WAGNER PEM-X1, Operating Manual

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

Page 2: ......

Page 3: ...Equipment 12 4 1 2 Staff Qualifications 12 4 1 3 Safe Work Environment 12 4 2 Safety Instructions for Staff 13 4 2 1 Safe Handling of WAGNER Powder Spray Devices 13 4 2 2 Grounding the Device 13 4 2...

Page 4: ...Spray Gun 38 8 3 Removing the Fan spray nozzle 39 8 4 Fitting the Fan spray nozzle 40 8 5 Removing the Round spray nozzle 41 8 6 Fitting the Round spray nozzle 42 8 7 Replacing the Protective Wedge 4...

Page 5: ...X1 Corona Manual Gun With a Fan spray nozzle 61 13 3 PEM X1 Corona Manual Gun With a Round spray nozzle 62 13 4 Electrode Holder X1 R 63 14 DECLARATION OF WARRANTY AND CONFORMITY 64 14 1 Important Not...

Page 6: ...esult in death or serious injury Warning possible imminent danger Non observance may result in death or serious injury Caution a possibly hazardous situation Non observance may result in minor injury...

Page 7: ...es German 2326019 English 2326020 French 2326021 Italian 2326022 Spanish 2326023 Russian 2333344 Chinese 2333345 Dutch 2337552 Swedish 2345951 Hungarian 2341080 Portuguese 2345347 Danish 2348202 Finni...

Page 8: ...ty for any damage resulting from non intended use Electrostatic manual coating systems may only be used in spray areas equipped in accordance with EN 12981 or under equivalent ventilation conditions 2...

Page 9: ...Spare parts and accessories may have safety relevant properties Use only WAGNER original spare parts and accessories The manual powder spray gun may only be operated under the following conditions if...

Page 10: ...rms of misuse listed below may result in physical injury or property damage Use of damp powder lacquer Incorrectly set values for powder discharge Incorrectly set electrostatic values Use of defective...

Page 11: ...ategory 2 D Ex atmosphere dust 2mJ Maximum ignition energy 2 mJ 85 C Maximum surface temperature Incorrect use Risk of injury and damage to the device Only connect original Wagner devices to the PEM X...

Page 12: ...the working area must be electrostatically conductive measurements according to EN 1081 and EN 61340 4 1 The footwear worn by the operators must comply with the requirements of ENISO20344 Themeasured...

Page 13: ...y gun against actuation Relieve pressure on spray gun and device In case of functional faults Identify and correct the problem proceed as described in the Fault Rectification chapter The electrostatic...

Page 14: ...accessed Most flammable solvents have an ignition energy of around 0 24 mJ or 60 nC The cleaning agent s flash point must be at least 15 K above the ambient temperature Only mobile industrial vacuum c...

Page 15: ...ar the grounded work piece This luminous discharge does not involve any ignition energy and has no effect on system handling When the electrode approaches the work piece the control unit automatically...

Page 16: ...nozzle or deflector 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 Incorrect use Risk of injury and d...

Page 17: ...nozzle Atomizing air connection Fan spray nozzle Buttons to adjust the powder quantity Spray gun body 5 2 FUNCTIONING OF THE SPRAY GUN High voltage is activated in the manual gun when the trigger is...

Page 18: ...51 psi Powder output quantity maximum 450 g min maximum 0 99 lbs min Ambient conditions Operating temperature range 5 45 C 41 113 F Relative humidity 5 3 TECHNICAL DATA Ambient conditions If low melti...

Page 19: ...PEM X1 A P_01662 B C OPERATING MANUAL VERSION 03 2014 ORDER NUMBER DOC 2326020 5 3 1 DIMENSIONS Measurement mm inch A 335 349 13 19 13 74 B 248 9 76 C 45 1 77 with fan spray nozzle with deflector con...

Page 20: ...ent includes 1 2326024 Declaration of conformity 1 2326019 Operating manual German 1 see Chapter 1 3 Operating manual in local language 5 5 SCOPE OF DELIVERY 5 4 PERMITTED ACCESSORIES Only the accesso...

Page 21: ...tionally required system components WARNING 6 2 STORAGE CONDITIONS Until the point of assembly the powder spray gun must be stored in a dry location free from vibrations and with a minimum of dust The...

Page 22: ...oud opening angle approx 60 Front sliding ring front turned by 90 Extra narrow cloud Cloud opening angle approx 40 Nozzle Application overview Powder cloud Fan spray nozzle Complex part geometries Wid...

