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WAGNER TOPFINISH DD10, Operating Manual

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Summary of Contents for TOPFINISH DD10

Page 1: ...TOPFINISH DD10 Pneumatic Double Diaphragm Pump Version 12 2017 B_05369 B_06420 ...

Page 2: ......

Page 3: ...instructions for the operator 10 4 2 Safety Instructions for Staff 11 5 DESCRIPTION 16 5 1 Components 16 5 2 Mode of operation 16 5 3 Protective and monitoring equipment 16 5 4 Included items 17 5 5 Data 17 5 6 Pressure regulator unit on TOPFINISH DD10 19 6 ASSEMBLY AND COMMISSIONING 20 6 1 Training of Assembly Commissioning Staff 20 6 2 Storage conditions 20 6 3 Installation conditions 20 6 4 Tra...

Page 4: ...36 10 1 Repair Staff 36 10 2 Repair Notes 36 10 3 Tools 36 10 4 Cleaning the parts after disassembly 37 10 5 Assembly of the Device 37 11 FUNCTION TEST AFTER THE REPAIR 38 12 DISPOSAL 38 13 ACCESSORIES 39 14 SPARE PARTS 40 14 1 How can spare parts be ordered 40 14 2 Overview of the Components 41 14 3 Liquidbody spare parts set 43 14 4 Diaphragm spare parts set 43 14 5 Valve spare parts set 43 14 6...

Page 5: ...rovides information about particular characteristics and how to proceed Explanation of warning LEVEL OF DANGER This notice warns you of a hazard Possible consequences of not observing the warning instructions The measures for preventing the hazard and its consequences 1 3 LANGUAGES The operating manual is available in the following languages Original Operating Manual Language Order No German 23666...

Page 6: ...on who based on his her technical training experience and recent vocational experience has sufficient technical knowledge in the areas of explosion protection protection from pressure hazards and electric hazards if applicable and is familiar with the relevant and generally accepted rules of technology so that he she can inspect and assess the status of devices and coating systems based on workpla...

Page 7: ...oriented model flow rate cycle product valves etc as indicated in Chapter 5 5 Check if the fluids and solvents used are compatible with the pump construction materials as indicated in Chapter 5 5 1 Wear caused by abrasive working materials is not covered by the warranty Typical applications Application TOPFINISH DD10 Furniture industry Kitchen manufacturers Joinery Window factories Steel processin...

Page 8: ...r 3 2 3 2 IDENTIFICATION X The maximum surface temperature corresponds to the permissible product temperature This and the permissible ambient temperature can be found in Chapter 5 5 2 Technical Data Safe handling of WAGNER spray devices Mechanical sparks can form if the device comes into contact with metal In an explosive atmosphere Knocking or pushing metal against metal is to be avoided Do not ...

Page 9: ...s working smoothly paying special attention to the presence of air in the pumped fluid Filling and emptying Flammable gas mixtures can form in the fluid section or product hoses if the pump must be emptied for maintenance Empty and fill the device slowly and in a controlled manner Avoid potentially explosive atmosphere in the surroundings 3 3 TYPE PLATE B_06916 max Fluid Pressure Tamb C F Article ...

Page 10: ...tective ground wire connection Keep liquids away from electrical devices 4 1 2 A SAFE WORK ENVIRONMENT Hazard due to dangerous fluids or steam Severe or fatal injuries due to explosion hazard or inhalation swallowing or contact with the skin or eyes Ensure that the floor in the working are is static dissipative in accordance withEN 61340 4 1 resistance must not exceed 100 MΩ Paint mist extraction ...

Page 11: ...ined and repaired by trained personnel Refer to the operating instructions for information about the required personnel qualifications 4 2 SAFETY INSTRUCTIONS FOR STAFF Always follow the information in this manual particularly the safety instructions and the warning instructions Always follow local regulations concerning occupational safety and accident prevention In electrostatics application any...

Page 12: ...an expert e g WAGNER Service Technician in accordance with the guidelines for liquid ejection devices ZH 1 406 and DGUV 100 500 Chapters 2 29 and 2 36 For shut down devices the check can be postponed until the next start up In the event of skin injuries caused by lacquer or flushing agents Note the lacquer or flushing agent that you have been using Consult a doctor immediately 4 2 3 GROUND THE UNI...

Page 13: ...run over by vehicles e g fork lift trucks or that the hoses are never put under pressure from the outside in any other way Ensure that the hoses are never kinked Observe maximum bending radii Ensure that no work is ever performed with a damaged hose Make sure that the hoses are never used to pull or move the equipment The electrical resistance of the product hose measured at both valves must be le...

