WAGNER ZIP182 Original Operating Manual
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WAGNER ZIP182 Original Operating Manual

Pneumatic double diaphragm pump
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Pneumatic double diaphragm pump
ZIP182 Aluminium
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: 02/2021

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Summary of Contents for WAGNER ZIP182

  • Page 1 Pneumatic double diaphragm pump ZIP182 Aluminium 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: 02/2021...

  • Page 3: Table Of Contents

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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...
  • Page 4 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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)

  • Page 5: About These Instructions

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.

  • Page 6: Languages

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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 ...
  • Page 7 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.

  • Page 8: Using In Accordance With The Instructions

    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.

  • Page 9: Misuse

    Chapter Materials of Paint-wetted Parts. Wear caused by abrasive working materials is not covered by the warranty. Info Contact your local WAGNER dealer and the lacquer manufacturer if you encounter application problems. Typical applications...

  • Page 10: Identification

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 3   Identification 3   IDENTIFICATION 3.1   EXPLOSION PROTECTION IDENTIFICATION The device is suitable for use in potentially explosive areas as defined by UK statutory requirement SI 2016 No. 1107. Device Type Pneumatic Double Diaphragm Pump ZIP182...

  • Page 11: Type Plate

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 3   Identification Cleaning If there are deposits on the surfaces, the device may form electrostatic charges. Flames or sparks can form during discharge. 4 Remove deposits from the surfaces to maintain conductivity.

  • Page 12: Basic Safety Instructions

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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 statutory provisions concerning occupational safety and accident prevention regulations.

  • Page 13: Safety Instructions For The Personnel

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 4   Basic Safety Instructions 4 Make sure that all people within the work area wear static dissipative shoes. The footwear must correspond to BS EN ISO 20344:2011. The measured insulation resistance must not exceed 100 MΩ.
  • Page 14 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.
  • Page 15 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.
  • Page 16 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.
  • Page 17 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 51] and that are assigned to the device.

  • Page 18: Description

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 5   Description 5   DESCRIPTION 5.1   COMPONENTS Delivery manifold Product input Air input Air outlet/connection of silencer Product output Air motor Grounding connection Product distributor 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.

  • Page 19: Scope Of Delivery

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 5   Description 5.4   SCOPE OF DELIVERY Order no. Designation ZIP 182 diaphragm pump The standard equipment includes: See Chapter Declaration of Conformity [8 55] Declaration of Conformity 2424271 Operating manual, in German See Chapter Languages [8 6] Operating manual in the local language The delivery note shows the exact scope of delivery.
  • Page 20 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 5   Description Pump body Aluminum Description Units ZIP182 Maximum solid body size Sound pressure equivalent 50 cycles/min. dB(A) (5 bar) Sound power at maximum flow rate dB(A) (6 bar) * Fluid connections 1"...
  • Page 21 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 5   Description 5.5.3   Dimensions and Connections ZIP182 Aluminum mm; inch 12.08 8.43 14.76 328.5 12.93 226 – 246 8.9-9.69 5.98 11.85 6.73 Order number 2431508 | Edition 02/2021...
  • Page 22 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 5   Description 5.5.4   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>...
  • Page 23 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 5   Description Diagram ZIP182 Product pressure in bar; (MPa); <psi> Characteristic curve for air pressure 8 bar; 0.8 MPa; 116 psi Air consumption in nl/min.; <scfm> Characteristic curve for air pressure 6 bar;...

  • Page 24: Assembly And Commissioning

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.
  • Page 25 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 6   Assembly and Commissioning Info Ensure that the national explosion prevention rules and regulations are observed when setting up the device. B_07835 Product cut-off valve Air cut-off valve Return tube Air pressure regulator...
  • Page 26 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 6   Assembly and Commissioning B_07832 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.

  • Page 27: Grounding

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.
  • Page 28 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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;...

  • Page 29: Commissioning

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 6   Assembly and Commissioning Info Safe operation of the pump is only guaranteed with a grounding connection. Connect all grounding cables using a short and direct route. B_07833 1. Remove the crimp connection delivered with the pump.
  • Page 30 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 6   Assembly and Commissioning 6.7.1   Preparation Before every commissioning, the following points should be observed as laid down in the operating manual: 1. Secure spray gun with safety lever. 2. Check the permissible pressures.

  • Page 31: Operation

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.

