Table of Contents
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Universal Control Unit for
Powder Coating Guns
P_01110
EPG
SPRIN T
II 3(2)D IP64 80°C
0102
Original Service Manual
EPG-SPRINT
EPG-SPRINT X
EPG-SPRINT XE
Version 09/2017
50
60
40
m /h
3
Tri
Cor
70
Ø
30
5
120
Tri
100
5.5
3.0
12
80
4
80
4.5
1.5
2x
2x
11
80
3
40
20
60
0.5
10
3.5
20
9
2
40
2.5
0.3
8
90
10
1
10
20
0.1
2.0
μA
kV
100
%
0
%
SPR INT X
EPG
P_01742
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Summary of Contents for WAGNER EPG-SPRINT
- Page 1 Original Service Manual EPG-SPRINT EPG-SPRINT X EPG-SPRINT XE Universal Control Unit for Version 09/2017 Powder Coating Guns m /h Ø μA SPR INT X SPRIN T P_01110 P_01742 II 3(2)D IP64 80°C 0102...
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Page 3: Table Of Contents
Connections on the Rear Side of the EPG-SPRINT Operating Elements of EPG-SPRINT X/EPG-SPRINT XE 5.6.1 Overview of Control Panel Front Side 5.6.2 Connections on the Rear Side of the EPG-SPRINT X 5.6.3 Connections on the Rear Side of the EPG-SPRINT XE... - Page 4 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Table of Contents SPARE PARTS How Can Spare Parts Be Ordered? EPG-SPRINT Control Unit EPG-SPRINT X Control Unit EPG-SPRINT XE Control Unit Resources and Special Tools Handling the Release Tool for the Air Diff user...
- Page 5 17.2 Warranty Claim 17.3 CE Declaration of Conformity EPG-SPRINT 17.4 EC Type Examination Certifi cate EPG-SPRINT 17.5 CE Declaration of Conformity EPG-SPRINT X/EPG-SPRINT XE 17.6 EC Type Examination Certifi cate EPG-SPRINT X/EPG-SPRINT XE 17.7 FM Identifi cation EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE...
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Page 6: General Information
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL GENERAL INFORMATION PREFACE This service manual contains information and instructions for the operation, repair, service and maintenance of the control units. This equipment can be hazardous if it is not operated in accordance with the information provided in this service manual and the corresponding operating manual. -
Page 7: Languages
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL LANGUAGES The service manual is available in the following languages: German 2309349 English 2309350 EPG-SPRINT: The operating manual is available in the following languages: German 2305220 English 2305222 French... -
Page 8: Correct Use
USE IN AN EXPLOSION HAZARD AREA The EPG-SPRINT/EPG-SPRINT X/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 prototype test PTB 06 ATEX 03/ PTB 12 ATEX 5001. -
Page 9: Safety Parameters
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. Only operate the device as a whole. Do not deactivate safety fi xtures. -
Page 10: Residual Risks
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL RESIDUAL RISKS Residual risks are risks which cannot be ruled out even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks. -
Page 11: Identification
EXPLOSION PROTECTION IDENTIFICATION IN ACCORDANCE WITH ATEX The device is suited for use in potentially explosive areas, in accordance with Test Certifi cate PTB 06 ATEX 5003 (EPG-SPRINT) or PTB 12 ATEX 5001 (EPG-SPRINT X/EPG-SPRINT XE). II 3(2)D IP 64 80 °C... -
Page 12: General Safety Instructions
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE 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. -
Page 13: 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 14: Cleaning
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE 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 15: Protective And Monitoring Equipment
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE 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. -
Page 16: Safety Feature Identification
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE 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;... -
Page 17: Description
EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE control unit. The EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE control unit can be used as a stand-alone unit in manual coating systems or can be used, together with other units, in a PrimaTech/ Profi Tech M automatic system. -
Page 18: Technical Data
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL TECHNICAL DATA 5.2.1 EPG-SPRINT Dimensions: Height 136 mm; 5.35 inches Width 270 mm; 10.63 inches Depth (without operating elements) 200 mm; 7.87 inches Weight 3.3 kg; 7.28 lb Electrical:... - Page 19 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 5.2.2 EPG-SPRINT X Dimensions: Height 136 mm; 5.35 inches Width 270 mm; 10.63 inches Depth (without operating elements) 200 mm; 7.87 inches Weight 3.3 kg; 7.28 lb Electrical: Mains (AC)
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Page 20: Epg-Sprint Xe
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 5.2.3 EPG-SPRINT XE Dimensions: Height 136 mm; 5.35 inches Width 270 mm; 10.63 inches Depth (without operating elements) 200 mm; 7.87 inches Weight 3.3 kg; 7.28 lb Electrical: Mains (AC) input terminal... - Page 21 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;...
