Um Sprint Xe Eng 2354920-1
Um Sprint Xe Eng 2354920-1
Um Sprint Xe Eng 2354920-1
Operating Manual
SPRINT XE
Version 07 / 2015
Manual Powder System
P_02640
VERSION 07/2015 ORDER NUMBER DOC2354920
SPRINT XE
OPERATING MANUAL
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
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 Potentially Explosive Areas 9
2.4 Safety Parameters 10
2.5 Processible Working Materials 10
2.6 Reasonably Foreseeable Misuse 11
2.7 Residual Risks 11
3 IDENTIFICATION 12
3.1 Explosion Protection Identification 12
3.1.1 Trolley Identification 12
3.1.2 Control Unit Identification 12
3.1.3 Spray Gun Identification 13
3.2 Permissible Device Combinations 13
3.3 Type Plates 14
3.3.1 Type Plate of Trolley 14
3.3.2 Type Plate of Control Unit 14
3.3.3 Type Plate of Powder Spray Gun 15
4 GENERAL SAFETY INSTRUCTIONS 16
4.1 Safety Instructions for the Operator 16
4.1.1 Electrical Devices and Equipment 16
4.1.2 Personnel Qualifications 16
4.1.3 Safe Work Environment 16
4.2 Safety Instructions for Staff 17
4.2.1 Safe Handling of WAGNER Powder Spray Devices 17
4.2.2 Grounding the Device 17
4.2.3 Product Hoses 17
4.2.4 Cleaning 18
4.2.5 Handling Powder Lacquers 18
4.3 Protective and Monitoring Equipment 19
5 DESCRIPTION 20
5.1 Areas of Application 20
5.1.1 Operation with Tribo Gun 20
5.1.2 Operation with Corona or Tribo Gun 20
5.2 Design Variants 21
5.3 Scope of Delivery 21
5.4 Permitted Accessories 21
5.5 Technical Data 22
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Table of Contents
5.6 Functioning of the Manual Powder System 24
5.6.1 Description of Sprint Airfluid XE 24
5.6.2 Description of Sprint 60 L XE Tank (Without Vibrator Table) 25
6 ASSEMBLY AND COMMISSIONING 27
6.1 Training Assembly/Commissioning Staff 27
6.2 Assembling the Trolley 27
6.3 Assembling the Control Unit 28
6.4 Connection Requirements 28
6.5 Connecting the Airfluid Manual System 30
6.6 Connecting the 60 L Tank Manual System 32
6.7 Grounding 34
6.7.1 Grounding the Powder Coating System 35
7 OPERATION 36
7.1 Training the Operating Staff 36
7.2 Safety Instructions 36
7.3 Operation of the Control Unit 38
7.4 Commissioning the Manual System 43
7.4.1 Switching on the Manual System 43
7.4.2 Adjusting Fluidization (Airfluid) 44
7.4.3 Adjusting Fluidization (60 L Tank without Vibrator Table) 45
7.5 Factory Setting Recipe Nos. 1-4 46
7.6 Interrupting the Coating Process 47
7.6.1 Airfluid Version 47
7.6.2 60 L Tank Version 48
7.7 "Double Click" Recipe (High Dynamic Remote) 49
8 CLEANING AND MAINTENANCE 50
8.1 Cleaning 50
8.1.1 Cleaning Staff 50
8.1.2 Safety Instructions 50
8.1.3 Cleaning Procedures 51
8.2 Maintenance 52
8.2.1 Maintenance Staff 52
8.2.2 Safety Instructions 52
8.2.3 Maintenance Procedures 53
8.3 Periodic Checking and Cleaning of the Manual System 54
8.3.1 Airfluid Version 54
8.3.2 60 L Tank Version 55
8.4 Performing a Paint Change (Airfluid) 56
8.5 Performing a Paint Change (60 L Tank) 57
8.5.1 Cleaning Process When Using a Single Powder Tank 57
8.5.2 Cleaning Process When Using Multiple Powder Tanks (60 L Tank) 58
8.5.3 Restarting the Manual System 59
9 INSPECTIONS IN ACCORDANCE WITH DIN EN 50050-2: 2014 60
9.1 Overview of Inspections 61
10 DISASSEMBLY AND DISPOSAL 62
10.1 Disassembly 62
10.2 Disposal 62
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Table of Contents
11 TROUBLESHOOTING AND RECTIFICATION 63
11.1 Faults on the Manual System 64
12 ACCESSORIES 66
12.1 Feed System SN-2 550/10 66
12.2 Maintenance Unit 66
12.3 Quick Coupling Set 67
12.4 Adapter Plate Switchbox 67
12.5 Spray Gun Switchbox 68
12.5.1 Installation of the Switchbox 68
12.5.2 Switching the Gun Types 70
12.6 PEM-T3 Manual Gun 71
12.7 PEM T3 300 Extension 71
12.8 Swivel Casters Set 72
12.9 Powder Hose 72
12.10 Sprint Dual Manual Coating Set 72
12.11 Wall Mount 73
12.12 Conversion Sets 73
12.13 Recipe Label 74
12.14 Extended Operating Manual 75
13 SPARE PARTS 77
13.1 How Can Spare Parts Be Ordered? 77
13.2 Scope of Delivery and Spare Parts List of Sprint Airfluid XE Manual Powder System 78
13.3 Scope of Delivery and Spare Parts List of Sprint 60 L XE Tank 80
13.4 Trolley Spare Parts List 81
13.5 Suction Tube ST 550/10 82
13.6 Feed System SN-2 550/10 83
13.7 Compressed Air Supply 84
13.8 PI-F1 Powder Injector 85
13.9 HiCoat-ED Pump F 86
13.10 60 L/25 L Tank 88
14 WEARING PARTS 90
15 DECLARATION OF WARRANTY AND CONFORMITY 91
