Universal Control Unit for Powder Guns Translation of the Original

Translation of the Original
Operating Manual
EPG-SPRINT X
Universal Control Unit
for Powder Guns
Version 06 / 2014
50
60
40
2x
2x
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
m3/h
20
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
80
2.5 0.3
90
2.0 0.1
μA
0%
100 %
EPG
P_01742
0102
II 3(2)D IP64 80 °C
SPRINT X
VERSION 06/2014
ORDER NUMBER DOC2329371
EPG-SPRINT X
OPERATING MANUAL
Table of Contents
1
1.1
1.2
1.3
1.4
GENERAL INFORMATION
Preface
Warnings, Notices, and Symbols in this Operating Manual
Languages
Abbreviations
6
6
6
7
7
2
2.1
2.2
2.3
2.4
2.5
2.6
CORRECT USE
Device Type
Type of Use
Use in Potentially Explosive Areas
Safety Parameters
Reasonably Foreseeable Misuse
Residual Risks
8
8
8
8
9
9
10
3
3.1
3.2
IDENTIFICATION
Explosion Protection Identification in Accordance with ATEX
Permissible Device Combinations
11
11
11
4
4.1
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.3
4.4
GENERAL SAFETY INSTRUCTIONS
Safety Instructions for the Operator
Electrical Devices and Equipment
Staff Qualifications
Safe Work Environment
Safety Instructions for Staff
Safe Handling of WAGNER Powder Spray Devices
Grounding the Device
Product Hoses
Cleaning
Handling Powder Lacquers
Protective and Monitoring Equipment
Safety Feature Identification
12
12
12
12
12
13
13
13
13
14
14
15
16
5
5.1
5.2
5.3
5.4
5.5
5.5.1
5.5.2
DESCRIPTION
Areas of Application
Technical Data
Permitted Accessories
Scope of Delivery
Operating Elements
Operating Elements Front Side
Connections on the Rear Side of the EPG-SPRINT X
17
17
18
20
20
21
21
26
6
6.1
6.2
6.3
6.4
6.5
6.6
6.6.1
ASSEMBLY AND COMMISSIONING
Training Assembly/Commissioning Staff
Storage Conditions
Installation Conditions
Connecting the Manual Gun
Connecting the Automatic Gun
Grounding
Grounding the Powder Coating System
28
28
28
28
29
30
31
32
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OPERATING MANUAL
Table of Contents
7
7.1
7.2
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.4
7.4.1
7.5
7.5.1
7.5.2
7.6
7.6.1
7.6.2
7.7
7.7.1
7.7.2
7.7.3
7.7.4
7.7.5
7.7.6
7.7.7
7.7.8
7.8
7.8.1
7.8.2
7.8.3
7.8.4
7.9
OPERATION
Training the Operating Staff
Safety Instructions
Preparations for Commissioning
Operating Modes
Gun Recognition
Manual Gun Mode with External Control
Basic and Factory Settings
Recipes
"Double Click" Recipe (High Dynamic Remote)
Air High Output Mode (High Powder Output)
Combining the Air Outputs
Activating High Output Mode (C17)
Changing and Saving Recipes
Recipe No. 1-4
Recipe No. 5-50
Setting and Changing Coating Parameters
Setting the Total Air Volume
Setting the Powder Feed Quantity
Setting the Additional Air (Atomizing/Ionizing/Tribo Air Volume)
Setting the High-voltage
Display of Actual High-voltage Value
Setting the Current Limitation
Displaying Actual Value of Current Limitation
Setting the U/I Characteristics
Purge Function
Hose Purge Function
Cleaning Purge Function
Procedure for Cleaning Purging with Manual Guns
Procedure for Cleaning Purging with Automatic Guns
Starting Output Setting (Zero Adjustment)
33
33
33
35
35
35
36
36
37
38
39
39
40
43
43
44
45
45
46
47
48
49
50
51
52
54
54
54
55
56
57
8
8.1
8.1.1
8.1.2
8.1.3
8.2
8.2.1
8.2.2
8.2.3
CLEANING AND MAINTENANCE
Cleaning
Cleaning Staff
Safety Instructions
Cleaning Procedures
Maintenance
Maintenance Staff
Safety Instructions
Maintenance Procedures
59
59
59
59
60
61
61
61
62
9
9.1
9.2
INSPECTIONS
Inspections in Accordance with DIN EN 50177: 2010
Inspections in Accordance with DIN EN 50050-2: 2014
63
63
67
10
10.1
10.2
DISASSEMBLY AND DISPOSAL
Disassembly
Disposal
69
69
70
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OPERATING MANUAL
Table of Contents
11
11.1
11.2
TROUBLESHOOTING AND RECTIFICATION
Warnings E01-E04
Faults
71
72
74
12
12.1
12.2
12.3
ACCESSORIES
Connection Cables
Wall Mount
Recipe Sticker
77
77
77
78
13
13.1
13.2
SPARE PARTS
How Can Spare Parts Be Ordered?
EPG-SPRINT X Control Unit
79
79
80
14
14.1
14.2
14.3
14.4
14.5
DECLARATION OF WARRANTY AND CONFORMITY
Important Notes Regarding Product Liability
Warranty Claim
CE Declaration of Conformity
EC Type Examination Certificate
FM Approval
81
81
81
82
83
84
DEVICE CONFIGURATION APPENDIX
A1
Setting Example: Parameter C11
A2
Setting Example: Parameter C13
A3
Table of Parameters
A4
Spray Current Reset when using Field Controllers
85
87
89
91
96
BRIEF DESCRIPTION
1
Changing Parameters
2
Calling / Changing / Saving Recipes 1-4
3
Calling / Changing / Saving Recipes 5-50
98
99
99
99
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OPERATING MANUAL
1
GENERAL INFORMATION
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 operating and service
staff.
Operating and service staff should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
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 THIS OPERATING MANUAL
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.
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 danger and its consequences.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
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 danger and its consequences.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
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 danger and its consequences.
Notice - a possibly hazardous situation.
Non-observance may result in material damage.
NOTICE
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 danger and its consequences.
Note - provides information about particular characteristics and how to proceed.
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OPERATING MANUAL
1.3
LANGUAGES
The operating manual is available in the following languages:
German
2327591
English
French
2330847
Italian
Spanish
2330849
Russian
Chinese
2333350
Hungarian
Portuguese
2342815
Swedish
Slovakian
2348856
Danish
1.4
2329371
2330848
2333349
2341081
2344282
2348523
ABBREVIATIONS
Order No.
Number of pieces
Position
Marking in the spare parts lists
Order number
Spare part
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OPERATING MANUAL
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 X control unit is intended for controlling electrostatic manual and
automatic spray guns of type A-P (2 mJ) according to DIN EN 50177.
WARNING
Incorrect use!
Risk of injury and damage to the device.
Only connect original Wagner spray 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.
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 zone (Zone 22) under the
following conditions:
Control unit correctly fitted in rack.
Rack correctly and securely sealed on rear with associated cover.
All connections not needed (mains output, remote control) are sealed with dust
protection caps.
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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.
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 operating manual,
the safety regulations listed in this operating manual are observed,
the operating, maintenance and repair information in this operating manual is
observed,
and the statutory requirements and accident prevention regulations standards in the
country of use are observed.
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
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2.6
RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk
Skin contact with
powder lacquers
and cleaning agents
Powder lacquer
in air outside the
defined working
area
Source
Handling powder
lacquers and
cleaning agents
Consequences
Skin irritation,
allergies
Specific measures
Wear protective
clothing,
observe safety data
sheets
Lacquering outside Inhalation of
Observe working
the defined working substances
and operating
area
hazardous to health instructions
Lifecycle phase
operation,
maintenance,
disassembly
operation,
maintenance
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3
IDENTIFICATION
3.1
EXPLOSION PROTECTION IDENTIFICATION IN ACCORDANCE WITH ATEX
The device is suited for use in potentially explosive areas, in accordance with Test Certificate
PTB 12 ATEX 5001.
0102
CE:
0102:
Ex:
II:
3:
(2):
D:
IP64:
80 °C:
3.2
II 3(2)D IP 64 80 °C
European Communities
Number of notified body which issues the recognition of quality assurance in
production.
Symbol for explosion protection
Device class II
Category 3 (Zone 22)
Impact on equipment of category 2
Ex-atmosphere dust
Protection class 64
Temperature class: maximum surface temperature < 80 °C; 176 °F
PERMISSIBLE DEVICE COMBINATIONS
The following powder spray guns may be connected to the EPG-SPRINT X:
Manual spray guns
Corona spray gun
Tribo spray gun
Automatic spray guns
Corona spray gun
Corona spray gun
Tribo spray gun
Tribo spray gun
PEM-X1, PEM-X1 CG, PEM-C3, PEM-C4,
PEM-C4-Ergo
PEM-T3
PEA-C3, PEA-C4
PEA-C3XL, PEA-C4XL
PEA-T3
PEA-T3XL
Older or other gun types may only be connected to the control unit after first checking
their suitability with Wagner.
For permissible device combinations for the USA and Canada, see Chapter 14.5 "FM Approval".
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4
GENERAL SAFETY INSTRUCTIONS
4.1
SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
4.1.1
ELECTRICAL DEVICES AND EQUIPMENT
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
May only be maintained by skilled electricians.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts.
Secure the device against being switched back on without authorization. Inform staff
about planned work.
Observe electrical safety regulations.
4.1.2
STAFF QUALIFICATIONS
Ensure that the device is operated, maintained, and repaired only by trained persons.
4.1.3
SAFE WORK ENVIRONMENT
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 requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.
The powder release must be electrically interlocked with the powder spray system's
exhaust air equipment.
Excess coating product (overspray) must be collected up safely.
Ensure that there are no ignition sources such as naked flames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
Maintain sufficient quantities of suitable fire extinguishers and ensure that they are
serviceable.
