WAGNER PEM-X1 User manual

0102 II 2D 2mJ
P_01660
Manual powder spray gun
PEM-X1
Version 03/2014
Translation of the Original
Operating Manual

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PEM-X1
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC 2326020
Table of Contents
1 ABOUT THIS MANUAL 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 Use in Potentially Explosive Areas 8
2.4 Safety Parameters 9
2.5 Processible Working Materials 9
2.6 Reasonably Foreseeable Misuse 10
2.7 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identication 11
3.2 Permissible Device Combinations 11
4 GENERAL SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 Sta Qualications 12
4.1.3 Safe Work Environment 12
4.2 Safety Instructions for Sta 13
4.2.1 Safe Handling of WAGNER Powder Spray Devices 13
4.2.2 Grounding the Device 13
4.2.3 Product Hoses 13
4.2.4 Cleaning 14
4.2.5 Handling Powder Lacquers 14
4.3 Information About Safe Discharges 15
4.4 Protective and Monitoring Equipment 16
5 DESCRIPTION 17
5.1 Spray Gun Design 17
5.2 Functioning of the Spray Gun 17
5.3 Technical Data 18
5.3.1 Dimensions 19
5.4 Permitted Accessories 20
5.5 Scope of Delivery 20
6 ASSEMBLY AND COMMISSIONING 21
6.1 Training Assembly/Commissioning Sta 21
6.2 Storage Conditions 21
6.3 Installation Conditions 21
6.4 Preparing the Spray Gun 22
6.4.1 Selection of the Suitable Nozzle System 22
6.5 Connecting the Spray Gun 24
6.6 Grounding 26
6.6.1 Grounding the Powder Coating System 27

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Table of Contents
7 OPERATION 28
7.1 Training the Operating Sta 28
7.2 Safety Instructions 28
7.3 Optimizing the Powder Cloud for Your Coating 29
7.3.1 Recommended Settings for Total Air Volume 29
7.4 Switching O the Spray Gun 30
7.5 Adjustment of Powder Quantity 31
7.6 "Double Click" Program (High Dynamic Remote) 32
7.7 Reproducible Setting of the Nozzle Position 33
8 CLEANING AND MAINTENANCE 34
8.1 Cleaning 34
8.1.1 Cleaning Sta 34
8.1.2 Safety Instructions 34
8.1.3 Cleaning Procedures 35
8.2 Maintenance 36
8.2.1 Maintenance Sta 36
8.2.2 Safety Instructions 36
8.2.3 Maintenance Procedures 37
8.2.4 Replacing the Spray Gun 38
8.3 Removing the Fan spray nozzle 39
8.4 Fitting the Fan spray nozzle 40
8.5 Removing the Round spray nozzle 41
8.6 Fitting the Round spray nozzle 42
8.7 Replacing the Protective Wedge 43
8.8 Changing from Fan spray nozzle to Round spray nozzle 45
8.9 Assembly of the CoronaStar 47
8.10 Replacing the Suspension Hook 48
9 INSPECTIONS IN ACCORDANCEWITH DIN EN 500502: 2014 49
9.1 Overview of Inspections 50
10 DISASSEMBLY AND DISPOSAL 51
10.1 Disassembly 51
10.2 Disposal 51
11 TROUBLESHOOTING AND RECTIFICATION 52
12 ACCESSORIES 54
12.1 Fan spray nozzle 54
12.2 Deector Cone 54
12.3 Electrode Holder 54
12.4 Hose Take-up 55
12.5 CoronaStar Retrot Set 55
12.6 Wedge Tool 55
12.7 Nozzle Extension, X1 VL 150/300/500 56
12.8 Nozzle Extension, X1 VL 750 56
12.9 Powder Hose 57
12.10 Gun Connection Cable 57
12.11 Wall Mount 57
12.12 Recipe Sticker 58
12.13 Powder Measuring Adapter 59

