TOPFINISH DD10
Pneumatic Double
Diaphragm Pump
Version 12/2017
B_06420
B_05369
VERSION 12/2017
ORDER NUMBER DOC 2366672
Table of Contents
1 ABOUT THESE INSTRUCTIONS 4
1.1 Preface 4
1.2 Warnings, Notices and Symbols in these Instructions 5
1.3 Languages 5
1.4 Abbreviations 5
1.5 Terminology for the Purpose of this Manual 6
2 CORRECT USE 6
2.1 Device types 6
2.2 Type of Use 6
2.3 For Use in Potentially Explosive Areas 6
2.4 Processible Working Materials 7
2.5 Misuse 7
3 IDENTIFICATION 8
3.1 Explosion protection identication 8
3.2 Identication "X" 8
3.3 Type plate 9
TOPFINISCH DD10
4 BASIC SAFETY INSTRUCTIONS 10
4.1 Safety instructions for the operator 10
4.2 Safety Instructions for Sta 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 Sta 20
6.2 Storage conditions 20
6.3 Installation conditions 20
6.4 Transportation 20
6.5 Assembly and Installation 21
6.6 Grounding 22
6.7 Commissioning 24
7 OPERATION 25
7.1 Training the operating sta 25
7.2 Emergency stop 25
7.3 Work 25
7.4 Pressure Relief/Work Interruption 26
7.5 Basic cleaning 27
8 CLEANING AND MAINTENANCE 28
8.1 Cleaning 28
8.2 Maintenance 29
8.3 Replacing the Diaphragm 33
8.4 Replacing Valves 34
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9 TROUBLESHOOTING AND RECTIFICATION 35
10 REPAIR WORK 36
10.1 Repair Sta 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 Air piston spare parts set 43
14.7 Product sealing spare parts set 43
14.8 Inlet spare parts set 43
14.9 Outlet spare parts set 44
14.10 Airbody spare parts set 44
14.11 Shaped packing spare parts set 44
14.12 Distributor spare parts set 44
14.13 Regulator unit spare parts set 44
14.14 Grounding spare parts set 44
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TOPFINISCH DD10
15 GUARANTEE AND CONFORMITY DECLARATIONS 45
15.1 Important notes on product liability 45
15.2 Warranty claim 45
15.3 EU Declaration of Conformity 46
1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual. Operating and service personnel should be instructed according to the
safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
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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:
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
DANGER
WARNING
CAUTION
NOTICE
Notice
Explanation of warning:
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential risk.
Non-observance can result in death or serious injury.
Potentially hazardous situation.
Non-observance may result in minor injury.
Potentially hazardous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and
how to proceed.
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 2366669
Translation of the Original Operating Manual
Language Order No. Language Order No.
English 2366672 Swedish 2391414
French 2369230 Russian 2369233
Italian 2369231 Dutch 2382562
Spanish 2369232 Finnish 2391437
Chinese 2369234 -- --
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order No. Order number Qty Number of pieces
ET Spare part DH Double stroke
K Marking in the spare parts lists SSt Stainless steel
Pos Position 2K Two components
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Product pressure
generator
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
Pump or pressure tank
associated with improper behavior as well as the necessary
protective devices and measures.
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient 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 workplace safety.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
2 CORRECT USE
2.1 DEVICE TYPES
Pneumatic double diaphragm pump and spray pack:
TOPFINISH DD10
2.2 TYPE OF USE
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classication into explosion classes IIA or IIB (see Chapter 2.4).
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 xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).
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2.4 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
Wax-based underside protection
Shear-sensitive lacquers
recommended limited suitability not suitable
NOTICE
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Use the application-oriented model (ow rate/cycle, product, valves, etc.) as
indicated in Chapter 5.5.
Check if the uids 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.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
Typical applications
Application TOPFINISH DD10
Furniture industry
Kitchen manufacturers
Joinery
Window factories
Steel-processing industry
Construction of vehicles
Shipbuilding
recommended limited suitability not suitable
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
no dry coating products, e.g. powder are processed.
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device types: Pneumatic double diaphragm pump TOPFINISH DD10
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
CE European Communities
Ex Symbol for explosion protection
II Device class II
2 Category 2 (Zone 1)
G Ex-atmosphere gas
Ex Ignition protection
h Ignition protection for non-electrical devices
IIB Explosion group
T4 Maximum surface temperature < 135 °C; 275 °F (with drying protection
active)
Gb Zone 1 high safety level
X Special notes (see Chapter 3.2)
TOPFINISCH DD10
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 drop the device.
Maximum surface temperature
The maximum surface temperature 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
Permissible ambient temperature: 10 °C to 60 °C; 50 °F to 140 °F.
Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.
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B_06916
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames
or sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.
