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

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

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Summary of Contents for WAGNER PEM-X1 CG

  • Page 1 Version 05/2019 PEM-X1 CG Powder Cup Gun P_01725 II 2D 2mJ 0102 P_00309...

  • Page 3: Table Of Contents

    4.1.2 A Safe Work Environment 4.1.3 Personnel Qualifications Safety Instructions for the Personnel 4.2.1 Personal Safety Equipment 4.2.2 Safe Handling of WAGNER Powder Spray Devices 4.2.3 Grounding the Device 4.2.4 Product Hoses 4.2.5 Electrical Connection Cables 4.2.6 Cleaning and Flushing 4.2.7...
  • Page 4 PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 Preparing the Cup Gun 6.4.1 Selection of a Suitable Nozzle System 6.4.2 Powder Cup 6.4.3 Assembling the Powder Cup 6.4.4 How to Use the Powder Cup Connecting the Manual Gun Grounding 6.6.1 Grounding the Powder Coating System...
  • Page 5 12.13.1 Powder Measuring Adapter for Flat Jet Nozzle X1 12.13.2 Powder Measuring Adapter for C4-F5/X1-F5 Flat Jet Nozzle SPARE PARTS 13.1 How Can Spare Parts Be Ordered? 13.2 PEM-X1 CG Corona Cup Gun 13.3 X1 R Electrode Holder 13.4 Powder Cup 13.5 Connecting Part 13.6...

  • Page 6: About These Instructions

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 ABOUT THESE INSTRUCTIONS 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.

  • Page 7: Languages

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 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...

  • Page 8: Terminology For The Purpose Of This Manual

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 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 associated with improper behavior as well as the necessary protective devices and measures.

  • Page 9: Correct Use

    DEVICE TYPE Powder cup guns for manual coating of grounded work pieces. 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;...

  • Page 10: Identification

    Device class II Category 2 Ex-atmosphere dust 2 mJ Maximum ignition energy 2 mJ FM APPROVAL The PEM-X1 CG powder cup gun is FM approved in the USA and Canada using control document no. 2309729. P_00309 TYPE PLATE PEM-X1 CG Serial Number:...

  • Page 11: Permissible Device Combinations

    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 –...

  • Page 12: Basic Safety Instructions

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 BASIC SAFETY INSTRUCTIONS 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.

  • Page 13: A Safe Work Environment

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 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 floor in the working area must be electrostatically conductive (measurements according to EN 1081 and EN 61340-4-1).

  • Page 14: Safety Instructions For The Personnel

    For sufficient 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.

  • Page 15: Grounding The Device

    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: –...

  • Page 16: Electrical Connection Cables

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 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.

  • Page 17: Maintenance And Repair

    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.

  • Page 18: Information About Safe Discharges

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 INFORMATION ABOUT SAFE DISCHARGES P_03884 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 effect can be seen when the electrode is brought near the grounded work piece.

  • Page 19: Description

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 DESCRIPTION CONSTRUCTION OF THE CUP GUN 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...

  • Page 20: Scope Of Delivery

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 SCOPE OF DELIVERY Order no. Designation 2322588 PEM-X1 CG powder cup gun Nozzle set The standard equipment includes: 2326024 Declaration of Conformity 2326959 Operating manual, in German see Chapter Operating manual in local language DATA 5.4.1 TECHNICAL DATA...

  • Page 21: Dimensions

    ACCESSORIES Only the accessories listed in Chapter of this operating manual may be connected to the PEM-X1 CG powder gun cup. The accessories listed in Chapter were included in the EC type examination and are approved for use with the manual gun.

  • Page 22: Assembly And Commissioning

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 ASSEMBLY AND COMMISSIONING TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL The assembly and commissioning personnel must have the technical skills to safely commission the device. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.
  • Page 23 PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 Application Distance to Powder Nozzle work piece discharge (mm) (g/min) Universal – Deep and complex part 120 … 300 50 … 300 geometries P_01664 – Extensive work pieces The spray width can be adjusted by the sliding ring.

  • Page 24: Powder Cup

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 6.4.2 POWDER CUP Powder cup with cover, 210 cm³ P_01730 6.4.3 ASSEMBLING THE POWDER CUP Insert powder cup in opening up to stop. P_01727...

  • Page 25: How To Use The Powder Cup

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 6.4.4 HOW TO USE THE POWDER CUP Cover 1 is only needed on the gun if the gun is angled such that powder escapes from the tank. During coating, the flip-flop latch 2 must be open.

  • Page 26: Connecting The Manual Gun

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 CONNECTING THE MANUAL GUN Designation 1 Powder cup gun 2 Electrical connection cable 3 Control unit 4 Dosing air hose (blue) 5 Feed air hose (red) 6 Atomizing air hose (black) 7 Use non-return valve with feed...

