WAGNER PEM-C4-Ergo Installation instructions

0102
P_01090
II 2 D EEx 2mJ 85°C
Powder Coating Guns
PEM-C4-Ergo
Version 02 / 2009
Translation of the original
Operating manual

3
PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Languages 5
1.2 Warnings, notes and symbols in these instructions 5
2 GENERAL SAFETY INSTRUCTIONS 6
2.1 Safety instructions for the operator 6
2.1.1 Electrical plant and units 6
2.1.2 Personnel qualifications 6
2.1.3 A safe work environment 6
2.2 Safety instructions for staff 7
2.2.1 Safe handling of WAGNER powder spray units 7
2.2.2 Earth the unit 7
2.2.3 Material hoses 7
2.2.4 Cleaning 7
2.2.5 Handling powder paints 8
2.3 Using in accordance with the instructions 8
2.4 For use in potentially explosive areas 8
2.4.1 Using in accordance with the instructions 8
2.4.2 Explosion protection identification 8
2.5 Note on harmless discharges 9
3 WARRANTY AND DECLARATION OF CONFORMITY 10
3.1 Important notes on product liability 10
3.2 Warranty 10
3.3 CE-conformity 11
4 DESCRIPTION 12
4.1 Fields of application, using in accordance with the instructions 12
4.1.1 Processing materials 12
4.2 Scope of delivery 12
4.3 Technical data 13
4.3.1 Dimensions 14
4.4 Functional description 15
4.4.1 Design of spray gun 15
4.4.2 Functioning of the spray gun 15
5 START-UP 16
5.1 Preparing the spray gun 16
5.1.1 Selection of the suitable nozzle system 16
5.2 Connecting the spray gun 18
5.3 Grounding 19
5.3.1 Grounding of the powder coating system 20
6 OPERATION 21
6.1 Optimizing the spray pattern for your coating 21
6.2 Switching off the spray gun 21
6.2.1 Flushing procedure in conjunction with EPG Sprint/EPG-D1 control unit 21
6.2.2 Flushing procedure in conjunction with EPG 2008/EPG Prima control unit 22

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
Contents
6.3 Performing a color change 22
6.3.1 Flushing procedure in conjunction with EPG Sprint/EPG-D1 control unit 22
6.3.2 Flushing procedure in conjunction with EPG 2008/EPG Prima control unit 23
6.4 Reproducible setting of the nozzle position 23
7 MAINTENANCE AND CLEANING 24
7.1 Replacing the spray gun 25
7.2 Cleaning the spray gun and dismantling the fan spray nozzle 26
7.3 Replacing the protective wedge 27
7.4 Fitting the round spray nozzle 29
7.5 Mounting the Corona-Star 31
7.6 Mounting the C4 gun extension 32
7.7 Mounting the C4-VL300/500 S gun extension 34
7.8 Replacing the protective wedge in the spray gun extension 36
7.9 Replacing the centring pins 40
7.10 Disposal 41
8 TROUBLE SHOOTING AND RECTIFICATION 42
9 ACCESSORY 43
9.1 Fan spray nozzles 43
9.2 Deflector cone 43
9.3 C4 gun extension (Corona) 44
9.4 C4-VL 300/500 S gun extension (Corona) 45
9.5 C4-VL fan spray nozzle 46
9.6 Retrofit-Set Corona-Star 46
9.7 Wedge tool 47
9.8 Powder measuring bag 48
10 SPARE PARTS 49
10.1 How to order spare parts? 49
10.2 PEM-C4-Ergo Corona manual gun 50
10.3 C4 R electrode holder with nozzles 51

