Manual Powder System Translation of the Original Operating Manual

Manual Powder System Translation of the Original Operating Manual
Translation of the Original
Operating Manual
SPRINT
Manual Powder System
Version 01 / 2013
P_01770
VERSION 01/2013
SPRINT
ORDER NUMBER DOC 2329368
OPERATING MANUAL
Contents
1
1.1
1.2
1.3
1.4
GENERAL INFORMATION
Preface
Warnings, Notes and Symbols in these Instructions
Languages
Abbreviations
6
6
6
7
7
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
CORRECT USE
Device Type
Correct Use
For Use in Potentially Explosive Areas
Safety Parameters
Processing Materials
Reasonably Foreseeable Misuse
Residual Risks
8
8
8
8
8
9
9
9
3
3.1
3.1.1
3.1.2
3.1.3
3.2
IDENTIFICATION
Explosion Protection Identification
Trolley Identification
Control Unit Identification
Powder Gun Identification
Permissible Device Combinations
10
10
10
10
11
11
4
4.1
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.3
GENERAL SAFETY INSTRUCTIONS
Safety Instructions for the Operator
Electrical Devices and Operating Equipment
Personnel Qualifications
A Safe Work Environment
Safety Instructions for Staff
Safe Handling of WAGNER Powder Spray Devices
Grounding the Device
Material Hoses
Cleaning
Handling Powder Paints
Protective and Monitoring Equipment
12
12
12
12
12
13
13
13
13
14
14
15
5
5.1
5.1.1
5.1.2
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2
DESCRIPTION
Areas of Application
Operation with Tribo Gun
Operation with Corona or Tribo Gun
Design Variants
Scope of Delivery
Permitted Accessories
Technical Data
Functioning of the Manual Powder System
Sprint Airfluid Description
Sprint 60 L Container Description (without Vibrator Table)
16
16
16
16
17
17
17
18
20
20
21
6
6.1
6.2
6.3
ASSEMBLY AND COMMISSIONING
Training Assembly/Commissioning Staff
Assembling the Equipment Trolley
Mounting the Control Unit
23
23
23
24
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Contents
6.4
6.5
6.6
6.7
6.7.1
Connection Requirements
Connecting the Airfluid Manual Powder System
Connecting the 60 L Container Manual Powder System
Grounding
Grounding the Powder Coating System
24
26
28
30
31
7
7.1
7.2
7.3
7.4
7.4.1
7.4.2
7.4.3
7.5
7.6
7.6.1
7.6.2
7.7
OPERATION
Training the Operating Staff
Safety Instructions
Operation of the Control Unit
Starting Up the Manual System
Switching on the Manual System
Adjusting Fluidization (Airfluid)
Adjusting Fluidization (60 L Container without Vibrator Table)
Recipes Nos. 1-4 Factory Settings
Interrupting the Coating Process
Airfluid Version
60 L Container Version
"Double Click" Recipe (High Dynamic Remote)
32
32
32
34
39
39
40
41
42
43
43
44
45
8
8.1
8.1.1
8.1.2
8.1.3
8.2
8.2.1
8.2.2
8.2.3
8.3
8.3.1
8.3.2
8.4
8.5
8.5.1
8.5.2
8.5.3
CLEANING AND MAINTENANCE
Cleaning
Cleaning Staff
Safety Instructions
Cleaning Procedures
Maintenance
Maintenance Staff
Safety Instructions
Maintenance Procedures
Periodically Check and Clean the Manual Powder System
Airfluid Version
60 L Container Version
Performing a Color Change (Airfluid)
Performing a Color Change (60 L Container)
Cleaning Process when Using a Single Powder Container
Cleaning Process when Using Multiple Powder Containers (60 L Container)
Restarting the Manual Powder System
46
46
46
46
47
48
48
48
49
50
50
51
52
53
53
54
55
9
9.1
INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010
Overview of Inspections
56
57
10
10.1
10.2
DISASSEMBLY AND DISPOSAL
Disassembly
Disposal
60
60
60
11
11.1
TROUBLESHOOTING AND RECTIFICATION
Faults at the Manual System
61
62
12
12.1
12.2
12.3
ACCESSORIES
Feed System SN-2 550/10
Maintenance Unit
Quick Coupling Set
64
64
64
65
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12.4
12.5
12.5.1
12.5.2
12.6
12.7
12.8
12.9
12.10
12.11
12.12
12.13
12.14
Adapter Plate Switch Box
Spray Gun Switch Box
Installation of the Switch Box
Switching the Gun Types
PEM-T3 Manual Gun
PEM-T3 300 Extension
Swivel Casters Set
Powder Hose
Sprint Dual Manual Coating Set
Wall Mount
Conversion sets
Recipe Sticker
Extended Operating Manuals
65
66
66
68
69
69
70
70
70
71
71
72
73
13
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
SPARE PARTS
How to order Spare Parts?
Scope of Delivery and Spare Parts List of Sprint Airfluid Manual Powder System
Scope of Delivery and Spare Parts List of Sprint with 60 L Container
Spare Parts List of the Trolley
Suction Tube ST 550/10
Feed System SN-2 550/10
Compressed Air Supply
PI-F1 Powder Injector
HiCoat-ED Pump F
60 L/25 L Container
74
74
75
77
78
79
80
81
82
83
84
14
WEARING PARTS
86
15
15.1
15.2
15.3
15.3.1
15.3.2
15.3.3
15.4
15.5
DECLARATION OF WARRANTY AND CONFORMITY
Important Notes on Product Liability
Warranty Claim
CE Declaration of Conformity
CE Declaration of Conformity for Trolley
CE Declaration of Conformity for Control Unit
CE Declaration of Conformity for Powder Guns
EC Type Examination Certificate
FM Approval
87
87
87
88
88
89
90
91
93
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1
GENERAL INFORMATION
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 operating and service
staff.
The operating and service staff 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 definitions in this
operating manual.
1.2
WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and
device and state measures for avoiding the hazard. These warning instructions fall into the
following categories:
DANGER
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
WARNING
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
CAUTION
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
NOTICE
This information warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
Note - provides information about particular characteristics and how to proceed.
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1.3
LANGUAGES
The operating manual is available in the following languages:
German
2327744
English
2329368
French
2330844
Italian
2330845
Spanish
2330846
Russian
2333351
Chinese
2333352
Dutch
2337609
1.4
ABBREVIATIONS
Order No.
Number of pieces
Item
Marking in the spare parts lists
Order number
Spare part
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2
CORRECT USE
2.1
DEVICE TYPE
Manual powder system for manual coating of grounded work pieces
2.2
CORRECT USE
The manual System is designed for single and serial coatings for industry and trade. The
components of the three different versions of the Sprint manual system (Airfluid version,
60 l container version) are mutually compatible.
2.3
FOR USE IN POTENTIALLY EXPLOSIVE AREAS
This manual powder system is suitable for processing industrial powder paints for coating
electrically conductive objects and can be used in potentially explosive atmospheres (zone
22). (See chapter 3.1 "Explosion Protection Identification").
2.4
SAFETY PARAMETERS
The manual powder system is only suited to the application of powder paint.
J. Wagner AG forbids any other use!
The manual powder system may only be operated under the following conditions if:
the operating staff have previously been trained on the basis of this operating manual,
the safety regulations listed in this operating manual are observed,
the operating, maintenance and repair information in this operating manual is
observed,
and the statutory requirements and accident prevention regulations standard in the
country of use are observed.
The transfer carriage may only be used if all parameters are set and all measurements/
safety checks are carried out correctly.
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2.5
PROCESSING MATERIALS
Types of powder which can be charged electrostatically
Metallic powder
2.6
REASONABLY FORESEEABLE MISUSE
Coating work pieces which are not grounded
Use of damp powder paint
Working with liquid coating materials
Incorrectly set values for powder discharge
Incorrectly set electrostatic values
Use of defective components and accessories
Use for foodstuffs
Use in the pharmaceutical sector
Use with not permissible control units and powder guns
2.7
RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk
Source
Skin contact with
powder paints and
cleaning agents
Handling powder
Skin irritation,
paints and cleaning
agents
allergies
Consequences
Specific measures
Lifecycle phase
Wear protective
clothing
Operation,
Note safety data
sheets
maintenance,
disassembly
Powder paint in air Painting outside
outside the defined the defined
working area
working area
Inhalation of
Observe working
substances
instructions
hazardous to health and operating
procedures
Operation,
maintenance
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3
IDENTIFICATION
3.1
EXPLOSION PROTECTION IDENTIFICATION
3.1.1
TROLLEY IDENTIFICATION
The device is suited for use in areas at risk from explosions, in accordance with Test
Certificate PTB 12 ATEX 5001.
Device type:
Manufacturer:
Airfluid trolley / 60 L trolley
J. Wagner AG
CH - 9450 Altstätten
II 3D 85 °C
CE:
European Communities
Ex:
Symbol for explosion protection
II:
Device class II
3:
Category 3
D:
Ex-atmosphere dust
85 °C:
Maximum surface temperature
3.1.2
CONTROL UNIT IDENTIFICATION
The device is suited for use in areas at risk from explosions, in accordance with Test
Certificate PTB 12 ATEX 5002.
Device type:
EPG-Sprint X
Manufacturer:
J. Wagner AG
CH - 9450 Altstätten
0102
II 3(2)D IP 64 80 °C
CE:
European Communities
0102:
Number of notified 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
IP64:
Protection class 64
80 °C:
Temperature class: maximum surface temperature < 80 °C; 176 °F
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3.1.3
POWDER GUN IDENTIFICATION
The device is suited for use in areas at risk from explosions, in accordance with Test
Certificate PTB 12 ATEX 5002.
