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OPERATING MANUAL

VERSION 09/2016

ORDER NUMBER DOC 2366672

1.2

WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:

Danger

- immediate risk of danger.

Non-observance will result in death or serious injury.

Warning

- possible imminent danger.

Non-observance may result in death or serious injury.

Caution

- a possibly hazardous situation.

Non-observance may result in minor injury.

Notice

- a possibly hazardous situation.

Non-observance may result in damage to property.

Note

- provides information about particular characteristics and how to proceed.

This notice 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.

DANGER

This notice 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

This notice 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

This notice 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

1.3

LANGUAGES

The operating manual is available in the following languages:

Language

Order No.

Language

Order No.

German

2366669

English

2366672

French

2369230

Italian

2369231

Spanish

2369232

Russian

2369233

Chinese

2369234

Additional languages on request or at:

1.4

ABBREVIATIONS IN THE TEXT

Number of pieces
Position
Marking in the spare parts lists

Order No.

Order number
Double stroke

Содержание 8286

Страница 1: ...B_05369 B_06420 Pneumatic Double Diaphragm Pump Version 09 2016 Translation of the Original Operating Manual II 2G c IIB T4 ...

Страница 2: ......

Страница 3: ...rotection Identification 9 3 2 Type Plate 10 4 GENERAL SAFETY INSTRUCTIONS 11 4 1 Safety Instructions for the Operator 11 4 2 Safety Instructions for Staff 12 5 DESCRIPTION 15 5 1 Components 15 5 2 Mode of Operation 15 5 3 Scope of Delivery 16 5 4 Data 16 5 5 Pressure Regulator Unit for the TOPFINISH DD10 20 5 6 Return Flow Valve 21 6 ASSEMBLING AND COMMISSIONING 22 6 1 Training Assembly Commissio...

Страница 4: ...angerous if it is not operated according to the instructions in this operating manual 8 CLEANING AND MAINTENANCE 32 8 1 Cleaning 32 8 2 Maintenance 34 8 3 Diaphragm Replacement 36 8 4 Replacing the Inlet and Outlet Valves 37 9 TROUBLESHOOTING MAINTENANCE AND REPAIR 38 9 1 Troubleshooting and Rectification 38 10 REPAIR WORK 39 10 1 Repair Staff 39 10 2 Safety Instructions 39 10 3 Cleaning the Parts...

Страница 5: ...el The measures for preventing the hazard and its consequences DANGER This notice 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 This notice warns you of a hazard Possible consequences of not observing the warning instructions The signal word indicat...

Страница 6: ...r and detect possible hazards based on his her technical training knowledge and experience in relevant provisions Skilled person A person 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 ...

Страница 7: ...nual must be observed The statutory requirements and accident prevention regulation standards in the country of use must be observed 2 5 PROCESSIBLE WORKING MATERIALS Fluid materials like paints and varnishes Application TOPFINISH DD10 Water dilutable products Solvent based lacquers and paints Two component coating products Emulsions UV lacquers Primers Epoxy and polyurethane lacquers phenolic lac...

Страница 8: ...ow may result in physical injury or property damage use of powder as coating product and incorrectly set values for processing WAGNER double diaphragm pumps are not designed for pumping food 2 7 RESIDUAL RISKS Residual risks are risks which cannot be ruled out even in the event of correct use If necessary warning and prohibition signs at the relevant points of risk indicate residual risks Residual...

Страница 9: ...e of the pump depends on the operating conditions heated product and not on the device frictional heat Ignition temperature of the coating product Ensure that the ignition temperature of the coating product is above the maximum surface temperature Ambient temperature The permissible ambient temperature is 10 C to 60 C 50 F to 140 F Medium supporting atomizing To atomize the product use only weakly...

Страница 10: ... Remove deposits from the surfaces to maintain conductivity Use only a damp cloth to clean the device Operation without Fluid Avoid running the pump so that it sucks in air without fluid inside The air combined with the vapor of flammable fluids can generate internal areas with an explosion hazard Periodically check that the pump is working paying special attention to the presence of air in the pu...