15.1 Important Notes Regarding Product Liability 91
15.2 Warranty Claim 91
15.3 CE Declaration of Conformity 92
15.3.1 CE Declaration of Conformity for Trolley 92
15.3.2 CE Declaration of Conformity for Control Unit 93
15.3.3 CE Declaration of Conformity for Spray Guns 94
15.4 EC Type Examination Certificate 95
15.5 FM Approval 98
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1 GENERAL INFORMATION
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 operating and service
staff.
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.
Electrostatic manual coating systems may only be operated by qualified personnel.
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:
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1.3 LANGUAGES
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
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Staff qualifications
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 Is instructed by an electrician about the tasks assigned to
person 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 A person, who, based on his/her technical training, experience
accordance with and recent vocational experience, has sufficient technical
TRBS 1203 (2010) 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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2 CORRECT USE
2.1 DEVICE TYPE
The Sprint XE manual system is designed for single and serial coatings for industry and
trade. Any other form of use is considered non-intended use. WAGNER disclaims liability for
any damage resulting from non-intended use.
Electrostatic manual coating systems may only be used in spray areas equipped in
accordance with EN 12981 or under equivalent ventilation conditions.
The components of the three different versions of the Sprint XE manual system (Airfluid
version, 60 L tank version) are mutually compatible.
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WAGNER accepts no liability for any damage arising from incorrect use.
The manual powder system is only suitable for the application of powder lacquer.
J. Wagner AG forbids any other use!
The manual powder system may only be operated under the following conditions if:
the operating staff 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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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.
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
The device is suited for use in potentially explosive areas, in accordance with Test Certificate
PTB 12 ATEX 5001.
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The device is suited for use in potentially explosive areas, in accordance with Test Certificate
PTB 12 ATEX 5002.
WARNING
Incorrect use!
Risk of injury and damage to the device.
Only use the manual system with the original WAGNER control
units and spray guns.
Only use the Sprint XE manual system with the following guns and control units:
Permissible device combinations for the USA and Canada, see Chapter 15.5 "FM Approval".
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Made in Switzerland
Typ: Manual Unit SPRINT
Type: Handanlage SPRINT
II 3D Dc T100°C
SPRINT Airfluid XE 230 VAC
2355400 50 Hz
CH - 9450 Altstätten
J. WAGNER AG
SPRINT Airfluid XE Jap. 100 VAC
2355800 50/60 Hz
SPRINT 60L XE 90-250 VAC
2355403 47-63 Hz
Main switch
I
Output to gun
Ausgang zur Pistole
U max. 22 Vpp
I max. 0,9 A Made in Switzerland 0102 II 3(2)D
PTB 12 ATEX 5001
Air input Made in Switzerland 0102 II 3(2)D
J. Wagner AG Lufteingang
CH 9450 Altstätten Tested / Geprüft : EN50050-2, EN50177
J. Wagner AG PTB 12 ATEX 5001
Acceptable equipment combination Type / Typ: EPG-SPRINT XE
see operator manual CH 9450 Altstätten Tested / Geprüft : EN50050-2, EN50177
Serial No.:
O Spraygun Remote Zulässige Gerätekombination Serie Nr.:
Hauptschalter Sprühpistole Fernsteuerung siehe Betriebsanleitung
Year of manufacture: Acceptable equipment combination Type / Typ: EPG-SPRINT XE
Baujahr :
Voltage: see operator manual
Spannung: 90-250 VAC 47-63 Hz
6.....8 bar Serial No.:
Line Power:
Eingangsleistung: max. 120 W
87..116 psi Zulässige Gerätekombination Serie Nr.:
F1 Fuse F2 Clean and
Sicherung 2 AT Prot. Class: dry air siehe Betriebsanleitung
2 AT
250VAC (slow blow) 250VAC
Do NOT disconnect when energized! For operation all ports must be fitted
Schutzart: IP64
Saubere und Year of manufacture:
NICHT unter Spannung trennen!
