WAGNER PEM-C2 Operating Manual
Operating Manual
Powder Spraygun
DANGER
High Voltage!
Turn power off
before servicing!
CAUTION
Read rules for safe
operation and
instructions
carefully!
PEM-C2
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PEM-C2
Powder Spraygun PEM-C2 Part No. 0351 021
A
B
D
H
C
E
G
F
A Electrode
B Deflector cone
C Outer nut
D Spraygun body
E Trigger
F Atomizing air supply
G Powder supply
H Power supply
The powder spraygun PEM-C2 is used for industrial powder coating.
This spraygun can be operated with the following control units:
• EPG 2007 with powder injector PJ 2020 PRS
• EPG Digiflow with powder injector PJ-D1
The high voltage in the spraygun is activated by pressing the trigger. At the same time, the
powder and compressed air supplies to the gun are turned on.
Caution
The user must ensure, that the spraygun is only connected to
Wagner equipment!
High ambient temperatures must be avoided; in particular, the hoses must not
be routed through factory areas exposed to direct sunlight!
To provide a safeguard against unintentional use of the spraygun, the control
unit must be turned off!
Powders containing metal pigments may only be processed in compliance with
the powder manufacturer’s instructions.
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Table of contents Page
1. Introduction .................................................................................................................5
1.1 Safety regulations..........................................................................................................6
1.2 General safety rules......................................................................................................6
1.3 Harmless discharge.......................................................................................................8
2. Preparing the spraygun for your application ...........................................................9
2.1 Select the suitable nozzle system.................................................................................9
2.2 Connecting the spraygun ............................................................................................10
2.3 Grounding....................................................................................................................10
2.4 Corona-Star.................................................................................................................11
3. Working with the spraygun ......................................................................................12
3.1 Starting up the spraygun.............................................................................................12
3.2 How to switch off the spraygun ...................................................................................13
3.3 How to carry out a change of color..............................................................................14
4. Maintenance and cleaning........................................................................................15
4.1 Replacing the spraygun...............................................................................................15
4.2 Cleaning the spraygun and replace the wear parts.....................................................16
5. Mounting the extension............................................................................................17
6. Trouble shooting.......................................................................................................18
7. Spare parts lists ........................................................................................................19
7.1 How to order................................................................................................................19
7.2 Spraygun PEM-C2 ......................................................................................................19
7.3 Round spray nozzle, extension...................................................................................20
7.4 Corona-Star Retrofit-Set..............................................................................................20
8. Specification..............................................................................................................21
9. Supplement................................................................................................................22
9.1 Applicable safety regulations and list of sources.........................................................22
9.2 Warranty......................................................................................................................23
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1. Introduction
This technical manual contains information and hints for the service, repair and maintenance
of the equipment. The observation of this manual is element of the warranty agreements.
Wagner powder systems are designed to meet the most stringent safety requirements. They
can be operated in compliance with generally applicable safety codes and applicable national
safety regulations.
Please pay particular attention to the parts marked by the following symbols. Follow the
instructions exactly, in the interests of both your own safety and the correct functioning of the
unit.
Warning
This warning draws attention to the fact that if the operating instructions,
working instructions, prescribed working sequences etc. are not followed
exactly, this can lead to injury or even fatal accidents.
Caution
This warning indicates that if the operating instructions, working instructions,
prescribed working sequences etc. are not followed exactly, this can lead to
damage to the unit.
Hint
This symbol draws your attention to useful additional information and tips.
Wagner hereby declares that the unit described in these operating instructions has
been designed and manufactured according to the provisions of EU Directive
98/37/EC.
The following harmonized standards have been applied:
EN 50014 EN 50053
EN 50050 EN 1953
The following German standards or guidelines have been applied:
ZH 1/443 VDE 0165
VDMA 24371 part 1
The certificate of conformity with the order No. 0351 932 is enclosed with this product. This
can be reordered from your WAGNER representative giving the product and serial number.
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1.1 Safety regulations
Warning
This equipment can be dangerous if it is not operated in accordance with
this operating manual! There might be additional regulations to be
observed, put into effect by governmental, state or other official agencies
or local security (fire) departments!
