PEM-C2 Airmatic Spraygun	07/96
Danger! High voltage! Turn power off before servicing! Read rules for safe operation and instructions carefully!
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	Operating Manual

Table of contents

1. Introduction

1.1. Safety regulations

1.2. Warranty

2. Description

2.1. Application

2.2. What powder materials can be used?

2.3. Specification

2.4. Operation of the spraygun

2.5. Part numbers of the spraygun

2.6. Control elements of the spraygun

2.7. Corona-Star Retrofit-Set

2.7.1. Description

2.7.2. Part numbers of Corona-Star Retrofit-Set

2.7.3. Assembling instructions

3. Start up

3.1. Connecting the spraygun to the control unit

3.1.1. Connecting to EPG 2007

3.1.2. Connecting to EPG 2020 TP und EPG 2010 R

3.2. Grounding

4. Operation

4.1. Adjusting the powder cloud

4.2. Application-related description of nozzle systems

4.3. Work interruption

4.4. Changing powder

5. Maintenance and cleaning

5.1. Cleaning the powder nozzle

5.2. Replacing the nozzle insert

6. Trouble shooting

7. Spare parts list with accessories

1. Introduction

This technical manual contains information and hints for the servicing, repairing and maintenance of the equipment. The observation of this manual is element of the warranty agreements.

 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.

This manual contains information which must be read and unterstood before using the equipment. When you come to an area which has one of the following symbols, pay particular attention and make certain to heed the safeguard.

"Warning"

Important safety information indicates a hazard which may cause serious injury or loss of life.

"Caution"

Important information that tells how to prevent damage to equipment or how to avoid causes of minor injuries.

"Recommendation"

Gives important information which should be given special attention.

Declaration of Conformity

 herewith declares that the equipment described in this manual has been developed and manufactured in agreement with the demands according to paragraph 5.1.2 of the European Norm
EN 50014.

Warning

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 metal objects from his or her person which are not grounded. The object being sprayed must be grounded. All metal 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 electri-city sparks, open flames such as pilot lights, hot objects such as cigarettes and sparks from connecting and disconnecting power cords and working light switches.
Explosion or fire. Mixtures of powder and air can explode or ignite causing property damage and/or severe injury.	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.
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.

1.1 Safety regulations

Warning

This equipment can be dangerous if it is not operated in accordance with this operating manual!

The following rules must be observed in order to ensure safe and efficient use of the equipment:

• The spraygun may only be operated in the hazard zone created by operation of the manual spraying equipment itself. 3)
• 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 observe particularly the safety guidelines of the VdS and the professional associations. 2) 3) 6) 9)
• The user has to ensure that the medium value of the powder/air concentration does not exceed 50% of the UEG * ⁾ (lower explosion limit). If the UEG is not known, the user should assume a value of 20 g/m³.
• If the powder concentration at high total powder output is higher than the allowed values, the user should consult the powder manufacturer.
• The mains power connection for operation of the powder equipment must be electrically interlocked with the exhaust system of the powder
  coating booth. 2) 3) 6)
• The 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 users 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 experts who are specially qualified for this work. 7)
• Repairs must never be performed in an explosion-hazard 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 (1.5 m at the sides, 2.5 m to the front and rear of every spray location or opening in the booth, as specified by EN 50053). 2) 3)
• Electrostatically conductive footwear must be worn by all persons inside the work area. 2) 3)
• If gloves are worn, they must be of antistatic material or have cut-out palm areas. 2) 3)

* ⁾ UEG: Lower explosion limit, i.e. maximum allowed concentration of powder in air.

Warning

Powders containing metal pigments may only be processed in compliance with the powder manufacturer's instructions.

