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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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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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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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.

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PEM-X1
OPERATING MANUAL
VERSION 09/2012 ORDER NUMBER DOC 2326020
4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL DEVICES AND OPERATING EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 A SAFE WORK ENVIRONMENT
Keep this operating manual to hand near the unit at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
May only be maintained by skilled electricians.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts.
Secure the device against being switched back on without authorization. Inform staff
about planned work.
Observe electrical safety regulations.
The oor in the working area must be electrostatically conductive (measurements
according to EN 1081 and EN 61340-4-1).
The footwear worn by the operators must comply with the requirements of
ENISO20344.Themeasuredinsulation resistancemustnotexceed100MΩ(megaohms).
The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 MΩ
(megaohms).
The powder release must be electrically interlocked with the powder spray system's
exhaust air equipment.
Excess coating material (overspray) must be collected up safely.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires or
hot surfaces in the vicinity. Do not smoke.
Provide sucient numbers of suitable re extinguishers and ensure that they are
serviceable.
The operating company must ensure that the average concentration of powder paint
in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted
concentration of powder to air). If no reliable LEL value is available, the average
concentration must not exceed 10 g/m³.
Ensure that the device is operated and repaired only by trained persons.

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OPERATING MANUAL
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4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
4.2.2 GROUNDING THE DEVICE
4.2.3 MATERIAL HOSES
4.2 SAFETY INSTRUCTIONS FOR STAFF
Only use original Wagner powder hose.
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
Under no circumstances may people with pacemakers enter the area where the
high-voltage eld between the spray gun and the work piece to be coated builds up!
Do not point spray guns at people.
Before all work on the device, in the event of work interruptions and malfunctions:
- Switch o the energy/compressed air supply.
- Lock spray guns against actuation.
- Relieve pressure on spray guns and device.
- In the event of malfunctions: Identify and correct the problem, proceed as
described in chapter "Elimination of Faults".
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. In the event of discharge, this may result in the formation of sparks or ames.
Ensure that the device is grounded before each coating process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. by wearing
electrostatically conductive shoes.
The function of grounding cables must be checked regularly (see EN 60204).

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4.2.5 HANDLING POWDER PAINTS
4.2.4 CLEANING
Before starting cleaning or any other manual work, the high-voltage in the spray area
must be shut down and locked to prevent it from being switched back on!
Lock the supply of compressed air and decompress system.
Secure the device against being switched back on without authorization.
Use only electrically conducting and grounded containers for cleaning liquids.
Preference should be given to non-ammable cleaning uids.
Flammable cleaning uids may only be used if, once the high-voltage has been
switched o, all parts carrying high-voltage are discharged to a discharge energy of
less than 0,24 mJ before they can be reached.
Most ammable solvents have a ring power of around 24 mJ or 60 nC.
The cleaning agent's ash point must be at least 15 K above the ambient temperature.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to
remove dust deposits.
Take note of the processing regulations laid down by the manufacturer of the powder
paint being used, when preparing or processing the powder.
Take note of the manufacturer’s notication and the relevant environmental protection
regulations when disposing of powder paints.
Take the prescribed safety measures, in particular wear of safety glasses and safety
clothing and use protective hand cream if required.
Use a mask or breathing apparatus if necessary.
To ensure sucient protection of health and the environment, only operate the device
in a powder booth or at a spray wall with activated ventilation (exhaust air).

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PEM-X1
P_01698
OPERATING MANUAL
VERSION 09/2012 ORDER NUMBER DOC 2326020
4.3 INFORMATION ABOUT HARMLESS DISCHARGES
With the high-voltage switched on, a luminous or corona discharge occurs at the electrode
tip; this can only be seen in the dark. This physical eect can be seen when the electrode
is brought near the grounded work piece. This luminous discharge does not involve any
ring power and has no eect on system handling. When the electrode approaches the
work piece, the control unit automatically reduces the high-voltage to a safe value. If you
touch plastic parts of the spray gun with your nger, harmless discharges may occur due to
the high-voltage eld around the spray gun (so-called brush discharges). However, these
do not contain any ring power.
Work piece
Luminous discharge
Nozzle
Electrode

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OPERATING MANUAL
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4.4 PROTECTIVE AND MONITORING EQUIPMENT
To prevent electrostatic ashover, the cup nut for securing the nozzles is designed in a
certain geometric shape.
This shape, together with the shape of the at spray nozzle or deector cone sleeve,
prevents the nozzles from coming loose unintentionally (see chapters 8.3, 8.5, 8.8).
To ensure safety, only use genuine Wagner spare parts!
Incorrect use!
Risk of injury and damage to the device.
Protective and monitoring equipment must not be removed,
modied or rendered unusable.
Regularly check that they are working perfectly.
If defects are detected on protective and monitoring equipment,
the system must not be operated until these defects are
remedied.
WARNING

