WAGNER EPG-SPRINT Translation Of The Original Operating Manual
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WAGNER EPG-SPRINT 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
Translation of the original
Operating manual
EPG-SPRINT
Version 08 / 2010
P_01110
EP G
SPRI NT

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Summary of Contents for WAGNER EPG-SPRINT

  • Page 1 Translation of the original Operating manual EPG-SPRINT Universal Control Unit for Version 08 / 2010 Powder Coating Guns EP G SPRI NT P_01110 II 3(2)D IP64 80°C 0102...

  • Page 3: Table Of Contents

    Delivery scope Technical data Control functions 4.4.1 Operating elements frontside 4.4.2 Connections on the rear side of the EPG-SPRINT unit PREPARATIONS FOR STARTING UP Connecting the manual gun Connecting the automatic spray guns Grounding 5.3.1 Grounding of the powder coating system...
  • Page 4 Disposal ELIMINATION OF FAULTS Warnings E01-E04 Malfunctions E11-E43 SPARE PARTS How to order spare parts? EPG-SPRINT control unit Accessories ATTACHMENT DEVICE CONFIGURATION BRIEF DESCRIPTION Changing the parameters Calling / changing / saving programs 1-4 Calling / changing / saving programs 5-50...

  • Page 5: About These Instructions

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES The operating manual is available in the following languages: Language: Order No. Language: Order No. German English 2305220 2305222 French 2305224 Dutch 2310775 Italian 2305225 Spanish 2305226...

  • Page 6: General Safety Instructions

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR 2.1.1 ELECTRICAL PLANT AND UNITS To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences.

  • Page 7: Safety Instructions For Staff

    field between the spray gun and the workpiece to be coated builds up! 2.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY UNITS Never point the powder spray gun at people. Before all work on the unit, in the event of work interruptions and functional faults: –...

  • Page 8: Handling Powder Paints

    2.4.1 USING IN ACCORDANCE WITH THE INSTRUCTIONS The EPG-SPRINT control units are intended for use with powder spray guns of types A-P up to 2 mJ in accordance with the prototype test PTB 06 ATEX 5003. The EPG-Sprint control unit may be used in the dust explosion zone (zone 22) under the following conditions: Control unit correctly fitted in rack.

  • Page 9: Safety Features

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL SAFETY FEATURES 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.

  • Page 10: Warranty And Conformity Declarations

    Components not manufactured by Wagner are subject to the warranty terms of the original maker. The replacement of a part does not extend the warranty period of the unit.

  • Page 11: Ce-Conformity

    - DIN EN 61000-6-4: 2002 - BGI 764 Marking: CE Certificate of Conformity The certificate is enclosed with this product.The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number: EPG-SPRINT 2305227...

  • Page 12: Fm-Identification

    P_01089 In using Control Document P/N 2309729 the approved Power Pack and spray guns including accessories can be identifi ed for correct combination. This control document is included in the packing, but can reordered anytime from Wagner under P/N 2309729.

  • Page 13: Description

    ➞ The PEM-C3R and PEM-T3R manual spray guns cannot be connected to the EPG-SPRINT control unit. The EPG-SPRINT 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.

  • Page 14: Delivery Scope

    VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL DELIVERY SCOPE Quantity Order No. Designation 2305109 EPG-SPRINT (for manual and automatic systems) 2305127 EPG-SPRINT FM (for USA) The standard equipment includes: 2305227 Declaration of conformity 2305220 Operating manual German see chapter 1.1...
  • Page 15 Compressed air quality, accessories Danger of equipment damage. Operate the control unit only with the prescribed compressed air quality. Only use the control unit with original Wagner accessories. Disregard of these conditions leads to expiring the warranty. SIHI_05054_ENG Ambient conditions: If low temperature powders are used, the ambient temperature may have to be lower than 30°C;...

  • Page 16: Control Functions

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL CONTROL FUNCTIONS 4.4.1 OPERATING ELEMENTS FRONTSIDE 20 22 23 18 13 EP G SP RIN T P_01111 30 29 31 32 37 35 Illuminated display: High-voltage Lights up green. ● Display range: 0-100 kV ●...
  • Page 17 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL Display: Tribo gun Lights up when a Tribo gun is connected and selected. ● Display: Corona gun Lights up when a Corona gun is connected and selected. ● Push button: Program for surface parts Push button: Program for second-coating Push button: Program for profi...
  • Page 18 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 19 Display LED: 7 segments, three-digit number Indicates the exact value depending on the activated function: ● “Overall air quantity; atomizing, ionising and Tribo air; additional recipes; high-voltage; current limiting; powder quantity“.
  • Page 19 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL To activate the function, the current limiting is set with the rotary controller 24 and ● is indicated in the LED display 19. Adjusting range: 5-120 µA ● Resolution: 1 µA ●...

