WAGNER EPG-SPRINT XE Operational 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 XE
Version 09/2017
Translation of the Original
Operating Manual

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EPG-SPRINT XE
OPERATING MANUAL
VERSION 09/2017 ORDER NUMBER DOC2354913
Table of Contents
1 GENERAL INFORMATION 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 Use in an Explosion Hazard Area 9
2.4 Safety Parameters 10
2.5 Reasonably Foreseeable Misuse 10
2.6 Residual Risks 11
3 IDENTIFICATION 12
3.1 Explosion Protection Identication in Accordance with ATEX 12
3.2 Permissible Device Combinations 12
3.3 Type Plate 13
4 GENERAL SAFETY INSTRUCTIONS 14
4.1 Safety Instructions for the Operator 14
4.1.1 Electrical Devices and Equipment 14
4.1.2 Personnel Qualications 14
4.1.3 Safe Work Environment 14
4.2 Safety Instructions for Sta 15
4.2.1 Safe Handling of WAGNER Powder Spray Devices 15
4.2.2 Grounding the Device 15
4.2.3 Product Hoses 15
4.2.4 Cleaning 16
4.2.5 Handling Powder Lacquers 16
4.3 Protective and Monitoring Equipment 16
4.4 Safety Feature Identication 17
5 DESCRIPTION 18
5.1 Areas of Application 18
5.2 Technical Data 19
5.3 Permitted Accessories 21
5.4 Scope of Delivery 21
5.5 Operating Elements 22
5.5.1 Operating Elements Front Side 22
5.5.2 Connections on the Rear Side of the EPG-SPRINT XE 27
6 ASSEMBLY AND COMMISSIONING 29
6.1 Training Assembly/Commissioning Sta 29
6.2 Storage Conditions 29
6.3 Conditions of Assembly and Commissioning 29
6.4 Connecting the Manual Gun 30
6.5 Connecting the Automatic Gun 31
6.6 Grounding 32
6.6.1 Grounding the Powder Coating System 33

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7 OPERATION 34
7.1 Training the Operating Sta 34
7.2 Safety Instructions 34
7.3 Preparations for Commissioning 36
7.3.1 Operating Modes 36
7.3.2 Gun Recognition 36
7.3.3 Manual Gun Mode with External Control 37
7.3.4 Basic and Factory Settings 37
7.4 Recipes 38
7.4.1 "Double Click" Recipe (High Dynamic Remote) 39
7.5 Air High Output Mode (High Powder Output) 40
7.5.1 Combining the Air Outputs 40
7.5.2 Activating High Output Mode (C17) 41
7.6 Changing and Saving Recipes 44
7.6.1 Recipe No. 1-4 44
7.6.2 Recipe No. 5-50 45
7.7 Setting and Changing Coating Parameters 46
7.7.1 Setting the Total Air Volume 46
7.7.2 Setting the Powder Feed Quantity 47
7.7.3 Setting the Additional Air (Atomizing/Ionizing/Tribo Air Volume) 48
7.7.4 Setting the High Voltage 49
7.7.5 Display of Actual High-voltage Value 50
7.7.6 Setting the Current Limitation 51
7.7.7 Displaying Actual Value of Current Limitation 52
7.7.8 Setting the U/I Characteristic Curves 53
7.8 Flush function 55
7.8.1 Hose Flush Function 55
7.8.2 Cleaning Flush Function 55
7.8.3 Procedure for Cleaning Flushing with Manual Guns 56
7.8.4 Procedure for Cleaning Flushing with Automatic Guns 57
7.9 Starting Output Setting (Zero Adjustment) 58
8 CLEANING AND MAINTENANCE 60
8.1 Cleaning 60
8.1.1 Cleaning Sta 60
8.1.2 Safety Instructions 60
8.1.3 Cleaning Procedures 61
8.2 Maintenance 62
8.2.1 Maintenance Sta 62
8.2.2 Safety Instructions 62
8.2.3 Maintenance Procedures 63
9 INSPECTIONS 64
9.1 Inspections in Accordance with DIN EN 50177: 2010 64
9.2 Inspections in Accordance with DIN EN 50050-2: 2014 68
10 DISASSEMBLY AND DISPOSAL 70
10.1 Disassembly 70
10.2 Disposal 71
11 TROUBLE SHOOTING AND RECTIFICATION 72
11.1 Warnings E01-E04 73
11.2 Faults 75

