Table of Contents
Advertisement
Quick Links
A t o
m i z
Z e r
i n g
s t ä
a i r
u b e
r l u f
t
F a n
a i r
F o r
m l u
f t
Control unit for electrostatic spray guns
EPG 5000
Original Operating Manual
II (2) G
For professional use.
Always observe the information in this manual, particularly the safety
instructions and the warning instructions. Store the manual in a safe place.
8 0
R 1
6 0
1 0 0
4 0
8 0
R 2
A u
t o
3 0
6 0
2 0
4 0
R 3
1 0
2 0
E X T
U [ k
1 0
V ]
F l u
s h
I [ µ
A ]
S p r
a y
S p r
a y
E P G
5 0 0
0
B_05549
Edition: 12/2021
Advertisement
Table of Contents
Related Manuals for WAGNER EPG 5000
Summary of Contents for WAGNER EPG 5000
- Page 1 S p r E P G B_05549 5 0 0 Control unit for electrostatic spray guns EPG 5000 Original Operating Manual II (2) G For professional use. Always observe the information in this manual, particularly the safety instructions and the warning instructions. Store the manual in a safe place.
-
Page 3: Table Of Contents
Operating manual Control unit for electrostatic spray guns EPG 5000 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 Control unit for electrostatic spray guns EPG 5000 Table of Contents Assembly Grounding Start up Ventilation of the Spray Booth 6.10 Verifying a Safe Operational Condition Operation Training the Operating Personnel Tasks 7.2.1 Emergency Deactivation Starting Up the Control Unit Setting and Saving Recipes 7.4.1...
-
Page 5: About These Instructions
Operating manual Control unit for electrostatic spray guns EPG 5000 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. -
Page 6: Languages
Operating manual Control unit for electrostatic spray guns EPG 5000 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 7: Using In Accordance With The Instructions
(control air, shaping air, atomizing air). The EPG 5000 may only be operated together with the above-mentioned spray guns. If the control unit is operated in combination with devices other than the above-mentioned spray guns, the CSAE authorization (type examination) ceases to be valid. -
Page 8: Identification
Operating manual Control unit for electrostatic spray guns EPG 5000 3 Identification 3 IDENTIFICATION 3.1 EXPLOSION PROTECTION IDENTIFICATION The control unit, together with the spray gun, is designed as defined by statutory requirement SI 2016/1107. The control unit must be placed outside the explosion-hazard area. -
Page 9: Type Plate
Operating manual Control unit for electrostatic spray guns EPG 5000 3 Identification Cleaning If there are deposits on the surfaces, the device may form electrostatic charges. Flames or sparks can form during discharge. 1. Remove deposits from the surfaces to maintain conductivity. -
Page 10: Basic Safety Instructions
Operating manual Control unit for electrostatic spray guns EPG 5000 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 statutory provisions concerning occupational safety and accident prevention regulations. -
Page 11: Personnel Qualifications
Operating manual Control unit for electrostatic spray guns EPG 5000 4 Basic Safety Instructions 4 Make sure that all people within the work area wear static dissipative shoes. The footwear must correspond to BS EN ISO 20344:2011. The measured insulation resistance must not exceed 100 MΩ. -
Page 12: Safe Handling Of Wagner Spray Devices
4 In the event of functional faults, remedy the fault as described in the chapter on troubleshooting and rectification. 4 If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER service technician) at least every 12 months for their work-safe condition in accordance with DGUV regulation 100-500 chapter 2.29 and chapter 2.36. -
Page 13: Product Hoses
Operating manual Control unit for electrostatic spray guns EPG 5000 4 Basic Safety Instructions 4 Wear static dissipative gloves when spraying. The grounding takes place via the spray gun's handle or its trigger. 4.2.4 Product Hoses Danger due to bursting of product hose! The product hose is under pressure and may cause dangerous injuries. -
Page 14: Touching Hot Surfaces
Danger due to improper maintenance and repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel. -
Page 15: Protective And Monitoring Equipment
Operating manual Control unit for electrostatic spray guns EPG 5000 4 Basic Safety Instructions 4 Switch off the energy and compressed air supply. 4 Disconnect the control unit from the mains. 4 Observe the operating and service manual for all work. -
Page 16: Description
Operating manual Control unit for electrostatic spray guns EPG 5000 5 Description 5 DESCRIPTION 5.1 COMPONENTS The EPG 5000 control unit, together with the matching automatic spray guns and other components, form an electrostatic spraying system. 5.2 FUNCTIONING The EPG 5000 control unit supplies the control voltage for the spray gun, in which high voltage is subsequently produced. -
Page 17: Dimensions
Operating manual Control unit for electrostatic spray guns EPG 5000 5 Description Description Values Protection class IP 40 Weight (without cables) 6.7 kg; 14.77 lb Operating temperature range 0 °C – 40 °C; 32 °F – 104 °F Input air pressure 6–8 bar; 0.6–0.8 MPa; 87–116 psi Compressed air quality: free from oil Quality standard 6.5.2 according to... - Page 18 Operating manual Control unit for electrostatic spray guns EPG 5000 5 Description Universal control dial – Dynamic digital control dial with 32 positions per revolution – Adjustment speed is proportional to rotational speed – Used to adjust high voltage and spray current –...
