WAGNER TOPFINISH DD10 Operational manual

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

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OPERATING MANUAL
VERSION 09/2016 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 in the Text 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 Use in an Explosion Hazard Area 6
2.4 Safety Parameters 7
2.5 Processible Working Materials 7
2.6 Reasonably Foreseeable Misuse 8
2.7 Residual Risks 8
3 IDENTIFICATION 9
3.1 Explosion Protection Identication 9
3.2 Type Plate 10
4 GENERAL SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.2 Safety Instructions for Sta 12
5 DESCRIPTION 15
5.1 Components 15
5.2 Mode of Operation 15
5.3 Scope of Delivery 16
5.4 Data 16
5.5 Pressure Regulator Unit for the TOPFINISH DD10 20
5.6 Return Flow Valve 21
6 ASSEMBLING AND COMMISSIONING 22
6.1 Training Assembly/Commissioning Sta 22
6.2 Storage Conditions 22
6.3 Installation Conditions 22
6.4 Transportation 22
6.5 Assembly and Installation 23
6.6 Grounding 25
6.7 Safety Checks 26
6.8 Commissioning 27
7 OPERATION 30
7.1 Training the Operating Sta 30
7.2 Safety Instructions 30
7.3 Working 31
7.4 Pressure Relief/Work Interruption 31

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Table of Contents
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.
8 CLEANING AND MAINTENANCE 32
8.1 Cleaning 32
8.2 Maintenance 34
8.3 Diaphragm Replacement 36
8.4 Replacing the Inlet and Outlet Valves 37
9 TROUBLESHOOTING, MAINTENANCE AND REPAIR 38
9.1 Troubleshooting and Rectication 38
10 REPAIR WORK 39
10.1 Repair Sta 39
10.2 Safety Instructions 39
10.3 Cleaning the Parts after Disassembly 40
11 FUNCTION TEST AFTER THE REPAIR 41
12 DISPOSAL 42
13 ACCESSORIES 42
14 SPARE PARTS 43
14.1 How Can Spare Parts Be Ordered? 43
14.2 Overview 44
14.3 Spare Part Sets 46
15 GUARANTEE AND CONFORMITY DECLARATIONS 49
15.1 Important Notes Regarding Product Liability 49
15.2 Warranty Claim 49
15.3 CE Declaration of Conformity 50

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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:
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No.
German 2366669 English 2366672
French 2369230 Italian 2369231
Spanish 2369232 Russian 2369233
Chinese 2369234
Additional languages on request or at:
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Double stroke

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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Product pressure
generator
Pump or pressure tank
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential
risks associated with improper behavior as well as the
necessary protective devices and measures.
Electrically trained
person
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.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient 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.
In accordance with TRBS
1203 (2010)
2 CORRECT USE
2.1 DEVICE TYPES
2.2 TYPE OF USE
Pneumatic double diaphragm pump and spray pack
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classication into explosion classes IIA or IIB.
2.3 USE IN AN EXPLOSION HAZARD AREA
The pneumatic double diaphragm pumps can be employed in potentially explosive areas
(zone 1).

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2.4 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 xtures.
Use only WAGNER original spare parts and accessories.
The double diaphragm pump may only be operated under the following conditions:
The operating personnel must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must
be observed.
The statutory requirements and accident prevention regulation standards in the
country of use must be observed.
2.5 PROCESSIBLE WORKING MATERIALS
Fluid materials like paints and varnishes.
Application TOPFINISH DD10
Water-dilutable products
Solvent-based lacquers and paints
Two-component coating products
Emulsions
UV lacquers
Primers
Epoxy and polyurethane lacquers, phenolic lacquers
Liquid plastics
Wax-based underside protection
Shear-sensitive lacquers
Legend
recommended limited suitability less suitable
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 5.4.2.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.4.1.
NOTICE

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2.5.1 RECOMMENDED APPLICATION AREAS
Legend
recommended limited suitability less suitable
Application
Furniture industry
Kitchen manufacturers
Joinery
Window factories
Steel-processing industry
Construction of vehicles
Shipbuilding
2.6 REASONABLY FORESEEABLE MISUSE
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modications to the double diaphragm pump,
processing dry or similar coating materials, and
using defective components, spare parts, or accessories other than those described
in Chapter 13 of this operating manual.
The forms of misuse listed below may result in physical injury or property damage:
use of powder as coating product and
incorrectly set values for processing.
WAGNER double diaphragm pumps are not designed for pumping food.
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritations, wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Lacquer in air
outside the dened
working area
Lacquering outside
the dened working
area
Inhalation of
substances which
are hazardous to
health
Observe working
and operating
manuals
Operation,
maintenance

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in
potentially explosive areas.
CE mark (European Communities)
Symbol for explosion protection
Device class II
Category 2 (Zone 1)
Ex-atmosphere gas
C Constructional security
Explosion group
Temperature class: maximum surface temperature < 135 °C; 275 °F
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
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.
Do not drop the device.
Use only tools that are made of a permitted material.

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max. Fluid Pressure
Tamb
Article No.
max. Air Pressure
Year of manufacture - Serial No.
Check user manual before use!
Designed by Wagner International AG CH-9450 Altstätten, assembled in China
II 2G c IIB T4
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Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.
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.
Operation without Fluid
Avoid running the pump so that it sucks in air (without uid inside). The air, combined with
the vapor of ammable uids, can generate internal areas with an explosion hazard.
Periodically check that the pump is working, paying special attention to the presence of air
in the pumped uid, which may be caused by damaged diaphragms.
Avoid operating the pump with damaged diaphragms.
3.2 TYPE PLATE
Example
1 Max. air pressure
2 Max. product pressure
3 Permissible ambient
temperature
4 Article number
5 Year of manufacture
6 Read the operating manual
before use
1
2
3
4
5
6

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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is only operated, maintained and repaired by trained persons.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
Ensure that all persons within the working area wear static dissipative shoes. Footwear
must comply with EN 20344. The measured insulation resistance must not exceed
100megohms.
Ensure that during spraying, persons wear static dissipative gloves. Grounding takes
place via the spray gun handle.
If protective clothing is worn, including gloves, it has to comply with EN1149-5. The
measured insulation resistance must not exceed 100 megohms.
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that the following components of a safe working environment are available:
– Product/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.

