WAGNER PEM-X1 CG Operational manual

P_01725
Powder Cup Gun
PEM-X1 CG
Translation of the Original Operating Manual
0102 II2D2mJ
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 Powder Cup Gun PEM-X1 CG
Table of Contents
Order number 2326960 | 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 General Characters and Symbols 6
1.4 Languages 7
1.5 Abbreviations 7
1.6 Terminology for the Purpose of this Manual 7
2 Using in Accordance with the Instructions 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
2.5 Misuse 9
3 Identification 10
3.1 Explosion Protection Identification 10
3.2 FM approval 10
3.3 Type Plate 10
3.4 Permissible device combinations 11
4 Basic Safety Instructions 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualifications 13
4.2 Safety Instructions for the Personnel 13
4.2.1 Personal Safety Equipment 13
4.2.2 Safe Handling of WAGNER Powder Spray Devices 14
4.2.3 Grounding the Device 14
4.2.4 Product Hoses 14
4.2.5 Electrical Connection Cables 15
4.2.6 Cleaning and Flushing 15
4.2.7 Maintenance and Repair 15
4.2.8 Protective and Monitoring Equipment 16
4.3 Information about safe discharges 16
5 Description 18
5.1 Construction of the Cup Gun 18
5.2 Mode of Operation of the Cup Gun 18
5.3 Extent of Delivery 19
5.4 Data 19
5.4.1 Technical Data 19
5.4.2 Dimensions 20
5.5 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 Powder Cup 23

Operating manual Powder Cup Gun PEM-X1 CG
Table of Contents
4 Order number 2326960 | Edition 10/2022
6.6 Assembling the Powder Cup 24
6.7 How to Use the Powder Cup 24
6.8 Connecting the Cup Gun 25
6.9 Grounding 25
6.9.1 Grounding the powder coating system 26
6.10 Safety Checks 26
7 Operation 27
7.1 Training the Operating Personnel 27
7.2 Tasks 27
7.3 Switching on the Manual Powder Spray Gun 27
7.4 Optimizing the Powder Cloud for Coating 27
7.4.1 Settings Recommendation for Total Air Volume 27
7.5 Double Click Program (High Dynamic Remote) 28
7.6 Switching off the Manual Gun 28
7.6.1 Pressure Relief / Work Interruption 29
7.7 Reproducible setting of the nozzle position 29
8 Cleaning and Maintenance 30
8.1 Cleaning 30
8.1.1 Cleaning Personnel 30
8.1.2 Cleaning Procedures 30
8.2 Maintenance 30
8.2.1 Maintenance Personnel 30
8.2.2 Maintenance Instructions 31
8.2.3 Safety Checks 31
8.2.4 Maintenance Procedures 31
8.3 Changing the Cup Gun 32
8.4 Changing the Flat Jet Nozzle 33
8.4.1 Removing the Flat Jet Nozzle 33
8.4.2 Fitting the Flat Jet Nozzle 34
8.5 Changing the Round Jet Nozzle 35
8.5.1 Removing the Round Jet Nozzle 35
8.5.2 Fitting the Round Jet Nozzle 36
8.6 Replacing the Protective Wedge 36
8.6.1 Removing the Protective Wedge 36
8.6.2 Installing the Protective Wedge 37
8.7 Changing Nozzle Types 38
8.8 Assembly of the CoronaStar 40
8.9 Replacing the Suspension Hook 41
8.10 Replacing the Collector Nozzle 41
8.11 Replacing the Connecting Tube 42
9 Troubleshooting and Rectification 44
10 Inspections in Accordance with DIN EN 50050-2: 2013 45
10.1 Abbreviations 45
10.2 Overview Table 46
11 Disassembly and Disposal 47
11.1 Disassembly 47
11.2 Disposal 47
12 Accessories 48
12.1 Nozzle systems 48
12.1.1 Flat Jet Nozzles System X1 48

