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B_07803 Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 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.
Identification "X" Type Plate Basic Safety Instructions Safety Instructions for the Operator Safety Instructions for the Personnel Description Components of ZIP52 Finishing Components of ZIP52 PF Eco-Finishing Mode of Operation Protective and Monitoring Equipment Scope of Delivery Data Assembly and Commissioning...
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12.2 Consumable products Accessories Spare Parts 14.1 How Can Spare Parts Be Ordered? 14.2 Notes on Using Spare Parts 14.3 ZIP52 Finishing 14.4 ZIP52 PF Eco-Finishing 14.5 ZIP52 Pump - Metallic 14.6 ZIP52 Pump - Conductive Acetal 14.7 ZIP Motor 14.8...
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 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.
Spanish 2335762 French 2335763 Russian 2357257 Italian 2332849 Swedish 2341254 Additional languages upon request or at: www.wagner-group.com 1.5 ABBREVIATIONS Order no. Order number Spare part Marking in the spare parts lists Position Number of pieces Double stroke Stainless steel Two components...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 1 About these instructions 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.
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 (PF Eco) Finishing 2 Correct Use NOTICE Abrasive working materials and pigments! Greater wear of product-wetted parts. 4 Use the application-oriented model (flow rate/cycle, product, valves, etc.) as indicated in the Chapter Technical Data. 4 Check if the fluids and solvents being used are compatible with the pump construction materials as indicated in the Chapter Materials of Paint-wetted Parts.
The maximum surface temperature corresponds to the permissible product temperature. This and the permissible ambient temperature can be found in Chapter Technical data. Safe Handling of WAGNER Spray Devices Mechanical sparks can form if the device comes into contact with metal.
4 Avoid potentially explosive atmosphere in the surroundings. 3.3 TYPE PLATE II 2 G Ex h IIB T4 Gb X Wagner International AG CH-9450 ALTSTÄTTEN Assembled by WAGNER in Switzerland ZIP52 Max. Fluid pressure: 8bar-0.8MPa-116psi Max. Air pressure: 8bar-0.8MPa-116psi Übersetzungsverhältnis / Ratio Fördermenge DH / Delivery DS...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 3 Identification Manufacturer Pump ratio Device type DH flow rate CE identification Max. product temperature Indication of origin Article number Max. product pressure Model year - serial number Max. air pressure Read the operating manual before Order number 2332848 | Edition 08/2020...
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 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 local regulations concerning occupational safety and accident prevention regulations.
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 4 Basic Safety Instructions 4 Ensure that all persons within the working 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 Troubleshooting chapter 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 (PF Eco) Finishing 4 Basic Safety Instructions 4.2.4 Product Hoses Danger due to bursting of product hose! The product hose is under pressure and may cause dangerous injuries. 4 Ensure that the hose material is chemically resistant to the sprayed products and the flushing agents used.
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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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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 4 Basic Safety Instructions 4 Do not use any defective components. 4 Before all work on the device and in the event of work interruptions: 4 Relieve the pressure from the spray gun, product hoses and all devices. 4 Secure the spray gun against actuation.
Designation Diaphragm pump ZIP52 Finishing/ZIP52 PF Eco-Fin- ishing See Chapter Spare Parts [8 55] Suction hose with filter Fine Flow Controller FFC (for ZIP52 Finishing) Product filter (for ZIP52 Eco-Finishing) Frame (for ZIP52 Eco-Finishing) Connection elements The standard equipment includes: See Chapter EU Declaration of Conformity Declaration of Conformity [8 71]...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 5 Description 5.6.2 Technical Data Pump body Acetal Description Units Zip 52 Zip 52 Zip 52 ZIP 52 PF Pump ratio 1 : 1 Volume flow per double stroke (DH) cm³ cu inch 6.59 3.78 Maximum operating pressure...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 5 Description ZIP52 on trolley B_04047 mm; inch mm; inch 520; 20.47 930; 36.61 481; 18.94 720; 28.35 1015; 39.96 Order number 2332848 | Edition 08/2020...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 5 Description ZIP52 PF B_04048 mm; inch mm; inch 405; 15.94 940; 37.01 335; 13.19 602; 23.70 Order number 2332848 | Edition 08/2020...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 5 Description 5.6.4 Performance Diagrams Example 8 bar 6 bar 4 bar B_00301 Product pressure in bar; (MPa); <psi> Air consumption in nl/min.; <scfm> Stroke frequency in DH/min. Flow rate of water in l/min.; <gpm> Order number 2332848 | Edition 08/2020...
