WAGNER PER-X1 Operational manual

P_04900

Robot powder spray gun

PER-X1

Translation of the Original Operating Manual

0102 II2D2mJ

For professional use.

Always observe the information in this manual, particularly the safety

instructions and the warning instructions. Store the manual in a safe place. Edition: 10/2022

Operating manual Robot powder spray gun PER-X1

Table of Contents

Order number 2444998 | Edition 10/2022 3

TABLE OF CONTENTS

1 About these Instructions 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 6

1.4 Abbreviations 7

1.5 Terminology for the Purpose of this Manual 7

2 Using in Accordance with the Instructions 8

2.1 Device Type 8

2.2 Type of Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Processible Working Materials 8

2.5 Misuse 8

3 Identification 9

3.1 Explosion Protection Identification 9

3.2 Type Plate 9

3.3 Permissible Device Combinations 9

4 Basic Safety Instructions 11

4.1 Safety Instructions for the Operator 11

4.1.1 Electrical Devices and Equipment 11

4.1.2 A Safe Work Environment 11

4.1.3 Personnel Qualifications 12

4.2 Safety Instructions for the Personnel 12

4.2.1 Personal Safety Equipment 12

4.2.2 Safe Handling of WAGNER Powder Spray Devices 13

4.2.3 Grounding the Device 13

4.2.4 Product Hoses 13

4.2.5 Electrical Connection Cables 14

4.2.6 Cleaning and Flushing 14

4.2.7 Maintenance and Repair 14

4.2.8 Protective and Monitoring Equipment 15

4.3 Information about safe discharges 15

5 Description 17

5.1 Design of the Robot Gun 17

5.2 Positive Cascade 17

5.3 Mode of Operation of the Robot Spray Gun 18

5.4 Extent of Delivery 18

5.5 Data 18

5.5.1 Technical Data 18

5.5.2 Dimensions 19

5.6 Accessories 20

6 Assembly and Commissioning 21

6.1 Training of Assembly/Commissioning Personnel 21

6.2 Storage Conditions 21

6.3 Installation Conditions 21

6.4 Preparation of the Spray Gun 21

6.4.1 Selection of a Suitable Nozzle System 21

6.5 Connecting the Robot Spray Gun 23

6.6 Assembly of the Variants 25

Operating manual Robot powder spray gun PER-X1

Table of Contents

4 Order number 2444998 | Edition 10/2022

6.6.1 PER-X1 Single Outside (SO) 25

6.6.2 PER-X1 Single Inside (SI) 26

6.6.3 PER-X1 Twin Outside (TO) 27

6.6.4 PER-X1 Twin Inside (TI) 28

6.7 Grounding 29

6.7.1 Grounding the powder coating system 30

6.8 Safety Checks 30

7 Operation 31

7.1 Training the Operating Personnel 31

7.2 Tasks 31

7.3 Switching on the Robot Powder Spray Gun 31

7.4 Optimizing the Powder Cloud for Coating 31

7.4.1 Recommended Settings for Total Air Volume 31

7.5 Switching Off the Automatic Powder Gun 31

7.5.1 Switching Off in Normal Operation 31

7.5.2 Switching Off the Automatic Gun in the Event of Faults or Emergencies 32

7.5.3 Pressure Relief / Work Interruption 32

7.6 Reproducible setting of the nozzle position 32

8 Cleaning and Maintenance 33

8.1 Cleaning 33

8.1.1 Cleaning Personnel 33

8.1.2 Cleaning Procedures 33

8.1.3 Performing a Paint Change 33

8.2 Maintenance 34

8.2.1 Maintenance Personnel 34

8.2.2 Maintenance Instructions 34

8.2.3 Safety Checks 34

8.2.4 Maintenance Procedures 34

8.3 Replacing the Robot Spray Gun 35

8.4 Changing the Flat Jet Nozzle 35

8.4.1 Removing the Flat Jet Nozzle 35

8.4.2 Fitting the Flat Jet Nozzle 36

8.5 Changing the Round Jet Nozzle 37

8.5.1 Removing the Round Jet Nozzle 37

8.5.2 Fitting the Round Jet Nozzle 38

8.6 Replacing the Protective Wedge 38

8.6.1 Removing the Protective Wedge 38

8.6.2 Installing the Protective Wedge 39

