WAGNER EPG S2 Operational manual

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

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EPG S2
OPERATING MANUAL
VERSION 09/2017 ORDER NUMBER DOC2317574
Table of Contents
1 GENERAL 5
1.1 Preface 5
1.2 Warnings, Notices and Symbols in these Instructions 5
1.3 Languages 6
1.4 Abbreviations 6
2 CORRECT USE 7
2.1 Device Type 7
2.2 Type of Use 7
2.3 Use in an Explosion Hazard Area 7
2.4 Safety Parameters 8
2.5 Reasonably Foreseeable Misuse 8
2.6 Residual Risks 8
3 IDENTIFICATION 9
3.1 Explosion Protection Identication 9
3.2 Permissible Device Combinations 9
4 GENERAL SAFETY INSTRUCTIONS 10
4.1 Safety Instructions for the Operator 10
4.1.1 Electrical Devices and Equipment 10
4.1.2 Personnel Qualications 10
4.1.3 Safe Work Environment 10
4.2 Safety Instructions for Sta 11
4.2.1 Safe Handling of WAGNER Powder Spray Devices 11
4.2.2 Grounding the Device 11
4.2.3 Product Hoses 11
4.2.4 Cleaning 12
4.2.5 Handling Powder Lacquers 12
4.3 Protective and Monitoring Equipment 13
4.4 Safety Feature Identication 14
5 DESCRIPTION 15
5.1 Fields of Application, Correct Use 15
5.2 Technical Data 16
5.3 Permitted Accessories 18
5.4 Scope of Delivery 18
5.5 Display and Operating Elements 19
5.5.1 Display Elements, Front Side 19
5.5.2 Connections on the Rear Side of the EPG S2 20
5.5.3 Connections on the Rear Side of the EPG S2 FM 22
5.5.4 CAN Bus Connection on the Rear Side 23
6 ASSEMBLY AND COMMISSIONING 24
6.1 Training Assembly/Commissioning Sta 24
6.2 Storage Conditions 24
6.3 Installation Conditions 24
6.4 Connecting the Automatic Spray Guns 25
6.5 Connecting the Manual Guns 26
6.6 Connection Diagram in the Rack 27

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6.7 Grounding 28
6.7.1 Grounding the Powder Coating System 30
6.8 Device Settings 31
6.8.1 CAN Bus Baud Rate Setting 31
6.8.2 CAN Bus Node ID Setting 32
7 OPERATION 33
7.1 Training the Operating Sta 33
7.2 Safety Instructions 33
7.3 Controllable Spray Guns 34
7.4 Gun Cable Lengths 34
7.5 Control Functions on EPG S2 Control Unit 35
7.5.1 Setting the High Voltage 35
7.5.2 Setting of Current Limiting 36
7.5.3 Settings of High-voltage Characteristic 37
7.5.4 Setting the Air Volume 38
7.5.5 Air Supply Pressure 38
7.6 Diagnosis and Monitoring 39
7.6.1 LED Displays 39
7.7 Emergency Operation 40
7.7.1 Activation of Emergency Mode 40
7.7.2 Functioning of the Emergency Mode 40
8 CLEANING AND MAINTENANCE 41
8.1 Cleaning 41
8.1.1 Cleaning Sta 41
8.1.2 Safety Instructions 41
8.1.3 Cleaning Procedures 42
8.2 Maintenance 43
8.2.1 Maintenance Sta 43
8.2.2 Safety Instructions 43
8.2.3 Maintenance Procedures 44
9 INSPECTIONS ACCORDING TO DIN EN 50177: 2010 45
10 DISASSEMBLY AND DISPOSAL 49
10.1 Disassembly 49
10.2 Disposal 49
11 TROUBLE SHOOTING AND RECTIFICATION 50
11.1 Faults 51
12 ACCESSORIES 52
13 SPARE PARTS 53
13.1 How Can Spare Parts Be Ordered? 53
13.2 EPG S2 Control Unit 54
14 WARRANTY AND CONFORMITY DECLARATIONS 55
14.1 Important Notes Regarding Product Liability 55
14.2 Warranty Claim 55
14.3 CE Declaration of Conformity 56
14.4 EC Type Examination Certicate 57
14.5 FM Identication EPG S2 FM 58

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EPG S2
OPERATING MANUAL
VERSION 09/2017 ORDER NUMBER DOC2317574
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
1 GENERAL
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Note - provides information about particular characteristics and how to proceed.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
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 and service personnel should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.1 PREFACE

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EPG S2
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1.3 LANGUAGES
The operating manual is available in the following languages:
German 2317573 English 2317574
French 2317575 Italian 2317576
Russian 2334207 Chinese 2335799
Hungarian 2338270 Czech 2348860
Spanish 2355652 Danish 2371619
Swedish 2371624 Portuguese 2392066
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
No. Number
Spare part

