WAGNER ZIP52 Translation Of The Original Operating Manual
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WAGNER ZIP52 Translation Of The Original Operating Manual

Pneumatic double diaphragm pump
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Version 11/2018
ZIP52 - ZIP80
Pneumatic Double
Diaphragm Pump
B_04001
B_04003
B_04002

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Summary of Contents for WAGNER ZIP52

  • Page 1 Version 11/2018 ZIP52 - ZIP80 Pneumatic Double Diaphragm Pump B_04001 B_04003 B_04002...

  • Page 3: Table Of Contents

    Electrical Devices and Equipment 4.1.2 A Safe Work Environment 4.1.3 Personnel Qualifications Safety Instructions for the Personnel 4.2.1 Personal Safety Equipment 4.2.2 Safe Handling of WAGNER Spray Devices 4.2.3 Grounding the Unit 4.2.4 Product Hose 4.2.5 Cleaning and Flushing 4.2.6 Touching Hot Surfaces 4.2.7...
  • Page 4 ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 ASSEMBLY AND COMMISSIONING Training of Assembly/Commissioning Personnel Storage Conditions Installation Conditions Transportation Assembly and Installation 6.5.1 Positioning 6.5.2 Ventilation of the Spray Booth 6.5.3 Air Supply Lines 6.5.4 Product supply lines Grounding Commissioning OPERATION Training the Operating Personnel...
  • Page 5 DISPOSAL ACCESSORIES SPARE PARTS 14.1 How can spare parts be ordered? 14.2 ZIP52 Pump - Metal - Universal Connections 14.3 ZIP 52 Pump - Metal - Independent Connections 14.4 ZIP 52 Pump - Conductive Acetal 14.5 ZIP 52 Pump - Polypropylene - Universal Connections 14.6...

  • Page 6: About These Instructions

    Translation of the original operating manual Language Order no. Language Order no. Language Order no. English 2330426 Spanish 2335555 Swedish 2341252 French 2335553 Chinese 2373697 Turkish 2372050 Italian 2332230 Russian 2359663 Hungarian 2353652 Additional languages on request or at: www.wagner-group.com...

  • Page 7: Abbreviations

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 ABBREVIATIONS Order no. Order number Fine Flow Controller Spare part Two components Marking in the spare parts lists Polypropylene Polypropylene Position Polyoxymethylene (Acetal) Number of pieces Polypropylene sulfide Double stroke PTFE Polytetrafluorethylene Stainless steel UHMWPE Ultra-high molecular polyethylene...

  • Page 8: Correct Use

    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 fixtures. Use only WAGNER original spare parts and accessories.

  • Page 9: Processible Working Materials

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 PROCESSIBLE WORKING MATERIALS Fluid materials like paints and lacquers. Application 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 recommended limited suitability...

  • Page 10: Identification

    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;...
  • Page 11 ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 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 range is: 10 °C to 40 °C; 50 °F to 104 °F. Surface spraying, electrostatics Do not spray device parts using electrostatic equipment.

  • Page 12: Basic Safety Instructions

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 BASIC SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention. 4.1.1 ELECTRICAL 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...

  • Page 13: Personnel Qualifications

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 Ensure that there are no ignition sources such as naked flames, 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.).

  • Page 14: Safe Handling Of Wagner Spray Devices

    "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).

  • Page 15: Product Hose

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 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 flushing agents used.

  • Page 16: Cleaning And Flushing

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 4.2.5 CLEANING AND FLUSHING Hazard due to cleaning and flushing! Explosion hazard and damage to the device. Preference should be given to non-ignitable cleaning and flushing agents. When carrying out cleaning work with flammable cleaning agents, make sure that all equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or static dissipative and grounded.

  • Page 17: Maintenance And Repair

    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.

  • Page 18: Description

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 DESCRIPTION COMPONENTS OF ZIP 52 Designation 1 Delivery manifold 2 Air inlet 3 Product outlet 4 Product inlet 5 Product distributor 6 Grounding connection B_06950 MODE OF OPERATION The double diaphragm pump is driven with compressed air. A pneumatic manifold alternates in supplying two diaphragms with compressed air.

  • Page 19: Data

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 DATA 5.5.1 MATERIALS OF PAINT-WETTED PARTS Type Order no. Pump body Diaphragm Diaphragm disc Valve Valve ball O-rings seat U550.ATRD7 Aluminum PTFE Acetal (POM) PTFE U550.ATSS7 Aluminum PTFE Stainless Stainless PTFE steel steel U550.ATSS8 Aluminum...

  • Page 20: Technical Data For Metallic Pump Versions

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 5.5.2 TECHNICAL DATA FOR METALLIC PUMP VERSIONS Pump body Description Units ZIP 52 Zip 52 ZIP 52 PF Zip 80 Pump ratio Volume flow per double stroke cu inch 6.59 3.78 13.73 Maximum operating pressure Maximum speed DH/min...

  • Page 21: Technical Data For Non-Metallic Pumps

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 5.5.3 TECHNICAL DATA FOR NON-METALLIC PUMPS Pump body Acetal Acetal ZIP 52 ZIP 52 PF Zip 52 ZIP 52 PF Description Units Pump ratio Volume flow per double stroke cu inch 6.59 6.59 3.78 3.78...

