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EPG-SPRINT X

OPERATING MANUAL

VERSION 06/2014

ORDER NUMBER DOC2329371

4.3

PROTECTIVE AND MONITORING EQUIPMENT

Protective and monitoring equipment!

Risk of injury and damage to the device.

Protective and monitoring equipment must not be removed,

modifi ed or rendered unusable.

Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment,

the system must not be operated until these defects are
remedied.

WARNING

Summary of Contents for EPG-Sprint X

Page 1: ...V 80 60 40 20 100 Tri Cor 5 4 3 2 1 120 80 40 20 10 10 20 30 40 50 60 70 80 90 Ø 12 10 11 9 8 m h 2 0 3 0 0 5 0 3 0 1 1 5 3 5 5 4 5 3 5 2 5 Tri μA Universal Control Unit for Powder Guns EPG SPRINT X Version 06 2014 Translation of the Original Operating Manual ...

Page 2: ......

Page 3: ...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 3 Product Hoses 13 4 2 4 Cleaning 14 4 2 5 Handling Powder Lacquers 14 4 3 Protective and Monitoring Equipment 15 4 4 Safety Feature Identification 16 5 DESCRIPTION 17 5 1 Areas of Application 17 5 2 Technical Data...

Page 4: ...e Additional Air Atomizing Ionizing Tribo Air Volume 47 7 7 4 Setting the High voltage 48 7 7 5 Display of Actual High voltage Value 49 7 7 6 Setting the Current Limitation 50 7 7 7 Displaying Actual Value of Current Limitation 51 7 7 8 Setting the U I Characteristics 52 7 8 Purge Function 54 7 8 1 Hose Purge Function 54 7 8 2 Cleaning Purge Function 54 7 8 3 Procedure for Cleaning Purging with Ma...

Page 5: ... Unit 80 14 DECLARATION OF WARRANTY AND CONFORMITY 81 14 1 Important Notes Regarding Product Liability 81 14 2 Warranty Claim 81 14 3 CE Declaration of Conformity 82 14 4 EC Type Examination Certificate 83 14 5 FM Approval 84 DEVICE CONFIGURATION APPENDIX 85 A1 Setting Example Parameter C11 87 A2 Setting Example Parameter C13 89 A3 Table of Parameters 91 A4 Spray Current Reset when using Field Con...

Page 6: ...rning possible imminent danger Non observance may result in death or serious injury Caution a possibly hazardous situation Non observance may result in minor injury Note provides information about particular characteristics and how to proceed Notice a possibly hazardous situation Non observance may result in material damage This notice warns you of a hazard Possible consequences of not observing t...

Page 7: ...e following languages German 2327591 English 2329371 French 2330847 Italian 2330848 Spanish 2330849 Russian 2333349 Chinese 2333350 Hungarian 2341081 Portuguese 2342815 Swedish 2344282 Slovakian 2348856 Danish 2348523 1 4 ABBREVIATIONS Number of pieces Position Marking in the spare parts lists Order No Order number Spare part ...

Page 8: ...ay guns to the EPG SPRINT X control unit The PEM C3R and PEM T3R manual spray guns cannot be connected to the EPG SPRINT X control unit WARNING 2 3 USE IN POTENTIALLY EXPLOSIVE AREAS The EPG SPRINT X control unit is intended for use with powder spray guns of types A P up to 2 mJ in accordance with the prototype test PTB 12 ATEX 5001 The EPG SPRINT X control unit may be used in the dust explosion z...

Page 9: ...device only to work with the products recommended by WAGNER Operate only the device as a whole Do not deactivate safety fixtures Spare parts and accessories may have safety relevant properties Use only WAGNER original spare parts and accessories The use of the control unit is only permissible under the following conditions the operating staff have previously been trained on the basis of this opera...

Page 10: ...al risk Source Consequences Specific measures Lifecycle phase Skin contact with powder lacquers and cleaning agents Handling powder lacquers and cleaning agents Skin irritation allergies Wear protective clothing operation observe safety data sheets maintenance disassembly Powder lacquer in air outside the defined working area Lacquering outside the defined working area Inhalation of substances haz...

Page 11: ...y gun PEA T3XL Older or other gun types may only be connected to the control unit after first checking their suitability with Wagner ForpermissibledevicecombinationsfortheUSAandCanada seeChapter14 5 FMApproval The device is suited for use in potentially explosive areas in accordance withTest Certificate PTB 12 ATEX 5001 0102 II 3 2 D IP 64 80 C CE European Communities 0102 Number of notified body ...

