WAGNER PEM-C4-Ergo Original Operating Manual
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WAGNER PEM-C4-Ergo Original Operating Manual

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

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Summary of Contents for WAGNER PEM-C4-Ergo

  • Page 1 Translation of the original Operating manual PEM-C4-Ergo Powder Coating Guns Version 02 / 2009 P_01090 II 2 D EEx 2mJ 85°C 0102...

  • Page 3: Table Of Contents

    Safety instructions for the operator 2.1.1 Electrical plant and units 2.1.2 Personnel qualifi cations 2.1.3 A safe work environment Safety instructions for staff 2.2.1 Safe handling of WAGNER powder spray units 2.2.2 Earth the unit 2.2.3 Material hoses 2.2.4 Cleaning 2.2.5 Handling powder paints...
  • Page 4 C4 gun extension (Corona) C4-VL 300/500 S gun extension (Corona) C4-VL fan spray nozzle Retrofi t-Set Corona-Star Wedge tool Powder measuring bag SPARE PARTS 10.1 How to order spare parts? 10.2 PEM-C4-Ergo Corona manual gun 10.3 C4 R electrode holder with nozzles...

  • Page 5: About These Instructions

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES The operating manual is available in the following languages: Language: Order No. Language: Order No. 2305053 2305054 German English 2305055 French Dutch 2305056 2305057 Italian Spanish WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard.

  • Page 6: General Safety Instructions

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR 2.1.1 ELECTRICAL PLANT AND UNITS To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences.

  • Page 7: Safety Instructions For Staff

    field between the spray gun and the workpiece to be coated builds up! 2.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY UNITS Never point the powder spray gun at people. Before all work on the unit, in the event of work interruptions and functional faults: –...

  • Page 8: Handling Powder Paints

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 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.

  • Page 9: Note On Harmless Discharges

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL NOTE ON HARMLESS DISCHARGES Nozzle Electrode Luminous discharge Workpiece P_01091 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.

  • Page 10: Warranty And Declaration Of Conformity

    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.

  • Page 11: Ce-Conformity

    - 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: PEM-C4-Ergo manual gun 2304981...

  • Page 12: Description

    DESCRIPTION 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 ●...

  • Page 13: Technical Data

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL TECHNICAL DATA 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.

  • Page 14: Dimensions

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 4.3.1 DIMENSIONS P_01092 Dimension inches 355/385 13.98/15.16 10.43 1.81 * with fan spray nozzle/with defl ector cone...

  • Page 15: Functional Description

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF SPRAY GUN P_01093 Description Suspension hook End part Spray gun body Trigger Outer nut Defl ector cone Electrode Fan spray nozzle Atomizing air connection Powder hose connection Electrical connection 4.4.2...

  • Page 16: Start-Up

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL START-UP 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.
  • Page 17 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL Nozzle Application Distance to Powder workpiece output (mm) (g/min) F3¹ Low powder application (faster powder cloud) Very good dispersion with ● 120 … 300 30 … 150 low air and powder quantities...

  • Page 18: Connecting The Spray Gun

    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.

  • Page 19: Grounding

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL GROUNDING 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 For safety reasons, the spray gun must be properly grounded. This occurs through the electrical cable.

  • Page 20: Grounding Of The Powder Coating System

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 5.3.1 GROUNDING OF THE POWDER COATING SYSTEM P_01120 Only use mains cables with grounding wire! Connect grounding cable with booth and system ground! Connect grounding cable to an uncoated metal part of the booth!

  • Page 21: Operation

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL OPERATION OPTIMIZING THE SPRAY PATTERN FOR YOUR COATING Procedure: 1. Switch on the high-voltage generation and the powder feed. Hint: To minimize the wear on the wearing parts, the total feed air and dosage air should be under 5 Nm³/h!

  • Page 22: Flushing Procedure In Conjunction With Epg 2008/Epg Prima Control Unit

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 6.2.2 FLUSHING PROCEDURE IN CONJUNCTION WITH EPG 2008/EPG PRIMA CONTROL UNIT If the spray gun is operated with an EPG 2008/EPG Prima control unit and a PI-P1 powder injector, proceed as follows: 1.

  • Page 23: Flushing Procedure In Conjunction With Epg 2008/Epg Prima Control Unit

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 6.3.2 FLUSHING PROCEDURE IN CONJUNCTION WITH EPG 2008/EPG PRIMA CONTROL UNIT If the spray gun is operated with an EPG 2008/EPG Prima control unit and a PI-P1 powder injector, proceed as follows: 1.