Gun type:
PEM-X1
Manufacturer:
J. Wagner AG
CH - 9450 Altstätten
0102
II 2D 2mJ 85 °C
CE:
European Communities
0102:
Number of notified 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
85 °C:
Maximum surface temperature
The EC Certificat of type examination are listed in chapter 15.4.
3.2
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 guns.
Only use the Sprint manual system with the following guns and control units:
Control Units
EPG-Sprint X
EPG-Sprint
AC- Guns
PEM-X1, PEM-X1 CG Corona spray guns
PEM-C4 Corona spray gun
PEM-C4-Ergo Corona spray gun
PEM-C4-Ergo Corona spray gun FM USA
PEM-T3 Tribo spray gun
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4
GENERAL 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 OPERATING EQUIPMENT
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
May only be maintained by skilled electricians.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts.
Secure the device against being switched back on without authorization. Inform staff
about planned work.
Observe electrical safety regulations.
4.1.2
PERSONNEL QUALIFICATIONS
Ensure that the device is operated and repaired only by trained persons.
4.1.3
A SAFE WORK ENVIRONMENT
The floor in the working area must be electrostatically conductive (measurements
according to EN 1081 and EN 61340-4-1).
The footwear worn by the operators must comply with the requirements of
EN ISO 2034. The measured insulation resistance must not exceed 100 Megaohms.
The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 Megaohms.
The powder release must be electrically interlocked with the powder spray system's
exhaust air equipment.
Excess coating material (overspray) must be collected up safely.
Ensure that there are no ignition sources such as naked flames, sparks, glowing wires or
hot surfaces in the vicinity. Do not smoke.
Provide sufficient numbers of suitable fire extinguishers and ensure that they are
serviceable.
The operating company must ensure that the average concentration of powder paint
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.
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4.2
SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
Under no circumstances may people with pacemakers enter the area where the
high-voltage field between the spray gun and the work piece to be coated builds up!
4.2.1
SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
Do not point spray guns at people.
Before all work on the device, in the event of work interruptions and functional faults:
- Switch off the energy/compressed air supply.
- Lock spray guns to prevent them actuating.
- Relieve pressure on spray guns and device.
- In the event of functional faults: Identify and correct the problem, proceed as
described in chapter "Elimination of Faults".
4.2.2
GROUNDING THE DEVICE
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. In the event of discharge, this may result in the formation of sparks or flames.
Ensure that the device is grounded before each coating process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. by wearing
electrostatically conductive shoes.
The function of grounding cables must be checked regularly (See EN 60204.).
4.2.3
MATERIAL HOSES
Only use original Wagner powder hoses.
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4.2.4
CLEANING
Before starting any cleaning work, the high-voltage must be switched off and secured
against being inadvertently switched on.
Secure the device against being switched back on without authorization.
Liquid cleaning agents must not be used!
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to
remove dust deposits.
4.2.5
HANDLING POWDER PAINTS
Take note of the processing regulations laid down by the manufacturer of the powder
paint being used, when preparing or processing the powder.
Take note of the manufacturer’s advice and the relevant environmental protection
regulations when disposing of powder paints.
Take the prescribed safety measures, in particular by wearing safety glasses and safety
clothing and by using protective hand cream if required.
Use a mask or breathing apparatus if necessary.
To ensure sufficient protection of health and the environment, only operate the device
in a powder booth or at a spray wall with activated ventilation (exhaust air).
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4.3
PROTECTIVE AND MONITORING EQUIPMENT
WARNING
Protective and monitoring equipment!
Risk of injury and damage to the device.
Protective and monitoring equipment must not be removed,
modified or rendered unusable.
Regularly check that they are working perfectly.
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
AREAS OF APPLICATION
The manual system is designed for single and serial coatings for industry and trade. The
following Wagner manual guns can be used with the manual system.
PEM-X1 Corona spray gun
PEM-C4 Corona spray gun
PEM-C4-Ergo Corona spray gun
PEM-C4-Ergo Corona spray gun FM (US version)
PEM-T3 Tribo spray gun
5.1.1
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 X 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 X control unit must be
changed to Tribo. Please refer to the control unit Operating Manual on the supplied CD for
the procedure.
5.1.2
OPERATION WITH CORONA OR 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 switch box, which is available as an accessory. For more details
see Chapter 12.5.
The set values for operating with the Tribo gun should be saved to individually selected
recipe locations.
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5.2
DESIGN VARIANTS
Order No.
2329483
Description
Sprint Airfluid Plus C manual powder system (standard version)
2329489
Sprint 60 L C manual powder system (standard version)
2329487
Sprint Airfluid C manual powder system (US version)
2329491
Sprint 60 L C manual powder system (US version)
When working with powders that are difficult to feed, the Sprint 60 L manual system can
be converted into a variant with a vibrator table (see chapter 12.12).
5.3
SCOPE OF DELIVERY
Stk
Order No.
Description
1
See Chapter 13.2
Sprint Airfluid C manual powder system
1
See Chapter 13.3
Sprint 60 L C manual powder system without container
The standard equipment includes:
1
See Chapter 15.3
1
2327744
1
See Chapter 1.3
1
5.4
Declaration of conformity
Operating manual German
Operating manual in local language
Accompanying CD
PERMITTED ACCESSORIES
Only the accessories listed in the chapter "Accessories" of this operating manual may be
connected to the Sprint manual powder system.
The accessories listed in the chapter "Accessories" were included in the EC type examination
and are approved for use with the manual powder system.
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5.5
TECHNICAL DATA
Dimensions:
Height
1120 mm; 44.10 inches
Width
595 mm; 23.43 inches
Depth
740 mm; 29.13 inches
Weight
approx. 38 kg; 83.77 lbs
Maximum box size
420x420x400 mm; 16.54x16.54x15.75 inches
Maximum filling weight of box
30 kg; 66.14 lbs
Electrical:
Mains (AC)
85 VAC-250 VAC
Frequency
47 Hz-440 Hz
Max. performance
40 W
Output voltage
maximum of 22 Vpp
Output current
maximum of 0.9 A
Corona current limitation
5 μA-120 μA (adjustable)
Tribo current cut off
higher than 12 μA
(ATEX: switch the unit off )
Protection class
IP 64
Pneumatic:
Air inlet connection
G1/4"
Connection hose diameter
18.5 x 12.5 mm
Pressure range input air
0.6-0.8 MPa ; 6-8 bar; 87-116 psi
Air volume
maximum of 20 m³/h; 706.2 cf/h
Sum of feed and dosage 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
Compressed air quality according
to ISO 8573.1
3.5.2
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Insufficient paint application quality.
Provide compressed air free from oil and water (quality standard
3.5.2 according to ISO 8573.1) 3.5.2 = 5 μm / +7 °C; 44.6 °F /
0.1 mg/m³.
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Ambient conditions:
If low-temperature powders are used, the ambient temperature may have to be below
30 °C; 86 °F.
Volume measures:
for volumes specified in Nm³ (standard cubic meters). One cubic meter of gas at 0 °C and
1.013 bar constitutes one standard cubic meter.
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
Ambient conditions:
Operating temperature range
5-45 °C; 41-113 °F
Noise development
< 63 dB (mains pressure 0.6 MPa; 6 bar; 87 psi)
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5.6 FUNCTIONING OF THE MANUAL POWDER SYSTEM
5.6.1 SPRINT AIRFLUID DESCRIPTION
2
3
5
6
4
1
P_01771
7
1
Equipment trolley
2
EPG-Sprint X control unit
3
PEM-X1 manual gun
4
ST 550/10 suction tube
5
PI-F1 powder injector
6
Fluid air throttle
7
Vibration table
Feed unit 4 is inserted directly into the original bundle. The powder is fed through powder
injector 5 to powder spray gun 3. Due to the special arrangement of the suction crown
and the vibration of the container, 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 control unit 2. The fluid air setting
is done using throttle 6.
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5.6.2
SPRINT 60 L CONTAINER DESCRIPTION (WITHOUT VIBRATOR TABLE)
2
3
5
6
4
1
P_01772
1
Equipment trolley
2
EPG-Sprint X control unit
3
PEM-X1 manual gun
4
60 L container
5
PI-F1 powder injector
6
Fluid air throttle
Function:
Through powder injector 5 the powder is transported from container 4 to spray gun 3. By
feeding fluid air into the fluid base of powder container 4, a homogeneous powder/air
mixture is generated and maintained during the entire process of the powder feed from
the container.
The powder quantity and the electrostatic charge of the color powder are regulated by
control unit 2. The fluid air setting is done using throttle 6.
Note:
We recommend using a vibrator table when working with powders that are difficult to feed
(see chapter 12.12).
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6
ASSEMBLY AND COMMISSIONING
6.1
TRAINING ASSEMBLY/COMMISSIONING STAFF
WARNING
Incorrect installation/operation!
Risk of injury and damage to the device.
The commissioning staff must have the technical skills to safely
undertake commissioning.
The commissioning staff must be familiar with the provisions of
the European standards DIN EN 50050-2 and DIN EN 50177.
When putting into operation and for all work, read and follow
the operating manual and safety regulations for the additionally
required system components.
6.2
ASSEMBLING THE EQUIPMENT TROLLEY
The manual system's trolley is supplied unassembled for reasons associated with transport.
It must be assembled as described below.
Procedure:
3
1.
2
25Nm;
18.44lb ft
2.
3.
1
4.
Open transport packaging with care
and carefully take all single parts out of
packaging.
Place lower trolley section 1 on a clean,
level surface.