The operating company must ensure that an average concentration of powder lacquer
in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted
concentration of powder to air). If no reliable LEL value is available, the average
concentration may not exceed 10 g/m³.
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4.2
SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
Under no circumstances may people with pacemakers enter the area where the highvoltage field between the spray gun and the work piece to be coated builds up!
4.2.1
SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
Do not point spray guns at people.
Before all work 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.
4.2.2
GROUNDING THE DEVICE
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. This may result in the formation of sparks or flames when discharging.
Ensure that the device is grounded before each coating process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., by wearing
electrostatically conductive shoes.
The functionality of grounding cables must be checked regularly (see EN 60204).
4.2.3
PRODUCT HOSES
Only use an original Wagner powder hose.
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4.2.4
CLEANING
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 fluids.
Preference should be given to non-flammable cleaning fluids.
Flammable cleaning liquids may only be used if, after switching off the high-voltage,
all high-voltage conducting parts are discharged to a discharge energy of less than
0.24 mJ before they can be accessed.
Most flammable solvents have an ignition energy of around 0.24 mJ or 60 nC.
The cleaning agent's flash point must be at least 15 K above the ambient temperature.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to
remove dust deposits.
4.2.5
HANDLING POWDER LACQUERS
When preparing or processing the powder and cleaning the device, take note of the
processing regulations, laid down by the manufacturer of the powder lacquers, being
used.
Take note of the manufacturer’s instructions and the relevant environmental protection
regulations when disposing of powder lacquers.
Take the prescribed safety measures, in particular the wearing of safety glasses and
safety clothing as well as the use of protective hand cream.
Use a mask or breathing apparatus if necessary.
To ensure sufficient protection of health and the environment, only operate the device
in a powder booth or on a spray wall with activated ventilation (exhaust air).
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4.3
PROTECTIVE AND MONITORING EQUIPMENT
WARNING
Protective 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.
If defects are detected on protective and monitoring equipment,
the system must not be operated until these defects are
remedied.
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4.4
SAFETY FEATURE IDENTIFICATION
Plates bearing information for the user have been attached to the work openings of the
powder coating booth.
The plate size corresponds to the standard category Ø 100 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
Danger of crushing!
Explosive atmosphere!
Forbidden for persons
with a cardiac pacemaker!
Risk of tripping!
Do not jump on the
booth floor!
Danger of slipping!
Smoking, fire, and open
flames are prohibited!
Forbidden for unauthorized
persons!
Wear electrostatically
conductive footwear!
Follow the instructions in the
operating manual!
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5
DESCRIPTION
5.1
AREAS OF APPLICATION
WARNING
Incorrect use!
Risk of injury and damage to the device.
Only connect original Wagner spray 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.
The EPG-SPRINT X control unit can be used as a stand-alone unit in manual coating systems
or can be connected to the PrimaTech automatic system together with other units.
When a Corona gun is connected, Corona current scale and the high-voltage supply
and control unit are active.
When a Tribo gun is connected, the Tribo current scale is activated, while the highvoltage supply and control unit are deactivated.
The control unit recognizes if a manual or automatic spray gun is connected. If an automatic
gun is connected, then the control unit can only be controlled via the CCM Prima interface.
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5.2
TECHNICAL DATA
Dimensions:
Height
Width
Depth (without operating elements)
Weight
Electrical:
Mains (AC)
Frequency
Input power
Output voltage
Output current
High-voltage
Corona current limitation
Tribo current measuring range
Tribo current limitation
Tribo current cut off
136 mm; 5.35 inches
270 mm; 10.63 inches
200 mm; 7.87 inches
3.3 kg; 7.28 lbs
Protection class:
Ex zone
85 VAC-250 VAC
47 Hz-440 Hz
maximum 40 W
maximum 22 Vpp
maximum 0.9 A
10-100 kV (adjustable in 1 kV steps)
5 μA-120 μA (adjustable in 1 μA steps)
0 μA-15 μA
0 μA-5 μA (adjustable in 0.1 μA steps)
greater than 12 μA
(ATEX: switching off of the unit)
IP 64
II 3(2)D 80 °C; 176 °F (Zone 22)
Pneumatic:
Air input pressure
Air volume
Sum of dosing and feed air
Gun air
Required compressed air quality as per ISO 8573.1
0.6-0.8 MPa; 6-8 bar; 87-116 psi
maximum 15 m³/h
1-6 m³/h
0.05-4.0 m³/h
3.5.2
Connection hose diameter
8 mm; 0.315 inches
Ambient conditions:
Operating temperature range
5-45 °C; 41-113 °F
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WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water
(Quality Standard 3.5.2 according to ISO 8573.1)
3.5.2 = 5 μm / +7 °C; 44.6 °F / 0.1 mg/m³.
NOTICE
Compressed air quality, 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 Nm³ (standard cubic meters). One cubic meter of a gas at 0 °C and
1.013 bar is called norm cubic meter.
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5.3
PERMITTED ACCESSORIES
Only the accessories listed in the chapter "Accessories" of this operating manual may be
connected to the EPG-SPRINT X control unit.
The accessories listed in the chapter "Accessories" were included in the EC type examination
and are approved for use with the control unit.
5.4
SCOPE OF DELIVERY
Stk
Order No.
Designation
EPG-SPRINT X (for manual and automatic systems)
The standard equipment includes:
see Chapter 1.3
Conformity certificate
Operating manual, German
Operating manual in local language
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OPERATING MANUAL
5.5
OPERATING ELEMENTS
5.5.1
OPERATING ELEMENTS FRONT SIDE
5
1
2
3 4
20 22 21 23 18 13
19
9
6
10
7
50
60
40
11
8
2x
2x
12
25
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
m3/h
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
16
80
2.5 0.3
15
90
2.0 0.1
μA
0%
26
14
70
Ø
17
100 %
EPG
SPRINT X
P_01743
28
27
30 29
31 32 34
36 37 35
33
24
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 and selected
Display and adjusting range: 0 [5]-120 μA,
0 [5]-20 μA Resolution 5 μA
20-40 μA Resolution 10 μA
40-120 μA Resolution 20 μA
Single LED display: "Trigger Point of Current Limitation"
Bar display: Corona current
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3 Display: "Tribo Gun"
Lights up when a Tribo gun is connected and selected
4 Display: "Corona Gun"
Lights up when a Corona gun is connected and selected
5 Push button: recipe for "Surface Parts"
6 Push button: recipe for "Second Coating"
7 Push button: recipe for "Profiles"
8 Push button: recipe for "Double Click"
To access the recipe, press the trigger lever on the spray gun twice in quick
succession and hold it down
9 Display LED: recipe for "Surface Parts"
Lights up green when the recipe for surface 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 LED: "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 mode
To reactivate normal mode, press the button again
16 Display LED: "Standby"
Lights up when the unit is in standby mode
17 Push button: "Purge"
To activate the injector and the hose rinsing
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18 Display LED: "Purge"
Lights up blue, when the purge function is activated
19 Display LED: 7 segments, three-digit number
Indicates the exact value depending on the activated function:
"Total air volume; atomizing, ionizing and Tribo air; additional recipes; high-voltage;
current limitation; powder quantity"
Display showing error number in the event of warnings and malfunctions
20 Push button: "Total Air Volume"
To activate the function, the value is precisely adjusted with rotary controller 24
and is indicated in LED display 19
Adjusting range: 1-6 m³/h
Resolution: 0.05 m³/h
21 Push button: "Atomizing, Ionizing and Tribo Air"
To activate the function, the value is precisely adjusted with rotary controller 24
and is indicated in LED display 19
Adjusting range: 0.05-4 m³/h
Resolution: 0.05 m³/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 air volume; atomizer, ionizer and Tribo air; additional recipes;
high-voltage; current limitation; powder quantity"
For setting parameter values in configuration mode
25 Push button: "Additional Recipes"
To activate the function, the additional recipe is set with the rotary controller 24
and is indicated in the LED display 19
Selection of the recipes 5 to 50
26 Display LED: "Additional Recipes"
Lights up yellow, when an additional recipe is selected
27 Push button: "High-voltage"
To activate the function, the high-voltage is set with Rotary Controller 24 and is
indicated in LED Display 19
Adjusting range: 10-100 kV
Resolution: 1 kV
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28 Display LED: "High-voltage"
Lights up yellow. The high-voltage is selected and can be adjusted using rotary
controller 24
29 Push button: "Current Limitation"
To activate the function, the current limitation is set with rotary controller 24 and
is indicated in LED display 19
Adjusting range: 5-120 μA
Resolution: 1 μA
30 Display LED: "Current Limitation"
Lights up yellow. The current limitation is selected and can be adjusted using
rotary controller 24
31 Push button: "Characteristic Slope"
To switch the characteristic slope
Display with LED 32
32 Display LED: "Characteristic Slope"
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 up green
Display range: 1-6 m³/h
Resolution: 0.2-0.5 m³/h
Single LED display: Set point (high-voltage and powder are deactivated)
Bar display: Actual value (high-voltage and powder are activated)
35 Illuminated display: "Atomizing, Ionizing and Tribo Air Volume"
Lights up green
Display range: 0.1-4 m³/h
Resolution: 0.1-1.0 m³/h
Single LED display: Set point (high-voltage and powder are deactivated)
Bar display: Actual value (high-voltage and powder are activated)
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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
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5.5.2
2
CONNECTIONS ON THE REAR SIDE OF THE EPG-SPRINT X
1
10
Main switch
11
Output to gun
Ausgang zur Pistole
I
12
14
6
U max. 22 Vpp
I max. 0,9 A
FM
C
O
Spraygun
Sprühpistole
Hauptschalter
Remote
Fernsteuerung
US
APPROVED
Overvoltage Category II
and Pollution Degree 2
Made in Switzerland
J. Wagner AG
CH 9450 Altstätten
0102
II 3(2)D IP64 80ºC
PTB 12 ATEX 5001
Tested / Geprüft EN50050-2, EN50177
Type / Typ:
EPG-SPRINT X
Serial No.:
Serie Nr.:
Prim. Fuse
Sicherung
1.0 AT
Air input
Lufteingang
6.....8 bar
87..116 psi
Voltage:
Spannung: 85-250 VAC 47-440 Hz
(slow blow)
Line Power:
Eingangsleistung:
Prot. Class:
Schutzklasse:
Do NOT disconnect under tension!
max. 40 W
IP 64
NICHT unter Spannung trennen!