Page 12: ...t the device is operated maintained and repaired only by trained persons The floor in 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 EN ISO 20344 The measured insulation resistance must not exceed 100 megohms The protective clothing including gloves must comply with the...

Page 13: ...rk on the device in the event of work interruptions and functional faults Switch off the energy compressed air supply Secure the spray gun against actuation Relieve pressure on spray guns and device In case of functional faults Identify and correct the problem proceed as described in the Fault Rectification chapter The electrostatic charge may in certain cases give rise to electrostatic charges on...

Page 14: ...ay wall with activated ventilation exhaust air 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 compressed air supply and decompress the device Secure the device against being switched back on without authorization Use only electrically conducting and grounded tanks for cleaning flui...

Page 15: ...ive and monitoring equipment Risk of injury and damage to the device Protective and monitoring equipment must not be removed modified or rendered unusable Regularly check for perfect functioning Ifdefectsaredetectedonprotectiveandmonitoringequipment the system must not be operated until these defects are remedied WARNING ...

Page 16: ...mm 3 94 inches The label plates which must be attached are shown below High voltage In the control cabinet 25 mm 0 98 inches Voltage before main switch Forbidden for unauthorized persons Explosive atmosphere Forbidden for persons with a cardiac pacemaker Follow the instructions in the operating manual Smoking fire and open flames are prohibited Wear electrostatically conductive footwear Danger of ...

Page 17: ...ply and control unit are active When a Tribo gun is connected the Tribo current scale is activated while the high voltage supply and control unit are deactivated Thecontrolunitrecognizesifamanualorautomaticspraygunisconnected Ifanautomatic gun is connected then the control unit can only be controlled via the CCM Prima interface Incorrect use Risk of injury and damage to the device Only connect ori...

Page 18: ...1 kV steps Corona current limitation 5 μA 120 μA adjustable in 1 μA steps Tribo current measuring range 0 μA 15 μA Tribo current limitation 0 μA 5 μA adjustable in 0 1 μA steps Tribo current cut off greater than 12 μA ATEX switching off of the unit Protection class IP 64 Ex zone II 3 2 D 80 C 176 F Zone 22 Pneumatic Air input pressure 0 6 0 8 MPa 6 8 bar 87 116 psi Air volume maximum 15 m h Sum of...

Page 19: ... accessories Danger of damage to the device Operate the control unit only with the prescribed compressed air quality Only use the control unit with original Wagner accessories Non observance of these conditions results in the warranty expiring Ambient conditions If low melting powders are used the ambient temperature may have to be lower than 30 C 86 F Volume measures for volumes specified in Nm s...

Page 20: ...ating manual may be connected to the EPG SPRINT X control unit Theaccessorieslistedinthechapter Accessories wereincludedintheECtypeexamination and are approved for use with the control unit Stk Order No Designation EPG SPRINT X for manual and automatic systems The standard equipment includes Conformity certificate Operating manual German see Chapter 1 3 Operating manual in local language ...

Page 21: ...IDE 1 Illuminated display High voltage Lights up green Display range 0 100 kV Resolution 10 kV Single LED display Nominal voltage Bar display Working voltage 2 Illuminated display Corona or Tribo Current Lights up green Tribo scale When a Tribo gun is connected and selected Bar display When powder feed is activated Display range 0 5 μA Resolution 0 5 μA Corona scale When a Corona gun is connected ...

Page 22: ...face part is selected 10 Display LED recipe for Second Coating Lights up green when the recipe for Second Coating is selected 11 Display LED recipe for Profiles Lights up green when the recipe for profile part is selected 12 Display LED recipe for Double Click Lights up green when the recipe for Double Click is selected 13 Display LED Fault Lights up when there is a fault on the device 14 Display ...

Page 23: ... 05 4 m h Resolution 0 05 m h 22 Display LED Overall Air Lights up yellow when the setting Overall Air is selected 23 Display LED Atomizing Ionizing and Tribo Air Lights up yellow when the setting Atomizing Ionizing and Tribo Air is selected 24 Universal control dial Dynamic digital control dial with 32 positions per revolution Adjustment speed is proportional to rotational speed Used to set Total...

