WAGNER SPRINT 2 Translation Of The Original Operating Manual
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WAGNER SPRINT 2 Translation Of The Original Operating Manual

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P_05968
Manual system
SPRINT 2
Translation of the Original Operating Manual
 
 II 3 D Ex h IIIB T100°C Dc
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: 04/2024

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Summary of Contents for WAGNER SPRINT 2

  • Page 1: Factory Setting Recipe Nos

    P_05968 Manual system SPRINT 2 Translation of the Original Operating Manual    II 3 D Ex h IIIB T100°C Dc 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: 04/2024...

  • Page 3: Table Of Contents

    Operating manual Manual system SPRINT 2 Table of Contents TABLE OF CONTENTS About these instructions Preface Warnings, notices and symbols in these instructions Languages Supplementary documentation Abbreviations Terminology for the purpose of this manual Using in accordance with the instructions...
  • Page 4 Setting the fluidization of Sprint 2 H (60 L tank) Factory setting recipe nos. 1–4 Interrupting the coating process of Sprint 2 B (box) Interrupting the coating process of Sprint 2 H (60 L tank) Performing a paint change 7.6.1 Box version 7.6.2...
  • Page 5 Operating manual Manual system SPRINT 2 Table of Contents Declaration of conformity EU declaration of conformity for mobile base 14.1 FM control document 14.2 Order number 2467031 | Edition 04/2024...

  • Page 6: About These Instructions

    Operating manual Manual system SPRINT 2 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.

  • Page 7: Supplementary Documentation

    2467037 French 2467032 Italian 2467034 Spanish 2467035 Chinese 2467036 Additional languages upon request or at: www.wagner-group.com 1.4   SUPPLEMENTARY DOCUMENTATION Operating manual for WACON Sprint 2 control unit Language Order no. Language Order no. German 2462920 Italian 2462923 English 2462921 Spanish...
  • Page 8 Operating manual Manual system SPRINT 2 1   About these instructions Personnel qualifications Trained person Is instructed in the tasks assigned to him/her, the potential risks associ- ated with improper behavior as well as the necessary protective devices and measures. Electrically...

  • Page 9: Using In Accordance With The Instructions

    The Sprint 2 manual system is designed for single and serial coatings for industry and commerce. The Sprint 2 manual system is comprised of a mobile base, WACON Sprint 2 control unit and PEM-X1 manual gun. 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.

  • Page 10: Identification

    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 2 manual system with the following guns and control units: Control units Guns...

  • Page 11: Type Plates

    Operating manual Manual system SPRINT 2 3   Identification 3.3   TYPE PLATES 3.3.1   Manual system type plate Typ: Handanlage Sprint 2 Type: Manual unit Sprint 2 90-250 VAC Sprint 2 H 2465745 47-63 Hz Sprint 2 B 230 VAC 2465744 50 Hz...

  • Page 12: Basic Safety Instructions

    Operating manual Manual system SPRINT 2 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.

  • Page 13: Personnel Qualifications

    Operating manual Manual system SPRINT 2 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.

  • Page 14: Safe Handling Of Wagner Powder Spray Devices

    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.

  • Page 15: Electrical Connection Cables

    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 2467031 | Edition 04/2024...

  • Page 16: Protective And Monitoring Equipment

    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.

  • Page 17: Description

    Operating manual Manual system SPRINT 2 5   Description 5   DESCRIPTION 5.1   CONSTRUCTION AND MODE OF OPERATION 5.1.1   Sprint 2 B P_05969 PEM-X1 manual gun Quick-Link powder injector, AF Vibration table Fluid air throttle Mobile base WACON Sprint 2 XE control unit...

  • Page 18: Sprint 2 H (Without Vibrator Table)

    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 WACON Sprint 2 control unit must be changed to Tribo (Please refer to the control unit operating manual for the procedure).

  • Page 19: Extent Of Delivery

    420 x 420 x 400 mm; 16.54 x 16.54 x 15.75 inches Maximum filling weight of box 30 kg; 66.14 lbs Electrical: For electrical data, see operating manual for WACON Sprint 2 control unit. Pneumatic: Compressed air connection G1/4" Connection hose diameter 18.5 x 12.5 mm Input air pressure 0.6–0.8 MPa;...

  • Page 20: Operating Elements

    87 psi) 5.4   OPERATING ELEMENTS 5.4.1   Operating elements on front side The operating elements on the front side of the control unit are described in the operating manual of the WACON Sprint 2 control unit. Order number 2467031 | Edition 04/2024...

  • Page 21: Assembly And Commissioning

    Operating manual Manual system SPRINT 2 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.
  • Page 22 Operating manual Manual system SPRINT 2 6   Assembly and commissioning P_06015 3. Swing base plate/vibrator table in the direction of the arrow. 4. Screw in and tighten Allen screws (1) on both sides of the mobile base (Detail A). 5. Tighten the hexagon screws (2) on both sides of the mobile base (Detail B).

