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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.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 Table of Contents TABLE OF CONTENTS About these instructions Preface Warnings, Notices and Symbols in these Instructions General Characters and Symbols Languages Abbreviations Terminology for the Purpose of this Manual Using in accordance with the instructions...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 Table of Contents Troubleshooting and Rectification Repairs 10.1 Repair Personnel 10.2 Repair Notes 10.3 Tools 10.4 Cleaning the Parts after Disassembly 10.5 Assembly of the Device 10.6 Replacing the Diaphragm (Due to Breakage)
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 1 About these instructions 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.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 1 About these instructions – 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 ...
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 1 About these instructions 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.
WAGNER explicitly prohibits any other use! The device may only be operated under the following conditions: 4 Use the device only to work with the materials recommended by WAGNER. 4 Do not deactivate safety fixtures. 4 Use only WAGNER original spare parts and accessories.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 2 Using in accordance with the instructions 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.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 2 Using in accordance with the instructions 2.5 MISUSE Misuse can lead to physical injury and/or property damage! Special attention must be paid that: 4 No dry coating products, e.g., powder are processed.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 3 Identification Safe Handling of WAGNER Spray Devices Mechanical sparks can form if the device comes into contact with metal. In an explosive atmosphere: 4 Knocking or pushing metal against metal is to be avoided.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 3 Identification Type plate of EX versions Wagner International AG II 2 G Ex h IIB T4 Gb X CH-9450 ALTSTÄTTEN Assembled by WAGNER in Switzerland ZIP52 Max. Fluid pressure: 8bar-0.8MPa-116psi Max.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 4 Basic Safety Instructions 4 BASIC SAFETY INSTRUCTIONS 4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR 4 Keep this operating manual at hand near the device at all times. 4 Always follow existing regulations concerning occupational safety and accident prevention regulations.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 4 Basic Safety Instructions 4 Make sure that all people within the work area wear static dissipative shoes. Footwear must comply with EN 20344. The measured insulation resistance must not exceed 100 MΩ.
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4 In the event of functional faults, remedy the fault as described in the chapter on troubleshooting and rectification. 4 If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER service technician) at least every 12 months for their work-safe condition in accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 4 Basic Safety Instructions 4 Earth the workpieces being painted. 4 Ensure that all persons inside the working area are grounded, e.g., that they are wearing static dissipative shoes. 4 Wear static dissipative gloves when spraying. The grounding takes place via the spray gun's handle or its trigger.
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Danger due to improper maintenance and repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel.
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4 Basic Safety Instructions 4 Use only WAGNER original spare parts and accessories. 4 Do not change or modify the device; if change is necessary, contact WAGNER. 4 Only repair and replace parts that are listed in Chapters Accessories and Spare Parts [8 56] and that are assigned to the device.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 5 Description 5 DESCRIPTION 5.1 COMPONENTS B_06950 Delivery manifold Product input Air input Product distributor Product output Grounding connection 5.2 MODE OF OPERATION The double diaphragm pump is driven with compressed air. A pneumatic manifold alternates in supplying two diaphragms with compressed air.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 5 Description 5.4 SCOPE OF DELIVERY Order no. Designation ZIP diaphragm pump The standard equipment includes: See Chapter Declaration of Conformity [8 70] Declaration of Conformity 2330425 Operating manual, in German See Chapter Languages [8 6] Operating manual in the local language The delivery note shows the exact scope of delivery.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 5 Description 5.5.2 Technical Data for Metallic Pump Versions Pump body Description Units Zip 52 Zip 52 ZIP 52 PF Zip 80 Pump ratio 1 : 1 Volume flow per double stroke (DH) cm³...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 5 Description Pump body Description Units Zip 52 Zip 52 ZIP 52 PF Zip 80 Product temperature °C 4 – 90 °F 39 – 194 Ambient temperature °C 4 – 40 °F...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 5 Description Pump body Acetal Acetal Description Units Zip 52 ZIP 52 PF Zip 52 ZIP 52 Air inlet connection (plug) BSP(R) 1/4" Maximum suction height 15.7 15.7 Maximum solid body size Inches 0.08...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 5 Description 5.5.4 Dimensions and Connections B_04007 S = E + (2 x N) B_04028 Wall mount ZIP52 ZIP52 ZIP52 ZIP52 PF ZIP52 PF ZIP80 Aluminum SSt mm; inch PP and acetal...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 5 Description ZIP52 ZIP52 ZIP52 ZIP52 PF ZIP52 PF ZIP80 Aluminum SSt mm; inch PP and acetal Aluminum PP and acetal Aluminum mm; inch mm; inch mm; inch mm; inch mm; inch 100;...
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 6 Assembly and Commissioning 6 ASSEMBLY AND COMMISSIONING 6.1 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.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 6 Assembly and Commissioning Info Ensure that the national explosion prevention rules and regulations are observed when setting up the device. Connections Configurations B_04021 B_07862 B_07863 Type 1 Type 2 Type 3...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 6 Assembly and Commissioning B_06951 Product delivery valve Air suction filter Product hose Suction hose Return valve Air cut-off valve Delivery manifold Air pressure regulator Suction manifold 1. Install the pump on a flat and horizontal foundation and screw it down tightly or mount it on a wall mount.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 6 Assembly and Commissioning × 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. Establish the connection to the pump fitting.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 6 Assembly and Commissioning 6.5.3 Product Supply Lines DANGER Bursting hose, bursting threaded joints! Danger to life from injection of product. 4 Ensure that the hose material is chemically resistant to the sprayed products.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 6 Assembly and Commissioning B_06952 Grounding scheme (example) Part / workstation Cable cross section Conveyor 16 mm²; AWG6 Work piece < 1 MΩ Spraying stand 16 mm²; AWG6 Alternative: Spray booth Floor, static dissipative Product tank 6 mm²;...
