WAGNER EPG-SPRINT Bedienungsanleitung

0102 II 3(2)D IP64 80°C

P_01110

Tribo Corona

120

100

μA

100

m /h

5.0

4.0

3.0

2.0

6.0

5.5

4.5

3.5

2.5

2.2

100

m /h

4.0

3.0

2.0

1.0

0.5

0.4

0.3

0.2

0.1

1.5

EPG

P_01742

EPG

SPRINT X

100

Tri Cor

120

m/h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

Tri

μA

Universal Control Unit for

Powder Coating Guns

EPG-SPRINT

EPG-SPRINT X

EPG-SPRINT XE

Version 09/2017

Original Service Manual

EPG-SPRINT / EPG-SPRINT X

SERVICE MANUAL

VERSION 09/2017 ORDER NUMBER DOC2309350

Table of Contents

1 GENERAL INFORMATION 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 7

1.4 Abbreviations 7

2 CORRECT USE 8

2.1 Device Type 8

2.2 Type of Use 8

2.3 Use in an Explosion Hazard Area 8

2.4 Safety Parameters 9

2.5 Reasonably Foreseeable Misuse 9

2.6 Residual Risks 10

3 IDENTIFICATION 11

3.1 Explosion Protection Identication in Accordance with ATEX 11

3.2 Permissible Device Combinations 11

4 GENERAL SAFETY INSTRUCTIONS 12

4.1 Safety Instructions for the Operator 12

4.1.1 Electrical Devices and Equipment 12

4.1.2 Personnel Qualications 12

4.1.3 Safe Work Environment 12

4.2 Safety Instructions for Sta 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 Identication 16

5 DESCRIPTION 17

5.1 Fields of Application, Correct Use 17

5.2 Technical Data 18

5.2.1 EPG-SPRINT 18

5.2.2 EPG-SPRINT X 19

5.2.3 EPG-SPRINT XE 20

5.3 Permitted Accessories 22

5.4 Scope of Delivery 22

5.4.1 Scope of Delivery of EPG-SPRINT 22

5.4.2 Scope of Delivery of EPG-SPRINT X 22

5.4.3 Scope of Delivery of EPG-SPRINT XE 22

5.5 Operating Elements of EPG-SPRINT 23

5.5.1 Overview of Control Panel Front Side 23

5.5.2 Connections on the Rear Side of the EPG-SPRINT 28

5.6 Operating Elements of EPG-SPRINT X/EPG-SPRINT XE 30

5.6.1 Overview of Control Panel Front Side 30

5.6.2 Connections on the Rear Side of the EPG-SPRINT X 35

5.6.3 Connections on the Rear Side of the EPG-SPRINT XE 37

EPG-SPRINT / EPG-SPRINT X

SERVICE MANUAL

VERSION 09/2017 ORDER NUMBER DOC2309350

Table of Contents

6 SPARE PARTS 39

6.1 How Can Spare Parts Be Ordered? 39

6.2 EPG-SPRINT Control Unit 40

6.3 EPG-SPRINT X Control Unit 43

6.4 EPG-SPRINT XE Control Unit 46

6.5 Resources and Special Tools 49

6.6 Handling the Release Tool for the Air Diuser 50

7 REPAIR WORK 51

7.1 Personnel Qualications 51

7.2 Safety Instructions 51

7.3 Replacing a Proportional Valve 53

7.4 Replacing the Incremental Encoder 55

7.5 Replacing the Display Print 56

8 PARAMETERS FOR SERVICE PURPOSES 57

8.1 Test Parameters 58

8.2 Calibration Parameters 58

8.3 Accessing the Service Level (C31-C34) 59

8.4 Accessing and Adjusting Parameter Value 60

9 SERVICE LEVEL 61

9.1 Parameter C31, Checking Air Outlets 61

9.2 Parameter C34, I/O Test (Input and Output) 64

10 PLANT LEVEL 68

10.1 Plant Level Parameters 68

10.2 Accessing the Plant Level Parameters 69

10.3 Parameter C41, Measuring and Calibrating Operating Pressure 70

10.4 Parameter C42, Calibrating Air Outlets 71

10.5 Parameter C43, Master Reset 74

10.6 Parameter C44, High-voltage Calibration 75

10.7 Parameter C45, Default Setting of Oset for Air Channels 78

11 MEASURING EQUIPMENT 81

11.1 Air Flow Measuring Device 81

11.2 Air Pressure Measuring Device 81

11.3 High-voltage Measuring Device 82

11.4 Voltmeter 82

12 EXTENDED INTERFACE FOR REMOTE CONTROL 83

12.1 Manual Gun Mode 83

12.2 Automatic Gun Mode 83

12.3 Manual Gun with External Control 84

12.4 Recipe Selection Input 84

12.4.1 Selection Via Pulse Length 84

12.4.2 Selection with Transfer Protocol 85

13 BLOCK DIAGRAMS 88

14 FURTHER ERROR MESSAGES 90

15 SOFTWARE UPDATE 93

EPG-SPRINT / EPG-SPRINT X

SERVICE MANUAL

VERSION 09/2017 ORDER NUMBER DOC2309350

16 SOFTWARE HISTORY 97

16.1 EPG-SPRINT 97

16.2 EPG-SPRINT X 98

16.3 EPG-SPRINT XE 98

17 WARRANTY AND CONFORMITY DECLARATIONS 99

17.1 Important Notes Regarding Product Liability 99

17.2 Warranty Claim 99

17.3 CE Declaration of Conformity EPG-SPRINT 100

17.4 EC Type Examination Certicate EPG-SPRINT 101

17.5 CE Declaration of Conformity EPG-SPRINT X/EPG-SPRINT XE 103

17.6 EC Type Examination Certicate EPG-SPRINT X/EPG-SPRINT XE 104

17.7 FM Identication EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE 105

Table of Contents

EPG-SPRINT / EPG-SPRINT X

SERVICE MANUAL

VERSION 09/2017 ORDER NUMBER DOC2309350

1 GENERAL INFORMATION

This service manual contains information and instructions for the operation, repair, service

and maintenance of the control units.

This equipment can be hazardous if it is not operated in accordance with the information