with a plug or the protection cap. trockene Luft Baujahr :
Für den Betrieb in der Zone 22 6.5.2 (ISO 8573.1)
müssen alle Anschlüsse mit Stecker
oder Schutzkappe versehen sein. Voltage:
Mains
power Spannung: 90-250 VAC 47-63 Hz
input
Netz- Feeding air Dosage air Atomizing air
eingang Förderluft Dosierluft Zerstäuberluft Line Power:
Eingangsleistung: max. 120 W
Overvoltage Category II
Mains and pollution Degree 2
output Prot. Class:
vibrator EPG-Sprint XE
Schutzart: IP64
Netz-
ausgang FM approved for CL II, Div 2, Grps E, F, &G
Rüttler Ambient temp range 5C to 40C T5
In accordance with control document: 2309729
P_02656
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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 influences.
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 staff
about planned work.
Observe electrical safety regulations.
Ensure that the device is operated, maintained and repaired only by trained persons.
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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 field between the spray gun and the work piece to be coated builds up!
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. This may result in the formation of sparks or flames when discharging.
Ensure that the device is grounded before each coating process.
All the system's conductive elements, such as floors, walls, ceilings, protective
grating, transport equipment, work pieces, powder tanks, automatic moving devices
or construction parts etc. in the spray area, with the exception of parts which carry
high-voltage during operation, must be connected to the grounding system.
Parts of the booth must be grounded in accordance with EN 12981.
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).
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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 fluids.
Preference should be given to non-flammable cleaning fluids.
Flammable cleaning liquids may only be used if, after switching off 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 flammable solvents have an ignition energy of around 0.24 mJ or 60 nC.
The cleaning agent's flash 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.
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 sufficient protection of health and the environment, only operate the device
in a powder booth or on a spray wall with activated ventilation (exhaust air).
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5 DESCRIPTION
5.1 AREAS OF APPLICATION
The manual system is designed for single and serial coatings for industry and trade.
The following WAGNER manual guns can be used with the manual system:
When operating the manual system with a Tribo gun, the set values (total air volume, feed
air volume, Tribo air volume) in recipes 1-4 must be adjusted. The setting of the values is
described in the operating manual of the EPG-Sprint XE control unit.
The set values for operating with the Tribo gun should be saved to individually selected
recipe locations.
When operating with a Tribo gun, parameter C11 on the EPG-Sprint XE control unit must
be changed to Tribo. Please refer to the control unit operating manual for the procedure.
To alternately operate a Corona or a Tribo gun, both guns can be connected to the system
at the same time through a switchbox, which is available as an accessory. For more details
see Chapter 12.5.
The set values for operating with the Tribo gun should be saved to individually selected
recipe locations.
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When working with powders that are difficult to feed, the Sprint 60 L XE manual system
can be converted into a variant with a vibrator table (see Chapter 12.12).
Only the accessories listed in the "Accessories" chapter of this operating manual may be
connected to the Sprint XE manual system.
The accessories listed in the chapter "Accessories" were included in the EC type examination
and are approved for use with the manual system.
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Dimensions:
Height 1120 mm; 44.10 inches
Width 595 mm; 23.43 inches
Depth 740 mm; 29.13 inches
Weight approx. 40 kg; 88.18 lbs
Maximum box size 420x420x400 mm; 16.54x16.54x15.75 inches
Maximum filling weight of box 30 kg; 66.14 lbs
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 maximum 0.9 A
Corona current limitation 5 μA-120 μA (adjustable)
Tribo current cut off greater than 12 μA
(ATEX: switching off of the unit)
Pneumatic:
Compressed air connection G1/4"
Connection hose diameter 18.5 x 12.5 mm
Pressure range input air 0.6-0.8 MPa ; 6-8 bar; 87-116 psi
Air volume maximum 15 m³/h; 529.63 cf/h
Sum of feed and dosing air 2-12 m³/h; 70.6-423.7 cf/h
Gun air 0.05-4.5 m³/h; 1.765-158.9 cf/h
WAGNER injector type PI-F1, HiCoat ED pump F, PI-F1-S
Compressed air quality according to 6.5.2 according to ISO 8573.1, 2010
ISO 8573.1
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Insufficient paint application quality.
