WAGNER PEM-X1 CG User manual

P_01725
PEM-X1 CG
Powder Cup Gun
Version 05/2019
II 2D 2mJ
0102
P_00309

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VERSION 05/2019 ORDER NUMBER DOC2326960 PEM-X1 CG
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 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 FM Approval 10
3.3 Type Plate 10
3.4 Permissible Device Combinations 11
4 BASIC SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 A Safe Work Environment 13
4.1.3 Personnel Qualications 13
4.2 Safety Instructions for the Personnel 14
4.2.1 Personal Safety Equipment 14
4.2.2 Safe Handling of WAGNER Powder Spray Devices 14
4.2.3 Grounding the Device 15
4.2.4 Product Hoses 15
4.2.5 Electrical Connection Cables 16
4.2.6 Cleaning and Flushing 16
4.2.7 Maintenance and Repair 17
4.2.8 Protective and Monitoring Equipment 17
4.3 Information about Safe Discharges 18
5 DESCRIPTION 19
5.1 Construction of the Cup Gun 19
5.2 Mode of Operation of the Cup Gun 19
5.3 Scope of Delivery 20
5.4 Data 20
5.4.1 Technical Data 20
5.4.2 Dimensions 21
5.5 Accessories 21
6 ASSEMBLY AND COMMISSIONING 22
6.1 Training of Assembly/Commissioning Personnel 22
6.2 Storage Conditions 22
6.3 Installation Conditions 22

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6.4 Preparing the Cup Gun 22
6.4.1 Selection of a Suitable Nozzle System 22
6.4.2 Powder Cup 24
6.4.3 Assembling the Powder Cup 24
6.4.4 How to Use the Powder Cup 25
6.5 Connecting the Manual Gun 26
6.6 Grounding 26
6.6.1 Grounding the Powder Coating System 27
6.7 Safety Checks 27
7 OPERATION 28
7.1 Training the Operating Personnel 28
7.2 Tasks 28
7.3 Operation of the Control Unit 28
7.4 Optimizing the Powder Cloud for Coating 33
7.4.1 Recommended Settings for Total Air Volume 33
7.5 Switching O the Cup Gun 33
7.5.1 Pressure Relief/Work Interruption 33
7.6 "Double Click" Program (High Dynamic Remote) 34
7.7 Reproducible Setting of the Nozzle Position 35
8 CLEANING AND MAINTENANCE 36
8.1 Cleaning 36
8.1.1 Cleaning Personnel 36
8.1.2 Cleaning Procedures 36
8.2 Maintenance 36
8.2.1 Maintenance Personnel 36
8.2.2 Maintenance Instructions 37
8.2.3 Safety Checks and Maintenance Intervals 37
8.2.4 Maintenance Procedures 37
8.3 Exchanging the Manual Gun 38
8.4 Changing the Flat Jet Nozzle 39
8.4.1 Removing the Flat Jet Nozzle 39
8.4.2 Fitting the Flat Jet Nozzle 40
8.5 Changing the Round Jet Nozzle 41
8.5.1 Removing the Round Jet Nozzle 41
8.5.2 Fitting the Round Jet Nozzle 42
8.6 Replacing the Protective Wedge 43
8.6.1 Removing the Protective Wedge 43
8.6.2 Installing the Protective Wedge 44
8.7 Changing from Flat Jet Nozzle to Round Jet Nozzle 45
8.8 Assembly of the CoronaStar 47
8.9 Replacing the Suspension Hook 48
8.10 Replacing the Collector Nozzle 49
8.11 Replacing the Connecting Tube 50
9 TROUBLESHOOTING AND RECTIFICATION 51
10 INSPECTIONS 52
11 DISASSEMBLY AND DISPOSAL 54
11.1 Disassembly 54
11.2 Disposal 54

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12 ACCESSORIES 55
12.1 Flat Jet Nozzle 55
12.2 Deector Cone 55
12.3 Electrode Holder 55
12.4 Set of X1 F5 Flat Jet Nozzles 55
12.4.1 Flat Jet Nozzle X1 F5-X 56
12.5 Powder Cup 56
12.5.1 Powder Cup - 210 cm³ 56
12.5.2 1L Powder Cup 56
12.6 Cup Holder 57
12.7 CoronaStar Retrot Set 57
12.8 Wedge Tool 57
12.9 X1 VL Nozzle Extension - 150/300/500 58
12.10 X1 VL Nozzle Extension - 750 58
12.11 Wall Mount 59
12.12 Recipe Sticker 59
12.13 Powder Measuring Adapter 60
12.13.1 Powder Measuring Adapter for Flat Jet Nozzle X1 60
12.13.2 Powder Measuring Adapter for C4-F5/X1-F5 Flat Jet Nozzle 60
13 SPARE PARTS 61
13.1 How Can Spare Parts Be Ordered? 61
13.2 PEM-X1 CG Corona Cup Gun 62
13.3 X1 R Electrode Holder 63
13.4 Powder Cup 64
13.5 Connecting Part 64
13.6 Connecting Tube, Collector Nozzle 65
14 PEMX1 CG PORTABLE SET 66
15 EU DECLARATION OF CONFORMITY 67
15.1 EU Declaration of Conformity - Manual Gun 67

