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Translation of the original
Operating Manual
Unica 4-270
High pressure
Double diaphragm pump
Edition 04 / 2007
II 2G IIB T4
EDITION 04 /2007
OPERATING MANUAL
Contents
PART NO. ZZB006ENG
1.1 Languages
1.2 Warnings, notes and symbols in these instructions
2 GENERAL SAFETY INSTRUCTIONS
2.1 Safety instructions for the operator
2.1.3 A safe work environment
2.2 Safety instructions for staff
2.2.1 Safe handling of WAGNER spray units
2.2.2 Earth the unit
2.2.4 Cleaning
2.2.5 Handling hazardous liquids, varnishes and paints
2.2.6 Touching hot surfaces
2.4 Use in an explosion hazard area
2.4.3 Max. surface temperature
3 PRODUCT LIABILITY AND WARRANTY
3.1 Important notes on product liability
3.2 Warranty
3.3 CE-CONFORMITY
4 DESCRIPTION
4.1 Field of application
4.1.1 Using in accordance with the instructions
4.1.2 Examples of application areas
4.2 Extent of delivery
4.3 Data
4.3.1 Materials used for components in contact with the product
4.3.3 Dimensions and connections
4.4 Functioning
4.4.1 Pump
4.4.2 Air supply unit (optional)
5 STARTING UP AND OPERATING
5.1 Installation and connection
5.1.2 Pump installation on ground frame
5.1.3 Compressed air supply circuit
Unica 4-270 .
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EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
Contents
5.1.6 Example of typical installation
5.1.7 Earthing
5.2.2 Pressure release procedure
5.2.3 Pump washing
5.2.4 Filling with working fl uid
5.3 Finishing work and cleaning
5.4 Storing for longer periods of time
6 FAULT LOCATION, MAINTENANCE AND REPAIR
6.1 Trouble shooting and solution
6.2 Maintenance
6.2.1 Lubrication
6.2.2 Washing and storing
6.2.3 Regular check of sealing and tightness
6.2.4 Plan of preventive maintenance
6.3.1 Maintenance of the hydraulic circuit
6.3.1.1 Operations on the hydraulic circuit during maintenance
6.3.1.2 Hydraulic circuit emptying
6.3.1.3 Hydraulic circuit fi lling
7 ACCESSORIES
7.1 Wall mounting kit
7.3 Air pressure regulator kit
8.1 How to order spare parts
8.3.2 Reversing valve
Unica 4-270 .
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4
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
1
ABOUT THESE INSTRUCTIONS
4HISOPERATINGMANUALCONTAINSINFORMATIONABOUTTHEOPERATIONREPAIRANDMAINTENANCE
OFTHEUNIT
!LWAYSFOLLOWTHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
1.1 LANGUAGES
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE
'ERMAN
0ART.O
,ANGUAGE
$UTCH
3PANISH
2 I
3WEDISH
4URKISH
( I
0ART.O
--
--
--
ZZB006SPA
1.2
WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
7ARNINGINSTRUCTIONSINTHISMANUALPOINTOUTPARTICULARDANGERSTOUSERSANDEQUIPMENT
ANDSTATEMEASURESFORAVOIDINGTHEHAZARD4HESEWARNINGINSTRUCTIONSFALLINTOTHEFOLLO
WINGCATEGORIES
$ANGERIMMINENTDANGER.ONOBSERVANCEWILLRESULT
INDEATHSERIOUSINJURYANDSERIOUSMATERIALDAMAGE
$!.'%2
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'"
7ARNINGPOSSIBLEDANGER.ONOBSERVANCECANRESULT
INDEATHSERIOUSINJURYANDSERIOUSMATERIALDAMAGE
3)()??'"
7!2.).'
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
#AUTION A POSSIBLY HAZARDOUS SITUATION .ONOBSER
VANCECANRESULTINMINORINJURY
#!54)/.
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'"
#AUTION A POSSIBLY HAZARDOUS SITUATION .ONOBSER
VANCECANCAUSEMATERIALDAMAGE
3)()??'"
#!54)/.
4HISLINEWARNSOFTHEHAZARD
0OSSIBLECONSEQUENCESOFFAILINGTOOBSERVETHEWARNINGINSTRUCTIONS4HESIGNALWORD
POINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
.OTEPROVIDEINFORMATIONONPARTICULARCHARACTERISTICSANDHOWTOPROCEED
5
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
2
GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
+EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
2.1.1 ELECTRICAL EQUIPMENT
%LECTRICALPLANTANDUNIT
4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE
OPERATINGMODEANDAMBIENTINmUENCES
-AYONLYBEMAINTAINEDBYSKILLEDELECTRICIANSORUNDERTHEIRSUPERVISION
-USTBEOPERATEDINACCORDANCEWITHTHESAFETYREGULATIONSANDELECTROTECHNICALREGU
LATIONS
-USTBEREPAIREDIMMEDIATELYINTHEEVENTOFPROBLEMS
-USTBEPUTOUTOFOPERATIONIFTHEYPOSEAHAZARD
-USTBEDEENERGIZEDBEFOREWORKISCOMMENCEDONACTIVEPARTS)NFORMSTAFFABOUT
PLANNEDWORKOBSERVEELECTRICALSAFETYREGULATIONS
2.1.2
PERSONNEL QUALIFICATIONS
%NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
2.1.3 A SAFE WORK ENVIRONMENT
%NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART
eMEASUREMENTINACCORDANCEWITH$).
%NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH
LEATHERSOLES
%NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHEDVIA
THEHANDLEOFTHESPRAYGUN
#USTOMERTOPROVIDEPAINTMISTEXTRACTIONSYSTEMSCONFORMINGTOLOCALREGULATIONS
%NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE n-ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE n0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION
%NSURETHATTHEREARENOIGNITIONSOURCESSUCHASNAKEDmAMEGLOWINGWIRESORHOT
SURFACESINTHEVICINITY$ONOTSMOKE
2.2 SAFETY INSTRUCTIONS FOR STAFF
!LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN
STRUCTIONSANDTHEWARNINGINSTRUCTIONS
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
6
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS
4HESPRAYJETISUNDERPRESSUREANDCANCAUSEDANGEROUSINJURIES
!VOIDINJECTIONOFPAINTORCLEANINGAGENTS
.EVERPOINTTHESPRAYGUNATPEOPLE
.EVERREACHINTOTHESPRAYJET
"EFORE ALL WORK ON THE UNIT IN THE EVENT OF WORK INTERRUPTIONS AND FUNCTIONAL
FAULTS n3WITCHOFFTHEENERGYCOMPRESSEDAIRSUPPLY n3ECURETHESPRAYGUNAGAINSTACTUATION n2ELIEVETHEPRESSUREFROMTHESPRAYGUNANDUNIT n"YFUNCTIONALFAULTS)DENTIFYANDCORRECTTHEPROBLEMPROCEEDASDESCRIBEDIN
CHAPu4ROUBLESHOOTINGh
)NTHEEVENTOFSKININJURIESCAUSEDBYPAINTORCLEANINGAGENTS
.OTEDOWNTHEPAINTORCLEANINGAGENTTHATYOUHAVEBEENUSING
#ONSULTADOCTORIMMEDIATELY
!VOIDDANGEROFINJURYTHROUGHRECOILFORCES
%NSURETHATYOUHAVEAlRMFOOTINGWHENOPERATINGTHESPRAYGUN
/NLYHOLDTHESPRAYGUNBRIEmYINANYONEPOSITION
2.2.2 EARTH THE UNIT
%LECTROSTATICCHARGESCANOCCURONTHEUNITDUETOTHEELECTROSTATICCHARGEANDTHEmOW
SPEEDINVOLVEDINSPRAYING4HESECANCAUSESPARKSANDmAMESUPONDISCHARGE
%NSURETHATTHEUNITISEARTHEDFOREVERYSPRAYINGOPERATION
%ARTHTHEWORKPIECESTOBECOATED
%NSURETHATALLPERSONSINSIDETHEWORKINGAREAAREEARTHEDEGTHATTHEYAREWEARING
ANTISTATICSHOES
7HENSPRAYINGWEARANTISTATICGLOVESTOEARTHYOURSELFVIATHESPRAYGUNHANDLE
2.2.3 MATERIAL HOSES
%NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS
%NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT
%NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE n -ANUFACTURER n 0ERMISSIBLEOPERATINGOVERPRESSURE n $ATEOFMANUFACTURE
4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN
-/HM
7
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
2.2.4 CLEANING
$EENERGIZETHEUNITELECTRICALLY
$ISCONNECTTHEPNEUMATICSUPPLYLINE
2ELIEVETHEPRESSUREFROMTHEUNIT
%NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM
PERATURE
4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON
CLEANINGAGENTSWITHAGUN
!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS
7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER
%ARTHTHECONTAINER
2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK
INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING
USED
4AKE THE SPECIlED PROTECTIVE MEASURES IN PARTICULAR WEAR SAFETY GOGGLES PROTECTIVE
CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY
5SEAMASKORBREATHINGAPPARATUSIFNECESSARY
&ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON
ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTION SWITCHEDON
7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS
2.2.6 TOUCHING HOT SURFACES
4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES
7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&
)DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh
/RDER.O
)NFORMATIONLABEL
3AFETYLABEL
2.3 CORRECT USE
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
/PERATETHEUNITONLYASANENTIREUNIT
$ONOTDEACTIVATESAFETYEQUIPMENT
5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
8
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
2.4 USE IN AN EXPLOSION HAZARD AREA
2.4.1 CORRECT USE
4HEUNITISSUITABLEFORWORKINGLIQUIDMATERIALSINACCORDANCEWITHTHECLASSIlCATIONINTO
EXPLOSIONCLASSES
CE:
Ex:
II:
2:
G:
IIB:
T4:
2.4.2 EXPLOSION PROTECTION IDENTIFICATION
As defined in the Directive 94/9/CE (ATEX 95), the unit is suitable for use in areas where there is an explosion hazard.
II 2G IIB T4
Communautés Européennes
Symbol for explosion protection
Unit class II
Category 2 (Zone 1)
Ex-atmosphere gas
Explosion class
Temperature class: maximum surface temperature < 135°C; 275°F.
2.4.3 MAX. SURFACE TEMPERATURE
Max. surface temperature: same as the permissible material temperature
Permissible ambient temperature: see under Technical data, Section 4.3.2
2.4.4 SAFETY REGULATIONS
Safe handling of WAGNER spray units
The maximum surface temperature of the pump can be reached if it runs dry.
Ensure that the pump is filled with sufficient working or cleaning medium.
Mechanical sparks can form if the unit comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the unit against steel or rusty iron.
Do not drop the unit.
Use only tools that are made of a permitted material.
Ignition temperature of the pumped material
Check that the ignition temperature of the pumped material is higher than the max. allowable surface temperature.
Medium supporting atomizing
To atomize the material, use only weakly oxidizing gases, e.g. air.
9
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
3URFACESPRAYINGELECTROSTATIC
$ONOTSPRAYUNITPARTSWITHELECTROSTATICEGELECTROSTATICSPRAYGUN
#LEANING
)FTHEREAREDEPOSITSONTHESURFACESTHEUNITMAYFORMELECTROSTATICCHARGES&LAMESOR
SPARKSCANFORMIFTHEREISADISCHARGE
2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY
5SEONLYADAMPCLOTHTOCLEANTHEUNIT
7!2.).'
'ASMIXTURESCANEXPLODEIFTHEREISANINCOMPLETELYlLLED
PUMP
$ANGERTOLIFEFROMmYINGPARTS
%NSURE THAT THE PISTON PUMP AND SUCTION SYSTEM ARE ALWAYS
COMPLETELYlLLEDWITHCLEANINGAGENTORWORKINGMEDIUM
$ONOTSPRAYTHEUNITEMPTYAFTERCLEANING
3)()??'"
10
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
3
PRODUCT LIABILITY AND WARRANTY
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
!SARESULTOFAN%#REGULATIONEFFECTIVEASFROM*ANUARYTHEMANUFACTURERSHALL
ONLYBELIABLEFORHISPRODUCTIFALLPARTSCOMEFROMHIMORAREAPPROVEDBYHIMANDIFTHE
DEVICESAREPROPERLYlTTEDOPERATEDANDMAINTAINED
)FOTHERMAKESOFACCESSORYANDSPAREPARTSAREUSEDTHEMANUFACTURER@SLIABILITYCOULDBE
FULLYORPARTIALLYNULLANDVOID
4HEUSAGEOFORIGINAL7!'.%2ACCESSORIESANDSPAREPARTSGUARANTEESTHATALLSAFETYRE
GULATIONSAREOBSERVED
3.2 WARRANTY
4HISUNITISCOVEREDBYOURWARRANTYONTHEFOLLOWINGTERMS
7EWILLATOURDISCRETIONREPAIRORREPLACEFREEOFCHARGEALLPARTSWHICHWITHINMONTHS
INSINGLESHIFTMONTHSINSHIFTORMONTHSINSHIFTOPERATIONFROMDATEOFRECEIPTBY
THE0URCHASERAREFOUNDTOBEWHOLLYORSUBSTANTIALLYUNUSABLEDUETOCAUSESPRIORTOTHE
SALEINPARTICULARFAULTYDESIGNDEFECTIVEMATERIALSORPOORWORKMANSHIP
4HETERMSOFTHEWARRANTYAREMETATOURDISCRETIONBYTHEREPAIRORREPLACEMENTOFTHE
UNITORPARTSTHEREOF4HERESULTINGCOSTSINPARTICULARSHIPPINGCHARGESROADTOLLSLABOUR
ANDMATERIALCOSTSWILLBEBORNEBYUSEXCEPTWHERETHESECOSTSAREINCREASEDDUETOTHE
SUBSEQUENTSHIPMENTOFTHEUNITTOALOCATIONOTHERTHANTHEADDRESSOFTHEPURCHASER
4HISWARRANTYDOESNOTCOVERDAMAGECAUSEDBY
5NSUITABLE OR IMPROPER USE FAULTY INSTALLATION OR COMMISSIONING BY THE PURCHASER OR A
THIRD PARTY NORMAL WEAR NEGLIGENT HANDLING DEFECTIVE MAINTENANCE UNSUITABLE COATING
PRODUCTS SUBSTITUTE MATERIALS AND THE ACTION OF CHEMICAL ELECTROCHEMICAL OR ELECTRICAL
AGENTSEXCEPTWHENTHEDAMAGEISATTRIBUTABLETOUS
!BRASIVE COATING PRODUCTS SUCH AS REDLEAD EMULSIONS GLAZES LIQUID ABRASIVES ZINC DUST
PAINTSANDSIMILARREDUCETHESERVICELIFEOFVALVESPACKINGSSPRAYGUNSNOZZLESCYLINDERS
PISTONSETC!NYWEARRESULTINGFROMTHEAFOREMENTIONEDCAUSESISNOTCOVEREDBYTHIS
WARRANTY
#OMPONENTSNOTMANUFACTUREDBY7AGNERARESUBJECTTOTHEWARRANTYTERMSOFTHEORIGI
NALMAKER
4HEREPLACEMENTOFAPARTDOESNOTEXTENDTHEWARRANTYPERIODOFTHEUNIT
4HEUNITSHOULDBEINSPECTEDIMMEDIATELYUPONRECEIPT
4OAVOIDLOSSWARRANTYANIYAPPARENTDEFECTSHOULDBENOTIlEDTOUSORTHEDEALERINWRI
TINGWITHINDAYSFROMDATEOFSALEOFTHEUNIT
4HERIGHTTOCOMMISSIONWARRANTYSERVICESTOATHIRDPARTYISRESERVED
7ARRANTYCLAIMSARESUBJECTTOPROOFOFPURCHASEBYSUBMITTINGANINVOICEORDELIVERYNOTE
)FANINSPECTIONlNDSDAMAGENOTCOVEREDBYTHEPRESENTWARRANTYTHEREPAIRWILLBECAR
RIEDOUTATTHEEXPENSEOFTHEPURCHASER
.OTETHATTHISWARRANTYDOESNOTINANYWAYRESTRICTLEGALLYENTITLEDCLAIMSORTHOSECONTRAC
TUALLYAGREEDTOINOURGENERALTERMSANDCONDITIONS
*7AGNER!'