Air in the pump uid
Flammable gas mixtures can form if air reaches the pump uid.
Prevent the pump from taking in air and running dry.
If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until
the air has escaped.
Air in the pumped uid can be caused by damaged diaphragms.
Avoid operating the pump with damaged diaphragms.
Periodically check that the pump is working smoothly, paying special attention to
the presence of air in the pumped uid.
Filling and emptying
Flammable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
3.3 TYPE PLATE
1
Wagner International AG, CH-9450 Altstätten
max. Air Pressure
2
max. Fluid Pressure
3
Tamb °C/°F
4
Article No.
5
Year of manufacture - Serial No.
6
Check user manual before use!
7
Designed and assembled by WAGNER in Switzerland.
8
Designation
1 Manufacturer and CE Identication
2 Max. air pressure
3 Max. product pressure
4 Permissible ambient temperature
5 Article number
6 Model year - serial number
7 Read the operating manual before use
8 Indication of origin
II 2G Ex h IIB T4 Gb X
0.8MPa; 116 psi
0.8MPa; 116 psi
4-40/39-104
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4 BASIC SAFETY INSTRUCTIONS
4.1 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
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform sta about planned work.
Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.
TOPFINISCH DD10
4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or steam!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working are is static dissipative in accordance
withEN61340-4-1 (resistance must not exceed 100 M).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M.
Ensure that during spraying, persons wear electrically conductive gloves. The
grounding takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M.
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Ensure that there are no ignition sources such as naked ames, 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.).
- Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
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: anyone tted with active implants (e.g., a pacemaker)
must not enter the high-voltage area!
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or steam!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents, and cleaning
agents being used.
Take the specied protective measures. In particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth
or on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint
or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
− Disconnect the control unit from the mains.
- In the event of functional faults, remedy the fault as described in the
"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).
− For shut-down devices, the check can be postponed until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
4.2.3 GROUND THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the
spray gun handle or the trigger.
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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 ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure
generated.
Ensure that the following information can be seen on the hose used:
− manufacturer
− permissible operating pressure
− date of manufacture
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
− in high traffic areas
− on sharp edges
− on moving parts or
− on hot surfaces
Ensure that the hoses are never 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.
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TOPFINISCH DD10
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 less
than 1 M.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coecient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid 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 ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
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4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ammable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure
that all equipment and resources (e.g., collection tank, funnel, transport cart) are
conductive or static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with units containing aluminium or galvanized and zinc-plated parts. They
may react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that an explosive
mixture may temporarily exist inside the lines and components of equipment:
−depending upon the used coating product,
−depending on the ushing agent (solvent) used.
explosive mixture inside the lines and items of equipment.
Only electrically conductive tanks may be used for cleaning and 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 ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects,
and never spray cleaning agents with a spray gun. Cleaning the device must not
damage it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F:
- Identify the device with a warning label "Warning – hot surface".
Order No.
9998910 Instruction label
9998911 Protection label
Note: Order the two stickers together.
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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.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in the 13 "Spare parts" chapter and 14
that are assigned to the unit.
Do not use any defective components.
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 o 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.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.
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5 DESCRIPTION
5.1 COMPONENTS
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
Designation
1 Air outlet for gun air
2 Product outlet
3 Product inlet
4 Air inlet
6
5
1
3
2
5 Pump housing
6 Pressure regulator unit
B_05370
4
5.2 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. The product is thus sucked in and displaced again. A series of four
non-return valves prevents the liquid from owing back, thus producing the suction and
delivery phases in each pumping chamber, and generating the pumping eect.
5.2.1 POSITIONING
The pump can be mounted horizontally (± 10°) as well as vertically (± 10°) in any position.
Ensure that all fastening screws are correctly tightened.
Tighten the xing 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 to align the control elements. For this purpose, the four screws (2) must be
removed.
1
2
B_05371
5.3 PROTECTIVE AND MONITORING EQUIPMENT
WARNING
Overpressure!
Danger to life from bursting components.
Never change the safety valve setting.
The air motor is tted with a safety valve. The safety valve has been set and sealed at the
factory. In case of pressures over and above the permissible operating pressure, the valve,
which is held with a spring, automatically opens and releases the excess pressure.
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5.4 INCLUDED ITEMS
Order No. Designation
1 -- TOPFINISH DD10 diaphragm pump
The standard equipment includes:
1 see Chapter 15.3 Declaration of Conformity
1 2366669 Operating manual, German
1 see Chapter 1.3 Operating manual in the local language
The delivery note shows the exact scope of delivery. Accessories: see Chapter .