  • Page 27: Grounding The Powder Coating System

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 Prerequisites for perfect grounding and coating of a work piece are: – clean suspension of the work piece to be coated, – the grounding resistance of the work piece must not exceed 1 M (resistance to ground measured at 500 V or 1000 V).

  • Page 28: Operation

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 OPERATION TRAINING THE OPERATING PERSONNEL The operating personnel must be qualified to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.
  • Page 29 PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 2 Illuminated display: "Corona or Tribo Current" – Lights up green Tribo scale: – When a Tribo gun is connected and selected – Bar display: When powder feed is activated – Display range: 0–5 µA Resolution 0.5 µA...
  • Page 30 PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 14 LED display: "Automatic gun" – Lights up, when an automatic gun is connected 15 Push button: "Standby" – To switch into standby mode – High voltage and powder feed cannot be activated in this mode –...
  • Page 31 PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 24 Universal control dial – Dynamic digital control dial with 32 positions per revolution – Adjustment speed is proportional to rotational speed – Used to set: "Total air volume; atomizer, ionizer and Tribo air; additional recipes;...
  • Page 32 PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 33 Illuminated display: "Powder quantity" – Lights up green – Display range: 0–100% – Resolution: 3.33% – Single LED display: Set point (high voltage and powder are deactivated) – Bar display: Actual value (high voltage and powder are activated) 34 Illuminated display: "Total air volume"...

  • Page 33: Optimizing The Powder Cloud For Coating

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 OPTIMIZING THE POWDER CLOUD FOR 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.

  • Page 34: Double Click" Program (High Dynamic Remote)

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 "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 manual gun, for example to recoat parts using different parameters (high-voltage, current limitation, air volumes etc.).

  • Page 35: Reproducible Setting Of The Nozzle Position

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 REPRODUCIBLE SETTING OF THE NOZZLE POSITION An adjustment tool is provided for the flat jet nozzle. It permits turning the flat jet nozzle without damaging the electrodes and without removing the union nut.

  • Page 36: Cleaning And Maintenance

    8.1.2 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 WAGNER's specialist personnel. Procedure: 1. End the coating procedure.

  • Page 37: Maintenance Instructions

    Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 38: Exchanging The Manual Gun

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 EXCHANGING THE MANUAL GUN Before exchanging the manual gun, any power residue must be thoroughly removed. The wearing parts in the manual gun, marked in the spare parts list with " ", must be regularly checked and replaced as necessary.

  • Page 39: Changing The Flat Jet Nozzle

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 CHANGING THE FLAT JET NOZZLE 8.4.1 REMOVING THE FLAT JET 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 Flat Jet Nozzle

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 8.4.2 FITTING THE FLAT JET NOZZLE Procedure: 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: Changing The Round Jet Nozzle

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 CHANGING THE ROUND JET NOZZLE 8.5.1 REMOVING THE ROUND JET NOZZLE Procedure: 1. Pull off deflector cone. 2. Unscrew union nut from gun housing. 3. Take union nut with nozzle system off gun body.

  • Page 42: Fitting The Round Jet Nozzle

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 8.5.2 FITTING THE ROUND JET NOZZLE Procedure: 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 CG VERSION 05/2019 ORDER NUMBER DOC2326960 REPLACING THE PROTECTIVE WEDGE 8.6.1 REMOVING 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...

  • Page 44: Installing The Protective Wedge

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 8.6.2 INSTALLING THE PROTECTIVE WEDGE Note: The same wedge tool is used to insert the protective wedge. Procedure: 1. Guide protective wedge into wedge tool. 2. Insert both parts into opening on electrode holder up to stop.

  • Page 45: Changing From Flat Jet Nozzle To Round Jet Nozzle

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 CHANGING FROM FLAT JET NOZZLE TO ROUND JET NOZZLE The standard Corona cup gun is delivered with a flat jet 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 CG VERSION 05/2019 ORDER NUMBER DOC2326960 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 CG VERSION 05/2019 ORDER NUMBER DOC2326960 ASSEMBLY OF THE CORONASTAR The CoronaStar is a retrofit set for the manual 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 CG VERSION 05/2019 ORDER NUMBER DOC2326960 REPLACING THE SUSPENSION HOOK Procedure: 1. Loosen fastening screws 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: Replacing The Collector Nozzle

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 8.10 REPLACING THE COLLECTOR NOZZLE The collector nozzle can be replaced if worn (for order number, see Chapter 13.6). 1. Remove the powder cup from the gun. Unscrew screws 1 and remove connecting part 2 from gun body.

  • Page 50: Replacing The Connecting Tube

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 8.11 REPLACING THE CONNECTING TUBE The connecting tube can be replaced if worn (for order number, see Chapter 13.6). 1. Remove the powder cup from the gun. Unscrew screws 1 and remove connecting part 2 from gun body.