  • Page 23: Connecting The Manual System

    Operating manual Manual system SPRINT 2 6   Assembly and commissioning 6. Set up mobile base. 7. Swivel in storage tray (3) (Detail A). 8. Swivel in mounting bracket (4) for the control unit (Detail A) and tighten hexagon screws (5) (Detail B).
  • Page 24 Main switch Output to vibrator motor Mains input terminal 6.4.2.2   Connecting the Sprint 2 B manual system P_06017 1. Screw on gun holder (7) with threaded rubber buffer (8) (Detail A). 2. Fasten the hose holder (9) to the left and right of the mobile base with four M8 nuts each (Detail B).
  • Page 25 Operating manual Manual system SPRINT 2 6   Assembly and commissioning P_06018 4. Fit the bracket (11) for the swivel arm to the mobile base using two hexagon screws (12) (Detail A). 5. Insert swivel arm (13) into the holder (11).
  • Page 26 Operating manual Manual system SPRINT 2 6   Assembly and commissioning 7. Slide the control unit (15) into the mobile base from the front and screw it onto the holder using the fastening screws (16) (Detail B). 8. Tighten the hexagon screws (17) of the storage tray (Detail A).
  • Page 27 Operating manual Manual system SPRINT 2 6   Assembly and commissioning P_06021 12. Guide fluid air hose (21) from the injector to the throttle valve and connect it. P_06022 13. Guide the compressed air line (22) from the filter separator to the control unit and connect it.
  • Page 28 Operating manual Manual system SPRINT 2 6   Assembly and commissioning P_06023 14. Guide the cable (23) from the vibrator motor along the tubular frame of the mobile base, fasten with cable ties and plug into the control unit. Order number 2467031 | Edition 04/2024...
  • Page 29 Operating manual Manual system SPRINT 2 6   Assembly and commissioning P_06024 15. Connect manual gun cable (24) to control unit. 16. Connect the atomizing air hose (25) to the control unit. 17. Connect powder hose (26) to the injector. Bundle the two hoses and the gun cable with Velcro cable binders.
  • Page 30 Operating manual Manual system SPRINT 2 6   Assembly and commissioning 6.4.2.3   Connecting the Sprint 2 H manual system P_06028 1. Screw on gun holder (7) with threaded rubber buffer (8) (Detail A). 2. Fasten the hose holder (9) to the left and right of the mobile base with four M8 nuts each (Detail B).
  • Page 31 Operating manual Manual system SPRINT 2 6   Assembly and commissioning P_06029 5. Slide the control unit (12) into the mobile base from the front and screw it onto the holder using the fastening screws (13) (Detail B). 6. Tighten the hexagon screws (14) of the storage tray (Detail A).
  • Page 32 Operating manual Manual system SPRINT 2 6   Assembly and commissioning P_06033 9. Connect the mobile base's grounding cable (17) to the grounding connection of the control unit. 10. Connect the control cable (18) from the solenoid valve on the control unit.
  • Page 33 Operating manual Manual system SPRINT 2 6   Assembly and commissioning P_06035 12. Guide the compressed air line (20) from the filter separator to the control unit and connect it. P_06036 13. Connect the atomizing air hose (21) to the control unit.

  • Page 34: Grounding

    Operating manual Manual system SPRINT 2 6   Assembly and commissioning 17. Attach the cover to the mains output terminal from the control unit. 18. Connect the control unit's grounding cable with the signal ground! 19. Connect compressed air from the compressed air network of the company to the manual system.

  • Page 35: Grounding The Powder Coating System

    Operating manual Manual system SPRINT 2 6   Assembly and commissioning 6.5.1   Grounding the powder coating system P_06025 Only use mains cables with grounding strand! Connect the mobile base's grounding cable to the grounding connection of the control unit! Connect the control unit's grounding cable with the signal ground!

  • Page 36: Operation

    Operating manual Manual system SPRINT 2 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.

  • Page 37: Setting The Fluidization Of Sprint 2 B (Box)

    10 s (factory setting). This setting can be changed by the user if required (see WACON Sprint 2 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.

  • Page 38: Setting The Fluidization Of Sprint 2 H (60 L Tank)

    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 WACON Sprint 2 control unit operating manual). 4. Actuate the trigger lever of the gun for a short time and release it.
  • Page 39 Operating manual Manual system SPRINT 2 7   Operation Order number 2467031 | Edition 04/2024...

  • Page 40: Interrupting The Coating Process Of Sprint 2 B (Box)

    Operating manual Manual system SPRINT 2 7   Operation 7.4   INTERRUPTING THE COATING PROCESS OF SPRINT 2 B (BOX) 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.

  • Page 41: Interrupting The Coating Process Of Sprint 2 H (60 L Tank)

    Info For a paint change, all components of the powder feed system must be thoroughly cleaned. 1. Perform cleaning in accordance with chapter Interrupting the coating process of Sprint 2 B (box) [8 40]. 2. Clean all powder feeding parts of the unit, such as the spray gun, the injector and the powder feed hose.

