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WAGNER U580.00 Translation Of The Original Operating Manual Download Page 12

12

Unica 4-270

.

II 2G IIB T4

OPERATING MANUAL

EDITION 04 /2007 

PART NO. ZZB006ENG

3.3 

CE-CONFORMITY

%##ERTIlCATEOF#ONFORMITY
4HECERTIlCATEISENCLOSEDWITHTHISPRODUCT4HECERTIlCATEOFCONFORMITYCANBEREORDERED
FROMYOUR7!'.%2REPRESENTATIVEQUOTINGTHEPRODUCTANDSERIALNUMBER

0ARTNUMBER

Complies with the following provisons apllying to it:

98/37/CE

94/9/CE Atex-directives

 
Applied standards, in particular:

UNI EN 292-1

UNI EN 809

UNI EN 1127-1

UNI EN 292-2

UNI EN 1050

EN 12621

UNI EN 563

UNI EN ISO 3746

UNI EN ISO 13463-1

Marking:

Unica 4-270 

ZDI.15

Herewith we declare that the supplied version of:
 Pneumatic pump with article no.:

Mod. Unica 4-270 

U580.00

Summary of Contents for U580.00

Page 1: ...II 2G IIB T4 High pressure Double diaphragm pump Unica 4 270 Edition 04 2007 Translation of the original Operating Manual ...

Page 2: ......

Page 3: ... 2 4 2 Explosion protection identification 9 2 4 3 Max surface temperature 9 2 4 4 Safety regulations 9 3 PRODUCT LIABILITY AND WARRANTY 11 3 1 Important notes on product liability 11 3 2 Warranty 11 3 3 CE CONFORMITY 12 4 DESCRIPTION 13 4 1 Field of application 13 4 1 1 Using in accordance with the instructions 13 4 1 2 Examples of application areas 13 4 2 Extent of delivery 14 4 3 Data 14 4 3 1 ...

Page 4: ...30 6 2 Maintenance 32 6 2 1 Lubrication 32 6 2 2 Washing and storing 32 6 2 3 Regular check of sealing and tightness 32 6 2 4 Plan of preventive maintenance 32 6 3 Pump repair 33 6 3 1 Maintenance of the hydraulic circuit 33 6 3 1 1 Operations on the hydraulic circuit during maintenance 35 6 3 1 2 Hydraulic circuit emptying 35 6 3 1 3 Hydraulic circuit filling 35 7 ACCESSORIES 36 7 1 Wall mounting...

Page 5: ...HAZARDOUS SITUATION ON OBSER VANCE CAN RESULT IN MINOR INJURY OTE PROVIDE INFORMATION ON PARTICULAR CHARACTERISTICS AND HOW TO PROCEED AUTION A POSSIBLY HAZARDOUS SITUATION ON OBSER VANCE CAN CAUSE MATERIAL DAMAGE 3 2 4HIS LINE WARNS OF THE HAZARD 0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC TIONS 4HE SIGNAL WORD POINTS OUT THE HAZARD LEVEL 4HE MEASURES FOR PREVENTING THE HAZARD...

Page 6: ...TIVE PARTS NFORM STAFF ABOUT PLANNED WORK OBSERVE ELECTRICAL SAFETY REGULATIONS NSURE THAT THE UNIT IS OPERATED AND REPAIRED ONLY BY TRAINED PERSONS LWAYS FOLLOW THE INFORMATION IN THESE INSTRUCTIONS PARTICULARLY THE GENERAL SAFETY IN STRUCTIONS AND THE WARNING INSTRUCTIONS LWAYS FOLLOW LOCAL REGULATIONS CONCERNING OCCUPATIONAL SAFETY AND ACCIDENT PREVEN TION NSURE THAT THE mOOR OF THE WORKING ARE...