- Page 19 Operating manual Control unit for electrostatic spray guns EPG 5000 5 Description 19 Pressure gauge [Atomizing air] – Pressure indicator for the atomizing air 20 Push button [Recipe 1] 21 Illuminated display [Recipe 1] – Lights up if recipe 1 is used 22 Push button [Recipe 2] 23 Illuminated display [Recipe 2]...
-
Page 20: Connections On The Rear Side
Operating manual Control unit for electrostatic spray guns EPG 5000 5 Description 5.5.2 Connections on the Rear Side 0102 II (2) G X Air input Atomizing air 0518 Main Switch SIRA 16 ATEX 5290X Lufteingang Zerstäuberluft Hauptschalter CSAE 21 UKEX 5232X... - Page 21 Operating manual Control unit for electrostatic spray guns EPG 5000 5 Description 12 Grounding connection – To connect the signal ground 13 Mains input terminal – Connection for mains cable with safety clip – Warning: Do not disconnect under voltage.
-
Page 22: Assembly And Commissioning
Operating manual Control unit for electrostatic spray guns EPG 5000 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. – When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components. -
Page 23: Location Of The Control Unit
Operating manual Control unit for electrostatic spray guns EPG 5000 6 Assembly and Commissioning 6.5 LOCATION OF THE CONTROL UNIT DANGER Incorrect installation of the device! Explosion hazard and damage to the device. 4 Set up the device outside the spray booth/spray zone. -
Page 24: Grounding
Operating manual Control unit for electrostatic spray guns EPG 5000 6 Assembly and Commissioning GA 5000 EPG 5000 Air input Atomizing air II (2) G Main Switch 0102 Lufteingang Zerstäuberluft Hauptschalter SIRA 16 ATEX 5290X Wagner International AG Industriestrasse 22 CH - 9450 Altstätten... -
Page 25: Start Up
Operating manual Control unit for electrostatic spray guns EPG 5000 6 Assembly and Commissioning – Connect the control unit to the signal ground. – Connect all grounding cables using a short and direct route. – Safety shoes and gloves, if used, must be static dissipative. -
Page 26: Ventilation Of The Spray Booth
Operating manual Control unit for electrostatic spray guns EPG 5000 6 Assembly and Commissioning 5. Check that all air-conveying connections are correctly connected. 6. Visually check the permissible pressures for all the system components. 7. Check the level of the separating agent in the pump and fill up if necessary. -
Page 27: Operation
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation 7 OPERATION 7.1 TRAINING THE OPERATING PERSONNEL – The operating personnel must be qualified to operate the entire system. – The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures. -
Page 28: Setting And Saving Recipes
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation Auto Flush Spray U [kV] I [µA] Spray EPG 5000 B_05707 ð For approx. 1 second, all LEDs light up → Display test B_03294 B_03295 ð In the display, the hardware status and software version are shown briefly, one after the other. -
Page 29: Setting The High Voltage
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation Recipes 1-3 can be selected and saved directly with the program buttons [R1], [R2] and [R3]. Once the recipe required has been called up, the individual coating parameters can be called up and changed using the corresponding selection buttons (see Chapters Setting the High Voltage [8 29], and Setting the Current Limitation [8 30]). -
Page 30: Setting The Current Limitation
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation 7.4.2 Setting the Current Limitation Auto Flush Spray U [kV] I [µA] Spray EPG 5000 B_05711 1. Press the [Current limitation] push button (12) to adjust the limitation of the spray current. -
Page 31: Display During Spraying Mode
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation 7.4.3 Display During Spraying Mode Control unit in standby position Auto Flush Spray U [kV] I [µA] Spray EPG 5000 B_05713 Ready to spray using R2 recipe: The LEDs for the set values light up in the dot display and the value for high voltage, is displayed digitally. -
