WAGNER Sprint 60 L XE, Sprint Airfluid XE Operating Manual

Page 1

Translation of the Original Operating Manual

SPRINT XE

Manual Powder System

For professional use. Always follow the information in this manual, particularly the safety instructions and the warning instructions. Store the manual in a safe place.

Version 05/2017

P_02640

Page 2

Page 3

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

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 7

2 CORRECT USE 8

2.1 Device Type 8

2.2 Type of Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Processible Working Materials 8

2.5 Misuse 8

3 IDENTIFICATION 9

3.1 Explosion Protection Identi cation 9

3.1.1 Trolley Identi cation 9

3.1.2 Control Unit Identi cation 9

3.1.3 Spray Gun Identi cation 10

3.2 Type Plates 10

3.2.1 Trolley Type Plate 10

3.2.2 Control Unit Type Plate 11

3.2.3 Powder Spray Gun Type Plate 11

3.3 Permissible Device Combinations 12

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 Sta 15

4.2.1 Use Personal Safety Equipment 15

4.2.2 Safe Handling of WAGNER Powder Spray Devices 15

4.2.3 Ground the Unit 16

4.2.4 Product Hoses 16

4.2.5 Cleaning and Flushing 17

4.2.6 Maintenance and Repair 17

4.2.7 Protective and Monitoring Equipment 18

5 DESCRIPTION 19

5.1 Construction and Mode of Operation 19

5.1.1 Description of Sprint Air uid XE 19

5.1.2 Description of Sprint 60 L XE tank (Without Vibrator Table) 20

5.1.3 Operating Modes 21

5.2 Included Items 21

5.2.1 Variants 21

5.2.2 Standard Equipment 21

5.2.3 Technical Data 22

5.3 Operation of the Control Unit 24

Page 4

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

6 COMMISSIONING 29

6.1 Training of Assembly/Commissioning Sta 29

6.2 Storage Conditions 29

6.3 Installation Conditions 29

6.4 Assembling the Manual System 30

6.4.1 Assembling the Equipment Trolley 30

6.4.2 Assembling the Control Unit 30

6.5 Connecting the Manual Powder System 31

6.5.1 Connection Requirements 31

6.5.2 Connecting the Air uid Manual Powder System 32

6.5.3 Connecting the 60 L Tank Manual System 34

6.6 Grounding 36

6.6.1 Grounding the Powder Coating System 36

6.7 Safety Checks 37

7 OPERATION 38

7.1 Training the Operating Sta 38

7.2 Work 38

7.2.1 Switching on the Manual System 39

7.2.2 Adjusting the Fluidization (Air uid) 40

7.2.3 Adjusting Fluidization (60 L Tank Without Vibrator Table) 41

7.3 Factory Setting Recipe Nos. 1–4 42

7.4 Interrupting the Coating Process 43

7.4.1 Air uid Version 43

7.4.2 60 L Tank Version 44

7.5 Performing a Paint Change 45

7.5.1 Air uid Version 45

7.5.2 60 L Tank Version 46

7.6 "Double Click" Recipe (High Dynamic Remote) 49

8 CLEANING AND MAINTENANCE 50

8.1 Cleaning 50

8.1.1 Cleaning Sta 50

8.1.2 Flushing and Cleaning the System 50

8.2 Maintenance 50

8.2.1 Maintenance Sta 50

8.2.2 Maintenance Instructions 50

8.2.3 Safety Checks 51

8.2.4 Maintenance Procedures 51

8.3 Periodic Checking of the Manual System 52

8.3.1 Air uid Version 52

8.3.2 60 L Tank Version 53

9 TROUBLESHOOTING AND RECTIFICATION 54

10 INSPECTIONS 56

11 DISASSEMBLY AND DISPOSAL 57

11.1 Disassembly 57

11.2 Disposal 57

12 ACCESSORIES 58

12.1 Feed System SN-2 550/10 58

12.2 Maintenance Unit 58

12.3 Quick Coupling Set 59

Page 5

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.4 Adapter Plate Switchbox 59

12.5 Spray Gun Switchbox 59

12.5.1 Installation of the Switchbox 60

12.5.2 Switching the Gun Types 61

12.6 PEM-T3 Manual Gun 62

12.7 PEM-T3 Extension 62

12.8 Retro t Set, Tribo Lance TL1 63

12.9 Swivel Casters Set 63

12.10 Powder Hose 64

12.11 Sprint Dual Manual Coating Set 64

12.12 Wall Mount 64

12.13 Conversion Sets 65

12.14 Recipe Label 66

12.15 Extended Operating Manual 66

13 SPARE PARTS 67

13.1 How to Order Spare Parts? 67

13.2 Spare Parts List of Sprint Air uid XE Manual Powder System 68

13.3 Spare Parts List of Sprint 60 L XE Manual Powder System Tank 70

13.4 Trolley Spare Parts 71

13.5 Intake Tube, ST 550/10 72

13.6 Feed System, SN-2 550/10 73

13.7 Compressed Air Supply 74

13.8 Powder Injector, PI-F1 75

13.9 HiCoat-ED Pump F 76

13.10 60 L/25 L Tank 77

14 WEARING PARTS 79

15 Guarantee and Conformity Declarations 80

15.1 Important Notes on Product Liability 80

15.2 Warranty Claim 80

15.3 EU Declaration of Conformity 81

15.3.1 EU Declaration of Conformity for Trolley 81

15.3.2 EU Declaration of Conformity for Control Unit 82

15.3.3 EU Declaration of Conformity for Spray Guns 83

15.4 EC Type Examination Certi cate 84

15.5 FM Approval 86

Page 6

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

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. Electrostatic manual coating systems may only be operated by quali ed personnel.

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

Potential risk. Non-observance may result in death or serious injury.

CAUTION

Potentially hazardous situation. Non-observance may result in minor injury.

NOTICE

Potentially hazardous situation. Non-observance may result in damage to property.

Note

Provides information about particular characteristics and how to proceed.

Explanation of warning:

LEVEL OF DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The measures for preventing the hazard and its consequences.

Page 7

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

1.3 LANGUAGES

The operating manual is available in the following languages:

Language Order No. Language Order No.

German 2354919 Chinese 2354925 English 2354920 Portuguese 2368373 French 2354921 Japanese 2367167 Italian 2354922 Danish 2374101 Spanish 2354923 Swedish 2374100 Russian 2354924 Czech 2382850

Additional languages on request or at:

www.wagner-group.com

1.4 ABBREVIATIONS

Order No. Order number

Spare part Marking in the spare parts lists Position Number of pieces

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

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/Revision 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.

Page 8

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

2 CORRECT USE

2.1 DEVICE TYPE

Manual powder system for manual coating of grounded work pieces.

2.2 TYPE OF USE

The Sprint XE manual system is designed for single and serial coatings for industry and trade.

WAGNER explicitly prohibits any other 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 di erent versions of the Sprint XE manual system (Air uid version, 60 L tank version) are mutually compatible.

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 device is suitable for use in potentially explosive areas as de ned in Directive 2014/34/EU (ATEX), (see Explosion protection marking Chapter 3.1). In explosion hazard areas, only use approved explosion-proof electrical devices.

2.4 PROCESSIBLE WORKING MATERIALS

– types of powder that can be charged electrostatically; – metallic powder.

Note:

Contact your local WAGNER 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:

Do not process liquid coating products, e.g. solvents or water-based lacquers; Do not process food, medicine or cosmetics.

Page 9

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

3.1.1 TROLLEY IDENTIFICATION

Device type: Air uid XE trolley/60 L XE trolley Manufacturer: Wagner International AG

9450 Altstätten Switzerland

II 3D Dc T100 °C

CE European Communities Ex Symbol for explosion protection II Device class II 3 Category 3 D Ex-atmosphere dust Dc Device protection level, suitable for use in Zone 22 T100 °C Maximum surface temperature

3.1.2 CONTROL UNIT IDENTIFICATION

The device is suited for use in potentially explosive areas, in accordance with Test Certi cate PTB 12 ATEX 5001.

Device type: EPG-Sprint XE control unit Manufacturer: Wagner International AG

9450 Altstätten Switzerland

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

Page 10

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

3.1.3 SPRAY GUN IDENTIFICATION

The device is suited for use in potentially explosive areas, in accordance with Test Certi cate PTB 12 ATEX 5001.

Device type: PEM-X1 manual gun Manufacturer: Wagner International AG

9450 Altstätten

Switzerland

0102

II 2D 2mJ

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 2 Category 2 D Ex-atmosphere dust 2mJ Maximum ignition energy 2 mJ

The EC-type examination certi cates are listed in Chapter

15.4.