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EPG S2
OPERATING MANUAL
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2 CORRECT USE
2.1 DEVICE TYPE
Universal control unit for controlling two electrostatic manual or automatic powder spray guns.
2.2 TYPE OF USE
The EPG S2 control unit is intended for controlling electrostatic manual and automatic
powder spray guns of type A-P (2 mJ) according to DIN EN 50177.
2.3 USE IN AN EXPLOSION HAZARD AREA
The EPG S2 control unit are intended for use with powder spray guns of types A-P up to 2 mJ
in accordance with the prototype test PTB 12 ATEX 5001.
The EPG S2 control unit may be used in the dust explosion zone (zone 22) under the
following conditions:
– Control unit correctly tted and connections on rear correctly and securely sealed with
associated cover.
– Not used electrical connections are sealed with protective caps.
Incorrect use!
Risk of injury and damage to the device.
Only connect original WAGNER spray guns to the EPG S2 control
unit.
WARNING

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2.5 REASONABLY FORESEEABLE MISUSE
– Coating work pieces which are not grounded
– Use of defective components and accessories
– Use with non-authorized power spray guns
2.4 SAFETY PARAMETERS
The control unit is only suited for controlling powder spray guns.
Wagner International AG prohibits any other use!
The use of the control unit is only permissible under the following conditions:
– the operating sta have previously been trained on the basis of this operating manual,
– the safety regulations listed in this operating manual are observed,
– the operating, maintenance and repair information in this operating manual is observed,
– and the statutory requirements and accident prevention regulations standards in the
country of use are observed.
The control unit may only be used if all parameters are set and all measurements/safety
checks are carried out correctly.
2.6 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.
Residual risk Source Consequences Specic measures Lifecycle
phase
Skin contact with
powder lacquers
and cleaning
agents
Handling powder
lacquers and
cleaning agents
Skin irritation, allergies Wear protective
clothing
Operation,
observe safety data
sheets
maintenance,
disassembly
Powder lacquer
in air outside the
dened working
area
Lacquering outside
the dened
working area
Inhalation of substances
which are hazardous to
health
Observe work and
operation instructions
Operation,
maintenance

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
The device is suited for use in potentially explosive areas, in accordance withTest Certicate
PTB 12 ATEX 5001.
0102 II 3(2)D IP 64 80 °C
CE: European Communities
0102: Notied body
Ex: Symbol for explosion protection
II: Device class II
3: Category 3 (Zone 22)
(2): Impact on equipment of category 2
D: Ex-atmosphere dust
IP64: Protection class 64
80 °C: Temperature class: maximum surface temperature < 80 °C; 176 °F
3.2 PERMISSIBLE DEVICE COMBINATIONS
The following powder spray guns may be connected to the EPG S2:
Automatic spray guns
– Corona spray gun PEA-C3, PEA-C4
– Corona spray gun PEA-C3XL, PEA-C4XL
– Tribo spray gun PEA-T3
– Tribo spray gun PEA-T3XL
Manual spray guns
– Corona spray gun PEM-C3, PEM-C4 HiCoat, PEM-C4 Ergo,
PEM-X1
Older or other gun types may only be connected to the control unit after rst checking
their suitability with WAGNER.

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EPG S2
OPERATING MANUAL
VERSION 09/2017 ORDER NUMBER DOC2317574
4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts.
Secure the device against being switched back on without authorization. Inform sta
about planned work.
Observe electrical safety regulations.
Theoorin theworking areamust beelectrostatically conductive (measurements according
to EN 1081).
Make sure that all persons within the working area are wearing electrostatic-conductive
shoes.
Ensure that gloves worn are made of conductive material.
The powder release must be electrically interlocked with the powder spray system's
exhaust air equipment.
Excess coating product (overspray) must be collected up safely.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.
Maintain sucient quantities of suitable re extinguishers and ensure that they are
serviceable.
The operating company must ensure that an average concentration of powder lacquer
in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted
concentration of powder to air). If no reliable LEL value is available, the average
concentration must not exceed 10 g/m³.
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident prevention.
Ensure that the device is operated, maintained and repaired only by trained persons.