Place upper trolley section 2 on the two
guide sleeves on lower trolley section 1,
press down gently until stop is reached
and use nuts and bolts (see details) to
screw to lower trolley section (tightening
torque 25 Nm; 18.44 lb ft).
Mount the gun holder 3 (see separate
Assembly Instruction).
P_01786
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6.3
MOUNTING THE CONTROL UNIT
Procedure:
3
4
1.
1
Carefully take control unit 1 out
of packaging and use the screws
2 supplied to screw to the holes
drilled in the angle bracket 3.
Mount the control unit such that it
is flush with the cover at the front.
2
P_01133
6.4
CONNECTION REQUIREMENTS
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 standard feature.
Nevertheless, a high compressed air quality is still required for safe operation of the system.
The plant operator is responsible ensuring the required compressed air quality.
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Insufficient paint application quality.
Provide compressed air free from oil and water (quality standard
3.5.2 according to ISO 8573.1) 3.5.2 = 5 μm / +7 °C; 44.6 °F /
0.1 mg/m³.
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WARNING
Danger from electric current!
Risk of injury and damage to the equipment.
Switch off main switch 1 on the back side of the equipment
before connecting the equipment.
CAUTION
Missing cover!
Protection class of device not guaranteed.
Contamination of the device.
The mains power output socket must remain closed in this manual system with the
cover closed.
I
1
0
Mains power input
Mains power output
P_01144
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6.5
CONNECTING THE AIRFLUID MANUAL POWDER SYSTEM
1.
2.
11.
12.
10.
5.
4.
3.
9.
8.
7.
6.
O
9.
Detail A
P_01775
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WARNING
Danger from electric current!
Risk of injury and damage to the equipment.
Switch off main switch 1 on the back side of the equipment
before connecting the equipment.
Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Connect the hose (black) for mains pressure.
Plug in the control cable from the solenoid valve on the control unit.
Connect the dosage air hose (blue).
Connect the feed air hose (red).
Connect the fluid air hose (black).
Bundle the three hoses with Velcro cable binders.
Connect the powder feed hose.
Plug in the gun connection cable on the control unit.
Connect the hose (transparent) for the atomizing or Tribo air.
Bundle the two hoses and the gun cable with Velcro cable binders.
Pull the hose (black) for the vibrator motor compressed air supply upwards through
the tube O (Detail A) and connect it to the solenoid valve.
Connect the compressed air hose (12.5 x 18.5 mm, order no. 9981951) to the
compressed air connection (G1/4") on the manual system.
Connect the trolley grounding cable to the control unit.
Connect the control unit's grounding cable with the system ground!
Plug in the control unit mains cable.
Connect power cable to the power supply.
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6.6
CONNECTING THE 60 L CONTAINER MANUAL POWDER SYSTEM
5.
4.
15.
16.
14.
8.
3.
7.
13.
6.
12.
11.
10.
9.
1.
Detail A
O
12.
Detail B
2.
P_01776
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WARNING
Danger from electric current!
Risk of injury and damage to the equipment.
Switch off main switch 1 on the back side of the equipment
before connecting the equipment.
Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Place the powder container on the trolley.
Connect the grounding cable to the grounding connection of the powder container
(Detail A).
Attach injector to powder container.
Connect the hose (black) for mains pressure.
Plug in the control cable from the solenoid valve on the control unit.
Connect the dosage air hose (blue).
Connect the feed air hose (red).
Connect the fluid air hose (black) to the control unit. Pull it through tube O and the
eyelet (Detail B) and connect it to the container (Detail A).
Bundle the three hoses with Velcro cable binders.
Connect the powder feed hose.
Plug in the gun connection cable on the control unit.
Connect the hose (transparent) for the atomizing or Tribo air.
Bundle the two hoses and the gun cable with Velcro cable binders.
When the manual system is equipped with a vibrator table, pull the hose (black) for
the vibrator motor compressed air supply upwards through the tube O (Detail B)
and connect it to the solenoid valve.
Connect exhaust air hose to the connection on the powder container.
The other end of the exhaust air hose must be routed to the extraction unit of the
powder spray booth.
Connect the compressed air hose (12.5 x 18.5 mm, order no. 9981951) to the
compressed air connection (G1/4") on the manual system.
Connect the trolley grounding cable to the control unit.
Connect the control unit's grounding cable with the system ground!
Plug in the control unit mains cable.
Connect power cable to the power supply.
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6.7
GROUNDING
DANGER
No Grounding!
Risk of explosion and risk of electric shock.
Electrostatic control units and the associated spray equipment
may only be connected to mains supplies with a protective
conductor connection (PE conductor)!
WARNING
Defective grounding will result in high levels of powder mist!
Danger of poisoning.
Insufficient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
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 earth cables as short as possible. Earth cables of an excessive
length must be shortened. Earth cables of an excessive length must never be wound up
on a roller.
A poorly grounded work piece causes:
Dangerous electric charging of the work piece.
Very bad wrap around.
Uneven coating.
Back-spray to the spray gun, i.e. contamination.
Prerequisites for perfect grounding and coating are:
Clean suspension of the work piece to be coated.
Grounding of spraying booth, conveyor system and suspension by the customer in
accordance with the operating manual or the manufacturer's information.
Grounding of all conductive parts within the working area.
The grounding resistance of the work piece may not exceed 1 Megaohm.
(Resistance to ground measured at 500 V or 1000 V).
The footwear worn by the operators must comply with the requirements of
EN ISO 20344. The measured insulation resistance must not exceed 100 Megaohms.
The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 Megaohms.
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Sparks between conveyor, conveyor hooks (hangers) and work piece can occur
if electric contact points between conveyor, conveyor hooks (hangers) and work
piece are not sufficiently cleaned and therefore the work pieces are not sufficiently
grounded!
These sparks can cause severe radio frequency interference (electro-magnetic
compatibility = EMC).
6.7.1
GROUNDING THE POWDER COATING SYSTEM
4
5
3
6
1
2
7
P_01827
8
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 system ground!
4
Connect grounding cable to an uncoated metal part of the booth!
5
Remove all paint from hooks and other hanger parts!
6
Wear electrostatically conductive gloves!
7
Wear electrostatically conductive shoes!
8
The floor must be electrostatically conductive!
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7
OPERATION
7.1
TRAINING THE OPERATING STAFF
WARNING
Incorrect operation!
Risk of injury and damage to the equipment.
The operating staff must be qualified to operate the entire
system.
Before work commences, the operating staff must receive
appropriate training.
The operating staff must be familiar with the provisions of
European standards DIN EN 50050-2 and DIN EN 50177.
7.2
SAFETY INSTRUCTIONS
WARNING
Incorrect operation!
Risk of injury and damage to the equipment.
If contact with powder materials or cleaning agents causes skin
irritation, appropriate precautionary measures must be taken,
e.g. wearing protective clothing.
The footwear worn by operating staff must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100 Megaohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 Megaohms.
DANGER
High-voltage field!
Danger to life from heart pacemaker failure.
Make sure that persons with pace makers:
Do not work with the electrostatic spray gun.
Remain outside the area of the electrostatic spray gun/work
piece.
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CAUTION
Electrostatic discharges!
Avoid directly spraying the control unit and the trolley.
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7.3
OPERATION OF THE CONTROL UNIT
5
1
2
3 4
20 22 21 23 18 13
19
9
6
10
7
50
60
40
11
8
2x
2x
12
25
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
m3/h
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
16
80
2.5 0.3
15
90
2.0 0.1
µA
0%
26
14
70
Ø
17
100 %
EPG
SPRINT X
P_01743
28
27
30 29
31 32 34
1
Illuminated display: "High-voltage"
Lights up green.
Display range: 0-100 kV
Resolution 10 kV
Single LED display: preset value of high-voltage
Bar graph LED: working voltage
2
Illuminated display: "Corona or Tribo Current"
Lights up green.
Tribo scale:
When a Tribo gun is connected and selected.
Bar graph LED: When powder feed is activated.
Display range: 0-5 μA
Resolution 0.5 μA
36 37 35
33
24
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: application point of current limiting
Bar graph LED: 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 "Profiles"
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 down.
9
Display LED: recipe for "Surface Parts"
Lights up green when the recipe for surface part is selected.
10 Display LED: recipe for "Second Coating"
Lights up green when the recipe for second coating is selected.
11 Display LED: recipe for "Profiles"
Lights up green when the recipe for profile part is selected.
12 Display LED: recipe for "Double Click"
Lights up green, when the recipe for double click is selected.
13 Display LED: "Fault"
Lights up, when there is a fault on the device.
14 Display LED: "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 standby mode.
To reactivate normal mode, press the button again.
16 Display LED: "Standby"
Lights up when the unit is in standby mode.
17 Push button: "Purge"
To activate the injector and the hose rinsing.
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18 Display LED: "Purge"
Lights up blue, when the purge function is activated.
19 Display LED: 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 limiting; powder quantity".
Display showing error number in the event of warnings and faults.
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 Display LED: "Overall Air"
Lights up yellow, when the setting "Overall Air" is selected.
23 Display LED: "Atomizing, Ionizing and Tribo Air"
Lights up yellow, when the setting "Atomizing, Ionizing and Tribo Air" is
selected.
24 Universal rotary controller
Dynamic digital rotary controller with 32 positions per turn.
Adjustment speed is proportional to rotational speed.
Used to set: "total air volume; atomizer, ionizer and Tribo air; additional recipes;
high voltage; current limiting; powder quantity".
For setting parameter values in configuration mode.
25 Push button: "Additional Recipes"
To activate the function, the additional recipes adjustment is set with Rotary
Controller 24 and is indicated in LED Display 19.
Selection of recipes 5 to 50.
26 Display LED: "Additional Recipes"
Lights up yellow, when an additional recipe is selected.