Page 24: ...pe Lights up green Lower LED characteristic curve flat Middle LED characteristic curve medium Upper LED characteristic curve steep 33 Illuminated display Powder Quantity Lights up green Display range 0 100 Resolution 3 33 Single LED display Set point high voltage and powder are deactivated Bar display Actual value high voltage and powder are activated 34 Illuminated display Total Air Volume Lights...

Page 25: ...29371 36 Push button Powder Quantity To activate the function the powder quantity is set with rotary controller 24 and is indicated in LED display 19 Adjusting range 1 100 Resolution 1 37 Display LED Powder Quantity Lights up yellow when the powder quantity is selected ...

Page 26: ...g Prot Class Schutzklasse EPG SPRINT X 85 250 VAC 47 440 Hz max 40 W IP 64 CH 9450 Altstätten J Wagner AG Made in Switzerland PTB 12 ATEX 5001 Tested Geprüft EN50050 2 EN50177 II 3 2 D IP64 80ºC 0102 2 1 10 13 4 3 5 9 8 7 13 6 11 12 P_01744 C US FM APPROVED Overvoltage Category II and Pollution Degree 2 14 14 EPG Sprint X FM approved for CL II Div 2 Grps E F G Ambient temp range 5C to 45C T5 In ac...

Page 27: ...Corona gun Atomizing air With a Tribo gun Tribo air 8 Compressed air outlet for dosing air For the powder injector 9 Compressed air outlet for feed air For the powder injector 10 Gun connection To connect a Corona or Tribo gun 11 Connection for the CCM Prima For connecting to the CCM Prima when fitting in a PrimaTech automatic system 12 Cover of the service connection For Wagner service personnel ...

Page 28: ...NG 6 2 STORAGE CONDITIONS Until the point of assembly the control unit must be stored in a dry location free from vibrations and with a minimum of dust The control unit must be stored in closed rooms The air temperature at the storage location must be between 5 45 C 41 113 F The relative air humidity at the storage location must not exceed 75 6 3 INSTALLATION CONDITIONS The air temperature at the ...

Page 29: ...rminal Grounding cable to the signal ground e g from the powder tank Compressed air main supply 0 6 0 8 MPa 6 8 bar 87 116 psi Hose diameter 8 mm 0 315 inches Powder injector Dosing air blue Feed air red Powder feed transparent Atomizing or Tribo air transparent Electrical connection cable Corona or Tribo spray gun EPG SPRINT X ...

Page 30: ...Compressed air main supply 0 6 0 8 MPa 6 8 bar 87 116 psi Hose diameter 8 mm 0 315 inches Powder injector Dosing air blue Feed air red Powder feed transparent Atomizing or Tribo air transparent Electrical connection cable EPG SPRINT X Mains output to next control unit Electrical connection Tribo air Atomizing air Powder hose connection To the CCM Prima A Y distributor Order No 9990149 is needed to...

Page 31: ...ry poor wrap around uneven coating back spraying to the spray gun i e contamination Prerequisites for perfect grounding and coating are Clean work piece suspension Grounding of spray booth conveyor system and suspension on the building side in accordance with the operating manuals or the manufacturer s information Grounding of all conductive parts within the working area The grounding resistance o...

Page 32: ...loor must be electrostatically conductive The footwear worn by the operators must comply with the requirements of ENISO20344 Themeasuredinsulationresistancemustnotexceed100MΩ megohms The protective clothing including gloves must comply with the requirements of EN ISO 1149 5 The measured insulation resistance must not exceed 100 MΩ megohms Sparks between conveyor conveyor hooks hangers and work pie...

Page 33: ... appropriate system training WARNING Incorrect operation Risk of injury and damage to the device If contact with powder products or cleaning agents causes skin irritation appropriate precautionary measures must be taken e g wearing protective clothing The footwear worn by operating staff must comply with EN ISO 20344 The measured insulation resistance must not exceed 100 megohms The protective clo...

Page 34: ...to be completed A function test is performed in the start up phase At the end of the tests the connected gun type is detected and displayed Do not actuate the trigger on a manual spray gun in the start up phase if the gun is used as a single device in a manual coating system If the trigger is actuated the control unit will detect it as an automatic gun and wait for the actuation signal from CCM Pr...

Page 35: ... a manual one The powder feed is switched on and off with the gun s manual trigger Functional faults Do not operate the spray gun s trigger while the control unit is being switched on and is powering up NOTICE 7 3 1 OPERATING MODES The EPG SPRINT X supports the following operating modes starting with software version B200 Manual gun mode manual system with vibrator control Automatic gun mode remot...