  • Page 20: Connections On The Rear Side Of The Epg-Sprint Unit

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 4.4.2 CONNECTIONS ON THE REAR SIDE OF THE EPG-SPRINT UNIT Main switch U max. 22 Vpp Output to gun Made in Switzerland Ausgang zur Pistole I max. 0,9 A J. Wagner AG CH 9450 Altstätten...
  • Page 21 11 Connection for the CCM Prima For connecting to the CCM Prima, if one is installed in the PrimaTech automatic ● system. 12 Cover of the service connections For Wagner service personnel only! ● 13 Fixing For screwing to the rack. ●...

  • Page 22: Preparations For Starting Up

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL PREPARATIONS FOR STARTING UP WARNING Incorrect installation/operation! Risk of injury and damage to equipment When putting into operation and for all work, read and follow the operating instructions and safety regulations for the addi- tionally required system components.

  • Page 23: Connecting The Manual Gun

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL CONNECTING THE MANUAL GUN Corona or Tribo spray gun Electrical connection cable EPG-SPRINT Compressed air main supply (0.6-0.8 MPa; 6-8bar; 87-116 psi) Mains power Hose diameter: 8 mm; 0.315 inches Atomizing or Tribo air,...

  • Page 24: Connecting The Automatic Spray Guns

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL CONNECTING THE AUTOMATIC SPRAY GUNS Tribo Corona spray gun* spray gun Electrical connection Atomizing air Tribo air Powder hose connection Electrical connection cable to the CCM Prima EPG-SPRINT Compressed air main supply (0.6-0.8 MPa;...

  • Page 25: Grounding

    For safety reasons, the EPG-SPRINT and/or the PrimaTech CCM system must be correctly grounded. Wagner recommends the use of copper cable of at least 4 mm² with suffi cient mechanical stability for the connection to the operating ground. It is important for systems safety and to achieve an optimum coating, that all system components such as workpieces, conveyors, color supply, control unit and booth or spray wall are perfectly grounded.

  • Page 26: Grounding Of The Powder Coating System

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 5.3.1 GROUNDING OF THE POWDER COATING SYSTEM P_01120 Only use mains cables with grounding strand! Connect grounding cable with booth and system ground! Connect grounding cable to an uncoated metal part of the booth!

  • Page 27: Starting Up And Operating

    ➞ Do not operate the gun‘s trigger while the control unit is being switched on and is powering up. The EPG-SPRINT control unit automatically detects whether a manual or automatic gun is connected to the control unit. It does this by checking whether the trigger switch is activated when it is switched on.

  • Page 28: Basic And Factory Settings

    U/I characteristic [standard, medium, soft] The EPG-SPRINT control unit has 50 pre-defined programs. 4 of these can be selected directly using buttons 5-8 and the remaining 46 by pressing the “additional programs“ button 25 above rotary controller 24. All programs can be adapted and stored by the user to suit individual requirements.

  • Page 29: Double Click" Program (High Dynamic Remote)

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.2.1 “DOUBLE CLICK“ PROGRAM (HIGH DYNAMIC REMOTE) This function is used to change quickly to another program during a coating operation. The operator can access a previously set recipe by double-clicking the trigger lever on the spray gun, for example to recoat parts using different parameters (high-voltage, current limiting, air quantity etc.).

  • Page 30: Air High Output Mode (High Powder Output)

    OPERATING MANUAL AIR HIGH OUTPUT MODE (HIGH POWDER OUTPUT) EPG-SPRINT can be used to combine the feed and atomizing air to achieve a higher feed air volume. A high powder volume does however depend on other factors. The length of the suction hose and the length and diameter of the powder hose also affect the maximum powder volume.