Page 7: ...MMEDIATELY VOID DANGER OF INJURY THROUGH RECOIL FORCES NSURE THAT YOU HAVE A lRM FOOTING WHEN OPERATING THE SPRAY GUN NLY HOLD THE SPRAY GUN BRIEmY IN ANY ONE POSITION LECTROSTATIC CHARGES CAN OCCUR ON THE UNIT DUE TO THE ELECTROSTATIC CHARGE AND THE mOW SPEED INVOLVED IN SPRAYING 4HESE CAN CAUSE SPARKS AND mAMES UPON DISCHARGE NSURE THAT THE UNIT IS EARTHED FOR EVERY SPRAYING OPERATION ARTH THE W...

Page 8: ... THE PAINTS SOLVENTS AND CLEANING AGENTS BEING USED 4AKE THE SPECIlED PROTECTIVE MEASURES IN PARTICULAR WEAR SAFETY GOGGLES PROTECTIVE CLOTHING AND GLOVES AS WELL AS HAND PROTECTION CREAM IF NECESSARY 5SE A MASK OR BREATHING APPARATUS IF NECESSARY OR SUFlCIENT HEALTH AND ENVIRONMENTAL SAFETY PERATE THE UNIT IN A SPRAY BOOTH OR ON A SPRAYING WALL WITH THE VENTILATION EXTRACTION SWITCHED ON 7EAR SUI...

Page 9: ...face temperature 135 C 275 F Max surface temperature same as the permissible material temperature Permissible ambient temperature see under Technical data Section 4 3 2 Safe handling of WAGNER spray units The maximum surface temperature of the pump can be reached if it runs dry Ensure that the pump is filled with sufficient working or cleaning medium Mechanical sparks can form if the unit comes in...

Page 10: ...URFACES TO MAINTAIN CONDUCTIVITY 5SE ONLY A DAMP CLOTH TO CLEAN THE UNIT 3URFACE SPRAYING ELECTROSTATIC O NOT SPRAY UNIT PARTS WITH ELECTROSTATIC E G ELECTROSTATIC SPRAY GUN 7 2 AS MIXTURES CAN EXPLODE IF THERE IS AN INCOMPLETELY lLLED PUMP ANGER TO LIFE FROM mYING PARTS NSURE THAT THE PISTON PUMP AND SUCTION SYSTEM ARE ALWAYS COMPLETELY lLLED WITH CLEANING AGENT OR WORKING MEDIUM O NOT SPRAY THE ...

Page 11: ...F THE UNIT TO A LOCATION OTHER THAN THE ADDRESS OF THE PURCHASER 4HIS WARRANTY DOES NOT COVER DAMAGE CAUSED BY 5NSUITABLE 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...

Page 12: ...PRESENTATIVE QUOTING THE PRODUCT AND SERIAL NUMBER 0ART NUMBER Complies with the following provisons apllying to it 98 37 CE 94 9 CE Atex directives Applied standards in particular UNI EN 292 1 UNI EN 809 UNI EN 1127 1 UNI EN 292 2 UNI EN 1050 EN 12621 UNI EN 563 UNI EN ISO 3746 UNI EN ISO 13463 1 Marking Unica 4 270 ZDI 15 Herewith we declare that the supplied version of Pneumatic pump with artic...

Page 13: ...erials used for the fluid unit Paragraph 4 3 1 is given 4 1 2 EXAMPLES OF APPLICATION AREAS The main use of the Unica 4 270 pump is for transfering liquids inside the service circuit Other typical applications are given below Application Unica 4 270 Furniture industry Kitchen manufactures Joinery Wooden hood manufacturers Metal industries Legend recommended limited suitability less suitable 54 BRA...

Page 14: ...NG Operating manual for the other language see Chapter 1 1 The delivery note shows the exact scope of delivery Accessories see chapter 7 4 3 DATA 4 3 1 MATERIALS USED FOR COMPONENTS IN CONTACT WITH THE PRODUCT Suction ducts Stainless steel EN 1 4301 X 5 CrNi 18 10 AISI 304 Valves balls Stainless steel EN 1 4028 X 30 Cr 13 AISI 420 Valves seats Stainless steel EN 1 4301 X 5 CrNi 18 10 AISI 304 Valv...