Страница 11: ...ctrical safety regulations Ensure that the device is only operated maintained and repaired by trained persons Ensure that the floor in the working area is static dissipative in accordance with EN 61340 4 1 resistance must not exceed 100 megohms Ensure that all persons within the working area wear static dissipative shoes Footwear must comply with EN 20344 The measured insulation resistance must no...

Страница 12: ...he DGUV regulation 100 500 For shut down devices the examination can be suspended until the next start up Carry out the work steps as described in the Pressure Relief chapter If pressure relief is required If the spraying work is interrupted or stopped Before the device is cleaned on the outside checked or serviced Before the spray nozzle is installed or cleaned In the event of skin injuries cause...

Страница 13: ...Several liquids have a high expansion coefficient In some cases their volume can rise with consequent damage to pipes fittings etc and cause fluid leakage When the pump sucks liquid from a closed tank ensure that air or a suitable gas can enter the tank Thus a negative pressure is avoided The vacuum could implode the tank squeeze and can cause it to break The tank would leak and the liquid would f...

Страница 14: ...rically 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 cleaning When cleaning the exterior of the device or its parts also observe the following Disconnect the pneumatic supply line Use only moistened cloths and brushes Never use abra...

Страница 15: ... double diaphragm pump is driven with compressed air A pneumatic manifold alternates in supplying two diaphragms with compressed air Diaphragm motion is created in this manner The product is thus sucked in and displaced again A series of four non return valves prevents the liquid from flowing back thus producing the suction and delivery phases in each pumping chamber and generating the pumping eff...

Страница 16: ...iquid leaks The entire pressure regulator unit 1 can be rotated in increments of 90 degrees to align the control elements For this purpose the four screws 2 must be removed 5 3 SCOPE OF DELIVERY Order No Designation 1 TOPFINISH DD10 diaphragm pump The standard equipment includes see Chapter 15 3 1 Declaration of conformity 2366669 1 Operating manual German see Chapter 1 3 1 Operating manual in the...

Страница 17: ... 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 A 64 0 Product inlet inside thread inch 1 2 Product outlet inside thread inch 3 8 Weight kg lb 4 1 Product pH value pH 3 5 9 Product viscosity DIN 4 sec 15 60 Product temperature C 4 60 F 39 2 140 Ambient temperature C 4 40 F 39 2 104 Allowable i...

Страница 18: ...B C D E F G H M L OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC 2366672 5 4 3 DIMENSIONS AND CONNECTIONS TOPFINISH DD10 mm inch 191 7 52 135 5 31 141 5 55 236 9 29 264 10 39 149 5 87 170 6 69 192 7 56 G1 2 G1 4 G3 8 ...

Страница 19: ...D B_06255 1 59 1 32 1 06 0 79 0 53 0 26 Material flow volume water water l min gpm 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 B 2 bar 0 2 MPa 29 psi air pressure OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC 2366672 5 4 4 PERFORMANCE DIAGRAMS Example Product pressure bar MPa psi Product flow rate water l min gpm Air consumption ...

Страница 20: ...ULATOR UNIT FOR THE TOPFINISH DD10 Positions of the ball valve 1 Open working position 2 Closed the air motor can still be under pressure 1 Pressure gauge pump 2 Pressure gauge atomizing air 3 Pressure regulator atomizing air 4 Pressure regulator pump 5 Compressed air Inlet 6 Ball valve 7 Air outlet for gun air ...

Страница 21: ...PERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC 2366672 5 6 RETURN FLOW VALVE Positions of the ball valve 1 Open working position 2 Closed the air motor can still be under pressure 3 Material return line 4 Product outlet ...

Страница 22: ...able state after it is installed and commissioned 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 w...

Страница 23: ...as a spray pack The nozzles must be selected according to the gun instructions Procedure 1 Mount the pump on a 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 Inclined ground Risk of accidents if the device rolls away falls Position the trolley with the pump horizontally If the surface ...

Страница 24: ...gun Dirt and moisture in the atomizing air worsens the spraying quality and spraying pattern Hose connections Risk of injury and damage to the device Do not exchange hose connections of product hose and air hose WARNING 6 5 3 PRODUCT SUPPLY Bursting hose bursting threaded joints Danger to life from injection of product Ensure that the hose material is chemically resistant to the sprayed products E...

