WAGNER TOPFINISH DD10 Translation Of The Original Operating Manual
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WAGNER TOPFINISH DD10 Translation Of The Original Operating Manual

Pneumatic double diaphragm pump
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Pneumatic Double
Diaphragm Pump
B_06420
Translation of the Original
Operating Manual
Version 09/2016
II 2G c IIB T4
B_05369

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Summary of Contents for WAGNER TOPFINISH DD10

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

  • Page 3: Table Of Contents

    Safety Instructions for the Operator Safety Instructions for Staff DESCRIPTION Components Mode of Operation Scope of Delivery Data Pressure Regulator Unit for the TOPFINISH DD10 Return Flow Valve ASSEMBLING AND COMMISSIONING Training Assembly/Commissioning Staff Storage Conditions Installation Conditions Transportation Assembly and Installation...

  • Page 4: About These Instructions

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL Table of Contents CLEANING AND MAINTENANCE Cleaning Maintenance Diaphragm Replacement Replacing the Inlet and Outlet Valves TROUBLESHOOTING, MAINTENANCE AND REPAIR Troubleshooting and Rectifi cation REPAIR WORK 10.1 Repair Staff 10.2 Safety Instructions 10.3 Cleaning the Parts after Disassembly FUNCTION TEST AFTER THE REPAIR...

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

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 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 Danger - immediate risk of danger.

  • Page 6: Terminology For The Purpose Of This Manual

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Manual cleaning of devices and device parts with cleaning agent Flushing Internal fl ushing of paint-wetted parts with fl ushing agent Product pressure Pump or pressure tank generator Staff qualifi cations Trained person...

  • Page 7: Safety Parameters

    OPERATING MANUAL SAFETY PARAMETERS WAGNER accepts no liability for any damage arising from incorrect use. Use the device only to work with the products recommended by WAGNER. Only operate the device as a whole. Do not deactivate safety fi xtures.

  • Page 8: Reasonably Foreseeable Misuse

    WAGNER double diaphragm pumps are not designed for pumping food. RESIDUAL RISKS Residual risks are risks which cannot be ruled out even in the event of correct use.

  • Page 9: Identification

    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 oxidizing gases, e.g., air. Safe handling of WAGNER spray devices Mechanical sparks can form if the device comes into contact with metal. In an explosive atmosphere: Do not knock or push the device against steel or rusty iron.

  • Page 10: Type Plate

    Tamb 4 Article number Article No. 5 Year of manufacture Year of manufacture - Serial No. 6 Read the operating manual Check user manual before use! before use Designed by Wagner International AG CH-9450 Altstätten, assembled in China B_05368...

  • Page 11: General Safety Instructions

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL GENERAL 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 EQUIPMENT Electrical devices and equipment To be provided in accordance with the local safety requirements with regard to the operating mode and ambient infl uences.

  • Page 12: Safety Instructions For Staff

    - In the event of functional faults, remedy the fault as described in the "Troubleshooting" chapter. If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER service technician) at least every 12 months to ensure they are safe for work in accordance with the DGUV regulation 100-500.
  • Page 13 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 4.2.3 PRODUCT HOSES Ensure that the hose material is chemically resistant to the sprayed products and the used fl ushing agents. Ensure that the product hose is suitable for the pressure generated. Ensure that the following information can be seen on the high-pressure hose: - Manufacturer - Permissible operating pressure...
  • Page 14 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL Only electrically conductive tanks may be used for cleaning and fl ushing 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 fl ushing. External cleaning When cleaning the exterior of the device or its parts, also observe the following: Disconnect the pneumatic supply line.

  • Page 15: Description

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL DESCRIPTION COMPONENTS B_05370 Air outlet for gun air Air inlet Product outlet Pump housing Product inlet Pressure regulator unit MODE OF OPERATION The 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.

  • Page 16: Scope Of Delivery

    (1) can be rotated in increments of 90 degrees to align the control elements. For this purpose, the four screws (2) must be removed. B_05371 SCOPE OF DELIVERY Order No. Designation TOPFINISH DD10 diaphragm pump The standard equipment includes: see Chapter 15.3 Declaration of conformity 2366669 Operating manual German see Chapter 1.3...
  • Page 17 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 5.4.2 TECHNICAL DATA Description Units TOPFINISH DD10 Pump ratio 1 : 1 Volume fl ow per double stroke 42.2 cu inch 25.75 Maximum operating pressure Air inlet pressure 0.15 – 0.8 1.5 – 8 22 –...
  • Page 18 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 5.4.3 DIMENSIONS AND CONNECTIONS B_05372 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"...
  • Page 19 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 5.4.4 PERFORMANCE DIAGRAMS Example Product fl ow rate - water l/min <gpm> TOPFINISH DD10 diagram bar (MPa) nl/min <psi> <scfm> 60.0 8.0 (0.8) <2.15> <116.0> 52.5 7.0 (0.7) <1.88> <101.5> 45.0 6.0 (0.6) <1.61>...

  • Page 20: Pressure Regulator Unit For The Topfinish Dd10

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL PRESSURE REGULATOR UNIT FOR THE TOPFINISH DD10 Pressure gauge - pump Pressure gauge - atomizing air Pressure regulator - atomizing air Pressure regulator - pump Compressed air Inlet Ball valve Air outlet for gun air...

  • Page 21: Return Flow Valve

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL RETURN FLOW VALVE Positions of the ball valve Open: working position Closed: the air motor can still be under pressure. Material return line Product outlet B_05382...