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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 specified in Nm³ (standard cubic meters). One cubic meter of a gas at 0 °C and
1.013 bar is called norm cubic meter.
Displays:
High-voltage 0-100 kV resolution 10 kV
Corona current 0-120 μA resolution 5-20 μA
Tribo current 0-5 μA resolution 0.5 μA
Recipes 50 preset recipes
Switch over from Tribo to Corona Automatic
Connectable spray gun types WAGNER guns PEM-X1, PEM-C4, PEM-C4-Ergo,
PEM-C4-Ergo FM, PEM-T3
Ambient conditions:
Operating temperature range 5-40 °C; 41-104 °F
Noise development < 63 dB (mains pressure 0.6 MPa ; 6 bar; 87 psi)
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6
4
P_02641
Equipment trolley
EPG-Sprint XE control unit
PEM-X1 manual gun
ST 550/10 suction tube
PI-F1 powder injector
Fluid air throttle
Vibration table
The feed unit (4) is inserted directly into the original bundle. The powder is fed through
the powder injector (5) to the powder spray gun (3). Due to the special arrangement of
the suction crown and the vibration of the tank, a homogeneous powder/air mixture is
generated and maintained during the entire duration of the powder feed. The powder
quantity and the electrostatic charge of the color powder are regulated by the control
unit (2). The fluid air setting is done using the throttle (6).
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4 6
P_02642
Equipment trolley
EPG-Sprint XE control unit
PEM-X1 manual gun
60 L tank
PI-F1 powder injector
Fluid air throttle
Function:
Through the powder injector (5), the powder is transported from the tank (4) to the spray
gun (3). By feeding fluid air into the fluid base of the powder tank (4), a homogeneous
powder/air mixture is generated and maintained during the entire process of the powder
feed from the tank.
The powder quantity and the electrostatic charge of the color powder are regulated by the
control unit (2). The fluid air setting is done using the throttle (6).
Note:
We recommend using a vibrator table when working with powders that are difficult to feed
(see Chapter 12.12).
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WARNING
Incorrect installation/operation!
Risk of injury and damage to the device.
The manual system's trolley is supplied unassembled for transport reasons. It must be
assembled as described below.
Procedure:
P_02643
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3 Procedure:
4
1 1. Carefully take control unit (1) out
of packaging and use the supplied
screws (2) to screw into the holes
drilled in the angle bracket (3).
Mount the control unit such that it is
flush with the cover at the front.
2
P_02644
The assembly of the manual powder system is the same for the Corona spray gun and for
the Tribo spray gun.
The manual system is equipped with a filter water separator (4) as a standard feature.
Nevertheless, a high compressed air quality is still required for safe operation of the system.
The plant operator is responsible ensuring the required compressed air quality.
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Insufficient paint application quality.
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WARNING
Danger from electric current!
Risk of injury and damage to the device.
Switch off main switch (1), on the back side of the device, before
connecting the device.
CAUTION
Missing cover!
Protection class of device not guaranteed.
The mains output socket must remain closed in manual systems without vibrator
motor with the cover closed.
I
1 0
I
1 0
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2. 1.
12.
11. 9.
10.
5.
4. 3.
8.
7.
6.
11.
P_02639
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WARNING
Danger from electric current!
Risk of injury and damage to the device.
Switch off main switch (1), on the back side of the device, before
connecting the device.
Procedure:
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5. 4.
15.
17.
16. 14.
8.
3.
13. 7. 6. 12.
11.
10.
9.
1.
Detail A Detail B
12.
2.
P_02645
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WARNING
Danger from electric current!
Risk of injury and damage to the device.
Switch off main switch (1), on the back side of the device, before
connecting the device.
Procedure:
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6.7 GROUNDING
DANGER
No Grounding!
Risk of explosion and risk of electric shock.
WARNING
Heavy powder mist if grounding is insufficient!
Danger of poisoning.
Insufficient paint application quality.
For security reasons the manual system must be properly grounded. Normally this is done
via the mains cable.
Good grounding of the work piece is also necessary for optimum powder coating.
It is important to keep the earth cables as short as possible. Earth cables of an excessive
length must be shortened. Earth cables of an excessive length must never be wound up
on a roller.