8.7 Changing Nozzle Types 40

8.8 Mounting the Double Adapter 42

8.8.1 Removing the Nozzle and Electrode Holder 42

8.8.2 Installation of the Double Adapter 43

8.8.3 Cleaning the Double Adapter 44

8.8.4 Replacing the Wearing Parts 44

8.9 Assembly of the CoronaStar 45

9 Troubleshooting and Rectification 46

10 Inspections in Accordance with DIN EN 50177: 2009 47

10.1 Abbreviations 47

10.2 Overview Table 48

11 Disassembly and Disposal 50

11.1 Disassembly 50

Operating manual Robot powder spray gun PER-X1

Table of Contents

Order number 2444998 | Edition 10/2022 5

11.2 Disposal 50

12 Accessories 51

12.1 Robot Flange Variants 51

12.2 Nozzle systems 51

12.2.1 Flat Jet Nozzles System X1 52

12.2.2 X1 F Flat Jet Nozzles System 52

12.2.3 X1 R Round Jet Nozzles System 53

12.2.4 Nozzle extension 53

12.3 Double Adapter 54

12.4 Corrugated Tubes 56

12.5 Retrofit Set CoronaStar 56

12.6 D10-D12 Powder Coupling 56

12.7 Wedge tool 56

12.8 Powder hose 57

12.9 Atomizing air hose 57

12.10 Gun Connection Cable 57

12.11 Powder measuring adapter 57

12.11.1 Powder Measuring Adapter for X1 Flat Jet Nozzle 57

13 Spare Parts 58

13.1 How to Order Spare Parts 58

13.2 Notes on the Use of Spare Parts 58

13.3 PER-X1 Corona Robot Spray Gun with a Flat Jet Nozzle 59

13.4 PER-X1 Corona Robot Spray Gun with a Round Jet Nozzle 60

13.5 X1 R Electrode Holder 61

13.6 X1 double adapter 62

14 Declaration of Conformity 63

14.1 EU Declaration of Conformity 63

Operating manual Robot powder spray gun PER-X1

1 About these Instructions

6 Order number 2444998 | Edition 10/2022

1 ABOUT THESE INSTRUCTIONS

1.1 PREFACE

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 personnel.

The device may only be operated by trained personnel and in compliance with this

operating manual. Operating and service personnel should be instructed according to the

safety instructions.

This equipment can be dangerous if it is not operated according to the instructions in this

operating manual.

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this manual highlight particular dangers to users and to the 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 or serious injury.

WARNING Potential danger.

Non-observance may result in death or serious injury.

CAUTION Potentially dangerous situation.

Non-observance may result in minor injury.

NOTICE Potentially dangerous situation.

Non-observance may result in damage to property.

Info Provides information about particular characteristics and how to

proceed.

Explanation of warning notice:

WARNING

This notice warns you of a danger!

Possible consequences of not observing the warning notice.

4The measures for preventing the hazard and its consequences.

1.3 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order no.

German 2426813

Translation of the original operating manual

Language Order no. Language Order no.

English 2426815 Spanish 2426818

French 2426816 Chinese 2426820

Italian 2426817

Additional languages upon request or at: www.wagner-group.com

Operating manual Robot powder spray gun PER-X1

1 About these Instructions

Order number 2444998 | Edition 10/2022 7

1.4 ABBREVIATIONS

Order no. Order number

ET Spare part

K Marking in the spare parts lists

Pos Position

Stk Number of pieces

-- Item not available as spare part

/ Item does not exist

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning agent.

Flushing Internal flushing of paint-wetted parts with compressed air.