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 6 Assembly and Commissioning 2. Crimp the grounding cable on the connection and screw it back onto the pump’s foot. 3. Ground the product tank to an on-site grounding connection. 4. Ground the other parts of the system to an on-site grounding connection.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 6 Assembly and Commissioning 6.7.3 Pressure Tightness Test WARNING Overpressure! Risk of injury from bursting components. 4 The operating pressure must not exceed the value shown on the type plate. 1. Gradually increase the pressure in pump with the pressure regulator until maximum pressure is reached.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 7 Operation 7 OPERATION 7.1 TRAINING THE OPERATING PERSONNEL – The operating personnel must be qualified to operate the entire system. – The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 7 Operation Info In case air accidentally flows into the pump suction inlet, the air pressure must immediately be reduced to avoid the pump working at an excessive speed. 7.4 PRESSURE RELIEF / WORK INTERRUPTION The pressure must always be relieved: –...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 7 Operation WARNING Incompatibility of cleaning/flushing agent and working medium! Risk of explosion and danger of poisoning by toxic gases. 4 Examine the compatibility of the flushing and cleaning agents and working media on the basis of the safety data sheets.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 7 Operation 6. Secure the spray gun. 7. Dispose of the contents of the tank (8) according to the local regulations. In case of start-up problems: 1. Close the air cut-off valve (4).
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 8 Cleaning and Maintenance 8 CLEANING AND MAINTENANCE 8.1 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.
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DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.
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Yearly or as required 1. In accordance with DGUV regulation 100-500, Chapters 2.29 and 2.36: 4 Have the liquid ejection devices checked by an expert (e.g. WAGNER service technician) as required, but no later than every 12 months to ensure that they are in safe working order.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 8 Cleaning and Maintenance 8.2.5 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.
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 8 Cleaning and Maintenance 6. Close return valve (2). Emptying up to the gun 1. Point the spray gun, without nozzle, into the tank (8) and open it. 2. Slowly open pressure regulator (3). Be ready for the switch from working product to air.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 8 Cleaning and Maintenance 6. Slowly open the air cut-off valve (4). 7. Slowly turn air pressure up on the pressure regulator (3) and only until the pump is running regularly. Be ready to switch from air to working product and prevent back spray.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 8 Cleaning and Maintenance 4. Remove the released diaphragm with its corresponding internal disc, and remove the shaft from the motor block. 5. Clamp the end of the shaft released from the diaphragm in a bench vice (with soft jaws to avoid damaging it) and remove the external diaphragm disc from the opposite end of the shaft.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 9 Troubleshooting and Rectification 9 TROUBLESHOOTING AND RECTIFICATION Problem Cause Remedy The pump does not The air motor does not work or Close the air cut-off valve, increase the pressure, work.
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 10 Repairs 10.3 TOOLS The following tools are required for assembling and disassembling the device (if possible, always bring entire tool sets with you): – Torque wrench set – Allen wrench set 10.4 ...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 10 Repairs 3.5 Nm 2.6 lbft 2 Nm; 1.5 lbft 2 Nm 1.5 lbft B_04018 1. Dismantle the motor in accordance with Chapter Replacing the Diaphragm (Preventive Maintenance) [8 46]. 2. Remove the reversing valve (2).
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 11 Function Test after Repair Work 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.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 12 Disposal 12 DISPOSAL 12.1 DEVICE When the devices must be scrapped, please differentiate the disposal of the waste materials. The following materials have been used: – Stainless steel – Aluminum –...
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 14 Spare Parts 14.8 ZIP MOTOR 3.5 Nm; 2.6 lbft 2 Nm; 1.5 lbft 2 Nm; 1.5 lbft B_04027 Zip 52 ZIP 52 PF Zip 80 Designation Order no. Order no.
Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 14 Spare Parts Zip 52 ZIP 52 PF Zip 80 Designation Order no. Order no. Order no. ⋆ ♦ F829.07 Shaft guide bushing F830.07 Cover (exhaust side) T6103.00A T6104.00A Motor block with safety valve ♦...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 14 Spare Parts Pump No. Diaphragm Valve seat Valve ball Service set O-ring set Air valve set U553.PHSD7 UHMWPE Stainless Acetal (POM) T9080.00G T9077.00 P4003.00 steel U553.PTSS7 PTFE Stainless Stainless steel T9080.00...
II 2 G Ex h IIB T4 Gb X 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 15.1.2 Non-Ex Versions...
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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 Order number DOC 2330426 | Edition 09/2021...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 15 Declaration of Conformity Order number DOC 2330426 | Edition 09/2021...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 15 Declaration of Conformity Order number DOC 2330426 | Edition 09/2021...
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Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80 15 Declaration of Conformity Order number DOC 2330426 | Edition 09/2021...
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Order number DOC 2330426 Edition 09/2021 Germany J. Wagner GmbH Otto-Lilienthal-Strasse 18 Postfach 1120 D-88677 Markdorf Telephone: +49 (0)7544 5050 Fax: +49 (0)7544 505200 E-mail: ts-liquid@wagner-group.com Switzerland Wagner International AG Industriestrasse 22 CH-9450 Altstätten Telephone: +41 (0)71 757 2211 Fax: +41 (0)71 757 2222 More contact addresses on the internet at: www.wagner-group.com...