3.2 TYPE PLATES

3.2.1 TROLLEY TYPE PLATE

P_02655

CH–9450 Altstätten

Made in Switzerland

Wagner International AG

II 3D Dc T100°C

Typ: Type:

Manual Unit SPRINT Handanlage SPRINT

SPRINT Airfluid XE

2355400

SPRINT Airfluid XE Jap.

2355800

SPRINT 60L XE

2355403

230 VAC

50 Hz

100 VAC 50/60 Hz

2355402

SPRINT 60L XE USA

2355404

SPRINT Airfluid XE USA

115 VAC

60 Hz

CL II, Div 2

Group F & G

Temperature 40C T4

Ambient

In accordance with control document: 2309729

90-250 VAC

47-63 Hz

90-250 VAC

47-63 Hz

Serial no. Serie Nr.:

Year of manufacture:

Baujahr:

Page 11

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

3.2.2 CONTROL UNIT TYPE PLATE

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

CHí9450 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

Netzeingang

Mains output vibrator

Netzausgang 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!

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

CHí9450 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 :

3.2.3 POWDER SPRAY GUN TYPE PLATE

P_02657

In accordance with control document: 2309729

PEM-X1

Output 100kV max.

Serial Number:

For Electro. Fin. Appl. CL. II Spray Materials

0102 II 2 D 2mJ

PTB 12 ATEX 5002 EN 50050-2

Ambient Temperature 45 °C

Made in Switzerland

Page 12

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

3.3 PERMISSIBLE DEVICE COMBINATIONS

WARNING

Incorrect use!

Risk of injury and damage to the device.

Only use the manual system with the original WAGNER control units and powder spray guns.

Only use the Sprint XE manual system with the following guns and control units:

Control units Guns

– EPG-Sprint XE – PEM-X1 Corona spray gun, PEM-X1 CG

– PEM-C4 Corona spray gun – PEM-C4-Ergo Corona spray gun – PEM-C4-Ergo Corona spray gun FM USA – PEM-T3 Tribo spray gun – Tribo lance TL 1

Permissible device combinations for the USA and Canada, see Chapter

15.5 "FM Approval".

Page 13

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

4 BASIC SAFETY INSTRUCTIONS

4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention.

4.1.1 ELECTRICAL DEVICES AND EQUIPMENT

Electric shock hazard!

Danger to life from electric shock.

Prepare device in accordance with the local safety requirements with regard to the operating mode and ambient in uences.

May only be maintained by skilled electricians or under their supervision. With open housings, there is a danger from line voltage.

Operate device in accordance with the safety regulations and electrotechnical regulations.

Must be repaired immediately in the event of problems. Decommission if it poses a hazard or is damaged. Must be de-energized before work is commenced. Secure the device against being

switched back on without authorization. Inform sta about planned work. Observe electrical safety regulations.

Ground all devices to a common grounding point. Only operate the device with a properly installed socket with a protective ground

wire connection. Keep liquids away from electrical devices.

Page 14

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

4.1.2 A SAFE WORK ENVIRONMENT

Danger due to dust formation!

Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with the skin or eyes.

The  oor in the working area must be electrostatically conductive (measurements according to EN 1081 and EN 61340-4-1).

Paint mist extraction systems/ventilation systems must be  tted on site according to local regulations.

Make sure that the ground connection and potential equalization of all system parts are reliable and continuous and can withstand the expected stress (e.g. mechanical stress, corrosion).

Ensure that personal protective equipment (see Chapter 4.2.1) is available and is used. Ensure that all persons within the working area wear static dissipative shoes.

Footwear must comply with EN 20344. The measured insulation resistance must not exceed 100 M

Protective clothing, including gloves, must comply with EN 1149-5. The measured insulation resistance must not exceed 100 M .

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 powder release must be electronically interlocked with the powder spray system exhaust equipment.

Excess coating product (overspray) must be collected up safely. 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.

In the event of defects, immediately bring the device or system to a stop and arrange to have repairs carried out immediately.

4.1.3 PERSONNEL QUALIFICATIONS

Hazard due to incorrect use of device!

Risk of death due to untrained personnel.

Ensure that the operating personnel has been instructed by the operator in accordance with the operating manual and the operating instructions. The device must only be operated, maintained and repaired by trained personnel. Refer to the operating instructions for information about the required personnel quali cations.

Page 15

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

4.2 SAFETY INSTRUCTIONS FOR STAFF

Always follow the information in this manual, particularly the safety instructions and the warning instructions.

Always follow local regulations concerning occupational safety and accident prevention.

Under no circumstances should people with pacemakers be in the area where the high-voltage  eld between the spray gun and the work piece to be coated builds up!

4.2.1 USE PERSONAL SAFETY EQUIPMENT

Danger due to dust formation!

Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.

Observe the processing regulations laid down by the manufacturer of the powder lacquer being used, when preparing or processing the powder.

Take note of the manufacturer’s noti cation and the relevant environmental protection regulations when disposing of powder lacquers.

Take the speci ed protective measures. In particular wear safety goggles, protective clothing and gloves, as well as hand protection cream if necessary.

Use a mask or breathing apparatus if necessary. For su cient health and environmental safety: Operate the device in a powder

coating booth or on a spraying wall with the ventilation (extraction) switched on.

4.2.2 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES

Danger due to dust formation!

Do not point spray guns at people. Do not spray device parts using electrostatic equipment. Before any work on the device, in the event of work interruptions and malfunctions:

– Switch o the energy/compressed air supply. – Relieve pressure on powder spray gun and device. – Secure the powder spray gun against actuation. – Disconnect the control unit from the mains. – In the event of functional faults: remedy the fault as described in the "Troubleshooting"

chapter.

Carry out the work steps as described in the "Pressure relief" chapter:

– if pressure relief is required, – if the coating work is interrupted or stopped, – before the device is cleaned on the outside, checked, or serviced, – before the spray nozzle is installed or cleaned.

Page 16

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

4.2.3 GROUND THE UNIT

Hazard due to electrostatic charge!

Explosion hazard and damage to the device. The electrostatic charge may, in certain cases, give rise to electrostatic charges on the

device. Flames or sparks can form during discharge. Correct grounding of the entire coating system prevents electrostatic charges:

Ensure that all devices and tanks are grounded before each coating process. All of the system's conductive elements, such as  oors, 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., that they are

wearing static dissipative shoes. Grounding cables must be checked regularly to ensure that they are serviceable

(see EN 60204).

4.2.4 PRODUCT HOSES

Danger due to damaged product hoses!

The product hose may cause dangerous injuries.

Use only an original WAGNER powder hose. Make sure that the hoses are laid only in suitable places. Hoses should not be laid in

the following places under any circumstances:

– in high trafﬁc areas, – on sharp edges, – on moving parts or – on hot surfaces.

Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses are never put under pressure from the outside in any other way.

Ensure that the hoses are never kinked. Observe maximum bending radii. Ensure that no work is ever performed with a damaged hose. Make sure that the hoses are never used to pull or move the equipment.

Page 17

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

4.2.5 CLEANING AND FLUSHING

Hazard due to cleaning and  ushing

Explosion hazard and damage to the device.

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. If  ammable cleaning  uids are used, all parts carrying high voltage must be

discharged to a discharge energy of less than 0.24 mJ, once the high voltage has been switched o , before they can be reached.

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 for

getting rid of dust build-ups. Take measures for workplace safety (see chapter 4.1.2).

4.2.6 MAINTENANCE AND REPAIR

Hazard due to improper maintenance and repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts.

Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by quali ed personnel.

Do not change or modify the device; if change is necessary, contact WAGNER. Only repair and replace parts that are listed in the 12 "Spare parts" chapter and 13

that are assigned to the unit. Do not use any defective components. Exclusively use accessories listed in Chapter 12 and that are assigned to the unit. Before all work on the device and in the event of work interruptions:

- Switch o the energy and compressed air supply.

- Relieve pressure on powder spray gun and device.

- Secure the powder spray gun against actuation.

Observe the operating and service manual for all work.

Page 18

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

4.2.7 PROTECTIVE AND MONITORING EQUIPMENT

Hazard due to removal of protective and monitoring equipment!

Danger to life and equipment damage.

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.

Page 19

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

5 DESCRIPTION

5.1 CONSTRUCTION AND MODE OF OPERATION

5.1.1 DESCRIPTION OF SPRINT AIRFLUID XE

P_02641

Pos Designation

1 Equipment trolley 2 EPG-Sprint XE control unit 3 PEM-X1 manual gun 4 intake tube ST 550/10 5 Powder injector, PI-F1 6 Fluid air throttle 7 Vibration table

Function:

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  uid air setting is done using the throttle (6).