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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
28 Display LED: "High-Voltage"
Lights up yellow. The high-voltage is selected and can be adjusted using Rotary
Controller 24.
29 Push button: "Current Limiting"
To activate the function, the current limiting is set with Rotary Controller 24 and
is indicated in LED Display 19.
Adjusting range: 5-120 μA
Resolution: 1 μA
30 Display LED: "Current Limiting"
Lights up yellow. The current limiting is selected and can be adjusted using
Rotary Controller 24.
31 Push button: "Characteristic Slope"
To switch the characteristic slope.
Display with LED 32.
32 Display LED: "Characteristic Slope"
Lights up green.
Lower LED characteristic curve, flat.
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 graph LED: 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 graph LED: Actual value (high-voltage and powder are activated).
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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 graph LED: Actual value (high-voltage and powder are activated).
36 Push button: "Powder Quantity"
To activate the function, the powder quantity is set with Rotary Controller 24
and is indicated in LED Display 19.
Adjusting range: 1-100%
Resolution: 1%
37 Display LED: "Powder Quantity"
Lights up yellow, when the powder quantity is selected.
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7.4
STARTING UP THE MANUAL SYSTEM
7.4.1
SWITCHING ON THE MANUAL SYSTEM
A
I
0
1
50
40
2x
2x
60
Tri
Cor
100
5
120
80
4
80
12
5.5 3.0
60
3
40
11
4.5 1.5
40
2
20
10
9
8
3.5 0.5
10
1
20
kV
m3/h
Ø
30
20
10
70
2
Tri
80
2.5 0.3
90
2.0 0.1
µA
0%
100 %
EPG
SPRINT X
P_01778
3
To turn the power supply of the manual powder system on, set the mains switch on the
back side A of the control unit to position "I".
After a few seconds the control unit is operational.
The system switches to recipe 1 "Surface parts" after every restart.
To switch the manual system off or on, actuate the "Standby" push button 2.
Note:
The fluid air must be adjusted using throttle 3, when commissioning the manual
system.
The control unit automatically recognizes the type of gun connected.
There are 50 recipes available for the spray gun.
When a Tribo gun is connected, the Tribo current scale is activated, while the
high-voltage supply and control unit are deactivated.
All airs are only switched on once the trigger has been operated.
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7.4.2
ADJUSTING FLUIDIZATION (AIRFLUID)
Procedure:
1.
2.
3.
4.
2
5.
1
Swivel the feed unit 1 to the right side.
Place an opened powder container (25-30 kg;
55.11-66.14 lbs) on the vibrator table.
Switch on control unit.
Swivel the feed system 1 into the powder
container and lower it the surface of the
powder. Actuate the trigger of the spray gun
for a short time and release it. The vibrator
motor and the fluid air overrun for 10 s
(factory setting). This setting can be changed
if required by the user (see operating manual
"EPG-Sprint X")
Adjust the fluid air at throttle 2 to the point
that makes the feed system sinks into the
powder due to its own weight.
Note:
P_01770
The amount of fluid air depends on the
characteristics of the powder.
The powder should be moving in the suction
area of the feed system (gently simmering).
Avoid dust build up in the powder container.
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7.4.3
ADJUSTING FLUIDIZATION (60 L CONTAINER WITHOUT VIBRATOR TABLE)
WARNING
Dust formation!
Danger of poisoning.
Danger due to escaping dust, contamination of device and device
components.
Only fill the powder container up to the halfway mark, because
fluidizing increases the powder volume.
Procedure:
1.
2.
3.
4.
5.
Open the lid and fill powder container 1
halfway with powder.
Switch on control unit.
Set the parameter "Vibrator motor control"
on the control unit to "ON" to permanently
activate the fluid air, see operating manual of
the EPG-Sprint X control unit).
Actuate the trigger of the spray gun for a short
time and release it.
Adjust the fluid air at the throttle 2 until
fluidization is recognizable.
2
Note:
1
The amount of fluid air depends on the characteristics
of the powder. Avoid a build up of powder dust (too
much fluid air) in the powder container!
6.
P_01779
Close powder container 1 and check whether
the exhaust air hose is leading in the direction
of the ventilation system of the powder
coating booth.
Note:
We recommend using a vibrator table when
working with powders that are difficult to feed (see
chapter 12.12).
41
70
80
Penetration
and reduced
build-up of
edges
Small
components
Profile part
Double click
variable
P03
P04
P05-50
80
100
20
40
20
Standard
soft
soft
soft
Standard
Characteristic
curve:
4.5
3.6
3.6
3.6
4.0
Overall air
[m³/h]
80
45
50
57
70
Feed air
[%]
0.1
0.1
0.1
0.1
0.1
Atomizer air
[m³/h]
Notes:
Under normal conditions, metallic powder can be processed well using recipes Nos.1-4.
When operating the system with a Tribo gun, the values for overall air, powder flow and Tribo air must be adjusted accordingly and saved.
With the 3 L container variant, the values must also be adjusted individually and saved.
individual
50
Avoidance of
spraying back
Second
coating
Layering
P02
80
Current limiting
[μA]
7.5
90
High surfaces
performance
Flat part
High-voltage
[kV]
P01
Characteristic
Description
Recipe
No.
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RECIPES NOS. 1-4 FACTORY SETTINGS
The following set values are stored in recipe Nos. 1-4 in the factory.
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7.6
INTERRUPTING THE COATING PROCESS
7.6.1
AIRFLUID VERSION
NOTICE
Danger of clogging the fluid disk!
Danger of blockage.
Before the control unit is deactivated, the feed system must be pulled out of the
powder container.
NOTICE
Powder residues!
Danger of equipment damage.
At every work interruption, blow through the spray gun and the powder feed
components and clean from any powder residues.
Procedure:
1.
50
60
40
m3/h
30
20
70
Ø
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
2.
Tri
80
2.5 0.3
90
2.0 0.1
0%
17
100 %
EPG
SPRINT X
3.
4.
P_01785
5.
Release the trigger on the spray gun.
The high-voltage and the powder feed are
deactivated.
Lift the feed unit up, underneath the injector, and
lift it out of the container until retaining clamp H
swivels downwards.
Lower the feed system into the parking position
and swivel it to the right side so that no more
powder is forwarded.
Guide the gun into the spray booth and start the
purge function by pressing "Purge" Button 1. The
injector and hoses are purged.
Now the control unit can be switched off.
H
P_1789
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7.6.2
60 L CONTAINER VERSION
NOTICE
Powder residues!
Danger of equipment damage.
At every work interruption, blow through the spray gun and the powder feed
components and clean any powder residues.
Procedure:
1.
50
60
40
m3/h
20
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
2.5 0.3
3.
90
2.0 0.1
0%
2.
80
17
100 %
EPG
SPRINT X
4.
Release the trigger on the spray gun.
The high-voltage and the powder feed are
deactivated.
Remove the injector from the holder to stop
powder feed.
Guide the gun into the spray booth and start the
purge function by pressing "Purge" Button 1. The
injector and hoses are purged.
Switch off control unit.
P_01785
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7.7
"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 different parameters (high-voltage, current
limiting, air volumes etc.)
To access the function, press the trigger lever on the spray gun twice in quick succession
and hold down. Upon releasing the trigger, the original recipe will be returned to.
2x
2x
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
µA
kV
2x
2x
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
µA
kV
2x
2x
Tri
Cor
100
5
120
80
4
80
60
3
40
40
2
20
20
1
10
kV
2x
µA
P_01701
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8
CLEANING AND MAINTENANCE
8.1
CLEANING
8.1.1
CLEANING STAFF
Cleaning work should be regularly and carefully undertaken by qualified and trained staff.
The staff must be familiar with the DIN EN 50050-2 and DIN EN 50177 provisions. They
should be informed of specific hazards during their training.
The following hazards may arise during cleaning work:
Health hazard from inhaling powder paint
Use of unsuitable cleaning tools and aids
8.1.2
SAFETY INSTRUCTIONS
DANGER
Explosive powder/air mixes!
Danger to life and equipment damage.
Before starting cleaning or other manual work, the high-voltage
must be shut down and locked to prevent it from being switched
back on!
The spray gun must be separated from the high-voltage supply
before any cleaning work is started!
Use only electrically conductive containers for cleaning liquids!
Ground the containers!
Preference should be given to non-flammable cleaning fluids.
Flammable cleaning fluids may only be used if, once the
high-voltage has been switched off and all parts carrying
high-voltage are discharged to a discharge energy of less than
0,24 mJ before they can be reached.
Most flammable solvents have a firing power of around 24 mJ or
60 nC.
The cleaning agent's flash 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 to remove dust deposits.
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WARNING
Incorrect Maintenance!
Risk of injury and damage to the equipment.
If contact with powder materials or cleaning agents causes skin
irritation, appropriate precautionary measures must be taken,
e.g. wearing protective clothing.
The footwear worn by operating staff must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100 Megaohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 Megaohms.
8.1.3
CLEANING PROCEDURES
The cleaning intervals should be adapted by the operator depending on the level of use
and if necessary the level of soiling.
In doubt, we recommend contacting J. Wagner AG's specialist personnel.
The valid health and safety specifications and the safety instructions provided in chapter 4
must be adhered to for all cleaning work.
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8.2
MAINTENANCE
8.2.1
MAINTENANCE STAFF
Maintenance work should be regularly and carefully undertaken by qualified and trained
staff. They should be informed of specific hazards during their training.
The following hazards may arise during maintenance work:
Health hazard from inhaling powder paint
Use of unsuitable tools and aids
Once the maintenance work is complete, the device must be checked by a qualified person
to ensure a reliable condition.