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German English
French Dutch
Italian Spanish
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
1.1 LANGUAGES
2305053 2305054
2305055 ---
2305056 2305057
Warning instructions in this manual point out particular dangers to users and equipment
and state measures for avoiding the hazard. These warning instructions fall into the follo-
wing categories:
Danger - imminent danger.Non-observance will result
in death, serious injury and serious material damage.
Warning - possible danger. Non-observance can result
in death, serious injury and serious material damage.
Caution - a possibly hazardous situation. Non-obser-
vance can result in minor injury.
Note - provide information on particular characteristics and how to proceed.
Caution - a possibly hazardous situation. Non-obser-
vance can cause material damage.
SIHI_0100_GB
DANGER
This line warns of the hazard!
Possible consequences of failing to observe the warning instruc-
tions. The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0103_GB
WARNING
This line warns of the hazard!
Possible consequences of failing to observe the warning instruc-
tions. The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0101_GB
CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instruc-
tions. The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0102_GB CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions. The signal word
points out the hazard level.
The measures for preventing the hazard and its consequences.
4HISOPERATINGMANUALCONTAINSINFORMATIONONTHEOPERATIONREPAIRANDMAINTENANCEOF
THEUNIT
 !LWAYSOBSERVETHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
#OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE WARRANTY
AGREEMENT

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.1 ELECTRICAL PLANT AND UNITS
2.1.2 PERSONNEL QUALIFICATIONS
2.1.3 A SAFE WORK ENVIRONMENT
 +EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES
 !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
 %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
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 control unit against being switched back on without authorisation. Inform
staff about planned work.
Observe electrical safety regulations.
ªEnsure that the floor of the working area is anti-static (measurement in accordance
with EN 1081).
ªEnsure that all persons within the working area wear anti-static shoes.
ªEnsure that gloves that are being worn, are made of conductive material.
ªThe powder release must be electronically interlocked with the powder spray system
exhaust equipment.
ªExcess coating material (overspray) must be collected up safely.
ªEnsure that there are no ignition sources such as naked flame, glowing wires or hot
surfaces in the vicinity. Do not smoke.
ªMaintain sufficient quantities of suitable fire extinguishers and ensure that they are
serviceable.
ªThe operating company must ensure that an 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 may not exceed 10g/m³.

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
2.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY UNITS
2.2.2 EARTH THE UNIT
2.2.3 MATERIAL HOSES
2.2 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 should persons with pacemakers be in the area where the
high voltage field between the spray gun and the workpiece to be coated builds up!
Never point the powder spray gun at people.
Before all work on the unit, in the event of work interruptions and functional faults:
– Switch off the energy/compressed air supply.
– Secure the powder spray gun against actuation.
– Relieve the pressure from the powder spray gun and unit.
– By functional faults: Identify and correct the problem, proceed as described in chap.
“Trouble shooting“.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device.These can involve with unloading transmitting or flame formation.
ªEnsure that the device is grounded before each coating process.
ªEarth the workpieces being painted.
ªEnsure that all persons inside the working area are earthed, e.g. that they are wearing
antistatic shoes.
ªGrounding cables must be checked regularly to ensure that they are serviceable
(see EN 60204).
2.2.4 CLEANING
 De-energize the unit electrically.
 Disconnect the pneumatic supply line.
 Relieve the pressure from the unit.
Secure the control unit against being switched back on without authorisation.
 Only mobile industrial vacuum cleaners of design 1 (see ZH 1/487 for C dusts) may be
used for getting rid of dust build-ups.

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PEM-C4-Ergo.
0102
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
2.3 USING IN ACCORDANCE WITH THE INSTRUCTIONS
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
 5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
 /PERATETHEUNITONLYASANENTIREUNIT
 $ONOTDEACTIVATESAFETYEQUIPMENT
 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
2.2.5 HANDLING POWDER PAINTS
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 advice and the relevant environmental protection
regulations when disposing of powder paints.
Implement the prescribed safety measures, in particular the wearing of safety glasses
and safety clothing as well as the use of protective hand cream.
Use dust masks or breathing apparatus.
To ensure sufficient protection of health and the environment,only operate the device
in a powder booth or at a spray wall with activated ventilation (exhaust air).
2.4.1 USING IN ACCORDANCE WITH THE INSTRUCTIONS
2.4.2 EXPLOSION PROTECTION IDENTIFICATION
2.4 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
II 2 D EEx 2mJ 85°C
CE: Communautés Européennes
Ex: Symbol for explosion protection
II: Unit class II
2: Category 2 gun
D: Ex-atmosphere dust
2mJ: max. firing power 2 mJ
85°C: max. surface temperature
This type A-P powder electrostatic gun is suited to processing industrial powder paints for
coating electro-conductive objects and can be used in potentially explosive atmospheres.
(See explosion protection identification).