  • Page 22: Dimensions And Connections

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 5.5.4 DIMENSIONS AND CONNECTIONS B_04007 S = E + (2 x N) Wall mount B_04028 Aluminum PP and acetal Aluminum PP and acetal Aluminum mm; inch mm; inch mm; inch mm; inch mm;...

  • Page 23: Performance Diagrams

    A = 8 bar; 0.8 MPa; 116 psi air pressure B = 6 bar; 0.6 MPa; 87 psi air pressure B_04032 C = 4 bar; 0.4 MPa; 58 psi air pressure Diagram ZIP52 PF Diagram ZIP80 bar (MPa) nl/min bar (MPa) nl/min <psi>...

  • Page 24: Assembly And Commissioning

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 ASSEMBLY AND COMMISSIONING TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL The assembly and commissioning personnel must have the technical skills to safely commission the device. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

  • Page 25: Positioning

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 6.5.1 POSITIONING × × B_04010 Procedure: 1. Install the pump on a flat and horizontal foundation and screw it down tightly or mount it on a wall mount. 2. Connect the suction system and air supply. 3.

  • Page 26: Ventilation Of The Spray Booth

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 × B_04011 Compressed air connection: The compressed air supply must be properly dimensioned. Connect the pump's compressed air connection to the pressure distribution network. The connection must be carried out on the pump's fitting. Do not replace the original connection. Use a pipeline with a suitable diameter for the connection.

  • Page 27: Grounding

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 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 insufficient! Danger of poisoning.

  • Page 28: Commissioning

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 COMMISSIONING WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ensure that the pump and suction system are always completely filled with flushing agent or working medium.

  • Page 29: Operation

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 OPERATION TRAINING THE OPERATING PERSONNEL The operating personnel must be qualified to operate the entire system. The operating personnel 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 personnel must receive appropriate system training.

  • Page 30: Pressure Relief/Work Interruption

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 PRESSURE RELIEF/WORK INTERRUPTION The pressure must always be relieved: − after the spraying tasks are finished, − before servicing or repairing the system, − before carrying out cleaning tasks on the system, −...

  • Page 31: Basic Flushing

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 BASIC FLUSHING Regular flushing Regular flushing, cleaning and maintenance ensures the pump's high pumping and extraction capacity. The cleaning and flushing agents used must be compatible with the working material. WARNING Incompatibility of flushing / cleaning agent with the working medium! Risk of explosion and danger of poisoning by toxic gases.

  • Page 32: Cleaning And Maintenance

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING PERSONNEL Cleaning work should be undertaken regularly and carefully by qualified and trained personnel. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: −...

  • Page 33: Maintenance

    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.

  • Page 34: Safety Checks And Maintenance Intervals

    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.

  • Page 35: Emptying Pump

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 8.2.4 EMPTYING PUMP WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ignition of potentially explosive surrounding atmosphere. Empty the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

  • Page 36: Filling The Empty Pump

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 8.2.5 FILLING THE EMPTY PUMP WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ignition of potentially explosive surrounding atmosphere. Fill the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

  • Page 37: Diaphragm Replacement (Preventive Maintenance)

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 DIAPHRAGM REPLACEMENT (PREVENTIVE MAINTENANCE) Mark the coupled parts (diaphragm covers, manifold, covers) with a felt-tip pen so as to make subsequent reassembly easier. Notice: When executing the following tasks it is imperative to avoid any rotation of the shaft in the motor block! 12 Nm 8.8 lbft...

  • Page 38: Cleaning / Replacement Of The Suction And Delivery Non-Return Valves

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 CLEANING / REPLACEMENT OF THE SUCTION AND DELIVERY NON-RETURN VALVES a) Remove the suction and delivery manifold. b) Remove the seals, seats and balls from the diaphragm covers and the manifold's housings. c) Check the condition of wear of the ball guide/stops inside the diaphragm cover and manifold.

  • Page 39: Troubleshooting And Rectification

    If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.

  • Page 40: Repair Work

    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.

  • Page 41: Cleaning The Parts After Disassembly

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 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.

  • Page 42: Replacing The Diaphragm (Due To Breakage)

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 10.6 REPLACING THE DIAPHRAGM (DUE TO BREAKAGE) If the diaphragms are replaced as a result of breakage, all the internal parts of the motor must be cleaned and the condition of the seals and reversing valve, which may have been damaged by contact with the pump fluid, must be checked.

  • Page 43: Function Test After Repair Work

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 11 FUNCTION TEST AFTER REPAIR WORK 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 personnel.

  • Page 44: Accessories

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 13 ACCESSORIES B_04029 Order no. Designation ZIP pump P123.00 Pressure regulator 9998677 Pressure gauge T760.00M Wall mount T406.00 Suction hose, stainless steel, complete H401.07 Filter support disc T453.03 Suction hose filter H206.03 Suction hose spring S402.06A Solvent resistant suction hose...
  • Page 45 ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 Connections Configurations B_04061 LEFT / LEFT B_04020 U55x.xxxx1 UNIVERSAL / UNIVERSAL U55x.xxxx7 U551.303 B_04021 INDEPENDENT / INDEPENDENT U55x.xxxx8...

