WAGNER EPG S2 Translation Of The Original Operating Manual
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WAGNER EPG S2 Translation Of The Original Operating Manual

Universal control unit for powder coating guns
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Universal Control Unit for
Powder Coating Guns
II 3(2)D IP64 80 °C
0102
P_00309
Translation of the Original
Operating Manual
EPG S2
EPG S2 FM
Version 09/2017
A
P_01486
S2
EPG
B

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Summary of Contents for WAGNER EPG S2

  • Page 1 Translation of the Original Operating Manual EPG S2 EPG S2 FM Universal Control Unit for Powder Coating Guns Version 09/2017 P_01486 II 3(2)D IP64 80 °C 0102 P_00309...

  • Page 3: Table Of Contents

    5.5.1 Display Elements, Front Side 5.5.2 Connections on the Rear Side of the EPG S2 5.5.3 Connections on the Rear Side of the EPG S2 FM 5.5.4 CAN Bus Connection on the Rear Side ASSEMBLY AND COMMISSIONING Training Assembly/Commissioning Staff...
  • Page 4 CAN Bus Node ID Setting OPERATION Training the Operating Staff Safety Instructions Controllable Spray Guns Gun Cable Lengths Control Functions on EPG S2 Control Unit 7.5.1 Setting the High Voltage 7.5.2 Setting of Current Limiting 7.5.3 Settings of High-voltage Characteristic 7.5.4...

  • Page 5: General

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL GENERAL PREFACE The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel.

  • Page 6: Languages

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL LANGUAGES The operating manual is available in the following languages: German 2317573 English 2317574 French 2317575 Italian 2317576 Russian 2334207 Chinese 2335799 Hungarian 2338270 Czech 2348860 Spanish 2355652 Danish 2371619 Swedish...

  • Page 7: Correct Use

    USE IN AN EXPLOSION HAZARD AREA The EPG S2 control unit are 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 S2 control unit may be used in the dust explosion zone (zone 22) under the following conditions: –...

  • Page 8: Safety Parameters

    SAFETY PARAMETERS The control unit is only suited for controlling powder spray guns. Wagner International AG prohibits any other use! 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, –...

  • Page 9: Identification

    Protection class 64 80 °C: Temperature class: maximum surface temperature < 80 °C; 176 °F PERMISSIBLE DEVICE COMBINATIONS The following powder spray guns may be connected to the EPG S2: Automatic spray guns – Corona spray gun PEA-C3, PEA-C4 – Corona spray gun PEA-C3XL, PEA-C4XL –...

  • Page 10: General Safety Instructions

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS 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...

  • Page 11: Safety Instructions For Staff

    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: –...

  • Page 12: Cleaning

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 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.

  • Page 13: Protective And Monitoring Equipment

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 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, modifi ed or rendered unusable. Regularly check for perfect functioning.

  • Page 14: Safety Feature Identification

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 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 100 mm; 3.94 inches.

  • Page 15: Description

    Only connect original WAGNER spray guns to the EPG S2 control unit. The EPG S2 control unit is used to supply air and voltage to two WAGNER automatic or manual powder spray guns, in Corona or Tribo versions. The control unit has no controls; various operating statuses are simply displayed.

  • Page 16: Technical Data

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL TECHNICAL DATA Dimensions: Height 136 mm; 5.35 inches Width 270 mm; 10.63 inches Depth (without operating elements) 300 mm; 11.81 inches Weight 5.5 kg; 12.13 lb Electrical: Mains (AC) 90 VAC–250 VAC Frequency 47 Hz–63 Hz...
  • Page 17 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;...

  • Page 18: Permitted Accessories

    PERMITTED ACCESSORIES Only the accessories listed in the "Accessories" chapter of this operating manual may be connected to the EPG S2 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.

  • Page 19: Display And Operating Elements

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL DISPLAY AND OPERATING ELEMENTS 5.5.1 DISPLAY ELEMENTS, FRONT SIDE EP G P_01487 1 LED display: "Operating voltage" – The LED lights up green when the operating voltage is activated 2 LED display: "CAN Data Communication"...