Page 14: ...d components of equipment depending upon the used coating product depending on the flushing agent solvent used explosive mixture inside the lines and items of equipment Only electrically conductive tanks may be used for cleaning and flushing agents The tanks must be grounded An explosive gas air mixture forms in closed tanks Never spray into a closed tank when using solvents for flushing External ...

Page 15: ...Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun hoses and all devices Secure the spray gun against actuation Switch off the energy and compressed air supply Disconnect the control unit from the mains Secure the spray gun against actuation Observe the operating and service manual for all work 4 2 8 PROTECTIVE AND MONITORING EQUIPMENT Haza...

Page 16: ...be mounted horizontally 10 as well as vertically 10 in any position Ensure that all fastening screws are correctly tightened Tighten the fixing screws regularly depending on pump use In the case of continuous or prolonged operation it is advisable to check at least once a week that there are no air and or liquid leaks The entire pressure regulator unit 1 can be rotated in increments of 90 degrees ...

Page 17: ...ording to ISO 8573 1 2010 7 Particle concentration 5 10 mg m 5 Humidity pressure dew point 7 C 4 Oil content 5 mg m3 Air inlet pressure MPa bar psi 0 15 0 8 1 5 8 22 116 Air inlet inside thread inch 1 4 Sound pressure level at 0 4 MPa 4 bar 58 psi air pressure dB A 58 4 Sound pressure level at 0 6 MPa 6 bar 87 psi air pressure dB A 61 6 Sound pressure level at 0 8 MPa 8 bar 116 psi air pressure dB...

Page 18: ... consumption nl min scfm Water delivery rate l min gpm 0 0 1 0 2 0 3 0 4 0 5 0 6 0 1 0 0 1 14 5 2 0 0 2 29 0 3 0 0 3 43 5 4 0 0 4 58 0 5 0 0 5 72 5 6 0 0 6 87 0 7 0 0 7 101 5 8 0 0 8 116 0 7 5 0 27 15 0 0 54 22 5 0 81 30 0 1 08 37 5 1 35 45 0 1 61 52 5 1 88 60 0 2 15 bar MPa psi nl min scfm l min gpm A B C D A B C D B_06255 1 59 1 32 1 06 0 79 0 53 0 26 TOPFINISH DD10 Stroke frequency min Product ...

Page 19: ...ator atomizing air 4 Pressure regulator pump 5 Compressed air Inlet 6 Ball valve 7 Air outlet for gun air Positions of the ball valve B_05379 1 2 1 Open working position 2 Closed the air motor can still be under pressure 5 6 1 RETURN VALVE Positions of the ball valve 1 Open working position 2 Closed the air motor can still be under pressure Designation 3 Material return line 4 Product outlet 1 2 B...

Page 20: ...issioned 6 2 STORAGE CONDITIONS Until the point of assembly the device must be stored in a dry location free from vibrations and with a minimum of dust The device must be stored in closed rooms The air temperature at the storage location must be between 20 C and 60 C 4 F and 140 F The relative air humidity at the storage location must be between 10 and 95 without condensation 6 3 INSTALLATION COND...

Page 21: ... frame trolley or wall mount 2 Connect the suction system and air supply 3 Connect the material and air supply of the gun in accordance with the operating manual B_05376 2 1 3 This pump can be used as part of a spraying system for Airspray applications The componentscanbefoundintheaccessorieslist providedthatthesystemwasnotobtained as a spray pack The nozzles must be selected according to the spra...

Page 22: ...se material is chemically resistant to the sprayed products Ensure that the spray gun fittings and product hose between the device and the spray gun are suitable for the pressure generated in the device Ensure that the following information can be seen on the hose Manufacturer Permissible operating pressure Date of manufacture 6 6 GROUNDING WARNING Discharge of electrostatically charged components...

Page 23: ...only guaranteed with a grounding connection Connect all ground cables using a short and direct route B_05377 Procedure 1 Screw on grounding cable with eye 2 Clamp the grounding cable clip to a grounding connection on site 3 Ground the product paint tank to an on site grounding connection 4 Ground the other parts of the system to an on site grounding connection Ex zone All devices and equipment mus...

Page 24: ... 8 2 3 Fill the pump with flushing agent The devices are tested during manufacturing with emulsifying oil pure oil or solvent Possible residues must be flushed out of the circuits with a solvent flushing agent before commissioning Fill the empty device with flushing agent in accordance with Chapter 8 2 5 Pressure tightness test WARNING Overpressure Risk of injury from bursting components The opera...