Applicable Safety Regulations and List of Sources

1)	EN 50050 DIN VDE 0745 Part 100	Electrical equipment for explosion-hazard areas Manual electrostatic spraying equipment	(published by VDE-Verlag, Berlin)
2)	EN 50053 - 2 DIN VDE 0745 Part 102	Requirements for selection, installation and use of electrostatic spraying equipment for flammable materials	(published by VDE-Verlag, Berlin)
3)	ZH 1/443	Electrostatic powder coating using manual spraying equipment	(published by C. Heymanns-Verlag, Cologne)
4)	EX-RL / ZH 1/10	Guidelines for explosion protection	(published by C. Heymanns-Verlag, Cologne)
5)	VDE 0165	Installation of electrical equipment in explosion-hazard areas	(published by VDE-Verlag, Berlin)
6)	VDMA 24371 Part 1	Guidelines for electrostatic coating using synthetic resin powders	(published by Beuth-Verlag, Berlin)
7)	ELEX V	Regulation for electrical systems in explosion-hazard areas	(published by VDE-Verlag, Berlin)
8)	VDE 0134	Instructions for first aid in case of accident	(published by Beuth-Verlag, Berlin)
9)	VDS 2093	Association of insurance companies	(Riehlerstr. 36 50668 Cologne)

Safety-related information concerning 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. When the electrode approaches the grounded workpiece, this physical phenomenon can be observed.

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.

If the finger comes in contact with the plastic parts of the spraygun, harmless discharges (so-called 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.

1.2 Warranty

What is covered by this warranty:

Faulty and useless parts are replaced according to our general delivery conditions.

Within the applicable warrant period, Wagner will repair or replace, at our option, defective parts without charge if such parts are returned with transportation charges prepaid to the nearest authorized service center. If Wagner is unable to repair this product so as to conform to this Limited Warranty after a reasonable number of attempts, Wagner will provide, at our option, either a replacement for this product or a full refund of the purchase price of this product.

These remedies are the sole and exclusive remedies available for breach of express and implied warranties.

What is not covered by this warranty:

This warranty does not cover any damage or defects:

1. caused by use or installation of repair or replacement parts or accessories not manufactured by Wagner,
2. caused by repair performed by anyone other than a Wagner authorized service center, or
3. caused by or related to abrasion, corrosion, abuse, misuse, negligence, accident, normal wear, faulty installation or tampering in a manner which impairs normal operation.

Limitation of remedies:

IN NO CASE SHALL WAGNER BE LIABLE FOR ANY INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS, INCLUDING TRANSPORTATION COSTS, WHETHER SUCH DAMAGES ARE BASED UPON A BREACH OF EXPRESS OR IMPLIED WARRANTIES, BREACH OF CONTRACT, NEGLIGENCE, STRICT TORT, OR ANY OTHER LEGAL THEORY.

Disclaimer of implied warranties:

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

No ability to transfer:

This warranty is extended to the original purchaser only and is not transferable.

Your rights under state law:

Some states do not allow limitations on how long an implied warranty lasts or the exclusion of incidental or consequential damages, so the above limitation and exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

2. Description

2.1 Application

The Airmatic spraygun PEM-C2 is used for industrial powder coating.

The gun can be used with the following control units:

• EPG 2007:
  This control unit is integrated in the manual powder coating equipment:
• 2007 - 70 LR
• 2007 - Airfluid
• EPG 2020 TP:
  This control unit is integrated in the manual powder coating equipment:
• Integral 2020 - G
• Integral 2020 - Airfluid
• EPG 2010 R:
  This control unit is integrated in the manual powder coating equipment:
• 2010 - 70 LR
• 2010 - Airfluid

Caution

The spraygun may only be used for the above described application.

2.2 What powder materials can be used?

Basically, all coating powders can be used with the Airmatic spraygun PEM-C2. e.g.: epoxy resin, polyester, blended powder EP / PES, PUR.

Caution

Powders containing metal pigments may only be processed in compliance with the powder manufacturer’s instructions.

