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

3
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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PEM-X1
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC 2326020
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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PEM-X1
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC 2326020
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
VERSION 03/2014 ORDER NUMBER DOC 2326020
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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PEM-X1
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC 2326020
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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PEM-X1
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC 2326020
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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PEM-X1
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC 2326020
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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PEM-X1
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC 2326020
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