WAGNER EPG-SPRINT User manual

0102 II 3(2)D IP64 80°C
P_01110
%
Tribo Corona
5
4
3
2
1
120
100
80
60
40
30
20
15
10
5
μA
μA
0
10
20
30
40
50
60
70
80
90
100
Ø
12
10
11
9
8
m /h
5.0
4.0
3.0
2.0
6.0
3
5.5
4.5
3.5
2.5
2.2
2x
kV
90
80
70
60
50
40
30
20
10
100
m /h
4.0
3.0
2.0
1.0
0.5
0.4
0.3
0.2
0.1
1.5
EPG
SP
R
I
NT
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 Coating Guns
EPG-SPRINT
EPG-SPRINT X
EPG-SPRINT XE
Version 09/2017
Original Service Manual

3
EPG-SPRINT / EPG-SPRINT X
SERVICE MANUAL
VERSION 09/2017 ORDER NUMBER DOC2309350
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
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 Use in an Explosion Hazard Area 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 Personnel 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 Fields of Application, Correct Use 17
5.2 Technical Data 18
5.2.1 EPG-SPRINT 18
5.2.2 EPG-SPRINT X 19
5.2.3 EPG-SPRINT XE 20
5.3 Permitted Accessories 22
5.4 Scope of Delivery 22
5.4.1 Scope of Delivery of EPG-SPRINT 22
5.4.2 Scope of Delivery of EPG-SPRINT X 22
5.4.3 Scope of Delivery of EPG-SPRINT XE 22
5.5 Operating Elements of EPG-SPRINT 23
5.5.1 Overview of Control Panel Front Side 23
5.5.2 Connections on the Rear Side of the EPG-SPRINT 28
5.6 Operating Elements of EPG-SPRINT X/EPG-SPRINT XE 30
5.6.1 Overview of Control Panel Front Side 30
5.6.2 Connections on the Rear Side of the EPG-SPRINT X 35
5.6.3 Connections on the Rear Side of the EPG-SPRINT XE 37

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EPG-SPRINT / EPG-SPRINT X
SERVICE MANUAL
VERSION 09/2017 ORDER NUMBER DOC2309350
Table of Contents
6 SPARE PARTS 39
6.1 How Can Spare Parts Be Ordered? 39
6.2 EPG-SPRINT Control Unit 40
6.3 EPG-SPRINT X Control Unit 43
6.4 EPG-SPRINT XE Control Unit 46
6.5 Resources and Special Tools 49
6.6 Handling the Release Tool for the Air Diuser 50
7 REPAIR WORK 51
7.1 Personnel Qualications 51
7.2 Safety Instructions 51
7.3 Replacing a Proportional Valve 53
7.4 Replacing the Incremental Encoder 55
7.5 Replacing the Display Print 56
8 PARAMETERS FOR SERVICE PURPOSES 57
8.1 Test Parameters 58
8.2 Calibration Parameters 58
8.3 Accessing the Service Level (C31-C34) 59
8.4 Accessing and Adjusting Parameter Value 60
9 SERVICE LEVEL 61
9.1 Parameter C31, Checking Air Outlets 61
9.2 Parameter C34, I/O Test (Input and Output) 64
10 PLANT LEVEL 68
10.1 Plant Level Parameters 68
10.2 Accessing the Plant Level Parameters 69
10.3 Parameter C41, Measuring and Calibrating Operating Pressure 70
10.4 Parameter C42, Calibrating Air Outlets 71
10.5 Parameter C43, Master Reset 74
10.6 Parameter C44, High-voltage Calibration 75
10.7 Parameter C45, Default Setting of Oset for Air Channels 78
11 MEASURING EQUIPMENT 81
11.1 Air Flow Measuring Device 81
11.2 Air Pressure Measuring Device 81
11.3 High-voltage Measuring Device 82
11.4 Voltmeter 82
12 EXTENDED INTERFACE FOR REMOTE CONTROL 83
12.1 Manual Gun Mode 83
12.2 Automatic Gun Mode 83
12.3 Manual Gun with External Control 84
12.4 Recipe Selection Input 84
12.4.1 Selection Via Pulse Length 84
12.4.2 Selection with Transfer Protocol 85
13 BLOCK DIAGRAMS 88
14 FURTHER ERROR MESSAGES 90
15 SOFTWARE UPDATE 93

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EPG-SPRINT / EPG-SPRINT X
SERVICE MANUAL
VERSION 09/2017 ORDER NUMBER DOC2309350
16 SOFTWARE HISTORY 97
16.1 EPG-SPRINT 97
16.2 EPG-SPRINT X 98
16.3 EPG-SPRINT XE 98
17 WARRANTY AND CONFORMITY DECLARATIONS 99
17.1 Important Notes Regarding Product Liability 99
17.2 Warranty Claim 99
17.3 CE Declaration of Conformity EPG-SPRINT 100
17.4 EC Type Examination Certicate EPG-SPRINT 101
17.5 CE Declaration of Conformity EPG-SPRINT X/EPG-SPRINT XE 103
17.6 EC Type Examination Certicate EPG-SPRINT X/EPG-SPRINT XE 104
17.7 FM Identication EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE 105
Table of Contents

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EPG-SPRINT / EPG-SPRINT X
SERVICE MANUAL
VERSION 09/2017 ORDER NUMBER DOC2309350
1 GENERAL INFORMATION
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.
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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EPG-SPRINT / EPG-SPRINT X
SERVICE MANUAL
VERSION 09/2017 ORDER NUMBER DOC2309350
1.3 LANGUAGES
The service manual is available in the following languages:
German 2309349 English 2309350
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
Wrench size
EPG-SPRINT:
The operating manual is available in the following languages:
German 2305220 English 2305222
French 2305224 Italian 2305225
Spanish 2305226 Russian 2321631
EPG-SPRINT X:
The operating manual is available in the following languages:
German 2327591 English 2329371
French 2330847 Italian 2330848
Spanish 2330849 Russian 2333349
Chinese 2333350
EPG-SPRINT XE:
The operating manual is available in the following languages:
German 2354911 English 2354913
French 2354914 Italian 2354915
Spanish 2354916 Russian 2354917
Chinese 2354918

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EPG-SPRINT / EPG-SPRINT X
SERVICE MANUAL
VERSION 09/2017 ORDER NUMBER DOC2309350
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/EPG-SPRINT X/EPG-SPRINT XE control unit is intended for controlling
electrostatic manual and automatic powder spray guns of type A-P (2 mJ) according to
DIN EN 50050-2 and DIN EN 50177.
Incorrect use!
Risk of injury and damage to the device.
Only connect original WAGNER spray guns to the EPG-SPRINT/
EPG-SPRINT X/EPG-SPRINT XE control unit.
The PEM-C3R and PEM-T3R manual spray guns may not be
connected to the EPG-SPRINT/EPG-SPRINT X/EPG-SPRINT XE
control unit.
WARNING
2.3 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.
The EPG-SPRINT/EPG-SPRINT X/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 plug connections are securely locked.
– All connections not needed (mains output, remote control) are sealed with dust
protection caps.

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EPG-SPRINT / EPG-SPRINT X
SERVICE MANUAL
VERSION 09/2017 ORDER NUMBER DOC2309350
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 service manual are observed,
the operating, maintenance and repair information in this service manual is observed,
and the statutory requirements and accident prevention regulations standards in the
country of use are observed.

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EPG-SPRINT / EPG-SPRINT X
SERVICE MANUAL
VERSION 09/2017 ORDER NUMBER DOC2309350
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