5.5 DATA
5.5.1 MATERIALS OF PAINT WETTED PARTS
Paint-wetted parts Product
Diaphragms PA (Polyamide)
Remaining material-wetted parts Stainless steel
5.5.2 TECHNICAL DATA
TOPFINISCH DD10
Description Units TOPFINISH DD10
Pump ratio 1 : 1
Volume ow per double stroke
Maximum operating pressure
Compressed air quality: free from oil and water
Air inlet pressure
Air inlet (inside thread) inch 1/4"
Sound pressure level at 0.4 MPa; 4bar; 58psi air pressure* dB(A) 58.4
Sound pressure level at 0.6 MPa; 6bar; 87psi air pressure* dB(A) 61.6
Sound pressure level at 0.8 MPa; 8bar; 116psi air
pressure*
Product inlet connection (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
Ambient temperature
Allowable inclination for operation ± 10
*A-rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2015. Reference
measurements have been made by SUVA (Swiss Accident Insurance Institute).
cm
cu inch
MPa
bar
psi
Quality standard 7.5.4 according to ISO 8573.1: 2010
7: Particle concentration 5–10mg/m³
5: Humidity: pressure dew point: ≤ +7 °C
4: Oil content ≤ 5mg/m3
MPa
bar
psi
dB(A) 64.0
°C
°F
°C
°F
42.2
25.75
0.8
8
116
0.15 – 0.8
1.5 – 8
22 – 116
4 – 60
39.2 – 140
4- 40
39.2 – 104
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water.
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A
D
ORDER NUMBER DOC 2366672
5.5.3 DIMENSIONS AND CONNECTIONS
mm; inch
A 191; 7.52
B 135; 5.31
C 141; 5.55
D 236; 9.29
E 264; 10.39
K
F 149; 5.87
G 170; 6.69
H 192; 7.56
J
I G1/2"
K G1/4"
L G1/4“
M G3/8"
TOPFINISCH DD10
L
E
M
B
C
G
H
F
B_05372
5.5.4 PERFORMANCE DIAGRAMS
Example
Stroke frequency /min
8 bar
8 bar
6 bar
4 bar
B_00301
Product pressure bar (MPa) psi
6 bar
4 bar
Water delivery rate l/min <gpm>
Air consumption nl/min <scfm>
TOPFINISH DD10
bar (MPa)
<psi>
Product pressure
Stroke frequency
8.0 (0.8)
<116.0>
7.0 (0.7)
<101.5>
6.0 (0.6)
5.0 (0.5)
4.0 (0.4)
3.0 (0.3)
2.0 (0.2)
1.0 (0.1)
A
B
<87.0>
<72.5>
<58.0>
<43.5>
<29.0>
<14.5>
C
D
0
0 1.0 2.0 3.0 4 .0 5.0 6.0
B_06255
/min
A
B
C
D
nl/min
<scfm>
60.0
<2.15>
52.5
<1.88>
45.0
<1.61>
37.5
<1.35>
30.0
<1.08>
22.5
<0.81>
<0.54>
<0.27>
<1.59><1.32><1.06><0.79><0.53><0.26>
15.0
7.5
l/min
<gpm>
Air consumption
Water ow rate
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
D = 2 bar; 0.2 MPa; 29 psi air pressure
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5.6 PRESSURE REGULATOR UNIT ON TOPFINISH DD10
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
Designation
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
Positions of the ball valve
1 Open: working position
2 Closed: the air motor can still be
under pressure.
5.6.1 RETURN VALVE
2
6
1
3
7
B_05381
4
5
1
B_05379
2
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
3
1
4
B_05382
2
19
VERSION 12/2017
ORDER NUMBER DOC 2366672
6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING OF ASSEMBLY/COMMISSIONING STAFF
The assembly and commissioning sta 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.
A skilled person must check to ensure that the device is in a reliable 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% (without
condensation).
TOPFINISCH DD10
6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be in a range between 0 °C and 40 °C; 32
°F and 132 °F.
The relative air humidity at the installation site must be between 10 and 95% (without
condensation).
6.4 TRANSPORTATION
The pump can be moved on a trolley or manually without lifting equipment e.g., a crane.
20
VERSION 12/2017
6.5 ASSEMBLY AND INSTALLATION
ORDER NUMBER DOC 2366672
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.
National regulations
Ensure that the national explosion prevention rules and regulations are observed
when setting up the device.
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.
1
TOPFINISCH DD10
3
2
This pump can be used as part of a spraying system for Airspray applications. The
components can be found in the accessories list, provided that the system was not obtained
as a spray pack. The nozzles must be selected according to the spray gun instructions.
6.5.1 VENTILATION OF THE SPRAY BOOTH
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.
Observe national and local regulations for the exhaust air speed.
B_05376
21
VERSION 12/2017
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.
Do not mix up hose connections of product hose and air hose.
6.5.3 PRODUCT SUPPLY LINES
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of product.
