WAGNER PER-X1, Translation Of The Original Operating Manual

Page 1: ...nslation of the Original Operating Manual 0102 II 2 D 2 mJ For professional use Always observe the information in this manual particularly the safety instructions and the warning instructions Store th...

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Page 3: ...vironment 11 4 1 3 Personnel Qualifications 12 4 2 Safety Instructions for the Personnel 12 4 2 1 Personal Safety Equipment 12 4 2 2 Safe Handling of WAGNER Powder Spray Devices 13 4 2 3 Grounding the...

Page 4: ...Personnel 33 8 1 2 Cleaning Procedures 33 8 1 3 Performing a Paint Change 33 8 2 Maintenance 34 8 2 1 Maintenance Personnel 34 8 2 2 Maintenance Instructions 34 8 2 3 Safety Checks 34 8 2 4 Maintenan...

Page 5: ...Retrofit Set CoronaStar 56 12 6 D10 D12 Powder Coupling 56 12 7 Wedge tool 56 12 8 Powder hose 57 12 9 Atomizing air hose 57 12 10 Gun Connection Cable 57 12 11 Powder measuring adapter 57 12 11 1Pow...

Page 6: ...iding the hazard These warning instructions fall into the following categories DANGER Immediate risk of danger Non observance will result in death or serious injury WARNING Potential danger Non observ...

Page 7: ...cian about the tasks assigned to him her the potential risks associated with improper behavior as well as the neces sary protective devices and measures Electrician Can assess the work assigned to him...

Page 8: ...tivate safety fixtures 4 Use only WAGNER original spare parts and accessories 4 The operating personnel must be trained on the basis of this operating manual 4 Follow the instructions in the operating...

Page 9: ...02 Notified body PTB Ex Symbol for explosion protection II Device class II 2 Category 2 D Ex atmosphere dust 2 mJ Maximum ignition energy 2 mJ 3 2 TYPE PLATE P_04901 PER X1 Serial Number PTB 22 ATEX 5...

Page 10: ...anual Robot powder spray gun PER X1 3 Identification 10 Order number 2444998 Edition 10 2022 Guns Control units EPG Sprint XE EPG Sprint EPG S2 HVM DP EPG DP5 EPG SL5 For accessories see chapter Acces...

Page 11: ...efore work is commenced 4 Secure the device against being switched back on without authorization 4 Inform personnel about planned work 4 Observe electrical safety regulations 4 Ground all devices to a...

Page 12: ...onnel Qualifications Danger due to incorrect use of device Risk of death due to untrained personnel 4 Ensure that the operating personnel has been instructed by the operator in accordance with the ope...

Page 13: ...pray nozzle is installed or cleaned 4 2 3 Grounding the Device Danger due to electrostatic charge Explosion hazard and damage to the device The electrostatic charge may in certain cases give rise to e...

Page 14: ...damage to the device 4 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 4 Lock the compressed...

Page 15: ...tch off the energy and compressed air supply 4 Relieve pressure on spray gun and device 4 Secure the spray gun against actuation 4 Observe the operating and service manual for all work 4 2 8 Protectiv...

Page 16: ...hysical effect can be seen when the electrode is brought near the grounded work piece This luminous discharge does not involve any ignition energy and has no effect on system handling When the electro...

Page 17: ...r connection 6 Powder hose connection 7 Flat jet nozzle 8 Round jet nozzle 9 Coronastar connection 5 2 POSITIVE CASCADE The version with positive cascade can be used for special applications for powde...

Page 18: ...st be switched off To prevent electrostatic flashover the union nut for securing the nozzles is designed with a labyrinth 5 4 EXTENT OF DELIVERY Stk Order no Designation 1 2423084 PER X1 robot spray g...

Page 19: ...Risk of poisoning if inhaled 4 Provide compressed air free from oil and water Ambient conditions If low melting powders are used the ambient temperature may have to be lower than 30 C 86 F Volume meas...

Page 20: ...der spray gun PER X1 5 Description 20 Order number 2444998 Edition 10 2022 5 6 ACCESSORIES Only the accessories listed in chapter Accessories 8 51 of this operating manual may be connected to the PER...

Page 21: ...rage location must be between 20 C and 60 C 4 F and 140 F The relative air humidity at the storage location must be between 10 and 95 without condensation 6 3 INSTALLATION CONDITIONS The air temperatu...

Page 22: ...g P_03821 Sliding ring at rear wide cloud Cloud opening angle approx 80 P_03822 Sliding ring at front narrow cloud Cloud opening angle approx 60 P_03823 Sliding ring at front turned by 90 extra narrow...

Page 23: ...P_01665 18 mm Smaller flat parts 100 300 R25 P_01666 25 mm Medium sized flat parts 100 300 R34 P_01667 34 mm Large flat parts 100 300 6 5 CONNECTING THE ROBOT SPRAY GUN Pos Designation 1 Robot powder...