11
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
3.3 CE-CONFORMITY
Herewith we declare that the supplied version of:
Pneumatic pump with article no.:
Mod. Unica 4-270
U580.00
Unica 4-270 .
Complies with the following provisons apllying to it:
98/37/CE
Applied standards, in particular:
94/9/CE Atex-directives
UNI EN 292-1
UNI EN 292-2
UNI EN 563
UNI EN 809
UNI EN 1050
UNI EN ISO 3746
UNI EN 1127-1
EN 12621
UNI EN ISO 13463-1
Marking:
II 2G IIB T4
%##ERTIlCATEOF#ONFORMITY
4HECERTIlCATEISENCLOSEDWITHTHISPRODUCT4HECERTIlCATEOFCONFORMITYCANBEREORDERED
FROMYOUR7!'.%2REPRESENTATIVEQUOTINGTHEPRODUCTANDSERIALNUMBER
0ARTNUMBER
Unica 4-270 ZDI.15
12
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
4
DESCRIPTION
4.1 FIELD OF APPLICATION
4.1.1 USING IN ACCORDANCE WITH THE INSTRUCTIONS
The pneumatic diaphragm pump can be used with various fl uids. Before proceding to use the pump with a certain fl uid, make sure that the compatibility between said fl uid and the materials used for the fl uid unit (Paragraph 4.3.1) is given.
#!54)/.
!BRASIVEMATERIALSANDPIGMENTS
'REATERWEAROFTHEPARTSCARRYINGTHEMATERIAL
5SESUITABLECOMBINATIONSOFDEVICESPACKAGESVALVESETC
3)()??'"
4.1.2 EXAMPLES OF APPLICATION AREAS
The main use of the Unica 4-270 pump is for transfering liquids inside the service circuit.
Other typical applications are given below.
Application
Furniture industry
Kitchen manufactures
Joinery
Wooden hood manufacturers
Metal industries
Legend recommended
➚
Unica 4-270
➚
➚
➚
➚
➟ limited suitability
➟ less suitable
➘
13
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
4.2 EXTENT OF DELIVERY
Double-diaphragm pneumatic pump composed of:
- Integrated pneumatic motor
- Pumping stage
CE-conformity see
Operating manual in english
Operating manual for the other language see
The delivery note shows the exact scope of delivery.
Accessories: see chapter 7.
Chapter 3.3
Part No.: ZZB006ENG
Chapter 1.1
Unica 4-270 .
4.3
DATA
4.3.1 MATERIALS USED FOR COMPONENTS IN CONTACT WITH THE PRODUCT
Suction ducts
Valves balls
Valves seats
Valve bodies
Stainless steel EN 1.4301 (X 5 CrNi 18-10, AISI 304)
Stainless steel EN 1.4028 (X 30 Cr 13, AISI 420)
Stainless steel EN 1.4301 (X 5 CrNi 18-10, AISI 304)
Acetal (POM)
Diaphragms PTFE
O-rings PTFE
14
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
4.3.2 TECHNICAL DATA
Description
Transmission ratio
Flow volume per double stroke (DS)
Max. operating pressure
Max. peak pressure cm³ (cc)
MPa bar psi
MPa bar psi
4,5 :1
270
2,7
27
391.6
3
30
435.1
Max. recommended operating speed
Min. - Max. air inlet pressure
Ø air inlet connection (male)
DH/min
DC/min
MPa bar psi
Zoll
Inch mm
Inch
22
0.2-0.6
2-6
29-87
G 1/2“
Min. Ø compressed air hose 13
0.512
16 Air consumption at 0.6 MPa; 6 bar; 87 psi per DS
Noise level* with max. allowable air supply pressure
Ø piston of air motor
Material inlet connection (female)
Material outlet connection (female)
Weight
Material pH value
Max. material pressure at pump inlet nl scf dB(A) mm
Inch
Zoll
Inch
Zoll
Inch kg lb pH
MPa bar psi
77.5
200
8.0
G 3/4“
G 3/4“
46
101.2
3.5 ÷ 9
2
20
90
Range of material temperature
Range of the ambient temperature
°C; F
°C; F
+5° ÷ +80°;
(+41 ÷ +176)
+4° ÷ +40° ;
(+39.2 ÷ +104)
± 10 Allowable sloping position at work <) °
Necessary fl uid quantity l 0.7
* A rated sound pressure level measured at 1m distance according to UNI EN ISO 3746-
1997.
15
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
7!2.).'
/UTGOINGAIRCONTAININGOIL
2ISKOFPOISONINGIFINHALED
&UNCTIONPROBLEMAIRMOTOR
0ROVIDEWATERFREEANDOILFREECOMPRESSEDAIRQUALITYSTANDARD
ASPER)3/ MMGMÃ
3)()??'"
16
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
4.3.3 DIMENSIONS AND CONNECTIONS
A
B
C
D
E
F
Unica 4-270 mm; inch
362; 14.3
83; 3.3
422; 16.6
180.5; 7.1
171.5; 6.8
384; 15.1
G
H
J
I
K
L
Unica 4-270 mm; inch
209; 8.2
164; 6.5
412; 16.2
G 3/4“
G 3/4“
G 1/2“
A
I
B
D E
J
G
Unica 4-270 .