The following rules must be observed in order to ensure a safe and efficient use of the
equipment:
• Under no circumstance may persons with a cardiac
pacemaker come close to the area between the tip of
the spraygun and the workpiece to be coated!
• The user has to observe particularly the safety
guidelines of the VdS or the local professional and
security institutions. 2) 3) 6) 9)
• The spraygun may only be operated in the hazard zone
created by operation of the manual spraying equipment
itself. 2) 3) 6)
• The spraygun may only be operated in powder spray
booths or powder spray benches equipped with
industrial ventilation. 2) 3) 6
• The user has to ensure that the medium value of the
powder/air concentration does not exceed 50% of the
LEL (maximum allowed concentration of powder in air).
If the LEL is not known, the user should assume a value
of 20 g/m³. 2) 3) 6)
• The main power connection for operation of the Wagner
powder equipment must be electrically interlocked with
the exhaust system of the powder coating booth. 2) 3) 6)
• The Wagner control unit must be installed outside the
hazard area. 2) 3)
• The user must conduct periodic checks of the powder
spray equipment (at least every year) with regard to
explosion-protection. 5) 7)
• In the event of faults or defects, repair work is to be
performed at the user's discretion. 7)
• The user must keep a test certificate of the device type
on file at the installation site. 7)
• The execution of repairs must not lead to an alteration in
the explosion-protection. 5) 7)
• Repairs may only be carried out by specially trained
personnel. 7)
• Repairs must never be performed in an explosionhazard area. 7)
• The work area must have an electrostatically conductive
floor (measured in accordance with DIN 51953) 2) 3) 6)
• All conductive parts in the work area must be
electrostatically grounded (work area = 1.5 m at the
sides, 2.5 m to the front and rear of every spray location
or opening in the booth). 2) 3)
• All persons inside the work area must wear
electrostatically conductive footwear. 2) 3)
• If gloves are used, they must be of antistatic material or
have cut-out palm areas. 2) 3)
x) See paragraph 9.1 “Applicable safety regulations and list of sources“
1.2 General safety rules
• Keep your workplace well organized
A disorganized workplace creates a hazard.
• Take the environmental influences into
consideration
Do not expose the manual system to rain. Do not use the
manual system in a damp or wet environment. Ensure
good illumination. Do not use power tools near
flammable liquids or gases.
• Store your tools carefully
Unused tools should be stored in a dry, locked room and
out of the reach of unauthorized persons.
• Do not use the cable for purposes other than those
intended
Do not carry the spraygun by the cable and do not use it
to pull the plug out of the socket. Protect the cable from
heat, oil and sharp objects.
• Do not over-reach your standing position
Avoid abnormal body positions. Ensure stable footing
and always keep your balance.
• Wear suitable work clothing
• Use breathing protection
Use breathing protection for work which produces
powder.
• Take good care of the system
Keep the system clean to ensure that it works well and
safely. Check the plug and line cord regularly and have
them replaced by customer service if damaged. Check
the extension cord regularly and replace it when
damaged.
• Always remain alert
Watch your work. Proceed in a reasonable manner. Do
not use tools when you lack concentration.
• Check your equipment for damage
Before using the system, carefully inspect slightly worn
parts for proper operation. Check whether the moving
parts operate properly, whether they jam and whether
parts are damaged.
All parts must be properly assembled in order to ensure
proper operation of the unit. Damaged parts should be
repaired or replaced by a Wagner customer service.
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Warning
For your own safety, use only accessories and equipment listed in the
operating manual. The use of individual parts other than those
recommended in the operating manual may create a hazard to personal
safety.
Use only original Wagner replacement parts!
HAZARD PREVENTION
Electrostatic arcing may cause an explosion or
fire. Mixtures of powder and air can explode or
ignite causing property damage and/or severe
injury.
• Operator must be grounded. Grounding straps must be
used when wearing rubber soled shoes.
• Operator must be in contact with the spraygun handle; cut
out palm section and trigger fingers of any work gloves to
be used.
• Operator must remove all metallic objects from his or her
person, which are not grounded.
• The object being sprayed must be grounded.