Operating manual Powder Cup Gun PEM-X1 CG
Table of Contents
Order number 2326960 | Edition 10/2022 5
12.1.2 X1 F Flat Jet Nozzles System 48
12.1.3 X1 R Round Jet Nozzles System 49
12.1.4 Nozzle extension 49
12.2 Powder Cup 51
12.2.1 Powder Cup, 210 ccm 51
12.2.2 Powder Cup, 1 Liter 51
12.3 Cup Holder 52
12.4 Retrofit Set CoronaStar 52
12.5 Wedge tool 52
12.6 Wall mount 53
12.7 Recipe sticker 53
12.8 Powder measuring adapter 53
12.8.1 Powder Measuring Adapter for X1 Flat Jet Nozzle 54
12.9 PEM-X1 CG portable set 54
13 Spare Parts 56
13.1 How to Order Spare Parts 56
13.2 Notes on the Use of Spare Parts 56
13.3 PEM-X1 CG Corona Cup Gun 57
13.4 X1 R Electrode Holder 58
13.5 Powder Cup 59
13.6 Connecting part 59
13.7 Connecting Tube, Collector Nozzle 59
14 Declaration of Conformity 61
14.1 EU Declaration of Conformity - Manual Gun 61
14.2 FM Control Document 61

Operating manual Powder Cup Gun PEM-X1 CG
1 About these Instructions
6 Order number 2326960 | 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 GENERAL CHARACTERS AND SYMBOLS
The characters and symbols in this operating manual indicate the following:
üRequirement that must be fulfilled before an action can be performed.
1. Step 1 of an action to be performed with several action steps.
4Second level action step
2. Step 2
ðIntermediate result of an action
ðResult of a complete action
4Action to be performed with an action step
1. Numbered list, first level
– Numbered list, second level

Operating manual Powder Cup Gun PEM-X1 CG
1 About these Instructions
Order number 2326960 | Edition 10/2022 7
– Non-numbered list, first level
– Non-numbered list, second level
= cross-reference on page
♦ = wearing parts
⋆ = included in service set
● = not part of the standard equipment but available as a special accessory
1.4 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2326959
Translation of the original operating manual
Language Order no. Language Order no.
English 2326960 Polish 2410120
French 2326961 Croatian 2417169
Italian 2326962
Spanish 2326963
Russian 2333347
Chinese 2333348
Additional languages upon request or at: www.wagner-group.com
1.5 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
1.6 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.

Operating manual Powder Cup Gun PEM-X1 CG
1 About these Instructions
8 Order number 2326960 | Edition 10/2022
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 Powder Cup Gun PEM-X1 CG
2 Using in Accordance with the Instructions
Order number 2326960 | Edition 10/2022 9
2 USING IN ACCORDANCE WITH THE INSTRUCTIONS
2.1 DEVICE TYPE
Powder cup guns for manual coating of grounded work pieces.
2.2 TYPE OF USE
The powder cup gun is designed for the electrostatic coating of work pieces with organic
powders.
WAGNER explicitly prohibits any other use!
The powder cup gun may only be operated in a temperature range from 5–40 °C; 41–104 °F
(FMscope of application 5–45 °C; 41–113 °F).
Electrostatic manual coating systems may only be used in spray areas equipped in
accordance with EN 16985:2018 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10]).
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 Powder Cup Gun PEM-X1 CG
3 Identification
10 Order number 2326960 | Edition 10/2022
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 PEM-X1 CG powder cup gun
Manufacturer Wagner International AG
9450 Altstätten
Switzerland
0102 II2D2mJ
CE European Communities
0102 Notified body: PTB
Ex Symbol for explosion protection
II Device class II
2 Category 2
D Ex-atmosphere dust
2mJ Maximum ignition energy 2 mJ
3.2 FM APPROVAL
P_00309
The PEM-X1 CG powder cup gun is FM approved in the USA and Canada using control
document no. 2309729.
3.3 TYPE PLATE
P_03875
PEM-X1 CG Serial Number:
In accordance with control document: 2309729
For Electro. Fin. Appl. CL. II Spray Materials
0102 0518 II 2 D 2mJ
PTB 12 ATEX 5002 / CSAE 21 UKEX 5704 EN 50050-2 / BS EN 50050-2
Output 100kV max. Ambient Temperature 45 °C
Patents: https://go.wagner-group.com/patents
Made in Switzerland Wagner International AG, CH-9450 Altstätten