8.2.2
SAFETY INSTRUCTIONS
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Repair or replacement of devices or parts of devices may only be
performed outside the hazard area by specialist personnel.
DANGER
Incorrect maintenance/repair!
Risk of injury and damage to the equipment.
Have repairs and part replacements be carried out by specially
trained staff or a WAGNER service center.
Before all work on the unit and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Decompress spray gun and device pressure.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying
out all work.
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WARNING
Incorrect maintenance!
Risk of injury and damage to the equipment.
If contact with powder materials or cleaning agents causes skin
irritation, appropriate precautionary measures must be taken,
e.g. wearing protective clothing.
The footwear worn by operating staff must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100 Megaohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 Megaohms.
8.2.3
MAINTENANCE PROCEDURES
The maintenance intervals should be adapted by the operator depending on the level of
use and if necessary the level of soiling.
In doubt, we recommend contacting J. Wagner AG's specialist personnel.
The valid health and safety specifications and safety instructions provided in chapter 4
must be adhered to for all maintenance work.
Maintenance work
Point in time
Per shift
Blow out gun and check for sintering
x
Check gun settings
x
Check gun discharge pressure
x
Blow out powder hoses
x
Weekly
Check grounding
x
Check compressed air quality
x
Check gun voltage
x
Check powder hoses for bends and sintering
x
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8.3
PERIODICALLY CHECK AND CLEAN THE MANUAL POWDER SYSTEM
8.3.1
AIRFLUID VERSION
Procedure:
1.
2.
50
60
40
m3/h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
3.
70
Ø
30
Tri
80
2.5 0.3
4.
90
2.0 0.1
0%
17
100 %
EPG
SPRINT X
5.
6.
P_01785
7.
8.
9.
H
10.
11.
P_1789
5
6
12.
13.
4
3
14.
Release the trigger on the spray gun.
The high-voltage and the powder feed are
deactivated.
Lift the feed unit up, underneath the injector,
and lift it out of the container until retaining
clamp H swivels downwards.
Lower the feed system into the parking position
and swivel it to the right side so that no more
powder is forwarded.
Guide the gun into the spray booth and start the
purge function by pressing "Purge" button 17.
The injector and hoses are purged.
Switch off control unit.
Release the outer nut on powder feed hose 3 and
disconnect powder feed hose 3 from injector 4.
Disconnect powder feed hose 5 (red) from
injector 4.
Disconnect dosage air hose 6 (blue) from injector 4.
Pull the fluid air hose (black) off suction
connector 2.
Pull injector 4 out of feed unit 1.
Check injector 4 for wear and replace worn parts
if necessary.
The wearing and spare parts can be found in the
operating manual of the powder injector.
Pull feed unit 1 out of the holder arm.
Blow out the suction tube of the feed unit 1
thoroughly and rub it clean with a dry cloth.
Check whether the fluid disk on the bottom of
the feed unit is blocked and replace if necessary.
2
1
P_01787
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8.3.2
60 L CONTAINER VERSION
Procedure:
1.
50
60
40
m3/h
70
Ø
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
Tri
2.
3.
80
2.5 0.3
90
2.0 0.1
0%
17
100 %
EPG
4.
5.
SPRINT X
P_01785
6.
7.
8.
4
5
6
1
3
9.
10.
7
2
8
11.
12.
P_01140
13.
9
14.
8
15
10
Release the trigger on the spray gun.
The high-voltage and the powder feed are
deactivated.
Remove injector 1 from holder 2.
Guide the gun into the spray booth and start the
purge function by pressing "Purge" Button 1. The
injector and hoses are purged.
Switch off control unit.
Release the outer nut on powder feed hose 3 and
disconnect powder feed hose 3 from injector 1.
Disconnect the red feed air hose 4 from injector 1.
Disconnect the blue dosage air hose 5 from the
injector 1.
Check the powder injector for wear and replace
worn parts. The wear and spare parts can be
found in the operating manual of the powder
injector.
Loosen exhaust air hose 6 from connection 7 of
powder container 8.
Remove the black fluid air hose 9 from powder
container 8.
Loosen grounding cable 10 from powder
container 8.
Lift the powder container in order to clean the
equipment trolley.
Take the lid of the powder container off, empty
the powder container and blow out the powder
container thoroughly.
Completely remove all residual powder from the
suction system.
Pay special attention when cleaning the fluid
base, check it for blockage or damage and replace
it if necessary.
The wearing and spare parts are in the chapter
"Spare Parts" of this operating manual.
P_01141
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8.4
PERFORMING A COLOR CHANGE (AIRFLUID)
Note:
For a color change, all components of the powder feed system must be thoroughly cleaned.
Procedure:
1.
2.
50
60
40
m3/h
30
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
3.
70
Ø
Tri
80
2.5 0.3
4.
90
2.0 0.1
0%
17
100 %
EPG
SPRINT X
5.
6.
P_01785
7.
8.
H
9.
P_1789
Release the trigger on the spray gun.
The high-voltage and the powder feed are
deactivated.
Lift the feed unit up underneath the injector
and lift it out of the container until the retaining
clamp H swivels downwards.
Lower the feed system into the parking position
and swivel it to the right side so that no more
powder is forwarded.
Guide the gun into the spray booth and start the
purge function by pressing "Purge" Button 1. The
injector and hoses are purged.
Switch off control unit.
Clean all powder feeding parts of the unit, such
as the spray gun, the injector and the powder
feed hose.
Place an opened powder container (25-30 kg;
55.11-66.14 lbs) with powder on the vibrator
table.
Swivel retaining clamp H away, lower the feed
unit to the powder surface, actuate the trigger of
the spray gun for a short time and then release it.
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 X
control unit's operating manual.
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8.5
PERFORMING A COLOR CHANGE (60 L CONTAINER)
8.5.1
CLEANING PROCESS WHEN USING A SINGLE POWDER CONTAINER
Note:
For a color change, all components of the powder feed system must be thoroughly cleaned.
Procedure:
1.
2.
3.
50
60
40
m3/h
20
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
4.
5.
70
Ø
30
Tri
80
2.5 0.3
90
2.0 0.1
0%
17
100 %
EPG
P_01785
SPRINT X
6.
Release the trigger on the spray gun.
The high-voltage and the powder feed are
deactivated.
Remove the injector from the holder to stop
powder feed.
Guide the gun into the spray booth and start the
purge function by pressing "Purge" Button 1. The
injector and hoses are purged.
Switch off control unit.
Open the powder container and clean all powder
feeding parts of the unit,
such as the spray gun, the injector, the powder
feed hose and the suction system.
Clean the powder container and pay special
attention to the fluid base.
Note:
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 X
control unit's operating manual.
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8.5.2
CLEANING PROCESS WHEN USING MULTIPLE POWDER CONTAINERS (60 L CONTAINER)
Procedure:
1.
2.
3.
50
m3/h
20
70
Ø
30
12
5.5 3.0
11
4.5 1.5
10
9
8
3.5 0.5
10
4.
5.
60
40
Tri
80
2.5 0.3
6.
90
2.0 0.1
0%
17
100 %
7.
EPG
SPRINT X
8.
P_01785
9.
10.
Release the trigger on the spray gun.
The high-voltage and the powder feed are
deactivated.
Remove the injector from the holder to stop
powder feed.
Guide the gun into the spray booth and start the
purge function by pressing "Purge" Button 17.
The injector and hoses are purged.
Switch off control unit.
Loosen the powder feed hose from the powder
injector and clean the spray gun and the powder
feed hose thoroughly.
Loosen the blue dosage air hose and the red feed
air hose from the powder injector.
Disconnect the black fluid air hose from the
powder container.
Loosen the grounding cable from the powder
container.
Replace the powder container.
Reconnect all the hoses and ground the powder
container by connecting to the grounding cable.
Note:
Proper fluidization is not possible with a damaged
and/or clogged fluid base.
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8.5.3
RESTARTING THE MANUAL POWDER SYSTEM
Procedure:
1.
2.
Check if the control unit is switched off.
Open the powder container and fill it halfway with powder.
WARNING
Dust formation!
Danger of poisoning.
Danger due to escaping dust, contamination of device and device
components.
Only fill the powder container up to the halfway mark, because
fluidization increases the powder volume.
3.
4.
5.
6.
Switch on the control unit and activate the "Powder feed quantity" function by
pressing "Powder Quantity" button 36.
Adjust the powder quantity to 0% with Universal Rotary Controller 24.
Actuate the trigger and keep it actuated.
Adjust the fluid air at the throttle until fluidization is recognizable.
Note:
The amount of fluid air depends on the characteristics of the powder. Avoid a build up of
powder dust (too much fluid air) in the powder container!
7.
Close the powder container and check whether the exhaust air hose is leading in
the direction of the ventilation system of the powder coating booth.
To adapt programs to the new applications, proceed as described in the EPG-Sprint X
control unit's operating manual.
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9
INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010
If the system is used for electrostatic coating with flammable coating powders, testing
should be undertaken in accordance with DIN EN 50177: 2010-04 as per Table 3 and
Table 4.
56
Interlock between technical
ventilation and high-voltage,
compressed air and coating
material supply
Effectiveness of grounding
measures
2
3
Key:
HE = Manufacturer
AG = Employer
BP = Capable person
BSB = Fire safety engineer
EFK = Electrician
UP = Trained person
Effectiveness of technical
ventilation check
Type of inspection
BP
BP
UP/BP
Inspection
by
FU = Function inspection
ME = Measurement
OP = Standard inspection
SI = Visual inspection
SÜ = Continuous inspection
TP = Technical inspection
All the system's conductive
elements, such as floors, walls,
ceilings, protective grating,
transport equipment, work pieces,
powder containers, machines 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 12215.