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Table of Contents
13 SPARE PARTS 60
13.1 How Can Spare Parts Be Ordered? 60
13.2 PEM-X1 Corona Manual Gun With a Fan spray nozzle 61
13.3 PEM-X1 Corona Manual Gun With a Round spray nozzle 62
13.4 Electrode Holder, X1 R 63
14 DECLARATION OF WARRANTY AND CONFORMITY 64
14.1 Important Notes Regarding Product Liability 64
14.2 Warranty Claim 64
14.3 Declaration of Conformity 65
14.4 EC Type Examination Certicate 66
14.5 FM Approval 67

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PEM-X1
OPERATING MANUAL
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1 ABOUT THIS MANUAL
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 operating and service
sta.
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 instructions in this
operating manual.
Electrostatic manual coating systems may only be operated by qualied personnel.
1.1 PREFACE
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
Warning instructions in this operating 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 - possible imminent danger.
Non-observance may result in death or serious injury.
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 notice 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 danger and its consequences.
DANGER
This notice 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 danger and its consequences.
WARNING
This notice 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 danger and its consequences.
CAUTION
This notice 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 danger and its consequences.
NOTICE

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1.3 LANGUAGES
The operating manual is available in the following languages:
German 2326019 English 2326020
French 2326021 Italian 2326022
Spanish 2326023 Russian 2333344
Chinese 2333345 Dutch 2337552
Swedish 2345951 Hungarian 2341080
Portuguese 2345347 Danish 2348202
Finnish 2348203 Norwegian 2348238
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part

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2 CORRECT USE
2.1 DEVICE TYPE
Powder spray guns for manual coating of grounded work pieces
2.2 TYPE OF 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 non-intended use.
Wagner disclaims liability for any damage resulting from non-intended use.
Electrostatic manual coating systems may only be used in spray areas equipped in
accordance with EN 12981 or under equivalent ventilation conditions.
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
In explosion hazard areas, only use approved explosion-proof electrical devices.
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
areas (zone 22). (See Chapter 3.1 Explosion Protection Identication).

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2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from non-intended use.
Electrostatic manual coating systems may only be operated in an undamaged condition.
Damaged devices must be decommissioned immediately and repaired immediately.
Use the device only to work with the products recommended by WAGNER.
Operate only the device as a whole.
Do not deactivate safety xtures.
Spare parts and accessories may have safety-relevant properties.
Use only WAGNER original spare parts and accessories.
The manual 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,
and the statutory requirements and accident prevention regulations standards in the
country of use are observed.
2.5 PROCESSIBLE WORKING MATERIALS
Types of powder which can be charged electrostatically
Metallic powder

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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 the spray gun,
processing liquid or similar coating products,
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 physical injury or property damage:
Use of damp powder lacquer
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 non-authorized control units
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
powder lacquers
and cleaning agents
Handling powder
lacquers and
cleaning agents
Skin irritation,
allergies
Wear protective
clothing,
Operation,
observe safety data
sheets
maintenance,
disassembly
Powder lacquer
in air outside the
dened working
area
Lacquering 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
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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 2 D 2mJ 85 °C
CE: European Communities
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 device.
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 the corresponding PI-F1/HiCoat ED-F powder injector
EPG-Sprint with the corresponding PI-F1/HiCoat ED-F powder injector*
EPG S2 with the corresponding PI-F1/HiCoat ED-F powder injector*
* The remote control function of the PEM-X1 spray gun is not available when using these
control units.
Permissible device combinations for the USA and Canada, see Chapter 14.5 "FM Approval".

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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
4.1.2 STAFF QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device 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 inuences.
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 decommissioned 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 sta
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 product (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.
Maintain sucient quantities of suitable re extinguishers and ensure that they are
serviceable.
The operating company must ensure that an average concentration of powder lacquer
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, maintained and repaired only by trained persons.

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4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
4.2.2 GROUNDING THE DEVICE
4.2.3 PRODUCT HOSES
4.2 SAFETY INSTRUCTIONS FOR STAFF
Only use an original Wagner powder hose.
Always follow the information in this manual, 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 functional faults:
- Switch o the energy/compressed air supply.
- Secure the spray gun against actuation.
- Relieve pressure on spray gun and device.
- In case of functional faults: Identify and correct the problem, proceed as described in
the "Fault Rectication" chapter.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. This may result in the formation of sparks or ames when discharging.
Ensure that the device is grounded before each coating process.
All the system's conductive elements, such as oors, walls, ceilings, protective
grating, transport equipment, work pieces, powder tanks, automatic moving devices
or construction parts etc. in the spray area, with the exception of parts which carry
high-voltage during operation, must be connected to the grounding system.
Parts of the booth must be grounded in accordance with EN 12981.
Ensure that all persons inside the working area are grounded, e.g., by wearing
electrostatically conductive shoes.
The functionality of grounding cables must be checked regularly (see EN 60204).

