WAGNER TOPFINISH DD10 Operating Manual
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WAGNER TOPFINISH DD10 Operating Manual

Pneumatic double diaphragm pump
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Version 12/2017
TOPFINISH DD10
Pneumatic Double
Diaphragm Pump
B_06420
B_05369

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Summary of Contents for WAGNER TOPFINISH DD10

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

  • Page 3: Table Of Contents

    Safety instructions for the operator Safety Instructions for Staff DESCRIPTION Components Mode of operation Protective and monitoring equipment Included items Data Pressure regulator unit on TOPFINISH DD10 ASSEMBLY AND COMMISSIONING Training of Assembly/Commissioning Staff Storage conditions Installation conditions Transportation Assembly and Installation Grounding...

  • Page 4: About These Instructions

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 TROUBLESHOOTING AND RECTIFICATION REPAIR WORK 10.1 Repair Staff 10.2 Repair Notes 10.3 Tools 10.4 Cleaning the parts after disassembly 10.5 Assembly of the Device FUNCTION TEST AFTER THE REPAIR DISPOSAL ACCESSORIES SPARE PARTS 14.1 How can spare parts be ordered? 14.2...

  • Page 5: Warnings, Notices And Symbols In These Instructions

    Italian 2369231 Dutch 2382562 Spanish 2369232 Finnish 2391437 Chinese 2369234 Additional languages on request or at: www.wagner-group.com ABBREVIATIONS Order No. Order number Number of pieces Spare part Double stroke Marking in the spare parts lists Stainless steel Position Two components...

  • Page 6: Terminology For The Purpose Of This Manual

    WAGNER explicitly prohibits any other use! The device may only be operated under the following conditions: Use the device only to work with the products recommended by WAGNER. Do not deactivate safety fixtures. Use only WAGNER original spare parts and accessories.

  • Page 7: Processible Working Materials

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 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 lacquers Liquid plastics...

  • Page 8: Identification

    ORDER NUMBER DOC 2366672 IDENTIFICATION EXPLOSION PROTECTION IDENTIFICATION As defined in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially explosive areas. Pneumatic double diaphragm pump TOPFINISH DD10 Device types: Manufacturer: Wagner International AG CH-9450 Altstätten, Switzerland European Communities...

  • Page 9: Type Plate

    0.8MPa; 116 psi Tamb °C/°F 4-40/39-104 Article No. Year of manufacture - Serial No. Check user manual before use! Designed and assembled by WAGNER in Switzerland. B_06916 Designation 1 Manufacturer and CE Identification 2 Max. air pressure 3 Max. product pressure...

  • Page 10: Basic Safety Instructions

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 BASIC SAFETY INSTRUCTIONS 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 EQUIPMENT Electric shock hazard! Danger to life from electric shock Prepare device in accordance with the local safety requirements with regard to the...

  • Page 11: Safety Instructions For Staff

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the vicinity. No smoking. Ensure that the pipe joints, hoses, equipment parts and connections are permanently, technically leak-proof: - Periodic preventative maintenance and service (replacing hoses, checking tightness strength of the connections etc.).
  • Page 12 "Troubleshooting" chapter. If necessary or at least every 12 months, the liquid ejection devices must be checked for safe working conditions by 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).
  • Page 13 TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 4.2.4 PRODUCT HOSE Hazard due to bursting of product hose! The product hose is under pressure and may cause dangerous injuries. Ensure that the hose material is chemically resistant to the sprayed products and the flushing agents used.
  • Page 14 TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 4.2.5 CLEANING AND FLUSHING Hazard due to cleaning and flushing! Explosion hazard and damage to the device. Preference should be given to non-flammable cleaning and flushing agents. When carrying out cleaning work with flammable cleaning agents, make sure that all equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or static dissipative and grounded.
  • Page 15 4.2.7 MAINTENANCE AND REPAIR Hazard due to improper maintenance and repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Use only WAGNER original spare parts and accessories.

  • Page 16: Description

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 DESCRIPTION COMPONENTS Designation 1 Air outlet for gun air 2 Product outlet 3 Product inlet 4 Air inlet 5 Pump housing 6 Pressure regulator unit B_05370 MODE OF OPERATION The double diaphragm pump is driven with compressed air. A pneumatic manifold alternates in supplying two diaphragms with compressed air.

  • Page 17: Included Items

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 INCLUDED ITEMS Order No. Designation TOPFINISH DD10 diaphragm pump The standard equipment includes: see Chapter 15.3 Declaration of Conformity 2366669 Operating manual, German see Chapter Operating manual in the local language The delivery note shows the exact scope of delivery. Accessories: see Chapter .
  • Page 18 141; 5.55 236; 9.29 264; 10.39 149; 5.87 170; 6.69 192; 7.56 G1/2" G1/4" G1/4“ G3/8" B_05372 5.5.4 PERFORMANCE DIAGRAMS Example TOPFINISH DD10 Stroke frequency /min Stroke frequency /min nl/min bar (MPa) <scfm> <psi> 8 bar 60.0 8.0 (0.8) <2.15>...

  • Page 19: Pressure Regulator Unit On Topfinish Dd10

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 PRESSURE REGULATOR UNIT ON TOPFINISH DD10 Designation 1 Pressure gauge - pump 2 Pressure gauge - atomizing air 3 Pressure regulator - atomizing 4 Pressure regulator - pump 5 Compressed air Inlet...