Mains
power
input
Netzeingang
FM approved for CL II, Div 2, Grps E, F, &G
Ambient temp range 5C to 45C T5
In accordance with control document: 2309729
P_01744
Mains
power
output
Netzausgang
13
1
EPG-Sprint X
4
Feeding air
Förderluft
Dosage air
Dosierluft
Atomizing air
Zerstäuberluft
For operation in Zone 22 all ports
must be fitted with a plug or the
protection cap.
Für den Betrieb in der Zone 22
müssen alle Anschlüsse mit Stecker
oder Schutzkappe versehen sein.
3
5
14
9
8
7
13
Mains supply switch
0 = The control unit is deactivated
I = the control unit is activated
2
Primary fuse
1 Ampere slow-acting
3
Mains input terminal
Universal input: 85 V AC - 250 V AC
4
Mains power output
Direct, not through the mains switch
To loop the mains through the PrimaTech system
5
Knurled nut
To connect the signal ground
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6
Compressed air inlet
Pressure range: 0.6-0.8 MPa; 6-8 bar; 87-116 psi
Air volume: maximum 15 m³/h
Connection hose diameter 8 mm; 0.315 inches
7
Compressed 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 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 only!
13 Fixations
For screwing to the rack
14 FM-Identification
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6
ASSEMBLY AND COMMISSIONING
6.1
TRAINING ASSEMBLY/COMMISSIONING STAFF
WARNING
Incorrect installation/operation!
Risk of injury and damage to the device.
The commissioning staff must have the technical skills to safely
undertake commissioning.
When commissioning and for all work, read and follow the
operating manual and safety regulations for the additionally
required system components.
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 assembly site must be between 5 - 45 °C; 41 - 113 °F.
Depending on the powder lacquer used, the maximum permissible ambient temperature
for reliable operation can be significantly below +40 °C; 104 °F.
The relative air humidity at the assembly location must not exceed 75%.
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6.4
CONNECTING THE MANUAL GUN
Corona or Tribo spray gun
Electrical connection cable
I
EPG-SPRINT X
O
Compressed air main supply
(0.6-0.8 MPa; 6-8 bar; 87-116 psi)
Hose diameter:
8 mm; 0.315 inches
P_01745
Mains input terminal
Atomizing or Tribo air,
transparent
Grounding cable to the signal ground
Dosing air, blue
Feed air, red
Powder injector
Powder feed, transparent
e.g., from the powder tank
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6.5
CONNECTING THE AUTOMATIC GUN
Tribo spray gun*
Electrical connection
Corona spray gun
Atomizing air
Tribo air
Powder hose connection
Electrical connection cable
To the CCM Prima
I
EPG-SPRINT X
Compressed air main supply
(0.6-0.8 MPa; 6-8 bar; 87-116 psi)
Hose diameter:
8 mm; 0.315 inches
O
P_01114
Mains input terminal
Mains output to
next control unit
Atomizing or Tribo air,
transparent
Grounding cable to the signal ground
Dosing air, blue
Feed air, red
Powder injector
Powder feed, transparent
e.g., from the powder tank
* A Y distributor (Order No. 9990149) is needed to divide the different types of air.
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6.6
GROUNDING
DANGER
No Grounding!
Risk of explosion and risk of electric shock.
Electrostatic control units and the associated spray equipment
may only be connected to mains supplies with a protective
conductor connection (PE conductor)!
WARNING
Heavy powder mist if grounding is insufficient!
Danger of poisoning.
Insufficient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
For safety reasons, the control unit must be properly grounded. The ground connection
to the energy supply (socket) takes the form of the mains connection cable's protective
conductor, while that to the work piece / system is via the knurled screw on the rear of the
control unit. Both connections are absolutely essential. If installed correctly as described
above, the spray gun is grounded via the gun cable between the control unit and spray
gun.
Good grounding of the work piece is also necessary for optimum powder coating.
A poorly grounded work piece causes:
dangerous electric charging of the work piece,
very 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 of the work piece may not exceed 1 MΩ (megohm).
(Resistance to ground measured at 500 V or 1000 V).
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The footwear worn by the operators must comply with the requirements of
EN ISO 20344. The measured insulation resistance must not exceed 100 MΩ (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 piece can occur
if electric contact points between conveyor, conveyor hooks (hangers) and work
piece are not sufficiently cleaned and therefore the work pieces are not sufficiently
grounded!
These sparks can cause heavy radio frequency interference (EMC).
6.6.1
GROUNDING THE POWDER COATING SYSTEM
3
4
5
1
2
6
P_01120
1
2
3
4
5
6
7
7
Only use mains cables with grounding strand!
Connect grounding cable with booth and signal ground!
Connect grounding cable to an uncoated metal part of the booth!
Remove all paint from hooks and other hanger parts!
Do not wear non-conducting gloves!
Wear electrostatically conductive footwear!
The floor must be electrostatically conductive!
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7
OPERATION
7.1
TRAINING THE OPERATING STAFF
WARNING
Incorrect operation!
Risk of injury and damage to the device.
The operating staff must be qualified to operate the entire
system.
Before work commences, the operating staff must receive
appropriate system training.
7.2
SAFETY INSTRUCTIONS
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 clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
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NOTICE
Damage to the device!
The control unit must be connected and grounded according to the directions in
chapter 5.
After switching on the unit, wait for the start up phase 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 Prima. The unit cannot be switched on.
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7.3
PREPARATIONS FOR COMMISSIONING
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 (remote interface for external control of the module)
Manual gun mode with external control (remote interface with external release
(required for coating and cleaning) and for external control of cleaning function)
In the first two listed operating modes, the configuration parameter C26 must be set to
OFF (factory setting). The operating mode is automatically recognized by the control unit
(parameter C26 must be set to "OFF", see Chapter 7.3.2).
7.3.2
GUN RECOGNITION
NOTICE
Functional faults!
Do not operate the spray gun's trigger while the control unit is being switched on
and is powering up.
The EPG-SPRINT X control unit automatically detects whether a manual or automatic
gun is connected to the control unit (parameter C26 must be set to "OFF"). It does this by
checking whether the trigger switch is activated when it is switched on.
If the trigger switch is pressed, the gun is an automatic one. The powder feed is
switched on and off by a primary controller (CCM 2007; CCM Prima or another original
Wagner device for controlling the EPG-SPRINT X).
If the trigger switch is not pressed, the gun is a manual one. The powder feed is
switched on and off with the gun's manual trigger.
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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 coat. The cleaning function (continuous purging) can also
be controlled externally.
Display on device:
"Automatic gun" LED flashes quickly
"Automatic gun" LED is dark
No release signal is present
Release signal is present
This operating mode is available starting with software version B200. The function must be
selected specifically via configuration parameter C26.
7.3.4
BASIC AND FACTORY SETTINGS
The EPG-SPRINT X control unit is factory-configured for operation with Corona manual
or automatic guns. Consequently, the control unit can be used in a manual system or
PrimaTech automatic system without any further settings being required.
However, if the control unit is used with a Tribo manual or automatic gun, the gun type
must be changed. This change is effected in the configuration settings.
For all other settings, configurations and special functions, please refer to the chapter
"Device Configuration".
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7.4
RECIPES
Recipes are used to avoid lengthy adjustment work when changing powder or work piece.
All parameters relevant for coating a work piece are combined and stored under a recipe
number instead.
If required, these can then be called up using the recipe buttons.
With the EPG-SPRINT X, a recipe comprises the following parameters:
Total air volume (feed and dosing air volume)
Powder quantity
Atomizing air/Tribo air
High-voltage
Current limitation
U/I characteristic curve
[m³/h]
[%]
[m³/h]
[kV]
[μA]
[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.
5
6
2x
2x
7
8
25
Recipe 1 for "Surface Parts": High powder quantity, high
powder charging
Recipe 2 for "Second Coating": Small powder quantity, low
powder charging
Recipe 3 for profile parts: Medium powder quantity, low
powder charging
Recipe 4 for "Double Click Function": Individual setting,
activated by a double click on the manual gun or once this
button has been pressed
Recipe no. 5 to 50: Can be selected with the rotary controller 24
after pressing the button
P_01746
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7.4.1
"DOUBLE CLICK" 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 succession
and hold down. Upon releasing the trigger, the original recipe will be returned to.
2x
2x
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
μA
kV
2x
2x
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
μA
kV
2x
2x
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
2x
μA
P_01701
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7.5
AIR HIGH OUTPUT MODE (HIGH POWDER OUTPUT)
With the EPG-SPRINT X, you can combine the feed and atomizing air to obtain a
higher feed air volume. A high powder volume however 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.
P_01177
Y-piece
Attention:
The atomizing air is not available in this mode.
Warning messages 1-3 "Insufficient Feed Air", "Insufficient Dosing Air", "Insufficient
Atomizing Air" are deactivated in this mode.
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7.5.2
ACTIVATING HIGH OUTPUT MODE (C17)
50
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
m3/h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
80
2.5 0.3
50
5
120
80
4
80
60
3
40
40
2
20
20
1
10
60
m3/h
Press "Characteristic Slope" button 31
and hold it down.
Turn the universal rotary controller 24
with the other hand until the LED display
19 shows the number "10". Then release
the "Characteristic Slope" button 31.
