WAGNER EPG-Sprint X User manual

0102 II 3(2)D IP64 80 °C
P_01742
EPG
SPRINT X
2x
2x
0
%
100
%
kV
80
60
40
20
100
Tri Cor
5
4
3
2
1
120
80
40
20
10
10
20
30
40
50
60
70
80
90
Ø
12
10
11
9
8
m /h
2.0
3.0
0.5
0.3
0.1
1.5
3
5.5
4.5
3.5
2.5
Tri
μA
Universal Control Unit
for Powder Guns
EPG-SPRINT X
Version 06 / 2014
Translation of the Original
Operating Manual

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EPG-SPRINT X
OPERATING MANUAL
VERSION 06/2014 ORDER NUMBER DOC2329371
Table of Contents
1 GENERAL INFORMATION 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 Use in Potentially Explosive Areas 8
2.4 Safety Parameters 9
2.5 Reasonably Foreseeable Misuse 9
2.6 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identication in Accordance with ATEX 11
3.2 Permissible Device Combinations 11
4 GENERAL SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 Sta Qualications 12
4.1.3 Safe Work Environment 12
4.2 Safety Instructions for Sta 13
4.2.1 Safe Handling of WAGNER Powder Spray Devices 13
4.2.2 Grounding the Device 13
4.2.3 Product Hoses 13
4.2.4 Cleaning 14
4.2.5 Handling Powder Lacquers 14
4.3 Protective and Monitoring Equipment 15
4.4 Safety Feature Identication 16
5 DESCRIPTION 17
5.1 Areas of Application 17
5.2 Technical Data 18
5.3 Permitted Accessories 20
5.4 Scope of Delivery 20
5.5 Operating Elements 21
5.5.1 Operating Elements Front Side 21
5.5.2 Connections on the Rear Side of the EPG-SPRINT X 26
6 ASSEMBLY AND COMMISSIONING 28
6.1 Training Assembly/Commissioning Sta 28
6.2 Storage Conditions 28
6.3 Installation Conditions 28
6.4 Connecting the Manual Gun 29
6.5 Connecting the Automatic Gun 30
6.6 Grounding 31
6.6.1 Grounding the Powder Coating System 32

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EPG-SPRINT X
OPERATING MANUAL
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Table of Contents
7 OPERATION 33
7.1 Training the Operating Sta 33
7.2 Safety Instructions 33
7.3 Preparations for Commissioning 35
7.3.1 Operating Modes 35
7.3.2 Gun Recognition 35
7.3.3 Manual Gun Mode with External Control 36
7.3.4 Basic and Factory Settings 36
7.4 Recipes 37
7.4.1 "Double Click" Recipe (High Dynamic Remote) 38
7.5 Air High Output Mode (High Powder Output) 39
7.5.1 Combining the Air Outputs 39
7.5.2 Activating High Output Mode (C17) 40
7.6 Changing and Saving Recipes 43
7.6.1 Recipe No. 1-4 43
7.6.2 Recipe No. 5-50 44
7.7 Setting and Changing Coating Parameters 45
7.7.1 Setting the Total Air Volume 45
7.7.2 Setting the Powder Feed Quantity 46
7.7.3 Setting the Additional Air (Atomizing/Ionizing/Tribo Air Volume) 47
7.7.4 Setting the High-voltage 48
7.7.5 Display of Actual High-voltage Value 49
7.7.6 Setting the Current Limitation 50
7.7.7 Displaying Actual Value of Current Limitation 51
7.7.8 Setting the U/I Characteristics 52
7.8 Purge Function 54
7.8.1 Hose Purge Function 54
7.8.2 Cleaning Purge Function 54
7.8.3 Procedure for Cleaning Purging with Manual Guns 55
7.8.4 Procedure for Cleaning Purging with Automatic Guns 56
7.9 Starting Output Setting (Zero Adjustment) 57
8 CLEANING AND MAINTENANCE 59
8.1 Cleaning 59
8.1.1 Cleaning Sta 59
8.1.2 Safety Instructions 59
8.1.3 Cleaning Procedures 60
8.2 Maintenance 61
8.2.1 Maintenance Sta 61
8.2.2 Safety Instructions 61
8.2.3 Maintenance Procedures 62
9 INSPECTIONS 63
9.1 Inspections in Accordance with DIN EN 50177: 2010 63
9.2 Inspections in Accordance with DIN EN 50050-2: 2014 67
10 DISASSEMBLY AND DISPOSAL 69
10.1 Disassembly 69
10.2 Disposal 70