Page 25: ...ust receive appropriate system training 7 2 EMERGENCY STOP In the case of unforeseen occurrences Close ball valve The air supply should be interrupted B_06917 open closed 7 3 WORK Ensure that commissioning is carried out in accordance with Chapter 6 7 1 Visual check personal safety equipment grounding and all devices ready to use 2 Secure spray gun and insert valve into the spray gun 3 Slowly open...

Page 26: ...Process for relieving pressure B_05380 2 3 4 5 7 6 8 1 1 Close the spray gun 2 Close ball valve 2 3 Release the system of pressure by opening the spray gun Attention If a blocked nozzle is preventing relief first carry out the additional steps 4 and 5 then clean the nozzle 4 Close and secure the spray gun 5 Open and close the return valve 3 slowly to completely depressurize the system Note Control...

Page 27: ... Adjust the pressure regulator 1 to approx 0 2 MPa 2 bar 29 psi Flush via the return flow valve 5 Open return valve 5 6 Slowly open the ball valve 8 7 Adjust the air pressure on the pressure regulator 1 so that the pump runs smoothly 8 Flush the system until clean flushing agent flows into the tank 7 9 Close ball valve 8 10 As soon as there is no pressure remaining in the system close the return v...

Page 28: ...n in accordance to its operating instructions 5 Clean and check the suction system and the suction filter 6 Clean the outside of the system WARNING Brittle filter pressure regulator The tank on the filter pressure regulator becomes brittle through contact with solvents and can burst Flying parts can cause injury Do not clean the tank on the filter pressure regulator with solvent 7 Fully assemble t...

Page 29: ...pair and replace parts that are listed in the Spare parts chapter and that are assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun product hoses and all devices Secure the spray gun against actuation Switch off the energy and compressed air supply Disconnect the control unit from the mains Observe the operating and servi...

Page 30: ...up 8 2 3 1 PRODUCT HOSES TUBES AND COUPLINGS The service life of the complete hoses between product pressure generator and application device is reduced due to environmental influences even when handled correctly Check hoses pipes and couplings every day and replace if necessary Before every commissioning check all connections for leaks Additionally the operator must regularly check the complete h...

Page 31: ...se pressure regulator 1 0 MPa 0 bar 0 psi Empty using return line 5 Open return valve 5 6 Slowly open the ball valve 8 7 Slowly turn air pressure up on the pressure regulator 1 and only until the pump is running normally approx 0 15 MPa 1 5 bar 21 75 psi 8 Be ready for the switch from working material to air 9 As soon as working material is no longer flowing from the return tube 6 close ball valve...

Page 32: ...regulator 1 0 MPa 0 bar 0 psi 5 Open return valve 5 6 Slowly open the ball valve 8 7 Slowly turn the air pressure up on the pressure regulator 1 and only until the pump is running normally approx 0 0 2 MPa 0 2 bar 0 29 psi Be ready to switch from working material to air and prevent back spray 8 Close ball valve 8 as soon as pure working material starts coming from the return tube 6 9 Close return ...

Page 33: ...ve the plate 4 from the pump 3 Unscrew the Allen screws 5 on both halves of the pump housing 4 Pull the pump housing 6 apart 5 The components 7 can be removed from the two housing halves with gentle movements B_05374 8 9 10 7 6 Unscrew the screws 8 on both components 7 The diaphragms 9 can now be removed from the components and can be replaced 8 Re assemble the pump in reverse order Spread Loctite...

Page 34: ...ON 12 2017 ORDER NUMBER DOC 2366672 TOPFINISCH DD10 8 4 REPLACING VALVES 1 1 2 2 3 3 B_05383 1 Unscrew the screws 1 2 Remove the valve housing 2 3 Replace the component 3 4 Re assemble the pump in reverse order ...

Page 35: ...structions Irregular operation of product pump spray jet collapses pulsation Viscosity is too high Thin spraying product Spraying pressure is too low Increase incoming air pressure Use a smaller nozzle Foreign body in suction valve Dismantle suction valve housing clean and check valve seat Diameter of compressed air line too small Assemble a larger supply line Technical data see Chapter 5 5 2 Worn...

Page 36: ...chapter and that are assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun hoses and all devices Secure the spray gun against actuation Switch off the energy and compressed air supply Disconnect the control unit from the mains Observe the operating and service manual for all work Before a Repair It should be ensured that t...

