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Translation of the Original Operating Manual For professional use. Version 05/2017 Always follow the information in this manual, particularly the safety instructions and the warning instructions. Store the manual in a safe place. SPRINT XE Manual Powder System P_02640...
Maintenance and Repair 4.2.7 Protective and Monitoring Equipment DESCRIPTION Construction and Mode of Operation 5.1.1 Description of Sprint Airfl uid XE 5.1.2 Description of Sprint 60 L XE tank (Without Vibrator Table) 5.1.3 Operating Modes Included Items 5.2.1 Variants 5.2.2 Standard Equipment 5.2.3...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL COMMISSIONING Training of Assembly/Commissioning Staff Storage Conditions Installation Conditions Assembling the Manual System 6.4.1 Assembling the Equipment Trolley 6.4.2 Assembling the Control Unit Connecting the Manual Powder System 6.5.1 Connection Requirements 6.5.2 Connecting the Airfl uid Manual Powder System 6.5.3...
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13.1 How to Order Spare Parts? 13.2 Spare Parts List of Sprint Airfl uid XE Manual Powder System 13.3 Spare Parts List of Sprint 60 L XE Manual Powder System Tank 13.4 Trolley Spare Parts 13.5 Intake Tube, ST 550/10 13.6...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL ABOUT THESE INSTRUCTIONS 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.
Spanish 2354923 Swedish 2374100 Russian 2354924 Czech 2382850 Additional languages on request or at: www.wagner-group.com ABBREVIATIONS Order No. Order number Spare part Marking in the spare parts lists Position Number of pieces TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning...
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 fi xtures.
OPERATING MANUAL IDENTIFICATION EXPLOSION PROTECTION IDENTIFICATION 3.1.1 TROLLEY IDENTIFICATION Device type: Airfl uid XE trolley/60 L XE trolley Manufacturer: Wagner International AG 9450 Altstätten Switzerland II 3D Dc T100 °C European Communities Symbol for explosion protection Device class II Category 3...
3.1.3 SPRAY GUN IDENTIFICATION The device is suited for use in potentially explosive areas, in accordance with Test Certifi cate PTB 12 ATEX 5001. Device type: PEM-X1 manual gun Manufacturer: Wagner International AG 9450 Altstätten Switzerland II 2D 2mJ 0102 European Communities...
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:...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL BASIC SAFETY INSTRUCTIONS 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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 fl oor in the working area must be electrostatically conductive (measurements according to EN 1081 and EN 61340-4-1).
For suffi 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.
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: –...
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 qualifi ed personnel.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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, modifi ed or rendered unusable.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL DESCRIPTION CONSTRUCTION AND MODE OF OPERATION 5.1.1 DESCRIPTION OF SPRINT AIRFLUID XE P_02641 Pos Designation Equipment trolley EPG-Sprint XE control unit PEM-X1 manual gun intake tube ST 550/10 Powder injector, PI-F1 Fluid air throttle Vibration table Function:...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 5.1.2 DESCRIPTION OF SPRINT 60 L XE TANK (WITHOUT VIBRATOR TABLE) P_02642 Pos Designation Equipment trolley EPG-Sprint XE control unit PEM-X1 manual gun 60 L tank Powder injector, PI-F1 Fluid air throttle...
15 m³/h; 529.63 cf/h Sum of feed and dosing air 2–12 m³/h; 70.6–423.7 cf/h Gun air 0.05–4.5 m³/h; 1.765–158.9 cf/h WAGNER injector type PI-F1, HiCoat ED pump F, PI-F1-S Compressed air quality according to 6.5.2 according to ISO 8573.1, 2010 ISO 8573.1...
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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...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL OPERATION OF THE CONTROL UNIT 20 22 23 18 13 m /h Co r Ø μA 10 0 SP R IN T X EP G P_01743 30 29 31 32 37 35 1 Illuminated display: "High voltage"...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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"...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 18 LED display: "Flush" – Lights up blue, when the fl ush function is activated 19 LED display: 7 segments, three-digit number – Indicates the exact value depending on the activated function: "Total air volume;...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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 –...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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% –...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL COMMISSIONING TRAINING OF ASSEMBLY/COMMISSIONING STAFF The assembly and commissioning staff 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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. Procedure: 1. Open transport packaging with care and carefully take all single parts out of packaging.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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 fi lter water separator (4) as a standard feature. Nevertheless, a high compressed air quality is still required for safe operation of the system.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 6.5.2 CONNECTING THE AIRFLUID MANUAL POWDER SYSTEM Detail A P_02639...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 6.5.3 CONNECTING THE 60 L TANK MANUAL SYSTEM Detail A P_03293...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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!
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF The operating staff must be qualifi ed to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 7.2.1 SWITCHING ON THE MANUAL SYSTEM m /h Ø μA SPRINT X P_02646 To turn the power supply of the manual powder system on, set the mains switch on the back side (A) of the control unit to position "I".