The device is now in configuration
mode. The scrolling text "Configuration"
is displayed.
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
3.
70
Ø
Tri
80
2.5 0.3
90
24
2.0 0.1
μA
kV
2.
SPRINT X
19
40
100
To access special device configuration,
switch the unit to "Standby" with
the "Standby" button 15. The yellow
"Standby" LED 16 lights up.
15
90
EPG
Cor
1.
100 %
0%
Tri
16
2.0 0.1
μA
kV
70
Ø
30
Procedure:
60
40
100 %
0%
EPG
SPRINT X
31
19
50
60
40
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
m3/h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
4.
70
Ø
30
Tri
80
2.5 0.3
90
2.0 0.1
μA
0%
100 %
EPG
P_01747
28
The LED display 19 now shows the first
configuration setting C11. At the same
time, the two yellow LED displays "Highvoltage" 28 and "Spray Current" 30 will
flash.
SPRINT X
30
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Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
5.
Use "High-voltage" 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 step
anticlockwise.
7.
To save the "on" setting, press
"Additional Programs" button 25 for
approx. 2 seconds. LED display 19
switches back to display C17.
2.0
μA
kV
0%
EPG
SPRINT X
27 29
19
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
2.0
μA
kV
24
0%
EPG
SPRINT X
31
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
2.0
μA
0%
EPG
SPRINT X
P_01748
25
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Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
8.
2.0
μA
0%
EPG
15
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.
SPRINT X
P_01749
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7.6
CHANGING AND SAVING RECIPES
7.6.1
RECIPE NO. 1-4
5
6
2x
2x
7
8
P_01750
Recipes 1-4 can be selected and saved directly using recipe buttons 5-8. Once the
recipe required has been called up, the individual coating parameters can be called up
and changed using the corresponding selection buttons. Descriptions of the individual
parameters are 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 and hold for approx.
2 seconds until the LED beside the button flashes quickly. The modified values are then
saved.
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7.6.2
RECIPE NO. 5-50
19
25
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
2.0
μA
0%
24
26
EPG
SPRINT X
P_01749
Recipes 5-50 can be indirectly selected and saved. First press the "Additional Recipes"
button 25. The yellow "Additional Recipes" LED 26 then lights up and the LED display 19
indicates the current recipe number. The required recipe can be set by turning the universal
rotary controller 24. In the following example, the values in recipe no. 10 are to be modified
and saved.
Procedure:
1.
2.
3.
4.
5.
Select recipe no. 10.
Set the desired values in the recipe (see Chapters 7.7.1-7.7.8).
Instead of showing the current recipe number, the LED display 19 now shows the
modified value.
To save the changes, hold down the "Additional Recipes" button 25 until the previous
recipe number flashes in the LED display 19.
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 until the yellow "Additional
Recipes" LED 26 flashes quickly. The modified values are then saved to the original
recipe.
To save the changes to another recipe number, use universal rotary controller 24
to set the desired recipe number - this is now displayed flashing. To save the values,
press and hold down the "Additional Recipes" button 25 for 2 seconds until the
yellow "Additional Recipes" LED 26 flashes quickly. The changes are thereby saved
to the set recipe number.
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OPERATING MANUAL
7.7
SETTING AND CHANGING COATING PARAMETERS
7.7.1
SETTING THE TOTAL AIR VOLUME
50
60
40
m3/h
30
22
20
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Procedure:
70
Ø
Tri
80
2.5 0.3
Press "Total Air Volume" button 20 to adjust the
total air volume. Yellow LED 22 indicates that the
total air volume is selected.
2.
The total air volume can now be adjusted using the
universal rotary controller 24 between 1-6 m³/h
with a resolution of 0.05 m³/h. The value is shown
in the LED display 19.
90
2.0 0.1
100 %
0%
EPG
60
m3/h
20
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
SPRINT X
19
50
40
34
1.
Tri
80
2.5 0.3
90
2.0 0.1
0%
24
100 %
EPG
SPRINT X
P_01751
To the right of the "Total Air Volume" button 20 is the "Total Air" bar graph display 34.
When the control unit is in the ready position, this light strip shows the set point as a dot
and when powder feeding is switched on it shows the actual value as a bar.
To the right of the bar graph is the scale for the total air volume. To 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
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 m³/h
The total air volume can be adjusted between 1-6 m³/h as described above. If this value
is further reduced from a value of 1 m³/h, the word "off " appears in the LED display 19 to
signal that the total air supply is deactivated. The total air supply is not therefore activated
when the powder feed is switched on.
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VERSION 06/2014
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OPERATING MANUAL
7.7.2
SETTING THE POWDER FEED QUANTITY
50
m3/h
70
Ø
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Procedure:
60
40
Tri
80
2.5 0.3
1.
Press "Powder Quantity" button 36 to adjust the
powder quantity. Yellow LED 37 indicates that the
powder quantity is selected.
2.
The powder quantity can now be adjusted
using the universal rotary controller 24 between
0% - 100% with a resolution of 1%. The value is
shown in the LED display 19.
90
2.0 0.1
100 %
0%
37
36
EPG
19
50
60
40
m3/h
20
33
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
SPRINT X
Tri
80
2.5 0.3
90
2.0 0.1
0%
24
100 %
EPG
SPRINT X
P_01752
When the control unit is in the ready position, the circular light strip 33 shows the set
point as a dot and, when powder 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.
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VERSION 06/2014
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EPG-SPRINT X
OPERATING MANUAL
7.7.3
SETTING THE ADDITIONAL AIR (ATOMIZING/IONIZING/TRIBO AIR VOLUME)
21 23
Procedure:
50
60
40
m3/h
70
Ø
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
1.
Press "Additional Air" button 21 to set the
additional air volume. Yellow LED 23 indicates that
the additional air is selected.
2.
The additional air volume can now be adjusted
using the universal rotary controller 24 between
0.05-4.0 m³/h with a resolution of 0.05 m³/h.
The value is shown in the LED display 19.
80
2.5 0.3
90
2.0 0.1
100 %
0%
EPG
SPRINT X
19
50
60
40
3
m /h
20
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
80
2.5 0.3
90
2.0 0.1
0%
24
100 %
EPG
SPRINT X
P_01753
35
The "Additional Air" bar graph display 35 can be found to the left of the "Additional Air"
button 21. When the control unit is in the ready position, this light strip shows the set 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 m³/h as described above.
The additional air cannot be fully deactivated, therefore the spray gun always receives
minimal additional air.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
7.7.4
SETTING THE HIGH-VOLTAGE
Procedure:
50
60
40
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
28
27
m3/h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
50
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
19
70
Ø
30
Tri
80
2.5 0.3
90
24
2.0 0.1
μA
0%
100 %
EPG
P_01754
SPRINT X
60
m3/h
20
The high-voltage can now be
adjusted using the universal rotary
controller 24 between 10 kV - 100 kV
with a resolution of 1 kV. The value
is shown in the LED display 19.
100 %
40
100
2.
90
EPG
Tri
Press the "High-voltage" button 27
to adjust the high-voltage.
The yellow LED 28 indicates that
high-voltage is selected.
2.0 0.1
0%
Cor
1.
80
2.5 0.3
μA
kV
70
Ø
30
SPRINT X
1
Above the "High-voltage" button 27 is the "High-voltage" bar graph display 1. 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 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 therefore
activated when the powder feed is switched on.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
7.7.5
DISPLAY OF ACTUAL HIGH-VOLTAGE VALUE
The actual high-voltage value can be displayed during the coating process in LED display 19.
Procedure:
50
19
60
40
3
28
27
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
m /h
20
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
80
2.5 0.3
90
24
2.0 0.1
μA
0%
100 %
EPG
P_01755
SPRINT X
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.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
7.7.6
SETTING THE CURRENT LIMITATION
Procedure:
50
60
40
3
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
m /h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
2.5 0.3
50
19
60
3
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
m /h
30
20
70
Ø
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
80
2.5 0.3
90
24
2.0 0.1
μA
0%
100 %
EPG
P_01756
The current limitation can now be
adjusted using the universal rotary
controller 24 between 5-120 μA
with a resolution of 1 μA. The value
is shown in the LED display 19.
SPRINT X
30
40
Cor
2.
90
EPG
Tri
Press the "Current Limitation"
button 29 to adjust the limitation of
the spray current. The yellow LED 30
indicates that current limitation is
selected.
100 %
0%
29
1.
80
2.0 0.1
μA
kV
70
Ø
30
SPRINT X
2
Above the "Current Limitation" button 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.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
7.7.7
DISPLAYING ACTUAL VALUE OF CURRENT LIMITATION
The actual current limitation value can be displayed in LED display 19 during the coating
process.
Procedure:
50
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
m3/h
20
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
19
60
40
Tri
80
2.5 0.3
90
24
2.0 0.1
μA
0%
100 %
EPG
P_01757
29
30
SPRINT X
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
controller.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
7.7.8
SETTING THE U/I CHARACTERISTICS
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
kV
32
10
1
20
Procedure:
μA
31
To change the characteristic slope, press the
"Characteristic Slope" button 31 once or twice until the
desired characteristic curve is shown in the "Characteristic
Slope" LED display 32.
P_01758
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.
120 [μA]
Spray current [μA]
Standard
Medium
Soft
P_01768
High-voltage [kV]
100 kV
The properties of the various characteristic curves and their use are described on the
following page.
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OPERATING MANUAL
Properties of the characteristic curve
Standard level (black)
Open-circuit voltage 100 kV
Maximum current 120 μA
(Current limitation at 120 μA)
Field of application/remarks
for poorly rechargeable types of powder
for high powder application
for high application effectiveness
This setting corresponds to the usual
Wagner high-voltage modules and
control units.
Medium level (gray)
Open-circuit voltage 100 kV
Maximum current 120 μA
for small surfaces
for types of powder that recharge well
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 sufficient powder charging.
