lifecycle phase

Skin contact with

powder paints and

cleaning agents

Handling powder

paints and cleaning

agents

Skin irritation,

allergies

Wear protective

clothing

Operation,

Note safety data

sheets

maintenance,

disassembly

Powder paint in air

outside the dened

working area

Painting outside

the dened

working area

Inhalation of

substances

hazardous to health

Observe working

and operating

instructions

Operation,

maintenance

PEM-X1

0102

OPERATING MANUAL

VERSION 09/2012 ORDER NUMBER DOC 2326020

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

The EC type examination certicate PTB 12 ATEX 5002 can be found in chapter 14.4.

3.2 PERMISSIBLE DEVICE COMBINATIONS

Gun type: PEM-X1

Manufacturer: J. Wagner AG

CH - 9450 Altstätten

II 2D 2mJ 85 °C

CE: Communautés Européennes

0102: Number of notied body which issues the recognition of quality

assurance in production

Ex: Symbol for explosion protection

II: Device class II

2: Category 2

D: Ex-atmosphere dust

2mJ: Maximum ignition energy 2 mJ

85 °C: Maximum surface temperature

Incorrect use!

Risk of injury and damage to the equipment.

Only connect original Wagner devices to the PEM-X1 powder

spray gun.

WARNING

The PEM-X1 powder spray gun may only be connected to the control devices listed below:

EPG-Sprint X with PI-F1/HiCoat ED-F powder injector

EPG-Sprint with PI-F1* powder injector

EPG S2 with PI-F1* powder injector

* The remote control function of the PEM-X1 spray gun is not available when using these

control units.

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