Ensure that the hose material is chemically resistant to the sprayed products.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
Ensure that the spray gun, ttings 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 in atmospheres containing
solvents!
Explosion hazard from electrostatic sparks.
Clean the pump only with a damp cloth.
WARNING
Heavy paint mist if grounding is insucient!
Danger of poisoning.
Insucient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
22
VERSION 12/2017
Grounding scheme (example)
Pump
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
Conveyor
Work piece
Product
Tank
R max < 1 MΩ
Spraying stand
B_05375
Floor, static dissipative
Part / workstation Cable cross section
Pump 4 mm; AWG12
Paint tank 6 mm; AWG10
Conveyor 16 mm; AWG6
Booth 16 mm; AWG6
Spraying stand 16 mm; AWG6
Safe operation of the pump is only guaranteed with a grounding connection.
Connect all ground cables using a short and direct route.
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 must be suitable for use in potentially explosive areas.
All paints, ushing agents and waste tanks have to be electrically conductive.
All tanks must be grounded.
B_05377
23
VERSION 12/2017
6.7 COMMISSIONING
WARNING
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from ying parts.
Ensure that the pump and suction system are always completely filled with ushing
agent or working medium.
Do not spray the device empty after cleaning.
NOTICE
Impurities in the spraying system!
Spray gun blockage.
Flush the spray gun and paint supply with a suitable ushing agent before
commissioning.
Emergency stop, see Chapter 7.2.
Preparation
Before every start-up, the following points should be observed as laid down in the operating manual:
− Secure spray gun with safety lever.
− Check the permissible pressures.
− Check all connections for leaks.
− Check hoses for damage in accordance with Chapter 8.2.3.
Fill the pump with ushing agent
The devices are tested during manufacturing with emulsifying oil, pure oil or solvent.
Possible residues must be ushed out of the circuits with a solvent (ushing agent) before commissioning.
− Fill the empty device with ushing agent in accordance with Chapter 8.2.5.
Pressure tightness test
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
WARNING
Overpressure!
Risk of injury from bursting components.
The operating pressure must not exceed the value shown on the type plate.
− Gradually increase the pressure in pump with the pressure regulator until maximum
pressure is reached. Maintain the pressure for 3 minutes and check all connection
points for leaks.
− Depressurization in accordance with Chapter 7.4.
Verifying a Safe Operational Condition
A skilled person must check to ensure that the device is in a reliable state after it is
installed and commissioned.
This includes:
− Carry out safety checks in accordance with Chapter 8.2.3.
Filling with working material
− According to Chapter 8.2.5.
24
VERSION 12/2017
ORDER NUMBER DOC 2366672
7 OPERATION
7.1 TRAINING THE OPERATING STAFF
The operating sta must be qualied to operate the entire system.
The operating sta 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 sta must receive appropriate system
training.
7.2 EMERGENCY STOP
In the case of unforeseen occurrences:
– Close ball valve.
– The air supply should be interrupted.
TOPFINISCH DD10
open
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 the ball valve.
4. Set the required working pressure on the pressure regulator.
5. Optimize the spray pattern as laid down in the spray gun instructions.
6. Start work process.
closed
B_06917
25
VERSION 12/2017
ORDER NUMBER DOC 2366672
7.4 PRESSURE RELIEF/WORK INTERRUPTION
The pressure must always be relieved:
− after the spraying tasks are nished.
− before servicing or repairing the system.
− before carrying out cleaning tasks on the system.
− before moving the system to another location.
− before something needs to be checked on the system.
− before the nozzle or the lter is removed from the spray gun.
The components for pressure relief on a CE-compliant spraying system include:
− Outlet equipment (return valve) mounted between pump and spray gun.
Process for relieving pressure
TOPFINISCH DD10
2
1
8
3
4
B_05380
6
5
7
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, rst 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 air pressure is still present.
If the system has been used with 2K products:
NOTICE
Hardened working material in the spraying system when 2K product is processed!
Destruction of pump and injection system.
Follow the manufacturer‘s processing rules, particularly regarding the pot life.
Flush thoroughly before the end of the pot life.
The pot life is decreased by warmth.
26
VERSION 12/2017
B_05380
7.5 BASIC CLEANING
Flush regularly
Regular ushing, cleaning and maintenance ensures the pumps' high pumping and
suction capacity.
The cleaning and ushing agents used must be compatible with the working material.
WARNING
Incompatibility of ushing / cleaning agent with the working medium!
Risk of explosion and danger of poisoning by toxic gases.
Examine the compatibility of the ushing and cleaning agents and working media
on the basis of the safety data sheets.