Page 36: ...unctions please refer to the chapter Device Configuration 7 3 3 MANUAL GUN MODE WITH EXTERNAL CONTROL Application is the recoating of work pieces in an automatic coating system The recoating is done with a manual gun but the powder supply is done by the powder center of the automatic system The EPG SPRINT X must receive a release signal via the remote interface so that the device may clean and coa...

Page 37: ...U I characteristic curve Standard medium soft The EPG SPRINT X control unit has 50 pre defined recipes 4 of these can be selected directly using buttons 5 8 and the remaining 46 by pressing the Additional Recipes button 25 above the rotary controller 24 All recipes can be adapted and stored by the user to suit individual requirements Recipe 1 for Surface Parts High powder quantity high powder char...

Page 38: ...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 different parameters high voltage current limitation air volumes etc To access the function press the trigger lever on the spray gun twice in quick s...

Page 39: ...owever still depends on other factors The length of the suction hose and the length and diameter of the powder hose also affect the maximum powder volume 7 5 1 COMBINING THE AIR OUTPUTS A Y piece Order No 9990149 is needed to combine the feed and atomizing air Attention The atomizing air is not available in this mode Warning messages 1 3 Insufficient Feed Air Insufficient Dosing Air Insufficient A...

Page 40: ... P_01747 19 24 16 15 19 28 30 31 OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 7 5 2 ACTIVATING HIGH OUTPUT MODE C17 Procedure 1 To access special device configuration switch the unit to Standby with the Standby button 15 The yellow Standby LED 16 lights up 2 Press Characteristic Slope button 31 and hold it down 3 Turn the universal rotary controller 24 withtheotherhanduntiltheLEDdispla...

Page 41: ... button 27 or Current Limitation button 29 to select parameter C17 6 The value set for parameter C17 is displayed by pressing Characteristic Slope button 31 in LED display 19 off High feed air volume switched off on High feed air volume switched on To change the value to on turn universal rotary controller 24 one step clockwise To change the value to off turn universal rotary controller 24 one ste...

Page 42: ...40 20 10 2 0 μA P_01749 15 OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 8 To exit configuration mode press the Standby button 15 twice The control unit is now in the operating mode with high powder flow switched on This setting is global and applies in all recipes ...

Page 43: ...provided in chapters 7 7 1 7 7 8 When a parameter is changed the LED on the left of the recipe button flashes to indicate that a parameter value has been changed The process for saving parameters is described below To reuse the originally set values press the corresponding recipe button briefly The modified values are not taken over To save the modified values press the appropriate recipe button a...

Page 44: ...7 7 8 3 Instead of showing the current recipe number the LED display 19 now shows the modified value 4 To save the changes hold down the Additional Recipes button 25 until the previous recipe number flashes in the LED display 19 5 To save the values there are two options To save the recipe to the recipe number currently displayed hold the Additional Recipes button 25 down for another 2 seconds unt...

Page 45: ...ar graph is another scale indicating the hose diameter This scale shows the correlation between the total air volume and the inner hose diameter see operating manuals for the powder injectors PI F1 and HiCoat ED Pump F The inner hose diameter is printed on the powder hose Example Inner hose diameter 11 mm Total air 4 5 m h The total air volume can be adjusted between 1 6 m h as described above If ...

Page 46: ...r feed is switched on it shows the actual value as a bar The powder quantity setting as refers to the percentage distribution between the different air types Example 75 powder quantity means that 75 of the total air volume is supplied to the feed air and 25 to the dosing air The greater the proportion of feed air the greater the powder quantity for the specified total air volume Procedure 1 Press ...

Page 47: ... point as a dot and when powder feeding is switched on it shows the actual value as a bar Different amounts of air are required depending on the type or gun and or nozzle For the correct settings please refer to the operating manual for the relevant powder spray gun The additional air volume can be set to 0 05 4 m h as described above The additional air cannot be fully deactivated therefore the sp...

Page 48: ...l unit is in the ready position this display shows the set point as a dot and when high voltage is switched on it shows the actual value as a bar The high voltage can be adjusted between 10 100 kV as described above If this value is further reduced from a value of 10 kV the word off appears in the LED display 19 to signal that the high voltage is deactivated The high voltage generation is not ther...

