Page 1
10 0 S P R IN T X EP G P_01742 Universal Control Unit for Powder Spray Guns EPG-SPRINT XE Translation of the Original Operating Manual 0102 II 3(2) D IP64 80 °C For professional use. Always observe the information in this manual, particularly the safety instructions and the warning instructions.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE Table of Contents TABLE OF CONTENTS About these Instructions Preface Warnings, Notices and Symbols in these Instructions General Characters and Symbols Languages Abbreviations Terminology for the Purpose of this Manual...
Page 4
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE Table of Contents 6.6.2 Safety Checks Operation Training the Operating Personnel Preparations for Commissioning 7.2.1 Tasks 7.2.2 Operating Modes 7.2.3 Gun Recognition 7.2.4 Manual Gun Mode with External Control 7.2.5...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE Table of Contents Disassembly and Disposal 12.1 Disassembly 12.2 Disposal Accessories 13.1 Connection cable 13.2 Wall mount 13.3 Recipe sticker Spare Parts 14.1 How to Order Spare Parts 14.2 Notes on the Use of Spare Parts 14.3...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 1 About these Instructions 1 ABOUT THESE INSTRUCTIONS 1.1 PREFACE The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 1 About these Instructions – Non-numbered list, first level – Non-numbered list, second level = cross-reference on page ♦ = wearing parts ⋆ = included in service set ● = not part of the standard equipment but available as a special accessory 1.4 ...
Page 8
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 1 About these Instructions Personnel qualifications Trained person Is instructed in the tasks assigned to him/her, the potential risks associ- ated with improper behavior as well as the necessary protective devices and measures.
4 Follow the instructions in the operating manual. 2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS The EPG-SPRINT XE control unit is intended for use with powder spray guns of types A-P up to 2 mJ in accordance with the type examination PTB 12 ATEX 5001.
Incorrect use! Risk of injury and damage to the device. 4 Only connect original WAGNER spray guns to the EPG-SPRINT XE control unit. 4 The PEM-C3R and PEM-T3R manual spray guns must not be connected to the EPG- SPRINT XE control unit.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 3 Identification 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 FM Control Document [8 67].
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 4 Basic Safety Instructions 4 BASIC SAFETY INSTRUCTIONS 4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR 4 Keep this operating manual at hand near the device at all times. 4 Always follow existing regulations concerning occupational safety and accident prevention regulations.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 4 Basic Safety Instructions 4 Protective clothing including gloves, must correspond to EN 1149-5. The measured insulation resistance must not exceed 100 MΩ. 4 Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the spray booth.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 4 Basic Safety Instructions 4 For sufficient health and environmental protection, only operate the device with technical ventilation (extraction) switched on. 4.2.2 Safe Handling of WAGNER Powder Spray Devices Danger due to dust formation! 4 Do not point spray guns at people.
4.2.7 Maintenance and Repair Danger due to improper maintenance and repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a specially trained person may carry out repairs and replace parts. Order number 2354913 | Edition 10/2022...
4 Use only WAGNER original spare parts and accessories. 4 WAGNER assumes no liability for changes to the product made by the operating company without the knowledge of WAGNER. Any adjustments to the documentation and the market release are the responsibility of the operating company.
Page 17
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 4 Basic Safety Instructions Follow the instructions in the operating Wear electrostatically conductive manual! footwear! Order number 2354913 | Edition 10/2022...
5 DESCRIPTION 5.1 APPLICATIONS The EPG-SPRINT XE control unit can be used as a stand-alone unit in manual coating systems or with an automatic coating device. – When a Corona gun is connected, the Corona current scale and the high-voltage supply and control unit are active.
Page 19
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 5 Description Pneumatic: Input air pressure 0.6 – 0.8 MPa; 6 – 8 bar; 87 – 116 psi Air flow maximum 15 m Sum of dosing and feed air 1 – 6 m Gun air 0.05 – 4.0 m Required compressed air quality as per 6.5.2...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 5 Description 5.4 OPERATING ELEMENTS 5.4.1 Operating Elements on Front Side 20 22 21 m /h Co r Ø µA 10 0 SP R IN T X P_01743 29 31...
Page 21
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 5 Description 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]...
Page 22
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 5 Description – Adjusting range: 0.05 – 4 m – Resolution: 0.05 m 22 LED display [Total air] – Lights up yellow, when the setting [Total air] is selected 23 LED display: [Atomizing, ionizing and Tribo air] –...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 5 Description – 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] –...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 6 Assembly and Commissioning 6 ASSEMBLY AND COMMISSIONING 6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL – The assembly and commissioning personnel must have the technical skills to safely commission the device.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 6 Assembly and Commissioning 6.4 CONNECTING THE MANUAL GUN Corona or Tribo spray gun Electrical connection cable Compressed air main supply (0.6 – 0.8 MPa; 6 – 8 bar; 87 – 116 psi) Hose diameter: 8 mm; 0.315 inch Atomizing or Tribo air, transparent...