K
L
17
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
4.3.4 PERFORMANCE DIAGRAMS
Example
4 bar
Stroke frequency DS/min
6 bar
6 bar
4 bar
2 bar
2 bar
C_41_00003
Material fl ow volume water l/min <gpm>
Diagram Unica 4-270
Stroke frequency DS/min bar (MPa)
<psi>
0
30 (3)
<435>
A
10 20 30 40
22.5 (2.25)
<326>
15 (1.5)
<218>
B
50 nl/min
<scfm>
A
60
1000
<35>
750
<26.5>
B
500
<17.7>
C
7.5 (0.75)
<109>
C
250
<8.8>
0
0 2.8
<0.74>
5.6
<1.48>
8.4
<2.22>
11.2
<2.96>
14.0
<3.70>
16.8
<4.44>
0 l/min
<gpm>
Material fl ow volume water
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
18
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
4.4 FUNCTIONING
4.4.1 PUMP
1 Product delivery manifold
2 Product suction manifold
3 Reversing valve unit
4 Compressed air inlet fi tting
5 Pneumatic motor protection
5
1
8 Product inlet fi tting
9 Product outlet fi tting
3
10
4
2
Generalities
The double-diaphragm pump is operated by a compressed-air reciprocating engine. The diaphragm movement inside the fl uid section (6) is obtained by a hold-and-grasp system that makes them integral with the motor stem.
At the end of each phase the compressed air is directed to the opposite chamber by dedicated commutating valves named feelers. The motor has a tandem confi guration: two pistons simultaneously push the pump stem.
During each stem stroke, the paint is sucked and pumped into the delivery ducts at the same time.
Pneumatic motor
Thanks to its inversion system (3) the pneumatic motor needs no lubrication. The compressed air supply is obtained by a pressure controller and a ballcock available on request with the pump.
The pneumatic motor is equipped with a safety valve containing a pre-loaded spring. The safety valve is mounted and calibrated in the factory. When the pressure exceeds the max. allowed operating value, the valve opens and discharges the exceeding pressure.
Safety valve
Besides having the aim to limit the max. inlet pressure of compressed air into the pneumatic motor, the safety valve (10) also serves as a depressurizing valve for the motor. To depressurize the motor, just pull the dedicated exhaust ring with closed ballcock (part n°3 in the diagram in Paragraph 4.4.2).
The ring on the safety valve also allows to check the good performance of the valve itself.
Use the safety valve ring to depressurize the pneumatic motor, in addition to the pressure outlet procedure in the fl uid side.
Depressurize the pneumatic motor before any pump disassembly or maintenance work.
9
6
7
8
19
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
WARNING
Overpressure!
Risk of injury from bursting components.
Frequently check the safety valve efficiency by pulling the ring.
C_SIHI_0026_GB
Fluid section
The fl uid section has been designed to work as a double-diaphragm pump with interchangeable suction and delivery valves.
4.4.2 AIR SUPPLY UNIT (OPTIONAL)
2 Control air gauge
3 Motor air shut-off cock
3
1
2
20
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
5
STARTING UP AND OPERATING
5.1 INSTALLATION AND CONNECTION
The Unica 4-270 diaphragm pum can be wall-mounted or fl oor-mounted.
For a diagram of the tipical installations, see Paragraph 5.1.6. The diagram does not represent the most suitable solution in all situations and is given as mere example. Please apply to a Wagner authorised engineer for further information about the best mounting solution for each user’s special needs.
To make pump operation and maintenance easier install the device so that the pneumatic supply inlet and the pneumatic supply/suction fi ttings of the pump are easily accessible.
Install the pump in a horizontal position.
For support to integrate the pump in a pre-existing plant or for a customised location, please apply to a Wagner authorised engineer.
Always use original Wagner spare parts.
5.1.1 PUMP WALL-INSTALLATION
The Unica 4-270 pump installation kit for wall-mounting can be supplied on request.I
Part number:
Wall mounting kit: T6151.00
For information regarding the kit contents and assembling, please see the relevant paragraph in chapter 7 - Accessories.
5.1.2 PUMP INSTALLATION ON GROUND FRAME
The Unica 4-270 pump installation kit on a ground frame can be supplied on request.
Part number:
Ground frame kit: T6148.00
For information regarding the kit contents and assembling, please see the relevant paragraph in chapter 7 - Accessories.
WARNING
Inclined surface!
Risk of accidents if the unit rolls away/falls.
Place the frame with the pump horizontally.
Lock the frame.
C_41_SIHI_0012_GB
21
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
5.1.3 COMPRESSED AIR SUPPLY CIRCUIT
Firmly install all components of the compressed air supply circuit, by anchoring them on a wall or frame. Make sure the system is correctly connected to a grounding terminal.
Install a general air shut-off valve (A), o that the compressed air fl ow in the supply circuit can be controlled.
Mount a compressed air line fi lter (B). Its function is to remove eventual dirt and condensate residues from the supply line.
Connect the S462.00A hose to the high-pressure special control fi tting (L) on the pneumatic inlet of the Unica 4-270 pump before the pressure controller.
Install a pressure controller (C) on the pump regulating the pressure of the air entering the pneumatic motor and allowing to choose the desired running speed. The Unica 4-270 pump conveys the working fl uid a pressure of 4.5 times the supply air pressure, with peak pressure values of 30 bar.
Install a motor air shut-off valve (D) downstream the pressure controller: this allows to open/shut off the air fl ow supplying the pneumatic motor.
5.1.4
SUCTION CIRCUIT
Use electrically conductive pipes (see Paragraph 2.2.3).
Connect the working fl uid suction system to the pump by means of a system of pipes and fi ttings (E). For the correct pump inlet thread diameters, please see Paragraph 4.3.2 - Technical Data. Use a systm of pipes suitable for the working conditions.
Make sure that the height difference between the product level in the tank and the pump suction unit does not exceed the max. allowed suction height given for the pump (see
Paragraph 4.3.2 - Technical Data).
5.1.5 DELIVERY CIRCUIT
Use electrically conductive pipes (see Paragraph 2.2.3).
Connect the pump to the delivery circuit through a system of pipes and fi ttings (F).For the correct pump outlet thread diameters, please see paragraph 4.3.2 - Technical Data.
Install a purge valve (G) for the fl uid, which allows to easily release the remaining pressure inside the system in case the working session stops. The risks deriving from an unattended system under pressure are thus reduced.
Install a product shut-off valve (H) allowing to isolate the pump from the service circuit.
22
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
5.1.6 EXAMPLE OF TYPICAL INSTALLATION
A
Unica 4-270 .
B
H
F
G
E
D
S462.00A
L
C
I
23
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
5.1.7 EARTHING
7!2.).'
$ISCHARGE OF ELECTROSTATICALLY CHARGED COMPONENTS IN ATMO
SPHERESCONTAININGSOLVENTS
%XPLOSIONHAZARDFROMELECTROSTATICSPARKS
#LEANTHEPISTONPUMPONLYWITHADAMPCLOTH
3)()??'"
7!2.).'
(EAVYPAINTMISTIFEARTHINGISINSUFlCIENT
2ISKOFPOISONING
)NSUFlCIENTPAINTAPPLICATIONQUALITY
%ARTHALLUNITCOMPONENTS
%ARTHTHEWORKPIECESBEINGPAINTED
3)()??'"
Earthing schema (example per painting applications)
Conveyor
Workpiece
C_41_00007
Pump
Paint container
R max < 1 M
Ω
Spraying stand
Anti-static fl oor
24
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
Cable cross sections
Pump
Paint container
Conveyor
Spraying booth
Spraying stand
4 mm²; AWG 11
6 mm²; AWG 10
16 mm²; AWG 5
16 mm²; AWG 5
16 mm²; AWG 5
Procedure:
1. Screw on earthing cable with eye.
2. Clamp the earthing cable clip to a earth connection on site.
3. Earth the material (paint) container to a local earth connection.
4. Earth the other parts of the system to a local earth connection.
Unica 4-270 .
