WAGNER SprayPackE User manual

SprayPackE
Version 01/2020

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VERSION 01/2020 ORDER NUMBER DOC2397091 SprayPackE
Table of Contents
1 ABOUT THESE INSTRUCTIONS 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 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Identication 10
3.2 Type Plates 10
3.3 Permissible Device Combinations 11
3.4 Safety Features 11
4 BASIC SAFETY INSTRUCTIONS 13
4.1 Safety Instructions for the Operator 13
4.1.1 Electrical Devices and Equipment 13
4.1.2 A Safe Work Environment 14
4.1.3 Personnel Qualications 14
4.2 Safety Instructions for the Personnel 15
4.2.1 Personal Safety Equipment 15
4.2.2 Safe Handling of WAGNER Powder Spray Devices 15
4.2.3 Grounding the Device 16
4.2.4 Product Hoses 16
4.2.5 Electrical Connection Cables 17
4.2.6 Cleaning and Flushing 17
4.2.7 Maintenance and Repair 18
4.2.8 Protective and Monitoring Equipment 18
5 DESCRIPTION 19
5.1 Mode of Operation 19
5.2 Display and Operating Elements 19
5.2.1 Front Side of Structure 19
5.2.2 Connections on Rear Side of MCE 20
5.3 Front Side of Structure, CPE/CPE-S 22
5.4 CPE Connections on Rear Side 23
5.5 CPE-S Connections on Rear Side 24
5.6 CPE/CPE-S Connections in Housing 25
5.6.1 Terminal Assignment 26
5.7 CAN Addresses 27
5.8 CPE/CPE-S Circuit Breakers in Housing 28
5.9 Components of SprayPackE 29
5.10 Components of MCE 32
5.11 Components of pulse generator 35

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VERSION 01/2020 ORDER NUMBER DOC2397091 SprayPackE
5.12 Components of Switching Light Curtain 36
5.13 Safety Functions 37
5.14 Scope of Delivery 38
5.15 Technical Data 38
5.15.1 Technical Data for MCE 38
5.15.2 Technical Data for CPE/CPE-S 38
5.15.3 Technical Data for Maximum SprayPackE Conguration 39
5.15.4 Rack (10 EPG S2) 40
5.15.5 EPG S2 40
5.15.6 EPG-Sprint X 41
5.15.7 Compressed Air Quality 42
6 ASSEMBLY AND COMMISSIONING 43
6.1 Training of Assembly/Commissioning Personnel 43
6.2 Storage Conditions 43
6.3 Installation Conditions 43
6.4 Connecting the Automatic Spray Guns on the EPG S2 44
6.5 Connection Diagram in the Rack 45
6.6 Connection Diagram for Entire SpraypackE System 46
6.7 Pneumatic Connections in Rack 47
6.8 Connection Diagram for CSL710 Light Curtain and Pulse Generator 48
6.8.1 Grounding of CSL710 Light Curtains 49
6.9 Description of CSL710 Light Curtains 49
6.9.1 Function Keys on the Light Curtain Display 49
6.9.2 LEDs on Receiver 50
6.9.3 LEDs on Transmitter 50
6.9.4 Meaning of Display Symbols 51
6.10 Settings on the Light Curtain 51
6.10.1 "Settings" menu 51
6.10.2 "Display" menu 53
6.10.3 "Digital IO" menu 54
6.11 Test and Diagnosis eXpertE Software 58
6.12 Grounding 59
6.12.1 Grounding of Control Units in Rack 60
6.13 Safety Checks 60
6.14 Interlocking 61
7 OPERATION 63
7.1 Training the Operating Personnel 63
7.2 Tasks 63
7.3 Controllable Spray Guns 63
7.4 Gun Cable Lengths 63
8 CLEANING AND MAINTENANCE 64
8.1 Cleaning 64
8.1.1 Cleaning Personnel 64
8.1.2 Cleaning Instructions 64
8.1.3 Cleaning Procedures 64
8.2 Maintenance 64
8.2.1 Maintenance Personnel 64
8.2.2 Maintenance Instructions 65
8.2.3 Maintenance Procedures 65
8.2.4 Safety Checks 65