Page 49: ...L HIGH VOLTAGE VALUE Procedure 1 Press High voltage button 27 for around 2 seconds Yellow LED 28 flashes quickly The actual high voltage value is shown in the LED display 19 for 5 seconds the display returns to the previous display after this time The actual value display can be interrupted also before expiration of the 5 seconds by pressing a selection button or turning rotary controller The actu...

Page 50: ... 29 is the Current Limitation bar graph display 2 When the control unit is in the ready position this display shows the set point as a dot and when high voltage is switched on it shows the actual value as a bar The current limitation is an adjustable threshold If this threshold is exceeded the high voltage is adjusted downwards until the threshold is no longer exceeded Procedure 1 Press the Curren...

Page 51: ...ENT LIMITATION Procedure 1 Press the Current Limitation pushbutton 29 approx 2 seconds Yellow LED 30 flashes quickly The actual current limitation value is shown in the LED display 19 for 5 seconds the display returns to the previous display after this time The actual value display can be interrupted also before expiration of the 5 seconds by pressing a selection button or turning rotary controlle...

Page 52: ...ce until the desired characteristic curve is shown in the Characteristic Slope LED display 32 U I characteristics for EPG SPRINT X The user can choose from three characteristic curves to achieve optimum coating results These enable optimum electrostatic charging of the powder despite different powder characteristics Standard Medium Soft High voltage kV 100 kV Spray current μA 120 μA The properties...

Page 53: ...he usual Wagner high voltage modules and control units Medium level gray for small surfaces Open circuit voltage 100 kV for types of powder that recharge well Maximum current 120 μA for metallic powder to reduce the effects of overcoating such as craters and orange peel Increasing the open circuit voltage allows for a greater distance between the spray gun and the work piece while maintaining suff...

Page 54: ...be changed in the parameter settings for parameters C22 and C23 see Device Configuration chapter 7 8 2 CLEANING PURGE FUNCTION This function is used at the end of a shift or during a change in color All parts carrying powder are purged The purge process is as described below First the atomizing air is activated After around 0 5 seconds the feed and dosing air are added increasing all the time Afte...

Page 55: ...NING PURGING WITH MANUAL GUNS Procedure 1 End coating operation 2 Remove powder suction unit suction lance powder injector from powder tank 3 Switch on purge function by pressing Purge button 17 on the control unit LED display 18 lights up permanently Close function by again pressing Purge button 17 The activated function is also indicated by the Overall Air indicator 34 and Atomizer Ionizer Tribo...

Page 56: ...ts to flash and indicates readiness for purging 4 Process should be repeated for each spray gun that is to be purged If you do not want a purging process press Standby button 15 5 Start purge process using Gun Start on unit s control 6 Stop purge process using Gun Stop on unit s control 7 Re activate control units in standby mode by pressing the Standby button 15 8 Press Purge button 17 to return ...

Page 57: ...9 e g 1 00 means a factory setting of 0 00 Nm h 2 Turn rotary controller 24 until just a small amount of powder is fed 3 To save hold down the Powder Quantity button 36 LED display 19 flashes To discard the set value press any button briefly The value that was originally set is reloaded Note The starting output value is set to 0 00 at the factory If the set value is changed the coating parameters ...

Page 58: ...00 90 0 50 1 00 4 50 4 00 3 50 3 00 2 00 1 50 2 50 10 20 30 40 50 60 70 80 100 90 0 0 P_02368 OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 Starting output 0 00 Nm3 h Powder Dosing air Feed air Starting output 1 00 Nm3 h Powder Dosing air Feed air Example Total air 4 00 Nm3 h ...

Page 59: ...tage must be shut down and locked to prevent it from being switched back on The spray gun must be separated from the high voltage supply before any cleaning work is started Use only electrically conductive tanks for cleaning liquids Ground the tank Preference should be given to non flammable cleaning fluids Flammable cleaning liquids may only be used if after switching off the high voltage all hig...

Page 60: ...r 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 irritation appropriate precautionary measures must be taken e g wearing protective clothing The footwear worn by operating staff must comply with EN ISO 20344 The measured insulation resistance must not e...

Page 61: ...INTENANCE STAFF 8 2 2 SAFETY INSTRUCTIONS Incorrect maintenance repair Danger to life and damage to the device Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel DANGER Incorrect maintenance repair Risk of injury and damage to the device Have repairs and part replacements carried out only by specially trained staff o...