  • Page 20: Connections On The Rear Side Of The Epg S2

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 5.5.2 CONNECTIONS ON THE REAR SIDE OF THE EPG S2 Do NOT disconnect under voltage! Air input Made in Switzerland NICHT unter Spannung trennen! Wagner International AG Lufteingang CH 9450 Altstätten º...
  • Page 21 EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 6 Gun connection B – To connect a Corona or Tribo gun 7 Gun connection A – To connect a Corona or Tribo gun 8 Fixations – For screwing to the rack 9 Cover of the service connection –...

  • Page 22: Connections On The Rear Side Of The Epg S2 Fm

    Zerstäuberluft 16 15 The model diff ers only in the version of the rear label from the EPG S2 variant described in Chapter 5.5.2. From a technical standpoint, the FM version is identical to the one described in Chapter 5.5.2.

  • Page 23: Can Bus Connection On The Rear Side

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 5.5.4 CAN BUS CONNECTION ON THE REAR SIDE Connector plug Equipment socket P_01508 CAN bus Data and interlock 5-pin plug M12, A coded No. Signal Shield/housing +24 VDC release CAN_H CAN_L...

  • Page 24: Assembly And Commissioning

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL ASSEMBLY AND COMMISSIONING 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. The commissioning staff must be familiar with the provisions of the European standards DIN EN 50050-2 and DIN EN 50177.

  • Page 25: Connecting The Automatic Spray Guns

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL CONNECTING THE AUTOMATIC SPRAY GUNS Tribo spray gun* Corona spray gun Atomizing air CAN bus output CAN bus input Compressed air Inlet Signal ground Mains input terminal Mains output to next control unit...

  • Page 26: Connecting The Manual Guns

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL CONNECTING THE MANUAL GUNS CAN bus output CAN bus input Compressed air Inlet Signal ground Mains input terminal Mains output to next control unit Powder injector Powder injector e.g., from the powder tank...

  • Page 27: Connection Diagram In The Rack

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL CONNECTION DIAGRAM IN THE RACK The CAN bus must be closed at the start and end. Master controller CAN bus Terminate BUS end on master controller Mains input terminal Compressed-air connection, min. 1"...

  • Page 28: Grounding

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 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)!
  • Page 29 EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL – 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...

  • Page 30: Grounding The Powder Coating System

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 6.7.1 GROUNDING THE POWDER COATING SYSTEM P_01506 The control unit is grounded with the grounding cable supplied. The grounding cable is secured to the control unit's grounding connection and the rack with the screws provided.

  • Page 31: Device Settings

    ORDER NUMBER DOC2317574 OPERATING MANUAL DEVICE SETTINGS The settings described below must be made and/or checked on the EPG S2 control unit before commissioning. The baud rate and node number setting for the CAN bus are set mechanically using the switches under the service cover.

  • Page 32: Can Bus Node Id Setting

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 6.8.2 CAN BUS NODE ID SETTING The node IDs for the CAN bus are set using two rotary buttons under the service cover. The node IDs can be set between 1 and 100 as follows:...

  • Page 33: Operation

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualifi ed to operate the entire system. Before work commences, the operating staff must receive appropriate system training.

  • Page 34: Controllable Spray Guns

    CONTROLLABLE SPRAY GUNS Two powder spray guns can be connected to the EPG S2 control unit. These two guns are controlled totally independently of one another. The automatic guns are activated and deactivated via the superordinate controller. The gun types which can be controlled are listed in Chapter 3.2.

  • Page 35: Control Functions On Epg S2 Control Unit

    OPERATING MANUAL CONTROL FUNCTIONS ON EPG S2 CONTROL UNIT The EPG S2 control unit does not have its own operating or display elements. All specifi cations (set points) and displays (actual values) are transferred by electric signals from a master controller via the CAN bus.

  • Page 36: Setting Of Current Limiting

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 7.5.2 SETTING OF CURRENT LIMITING The spray current limitation can be set and measured independently in both of the control unit's channels. If the measured spray current reaches or exceeds the set value, the high voltage is adjusted downwards until the set spray current is reduced to maximum.

  • Page 37: Settings Of High-Voltage Characteristic

    SETTINGS OF HIGH-VOLTAGE CHARACTERISTIC Regardless of the high voltage and spray current limitation set, the characteristic curve of the voltage/current curve can be set on the EPG S2 control unit. Three levels are possible: 1. Standard level -> maximum EPG S2 performance 2.