The technical ventilation should be
interlocked such that the
high-voltage cannot be switched
on while the technical ventilation is
not working effectively.
Effectiveness of technical
ventilation check
Requirements
Continuously
Inspection
interval
SI/ME/SÜ
Visual check of ground
connections, perform function
test on grounding switch,
measurement of grounding
resistors.
Weekly
Annually
FU
Test whether the system is safely
stopped and the material supply,
supply air and high-voltage
are switched off when the
ventilation is shut down.
ME
Measurements of air flow speed
/ air quantities.
Check the differential pressure
indicator.
Type of inspection
9.1
1
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OVERVIEW OF INSPECTIONS
57
Resistance to ground of work
piece's locating point
5
Key:
HE = Manufacturer
AG = Employer
BP = Capable person
BSB = Fire safety engineer
EFK = Electrician
UP = Trained person
Measures to take if conductive
components are insufficiently
grounded
Type of inspection
4
Section
ME/SÜ
Measurement of discharge
energy.
ME/SÜ
Measure resistance to ground
(work piece receiver - ground
potential)
max. 1 MOhm @ 1000 V.
BP
Type of inspection
BP
Inspection
by
FU = Function inspection
ME = Measurement
OP = Standard inspection
SI = Visual inspection
SÜ = Continuous inspection
TP = Technical inspection
The resistance to ground of
every work piece's locating point
must not exceed 1 megaohm
(measurement voltage must be
1000 V). The design of the work
piece receiver must ensure that the
adapters remain grounded during
coating.
If sufficient grounding of
conductive parts cannot be
ensured, their discharge energy
must not exceed the permissible
value.
Requirements
Weekly
Weekly
Inspection
interval
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58
Measures to take if the work pieces
are insufficiently grounded
Effectiveness of the manually
or automatically actuated fire
extinguishing systems (room
protection system)
6
7
Key:
HE = Manufacturer
AG = Employer
BP = Capable person
BSB = Fire safety engineer
EFK = Electrician
UP = Trained person
Type of inspection
Section
HE/BSB
BP
Inspection
by
FU = Function inspection
ME = Measurement
OP = Standard inspection
SI = Visual inspection
SÜ = Continuous inspection
TP = Technical inspection
Effectiveness of the manually
or automatically actuated fire
extinguishing systems (room
protection system).
If sufficient work piece grounding
in accordance with section 6
cannot be ensured, appropriate
equipment, e.g. ionizers, may be
used to discharge electric charges
on the work piece. Such equipment
must not exceed the permitted
discharge energy of the spray
systems with which it is used. In
terms of permitted discharge
energy, this equipment must be
put through the same inspections
as the powder spray systems used
with it. The discharge equipment
must be interlocked with the spray
system such that the high-voltage
is switched off and that coating
cannot take place if the discharge
equipment malfunctions.
Requirements
FU
Trigger fire extinguishing
system, observe manufacturer's
requirements.
ME/FU/SÜ
Measurement of discharge
energy, check the monitoring
equipment's test function by
triggering it.
Type of inspection
6 months
Weekly
Inspection
interval
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10 DISASSEMBLY AND DISPOSAL
10.1
DISASSEMBLY
WARNING
Incorrect disassembly!
Risk of injury and damage to the equipment.
Before starting disassembly:
- Switch off the energy/compressed air supply.
- Ensure that all system components are grounded.
- Secure system against being switched back on without
authorization.
Observe the operating manual when carrying out all work.
Procedure:
1.
2.
3.
4.
5.
Switch off the system.
Pull the connection cable out from socket.
Lock the supply of compressed air and decompress system.
Separate the connection cable from the compressed air supply.
Separate the grounding cable from the system ground.
10.2
DISPOSAL
NOTICE
Do not dispose of used electrical equipment with household
refuse!
In accordance with European Directive 2002/96/EC on the disposal
of used electrical equipment and its implementation in national
law, this product may not be disposed of with the household refuse,
but must be recycled in an environmentally correct manner.
Wagner, or one of our dealers, will take back your used Wagner
equipment and will dispose of it for you in an environmentally
friendly way. Please contact one of our service points, one of our
representatives, or us directly to arrange this.
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11 TROUBLESHOOTING AND RECTIFICATION
DANGER
Incorrect maintenance/repair!
Risk of injury and damage to the equipment.
Have repairs and part replacements be carried out by specially
trained staff or a WAGNER service center.
Before all work on the unit and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Decompress spray gun and device pressure.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying
out all work.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Wagner devices, protective systems and safety, monitoring
and control equipment may only be repaired as defined in
Directive 94/9/EC (ATEX) by trained Wagner service personnel
or capable persons in accordance with TRBS 1203! Note national
regulations!
Repair or replacement of devices or parts of devices may only be
performed outside the hazard area!
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11.1
FAULTS AT THE MANUAL SYSTEM
Malfunction
Power indicator does not light up
No Corona power supply
Sputtering powder feed
Dust buildup above the container
or the powder container
Bad wrap around, back-spray
Cause
Remedy
Mains not switched on.
Turn on mains.
1 AT fuses defective.
Replace fuses.
The connection cable to the
To replace the connection cable,
powder spray gun is interrupted.
notify Wagner services or your
qualified personnel.
The powder spray gun is too
Switch off the high-voltage,
close to the work piece.
increase the distance between
the spray gun and the work
piece and then switch the
high-voltage on again.
Should an error message be
displayed again, inform the
Wagner service center.
The grounding between control
Inform Wagner service center.
unit and powder spray gun is
interrupted.
The flow rate in the powder
Increase the total feed and
feed hose is too low.
dosage air and readjust the ratio
of the airs to each other.
Cross section of the powder feed
Use a powder hose that prevents
hose reduced by movement.
the cross section from narrowing
(Select a hose with a thicker
wall.).
Fluctuations in the compressed
Install
compressed
air
air caused by short-term
storage directly in front of
increase of the compressed
high
consumption
system
air consumption in the supply
components.
system.
Too much fluid air.
Reduce the fluid air at the
throttle.
The throttle is not connected to
Connect the throttle to the fluid
the fluid air connection of the
air connection of the control
control unit.
unit and readjust the fluid air
volume.
Insufficient grounding.
Make sure that all components
are well grounded, see Chapter
6.7 "Grounding".
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Malfunction
No powder feed
Cause
Container or powder container
empty.
The spray gun is clogged.
The powder feed hose is
clogged.
The powder suction system
in the powder container is
clogged.
The feed air hose is bent.
The powder feed hose is bent.
The feed unit does not sink into
the powder.
The guide of the feed unit
holder is jammed.
Remedy
Refill powder.
Blow through the spray gun.
Blow through the powder feed
hose.
Blow through the powder
suction system.
Straighten or replace the feed air
hose.
Straighten or replace the powder
feed hose.
Enable the guide to move
smoothly.
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12 ACCESSORIES
12.1
FEED SYSTEM SN-2 550/10
P_00418
Order No.
265272
12.2
Description
Feed system SN-2 550/10
MAINTENANCE UNIT
P_01355
Order No.
Description
2314265
Maintenance unit
2314308
Filter cartridge (spare part)
2314309
Fine-filter cartridge (spare part)
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12.3
QUICK COUPLING SET
Order No.
Description
2312543
Quick coupling set
935658
Compressed air hose
12.4
9.5 mm
ADAPTER PLATE SWITCH BOX
P_01158
Order No.
2308079
Description
Adapter plate switch box
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12.5
SPRAY GUN SWITCH BOX
P_00670
Order No.
Description
265911
Spray gun switch box
When alternately a Corona or a Tribo gun is operated
2313993
Hose (black,
4x6 mm)
12.5.1INSTALLATION OF THE SWITCH BOX
WARNING
Danger from electric current!
Risk of injury and damage to the equipment.
Before starting with the installation of the switch box, the
manual powder system must be switched off and the mains
plug disconnected.
Procedure:
3
1
1.
Screw switch box 1 with screws 2
to adapter plate 3.
2
P_01159
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4
2.
Use screws 4 to screw adapter
plate with fitted switch box onto
the back side of trolley's front
plate.
3.
Pull the spray gun cable out of
socket A on the control unit.
4.
Plug electrical cable B of the
switch box into socket A on the
control unit and secure it with
the protective sleeve.
5.
Connect the spray gun to the
appropriate connection on the
switch box and secure it with
the protective sleeve of the
spray gun cable.
6.
Set switch C on the switch box
to the desired spray gun type.
P_01183
A
P_01184
B
Connection
Corona gun
Connection
Tribo gun
C
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12.5.2SWITCHING THE GUN TYPES
Note:
Clean the powder residues from all powder-conveying parts thoroughly, before changing
to another gun type.
1
P_01185
2
Procedure:
(For example: switching from Corona to Tribo)
1.
Switch off control unit with Switch 1 on the back side.
2.
Change the coating powder from Corona to Tribo.
3.
Disconnect hose 2 (transparent, atomizing air) from the Corona gun and connect it
to the Tribo gun (Tribo air).
4.
Disconnect the powder feed hose of the Corona spray gun from the powder injector
and connect the Tribo gun hose to the powder injector.
5.
Set switch C on the switch box to Tribo.
Note:
Parameter C11, in the EPG-Sprint X 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.
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12.6
PEM-T3 MANUAL GUN
P_01422
Order No.
351019
12.7
Description
PEM-T3 Tribo manual gun
PEM-T3 300 EXTENSION
P_00923
Order No.
260934
Description
PEM-T3 300 extension
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12.8
SWIVEL CASTERS SET
P_01680
P_01685
Order No.