2
1
8
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
3
4
6
5
7
Procedure
1. Visual check: personal safety equipment, grounding and all devices ready to use.
2. Place empty, grounded tank (7) under the return tube (6).
3. Place the suction hose (3) in the grounded tank with ushing agent (4).
4. Adjust the pressure regulator (1) to approx. 0.2 MPa; 2 bar; 29 psi.
Flush via the return ow 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 ushing agent ows 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 ball valve (8).
13. Flush until clean cleaning agent ows from the spray gun.
14. Close ball valve (8).
15. When there is no pressure remaining in the system, close the spray gun.
16. Secure the spray gun.
17. Dispose of the contents of the tank (7) according to the local regulations.
7.5.1 FILLING WITH WORKING MATERIAL
After basic ushing, the pump can be lled with working material. Proceed according to
Chapter 8.2.5, but use working material instead of ushing agent.
27
VERSION 12/2017
ORDER NUMBER DOC 2366672
8 CLEANING AND MAINTENANCE
8.1 CLEANING
8.1.1 CLEANING STAFF
Cleaning work should be undertaken regularly and carefully by qualied and trained sta.
They should be informed of specic 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.
8.1.2 DECOMMISSIONING AND CLEANING
The device should be cleaned for maintenance purposes, etc. Ensure that no remaining
product dries on and sticks to the device.
Procedure
1. Carry out work interruption Chapter 7.4.
2. Carry out the basic ushing Chapter 7.5.
3. Empty system in a controlled manner Chapter 8.2.4.
4. Service spray gun in accordance to its operating instructions.
5. Clean and check the suction system and the suction lter.
6. Clean the outside of the system.
TOPFINISCH DD10
WARNING
Brittle lter pressure regulator!
The tank on the lter pressure regulator becomes brittle through contact with solvents and
can burst. Flying parts can cause injury.
Do not clean the tank on the lter pressure regulator with solvent.
7. Fully assemble the system.
8. Fill the system with ushing agent in accordance with Chapter 8.2.5.
8.1.3 LONGTERM STORAGE
If storing the system for a prolonged period of time, thorough cleaning and corrosion
protection are necessary. Replace the water or solvent in the product pump with a suitable
preserving oil.
Procedure
1. Carry out points 1 to 7 in Chapter 8.1.2 "Decommissioning and Cleaning".
2. Fill the system with preservative in accordance with Chapter 8.2.5.
3. Empty the system in a controlled manner in accordance with Chapter 8.2.4 and seal
the openings.
28
VERSION 12/2017
8.2 MAINTENANCE
8.2.1 MAINTENANCE STAFF
Maintenance work should be undertaken regularly and carefully by qualied and trained
sta. They should be informed of specic hazards during their training.
The following hazards may arise during maintenance work:
− Health hazard from inhaling solvent vapors.
− Use of unsuitable tools and aids.
An authorized person must ensure that the device is checked for being in a reliable state
after maintenance work is completed.
8.2.2 MAINTENANCE INSTRUCTIONS
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.
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 o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
Prior to maintenance
It should be ensured that the device is in the following state before carrying out any work
on it:
− Flush and clean the system. Chapter 8.1.2.
− Relieve the pressure from the pump, product hose and spray gun.
− Secure spray gun with safety lever.
− The air supply should be interrupted.
After maintenance
− Carry out safety checks in accordance with Chapter 8.2.3.
− Put the system into operation and check for leaks as described in Chapter 6.7.
− Have the system checked for safe condition by an authorized person.
− Function test in accordance with section 11.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
29
VERSION 12/2017
8.2.3 SAFETY CHECKS AND MAINTENANCE INTERVALS
Every day
Check grounding: see Chapter 6.5.
Check hoses, tubes and couplings: see Chapter 8.2.3.1
For each decommissioning, the process according to Chapter 8.1.2 must be
followed.
If the pump has to be emptied for maintenance work, proceed according to
Chapter 8.2.4.
Weekly
Check system for damage.
Check that the safety xtures function properly (see Chapter 5.3).
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.
– For shut down devices, the examination can be suspended until the next start-
up.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
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 inuences 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 for wear and
tear as well as for damage at intervals that he/she has set. Records of these checks
must be kept.
The complete hose is to be replaced as soon as one of the two following intervals
has been exceeded:
−6 years from the date of the hose crimping (see tting embossing).
−10 years from the date of the hose imprinting.
Fitting embossing Meaning
xxx bar Pressure
yymm Crimping date (year/month)
XX Internal code
Hose imprinting Meaning
Wagner Name / Manufacturer
yymm Date of manufacture (year/month)
xxx bar (xx MPa)
e.g., 270 bar (27 MPa)
XX Internal code
DNxx (e.g., DN10) Nominal diameter
Pressure
30
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 ying parts.
Ignition of potentially explosive surrounding atmosphere.
Empty the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
If the pumping product becomes heated, switch o all heaters and let the product
cool o.