  • Page 42: Tank Version

    Info For a paint change, all components of the powder feed system must be thoroughly cleaned. 1. Perform cleaning in accordance with chapter Interrupting the coating process of Sprint 2 H (60 L tank) [8 41]. 2. Open the powder tank and clean all powder feeding parts such as: the spray gun, the powder injector, the powder feed hose and the suction system.
  • Page 43 Operating manual Manual system SPRINT 2 7   Operation WARNING Dust formation! Risk of poisoning if inhaled. Danger due to escaping dust, contamination of the device and device components. 4 The powder tank may only be filled to the halfway mark, because fluidizing increases the volume of powder.

  • Page 44: Cleaning And Maintenance

    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.

  • Page 45: Safety Checks

    Check powder hoses for bends and sintering 8.3   PERIODIC CHECKING OF THE MANUAL SYSTEM 8.3.1   Sprint 2 B version (box) 1. Perform cleaning in accordance with chapter Interrupting the coating process of Sprint 2 B (box) [8 40]. P_06030 2. Press the catches (4) together at the corrugated surfaces and pull the hose connection part (1) off the injector housing (3) towards the front.

  • Page 46: Sprint 2 H Version (60 L Tank)

    7. Check whether the fluid disk (6) on the bottom of the feed unit is blocked and replace if necessary. 8.3.2   Sprint 2 H version (60 L tank) 1. Perform cleaning in accordance with chapter Interrupting the coating process of Sprint 2 H (60 L tank) [8 41]. P_06031 2.
  • Page 47 Operating manual Manual system SPRINT 2 8   Cleaning and maintenance P_06032 6. Pull the black fluid air hose (9) off the powder tank (8). 7. Loosen the grounding cable 10 from the powder tank 8. 8. Lift the powder tank off of the equipment mobile base for cleaning.

  • Page 48: Troubleshooting And Rectification

    Operating manual Manual system SPRINT 2 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-...

  • Page 49: Inspections In Accordance With Din En 50050-2: 2013

    Operating manual Manual system SPRINT 2 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 Table...
  • Page 50 Operating manual Manual system SPRINT 2 10   Inspections in Accordance with DIN EN 50050-2: 2013 Order number 2467031 | Edition 04/2024...

  • Page 51: Disassembly And Disposal

    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.

  • Page 52: Accessories

    Operating manual Manual system SPRINT 2 12   Accessories 12   ACCESSORIES 12.1   PEM-T3 MANUAL GUN Order no. Designation 351019 PEM-T3 Tribo manual gun 12.2   PEM-T3 EXTENSION P_00923 Order no. Designation 260934 Nozzle extension, PEM-T3 Order number 2467031 | Edition 04/2024...

  • Page 53: Spare Parts

    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.

  • Page 54: Spare Parts List For Sprint 2 B Manual System

    Operating manual Manual system SPRINT 2 13   Spare parts 13.3   SPARE PARTS LIST FOR SPRINT 2 B MANUAL SYSTEM P_05978 Order no. Designation 2465744 Sprint 2 B manual system (standard version) 2466208 Sprint 2 B manual system (US version) 2466210...

  • Page 55: Spare Parts List For Sprint 2 H Manual System

    Operating manual Manual system SPRINT 2 13   Spare parts 13.4   SPARE PARTS LIST FOR SPRINT 2 H MANUAL SYSTEM P_05979 (without vibrator table) Order no. Designation 2465745 Sprint 2 H manual system (standard version) 2466209 Sprint 2 H manual system (US version)

  • Page 56: Mobile Base

    Operating manual Manual system SPRINT 2 13   Spare parts 13.5   MOBILE BASE P_06042 Order no. Designation 2467408 Gun holder, ET 2467348 Sprint 2 storage tray 2467410 Hose holder 2467345 Quick connection coupling 2467346 Quick connection coupling (Switzerland) 2467279 Swivel castor set ♦...

  • Page 57: Swivel Arm Set

    Operating manual Manual system SPRINT 2 13   Spare parts Order no. Designation 2467275 Vibrator table, Sprint 2 230 V/50 Hz ET 2362487 Pipe clamp 2355337 Vibrator motor, 230 V/50 Hz ET 2355338 Vibrator motor, 115 V/60 Hz ET ♦ = wearing parts 13.7   SWIVEL ARM SET P_06041 Order no.

  • Page 58: 25 L Tank

    Operating manual Manual system SPRINT 2 13   Spare parts 13.8   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...
  • Page 59 Operating manual Manual system SPRINT 2 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 ♦...

  • Page 60: Declaration Of Conformity

     II 3 D Ex h IIIB  T100°C Dc 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: 2467100 14.2   FM CONTROL DOCUMENT Identification: FM Control Document The FM Control Document is enclosed with this product.
  • Page 61 Operating manual Manual system SPRINT 2 14   Declaration of Conformity Order number 2467031 | Edition 04/2024...
  • Page 62 Operating manual Manual system SPRINT 2 14   Declaration of Conformity Order number 2467031 | Edition 04/2024...
  • Page 64 Order number 2467031 Edition 04/2024 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 Switzerland Wagner International AG Industriestrasse 22 CH-9450 Altstätten Telephone: +41 (0)71 757 2211 Fax: +41 (0)71 757 2222 More contact addresses on the internet at: www.wagner-group.com Subject to changes without notice...

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