Soft level (white)
Open-circuit voltage 100 kV
Maximum current 80 μA
for types of powder that recharge well
for small powder application
for post-coatings
53
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EPG-SPRINT X
OPERATING MANUAL
7.8
PURGE FUNCTION
The EPG-SPRINT X control unit has two different purge functions:
Hose purge function
Cleaning purge function
7.8.1
HOSE PURGE FUNCTION
This function blows dosing air through the powder feed hose and spray guns when the
powder flow is switched off (manual guns - releasing of trigger lever, automatic guns-signal
from control).
This function is set to the "OFF" parameter value in the factory. The values can 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. After a total of 2.5 seconds, the feed and dosing air purge in
pulses while the atomizing air remains constant throughout.
The cleaning purge function is only available when the control unit is switched on and in
the operating mode. In standby mode or in configuration mode, this function is inactive.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
7.8.3
PROCEDURE FOR CLEANING PURGING WITH MANUAL GUNS
50
60
40
m3/h
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
18
70
Ø
Tri
80
2.5 0.3
17
90
2.0 0.1
100 %
0%
EPG
SPRINT X
P_01759
34
35
Procedure:
1.
2.
3.
End coating operation.
Remove powder suction unit (suction lance, powder injector) from powder tank.
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 Air" indicator 35 lighting up.
55
VERSION 06/2014
EPG-SPRINT X
ORDER NUMBER DOC2329371
OPERATING MANUAL
7.8.4
PROCEDURE FOR CLEANING PURGING WITH AUTOMATIC GUNS
50
60
40
m3/h
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
18
70
Ø
Tri
80
2.5 0.3
90
2.0 0.1
15
17
100 %
0%
EPG
SPRINT X
P_01759
34
35
Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
9.
End coating operation.
Remove powder suction unit (suction lance, powder injector) from powder tank.
Switch on purge function by pressing "Purge" button 17 on the control unit.
LED display 18 starts to flash and indicates readiness for purging.
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.
Start purge process using "Gun Start" on unit's control.
Stop purge process using "Gun Stop" on unit's control.
Re-activate control units in standby mode by pressing the "Standby" button 15.
Press "Purge" button 17 to return to normal coating mode.
The LED display 18 no longer flashes.
Once the suction lance has been lowered into the powder tank, the coating operation
can be continued again.
Note:
If configuration parameter C16 is set to "ON", the purge function can only be activated via
the serial interface.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
7.9
STARTING OUTPUT SETTING (ZERO ADJUSTMENT)
This function can be used to set the point from which powder is fed.
The starting output setting is subject to:
The diameter of the powder hose
The length of the powder hose
The feed properties of the powder
50
60
40
m3/h
30
20
33
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
19
70
Ø
Tri
80
2.5 0.3
90
2.0 0.1
24
100 %
0%
EPG
SPRINT X
P_01769
36
37
Procedure: (if no powder is fed at 0%)
1.
2.
3.
Press "Powder Quantity" button 36 for around 2 seconds. The "Powder Quantity"
LED 37 flashes rapidly, the powder quantity display 33 flashes. The current value is
shown in the LED display 19 (e.g., 1.00 means a factory setting of 0.00 Nm³/h).
Turn rotary controller 24 until just a small amount of powder is fed.
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 also change, as altering the value alters
the feed air (see diagram).
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
Example: Total air = 4.00 Nm3/h
Starting output 0.00
Nm3/h
4.50
4.00
3.50
3.00
2.50
2.00
1.50
1.00
0.50
Dosing air
Feed air
Powder %
0
10
20
30
40
50
60
70
80
90
100
80
90
100
Starting output 1.00
Nm3/h
4.50
4.00
3.50
3.00
2.50
2.00
1.50
1.00
0.50
Dosing air
Feed air
0
10
20
30
40
50
60
70
Powder %
P_02368
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VERSION 06/2014
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EPG-SPRINT X
OPERATING MANUAL
8
CLEANING AND MAINTENANCE
8.1
CLEANING
8.1.1
CLEANING STAFF
Cleaning work should be undertaken regularly and carefully by qualified and trained staff.
They should be informed of specific hazards during their training.
The following hazards may arise during cleaning work:
Health hazard from inhaling powder lacquer
Use of unsuitable cleaning tools and aids
8.1.2
SAFETY INSTRUCTIONS
DANGER
Explosive powder/air mixes!
Danger to life and damage to the device.
Before starting cleaning or other manual work, the high-voltage
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 high-voltage conducting parts are
discharged to a discharge energy of less than 0.24 mJ before
they can be accessed.
Most flammable solvents have an ignition energy of around
0.24 mJ or 60 nC.
The cleaning agent's flash point must be at least 15 K above the
ambient temperature.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2)
may be used to remove dust deposits.
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OPERATING MANUAL
WARNING
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
exceed 100 megohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
8.1.3
CLEANING PROCEDURES
The cleaning intervals should be adapted by the operator depending on the level of use
and if necessary the level of soiling.
If in doubt, we recommend contacting J. Wagner AG's specialist personnel.
The valid health and safety specifications and the safety instructions provided in Chapter 4
must be adhered to for all cleaning work.
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OPERATING MANUAL
8.2
MAINTENANCE
8.2.1
MAINTENANCE STAFF
Maintenance work should be undertaken regularly and carefully by qualified and trained
staff. They should be informed of specific hazards during their training.
The following hazards may arise during maintenance work:
Health hazard from inhaling powder lacquer
Use of unsuitable tools and aids
Once the maintenance work is complete, the device must be checked by a qualified person
to ensure a reliable condition.
8.2.2
SAFETY INSTRUCTIONS
DANGER
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 or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch off the energy/compressed air supply.
- Relieve spray gun and device pressure.
- Secure the spray gun against actuation.
Observe the operating manual and service manuals at all times
when carrying out work.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
WARNING
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
exceed 100 megohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
8.2.3
MAINTENANCE PROCEDURES
The maintenance intervals should be adapted by the operator depending on the level of
use and if necessary the level of soiling.
If in doubt, we recommend contacting J. Wagner AG's specialist personnel.
The valid health and safety specifications and safety instructions provided in Chapter 4
must be adhered to for all maintenance work.
Maintenance work
Blow out gun and check for sintering
Check gun settings
Check gun discharge pressure
Blow out powder hoses
Check grounding
Check compressed air quality
Check gun voltage
Check powder hoses for bends and sintering
Point in time
per shift
x
x
x
x
weekly
x
x
x
x
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VERSION 06/2014
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OPERATING MANUAL
9
INSPECTIONS
9.1
INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010
If the control unit is used in a stationary system for electrostatic coating with flammable coating
powders, testing should be undertaken in accordance with DIN EN 50177: 2010-04 as per
Table 3 and Table 4.
63
Legend:
MA = Manufacturer
EM = Employer
SP = Skilled person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
Parts carrying high-voltage outside
the spray area
3
ME
Measurements of air flow speed /
air quantities
Check the differential pressure
indicator.
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.
FI
Inspect and test
(e.g., by measurement) whether
all parts carrying high-voltage
do not result in discharge which
puts people at risk.
TP/CP
CP
CP
Type of inspection
Inspection
by
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
Parts carrying high-voltage outside
the spray area must be routed such
that discharges which put people at
risk do not occur.
Interlock between technical
The technical ventilation should
ventilation and high-voltage,
be interlocked so that the powder
compressed air and coating product feed and high-voltage cannot be
supply
switched on while the technical
ventilation is not working
effectively.
2
Effectiveness of technical
ventilation check
Requirements
Effectiveness of technical
ventilation check
Type of inspection
1
Section
weekly
annually
continuously
Inspection
interval
VERSION 06/2014
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EPG-SPRINT X
OPERATING MANUAL
64
Measures to take if conductive
components are insufficiently
grounded
Resistance to ground of work
piece's locating point
5
6
ME/CI
Measurement of discharge
energy.
ME/CI
Measure resistance to ground
(work piece receiver - ground
potential)
max. 1 megohm @ 1,000 V.
CP
VI/ME/CI
Visual check of ground
connections, perform function
test on grounding switch,
measurement of grounding
resistors.
Type of inspection
CP
CP
Inspection
by
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
The resistance to ground of
every work piece's locating point
must not exceed 1 megohm
(measurement voltage must be
1,000 V). The design of the work
piece receiver must ensure that the
adapters remain grounded during
coating.
If sufficient grounding of
conductive parts cannot be
ensured, their discharge energy
must not exceed the permissible
value.
All the system's conductive
elements, such as floors, walls,
ceilings, protective grating,
transport equipment, work
pieces, powder tanks, machines or
construction parts etc. in the spray
area, with the exception of parts
which carry high-voltage during
operation, must be connected to
the grounding system. Parts of
the booth must be grounded in
accordance with EN 12215.
Requirements
weekly
weekly
weekly
Inspection
interval
ORDER NUMBER DOC2329371
Legend:
MA = Manufacturer
EM = Employer
SP = Skilled person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
Effectiveness of grounding
measures
Type of inspection
4
Section
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OPERATING MANUAL
65
Measures to take if the work pieces
are insufficiently grounded
Effectiveness of the manually
or automatically actuated fire
extinguishing systems
(room protection system)
7
8
Legend:
MA = Manufacturer
EM = Employer
SP = Skilled person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
Type of inspection
Section
HE/BSB
CP
Inspection
by
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
Effectiveness of the manually
or automatically actuated fire
extinguishing systems
(room protection system).
If sufficient work piece grounding
in accordance with section 6
cannot be ensured, appropriate
equipment, e.g,. ionizers, must
be used to discharge electric
charges on the work piece. Such
equipment must not exceed the
permitted discharge energy of the
spray systems with which it is used.
In terms of permitted discharge
energy, this equipment must be
put through the same inspections
as the powder spray systems used
with 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.