Page 32: Perform Service Display
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation 1. Briefly press push button (4). ð Illuminated display [Standby] (5) lights up. All the other LEDs go out. Auto Flush Spray U [kV] I [µA] Spray EPG 5000 B_05713 2. -
Page 33: Parameter Overview Of Level 1 For Users
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation 7.7.1 Parameter Overview of Level 1 for Users Parameter Value Description Operating mode The device functions as a standalone device in conjunction Manual gun with a manual gun. - Page 34 Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation Parameter Value Description 2K operation Normal operation (factory set- ting) Manual mode is not possible (2K operation with superordinate control). Automatic mode is not possible (2K system signals are only releases).
-
Page 35: Getting Started In Configuration Mode
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation Parameter Value Description Reduced luminosity of the LEDs. Normal luminosity of the 7-segment display. Reduced luminosity of the LEDs. Reduced luminosity of the 7-segment display. Operation with exter-... - Page 36 For ease of operation the configuration settings are divided into three levels. The first level is for the end user, the other two levels are password protected and reserved for the WAGNER service department and the WAGNER production sites or the WAGNER service center, which have the necessary infrastructure.
-
Page 37: Setting Example For Parameter C11
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation Auto Flush Spray U [kV] I [µA] Spray EPG 5000 B_05719 – Level 1 (20) illuminated display: Parameters [C11] to [C20] (for the end user) – Level 2 (22): Parameters [C21] to [C30] (for WAGNER service department) –... -
Page 38: Operating Hours Counter/Service Display
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation ð The content of [C11] is displayed (32). ð The flashing illuminated display (3) indicates that the parameter value in the display (32) can be changed. 3. Set the parameter value with the universal control dial (1). Possible values in [C11] are [1], [2], [3] or [4]. -
Page 39: Maintenance Counter Set Up And Reading
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation Maintenance menu structure (illuminated display (3) is activated) Push but- Description of display Display of the spray gun's absolute accrued operating hours. Display format: Counter reading < 999 hours: 001 = 1 h; 291 = 291 h Counter reading >... -
Page 40: External Interface
Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation Review counter reading since last service carried out on the spray gun Auto Flush Spray U [kV] I [µA] Spray EPG 5000 B_05725 1. Press the push button (22) briefly. - Page 41 Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation +24V LTV357 +24V LTV357 +24V LTV357 +24V LTV357 +24V LTV357 +24V STN3PF06 +24V STN3PF06 STN3PF06 DIN12 B_05728 In/Out Color Designation Description — — Interface cable — — —...
- Page 42 Operating manual Control unit for electrostatic spray guns EPG 5000 7 Operation In/Out Color Designation Description Green Spraying without Potential-free contact between pin 3 and pin 12 (ground) – Closed → gun switched on (spraying without high high voltage voltage) – Open → gun switched off...
-
Page 43: Cleaning And Maintenance
Operating manual Control unit for electrostatic spray guns EPG 5000 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. -
Page 44: Maintenance Instructions
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably 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 45 Operating manual Control unit for electrostatic spray guns EPG 5000 8 Cleaning and Maintenance Inspection point Inspection Remarks interval Locking of the technical ventilation Annually Chapter Ventilation of the Spray with the electrostatic spraying equip- Booth [8 26] ment The above recommended intervals are maximum values a nd may be modified by the operator depending on the local and operational conditions and the contamination.