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The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 MΩ
(megohms).
Sparks between conveyor, conveyor hooks (hangers) and work piece can occur
if electric contact points between conveyor, conveyor hooks (hangers) and work
piece are not sufficiently cleaned and therefore the work pieces are not sufficiently
grounded!
These sparks can cause heavy radio frequency interference (EMC).
3 5
6
1
P_01827
8
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7 OPERATION
7.1 TRAINING THE OPERATING STAFF
WARNING
Incorrect operation!
Risk of injury and damage to the device.
WARNING
Incorrect operation!
Risk of injury and damage to the device.
DANGER
High-voltage field!
Danger to life from malfunction of heart pacemakers.
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CAUTION
Electrostatic discharges!
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5 1 2 3 4 20 22 21 23 18 13 19
9
6
10
7 50
60
40
11 Tri Cor
Ø
m3/h
70
14
5 120 30
100 Tri
5.5 3.0
8 4 80
12
2x
2x
80
11 4.5 1.5 80 16
12 60 3 40 20
10 3.5 0.5
20 9
40 2
8 2.5 0.3 90 15
25 20 1 10 10
2.0 0.1
kV μA
0%
100 %
17
26
EPG SPRINT X
P_01743
28 27 30 29 31 32 34 36 37 35 33 24
Corona scale:
When a Corona gun is connected and selected
Display and adjusting range: 0 [5]-120 μA,
0 [5]-20 μA resolution 5 μA
20-40 μA resolution 10 μA
40-120 μA resolution 20 μA
Single LED display: "Trigger Point of Current Limitation"
Bar display: Corona current
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A
I
0
1
50
40 60
Tri Cor
m3/h
100 5 120 Ø
30 70
2x
2x 80 4 80 12
11
5.5 3.0
4.5 1.5
Tri
2
60 3 40
20 80
40 2 20 10 3.5 0.5
9
20 1 10 8 2.5 0.3
10 90
kV μA 2.0 0.1
0% 100 %
EPG SPRINT X
P_02646
To turn the power supply of the manual powder system on, set the mains switch on the
back side (A) of the control unit to position "I".
Note:
The fluid air must be adjusted using the throttle (3), when first commissioning the
manual system.
The control unit automatically recognizes the type of gun connected.
There are 50 recipes available for the spray gun.
When a Tribo gun is connected, the Tribo current scale is activated, while the high-voltage
supply and control unit are deactivated.
All airs are only switched on once the manual gun's trigger has been actuated.
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Procedure:
Note:
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WARNING
Dust formation!
Danger of poisoning.
Danger due to escaping dust, contamination of the device and
device components.
Procedure:
Note:
Note:
We recommend using a vibrator table when
working with powders that are difficult to feed (see
Chapter 12.12).
45
Recipe no. Designation Characteristic High-voltage Current limitation Characteristic Total air Feed air Atomizing air
7.5
[kV] [μA] curve [m³/h] [%] [m³/h]
High surface
G01 Flat part 90 80 Standard 4.0 70 0.1
coverage
Second Avoidance of
G02 50 20 Soft 3.6 57 0.1
VERSION 07/2015
build-up of
edges
Small
G04 Double click 80 20 Soft 3.6 45 0.1
components
P05-50 variable individual 80 100 Standard 4.5 80 0.1
FACTORY SETTING RECIPE NOS. 1-4
Notes:
Under normal conditions, metallic powder can be processed well using recipes Nos.1-4.
When operating the system with a Tribo gun, the values for total air, powder flow and Tribo air must be adjusted accordingly and saved.
With the 3 L tank variant, the values must also be adjusted individually and saved.
ORDER NUMBER DOC2354920
The following set values are stored in recipe Nos. 1-4 in the factory.
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OPERATING MANUAL
NOTICE
Danger of clogging the fluid disk!
Danger of blockage.
Before the control unit is deactivated, the feed system must be pulled out of the
powder tank.
NOTICE
Powder residues!
Danger of damage to the device.
At every work interruption, blow through the spray gun and the powder feed
components and clean from any powder residues.
Procedure:
5.5 3.0
Tri
2. Lift the feed unit up, underneath the injector,
12
11 4.5 1.5 80
and lift it out of the tank until retaining clamp (H)
20
10
9
3.5 0.5 swivels downwards.
8 2.5 0.3
10
2.0 0.1
90
3. Lower the feed system into the parking position
17 and swivel it to the right side so that no more
100 %
0%
powder is forwarded.