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4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
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 all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
- 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.
- For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief" chapter:
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briey in a position.
4.2.2 GROUNDING THE DEVICE
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge.
Ensure that the device is grounded for every spraying operation.
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.

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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
used 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
- 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 lifts), or that the hoses are
never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
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 megohm.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coecient. 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.
4.2.4 CLEANING AND RINSING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non-ammable cleaning and ushing agents.
Observe the specications 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.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items of equipment.

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When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents and cleaning agents
being used.
Take the specied protective measures; in particular, make sure that you wear safety
goggles, protective clothing, and gloves, as well as skin protection cream if necessary.
Use a mask or a breathing apparatus if necessary.
For sucient 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.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
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:
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 gun. Cleaning the device must not damage it in any
way.
Ensure that no electrical component is cleaned with nor even immersed into solvent.
4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109.4°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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5 DESCRIPTION
5.1 COMPONENTS
1 Air outlet for gun air 4 Air inlet
2 Product outlet 5 Pump housing
3 Product inlet 6 Pressure regulator unit
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 eect.
5.2 MODE OF OPERATION

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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.
5.3 SCOPE OF DELIVERY
Order No. Designation
- 1 TOPFINISH DD10 diaphragm pump
The standard equipment includes:
see Chapter 15.3 1 Declaration of conformity
2366669 1 Operating manual German
see Chapter 1.3 1 Operating manual in the local language
The delivery note shows the exact scope of delivery.
Accessories: see Chapter 13.
5.4 DATA
Diaphragms PA (polyamide)
Remaining material-wetted parts Stainless steel
5.4.1 MATERIALS OF PAINTWETTED PARTS

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Compressed air quality
Quality standard 7.5.4 according to ISO 8573.1: 2010
7: Solid particles with mass concentration of 5-10 mg/m³
5: Air humidity: pressure dew point ≤ +7 °C
4: Oil content: ≤ 5 mg/m³
Description Units TOPFINISH DD10
Pump ratio 1 : 1
Volume ow per double stroke cm 42.2
cu inch 25.75
Maximum operating pressure MPa 0.8
bar 8
psi 116
Air inlet pressure MPa 0.15 – 0.8
bar 1.5 – 8
psi 22 – 116
Air inlet (inside thread) inch 1/4"
Sound pressure level at 0.4 MPa; 4bar; 58psi air pressure* dB(A) 58.4
Sound pressure level at 0.6 MPa; 6bar; 87psi air pressure* dB(A) 61.6
Sound pressure level at 0.8 MPa; 8bar; 116psi air pressure* dB(A) 64.0
Product inlet (inside thread) inch 1/2"
Product outlet (inside thread) inch 3/8"
Weight kg; lb 4.1
Product pH value pH 3.5 – 9
Product viscosity DIN 4 sec 15 – 60
Product temperature °C 4 – 60
°F 39.2 – 140
Ambient temperature °C 4 – 40
°F 39.2 – 104
Allowable inclination for operation ± 10
* A-rated sound pressure level measured at 1 m distance, LpA1m according to DIN EN 14462: 2005.
Reference measurements have been made by SUVA (Swiss Accident Insurance Institute).
5.4.2 TECHNICAL DATA
Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide water-free and oil-free compressed air
WARNING

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5.4.3 DIMENSIONS AND CONNECTIONS
TOPFINISH DD10
mm; inch
191; 7.52
135; 5.31
141; 5.55
236; 9.29
264; 10.39
149; 5.87
170; 6.69
192; 7.56
G1/2"
G1/4"
G3/8"

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BAR
BAR
BAR
BAR
BAR
BAR
"?
0
0 1.0 2.0 3.0 4.0 5.0 6.0
1.0 (0.1)
<14.5>
2.0 (0.2)
<29.0>
3.0 (0.3)
<43.5>
4.0 (0.4)
<58.0>
5.0 (0.5)
<72.5>
6.0 (0.6)
<87.0>
7.0 (0.7)
<101.5>
8.0 (0.8)
<116.0>
7.5
<0.27>
15.0
<0.54>
22.5
<0.81>
30.0
<1.08>
37.5
<1.35>
45.0
<1.61>
52.5
<1.88>
60.0
<2.15>
bar (MPa)
<psi>
nl/min
<scfm>
l/min
<gpm>
A
B
C
D
A
B
C
D
B_06255 <1.59><1.32><1.06><0.79><0.53><0.26>
Material ow volume - water - water l/min <gpm>
A = 8 bar; 0.8 MPa; 116 psi air pressure
B = 6 bar; 0.6 MPa; 87 psi air pressure
C = 4 bar; 0.4 MPa; 58 psi air pressure
B = 2 bar; 0.2 MPa; 29 psi air pressure
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5.4.4 PERFORMANCE DIAGRAMS
Example
Product pressure bar (MPa) <psi>
Product ow rate - water l/min <gpm>
Air consumption nl/min <scfm>
TOPFINISH DD10 diagram
Product pressure bar (MPa) <psi>
Air consumption nl/min <scfm>

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