  • Page 38: Setting The Air Volume

    7.5.5 AIR SUPPLY PRESSURE The EPG S2 control units are calibrated in the factory to a primary pressure of between 0.6-0.8 MPa; 6-8 bar; 87-116 psi. It is important that the atmospheric pressure supply line has a large cross-section and that the air supply pressure does not drop during high...

  • Page 39: Diagnosis And Monitoring

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL DIAGNOSIS AND MONITORING 7.6.1 LED DISPLAYS 9 colored LEDs show various states, activities and malfunctions. P_01505 LED Power – Lights up green as soon as the device is switched on LED CAN –...

  • Page 40: Emergency Operation

    OPERATING MANUAL EMERGENCY OPERATION The EPG S2 has a simple emergency mode. The aim of the emergency mode is to permit minimal further work should the CAN bus or superordinate controller fail. The emergency mode parameters must be set before the CAN bus fails, otherwise emergency mode does not function.

  • Page 41: Cleaning And Maintenance

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING STAFF Cleaning work should be undertaken regularly and carefully by qualifi ed and trained staff . The staff must be familiar with the DIN EN 50050-2 and DIN EN 50177 provisions. They should be informed of specifi c hazards during their training.

  • Page 42: 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 WAGNER's specialist personnel. The valid health and safety specifi cations and the safety instructions provided in Chapter 4...

  • Page 43: Maintenance

    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.

  • Page 44: 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 WAGNER's specialist personnel. The valid health and safety specifi cations and safety instructions provided in Chapter 4 must be adhered to for all maintenance work.

  • Page 45: Inspections According To Din En 50177: 2010

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL INSPECTIONS ACCORDING TO DIN EN 50177: 2010 If the system is used for electrostatic coating with fl ammable coating powders, testing should be undertaken in accordance with DIN EN 50177: 2010-04 as per Table 3 and Table 4.
  • Page 46 EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL...
  • Page 47 EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL...
  • Page 48 EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL...

  • Page 49: Disassembly And Disposal

    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.

  • Page 50: Trouble Shooting And Rectification

    Danger to life and equipment damage. WAGNER devices, protective systems and safety, monitoring and control equipment may only be maintained/repaired as defi ned in Directive 2014/34/EC (ATEX) by trained WAGNER service personnel or capable persons in accordance with TRBS 1203! Note national regulations!

  • Page 51: Faults

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 11.1 FAULTS In the event of malfunctions, the red "Malfunction" LED lights up. The malfunction is described in detail in the superordinate controller. P_01498...

  • Page 52: Accessories

    CAN bus connection cable, 0.6 m; 1.97 ft 2320128 CAN bus connection cable, 2.0 m; 6.56 ft 2320129 CAN bus connection cable, 5.0 m; 16.40 ft 2320130 CAN bus connection cable, 10.0 m; 32.81 ft 2321529 Connection set EPG S2 2321744 Set of stickers, gun numbers 1-32...

  • Page 53: Spare Parts

    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.

  • Page 54: Epg S2 Control Unit

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 13.2 EPG S2 CONTROL UNIT Order No. Designation 2316991 EPG S2 control unit 2343176 EPG S2 FM control unit (USA version) 9951117 Slow fuses 1.0 A (included in EPG S2)

  • Page 55: Warranty And Conformity Declarations

    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.

  • Page 56: Ce Declaration Of Conformity

    II 3(2)D IP 64 80 °C 0102 CE Declaration of Conformity The Declaration 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 S2 2322580...

  • Page 57: Ec Type Examination Certificate

    EPG S2 VERSION 09/2017 ORDER NUMBER DOC2317574 OPERATING MANUAL 14.4 EC TYPE EXAMINATION CERTIFICATE...

  • Page 58: Fm Identification Epg S2 Fm

    ORDER NUMBER DOC2317574 OPERATING MANUAL 14.5 FM IDENTIFICATION EPG S2 FM The EPG S2 FM control unit is FM approved in the USA and Canada using confi guration drawing no. 2309729. P_00309 Special conditions of use: The source electrical connection for the Control Units are to be connected in an unclassified...
  • Page 60 Order No. 2317574 Version 09/2017 Germany 88677 Phone Telefax E-mail ts-powder@wagner-group.com Switzerland 9450 Phone Telefax More contact addresses: Company/Locations/WAGNER worldwide Subject to changes without notice...

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