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Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE
9 Troubleshooting and Rectification

Order number 2354913 | Edition 10/2022

57

Fault number

Malfunction

Cause

Rectification

No general release
from IPS for coating
(only for EPG-Sprint
X)

Extraction in ECO-mode or
switched off

Activate coating release on
IPS

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Содержание EPG-SPRINT XE

Страница 1: ...3 0 1 1 5 3 5 5 4 5 3 5 2 5 Tri A Universal Control Unit for Powder Spray Guns EPG SPRINT XE Translation of the Original Operating Manual 0102 II 3 2 D IP64 80 C For professional use Always observe th...

Страница 2: ......

Страница 3: ...1 1 Electrical Devices and Equipment 12 4 1 2 A Safe Work Environment 12 4 1 3 Personnel Qualifications 13 4 2 Safety Instructions for the Personnel 13 4 2 1 Personal Safety Equipment 13 4 2 2 Safe H...

Страница 4: ...Atomizing Ionizing Tribo Air Volume 41 7 6 4 Setting the High Voltage 42 7 6 5 Displaying Actual High voltage Value 43 7 6 6 Setting the Current Limitation 44 7 6 7 Displaying Actual Value of Current...

Страница 5: ...ticker 64 14 Spare Parts 65 14 1 How to Order Spare Parts 65 14 2 Notes on the Use of Spare Parts 65 14 3 EPG SPRINT XE control unit 65 15 Declaration of Conformity 67 15 1 EU Declaration of Conformit...

Страница 6: ...ng instructions fall into the following categories DANGER Immediate risk of danger Non observance will result in death or serious injury WARNING Potential danger Non observance may result in death or...

Страница 7: ...riginal operating manual Language Order no Language Order no English 2354913 Portuguese 2368375 French 2354914 Dutch 2388017 Italian 2354915 Bulgarian 2391612 Spanish 2354916 Romanian 2397414 Russian...

Страница 8: ...ess the work assigned to him her and detect possible hazards based on his her technical training knowledge and experience in rele vant provisions Skilled person in the context of DGUV 209 052 A person...

Страница 9: ...manual 4 Follow the instructions in the operating manual 2 3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS The EPG SPRINT XE control unit is intended for use with powder spray guns of types A P up to 2 mJ in...

Страница 10: ...evice class II 3 Category 3 zone 22 2 Impact on equipment of category 2 D Ex atmosphere dust IP 64 Protection class IP64 80 C Temperature class maximum surface temperature 80 C 176 F 3 2 PERMISSIBLE D...

Страница 11: ...Luft 6 5 2 ISO 8573 1 Do NOT disconnect when energized NICHT unter Spannung trennen I O Air input Lufteingang For operation all ports must be fitted with a plug or the protection cap F r den Betrieb...

Страница 12: ...de energized before 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 a...

Страница 13: ...eded 4 1 3 Personnel 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 accordan...

Страница 14: ...4 Before the spray 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...

Страница 15: ...on hazard and 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...

Страница 16: ...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 Protective and Monitoring Equipment Danger due to remov...

Страница 17: ...Universal Control Unit for Powder Spray Guns EPG SPRINT XE 4 Basic Safety Instructions Order number 2354913 Edition 10 2022 17 Follow the instructions in the operating manual Wear electrostatically co...

Страница 18: ...signation 1 2353221 EPG SPRINT XE The standard equipment includes 2327595 Declaration of Conformity 2354911 Operating manual in German see Languages 8 7 Operating manual in local language 5 3 TECHNICA...

Страница 19: ...4 The compressed air must meet the following quality requirements Quality Standard 6 5 2 according to ISO 8573 1 2010 6 5 2 particle density 5 mg m pressure dew point 7 C oil content 0 1 mg m NOTICE C...

Страница 20: ...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...

Страница 21: ...lt on the device 14 LED display Automatic gun Lights up when an automatic gun is connected 15 Push button Standby To switch into standby mode High voltage and powder feed cannot be activated in this m...

Страница 22: ...with the control dial 24 and is indicated in the LED display 19 Selection of the recipes 5 to 50 26 LED display Additional recipes Lights up yellow when an additional recipe is selected 27 Push butto...

Страница 23: ...ltage Spannung Line Power Eingangsleistung Prot Class Schutzart EPG SPRINT XE 90 250 VAC 47 63 Hz max 110 W IP64 CH 9450 Altst tten Wagner International AG Made in Switzerland PTB 12 ATEX 5001 II 3 2...

Страница 24: ...sed air outlet for additional air With a 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...

Страница 25: ...ter it is assembled and commissioned 6 2 STORAGE CONDITIONS Until the point of assembly the device must be stored in a dry location free from vibrations and with a minimum of dust The device must be s...

Страница 26: ...r 2354913 Edition 10 2022 6 4 CONNECTING THE MANUAL GUN P_01745 1 3 8 7 6 5 4 2 11 9 10 12 1 Corona or Tribo spray gun 2 Electrical connection cable 3 Compressed air main supply 0 6 0 8 MPa 6 8 bar 87...