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 7.2.2 ADJUSTING THE FLUIDIZATION (AIRFLUID) 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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 fi lled to the halfway mark, because fl uidizing increases the volume of powder.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL FACTORY SETTING RECIPE NOS. 1–4 The following set values are stored in recipe Nos. 1–4 in the factory.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL INTERRUPTING THE COATING PROCESS 7.4.1 AIRFLUID VERSION NOTICE Powder residues and sticking fl 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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. Procedure: 1.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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. Procedure: 1. Release the trigger on the spray gun. The high voltage and the powder feed are deactivated.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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. Procedure: 1.
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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. Procedure: 1. Release the trigger on the spray gun. The high voltage and the powder feed are deactivated.
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 7.5.2.3 RESTARTING THE MANUAL POWDER SYSTEM Procedure: 1. Check if the control unit is switched off . 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL "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 diff erent parameters (high voltage, current limitation, air volumes etc.).
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.
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...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL PERIODIC CHECKING OF THE MANUAL SYSTEM 8.3.1 AIRFLUID VERSION 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, m /h and lift it out of the tank until retaining clamp Ø...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 8.3.2 60 L TANK VERSION 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). m /h Ø...
Should an error message be displayed again, inform WAGNER Service Department. – The grounding between control – Contact WAGNER Service unit and powder spray gun is Department interrupted. Sputtering powder feed – The fl ow rate in the powder feed –...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL Malfunction Cause Remedy No powder feed – Tank or powder tank empty – Refi ll the powder. – The spray gun is clogged. – Blow through the spray gun. – The powder feed hose is –...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 10 INSPECTIONS If the system is used for electrostatic coating with fl ammable coating powders, testing should be undertaken in accordance with DIN EN 50050-2: 2014 as per Table 1.
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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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 off and the mains plug disconnected.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 12.5.2 SWITCHING THE GUN TYPES Note: Clean the powder residues from all powder-conveying parts thoroughly, before changing to another gun type. m /h Ø P_02719 SP RI N T X P_01785 Procedure: (For example: switching from Corona to Tribo)
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 12.13 CONVERSION SETS When working with powders that are diffi 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.
[μA] [Nm³/h] [Nm³/h] > 0.2 name ✆ ______________________________ ______________________________ www.wagner-group.com/industry 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: –...
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.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 13.2 SPARE PARTS LIST OF SPRINT AIRFLUID XE MANUAL POWDER SYSTEM P_02640 Order No. Designation 2355400 Sprint Airfl uid XE manual system (standard version) 2355402 Sprint Airfl uid XE manual system (USA version) 2355800 Sprint Airfl uid XE manual system (Japanese version) 2355405...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 241270 Mains cable (Europe) 264626 Mains cable (USA) 264625 Mains cable (Japan) Not included in the scope of delivery, please order separately: 2331976 Sprint round spray spare parts starter set 2349959 Sprint fan spray spare parts starter set...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 13.3 SPARE PARTS LIST OF SPRINT 60 L XE MANUAL POWDER SYSTEM TANK (without vibration table) P_02651 Pos K Order No. Designation 2355403 Sprint 60 L XE manual system (standard version)
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL Not included in the scope of delivery, please order separately: Powder tank, 60 L 264268 264224 Powder tank, 25 L Sprint round spray spare parts starter set 2331976 2349959 Sprint fan spray spare parts starter set 13.4 TROLLEY SPARE PARTS P_02652 Order No.
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 13.5 INTAKE TUBE, ST 550/10 P_01155 Pos K Order No. Designation 265281 Intake tube, ST 550/10 265401 Fluid crown 265402 Fluid ring 2303716 Plug-in fi tting, G1/8" 2307727 Extension = Wearing parts...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 13.7 COMPRESSED AIR SUPPLY Rear view of the control unit P_02720 Pos K Order No. Designation 2303294 Solenoid valve, 2/2 way 2304119 Fluid air throttle 2305860 Filter precipitator 9981951 Compressed air connection hose, 18.5x12.5 mm...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 13.8 POWDER INJECTOR, PI-F1 P_00894 Order No. Designation 241622 Powder injector, PI-F1 241225 Annular gap collector nozzle Hose sleeve 241476 Union nut 241466 241923 Air nozzle Spring check valve 241460 9970149 Sealing ring Quick-release plug...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 13.9 HICOAT-ED PUMP F P_00889 Pos K Order No. Designation 241624 HiCoat-ED pump F 241229 Collector nozzle low air 241479 Hose sleeve 241466 Union nut 241930 Air nozzle 241460 Spring check valve 9970149 Sealing ring 9992709...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 13.10 60 L/25 L TANK P_01156...
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SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL Pos K Order No. Designation 264268 Powder tank, 60 L 264224 Powder tank, 25 L 264215 Base housing 264381 264382 Fluidized bed 1.10 m 9971527 Foam rubber seal 9994703 Spring clip 9900717 Socket cap screw 9992270...
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.
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:...
II 3(2)D Identifi cation: 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...
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...
SPRINT XE VERSION 05/2017 ORDER NUMBER DOC 2354920 OPERATING MANUAL 15.5 FM APPROVAL The Sprint manual system is FM approved in the USA and Canada using the confi guration drawing no. 2309729. P_00309...
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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...
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