WAGNER ZIP52 Operating Manual
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WAGNER ZIP52 Operating Manual

Pneumatic double diaphragm pump
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See also: Instruction Manual , Operating Manual
Pneumatic Double
Diaphragm Pump
ZIP52 - ZIP80
B_04003
Translation of the Original
Operating Manual
Version 12/2012
B_04001
B_04002

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Summary of Contents for WAGNER ZIP52

  • Page 1 Translation of the Original Operating Manual Version 12/2012 Pneumatic Double Diaphragm Pump ZIP52 - ZIP80 B_04001 B_04002 B_04003...

  • Page 3: Table Of Contents

    4.1.1 Electrical Equipment 4.1.2 Personnel Qualifi cations 4.1.3 Safe Work Environment Safety Instructions for Staff 4.2.1 Safe Handling of WAGNER Spray Units 4.2.2 Grounding the Unit (Except for Non-Conductive Plastic Units) 4.2.3 Material Hoses 4.2.4 Cleaning 4.2.5 Handling Hazardous Liquids, Varnishes and Paints 4.2.6...
  • Page 4 Decommisioning ACCESSORIES SPARE PARTS 11.1 How can Spare Parts be Ordered? 11.2 ZIP52 Pump - Metal - Universal Connections 11.3 ZIP52 Pump - Metal - Independent Connections 11.4 ZIP52 Pump - Conductive Acetal 11.45 ZIP52 Pump - Polypropylene - Universal Connections 11.6...

  • Page 5: About These Instructions

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL ABOUT THESE INSTRUCTIONS 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 operating and service staff .

  • Page 6: Languages

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL LANGUAGES The operating manual is available in the following languages: Language: Order No. Language: Order No. German 2330425 English 2330426 Italian 2332230 French 2335553 Spanish 2335555 ABBEVIATIONS IN THE TEXT Number of pieces Position Marking in the spare parts lists Order No.

  • Page 7: Correct Use

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL CORRECT USE DEVICE TYPES A) Metallic versions (aluminum and stainless steel): Pneumatic double diaphragm pumps with order number U550.ATRD7 U551.ATSS7 U555.ATSS7 U550.ATSS7 U551.303 U550.ATSS8 U550.STSS7 B) Conductive Acetal versions: Pneumatic double diaphragm pumps with order number U552.GHSS1 U553.GTSS1 U552.GHSS7...

  • Page 8: Safety Parameters

    OPERATING MANUAL SAFETY PARAMETERS WAGNER accepts no liability for any damage arising from incorrect use. Use the unit only to work with the materials recommended by WAGNER. Operate only the entire unit. Do not deactivate safety fi xtures. Use only WAGNER original spare parts and accessories.

  • Page 9: Reasonably Foreseeable Misuse

    Wagner double diaphragm pumps are not designed for pumping food. RESIDUAL RISKS Residual risks are risks which cannot be excluded even in the event of correct use.

  • Page 10: Identification

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL IDENTIFICATION EXPLOSION PROTECTION IDENTIFICATION A) Metallic versions (aluminum and stainless steel) and conductive Acetal: Pneumatic double diaphragm pumps with order number U550.ATRD7 U551.ATSS7 U555.ATSS7 U550.ATSS7 U551.303 U550.ATSS8 U553.GTSS1 U550.STSS7 U552.GHSS1 U552.GHSS7 As defi ned in the Directive 94/9/EC (ATEX 95), the unit is suitable for use in areas where there is an explosion hazard.

  • Page 11: General Safety Instructions

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL GENERAL 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 EQUIPMENT Electrical devices and equipment To be provided in accordance with the local safety requirements with regard to the operating mode and ambient infl uences.

  • Page 12: Safe Handling Of Wagner Spray Units

    The liquid emitters are to be checked for safe working conditions by an expert (e.g. Wagner Service Technician) as often as necessary or at least every 12 months, in accordance with the guidelines for liquid emitters (ZH 1/406 and BGR 500 Part 2 Chapter 2.36).

  • Page 13: Cleaning

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Several liquids have a high expansion coeffi cient. In some cases its volume can rise with consequent damage to hoses, fi ttings and cause fl uid leakage. When the pump sucks liquid from a closed container, ensure that air or suitable gas can enter the container to avoid a vacuum being generated in the container itself.