Страница 27: ...missioning Order number 2354913 Edition 10 2022 27 7 Powder injector 8 Powder feed e g from the powder tank 9 Feed air red 10 Grounding cable to the signal ground 11 Mains input terminal 12 EPG Sprint...

Страница 28: ...NG THE AUTOMATIC GUN PEA C4 1 2 3 5 6 7 9 8 4 13 18 17 15 14 12 10 16 11 15 6 6 6 6 15 15 15 5 5 5 5 3 3 PEA X1 PER X1 P_01114 I O 5 1 Tribo spray gun 2 Atomizing air 3 Corona spray gun 4 Compressed a...

Страница 29: ...protective conductor while that to the work piece system is made via the knurled screw on the rear of the control unit Both connections are absolutely essential The gun is grounded according to instru...

Страница 30: ...all and signal ground 3 Connect grounding cable to an uncoated metal part of the booth or spray wall 4 Remove all paint from hooks and other hanger parts 5 Do not wear insulating gloves 6 Wear electro...

Страница 31: ...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 remote control The device cannot be...

Страница 32: ...leaning function continuous flushing can also be controlled externally Display on device Automatic gun LED flashes quickly No release signal is present Automatic gun LED is off not lit Release signal...

Страница 33: ...harging 7 Recipe 3 for Profile parts Medium powder quantity low powder charging 8 Recipe 4 for Double click function Individual setting activated by a double click on the manual gun or once this butto...

Страница 34: ...40 20 100 Tri Cor 5 4 3 2 1 120 80 40 20 10 A 7 4 AIR HIGH OUTPUT MODE HIGH POWDER DISCHARGE With the EPG SPRINT XE you can combine the feed and atomizing air to obtain a higher feed air volume A high...

Страница 35: ...feed air Insufficient dosing air Insufficient atomizing air are deactivated in this mode 7 4 2 Activating High Output Mode C17 EPG SPRINT X 0 100 kV 80 60 40 20 100 Tri Cor 5 4 3 2 1 120 80 40 20 10...

Страница 36: ...number 10 Then release the Characteristic slope button 31 The device is now in configuration mode The scrolling text Configuration is displayed EPG SPRINT X 0 100 kV 80 60 40 20 100 Tri Cor 5 4 3 2 1...

Страница 37: ...High feed air volume switched off 4 on High feed air volume switched on 7 To change the value to on turn universal control dial 24 one step clockwise To change the value to off turn universal control...

Страница 38: ...using the corresponding selection buttons Descriptions of the individual parameters are provided in Chapter Setting the Total Air Volume 8 39 and in the following chapters When a parameter is changed...

Страница 39: ...ecipe number flashes in the LED display 19 5 To save the values there are two options 4 To save the recipe to the recipe number currently displayed hold the Additional recipes button 25 down for anoth...

Страница 40: ...the left of the bar 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...

Страница 41: ...when powder feed is switched on it shows the actual value as a bar The powder quantity setting as a refers to the percentage distribution of the different air types Example 75 powder quantity means t...

Страница 42: ...ows the set point as a dot and when powder feed 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 setti...

Страница 43: ...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 t...

Страница 44: ...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 A P_01756 19 24 2 2 The current limitation can now be set using the universal control dial 24 between 5 120 A with a resolution of 1 A The v...

Страница 45: ...the previous display after this time The actual value display can also be interrupted before expiration of the 5 seconds by pressing a selection button or turning the universal control dial 24 7 6 8 S...

Страница 46: ...ntrol units Medium level gray Open circuit voltage 100 kV Maximum current 120 A for small surfaces for types of powder that recharge well for metallic powder to reduce the effects of overcoating such...

Страница 47: ...d dosing air flush in pulses while the atomizing air remains constant throughout The cleaning flush function is only available when the control unit is switched on and in the operating mode In standby...

Страница 48: ...you do not want a flushing process press Standby button 15 6 Start flushing process using Gun start on the system controller 7 Stop flushing process using Gun Stop on the system controller 8 Re activ...

Страница 49: ...n the LED display 19 e g 1 00 means 1 00 Nm3 h The factory setting is set to 0 00 Nm3 h 2 Turn universal control dial 24 until just a small amount of powder is fed 3 To save hold down the Powder quant...

Страница 50: ...ns EPG SPRINT XE 7 Operation 50 Order number 2354913 Edition 10 2022 DL Dosing air FL Feed air P Powder Starting output 1 00 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...

Страница 51: ...by the operator depending on the level of use and if necessary the level of soiling If in doubt we recommend contacting WAGNER s specialist personnel The valid health and safety specifications and the...

Страница 52: ...individual components for all work Prior to maintenance Flush and clean the system according to Chapter Cleaning Procedures 8 51 After maintenance Carry out safety checks in accordance with Chapter Sa...