Page 20

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

5.1.2 DESCRIPTION OF SPRINT 60 L XE TANK (WITHOUT VIBRATOR TABLE)

P_02642

Pos Designation

1 Equipment trolley 2 EPG-Sprint XE control unit 3 PEM-X1 manual gun 4 60 L tank 5 Powder injector, PI-F1 6 Fluid air throttle

Function:

Through the powder injector (5), the powder is transported from the tank (4) to the spray gun (3). By feeding  uid air into the  uid 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  uid air setting is done using the throttle (6).

Note:

We recommend using a vibrator table when working with powders that are di cult to feed (see Chapter

12.13).

Page 21

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

5.1.3 OPERATING MODES

5.1.3.1 OPERATION WITH TRIBO GUN

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.

5.1.3.2 OPERATION WITH CORONA AND TRIBO GUN

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 .

The set values for operating with the Tribo gun should be saved to individually selected recipe locations.

5.2 INCLUDED ITEMS

5.2.1 VARIANTS

Order No. Designation

2355400 Sprint Air uid XE manual system (standard version) 2355403 Sprint 60 L XE manual system (standard version) 2355402 Sprint Air uid XE manual system (US version) 2355404 Sprint 60 L XE manual system (US version) 2355800 Sprint Air uid XE manual system (Japanese version)

When working with powders that are di cult to feed, the Sprint 60L XE manual system can be converted into a variant with a vibrator table (see Chapter

12.13).

5.2.2 STANDARD EQUIPMENT

Stk Order No. Designation

See Chapter 13.2 Sprint Air uid XE manual system

1 See Chapter 13.3 Sprint 60 L XE manual system without tank

The standard equipment includes:

1 See Chapter 15.3 Declaration of Conformity 1 2354919 Operating manual, German 1

See Chapter 1.3 Operating manual in local language

Manual systems with a Tribo lance are described in the corresponding operating manual (see Chapter

12.8).

Page 22

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

5.2.3 TECHNICAL DATA

Dimensions:

Height 1,120 mm; 44.10 inch Width 595 mm; 23.43 inch Depth 740 mm; 29.13 inch Weight approx. 40 kg; 88.18 lbs Maximum box size 420x420x400 mm; 16.54x16.54x15.75 inches Maximum  lling 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 110 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 Corona current limitation 5 µA–120 µA (adjustable) Tribo current cut o greater than 12 µA

(ATEX: switching o of the unit)

Pneumatic:

Compressed air connection G1/4" Connection hose diameter 18.5x12.5 mm Pressure range input air 0.6–0.8 MPa ; 6–8 bar; 87–116 psi Air  ow 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

ISO 8573.1

6.5.2 according to ISO 8573.1, 2010

WARNING

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

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.

Page 23

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

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, Tribo lance TL 1

Ambient conditions:

Operating temperature range 5–40 °C; 41–104 °F Noise development < 63 dB (mains pressure 0.6 MPa ; 6 bar; 87 psi)

Page 24

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

5.3 OPERATION OF THE CONTROL UNIT

P_01743

EPG

SPRINT X

100

Tri Cor

120

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

Tri

μA

28 27 30 29 31 32 37 35 2434 36 33

1 2 3 4 20 22 23 18 13 1921

1 Illuminated display: "High voltage"

– Lights up green – Display range: 0-100 kV – Resolution 10 kV – Single LED display: Nominal voltage – Bar display: Working voltage

2 Illuminated display: "Corona or Tribo Current"

– Lights up green

Tribo scale:

– When a Tribo gun is connected and selected – Bar display: When powder feed is activated – Display range: 0-5 µA

Resolution 0.5 µA

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

Page 25

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

3 Display: "Tribo Gun"

– Lights up when a Tribo gun is connected and selected

4 Display: "Corona Gun"

– Lights up when a Corona gun is connected and selected

5 Push button: recipe for "Surface Parts"

6 Push button: recipe for "Second Coating"

7 Push button: recipe for "Pro les"

8 Push button: recipe for "Double Click"

– To access the recipe, press the trigger lever on the spray gun twice in quick succession

and hold it down

9 LED display: recipe for "Surface Parts"

– Lights up green when the recipe for surface part is selected

10 LED display: recipe for "Second Coating"

– Lights up green when the recipe for "Second Coating" is selected

11 LED display: recipe for "Pro les"

– Lights up green when the recipe for pro le part is selected

12 LED display: recipe for "Double Click"

– Lights up green, when the recipe for "Double Click" is selected

13 LED display: "Fault"

– Lights up, when there is a fault on the device

14 LED display: "Automatic Gun"

– Lights up, when an automatic gun is connected

15 Push button: "Standby"

– To switch into standby mode – High voltage and powder feed cannot be activated in this mode – To reactivate normal mode, press the button again

16 LED display: "Standby"

– Lights up when the unit is in standby mode

17 Push button: "Flush"

– To activate the injector and the hose  ushing

Page 26

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

18 LED display: "Flush"

– Lights up blue, when the  ush function is activated

19 LED display: 7 segments, three-digit number

– Indicates the exact value depending on the activated function:

"Total air volume; atomizing, ionizing and Tribo air; additional recipes; high voltage;

current limitation; powder quantity" – Display showing error number in the event of warnings and malfunctions

20 Push button: "Total Air Volume"

– To activate the function, the value is precisely adjusted with rotary controller 24

and is indicated in LED display 19 – Adjusting range: 2-6 m³/h – Resolution: 0.05 m³/h

21 Push button: "Atomizing, Ionizing and Tribo Air"

– To activate the function, the value is precisely adjusted with rotary controller 24

and is indicated in LED display 19 – Adjusting range: 0.1-4 m³/h – Resolution: 0.05 m³/h

22 LED display: "Total Air"

– Lights up yellow, when the setting "Total Air" is selected

23 LED display: "Atomizing, Ionizing and Tribo Air"

– Lights up yellow, when the setting "Atomizing, Ionizing and Tribo Air" is selected

24 Universal control dial

– Dynamic digital control dial with 32 positions per revolution – Adjustment speed is proportional to rotational speed – Used to set: "Total air volume; atomizer, ionizer and Tribo air; additional recipes;

high voltage; current limitation; powder quantity" – For setting parameter values in con guration mode

25 Push button: "Additional Recipes"

– To activate the function, the additional recipes adjustment is set with the rotary

controller (24) and is indicated in the LED display (19). – Selection of the recipes 5 to 50

26 LED display: "Additional Recipes"

– Lights up yellow, when an additional recipe is selected

27 Push button "High voltage"

– To activate the function, the high voltage is set with rotary controller 24 and is

indicated in LED Display 19 – Adjusting range: 10–100 kV – Resolution: 1 kV

Page 27

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

28 LED display: "High Voltage"

– Lights up yellow. The high voltage is selected and can be adjusted using rotary

controller 24

29 Push button: "Current Limitation"

– To activate the function, the current limitation is set with the control dial 24 and is

indicated in the LED display 19 – Adjusting range: 5–120 μA – Resolution: 1 μA

30 LED display: "Current Limitation"

– Lights up yellow. The current limitation is selected and can be adjusted using the

rotary controller (24).

31 Push button: "Characteristic Slope"

– To switch the characteristic slope – Display with LED 32

32 LED display: "Characteristic Slope"

– Lights up green – Lower LED characteristic curve,  at – Middle LED characteristic curve, medium – Upper LED characteristic curve, steep

33 Illuminated display: "Powder Quantity"

– Lights up green – Display range: 0–100 % – Resolution: 3.33 % – Single LED display: Set point (high voltage and powder are deactivated) – Bar display: Actual value (high voltage and powder are activated)

34 Illuminated display: "Total Air Volume"

– Lights up green – Display range: 2–6 m³/h – Resolution: 0.2–0.5 m³/h – Single LED display: Set point (high voltage and powder are deactivated) – Bar display: Actual value (high voltage and powder are activated)

35 Illuminated display: "Atomizing, Ionizing and Tribo Air Volume"

– Lights up green – Display range: 0.1–4 m³/h – Resolution: 0.1–1.0 m³/h – Single LED display: Set point (high voltage and powder are deactivated) – Bar display: Actual value (high voltage and powder are activated)

Page 28

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

36 Push button: "Powder Quantity"

– To activate the function, the powder quantity is set with rotary controller 24 and is

indicated in LED display 19. – Adjusting range: 1–100% – Resolution: 1%

37 LED display: "Powder Quantity"

– Lights up yellow, when the powder quantity is selected

Page 29

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

6 COMMISSIONING

6.1 TRAINING OF ASSEMBLY/COMMISSIONING STAFF

The assembly and commissioning sta must have the technical skills to safely commission the device.

