WAGNER EPG-SPRINT XE Betriebshandbuch

P_01742

EPG

SPRINT X

0 %100 %

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

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 the information in this manual, particularly the safety

instructions and the warning instructions. Store the manual in a safe place. Edition: 10/2022

Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE

Table of Contents

Order number 2354913 | Edition 10/2022 3

TABLE OF CONTENTS

1 About these Instructions 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 General Characters and Symbols 6

1.4 Languages 7

1.5 Abbreviations 7

1.6 Terminology for the Purpose of this Manual 7

2 Using in Accordance with the Instructions 9

2.1 Device Type 9

2.2 Type of Use 9

2.3 For Use in Potentially Explosive Areas 9

2.4 Processible Working Materials 9

2.5 Misuse 9

3 Identification 10

3.1 Explosion Protection Identification 10

3.2 Permissible device combinations 10

3.3 Type Plate 11

4 Basic Safety Instructions 12

4.1 Safety Instructions for the Operator 12

4.1.1 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 Handling of WAGNER Powder Spray Devices 14

4.2.3 Grounding the Device 14

4.2.4 Product Hoses 14

4.2.5 Electrical Connection Cables 15

4.2.6 Cleaning and Flushing 15

4.2.7 Maintenance and Repair 15

4.2.8 Protective and Monitoring Equipment 16

4.3 Safety Features 16

5 Description 18

5.1 Applications 18

5.2 Extent of Delivery 18

5.3 Technical Data 18

5.4 Operating Elements 20

5.4.1 Operating Elements on Front Side 20

5.4.2 Connections on the Rear Side 23

5.5 Accessories 24

6 Assembly and Commissioning 25

6.1 Training of Assembly/Commissioning Personnel 25

6.2 Storage conditions 25

6.3 Installation Conditions 25

6.4 Connecting the Manual Gun 26

6.5 Connecting the Automatic Gun 28

6.6 Grounding 29

6.6.1 Grounding the powder coating system 30

Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE

Table of Contents

4 Order number 2354913 | Edition 10/2022

6.6.2 Safety Checks 30

7 Operation 31

7.1 Training the Operating Personnel 31

7.2 Preparations for Commissioning 31

7.2.1 Tasks 31

7.2.2 Operating Modes 31

7.2.3 Gun Recognition 32

7.2.4 Manual Gun Mode with External Control 32

7.2.5 Basic and Factory Settings 32

7.3 Recipes 32

7.3.1 Double-click recipe (High Dynamic Remote) 33

7.4 Air High Output Mode (High Powder Discharge) 34

7.4.1 Combining the Air Outputs 34

7.4.2 Activating High Output Mode (C17) 35

7.5 Changing and Saving Recipes 38

7.5.1 Recipe Nos. 1 - 4 38

7.5.2 Recipe Nos. 5 - 50 38

7.6 Setting and Changing Coating Parameters 39

7.6.1 Setting the Total Air Volume 39

7.6.2 Setting the Powder Feed Quantity 40

7.6.3 Setting the Additional Air (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 Limitation 44

7.6.8 Setting the U/I Characteristic Curves 45

7.7 Flush Function 46

7.7.1 Hose Flush Function 46

7.7.2 Cleaning Flush Function 47

7.7.3 Procedure for Cleaning Flushing with Manual Guns 47

7.7.4 Procedure for Cleaning Flushing with Automatic Guns 48

7.8 Starting Output Setting (Zero Adjustment) 48

8 Cleaning and Maintenance 51

8.1 Cleaning 51

8.1.1 Cleaning Personnel 51

8.1.2 Cleaning Procedures 51

8.2 Maintenance 51

8.2.1 Maintenance Personnel 51

8.2.2 Maintenance Instructions 52

8.2.3 Safety Checks 52

8.2.4 Maintenance Procedures 52

9 Troubleshooting and Rectification 53

9.1 Warnings E01 - E04 53

9.2 Faults 54

10 Inspections in Accordance with DIN EN 50177: 2009 58

10.1 Abbreviations 58

10.2 Overview Table 59

11 Inspections in Accordance with DIN EN 50050-2: 2013 61

11.1 Abbreviations 61

11.2 Overview Table 62

Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE

Table of Contents

Order number 2354913 | Edition 10/2022 5

12 Disassembly and Disposal 63

12.1 Disassembly 63

12.2 Disposal 63

13 Accessories 64

13.1 Connection cable 64

13.2 Wall mount 64

13.3 Recipe sticker 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 Conformity for Controller 67

15.2 FM Control Document 67

16 Appendix Device Configuration 68

16.1 Setting example: Parameter C11 69

16.2 Setting example: Parameter C13 71

16.3 Table of Parameters 74

17 Brief description 77

17.1 Operating Elements 77

17.2 Operation of the Control Unit 78

Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE

1 About these Instructions

6 Order number 2354913 | Edition 10/2022

1 ABOUT THESE INSTRUCTIONS

1.1 PREFACE

The operating manual contains information about safely operating, maintaining, cleaning

and repairing the device. The operating manual is part of the device and must be available

to the operating and service personnel.

The device may only be operated by trained personnel and in compliance with this

operating manual. Operating and service personnel should be instructed according to the

safety instructions.

This equipment can be dangerous if it is not operated according to the instructions in this

operating manual.

