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

Manual powder spray gun
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Translation of the Original
Operating Manual
PEM-X1
Manual Powder Spray Gun
Version 09/2012
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 09/2012 P_01660 II 2D 2mJ 0102...

  • Page 3: Table Of Contents

    4.1.1 Electrical Devices and Operating Equipment 4.1.2 Personnel Qualifi cations 4.1.3 A 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 Material Hoses 4.2.4 Cleaning 4.2.5 Handling Powder Paints...
  • Page 4 PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL Contents OPERATION Qualifi cation of the Operating Staff Safety Instructions Optimizing the Powder Cloud for Coating 7.3.1 Recommended Settings for Total Air Volume Switching off the Spray Gun Adjustment of Powder Quantity "Double Click"...
  • Page 5 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL SPARE PARTS 13.1 How to order Spare Parts? 13.2 PEM-X1 Corona Manual Spray Gun 13.3 Electrode Holder X1 R DECLARATION OF WARRANTY AND CONFORMITY 14.1 Important Notes on Product Liability 14.2 Warranty Claim 14.3...

  • Page 6: General Information

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL GENERAL INFORMATION 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 staff .

  • Page 7: Languages

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL LANGUAGES The this operating manual is available in the following languages: German 2326019 English 2326020 French 2326021 Italian 2326022 Spanish 2326023 ABBREVIATIONS Piece Item Marking in the spare parts lists Number...

  • Page 8: Correct Use

    Powder spray guns for manual coating of grounded work pieces CORRECT 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 not intended use.

  • Page 9: Processing Materials

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL PROCESSING MATERIALS Types of powder which can be charged electrostatically Metallic powder REASONABLY FORESEEABLE MISUSE The following is prohibited: Coating work pieces which are not grounded Unauthorized conversions and modifi cations to spray guns...

  • Page 10: Identification

    The PEM-X1 powder spray gun may only be connected to the control devices listed below: EPG-Sprint X with PI-F1/HiCoat ED-F powder injector EPG-Sprint with PI-F1* powder injector EPG S2 with PI-F1* powder injector * The remote control function of the PEM-X1 spray gun is not available when using these control units.

  • Page 11: General Safety Instructions

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 4.1.1...

  • Page 12: 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 malfunctions: - Switch off the energy/compressed air supply.

  • Page 13: Cleaning

    PEM-X1 VERSION 09/2012 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 supply of compressed air and decompress system.

  • Page 14: Information About Harmless Discharges

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL INFORMATION ABOUT HARMLESS 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 15: Protective And Monitoring Equipment

    This shape, together with the shape of the fl at 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 16: Description

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL DESCRIPTION DESIGN OF THE SPRAY GUN P_01663 Designation Suspension hook Handle Electrical connection cable Powder hose connection Trigger lever Cap nut Round spray nozzle Atomizer air connection Flat spray nozzle Buttons to adjust the powder quantity...

  • Page 17: Technical Data

    PEM-X1 VERSION 09/2012 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 of 22 Vpp Input current maximum of 0.9 A Frequency 19 - 30 kHz Output voltage maximum of 100 kV DC max.

  • Page 18: Dimensions

    PEM-X1 VERSION 09/2012 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 fl at spray nozzle/with defl ector cone...

  • Page 19: Permitted Accessories

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

  • Page 20: Assembly And Commissioning

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL ASSEMBLY AND COMMISSIONING QUALIFICATION OF THE ASSEMBLY/COMMISSIONING STAFF WARNING Incorrect installation/operation! Risk of injury and damage to the equipment. The commissioning staff must have the technical skills to safely undertake commissioning.

  • Page 21: Preparing The Spray Gun

    PEM-X1 VERSION 09/2012 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 fl at spray nozzle to the defl ector cone is described in chapter 8.8 "Changing from Flat Spray Nozzle to Round Spray Nozzle".
  • Page 22 PEM-X1 VERSION 09/2012 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 23: Connecting The Spray Gun

    PEM-X1 VERSION 09/2012 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 24 PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL Powder spray gun to the electrical connection on the control unit Control unit Atomizing air from the control unit blue Powder feed from the powder injector transparent Powder injector...