  • Page 20: Assembly And Commissioning

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 ASSEMBLY AND COMMISSIONING TRAINING OF ASSEMBLY/COMMISSIONING STAFF The assembly and commissioning staff must have the technical skills to safely commission the device. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

  • Page 21: Assembly And Installation

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 ASSEMBLY AND INSTALLATION WARNING Inclined ground! Risk of accidents if the device rolls away/falls. Position the trolley with the double diaphragm pump horizontally. If the surface is inclined, position the feet of the trolley towards the gradient. Secure the trolley.

  • Page 22: Grounding

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 6.5.2 AIR SUPPLY LINES Ensure that only dry, clean atomizing air is used in the spray gun! Dirt and moisture in the atomizing air worsens the spraying quality and spray pattern. WARNING Hose connections! Risk of injury and damage to the device.
  • Page 23 TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 Grounding scheme (example) Conveyor Work piece Pump Product R max < 1 MΩ Tank Spraying stand Floor, static dissipative B_05375 Part / workstation Cable cross section Pump 4 mm2; AWG12 Paint tank 6 mm2;...

  • Page 24: Commissioning

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 COMMISSIONING 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 flushing agent or working medium.

  • Page 25: Operation

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 OPERATION TRAINING THE OPERATING STAFF The operating staff must be qualified to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures. Before work commences, the operating staff must receive appropriate system training.

  • Page 26: Pressure Relief/Work Interruption

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 PRESSURE RELIEF/WORK INTERRUPTION The pressure must always be relieved: − after the spraying tasks are finished. − before servicing or repairing the system. − before carrying out cleaning tasks on the system. −...

  • Page 27: Basic Cleaning

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 BASIC CLEANING Flush regularly Regular flushing, cleaning and maintenance ensures the pumps' high pumping and suction capacity. The cleaning and flushing agents used must be compatible with the working material. WARNING Incompatibility of flushing / cleaning agent with the working medium! Risk of explosion and danger of poisoning by toxic gases.

  • Page 28: Cleaning And Maintenance

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING STAFF Cleaning work should be undertaken regularly and carefully by qualified and trained staff. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: −...

  • Page 29: Maintenance

    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. Use only WAGNER original spare parts and accessories. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.
  • Page 30 Yearly or as required In accordance with DGUV regulation 100-500 Chapter 2.29 and 2.36: – 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.
  • Page 31 TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 8.2.4 EMPTYING PUMP WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ignition of potentially explosive surrounding atmosphere. Empty the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.
  • Page 32 TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 8.2.5 FILLING THE EMPTY PUMP WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ignition of potentially explosive surrounding atmosphere. Empty and fill the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

  • Page 33: Replacing The Diaphragm

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 REPLACING THE DIAPHRAGM B_05373 7 Nm; 5.16 lbft 5 Nm; 3.68 lbft 1. Unscrew the four screws (1) and remove the plate (2) from the pump. 2. Unscrew the four screws (3) and remove the plate (4) from the pump. 3.

  • Page 34: Replacing Valves

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 REPLACING VALVES 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: Troubleshooting And Rectification

    Loss of power due to There is a lot of condensation water in Install a water separator. severe icing. the air supply. If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.

  • Page 36: Repair Work

    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. Use only WAGNER original spare parts and accessories. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 37: Cleaning The Parts After Disassembly

    1 pc ≙ 50 ml 9992590 Loctite 222 1 pc ≙ 250 ml 322912 Hydraulic oil - Wagner Brand notice The brands specified in this document are property of the respective owners. Loctite , for example, is a registered brand of Henkel.

  • Page 38: Function Test After The Repair

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 11 FUNCTION TEST AFTER THE REPAIR After all repairs, the device must be checked for safe condition before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair staff.

  • Page 39: Accessories

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 13 ACCESSORIES 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...

  • Page 40: Spare Parts

    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. Use only WAGNER original spare parts and accessories. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 41: Overview Of The Components

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 14.2 OVERVIEW OF THE COMPONENTS B_06252 Order No. Designation 2370189 Cover spare parts set 2370193 Selection spare parts set 2370195 Liquidbody spare parts set 2370200 Diaphragm spare parts set 2370202 Valve spare parts set 2370203 Air piston spare parts set 2370181...
  • Page 42 TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 14.2.1 COVER SPARE PARTS SET 7 Nm; 5.16 lbft B_06240 Order No. Designation 2370189 Cover spare parts set Cover Screw, M8x180 Nut, M8 Type plate Cable lug Screw for cable lug 14.2.2 SPARE PARTS SET FOR SWITCHING COMPONENT 5 Nm;...

  • Page 43: Liquidbody Spare Parts Set

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 14.3 LIQUIDBODY SPARE PARTS SET Order No. Designation 2370195 Liquidbody incl. safety valve B_06241 14.4 DIAPHRAGM SPARE PARTS SET Order No. Designation 2370200 Diaphragm spare parts set – Diaphragms – Washer – Screw –...

  • Page 44: Outlet Spare Parts Set

    TOPFINISCH DD10 VERSION 12/2017 ORDER NUMBER DOC 2366672 14.9 OUTLET SPARE PARTS SET Order No. Designation 2370214 Outlet spare parts set – Outlet distributor – Screw B_06247 14.10 AIRBODY SPARE PARTS SET Order No. Designation 2370215 Airbody spare parts set –...

  • Page 45: Guarantee And Conformity Declarations

    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.

  • Page 46: Eu Declaration Of Conformity

    Chapter 2.29 and Chapter 2.36 Identification: EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2367686...
  • Page 48 2366672 Order No. Edition 12/2017 ts-liquid@wagner-group.com ts-powder@wagner-group.com www.wagner-group.com...

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