2324869
12.9
Description
Swivel casters set
POWDER HOSE
Order No.
Description
351794
Powder hose
9 mm
2310699
Powder hose
10 mm
2307502
Powder hose
11 mm
2310700
Powder hose
12 mm
12.10 SPRINT DUAL MANUAL COATING SET
This accessory is used to operate two manual guns with the manual system.
The set consists of the control unit, the manual spray gun, a feed unit and different
connecting parts and cables.
Order No.
Description
Sprint dual manual coating set
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12.11 WALL MOUNT
P_01861
Order No.
Description
Wall mount with bracket
12.12 CONVERSION SETS
When working with powders that are difficult to feed, the manual system can be converted
into a variant with a vibrator table.
Order No.
Description
Sprint 60 L V conversion set
Sprint 3 L V conversion set
P_01868
Sprint 60 L V
P_01869
Sprint 3 L V
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12.13 RECIPE STICKER
50
40
60
m3/h
m3/h
Ø
Tribo Corona
2x
2x
name
12
5.5
11
4.5
10
9
8
3.5
2.5
2.0
30
70
10
90
3.0
Tri
1.5
80
20
0.5
0%
0.3
0.1
100 %
[Nm³/h]
[kV]
[μA]
[Nm³/h]
[%]
90
80
4.0
70
0.1
50
20
3.6
57
> 0.2
70
40
3.6
50
82
20
3.6
45
80
100
4.5
80
2x
P5
P6
✆
______________________________
@
______________________________
P7
P8
P9
www
www.wagner-group.com/industry
P10
P_01829
Order No.
Designation
2331223
Recipe sticker
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OPERATING MANUAL
12.14 EXTENDED OPERATING MANUALS
If additional information regarding the individual components is desired, the operating
manuals listed below can be resorted to. These operating manuals are saved on the
provided CD.
This extended operating manual includes:
important instructions that are necessary for connection, start-up and operation
(e.g. color change) of the relevant components,
the very important chapter "Maintenance and Cleaning" for the relevant components,
troubleshooting and error correction for the relevant components,
spare parts, wearing parts and accessories.
Description
Operating manual
Language
EPG-Sprint X control unit
2327591
German
2329371
English
241890
German
241891
English
PI-F1 powder injector
Hicoat ED-Pump F powder injector
PEM-X1 manual gun
PEM-T3 manual gun
241885
German
241886
English
2326019
German
2326020
English
351708
German
351709
English
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13 SPARE PARTS
13.1
HOW TO ORDER SPARE PARTS?
To ensure proper spare parts delivery, the following information is necessary:
Order number, designation and quantity
The quantity does not have to be identical to the numbers in the "Stk" columns of the lists.
This number merely indicates how many of the respective parts are used in each module.
The following information is also required to ensure smooth processing of your order:
-
Billing address
Delivery address
Name of the person to be contacted in the event of any queries
Type of delivery ( normal mail, express delivery, or courier etc.)
Identification in spare parts lists
Explanation of column "K" (labeling) in the following spare parts lists.
= Wearing part
Note: No liability is assumed for wearing parts.
= Not part of standard equipment, available, however, as a special accessory.
WARNING
Incorrect maintenance/repair!
Risk of injury and damage to the device.
Have repairs and part replacements be carried out by specially
trained staff or a WAGNER service center.
Before all work on the unit and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Ensure that all system components are grounded.
- Secure the unit against being switched back on without
authorization.
Observe the operating and service instructions when carrying
out all work.
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13.2
SCOPE OF DELIVERY AND SPARE PARTS LIST OF SPRINT AIRFLUID MANUAL POWDER SYSTEM
2
5
3
4
6
1
8
7
P_01770
Pos
K
Stk
Order No.
2329483
Description
Sprint Airfluid Plus C manual powder system (standard version)
2329487
Sprint Airfluid Plus C manual powder system (USA version)
1
1
2303258
Airfluid trolley
2
1
2324731
EPG-Sprint X control unit
9951117
Thermal delay fuse 1A (included in EPG-Sprint X)
2
1
EPG-Sprint X control unit (US version)
9951117
Thermal delay fuse 1A (included in EPG-Sprint X)
3
1
241622
PI-F1 powder injector
4
1
265281
Suction tube ST 550/10
5
1
6
2322587
PEM-X1 manual gun
2306401
Sprint connection parts
6/1
1
2303714
Sealing coupling with anti-kink spring
6/2
1.3 m
9982079
Hose, black
6/3
1.3 m
700370
Hose, blue
6/4
1
935973
Sealing coupling with anti-kink spring
6/5
1.3 m
2302060
Hose, red
6/6
1
935974
Coupling plug with anti-kink spring
6/7
5
2327855
Velcro cable ties
6 mm
8 mm
8 mm
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7
1
8
Piston vibrator, complete
Powder hose set
11x5000 mm; 0.43x196.85 inches
9
1
Grounding cable 10 m; 32.81 ft
10
1
Power cable
11
1
Sprint spare parts starter kit (not included in the scope of delivery)
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13.3
SCOPE OF DELIVERY AND SPARE PARTS LIST OF SPRINT WITH 60 L CONTAINER
(without vibration table)
2
5
4
3
9
6
1
P_01782
Pos
K
Stk
Order No.
Description
2329489
Sprint 60 L C manual powder system (standard version)
2329491
Sprint 60 L C manual powder system (US version)
1
1
2303764
Trolley 60 L
2
1
2324731
EPG-Sprint X control unit
9951117
Thermal delay fuse 1A (included in EPG-Sprint X)
2
1
9951117
Thermal delay fuse 1A (included in EPG-Sprint X)
3
1
241622
PI-F1 powder injector
4
1
2322587
PEM-X1 manual gun
2306401
Sprint connection parts
5
EPG-Sprint X control unit (US version)
5/1
1
2303714
Sealing coupling with anti-kink spring
5/2
1.3 m
9982079
Hose, black
5/3
1.3 m
700370
Hose, blue
5/4
1
935973
Sealing coupling with anti-kink spring
5/5
1.3 m
2302060
Hose, red
6 mm
8 mm
8 mm
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5/6
1
Coupling plug with anti-kink spring
5/7
5
Velcro cable ties
6
Powder hose set
11 x 5000 mm; 0.43 x 196.85 inches
7
1
Grounding cable 10 m; 32.81 ft
8
1
Power cable
Not included in the scope of delivery, please order separately:
9
1
60 L powder container
9
1
25 L powder container
10
1
Sprint spare parts starter kit
13.4
SPARE PARTS LIST OF THE TROLLEY
8
7
2
6
3
5
1
P_01784
Pos
K
Stk
Order No.
4
Description
1
1
Sprint injector bracket, complete
2
1
Suction tube bush
3
1
Retaining clamp
4
2
Adjustment foot
5
1
Nut
6
1
Guide bush
7
1
Gun holder
8
1
9950817
Cable socket
Wearing part
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OPERATING MANUAL
13.5
SUCTION TUBE ST 550/10
4
5
1
3
2
P_01155
Pos
K
Stk
Order No.
Description
1
1
265281
Suction tube ST 550/10
2
1
265401
Fluid crown
3
1
265402
Fluid ring
4
1
2303716
Plug-in nipple G1/8"
5
1
2307727
Extension
Wearing part
Not part of the standard equipment but available as a special accessory
only available as a set
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OPERATING MANUAL
13.6
FEED SYSTEM SN-2 550/10
3
2
1
P_00577
Pos
K
Stk
Order No.
Description
265272
Feed system SN-2 550/10
1
2
265401
Fluid crown
2
2
265402
Fluid ring
3
1
9999047
Plug-in nipple G1/8"
Wearing part
Not part of the standard equipment but available as a special accessory
only available as a set
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OPERATING MANUAL
13.7
COMPRESSED AIR SUPPLY
Back side view of the control unit
3
2
P_01154
1
Pos K
Stk
Order No.
Description
1
1
2303294
Solenoid valve, 2/2 way
2
1
2304119
Fluid air throttle
3
1
2305860
Filter precipitator
9981151
Compressed air connection hose 18.5 x 12.5 mm
Wearing part
Not part of the standard equipment but available as a special accessory
only available as a set
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OPERATING MANUAL
13.8
PI-F1 POWDER INJECTOR
8
9
10
5
5
7
4
1
11
2
3
P_00894
Pos
1
2
3
4
5
7
8
9
10
11
K
Stk
1
1
1
1
2
1
1
1
1
2
Order No.
241622
241225
241476
241466
241923
241460
9970149
9992709
9992710
9970150
9974023
Description
PI-F1 powder injector
Collector nozzle
Conductive nozzle
Cap nut
Injector nozzle
Spring check valve
Sealing ring
Quick-release plug
Quick-release socket
Sealing ring
Sealing ring, electrically conductive
Wearing part
Not part of the standard equipment but available as a special accessory
only available as a set
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OPERATING MANUAL
13.9
HICOAT-ED PUMP F
8
9
10
5
5
7
4
1
11
2
3
P_00889
Pos
K
1
2
3
4
5
7
8
9
10
11
Stk
1
1
1
1
2
1
1
1
1
2
Order No.
241624
241229
241479
241466
241930
241460
9970149
9992709
9992710
9970150
9974023
Description
HiCoat-ED pump F
Collector nozzle low air
Hose sleeve
Cap nut
Injector nozzle
Spring check valve
Sealing ring
Quick-release plug
Quick-release socket
Sealing ring
O-ring, electrically conductive
Wearing part
Not part of the standard equipment but available as a special accessory
only available as a set
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13.10 60 L/25 L CONTAINER
11
9
13
3
10
5
19
24
20
1
6
7
17
4
21
2
8
15
P_01156
14
16
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Pos
1
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
19
20
20
21
24
K
Stk
1
1
1
1
1
1
1
1.10 m
6
12
1
1
1
1
1
2
1
12
1
1
1
1.10 m
2
Order No.
