WAGNER PEM-X1 Operating Manual
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WAGNER PEM-X1 Operating Manual

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

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Summary of Contents for WAGNER PEM-X1

  • Page 1 Translation of the Original Operating Manual PEM-X1 Manual powder spray gun Version 03/2014 P_01660 II 2D 2mJ 0102...

  • Page 3: Table Of Contents

    Safety Instructions for the Operator 4.1.1 Electrical Devices and Equipment 4.1.2 Staff Qualifi cations 4.1.3 Safe Work Environment Safety Instructions for Staff 4.2.1 Safe Handling of WAGNER Powder Spray Devices 4.2.2 Grounding the Device 4.2.3 Product Hoses 4.2.4 Cleaning 4.2.5 Handling Powder Lacquers...
  • Page 4 PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL Table of Contents OPERATION Training the Operating Staff Safety Instructions Optimizing the Powder Cloud for Your Coating 7.3.1 Recommended Settings for Total Air Volume Switching Off the Spray Gun Adjustment of Powder Quantity "Double Click"...
  • Page 5 Table of Contents SPARE PARTS 13.1 How Can Spare Parts Be Ordered? 13.2 PEM-X1 Corona Manual Gun With a Fan spray nozzle 13.3 PEM-X1 Corona Manual Gun With a Round spray nozzle 13.4 Electrode Holder, X1 R DECLARATION OF WARRANTY AND CONFORMITY 14.1...

  • Page 6: About This Manual

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL ABOUT THIS MANUAL 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 operating and service staff .

  • Page 7: Languages

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

  • Page 8: Correct Use

    Powder spray guns for manual coating of grounded work pieces 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.

  • Page 9: Safety Parameters

    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.

  • Page 10: Reasonably Foreseeable Misuse

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL REASONABLY FORESEEABLE MISUSE The following is prohibited: coating work pieces which are not grounded, unauthorized conversions and modifi 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.

  • Page 11: Identification

    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".

  • Page 12: General Safety Instructions

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention. 4.1.1...

  • Page 13: Safety Instructions For Staff

    4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES Do not point spray guns at people. Before all work on the device, in the event of work interruptions and functional faults: - Switch off the energy/compressed air supply.

  • Page 14: Cleaning

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

  • Page 15: Information About Safe Discharges

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL INFORMATION ABOUT SAFE DISCHARGES Nozzle Electrode Luminous discharge Work piece P_01698 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 eff ect can be seen when the electrode is brought near the grounded work piece.

  • Page 16: Protective And Monitoring Equipment

    This shape, together with the shape of the fan spray nozzle or defl 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!

  • Page 17: Description

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL DESCRIPTION SPRAY GUN DESIGN P_01663 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...

  • Page 18: Technical Data

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL TECHNICAL DATA 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...

  • Page 19: Dimensions

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 5.3.1 DIMENSIONS P_01662 Measurement inch 335/349 13.19/13.74 9.76 1.77 * with fan spray nozzle/with defl ector cone...

  • Page 20: Permitted Accessories

    The accessories listed in the "Accessories" chapter were included in the EC type examination and are approved for use with the gun. SCOPE OF DELIVERY Order No. Designation 2322587 PEM-X1 manual gun with a fan spray nozzle 2335844 PEM-X1 manual gun with a round spray nozzle Nozzle set The standard equipment includes: 2326024...

  • Page 21: Assembly And Commissioning

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL ASSEMBLY AND COMMISSIONING TRAINING ASSEMBLY/COMMISSIONING STAFF WARNING Incorrect installation/operation! Risk of injury and damage to the device. The commissioning staff must have the technical skills to safely undertake commissioning. The commissioning staff must be familiar with the provisions of European standard DIN EN 50050-2.

  • Page 22: Preparing The Spray Gun

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL PREPARING THE SPRAY GUN 6.4.1 SELECTION OF THE SUITABLE NOZZLE SYSTEM The process of changing from the fan spray nozzle to the defl ector cone is described in Chapter 8.8 "Changing from Fan spray nozzle to Round spray nozzle".
  • Page 23 PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL Defl ector cone Application Distance to work piece (mm) 18 mm 100 ... 300 Smaller fl at parts P_01665 25 mm 100 ... 300 Medium sized fl at parts P_01666 34 mm 100 ...