Страница 25: ...ly charged components in atmospheres containing solvents Explosion hazard from electrostatic sparks Clean the pump only with a damp cloth WARNING Heavy paint mist if grounding is insufficient Danger of poisoning Insufficient paint application quality Ground all device components Ground the work pieces to be coated WARNING Cable cross sections Pump 4 mm2 Conveyor 16 mm2 Product tank 6 mm2 Booth 16 ...

Страница 26: ...permissible pressures Check all connections for leaks Check hoses for damage It should be ensured that the device is in the following state before carrying out any work on it The pressure should be released from the pump and high pressure hose with gun The gun should be secured with the safety clip The air supply should be interrupted Pressure tightness test For pressure tightness control of the e...

Страница 27: ...e working materials or Operate the device on an appropriate spraying wall with the ventilation extraction switched on Observe national and local regulations for the exhaust air speed WARNING Gas mixtures can explode if there is an incompletely ﬁlled pump Danger to life from flying parts Ensure that the pump and suction system are always completely ﬁlled with cleaning agent or working medium Do not...

Страница 28: ... 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 valve 5 Flush using gun 11 Point the spray gun without nozzle into the tank 7 and open it 12 Slowly open the b...

Страница 29: ...with the working material 1 2 Slowly open the ball valve 3 3 Adjust the pressure regulator 2 to approx 0 2 MPa 2 bar 29 psi 4 Point the gun without nozzle into an empty tank and open it 5 Close ball valve 3 as soon as pure working material starts coming from the gun 6 When there is no pressure remaining in the system close the gun 7 Secure the gun ...

Страница 30: ...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 megohms The protective clothing including gloves must comply with EN ISO 1149 5 The measured insulation resistance must not exceed 100 megohms WARNING Observe...

Страница 31: ...ng out cleaning tasks on the system Moving the system to another location Something needs to be checked on the system The nozzle is removed from the gun Observe general safety instructions in Chapter 4 Process for relieving pressure 1 Close gun 2 Close ball valve 3 Vent the pump 4 Release the system by opening the gun 5 Close and secure gun If the system has been used with 2 component materials Ha...

Страница 32: ...ng tools and aids 8 1 CLEANING 8 1 1 CLEANING STAFF Brittle filter pressure regulator Thetankonthefilterpressureregulatorbecomesbrittlethroughcontact with solvents and can burst Flying parts can cause injury Do not clean the tank on the filter pressure regulator with solvent WARNING Gas mixtures can explode if there is an incompletely ﬁlled pump Danger to life from flying parts Ensure that the pum...

Страница 33: ...Replace the water or solvent in the product pump with a suitable preserving oil and fill the separating agent cup with separating agent Procedure 1 Carry out points 1 to 7 in Chapter 8 1 3 Flushing and Cleaning Device 2 Flushing with preserving fluid according to Chapter 6 8 3 8 1 3 CLEANING AND FLUSHING DEVICE DANGER Incorrect maintenance repair Danger to life and equipment damage Only a WAGNER s...

Страница 34: ...em into operation and check for leaks as described in Chapter 6 7 Carry out a function test if required in accordance with Chapter 11 According DGUV regulation 100 500 The liquid ejection devices should be checked by an expert e g WAGNER service technician for their safe working conditions as required and at least every 12 months For shut down devices the examination can be suspended until the nex...

Страница 35: ...ing pressure Date of manufacture DANGER 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 hoses ...

Страница 36: ...crew the four screws 3 and remove the plate 4 from the pump 3 Unscrew the Allen screws 3 on both halves of the pump housing 4 Pull the pump housing 4 apart 5 The components 5 can be removed from the two housing halves with gentle movements 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 ...

Страница 37: ...383 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC 2366672 8 4 REPLACING THE INLET AND OUTLET VALVES 1 Unscrew the screws 1 2 Remove the valve housing 2 3 Replace the component 3 4 Re assemble the pump in reverse order ...

