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P_02640 Manual Powder System SPRINT XE Translation of the Original Operating Manual For professional use. Always observe the information in this manual, particularly the safety instructions and the warning instructions. Store the manual in a safe place. Edition: 01/2023...
Operating manual Manual Powder System SPRINT XE Table of Contents TABLE OF CONTENTS About these Instructions Preface Warnings, Notices and Symbols in these Instructions Languages Abbreviations Terminology for the Purpose of this Manual Using in Accordance with the Instructions Device type...
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Operating manual Manual Powder System SPRINT XE Table of Contents Training of Assembly/Commissioning Personnel Storage conditions Installation Conditions Assembly of the manual system 6.4.1 Assembly of the trolley 6.4.2 Assembling the control unit Connecting the manual system 6.5.1 Connection requirements 6.5.2...
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Operating manual Manual Powder System SPRINT XE Table of Contents 12.4 Adapter plate switchbox 12.5 Spray gun switchbox 12.5.1 Installation of the switchbox 12.5.2 Switching the gun type 12.6 PEM-T3 manual gun 12.7 PEM-T3 Extension 12.8 Swivel casters set 12.9 Powder hose 12.10 Sprint dual manual coating set...
Operating manual Manual Powder System SPRINT XE 1 About these Instructions 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 manual Manual Powder System SPRINT XE 1 About these Instructions Language Order no. Language Order no. Russian 2354924 Slovakian 2428408 Chinese 2354925 Czech 2382850 Dutch 2388048 Romanian 2390470 Swedish 2374100 Polish 2393489 Hungarian 2425076 Japanese 2367167 Additional languages upon request or at: www.wagner-group.com 1.4 ...
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 16985:2018 or under equivalent ventilation conditions.
Operating manual Manual Powder System SPRINT XE 3 Identification 3 IDENTIFICATION 3.1 EXPLOSION PROTECTION IDENTIFICATION 3.1.1 Trolley identification Device type Airfluid XE trolley/60L XE trolley manufacturer Wagner International AG 9450 Altstätten Switzerland II 3 D Ex h IIIB T100°C Dc European Communities Symbol for explosion protection Device class II...
Risk of injury and damage to the device. 4 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...
Operating manual Manual Powder System SPRINT XE 4 Basic Safety Instructions 4 BASIC SAFETY INSTRUCTIONS 4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR 4 Keep this operating manual at hand near the device at all times. 4 Always follow existing regulations concerning occupational safety and accident prevention regulations.
Operating manual Manual Powder System SPRINT XE 4 Basic Safety Instructions 4 Protective clothing including gloves, must correspond to EN 1149-5. The measured insulation resistance must not exceed 100 MΩ. 4 Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the spray booth.
Operating manual Manual Powder System SPRINT XE 4 Basic Safety Instructions 4 For sufficient health and environmental protection, only operate the device with technical ventilation (extraction) switched on. 4.2.2 Safe Handling of WAGNER Powder Spray Devices Danger due to dust formation! 4 Do not point spray guns at people.
4.2.7 Maintenance and Repair Danger due to improper maintenance and repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a specially trained person may carry out repairs and replace parts. Order number 2354920 | Edition 01/2023...
4 Use only WAGNER original spare parts and accessories. 4 WAGNER assumes no liability for changes to the product made by the operating company without the knowledge of WAGNER. Any adjustments to the documentation and the market release are the responsibility of the operating company.
Operating manual Manual Powder System SPRINT XE 5 Description 5 DESCRIPTION 5.1 CONSTRUCTION AND MODE OF OPERATION 5.1.1 Sprint Airfluid XE P_02641 Equipment trolley Powder injector, PI-F1 EPG-Sprint XE control unit Fluid air throttle PEM-X1 manual gun Vibration table Suction tube, ST 550/10 Mode of operation: The feed unit (4) is inserted directly into the original tank.
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.
Operating manual Manual Powder System SPRINT XE 5 Description 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 Spray gun switchbox [8 54].
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Operating manual Manual Powder System SPRINT XE 5 Description Electrical: Mains (AC) 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 of gun maximum 22 Vpp Output current of gun maximum 0.9 A...
Operating manual Manual Powder System SPRINT XE 5 Description Ambient conditions: Operating temperature range 5 – 40 °C; 41 – 104 °F Noise development < 63 dB (mains pressure 0.6 MPa ; 6 bar; 87 psi) 5.4 OPERATING ELEMENTS 5.4.1 Operating Elements on Front Side 20 22 21 m /h Co r Ø...
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Operating manual Manual Powder System SPRINT XE 5 Description – Single LED display: "Trigger Point of Current Limitation" – Bar display: Corona current 3 Display [Tribo gun] – Lights up when a Tribo gun is connected and selected 4 Display [Corona gun] –...
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Operating manual Manual Powder System SPRINT XE 5 Description – Resolution: 0.05 m 21 Push button [Atomizing, ionizing and Tribo air] – To activate the function, the value is precisely adjusted with control dial 24 and is indicated in LED display 19 –...
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Operating manual Manual Powder System SPRINT XE 5 Description – 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) –...