  • Page 25: Grounding

    PEM-X1 VERSION 09/2012 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 26: Grounding The Powder Coating System

    PEM-X1 VERSION 09/2012 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 (megaohms). The protective clothing, including gloves, must comply with the requirements of EN ISO 1149-5.

  • Page 27: Operation

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL OPERATION QUALIFICATION OF THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the equipment. The operating staff must be qualifi ed to operate the entire system. Before work commences, the operating staff must receive appropriate training.

  • Page 28: Optimizing The Powder Cloud For Coating

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL 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! The atomizing air should be adjusted for the fl at spray nozzle to 0.1 Nm³/h...

  • Page 29: Switching Off The Spray Gun

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL SWITCHING OFF THE SPRAY GUN By releasing the trigger the powder supply 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 30: Adjustment Of Powder Quantity

    PEM-X1 VERSION 09/2012 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 31: Double Click" Recipe (High Dynamic Remote)

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL "DOUBLE CLICK" RECIPE (HIGH DYNAMIC REMOTE) This function is used to change quickly to another recipe during a coating operation. The operator can access a previously set recipe by double-clicking on the trigger lever on the spray gun, for example to recoat parts using diff erent parameters (high-voltage, current limiting, air volumes etc.)

  • Page 32: Reproducible Setting Of The Nozzle Position

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL REPRODUCIBLE SETTING OF THE NOZZLE POSITION An adjustment tool is provided for the fl at spray nozzle. This allows all fl at spray nozzles to be turned without damaging the electrodes and without removing the cap nut.

  • Page 33: Cleaning And Maintenance

    PEM-X1 VERSION 09/2012 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 and DIN EN 50177 provisions. They should be informed of specifi c hazards during their training.

  • Page 34: Cleaning Procedures

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

  • Page 35: Maintenance

    Risk of injury and damage to the equipment. Have repairs and part replacements 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 36: Maintenance Procedures

    The maintenance intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. In doubt, we recommend to contact 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 37: Replacing The Spray Gun

    PEM-X1 VERSION 09/2012 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 wear parts in the spray gun, marked in the spare parts list with " ", must be regularly checked and, if necessary replaced.

  • Page 38: Removing The Flat Spray Nozzle

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL REMOVING THE FLAT SPRAY NOZZLE Procedure: 1. Unscrew cap nut from the gun housing. 2. Take cap nut with nozzle system off gun body. The nozzle system remains inserted in the cap nut.

  • Page 39: Fitting The Flat Spray Nozzle

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL FITTING THE FLAT 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 40: Removing The Round Spray Nozzle

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL REMOVING THE ROUND SPRAY NOZZLE Procedure: 1. Pull off defl ector cone. 2. Unscrew cap nut from the gun housing. 3. Take cap nut with nozzle system off gun body. The nozzle system remains inserted in the cap nut.

  • Page 41: Fitting The Round Spray Nozzle

    PEM-X1 VERSION 09/2012 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 42: Replacing The Protective Wedge

    PEM-X1 VERSION 09/2012 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 43 PEM-X1 VERSION 09/2012 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 until they stop.

  • Page 44: Changing From Flat Spray Nozzle To Round Spray Nozzle

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL CHANGING FROM FLAT SPRAY NOZZLE TO ROUND SPRAY NOZZLE The standard Corona spray gun is delivered with a fl at spray nozzle. The nozzle can be changed easily, as described below.
  • Page 45 PEM-X1 VERSION 09/2012 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 46: Mounting The Corona-Star

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 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 (e.g. reduction of "orange peel"). WARNING Danger from electric current! Risk of injury and damage to the equipment.

  • Page 47: Replacing The Suspension Hook

    PEM-X1 VERSION 09/2012 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 48: Inspections In Accordance With Din En 50177: 2010

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010 If the system is used for electrostatic coating with fl ammable coating powders, testing should be undertaken in accordance with DIN EN 50177: 2010-04 as per Table 3 and...

  • Page 49: Overview Of Inspections

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL OVERVIEW OF INSPECTIONS...
  • Page 50 PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL...
  • Page 51 PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL...