9
PEM-C4-Ergo.
P_01091
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
2.5 NOTE ON 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 effect can be seen when the electrode
is near the grounded workpiece. This luminous discharge does not involve any ignition
energy and has no effect on the usage of the plant. When the electrode approaches the
workpiece, the control unit automatically reduces the high-voltage to a safe value. If you
touch plastic parts of the spray gun with the finger, harmless discharges may occur due to
the high-voltage field around the spray gun (so-called brush discharges). However, these
do not contain any ignition energy.
Workpiece
Luminous discharge
Nozzle
Electrode

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
3 WARRANTY AND DECLARATION OF CONFORMITY
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 WARRANTY
!SARESULTOFAN%#REGULATIONEFFECTIVEASFROM*ANUARYTHEMANUFACTURERSHALL
ONLYBELIABLEFORHISPRODUCTIFALLPARTSCOMEFROMHIMORAREAPPROVEDBYHIMANDIFTHE
DEVICESAREPROPERLYlTTEDOPERATEDANDMAINTAINED
)FOTHERMAKESOFACCESSORYANDSPAREPARTSAREUSEDTHEMANUFACTURER@SLIABILITYCOULDBE
FULLYORPARTIALLYNULLANDVOID
4HEUSAGEOFORIGINAL7!'.%2ACCESSORIESANDSPAREPARTSGUARANTEESTHATALLSAFETYRE
GULATIONSAREOBSERVED
This equipment is covered by the following manufacturing warranty.
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the Purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The terms of the warranty are met at our discretion by the repair or replacement of the
unit or parts thereof. The resulting costs, in particular shipping charges, road tolls, labour
and material costs will be borne by us except where these costs are increased due to the
subsequent shipment of the unit to a location other than the address of the purchaser.
This warranty does not cover damage caused by:
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute materials and the action of chemical, electrochemical or electrical
agents, except when the damage is attributable to us.
This warranty does not cover damage caused by:
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute materials and the action of chemical, electrochemical or electrical
agents, except when the damage is attributable to us.
Components not manufactured by Wagner are subject to the warranty terms of the
original maker.
The replacement of a part does not extend the warranty period of the unit.
The unit should be inspected immediately upon receipt.
To avoid loss warranty, aniy apparent defect should be notified to us or the dealer in
writing within 14 days from date of sale of the unit.
The right to commission warranty services to a third party is reserved.
Warranty claims are subject to proof of purchase by submitting an invoice or delivery
note. If an inspection finds damage not covered by the present warranty, the repair will be
carried out at the expense of the purchaser.
Note that this warranty does not in any way restrict legally entitled claims or those
contractually agreed to in our general terms and conditions.
J.Wagner AG

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
3.3 CE-CONFORMITY
PEM-C4-Ergo manual gun 2304981
Herewith we declare that the supplied version of
- PEM-C4-Ergo manual gun, order no. 2305069
complies with the following provisons applying to it:
- 94/9/EG (Atex-directive)
- 2002/95/EG (RoHs-directive)
- 2002/96/EG (WEEE-directive)
Applied standards, in particular:
- DIN EN 1127-1: 2008
- DIN EN 50050: 2007
- DIN EN 50053-2: 1990
- DIN EN 61241-0: 2007
- DIN EN 61241-1: 2005
- DIN EN 61241-14: 2005
- DIN EN 60529: 2000
- BGI 764
Marking:
CE Certificate of Conformity
The certificate is enclosed with this product.The certificate of conformity can be reordered
from your WAGNER representative, quoting the product and serial number.
Part number:

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
4 DESCRIPTION
4.1 FIELDS OF APPLICATION, USING IN ACCORDANCE WITH THE INSTRUCTIONS
The PEM-C4-Ergo spray gun is used for industrial powder coating.
The PEM-C4-Ergo spray gun can be operated with the following control units:
●EPG Sprint with PI-F1 powder injector
●EPG-D1 with PI-F1 powder injector
●EPG 2008/EPG Prima with PI-P1 powder injector
●HVM-DP controller module
Quantity Order No. Description
1 2305069 PEM-C4-Ergo manual gun
The standard equipment includes:
1 2304981 Declaration of conformity
1 2305053 Operating manual German
1 see chapter 1.1 Operating manual in the local language
4.2 SCOPE OF DELIVERY
SIHI_05056_ENG
WARNING
Incorrect use of the spray gun!
Risk of injury and damage to the equipment
 Only connect original Wagner devices to the PEM-C4-Ergo spray
gun.
4.1.1 PROCESSING MATERIALS
Conventional types of powder and metal powder that can be electrostatically charged.
High room temperatures and, in particular, laying hoses in areas exposed to sunlight in
factory buildings must be avoided.

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
Dimensions:
Length/width/height see chapter 4.3.1
Weight 504 g; 1.11 lbs
Electrical:
Input voltage max. 22 Vpp
Input current max. 0.9 A
Frequency 19-30 kHz
Output voltage max. 100 kV DC
max. Corona current 120 µA
Polarity negative
Design as per EN 50050
Protection class IP 54
Pneumatic:
Compressed air input pressure
(atomizing air quantity)
max. 3 bar; 0.3 MPa, 43.51 psi
Powder output quantity max. 450 g/min; max. 0.99 lbs/min.
Operating temperature range 5-45°C; 41-113°F
4.3 TECHNICAL DATA
SIHI_05034_ENG
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled
 Provide water-free and oil-free compressed air (quality standard
3.5.2 as per ISO 8573.1) 3.5.2 = 5 μm / +7°C; 44.6°F / 5mg/m³.
Ambient conditions:
If low temperature powders are used, the ambient temperature may have to be lower than
30°C; 86°F.
Volume measures:
For volumes,specified in Nm³ (standard cubic meters). One cubic meter of a gas at 0°C; 32°F
and 1.013 bar is called norm cubic meter. 1 Nm³/h = 35.3ft³/h; 1 bar = 14.504 psi.

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PEM-C4-Ergo.
P_01092
A
B
C
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
4.3.1 DIMENSIONS
Dimension mm inches
A* 355/385 13.98/15.16
B 265 10.43
C 46 1.81
* with fan spray nozzle/with deflector cone

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PEM-C4-Ergo.
A
B
C
D
E
F
G
E
HI
K
L
P_01093
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
4.4 FUNCTIONAL DESCRIPTION
4.4.1 DESIGN OF SPRAY GUN
Description
A Suspension hook
B End part
C Spray gun body
D Trigger
E Outer nut
FDeflector cone
G Electrode
H Fan spray nozzle
I Atomizing air connection
K Powder hose connection
L Electrical connection
4.4.2 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 off in order to lock the spray gun.