25
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
5.2 START UP
5.2.1 SAFETY REGULATIONS
Every time before starting up the following points should be observed as laid down in the operating instructions:
- That it is possible to observe the safety regulations in Chap. 2.
- The starting up procedure, has been carried out properly.
7!2.).'
(IGHPRESSURESPRAYJET
$ANGERTOLIFEFROMINJECTINGPAINTORSOLVENT
.EVERREACHINTOTHESPRAYJET
.EVERPOINTTHESPRAYGUNATPEOPLE
#ONSULTADOCTORIMMEDIATELYINTHEEVENTOFSKININJURIESCAUSED
BYPAINTORSOLVENT)NFORMTHEDOCTORABOUTTHEPAINTORSOLVENT
USED
.EVER SEAL DEFECTIVE HIGHPRESSURE PARTS INSTEAD RELIEVE THE
PRESSUREFROMTHEMANDREPLACE
3)()??'"
7!2.).'
4OXICANDORmAMMABLEVAPORMIXTURES
2ISKOFPOISONINGANDBURNS
/PERATETHEUNITINASPRAYINGBOOTHAPPROVEDFORTHEWORKING
MATERIALS
OR
/PERATETHEUNITONANAPPROPRIATESPRAYINGWALLWITHTHEVENTI
LATIONEXTRACTION SWITCHEDON
/BSERVE NATIONAL AND LOCAL REGULATIONS FOR THE OUTGOING AIR
SPEED
3)()??'"
7!2.).'
'ASMIXTURESCANEXPLODEIFTHEREISANINCOMPLETELYlLLED
PUMP
$ANGERTOLIFEFROMmYINGPARTS
%NSURE THAT THE PISTON PUMP AND SUCTION SYSTEM ARE ALWAYS
COMPLETELYlLLEDWITHCLEANINGAGENTORWORKINGMEDIUM
$ONOTSPRAYTHEUNITEMPTYAFTERCLEANING
3)()??'"
26
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
Before every start-up, the following points should be observed as laid down in the operating manual:
- Check the permissible pressures
- Check all connections for leaks
- Check hose for damage
It should be ensured that the unit is in the following state before carrying out any work on it:
- Interrupt compressed air supply.
- Depressurise the pump and the product delivery circuit.
Emergency stop
In case of unexpected events, it is necessary to immediately close the compressed air supply and discharge the pressure from the pump service circuit.
27
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
5.2.2 PRESSURE RELEASE PROCEDURE
1. Interrupt the pump compressed air supply.
2. Open the usage and discharge the remaining pressure inside the pump and circuit.
3. To guarantee a complete depressurisation of the pneumatic motor, pull the ring on the safety valve (see Paragraph 4.4.1).
5.2.3
PUMP WASHING
The Unica 4-270 pump is tested in the factory with oil.
In case eventual testing fl uid residues may contaminate the working material, carry out a preliminary washing using a solvent compliant with the product. To perform the washing follow the instructions in the following paragraph, considering the solvent instead of the working material.
5.2.4 FILLING WITH WORKING FLUID
In this description reference is made to the exemplifying diagram given in Paragraph
5.1.6.
1. Make sure the pump is correctly connected to a grounding terminal. Please see
Pragraph 5.1.7 - “Grounding” for further informaion.
2. Check the tightness of all fi ttings and make sure they are tight enough.
3. Connect the pump suction duct to the tank with the working fl uid (I). For example, if a drip-in pipe is used, dip it in the barrel of the product to be pumped.
4. Connect the pump delivery duct to the usage. If a washing is in progress, direct the product outlet pipe into the container collecting the solvent.
5. Close the pump air pressure controller (C) , pressurise the compressed air supply line and open the air shut-off valve on the pump (D).
6. Slowly open the air pressure controller on the pump (C) until it starts to work. Have the pump work slowly until all the air left inside the suction and delivery circuits has been discharged. Continue until the pump has correctly primed.
7. Only if the pump is being washed with solvent, have it cycle until the clean solvent fl ows inside the delivery circuit. Then close the pump air pressure controller (C).
5.2.5 PUMP STOP
For a short-term stop, perform the pressure release procedure (Paragraph 5.2.2).
For a permanent stop, such as for example an overnight standstill:
1. Clean the pump fl uid section by washing it with a compliant solvent.
2. Leave the solvent inside the pump fl uid section.
3. Perform the pressure release procedure (Paragraph 5.2.2).
For a stop preceding maintenance or disconnection of the pump, see the instructions given in Paragraph 5.3.
28
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
5.3 FINISHING WORK AND CLEANING
Note
The device should be cleaned for maintenance purposes, etc. Ensure that no remaining material dries and sticks.
Procedure:
1. Follow the procedure foreseen to stop the pump -> chapter 5.2.5
2. Follow the procedure foreseen for washing -> chapter 5.2.3.
3. Clean and check the suction system and, in particular, the suction fi lter.
4. When using a high-pressure fi lter: Clean and check the fi lter insert
5. Clean the outside of the system.
7!2.).'
"RITTLElLTERPRESSUREREGULATOR
4HE CONTAINER ON THE lLTER PRESSURE REGULATOR BECOMES BRITTLE
THROUGHCONTACTWITHSOLVENTSANDCANBURST
&LYINGPARTSCANCAUSEINJURY
$ONOTCLEANTHECONTAINERONTHEPRESSUREREGULATORWITHSOL
VENT
3)()??'"
6. Fill the system with detergent following the instructions given in paragraph 5.2.4
“Filling with working fl uid”.
7!2.).'
'ASMIXTURESCANEXPLODEIFTHEREISANINCOMPLETELYlLLED
PUMP
$ANGERTOLIFEFROMmYINGPARTS
%NSURE THAT THE PISTON PUMP AND SUCTION SYSTEM ARE ALWAYS
COMPLETELYlLLEDWITHCLEANINGAGENTORWORKINGMEDIUM
$ONOTSPRAYTHEUNITEMPTYAFTERCLEANING
3)()??'"
5.4
STORING FOR LONGER PERIODS OF TIME
When storing the device for longer periods of time it is necessary to thoroughly clean it and protect it from corrosion. Replace the water or the solvent in the pump delivery circuit with a suitable preservative oil.
Procedure:
1. Carry out Paragraph 5.3 „Shutting down and cleaning“, points 1 through 6.
2. Fill the system with conservative liquid following the instructions given in paragraph
5.2.4.
3. Protect the air motor with pneumatic oil: connect an oiler to the compressed air inlet and run for a few double strokes.
29
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
6
FAULT LOCATION, MAINTENANCE AND REPAIR
6.1 TROUBLE SHOOTING AND SOLUTION
Problem
The pump does not work
Cause Solution
• Air motor does not work or stops • Open and close ball valve on the pressure regulator unit or disconnect compressed air supply shortly
• No pressure indication (pressure regulator defect)
• Disconnect the compressed air supply for a short time or repair or replace the pressure controller.