Requirements
FI
Trigger fire extinguishing
system, observe manufacturer's
requirements.
ME/FU/SÜ
Measurement of discharge
energy, check the monitoring
equipment's test function by
triggering it.
Type of inspection
6 months
weekly
Inspection
interval
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66
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9.2
INSPECTIONS IN ACCORDANCE WITH DIN EN 50050-2: 2014
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.
67
Requirements
Inspection of the electrostatic
manual spray equipment for
damage
CP
FI
Inspect and test
(e.g., by measurement) whether
all parts carrying high-voltage
do not result in discharge which
puts people at risk.
weekly
annually
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.
CP
Inspection
interval
weekly
ME/CI
Measure resistance to ground
(work piece receiver - ground
potential)
max. 1 megohm @ 1,000 V.
Type of inspection
CP
Inspection by
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
Electrostatic manual spray
equipment may only be operated
in an intact condition, damaged
devices must be decommissioned
immediately and repaired.
The resistance to ground of
every work piece's locating point
must not exceed 1 megohm
(measurement voltage must be
1,000 V). The design of the work
piece receiver must ensure that the
adapters remain grounded during
coating.
The technical ventilation should
Interlock between technical
be interlocked such that the highventilation and high-voltage,
compressed air and coating product voltage cannot be switched on
while the technical ventilation is not
supply
working effectively.
Resistance to ground of work
piece's locating point
Type of inspection
ORDER NUMBER DOC2329371
Legend:
MA = Manufacturer
EM = Employer
SP = Skilled person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
3
2
1
Section
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OPERATING MANUAL
10 DISASSEMBLY AND DISPOSAL
10.1
DISASSEMBLY
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 against being switched back on without
authorization.
Observe the operating manuals for any work.
Procedure:
1.
2.
3.
4.
5.
6.
7.
Switching off the system.
Lock the compressed air supply and decompress system.
Release electrical cable on control unit.
Detach hose for compressed air supply on control unit.
Detach hoses for the feed air, dosing air and atomizing air on the control unit.
Remove grounding cable on control unit.
Loosen retaining nuts and dismount control unit.
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10.2
DISPOSAL
NOTICE
Do not dispose of used electrical equipment with household
refuse!
In accordance with European Directive 2002/96/EC on the disposal
of used electrical equipment 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 used Wagner 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 representatives or us directly to arrange this.
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OPERATING MANUAL
11 TROUBLESHOOTING AND RECTIFICATION
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 energy/compressed air supply.
- Relieve spray gun and device pressure.
- Secure the spray gun against actuation.
Observe the operating manual and service manuals at all times
when carrying out work.
DANGER
Incorrect maintenance/repair!
Danger to life and damage to the device.
Wagner devices, protective systems and safety, monitoring
and control equipment may only be repaired as defined in
Directive 94/9/EC (ATEX) by trained Wagner service personnel or
capable persons in accordance with TRBS 1203! Note national
regulations!
Repair or replacement of devices or parts of devices may only be
performed outside the hazard area!
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OPERATING MANUAL
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.
50
60
40
m3/h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
19
70
Ø
30
Tri
80
2.5 0.3
13
90
2.0 0.1
0%
100 %
EPG
SPRINT X
P_01760
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OPERATING MANUAL
Warning No.
E01
E02
E03
Warning
Cause
Atomizing air too low Set point cannot be reached
Causes:
Hose kinked / blocked
Input air pressure too low
Dosing air too low
Feed air too low
System cannot reach target
setting
Set point cannot be reached
Causes:
Hose kinked / blocked
Input air pressure too low
Injector is not connected
System cannot reach target
setting
Set point cannot be reached
Causes:
Hose kinked / blocked
Input air pressure too low
Injector is not connected
System cannot reach target
setting
E04
Fallen below Tribo
current limit for 10 s
The Tribo current set in the
configuration cannot be reached
Causes:
Tribo air set too low
Powder not flowing due to
incorrect settings for feed air
and total air
No powder in tank
The powder does not have
the required charging
characteristics
Remedy
Check hoses and hose laying
Ensure that input pressure is
greater than 6 bar
Check gun and nozzle
system
Check hoses and hose laying
Ensure that input pressure is
greater than 6 bar
Connect injector correctly
Check hoses and hose laying
Check hoses and hose laying
Ensure that input pressure is
greater than 6 bar
Connect injector correctly
Select smaller set point
value
Example: Feed air for ED
pump max. 3.5 Nm³/h
Increase Tribo air
Correct feed air and total air
settings
Fill powder tank
Use suitable powder
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ORDER NUMBER DOC2329371
OPERATING MANUAL
11.2
FAULTS
Faults are indicated by fault LED 13 lighting up. In addition, the error number "Exx" (xx
stands for the fault number) is shown in the LED display 19 (7-segment LED). If a fault
occurs, high-voltage, air, etc. is immediately switched off. Work can be continued only after
removing the fault and pressing any button.
50
60
40
m3/h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
19
70
Ø
30
Tri
80
2.5 0.3
13
90
2.0 0.1
0%
100 %
EPG
SPRINT X
P_01761
Fault number
E11
Fault
Ground monitoring
E12
No coil current/
cascade interrupt
E13
Coil current too big
E14
Tribo current too high
Cause
Grounding cable is
interrupted
Gun is not connected
Gun is not connected
Gun cable is interrupted
Cascade in gun is
interrupted --> defective
Cascade of the connected
gun is defective
The Tribo current has
exceeded the upper limit
value of 12 μA
ATEX guidelines do not
permit higher values.
Remedy
Check/replace gun cable
Check/replace gun
Connect gun
Connect gun
Check/replace gun cable
Check/replace gun
Check/replace gun
Reduce Tribo air
Reduce powder quantity
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Fault number
E15-E17
Fault
High-voltage
generator error
Cause
Hardware defect
E18
Hardware defect
E20
Result of corona
measurement is
implausible
Password error
E21-E25
Exception error
E31
Gun switch
monitoring in
automatic mode
E41
No flow of atomizing
air
E42
No flow of dosing air
Remedy
If problem persists, contact
Wagner Service Team
Switch off unit and after
10 seconds, switch on again
If problem persists, contact
Wagner Service Team
The password for enabling
Inform Wagner service
the device is not set or has
center
been lost
Hardware defect has
If problem persists, contact
occurred
Wagner Service Team
The gun switch line has
Check gun cable
been interrupted
Gun unplugged during
Check gun
operation
No air is flowing out of the
Check:
control unit
Causes:
Hose kinked / blocked
The hose laying
Gun blocked
The air supply to the
control unit
Input pressure > 6 bar
Compressed air switched
Open compressed air
off
No air is flowing out of the
Check:
control unit
Causes:
Hose kinked / blocked
The hose laying
The air supply to the
control unit
Input pressure > 6 bar
Injector is not connected
Connect injector
Compressed air switched
Open compressed air
off
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OPERATING MANUAL
Fault number
E43
Fault
No flow of feed air
Cause
No air is flowing out of the
control unit
Causes:
Hose kinked / blocked
Injector is not connected
Compressed air switched
off
Hardware defect has
occurred
Hardware defect has
occurred
Atomizing air duct valve
leaking
Remedy
Gun unplugged during
operation
Check:
The hose laying
The air supply to the
control unit
Input pressure > 6 bar
Connect injector
Open compressed air
E51-E53
Exception error
E54
Hardware error
E55
Hardware error
Hardware defect has
occurred
Dosing air duct valve
leaking
Detach hose on rear of
valve and in standby
mode, check the valve for
seal integrity (air supply
must be connected)
E56
Hardware error
Hardware defect has
occurred
Feed air duct valve leaking
Detach hose on rear of
valve and in standby
mode, check the valve for
seal integrity (air supply
must be connected)
E60
Operation without
external release (only
for manual gun with
external control)
No release from
Check external control
If problem persists, contact
Wagner Service Team
Detach hose on rear of
valve and in standby
mode, check the valve for
seal integrity (air supply
must be connected)
Missing or defective
wiring
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EPG-SPRINT X
OPERATING MANUAL
12 ACCESSORIES
12.1
CONNECTION CABLES
Order No.
241270
241271
264626
264625
Designation
Mains cable Europe
Mains cable Switzerland
Mains cable USA
Mains cable Japan
130215
263219
Grounding cable, 10 m; 32.8 ft
Grounding cable Japan
9990149
Y-piece
12.2
WALL MOUNT
P_01861
Order No.
Designation
Wall mount with bracket
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EPG-SPRINT X
OPERATING MANUAL
12.3
RECIPE STICKER
50
40
60
m3/h
m3/h
Ø
Tribo Corona
2x
2x
name
70
30
12
5.5
11
4.5
10
9
8
3.5
2.5
2.0
3.0
20
Tri
1.5
80
0.5
90
10
0%
0.3
0.1
100 %
[Nm³/h]
[kV]
[μA]
[Nm³/h]
[%]
90
80
4.0
70
0.1
50
20
3.6
57
> 0.2
70
40
3.6
50
82
20
3.6
45
80
100
4.5
80
2x
P5
P6
✆
______________________________
@
______________________________
P7
P8
P9
www
www.wagner-group.com/industry
P10
P_01829
Order No.
2331223
Designation
Recipe sticker
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OPERATING MANUAL
13 SPARE PARTS
13.1
HOW CAN SPARE PARTS BE ORDERED?
To ensure proper spare parts delivery, the following information is necessary:
Order number, designation, and quantity
The quantity need not be the same as the number given in the quantity column "Stk" on
the lists. This number merely indicates how many of the respective parts are used in each
component.
The following information is also required to ensure smooth processing of your order:
-
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.)
Identification in spare parts lists
Explanation of column "K" (labeling) in the following spare parts lists.
= Wearing parts
Note: These parts are not covered by warranty terms
= Not part of the standard equipment but available as a special accessory.