Страница 53: ...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 EPG SPRINT X 0 10 20 30 40 50 12 10 11 9...

Страница 54: ...bo current limit for 10 s The Tribo current set in the configuration cannot be reached Causes Tribo air set too low Increase Tribo air Powder not flowing due to in correct settings for feed air and to...

Страница 55: ...the WAGNER service depart ment Switch off unit and after 10 seconds switch on again E18 Result of spray cur rent measurement is implausible Hardware defect If problem persists contact the WAGNER servi...

Страница 56: ...lve leaking E55 Hardware error Hardware defect has oc curred 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 leak...

Страница 57: ...SPRINT XE 9 Troubleshooting and Rectification Order number 2354913 Edition 10 2022 57 Fault number Malfunction Cause Rectification No general release from IPS for coating only for EPG Sprint X Extrac...

Страница 58: ...is used for electrostatic 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 59 10 1 ABBREVIATIONS E...

Страница 59: ...n the ven tilation 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...

Страница 60: ...ordance with section 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...

Страница 61: ...em is used for electrostatic coating with ignitable coating powders the test must be performed in accordance with DIN EN 50050 2 2013 according to the following Overview Table 8 62 11 1 ABBREVIATIONS...

Страница 62: ...ial max 1 M 1000 V Weekly 2 Link between technical ven tilation equipment and high voltage compressed air and powder feed The technical ventilation should be interlocked such that the powder feed and...

Страница 63: ...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 12 2 DISPOSAL NOTICE Do...

Страница 64: ...t 263219 Grounding cable Japan 9990149 Y piece 13 2 WALL MOUNT P_01861 Order no Designation 2330223 Wall mount with bracket 13 3 RECIPE STICKER 2x 2x Tribo Corona m h 3 0 0 5 0 3 0 1 1 5 3 Tri 12 10 1...

Страница 65: ...ing parts are not included in the warranty Included in service set Not part of the standard equipment but available as a special accessory Explanation of order no column Item not available as spare pa...

Страница 66: ...Operating manual Universal Control Unit for Powder Spray Guns EPG SPRINT XE 14 Spare Parts 66 Order number 2354913 Edition 10 2022 wearing parts...

Страница 67: ...A2 2013 EN IEC 61000 6 2 2019 EN 50050 2 2013 EN IEC 61000 6 4 2019 EN 50177 2009 A1 2012 EN IEC 63000 2018 EN IEC 60079 0 2018 Applied national technical standards and specifications in particular D...

Страница 68: ...by LED 16 lights up EPG SPRINT X 0 100 kV 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 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 A P_05016 24 19 31...

Страница 69: ...ch have the necessary infrastructure 2x 2x P_01750 5 6 7 8 5 Group 1 Parameters C11 to C20 6 Group 2 Parameters C21 to C30 7 Group 3 Parameters C31 to C40 WAGNER service department 8 Group 4 Parameter...

Страница 70: ...play shows 4 cor for Corona manual and automatic guns 4 tri for Tribo manual and automatic guns 4 aut for automatic switching from Tribo to Corona if the user frequently switches between Tribo and Cor...

Страница 71: ...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 an overview of all the other parameters EPG SPRINT X 0...

Страница 72: ...ntrol unit select parameter group 1 by pressing recipe button 5 and use the High voltage button 27 and the Current limitation button 29 to set the parameter to C13 EPG SPRINT X 0 kV 80 60 40 20 100 Tr...

Страница 73: ...rently displayed press the Characteristic slope button 31 again The LED display 19 shows C13 again EPG SPRINT X 0 kV 80 60 40 20 100 Tri Cor 5 4 3 2 1 120 80 40 20 10 2 0 A P_05030 19 18 25 4 If you w...

Страница 74: ...tion is switched off A selection is retained until another selec tion is made ON factory setting Selection function is switched on after 5 seconds the selection automatically re turns to the powder qu...

Страница 75: ...ger available to the spray gun and must be obtained from a dif ferent source OFF factory setting Standard setting for separate hosing for feed dosing and atomizing air ON The feed air and atomizing ai...

Страница 76: ...ting mode are described in the Chapter on Prepara tions for Commissioning 8 31 and in the service manuals 1 Operation always with manual gun The remote interface is not used for control ling the vibra...

Страница 77: ...andby mode 2 Universal control dial to select recipes and parameters 3 Selection button Atomizing Tribo air m3 h 4 Selection button Powder quantity 5 Selection button Total air volume m3 h 6 Selection...

Страница 78: ...tton required for around 2 seconds until the LED display flashes rapidly The recipe is saved with new parameters and can be called up again at any time at the touch of a button 3 Calling Up Changing S...

Страница 79: ......

Страница 80: ...ne 41 0 71 757 2211 Fax 41 0 71 757 2222 Germany J Wagner GmbH Otto Lilienthal Strasse 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 5050 Fax 49 0 7544 505200 E mail ts powder wagner group com...

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