  • Page 51: Troubleshooting And Rectification

    WAGNER devices, protective systems and safety, monitoring and control equipment may only be serviced/repaired as defined in Directive 2014/34/EC (ATEX) by trained WAGNER service personnel or skilled persons in accordance with TRBS 1203! Note national regulations! Service, repair or replacement of devices or parts of devices may only be performed...

  • Page 52: Inspections

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 10 INSPECTIONS If the system is used for electrostatic coating with ignitable coating powders, testing should be undertaken in accordance with DIN EN 50050-2: 2014 as per Table 1.
  • Page 53 PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960...

  • Page 54: Disassembly And Disposal

    WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way.

  • Page 55: Accessories

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 12 ACCESSORIES 12.1 FLAT JET NOZZLE Order no. Designation 2321976 Flat jet nozzle, X1, complete P_01664 12.2 DEFLECTOR CONE Order no. Designation 2321981 Deflector cone, D18, complete P_01665 2321980 Deflector cone, D25, complete...

  • Page 56: Flat Jet Nozzle X1 F5-X

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 12.4.1 FLAT JET NOZZLE X1 F5-X Order no. Designation 2390036 Flat jet nozzle X1 F5-X P_03594 12.5 POWDER CUP 12.5.1 POWDER CUP - 210 CM³ P_01730 Order no. Designation 2324139 1 x cup with cover...

  • Page 57: Cup Holder

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 12.6 CUP HOLDER P_03878 Order no. Designation 2399470 Cup holder for PEM-X1 CG 1L cup 12.7 CORONASTAR RETROFIT SET P_01695 Order no. Designation 2322868 CoronaStar, PEM-X1, complete 2322835 CoronaStar electrode, PEM-X1 ET 12.8 WEDGE TOOL P_01696 Order no.

  • Page 58: X1 Vl Nozzle Extension - 150/300/500

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 12.9 X1 VL NOZZLE EXTENSION - 150/300/500 P_01697 Order no. Designation 2323366 Nozzle extension, X1 VL 150 (150 mm; 5.91 inches) 2323356 Nozzle extension, X1 VL 300 (300 mm; 11.81 inches) 2323338 Nozzle extension, X1 VL 500 (500 mm; 19.68 inches)

  • Page 59: Wall Mount

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 12.11 WALL MOUNT P_01861 Order no. Designation 2330223 Wall mount with bracket 12.12 RECIPE STICKER m /h m /h Ø Tribo Corona [Nm³/h] [kV] [µA] [Nm³/h] > 0.2 name ¥ ______________________________ ______________________________ www.wagner-group.com/industry P_01829 Order no.

  • Page 60: Powder Measuring Adapter

    Danger to life and equipment damage. Only use powder measurement adapter when high voltage is switched off! The powder measuring adapter serves to measure powder quantities for the PEM-X1 CG gun. The powder measuring adapter is slid onto the nozzle.

  • Page 61: Spare Parts

    DANGER Incorrect maintenance/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. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 62: Pem-X1 Cg Corona Cup Gun

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 13.2 PEM-X1 CG CORONA CUP GUN P_01737...

  • Page 63: X1 R Electrode Holder

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 Order no. Designation 2322588 Corona cup gun, PEM-X1 CG 2320464 Union nut, X1 2321976 Flat jet nozzle, X1, complete 2322529 Electrode holder, X1 F ET 2320488 Replacement protective wedge X1 2320330 Gun hook, X1 ET...

  • Page 64: Powder Cup

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 13.4 POWDER CUP 1, 2 P_01730 Order no. Designation 2324139 Cup with cover, X1 ET 2324140 Cup with cover, X1 ET 2323145 Cup, X1 2322906 Cover 13.5 CONNECTING PART P_01738 Order no. Designation...

  • Page 65: Connecting Tube, Collector Nozzle

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 13.6 CONNECTING TUBE, COLLECTOR NOZZLE P_01739 Order no. Designation 2324135 Connecting tube, ET 9971445 O-ring 2324133 Collector nozzle, ET 9974210 O-ring 9971462 O-ring...

  • Page 66: Pem-X1 Cg Portable Set

    PEM-X1 CG VERSION 05/2019 ORDER NUMBER DOC2326960 14 PEM-X1 CG PORTABLE SET The PEM-X1 CG portable set is mainly designed for laboratory tests, sample coatings or small series production. Order no. Designation 2328172 PEM-X1 CG portable set Operating position and connecting parts...

  • Page 67: Eu Declaration Of Conformity

    PTB 12 ATEX 5002 EN 50050-2:2013 EU Declaration of Conformity The EU Declaration 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: 2326024...
  • Page 72 Order no. 2326960 Edition 05/2019 ts-powder@wagner-group.com www.wagner-group.com...

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