Page 62: ...un settings x Check gun discharge pressure x Blow out powder hoses x Check grounding x Check compressed air quality x Check gun voltage x Check powder hoses for bends and sintering x 8 2 3 MAINTENANCE PROCEDURES Incorrect maintenance Risk of injury and damage to the device If contact with powder products or cleaning agents causes skin irritation appropriate precautionary measures must be taken e g...

Page 63: ...OC2329371 9 INSPECTIONS Ifthecontrolunitisusedinastationarysystemforelectrostaticcoatingwithflammablecoating powders testing should be undertaken in accordance with DIN EN 50177 2010 04 as per Table 3 andTable 4 9 1 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177 2010 ...

Page 64: ...n while the technical ventilation is not working eff ectively CP FI Test whether the system is safely stopped and the product supply supply air and high voltage are switched off when the ventilation 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 occur C...

Page 65: ...esistors weekly 5 Measures to take if conductive components are insuffi ciently grounded If suffi cient grounding of conductive parts cannot be ensured their discharge energy must not exceed the permissible value CP ME CI Measurement of discharge energy weekly 6 Resistance to ground of work piece s locating point The resistance to ground of every work piece s locating point must not exceed 1 megoh...

Page 66: ...it The discharge equipment must be interlocked with the spray system such that the high voltage is switched off and that coating cannot take place if the discharge equipment malfunctions CP ME FU SÜ Measurement of discharge energy check the monitoring equipment s test function by triggering it weekly 8 Eff ectiveness of the manually or automatically actuated fi re extinguishing systems room protec...

Page 67: ... DOC2329371 If the control unit is used in a manual spray system for electrostatic coating with flammable coating powders testing should be undertaken in accordance with DIN EN 50050 2 2014 03 as per Table 1 9 2 INSPECTIONS IN ACCORDANCE WITH DIN EN 50050 2 2014 ...

Page 68: ...be interlocked such that the 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 product supply supply air and high voltage are switched off when the ventilation is shut down annually 3 Inspection of the electrostatic manual spray equipment for damage Electrostatic manual spray equipment may only be ...

Page 69: ...ply on control unit 5 Detach hoses for the feed air dosing air and atomizing air on the control unit 6 Remove grounding cable on control unit 7 Loosen retaining nuts and dismount control unit WARNING Incorrect disassembly Risk of injury and damage to the device Before starting disassembly Switch off the energy compressed air supply Ensure that all system components are grounded Secure system again...

Page 70: ...quipment and its implementation in national law this product may not be disposed of with the household refuse but must be recycled in an environmentally correct manner Wagner or one of our dealers will take back your usedWagner waste electrical or electronic equipment and will dispose of it for you in an environmentally friendly way Please contact one of our service points one of our representativ...

Page 71: ... 1203 Note national regulations Repair or replacement of devices or parts of devices may only be performed outside the hazard area DANGER Incorrect maintenance repair Risk of injury and damage to the device Have repairs and part replacements 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 ene...

Page 72: ...3 5 2 5 80 100 Tri 90 60 70 19 13 OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 11 1 WARNINGS E01 E04 The fault LED 13 flashes to indicate warnings In addition Exx is shown alternately in the LED display 19 7 segment LED xx stands for the warning number Work can continue if a warning is displayed ...

Page 73: ... System cannot reach target setting Check hoses and hose laying E03 Feed air too low Set point cannot be reached Causes Hose kinked blocked Check hoses and hose laying Input air pressure too low Ensure that input pressure is greater than 6 bar Injector is not connected Connect injector correctly System cannot reach target setting Select smaller set point value Example Feed air for ED pump max 3 5 ...

Page 74: ...nued only after removing the fault and pressing any button Fault number Fault Cause Remedy E11 Ground monitoring Grounding cable is interrupted Check replace gun cable Check replace gun Gun is not connected Connect gun E12 No coil current cascade interrupt Gun is not connected Connect gun Gun cable is interrupted Check replace gun cable Cascade in gun is interrupted defective Check replace gun E13...

Page 75: ...ware defect has occurred If problem persists contact Wagner Service Team E31 Gun switch monitoring in automatic mode The gun switch line has been interrupted Check gun cable Gun unplugged during operation Check gun E41 No flow of atomizing air No air is flowing out of the control unit Causes Check Hose kinked blocked The hose laying Gun blocked The air supply to the control unit Input pressure 6 b...