Page 24: ...generation on the control unit 2 Before connecting the robot spray gun check that all components such as the nozzle system and union nut are correctly fitted 3 Connect electrical cable of the robot s...

Page 25: ...and connect to the spray gun 3 Screw the spray gun onto the adapter using the clamping ring Disassembly Note Disassembly is carried out in reverse order to assembly Before replacing the robot spray g...

Page 26: ...ew the robot spray gun with the RSI robot flange onto the robot arm Disassembly Note Disassembly is carried out in reverse order to assembly Before replacing the robot spray gun any powder residue mus...

Page 27: ...Assembly 1 Screw the PER X1 TO elbow to the robot arm with the screws 6x 2 Guide the connection cable as well as the powder and atomizing air hoses through the clamping rings and the PER X1 TO elbow a...

Page 28: ...ts must be ensured for the operation of the PER X1 Twin spray gun 4 Both spray guns must always be operated with the same settings for high voltage current limitation and characteristic curve quality...

Page 29: ...pray gun and assemble it again as described in Assembly 6 7 GROUNDING For safety reasons the control unit must be properly grounded The grounding connection to the energy supply socket is made via the...

Page 30: ...ith the signal ground 3 Connect grounding cable to an uncoated metal part of the booth 4 Remove all paint from hooks and other hanger parts 5 Connect the robot s grounding cable with the signal ground...

Page 31: ...E POWDER CLOUD FOR COATING 1 Switch on high voltage generator and powder feed Note To minimize wear on the wearing parts the total air volume should be below 5 Nm h The atomizing air should be set for...

Page 32: ...un 6 The powder feed can now be switched off 7 5 2 Switching Off the Automatic Gun in the Event of Faults or Emergencies In the event of faults or emergencies use the emergency stop device to switch o...

Page 33: ...d to prevent it from being switched back on 4 During every paint change the extraction system of the booth and the filter cleaning system must remain switched on In the case of a paint change powder r...

Page 34: ...ir and replace parts that are listed in the spare parts chapter and that are assigned to the device 4 Before all work on the device and in the event of work interruptions 4 Switch off the energy and c...

Page 35: ...emoved The wearing parts in the robot powder spray gun marked in the spare parts list with must be regularly checked and replaced as necessary To replace the robot spray gun proceed in accordance with...

Page 36: ...d if necessary 8 4 2 Fitting the Flat Jet Nozzle 2 4 3 P_04983 1 Before inserting the electrode holder the spring contact of the gun body and contact surface of the electrode holder should be checked...

Page 37: ...the nozzle system from the gun body The nozzle system remains 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 repla...

Page 38: ...trode holder 3 Insert electrode holder into gun housing 4 Slide union nut onto gun housing 5 Screw union nut onto gun housing hand tight 6 Slide deflector cone over deflector cone sleeve 8 6 REPLACING...

Page 39: ...cut away view to improve comprehension 3 Protective wedge when positioned 1 Guide wedge tool 1 into electrode holder 2 up to stop 2 Pull protective wedge 3 out of electrode holder 2 using wedge tool...

Page 40: ...tective wedge remains inserted in the electrode holder Prior to re fitting check whether the contact points on the electrode holder and in the gun housing have been thoroughly cleaned so that the elec...

Page 41: ...l must be adjusted The round jet nozzle requires increased atomized air volumes of approx 0 5 Nm3 h 1 4 2 3 P_01679 1 Unscrew the union nut from gun housing 2 Remove the union nut with the nozzle syst...

Page 42: ...Insert electrode holder into gun housing 7 Slide union nut onto gun housing 8 Screw union nut onto gun housing hand tight 9 Slide deflector cone over deflector cone sleeve 8 8 MOUNTING THE DOUBLE ADA...

Page 43: ...union nut Note If the nozzle system doesn t remain inserted in the union nut the nozzle system and union nut must be replaced 3 The parts can be separated by applying slight pressure to the flat jet...

Page 44: ...gun body and tighten it 8 8 3 Cleaning the Double Adapter A A A P_05465 1 2 3 4 5 1 Loosen the double adapter 5 and separate it from the gun body 2 Unscrew union nut 1 and carefully pull out electrod...

Page 45: ...wder residues 7 Replace the wearing parts with new components 8 Assembly in reverse order For spare and wear parts see chapter X1 double adapter 8 62 8 9 ASSEMBLY OF THE CORONASTAR The CoronaStar is a...

Page 46: ...ce center Cascade in gun faulty Contact a WAGNER service center Poor powder wrap around back spray Insufficient or no grounding See chapter Grounding 8 29 Spray pattern is uneven Parts of nozzle syste...

Page 47: ...ectrostatic coating with ignitable coating powders the test must be performed in accordance with EN 50177 2009 A1 2012 according to the following overview table 8 48 10 1 ABBREVIATIONS ER Employer FT...