  • Page 24: Maintenance And Cleaning

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup- tions: - Switch off the energy/compressed air supply.

  • Page 25: Replacing The Spray Gun

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL REPLACING THE SPRAY GUN Before you commence the replacement of the spray gun any powder residue must be removed thoroughly. The wearing parts in the spray gun, marked in the spare parts list with ”◆” , must be regularly checked and, if necessary replaced.

  • Page 26: Cleaning The Spray Gun And Dismantling The Fan Spray Nozzle

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL CLEANING THE SPRAY GUN AND DISMANTLING THE FAN SPRAY NOZZLE Procedure: 1. Unscrew the outer nut 1 from the spray gun housing 5. 2. Pull the fan spray nozzle 2 off the electrode holder 3.

  • Page 27: Replacing The Protective Wedge

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL REPLACING THE PROTECTIVE WEDGE Hint: To ensure that the protective wedge is not damaged when dismantling and inserting them, a wedge tool is available for assembly. You will fi nd the necessary wearing parts and spare parts in chapter 10 “Spare parts“ of this manual.
  • Page 28 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL Hint: For inserting the protective wedge the same wedge tool will be used. 1 Wedge tool 2 Protective wedge 3 Electrode holder (cut open view) P_00597 Procedure: 1. Guide the protective wedge 2 into the wedge tool 1.

  • Page 29: Fitting The Round Spray Nozzle

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 5. Prior to re-fi tting, check whether the mating surface on the electrode holder 3 and in the spray gun housing 5 have been thoroughly cleaned so that the electrode tip is electrically connected to the high-voltage generator.
  • Page 30 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL CAUTION Electrode tip! Risk of injury. Take care when fitting the C4 R electrode holder. SIHI_05032_ENG 5. Carefully fi t the new C4 R electrode holder 6 into the spray gun housing 5.

  • Page 31: Mounting The Corona-Star

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL MOUNTING THE CORONA-STAR The Corona-Star is a Retrofi t-Set for the spray gun, which helps to achieve a better surface quality (reduction of “orange peel“). WARNING Danger from electric current! Risk of injury and damage to the equipment.

  • Page 32: Mounting The C4 Gun Extension

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL MOUNTING THE C4 GUN EXTENSION DANGER Exploding dust/air mixture! Danger to life from flying parts and burns. The inside coating of hollow bodies and/or in narrow spaces is forbidden in accordance with BGI 764.
  • Page 33 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 5. Unscrew the outer nut 11 from the extension 12. 6. Slide the extension 12 over the gun housing 5 and tighten it. 7. Carefully fi t the electrode holder 3 into the extension 12.

  • Page 34: Mounting The C4-Vl300/500 S Gun Extension

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL MOUNTING THE C4-VL300/500 S GUN EXTENSION DANGER Exploding dust/air mixture! Danger to life from flying parts and burns. The inside coating of hollow bodies and/or in narrow spaces is forbidden in accordance with BGI 764.
  • Page 35 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL P_01100 5. Locate gun extension 6 onto the gun housing 5 and tighten the outer nut 7. P_00926 6. Depending on the planned usage, either locate defl ector cone 8 or atomizer sleeve 9 and fan spray nozzle 10 carefully on the gun extension 6.

  • Page 36: Replacing The Protective Wedge In The Spray Gun Extension

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL REPLACING THE PROTECTIVE WEDGE IN THE SPRAY GUN EXTENSION Hint: To ensure that the protective wedge is not damaged when dismantling and inserting them, a wedge tool is available for assembly. The necessary wear and spare parts are in chapter 10 “Spare parts“ of this Operating manual.
  • Page 37 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL P_00927 3. Pull the O ring 7 out of the groove, slide it and outer nut 5 forwards. 4. Guide the wedge tool 8 into the electrode holder 9 to the stop.
  • Page 38 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL Hint: For inserting the protective wedge the same wedge tool will be used. P_00929 7. Guide the protective wedge 10 into the wedge tool 8. 8. Insert both parts in the opening on the electrode holder 9 to the stop.
  • Page 39 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL P_01100 12. Locate gun extension 4 onto the gun housing 6 and tighten the outer nut 5. 13. Secure outer nut 5 again with the O ring. To do this, press the O ring into the groove again.