  • Page 14: Explosion Hazard

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 4.2.7 EXPLOSION HAZARD Do not ever use chloride or halogenated solvents (such as trichlorothane and methylene chloride) with units containing aluminum or galvanized and zinc-plated parts. As they may react chemically thus producing an explosion danger. Read the classifi cation and information leafl et concerning the product and solvent to be used.

  • Page 15: Use In Areas Subject To Explosion Hazards

    4.3.1 SAFETY REGULATIONS Safe handling of WAGNER spray units 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.

  • Page 16: Operation Without Fluid

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 4.3.2 OPERATION WITHOUT FLUID Avoid running the pump sucking air, without fl uid inside. The air, combined with the vapour of fl ammable fl uids, can generate internal areas with an explosion hazard. Periodically check that the pump is working regularly, paying special attention to presence of air in the pumped fl uid, which may be caused by a breakage in the pump.

  • Page 17: Description

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL DESCRIPTION AREAS OF APPLICATION NOTICE Abrasive materials and pigments! Greater wear of the parts carrying the material. Use the application-oriented model (fl ow rate/cycle, material, valve, etc.) as indicated in section 5.3.2. Check if the fl uids and solvents used are compatible with the pump construction materials as indicated in section 5.3.1.

  • Page 18: Technical Data

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 5.3.2 TECHNICAL DATA 5.3.2.1 TECHNICAL DATA FOR METALLIC PUMPS Description Unit Wetted parts materials Transmission ratio Flow volume per double cm³ stroke (DH) Maximum operating pressure Maximum possible speed DH/min Maximum fl ow rate l/min (free fl ow - fl ooded inlet) 13.7...
  • Page 19 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Description Unit Wetted parts materials Material temperature °C +4÷90 +4÷90 +4÷90 +4÷90 °F +39÷194 +39÷194 +39÷194 +39÷194 Ambient temperature °C +4 ÷ +40 °F +39 ÷ +104 Allowable sloping position 10° for operation PF = Perfect Flow = low pulsation pump with a shorter stroke Pump with stainless steel valves (start condition: empty pump / dry valves) Pump with plastic valves (start condition: empty pump / dry valves)

  • Page 20: Technical Data For Non-Metallic Pumps

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 5.3.2.2 TECHNICAL DATA FOR NON-METALLIC PUMPS Description Unit Wetted parts materials Transmission ratio Flow volume per double cm³ stroke ( Maximum operating pressure Maximum possible speed /min Maximum fl ow rate l/min (free fl ow - fl ooded inlet) 13.7 13.7...
  • Page 21 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Description Unit Wetted parts materials Maximum material pressure at the pump's inlet 14.5 Material temperature °C +4÷60 +4÷60 +4÷80 +4÷80 °F +39÷140 +39÷140 +39÷176 +39÷176 Ambient temperature °C +4 ÷ +40 °F +39 ÷...

  • Page 22: Dimensions And Connections

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 5.3.3 DIMENSIONS AND CONNECTIONS B_04007 S = E + (2 x N) Wall mount B_04028...
  • Page 23 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Aluminum Stainless steel Polypropylene Aluminum Polypropylene Aluminum conductive conductive Acetal Acetal mm; inch mm; inch mm; inch mm; inch mm; inch mm; inch 200.5; 7.89 210.0; 8.27 205.0; 8.07 200.5; 7.89 205.0; 8.07 220.0;...

  • Page 24: Performance Diagrams

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 5.3.4 PERFORMANCE DIAGRAMS Example Material fl ow volume - water l/min <gpm> Diagram ZIP52 bar (MPa) nl/min <psi> <scfm> 10 (1.0) <145> <26.9> 8.0 (0.8) <21.4> <116> 6.0 (0.6) <16.1> <87> 4.0 (0.4) <10.7>...
  • Page 25 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Diagram ZIP52 PF bar (MPa) nl/min <psi> <scfm> 10 (1.0) <145> <8.9> 8.0 (0.8) <7.1> <116> 6.0 (0.6) <5.4> <87> 4.0 (0.4) <3.6> <58> 2.0 (0.2) <1.8> <29> l/min <1.32> <2.64> <3.96>...