When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned.

6.2 STORAGE CONDITIONS

Until the point of assembly, the device must be stored in a dry location, free from vibrations and with a minimum of dust. The device must be stored in closed rooms.

The air temperature at the storage location must be between -20 °C and +60 °C (-4 °F and +140 °F).

The relative air humidity at the storage location must be between 10 and 95% (without condensation).

6.3 INSTALLATION CONDITIONS

The air temperature at the installation site must be in a range between 0 °C and 40 °C; 32 °F and 104 °F.

The relative air humidity at the installation site must be between 10 and 95% (without condensation).

Page 30

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

6.4 ASSEMBLING THE MANUAL SYSTEM

6.4.1 ASSEMBLING THE EQUIPMENT TROLLEY

The manual system's trolley is supplied unassembled for transport reasons. It must be assembled as described below.

P_02643

25Nm;

18.44lb ft

Procedure:

1. Open transport packaging with care and carefully take all single parts out of packaging.

2. Place lower trolley section (1) on a clean, level surface.

3. Place upper trolley section (2) on the two guide sleeves on the lower trolley section (1), press down gently until stop is reached and use nuts and bolts (see detail) to screw to lower trolley section (tightening torque 25 Nm; 18.44 lb/ft).

4. Mount the gun holder (3) (see separate assembly manual).

6.4.2 ASSEMBLING THE CONTROL UNIT

P_02644

Procedure:

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  ush with the cover at the front.

Page 31

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

6.5 CONNECTING THE MANUAL POWDER SYSTEM

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  lter 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.

6.5.1 CONNECTION REQUIREMENTS

DANGER

Danger from electric current!

Danger to life and equipment damage.

Switch o the main switch 1 on the rear of the equipment before connecting the equipment.

NOTICE

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.

without vibrator motor:

P_02717

Mains input terminal

Mains output terminal

Attach the cover

with vibrator motor:

P_02638

Mains input terminal

Mains output terminal to the

vibrator motor

Page 32

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

6.5.2 CONNECTING THE AIRFLUID MANUAL POWDER SYSTEM

Detail A

11.

P_02639

10.

12.

11.

Page 33

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

Procedure:

1. Connect the hose (black) for mains pressure.

2. Plug in the control cable from the solenoid valve on the control unit.

3. Connect the dosing air hose (blue).

4. Connect the feed air hose (red).

5. Connect the  uid air hose (black). Bundle the three hoses with Velcro cable binders.

6. Connect the powder feed hose.

7. Plug in the gun connection cable on the control unit.

8. Connect the hose (transparent) for the atomizing or Tribo air. Bundle the two hoses and the gun cable with Velcro cable binders.

9. Connect the compressed air hose (12.5x18.5 mm, Order No. 9981951) to the compressed air connection (G1/4") on the manual system.

10. Connect the trolley grounding cable to the control unit. Connect the control unit's grounding cable with the signal ground!

11. Plug in the connection cable from the vibrator motor on the control unit. Fasten the connection cable to the trolley with the delivered Velcro cable binders

(Detail A).

12. Plug in the control unit mains cable.

13. Connect mains cable to the power supply.

Page 34

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

6.5.3 CONNECTING THE 60 L TANK MANUAL SYSTEM

P_03293

10.

14.

16.

13.

11.

12.

15.

Detail A

Page 35

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

Procedure:

1. Place the powder tank on the trolley.

2. Connect the grounding cable to the grounding connection of the powder tank (Detail A).

3. Attach injector to powder tank.

4. Connect the hose (black) for mains pressure.

5. Plug in the control cable from the solenoid valve on the control unit.

6. Connect the dosing air hose (blue).

7. Connect the feed air hose (red).

8. Connect hose (black) for the  uid air to the valve and to the tank (Detail A). Bundle the three hoses with Velcro cable binders.

9. Connect the powder feed hose.

10. Plug in the gun connection cable on the control unit.

11. Connect the hose (transparent) for the atomizing or Tribo air. Bundle the two hoses and the gun cable with Velcro cable binders.

12. Connect exhaust air hose to the connection on the powder tank. The other end of the exhaust air hose must be routed to the extraction unit of the

powder spray booth.

13. Connect the compressed air hose (12.5x18.5 mm, Order No. 9981951) to the compressed air connection (G1/4") on the manual system.

14. Connect the trolley grounding cable to the control unit. Connect the control unit's grounding cable with the signal ground!

15. Attach the cover to the mains output terminal from the controller.

16. Plug in the control unit mains cable.

17. Connect mains cable to the power supply.

Page 36

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

6.6 GROUNDING

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 ground cables as short as possible. Ground cables of an excessive length must be shortened. Ground cables of an excessive length must never be wound up on a roller.

A poorly grounded work piece causes:

– dangerous electric charging of the work piece, – very poor wrap-around, – uneven coating, – back spraying to the spray gun, i.e., contamination.

Prerequisites for perfect grounding and coating of a work piece are:

– clean suspension of the work piece to be coated, – The grounding resistance of the work piece must not exceed 1 M

(Resistance to ground measured at 500 V or 1000 V).

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 su ciently cleaned and therefore the work pieces are not su ciently grounded! These sparks can cause heavy radio frequency interference (EMC).

6.6.1 GROUNDING THE POWDER COATING SYSTEM

P_01827

Page 37

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

1 Only use mains cables with grounding strand! 2 Connect the trolley's grounding cable to the grounding connection of the control unit! 3 Connect the control unit's grounding cable with the signal ground! 4 Connect grounding cable to an uncoated metal part of the booth! 5 Remove all paint from hooks and other hanger parts! 6 Wear electrostatically conductive gloves! 7 Wear electrostatically conductive footwear! 8 The  oor must be electrostatically conductive!

6.7 SAFETY CHECKS

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned. This includes:

– Carry out a safety checks in accordance with Chapter 8.2.3.

Page 38

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7 OPERATION

7.1 TRAINING THE OPERATING STAFF

The operating sta must be quali ed to operate the entire system.

The operating sta must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.

Before work commences, the operating sta must receive appropriate system training.

7.2 WORK

Ensure that:

The regular safety checks are carried out in accordance with Chapter 8.2.3, commissioning is carried out in accordance with Chapters 6.4 and 6.5.

Page 39

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.2.1 SWITCHING ON THE MANUAL SYSTEM

EPG SPRINT X

0 %

100 %

100

Tri Cor

120

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

Tri

μA

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".

– After a few seconds the control unit is operational. – The system switches to recipe 1 "Surface parts" after every restart. – To switch the manual system o or on, actuate the "Standby" push button (2).

Note:

– The  uid air must be adjusted using the throttle (3), when  rst 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.

Page 40

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.2.2 ADJUSTING THE FLUIDIZATION (AIRFLUID)

P_02640

Procedure:

1. Swivel the feed unit (1) to the right side.

2. Place an opened powder tank (25–30 kg; 55.11–

66.14 lbs) on the vibrator table.

3. Switch on the control unit.

4. Swivel the feed system (1) into the powder tank and lower it down to the powder surface. Actuate the trigger of the spray gun for a short time and release it. The vibrator motor and the  uid air overrun for 10 s (factory setting). This setting can be changed by the user if required (see EPGSprint XE control unit operating manual).

5. Adjust the  uid air at the throttle (2) to the point that it makes the feed system sink into the powder due to its own weight.

Note:

– The amount of  uid air depends on the

characteristics of the powder.

– The powder should be moving in the suction

area of the feed unit (gently simmering).

– Avoid a dust build up in the powder tank.

Page 41

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.2.3 ADJUSTING FLUIDIZATION (60 L TANK WITHOUT VIBRATOR TABLE)

WARNING

Dust formation!

Risk of poisoning if inhaled. Danger due to escaping dust, contamination of the device and device components.

The powder tank may only be  lled to the halfway mark, because  uidizing increases the volume of powder.

P_02647

Procedure:

1. Open the lid and  ll the powder tank (1) halfway with powder.

2. Switch on the control unit.

3. Set the "Vibrator motor controller" parameter, on the control unit, to "ON" to permanently activate the  uid air (see the EPG-Sprint XE control unit operating manual).