Page 15: ...d air hose mm Inch 13 0 512 Air consumption at 0 6 MPa 6 bar 87 psi per DS nl scf 16 Noise level with max allowable air supply pressure dB A 77 5 Ø piston of air motor mm Inch 200 8 0 Material inlet connection female Zoll Inch G 3 4 Material outlet connection female Zoll Inch G 3 4 Weight kg lb 46 101 2 Material pH value pH 3 5 9 Max material pressure at pump inlet MPa bar psi 2 20 90 Range of mat...

Page 16: ...PERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG 7 2 UTGOING AIR CONTAINING OIL 2ISK OF POISONING IF INHALED UNCTION PROBLEM AIRMOTOR 0ROVIDE WATER FREE AND OIL FREE COMPRESSED AIR QUALITY STANDARD AS PER 3 M MG MÃ 3 ...

Page 17: ...ica 4 270 mm inch Unica 4 270 mm inch A 362 14 3 G 209 8 2 B 83 3 3 H 164 6 5 C 422 16 6 I 412 16 2 D 180 5 7 1 J G 3 4 E 171 5 6 8 K G 3 4 F 384 15 1 L G 1 2 OPERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG 4 3 3 DIMENSIONS AND CONNECTIONS ...

Page 18: ...4 bar C_41_00003 2 bar 2 bar OPERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG Diagram Unica 4 270 Stroke frequency DS min Material pressure Air consumption Material flow volume water A 8 bar 0 8 MPa 116 psi Air pressure B 6 bar 0 6 MPa 87 psi Air pressure C 4 bar 0 4 MPa 58 psi Air pressure 4 3 4 PERFORMANCE DIAGRAMS Example Stroke frequency DS min Material pressure bar MPa psi Material flow vol...

Page 19: ...he same time Pneumatic motor Thanks to its inversion system 3 the pneumatic motor needs no lubrication The com pressed air supply is obtained by a pressure controller and a ballcock available on request with the pump The pneumatic motor is equipped with a safety valve containing a pre loaded spring The safety valve is mounted and calibrated in the factory When the pressure exceeds the max allowed ...

Page 20: ...ntrol air gauge 3 Motor air shut off cock 3 1 2 Fluid section The fluid section has been designed to work as a double diaphragm pump with interchan geable suction and delivery valves WARNING Overpressure Risk of injury from bursting components C_SIHI_0026_GB Frequently check the safety valve efficiency by pulling the ring ...

Page 21: ...a horizontal position For support to integrate the pump in a pre existing plant or for a customised location please apply to a Wagner authorised engineer Always use original Wagner spare parts 5 1 1 PUMP WALL INSTALLATION The Unica 4 270 pump installation kit for wall mounting can be supplied on request I Part number Wall mounting kit T6151 00 For information regarding the kit contents and assembl...

Page 22: ...D downstream the pressure controller this allows to open shut off the air flow supplying the pneumatic motor 5 1 4 SUCTION CIRCUIT Use electrically conductive pipes see Paragraph 2 2 3 Connect the working fluid suction system to the pump by means of a system of pipes and fittings E For the correct pump inlet thread diameters please see Paragraph 4 3 2 Tech nical Data Use a systm of pipes suitable ...

Page 23: ...23 Unica 4 270 OPERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG 5 1 6 EXAMPLE OF TYPICAL INSTALLATION F B A E C D H G S462 00A L I ...

Page 24: ...ALLY CHARGED COMPONENTS IN ATMO SPHERES CONTAINING SOLVENTS XPLOSION HAZARD FROM ELECTROSTATIC SPARKS LEAN THE PISTON PUMP ONLY WITH A DAMP CLOTH 3 7 2 EAVY PAINT MIST IF EARTHING IS INSUFlCIENT 2ISK OF POISONING NSUFlCIENT PAINT APPLICATION QUALITY ARTH ALL UNIT COMPONENTS ARTH THE WORKPIECES BEING PAINTED 3 Paint container Workpiece Conveyor Anti static floor Pump Spraying stand ...