Operating manual Manual Powder System SPRINT XE 6 Assembly and Commissioning 6 ASSEMBLY AND COMMISSIONING 6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL – The assembly and commissioning personnel 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.
Operating manual Manual Powder System SPRINT XE 6 Assembly and Commissioning 25Nm; 18.44lb ft P_02643 1. Open transport packaging with care and carefully take all individual parts out of packaging. 2. Place lower trolley section (1) on a clean, level surface.
Operating manual Manual Powder System SPRINT XE 6 Assembly and Commissioning 6.5 CONNECTING THE MANUAL 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 filter water separator (4) as a standard feature.
Operating manual Manual Powder System SPRINT XE 6 Assembly and Commissioning 6.5.2 Connecting the Airfluid manual system P_02639 Detail 1. Connect the hose (black) for mains pressure. 2. Plug in the control cable from the solenoid valve on the control unit.
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Operating manual Manual Powder System SPRINT XE 6 Assembly and Commissioning 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.
Operating manual Manual Powder System SPRINT XE 6 Assembly and Commissioning 6.5.3 Connecting the 60 L tank manual system P_03293 Detail 1. Place the powder tank on the trolley. 2. Connect the grounding cable to the grounding connection of the powder tank (A).
Operating manual Manual Powder System SPRINT XE 6 Assembly and Commissioning 6. Connect the dosing air hose (blue). 7. Connect the feed air hose (red). 8. Connect hose (black) for the fluid air to the throttle and to the tank (A). Bundle the three hoses with Velcro cable binders.
Operating manual Manual Powder System SPRINT XE 6 Assembly and Commissioning 6.6.1 Grounding the powder coating system P_01827 Only use mains cables with grounding strand! Connect the trolley's grounding cable to the grounding connection of the control unit! Connect the control unit's grounding cable with the signal ground!
Operating manual Manual Powder System SPRINT XE 7 Operation 7 OPERATION 7.1 TRAINING THE OPERATING PERSONNEL – The operating personnel must be qualified 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.
10 s (factory setting). This setting can be changed by the user if required (see EPG-Sprint XE control unit operating manual). 5. Adjust the fluid air at the throttle (2) to the point the feed unit sinks into the powder due to its own weight.
2. Switch on the control unit. 3. Set the [Vibrator motor controller] parameter, on the control unit, to [ON] to permanently activate the fluid air (see the EPG-Sprint XE control unit operating manual). 4. Actuate the trigger lever of the gun for a short time and release it.
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 Current limitation Character- Total air Feed air Atomizing air istic [kV] [µA] Flat part High surface cov- Standard erage Second coat-...
Operating manual Manual Powder System SPRINT XE 7 Operation 7.4 INTERRUPTING THE COATING PROCESS 7.4.1 Airfluid version NOTICE Powder residues and sticking fluid disk! Equipment damage and danger of blockage. 4 Before the control unit is deactivated, the feed unit must be pulled out of the powder tank.
Operating manual Manual Powder System SPRINT XE 7 Operation 7.4.2 60 L tank version NOTICE Powder residues! Damage to the device. 4 At every work interruption, blow through the powder spray gun and the powder feeding parts and clean any powder residues.
9. Adjust the fluid 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.
6. Clean the powder tank and pay special attention to the fluid base. Info Proper fluidization is not possible with a damaged and/or clogged fluid base. To adapt the programs to the new applications, proceed as described in the EPG-Sprint XE control unit's operating manual. Order number 2354920 | Edition 01/2023...
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Operating manual Manual Powder System SPRINT XE 7 Operation 7.5.2.2 Cleaning process when using multiple powder tanks Info For a paint change, all components of the powder feed system must be thoroughly cleaned. m /h Ø SP RI N T X P_05051 1.
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7. Close the powder tank and check whether the exhaust air hose is leading in the direction of the exhaust 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.
Operating manual Manual Powder System SPRINT XE 7 Operation 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 call up a previously set recipe by double-clicking on the trigger lever on the spray gun, for example to recoat parts using different parameters (high voltage, current limitation, air volumes etc.).
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a specially trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.
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...
Operating manual Manual Powder System SPRINT XE 8 Cleaning and Maintenance m /h Ø SP RI N T X P_05051 4. Hold the gun in the spray booth and start the flush function by pressing the [Flush] button (17). ð The injector and hoses are flushed.
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Operating manual Manual Powder System SPRINT XE 8 Cleaning and Maintenance 2. Remove powder injector (1) from holder (2). m /h Ø SP RI N T X P_05051 3. Hold the gun in the spray booth and start the flush function by pressing the [Flush] button (17).
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Operating manual Manual Powder System SPRINT XE 8 Cleaning and Maintenance 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.
Operating manual Manual Powder System SPRINT XE 9 Troubleshooting and rectification 9 TROUBLESHOOTING AND RECTIFICATION Malfunction Cause Rectification Power indicator does Mains supply not switched on Turn on mains. not light up 2 AT fuses defective Replace fuses No Corona power sup-...