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Page 22: Permitted Accessories
PERMITTED ACCESSORIES Only the accessories listed in the "Accessories" chapter of the operating manual may be connected to the EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE 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 23: Operating Elements Of Epg-Sprint
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL OPERATING ELEMENTS OF EPG-SPRINT 5.5.1 OVERVIEW OF CONTROL PANEL FRONT SIDE 20 22 23 18 13 EP G SP RIN T P_01111 30 29 31 32 37 35 1 Illuminated display "High voltage"... - Page 24 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 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"...
- Page 25 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 18 LED display: "Flush" – Lights up blue, when the fl ush function is activated 19 LED display: 7 segments, three-digit number – Indicates the exact value depending on the activated function: "Total air volume;...
- Page 26 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 28 LED display: "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 the control dial 24 and is indicated in the LED display 19 –...
- Page 27 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 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% –...
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Page 28: Connections On The Rear Side Of The Epg-Sprint
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 5.5.2 CONNECTIONS ON THE REAR SIDE OF THE EPG-SPRINT 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 29 11 Connection for the CCM Prima – For connecting to the CCM Prima when fi tting 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 Identifi cation –...
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Page 30: Operating Elements Of Epg-Sprint X/Epg-Sprint Xe
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL OPERATING ELEMENTS OF EPG-SPRINT X/EPG-SPRINT XE 5.6.1 OVERVIEW OF CONTROL PANEL FRONT SIDE 20 22 23 18 13 m /h Co r Ø μA 10 0 SP R IN T X... - Page 31 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 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"...
- Page 32 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 18 LED display: "Flush" – Lights up blue, when the fl ush function is activated 19 LED display: 7 segments, three-digit number – Indicates the exact value depending on the activated function: "Total air volume;...
- Page 33 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 28 LED display: "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 the control dial 24 and is indicated in the LED display 19 –...
- Page 34 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 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% –...
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Page 35: Connections On The Rear Side Of The Epg-Sprint X
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 5.6.2 CONNECTIONS ON THE REAR SIDE OF THE EPG-SPRINT X Main switch U max. 22 Vpp Output to gun II 3(2)D Air input 0102 Made in Switzerland Ausgang zur Pistole I max. - Page 36 – To connect a Corona or Tribo gun 11 Remote control connection – For connecting to a higher-level controller 12 Cover of the service connection – For WAGNER service personnel only! 13 Fixations – For screwing to the rack 14 FM Identifi cation...
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Page 37: Connections On The Rear Side Of The Epg-Sprint Xe
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 5.6.3 CONNECTIONS ON THE REAR SIDE OF THE EPG-SPRINT XE Main switch U max. 22 Vpp Output to gun II 3(2)D Air input 0102 Made in Switzerland Ausgang zur Pistole I max. - Page 38 11 Remote control connection – Start/Stop input for automatic spray guns – Wiring see Chapter 13 12 Cover of the service connection – For WAGNER service personnel only! 13 Fixations – For screwing to the rack 14 FM Identifi cation...
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Page 39: 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 40: Epg-Sprint Control Unit
Front display 2304462 Rotary knob for cover, gray 2304461 Rotary knob 2310722 EPG-SPRINT rear panel print complete with sensor hoses 2304487 Print connection cable 2311873 WAGNER proportional valve with O-ring Wearing parts Not part of the standard equipment, but available as a special accessory Up to unit serial number 1119, a round valve body is fi tted. - Page 41 2310723 EPG-SPRINT display print complete without encoder 2311875 Incremental encoder 9955176 Switching power supply 9910522 Knurled nut 2312335 Set of screws for EPG-SPRINT rear wall 9952587 Connector plug STASEI 200 360472 Cover cap 9952586 Socket STAKEI 200 9950330 Safety clip...
