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

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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

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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

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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

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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

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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

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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.

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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

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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.