  • Page 24: Connecting The Spray Gun

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL CONNECTING THE SPRAY GUN WARNING Unintentional putting into operation! Risk of injury. Before any work on the device, in the event of work interruptions and malfunctions: Switch off the energy/compressed air supply.
  • Page 25 PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL Powder spray gun to the electrical connection on the control unit Control unit Atomizing air from control unit blue Powder feed from the powder injector transparent Powder injector...

  • Page 26: Grounding

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL GROUNDING DANGER No Grounding! Risk of explosion and risk of electric shock. Electrostatic control units and the associated spray equipment may only be connected to mains supplies with a protective conductor connection (PE conductor)!

  • Page 27: Grounding The Powder Coating System

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL The footwear worn by the operators must comply with the requirements of EN ISO 20344. The measured insulation resistance must not exceed 100 MΩ (megohms). The protective clothing, including gloves, must comply with the requirements of EN ISO 1149-5.

  • Page 28: Operation

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualifi ed to operate the entire system. Before work commences, the operating staff must receive appropriate system training.

  • Page 29: Optimizing The Powder Cloud For Your Coating

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL OPTIMIZING THE POWDER CLOUD FOR YOUR COATING Procedure: 1. Switch on the high-voltage generation and the powder feed. Note: To minimize wear on the wearing parts, the total air volume should be below 5 Nm³/h! The atomizing air should be adjusted for the: fan spray nozzle to 0.1 Nm³/h,...

  • Page 30: Switching Off The Spray Gun

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL SWITCHING OFF THE SPRAY GUN By releasing the trigger the powder feed is stopped and the high-voltage switched off . To safely switch off the spray gun, e.g., for maintenance work, the control unit must be...

  • Page 31: Adjustment Of Powder Quantity

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL ADJUSTMENT OF POWDER QUANTITY Note: This function can only be activated in combination with the EPG-Sprint X control unit. By pressing the buttons "+/-" the preset program values of the feed air (powder quantity) can be changed in the desired direction.

  • Page 32: Double Click" Program (High Dynamic Remote)

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL "DOUBLE CLICK" PROGRAM (HIGH DYNAMIC REMOTE) This function is used to change quickly to another program during a coating operation. The operator can access a previously set program by double-clicking on the trigger lever on the spray gun, for example to recoat parts using diff erent parameters (high-voltage, current limitation, air volumes etc.).

  • Page 33: Reproducible Setting Of The Nozzle Position

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL REPRODUCIBLE SETTING OF THE NOZZLE POSITION An adjustment tool is provided for the fan spray nozzle. It permits turning the fan spray nozzle without damaging the electrodes and without removing the union nut.

  • Page 34: Cleaning And Maintenance

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING STAFF Cleaning work should be undertaken regularly and carefully by qualifi ed and trained staff . The staff must be familiar with the DIN EN 50050-2 provisions. They should be informed of specifi c hazards during their training.

  • Page 35: Cleaning Procedures

    The cleaning intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting J. Wagner AG's specialist personnel. The valid health and safety specifi cations and the safety instructions provided in Chapter 4...

  • Page 36: Maintenance

    Incorrect maintenance/repair! Risk of injury and damage to the device. Have repairs and part replacements carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 37: Maintenance Procedures

    The maintenance intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting J. Wagner AG's specialist personnel. The valid health and safety specifi cations and safety instructions provided in Chapter 4 must be adhered to for all maintenance work.

  • Page 38: Replacing The Spray Gun

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 8.2.4 REPLACING THE SPRAY GUN Before replacing the spray gun, any powder residue must be thoroughly removed. The wearing parts in the spray gun, marked in the spare parts list with " ", must be regularly checked and, if necessary replaced.

  • Page 39: Removing The Fan Spray Nozzle

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL REMOVING THE FAN SPRAY NOZZLE Procedure: 1. Unscrew union nut from gun housing. 2. Take union nut with nozzle system off gun body. The nozzle system remains inserted in the union nut.