• Clean nozzle as laid down in the instructions
• In painting applications, obstruction of the spraying nozzle
• Insuffi cient supply of compressed air
• In painting applications, obstruction of the cartidge fi lter inside spray gun or of the highpressure fi lter
• Overhaul the pneumatic delivery plant
• Clean the parts and use a suitable working material
• Obstruction of the pump fl uid section or of the high-pressure pipes (for example, hardened products inside the delivery pipes)
• Lack/excess of grease inside the reversing valve spool (the pneumatic motor stops at end stroke)
• Dismantle the pump and clean, replace high-pressure hose
• Grease/remove grease in excess. Check the reversing valve body.
• Please see instructions for use of the spraying device (for example, a spraygun) In painting applications, unsatisfactory spraying quality
IMPORTANT:
In all cases where pump parts or pressurized pipes need to be disassembled, follow the pressure release procedure as described in Paragraph 5.2.2 before performing maintenance.
30
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
Trouble shooting and solution
Problem
Irregular working cycle of the pump; in painting applications the material jet gives away (pulsation)
Cause
• Excessive material viscosity
• Spraying pressure to low
Solution
• Dilute working material
• Increase air inlet pressure, without ever exceeding the max. value on plate. Use smaller nozzle.
The pump works regularly but does not suck the working fl uid
• Product valves lock
• Foreign body in suction valves
• Clean pump fl uid section, if necessary let the detergent act inside it for some time.
• Remove the obstructed suction valves, clean and check the valve seats.
• Insuffi cient diameter of compressed air supply pipe
• Mount a pneumatic supply pipe with larger diameter -> technical data, paragraph 4.3.2
• Worn valves, seals or diaphragms • Replace the worn components
• Obstructed control air fi lter or working air fi lter.
• The connections on the suction system leak and the pump sucks air
• Obstructed suction fi lter
• Check fi lters and if necessary clean them
• Tighten the fi ttings and remove leaks
• Clean fi lter
• Obstructed suction valves
Packings, valves worn
• Clean the pump fl uid section with detergent and if necessary let the detergent act for some time (in case, purge the device)
Replace parts Pump runs when the gun is closed
Loss of power due to ice formation in the pneumatic motor
Presence of large quantities of condensate in the compressed air supply circuit
Install a drier in the compressed air supply circuit or, if already existinig, check its performance
IMPORTANT:
In all cases where pump parts or pressurized pipes need to be disassembled, follow the pressure release procedure as described in Paragraph 5.2.2 before performing maintenance.
If the problem is not listed above consult your WAGNER Service Center.
31
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
6.2 MAINTENANCE
7!2.).'
)NCORRECTMAINTENANCEREPAIR
$ANGERTOLIFEANDEQUIPMENTDAMAGE
/NLYA7!'.%2SERVICECENTERORASUITABLYTRAINEDPERSONMAY
CARRYOUTREPAIRSANDREPLACEPARTS
/NLYREPAIRANDREPLACEPARTSTHATARELISTEDINTHECHAPTER3PARE
PARTSCATALOG
"EFOREALLWORKONTHEUNITANDINTHEEVENTOFWORKINTERRUP
TIONS
$ISCONNECTTHECONTROLUNITFROMTHEMAINS
2ELIEVETHEPRESSUREFROMTHESPRAYGUNANDUNIT
3ECURETHESPRAYGUNAGAINSTACTUATION
/BSERVETHEOPERATINGANDSERVICEINSTRUCTIONSWHENCARRYING
OUTALLWORK
3)()??'"
6.2.1 LUBRICATION
No lubrication is required for the pneumatic motor. An excessive lubrication may cause system failure.
Regularly check the condition of compressed air fi lters mounted on the pneumatic motor pilot system (parts nr. 25 in the diagram in Paragraph 8.3). Replace them if necessary.
6.2.2 WASHING AND STORING
Before stopping the pump for a period of time in which the fl uid may harden inside the curcuit and damage the system, carry out a washing with compliant solvent. Please see
Paragraph 5.3 “Disconnection and cleaning” for the relevant procedure.
6.2.3 REGULAR CHECK OF SEALING AND TIGHTNESS
Before each usage of the pump :
1. Make sure that all fl uid conveying pipes have no wear signs o damages. Replace them if necessary.
2. Check sealing and tightness of all threaded fi ttings. Make sure there are no leaks.
Check screws tightness at least once every two months. Please see this manual for information about the correct tightening torques.
6.2.4 PLAN OF PREVENTIVE MAINTENANCE
Work out a plan of preventive maintenance including the above checks, basing on the usage history of the pump. The wear of components depends on the using conditions. It is important to replace the parts subject to wear (e.g. valve seats or membranes) in due time, in order not to have the system damaged, which can be avoided by means of a plan of preventive maintenance.
32
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
6.3 PUMP REPAIR
Before carrying out any maintenance measure:
1. Possibly wash the pump fl uid section(see Paragraph 5.2.3)
2. Release the pressure inside the pump following the procedure described in Paragraph
5.2.2.
3. Disconnect the pump from the compressed air supply line and disconnect the fl uid section from the external suction and service circuits.
4. Remove the pump from the installation site and take it to a suitable place for the maintenance work.
How to carry out a repair
Ordinary and extraordinary maintenance is to be carried out according to the schemes and procedures given in this manual for Use and Maintenance,
In all cases:
1. Apply to a Wagner authorised engineer.
2. Use only Wagner original spare parts.
3. Before assembling parts, make sure they are clean and, if necessary, lubricated.
4. Avoid damaging gasket sealing surfaces during maintenance.
5. Whenever the pump is assembled, replace all o-rings in the fl uid section whcih have already been subject to previous tightening.
6. Avoid using silicone-based or silicone-contanining lubricants.
6.3.1
MAINTENANCE OF THE HYDRAULIC CIRCUIT
The Unica 4-270 pump includes a fl uid-mechanical conservation system granting the best possible performance of the diaphragms under normal working conditions.
The hydraulic circuit is normally full of working fl uid fi lled in the factory. The safety card of the working fl uid can be supplied on request
Before carrying out any maintenance involving the hydraulic circuit, the working fl uid is to be extracted as described in Paragraph 6.3.1.1.
The quantity of working fl uid necessary to fi ll the circuit is about 1 l. It is advisable to use only Wagner spare fl uid:
Order number
Hydraulic fl uid Unica 4-270 pump (1-litre bottle) Z126.00
The fl uid-mechanical system inside the hydraulic circuit needs no maintenance and the circuit doesn’t usually need disassembling. The need to disassemble it may arise in case it is necessary to add parts inside the pump which are subject to maintenance.
If lacking Wagner spare fl uid after carrying out the maintenance, it is possible to temporarily fi ll the hydraulic circuit with water; however, it is advisable to replace it with Wagner working fl uid soonest possible. For further information please apply to a Wagner authorised engineer.
An explanatory picture is given below.
The assembling diagram of the hydraulic circuit is given in Paragraph 8.4.
33
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
Unica 4-270 .
Cap
Outlet valve
Working fl uid
34
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
6.3.1.1 OPERATIONS ON THE HYDRAULIC CIRCUIT DURING MAINTENANCE
• If the pump is subject to maintenance regarding the fl uid section not implying disassembling the diaphragm covers (parts °16 given in the diagram in Paragraph 8.5), the hydraulic circuit system does not undergo any particular changes and the following operations are not necessary.