  • Page 40: Replacing The Centring Pins

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL REPLACING THE CENTRING PINS The charging body is secured in place in the gun extension with 3 centring pins. Over time, the centring pins wear and in this case, must be exchanged for new centring pins. The amount of wear can be determined by a visual check or when the charging body exhibits an amount of play in the gun extension.

  • Page 41: Disposal

    Your waste Wagner device will be taken back by us or our represen- tatives and disposed of environmentally correctly. Please contact one of our service points or one of our representatives or us directly to this purpose.

  • Page 42: Trouble Shooting And Rectification

    OPERATING MANUAL TROUBLE SHOOTING AND RECTIFICATION Malfunction Cause Rectifi cation No electrostatic (e.g. no wrap Fault in the high-voltage Contact Wagner Service ● ● around or no powder adhesion) generator Electrical cable from spray gun ● to control unit faulty Cascade in spray gun faulty ●...

  • Page 43: Accessory

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL ACCESSORY FAN SPRAY NOZZLES Order No. Description 0390324 F1 fan spray nozzle P_00694 0390325 F2 fan spray nozzle P_00694 0390326 F3 fan spray nozzle P_00694 0390331 HPO-1 wide fan spray nozzle P_00694 DEFLECTOR CONE Order No.

  • Page 44: C4 Gun Extension (Corona)

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL C4 GUN EXTENSION (CORONA) FM approved P_00934 Item K Quantity Order No. Description 0390901 C4 gun extension 150 mm; 5.90 inches 0390902 C4 gun extension 300 mm; 11.81 inches...

  • Page 45: C4-Vl 300/500 S Gun Extension (Corona)

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL C4-VL 300/500 S GUN EXTENSION (CORONA) not FM approved P_00930 P_00931 Item K Quantity Order No. Description 0390977 C4-VL 300 S gun extension (300 mm; 11.81 inches) 2301006 C4-VL 500 S gun extension (500 mm; 19.86 inches) ◆...

  • Page 46: C4-Vl Fan Spray Nozzle

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL C4-VL FAN SPRAY NOZZLE P_00932 Item K Quantity Order No. Description ◆ 0390978 C4-VL fan spray nozzle (complete) 0390116 C4-VL fan spray nozzle 0390448 Atomizer sleeve 9971018 O ring RETROFIT-SET CORONA-STAR P_01104...

  • Page 47: Wedge Tool

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL WEDGE TOOL P_00714 Item Quantity Order No. Description ★ 0390900 Wedge tool including 20 protective wedges ★ only available as a set...

  • Page 48: Powder Measuring Bag

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL POWDER MEASURING BAG For measuring powder quantities for the C4 gun generation. Order No. Description 0390940 Powder measuring bag (complete) P_01106 The powder measuring bag is slid onto the nozzle..

  • Page 49: Spare Parts

    Risk of injury and damage to the equipment ➞ Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. ➞ Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 50: Pem-C4-Ergo Corona Manual Gun

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 10.2 PEM-C4-ERGO CORONA MANUAL GUN P_01101 PEM-C4-Ergo manual gun Item Quantity Order No. Description 2305069 PEM-C4-Ergo Corona manual gun 0390311 Outer nut ◆ 0390324 F1 fan spray nozzle ◆ 0390325 F2 fan spray nozzle ◆...

  • Page 51: C4 R Electrode Holder With Nozzles

    PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL 10.3 C4 R ELECTRODE HOLDER WITH NOZZLES P_01103 C4 R electrode holder with nozzles Item Quantity Order No. Description ★ 0390917 C4 R electrode holder (complete) ★ 0390916 C4 R electrode holder ◆...
  • Page 52 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL...
  • Page 53 PEM-C4-Ergo. VERSION 02/2009 ORDER NUMBER DOC2305054 OPERATING MANUAL...
  • Page 54 Fax: ++41/ (0)71 / 757 2222 E-mail: service.standard@wagner-group.com E-mail: rep-ch@wagner-group.ch Belgium Denmark Estee Industries WAGNER Industrial Solution Scandinavia AB (WISS) Leenbeekstraat 9 Kabingatan 28 B- 9770 Kruishoutem S-25467 Helsingborg Phone: ++32/ 9 / 388 5410 Phone: ++46/ 42 150 020...
  • Page 56 2305054...

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