4. Hold the gun in the spray booth and start the
EPG SPRINT X
flush function by pressing the "Flush" button (17).
P_01785 The injector and hoses are flushed.
5. Now the control unit can be switched off.
P_1789
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NOTICE
Powder residues!
Danger of damage to the device.
At every work interruption, blow through the spray gun and the powder feed
components and clean from any powder residues.
Procedure:
P_01785
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This function is used to change quickly to another recipe during a coating operation.
The operator can access a previously set recipe by double-clicking on the trigger lever
on the spray gun, for example to recoat parts using different parameters (high-voltage,
current limitation, air volumes etc.).
To access the function, press the trigger lever on the spray gun twice in quick succession
and hold down. Upon releasing the trigger, the original recipe will be returned to.
Tri Cor
5 120
100
4 80
2x
2x
80
3 40
60
2 20
40
1 10
20
kV μA
Tri Cor
5 120
100
4 80
2x
2x
80
40
60 3
2 20
2x
40
1 10
20
kV μA
Tri Cor
5 120
100
4 80
2x
2x
80
3 40
60
2 20
40
1 10
20
kV μA
P_01701
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Cleaning work should be undertaken regularly and carefully by qualified and trained staff.
The staff must be familiar with the DIN EN 50050-2 provisions. They should be informed of
specific hazards during their training.
DANGER
Explosive powder/air mixes!
Danger to life and equipment damage.
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WARNING
Incorrect maintenance!
Risk of injury and damage to the device.
The cleaning intervals should be adapted by the operator depending on the level of use
and if necessary the level of soiling.
If in doubt, we recommend contacting J. Wagner AG's specialist personnel.
The valid health and safety specifications and the safety instructions provided in Chapter 4
must be adhered to for all cleaning work.
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8.2 MAINTENANCE
Maintenance work should be undertaken regularly and carefully by qualified and trained
staff. They should be informed of specific hazards during their training.
Once the maintenance work is complete, the device must be checked by a qualified person
to ensure a reliable condition.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
DANGER
Incorrect maintenance/repair!
Risk of injury and damage to the device.
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WARNING
Incorrect maintenance!
Risk of injury and damage to the device.
The maintenance intervals should be adapted by the operator depending on the level of
use and if necessary the level of soiling.
If in doubt, we recommend contacting J. Wagner AG's specialist personnel.
The valid health and safety specifications and safety instructions provided in Chapter 4
must be adhered to for all maintenance work.
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Procedure:
Ø
m3/h
70
3. Lower the feed system into the parking position
30
12 5.5 3.0
Tri and swivel it to the right side so that no more
20
11 4.5 1.5 80 powder is forwarded.
10 3.5 0.5
9
8 2.5 0.3 90
4. Hold the gun in the spray booth and start the
10
2.0 0.1 flush function by pressing the "Flush" button (17).
0%
100 %
17 The injector and hoses are flushed.
5. Switch off control unit.
EPG SPRINT
X 6. Remove the union nut on powder feed hose (3)
P_01785
and disconnect powder feed hose (3) from
injector (4).
7. Disconnect powder feed hose (5) (red) from
injector (4).
8. Disconnect dosing air hose (6) (blue) from
injector (4).
9. Pull the fluid air hose (black) off suction connector (2).
H 10. Pull injector (4) out of feed unit (1).
11. Check injector 4 for wear and replace worn parts
P_1789 if necessary.
The wearing and spare parts can be found in the
powder injector's operating manual.
5 6 12. Pull feed unit (1) out of the holder arm.
13. Blow out the suction tube of the feed unit (1)
thoroughly and rub it clean with a dry cloth.
4 14. Check whether the fluid disk on the bottom of
3 the feed unit is blocked and replace if necessary.
2
P_01787
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Procedure:
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Note:
For a paint change, all components of the powder feed system must be thoroughly cleaned.
Procedure:
30
Ø 70
3. Lower the feed system into the parking position
Tri
12 5.5 3.0
4.5 1.5
and swivel it to the right side so that no more
11 80
20
10 3.5 0.5 powder is forwarded.
9
10
8 2.5 0.3 90 4. Hold the gun in the spray booth and start the
2.0 0.1
To adapt the programs to the new applications proceed as described in the EPG-Sprint XE
control unit's operating manual.
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Note:
For a paint change, all components of the powder feed system must be thoroughly cleaned.
Procedure:
5.5 3.0
Tri
5. Open the powder tank and clean all powder
12
11 4.5 1.5 80
feeding parts of the unit,
20
10
9
3.5 0.5
such as the spray gun, the injector, the powder
8 2.5 0.3
10
2.0 0.1
90
feed hose and the suction system.