  • Page 40: Fitting The Fan Spray Nozzle

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL FITTING THE FAN SPRAY NOZZLE Procedure: Note: 1. Before inserting the electrode holder, the spring contact of the gun body and contact surface of the electrode holder should be checked. The spring contact must be clean and smooth-running, the gun body must also be clean and free of powder deposits.

  • Page 41: Removing The Round Spray Nozzle

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL REMOVING THE ROUND SPRAY NOZZLE Procedure: 1. Pull off defl ector cone. 2. Unscrew union nut from gun housing. 3. Take union nut with nozzle system off gun body. The nozzle system remains inserted in the union nut.

  • Page 42: Fitting The Round Spray Nozzle

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL FITTING THE ROUND SPRAY NOZZLE Procedure: Note: 1. Before inserting the electrode holder, the spring contact of the gun body and contact surface of the electrode holder should be checked. The spring contact must be clean and smooth- running, the gun body must also be clean and free of powder deposits.

  • Page 43: Replacing The Protective Wedge

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL REPLACING THE PROTECTIVE WEDGE Note: A wedge tool is available to prevent the protective wedge from being damaged when dismantling and inserting. The wedge tool has a removal side (E) and an attachment side (A). Use the right side for the corresponding procedure! You will fi nd the necessary wearing parts and spare parts in Chapter 13 "Spare Parts"...
  • Page 44 PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL Note: The same wedge tool is used to insert the protective wedge. Procedure: 1. Guide protective wedge 2 into wedge tool 1. 2. Insert both parts into opening on electrode holder up to stop.

  • Page 45: Changing From Fan Spray Nozzle To Round Spray Nozzle

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL CHANGING FROM FAN SPRAY NOZZLE TO ROUND SPRAY NOZZLE The standard Corona spray gun is delivered with a fan spray nozzle. The nozzle can be changed easily, as described below. The X1 R electrode holder is necessary to perform the change.
  • Page 46 PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL Procedure: 5. Before inserting the electrode holder, the spring contact of the gun body and contact surface of the electrode holder should be checked. The spring contact must be clean and smooth-running, the gun body must also be clean and free of powder deposits.

  • Page 47: Assembly Of The Coronastar

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL ASSEMBLY OF THE CORONASTAR The CoronaStar is a retrofi t set for the spray gun, which helps to achieve a better surface quality (e.g., reduction of "orange peel"). WARNING Danger from electric current! Risk of injury and damage to the device.

  • Page 48: Replacing The Suspension Hook

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 8.10 REPLACING THE SUSPENSION HOOK Procedure: 1. Loosen retaining bolts on rear of hook and unscrew. 2. Slide hook in direction indicated by arrow and remove from gun housing. 3. Fit new hook on receiver and slide in direction indicated by arrow.

  • Page 49: Inspections In Accordance With Din En 50050-2: 2014

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL INSPECTIONS IN ACCORDANCE WITH DIN EN 50050-2: 2014 If the system is used for electrostatic coating with fl ammable coating powders, testing should be undertaken in accordance with DIN EN 50050-2: 2014 as per Table 1.

  • Page 50: Overview Of Inspections

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL OVERVIEW OF INSPECTIONS...

  • Page 51: Disassembly And Disposal

    Wagner or one of our dealers will take back your used Wagner waste electrical or electronic equipment and will dispose of it for you in an environmentally friendly way.

  • Page 52: Troubleshooting And Rectification

    Danger to life and damage to the device. Wagner devices, protective systems and safety, monitoring and control equipment may only be maintained/repaired as defi ned in Directive 94/9/EC (ATEX) by trained Wagner service personnel or capable persons in accordance with TRBS 1203! Note national regulations!
  • Page 53 OPERATING MANUAL Fault Cause Remedy No electrostatic (e.g., no wrap Fault in the high-voltage Contact a Wagner service center around or no powder adhesion) generator Electrical cable from spray gun Contact a Wagner service center to control unit faulty Cascade in spray gun faulty...

  • Page 54: Accessories

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL ACCESSORIES 12.1 FAN SPRAY NOZZLE Order No. Designation Fan spray nozzle, X1, complete P_01664 12.2 DEFLECTOR CONE Order No. Designation Defl ector cone, D18, complete P_01665 Defl ector cone, D25, complete...