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PEM-C4-Ergo.
P_00935
P_00694
P_00694
P_00694
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
5.1 PREPARING THE SPRAY GUN
5 START-UP
5.1.1 SELECTION OF THE SUITABLE NOZZLE SYSTEM
Nozzle Overview Application Spray pattern
Fan spray nozzle Difficult workpieces
●Undercuts
●Profiles
●Flat workpieces
(reduced picture frame)
Widely spread flat powder
cloud
Deflector cone
●Wire goods
●Grid designs
Oval powder cloud:
Size of the powder cloud is
dependent on the deflector
cone diameter
Nozzle Application Distance to
workpiece
(mm)
Powder
output
(g/min)
F1¹ Universal application
(slow powder cloud)
●Deep and complex shapes
●Extensive workpieces
120 … 300 50 … 250
F2¹ Targeted application
(dense powder cloud)
●High penetration
●Wide coating range
120 … 400 30 … 200
WARNING
Incorrect installation/operation!
Risk of injury and damage to equipment
 When putting into operation and for all work, read and follow
the operating instructions and safety regulations for the addi-
tionally required system components.
SIHI_0050_GB

17
PEM-C4-Ergo.
P_00935
P_00695
P_00694
P_00694
F1
P_01107
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
Nozzle Application Distance to
workpiece
(mm)
Powder
output
(g/min)
F3¹ Low powder application
(faster powder cloud)
●Very good dispersion with
low air and powder
quantities
●For all workpieces
120 … 300 30 … 150
HPO-1¹ Wide fan spray nozzle for high
powder application
(slow powder cloud)
●Good dispersion
●Special for extensive
workpieces
> 200
(total air
> 4.5 Nm³/h)
150 … 400
1.) Nozzles are labeled on the back.
Deflector cone Application Distance to
workpiece
(mm)
Powder
output
(g/min)
R20
∅ 20 mm
●Small even workpieces 100 … 300 30 … 250
R28 ∅ 28 mm
●Medium sized, even
workpieces
●Lateral application with
Z-axis
100 … 300 50 … 250
You will find the article numbers of the different nozzles in chapter 9“Accessories“.

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PEM-C4-Ergo.
P_01094
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
Procedure:
1. Switch off the high-voltage generation at the control unit.
2. Connect the spray gun to the control unit using the electrical cable.
3. Connect the powder feed hose to the spray gun and to the powder injector.
4. Connect the atomizing air hose to the spray gun and to the control unit.
Hint:
Using a Wagner PI-F1 powder injector and a suitable control unit, it is possible to
automatically blow out or purge the spray gun each time prior to switch off.
Atomizing air from the
control unit
Powder feed from the
powder injector
to the electrical
connection at the
control unit
SIHI_05057_ENG
WARNING
Unintentional putting into operation!
Risk of injury
Before all work on the unit, in the event of work interruptions and
functional faults:
 Switch off the energy/compressed air supply.
 Relieve spray gun and unit pressure.
 Secure the spray gun against actuation.
 In the event of functional faults,remedy the fault as described in
the“Troubleshooting“ chapter.
5.2 CONNECTING THE SPRAY GUN

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PEM-C4-Ergo.
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
5.3 GROUNDING
For safety reasons, the spray gun must be properly grounded. This occurs through the
electrical cable.
Good grounding of the workpiece is also necessary for optimum powder coating.
A poorly grounded workpiece causes:
●Dangerous electric charging of the workpiece
●Very bad wrap around
●Uneven coating
●Backspraying to the spray gun, i.e. contamination
Sparks between workpiece and conveyor hooks (hangers) can occur if hooks or
other hanger parts are not completely cleaned! These sparks can cause heavy radio
frequency interference (Electro-magnetic compatibility = EMC).
WARNING
Heavy paint mist if earthing is insufficient!
Risk of poisoning
Insufficient paint application quality
Earth all unit components.
Earth the workpieces being painted.
SIHI_0003_GB

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PEM-C4-Ergo.
P_01120
1
2
3
6
7
5
4
OPERATING MANUAL
VERSION 02/2009 ORDER NUMBER DOC2305054
5.3.1 GROUNDING OF THE POWDER COATING SYSTEM
1 Only use mains cables with grounding wire!
2 Connect grounding cable with booth and system ground!
3 Connect grounding cable to an uncoated metal part of the booth!
4 Remove all paint from hooks and other hanger parts!
5 Do not wear non-conducting gloves!
6 Wear electrostatically conductive shoes!
7 The floor must be electrostatically conductive!