- Page 42 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL P_01288 Order No. Designation 2311879 Pressure regulator, 0-116 psi (0-8 bar), preset to 87 psi (6 bar) 9998253 Threaded elbow fi tting 9955628 L plug connection 9999310 Extension piece...
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Page 43: Epg-Sprint X Control Unit
2324581 Front display 2324595 Rotary knob for cover, blue 2304461 Rotary knob 2334230 EPG-SPRINT X rear panel print, complete 2365431 EPG-SPRINT X/XE rear panel print, complete 2304487 Print connection cable 2311873 WAGNER proportional valve with O-ring Order No. 2334230 is no longer available and will be entirely replaced with Order No. 2365431. - Page 44 2-pin rocker switch, complete with rubber sleeve 9952506 Socket 9952585 Socket 9955130 Protective cap 241323 Cover, white 2324730 EPG-SPRINT X rear label (enter serial number manually) Wearing parts Not part of the standard equipment, but available as a special accessory Only available as a set...
- Page 45 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL P_01966 Order No. Designation 2334272 Pressure regulator, preset to 87 psi (6 bar) 9998253 Threaded elbow fi tting 2320486 Air diff user 9999310 Extension piece 9998254 Straight screw-in fi tting...
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Page 46: Epg-Sprint Xe Control Unit
Front display 2353210 Rotary knob for cover, yellow 2304461 Rotary knob 2365431 EPG-SPRINT X/XE rear panel print, complete 2304487 Print connection cable 2311873 WAGNER proportional valve with O-ring Wearing parts Not part of the standard equipment, but available as a special accessory... - Page 47 Socket 9952585 Socket 9955130 Protective cap 241323 Cover, white 2353215 EPG-SPRINT XE rear label (enter serial number manually) 2355060 Relay, 24VDC/30A Wearing parts Not part of the standard equipment, but available as a special accessory Only available as a set...
- Page 48 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL P_01966 Order No. Designation 2334272 Pressure regulator, preset to 87 psi (6 bar) 9998253 Threaded elbow fi tting 2320486 Air diff user 9999310 Extension piece 9998254 Straight screw-in fi tting...
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Page 49: Resources And Special Tools
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL RESOURCES AND SPECIAL TOOLS Description Article No. Application USB/TTL cable for updating 2305858 PC/laptop connection for updating software software Cable adapter 2312065 Transfer cable for connecting diagnosis for the menu items of the... -
Page 50: Handling The Release Tool For The Air Diffuser
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL HANDLING THE RELEASE TOOL FOR THE AIR DIFFUSER Procedure: 1. Place tool part 1 at air diff user. 2. Place tool part 2 at air diff user. 3. Carefully push both parts together. -
Page 51: Repair Work
ORDER NUMBER DOC2309350 SERVICE MANUAL REPAIR WORK PERSONNEL QUALIFICATIONS Only specialist staff trained by WAGNER or WAGNER staff may carry out maintenance or repair work. The following hazards may arise during repair work: – Health hazard from inhaling powder lacquer –... - Page 52 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.
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Page 53: Replacing A Proportional Valve
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL REPLACING A PROPORTIONAL VALVE Procedure: 1. Remove cable 1 from connections. 2. Remove hose 2 from valve. P_01381 3. Unscrew screws 3 and carefully pry out valve. P_01382 4. Mark depth of insertion on both hoses. - Page 54 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 9. Use screws 3 to fasten valve back onto housing. P_01382 10. Insert hose 2 on valve. 11. Attach cable to connections as shown in the diagram below. P_01381...