Page 27
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 6 Assembly and Commissioning Powder injector Powder feed, e.g., from the powder tank Feed air, red 10 Grounding cable to the signal ground 11 Mains input terminal 12 EPG-Sprint X: mains output terminal (no application)
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 6 Assembly and Commissioning Powder injector Powder feed, e.g., from the powder tank 10 Feed air, red 11 Grounding cable to the signal ground 12 EPG-Sprint X: mains output to next control unit...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 6 Assembly and Commissioning 6.6.1 Grounding the powder coating system P_01120 Only use mains cables with grounding strand! Connect grounding cable with booth or spray wall and signal ground!
4 commissioning is carried out in accordance with chapter Assembly and Commissioning [8 25]. 7.2.2 Operating Modes The EPG-SPRINT XE supports the following operating modes (from software version B200): – Manual gun mode (manual system with vibrator control) – Manual gun mode with external control (remote interface with external release (required for coating and cleaning) and for external control of cleaning function) –...
4 Do not operate the spray gun's trigger while the control unit is being switched on and is powering up. The EPG-SPRINT XE 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.
[standard, medium, soft] The EPG-SPRINT XE 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 control dial (24). All recipes can be adapted and stored by the user to suit individual requirements.
7.4 AIR HIGH OUTPUT MODE (HIGH POWDER DISCHARGE) With the EPG-SPRINT XE, 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.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation 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.
Page 36
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation m /h Ø µA SP RI N T X P_05016 2. Press [Characteristic slope] button (31) and hold it down. 3. Turn the universal control dial (24) with the other hand until the LED display (19) shows the number 10.
Page 37
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation µA SP RI N T X P_05018 6. The value set for parameter C17 is displayed by pressing the [Characteristic slope] button (31) on the LED display (19).
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation 9. To exit the configuration mode, press the [Standby] button (15) twice. The control unit is now in the operating mode with high powder feed switched on. This setting is global and applies in all recipes.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation Recipes 5 – 50 can be indirectly selected and saved. First press the [Additional recipes] push button (25). The yellow [Additional recipes] LED (26) then lights up and the LED display (19) indicates the current recipe number.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation m /h Ø SP RI N T X P_01751 2. The total air volume can now be set using the universal control dial (24) between 1 – 6 m /h with a resolution of 0.05 m...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation m /h Ø SP RI N T X P_01752 2. The powder quantity can now be set using the universal control dial (24) between 0 – 100% with a resolution of 1%. The value is shown in the LED display (19).
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation m /h Ø SP RI N T X P_01753 2. The additional air volume can now be set using the universal control dial (24) between 0.05 – 4.0 m /h with a resolution of 0.05 m /h.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation m /h Ø µA SP RI N T X P_01754 2. The high voltage can now be set using the universal control dial (24) between 10 – 100 kV with a resolution of 1 kV. The value is shown in the LED display (19).
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation 7.6.6 Setting the Current Limitation m /h Ø µA SP RI N T X P_05023 1. Press the [Current limitation] push button (29) to adjust the limitation of the spray current.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation m /h Ø µA SP RI N T X P_01757 4 Press the [Current limitation] push button (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.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation 120 µA P_01768 U [kV] 100 kV Soft Medium Standard High voltage Spray current The properties of the various characteristic curves and their use are described on the following page.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation 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 Chapter Appendix Device Configuration [8 68]).
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation 7.7.4 Procedure for Cleaning Flushing with Automatic Guns m /h Ø SP RI N T X P_01759 1. End coating operation. 2. Remove powder suction unit (suction lance, powder injector) from powder tank.
Page 49
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation m /h Ø SP RI N T X P_01769 If no powder is fed at 0%: 1. Press [Powder quantity] push button (36) for around 2 seconds. The [Powder quantity] LED (37) flashes rapidly, the [Powder quantity display] (33) flashes.
Page 50
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 7 Operation DL Dosing air FL Feed air Powder Starting output 1.00 4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 P_02368 DL Dosing air FL Feed air Powder...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 8 Cleaning and Maintenance 8 CLEANING AND MAINTENANCE 8.1 CLEANING 8.1.1 Cleaning Personnel Cleaning work should be undertaken regularly and carefully by qualified and trained personnel. They should be informed of specific hazards during their training.
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a specially trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 9 Troubleshooting and Rectification 9 TROUBLESHOOTING AND RECTIFICATION DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 WAGNER devices, protective systems and safety, monitoring and control equipment may only be serviced/repaired as defined in Directive 2014/34/EC (ATEX) by trained...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 9 Troubleshooting and Rectification Warning No. Warning Cause Rectification System cannot reach target set- Check hoses and hose laying ting Feed air too low Set point cannot be reached...
Page 55
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 9 Troubleshooting and Rectification Fault number Malfunction Cause Rectification Ground monitoring Grounding cable is inter- Check/replace gun cable rupted Check/replace gun Gun is not connected Connect gun No coil current/cas-...