  • Page 31: Activate High Output Mode (C17)

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.3.2 ACTIVATE HIGH OUTPUT MODE (C17) Procedure: 1. To access special device confi guration, switch the unit to “standby“ with the “standby“ button 15. The yellow “standby“ LED 16 lights up.
  • Page 32 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 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.
  • Page 33 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 8. To exit confi guration mode press “standby“ button twice. The control unit is now in the operating mode with high powder fl ow switched This setting is “global“ and applies in all programs.

  • Page 34: Changing And Saving Programs

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL CHANGING AND SAVING PROGRAMS 6.4.1 PROGRAMS NO. 1-4 P_01125 Programs 1-4 can be selected and saved directly using program buttons 5-8. Once the program required has been called up, the individual coating parameters can be called up and changed using the corresponding selection buttons.

  • Page 35: Programs No

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.4.2 PROGRAMS NO. 5-50 P_01174 The programs 5 to 50 are selected and saved indirectly. The “additional programs“ button 25 must be pressed fi rst. The yellow “additional programs“ LED 26 then lights up and the LED display 19 indicates the current program number.

  • Page 36: Setting And Changing The Coating Parameters

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL SETTING AND CHANGING THE COATING PARAMETERS 6.5.1 SETTING THE OVERALL AIR QUANTITY Procedure: 1. Press the “overall air quantity“ button 20 to adjust the overall air quantity. The yellow LED 22 indicates that the overall air quantity is selected.

  • Page 37: Setting The Powder Feed Quantity

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.5.2 SETTING THE POWDER FEED QUANTITY Procedure: 1. Press the “powder quantity“ button 36 to adjust the powder quantity. The yellow LED 37 indicates that the powder quantity is selected. EP G SPR INT 2.

  • Page 38: Setting The Additional Air (Atomizing/Ionising/Tribo Air Quantity)

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.5.3 SETTING THE ADDITIONAL AIR (ATOMIZING/IONISING/TRIBO AIR QUANTITY) 21 23 Procedure: 1. Press the “additional air“ button 21 to adjust the additional air quantity. The yellow LED 23 indicates that additional air is selected.

  • Page 39: Setting The High-Voltage

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.5.4 SETTING THE HIGH-VOLTAGE Procedure: 1. Press the “high-voltage“ button 27 to adjust the high-voltage. The yellow LED 28 indicates that high-voltage is selected. EP G SPR INT 2. The high-voltage...

  • Page 40: Display Of Actual High-Voltage Value

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.5.5 DISPLAY OF ACTUAL HIGH-VOLTAGE VALUE The actual high-voltage value can be displayed during the coating process in LED display Procedure: 1. Press “high-voltage“ button 27 for around 2 seconds. Yellow LED 28 fl...

  • Page 41: Setting The Current Limiting

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.5.6 SETTING THE CURRENT LIMITING Procedure: 1. Press the “current limiting“ button 29 to adjust the limitation of the spray current. The yellow LED 30 indicates that current limiting is selected.

  • Page 42: Displaying Actual Value Of Current Limiting

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.5.7 DISPLAYING ACTUAL VALUE OF CURRENT LIMITING The actual current limitation value can be displayed in LED display 19 during the coating process. Procedure: 1. Press “current limitation“ button 29 for around 2 seconds. Yellow LED 30 fl...

  • Page 43: Setting The U/I Characteristics

    “characteristic slope“ LED display. P_01123 EPG-SPRINT U/I characteristics 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.
  • Page 44 ● (current limiting at 120 µA) For high application effectiveness. ● This setting corresponds to the usual ● Wagner high-voltage modules and control units. Medium level (blue) For small surfaces. ● Open-circuit voltage 100 kV For well rechargeable types of powder.

  • Page 45: Rinse Function

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL RINSE FUNCTION The EPG-Sprint control unit has two different purge functions: Hose purge function ● Cleaning purge function ● 6.6.1 HOSE PURGE FUNCTION This function blows dosage air through the powder feed hose and guns when the powder fl...

  • Page 46: Procedure For Cleaning Purging

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 6.6.3 PROCEDURE FOR CLEANING PURGING EP G SPR INT P_01128 Procedure: 1. End coating operation. 2. Remove powder delivery module (suction lance, powder injector) from powder container. 3. Switch on purge function by pressing “purge“ button 17 on the control unit.

  • Page 47: Disposal

    Your waste Wagner electrical device will be taken back by us or our representatives and disposed of environmentally correctly. Please contact one of our service points or one of our representatives or us directly to this purpose.