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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.
Electrostatic manual coating systems may only be operated by qualied personnel.
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.
Note: Provides information about particular characteristics and how
to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2326959
Translation of the original operating manual
Language Order no. Language Order no.
English 2326960 Polish 2410120
French 2326961
Italian 2326962
Spanish 2326963
Russian 2333347
Chinese 2333348
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number
Spare part
Marking in the spare parts lists
Position
Number of pieces
-- Item not available as spare part
/ Item does not exist

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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with compressed air
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated 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 necessary 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 relevant provisions.
Skilled person in the
context of
DGUV 209-052
A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the area of electrostatic coating and is familiar
with the relevant and generally 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).

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2 CORRECT USE
2.1 DEVICE TYPE
Powder cup guns for manual coating of grounded work pieces.
2.2 TYPE OF USE
The PEM-X1 CG powder cup gun is designed for the electrostatic coating of work pieces with
organic powders.
WAGNER explicitly prohibits any other use!
The powder cup gun may only be operated in a temperature range from 5–40 °C; 41–104 °F
(FMscope of application 5–45 °C; 41–113 °F).
Electrostatic manual coating systemsmay only beused in sprayareas equippedin accordance
with EN 12981 or under equivalent ventilation conditions.
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow 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
lacquer for coating electrically conductive objects and can be used in potentially
explosive areas (zone 22). (See Explosion Protection Identication, Chapter 3.1).
In explosion hazard areas, only use approved explosion-proof electrical devices.
2.4 PROCESSIBLE WORKING MATERIALS
– types of powder that can be charged electrostatically;
– metallic powder.
Note:
Contact your localWAGNER 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:
liquid coating products, e.g., solvents or water-based lacquers are not processed;
no food, medicine or cosmetics are processed.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
Device type: PEM-X1 CG powder cup gun
Manufacturer: Wagner International AG
9450 Altstätten
Switzerland
0102 II 2D 2mJ
CE European Communities
0102 Notied 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 FM APPROVAL
The PEM-X1 CG powder cup gun is FM approved in the USA and Canada using control
document no. 2309729.
P_00309
3.3 TYPE PLATE
P_03875
In accordance with control document: 2309729
PEM-X1 CG
Output 100kV max.
Serial Number:
For Electro. Fin. Appl. CL. II Spray Materials
0102 II 2 D 2mJ
PTB 12 ATEX 5002 EN 50050-2
Ambient Temperature 45 °C
Made in Switzerland

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3.4 PERMISSIBLE DEVICE COMBINATIONS
WARNING
Incorrect use!
Risk of injury and damage to the device.
Only connect the powder cup gun to original WAGNER devices.
Only use the PEM-X1 CG powder gun cup with the following guns and control units:
Guns Control units
– PEM-X1 CG – EPG-Sprint X
– EPG-Sprint XE
– EPG-Sprint
– EPG S2

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning accident prevention regulations.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Danger of electric shock!
Danger to life from electric shock.
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision.
With open housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if device poses a danger or is damaged.
Must be de-energized before work is commenced. Secure the device against being
switched back on without authorization. Inform personnel about planned work.
Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground wire
connection.
Keep liquids away from electrical devices.

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4.1.2 A SAFE WORK ENVIRONMENT
Danger due to dust formation!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with the
skin or eyes.
The oor in the working area must be electrostatically conductive
(measurements according to EN 1081 and EN 61340-4-1).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g., mechanical
stress, corrosion).
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M .
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M .
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.
Maintain sucient quantities of suitable re extinguishers and ensure that they are
serviceable.
The powder release must be electronically interlocked with the powder spray system
exhaust equipment.
Excess coating product (overspray) must be collected up safely.
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 maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Danger due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.