Page 76: ...re error Hardware defect has occurred Detach hose on rear of valve and in standby mode check the valve for seal integrity air supply must be connected Atomizing air duct valve leaking E55 Hardware error Hardware defect has occurred Detach hose on rear of valve and in standby mode check the valve for seal integrity air supply must be connected Dosing air duct valve leaking E56 Hardware error Hardwa...

Page 77: ...ES 12 2 WALL MOUNT Order No Designation Wall mount with bracket 12 1 CONNECTION CABLES Order No Designation 241270 Mains cable Europe 241271 Mains cable Switzerland 264626 Mains cable USA 264625 Mains cable Japan 130215 Grounding cable 10 m 32 8 ft 263219 Grounding cable Japan 9990149 Y piece ...

Page 78: ...μA Nm h 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 6 45 P_01829 OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 12 3 RECIPE STICKER Order No Designation 2331223 Recipe sticker ...

Page 79: ...ts lists 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 are not covered by warranty terms Not part of the standard equipment but available as a special accessory Incorrect maintenance repair Risk of injury and damage to the device Repairs and part re...

Page 80: ...NG MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 13 2 EPG SPRINT X CONTROL UNIT Pos K Stk Order No Designation 1 EPG SPRINT X control unit for manual and automatic systems 2 Thermal delay fuses 1 0 A included in EPG SPRINT X ...

Page 81: ...e of chemical electrochemical or electrical agents except when the damage is attributable to us Components that have not been manufactured by WAGNER are subject to the original warranty of the manufacturer Replacement of a component does not extend the period of warranty of the device The device should be inspected immediately upon receipt To avoid losing the warranty we or the supplier company ar...

Page 82: ...ollowing provisions applying to it 94 9 EC ATEX Directive 2004 108 EC EMC Directive 2002 95 EC RoHS Directive 2002 96 EC WEEE Directive Applied standards in particular Identification 0102 II 3 2 D IP 64 80 C CE Certificate of Conformity The CE certificate of conformity is enclosed with this product If needed further copies can be ordered through your WAGNER dealer by specifying the product name an...

Page 83: ...83 EPG SPRINT X OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 14 4 EC TYPE EXAMINATION CERTIFICATE ...

Page 84: ...ion for the Control Units are to be connected in an unclassified ordinary location only P_00309 OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 14 5 FM APPROVAL The EPG SPRINT X control unit is approved in the USA and Canada using configuration drawing no 2309729 ...

Page 85: ...A P_01747 31 19 24 16 15 19 28 30 OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 DEVICE CONFIGURATION APPENDIX Procedure 1 To access special device configuration switch the unit to Standby with the Standby button 15 The yellow Standby LED 16 lights up 2 Press Characteristic Slope button 31 and hold it down 3 Turn the universal rotary controller 24 with the other hand until the LED displa...

Page 86: ...ird group is for Wagner Service and the fourth group is reserved for Wagner production sites or the Wagner Service Center which have the necessary infrastructure Group 1 Parameters C11 to C20 Group 2 Parameters C21 to C30 Group 3 Parameters C31 to C40 Wagner Service Group 4 Parameters C41 to C99 production plant service center It is possible to switch between the different groups using the Recipe ...

Page 87: ...ent Limitation button 29 to set the parameter to C11 2 The parameter value is now shown by pressing the Characteristic Slope button 31 3 The LED display 19 shows cor At the same time the blue Purge LED 18 will flash 4 All setting options can then be viewed in turn by turning the universal rotary controller 24 The display shows cor for Corona manual and automatic guns tri for Tribo manual and autom...

Page 88: ...currently displayed press the Characteristic Slope button 31 again The LED display 19 shows C11 again b If you want to save the changed setting press the Additional Recipes button 25 to save the setting until the blue Purge LED 18 no longer flashes The LED display 19 then shows the parameter number again in this example C11 Proceed in the same way for all other parameters The list below provides a...

Page 89: ...is factory set to OFF lock deactivated Procedure 1 If parameter C13 is not set on the control unit select parameter group 1 by pressing recipe button 5 and use the High voltage button 27 or the Current Limitation button 29 to set the parameter to C13 2 The parameter value is now shown by pressing the Characteristic Slope button 31 3 The LED display 19 shows off At the same time the blue Purge LED ...