Страница 38: ...rregular 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 Valves are clogged Press valve depressor Clean product pump and leave to soak in cleaning agent if necessary Foreign body in suction valve Dismantle suction valve housing clean and check valve seat Diameter of ...

Страница 39: ...m inhaling solvent vapors Use of unsuitable tools and aids A skilled person must check to ensure that the device is in a reliable state after it is repaired Carry out function test in accordance with Chapter 11 10 2 SAFETY INSTRUCTIONS Observe the safety instructions in Chapter 4 and Chapter 8 1 2 Before a Repair Flush and clean the system Chapter 8 1 3 After a Repair Carry out a safety checks in ...

Страница 40: ...f poisoning by toxic gases Examine the compatibility of the cleaning agents and working media on the basis of the safety data sheets WARNING Use torques greases and glues in accordance with Chapter 14 DANGER Incorrect maintenance repair Danger to life and equipment damage Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts Only repair and replace parts...

Страница 41: ...ter 1 2 Testing for Leaks Connect the pump to the air supply 6 bar To perform a leak test on the device the product pressure with the flushing agent is slowly increased in increments until the maximum pressure indicated on the 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...

Страница 42: ...nce with all applicable legal requirements 13ACCESSORIES Designation Order No Hi Boy 2368206 Lo Boy 2368231 Wall mount 2368422 Circulation 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 Fin...

Страница 43: ... queries Type of delivery normal mail express delivery air freight courier etc Identification in spare parts lists Explanation of column K labeling in the following spare parts lists Wearing parts Note Wear parts are not included in the warranty terms Not part of standard equipment available however as additional extra Incorrect maintenance repair Risk of injury and damage to the device Repairs an...

Страница 44: ...44 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B_06252 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC 2366672 14 2 OVERVIEW ...

Страница 45: ...re parts set 2370200 5 Valve spare parts set 2370202 6 Air piston spare parts set 2370203 7 Product sealing spare parts set 2370181 8 Inlet spare parts set 2370212 9 Outlet spare parts set 2370214 10 Airbody spare parts set 2370215 11 Shaped packing spare parts set 2370219 12 Distributor spare parts set 2370220 13 Regulator unit spare parts set 2370221 14 Grounding spare parts set 2370222 For deta...

Страница 46: ...rts set Designation Order No 1 1 Cover spare parts set 2370189 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 Selection spare parts set Designation Order No 1 1 Selection spare parts set 2370193 2 1 Switch unit preassembled 3 2 Shaped packing 4 4 Screw 14 3 SPARE PART SETS ...

Страница 47: ... 2 2 Diaphragms 3 2 Washer 4 2 Screw 5 1 Loctite 222 Wearing part Valve spare parts set Designation Order No 1 1 Valve spare parts set 2370202 2 4 Valve seat 3 4 Ball 4 4 Spring support ring 5 4 Spring 6 4 O ring Wearing part Air piston spare parts set Designation Order No 1 1 Air piston spare parts set 2370203 2 2 Air piston 3 2 Air cylinder 4 2 O ring 42x3 Wearing part Product sealing spare part...

Страница 48: ...rts set Designation Order No 1 1 Airbody spare parts set 2370215 2 2 Air body preassembled Shaped packing spare parts set Designation Order No 1 1 Shaped packing spare parts set 2370219 2 2 Shaped packing Distributor spare parts set Designation Order No 1 1 Distributor spare parts set 2370220 2 1 Distributor unit complete 3 4 Screw Regulator unit spare parts set Designation Order No 1 1 Regulator ...

Страница 49: ...han 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 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 ex...

Страница 50: ...can be ordered through your WAGNER dealer by specifying the product name and serial number Order number 2367686 complies with the following guidelines 2006 42 EC 2014 34 EU Applied standards in particular Applied national technical standards and specifications in particular DGUV regulation 100 500 Identification We hereby declare that the supplied version of the diaphragm pump and its spray packs ...

Страница 51: ......

Страница 52: ...ion 09 2016 People s Republic of China Phone Telefax Germany J Wagner GmbH Phone Telefax E mail More contact addresses on the internet at Company Locations WAGNER worldwide Subject to changes without notice Document No 11183212 Version B ...

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