4. Actuate the trigger of the spray gun for a short time and release it.

5. Adjust the  uid air at the throttle (2) until  uidization is recognizable.

Note:

– The amount of  uid air depends on the

characteristics of the powder. Avoid a build up of powder dust (too much  uid

air) in the powder tank!

6. Close the powder tank 1 and check whether the exhaust air hose is leading in the direction of the ventilation system of the powder coating booth.

Note:

–

We recommend using a vibrator table when working with powders that are di cult to feed (see Chapter

12.13).

Page 42

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.3 FACTORY SETTING RECIPE NOS. 1–4

The following set values are stored in recipe Nos. 1–4 in the factory.

Recipe no. Designation Characteristic High voltage

[kV]

Current limitation

[μA]

Characteristic

curve

Total air

[m³/h]

Feed air

[%]

Atomizing air

[m³/h]

P01 Flat part

High surface

coverage

90 80 Standard 4.0 70 0.1

P02

Second

coating

Avoidance of

spraying back

50 20 Soft 3.6 57 0.1

P03 Pro le part

Penetration

and reduced

build-up of

edges

70 40 Soft 3.6 50 0.1

P04 Double click

Small

components

80 20 Soft 3.6 45 0.1

P05–50 variable individual 80 100 Standard 4.5 80 0.1

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  ow and Tribo air must be adjusted

accordingly and saved.

With the 3 L tank variant, the values must also be adjusted individually and saved.

Page 43

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.4 INTERRUPTING THE COATING PROCESS

7.4.1 AIRFLUID VERSION

NOTICE

Powder residues and sticking  uid disk!

Equipment damage and danger of blockage.

Before the control unit is deactivated, the feed unit must be pulled out of the powder tank.

At every work interruption, blow through the spray gun and the powder feed components and clean from any powder residues.

P_01785

EPG

SPRINT X

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

100

Tri

P_1789

Procedure:

1. Release the trigger on the spray gun.

The high voltage and the powder feed are deactivated.

2. Lift the feed unit up, underneath the injector,

and lift it out of the tank until retaining clamp (H) swivels downwards.

3. Lower the feed system into the parking position

and swivel it to the right side so that no more powder is forwarded.

4. Hold the gun in the spray booth and start the

 ush function by pressing the "Flush" button (17). The injector and hoses are  ushed.

5. Now the control unit can be switched o .

Page 44

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.4.2 60 L TANK VERSION

NOTICE

Powder residues!

Damage to the device.

At every work interruption, blow through the spray gun and the powder feed components and clean from any powder residues.

P_01785

EPG

SPRINT X

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

100

Tri

Procedure:

1. Release the trigger on the spray gun.

The high voltage and the powder feed are deactivated.

2. Remove the injector from the holder to stop

powder feed.

3. Hold the gun in the spray booth and start the

 ush function by pressing the "Flush" button (17). The injector and hoses are  ushed.

4. Switch o control unit.

Page 45

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.5 PERFORMING A PAINT CHANGE

7.5.1 AIRFLUID VERSION

Note:

For a paint change, all components of the powder feed system must be thoroughly cleaned.

P_01785

EPG

SPRINT X

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

100

Tri

P_1789

Procedure:

1. Release the trigger on the spray gun.

The high voltage and the powder feed are deactivated.

2. Lift the feed unit up, underneath the injector,

and lift it out of the tank until retaining clamp (H) swivels downwards.

3. Lower the feed system into the parking position

and swivel it to the right side so that no more powder is forwarded.

4. Hold the gun in the spray booth and start the

 ush function by pressing the "Flush" button (17). The injector and hoses are  ushed.

5. Switch o control unit.

6. Clean all powder feeding parts of the unit, such

as the spray gun, the injector and the powder feed hose.

7. Place an opened powder tank (25–30 kg; 55.11–

66.14 lbs) with the new powder on the vibrator table.

8. Swivel retaining clamp (H) away, lower the feed

unit to the powder surface, actuate the trigger of the spray gun for a short time and then release it.

9. Adjust the  uid air at the throttle to the point

that the feed unit sinks into the powder due to its own weight.

To adapt the programs to the new applications proceed as described in the EPG-Sprint XE control unit's operating manual.

Page 46

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.5.2 60 L TANK VERSION

7.5.2.1 CLEANING PROCESS WHEN USING A SINGLE POWDER TANK

Note:

For a paint change, all components of the powder feed system must be thoroughly cleaned.

P_01785

EPG

SPRINT X

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

100

Tri

Procedure:

1. Release the trigger on the spray gun.

The high voltage and the powder feed are deactivated.

2. Remove the injector from the holder to stop

powder feed.

3. Hold the gun in the spray booth and start the

 ush function by pressing the "Flush" button (17). The injector and hoses are  ushed.

4. Switch o control unit.

5. Open the powder tank and clean all powder

feeding parts of the unit, such as the spray gun, the injector, the powder

feed hose and the suction system.

6. Clean the powder tank and pay special attention

to the  uid base.

Note:

Proper  uidization is not possible with a damaged and/or clogged  uid base.

To adapt the programs to the new applications proceed as described in the EPG-Sprint XE control unit's operating manual.

Page 47

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.5.2.2 CLEANING PROCESS WHEN USING MULTIPLE POWDER TANKS

Note:

For a paint change, all components of the powder feed system must be thoroughly cleaned.

P_01785

EPG

SPRINT X

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

100

Tri

Procedure:

1. Release the trigger on the spray gun.

The high voltage and the powder feed are deactivated.

2. Remove the injector from the holder to stop

powder feed.

3. Hold the gun in the spray booth and start the

 ush function by pressing the "Flush" button (17). The injector and hoses are  ushed.

4. Switch o control unit.

5. Loosen the powder feed hose from the powder

injector and clean the spray gun and the powder feed hose thoroughly.

6. Loosen the blue dosing air hose and the red

feed air hose from the powder injector.

7. Disconnect the black  uid air hose from the

powder tank.

8. Loosen the grounding cable from the powder

tank.

9. Replace the powder tank.

10. Reconnect all the hoses and ground the powder tank by connecting to the grounding cable.

Note:

Proper  uidization is not possible with a damaged and/or clogged  uid base.

Page 48

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.5.2.3 RESTARTING THE MANUAL POWDER SYSTEM

Procedure:

1. Check if the control unit is switched o .

2. Open the powder tank.

WARNING

Dust formation!

Risk of poisoning if inhaled. Danger due to escaping dust, contamination of the device and device components.

The powder tank may only be  lled to the halfway mark, because  uidizing increases the volume of powder.

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  uid air at the throttle until  uidization is recognizable.

Note:

The  uid air quantity is dependent on the powder condition. Avoid a build up of powder dust (too much  uid 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.

Page 49

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

7.6 "DOUBLE CLICK" RECIPE (HIGH DYNAMIC REMOTE)

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 di erent 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.

P_01701

100

Tri Cor

120

μA

100

Tri Cor

120

μA

100

Tri

Cor

120

μA

Page 50

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

8 CLEANING AND MAINTENANCE

8.1 CLEANING

8.1.1 CLEANING STAFF

Cleaning work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during cleaning work:

– Health hazard from inhaling powder lacquer – Use of unsuitable cleaning tools and aids

8.1.2 FLUSHING AND CLEANING THE SYSTEM

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 WAGNER's specialist personnel.

8.2 MAINTENANCE

8.2.1 MAINTENANCE STAFF

Maintenance work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during maintenance work:

– Health hazard from inhaling powder lacquer – Use of unsuitable tools and aids

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

8.2.2 MAINTENANCE INSTRUCTIONS

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy and compressed air supply.

- Relieve spray gun and device pressure.

- Secure the spray gun against actuation.

Observe the operating and service manual for all work.

Page 51

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

Prior to maintenance

– Flush and clean the system. Chapter 8.1.2.

After maintenance

– Carry out safety checks in accordance with Chapter 8.2.3.

8.2.3 SAFETY CHECKS

8.2.3.1 GROUNDING CHECK

Daily: Before starting work, carry out a visual inspection to ensure that the system is grounded.

8.2.4 MAINTENANCE PROCEDURES

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 WAGNER's specialist personnel.

Maintenance work Time stamp

per shift weekly

Blow out gun and check for sintering

Check gun settings Check gun discharge pressure Blow out powder hoses Check grounding Check compressed air quality Check gun voltage Check powder hoses for bends and sintering

Page 52

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

8.3 PERIODIC CHECKING OF THE MANUAL SYSTEM

8.3.1 AIRFLUID VERSION

P_01785

EPG

SPRINT X

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

100

Tri

P_01787

P_1789

Procedure:

1. Release the trigger on the spray gun. The high voltage and the powder feed are

deactivated.