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12 ACCESSORIES 78
12.1 Connection Cables 78
12.2 Wall Mount 78
12.3 Recipe Label 79
13 SPARE PARTS 80
13.1 How Can Spare Parts Be Ordered? 80
13.2 EPG-SPRINT XE Control Unit 81
14 DECLARATION OF WARRANTY AND CONFORMITY 82
14.1 Important Notes Regarding Product Liability 82
14.2 Warranty Claim 82
14.3 CE Declaration of Conformity 83
14.4 EC Type Examination Certicate 84
14.5 FM Approval 86
APPENDIX DEVICE CONFIGURATION 87
A1 Setting Example: Parameter C11 89
A2 Setting Example: Parameter C13 91
A3 Table of Parameters 93
BRIEF DESCRIPTION 97
1 Changing Parameters 98
2 Calling / Changing / Saving Recipes 1-4 98
3 Calling / Changing / Saving Recipes 5-50 98

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EPG-SPRINT XE
OPERATING MANUAL
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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 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
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
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

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1.3 LANGUAGES
The operating manual is available in the following languages:
German 2354911 English 2354913
French 2354914 Italian 2354915
Spanish 2354916 Russian 2354917
Chinese 2354918 Portuguese 2368375
Dutch 2388017 Bulgarian 2391612
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part

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OPERATING MANUAL
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing with compressed air of parts carrying paint
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person in
accordance with TRBS
1203 (2010)
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) and
is familiar with the relevant and generally accepted rules of
technology so that he/she can inspect and assess the status of
devices and coating systems based on workplace safety.

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EPG-SPRINT XE
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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 XE 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XE
control unit.
The PEM-C3R and PEM-T3R manual spray guns cannot be
connected to the EPG-SPRINT XE control unit.
WARNING
2.3 USE IN AN EXPLOSION HAZARD AREA
The EPG-SPRINT XE control unit is intended for use with powder spray guns of types A-P up
to 2 mJ in accordance with the prototype test PTB 12 ATEX 5001.
The EPG-SPRINT XE 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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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.
Only operate 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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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 IN ACCORDANCE WITH ATEX
3.2 PERMISSIBLE DEVICE COMBINATIONS
The following powder spray guns may be connected to the EPG-SPRINT XE:
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.
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
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