WARNING
Incorrect maintenance/repair!
Risk of injury and damage to the device.
Repairs and part replacement may only be carried out 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 energy/compressed air supply.
- Ensure that all system components are grounded.
- Secure the device against being switched back on without
authorization.
Observe the operating and service manual at all times when
carrying out work!
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VERSION 06/2014
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EPG-SPRINT X
OPERATING MANUAL
13.2
Pos
EPG-SPRINT X CONTROL UNIT
K
Stk
1
2
Order No.
Designation
EPG-SPRINT X control unit (for manual and automatic systems)
Thermal delay fuses 1.0 A (included in EPG-SPRINT X)
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OPERATING MANUAL
14 DECLARATION OF WARRANTY AND CONFORMITY
14.1
IMPORTANT NOTES REGARDING PRODUCT LIABILITY
As a result of an EC regulation effective from January 1, 1990, the manufacturer shall only
be liable for his product if all parts originate from him or are approved by him, and if the
devices are properly mounted, operated and maintained.
The manufacturer will not be held liable or will only be held partially liable if third-party
accessories or spare parts have been used.
With genuine WAGNER accessories and spare parts, you have the guarantee that all safety
regulations are complied with.
14.2
WARRANTY CLAIM
Full warranty is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of warranty provided is such that the device or individual components of the
device are either replaced or repaired as we see fit. The resulting costs, in particular
shipping charges, road tolls, labor and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the device to a location other
than the address of the purchaser.
We do not provide warranty for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute products and the influence 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 are to be informed in writing about obvious faults within
14 days upon receipt of the device.
We reserve the right to have the warranty compliance met by a contracting company.
The services provided by this warranty are dependent on evidence being provided in the
form of an invoice or delivery note. If the examination discovers that no warranty claim
exists, the costs of repairs are charged to the purchaser.
It is clearly stipulated that this warranty claim does not represent any constraint on statutory
regulations or regulations agreed to contractually in our general terms and conditions.
J. Wagner AG
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OPERATING MANUAL
14.3
CE DECLARATION OF CONFORMITY
Herewith we declare that the supplied version of
- EPG-SPRINT X, Order No. 2324731
complies with the following 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 and serial
number.
Order number:
EPG-SPRINT X 2327595
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OPERATING MANUAL
14.4
EC TYPE EXAMINATION CERTIFICATE
83
VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
14.5
FM APPROVAL
The EPG-SPRINT X control unit is approved in the USA and Canada using configuration
drawing no. 2309729.
P_00309
Specialconditionsofuse:
ThesourceelectricalconnectionfortheControlUnitsaretobeconnectedinanunclassified
(ordinary)locationonly.
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
DEVICE CONFIGURATION APPENDIX
Procedure:
50
60
40
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
m3/h
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
80
2.5 0.3
15
90
100 %
0%
EPG
Tri
Cor
5
120
60
80
4
80
60
3
40
40
2
20
20
1
10
m3/h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
80
2.5 0.3
90
24
2.0 0.1
μA
kV
70
Ø
30
SPRINT X
19
50
40
100
16
1. To access special device configuration,
switch the unit to "Standby" with the
"Standby" button 15.
The yellow "Standby" LED 16 lights up.
2.0 0.1
μA
kV
70
Ø
100 %
0%
EPG
2. Press "Characteristic Slope" button 31
and hold it down.
3. Turn the universal rotary controller 24
with the other hand until the LED display
19 shows the number "10". Then release
the "Characteristic Slope" button 31.
The unit is now in configuration mode.
The scrolling text "Configuration" is
displayed.
SPRINT X
31
19
50
60
40
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
m3/h
20
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
80
2.5 0.3
90
2.0 0.1
μA
0%
100 %
EPG
P_01747
28
4. The LED display 19 now shows the first
configuration setting C11. At the same
time, the two yellow LED displays "Highvoltage" 28 and "Spray Current" 30 will
flash.
SPRINT X
30
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VERSION 06/2014
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OPERATING MANUAL
For ease of operation the configuration settings are divided into 4 groups. The first two
groups are for the end user, the third 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.
5
Group 1: Parameters C11 to C20
6
2x
2x
7
Group 2: Parameters C21 to C30
Group 3: Parameters C31 to C40 (Wagner Service)
8
Group 4: Parameters C41 to C99 (production plant; service center)
P_01750
It is possible to switch between the different groups using the "Recipe" buttons 5, 6, 7 and 8.
86
VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
A1
SETTING EXAMPLE: PARAMETER C11
This parameter is used to set the gun type (Tribo or Corona). The control unit is factory-set
to Corona.
Procedure:
5
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
1. If parameter C11 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 C11.
2.0
μA
kV
0%
EPG
27
SPRINT X
29
19
Tri
Cor
100
5
120
80
4
80
40
60
3
40
2
20
20
1
10
kV
18
2.0
μA
0%
EPG
P_01762
31
SPRINT X
24
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 automatic
guns
"aut" for automatic switching from
Tribo to Corona, if the user frequently
switches between Tribo and Corona.
Limitation: A Corona spray gun is always
shown when the control unit is switched
on. A Tribo gun is only recognized when
the high-voltage and powder feed are
activated.
This setting is retained until the control
unit is switched off.
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VERSION 06/2014
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EPG-SPRINT X
OPERATING MANUAL
19
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
2.0
5. There are now two options:
a) If you want to keep the old setting,
regardless of what is currently
displayed, press the "Characteristic
Slope" button 31 again. The LED
display 19 shows C11 again.
μA
kV
0%
EPG
SPRINT X
31
19
Tri
Cor
100
5
120
80
4
80
40
60
3
40
2
20
20
1
10
18
2.0
μA
kV
0%
EPG
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 an
overview of all the other parameters.
SPRINT X
25
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
6. To exit the configuration, switch control
unit to standby mode by pressing the
"Standby" button 15. Pressing this button
again returns the control unit to normal
operating mode.
2.0
15
μA
0%
EPG
SPRINT X
P_01763
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VERSION 06/2014
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ORDER NUMBER DOC2329371
OPERATING MANUAL
A2
SETTING EXAMPLE: PARAMETER C13
The lock is activated and deactivated with this parameter. The control unit is factory-set to
"OFF" (lock deactivated).
5
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
2.0
μA
kV
0%
Procedure:
EPG
27
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
SPRINT X
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.
29
2.0
μA
kV
0%
EPG
SPRINT X
19
Tri
Cor
100
5
120
80
4
80
40
60
3
40
2
20
20
1
10
kV
18
2.0
μA
0%
EPG
SPRINT X
24
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 18 will
flash.
4. All setting options can then be viewed
in turn by turning the universal rotary
controller 24.
The display shows:
OFF with lock deactivated.
ON with lock activated.
No program values can be adjusted
when the lock is activated.
P_01764
31
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OPERATING MANUAL
19
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
5. There are now two options:
a) If you want to keep the old setting,
regardless of what is currently
displayed, press the "Characteristic
Slope" button 31 again. The LED display
19 shows C13 again.
2.0
μA
kV
0%
EPG
SPRINT X
31
19
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
18
2.0
μA
kV
0%
EPG
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 provides an
overview of all the other parameters.
SPRINT X
25
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
6. To exit the configuration, switch control unit
to standby mode by pressing the "Standby"
button 15. Pressing this button again returns
the control unit to normal operating mode.
2.0
15
μA
0%
EPG
SPRINT X
P_01765
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A3
TABLE OF PARAMETERS
Parameter
Value
cor
(Factory setting)
tri
C11
Gun charging type
aut
OFF
C12
Selection reset function
ON
(Factory setting)
OFF
(Factory setting)
ON
C13
Lock
Pro
C14
"Double Click" function
OFF
ON
(Factory setting)
only display
C15
Operating hours counter
Description
Wagner Corona spray guns can be
connected to the unit; a Tribo gun will
trigger a fault.
Wagner Tribo guns can be connected to the
unit; a Corona gun will not trigger a fault.
Tribo or Corona spray guns can be
connected to the unit. The system only
changes to the correct type after it is first
switched on with the spray gun's trigger or
the connected CCM module.
The selection function is switched off. A
selection is retained until another selection
is made.
Selection function is switched on: after
5 seconds, the selection automatically
returns to the powder quantity setting.
Lock is deactivated.
Lock is activated, values cannot be
changed, user can only select recipes and
control functions.
Recipe values cannot be changed.
Operating inhibit sometimes activated.
Recipe storage is blocked, otherwise
function as in the "OFF" position. Values
can be changed temporarily.
"Double Click" function is deactivated.
The "Double Click" function is activated when the manual gun's trigger is pressed
twice to switch on, the program jumps to
the "Double Click" recipe; at the next switchon the previous recipe is selected again.
The actual coating hours are counted.
The numerical value displayed should be
multiplied by 100.
Examples:
0.15 0.15 * 100 h = 15 operating hours
050 50 * 100 h = 5,000 operating hours
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Parameter
C16
C17
C18
C19
External recipe selection
(Pulse control using remote
control bush)
Value
OFF
(Factory setting)
ON
Powder output
OFF
(Factory setting)
Increase in powder output
by activating the feed and
ON
atomizing air in 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.
Display luminance
The display luminance can be
set to one of three levels.
Delete created recipes
Description
The recipe is selected using 4 different
pulse lengths to select recipes 1-4.
This setting is compatible with the
CCM Prima.
The recipe is selected by using an extended
pulse/pause protocol to select all 50 recipes
and call up the purge function.
This setting should be used if control by a
programmable logic controller (PLC) is the
same as with a ProfiTech Sprint system.
For protocol, see service manuals for
EPG-SPRINT X.
"Standard" setting for separate hosing for
feed, dosing and atomizing air.
The feed air and atomizing air outputs are
combined for a larger feed air quantity
(higher powder output quantity).