Page 56
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 9 Troubleshooting and Rectification Fault number Malfunction Cause Rectification The air supply to the control unit Input pressure > 6 bar Injector is not connected Connect injector Compressed air switched off Open compressed air...
Page 57
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 9 Troubleshooting and Rectification Fault number Malfunction Cause Rectification No general release Extraction in ECO-mode or Activate coating release on from IPS for coating switched off (only for EPG-Sprint...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 10 Inspections in Accordance with DIN EN 50177: 2009 10 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2009 If the system is used for electrostatic coating with ignitable coating powders, the test must be performed in accordance with EN 50177:2009+A1:2012 according to the following...
10.2 OVERVIEW TABLE Section Type of inspection Requirements Inspection Type of inspection Inspection in- terval Checking the effectiveness Checking the effectiveness of technical ventila- TP/SP Continuously of technical ventilation tion Measurements of air flow speed/ air quantities Check the differential pressure in- dicator.
Page 60
Section Type of inspection Requirements Inspection Type of inspection Inspection in- terval Ground leaking resistance The ground leaking resistance of the attachment ME/CM Weekly from the work piece attach- point of every work piece may be 1 megohm at Measure the ground leaking resis- ment point most (measuring voltage must be 500 V or tance (ground potential of the...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 11 Inspections in Accordance with DIN EN 50050-2: 2013 11 INSPECTIONS IN ACCORDANCE WITH DIN EN 50050-2: 2013 If the system is used for electrostatic coating with ignitable coating powders, the test must be performed in accordance with DIN EN 50050-2: 2013 according to the following Overview...
11.2 OVERVIEW TABLE Section Type of inspection Requirements Inspection Type of inspection Inspection in- terval Ground leaking resistance The resistance to ground of the hold point of ev- ME/CM Weekly from the work piece attach- ery work piece may be 1 MΩ at the most (mea- Measure resistance to ground ment point suring voltage must be 1000 V).
4 WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way.
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a specially trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.
Page 66
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 14 Spare Parts ♦ = wearing parts Order number 2354913 | Edition 10/2022...
0102 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: 2327595 15.2 FM CONTROL DOCUMENT Identification: FM Control Document The FM Control Document is enclosed with this product.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 16 Appendix Device Configuration 16 APPENDIX DEVICE CONFIGURATION m /h Ø µA SP RI N T X P_05015 1. To access special device configuration, switch the device to [Standby] with the [Standby] button (15).
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 department and the fourth group is reserved for WAGNER production sites or the WAGNER service center, which have the necessary infrastructure.
Page 70
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 16 Appendix Device Configuration µA SP RI N T X P_01762 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 [Flushing] LED (18) will flash.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 16 Appendix Device Configuration µA SP RI N T X P_05026 4 If you want to save the changed setting, press the [Additional recipes] button (25) to save the setting until the blue [Flushing] LED (18) no longer flashes. The LED display (19) then shows the parameter number again (in this example, C11).
Page 72
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 16 Appendix Device Configuration µA SP RI N T X P_05027 27 29 µA SP RI N T X P_05028 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) and the [Current limitation] button (29) to set the parameter to C13.
Page 73
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 16 Appendix Device Configuration 4 ON with lock activated. No program values can be adjusted when the lock is activated. µA SP RI N T X P_05029 5. There are now two options: 4 If you want to keep the old setting, regardless of what is currently displayed, press the [Characteristic slope] button (31) again.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 16 Appendix Device Configuration 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.
Page 75
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 16 Appendix Device Configuration Parameter Value Description External recipe selection The recipe is selected using 4 different pulse lengths to select recipes 1 – 4. (Pulse controller using (factory setting) This setting is compatible with the master remote control bush) controller.
Page 76
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 16 Appendix Device Configuration Parameter Value Description Hose flushing (dosing air with- Hose flushing switched off. out feed air) (factory setting) 1 s - 10 s Hose flushing after-run time in seconds.
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 17 Brief description 17 BRIEF DESCRIPTION 17.1 OPERATING ELEMENTS m /h Ø µA SPRINT X P_01766 Recipes Electrostatic parameters Air parameters Selection/display elements [Standby] button To switch into standby mode...
Operating manual Universal Control Unit for Powder Spray Guns EPG-SPRINT XE 17 Brief description 17.2 OPERATION OF THE CONTROL UNIT 1 Changing Parameters 1. Use selection button to select the parameters required. ð The yellow LED lights up. 2. Set parameter value with control dial.
Page 80
Order number 2354913 Edition 10/2022 Switzerland Wagner International AG Industriestrasse 22 CH-9450 Altstätten Telephone: +41 (0)71 757 2211 Fax: +41 (0)71 757 2222 Germany J. Wagner GmbH Otto-Lilienthal-Strasse 18 Postfach 1120 D-88677 Markdorf Telephone: +49 (0)7544 5050 Fax: +49 (0)7544 505200 E-mail: ts-powder@wagner-group.com More contact addresses on the internet at: www.wagner-group.com Subject to changes without notice...
Need help?
Do you have a question about the EPG-SPRINT XE and is the answer not in the manual?
Questions and answers