Personnel qualifications

Trained person Is instructed in the tasks assigned to him/her, the potential risks associ-

ated with improper behavior as well as the necessary protective devices

and measures.

Electrically

trained person

Is instructed by an electrician about the tasks assigned to him/her, the

potential risks associated with improper behavior as well as the neces-

sary protective devices and measures.

Electrician Can assess the work assigned to him/her and detect possible hazards

based on his/her technical training, knowledge and experience in rele-

vant provisions.

Skilled person in

the context of

DGUV209‑052

A person who, based on his/her technical training, experience and re-

cent vocational experience, has sufficient technical knowledge in the

area of electrostatic coating and is familiar with the relevant and gener-

ally accepted rules of technology so that he/she can inspect and assess

the status of devices and coating systems based on workplace safety.

Additional requirements for skilled persons can also be found in

TRBS1203(2010/amendment 2012): Expert knowledge in the areas of

protection against excessive pressure, electrical hazards and explosion

protection (where applicable).

Operating manual Robot powder spray gun PER-X1

2 Using in Accordance with the Instructions

8 Order number 2444998 | Edition 10/2022

2 USING IN ACCORDANCE WITH THE INSTRUCTIONS

2.1 DEVICE TYPE

Robot powder spray gun for coating work pieces which are grounded.

2.2 TYPE OF USE

The robot powder spray gun is designed for the electrostatic coating of work pieces with

organic powders.

WAGNER explicitly prohibits any other use!

The robot powder spray gun may only be operated in a temperature range from 5–40 °C; 41–

104 °F.

Electrostatic coating systems may only be used in spray areas equipped in accordance with

EN 16985 or under equivalent ventilation conditions.

The device may only be operated under the following conditions:

4Use the device only to work with the materials recommended by WAGNER.

4Do not deactivate safety fixtures.

4Use only WAGNER original spare parts and accessories.

4The operating personnel must be trained on the basis of this operating manual.

4Follow the instructions in the operating manual.

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

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

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

areas (zone 22). (see chapter Identification [89]).

In explosion hazard areas, only use approved explosion-proof electrical devices.

2.4 PROCESSIBLE WORKING MATERIALS

– Types of powder which can be charged electrostatically

– Metallic powder

Info

Contact your local WAGNER dealer and the lacquer manufacturer if you encounter

application problems.

2.5 MISUSE

Misuse can lead to physical injury and/or property damage! Special attention must be paid

that:

4No liquid coating products, e.g. solvents or water-based lacquers, are processed.

4No food, medicine or cosmetics are processed.

Operating manual Robot powder spray gun PER-X1

3 Identification

Order number 2444998 | Edition 10/2022 9

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

As defined in Directive 2014/34/EU(ATEX), the device is suitable for use in potentially

explosive areas.

Device Type PER-X1 automatic gun

Manufacturer Wagner International AG

9450 Altstätten

Switzerland

0102 II2 D2mJ

CE European Communities

0102 Notified body: PTB

Ex Symbol for explosion protection

II Device class II

2 Category 2

D Ex-atmosphere dust

2mJ Maximum ignition energy 2 mJ

3.2 TYPE PLATE

P_04901

PER-X1 Serial Number:

PTB 22 ATEX 5001

EN 50050-2 / EN 50177

Wagner International AG, CH-9450 Altstätten

Made in Switzerland

0102 II 2 D 2mJ

3.3 PERMISSIBLE DEVICE COMBINATIONS

WARNING

Incorrect use!

Risk of injury and damage to the device.

4Only connect the powder spray gun to original WAGNER devices.

The PER-X1 robot powder spray gun may only be used with the following control units:

Guns Control units

PER-X1 (with accessories) EPG-Sprint X

Operating manual Robot powder spray gun PER-X1

3 Identification

10 Order number 2444998 | Edition 10/2022

Guns Control units

EPG-Sprint XE

EPG-Sprint

EPG S2

HVM-DP

EPG-DP5

EPG-SL5

For accessories, see chapter Accessories [851]

This manual suits for next models

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