• All metallic objects within the spray area must be
grounded (including spray booth, part hangers, fire
extinguishers, etc.)
• Grounded conductive floor must be provided in spray area.
• Turn off the Power Pack and unplug from outlet before
flushing out the gun, cleaning or replacing parts on the gun
such as changing tips.
Explosion or fire. Mixtures of powder and air
can explode or ignite causing property damage
and/or severe injury.
• Exhaust and fresh air introduction must be provided to
keep the air within the spray area free of accumulation of
flammable atmosphere.
• Smoking must not be allowed in spray area.
• Fire extinguishing equipment must be present and in
working order.
• Electrostatic arcing must be prevented. (See Electrostatic
arcing)
• When cleaning the system, use only materials
recommended by the coatings manufacturer. Be sure
Power Pack is turned off and unplugged.
• Avoid all ignition sources such as static electricity sparks,
open flames such as pilot lights, hot objects such as
cigarettes and sparks from connecting and disconnecting
power cords and working light switches.
• To prevent hazardous concentrations of flammable
atmospheres, spray only in a properly ventilated spray
booth.
• Never operate spraygun unless ventilation fans are
operating properly.
• Check and follow all National, State and Local codes
regarding air exhaust velocity requirements.
• Ventilation must be maintained during the cleaning
operation.
Toxic Substances: Some materials may be
harmful if swallowed or come in contact with
the skin.
• Follow the requirements of the Material Safety Data Sheet
supplied by the coatings manufacturer.
• Exhaust and fresh air introduction must be provided within
the spray area to keep the air free of high powder
accumulations.
• Wear a mask or respirator. Read all instructions for the
mask to insure that it will provide the necessary protection
against the inhalation of powder.
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HAZARD PREVENTION
General
• Read all instructions and safety precautions before
operating.
• Comply with all appropriate local, state and national
codes governing ventilation, fire prevention, and
operation of Electrostatic equipment usage.
• The United States Government Safety Standards have
been adopted under the Occupational Safety and Health
Act. These standards, particularly the General
Standards, Part 1910 and the Construction Standard,
Part 1926, should be consulted.
• NFPA Standard No. 33 is to be followed when setting up
your spray area. Contact the National Fire Protection
Association, Batterymarch Park, Quincy, Massachusetts,
02269 for more information.
• Check with insurance company for additional
requirements.
• Use only identical replacement parts.
• Personnel must be given training in accordance with the
requirements of NFPA Standard No. 33 chapter 15.
• It is the duty of all personnel responsible for the spray
equipment operation and maintenance to read and
understand all safety information furnished with this
equipment.
1.3 Harmless discharge
When the high voltage is turned on, a glow or
Corona discharge, that is only visible in a dark
environment, occurs at the electrode tip. This
physical phenomenon can be observed when
the electrode approaches the grounded
workpiece.
This glow discharge does not provide any
ignition power and does not have any influence
on the handling of the installation. When the
electrode approaches the workpiece, the
control device automatically reduces the high
voltage to a safe level or turns off the high
voltage, depending on the setting.
nozzle
electrode
glow discharge
workpiece
If the finger comes in contact with the plastic parts of the spraygun, harmless discharges (socalled brush discharges) can occur. The charging of the plastic parts is caused by the high
voltage electrostatic field of the gun. However, these discharges do not provide any ignition
power.
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2. Preparing the spraygun for your application
2.1 Select the suitable nozzle system
Nozzle Workpiece Spray cloud Remarks
Deflector cone
Wire goods
Gratings
Aluminum cross
sections
Round spray cloud:
the size depends on
the diameter of the
deflector cone.
for powder quantities
from 50 ... 300 g/min
Fan spray nozzle
Difficult workpieces:
undercuts
broken edges
Widely-spread fan
spray.
for powder quantities
from 50 ... 150 g/min
Round spray nozzle,
extension 300 or 180 mm
Objects with large
indentations:
e.g. cabinets
The spray cloud
depends on the nozzle
used.
A deflector cone or a
fan spray nozzle can
be mounted to the
extension.
The part numbers are listed in section 7. “Spare parts lists“
Chapter 5. “Mounting the extension“ describes how an extension is mounted.
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