2. Lift the feed unit up, underneath the injector, and lift it out of the tank until retaining clamp (H) swivels downwards.

3. Lower the feed system into the parking position and swivel it to the right side so that no more powder is forwarded.

4. Hold the gun in the spray booth and start the  ush function by pressing the "Flush" button (17).

The injector and hoses are  ushed.

5. Switch o control unit.

6. Remove the union nut on powder feed hose (3) 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  uid air hose (black) o suction connector (2).

10. Pull injector (4) out of feed unit (1).

11. Check injector 4 for wear and replace worn parts if necessary.

The wearing and spare parts can be found in the powder injector's operating manual.

12. Pull feed unit (1) out of the holder arm.

13. Blow out the intake tube of the feed unit (1) thoroughly and rub it clean with a dry cloth.

14. Check whether the  uid disk on the bottom of the feed unit is blocked and replace if necessary.

Page 53

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

8.3.2 60 L TANK VERSION

P_01785

EPG

SPRINT X

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

100

Tri

P_01140

P_01141

Procedure:

1. Release the trigger on the spray gun. The high voltage and the powder feed are

deactivated.

2. Remove powder injector (1) from holder (2).

3. Hold the gun in the spray booth and start the  ush function by pressing the "Flush" button (17).

The injector and hoses are  ushed.

4. Switch o control unit.

5. Release the union nut on powder feed hose (3) and disconnect powder feed hose (3) from injector (1).

6. Disconnect the red feed air hose (4) from injector (1).

7. Disconnect the blue dosing air hose (5) from the injector (1).

8. Check powder injector for wear and replace worn parts if necessary.

The wearing and spare parts can be found in the powder injector's operating manual.

9. Loosen the exhaust air hose (6) from the connection (7) of the powder tank (8).

10. Pull the black  uid air hose (9) o the powder tank (8).

11. Loosen the grounding cable (10) from the powder tank (8).

12. Lift the powder tank o from the equipment trolley for cleaning.

13. Open the lid of the powder tank to empty the powder tank and thoroughly blow out the powder tank.

14. Completely remove all residual powder from the suction system.

15. Pay special attention when cleaning the  uid base, check it for blockage or damage and replace it if necessary.

The wearing and spare parts are in the "Spare Parts" chapter of this operating manual.

Page 54

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

9 TROUBLESHOOTING AND RECTIFICATION

Malfunction Cause Remedy

Power indicator does not light up – Mains supply not switched on – Turn on mains. No Corona power supply – 2 AT fuses defective. – Replace fuses.

– The connection cable to the

powder spray gun is interrupted.

– To replace the connection cable,

notify the WAGNER service department or quali ed personnel.

– The powder spray gun is too

close to the work piece.

– Switch o the high voltage,

increase the distance between the spray gun and the work piece and then switch the high voltage on again.

Should an error message be displayed again, inform the WAGNER Service Department.

– The grounding between control

unit and powder spray gun is interrupted.

– Contact WAGNER Service

Department

Sputtering powder feed – The  ow rate in the powder feed

hose is too low.

– Increase the total feed and dosing

air and readjust the ratio of the airs to each other.

– The cross section of the powder

feed hose is reduced by movement.

– Use a powder hose that prevents

the cross section from narrowing (Select a hose with a thicker wall.).

– Fluctuations in the compressed

air caused by short-term increase of the compressed air consumption in the supply system.

– Install compressed air storage

directly in front of high consumption system components.

Dust buildup above the drum or the powder tank

– Too much  uid air. – Reduce the  uid air at the throttle. – The throttle is not connected to

the  uid air connection of the control unit.

– Connect the throttle to the  uid

air connection of the control unit and readjust the  uid air volume.

Bad wrap around, back-spray – Insu cient grounding –

Make sure that all components are well grounded, see Chapter 6.6 "Grounding".

Page 55

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

Malfunction Cause Remedy

No powder feed – Tank or powder tank empty – Re ll the powder.

– The spray gun is clogged. – Blow through the spray gun. – The powder feed hose is

clogged.

– Blow through the powder feed

hose.

– The powder suction system in

the powder tank is clogged.

– Blow through the powder suction

system.

– The feed air hose is bent. – Straighten or replace the feed air

hose.

– The powder feed hose is kinked. – Straighten or replace the powder

feed hose.

The feed unit does not sink into the powder

– The guide of the feed unit

holder is jammed.

– Enable the guide to move smoothly.

Page 56

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

10 INSPECTIONS

If the system is used for electrostatic coating with  ammable coating powders, testing should be undertaken in accordance with DIN EN 50050-2: 2014 as per Table 1.

Section Type of inspection Requirements Inspection by Type of inspection Inspection

interval

1 Ground leaking resistance

from the work piece

attachment point

The resistance to ground of every

work piece's locating point must

not exceed 1 MΩ (measurement

voltage must be 1000 V). The form

of construction of the work piece

mount must guarantee that the

work pieces remain grounded

during coating.

SP ME/CM

Measure resistance to ground

(work piece receiver - ground

potential)

max. 1 MΩ @ 1000 V.

weekly

2 Link between technical

ventilation equipment and

high voltage, compressed air

and powder feed

The technical ventilation should

be interlocked such that the

powder feed and high voltage

cannot be switched on, while the

technical ventilation is not working

e ectively.

SP FT

Test whether the system is safely

stopped and the powder feed,

supply air, and high voltage

are switched o when the

ventilation is shut down.

annually

3 Checking the electrostatic

manual coating system for

damage

Electrostatic manual coating

systems may only be operated in an

undamaged condition. Damaged

devices must be decommissioned

immediately and repaired

immediately.

SP FT

Inspect and test

(e.g., by measurement) whether

all parts carrying high voltage

do not result in discharge which

puts people at risk.

weekly

Legend:

MF = Manufacturer FT = Function test

ER = Employer ME = Measurement

SP = Skilled person OC = Organization check

FPO = Fire prevention o cer VI = Visual inspection

ELT = Electrician CM = Constant monitoring

TP = Trained person TT = Technical testing

Page 57

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

11 DISASSEMBLY AND DISPOSAL

11.1 DISASSEMBLY

WARNING

Incorrect disassembly!

Risk of injury and damage to the device.

Before starting disassembly:

- Switch o the energy and compressed air supply. – Ensure that all system components are grounded. – Secure system against being switched back on without authorization.

Observe the operating manuals when carrying out all work.

Procedure:

1. Switch o the system.

2. Pull the connection cable out of the socket.

3. Lock the compressed air supply and decompress system.

4. Separate the connection cable from the compressed air connection.

5. Separate the grounding cable from the signal ground.

11.2 DISPOSAL

NOTICE

Do not dispose of used electrical equipment with household refuse!

In accordance with European Directive 2012/19/EU 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 electric 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.

Page 58

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12 ACCESSORIES

12.1 FEED SYSTEM SN-2 550/10

P_00418

Order No. Designation

265272 Feed system, SN-2 550/10

12.2 MAINTENANCE UNIT

P_01355

Order No. Designation

2314265 Maintenance unit 2314308 Filter cartridge (spare part) 2314309 Fine- lter cartridge (spare part)

Page 59

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.3 QUICK COUPLING SET

Order No. Designation

2312543 Quick coupling set

935658 Compressed air hose 9.5 mm

12.4 ADAPTER PLATE SWITCHBOX

P_01158

Order No. Designation

2308079 Adapter plate switchbox

12.5 SPRAY GUN SWITCHBOX

P_00670

Order No. Designation

265911 Spray gun switchbox

When alternately a Corona or a Tribo gun is operated

2313993 Hose (black,

4x6 mm)

Page 60

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.5.1 INSTALLATION OF THE SWITCHBOX

WARNING

Danger from electric current!

Risk of injury and damage to the device.

Before starting with the installation of the switchbox, the manual system must be switched o and the mains plug disconnected.

P_01159

Procedure:

1. Screw switchbox (1) to adapter plate (3) with screws (2).

P_01183

2. Use screws (4) to screw adapter plate with  tted switchbox onto the back side of trolley's front plate.

P_02718

Connection for Corona guns Connection for Tribo guns

3. Pull the spray gun cable out of the socket (A) on the control unit.

4. Plug the switchbox's electrical cable (B) into the socket (A) on the control unit and secure it with the protective sleeve.

5. Connect the spray gun to the appropriate connection on the switchbox and secure it with the protective sleeve of the spray gun cable.

6. Set the switch (C) on the switchbox to the desired spray gun type.

Page 61

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.5.2 SWITCHING THE GUN TYPES

Note:

Clean the powder residues from all powder-conveying parts thoroughly, before changing to another gun type.