0%
100 % 17 6. Clean the powder tank and pay special attention
to the fluid base.
EPG SPRINT X
Note:
P_01785
Proper fluidization is not possible with a damaged and/
or clogged fluid base.
To adapt the programs to the new applications proceed as described in the EPG-Sprint XE
control unit's operating manual.
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8.5.2 CLEANING PROCESS WHEN USING MULTIPLE POWDER TANKS (60 L TANK)
Procedure:
Note:
Proper fluidization is not possible with a damaged and/or
clogged fluid base.
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Procedure:
WARNING
Dust formation!
Danger of poisoning.
Danger due to escaping dust, contamination of the device and
device components.
3. Switch on the control unit and activate the "Powder Feed Quantity" function by
pressing the "Powder Quantity" button (36).
4. Adjust the powder quantity to 0% with the universal rotary controller (24).
5. Actuate the trigger and keep it actuated.
6. Adjust the fluid air at the throttle until fluidization is recognizable.
Note:
The amount of fluid air depends on the characteristics of the powder. Avoid a build up of
powder dust (too much fluid air) in the powder tank!
7. Close the powder tank and check whether the exhaust air hose is leading in the
direction of the ventilation system of the powder coating booth.
To adapt the programs to the new applications proceed as described in the EPG-Sprint XE
control unit's operating manual.
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If the system is used for electrostatic coating with flammable coating powders, testing
should be undertaken in accordance with DIN EN 50050-2: 2014 as per Table 1.
60
Section Type of inspection Requirements Inspection by Type of inspection Inspection
9.1
interval
1 Resistance to ground of work The resistance to ground of CP ME/CI weekly
piece's locating point every work piece's locating point Measure resistance to ground
must not exceed 1 megohm (work piece receiver - ground
(measurement voltage must be potential)
VERSION 07/2015
supply cannot be switched on, while the supply air, and high-voltage
technical ventilation is not working are switched off when the
effectively. ventilation is shut down.
Legend:
MA = Manufacturer FI = Function inspection
EM = Employer ME = Measurement
CP = Capable person SI = Standard inspection
FSE = Fire safety engineer VI = Visual inspection
ELC = Electrician CI = Continuous inspection
TP = Trained person TI = Technical inspection
61
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WARNING
Incorrect disassembly!
Risk of injury and damage to the device.
Procedure:
10.2 DISPOSAL
NOTICE
Do not dispose of used electrical equipment with household
refuse!
In accordance with European Directive 2002/96/EC on the disposal
of used electrical equipment and its implementation in national
law, this product may not be disposed of with the household refuse,
but must be recycled in an environmentally correct manner.
WAGNER or one of our dealers will take back your used WAGNER
waste electrical or electronic equipment and will dispose of it for
you in an environmentally friendly way. Please contact one of our
service points, one of our representatives or us directly to arrange
this.
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DANGER
Incorrect maintenance/repair!
Risk of injury and damage to the device.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
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12 ACCESSORIES
12.1 FEED SYSTEM SN-2 550/10
P_00418
P_01355
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P_01158
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P_00670
WARNING
Danger from electric current!
Risk of injury and damage to the device.
3 Procedure:
1
1. Screw switchbox (1) to adapter
plate (3) with screws (2).
P_01159
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P_01183
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OPERATING MANUAL
Note:
Clean the powder residues from all powder-conveying parts thoroughly, before changing
to another gun type.
50
60
40
m3/h
Ø 70
30
Tri
12 5.5 3.0
11 4.5 1.5 80
20
10 3.5 0.5
9
8 2.5 0.3 90
10
2.0 0.1
15
P_01185 100 %
0%
2
EPG SPRINT X
P_01785
Procedure:
(For example: switching from Corona to Tribo)
1. Switch off control unit with switch (1) on the back side or with "Standby" button (15)
on the front.
2. Change the coating powder from Corona to Tribo.
3. Disconnect the hose (2) (transparent, atomizing air) from the Corona gun and
connect it to the Tribo gun (Tribo air).
4. Disconnect the powder feed hose of the Corona spray gun from the powder injector
and connect the Tribo gun hose to the powder injector.
5. Set the switch (C) on the switchbox to Tribo.
6. Switch on control unit with switch (1) on the back side or with "Standby" button (15)
on the front.
Note:
Parameter C11, in the EPG-Sprint XE control unit device configuration, must be set to
"aut". No gun is selected at first after the control unit is switched on. This will however be
automatically selected and displayed after 1 second.