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EPG-SPRINT X
OPERATING MANUAL
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Table of Contents
11 TROUBLESHOOTING AND RECTIFICATION 71
11.1 Warnings E01-E04 72
11.2 Faults 74
12 ACCESSORIES 77
12.1 Connection Cables 77
12.2 Wall Mount 77
12.3 Recipe Sticker 78
13 SPARE PARTS 79
13.1 How Can Spare Parts Be Ordered? 79
13.2 EPG-SPRINT X Control Unit 80
14 DECLARATION OF WARRANTY AND CONFORMITY 81
14.1 Important Notes Regarding Product Liability 81
14.2 Warranty Claim 81
14.3 CE Declaration of Conformity 82
14.4 EC Type Examination Certicate 83
14.5 FM Approval 84
DEVICE CONFIGURATION APPENDIX 85
A1 Setting Example: Parameter C11 87
A2 Setting Example: Parameter C13 89
A3 Table of Parameters 91
A4 Spray Current Reset when using Field Controllers 96
BRIEF DESCRIPTION 98
1 Changing Parameters 99
2 Calling / Changing / Saving Recipes 1-4 99
3 Calling / Changing / Saving Recipes 5-50 99

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EPG-SPRINT X
OPERATING MANUAL
VERSION 06/2014 ORDER NUMBER DOC2329371
1 GENERAL INFORMATION
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 operating and service
sta.
Operating and service sta 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
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
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 material damage.
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 danger 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 danger 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 danger 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 danger and its consequences.
NOTICE

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EPG-SPRINT X
OPERATING MANUAL
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1.3 LANGUAGES
The operating manual is available in the following languages:
German 2327591 English 2329371
French 2330847 Italian 2330848
Spanish 2330849 Russian 2333349
Chinese 2333350 Hungarian 2341081
Portuguese 2342815 Swedish 2344282
Slovakian 2348856 Danish 2348523
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part

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EPG-SPRINT X
OPERATING MANUAL
VERSION 06/2014 ORDER NUMBER DOC2329371
2 CORRECT USE
2.1 DEVICE TYPE
Universal control unit for controlling electrostatic manual and automatic spray guns
2.2 TYPE OF USE
The EPG-SPRINT X control unit is intended for controlling electrostatic manual and
automatic spray guns of type A-P (2 mJ) according to DIN EN 50177.
Incorrect use!
Risk of injury and damage to the device.
Only connect original Wagner spray guns to the EPG-SPRINT X
control unit.
The PEM-C3R and PEM-T3R manual spray guns cannot be
connected to the EPG-SPRINT X control unit.
WARNING
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
The EPG-SPRINT X 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 12 ATEX 5001.
The EPG-SPRINT X control unit may be used in the dust explosion zone (Zone 22) under the
following conditions:
Control unit correctly tted in rack.
Rack correctly and securely sealed on rear with associated cover.
All connections not needed (mains output, remote control) are sealed with dust
protection caps.

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EPG-SPRINT X
OPERATING MANUAL
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2.5 REASONABLY FORESEEABLE MISUSE
Coating work pieces which are not grounded
Use of defective components and accessories
Use with not permissible powder coating guns
2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from incorrect use.
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.
Operate only the device as a whole.
Do not deactivate safety xtures.
Spare parts and accessories may have safety-relevant properties:
Use only WAGNER original spare parts and accessories.
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.