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Page 55: Replacing The Incremental Encoder
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL REPLACING THE INCREMENTAL ENCODER Procedure: 1. Use side cutter to cut through connection wires. This makes it easier to unsolder the individual wires from the print. P_01385 2. Remove cover from rotary knob 1. -
Page 56: Replacing The Display Print
If a print (Order No. 2333661) is used, an additional 9 spacer sleeves (Order No. 2324703) must be used. Variant 2 with clip and locknut (order No. 2333661) This part can be used in EPG-SPRINT and in EPG-SPRINT X. Locknut Housing wall thickness 1.5 mm... -
Page 57: Parameters For Service Purposes
If an air valve incurs water or oil damage, it cannot be repaired by recalibrating it. It must fi rst be cleaned or replaced. Recalibration undertaken inaccurately or with unsuitable measuring equipment may quickly be outside the tolerance established by WAGNER. In such cases, it is better not to undertake calibration. -
Page 58: Test Parameters
"AFA" Calibrate air outlets: Indication of off set values, calibrate and manually adjust the correction factors, check air controllers individually "rES" Master reset: Reset entire EEPROM to WAGNER's default setting "HVA" High-voltage calibration "AFo" Default setting of off set for air channels This is a default setting that must be performed in case of a sensor or PCB replacement. -
Page 59: Accessing The Service Level (C31-C34)
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL ACCESSING THE SERVICE LEVEL (C31-C34) μA SP RI N T X P_01271 P_01830 Procedure: 1. Press "Standby" button 15. The yellow "Standby" LED 16 lights up. 2. Press “Characteristic Slope“ button 31 and hold it down. -
Page 60: Accessing And Adjusting Parameter Value
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL ACCESSING AND ADJUSTING PARAMETER VALUE Example: Accessing test LED "C33" μA SP RI N T X P_01271 P_01830 Procedure: 1. Access parameter C33 (refer to Chapter 8.3 for procedure). -
Page 61: Service Level
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL SERVICE LEVEL PARAMETER C31, CHECKING AIR OUTLETS Purpose: – To check AFC channels with an air fl ow measuring device – To display calibration values and check the air volume controller... - Page 62 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL μA SP RI N T X P_01271 P_01830 Procedure: 1. Access parameter C31 (refer to Chapter 8.3 for procedure). 2. Press the "Characteristic Slope" button 31. "no" is displayed on LED display 19.
- Page 63 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Step Display Description Possible values e.g., 262 High-gain off set 200-700 e.g., 23 Low-gain off set 2-100 0.00 Use rotary controller 24 to set value and compare 0.00 to 6.00 with measuring device.
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Page 64: Parameter C34, I/O Test (Input And Output)
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL The comparison measurement should be within 0.2 m³/h of the limit position. If the values are too far apart or once a valve has been replaced, the device can be recalibrated (see parameter C42, chapter 10.4). - Page 65 SERVICE MANUAL Test of gun remote control: (only for manual gun PEM-X1 in conjunction with EPG-SPRINT X or EPG-SPRINT XE control unit) 7. If the remote control button "Powder +" is pressed, the "Corona" LED 4 lights up. 8. If the remote control button "Powder -" is pressed, the "Tribo" LED 3 lights up.
- Page 66 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Note: This test can also be used as a function test for the gun cable. If the ground monitoring circuit is interrupted, the LED bar 1 does not light up. A loose connection in the plug or gun connection can also be detected by moving the cable.
- Page 67 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Testing the 2 outputs of the CCM bushing for remote control: 1. If the input test functions as described above, the output for pin 4 is fi ne. 2. Press "Atomizing Air" button 21; a fault is triggered in the CCM (red lamp lights up).
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Page 68: Plant Level
PLANT LEVEL 10.1 PLANT LEVEL PARAMETERS DANGER Incorrect calibration! ATEX/FM approval ceases to apply. Only allow a technical expert from a tested WAGNER service department to undertake calibration. The following parameters are available at plant level: Parameter Display Description "PrE"... -
Page 69: Accessing The Plant Level Parameters
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 10.2 ACCESSING THE PLANT LEVEL PARAMETERS μA SP RI N T X P_01271 P_01830 Procedure: 1. Press "Standby" button 15. The yellow "Standby" LED 16 lights up. 2. Press “Characteristic Slope“ button 31 and hold it down. -
Page 70: Parameter C41, Measuring And Calibrating Operating Pressure
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 10.3 PARAMETER C41, MEASURING AND CALIBRATING OPERATING PRESSURE Purpose: – To test the operating pressure and internal preliminary pressure controller Note: We would only recommend adjusting the preliminary pressure controller in the event of major deviations due to a diffi cult installation position. -
Page 71: Parameter C42, Calibrating Air Outlets
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Switch off the input pressure to vent the system. Press "High-voltage" button 27 to access step 2. Step 2: The dosing air valve is opened and the system's residual air is blown out. - Page 72 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL μA SP RI N T X P_01271 P_01830 Procedure: 1. Access parameter C42 (refer to Chapter 10.2). 2. Press the "Characteristic Slope" button 31. "no" is displayed on LED display 19.