2
1
8
TOPFINISCH DD10
3
4
B_05380
6
5
7
1. Carry out basic ushing in accordance with Chapter 7.5.
2. Place an empty, grounded collection tank (7) under the return tube (6).
3. Place the suction hose (3) in an empty, grounded tank (4).
4. Close pressure regulator (1) (0MPa; 0bar; 0psi).
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 owing from the return tube (6), close ball valve (8).
10. Close return valve (5).
Empty up to the gun
11. Point the spray gun, without nozzle, into the tank (7) and open it.
12. Slowly open the ball valve (8). Be ready for the switch from working material to air.
13. As soon as working material is no longer owing from the return tube, close the ball valve (8).
14. Close and secure the spray gun.
15. Depressurization in accordance with Chapter 7.4.
16. Dispose of the contents of the tank (7) according to the local regulations.
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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 ying parts.
Ignition of potentially explosive surrounding atmosphere.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
2
1
8
3
4
6
5
TOPFINISCH DD10
7
B_05380
1. Visual check: personal safety equipment, grounding and all devices ready to use.
2. Place grounded collection tank (7) under the return tube (6).
3. Place the suction hose (3) in a grounded tank with working material (4).
4. Close pressure regulator (1) (0MPa; 0bar; 0psi).
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. 0–0.2MPa; 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 valve (5).
10. Point the spray gun, without nozzle, into the tank (*) and open it.
11. Slowly open the ball valve (8).
Be ready to switch from working material to air and prevent back spray.
12. As soon as pure working material without air bubbles is owing, close ball valve (8).
13. Close and secure the spray gun.
14. Depressurization in accordance with Chapter 7.4.
15. Dispose of the contents of the tank (7) according to the local regulations.
32
VERSION 12/2017
ORDER NUMBER DOC 2366672
8.3 REPLACING THE DIAPHRAGM
1
TOPFINISCH DD10
5
5 Nm; 3.68 lbft
2
6
6
5
4
3
B_05373
7 Nm; 5.16 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. 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.
7
8
9
10
B_05374
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® 222 (10) on screws (8). Observe tightening
torque.
33
VERSION 12/2017
8.4 REPLACING VALVES
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
1
2
3
2
1
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.
34
VERSION 12/2017
ORDER NUMBER DOC 2366672
9 TROUBLESHOOTING AND RECTIFICATION
Problem Cause Remedy
TOPFINISCH DD10
The pump does not
work.
Poor spray pattern. See the gun instructions.
Irregular operation of
product pump: spray jet
collapses (pulsation)
Strongly irregular
operation of product
pump.
The pump runs evenly,
does not however, suck
up product.
Pump runs fast when
the spray gun is closed.
Loss of power due to
severe icing.
If none of the causes of malfunction mentioned are present, the defect can be remedied
by a WAGNER Service Center.
The pump does not start or stops. Open and close ball valve on the
pressure regulator unit or briey
disconnect compressed air supply.
No pressure indication on the pressure
gauge (air pressure regulator defective).
Spray nozzle is clogged. Clean the nozzle according to the
Insucient compressed air supply. Check compressed air supply.
Filter insert in spray gun is clogged. Clean the parts and use a suitable
The uid section or hose are blocked
(e.g., 2K product hardened).
Grease in spool and sleeve assembly. Degrease spool and sleeve assembly.
Pump stops at the stroke end
occasionally.
Viscosity is too high. Thin spraying product.
Spraying pressure is too low. Increase incoming air pressure.
Foreign body in suction valve. Dismantle suction valve housing, clean
Diameter of compressed air line too
small.
Worn out valves. Replace the parts.
Control air lter or work air lter is
clogged.
Diaphragms "blocked" because suction
is too fast.
The suction system's union nut is loose;
the pump is taking in air.
Suction lter is clogged. Clean lter.
Valves worn. Replace the parts.
There is a lot of condensation water in
the air supply.
Disconnect compressed air supply briey
or repair or change pressure regulator.
instructions.
working material.
Dismount and clean uid section, replace
high-pressure hose.
Check detent body.
Use a smaller nozzle.
and check valve seat.
Assemble a larger supply line ->
Technical data, see Chapter 5.5.2.
Check lter and clean it if necessary.
Operate pump with ball valve opened a
minimal amount for a while.
Tighten.
Install a water separator.
35
VERSION 12/2017
ORDER NUMBER DOC 2366672
10 REPAIR WORK
10.1 REPAIR STAFF
Repair work must be carried out carefully and by qualied and trained personnel. They
should be informed of specic hazards during their training.
The following hazards may arise during repair work:
− Health hazard from 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 .
10.2 REPAIR NOTES
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.