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4.2.5 HANDLING POWDER LACQUERS
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 compressed air supply and decompress the device.
Secure the device against being switched back on without authorization.
Use only electrically conducting and grounded tanks for cleaning uids.
Preference should be given to non-ammable cleaning uids.
Flammable cleaning liquids may only be used if, after switching o the high-voltage,
all high-voltage conducting parts are discharged to a discharge energy of less than
0.24mJ before they can be accessed.
Most ammable solvents have an ignition energy of around 0.24 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.
When preparing or processing the powder and cleaning the device, take note of the
processing regulations, laid down by the manufacturer of the powder lacquers, being
used.
Take note of the manufacturer’s instructions and the relevant environmental protection
regulations when disposing of powder lacquers.
Take the prescribed safety measures, in particular the wearing of safety glasses and
safety clothing as well as the use of protective hand cream.
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 on a spray wall with activated ventilation (exhaust air).

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4.3 INFORMATION ABOUT SAFE 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
ignition energy 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 ignition energy.
Work piece
Luminous discharge
Nozzle
Electrode

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4.4 PROTECTIVE AND MONITORING EQUIPMENT
To prevent electrostatic ashover, the union nut for securing the nozzles is designed in a
certain geometric shape.
This shape, together with the shape of the fan 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 for perfect functioning.
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 03/2014 ORDER NUMBER DOC 2326020
5 DESCRIPTION
5.1 SPRAY GUN DESIGN
Designation
Suspension hook
Handle
Electrical connection cable
Powder hose connection
Trigger lever
Union nut
Round spray nozzle
Atomizing air connection
Fan spray nozzle
Buttons to adjust the powder quantity
Spray gun body
5.2 FUNCTIONING OF THE SPRAY GUN
High-voltage is activated in the manual 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 union nut for securing the nozzles is designed with
a labyrinth.

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Dimensions:
Length/width/height see Chapter 5.3.1
Weight 490 g; 1.08 lbs
Electrical:
Input voltage maximum 22 Vpp
Input current maximum 0.9 A
Frequency 19 - 30 kHz
Output voltage maximum 100 kV DC
Maximum Corona current 120 μA
Polarity negative
Construction type in accordance with EN 50050-2
Protection class
Pneumatic:
Input air pressure (atomizing air volume) maximum 3 bar; 0.3 MPa, 43.51 psi
Powder output quantity maximum 450 g/min;
maximum 0.99 lbs/min
Ambient conditions:
Operating temperature range 5 - 45 °C; 41 - 113 °F
Relative humidity
5.3 TECHNICAL DATA
Ambient conditions:
If low-melting powders are used, the ambient temperature may have to be lower than
30 °C; 86 °F.
Volume measures:
for volumes specied in Nm³ (standard cubic meters). One cubic meter of a gas at 0 °C and
1.013 bar is called norm cubic meter.
Outgoing air containing oil!
Risk of poisoning if inhaled.
Insucient paint application quality.
Provide compressed air free from oil and water
(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 03/2014 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 fan spray nozzle/with deector cone

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Stk Order No. Designation
1 2322587 PEM-X1 manual gun with a fan spray nozzle
2335844 PEM-X1 manual gun with a round spray nozzle
1Nozzle set
The standard equipment includes:
1 2326024 Declaration of conformity
1 2326019 Operating manual, German
1 see Chapter 1.3 Operating manual in local language
5.5 SCOPE OF DELIVERY
5.4 PERMITTED ACCESSORIES
Only the accessories listed in the "Accessories" chapter of this operating manual may be
connected to the PEM-X1 powder spray gun.
The accessories listed in the "Accessories" chapter were included in the EC type examination
and are approved for use with the gun.