2.3 Specification

Weight:	498 g (without supply lines)
Electrical:
Input voltage:	max. 22 Vpp
Input current:	max. 0,9 A
Frequency:	19...30 kHz
Output voltage:	max. 100 kV DC
Output current:	max. 160 µ A DC
Polarity:	negatie
Design:	accord. to EN 50050
Protection class:	IP 54
Pneumatic:
Input air pressure (atomizing air):	max. 3 bar
Powder output:	max. 450 g/min
Compressed air quality acc. to ISO 8573.1:
Residual water content in compressed air:	max. 1,3 g H2O/Nm3 at a dew point of 7°C
Residual oil content in compressed air:	max. 0,01 mg oil/Nm3
Residual dust content in compressed air:	max. 1 mg dust/Nm3
Ambient conditions:	If low temperature powders are used the ambient temperature may have to be lower than 30°C.

2.4 Operation of the spraygun

When the trigger (E, see paragraph 2.6) is pulled (control unit EPG 2007 is turned on), the high voltage is activated in the PEM-C2. At the same time, the powder and compressed air supplies to the gun are turned on.

A high DC voltage (up to 100 kV), applied across the grounded workpiece and the electrode fitted to the gun body generates an electric field and applies a negative charge to the powder particles. These repel each other as they move from gun to workpiece and so distribute evenly through the fine spray cloud and then uniformly deposit on the grounded surface. Particles shooting past the component remain trapped in the electric field and deposit on the backside of the work object. Effective material yield, time savings, markedly improved quality of finish, less cleaning and a healthier environment are the principal properties of the process.

Caution

To provide a safeguard against unintentional use of the spraygun, the control unit must be turned off.

2.5 Part numbers of the spraygun

Airmatic Spraygun PEM-C2 Part No. 0351 021

Standard version:

with round spray nozzle, externally charged and deflector cone Ø17, Ø25, Ø32 mm

Accessories: see paragraph 7.

2.6 Control elements of the spraygun

A Electrode	E Trigger
B Deflector cone	F Atomizing air supply
C Outer nut	G Powder supply
D Spraygun body	H Electric supply

2.7 Corona-Star Retrofit-Set

2.7.1 Description

The Corona-Star is a Retrofit-Set for the powder spraygun PEM-C2 which helps to achieve a better surface quality.

The development of the "orange peel" can be avoided for most powder types.

Caution

The gun cable must be connected via the adapter cable (1) to the control unit, when the Corona-Star Retrofit-Set is used!

2.7.2 Part numbers of Corona-Star Retrofit-Set

Part No. 0351 110

Item	Part No.	Quantity	Description
1	0259 608	1	Adapter cable
2	0351 111	1	Corona-Star cpl.
3*	0260 296	1	Electrode Corona-Star (included in pos. 2)

* Wear part

2.7.3 Assembling instructions

Caution

The assembling of the Corona-Star may only be carried out by trained personnel!

Course order:

1. Switch off control unit.
2. Detach the gun cable (A) from the control unit.
3. Connect the cable with the knurled screw (B) at the cover plate (C).
4. Attach the Corona-Star (D) to the gun housing (E).
5. Connect the gun cable (A) and the adapter cable (F).
6. Connect the adapter cable (F) at the control unit.
7. The spraygun is ready to operate.

Connect adapter cable (F) at the control unit

Connect gun cable (A) and adapter cable (F)

3. Start up

Recommendation

Before installing and starting up, become familiar with the corresponding operating manual.

3.1 Connecting the spraygun to the control unit

Recommendation

The user must ensure, that the spraygun is only connected to equipment.

• Connecting the Airmatic Spraygun PEM-C2:
• to EPG 2007, see paragraph 3.1.1.
• to EPG 2020 TP, see paragraph 3.1.2.
• to EPG 2010 R, see paragraph 3.1.2.

Caution

The spraygun may only be used for the above described
application.

3.1.1 Connecting to EPG 2007

Electrical connection:

• Leave the control unit turned off. See operating manual of the control unit, paragraph "Start up".
• Connect electrical cable of the Airmatic Spraygun at the control unit.