• If the maintenance in the fl uid section concerns components whose access to or disassembly of require disassembling the pump covers (diagram Paragraph 8.5), then the following operations to empty and fi ll up the hydraulic circuit with working fl uid are necessary.
• If the maintenance concerns the pneumatic motor or the hydraulic circuit itself, the following operations are necessary.
WARNING: the best possible performance of the vacuum system inside the hydraulic circuit is important to guarantee the longest possible life of the membranes. The following operations are hence to be carried out only by Wagner authorised engineers.
6.3.1.2
HYDRAULIC CIRCUIT EMPTYING
Referring to the assemblying diagram in Paragraph 8.4:
1. Get a container to collect the hydraulic fl uid and place it under the pump.
2. Disconnect pipe nr. 17 from quick coupling nr. 10 and extract the hydraulic fl uid collecting it in the dedicated container. Dispose of the fl uid in compliance with the local law regulation.
6.3.1.3 HYDRAULIC CIRCUIT FILLING
After maintenance, remount the various pump sections except the outer protections (parts
3 and 4 in the diagram in Paragraph 8.2), connect the pump to the compressed air supply line, see diagram given in Paragraph 8.4 and proceed as follows:
1. Unscrew caps nr. 11 and valve bodies nr. 12.
2. Fill the pump hydraulic circuit with working fl uid.
3. Completely close the pump air pressure reducer and open the motor air shut-off valve (parts C and D, diagram in
Paragraph 5.1.6).
4. Paying great attention to squirts, slowly open the air pressure reducer and run one/two cycles of the pneumatic motor. Then close the pressure controller. This operation allows emptying the residual air in the hollows of the hydraulic circuit.
5. Refi ll the hydraulic circuit with working fl uid.
6. Remount valves nr. 12.
7. Run the pump for about one minute, collecting the excess hydraulic fl uid discharged by valves nr. 12 in the previously used container.
8. Remount caps nr. 11 and the rest of the pump.
11
12
D
C
35
EDITION 04 /2007
OPERATING MANUAL
7
ACCESSORIES
7.1 WALL MOUNTING KIT
PART NO. ZZB006ENG
Unica 4-270 .
4
3
2
1
Pos .
K Qty. Description
Wall mounting kit
1
2
4 Washer
2 Wall bracket
3 4 Contact washer
4 4 M8x20 screw
◆ = Wearing part
No.
T6151.00
K509.62
E3239.62
K572.62
K120.62
36
EDITION 04 /2007
OPERATING MANUAL
7.2 STAND KIT
PART NO. ZZB006ENG
Unica 4-270 .
3
2
1
Pos .
K Qty. Description
Stand kit
1
2
2
8
Stand frame
Contact washer
3 8 M8x70 screw
◆ = Wearing part
No.
T6148.00
E3238.92
K572.62
K193.62
37
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
7.3 COMPRESSED AIR SUPPLY KIT
Unica 4-270 .
Pos .
K Qty. Description
Compressed air supply kit
1
2
1
1
Air cut-off valve
Nipple
3
4
1 Pressure regulator
1 Reduction unit
5 1 Pressure gauge
6 1 Hose nylon d4 L=370 mm
◆ = Wearing parts
1
2
5
4
3
No.
T6152.00
M104.00
M206.04
9999312
M203.04
P903.00
S462.00A
6
38
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
8
SPARE PARTS
8.1 HOW TO ORDER SPARE PARTS
!LWAYSSUPPLYTHEFOLLOWINGINFORMATIONTOENSUREDELIVERYOFTHERIGHTSPAREPART
0ART.UMBERDESCRIPTIONANDQUANTITY
4HEQUANTITYNEEDNOTBETHESAMEASTHENUMBERGIVENINTHEu1UANTITYhCOLUMN4HIS
NUMBERMERELYINDICATESHOWMANYOFTHERESPECTIVEPARTSAREUSEDINEACHSUBASSEMBLY
4HEFOLLOWINGINFORMATIONISALSOREQUIREDTOENSURESMOOTHPROCESSINGOFYOURORDER
!DDRESSFORTHEINVOICE
!DDRESSFORDELIVERY
.AMEOFTHEPERSONTOBECONTACTEDINTHEEVENTOFANYQUERIES
4YPEOFDELIVERYREQUIREDAIRFREIGHTORMAILSEAROUTEOROVERLANDROUTEETC
-ARKSINSPAREPARTSLISTS
.OTETOCOLUMNu+hINTHEFOLLOWINGSPAREPARTSLISTS
U 7EARINGPARTS
.OTE.OLIABILITYISASSUMEDFORWEARINGPARTS
L .OTPARTOFSTANDARDEQUIPMENTAVAILABLEHOWEVERASADDITIONALEXTRA
7!2.).'
)NCORRECTMAINTENANCEREPAIR
2ISKOFINJURYANDDAMAGETOTHEEQUIPMENT
2EPAIRSANDPARTREPLACEMENTMAYONLYBECARRIEDOUTBYSPE
CIALLYTRAINEDSTAFFORA7!'.%2SERVICECENTER
"EFOREALLWORKONTHEUNITANDINTHEEVENTOFWORKINTERRUP
TIONS
3WITCHOFFTHEENERGYCOMPRESSEDAIRSUPPLY
2ELIEVETHEPRESSUREFROMTHESPRAYGUNANDUNIT
3ECURETHESPRAYGUNAGAINSTACTUATION
/BSERVETHEOPERATINGANDSERVICEINSTRUCTIONSWHENCARRYING
OUTALLWORK
3)()??'"
39
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
Unica 4-270 .
40
EDITION 04 /2007
OPERATING MANUAL
8.2 OVERVIEW MODULES
1
PART NO. ZZB006ENG
1
2 (*)
3
2 (**)
Hydraulic circuit
(Ref. Par. 6.3.1) 1
Fluid section
1
(*)
Unica 4-270 .
(**)
Fluid section
Air motor
1
2 (*)
1
2 (**)
4
1
1
Pos .
K Qty. Description
1 16 5x8 screw
2
3
8
1
Contact washer
Pump upper protection
4 1 Pump lower protection
◆ = Wearing parts
No.
K1072.03
K571.62
E3235.71
E3236.71
41
EDITION 04 /2007
OPERATING MANUAL
8.3 AIR MOTOR
PART NO. ZZB006ENG
1
2
3 a)
4
6
4
(*)
14+15
14+15
Unica 4-270 .
25+14+22
20 a)
50 Nm; 37 lbft
15 Nm; 11.1 lbft
24
10 11
(*)
19(***)
8
7 14
15
14
14 22
14+15
17
18+17
18+21
25+16+22+22
14+15
(***) (**)
18
25
22
19(**)
16
5 a)
3 a)
50 Nm; 37 lbft
20 a)
1
2
13
26
9 7
12
24
15 Nm; 11.1 lbft
14
15
14
4
6
4
23
27
28
18
23
21 a) Apply a small quantity of grease
42
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
12
13
14
15
10
11
8
9
6
7
4
5
Pos .