  • Page 46: Spare Parts

    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.

  • Page 48: Zip52 Pump - Metal - Universal Connections

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 14.2 ZIP52 PUMP - METAL - UNIVERSAL CONNECTIONS 5 Nm; 3.7 lbft (U551.303) 12 Nm; 8.8 lbft 5 Nm; 3.7 lbft 5 Nm; 3.7 lbft B_04022...
  • Page 49 ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 Order no. Order no. Order no. Order no. Order no. Designation U550.ATRD7 U550.ATSS7 U550.STSS7 U551.303 U551.ATSS7 DDP ZIP F184.01C F184.01C F188.03C F184.01C F184.01C Suction manifold F185.01C F185.01C F189.03C T6133.00 F185.01C Delivery manifold F834.07R F834.07R F834.07R...

  • Page 50: Zip 52 Pump - Metal - Independent Connections

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 14.3 ZIP 52 PUMP - METAL - INDEPENDENT CONNECTIONS 5 Nm; 3.7 lbft 12 Nm; 8.8 lbft 5 Nm; 3.7 lbft 5 Nm; 3.7 lbft B_04023...
  • Page 51 ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 Order no. Designation U550.ATSS8 DDP ZIP52 F184.01D Suction manifold F185.01D Delivery manifold F834.07R Outer diaphragm disc F978.01 Diaphragm cover G921.05 Product diaphragm G921.06 Support diaphragm K142.62 Screw, M6x35 K183.62 Screw, M6x30 K311.62...

  • Page 52: Zip 52 Pump - Conductive Acetal

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 14.4 ZIP 52 PUMP - CONDUCTIVE ACETAL 4.5 Nm; 3.3 lbft (U55x.xxxx7) (U55x.xxxx1) 12 Nm; 8.8 lbft 7 Nm; 5.2 lbft (U55x.xxxx7) B_04062 4.5 Nm; 3.3 lbft (U55x.xxxx1)
  • Page 53 ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 Order no. Order no. Order no. Designation U552.GHSS1 U552.GHSS7 U553.GTSS1 DDP ZIP52 F1017.07G-C Suction manifold - universal F833.07G-A F833.07G-A Suction manifold - left F1016.07G-C Delivery manifold - universal F859.07G F859.07G Delivery manifold - left F834.07D...

  • Page 54: Zip 52 Pump - Polypropylene - Universal Connections

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 14.5 ZIP 52 PUMP - POLYPROPYLENE - UNIVERSAL CONNECTIONS 5 Nm; 3.7 lbft 12 Nm; 8.8 lbft 7 Nm; 5.2 lbft 5 Nm; 3.7 lbft B_04024...
  • Page 55 ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 Order no. Order no. Order no. Designation U552.PTSS7 U553.PHSD7 U553.PTSS7 DDP ZIP52 F1017.07P-C F1017.07P-C F1017.07P-C Suction manifold F1016.07P-C F1016.07P-C F1016.07P-C Delivery manifold F834.07P F834.07P F834.07P Outer diaphragm disc F831.07P-A F831.07P-A F831.07P-A Diaphragm cover G921.05...

  • Page 56: Zip 80 Pump - Aluminum - Universal Connections

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 14.6 ZIP 80 PUMP - ALUMINUM - UNIVERSAL CONNECTIONS 5 Nm; 3.7 lbft 12 Nm; 8.8 lbft 5.5 Nm; 4.06 lbft 5 Nm; 3.7 lbft B_04026...
  • Page 57 ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 Order no. Designation U555.ATSS7 DDP ZIP80 F186.01C Suction manifold F187.01C Delivery manifold F838.07R Outer diaphragm disc F981.01 Diaphragm cover G922.07AB Diaphragm K128.62 Screw, M6x40 K142.62 Screw, M6x35 9910208 Nut, M8 K311.62 Nut, M6 9920102 Washer, 8 K1057.62...

  • Page 58: Zip Motor

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 14.7 ZIP MOTOR 3.5 Nm; 2.6 lbft 2 Nm; 1.5 lbft 2 Nm; 1.5 lbft B_04027...

  • Page 59: Service Sets

    ZIP 52/80 VERSION 11/2018 ORDER NUMBER DOC 2330426 Zip 52 ZIP 52 PF Zip 80 Order no. Order no. Order no. Designation T6103.00 T6103.00S T6104.00 Motor B0146.04 B0146.04 B0146.04 Feeler pin B0147.71 B0147.71 B0151.71 Inner diaphragm disc B0150.03 B0150.03S B0150.03 Shaft F194.91 F194.91...

  • Page 60: Eu Declaration Of Conformity

    Chapter 2.29 and Chapter 2.36 Identification: 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: 2334618...
  • Page 61 Chapter 2.29 and Chapter 2.36 Identification: 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: 2334619...
  • Page 64 Order no. 2330426 Edition 11/2018 ts-liquid@wagner-group.com www.wagner-group.com...

This manual is also suitable for:

Zip52 pfZip80

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