Page 23: ...0 34 mm Large flat parts Output quantity g min Overall air Feed air 4 00 Nm h 5 00 Nm h 6 00 Nm h 50 140 170 210 60 200 240 260 70 250 270 300 80 300 320 350 90 330 360 380 100 370 400 420 Thevaluesha...

Page 24: ...ct the powder feed hose to the spray gun and to the powder injector 5 Connect the atomizing air hose to the spray gun and to the control unit 6 5 CONNECTING THE SPRAY GUN Unintentional putting into op...

Page 25: ...MANUAL VERSION 03 2014 ORDER NUMBER DOC 2326020 to the electrical connection on the control unit Powder feed from the powder injector Atomizing air from control unit Powder spray gun Control unit Powd...

Page 26: ...e system is via the knurled screw on the rear of the control unit Both connections are absolutely essential If installed correctly as described above the spray gun is grounded via the gun cable betwee...

Page 27: ...conveyor conveyor hooks hangers and work piece can occur if electric contact points between conveyor conveyor hooks hangers and work piece are not sufficiently cleaned and therefore the work pieces ar...

Page 28: ...e familiar with the provisions of European standard DIN EN 50050 2 WARNING Incorrect operation Risk of injury and damage to the device If contact with powder products or cleaning agents causes skin ir...

Page 29: ...ing air should be adjusted for the fan spray nozzle to 0 1 Nm h round spray nozzle to 0 2 Nm h 2 Adjust the powder quantity and the powder speed on a test piece 7 3 OPTIMIZING THE POWDER CLOUD FOR YOU...

Page 30: ...ORDER NUMBER DOC 2326020 7 4 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 w...

Page 31: ...to flashing By saving these settings the current values of the powder feed are taken over in the current program The blinking changes back to flashing By activating the Double Click function the blin...

Page 32: ...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 th...

Page 33: ...DOC 2326020 7 7 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...

Page 34: ...manual work the high voltage mustbeshutdownandlockedtopreventitfrombeingswitched back on The spray gun must be separated from the high voltage supply and compressed air supply before any cleaning work...

Page 35: ...4 must be adhered to for all cleaning work 8 1 3 CLEANING PROCEDURES Incorrect maintenance Risk of injury and damage to the device If contact with powder products or cleaning agents causes skin irrit...

Page 36: ...placements 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 Relie...

Page 37: ...gun settings Check gun discharge pressure Blow out powder hoses Check grounding Check compressed air quality Check gun voltage Check powder hoses for bends and sintering 8 2 3 MAINTENANCE PROCEDURES...

Page 38: ...in the spare parts list with must be regularly checked and if necessary replaced Procedure 1 Switch off control unit 2 Disconnect electrical cable 1 from control unit 2 3 Disconnect powder feed hose 3...

Page 39: ...ed and from the spray gun Note Never place the spray gun or parts of the spray gun in cleaning agent As a rule the protective wedge needs to be checked for wear and replaced if necessary Procedure 1 U...

Page 40: ...be turned by hand Procedure Note 1 Beforeinsertingtheelectrodeholder thespringcontact of the gun body and contact surface of the electrode holder should be checked The spring contact must be clean an...

Page 41: ...mains inserted in the union nut Note If the nozzle system doesn t remain inserted in the union nut the nozzle system and union nut must be replaced 4 Press nozzle system out of union nut by gently pre...

Page 42: ...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 2 Attach deflector co...

Page 43: ...r 2 up to stop 3 Press protective wedge 3 sideways out of wedge tool 1 manually without tool Note A wedge tool is available to prevent the protective wedge from being damaged when dismantling and inse...

Page 44: ...lush with theY end of the electrode holder 3 The protective wedge is now correctly assembled and the wedge tool can be pulled out of the electrode holder 4 The protective wedge remains inserted in the...

Page 45: ...PRAY 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 Note If the nozzle system doesn t remain...

Page 46: ...e 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 6 Insert electr...

Page 47: ...1 Guide plug in contact 1 of CoronaStar into drilled hole B on hook 2 Attach clip 2 of CoronaStar to housing Flexible positioning in a range of 90 is possible Danger from electric current Risk of inju...

Page 48: ...6020 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 receiv...

Page 49: ...2014 ORDER NUMBER DOC 2326020 9 INSPECTIONSINACCORDANCEWITHDINEN50050 2 2014 If the system is used for electrostatic coating with flammable coating powders testing should be undertaken in accordance w...

Page 50: ...interlocked such that the powder feed and high voltage cannot be switched on while the technical ventilation is not working eff ectively CP FI Test whether the system is safely stopped and the produc...