Page 90: ...is currently displayed press the Characteristic Slope button 31 again The LED display 19 shows C13 again b If you want to save the changed setting press the Additional Recipes button 25 to save the setting until the blue Purge LED 18 no longer flashes The LED display 19 then shows the parameter number again in this example C13 Proceed in the same way for all other parameters The list below provide...

Page 91: ...on after 5 seconds the selection automatically returns to the powder quantity setting C13 Lock OFF Factory setting Lock is deactivated ON Lock is activated values cannot be changed user can only select recipes and control functions Recipe values cannot be changed Pro Operating inhibit sometimes activated Recipe storage is blocked otherwise function as in the OFF position Values can be changed temp...

Page 92: ...n parallel Both these airs must be combined externally by a Y piece and supplied to the injector s feed air connection The additional volume differs depending on injector type The atomizing and Tribo air is no longer available to the spray gun and must be obtained from a different source OFF Factory setting Standard setting for separate hosing for feed dosing and atomizing air ON The feed air and ...

Page 93: ...itched on 1 s 240 s Vibrator motor is switched on with the manual gun s trigger lever and overruns for X seconds can be set from 1 second to 240 seconds C22 Hose purging dosing air without feed air OFF Factory setting Hose purging switched off 1 s 10 s Hose purging time overrun in seconds C23 Hose purging intensity of dosing air 100 Factory setting Hose purging intensity 100 1 100 Hose purging int...

Page 94: ...n always with manual gun The remote interface is not used for controlling the vibrator instead the remote interface provides the device with a release and the OFF ON command for cleaning continuous purging The remote interface is described in the service manuals 2 Same as described for value 1 but the purge button at the operating front is without function disabled C31 C40 Password protection Pass...

Page 95: ...operation with gun ON Special application if a field controller is connected to this control unit The open circuit voltage cannot exceed a value of 40 kV C28 High voltage module Automatic spray current reset OFF This setting must be selected if a field controller is used in the system as a whole It makes no difference whether a gun or a field controller is connected to this control unit ON Default...

Page 96: ...ield controller any high voltage module has been used for spraying 10 seconds before the reset takes place Manual spray current reset option 1 The reset can be performed by the operator He she is responsible for complying with the basic conditions The reset can be performed by holding down the characteristic slope button for more than 2 seconds If the reset has been successful the 3 LEDs on the ch...

Page 97: ...329371 Configuration Guns only no field controller Combination of guns and field controller EPG Sprint X configuration EPG Sprint X configuration guns EPG Sprint X configuration field controller C27 OFF C27 OFF C27 ON C28 ON C28 OFF C28 OFF Further information can be found in the field controller operating manual Guns Guns Field controller ...

Page 98: ...Selection button Powder Quantity 5 Selection button Total Air Volume m h 6 Selection button Characteristic Slope 7 Selection button Current Limitation μA 8 Selection button High voltage kV 9 Recipe button Surface Parts coating surface parts 10 Recipe button Second Coating 11 Recipe button Profile Parts coating profile parts 12 Recipe button Double Click for rapid recipe changes without interruptin...

Page 99: ...e touch of a button 3 CALLING CHANGING SAVING RECIPES 5 50 1 Press Additional Recipes button 2 Set recipe number with rotary controller The recipe number is displayed in the LED display 3 Set new parameters see 1 4 Press Additional Recipes button for around 2 seconds The changed parameters are saved 5 The recipe number is shown flashing in the LED display 6 Set required recipe number with rotary c...

Page 100: ...100 EPG SPRINT X OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 ...

Page 101: ...101 EPG SPRINT X OPERATING MANUAL VERSION 06 2014 ORDER NUMBER DOC2329371 ...

Page 102: ...france fr Netherlands WAGNER Systemen Nederland Proostwetering 105 C NL 3543 AC Utrecht Phone 31 30 2410 688 Fax 31 30 2410 765 E mail info wagnersystemen nl Italy WAGNER Itep S p A Via Santa Veccia 109 I 22049 Valmadrera LC Phone 39 0341 212211 Fax 39 0341 210200 E mail wagnerit tin it Japan WAGNER HOSOKAWA Micron Ltd No 9 1 Chome Shodai Tajka Hirakata Shi Osaka 673 1132 Phone 81 728 566 751 Fax ...

Page 103: ......

Page 104: ...CERTI F I E D Order No 2329371 Germany Phone Fax E mail Switzerland Phone Fax E mail ...

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WAGNER EPG-Sprint X, Operating Manual

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