1
2
3
20
21
22
23
16
17
18
19
24
25
26
27
28
K
◆ ★
◆ ★
◆ ★
◆
◆
◆ ★
◆ ★
◆ ★
Qty. Description
2 Motor piston
2 NBR O-Ring seal
2 NBR O-Ring seal
4 NBR O-Ring seal
1 Motor rod
2 Motor cylinder
4 Muffl er
1 Motor body
1 Reversing valve unit ISO 3
1 Air inlet block
1 NBR O-Ring seal
1 Conical nipple 1/2”
4 M8x75 SS Socket screw
5 Fast fi tting L 1/8x4
2 Hose nylon d4 L=130 mm
1 Fast fi tting T 1/8”x4
1 Hose PU d14x10 L=210 mm
2 Fast fi tting L 1/2x14
2 Lip seal
2 Pump rod
1 Hose PU d14x10 L=610 mm
1 Hose nylon d4 L=370 mm
Loctite 542
50ml; 50cc
1
2
1
1
1
Pneumatic feeler
Filter
Safety valve
Air fi tting 1/2”
Fitting M5x4
Pneumatic motor service set
◆
★
= Wearing parts
= Included in motor service set T9089.00
No.
B0329.01
L115.06
L224.06
L145.06
D449.03
D635.12
H527.07
F1012.01
P497.00A
B0330.71A
L105.06
M206.04
K106.62
M335.00
S462.00
M348.00
S463.00
M415.00
L481.06
D450.03
S463.00A
S462.00A
Z201.00
T714.00
0367314
P484.00C2
M428.00
M303.00
T9089.00
Unica 4-270 .
43
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
8.3.1 PNEUMATIC FEELER
PART NO. ZZB006ENG
10
1
2
3
4
3
4
1
2
Spare parts list
Feeler
Pos .
K Qty. Description
Pneumatic feeler
◆ ★
◆ ★
1
1
1
1
Feeler cap
NBR O-Ring seal
Seal gasket
Feeler rod
7
8
5
6 ◆ ★
◆ ★
1
1
1
1
Feeler body
NBR O-Ring seal
Seal gasket
Feeler shutter
9 1 Feeler spring
10 Loctite 542
50ml; 50cc
◆
★
= Wearing parts
= Included in motor service set T9089.00
5
6
7
8
9
No.
T714.00
B0331.04
L118.06
L420.06
B0333.03
B0332.04
L230.06
G602.06
A144.04
H202.03
Z201.00
44
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
8.3.2 REVERSING VALVE
PART NO. ZZB006ENG
1
2
3
4
5
6
7
8
9
6
10
3
11
1
C_41_00022
Spare parts list
Reversing valve
9
10
11
12
13
Pos K Qty. Description
Reversing valve
1
2
3
4
4
1
2
1
Socket screw
Rod cover
Cover seal gasket
O-Ring seal
5
6
7
8
1
2
1
6
Rod
Damper
Valve body
O-Ring seal
1 Spool assembly
1 Detent
1 Detent cap
1 Valve seal gasket
1 Pos. seal gasket set 3,4,6,8,12
12
No.
P497.00A
K183.62
B0055.71A
G7010.07B
L172.06
B0049.04B
P519.00A
B0053.71A
L199.06
P519.00B
P519.00E
B0054.71A
G737.06BA
T9076.00A
13
45
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
8.4 HYDRAULIC CIRCUIT
1
55 Nm; 40.7 lbft
5
2
18
6
7
8
9 (**)
3
4
10
11
12
13
14
15
Part 4 Pneumatic
Motor unit
(Ref. Par. 8.3)
(*) (**)
5
55 Nm; 40.7 lbft
16
10
11
Part 4 Pneumatic
Motor unit
(Rif. Par. 8.3)
Hydraulic fl uid compartment
(Ref. Par. 6.3.1)
REMARK:
The hydraulic circuit is normally full of working fl uid fi lled in the factory. In case of disassembly of the hydraulic circuit, the fl uid is to be previously extracted as indicated in the instructions given in Paragraph 6.3.1, and later refi lled.
17
10
10
12
13
14
55 Nm; 40.7 lbft
5
9 (*)
8
7
6
18
2
1
16
4
3
5
55 Nm; 40.7 lbft
46
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
14
15
16
17
10
11
12
13
8
9
6
7
Pos .
K Qty. Description
1 2 Inner diaphragm disc
4
5
2
3
2
12
12
4
Bellows ring
5x16 screw
Washer 5
12x270 screw
◆ ■
◆ ■
◆ ■
◆ ■
2
2
2
2
Bellows
NBR O-Ring seal
Slip band
Lip seal
◆ ■
◆
4 Fast fi tting 1/2x14
2 Bleed plug
2 Check valve housing
2 NBR O-Ring seal
2 Check valve
2 Inner fl ange
2 Reduction unit 3/4x1/2
1 Hose PU d14x10 L=210 mm
18 2 Bellows fl ange (2 parts)
■ 1 Hydraulic fl uid (1L bottle)
◆
■
= Wearing parts
= Included in the cpl. hydraulic circuit service-set T9093.00
No.
B0337.01
B0335.03
K114.03
K515.03
K1071.62
G010.07
L137.06A
L823.08
L481.06
M415.00
M071.07
B0336.03
L225.06
T132.00
F1013.71
M427.00
S463.00
B0334.03
Z126.00
Unica 4-270 .
47
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
8.5 FLUID SECTION
PART NO. ZZB006ENG
45 N/m; 33 lbft
9
10
11
26
4
5
6
7
8
60 N/m; 44 lbft
17
18
19 20
21 (*)
24
25
12
13
14
15
16
23
5
6
7
8
4
3
23
25 N/m; 18.5 lbft
1
2
3
4
5
6
7
8
21 (*)
20
19
18
60 N/m; 44 lbft
17
11
10
45 N/m;
33 lbft
9
22
16
5
6
7
8
4
1
25 N/m; 18.5 lbft
(*) The diaphragms are the outer walls of the hydraulic circuit, which is normally fi lled with working fl uid. Before removing them, extract the fl uid as described in Paragraph
6.3.1.
48
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
12
13
14
15
Pos
1
2
9
10
11
.
K Qty. Description
8
20
M8x35 socket screw
1 Delivery manifold
3 8 M8 self-locking nut
4 ◆ ▼▲● 4 PTFE O-Ring seal
5 ◆ ▲ 4 Ball rest
6 ◆ ▲
7 ◆ ▲
4
4
1 1/8” ball
Ball seat
8 ◆ ▼▲● 4 PTFE O-Ring seal
10x30 socket screw
No.
K138.62
F1015.03M
K312.62
L228.05
0368507
K814.03
B0339.03
L227.05
K105.62
4 Self-threading rivet K1041.62A
2 Plate Z5026.00
1
1
1
1
Anti-rotation bracket
Eyelet terminal
Square nut 6
Grub screw 6x25
E0042.62
Y622.00B
K343.62A
K040.02D
16
17
18 2 12x36 washer
19 ◆ ▼▲● 2 PTFE O-Ring seal
2 Outer diaphragm disc 20
21 ◆
22
23
●
2
4
2
1
Outer cover
M12x1,25 nut
Diaphragm
Suction manifold
Loctite 542
50ml; 50cc
24
25
1
1
Washer
Nut 6
26 1 Stick label
◆
●
▲
▼
=Wearing parts
= Included in cpl. diaphragms service-set T9092.00
= Included in cpl. valve service-set T9090.00
= Included in product o-ring set T9091.00
F1014.03
B0346.03
K536.03
L229.05
B0338.03
G930.07
F1015.03A
Z201.00
K562.02
K316.62
Z510.00
49
Unica 4-270 .
EDITION 04 /2007
OPERATING MANUAL
PART NO. ZZB006ENG
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