Page 48: ...ion is shut down Annually 3 Parts carrying high voltage outside the spray area Parts carrying high voltage outside the spray area must be routed such that discharges which put people at risk do not oc...

Page 49: ...ction 6 cannot be ensured appropriate equipment e g ionizers must be used to dis charge electric charges on the work piece Such equipment must not exceed the permitted dis charge energy of the sprayin...

Page 50: ...gun connection cable from control unit 4 Remove the powder feed hose from the spray gun and from the powder injector 5 Remove the atomizing air hose from the spray gun and from the control unit 11 2...

Page 51: ...ER X1 SI P_04911 2434678 Robot mounting bracket PER X1 TO P_04112 2434467 Robot mounting bracket PER X1 TI P_04913 2434683 Robot mounting bracket PER X1 SO Lesta P_05405 12 2 NOZZLE SYSTEMS NOTICE Wro...

Page 52: ...2420243 X1 flat jet nozzle F1 P_04985 2428515 X1 cross nozzle 90 P_04987 2428283 X1 angular nozzle 30 P_04988 2428284 X1 angular nozzle 45 P_04989 2428285 X1 angular nozzle 60 P_04990 Wearing parts 12...

Page 53: ...plete P_01666 2321171 Deflector cone D34 complete P_01667 Wearing parts 12 2 4 Nozzle extension P_01697 P_02163 X1 VL Nozzle Extension 150 300 500 X1 VL Nozzle Extension 750 Order no K Designation 232...

Page 54: ...ation 2323461 Nozzle insert X1 VL R yellow P_04992 Can be combined with 2321981 Deflector cone D18 complete P_01665 2321980 Deflector cone D25 complete P_01666 2321171 Deflector cone D34 complete P_01...

Page 55: ...8284 X1 angular nozzle 45 P_04989 2428285 X1 angular nozzle 60 P_04990 For round jet application 2322493 Electrode holder X1 R yellow nozzles P_01692 2322490 X1 electrode holder X1 R ET yellow P_01692...

Page 56: ...e 2419989 Corrugated tube divisible 12 5 RETROFIT SET CORONASTAR P_01695 1 Order no K Designation 2322868 CoronaStar PEM X1 complete 2322835 CoronaStar electrode PEM X1 ET 12 6 D10 D12 POWDER COUPLING...

Page 57: ...1 Connection cable PER X1 2 5 m 2422870 Connection cable PER X1 6 m 12 11 POWDER MEASURING ADAPTER WARNING Risk of explosion due to electrostatic charging Danger to life and equipment damage 4 Only us...

Page 58: ...mn K marking in the following spare parts lists Wearing parts Wearing parts are not included in the warranty Included in service set Not part of the standard equipment but available as a special acces...

Page 59: ...P_04908 2 3 Pos K Stk Order no Designation 1 1 2423084 Corona robot spray gun PER X1 2 1 SeeAcces sories 8 51 Connection cable PER X1 3 1 2434666 Handle complete 4 1 2320464 Union nut X1 5 1 2420243 X...

Page 60: ...ignation 1 1 2423084 Corona robot spray gun PER X1 2 1 SeeAcces sories 8 51 Connection cable PER X1 3 1 2434666 Handle complete 4 1 2320464 Union nut X1 5 1 2322493 Electrode holder X1 R with nozzle 6...

Page 61: ..._01700 2 1 Pos K Stk Order no Designation 1 1 2322493 Electrode holder X1 R with nozzle 2 1 2322490 Electrode holder X1 R ET 3 1 2429695 X1 replacement protective wedge 4 1 2320503 Deflector cone slee...

Page 62: ...3b 4 5 P_05467 Pos K Stk Order no Designation 1a 1 2436638 X1 double adapter 1b 1 2436625 X1 double adapter HC1 2 1 2428235 Union nut 55 mm 3a 1 2443914 Basic device X1 double nozzle ET 3b 1 2443913...

Page 63: ...177 2009 A1 2012 EN 1953 2013 EN IEC 60079 0 2018 EN ISO 13732 1 2008 EN 1127 1 2019 EN 14462 2015 EN IEC 61000 6 2 2019 EN 60529 1991 A1 2000 A2 2013 EN IEC 61000 6 4 2019 EN 50050 2 2013 EN IEC 6300...

Page 64: ...Operating manual Robot powder spray gun PER X1 14 Declaration of Conformity 64 Order number 2444998 Edition 10 2022...

Page 65: ...Operating manual Robot powder spray gun PER X1 14 Declaration of Conformity Order number 2444998 Edition 10 2022 65...

Page 66: ...Operating manual Robot powder spray gun PER X1 14 Declaration of Conformity 66 Order number 2444998 Edition 10 2022...

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Page 68: ...lephone 49 0 7544 5050 Fax 49 0 7544 505200 E mail ts powder wagner group com Switzerland Wagner International AG Industriestrasse 22 CH 9450 Altst tten Telephone 41 0 71 757 2211 Fax 41 0 71 757 2222...