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PEM-X1
A
B
C
K
I
F
P_01663
E
D
G
F
L
H
OPERATING MANUAL
VERSION 09/2012 ORDER NUMBER DOC 2326020
5 DESCRIPTION
5.1 DESIGN OF THE SPRAY GUN
Designation
A Suspension hook
B Handle
C Electrical connection cable
D Powder hose connection
E Trigger lever
F Cap nut
G Round spray nozzle
H Atomizer air connection
I Flat spray nozzle
K Buttons to adjust the powder quantity
L Gun body
5.2 FUNCTIONING OF THE SPRAY GUN
High-voltage is activated in the hand gun when the trigger is actuated.
The powder supply and air supply to the gun are activated at the same time.
The control unit must be switched o in order to lock the spray gun.
To prevent electrostatic ashover, the cap nut for securing the nozzles is designed with a
labyrinth.

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PEM-X1
OPERATING MANUAL
VERSION 09/2012 ORDER NUMBER DOC 2326020
Dimensions:
Length/width/height see chapter 5.3.1
Weight 490 g; 1.08 lbs
Electrical:
Input voltage maximum of 22 Vpp
Input current maximum of 0.9 A
Frequency 19 - 30 kHz
Output voltage maximum of 100 kV DC
max. Corona current 120 μA
Polarity negative
Construction type in accordance with EN 50050-2
Protection class IP 64
Pneumatic:
Input air pressure (atomizer air volume) maximum of 3 bar; 0.3 MPa, 43.51 psi
Powder output quantity maximum of 450 g/min; 0.99 lbs/min.
Ambient conditions:
Operating temperature range 5 - 45 °C; 41 - 113 °F
Relative humidity < 75 %
5.3 TECHNICAL DATA
Ambient conditions:
If low-melting powders are used, the ambient temperature may have to be below 30 °C;
86 °F.
Volume measures:
for volumes specied in Nm³ (standard cubic meters). One standard cubic meter is one
cubic meter of gas at 0 °C and 1.013 bar.
Outgoing air containing oil!
Risk of poisoning if inhaled.
Insucient paint application quality.
Make compressed air free from oil and water available (quality
standard 3.5.2 according to ISO 8573.1) 3.5.2 = 5 μm / +7 °C;
44.6 °F / 0.1 mg/m³.
WARNING

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PEM-X1
A
P_01662
B
C
OPERATING MANUAL
VERSION 09/2012 ORDER NUMBER DOC 2326020
5.3.1 DIMENSIONS
Measurement mm inch
A* 335/349 13.19/13.74
B 248 9.76
C 45 1.77
* with at spray nozzle/with deector cone

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PEM-X1
OPERATING MANUAL
VERSION 09/2012 ORDER NUMBER DOC 2326020
Stk Order No. Designation
1 2322587 PEM-X1 manual spray gun
1 --- Nozzle set
The standard equipment includes:
1 2326024 Declaration of conformity
1 2326019 Operating manual German
1 see chapter 1.5 Operating manual in the local language
5.5 SCOPE OF DELIVERY
5.4 PERMITTED ACCESSORIES
Only the accessories listed in the chapter "Accessories" of this operating manual may be
connected to the PEM-X1 powder spray gun.
The accessories listed in the chapter "Accessories" were included in the EC type examination
and are approved for use with the gun.

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PEM-X1
OPERATING MANUAL
VERSION 09/2012 ORDER NUMBER DOC 2326020
6 ASSEMBLY AND COMMISSIONING
6.1 QUALIFICATION OF THE ASSEMBLY/COMMISSIONING STAFF
Incorrect installation/operation!
Risk of injury and damage to the equipment.
The commissioning sta must have the technical skills to safely
undertake commissioning.
The commissioning sta must be familiar with the provisions of
European standards DIN EN 50050-2 and DIN EN 50177.
When putting into operation and for all work, read and follow
the operating instructions and safety regulations for the
additionally required system components.
WARNING
6.2 STORAGE CONDITIONS
Until the point of installation, the powder coating gun must be stored in a dry location,
free from vibrations and with a minimum of dust. The powder coating gun must be stored
in closed rooms.
The air temperature at the storage location must be between 5 - 45 °C; 41 - 113 °F.
The relative air humidity at the storage location must not exceed 75%.
6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be between 5 - 45 °C; 41 - 113 °F.
Depending on the powder paint used, the maximum permissible ambient temperature for
reliable operation can be signicantly below +40 °C; 104 °F.
The relative air humidity at the storage location must not exceed 75%.