WAGNER PER-X1 Operational manual

P_04900
Robot powder spray gun
PER-X1
Translation of the Original Operating Manual
0102 II2D2mJ
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 Robot powder spray gun PER-X1
Table of Contents
Order number 2444998 | 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 Languages 6
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 7
2 Using in Accordance with the Instructions 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 8
2.5 Misuse 8
3 Identification 9
3.1 Explosion Protection Identification 9
3.2 Type Plate 9
3.3 Permissible Device Combinations 9
4 Basic Safety Instructions 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Devices and Equipment 11
4.1.2 A Safe Work Environment 11
4.1.3 Personnel Qualifications 12
4.2 Safety Instructions for the Personnel 12
4.2.1 Personal Safety Equipment 12
4.2.2 Safe Handling of WAGNER Powder Spray Devices 13
4.2.3 Grounding the Device 13
4.2.4 Product Hoses 13
4.2.5 Electrical Connection Cables 14
4.2.6 Cleaning and Flushing 14
4.2.7 Maintenance and Repair 14
4.2.8 Protective and Monitoring Equipment 15
4.3 Information about safe discharges 15
5 Description 17
5.1 Design of the Robot Gun 17
5.2 Positive Cascade 17
5.3 Mode of Operation of the Robot Spray Gun 18
5.4 Extent of Delivery 18
5.5 Data 18
5.5.1 Technical Data 18
5.5.2 Dimensions 19
5.6 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 Connecting the Robot Spray Gun 23
6.6 Assembly of the Variants 25

Operating manual Robot powder spray gun PER-X1
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6.6.1 PER-X1 Single Outside (SO) 25
6.6.2 PER-X1 Single Inside (SI) 26
6.6.3 PER-X1 Twin Outside (TO) 27
6.6.4 PER-X1 Twin Inside (TI) 28
6.7 Grounding 29
6.7.1 Grounding the powder coating system 30
6.8 Safety Checks 30
7 Operation 31
7.1 Training the Operating Personnel 31
7.2 Tasks 31
7.3 Switching on the Robot Powder Spray Gun 31
7.4 Optimizing the Powder Cloud for Coating 31
7.4.1 Recommended Settings for Total Air Volume 31
7.5 Switching Off the Automatic Powder Gun 31
7.5.1 Switching Off in Normal Operation 31
7.5.2 Switching Off the Automatic Gun in the Event of Faults or Emergencies 32
7.5.3 Pressure Relief / Work Interruption 32
7.6 Reproducible setting of the nozzle position 32
8 Cleaning and Maintenance 33
8.1 Cleaning 33
8.1.1 Cleaning Personnel 33
8.1.2 Cleaning Procedures 33
8.1.3 Performing a Paint Change 33
8.2 Maintenance 34
8.2.1 Maintenance Personnel 34
8.2.2 Maintenance Instructions 34
8.2.3 Safety Checks 34
8.2.4 Maintenance Procedures 34
8.3 Replacing the Robot Spray Gun 35
8.4 Changing the Flat Jet Nozzle 35
8.4.1 Removing the Flat Jet Nozzle 35
8.4.2 Fitting the Flat Jet Nozzle 36
8.5 Changing the Round Jet Nozzle 37
8.5.1 Removing the Round Jet Nozzle 37
8.5.2 Fitting the Round Jet Nozzle 38
8.6 Replacing the Protective Wedge 38
8.6.1 Removing the Protective Wedge 38
8.6.2 Installing the Protective Wedge 39
8.7 Changing Nozzle Types 40
8.8 Mounting the Double Adapter 42
8.8.1 Removing the Nozzle and Electrode Holder 42
8.8.2 Installation of the Double Adapter 43
8.8.3 Cleaning the Double Adapter 44
8.8.4 Replacing the Wearing Parts 44
8.9 Assembly of the CoronaStar 45
9 Troubleshooting and Rectification 46
10 Inspections in Accordance with DIN EN 50177: 2009 47
10.1 Abbreviations 47
10.2 Overview Table 48
11 Disassembly and Disposal 50
11.1 Disassembly 50