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EPG S2
OPERATING MANUAL
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4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
4.2.2 GROUNDING THE DEVICE
4.2.3 PRODUCT HOSES
4.2 SAFETY INSTRUCTIONS FOR STAFF
Use only an original WAGNER powder hose.
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
Under no circumstances may anyone tted with active implants (e.g., a pacemaker)
enter the area where the high-voltage eld between the spray gun and the work piece
to be coated builds up!
Do not point spray guns at people.
Before all work on the device, in the event of work interruptions and functional faults:
– Switch o the energy/compressed air supply.
– Secure the spray gun against actuation.
– Relieve pressure on spray gun and device.
– In case of functional faults: Identify and correct the problem, proceed as described in
the "Fault Rectication" chapter.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. This may result in the formation of sparks or ames when discharging.
Ensure that the device is grounded before each coating process.
Ground the work pieces to be coated.
Ensurethatallpersonsinsidetheworkingareaaregrounded,e.g.,bywearingelectrostatically
conductive shoes.
The functionality of grounding cables must be checked regularly (see EN 60204).

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4.2.5 HANDLING POWDER LACQUERS
When preparing or processing the powder and cleaning the device, take note of the
processing regulations laid down by the manufacturer of the powder lacquers being
used.
Take note of the manufacturer’s instructions and the relevant environmental protection
regulations when disposing of powder lacquers.
Implement the prescribed safety measures, in particular the wearing of safety glasses
and safety clothing as well as the use of protective hand cream.
Use a mask or breathing apparatus if necessary.
To ensure sucient protection of health and the environment, only operate the device
in a powder booth or on a spray wall with activated ventilation (exhaust air).
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.
Lock the compressed air supply and decompress the device.
Secure the device against being switched back on without authorization.
Use only electrically conducting and grounded tanks for cleaning uids.
Preference should be given to non-ammable cleaning uids.
Flammable cleaning liquids may only be used if, after switching o the high voltage, all
high-voltage conducting parts are discharged to a discharge energy of less than 0.24 mJ
before they can be accessed.
Most ammable solvents have an ignition energy of around 0.24 mJ or 60 nC.
The cleaning agent's ash point must be at least 15 K above the ambient temperature.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to
remove dust deposits.

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4.3 PROTECTIVE AND MONITORING EQUIPMENT
Protective and monitoring equipment!
Risk of injury and damage to the device.
Protective and monitoring equipment must not be removed,
modied or rendered unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment,
the system must not be operated until these defects are remedied.
WARNING

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EPG S2
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4.4 SAFETY FEATURE IDENTIFICATION
Plates bearing information for the user have been attached to the work openings of the powder
coating booth.
The plate size corresponds to the standard category 100 mm; 3.94 inches.
The label plates, which must be attached, are shown below:
High voltage!
In the control cabinet:
(25 mm; 0.98 inches)
Voltage before main switch
Forbidden for unauthorized
persons!
Explosive atmosphere!
Forbidden for anyone
tted with active implants
(e.g., a pacemaker) must!
Follow the instructions in the
operating manual!
Smoking, re, and open
ames are prohibited!
Wear electrostatically
conductive footwear!
Danger of crushing!
Risk of tripping!
Do not jump on the
booth oor!
Danger of slipping!

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EPG S2
OPERATING MANUAL
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5 DESCRIPTION
5.1 FIELDS OF APPLICATION, CORRECT USE
The EPG S2 control unit is used to supply air and voltage to two WAGNER automatic or
manual powder spray guns, in Corona or Tribo versions.
The control unit has no controls; various operating statuses are simply displayed.
The module is operated with a superordinate controller (e.g. PLC) from which it receives
the necessary information.
The interface between the EPG S2 and master controller takes place by means of the CANopen.
Incorrect use!
Risk of injury and damage to the device.
Only connect original WAGNER spray guns to the EPG S2 control
unit.
WARNING

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EPG S2
OPERATING MANUAL
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Dimensions:
Height 136 mm; 5.35 inches
Width 270 mm; 10.63 inches
Depth (without operating elements) 300 mm; 11.81 inches
Weight 5.5 kg; 12.13 lb
Electrical:
Mains (AC) 90 VAC–250 VAC
Frequency 47 Hz–63 Hz
AC input power maximum 60 W
Output voltage to guns 2x maximum 22 Vpp
Output current 2x maximum 0.9 A
High voltage 2x 10-100 kV (adjustable in 1 kV steps)
Corona current limitation 5 μA - 120 μA (adjustable in 1 μA steps)
Tribo current measurement 0 μA - 20 μA (resolution 0.1 μA)
Minimum Tribo current limit 0 μA - 5 μA (adjustable in 0.1 μA steps)
Maximum Tribo current cut o greater than 12 μA
(ATEX: switching o of the unit)
CAN bus IN/OUT Signal optically separated
Protocol: CANopen
Release 24 V DC
Protection class IP 64
Ex zone II 3(2)D 80 °C; 176 °F
Pneumatic:
Input air pressure 0.6–0.8 MPa; 6–8 bar; 87–116 psi
Air ow maximum 30 m³/h
6 x air quantity regulator with
ACTUAL value measurement
0.00 - 6.00 m³/h
(adjustable in 0.025 m³/h steps)
Required compressed air quality as per
ISO8573.1
6.5.2 (5 μm/+7 °C; +44.6 °F/0.1 mg/m³)
Connection hose diameter 8 mm; 0.315 inches
Ambient conditions:
Operating temperature range +5 °C up to +45 °C; +41 °F up to +113 °F
5.2 TECHNICAL DATA