Operating manual Manual Powder System SPRINT XE 10 Inspections in Accordance with DIN EN 50050-2: 2013 10 INSPECTIONS IN ACCORDANCE WITH DIN EN 50050-2: 2013 If the system is used for electrostatic coating with ignitable coating powders, the test must be performed in accordance with DIN EN 50050-2: 2013 according to the following Overview...
10.2 OVERVIEW TABLE Section Type of inspection Requirements Inspection Type of inspection Inspection in- terval Ground leaking resistance The resistance to ground of the hold point of ev- ME/CM Weekly from the work piece attach- ery work piece may be 1 MΩ at the most (mea- Measure resistance to ground ment point suring voltage must be 1000 V).
4 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.
Operating manual Manual Powder System SPRINT XE 12 Accessories 12.5.1 Installation of the switchbox WARNING Danger from electric current! Risk of injury and damage to the device. 4 Before starting with the installation of the switchbox, the manual system must be switched off and the mains plug disconnected.
Info Parameter C11, in the EPG-Sprint XE control unit device configuration, must be set to [aut]. No gun is selected at first after the control unit is switched on. This will however be automatically selected and displayed after 1 second.
Operating manual Manual Powder System SPRINT XE 12 Accessories 12.12 CONVERSION SETS When working with powders that are difficult 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.
Operating manual Manual Powder System SPRINT XE 12 Accessories 12.14 EXTENDED OPERATING MANUAL If additional information regarding the individual components is desired, the operating manuals listed below can be consulted. This operating manual includes: – important notes regarding connecting, commissioning and the use (e.g., paint change) of the relevant components, –...
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a specially trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.
Operating manual Manual Powder System SPRINT XE 13 Spare Parts 13.3 SPARE PARTS LIST OF SPRINT AIRFLUID XE MANUAL POWDER SYSTEM P_05054 Order no. Designation 2355400 Sprint Airfluid XE manual system (standard version) 2355402 Sprint Airfluid XE manual system (USA version)
Operating manual Manual Powder System SPRINT XE 13 Spare Parts Order no. Designation 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 jet spare parts starter set...
Operating manual Manual Powder System SPRINT XE 13 Spare Parts Order no. Designation 935974 Coupling plug with anti-kink spring 2327855 Velcro cable ties 265266 Powder hose set, Ø 11x5000 mm; 0.43x196.85 inches 130215 Grounding cable, 10 m; 32.81 ft 241270...
Operating manual Manual Powder System SPRINT XE 13 Spare Parts 13.10 HICOAT-ED PUMP F P_00889 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 ♦...
Operating manual Manual Powder System SPRINT XE 13 Spare Parts 13.11 60 L/25 L TANK P_01156 Order no. Designation 264268 Powder tank, 60 L 264224 Powder tank, 25 L 264215 Base housing 264381 Cover ♦ 264382 Fluid bed ♦ 1.10 m...
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Operating manual Manual Powder System SPRINT XE 13 Spare Parts Order no. Designation 9982058 Exhaust air hose, 17x3 mm 241372 Injector connection, complete 170533 Knurled nut 9920118 Washer 241276 Grounding cable, complete 9922102 Toothed lock washer 241376 Cable connection 263357 Suction tube, 60 L ♦...
Operating manual Manual Powder System SPRINT XE 14 Wearing parts 14 WEARING PARTS Order no. Designation 265401 Fluid crown of suction unit P_00723 265402 Fluid ring of suction unit P_00698 241225 Clearance collector nozzle of PI-F1 injector P_00699 241229 Collector nozzle, ED pump P_01826 14.1 ...
Operating manual Manual Powder System SPRINT XE 14 Wearing parts 14.1.2 X1 F Flat Jet Nozzles System Order no.. Designation 2322529 ♦ Electrode holder, X1 F ET (yellow) P_01691 Can be combined with: 2321976 Flat jet nozzle, X1, complete ♦...
Declaration of Conformity The 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 Order number 2354920 | Edition 01/2023...
Declaration of Conformity The 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 Order number 2354920 | Edition 01/2023...
EN 50050-2:2013 Declaration of Conformity The 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 15.2 FM CONTROL DOCUMENT...
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Operating manual Manual Powder System SPRINT XE 15 Declaration of Conformity Order number 2354920 | Edition 01/2023...
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Operating manual Manual Powder System SPRINT XE 15 Declaration of Conformity Order number 2354920 | Edition 01/2023...
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Operating manual Manual Powder System SPRINT XE 15 Declaration of Conformity Order number 2354920 | Edition 01/2023...
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Order number 2354920 Edition 01/2023 Switzerland Wagner International AG Industriestrasse 22 CH-9450 Altstätten Telephone: +41 (0)71 757 2211 Fax: +41 (0)71 757 2222 Germany J. Wagner GmbH Otto-Lilienthal-Strasse 18 Postfach 1120 D-88677 Markdorf Telephone: +49 (0)7544 5050 Fax: +49 (0)7544 505200 E-mail: ts-powder@wagner-group.com More contact addresses on the internet at: www.wagner-group.com Subject to changes without notice...
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