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P_01422
P_00923
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P_01680
P_02648
This accessory is used to operate two manual guns with the manual system.
The set consists of the control unit, the manual gun, a feed unit and different connecting
parts and cables.
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OPERATING MANUAL
P_01861
When working with powders that are difficult to feed, the manual system can be converted
into a variant with a vibrator table.
P_02649 P_02650
Sprint 60 L V Sprint 3 L V
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SPRINT XE
OPERATING MANUAL
50
40 60
m3/h m3/h
Ø
30 70
11 4.5 20 80 1.5
10 3.5 0.5
9
10 90
8 2.5 0.3
90 80 4.0 70 0.1
2x
2x
50 20 3.6 57 > 0.2
70 40 3.6 50
82 20 3.6 45
P5
P6 ✆ ______________________________
P7
P8 @ ______________________________
P9
www www.wagner-group.com/industry
P10
P_01829
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13 SPARE PARTS
13.1 HOW CAN SPARE PARTS BE ORDERED?
Always supply the following information to ensure delivery of the right spare part:
The quantity need not be the same as the number given in the quantity column "Stk" on
the list. This number merely indicates how many of the respective parts are used in each
component.
The following information is also required to ensure smooth processing of your order:
- Address for the invoice
- Address for delivery
- Name of the person to be contacted in the event of any queries
- Type of delivery (normal mail, express delivery, air freight, courier etc.)
= Wearing parts
Note: These parts are not covered by warranty terms
WARNING
Incorrect maintenance/repair!
Risk of injury and damage to the device.
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OPERATING MANUAL
13.2 SCOPE OF DELIVERY AND SPARE PARTS LIST OF SPRINT AIRFLUID XE MANUAL POWDER SYSTEM
4
6
1 8
P_02640
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VERSION 07/2015 ORDER NUMBER DOC2354920
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OPERATING MANUAL
79
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OPERATING MANUAL
5
4
3
P_02651
80
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SPRINT XE
OPERATING MANUAL
8
2 7
1
3 6
P_02652
5
81
VERSION 07/2015 ORDER NUMBER DOC2354920
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OPERATING MANUAL
P_01155
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
82
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OPERATING MANUAL
P_00577
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
83
VERSION 07/2015 ORDER NUMBER DOC2354920
SPRINT XE
OPERATING MANUAL
3
2
P_02720
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
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OPERATING MANUAL
8 9
10
5
5 7
4 1
11
2
3
P_00894
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
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VERSION 07/2015 ORDER NUMBER DOC2354920
SPRINT XE
OPERATING MANUAL
8 9
10
5
5 7
4 1
11 2
3
P_00889
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
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OPERATING MANUAL
11
9
13
10
5
19
24
20
6
7
17
4
21
8
15
P_01156
14
16
88
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OPERATING MANUAL
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
89
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OPERATING MANUAL
14 WEARING PARTS
90
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OPERATING MANUAL
As a result of an EC regulation effective from January 1, 1990, the manufacturer shall only
be liable for his product if all parts originate from him or are approved by him, and if the
devices are properly mounted, operated and maintained.
The manufacturer will not be held liable or will only be held partially liable if third-party
accessories or spare parts have been used.
With genuine WAGNER accessories and spare parts, you have the guarantee that all safety
regulations are complied with.
J. Wagner AG
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Identification:
II 3D Dc T100 °C
EC Certificate of Conformity
The CE certificate of conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number:
Sprint Airfluid XE trolley/Sprint 60 L XE trolley 2354822
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OPERATING MANUAL
Identification:
0102
II 3(2)D
EC Certificate of Conformity
The CE certificate of conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number:
EPG-Sprint XE 2327595
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SPRINT XE
OPERATING MANUAL
Identification:
0102
II 2D 2mJ
PTB 12 ATEX 5002
EN 50050-2: 2012
EC Certificate of Conformity
The CE certificate of conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number:
PEM-X1 manual gun 2326024
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OPERATING MANUAL
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VERSION 07/2015 ORDER NUMBER DOC2354920
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OPERATING MANUAL
%
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96
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OPERATING MANUAL
97
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OPERATING MANUAL
15.5 FM APPROVAL
The Sprint manual system is FM approved in the USA and Canada using the configuration
drawing no. 2309729.
P_00309
98
ED
FI
I
CERT
Germany
Phone
Telefax
E-mail
Switzerland
Phone
Telefax
Document No. 11169083
Company/Locations/WAGNER worldwide
Version -