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OPERATING MANUAL
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2.6 RESIDUAL RISKS
Residual risks are risks which cannot be excluded 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
hazardous to health
Observe working
and operating
instructions
operation,
maintenance

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EPG-SPRINT X
OPERATING MANUAL
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION IN ACCORDANCE WITH ATEX
3.2 PERMISSIBLE DEVICE COMBINATIONS
The following powder spray guns may be connected to the EPG-SPRINT X:
Manual spray guns
Corona spray gun PEM-X1, PEM-X1 CG, PEM-C3, PEM-C4,
PEM-C4-Ergo
Tribo spray gun PEM-T3
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
Older or other gun types may only be connected to the control unit after rst checking
their suitability with Wagner.
For permissible device combinations for the USA and Canada, see Chapter 14.5 "FM Approval".
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: Number of notied body which issues the recognition of quality assurance in
production.
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

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EPG-SPRINT X
OPERATING MANUAL
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
4.1.2 STAFF QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
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.
Ensure that the device is operated, maintained, and repaired only by trained persons.
The oor in the working area must be electrostatically conductive (measurements
according to EN 1081 and EN 61340-4-1).
The footwear worn by the operators must comply with the requirements of
ENISO20344. The measured insulation resistance must not exceed 100 megohms.
The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.
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. Do not smoke.
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 may not exceed 10 g/m³.

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EPG-SPRINT X
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
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 people with pacemakers 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 guns 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.
Ensure that all persons inside the working area are grounded, e.g., by wearing
electrostatically conductive shoes.
The functionality of grounding cables must be checked regularly (see EN 60204).
Only use an original Wagner powder hose.

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EPG-SPRINT X
OPERATING MANUAL
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4.2.5 HANDLING POWDER LACQUERS
4.2.4 CLEANING
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.
Take 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).
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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OPERATING MANUAL
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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-SPRINT X
OPERATING MANUAL
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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 Ø 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 persons
with a cardiac pacemaker!
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-SPRINT X
OPERATING MANUAL
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5 DESCRIPTION
5.1 AREAS OF APPLICATION
The EPG-SPRINT X control unit can be used as a stand-alone unit in manual coating systems
or can be connected to the PrimaTech automatic system together with other units.
When a Corona gun is connected, Corona current scale and the high-voltage supply
and control unit are active.
When a Tribo gun is connected, the Tribo current scale is activated, while the high-
voltage supply and control unit are deactivated.
The control unit recognizes if a manual or automatic spray gun is connected. If an automatic
gun is connected, then the control unit can only be controlled via the CCM Prima interface.
Incorrect use!
Risk of injury and damage to the device.
Only connect original Wagner spray guns to the EPG-SPRINT X
control unit.
The PEM-C3R and PEM-T3R manual spray guns cannot be
connected to the EPG-SPRINT X control unit.
WARNING

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EPG-SPRINT X
OPERATING MANUAL
VERSION 06/2014 ORDER NUMBER DOC2329371
5.2 TECHNICAL DATA
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 lbs
Electrical:
Mains (AC) 85 VAC-250 VAC
Frequency 47 Hz-440 Hz
Input power maximum 40 W
Output voltage maximum 22 Vpp
Output current maximum 0.9 A
High-voltage 10-100 kV (adjustable in 1 kV steps)
Corona current limitation 5 µA-120 µA (adjustable in 1 µA steps)
Tribo current measuring range 0 µA-15 µA
Tribo current limitation 0 µA-5 µA (adjustable in 0.1 µA steps)
Tribo current cut o greater than 12 µA
(ATEX: switching o of the unit)
Protection class: IP 64
Ex zone II 3(2)D 80 °C; 176 °F (Zone 22)
Pneumatic:
Air input pressure 0.6-0.8 MPa; 6-8 bar; 87-116 psi
Air volume maximum 15 m³/h
Sum of dosing and feed air 1-6 m³/h
Gun air 0.05-4.0 m³/h
Required compressed air quality as per ISO8573.1 3.5.2
Connection hose diameter 8 mm; 0.315 inches
Ambient conditions:
Operating temperature range 5-45 °C; 41-113 °F

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EPG-SPRINT X
OPERATING MANUAL
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Outgoing 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-SPRINT X
OPERATING MANUAL
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5.4 SCOPE OF DELIVERY
5.3 PERMITTED ACCESSORIES
Only the accessories listed in the chapter "Accessories" of this operating manual may be
connected to the EPG-SPRINT X 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.
Stk Order No. Designation
EPG-SPRINT X (for manual and automatic systems)
The standard equipment includes:
Conformity certicate
Operating manual, German
see Chapter 1.3 Operating manual in local language