Attention: The Tribo and atomizing air is no
longer available.
0
Full display luminance (default setting)
1
Medium luminance (reduced brightness)
2
Minimum luminance
(brightness greatly reduced)
NO
(Factory setting)
res
No action.
All recipes are reset to the delivery
condition if "res" is saved with button 25.
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Parameter
C20
C21
C22
C23
C25
Reset unit to delivery
condition
Vibrator motor control
after-run
Value
NO
(Factory setting)
res
10 s
(Factory setting)
OFF
ON
1 s - 240 s
OFF
Hose purging
(Factory setting)
(dosing air without feed air)
1 s - 10 s
100%
Hose purging intensity of
(Factory setting)
dosing air
1% - 100%
OFF
(Factory setting)
Tribo current minimum
0.1 μA - 5 μA
monitoring
Description
No action.
All settings except recipes are reset to the
delivery condition if "res" is saved with
button 25.
Vibrator motor overruns for 10 seconds.
Vibrator motor is not controlled; always off.
Vibrator motor is always switched on.
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.
Hose purging switched off.
Hose purging time overrun in seconds.
Hose purging intensity 100%.
Hose purging intensity from 1% to 100%.
Tribo current is not monitored.
If the Tribo current does not reach the set
values for more than 10 seconds, a warning
is issued (see Warnings and Fault Messages).
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OPERATING MANUAL
Parameter
C26
Manual gun with external
control operating mode
Value
OFF
(Factory setting)
1
2
C31-C40 Password protection
C41-C99 Password protection
Description
Standard function. The device
automatically recognizes the manual
or automatic gun. The properties of the
corresponding manual or automatic
gun operating mode is described in the
chapter on "Commissioning" and in the
service manuals.
Operation 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.
Same as described for value 1, but the
purge button at the operating front is
without function (disabled).
Password-protected; only for Wagner
personnel or appropriately trained persons.
Password-protected; only for Wagner
production sites or the Wagner Service
Center with appropriate test equipment.
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From software version 2.10, two additional parameters are available for special operation
with field controllers.
Parameter
C27
Value
OFF
(Default)
Open-circuit voltage limited ON
to a maximum of 40 kV
OFF
C28
High-voltage module:
Automatic spray current
reset
ON
(Default)
Description
Normal operation with gun
Special application if a field controller is
connected to this control unit.
The open-circuit voltage cannot exceed a
value of 40 kV.
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.
This setting must be selected if a field
controller is not used in the system as a
whole.
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A4
SPRAY CURRENT RESET WHEN USING FIELD CONTROLLERS
Problems when combining field controllers and guns:
When the control unit is operated in normal mode, the automatic spray current reset can
suffer a functional fault when positive and negative cascades are combined if all of the
guns and field controllers are not connected simultaneously.
Switching off the automatic spray current reset:
The automatic spray current reset can be switched off via configuration parameter
"C28 High-voltage module: Automatic spray current reset".
The spray current reset must then be performed manually. There are several ways of doing
this.
Spray current reset using the control unit:
When the EPG-SPRINT X control unit is powered up, the reset takes place via the control
unit itself.
For this reason, never switch a device on using the mains switch if guns or field controllers
are already being used for spraying in the same system. The operator must ensure that this
cannot happen.
Basic conditions for manually resetting the spray current:
The operator or higher-level controller must ensure that no gun or field 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
characteristic slope button light up for approx. 2 seconds in quick succession.
Manual spray current reset option 2:
If the purge function is carried out at the control unit, the spray current is reset once
following the completion of the purging process. If the EPG-SPRINT X is used as an
automatic gun control unit with an extended transfer protocol at the recipe input of the
remote control bush (C26 = "ON"), the reset is not performed during purging as a separate
command "63" is available.
Manual spray current reset option 3:
If the EPG-SPRINT X is used as an automatic gun control unit with an extended transfer
protocol at the recipe input of the remote control bush (C26 = "ON"), the reset can be called
up by sending command "63". (Further information can be found in the service manual in
the "Documentation for the Extended Transfer Protocol at the Recipe Input" chapter).
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Configuration:
Guns only, no field controller
Combination of guns and field controller
Field controller
Guns
EPG-Sprint X EPG-Sprint X
EPG-Sprint X configuration:
C27 = "OFF"
C28 = "ON"
Guns
EPG-Sprint X EPG-Sprint X
EPG-Sprint X configuration
(guns):
C27 = "OFF"
C28 = "OFF"
P_02372
EPG-Sprint X
EPG-Sprint X configuration
(field controller)
C27 = "ON"
C28 = "OFF"
Further information can be found in the field controller operating manual.
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BRIEF DESCRIPTION
Operating elements
Recipes
Electrostatic
parameters
Air parameters
Selection/display
elements
9
14
50
10
40
11
2x
2x
12
13
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
60
15
m3/h
Ø
30
20
10
70
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
Tri
80
2.5 0.3
90
2
2.0 0.1
μA
0%
1
100 %
EPG
SPRINT X
P_01766
8
7
6
5
4
3
1
2
3
4
5
6
7
8
9
10
11
12
Button: "Standby" (for switching to standby mode)
Rotary controller (for selecting recipes and parameters)
Selection button: "Atomizing/Tribo Air" [m³/h]
Selection button: "Powder Quantity" [%]
Selection button: "Total Air Volume" [m³/h]
Selection button: "Characteristic Slope"
Selection button: "Current Limitation" [μA]
Selection button: "High-voltage" [kV]
Recipe button: "Surface Parts" (coating surface parts)
Recipe button: "Second Coating"
Recipe button: "Profile Parts" (coating profile parts)
Recipe button: "Double Click" (for rapid recipe changes without interrupting the coating
process, by simply double-clicking on the gun trigger)
13 Recipe button: "Additional Recipes 5-50"
14 Display LED: "Fault"
15 Button: "Purge" (for quick and easy cleaning of components carrying powder)
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OPERATING MANUAL
Operation of the control unit
1
CHANGING PARAMETERS
1. Use selection button to select the parameters required.
The yellow LED lights up.
2. Set parameter value with rotary controller.
The value set is shown in LED display.
2
CALLING / CHANGING / SAVING RECIPES 1-4
2x
2x
1. Select required recipe by pressing the corresponding recipe button.
2. Set new parameters (electrostatic, air volume) (see 1).
2x
2x
3
3. Press the recipe button required for around 2 seconds until the LED flashes rapidly.
The recipe is saved with new parameters and can be called up again at any time at
the touch of a button.
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 controller.
(Only necessary if the parameters are to be saved under another recipe number.)
7. Press Additional Recipes button for around 2 seconds.
8. LED display flashes quickly.
Recipe is saved with new parameters.
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Germany
J. WAGNER GmbH
Otto-Lilienthal-Str. 18
Postfach 1120
D- 88677 Markdorf
Phone: +49/ 7544/ 505-0
Fax: +49/ 7544/ 505-200
E-mail: service.standard@wagner-group.com
Switzerland
J. WAGNER AG
Industriestrasse 22
Postfach 663
CH- 9450 Altstätten
Phone: +41/ 71/ 757 2211
Fax: +41/ 71/ 757 2222
E-mail: rep-ch@wagner-group.ch
Belgium
Estee Industries
Leenbeekstraat 9
B- 9770 Kruishoutem
Phone: +32/ 9/ 388 5410
Fax: +32/ 9/ 388 5440
E-mail: info@estee-industries.com
Denmark
WAGNER Industrial Solution Scandinavia
Viborgvej 100, Skægkær
DK-8600 SILKEBORG
Phone: +45/ 70 200 245
Fax: +45/ 86 856 027
E-mail: info@wagner-industri.com
Great Britain
WAGNER Spraytech (UK) Ltd.
The Couch House
2, Main Road
GB- Middleton Cheney OX17 2ND
Phone: +44/ 1295/ 714200
Fax: +44/ 1295/ 710100
E-mail: enquiry@wagnerspraytech.co.uk
France
Wagner - Division Solutions Industrielles
Parc Gutenberg - Bâtiment F
8 voie la Cardon
F- 91127 PALAISEAU Cedex
Phone: +33/ 1/ 825/ 011111
Fax: +33/ 1/ 69 19 46 55
E-mail: division.solutionsindustrielles@wagner-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: +81/ 728/ 573 722
E-mail: sempara@kornet.net
Austria
J. WAGNER GmbH
Otto-Lilienthal-Str. 18
Postfach 1120
D- 88677 Markdorf
Phone: +49/ 7544/ 505-0
Fax: +49/ 7544/ 505-200
E-mail: service.standard@wagner-group.com
Sweden
WAGNER Industrial Solutions Scandinavia
Skolgatan 61
SE - 568 31 SKILLINGARYD
Phone: +46/ 370/ 798 30
Fax: +46/ 370/ 798 48
E-mail: info@wagner-industri.com
Spain
WAGNER Spraytech Iberica S.A.
P.O. Boc., 132, Ctra. N- 340, KM 1245,4
E- 08750 Molins de Rei (Barcelona)
Phone: +34/ 93/ 680 0028
Fax: +34/ 93/ 680 0555
E-mail: info@wagnerspain.com
China
WAGNER Spraytech Shanghai Co Ltd.
4 th Flr. No. 395 Jiangchanxi Road
Shibei Industrial Zone
Shanghai 200436
Phone: +86/ 2166 5221 858
Fax: +86/ 2166 5298 19
E-mail: wagnersh@public8.sta.net.cn
USA
WAGNER Systems Inc.
300 Airport Road, Unit 1
Elgin, IL 60123
Phone: +1/ 630/ 503-2400
Fax: +1/ 630/ 503-2377
E-mail: info@wagnersystemsinc.com
102
ED
FI
CERT
I
Order No. 2329371
Germany
Phone
Fax:
E-mail:
Switzerland
Phone
Fax:
E-mail:
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