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 o 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 the device is in the following state before carrying out any work
on it:
− Flush and clean the system. Section 8.1.2
− Empty pump according to Chapter 8.2.4.
− The air supply should be interrupted.
After a Repair
− Carry out safety checks in accordance with Chapter 8.2.3.
− Put the system into operation in accordance with Chapter 6.7 and check for leaks in
accordance with Chapter 11.
− Function test in accordance with section 11.
TOPFINISCH DD10
10.3 TOOLS
The following tools are required for assembling and disassembling the device (if possible,
always bring entire tool sets with you):
– Torque wrench with Torx 5 Nm; 3.68 lbft, 7 Nm; 5.16 lbft.
– Allen wrench set
36
VERSION 12/2017
10.4 CLEANING THE PARTS AFTER DISASSEMBLY
WARNING
Incompatibility of cleaning agent and working medium!
Risk of explosion and danger of poisoning by toxic gases.
Examine the compatibility of the cleaning agents and working media on the basis
of the safety data sheets.
Please note:
Thoroughly clean all reusable parts with a suitable cleaning agent.
All uninstalled parts have to be clean and dry after cleaning. Care should be taken
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.
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
Defective parts, O-rings and seal sets must always be re-placed.
Use greases and glues in accordance with Chapter 14.
Observe torque specications in Chapter 14.
Mounting materials
Order No. Quantity Designation Smaller tanks
9992590 1 pc ≙ 50 ml Loctite 222
322912 1 pc ≙ 250 ml Hydraulic oil - Wagner
Brand notice
The brands specied in this document are property of the respective owners. Loctite , for example, is a
registered brand of Henkel.
37
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 sta.
Activities Aid tools
1. EX-relevant inspections
TOPFINISCH DD10
− Check mass connection between grounding connection of the pump and
the frame/trolley and between the individual components of the frame/
trolley: <100k
These inspections are − relevant!!
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
ushing 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 o.
Close air-supply ball-valve without relieving and check for pressure-loss.
3. General inspections
− Check tightening torque of various screws. see Chapter . Torque wrench
− Check all threaded connections.
− Empty device (Chapter 8.2.4) and depressurize it (Chapter 7.4).
− Check function of frame or transport trolley. Check whether the pump is
mounted
horizontally on the frame.
Ohmmeter
Air motor:
Test medium com-
pressed air
Leak spray
Fluid section:
Test medium: suitable
ushing agent
Visual check
12 DISPOSAL
When the equipment must be scrapped, please dierentiate the disposal of the waste
materials.
The following materials have been used:
Stainless steel
Aluminum
Elastomerics
Plastics
Ceramic
Consumable products
Consumable products (lacquers, adhesives, ushing and cleaning agents, solvents) must
be disposed of in accordance with all applicable legal requirements.
38
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
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
TOPFINISCH DD10
39
VERSION 12/2017
ORDER NUMBER DOC 2366672
14 SPARE PARTS
14.1 HOW CAN SPARE PARTS BE ORDERED?
Always supply the following information to ensure delivery of the right spare part:
Order number, designation and quantity
The quantity need not be the same as the number given in the quantity column " " on
the list. This number merely indicates how many of the respective parts are used in each
component.
The following information is also required to ensure smooth processing of your order:
− Address for the invoice
− Address for delivery
− Name of the person to be contacted in the event of any queries
− Type of delivery (normal mail, express delivery, air freight, courier etc.)
Identication in spare parts lists
Explanation of column " " (labeling) in the following spare 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.
TOPFINISCH DD10
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.