  • Page 26: Mode Of Operation

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL MODE OF OPERATION B_04006 Double diaphragm pump - operating principle The double diaphragm pump is driven with compressed air. Two diaphragms (A) are mechanically connected to each other by means of a shaft (B). Each diaphragm generates two chambers: pumping chamber (P) and motor chamber (M).

  • Page 27: Assembly And Commissioning

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL ASSEMBLY AND COMMISSIONING TRANSPORTATION The pump may be moved manually, without lifts and cranes. STORAGE Store the pump in a closed and dry environment. Thoroughly clean the pump, if a long-term decommissioning is planned. When resuming pump operation, proceed as described in the following sections.
  • Page 28 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Material delivery valve Material hose Delivery manifold Material return valve Air pressure regulator Air cutoff valve Suction hose Suction manifold Air suction fi lter B_04008 Material connection: On the suction manifold of the pump (bottom) connect the suction hose. On the delivery manifold (top) connect the material hose.
  • Page 29 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL All hoses and components connected to the supply line must be able to operate at the pump’s maximum pressure with the pump working at a pulsating pressure. All items connected to the suction manifold must not get crushed as a result of the depression produced by the pump.

  • Page 30: Grounding (Except For Non-Conductive Plastic Units)

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL GROUNDING (EXCEPT FOR NON-CONDUCTIVE PLASTIC UNITS) 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 insuffi cient! Danger of poisoning.
  • Page 31 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL The ground connection is at the pumps of metal and conductive acetal imperative. Note: Pump of nonconductive plastic have no ground connection. B_04001 Procedure: 1. Remove the crimp connection delivered with the pump. 2.

  • Page 32: Commissioning

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL COMMISSIONING 6.5.1 SAFETY REGULATIONS Every time before starting up the following points should be observed as laid down in the operating instructions: - Observe all safety regulations in accordance with chapter 4. - Carry out commissioning properly.

  • Page 33: Preliminary Operations

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 6.5.2 PRELIMINARY OPERATIONS Preliminary fl ushing The pump was tested with oil or other fl uids, depending on the model. Before use, it is necessary to wash the pump once using an adequate solvent. Ensure that: - The pressure regulator knob is turned fully counterclockwise (0 bar pressure).

  • Page 34: Unit Pressure Tightness Test

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Close the return valve, if installed. Delivery Opened Closed Discharge (Return line) Opened B_04014 Let the solvent fl ow through the pump for 2 or 3 minutes. 6.5.3 UNIT PRESSURE TIGHTNESS TEST Close the material delivery valve, once the pump is primed.

  • Page 35: Operation

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL OPERATION OPERATION Suction: Make sure that the air pressure regulator knob is turned fully counterclockwise (0 bar pressure). Open the compressed air and material delivery valve, then increase the air pressure until the pump starts.

  • Page 36: Trouble Shooting And Problem Solving

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL TROUBLE SHOOTING AND PROBLEM SOLVING Problem Cause Remedy The pump does not The air motor does not work or Close the air cutoff valve, increase the work. stops. pressure and open the air cutoff valve immediately.
  • Page 37 Clean the check valves and replace them if continues to run even valves in the delivery and suction they are worn. if the supply's air cutoff manifold. vale is closed. If the problem is not listed above consult your WAGNER Service Center.

  • Page 38: Maintenance

    In accordance with the guideline for liquid emitters (ZH 1/406 and BGR  500 Part  2 Chapter 2.3): - The liquid emitters 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 39: Safety Instructions

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL SAFETY INSTRUCTIONS Prior to maintenance and cleaning measures note: Wear protective clothing and use specifi c protection devices with regard to the nature of the fl uids involved. Close the compressed air supply and release the pressure from the pump and pipes connected to it. Depending on the operation, disconnect the material and air side connection pipes.
  • Page 40 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL c) Hald the end nut of an outer diphragm disk with a wrench. Loose the end nut of the other diaphragm disk and remove. d) Remove the freed diaphragm with its corresponding internal disc, and remove the shaft from the motor block.