P_01785

EPG

SPRINT X

m /h

2.0

3.0

0.5

0.3

0.1

1.5

5.5

4.5

3.5

2.5

100

Tri

P_02719

Procedure:

(For example: switching from Corona to Tribo)

1. Switch o control unit with switch 1 on the rear 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 rear or with "Standby" button 15 on the front.

Note:

Parameter C11, in the EPG-Sprint XE control unit device con guration, must be set to "aut". No gun is selected at  rst after the control unit is switched on. This will however be automatically selected and displayed after 1 second.

Page 62

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.6 PEM-T3 MANUAL GUN

P_01422

Order No. Designation

351019 PEM-T3 Tribo manual gun

12.7 PEM-T3 EXTENSION

P_00923

Order No. Designation

260934 Nozzle extension, PEM-T3

Page 63

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.8 RETROFIT SET, TRIBO LANCE TL1

P_03027

Order No. Designation

2370544 Retro t set, Tribo lance TL1-1000 2370545 Retro t set, Tribo lance TL1-1800 2370546 Retro t set, Tribo lance TL1-2800 2369617 Hose set, TL 1-8 m 2369618 Hose set, TL 1-12 m 2369619 Hose set, TL 1-16 m

12.9 SWIVEL CASTERS SET

P_01680

P_02648

Order No. Designation

2324869 Swivel casters set

Page 64

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.10 POWDER HOSE

Order No. Designation

351794 Powder hose

9 mm 2310699 Powder hose 10 mm 2307502 Powder hose 11 mm 2310700 Powder hose 12 mm

12.11 SPRINT DUAL MANUAL COATING SET

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 di erent connecting parts and cables.

Order No. Designation

2331417 Sprint dual manual coating set

12.12 WALL MOUNT

P_01861

Order No. Designation

2330223 Wall mount with bracket

Page 65

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.13 CONVERSION SETS

When working with powders that are di cult to feed, the manual system can be converted into a variant with a 60L vibrator table. When working with small components or small batches, the manual system can be converted into a variant with a 3L vibrator table.

Note:

The conversion sets have no FM approval!

P_02649

P_02650

Sprint 60 L V Sprint 3 L V

Order No. Designation

2373856 Sprint XE 60L 230V/50Hz conversion set 2383231 Sprint XE 60L 115V/60Hz conversion set (USA/Japan) 2373883 Sprint XE 3L 230V/50Hz conversion set 2383232 Sprint XE 3L 115V/60Hz conversion set (USA/Japan)

Page 66

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

12.14 RECIPE LABEL

Tribo Corona

m /h

3.0

0.5

0.3

0.1

1.5

Tri

m /h

2.0

5.5

4.5

3.5

2.5

0 %

100 %

[μA] [Nm³/h] [%][kV]

[Nm³/h]

0.1

> 0.2

90 80 4.0 70

50 20 3.6 57

70 40 3.6 50

P10

name 80 100 4.5 80

______________________________

www

✆

www.wagner-group.com/industry

______________________________

82 20 3.6 45

P_01829

Order No. Designation

2331223 Recipe label

12.15 EXTENDED OPERATING MANUAL

If additional information regarding the individual components is desired, the operating manuals listed below can be resorted to.

This extended operating manual includes:

– important notes regarding connecting, commissioning and the operation (e.g., paint

change) of the relevant components, – the very important chapter “Maintenance and Cleaning" for the relevant components, – troubleshooting and error correction for the relevant components, – spare parts, wearing parts and accessories.

Description Language Order No.

EPG-Sprint XE control unit German 2354911

English 2354913

Powder injector, PI-F1 German 241890

English 241891

HiCoat ED-Pump F powder injector German 241885

English 241886

PEM-X1 manual gun German 2326019

English 2326020

PEM-T3 manual gun German 351708

English 351709

Tribo lance, TL1 German 2371010

English 2371011

Page 67

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13 SPARE PARTS

13.1 HOW TO ORDER SPARE PARTS?

Always supply the following information to ensure delivery of the right spare part:

Order number, designation and quantity

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.)

Identi cation in spare parts lists.

Explanation of column "K" (labeling) in the following spare parts lists:

Wearing parts

Note: These parts are not covered by warranty terms.

Not part of standard equipment, available, however, as additional extra.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and

replace parts.

Only repair and replace parts that are listed in the "Spare parts" chapter and that are

assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy and compressed air supply.

- Relieve spray gun and device pressure.

- Secure the spray gun against actuation.

Observe the operating and service manual for all work.

Page 68

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13.2 SPARE PARTS LIST OF SPRINT AIRFLUID XE MANUAL POWDER SYSTEM

P_02640

Pos K Stk Order No. Designation

2355400 Sprint Air uid XE manual system (standard version) 2355402 Sprint Air uid XE manual system (USA version)

2355800 Sprint Air uid XE manual system (Japanese version) 1 1 2355405 Air uid XE trolley (standard version) 1 1 2356434 Air uid XE trolley (US/Japanese version) 2 1 2353221 EPG-Sprint XE control unit

9951116 Thermal delay fuse 2A (included in EPG-Sprint XE) 3 1 241622 Powder injector, PI-F1 4 1 265281 Intake tube, ST 550/10 5 1 2322587 PEM-X1 manual gun 6 2306401 Sprint connection parts

6/1 1 2303714 Sealing coupling with anti-kink spring 6/2 1.3 m 9982079 Hose, black

6 mm 6/3 1.3 m 700370 Hose, blue 8 mm 6/4 1 935973 Sealing coupling with anti-kink spring 6/5 1.3 m 2302060 Hose, red

8 mm 6/6 1 935974 Coupling plug with anti-kink spring 6/7 5 2327855 Velcro cable ties

7 1 2355337 Vibrator motor 230V/50Hz (standard version) 7 1 2355338 Vibrator motor 115V/60Hz (US/Japanese version) 8 265266 Powder hose set

11x5000 mm; 0.43x196.85 inches

9 1 130215 Grounding cable 10 m; 32.81 ft

Page 69

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

10 1 241270 Mains cable (Europe) 10 1 264626 Mains cable (USA) 10 1 264625 Mains cable (Japan)

Not included in the scope of delivery, please order separately:

11 1 2331976 Sprint round spray spare parts starter set 11 1 2349959 Sprint fan spray spare parts starter set

Page 70

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13.3 SPARE PARTS LIST OF SPRINT 60 L XE MANUAL POWDER SYSTEM TANK

(without vibration table)

P_02651

Pos K Stk Order No. Designation

2355403 Sprint 60 L XE manual system (standard version)

2355404 Sprint 60 L XE manual system (US version) 1 1 2355407 60 L XE trolley 2 1 2353221 EPG-Sprint XE control unit

9951116 Thermal delay fuse 2A (included in EPG-Sprint XE) 3 1 241622 Powder injector, PI-F1 4 1 2322587 PEM-X1 manual gun 5 2306401 Sprint connection parts

5/1 1 2303714 Sealing coupling with anti-kink spring 5/2 1.3 m 9982079 Hose, black

6 mm 5/3 1.3 m 700370 Hose, blue 8 mm 5/4 1 935973 Sealing coupling with anti-kink spring 5/5 1.3 m 2302060 Hose, red

8 mm 5/6 1 935974 Coupling plug with anti-kink spring 5/7 5 2327855 Velcro cable ties

6 265266 Powder hose set 11x5000 mm; 0.43x196.85 inches 7 1 130215 Grounding cable 10 m; 32.81 ft 8 1 241270 Mains cable (Europe) 8 1 264626 Mains cable (USA)

Page 71

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

Not included in the scope of delivery, please order separately:

1 264268

Powder tank, 60 L

9 1 264224

Powder tank, 25 L

10 1

2331976

Sprint round spray spare parts starter set

10 1 2349959

Sprint fan spray spare parts starter set

13.4 TROLLEY SPARE PARTS

P_02652

Pos K Stk Order No. Designation

2307117

Sprint injector bracket, complete

2325026

intake tube bush

2325022

Retaining clamp

2362487

Pipe clamp (capacitor seat vibrator motor)

2305431

Adjustment foot

2305421

Nut

2303279

Guide bush

2330599

Gun holder

9950817

Cable entry grommet

= Wearing parts

Page 72

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13.5 INTAKE TUBE, ST 550/10

P_01155

Pos K Stk Order No. Designation

1 1 265281 Intake tube, ST 550/10 2

1 265401 Fluid crown 3 1 265402 Fluid ring 4 1 2303716 Plug-in  tting, G1/8" 5 1 2307727 Extension