Page 37: ...en that these parts remain free of solvents grease or sweat from the hands salt water Clean and mount wearing gloves 10 5 ASSEMBLY OF THE DEVICE In Chapter 14 the order numbers for device spare parts can be found as well as for wearing parts such as seals Defective parts O rings and seal sets must always be re placed Use greases and glues in accordance with Chapter 14 Observe torque specifications...

Page 38: ...type plate is reached Close pump outlet Allow to stand in this position for 0 5 1 minute and listen for audible blowing off Close air supply ball valve without relieving and check for pressure loss Air motor Test medium com pressed air Leak spray Fluid section Test medium suitable flushing agent 3 General inspections Check tightening torque of various screws see Chapter Torque wrench Visual check ...

Page 39: ...ation 2368428 5 liter hopper 2368487 2 liter hopper 2368788 Product distributor 4 fold 2369013 Suction hose 2369022 Sliding tables 2368424 Filter 2368427 Filter with circulation 2368434 Distributor for 2 guns 2368439 Product pressure regulator manual T6232 00 FFC Fine Flow Control 2368735 Drum cover 2368238 Agitator Ex 2370629 Agitator non Ex T6233 00 ...

Page 40: ... parts lists Wearing parts Wearing parts are not included in the warranty terms Included in service set Notice Note These parts are not covered by warranty terms Not part of standard equipment available however as additional extra Explanation of Order No column Item not available as spare part Position does not exist DANGER Incorrect maintenance repair Danger to life and equipment damage Only a WA...

Page 41: ...dy spare parts set 4 1 2370200 Diaphragm spare parts set 5 1 2370202 Valve spare parts set 6 1 2370203 Air piston spare parts set 7 1 2370181 Product sealing spare parts set 8 1 2370212 Inlet spare parts set 9 1 2370214 Outlet spare parts set 10 1 2370215 Airbody spare parts set 11 1 2370219 Shaped packing spare parts set 12 1 2370220 Distributor spare parts set 13 1 2370221 Regulator unit spare p...

Page 42: ... No Designation 1 1 2370189 Cover spare parts set 2 2 Cover 3 4 Screw M8x180 4 4 Nut M8 5 1 Type plate 6 1 Cable lug 7 1 Screw for cable lug 14 2 2SPARE PARTS SET FOR SWITCHING COMPONENT 1 2 3 4 B_06244 5 Nm 3 68 lbft Order No Designation 1 1 2370193 Selection spare parts set 2 1 Switch unit preassembled 3 2 Shaped packing 4 4 Screw ...

Page 43: ...nation B_05385 1 2 3 4 5 6 1 1 2370202 Valve spare parts set 2 4 Valve seat 3 4 Ball 4 4 Spring support ring 5 4 Spring 6 4 O ring Wearing parts 14 6 AIR PISTON SPARE PARTS SET Order No Designation 1 2 3 4 B_06243 1 1 2370203 Air piston spare parts set 2 2 Air piston 3 2 Air cylinder 4 2 O ring 42x3 Wearing parts 14 7 PRODUCT SEALING SPARE PARTS SET Order No Designation 2 B_06245 1 1 1 2370181 Pro...

Page 44: ...S SET Order No Designation B_06249 1 2 1 1 2370219 Shaped packing spare parts set 2 2 Shaped packing 14 12 DISTRIBUTOR SPARE PARTS SET Order No Designation 1 2 3 B_06250 1 1 2370220 Distributor spare parts set 2 1 Distributor unit complete 3 4 Screw 14 13 REGULATOR UNIT SPARE PARTS SET Order No Designation 1 2 3 B_06251 1 1 2370221 Regulator unit spare parts set 2 1 Regulator unit preassembled 3 4...

Page 45: ...ress 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 assembly or commissioning by the purchaser or a third party normal wear negligent handling defective maintenance unsuitable coating products substitute products and the influence of chemical electrochemical or electrical agents except when t...

Page 46: ...A1 2010 EN 809 1998 A1 2009 AC 2010 EN 1127 1 2011 EN ISO 4413 2010 EN ISO 80079 36 2016 EN ISO 4414 2010 EN ISO 80079 37 2016 EN ISO 13732 1 2008 EN ISO IEC 80079 34 2011 EN 14462 2015 Applied national technical standards and specifications in particular Chapter 2 29 and Chapter 2 36 Identification EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product If need...

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Page 48: ...48 CERTI F I E D ts liquid wagner group com ts powder wagner group com www wagner group com Document No 11183212 Version C Order No 2366672 Edition 12 2017 ...

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