13
EPG-SPRINT XE
P_02656
Type / Typ:
Serial No.:
Serie Nr.:
Voltage:
Spannung:
Line Power:
Eingangsleistung:
Prot. Class:
Schutzart:
EPG-SPRINT XE
90-250 VAC 47-63 Hz
max. 110 W
IP64
CH−9450 Altstätten
Wagner International AG
Made in Switzerland
PTB 12 ATEX 5001
II 3(2)D
Tested / Geprüft : EN50050-2, EN50177
0102
For operation all ports must be fitted
with a plug or the protection cap.
Für den Betrieb in der Zone 22
müssen alle Anschlüsse mit Stecker
oder Schutzkappe versehen sein.
Acceptable equipment combination
see operator manual
Zulässige Gerätekombination
siehe Betriebsanleitung Year of manufacture:
Baujahr :
Type / Typ:
Serial No.:
Serie Nr.:
Voltage:
Spannung:
Line Power:
Eingangsleistung:
Prot. Class:
Schutzart:
EPG-SPRINT XE
90-250 VAC 47-63 Hz
max.
IP64
Made in Switzerland
PTB 12 ATEX 5001
II 3(2)D
Tested / Geprüft : EN50050-2, EN50177
0102
F1 Fuse F2
Sicherung 2 AT
250VAC
2 AT
250VAC (slow blow)
Hauptschalter
Main switch
Spraygun
Sprühpistole
Remote
Fernsteuerung
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
input
Netz-
eingang
Mains
output
vibrator
Netz-
ausgang
Rüttler
6.....8 bar
87..116 psi
Clean and
dry air
Saubere und
trockene Luft
6.5.2 (ISO 8573.1)
Do NOT disconnect when energized!
NICHT unter Spannung trennen!
I
O
Air input
Lufteingang
For operation all ports must be fitted
with a plug or the protection cap.
Für den Betrieb in der Zone 22
müssen alle Anschlüsse mit Stecker
oder Schutzkappe versehen sein.
Overvoltage Category II
and pollution Degree 2
EPG-Sprint XE
FM approved for CL II, Div 2, Grps E, F, &G
Ambient temp range 5C to 40C T5
In accordance with control document: 2309729
Acceptable equipment combination
see operator manual
Zulässige Gerätekombination
siehe Betriebsanleitung Year of manufacture:
Baujahr : Type / Typ:
Serial No.:
Serie Nr.:
Voltage:
Spannung:
Line Power:
Eingangsleistung:
Prot. Class:
Schutzart:
EPG-SPRINT XE
90-250 VAC 47-63 Hz
max. 110 W
IP64
CH−9450 Altstätten
Wagner International AG
Made in Switzerland
PTB 12 ATEX 5001
II 3(2)D
Tested / Geprüft : EN50050-2, EN50177
0102
Acceptable equipment combination
see operator manual
Zulässige Gerätekombination
siehe Betriebsanleitung Year of manufacture:
Baujahr :
OPERATING MANUAL
VERSION 09/2017 ORDER NUMBER DOC2354913
3.3 TYPE PLATE

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EPG-SPRINT XE
OPERATING MANUAL
VERSION 09/2017 ORDER NUMBER DOC2354913
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
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. 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.

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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 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.
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).
Use only an original WAGNER powder hose.

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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.
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).
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.
4.3 PROTECTIVE AND MONITORING EQUIPMENT
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.

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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 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 XE
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5 DESCRIPTION
5.1 AREAS OF APPLICATION
The EPG-SPRINT XE control unit can be used as a stand-alone unit in manual coating
systems or with an automatic coating system.
–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 remote interface.
Incorrect use!
Risk of injury and damage to the device.
Only connect original WAGNER spray guns to the EPG-SPRINT XE
control unit.
The PEM-C3R and PEM-T3R manual spray guns cannot be
connected to the EPG-SPRINT XE control unit.
WARNING

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EPG-SPRINT XE
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5.2 TECHNICAL DATA
Dimensions:
Height 136 mm; 5.35 inch
Width 270 mm; 10.63 inch
Depth (without operating elements) 200 mm; 7.87 inch
Weight 3.3 kg; 7.28 lb
Electrical:
Mains (AC) input terminal 90 VAC–250 VAC
Frequency 47 Hz–63 Hz
Input power maximum 120 W
Mains (AC) output terminal Vibrator motor maximum 70 W
Output voltage spray gun maximum 22 Vpp
Output current spray gun Max. 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)
Ex identication:
according to EN (ATEX, EN) II 3(2)D
according to Class & Division (North
America)
Class II, Division 2, Group E, F and G
Pneumatic:
Input air pressure 0.6–0.8 MPa; 6–8 bar; 87–116 psi
Air ow 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, 2010
6.5.2
Connection hose diameter 8 mm; 0.315 inch
Ambient conditions:
Operating temperature range 5–40 °C; 41–104 °F

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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.
Exhaust air containing oil!
Risk of poisoning if inhaled.
Insucient paint application quality.
Provide compressed air free from oil and water (Quality Standard
6.5.2 according to ISO 8573.1, 2010) 6.5.2 = particle density ≤ 5
mg/m; pressure dew point ≤ +7 °C; oil content ≤ 0.1mg/m
WARNING