  • Page 52: 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 53: Troubleshooting And Rectification

    Danger to life and equipment damage. Wagner devices, protective systems and safety, monitoring and control equipment may only be 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 54 OPERATING MANUAL Malfunction Cause Remedy No electrostatics (e.g. no wrap Fault in the high-voltage Contact Wagner Service center. around or powder adhesion) generator. Electrical cable from spray gun Contact Wagner Service center. to control unit faulty. Cascade in spray gun faulty.

  • Page 55: Accessories

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL ACCESSORIES 12.1 FLAT SPRAY NOZZLE Order No. Designation 2321976 X1 fl at spray nozzle, complete P_01664 12.2 DEFLECTOR CONE Order No. Designation 2321981 D18 defl ector cone, complete P_01665 2321980 D25 defl ector cone, complete...

  • Page 56: Hose Take-Up

    12.5 RETROFIT SET CORONA-STAR Order No. Designation 2322868 PEM-X1 Corona-Star, complete P_01695 2322835 PEM-X1 Corona-Star electrode, complete 12.6 WEDGE TOOL P_01696 Order No. Designation 2324124 X1 wedge tool + 20 protective wedges available as accessory, not included in the purchased parts package...

  • Page 57: Nozzle Extension X1 Vl 150/300

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL 12.7 NOZZLE EXTENSION X1 VL 150/300 P_01697 Order No. Designation 2323366 X1 VL 150 nozzle extension (150 mm; 5.91 inches) 2323356 X1 VL 300 nozzle extension (300 mm; 11.81 inches) 2324148...

  • Page 58: Wall Mount

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL 12.9 WALL MOUNT P_01861 Order No. Designation 2330223 Wall mount with bracket...

  • Page 59: Powder Measuring Adapter

    Risk of explosion due to electrostatic charging! Danger to life and equipment damage. Only use powder measurement bag when high-voltage is switched off ! for measuring powder quantities for the PEM-X1 spray gun Order No. Designation 2325320 X1 powder measuring adapter with...

  • Page 60: Spare Parts

    Risk of injury and damage to the device. Have repairs and part replacements 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 61: Pem-X1 Corona Manual Spray Gun

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL 13.2 PEM-X1 CORONA MANUAL SPRAY GUN P_01699 PEM-X1 Manual Spray Gun Order No. Designation 2322587 PEM-X1 Corona manual spray gun 2322761 Hose take-up D10-12, complete 9971364 O-ring 2320464 Cap nut X1...

  • Page 62: Electrode Holder X1 R

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL 13.3 ELECTRODE HOLDER X1 R P_01700 Electrode Holder X1 R with Nozzles Order No. Designation 2322493 Electrode holder X1 R with nozzle 2322490 Electrode holder X1 R ET 2320488 Replacement protective wedge X1...

  • Page 63: 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 64: Declaration Of Conformity

    EN 50050-2: 2012 EC 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 65: Ec Type Examination Certifi Cate

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL 14.4 EC TYPE EXAMINATION CERTIFICATE...
  • Page 66 PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL...
  • Page 67 PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL...

  • Page 68: Fm Approval

    PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL 14.5 FM APPROVAL in submission...
  • Page 69 PEM-X1 VERSION 09/2012 ORDER NUMBER DOC 2326020 OPERATING MANUAL...
  • Page 70 Fax: +45/ 86 856 027 E-mail: info@estee-industries.com E-mail: info@wagner-industri.com Great Britain France WAGNER Spraytech (UK) Ltd. Wagner - Division Solutions Industrielles The Couch House Parc Gutenberg - Bâtiment F 2, Main Road 8 voie la Cardon GB- Middleton Cheney OX17 2ND...
  • Page 72 Order No. 2326020 Germany J. WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 Markdorf Tel. +49/ (0)7544 / 5050 Fax +49/ (0)7544 / 505200 E-mail: service.standard@wagner-group.com Switzerland J. WAGNER AG Industriestrasse 22 Postfach 663 CH- 9450 Altstätten Tel. +41/ (0)71 / 757 2211 Fax +41/ (0)71 / 757 2222 E-mail: rep-ch@wagner-group.ch...

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