264268
264224
263375
264212
264215
264381
264382
9971527
9994703
9900717
9992270
184336
9910109
9982058
241372
170533
9920118
241276
9922102
241376
263357
264420
8324008
9971178
Description
60 L powder container
25 L powder container
60 L container
25 L container
Base housing
Cover
Fluidized bed
Foam rubber gasket
Spring clip
Cylinder head screw
Quick coupling for screw-on connector
Hose nipple
Hexagon nut
Exhaust hose 17x3
Injector connection, complete
Knurled nut
Washer
Grounding cable, complete
Star washer
Cable connection
60 L suction tube
25 L suction tube
Base seal
O-ring
Wearing part
Not part of the standard equipment but available as a special accessory
only available as a set
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14 WEARING PARTS
Order No.
Description
2321976
Flat spray nozzle X1, complete
2321981
2321980
2321171
D18 deflector cone, complete
D25 deflector cone, complete
D34 deflector cone, complete
260928
Fan spray nozzle for PEM-T3
259474
Deflector cone ( 25 mm; 0.87 inch) for PEM-T3
265401
Fluid crown of suction unit
265402
Fluid ring of suction unit
241225
Clearance collector nozzle of PI-F1 Injector
241229
Collector nozzle ED pump
P_01664
P_01665
P_00696
P_00697
P_00723
P_00698
P_00699
P_01826
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15 DECLARATION OF WARRANTY AND CONFORMITY
15.1
IMPORTANT NOTES ON PRODUCT LIABILITY
As a result of an EC regulation effective from January 1, 1990, the manufacturer shall only
be liable for his product if all parts originate from him or are approved by him, and if the
devices are properly mounted, operated and maintained.
The manufacturer will not be held liable or will only be held partially liable if third-party
accessories or spare parts have been used.
With genuine WAGNER accessories and spare parts, you have the guarantee that all safety
regulations are complied with.
15.2
WARRANTY CLAIM
Full warranty is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the Purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of warranty provided is such that the device or individual components of the
device are either replaced or repaired as we see fit. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the unit to a location other
than the address of the purchaser.
We do not provide warranty for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute materials and the action of chemical, electrochemical or electrical
agents, except when the damage is attributable to us.
Components that have not been manufactured by WAGNER are subject to the original
warranty of the manufacturer.
Replacement of a component does not extend the period of warranty of the device.
The unit should be inspected immediately upon receipt. To avoid losing the warranty, we
or the supplier company are to be informed in writing about obvious faults within 14 days
upon receipt of the device.
We reserve the right to have the warranty compliance met by a contracting company.
The services provided by this warranty depend on evidence being provided in the form of
an invoice or a delivery note. If upon examination it is discovered, that no warranty claim
exists, the costs of repairs are charged to the purchaser.
It is clearly stipulated that this warranty claim does not represent any constraint on statutory
regulations or regulations agreed to contractually in our general terms and conditions.
J. Wagner AG
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15.3
CE DECLARATION OF CONFORMITY
15.3.1CE DECLARATION OF CONFORMITY FOR TROLLEY
Herewith we declare that the supplied version of
- Airfluid Trolley/60 L Trolley
complies with the following provisions applying to it:
- 94/9/EC (ATEX Directive)
- 2006/42/EC (Machinery directive)
- 2002/95/EC (RoHs Directive)
- 2002/96/EC (WEEE Directive)
Applied standards, in particular:
-
Applied national technical standards and specifications, in particular:
- BGI 764
Identification:
II 3D c 80 °C
EC Certificate of Conformity
The CE certificate 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:
Airfluid Trolley/60 L Trolley 2329128
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15.3.2CE DECLARATION OF CONFORMITY FOR CONTROL UNIT
Herewith we declare that the supplied version of
- EPG-Sprint X, Order No. 2324731
complies with the following provisions applying to it:
- 94/9/EC (ATEX Directive)
- 2004/108/EC (EMC Directive)
- 2002/95/EC (RoHs Directive)
- 2002/96/EC (WEEE Directive)
Applied standards, in particular:
Identification:
0102
II 3(2)D IP 64 80 °C
EC Certificate of Conformity
The CE certificate 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:
EPG-Sprint X 2327595
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15.3.3CE DECLARATION OF CONFORMITY FOR POWDER GUNS
Herewith we declare that the supplied version of
- PEM-X1 Manual Gun, Order No. 2322587
complies with the following provisions applying to it:
- 94/9/EC (ATEX Directive)
- 2006/42/EC (Machinery Directive)
- 2004/108/EC (EMC Directive)
- 2002/95/EC (RoHs Directive)
- 2002/96/EC (WEEE Directive)
Applied standards, in particular:
Applied national technical standards and specifications, in particular:
- BGI 764
Identification:
II 2D 2mJ
0102
PTB 12 ATEX 5002
EN 50050-2: 2012
EC Certificate of Conformity
The CE certificate 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:
PEM-X1 Manual Gun 2326024
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15.4
EC TYPE EXAMINATION CERTIFICATE
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15.5
FM APPROVAL
in submission
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Germany
J. WAGNER GmbH
Otto-Lilienthal-Str. 18
Postfach 1120
D- 88677 Markdorf
Phone: +49/ 7544/ 505-0
Fax: +49/ 7544/ 505-200
E-mail: service.standard@wagner-group.com
Switzerland
J. WAGNER AG
Industriestrasse 22
Postfach 663
CH- 9450 Altstätten
Phone: +41/ 71/ 757 2211
Fax: +41/ 71/ 757 2222
E-mail: rep-ch@wagner-group.ch
Belgium
Estee Industries
Leenbeekstraat 9
B- 9770 Kruishoutem
Phone: +32/ 9/ 388 5410
Fax: +32/ 9/ 388 5440
E-mail: info@estee-industries.com
Denmark
WAGNER Industrial Solution Scandinavia
Viborgvej 100, Skægkær
DK-8600 SILKEBORG
Phone: +45/ 70 200 245
Fax: +45/ 86 856 027
E-mail: info@wagner-industri.com
Great Britain
WAGNER Spraytech (UK) Ltd.
The Couch House
2, Main Road
GB- Middleton Cheney OX17 2ND
Phone: +44/ 1295/ 714200
Fax: +44/ 1295/ 710100
E-mail: enquiry@wagnerspraytech.co.uk
France
Wagner - Division Solutions Industrielles
Parc Gutenberg - Bâtiment F
8 voie la Cardon
F- 91127 PALAISEAU Cedex
Phone: +33/ 1/ 825/ 011111
Fax: +33/ 1/ 69 19 46 55
E-mail: division.solutionsindustrielles@wagner-france.fr
Netherlands
WAGNER Systemen Nederland
Proostwetering 105 C
NL- 3543 AC Utrecht
Phone: +31/ 30/ 2410 688
Fax: +31/ 30/ 2410 765
E-mail: info@wagnersystemen.nl
Italy
WAGNER Itep S.p.A
Via Santa Veccia, 109
I- 22049 Valmadrera - LC
Phone: +39/ 0341/ 212211
Fax: +39/ 0341/ 210200
E-mail: wagnerit@tin.it
Japan
WAGNER HOSOKAWA Micron Ltd.
No. 9, 1-Chome
Shodai Tajka, Hirakata-Shi
Osaka 673-1132
Phone: +81/ 728/ 566 751
Fax: +81/ 728/ 573 722
E-mail: sempara@kornet.net
Austria
J. WAGNER GmbH
Otto-Lilienthal-Str. 18
Postfach 1120
D- 88677 Markdorf
Phone: +49/ 7544/ 505-0
Fax: +49/ 7544/ 505-200
E-mail: service.standard@wagner-group.com
Sweden
WAGNER Industrial Solutions Scandinavia
Skolgatan 61
SE - 568 31 SKILLINGARYD
Phone: +46/ 370/ 798 30
Fax: +46/ 370/ 798 48
E-mail: info@wagner-industri.com
Spain
WAGNER Spraytech Iberica S.A.
P.O. Boc., 132, Ctra. N- 340, KM 1245,4
E- 08750 Molins de Rei (Barcelona)
Phone: +34/ 93/ 680 0028
Fax: +34/ 93/ 680 0555
E-mail: info@wagnerspain.com
China
WAGNER Spraytech Shanghai Co Ltd.
4 th Flr. No. 395 Jiangchanxi Road
Shibei Industrial Zone
Shanghai 200436
Phone: +86/ 2166 5221 858
Fax: +86/ 2166 5298 19
E-mail: wagnersh@public8.sta.net.cn
USA
WAGNER Systems Inc.
300 Airport Road, Unit 1
Elgin, IL 60123
Phone: +1/ 630/ 503-2400
Fax: +1/ 630/ 503-2377
E-mail: info@wagnersystemsinc.com
94
ED
FI
CERT
I
Order No. 2329368
Germany
J. WAGNER GmbH
Otto-Lilienthal-Str. 18
Postfach 1120
D- 88677 Markdorf
Tel. +49/ (0)7544 / 5050
Fax +49/ (0)7544 / 505200
E-mail: service.standard@wagner-group.com
Switzerland
J. WAGNER AG
Industriestrasse 22
Postfach 663
CH- 9450 Altstätten
Tel. +41/ (0)71 / 757 2211
Fax +41/ (0)71 / 757 2222
E-mail: rep-ch@wagner-group.ch
www.wagner-group.com
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