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EPG S2
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Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water
(Quality Standard 3.5.2 according to ISO 8573.1)
3.5.2 = 5 μm / +7 °C; +44.6 °F / 0.1 mg/m³.
WARNING
NOTICE
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;
+86 °F.
Volume measures:
for volumes specied in Nm³ (standard cubic meters). One cubic meter of a gas at 0 °C and
1.013 bar is called norm cubic meter.

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EPG S2
OPERATING MANUAL
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Stk Order No. Designation
1 2316991 EPG S2
1 2343176 EPG S2 FM (USA edition)
The standard equipment includes:
1 2322580 Declaration of Conformity
1 2317573 Operating manual, German
1 see Chapter 1.3 Operating manual in local language
5.4 SCOPE OF DELIVERY
5.3 PERMITTED ACCESSORIES
Only the accessories listed in the "Accessories" chapter of this operating manual may be
connected to the EPG S2 control unit.
The accessories listed in the chapter "Accessories" were included in the EC type examination
and are approved for use with the control unit.

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EPG S2
P_01487
A B
S2
EPG
654312456
OPERATING MANUAL
VERSION 09/2017 ORDER NUMBER DOC2317574
5.5 DISPLAY AND OPERATING ELEMENTS
5.5.1 DISPLAY ELEMENTS, FRONT SIDE
1 LED display: "Operating voltage"
– The LED lights up green when the operating voltage is activated
2 LED display: "CAN Data Communication"
– The LED lights up green during data communication with the master
3 LED display: "Release"
– The LED lights up green when enabling has taken place
4 LED display: "Air"
– The LED lights up green when the air module is activated
5 LED display: "High voltage"
– The LED lights up green when the high voltage is activated
6 LED display: "Warning/Malfunction"
– TheLED ashes inthe event ofa warning and lightsupred inthe event ofa malfunction
Displays 4 - 6 exist for both gun A and gun B.

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EPG S2
Year of build:
Baujahr:
B
Für den Betrieb in der Zone 22
müssen alle Anschlüsse mit Stecker
oder Schutzkappe versehen sein.
Prim. Fuse
Sicherung
1.0 AT
(slow blow)
Spraygun
Sprühpistole
IN CAN Bus OUT
Data and Interlock
Daten und Verriegelung
Ausgang zur Pistole
Output to gun
I max. 0,9 A
U max. 22 Vpp
Dosage air
Dosierluft
Feeding air
Förderluft Atomizing air Zerstäuberluft
Mains power IN / OUT
Netz EIn / Ausgang
6.....8 bar
87..116 psi
Clean and
dry air
Saubere und
trockene Luft
3.5.2 (ISO 8573.1)
Do NOT disconnect under voltage!
NICHT unter Spannung trennen!
Air input
Lufteingang
Dosage air
Dosierluft
Feeding air
Förderluft Atomizing air Zerstäuberluft
A
AABB
Type / Typ:
Serial No.:
Serie Nr.:
Voltage:
Spannung:
Line Power:
Eingangsleistung:
Prot. Class:
Schutzklasse:
EPG S2
90-250 VAC 47-63 Hz
max. 60 W
IP 64
CH 9450 Altstätten
Made in Switzerland
II 3(2)D IP64 80ºC
Tested / Geprüft EN50050, EN50177
For operation all ports must be fitted
with a plug or the protection cap.
PTB 12 ATEX 5001
Wagner International AG
1 2
8 17 16 15 11 10 9 8
73 4
P_01488
14
5 6
1213
0102
OPERATING MANUAL
VERSION 09/2017 ORDER NUMBER DOC2317574
5.5.2 CONNECTIONS ON THE REAR SIDE OF THE EPG S2
1 Primary fuse
– 1 ampere, slow-acting
2 Grounding connection
– To connect the signal ground
3 Compressed air Inlet
– The LED lights up green when enabling has taken place
– Pressure range: 0.6-0.8 MPa; 6-8 bar; 87-116 psi
– Air volume: 2x maximum 15 m³/h
– Connection hose diameter 8 mm; 0.315 inches
4 Input: CAN bus connector plug
– CANopen communication signal
– Release signal
5 Output: CAN bus bushing
– CANopen communication signal
– Release signal