Operating manual Robot powder spray gun PER-X1
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11.2 Disposal 50
12 Accessories 51
12.1 Robot Flange Variants 51
12.2 Nozzle systems 51
12.2.1 Flat Jet Nozzles System X1 52
12.2.2 X1 F Flat Jet Nozzles System 52
12.2.3 X1 R Round Jet Nozzles System 53
12.2.4 Nozzle extension 53
12.3 Double Adapter 54
12.4 Corrugated Tubes 56
12.5 Retrofit Set CoronaStar 56
12.6 D10-D12 Powder Coupling 56
12.7 Wedge tool 56
12.8 Powder hose 57
12.9 Atomizing air hose 57
12.10 Gun Connection Cable 57
12.11 Powder measuring adapter 57
12.11.1 Powder Measuring Adapter for X1 Flat Jet Nozzle 57
13 Spare Parts 58
13.1 How to Order Spare Parts 58
13.2 Notes on the Use of Spare Parts 58
13.3 PER-X1 Corona Robot Spray Gun with a Flat Jet Nozzle 59
13.4 PER-X1 Corona Robot Spray Gun with a Round Jet Nozzle 60
13.5 X1 R Electrode Holder 61
13.6 X1 double adapter 62
14 Declaration of Conformity 63
14.1 EU Declaration of Conformity 63

Operating manual Robot powder spray gun PER-X1
1 About these Instructions
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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 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2426813
Translation of the original operating manual
Language Order no. Language Order no.
English 2426815 Spanish 2426818
French 2426816 Chinese 2426820
Italian 2426817
Additional languages upon request or at: www.wagner-group.com

Operating manual Robot powder spray gun PER-X1
1 About these Instructions
Order number 2444998 | Edition 10/2022 7
1.4 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
1.5 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.
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 Robot powder spray gun PER-X1
2 Using in Accordance with the Instructions
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2 USING IN ACCORDANCE WITH THE INSTRUCTIONS
2.1 DEVICE TYPE
Robot powder spray gun for coating work pieces which are grounded.
2.2 TYPE OF USE
The robot powder spray gun is designed for the electrostatic coating of work pieces with
organic powders.
WAGNER explicitly prohibits any other use!
The robot powder spray gun may only be operated in a temperature range from 5–40 °C; 41–
104 °F.
Electrostatic coating systems may only be used in spray areas equipped in accordance with
EN 16985 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9]).
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 Robot powder spray gun PER-X1
3 Identification
Order number 2444998 | Edition 10/2022 9
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 PER-X1 automatic gun
Manufacturer Wagner International AG
9450 Altstätten
Switzerland
0102 II2 D2mJ
CE European Communities
0102 Notified body: PTB
Ex Symbol for explosion protection
II Device class II
2 Category 2
D Ex-atmosphere dust
2mJ Maximum ignition energy 2 mJ
3.2 TYPE PLATE
P_04901
PER-X1 Serial Number:
PTB 22 ATEX 5001
EN 50050-2 / EN 50177
Wagner International AG, CH-9450 Altstätten
Made in Switzerland
0102 II 2 D 2mJ
3.3 PERMISSIBLE DEVICE COMBINATIONS
WARNING
Incorrect use!
Risk of injury and damage to the device.
4Only connect the powder spray gun to original WAGNER devices.
The PER-X1 robot powder spray gun may only be used with the following control units:
Guns Control units
PER-X1 (with accessories) EPG-Sprint X

Operating manual Robot powder spray gun PER-X1
3 Identification
10 Order number 2444998 | Edition 10/2022
Guns Control units
EPG-Sprint XE
EPG-Sprint
EPG S2
HVM-DP
EPG-DP5
EPG-SL5
For accessories, see chapter Accessories [851]