Pneumatic connection:

• Atomizing air: Control unit Spraygun
• Feeding air: Control unit Powder injector
• Dosage air: Control unit Powder injector
• Powder hose: Powder injector Spraygun
• Fluid air:
  EPG 2007: Throttle valve Feed system / Fluid connection

Connection diagram, see following page.

Connection diagram with the control unit EPG 2007

3.1.2 Connecting to EPG 2020 TP und EPG 2010 R

Electrical connection:

• Leave the control unit turned off. See operating manual of the control unit, paragraph "Start up".
• Connect electrical cable of the Airmatic Spraygun at the control unit.

Pneumatic connection:

• Atomizing air: Control unit Spraygun
• Feeding air: Control unit Powder injector
• Dosage air: Control unit Powder injector
• Powder hose: Powder injector Spraygun
• Fluid air:
  EPG 2020 TP: Control unit Feed system / Fluid connection
  EPG 2010 R: Throttle valve Feed system / Fluid connection

Connection diagram, see following page.

Connection diagram with the control unit EPG 2020 TP

Connection diagram with the control unit EPG 2010 R

3.2 Grounding

Good grounding of the workpiece is necessary for optimum powder coating. A poorly grounded workpiece causes:

• very bad wrap-around
• uneven coating
• back-spray onto spraygun and user
• dangerous electric charging of the workpiece

Warning

Sparks between workpiece and conveyor hooks (hangers)
can occur if hooks or other hanger parts are not completely
cleaned!

Preconditions for good grounding as well as coating are:

• Good grounding of the workpiece to be coated, of conveyors and hangers.
• Grounding of the powder spray booth and the transport and mounting equipment with the installation of a > 10 mm2 copper conductor to system ground.
• Regular cleaning of hangers from powder deposits.
• The grounding resistance of the workpiece must not exceed 1 MW (Mega Ohm).
• For connection of the ground strap at the control unit, see paragraph 3.1. "Connection diagram"

4. Operation

4.1 Adjusting the powder cloud

Preconditions:

• The control unit must be connected to electrical mains power, but not turned on.
• The compressed air must be connected.
• Connect the Airmatic Spraygun PEM-C2 electrically and pneumatically to the control unit as shown in the connection diagram, see paragraph 3.1. and 3.2. .

Course order:

1. Turn on the control unit.
2. For adjusting the high voltage, see operating manual of the control unit.
3. Hold the spraygun in the spray booth and pull the trigger: The voltage display changes from preset to actual value. (single LED display bar graph LED).
4. Open feeding air and dosage air.

Caution

To reduce wear, the total of feeding air and dosage air must be in between 4 - 6 Nm³/h (see following diagram).

Feeding air			Dosage air

Feeding air + Dosage air: min. 4 Nm³/h und max. 6 Nm³/h
(depending on hose diameter / length)

5. Open the atomizing air at the control unit until the deflector cone remains free of powder deposits.
6. Adjust powder cloud on test object - see operating manual of the control unit, paragraph "Adjusting the powder cloud".
7. Turn off the control unit.

4.2. Application-related description of nozzle systems

Nozzle	Workpiece	Spray cloud	Air adjustments	Coating distance
Deflector cone, externally charged	Wire goods, Gratings, Aluminum cross sections	Round spray cloud depending on the size of the deflector cone	Feeding air, dosage air and atomizing air, see operating manual of the control unit	100-160 mm
Fan spray nozzle cap, externally charged	difficult workpieces, undercuts, broken edges	widely-spread fan spray, adjustable	Feeding air, dosage air and atomizing air, see operating manual of the control unit	120-180 mm

4.3 Work interruption

Recommendation

The Airmatic Spraygun should be blown through and cleaned from powder deposits with every interruption of work.