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VERSION 01/2020 ORDER NUMBER DOC2397091 SprayPackE
9 REPAIRS 66
9.1 Repair Personnel 66
9.2 Repair Notes 66
10 FUNCTION TEST AFTER REPAIR WORK 67
11 DISASSEMBLY AND DISPOSAL 67
12 ACCESSORIES 68
13 SPARE PARTS 69
13.1 How Can Spare Parts Be Ordered? 69
13.2 Spare Parts List for MCE Control Unit 69
13.3 Spare Parts List for Maintenance Unit 70
13.4 Spare Parts List for Air Diuser 70
13.5 Spare Parts List for Digital Pressure Sensor 71
14 DECLARATION OF CONFORMITY 72
14.1 EU Declaration of Conformity 72

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VERSION 01/2020 ORDER NUMBER DOC2397091 SprayPackE
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.
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.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this 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 Potential danger.
Non-observance may result in death or serious injury.
CAUTION Potentially dangerous situation.
Non-observance may result in minor injury.
NOTICE Potentially dangerous situation.
Non-observance may result in damage to property.
Note: Provides information about particular characteristics and
how to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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VERSION 01/2020 ORDER NUMBER DOC2397091 SprayPackE
1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2397090
Translation of the original operating manual
Language Order no. Language Order no.
English 2397091 Russian 2397095
French 2397092 Chinese 2397096
Italian 2397093 Polish 2414158
Spanish 2397094 Czech 2414159
Hungarian 2414161 -- --
The software documentation is available in the following languages:
Original software documentation
Language Order no.
German 2397152
Translation of the original software documentation
Language Order no. Language Order no.
English 2397153 Russian 2397158
French 2397154 Chinese 2397159
Italian 2397156 -- --
Spanish 2397157 -- --
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number Number of pieces
Spare part OK okay
Marking in the spare parts lists IO Input/output
Position

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VERSION 01/2020 ORDER NUMBER DOC2397091 SprayPackE
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with compressed air
Personnel 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/Modication 2012)
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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VERSION 01/2020 ORDER NUMBER DOC2397091 SprayPackE
2 CORRECT USE
2.1 DEVICE TYPE
Controller for automatic powder coating systems.
2.2 TYPE OF USE
The SprayPackE controller serves to control the EPG S2 control units for powder guns and
powder conveying equipment, reciprocators and sliding tables.
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The SprayPackE controller must not be used in the dust Ex zone (zone22).
2.4 PROCESSIBLE WORKING MATERIALS
– Types of powder which can be charged electrostatically
– Metallic powder
– Tribo powder
Note:
Contact your localWAGNER dealer and the lacquer manufacturer if you encounter application
problems.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
liquid coating products, e.g., solvents or water-based lacquers are not processed;
no food, medicine or cosmetics are processed.

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VERSION 01/2020 ORDER NUMBER DOC2397091 SprayPackE
3 IDENTIFICATION
3.1 IDENTIFICATION
Device type: MCE/CPE control unit
Manufacturer: Wagner International AG
9450 Altstätten
Switzerland
CE European Communities
3.2 TYPE PLATES
Type / Typ:
Serie Nr.:
Serial No.:
Eingangsspannung:
Input Voltage:
Leistungsverbrauch:
Power use:
Vorsicherung:
Pre-fuse:
MCE
100-240VAC
MCE: 60W
10Amp D Type
Baujahr:
Year of manufactur:
x EPG-S2 @ 60W
Wagner International AG
CH 9450 Altstätten
Designed by WAGNER in Switzerland
50/60Hz
P_03706
1
2
4
5
6
7
3
P_03746
1
2
4
5
6
7
3
Typ / Type:
Serie Nr.:
Serial No.:
Eingangsspannung:
Input Voltage:
Eingangsleistung:
Line Power:
Vorsicherung:
Main fuse:
CPE
3P+N+PE
230/400V 50/60Hz
max. 3.0kW
max. 25 A gL/gG
Baujahr:
Year of manufactur:
Wagner International AG
CH 9450 Altstätten
Designed by WAGNER in Switzerland
1 Manufacturer 1 Manufacturer
2 Type: MCE 2 Type: CPE
3 Serial number 3 Serial number
4 Year of manufacture 4 Year of manufacture
5 Input voltage 5 Input voltage
6 Back-up fuse 6 Input power
7 Power consumption 7 Back-up fuse