  • Page 55: Hose Take-Up

    Hose take-up, D8-D10, complete P_01694 12.5 CORONASTAR RETROFIT SET Order No. Designation CoronaStar, PEM-X1, complete P_01695 CoronaStar electrode, PEM-X1 ET 12.6 WEDGE TOOL P_01696 Order No. Designation Wedge tool, X1 + 20 wedges available as accessory, not included in the purchased parts package...

  • Page 56: Nozzle Extension, X1 Vl 150/300/500

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 12.7 NOZZLE EXTENSION, X1 VL 150/300/500 P_01697 Order No. Designation Nozzle extension, X1 VL 150 (150 mm; 5.91 inches) Nozzle extension, X1 VL 300 (300 mm; 11.81 inches) 2323338 Nozzle extension, X1 VL 500 (500 mm; 19.68 inches)

  • Page 57: Powder Hose

    Designation 2334275 Manual gun cable, PEM-X1 6m ET 2334568 Manual gun cable, PEM-X1 15m ET Note: The replacement of the gun cable may only be performed by Wagner service personnel! 12.11 WALL MOUNT P_01861 Order No. Designation Wall mount with bracket...

  • Page 58: Recipe Sticker

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 12.12 RECIPE STICKER m /h m /h Ø Tribo Corona [kV] [μA] [Nm³/h] [Nm³/h] > 0.2 name ✆ ______________________________ ______________________________ www.wagner-group.com/industry P_01829 Order No. Designation 2331223 Recipe sticker...

  • Page 59: Powder Measuring Adapter

    Risk of explosion due to electrostatic charging! Danger to life and damage to the device. Only use powder measuring adapter when high-voltage is switched off ! for measuring powder quantities for the PEM-X1 spray gun Order No. Designation Powder measuring adapter with X1 bag, complete P_01716 The powder measuring adapter is slid onto the nozzle.

  • Page 60: Spare Parts

    Incorrect maintenance/repair! Risk of injury and damage to the device. Have repairs and part replacements carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 61: Pem-X1 Corona Manual Gun With A Fan Spray Nozzle

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 13.2 PEM-X1 CORONA MANUAL GUN WITH A FAN SPRAY NOZZLE P_01699 PEM-X1 manual gun Order No. Designation PEM-X1 Corona manual gun Hose take-up, D10-12, complete O-ring Union nut, X1 Fan spray nozzle, X1, complete...

  • Page 62: Pem-X1 Corona Manual Gun With A Round Spray Nozzle

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 13.3 PEM-X1 CORONA MANUAL GUN WITH A ROUND SPRAY NOZZLE P_01661 PEM-X1 manual gun Order No. Designation 2335844 PEM-X1 Corona manual gun 2322761 Hose take-up, D10-12, complete 9971364 O-ring 2320464 Union nut, X1...

  • Page 63: Electrode Holder, X1 R

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 13.4 ELECTRODE HOLDER, X1 R P_01700 Electrode holder, X1 R, with nozzles Order No. Designation Electrode holder, X1 R, with nozzle Electrode holder, X1 R ET Replacement protective wedge, X1 Defl ector cone sleeve, X1...

  • Page 64: Declaration Of Warranty And Conformity

    The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

  • Page 65: Declaration Of Conformity

    EN 50050-2: 2012 CE Certifi cate of Conformity The CE certifi cate of conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number:...

  • Page 66: Ec Type Examination Certifi Cate

    PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL 14.4 EC TYPE EXAMINATION CERTIFICATE...

  • Page 67: Fm Approval

    ORDER NUMBER DOC 2326020 OPERATING MANUAL 14.5 FM APPROVAL The PEM-X1 powder spray gun is approved in the USA and Canada using confi guration drawing no. 2309729. P_00309 Special conditions of use: The source electrical connection for the Control Units are to be connected in an unclassified...
  • Page 68 PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL...
  • Page 69 PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL...
  • Page 70 PEM-X1 VERSION 03/2014 ORDER NUMBER DOC 2326020 OPERATING MANUAL...
  • Page 72 Order No. 2326020 Edition 03/2014 Germany Phone E-mail Switzerland Phone More contact addresses on the internet at: Company/Locations/WAGNER worldwide Subject to changes without notice...

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