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this 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 Potential danger.

Non-observance may result in death or serious injury.

CAUTION Potentially dangerous situation.

Non-observance may result in minor injury.

NOTICE Potentially dangerous situation.

Non-observance may result in damage to property.

Info Provides information about particular characteristics and how to

proceed.

Explanation of warning notice:

WARNING

This notice warns you of a danger!

Possible consequences of not observing the warning notice.

4The measures for preventing the hazard and its consequences.

1.3 GENERAL CHARACTERS AND SYMBOLS

The characters and symbols in this operating manual indicate the following:

üRequirement that must be fulfilled before an action can be performed.

1. Step 1 of an action to be performed with several action steps.

4Second level action step

2. Step 2

ðIntermediate result of an action

ðResult of a complete action

4Action to be performed with an action step

1. Numbered list, first level

– Numbered list, second level

Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE

1 About these Instructions

Order number 2354913 | Edition 10/2022 7

– Non-numbered list, first level

– Non-numbered list, second level

= cross-reference on page

♦ = wearing parts

⋆ = included in service set

● = not part of the standard equipment but available as a special accessory

1.4 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order no.

German 2354911

Translation of the original 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 2354917 Polish 2412518

Chinese 2354918 Norwegian 2414220

Additional languages upon request or at: www.wagner-group.com

1.5 ABBREVIATIONS

Order no. Order number

ET Spare part

K Marking in the spare parts lists

Pos Position

Stk Number of pieces

-- Item not available as spare part

/ Item does not exist

1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning agent.

Flushing Internal flushing of paint-wetted parts with compressed air.

Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE

1 About these Instructions

8 Order number 2354913 | Edition 10/2022

Personnel qualifications

Trained person Is instructed in the tasks assigned to him/her, the potential risks associ-

ated with improper behavior as well as the necessary protective devices

and measures.

Electrically

trained person

Is instructed by an electrician about the tasks assigned to him/her, the

potential risks associated with improper behavior as well as the neces-

sary protective devices and measures.

Electrician Can assess 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 who, based on his/her technical training, experience and re-

cent vocational experience, has sufficient technical knowledge in the

area of electrostatic coating and is familiar with the relevant and gener-

ally accepted rules of technology so that he/she can inspect and assess

the status of devices and coating systems based on workplace safety.

Additional requirements for skilled persons can also be found in

TRBS1203(2010/amendment 2012): Expert knowledge in the areas of

protection against excessive pressure, electrical hazards and explosion

protection (where applicable).

Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE

2 Using in Accordance with the Instructions

Order number 2354913 | Edition 10/2022 9

2 USING IN ACCORDANCE WITH THE INSTRUCTIONS

2.1 DEVICE TYPE

Universal control unit for controlling electrostatic manual and automatic spray guns

2.2 TYPE OF USE

The EPG-SPRINT XE control unit is intended for controlling electrostatic manual and

automatic powder spray guns of types A-P (2 mJ) according to DIN EN 50177.

The device may only be operated under the following conditions:

4Use the device only to work with the materials recommended by WAGNER.

4Only operate the device as a whole.

4Do not deactivate safety fixtures.

4Use only WAGNER original spare parts and accessories.

4The operating personnel must be trained on the basis of this operating manual.

4Follow 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 accordance with the type examination PTB 12 ATEX 5001.

The EPG-SPRINT XE control unit may be used in the dust explosion zone (zone 22) under the

following conditions:

– Control unit correctly fitted in rack.

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

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

protection caps.

2.4 PROCESSIBLE WORKING MATERIALS

– Types of powder which can be charged electrostatically

– Metallic powder

Info

Contact your local WAGNER dealer and the lacquer manufacturer if you encounter

application problems.

2.5 MISUSE

Misuse can lead to physical injury and/or property damage! Special attention must be paid

that:

4No liquid coating products, e.g. solvents or water-based lacquers, are processed.

4No food, medicine or cosmetics are processed.

Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE

3 Identification

10 Order number 2354913 | Edition 10/2022

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

The device is suited for use in potentially explosive areas, in accordance with Test Certificate

PTB12ATEX5001.

Device Type Universal control unit EPG-SPRINT XE

Manufacturer Wagner International AG

9450 Altstätten

Switzerland

0102 II3(2)DIP6480°C

CE European Communities

0102 Number of notified body which issues the recognition of quality

assurance in production.

Ex Symbol for explosion protection

II Device 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 DEVICE COMBINATIONS

WARNING

Incorrect use!

Risk of injury and damage to the device.

4Only connect original WAGNER spray guns to the EPG-SPRINT XE control unit.

4The PEM-C3R and PEM-T3R manual spray guns must not be connected to the EPG-

SPRINT XE control unit.

The following powder spray guns may be connected to the EPG-SPRINT XE:

Manual spray guns

Corona spray gun PEM-X1, PEM-X1 CG, PEM-C3, PEM-C4,

PEM-C4-Ergo

Tribo spray gun PEM-T3

Automatic spray guns

Corona spray gun PEA-C3, PEA-C4, PEA-X1, PER-X1

PEA-C3XL, PEA-C4XL

Tribo spray gun PEA-T3

PEA-T3XL

Tribo lance TL1 (from software version B212, C212,

D212)

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