Page 51: ...contact one of our service points one of our representatives or us directly to arrange this NOTICE 10 2 DISPOSAL 10DISASSEMBLY AND DISPOSAL 10 1 DISASSEMBLY Procedure 1 Switching off the system 2 Loc...

Page 52: ...eve spray gun and device pressure Secure the spray gun against actuation Observe the operating manual and service manuals at all times when carrying out work DANGER Incorrect maintenance repair Danger...

Page 53: ...ding Powder outlet uneven or inadequate Contamination Blow through parts carrying powder Powder sintering Clean parts carrying powder Feed device contaminated See operating manuals for the related dev...

Page 54: ...26020 12ACCESSORIES 12 1 FAN SPRAY NOZZLE Order No Designation Fan spray nozzle X1 complete 12 2 DEFLECTOR CONE Order No Designation Deflector cone D18 complete Deflector cone D25 complete Deflector c...

Page 55: ...o Designation Hose take up D10 D12 complete Hose take up D8 D10 complete 12 5 CORONASTAR RETROFIT SET Pos Order No Designation CoronaStar PEM X1 complete CoronaStar electrode PEM X1 ET 12 6 WEDGE TOOL...

Page 56: ...s 1 2323338 Nozzle extension X1 VL 500 500 mm 19 68 inches 1 2324147 Fan spray nozzle X1 VL ET Round spray nozzle X1 VL ET available as accessory not included in the purchased parts package 12 8 NOZZL...

Page 57: ...Powder hose 10 mm Powder hose 11 mm Powder hose 12 mm 12 10 GUN CONNECTION CABLE Order No Designation 2334275 Manual gun cable PEM X1 6m ET 2334568 Manual gun cable PEM X1 15m ET Note The replacement...

Page 58: ...kV Nm h 0 1 0 2 90 80 4 0 70 50 20 3 6 57 70 40 3 6 50 P5 P6 P7 P8 P9 P10 name 80 100 4 5 80 ______________________________ www www wagner group com industry ______________________________ 2x 82 20 3...

Page 59: ...tion Powder measuring adapter with X1 bag complete for measuring powder quantities for the PEM X1 spray gun The powder measuring adapter is slid onto the nozzle Risk of explosion due to electrostatic...

Page 60: ...s Billing address Delivery address Name of the person to be contacted in the event of any queries Type of delivery normal mail express delivery air freight courier etc Wearing parts Note These parts a...

Page 61: ...os K Stk Order No Designation PEM X1 Corona manual gun Hose take up D10 12 complete O ring Union nut X1 Fan spray nozzle X1 complete Electrode holder X1 F ET Replacement protective wedge X1 Gun hook X...

Page 62: ...r No Designation 2335844 PEM X1 Corona manual gun 2322761 Hose take up D10 12 complete 9971364 O ring 2320464 Union nut X1 Electrode holder X1 R with nozzle 6 1 Replacement protective wedge X1 7 Gun h...

Page 63: ...signation Electrode holder X1 R with nozzle Electrode holder X1 R ET Replacement protective wedge X1 Deflector cone sleeve X1 Deflector cone D18 complete Deflector cone D25 complete Deflector cone D34...

Page 64: ...erial costs will be borne by us except where these costs are increased due to the subsequent shipment of the device to a location other than the address of the purchaser We do not provide warranty for...

Page 65: ...6 42 EC Machine Directive 2004 108 EC EMV Directive 2002 95 EC RoHs Directive 2002 96 EC WEEE Directive Applied standards in particular Applied national technical standards and specifications in parti...

Page 66: ...66 PEM X1 OPERATING MANUAL VERSION 03 2014 ORDER NUMBER DOC 2326020 14 4 EC TYPE EXAMINATION CERTIFICATE...

Page 67: ...for the Control Units are to be connected in an unclassified ordinary location only P_00309 OPERATING MANUAL VERSION 03 2014 ORDER NUMBER DOC 2326020 14 5 FM APPROVAL The PEM X1 powder spray gun is a...

Page 68: ...68 PEM X1 OPERATING MANUAL VERSION 03 2014 ORDER NUMBER DOC 2326020...

Page 69: ...69 PEM X1 OPERATING MANUAL VERSION 03 2014 ORDER NUMBER DOC 2326020...

Page 70: ...70 PEM X1 OPERATING MANUAL VERSION 03 2014 ORDER NUMBER DOC 2326020...

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Page 72: ...r No 2326020 Edition 03 2014 Germany Phone Fax E mail Switzerland Phone Fax More contact addresses on the internet at Company Locations WAGNER worldwide Subject to changes without notice Document No 1...