WAGNER ZIP52 Finishing Manuel d'exploitation

B_07802

Pneumatic double diaphragm pump

ZIP52 - ZIP80

Translation of the Original Operating Manual

+  II2GExhIIBT4GbX

For professional use.

Always observe the information in this manual, particularly the safety

instructions and the warning instructions. Store the manual in a safe place. Edition: 09/2021

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80

Table of Contents

Order number DOC 2330426 | Edition 09/2021 3

TABLE OF CONTENTS

1 About these instructions 5

1.1 Preface 5

1.2 Warnings, Notices and Symbols in these Instructions 5

1.3 General Characters and Symbols 5

1.4 Languages 6

1.5 Abbreviations 6

1.6 Terminology for the Purpose of this Manual 7

2 Using in accordance with the instructions 8

2.1 Device Type 8

2.2 Type of Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Processible Working Materials 9

2.5 Misuse 10

3 Identification 11

3.1 Identification of Non-ignitable Products 11

3.2 Explosion Protection Identification 11

3.3 Identification "X" 11

3.4 Type Plate 12

4 Basic Safety Instructions 14

4.1 Safety Instructions for the Operator 14

4.2 Safety Instructions for the Personnel 15

5 Description 20

5.1 Components 20

5.2 Mode of Operation 20

5.3 Protective and Monitoring Equipment 20

5.4 Scope of Delivery 21

5.5 Data 21

6 Assembly and Commissioning 29

6.1 Training of Assembly/Commissioning Personnel 29

6.2 Storage Conditions 29

6.3 Installation Conditions 29

6.4 Transportation 29

6.5 Assembly and Installation 29

6.6 Grounding 33

6.7 Commissioning 35

7 Operation 37

7.1 Training the Operating Personnel 37

7.2 Emergency Stop 37

7.3 Tasks 37

7.4 Pressure Relief / Work Interruption 38

7.5 Basic Flushing 38

8 Cleaning and Maintenance 41

8.1 Cleaning 41

8.2 Maintenance 41

8.3 Replacing the Diaphragm (Preventive Maintenance) 46

8.4 Cleaning/Replacement of the Suction and Delivery Non-Return Valves 47

8.5 Replacement of the Reversing Valve 47

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80

Table of Contents

4 Order number DOC 2330426 | Edition 09/2021

9 Troubleshooting and Rectification 48

10 Repairs 49

10.1 Repair Personnel 49

10.2 Repair Notes 49

10.3 Tools 50

10.4 Cleaning the Parts after Disassembly 50

10.5 Assembly of the Device 50

10.6 Replacing the Diaphragm (Due to Breakage) 50

11 Function Test after Repair Work 52

12 Disposal 53

12.1 Device 53

12.2 Consumable products 53

13 Accessories 54

14 Spare Parts 56

14.1 How to order spare parts 56

14.2 Notes on Using Spare Parts 56

14.3 ZIP52 Pump - Metallic - Universal Connections 57

14.4 ZIP52 Pump - Metallic - Independent Connections 59

14.5 ZIP52 Pump - Conductive Acetal 61

14.6 ZIP52 Pump - Polypropylene - Universal Connections 63

14.7 ZIP80 Pump - Aluminum - Universal Connections 65

14.8 ZIP Motor 67

14.9 Service Sets 68

15 Declaration of Conformity 70

15.1 EU Declaration of Conformity 70

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80

1 About these instructions

Order number DOC 2330426 | Edition 09/2021 5

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.

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this 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 Potential danger.

Non-observance may result in death or serious injury.

CAUTION Potentially dangerous situation.

Non-observance may result in minor injury.

NOTICE Potentially dangerous situation.

Non-observance may result in damage to property.

Info Provides information about particular characteristics and how to

proceed.

Explanation of warning notice:

WARNING

This notice warns you of a danger!

Possible consequences of not observing the warning notice.

4The measures for preventing the hazard and its consequences.

1.3 GENERAL CHARACTERS AND SYMBOLS

The characters and symbols in this operating manual indicate the following:

üRequirement that must be fulfilled before an action can be performed.

1. Step 1 of an action to be performed with several action steps.

4Second level action step

2. Step 2

ðIntermediate result of an action

ðResult of a complete action

4Action to be performed with an action step

1. Numbered list, first level

– Numbered list, second level

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80

1 About these instructions

6 Order number DOC 2330426 | Edition 09/2021

– Non-numbered list, first level

– Non-numbered list, second level

= cross-reference on page

♦ = wearing parts

⋆ = included in service set

● = not part of the standard equipment but available as a special accessory

1.4 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order no.

German 2330425

Translation of the original operating manual

Language Order no. Language Order no.