Page 25: ...er 6 mm AWG 10 Conveyor 16 mm AWG 5 Spraying booth 16 mm AWG 5 Spraying stand 16 mm AWG 5 Procedure 1 Screw on earthing cable with eye 2 Clamptheearthingcablecliptoaearthconnection on site 3 Earth the material paint container to a local earth connection 4 Earth the other parts of the system to a local earth connection ...

Page 26: ...RIES CAUSED BY PAINT OR SOLVENT NFORM THE DOCTOR ABOUT THE PAINT OR SOLVENT USED EVER SEAL DEFECTIVE HIGH PRESSURE PARTS INSTEAD RELIEVE THE PRESSURE FROM THEM AND REPLACE 3 7 2 4OXIC AND OR mAMMABLE VAPOR MIXTURES 2ISK OF POISONING AND BURNS PERATE THE UNIT IN A SPRAYING BOOTH APPROVED FOR THE WORKING MATERIALS OR PERATE THE UNIT ON AN APPROPRIATE SPRAYING WALL WITH THE VENTI LATION EXTRACTION SW...

Page 27: ...l connections for leaks Check hose for damage It should be ensured that the unit is in the following state before carrying out any work on it Interrupt compressed air supply Depressurise the pump and the product delivery circuit Emergency stop In case of unexpected events it is necessary to immediately close the compressed air sup ply and discharge the pressure from the pump service circuit ...

Page 28: ...ly line and open the air shut off valve on the pump D 6 Slowly open the air pressure controller on the pump C until it starts to work Have the pump work slowly until all the air left inside the suction and delivery circuits has been discharged Continue until the pump has correctly primed 7 Only if the pump is being washed with solvent have it cycle until the clean solvent flows inside the delivery...

Page 29: ... CONTACT WITH SOLVENTS AND CAN BURST LYING PARTS CAN CAUSE INJURY O NOT CLEAN THE CONTAINER ON THE PRESSURE REGULATOR WITH SOL VENT 3 7 2 AS MIXTURES CAN EXPLODE IF THERE IS AN INCOMPLETELY lLLED PUMP ANGER TO LIFE FROM mYING PARTS NSURE THAT THE PISTON PUMP AND SUCTION SYSTEM ARE ALWAYS COMPLETELY lLLED WITH CLEANING AGENT OR WORKING MEDIUM O NOT SPRAY THE UNIT EMPTY AFTER CLEANING 3 5 4 STORING ...

Page 30: ...c delivery plant In painting applications obstruction of the cartidge filter inside spray gun or of the high pressure filter Clean the parts and use a suitable working material Obstruction of the pump fluid section or of the high pressure pipes for example hardened products inside the delivery pipes Dismantle the pump and clean replace high pressure hose Lack excess of grease inside the reversing ...

Page 31: ...g air filter Check filters and if necessary clean them The pump works regularly but does not suck the working fluid The connections on the suction system leak and the pump sucks air Tighten the fittings and remove leaks Obstructed suction filter Clean filter Obstructed suction valves Clean the pump fluid section with detergent and if necessary let the detergent act for some time in case purge the ...

Page 32: ...e sure there are no leaks Check screws tightness at least once every two months Please see this manual for information about the correct tightening torques 6 2 4 PLAN OF PREVENTIVE MAINTENANCE Work out a plan of preventive maintenance including the above checks basing on the usage history of the pump The wear of components depends on the using conditions It is important to replace the parts subjec...

Page 33: ... 1 MAINTENANCE OF THE HYDRAULIC CIRCUIT The Unica 4 270 pump includes a fluid mechanical conservation system granting the best possible performance of the diaphragms under normal working conditions The hydraulic circuit is normally full of working fluid filled in the factory The safety card of the working fluid can be supplied on request Before carrying out any maintenance involving the hydraulic ...

Page 34: ...34 Unica 4 270 OPERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG Cap Outlet valve Working fluid ...

Page 35: ...the following operations are not necessary If the maintenance in the fluid section concerns components whose access to or di sassembly of require disassembling the pump covers diagram Paragraph 8 5 then the following operations to empty and fill up the hydraulic circuit with working fluid are ne cessary If the maintenance concerns the pneumatic motor or the hydraulic circuit itself the fol lowing ...