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 o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
40
VERSION 12/2017
14.2 OVERVIEW OF THE COMPONENTS
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
1
13
14
12
6
9
3
10
4
8
7
11
2
Order No. Designation
1 1 2370189 Cover spare parts set
2 1 2370193 Selection spare parts set
3 1 2370195 Liquidbody 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 parts set
14 1 2370222 Grounding spare parts set
5
B_06252
41
VERSION 12/2017
14.2.1 COVER SPARE PARTS SET
4
7
6
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
1
2
2
5
Order No. Designation
1
2
3
4
5
6
7
14.2.2 SPARE PARTS SET FOR SWITCHING COMPONENT
1 2370189 Cover spare parts set
2 -- Cover
4 -- Screw, M8x180
4 -- Nut, M8
1 -- Type plate
1 -- Cable lug
1 -- Screw for cable lug
3
1
2
5 Nm;
3.68 lbft
7 Nm; 5.16 lbft
B_06240
3
4
B_06244
Order No. Designation
1
2
3
4
1 2370193 Selection spare parts set
1 – Switch unit preassembled
2 – Shaped packing
4 – Screw
42
VERSION 12/2017
B_06245
ORDER NUMBER DOC 2366672
14.3 LIQUIDBODY SPARE PARTS SET
Order No. Designation
1 1 2370195 Liquidbody incl. safety valve
14.4 DIAPHRAGM SPARE PARTS SET
TOPFINISCH DD10
1
B_06241
Order No. Designation
1
1 2370200 Diaphragm spare parts set
2 2 – Diaphragms
3 2 – Washer
4 2 – Screw
5 1 – Loctite® 222
= Wearing parts
14.5 VALVE SPARE PARTS SET
Order No. Designation
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 1 2370203 Air piston spare parts set
2 2 – Air piston
3 2 – Air cylinder
4 2 – O-ring, 42x3
= Wearing parts
4
2
3
1
5
B_06242
5
4
3
2
6
1
B_05385
2
3
4
1
B_06243
14.7 PRODUCT SEALING SPARE PARTS SET
Order No. Designation
1 1 2370181 Product sealing spare parts set
2 4 – O-ring
= Wearing parts
14.8 INLET SPARE PARTS SET
Order No. Designation
1 1 2370212 Inlet spare parts set
2 1 – Inlet distributor
3 4 – Screw
2
1
3
1
2
B_06246
43
VERSION 12/2017
B_06248
1
2
1
2 3
B_06250
14.9 OUTLET SPARE PARTS SET
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
Order No. Designation
1 1 2370214 Outlet spare parts set
2 1 – Outlet distributor
3 4 – Screw
14.10 AIRBODY SPARE PARTS SET
Order No. Designation
1 1 2370215 Airbody spare parts set
2 2 – Air body preassembled
14.11 SHAPED PACKING SPARE PARTS SET
Order No. Designation
1 1 2370219 Shaped packing spare parts set
2 2 – Shaped packing
14.12 DISTRIBUTOR SPARE PARTS SET
Order No. Designation
1 1 2370220 Distributor spare parts set
2 1 – Distributor unit, complete
3 4 – Screw
2
3
1
B_06247
2
1
B_06249
14.13 REGULATOR UNIT SPARE PARTS SET
Order No. Designation
1 1 2370221 Regulator unit spare parts set
2 1 – Regulator unit preassembled
3 4 – Screw
14.14 GROUNDING SPARE PARTS SET
Order No. Designation
1 1 2370222 Grounding spare parts set
2 1 – Cable lug
3 1 – Screw for cable lug
3
1
2
B_06251
2
1
3
B_06253
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VERSION 12/2017
ORDER NUMBER DOC 2366672
15 GUARANTEE AND CONFORMITY DECLARATIONS
15.1 IMPORTANT NOTES ON PRODUCT LIABILITY
As a result of an EC regulation eective from January 1, 1990, the manufacturer shall only
be liable for his product if all parts originate from him or are approved by him, and if the
devices are properly mounted, operated and maintained.
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.
15.2 WARRANTY CLAIM
Full warranty is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of warranty provided is such that the device or individual components of the
device are either replaced or repaired as we see t. The resulting costs, in particular
shipping charges, road tolls, labor and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the device to a location other
than 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 inuence of chemical, electrochemical or electrical
agents, except when the damage is attributable to us.
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc
dust paints and so forth reduce the service life of valves, packings, spray guns, nozzles,
cylinders, pistons etc. Wear and tear due to such causes are not covered by this warranty.
Components that have not been manufactured by WAGNER are subject to the original
warranty of the manufacturer.
Replacement of a component does not extend the period of warranty of the device.
The device should be inspected immediately upon receipt. To avoid losing the warranty,
we or the supplier company are to be informed in writing about obvious faults within
14days upon receipt of the device. We reserve the right to have the warranty compliance
met by a contracting company. The services provided by this warranty are dependent on
evidence being provided in the form of an invoice or delivery note. If the examination
discovers that no warranty claim exists, the costs of repairs are charged to the purchaser. It
is clearly stipulated that this warranty claim does not represent any constraint on statutory
regulations or regulations agreed to contractually in our general terms and conditions.
TOPFINISCH DD10
Wagner International AG
45
VERSION 12/2017
15.3 EU DECLARATION OF CONFORMITY
We hereby declare that the supplied version of diaphragm pumps and spray packs:
TOPFINISH DD10
complies with the following guidelines:
2006/42/EC
2014/34/EU (ATEX Directive)
Applied standards, in particular:
EN ISO 12100:2010 EN 12621: 2006+A1: 2010
EN809: 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
EN14462:2015
ORDER NUMBER DOC 2366672
TOPFINISCH DD10
Applied national technical standards and specications, in particular:
Chapter 2.29 and Chapter 2.36
Identication:
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
46
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Order No.
Edition 12/2017
2366672
ts-liquid@wagner-group.com
ts-powder@wagner-group.com
Document No. 11183212
Version C
www.wagner-group.com
48
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