provided in this service manual and the corresponding operating manual.

1.1 PREFACE

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this operating manual highlight particular dangers to users and to

the device and state measures for avoiding the hazard. These warning instructions fall into

the following categories:

Danger - immediate risk of danger.

Non-observance will result in death or serious injury.

Warning - 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 damage to property.

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

WARNING

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

CAUTION

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions. The signal word

indicates the hazard level.

The measures for preventing the hazard and its consequences.

NOTICE

EPG-SPRINT / EPG-SPRINT X

SERVICE MANUAL

VERSION 09/2017 ORDER NUMBER DOC2309350

1.3 LANGUAGES

The service manual is available in the following languages:

German 2309349 English 2309350

1.4 ABBREVIATIONS

Number of pieces

Position

Marking in the spare parts lists

Order No. Order number

Spare part

Wrench size

EPG-SPRINT:

The operating manual is available in the following languages:

German 2305220 English 2305222

French 2305224 Italian 2305225

Spanish 2305226 Russian 2321631

EPG-SPRINT X:

The operating manual is available in the following languages:

German 2327591 English 2329371

French 2330847 Italian 2330848

Spanish 2330849 Russian 2333349

Chinese 2333350

EPG-SPRINT XE:

The operating manual is available in the following languages:

German 2354911 English 2354913

French 2354914 Italian 2354915

Spanish 2354916 Russian 2354917

Chinese 2354918

EPG-SPRINT / EPG-SPRINT X

SERVICE MANUAL

VERSION 09/2017 ORDER NUMBER DOC2309350

2 CORRECT USE

2.1 DEVICE TYPE

Universal control unit for controlling electrostatic manual and automatic spray guns

2.2 TYPE OF USE

The EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE control unit is intended for controlling

electrostatic manual and automatic powder spray guns of type A-P (2 mJ) according to

DIN EN 50050-2 and DIN EN 50177.

Incorrect use!

Risk of injury and damage to the device.

Only connect original WAGNER spray guns to the EPG-SPRINT/

EPG-SPRINT X/EPG-SPRINT XE control unit.

The PEM-C3R and PEM-T3R manual spray guns may not be

connected to the EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE

control unit.

WARNING

2.3 USE IN AN EXPLOSION HAZARD AREA

The EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE 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 06 ATEX 03/

PTB 12 ATEX 5001.

The EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE control unit may be used in the dust

explosion zone (Zone 22) under the following conditions:

– Control unit correctly tted in rack.

– Rack correctly and securely sealed on rear with associated cover.

– All plug connections are securely locked.

– All connections not needed (mains output, remote control) are sealed with dust

protection caps.

EPG-SPRINT / EPG-SPRINT X

SERVICE MANUAL

VERSION 09/2017 ORDER NUMBER DOC2309350

2.5 REASONABLY FORESEEABLE MISUSE

– Coating work pieces which are not grounded

– Use of defective components and accessories

– Use with not permissible powder coating guns

2.4 SAFETY PARAMETERS

WAGNER accepts no liability for any damage arising from incorrect use.

Electrostatic spray equipment may only be operated in an intact condition, damaged

devices must be decommissioned immediately and repaired.

Use the device only to work with the products recommended by WAGNER.

Only operate the device as a whole.

Do not deactivate safety xtures.

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 sta have previously been trained on the basis of this operating manual,

the safety regulations listed in this service manual are observed,

the operating, maintenance and repair information in this service manual is observed,

and the statutory requirements and accident prevention regulations standards in the

country of use are observed.

EPG-SPRINT / EPG-SPRINT X

SERVICE MANUAL

VERSION 09/2017 ORDER NUMBER DOC2309350

2.6 RESIDUAL RISKS

Residual risks are risks which cannot be ruled out even in the event of correct use.

If necessary, warning and prohibition signs at the relevant points of risk indicate residual

risks.

Residual risk Source Consequences Specic 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

dened working

area

Lacquering

outside the

dened working

area

Inhalation of substances

which are hazardous to

health

Observe work

and operation

instructions

Operation,

maintenance

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