English 2330426 Swedish 2341252

French 2335553 Turkish 2372050

Italian 2332230 Hungarian 2353652

Spanish 2335555 Portuguese 2404241

Chinese 2373697 Romanian 2408586

Russian 2359663

Additional languages upon request or at: www.wagner-group.com

1.5 ABBREVIATIONS

Order no. Order number

ET Spare part

K Marking in the spare parts lists

Pos Position

Stk Number of pieces

DH Double stroke

SSt Stainless steel

2K Two components

Al Aluminum

FFC Fine-Flow Controller (precisely adjustable filter flow controller with inte-

grated pulsation damper)

PP Polypropylene

POM Polyoxymethylene (Acetal)

PPS Polypropylene sulfide

PTFE Polytetrafluorethylene

UHMWPE Ultra-high molecular polyethylene

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80

1 About these instructions

Order number DOC 2330426 | Edition 09/2021 7

1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning agent.

Flushing Internal flushing of paint-wetted parts with flushing agent.

Product pressure

generator

Pump or pressure tank.

Personnel qualifications

Trained person Is instructed in the tasks assigned to him/her, the potential risks associ-

ated 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 neces-

sary 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 rele-

vant provisions.

Skilled person in

accordance with

TRBS 1203

(2010/Revision

2012)

A person, who, based on his/her technical training, experience and re-

cent vocational experience, has sufficient technical knowledge in the ar-

eas of explosion protection, protection from pressure hazards and elec-

tric 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.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80

2 Using in accordance with the instructions

8 Order number DOC 2330426 | Edition 09/2021

2 USING IN ACCORDANCE WITH THE INSTRUCTIONS

2.1 DEVICE TYPE

Pneumatic double diaphragm pump with order no.:

A: Metallic versions in aluminum and stainless steel.

ZIP52 ZIP52 PF ZIP80

U550.ATRD7 U551.ATSS7 U555.ATSS7

U550.ATSS7 U551.303 --

U550.ATSS8 -- --

U550.STSS7 -- --

B: Conductive acetal versions.

ZIP52 ZIP52 PF

U552.GHSS7 U553.GTSS1

C: Non-conductive polypropylene versions.

ZIP52 ZIP52 PF

U552.PTSS7 U553.PHSD7

-- U553.PTSS7

2.2 TYPE OF USE

The device is suitable for processing liquid products like paints and lacquers:

A) Metallic versions (aluminum and stainless steel)

B) Conductive acetal versions

– Products in accordance with their classification in explosion class IIB.

– Non-ignitable products.

C) Non-conductive polypropylene versions

– Non-ignitable products.

WAGNER explicitly prohibits any other use!

The device may only be operated under the following conditions:

4Use the device only to work with the materials recommended by WAGNER.

4Do not deactivate safety fixtures.

4Use only WAGNER original spare parts and accessories.

4The operating personnel must be trained on the basis of this operating manual.

4Follow the instructions in the operating manual.

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

A) Metallic versions (aluminum and stainless steel)

B) Conductive acetal versions

The device can be employed in explosion hazard zones (Zone 1) (see Chapter Identification

[811]).

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80

2 Using in accordance with the instructions

Order number DOC 2330426 | Edition 09/2021 9

C) Non-conductive polypropylene versions

The pneumatic double diaphragm pump must be employed outside of explosion hazard

zones.

2.4 PROCESSIBLE WORKING MATERIALS

Fluid materials like paints and lacquers.

Application ZIP80 ZIP52 ZIP52 PF

Water-dilutable products ↗↗↗

Solvent-based lacquers and paints ↗↗↗

Two-component coating products ↗↗↗

Emulsions ↗↗↗

UV lacquers ↗↗↗

Primers ↗↗↗

Epoxy and polyurethane lacquers,

phenolic lacquers

↗↗↗

Wax-based underside protection ↘↘↘

Shear-sensitive lacquers ↗↗↗

Signs and definitions: ↗recommended

→limited suitability

↘not suitable

NOTICE

Abrasive working materials and pigments!

Greater wear of product-wetted parts.

4Use the application-oriented model (flow rate/cycle, product, valves, etc.) as

indicated in the Chapter Technical Data.

4Check if the fluids and solvents being used are compatible with the pump

construction materials as indicated in the Chapter Materials of Paint-wetted Parts.

Wear caused by abrasive working materials is not covered by the warranty.

Typical applications

Application ZIP80 ZIP52 ZIP52 PF

Furniture industry ↗↗↗

Kitchen manufacturers ↗↗↗

Joinery ↗↗↗

Window factories ↗↗↗

Steel-processing industry ↗↗↗

Construction of vehicles ↗↗↗

Shipbuilding ↘↘↘

Signs and definitions: ↗recommended

→limited suitability

↘not suitable

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80

2 Using in accordance with the instructions

10 Order number DOC 2330426 | Edition 09/2021

2.5 MISUSE

Misuse can lead to physical injury and/or property damage! Special attention must be paid

that:

4No dry coating products, e.g., powder are processed.

4No food, medicine or cosmetics are processed. It is important to note that the device's

materials are not food-safe.

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