- Page 73 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Step Display Description Possible values e.g., 263 High-gain off set is determined automatically. 200-700 e.g., 23 Low-gain off set is determined automatically. 2-100 0.0-100% Turn rotary controller 24 clockwise until 1.00 m³/h is External measuring device displayed on the external measuring device.
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Page 74: Parameter C43, Master Reset
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 10.5 PARAMETER C43, MASTER RESET Purpose: – To reset all values in the memory. All air and high-voltage calibration values, all recipes and confi guration values are reset to a basic value. -
Page 75: Parameter C44, High-Voltage Calibration
PARAMETER C44, HIGH-VOLTAGE CALIBRATION DANGER Incorrect calibration! ATEX/FM approval ceases to apply. Only allow a technical expert from a tested WAGNER service department to undertake calibration. Purpose: – To check internal off set values and calibrate the maximum operating voltage for high-voltage production –... - Page 76 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL EP G SPR INT P_01291 Procedure: 1. Insert the gun simulation (order No. 2312448). 2. Switch the unit on at the main power switch. An automatic gun is being recognized.
- Page 77 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Step Display Description Possible values e.g., 532 Spray current off set value 200-700 e.g., 0 Coil current off set value 0-100 e.g., 7 Use rotary controller 24 to calibrate to maximum of 21 V 16.5 - 22.5 V on multimeter New correction is saved to the memory.
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Page 78: Parameter C45, Default Setting Of Offset For Air Channels
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 10.7 PARAMETER C45, DEFAULT SETTING OF OFFSET FOR AIR CHANNELS Purpose: In standard operation of the unit, it automatically performs a repeating off set correction (automatic off set correction) of the air channels. But it can be performed only in certain limits, otherwise it triggers a fault message. - Page 79 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 6. The "High-voltage" button 27 and "Current Limitation" button 29 can now be used to select the steps according to the following table. The display of the step number is done by the number of illuminated LEDs on the "High voltage"...
- Page 80 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Procedure for the check: 7. Perform the preparation. Preselect the corresponding channel. 8. Select step 2 by pressing the "High-voltage" button 27. 9. The display value on LED display 19 must be compared with the limits in the previous table.
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Page 81: Measuring Equipment
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL MEASURING EQUIPMENT The quality and accuracy of the measuring equipment ultimately determines the calibration accuracy. If this quality measuring equipment is not available or if it is not correctly used, the EPG control units should not be calibrated. -
Page 82: High-Voltage Measuring Device
SERVICE MANUAL 11.3 HIGH-VOLTAGE MEASURING DEVICE High-ohm high-voltage measuring device such as the WAGNER HV200 tester is needed for the high voltage measurement. The internal resistance should be at least 20 Gohm such that a measuring current of maximum 5 μA is possible. -
Page 83: Extended Interface For Remote Control
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL EXTENDED INTERFACE FOR REMOTE CONTROL The "Remote Control" interface changes the assignments of the signals depending on the operating mode. EPG-Sprint / X 24VDC Interface with Interface with internal supply external supply 6.6k... -
Page 84: Manual Gun With External Control
SERVICE MANUAL 12.3 MANUAL GUN WITH EXTERNAL CONTROL (Function possible only for EPG-SPRINT X starting with software version B200/C200) The operating mode must be selected specifi cally via confi guration parameter C26. Hardware interface/signal description: Pin 1 = fault output 24 VDC/300 mA maximum Pin 2 = cleaning input ON/OFF 24 VDC/3.3 mA (high level: continuous fl ushing ON) -
Page 85: Selection With Transfer Protocol
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 12.4.2 SELECTION WITH TRANSFER PROTOCOL A simple serial protocol is used to transfer a 6-bit piece of information. First, a start sequence must be transmitted, followed by the 6 data bits and a stop sequence. The MSB is transmitted as the fi rst data bit. - Page 86 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Example for accessing recipe 11 If recipe 11 is to be selected by way of example, the 0 0 1 0 1 1 data bit combination must be transferred.
- Page 87 Attention: The higher-level controller must ensure that no high-voltage module was switched on in the system 10 seconds before calling up the command! The exact application is described in more detail in the appendix of the EPG-SPRINT X operating manual.
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Page 88: Block Diagrams
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL BLOCK DIAGRAMS... - Page 89 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL...