  • Page 32: Pressure Relief / Work Interruption

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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: –...
  • Page 33 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.
  • Page 34 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 7   Operation 2. Turn the air pressure regulator (7) counterclockwise (0 bar pressure). 3. Open the air cut-off valve (6) for air. 4. Close air pressure regulator (7). 5. Turn the air pressure regulator (7) clockwise until the pump starts. If necessary, repeat the operation several times.

  • Page 35: Cleaning And Maintenance

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.
  • Page 36 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.
  • Page 37 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.
  • Page 38 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.
  • Page 39 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 8   Cleaning and Maintenance 5. As soon as working product is no longer flowing from the return tube (2), close air pressure regulator (7). 6. Close return valve (3). Emptying up to the gun 1.

  • Page 40: Replacing The Diaphragm (Preventive Maintenance)

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 8   Cleaning and Maintenance 7. Slowly turn air pressure up on the air pressure regulator (7) and only until the pump is running regularly. Be prepared for the switch from air to working product and avoid backspray.
  • Page 41 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 8   Cleaning and Maintenance Info When executing the following operations it is imperative to avoid any rotation of the shaft in the motor block! Disassembly 1. Remove the suction and delivery manifolds.

  • Page 42: Cleaning/Replacement Of The Suction And Delivery Non-Return Valves

    Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 8   Cleaning and Maintenance 6. Screw on and tighten the cover screws. Fasten the manifold screws. Apply the correct torque, in accordance with Chapter Spare Parts [8 51]. 8.3.1   Screw Tightening Sequence 4 Observe the correct tightening sequence of the screws (see figure).
  • Page 43 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 8   Cleaning and Maintenance 2. To clean it, blow the housing cavity of the reversing valve out with a jet of compressed air (wear safety goggles). 3. Install the new reversing valve. When doing so, apply the correct torque (see figure in Chapter Replacing the Diaphragm (Due to Breakage) [8 46]).
  • Page 44 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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. stops.
  • Page 45 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.
  • Page 46 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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 ...
  • Page 47 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 10   Repairs 1. Dismantle the motor in accordance with Chapter Replacing the Diaphragm (Preventive Maintenance) [8 40]. 2. Remove the reversing valve (2). 3. Remove the shaft's plastic bushings (3) located at each end of the motor block, the lip seals (4) and the feeler pins (5).
  • Page 48 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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.
  • Page 49 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 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 – Elastomers –...
  • Page 50 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 13   Accessories 13   ACCESSORIES No standardized accessories available for the ZIP182. Order number 2431508 | Edition 02/2021...
  • Page 51 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.
  • Page 52 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 14   Spare Parts 14.3   ZIP182 PUMP - ALUMINUM Order no. Designation U560.ATSS1 DDP ZIP182 ATSS1 F9005.01 Outer diaphragm disc B0315.03 Sealing washer F1001.01 Distributor, pressure side F1002.01 Distributor, suction side F994.01 Diaphragm cover ⋆...
  • Page 53 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 14   Spare Parts Order no. Designation T6124.00 Motor ⋆ ♦ T6125.00 Liquid valve unit (U560.ATSS1) Y622.00A Cable lug Z595.00 Type Plate Z596.00X Cover type plate K1060.03 Screw ♦ = wearing parts ⋆ = Included in service set ●...
  • Page 54 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 14   Spare Parts Order no. Designation F1006.91 Motor block F9003.01 Cover, pressure side F9004.01 Inner diaphragm disc F9006.01 Air flange ♦ G7024.06 Pressure cover seals G7025.06 Flange seal G7026.06 Seal for flange center K1058.62...
  • Page 55  II 2 G Ex h IIB T4 Gb X UK Declaration of Conformity The UK 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 2431508 | Edition 02/2021...
  • Page 56 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 15   Declaration of Conformity Order number 2431508 | Edition 02/2021...
  • Page 57 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 15   Declaration of Conformity Order number 2431508 | Edition 02/2021...
  • Page 58 Operating Manual Pneumatic double diaphragm pump ZIP182 Aluminium 15   Declaration of Conformity Order number 2431508 | Edition 02/2021...
  • Page 60 Order number 2431508 Edition 02/2021 United Kingdom Germany Wagner Spraytech (UK) ltd. J. Wagner GmbH Innovation Centre Otto-Lilienthal-Strasse 18 Silverstone Park Silverstone Postfach 1120 NN12 8GX Northants D-88677 Markdorf Telephone: +44 (0) 1327 368 410 Telephone: +49 (0)7544 5050 E-mail: enquiries@wagner-group.com Fax: +49 (0)7544 505200 E-mail: ts-liquid@wagner-group.com Switzerland Wagner International AG Industriestrasse 22...

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U560.atss1

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