= Wearing parts

Page 73

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13.6 FEED SYSTEM, SN2 550/10

P_00577

Pos K Stk Order No. Designation

265272 Feed system, SN-2 550/10

1 265401 Fluid crown 2 1 265402 Fluid ring 3 1 9999047 Plug-in  tting, G1/8"

= Wearing parts

Page 74

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13.7 COMPRESSED AIR SUPPLY

Rear view of the control unit

P_02720

Pos K Stk Order No. Designation

1 1 2303294 Solenoid valve, 2/2 way 2 1 2304119 Fluid air throttle 3 1 2305860 Filter precipitator

9981951 Compressed air connection hose, 18.5x12.5 mm

Page 75

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13.8 POWDER INJECTOR, PIF1

P_00894

Pos K Stk Order No. Designation

241622 Powder injector, PI-F1 1 1 241225 Annular gap collector nozzle 21

241476

Hose sleeve

241466

Union nut

1 241923 Air nozzle

241460

Spring check valve

1 9970149 Sealing ring

9992709

Quick-release plug

9992710

Quick-release socket

1 9970150 Sealing ring

11 2 9974023 Sealing ring, electrically conductive

= Wearing parts

Page 76

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13.9 HICOATED PUMP F

P_00889

Pos K Stk Order No. Designation

241624 HiCoat-ED pump F 1 1 241229 Collector nozzle low air 2 1 241479 Hose sleeve 3 1 241466 Union nut 4

1 241930 Air nozzle 5 2 241460 Spring check valve 7 1 9970149 Sealing ring 8 1 9992709 Quick-release plug 9 1 9992710 Quick-release socket

1 9970150 Sealing ring

11 2 9974023 O-ring, electrically conductive

= Wearing parts

Page 77

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

13.10 60 L/25 L TANK

P_01156

Page 78

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

Pos K Stk Order No. Designation

1 1 264268 Powder tank, 60 L 1 1 264224 Powder tank, 25 L 2 1 264215 Base housing 3 1 264381 Lid 4

1 264382 Fluidized bed 5 1.10 m 9971527 Foam rubber seal 6 6 9994703 Spring clip 7 12 9900717 Socket cap screw 8 1 9992270 Quick coupling for screw-on connector 9 1 184336 Hose  tting

10 1 9910109 Hexagon nut 11 9982058 Exhaust hose, 17x3 mm 13 1 241372 Injector connection, complete 14 1 170533 Knurled nut 15 2 9920118 Washer 16 1 241276 Grounding cable, complete 17 12 9922102 Star washer 19 1 241376 Cable connection 20

1 263357 Intake tube, 60 L

20 1 264420 Intake tube, 25 L 21 1.10 m 8324008 Base seal 24

2 9971178 O-ring

= Wearing parts

Page 79

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

14 WEARING PARTS

Order No. Designation

P_01664

2321976 Fan spray nozzle, X1, complete

P_01665

2321981 De ector cone 18 mm, complete 2321980 De ector cone 25 mm, complete 2321171 De ector cone 34 mm, complete

P_00696

260928 Fan spray nozzle for PEM-T3

P_00697

259474 De ector cone 22 mm for PEM-T3

P_00723

265401 Fluid crown of suction unit

P_00698

265402 Fluid ring of suction unit

P_00699

241225 Clearance collector nozzle of PI-F1 Injector

P_01826

241229 Collector nozzle ED pump

Page 80

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

15 GUARANTEE AND CONFORMITY DECLARATIONS

15.1 IMPORTANT NOTES ON PRODUCT LIABILITY

As a result of an EC regulation e ective 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.

15.2 WARRANTY CLAIM

Full warranty is provided for this device: We will at our discretion repair or replace free of charge all parts which within 24 months in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by the purchaser are found to be wholly or substantially unusable due to causes prior to the sale, in particular faulty design, defective materials or poor workmanship. The type of warranty provided is such that the device or individual components of the device are either replaced or repaired as we see  t. The resulting costs, in particular shipping charges, road tolls, labour and material costs will be borne by us except where these costs are increased due to the subsequent shipment of the device to a location other than the address of the purchaser. We do not provide warranty for damage that has been caused or contributed to for the following reasons: Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a third party, normal wear, negligent handling, defective maintenance, unsuitable coating products, substitute products and the in uence of chemical, electrochemical or electrical agents, except when the damage is attributable to us. Components that have not been manufactured by WAGNER are subject to the original warranty of the manufacturer. Replacement of a component does not extend the period of warranty of the device. The device should be inspected immediately upon receipt. To avoid losing the warranty, we or the supplier company are to be informed in writing about obvious faults within 14days upon receipt of the device. We reserve the right to have the warranty compliance met by a contracting company. The services provided by this warranty are dependent on evidence being provided in the form of an invoice or delivery note. If the examination discovers that no warranty claim exists, the costs of repairs are charged to the purchaser. It is clearly stipulated that this warranty claim does not represent any constraint on statutory regulations or regulations agreed to contractually in our general terms and conditions.

Wagner International AG

Page 81

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

15.3 EU DECLARATION OF CONFORMITY

15.3.1 EU DECLARATION OF CONFORMITY FOR TROLLEY

Herewith we declare that the supplied version of:

Air uid XE trolley/60 L XE trolley

complies with the following guidelines:

2006/42/EC 2014/34/EU 2011/65/EC 2002/96/EC

Applied standards, in particular:

EN ISO 12100: 2010 EN 13463-5:2011 EN 1127-1:2011 EN 61010-1:2010 EN 60079-0:2012 EN 60204-1: 2006 +A1: 2009 EN 60079-31:2014 EN 61000-6-2: 2005 EN 13463-1:2009 EN 61000-6-4: 2007 +A1: 2011

Applied national technical standards and speci cations, in particular:

BGI 764

Identi cation:

II 3D Dc T100 °C

EU Declaration of Conformity

The EU Declaration 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: 2354822

Page 82

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

15.3.2 EU DECLARATION OF CONFORMITY FOR CONTROL UNIT

Herewith we declare that the supplied version of:

EPG-SPRINT XE

complies with the following guidelines:

2014/34/EU 2004/108/EC 2011/65/EC 2002/96/EC

Applied standards, in particular:

EN 50050-2:2013 EN ISO 80079-34: 2011 EN 50177: 2009 +A1: 2012 EN ISO 13849-1: 2008 EN 1127-1:2011 EN 60529: 1991 +A1: 2000 +A2: 2013 EN 60079-0: 2012 +A11: 2013 EN ISO 12100: 2010 EN 60079-31:2014 EN 61000-6-2: 2005 EN 60204-1: 2006 +A1: 2009 EN 61000-6-4: 2007 +A1: 2011

Applied national technical standards and speci cations, in particular:

BGI 764

Identi cation:

II 3(2)D

0102

EU Declaration of Conformity

The EU Declaration 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: 2327595

Page 83

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

15.3.3 EU DECLARATION OF CONFORMITY FOR SPRAY GUNS

Herewith we declare that the supplied version of:

PEM-X1

complies with the following guidelines:

2014/34/EU 2006/42/EC 2004/108/EC 2011/65/EC 2002/96/EC

Applied standards, in particular:

pr EN 50050-2: 2011 EN 14462:2010 EN 50050:2007 EN 60529:2000 EN 1127-1:2011 EN ISO 12100: 2011 EN 60079-0:2010 EN 61000-6-2: 2011 EN 60079-7:2007 EN 61000-6-4: 2011 EN 60079-31:2010 EN 62061:2010 EN 1953:2010 EN ISO 13849-1: 2008 EN 60204-1:2007 EN 50177:2010 EN ISO 80079-34: 2012

Applied national technical standards and speci cations, in particular:

BGI 764

Identi cation:

II 2D 2mJ

0102

PTB 12 ATEX 5002 EN 50050-2:2012

EU Declaration of Conformity

The EU Declaration 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: 2326024

Page 84

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

15.4 EC TYPE EXAMINATION CERTIFICATE

Page 85

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

Page 86

OPERATING MANUAL

VERSION 05/2017 ORDER NUMBER DOC 2354920

SPRINT XE

15.5 FM APPROVAL

The Sprint manual system is FM approved in the USA and Canada using the con guration drawing no. 2309729.

P_00309

Page 87

Page 88

Order No. 2354920 Version 05/2017

Germany

Phone Telefax E-mail ts-powder@wagner-group.com

Switzerland

Phone Telefax

More contact addresses:

www.wagner-group.com

Subject to changes without notice

Document No. 11169083

Version A