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 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 (PF Eco) Finishing 6 Assembly and Commissioning Info Ensure that the national explosion prevention rules and regulations are observed when setting up the device. ZIP52 ZIP52 PF B_07804 Product output Product pressure regulator (ZIP52) Product return valve Pump pressure regulator Fine Flow Controller (ZIP52)
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 6 Assembly and Commissioning – Observe national and local regulations for the exhaust air speed. 6.5.2 Air Supply Lines WARNING Hose connections! Risk of injury and damage to the device. 4 Do not mix up hose connections of product hose and air hose.
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 6 Assembly and Commissioning B_06945 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 (PF Eco) Finishing 6 Assembly and Commissioning 4. Ground the other parts of the system to an on-site grounding connection. Ex zone All devices and equipment must be suitable for use in potentially explosive areas. –...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 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.
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 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 (PF Eco) Finishing 7 Operation 7. Start work process. 7.3.1 Pump Shaking / Air Suctioning If the pump speeds up suddenly and starts to shake, there is no lacquer left inside the device and the pump is sucking in air.
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 7 Operation Info Control air pressure is still present. NOTICE Hardened working product in the spraying system when 2K product is processed! Using 2K materials can destroy the pump and spraying system. 4 Observe the manufacturer's processing rules, particularly in regards to the pot life.
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 7 Operation 4. Fully close the pressure regulator (1) and atomizing air pressure regulator (3) (0 mpa; 0 bar; 0 psi). Flushing via the return valve 1. Open return valve (5). 2. Slowly open the air cut-off valve (4). 3.
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 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. The following hazards may arise during cleaning work: –...
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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 (PF Eco) Finishing 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. 4 Empty and fill the device slowly and in a controlled manner.
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 8 Cleaning and Maintenance 6. Close return valve (5). Emptying up to the gun 1. Point the spray gun, without nozzle, into the tank (7) and open it. 2. Slowly open pressure regulator (1). Be ready for the switch from working product to air. 3.
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 8 Cleaning and Maintenance 6. Slowly open the air cut-off valve (4). 7. Turn the pump pressure regulator (1) clockwise until the pump starts. 8. Be ready to switch from air to working product and prevent back spray. 9.
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 8 Cleaning and Maintenance 8.2.7.2 Fine Flow Controller (ZIP52 Finishing) B_04052 To clean the filter of the Fine Flow Controller, unscrew the union nut (1) from the metal body and lift the filter cup (2). When doing so, pay attention to the PTFE seal on the edge. Remove the filter (3) from the base (4), pulling it upward, since it has a very simple clip fixing.
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 8 Cleaning and Maintenance 12 Nm 8.8 lbft B_07801 Info When executing the following operations it is imperative to avoid any rotation of the shaft in the motor block! Disassembly 1.
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 8 Cleaning and Maintenance 4. Remove all dirt particles as well as hardened product residues. Check the balls and seats for excessive wear. Clean or replace the components. 5. Clean the contact surfaces of the manifolds and the diaphragm cover and mount the components.
Check the compressed air maintenance device (if available). The product pressure regulator is Check the pressure setting on the product pres- set to 0 (ZIP52 Finishing). sure regulator. If necessary, increase the pres- sure. The pump is blocked near the re- Close the air cut-off valve.
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 (PF Eco) Finishing 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 (PF Eco) Finishing 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 44]. 2. Remove the reversing valve (2). 3.
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 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 (PF Eco) Finishing 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 (PF Eco) Finishing 14 Spare Parts 14.8 TROLLEY, FRAME SET, AND WHEEL SET B_04035 Sliding tables Frame set Wheel set Designation Order no. Order no. Order no. T760.00SR Sliding tables T760.00S T760.00S Frame set T760.00R T760.00R Wheel set with han-...
Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 14 Spare Parts Order no. Order no. Designation T0180.00A T0180.00AI Fine Flow Controller, 14/0.5-8 bar A588.03 Diaphragm disc - product side A590.03 Diaphragm disc - air side B0172.03 Ball guide B0180.01 B0180.03 Housing - product side...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 14 Spare Parts – 4 O-rings for the valve units (non-return valves) Air valve set consists of: – 1 reversing valve – 1 reversing valve seal – 1 pressure cover seal Service sets for Fine Flow Controller Pump No.
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 Order number 2332848 | Edition 08/2020...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 15 Declaration of Conformity Order number 2332848 | Edition 08/2020...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 15 Declaration of Conformity Order number 2332848 | Edition 08/2020...
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Operating manual Pneumatic double diaphragm pump ZIP52 (PF Eco) Finishing 15 Declaration of Conformity Order number 2332848 | Edition 08/2020...
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Order number 2332848 Edition 08/2020 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 Subject to changes without notice...