  • Page 48: Elimination Of Faults

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL ELIMINATION OF FAULTS DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Maintenance, repairs or the exchange of units or parts there of must be carried out by trained personnel, outside the danger areas.
  • Page 49 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL Warning No. Warning Cause Rectifi cation Dosage air too low. Set set point cannot be reached. Causes: Hose kinked / blocked. Check hoses and hose ● ● laying. Input air pressure too low.

  • Page 50: Malfunctions

    ATEX guidelines do not permit higher values. E15-E17 High-voltage Hardware defect. If problem persists, ● ● generator error. contact Wagner Service Team. Password error. The password for enabling Inform Wagner service ● ● the device is not set or has center.
  • Page 51 Faults Cause Rectifi cation E21-E25 Exception error. Hardware defect has If problem persists, ● ● occurred. contact Wagner Service Team. Gun switch The gun switch line has Check gun cable. ● ● monitoring in been interrupted. automatic mode. Gun unplugged during Check gun.

  • Page 52: Spare Parts

    Risk of injury and damage to the equipment. ➞ Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. ➞ Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 53: Epg-Sprint Control Unit

    ORDER NUMBER DOC 2305222 OPERATING MANUAL EPG-SPRINT CONTROL UNIT Item Quantity Order No. Designation 2305109 EPG-SPRINT control unit (for manual and automatic systems) 2305127 EPG-SPRINT control unit (for USA) 9951117 Thermal delay fuses 1.0 A (included in EPG-SPRINT) ACCESSORIES Item Quantity Order No.

  • Page 54: Attachment Device Configuration

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL ATTACHMENT DEVICE CONFIGURATION Procedure: 1. To access special device confi guration, switch the unit to “standby“ with the “standby“ button 15. The yellow “standby“ LED 16 lights up. EP G SPR INT 2.
  • Page 55 For ease of operation the confi guration settings are divided into four groups. The fi rst 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.
  • Page 56 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL Setting example: Parameter C11 This parameter is used to set the gun type (Tribo or Corona). The control unit is factory-set to Corona “cor“. Procedure: 1. If parameter C11 is not set on the...
  • Page 57 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 5. There are now two options: a) If you want to keep the old setting, regardless what currently displayed, press the “characteristic slope“ button 31 again. The LED display 19 shows C11 again.
  • Page 58 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL Setting example: Parameter C13 The lock is activated and deactivated with this parameter. The control unit is factory-set to “OFF“ (lock deactivated). Procedure: 1. If parameter C13 is not set on the...
  • Page 59 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL 5. There are now two options: a) If you want to keep the old setting, regardless what currently displayed, press the “characteristic slope“ button 31 again. The LED display 19 shows C13 again.
  • Page 60 Table of parameters Parameter Value Designation Wagner Corona guns can be connected to (factory setting) 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.
  • Page 61 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL Parameter Value Designation The program is selected using 4 different (factory setting) pulse lengths to select programs 1-4. This setting is compatible with the CCM Prima. The program is selected by using an...
  • Page 62 10 seconds, a warning is issued (see Warnings and fault messages). Password-protected; only for Wagner C31-C40 Password protection personnel appropriately trained persons. Password-protected; only for Wagner C41-C99 Password protection production sites or the Wagner Service Center with appropriate test equipment.

  • Page 63: Brief Description

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL BRIEF DESCRIPTION Operating elements Programs Electrostatic Air parameters Selection/display parameters elements Tribo Corona m /h m /h Ø μA μA SPRINT P_01182 1 Button: Standby (to switch into standby mode) 2 Rotary controller (for selecting programs and parameters) 3 Selection button: Atomizing air/Tribo air [m³/h]...

  • Page 64: Changing The Parameters

    EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL Operation of the control unit CHANGING THE 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.
  • Page 65 EPG-SPRINT. VERSION 08/2010 ORDER NUMBER DOC 2305222 OPERATING MANUAL...
  • Page 66 Fax: +45/ 86 856 027 E-mail: info@estee-industries.com E-mail: info@wagner-industri.com Great Britain France WAGNER Spraytech (UK) Ltd. Wagner - Division Solutions Industrielles The Couch House Parc Gutenberg - Bâtiment F 2, Main Road 8 voie la Cardon GB- Middleton Cheney OX17 2ND...
  • Page 68 2305222...

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