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Page 90: Further Error Messages
DANGER Incorrect maintenance/repair! 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/EU (ATEX) by trained WAGNER service personnel or capable persons in accordance with TRBS 1203! - Page 91 7. Workpiece and control unit earthed correctly as specifi ed 8. Only a WAGNER gun is approved 9. If all points have been checked, the whole gun can be replaced as a quick test.
- Page 92 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL Error code E24 Read error from internal ADC Fault rectifi cation: Replace the rear panel circuit board Error code E25 Processor safety monitoring is triggered Fault rectifi cation: Replace the rear panel circuit board...
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Page 93: Software Update
SERVICE MANUAL SOFTWARE UPDATE The software for the EPG-SPRINT/EPG-SPRINT X and EPG-SPRINT XE control unit can be updated using a PC/laptop with a USB connection. Please follow the steps listed below to install the hardware and software needed on your PC/laptop. - Page 94 Connecting cable to EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE: Attention! 4. Before connecting the programming cable to the EPG-SPRINT/EPG-SPRINT X/ EPG-SPRINT XE, switch off the control unit using its main switch. 5. Connect the 24-pin connection piece to the control unit as shown below.
- Page 95 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 7. Copy the folder containing the MicroBoot program to any location on your PC/ laptop. You can obtain the MicroBoot program for loading the software from the service department in Markdorf.
- Page 96 ORDER NUMBER DOC2309350 SERVICE MANUAL P_01368 13. Select the EPG-SPRINT fi le you received from the service department in Markdorf. 14. Once you have clicked on "Open", the update starts immediately. Update progress is shown in a bar display. P_01369 15.
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Page 97: Software History
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL SOFTWARE HISTORY 16.1 EPG-SPRINT Software version Introduced from Modifi cation/Description A100 July 2009 First serial version A101 August 2009 Changes in the calibration menu (confi guration parameter "C41" and "C42") -
Page 98: Epg-Sprint Xe
Introduced Modifi cation/Description from B195 March 2012 First version of EPG-SPRINT X B200 December 2012 1. New operating mode: Manual gun in automatic system network C200 (new confi guration parameter C26 and new fault message E60) 2. Spray current measurement plausibility check... -
Page 99: 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 100: Ce Declaration Of Conformity Epg-Sprint
0102 EC Certifi cate of Conformity The CE certifi cate 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 2305227... -
Page 101: Ec Type Examination Certificate Epg-Sprint
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 17.4 EC TYPE EXAMINATION CERTIFICATE EPG-SPRINT... - Page 102 EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL...
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Page 103: Ce Declaration Of Conformity Epg-Sprint X/Epg-Sprint Xe
0102 EC Certifi cate of Conformity The CE certifi cate 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/EPG-SPRINT XE 2327595... -
Page 104: Ec Type Examination Certificate Epg-Sprint X/Epg-Sprint Xe
EPG-SPRINT / EPG-SPRINT X VERSION 09/2017 ORDER NUMBER DOC2309350 SERVICE MANUAL 17.6 EC TYPE EXAMINATION CERTIFICATE EPG-SPRINT X/EPG-SPRINT XE... -
Page 105: Fm Identification Epg-Sprint/Epg-Sprint X/Epg-Sprint Xe
SERVICE MANUAL 17.7 FM IDENTIFICATION EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE The EPG-SPRINT/EPG-SPRINT X and EPG-SPRINT XE control unit is FM approved in the USA and Canada using confi guration drawing No. 2309729. CERTIFICATE OF CONFORMITY HAZARDOUS (CLASSIFIED) LOCATION ELECTRICAL EQUIPMENT PER US REQUIREMENTS... - Page 106 Spray Systems and Trolleys. PEM-X, PEM-X1-CG, PEM-C4-Hicoat FM and PEM-C4- ERGO FM Manual Applicators. PEA-C4-HiCoat FM and PEA-C4XL-HiCoat FM Automatic Applicators. EPG-Sprint X, EPG-Sprint XE, EPG-Sprint FM, EPG- S2 FM, EPG-Prima and EPG-2008 Control Units. Name of Listing Company: Wagner International AG...
- Page 108 Order No. 2309350 Version 09/2017 Germany 88677 Phone Telefax E-mail ts-powder@wagner-group.com Switzerland Wagner International AG 9450 Phone Telefax More contact addresses on the internet at: Company/Locations/WAGNER worldwide Subject to changes without notice...
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