  • Page 22: Assembling And Commissioning

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL ASSEMBLING AND COMMISSIONING TRAINING ASSEMBLY/COMMISSIONING STAFF WARNING Incorrect installation/operation! Risk of injury and damage to the device. 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 23: Assembly And Installation

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL ASSEMBLY AND INSTALLATION Note: This pump can be used as part of a spraying system for Airless or AirCoat applications. The components can be found in the accessories list, provided that the system was not obtained as a spray pack.
  • Page 24 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 6.5.1 VENTILATION OF THE SPRAY BOOTH WARNING Toxic and/or fl ammable vapor mixtures! Risk of poisoning and burns. Operate the device in a spray booth approved for the working materials. -or- Operate the device on an appropriate spraying wall with the ventilation (extraction) switched on.

  • Page 25: Grounding

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL GROUNDING WARNING Discharge of electrostatically 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 insuffi cient! Danger of poisoning.

  • Page 26: Safety Checks

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 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.

  • Page 27: Commissioning

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL COMMISSIONING 6.8.1 SAFETY INSTRUCTIONS Every time before starting up, the following points should be observed as laid down in the operating manual: - Observe all safety regulations in accordance with Chapter 4. - Carry out commissioning properly.
  • Page 28 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 6.8.3 BASIC CLEANING Procedure 1. Visual check: personal safety equipment, grounding and all devices ready to use. 2. Place an empty, grounded collection tank (7) under the return tube (6). 3. Place the suction hose (3) in the grounded tank with fl ushing agent (4). 4.
  • Page 29 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 6.8.4 FILLING WITH WORKING MATERIAL 1. Place the suction hose in the tank 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.

  • Page 30: Operation

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualifi ed 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.

  • Page 31: Working

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL WORKING 1. Secure gun and place nozzle in the gun. 2. Slowly open the ball valve. 3. Set the required working pressure on the pressure regulator. 4. Optimize the spraying results as laid down in the gun instructions. 5.

  • Page 32: Cleaning And Maintenance

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING STAFF Cleaning work should be undertaken regularly and carefully by qualifi ed and trained staff . They should be informed of specifi c hazards during their training. The following hazards may arise during cleaning work: - Health hazard from inhaling solvent vapors - Use of unsuitable cleaning tools and aids...
  • Page 33 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 that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 34: Maintenance

    - 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.
  • Page 35 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 8.2.3 SAFETY CHECKS WAGNER recommends having all spraying devices checked annually by a technical expert (e.g., a WAGNER service technician) for safety reasons. 8.2.3.1 GROUNDING CHECK Daily Before starting work, carry out a visual check to ensure that the grounding connection is present in the device and in all relevant components.

  • Page 36: Diaphragm Replacement

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL DIAPHRAGM REPLACEMENT 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. Unscrew the Allen screws (3) on both halves of the pump housing. 4.

  • Page 37: Replacing The Inlet And Outlet Valves

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 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. B_05383...

  • Page 38: Troubleshooting, Maintenance And Repair

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL TROUBLESHOOTING, MAINTENANCE AND REPAIR TROUBLESHOOTING AND RECTIFICATION Problem Cause Remedy The pump does not work. The pump does not start or stops. Open and close ball valve on the pressure regulator unit or briefl y disconnect compressed air supply.

  • Page 39: Repair Work

    There is a lot of condensation Install a water separator. icing. water in the air supply. If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center. REPAIR WORK 10.1 REPAIR STAFF Repair work should be undertaken carefully by qualifi ed and trained personnel.

  • Page 40: Cleaning The Parts After Disassembly

    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 that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 41: Function Test After The Repair

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 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 42: Disposal

    - Carbide Consumable products (lacquers, adhesives, fl ushing and cleaning agents, solvents) must be disposed of in accordance with all applicable legal requirements. ACCESSORIES The following accessories are available for the TOPFINISH DD10 pump: Designation Order No. Hi Boy 2368206...

  • Page 43: Spare Parts

    Incorrect maintenance/repair! Risk of injury and damage to the device. Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 44: Overview

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 14.2 OVERVIEW...
  • Page 45 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL Spare part sets* Designation Order No. Cover spare parts set 2370189 Selection spare parts set 2370193 Liquidbody spare parts set 2370195 Diaphragm spare parts set 2370200 Valve spare parts set 2370202 Air piston spare parts set 2370203 Product sealing spare parts set 2370181...

  • Page 46: Spare Part Sets

    VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL 14.3 SPARE PART SETS Cover spare parts set Designation Order No. Cover spare parts set 2370189 Cover – Screw, M8x180 – Nut, M8 – Type plate – Cable lug – Screw for cable lug –...
  • Page 47 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL Liquidbody spare parts set Designation Order No. Liquid body 2370195 B_06241 Diaphragm spare parts set Designation Order No. Diaphragm spare parts set 2370200 Diaphragms – Washer – Screw – Loctite® 222 – B_06242 = Wearing part Valve spare parts set...
  • Page 48 VERSION 09/2016 ORDER NUMBER DOC 2366672 OPERATING MANUAL Inlet spare parts set Designation Order No. Inlet spare parts set 2370212 Inlet distributor – Screw – B_06246 Outlet spare parts set Designation Order No. Outlet spare parts set 2370214 Outlet distributor –...

  • Page 49: 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 50: Ce Declaration Of Conformity

    II 2G c IIB T4 EC Certifi cate of Conformity The CE certifi cate 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:...
  • Page 52 Order No. 2366672 Edition 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...

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