Page 36: ...ANUAL EDITION 04 2007 PART NO ZZB006ENG 7 ACCESSORIES 7 1 WALL MOUNTING KIT Pos K Qty Description No Wall mounting kit T6151 00 1 4 Washer K509 62 2 2 Wall bracket E3239 62 3 4 Contact washer K572 62 4 4 M8x20 screw K120 62 Wearing part ...

Page 37: ... 4 270 OPERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG 7 2 STAND KIT 3 1 2 Pos K Qty Description No Stand kit T6148 00 1 2 Stand frame E3238 92 2 8 Contact washer K572 62 3 8 M8x70 screw K193 62 Wearing part ...

Page 38: ...NG 7 3 COMPRESSED AIR SUPPLY KIT Pos K Qty Description No Compressed air supply kit T6152 00 1 1 Air cut off valve M104 00 2 1 Nipple M206 04 3 1 Pressure regulator 9999312 4 1 Reduction unit M203 04 5 1 Pressure gauge P903 00 6 1 Hose nylon d4 L 370 mm S462 00A Wearing parts ...

Page 39: ...QUIRED AIR FREIGHT OR MAIL SEA ROUTE OR OVERLAND ROUTE ETC ARKS IN SPARE PARTS LISTS OTE TO COLUMNu h IN THE FOLLOWING SPARE PARTS LISTS U 7EARING PARTS OTE O LIABILITY IS ASSUMED FOR WEARING PARTS L OT PART OF STANDARD EQUIPMENT AVAILABLE HOWEVER AS ADDITIONAL EXTRA 8 SPARE PARTS 8 1 HOW TO ORDER SPARE PARTS 3 7 2 NCORRECT MAINTENANCE REPAIR 2ISK OF INJURY AND DAMAGE TO THE EQUIPMENT 2EPAIRS AND ...

Page 40: ...40 Unica 4 270 OPERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG ...

Page 41: ...2007 PART NO ZZB006ENG 8 2 OVERVIEW MODULES Hydraulic circuit Ref Par 6 3 1 Fluid section Fluid section Air motor Pos K Qty Description No 1 16 5x8 screw K1072 03 2 8 Contact washer K571 62 3 1 Pump upper protection E3235 71 4 1 Pump lower protection E3236 71 Wearing parts ...

Page 42: ...t 19 8 13 10 12 11 9 23 16 7 14 15 14 22 24 15 Nm 11 1 lbft 22 17 18 21 18 5 a 3 a 1 20 a 50 Nm 37 lbft 2 6 4 25 23 14 15 14 15 14 15 25 14 22 25 16 22 22 14 15 18 17 18 21 4 26 27 28 OPERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG 8 3 AIR MOTOR a Apply a small quantity of grease ...

Page 43: ...l nipple 1 2 M206 04 13 4 M8x75 SS Socket screw K106 62 14 5 Fast fitting L 1 8x4 M335 00 15 2 Hose nylon d4 L 130 mm S462 00 16 1 Fast fitting T 1 8 x4 M348 00 17 1 Hose PU d14x10 L 210 mm S463 00 18 2 Fast fitting L 1 2x14 M415 00 19 2 Lip seal L481 06 20 2 Pump rod D450 03 21 1 Hose PU d14x10 L 610 mm S463 00A 22 1 Hose nylon d4 L 370 mm S462 00A 23 Loctite 542 50ml 50cc Z201 00 24 1 Pneumatic ...

Page 44: ...iption No Pneumatic feeler T714 00 1 1 Feeler cap B0331 04 2 1 NBR O Ring seal L118 06 3 1 Seal gasket L420 06 4 1 Feeler rod B0333 03 5 1 Feeler body B0332 04 6 1 NBR O Ring seal L230 06 7 1 Seal gasket G602 06 8 1 Feeler shutter A144 04 9 1 Feeler spring H202 03 10 Loctite 542 50ml 50cc Z201 00 Wearing parts Included in motor service set T9089 00 ...