  • Page 41: Diaphragm Replacement (Due To Breakage)

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL DIAPHRAGM REPLACEMENT (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 3.5 Nm fl uid, must be checked.

  • Page 42: Replacement Of The Reversing Valve

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL REPLACEMENT OF THE REVERSING VALVE a) Disassemble the pressure side cover and remove the reversing valve. b) To clean it, blow the housing cavity of the reversing valve out with a jet of compressed air (wear safety goggles).

  • Page 43: Accessories

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL ACCESSORIES B_04029 Accessory list Order No. Description ZIP pump P123.00 Pressure regulator 9998677 Pressure gauge T760.00M Wall mount T406.00 Suction hose stainless steel assy. H401.07 Filter support disc T453.03 Suction hose fi lter H206.03 Suction hose spring S402.06A...
  • Page 44 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Connections confi gurations B_04061 B_04020 LEFT / LEFT UNIVERSAL / UNIVERSAL U55x.xxxx1 U55x.xxxx7 U551.303 B_04021 INDEPENDENT / INDEPENDENT U55x.xxxx8...

  • Page 45: Spare Parts

    Risk of injury and damage to the device. Have repairs and part replacements carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 46: Zip52 Pump - Metal - Universal Connections

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 11.2 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 47 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Zip52 metal - universal Order No. Order No. Order No. Order No. Order No. Description 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...

  • Page 48: Zip52 Pump - Metal - Independent Connections

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 11.3 ZIP52 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 49 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL ZIP52 metallic - independent Order No. Description U550.ATSS8 DDP ZIP52 F184.01D Suction manifold F185.01D Delivery manifold F834.07R Outer diaphragm disc F978.01 Diaphragm cover G921.05 Material diaphragm G921.06 Support diaphragm K142.62 Screw M6x35 K183.62...

  • Page 50: Zip52 Pump - Conductive Acetal

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 11.4 ZIP52 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 51 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL ZIP52 Conductive Acetal U552.GHSS1 U552.GHSS7 U553.GTSS1 Order No. Order No. Order No. Description 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...

  • Page 52: Zip52 Pump - Polypropylene - Universal Connections

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 11.45 ZIP52 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 53 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL ZIP52 polypropylene - universal Order No. Order No. Order No. Description 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...

  • Page 54: Zip80 Pump - Aluminum - Universal Connections

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 11.6 ZIP80 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 55 VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL Zip 80 aluminum - universal Order No. Description 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...

  • Page 56: Zip Motor

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 11.7 ZIP MOTOR 3.5 Nm; 2.6 lbft 2 Nm; 1.5 lbft 2 Nm; 1.5 lbft B_04027...
  • Page 57 WARNING 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. Only repair and replace parts that are listed in the chapter "Spare Parts Catalogue" and that are assigned to the unit.

  • Page 58: Service Sets

    VERSION 12/2012 ORDER NUMBER DOC 2330426 OPERATING MANUAL 11.8 SERVICE SETS Pump No. Diaphragm Valve seat Valve ball Service set O-ring set Air valve set U550.ATRD7 PTFE Acetal (POM) T9080.00A T9077.00 P4003.00 U550.ATSS7 PTFE Stainless steel Stainless steel T9080.00 T9077.00 P4003.00 U550.ATSS8 PTFE...

  • Page 59: Guarantee And Conformity Declarations

    The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

  • Page 60: Ce Declaration Of Conformity

    II 2G IIB T4 +4°C Tamb +40°C CE Certifi cate of Conformity The CE certifi cate 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:...
  • Page 61 Identifi cation: CE Certifi cate of Conformity The CE certifi cate 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 62 DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675 Telephone: +45 70 200 245 Telefax: +32 (0)2 269 7845 Telefax: +45 86 856 027 E-Mail: info@wsb-wagner.be / HP www.wsb-wagner.eu E-Mail info@wagner-industri.com United Kingdom France WAGNER Spraytech (UK) Ltd. J. WAGNER France S.A.R.L.
  • Page 64 Order No. 2330426 People‘s Republic of China Tel. +86 / (0)21 6652 / 1858 +86 / (0)21 6630 / 8085 Germany Tel. E-mail...

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