-
Page 46: Trouble Shooting And Solution
See operating manual of spray quer Malfunction LED (31) lights up. See the following table See the following table Fault message in display (32) If the problem is not listed above consult your WAGNER Service Center. Auto Flush Spray U [kV] I [µA]... - Page 47 Operating manual Control unit for electrostatic spray guns EPG 5000 9 Trouble shooting and solution Code Malfunction Cause Solution The spray gun is not connected Connect spray gun No coil current/cas- The spray gun is not connected Connect spray gun...
-
Page 48: Repairs
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably 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 49: Disposal
This product may not be disposed of with the household refuse, but must be recycled in an environmentally correct manner. 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. -
Page 50: Accessories
Operating manual Control unit for electrostatic spray guns EPG 5000 12 Accessories 12 ACCESSORIES Order no. Designation 241270 Mains cable for Europe 3 m; 9.8 ft 2330628 Mains cable for Europe 10 m; 32.8 ft 241271 Mains cable for Switzerland 3 m; 9.8 ft 264626 Mains cable for USA 2 m;... -
Page 51: Spare Parts
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably 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 52: Spare Parts List For Epg 5000 Control Unit
Operating manual Control unit for electrostatic spray guns EPG 5000 13 Spare Parts 13.3 SPARE PARTS LIST FOR EPG 5000 CONTROL UNIT 9 10 11 12 13 15 16 26 25 59 60 61 62 B_05734 Order no. Designation 9998614... - Page 53 Operating manual Control unit for electrostatic spray guns EPG 5000 13 Spare Parts Order no. Designation 9998770 Coding ring, blue 9998995 Coding ring, red 2316679 Socket, M12, 5-pin 2359283 CAN plug protective cap 9903311 Recessed head fillister head screw, H form...
- Page 54 Operating manual Control unit for electrostatic spray guns EPG 5000 13 Spare Parts Order no. Designation 9998255 Straight threaded fitting 9900386 Hexagon socket head cap screw 9900308 Hexagon socket head cap screw 2309972 Pressure regulator valve 9971313 O-ring 2335187 Air output, 3-fold...
-
Page 55: Declaration Of Conformity
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: 2360925 Order number 2432003 | Edition 12/2021... -
Page 56: Connection Plans
Operating manual Control unit for electrostatic spray guns EPG 5000 15 Connection Plans 15 CONNECTION PLANS 15.1 GA 5000 EC PNEUMATIC DIAGRAM B_05729 EPG 5000 Product GA 5000EC Control air Inlet air Atomizing air Atomizing air Shaping air Shaping air Nozzle Order number 2432003 | Edition 12/2021... -
Page 57: Ga 5000 Ic Pneumatic Diagram
Operating manual Control unit for electrostatic spray guns EPG 5000 15 Connection Plans 15.2 GA 5000 IC PNEUMATIC DIAGRAM B_05733 EPG 5000 Control air GA 5000IC Nozzle Inlet air Shaping air Product Atomizing air Shaping air atomizing air Order number 2432003 | Edition 12/2021... - Page 58 Operating manual Control unit for electrostatic spray guns EPG 5000 15 Connection Plans Order number 2432003 | Edition 12/2021...
- Page 60 Order number 2432003 Edition 12/2021 United Kingdom Germany Wagner Spraytech (UK) ltd. J. Wagner GmbH Innovation Centre Otto-Lilienthal-Strasse 18 Silverstone Park Silverstone Postfach 1120 NN12 8GX Northants D-88677 Markdorf Telephone: +44 (0) 1327 368 410 Telephone: +49 (0)7544 5050 E-Mail: enquiries@wagner-group.com Fax: +49 (0)7544 505200 E-mail: ts-liquid@wagner-group.com Switzerland Wagner International AG Industriestrasse 22...
Need help?
Do you have a question about the EPG 5000 and is the answer not in the manual?
Questions and answers