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
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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
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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
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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
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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.
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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.
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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.
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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
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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:
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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!
I
O
Air input
Lufteingang
For operation all ports must be fitted
with a plug or the protection cap.
Für den Betrieb in der Zone 22
müssen alle Anschlüsse mit Stecker
oder Schutzkappe versehen sein.
Overvoltage Category II
and pollution Degree 2
EPG-Sprint XE
FM approved for CL II, Div 2, Grps E, F, &G
Ambient temp range 5C to 40C T5
In accordance with control document: 2309729
Acceptable equipment combination
see operator manual
Zulässige Gerätekombination
siehe Betriebsanleitung
Year of manufacture:
Baujahr :
Type / Typ:
Serial No.:
Serie Nr.:
Voltage:
Spannung:
Line Power:
Eingangsleistung:
Prot. Class:
Schutzart:
EPG-SPRINT XE
90-250 VAC 47-63 Hz
max. 110 W
IP64
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
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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".
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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.
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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.
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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.
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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.
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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.
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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.
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5 DESCRIPTION
5.1 CONSTRUCTION AND MODE OF OPERATION
5.1.1 DESCRIPTION OF SPRINT AIRFLUID XE
5
4
7
3
2
1
6
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).
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5.1.2 DESCRIPTION OF SPRINT 60 L XE TANK (WITHOUT VIBRATOR TABLE)
5
4
3
2
1
6
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).
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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
1
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).
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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. 0.9A
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 ≤ 0.1mg/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.
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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)
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5.3 OPERATION OF THE CONTROL UNIT
P_01743
EPG
SPRINT X
2x
2x
0
%
100
%
kV
80
60
40
20
100
Tri Cor
5
4
3
2
1
120
80
40
20
10
10
20
30
40
50
60
70
80
90
Ø
12
10
11
9
8
m /h
2.0
3.0
0.5
0.3
0.1
1.5
3
5.5
4.5
3.5
2.5
Tri
μA
28 27 30 29 31 32 37 35 2434 36 33
1 2 3 4 20 22 23 18 13 1921
12
8
11
7
10
6
9
25
26
16
17
15
14
5
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
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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
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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
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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)
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