Page 45: ...cription No Reversing valve P497 00A 1 4 Socket screw K183 62 2 1 Rod cover B0055 71A 3 2 Cover seal gasket G7010 07B 4 1 O Ring seal L172 06 5 1 Rod B0049 04B 6 2 Damper P519 00A 7 1 Valve body B0053 71A 8 6 O Ring seal L199 06 9 1 Spool assembly P519 00B 10 1 Detent P519 00E 11 1 Detent cap B0054 71A 12 1 Valve seal gasket G737 06BA 13 1 Pos seal gasket set 3 4 6 8 12 T9076 00A ...

Page 46: ...T NO ZZB006ENG 8 4 HYDRAULIC CIRCUIT Hydraulic fluid compartment Ref Par 6 3 1 REMARK The hydraulic circuit is normally full of wor king fluid filled in the factory In case of di sassembly of the hydraulic circuit the fluid is to be previously extracted as indicated in the instructions given in Paragraph 6 3 1 and later refilled Part 4 Pneumatic Motor unit Rif Par 8 3 Part 4 Pneumatic Motor unit R...

Page 47: ... Ring seal L137 06A 8 2 Slip band L823 08 9 2 Lip seal L481 06 10 4 Fast fitting 1 2x14 M415 00 11 2 Bleed plug M071 07 12 2 Check valve housing B0336 03 13 2 NBR O Ring seal L225 06 14 2 Check valve T132 00 15 2 Inner flange F1013 71 16 2 Reduction unit 3 4x1 2 M427 00 17 1 Hose PU d14x10 L 210 mm S463 00 18 2 Bellows flange 2 parts B0334 03 1 Hydraulic fluid 1L bottle Z126 00 Wearing parts Inclu...

Page 48: ...0 N m 44 lbft 17 21 20 19 18 21 20 19 18 4 6 8 5 7 10 11 5 7 6 8 4 23 23 24 25 26 17 60 N m 44 lbft OPERATING MANUAL EDITION 04 2007 PART NO ZZB006ENG 8 5 FLUID SECTION The diaphragms are the outer walls of the hydraulic circuit which is normally filled with working fluid Before removing them extract the fluid as described in Paragraph 6 3 1 ...

Page 49: ...1 2 Plate Z5026 00 12 1 Anti rotation bracket E0042 62 13 1 Eyelet terminal Y622 00B 14 1 Square nut 6 K343 62A 15 1 Grub screw 6x25 K040 02D 16 2 Outer cover F1014 03 17 4 M12x1 25 nut B0346 03 18 2 12x36 washer K536 03 19 2 PTFE O Ring seal L229 05 20 2 Outer diaphragm disc B0338 03 21 2 Diaphragm G930 07 22 1 Suction manifold F1015 03A 23 Loctite 542 50ml 50cc Z201 00 24 1 Washer K562 02 25 1 N...

Page 50: ...ISEAU EDEX 4ELEPHONE 4ELEFAX AIL DIVISION BATIMENT WAGNER FRANCE FR ETHERLANDS 7 2 302 94 ENELUX 6 ONNEBAAN 5TRECHT 0 OX 2 AARSSEN 4ELEPHONE 4ELEFAX AIL INFO WAGNER GROUP NL TALY 7 2 2 3 R L 6IA ERMI URAGO DI OLGORA 4ELEPHONE 4ELEFAX AIL INFO WAGNERCOLORA COM APAN 7 2 3PRAYTECH TD 3HINDEN ISHIMACHI AITO 3HI SAKA 4ELEPHONE 4ELEFAX AIL MARKETING WAGNER JAPAN CO JP USTRIA 7 2 MB TTO ILIENTHAL 3TR 0OS...

Page 51: ......

Page 52: ...7 2 MB TTO ILIENTHAL 3TR 0OSTFACH ARKDORF 4ELEPHONE 4ELEFAX AIL SERVICE STANDARD WAGNER GROUP COM 3WITZERLAND 7 2 NDUSTRIESTRASSE 0OSTFACH LTSTËTTEN 4ELEPHONE 4ELEFAX AIL REP CH WAGNER GROUP CH WWW WAGNER GROUP COM ZZB006ENG ...

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