Course order:

1. Don’t turn off atomizing air.
2. Don’t turn off feeding air and dosage air.
3. Remove powder injector from injector connection to prevent further powder delivery.
4. Hold the spraygun in the spray booth, pull the trigger and blow through via powder injector.
5. Turn off high voltage at the control unit.
6. Turn off control unit.

4.4 Changing powder

Course order:

1. Clean the spraygun, see paragraph 4.3. "Work interruption".
2. Remove deflector cone from the nozzle insert.
3. Unscrew outer nut from the gun housing.
4. Carefully extract nozzle insert from the gun housing.
5. Clean dismantled parts and the spraygun from powder deposits (assembling in reverse order).
6. For re-starting operation, see paragraph 4.1. "Adjusting the powder cloud".

5. Maintenance and cleaning

Preconditions:

• Turn off control unit.
• Remove the mains power plug!

Recommendation

The wear parts marked with (*) in the spare parts list of the Airmatic Spraygun PEM-C2, must be regularily checked and replaced if necessary.

Warning

• Do not disassemble gun cable for cleaning. It could lead to malfunction of the spraygun when not reassembled properly.
• No guarantee for the safety of the user can be accepted in this case.

5.1 Cleaning the powder nozzle

1. Clean the spraygun, see paragraph 4.3. "Work interruption".
2. Remove the nozzle system from the spraygun and clean it as described in paragraph 4.4. "Changing powder".

Caution

Never place the spraygun or parts of it into any cleaning agent!

5.2 Replacing the nozzle insert

Course order: for example round spray nozzle

1. Remove the deflector cone.
2. Unscrew the outer nut from the gun housing.
3. Extract nozzle insert.

Caution

When pulling out and inserting the new nozzle insert, take care that the contact points are thoroughly cleaned.

The cleaning of the other nozzle systems is performed in the same manner.

Warning / Caution

WARNING

CAUTION

WHEN CLEANING THE ELECTROSTATIC SYSTEM, THESE SAFETY PROCEDURES MUST BE FOLLOWED. FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN AN EXPLOSION/FIRE. Turn power pack to the "OFF" position and unplug from power source before starting to clean. Exhaust and fresh air introduction must be maintained during the clean up operation. Keep cleaning materials in approved safety containers. All personnel and cleaning equipment, including container used in cleaning operation, must be grounded. DO NOT turn on the POWER PACK until the cleaning operation has been completed, all cleaning materials have been removed from spray area, and spray area is free of any mixtures of powder and air produced by the cleaning operation. If defects in the equipment are found, DO NOT use until repairs are completed.

Clean equipment immediately after use. NEVER IMMERSE SPRAYGUN OR PARTS OF IT IN ANY FLUID AT ANY TIME. Be sure the Power Pack is turned off and unplugged from the power source.   NOTE The powder passages of the spraygun should be cleaned while cleaning the powder hose and powder pump, following instructions, provided with the powder pump (injector). (See document No. PJ 2020 PRS) Clean the spray tip by removing from spraygun, flushing with air and replacing on spraygun.

6. Trouble shooting

Caution

Maintenance, repair or replacement of the powder spray unit (Airmatic Spraygun) or its components may only be performed by trained personnel outside the hazard area in a suitable location.

Malfunction	Cause	Remedy
No powder output, no electrostatic charge	Fuse at control unit is defective	Replace fuse, see operating manual of the control unit
No electrostatic charge (e.g. no wrap-around or no powder adhesion)	Fault at high voltage generator Electrical cable between spraygun and control unit defective Cascade in spraygun is defective	Inform service center Inform service center Inform service center
Poor wrap-around Back-spray	Bad grounding No grounding	See paragraph 3.2. See paragraph 3.2.
Powder output irregular or insufficient	Compressed air main supply insufficient Feeding air / dosage air proportion not correct Wear	Check air main supply Readjust at the control unit Change worn out parts
Spray cloud not correct	Nozzle system worn out	Replace nozzle system