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4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning accident prevention regulations.
In electrostatics applications: Persons belonging to a risk group according to
EMF guideline 2013/35/EU (e.g., carriers of active implants), must not enter the
high-voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Danger due to dust formation!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
Observe the processing regulations laid down by the manufacturer of the powder
lacquer 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 lacquers.
Take the specied protective measures. In particular, wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a powder coating
booth or on a spraying wall with the ventilation (extraction) switched on.
4.2.2 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
Danger due to dust formation!
Do not point spray guns at people.
Do not spray device parts using electrostatic equipment.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.

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4.2.3 GROUNDING THE DEVICE
Danger due to electrostatic charge!
Explosion hazard and damage to the device.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the device.
Flames or sparks can form during discharge.
Correct grounding of the entire coating system prevents electrostatic charges:
Ensure that all devices and tanks are grounded before each coating process.
All of 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., that they are
wearing static dissipative shoes.
Grounding cables must be checked regularly to ensure that they are serviceable
(see EN 60204).
4.2.4 PRODUCT HOSES
Danger due to damaged product hoses!
The product hose may cause dangerous injuries.
Use only an original WAGNER powder hose.
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses
are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the device.

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4.2.5 ELECTRICAL CONNECTION CABLES
Risk caused by improperly laid cables!
Risk of injury and damage to the device.
Properly lay connection cables and check them regularly.
Immediately replace damaged connection cables.
Ensure that no work is ever performed with a damaged connection cable.
Do not lay connection cables on routes used by product handling vehicles and not
through doors/gates.
Do not route connection cables near aisles or walkways in order to avoid tripping.
4.2.6 CLEANING AND FLUSHING
Danger due to cleaning and ushing!
Explosion hazard and damage to the device.
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-ignitable cleaning uids.
If ignitable cleaning uids are used, all parts carrying high voltage must be discharged
to a discharge energy of less than 0.24 mJ, once the high voltage has been switched
o, before they can be reached. Most ignitable 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.
Note the details provided by the powder lacquer manufacturer.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used for
getting rid of dust build-up.
Take measures for workplace safety (see Chapter 4.1.2).

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4.2.7 MAINTENANCE AND REPAIR
Danger due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 12 and Chapter 13 that are
assigned to the device.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
Observe the operating and service manual for all work.
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Danger due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
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.
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 at jet nozzle or deector cone sleeve, prevents
the nozzles from coming loose unintentionally (see chapters 8.4, 8.5, 8.7).
To ensure safety, only use genuine WAGNER spare parts!

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4.3 INFORMATION ABOUT SAFE DISCHARGES
P_03884
1
2
3
4
Designation
1 Nozzle
2 Electrode
3 Luminous discharge
4 Work piece
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.

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5 DESCRIPTION
5.1 CONSTRUCTION OF THE CUP GUN
4
10
9
7
7
8
1
2
3
11
12
6 5
P_01731
Designation
1 Spray gun body
2 Handle
3 Electrical connection cable
4 Atomizer air connection
5 Feed air connection
6 Dosing air connection
7 Union nut
8 Trigger lever
9 Round jet nozzle
10 Flat jet nozzle
11 Suspension hook
12 Powder Cup
5.2 MODE OF OPERATION OF THE CUP GUN
High voltage is activated in the manual gun when the trigger is actuated!
The air supply of the feed, dosage and atomizing air are activated at the same time, for the
powder feed.
To secure the cup gun, the control unit must be switched o.
To prevent electrostatic ashover, the union nut for securing the nozzles is designed with
a labyrinth.

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5.3 SCOPE OF DELIVERY
Order no. Designation
1 2322588 PEM-X1 CG powder cup gun
-- Nozzle set
The standard equipment includes:
1 2326024 Declaration of Conformity
1 2326959 Operating manual, in German
1 see Chapter 1.3 Operating manual in local language
5.4 DATA
5.4.1 TECHNICAL DATA
Dimensions:
Length/width/height see Chapter 5.4.2
Weight 550 g; 1.21 lbs
Cup capacity 130 g; 0.29 lb
Cup lling volume 210 cm³; 7.93 ci
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 DIN EN 50050-2
Protection class
Pneumatic:
Input air pressure (atomizing air volume) maximum 3 bar; 0.3 MPa, 43.51 psi
Powder discharge quantity maximum 200 g/min;
maximum 0.44 lbs/min
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Insucient paint application quality
Provide compressed air free from oil and water
(Quality Standard 6.5.2 according to ISO 8573.1, 2010)
6.5.2 = particle density ≤ 5 mg/m; pressure dew point ≤ +7 °C; oil content ≤ 0.1mg/m