WAGNER Zip 52 Finishing, ZIP 52 PF Eco-Finishing Operating Manual

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B_04043

Zip 52 Finishing ZIP 52 PF Eco-Finishing

Pneumatic Double Diaphragm Pump Spraypack

Version 11/2018

B_04045

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

Table of Contents

1 ABOUT THESE INSTRUCTIONS 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 6

1.4 Abbreviations 6

1.5 Terminology for the Purpose of this Manual 7

2 CORRECT USE 7

2.1 Device Types 7

2.2 Type of Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Processible Working Materials 8

2.5 Misuse 9

3 IDENTIFICATION 9

3.1 Explosion Protection Identication 9

3.2 Identication "X" 10

4 BASIC SAFETY INSTRUCTIONS 11

4.1 Safety Instructions for the Operator 11

4.1.1 Electrical Devices and Equipment 11

4.1.2 A Safe Work Environment 12

4.1.3 Personnel Qualications 13

4.2 Safety Instructions for the Personnel 13

4.2.1 Personal Safety Equipment 13

4.2.2 Safe Handling of WAGNER Spray Devices 13

4.2.3 Grounding the Unit 14

4.2.4 Product hose 14

4.2.5 Cleaning and Flushing 15

4.2.6 Touching Hot Surfaces 16

4.2.7 Maintenance and Repair 16

4.2.8 Protective and Monitoring Equipment 17

5 DESCRIPTION 17

5.1 Components of ZIP 52 Finishing 17

5.2 Components of ZIP 52 PF Eco-Finishing 18

5.3 Mode of Operation 18

5.4 Protective and monitoring equipment 18

5.5 Included Items 19

5.6 Data 19

5.6.1 Materials of Paint-wetted Parts 19

5.6.2 Technical data 19

5.6.3 Dimensions and connections 20

5.6.4 Performance diagrams 22

5.6.5 Operating elements 23

VERSION 11/2018

6 ASSEMBLY AND COMMISSIONING 23

6.1 Training of Assembly/Commissioning Personnel 24

6.2 Storage Conditions 24

6.3 Installation Conditions 24

6.4 Transportation 24

6.5 Assembly and Installation 24

6.5.1 Positioning 24

6.5.2 Ventilation of the Spray Booth 25

6.5.3 Air Supply Lines 26

6.5.4 Product supply lines 26

6.6 Grounding 26

6.7 Commissioning 27

7 OPERATION 28

7.1 Training the Operating Personnel 28

7.2 Emergency Stop 29

7.3 Tasks 29

7.3.1 Pump shaking / air suctioning 29

7.3.2 Product pressure and atomizing air pressure 30

7.4 Pressure Relief/Work Interruption 30

7.5 Basic Flushing 30

7.5.1 Filling with Working Material 31

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8 CLEANING AND MAINTENANCE 31

8.1 Cleaning 31

8.1.1 Cleaning Personnel 31

8.1.2 Decommissioning and Cleaning 32

8.1.3 Long-term Storage 32

8.2 Maintenance 32

8.2.1 Maintenance Personnel 32

8.2.2 Maintenance Instructions 32

8.2.3 Safety Checks and Maintenance Intervals 33

8.2.4 Emptying Pump 34

8.2.5 Filling the Empty Pump 35

8.3 Cleaning the Filter 36

8.3.1 Suction Tube Filter 36

8.3.2 Fine Flow Controller (ZIP52 Finishing) 37

8.3.3 Filter ZIP52 Eco-Finishing 37

8.4 Diaphragm Replacement (Preventive Maintenance) 37

8.5 Cleaning / Replacement of the Suction and Delivery Non-Return Valves 38

8.6 Replacement of the Reversing Valve 39

9 TROUBLESHOOTING AND RECTIFICATION 39

10 REPAIR WORK 40

10.1 Repair Personnel 40

10.2 Repair Notes 41

10.3 Tools 41

10.4 Cleaning the Parts After Disassembly 41

10.5 Assembly of the Device 42

10.6 Replacing the Diaphragm (Due to Breakage) 42

VERSION 11/2018

11 FUNCTION TEST AFTER REPAIR WORK 43

12 DISPOSAL 44

13 ACCESSORIES 44

14 SPARE PARTS 47

14.1 How can spare parts be ordered? 47

14.2 Spare Parts for ZIP 52 Finishing 48

14.3 Zip 52 PF Eco-Finishing 51

14.4 ZIP 52 Metal Pump 53

14.5 ZIP 52 Pump - Conductive Acetal 55

14.6 ZIP motor 57

14.7 Trolley, Frame Set, and Wheel Set 59

14.8 Material lter 60

14.9 Fine Flow Controller 61

14.10 Service sets 63

15 EU DECLARATION OF CONFORMITY 64

ORDER NUMBER DOC 2332848

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VERSION 11/2018

ORDER NUMBER DOC 2332848

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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. The device may only be operated by trained personnel and in compliance with this operating manual. Operating and service personnel should be instructed according to the safety instructions. This equipment can be dangerous if it is not operated according to the instructions in this operating manual.

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this manual highlight particular dangers to users and to the device and state measures for avoiding the hazard. These warning instructions fall into the following categories:

DANGER

WARNING

CAUTION

NOTICE

Notice

Explanation of warning notice:

Immediate risk of danger. Non-observance will result in death or serious injury.

Potential risk. Non-observance can result in death or serious injury.

Potentially hazardous situation. Non-observance may result in minor injury.

Potentially hazardous situation. Non-observance may result in damage to property.

Provides information about particular characteristics and how to proceed.

LEVEL OF DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning notice.

The measures for preventing the hazard and its consequences.

1.3 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order no.

German 2332847

Translation of the original operating manual

Language Order no. Language Order no.

English 2332848 Spanish 2335762 French 2335763 Russian 2357257 Italian 2332849 Swedish 2341254

Additional languages on request or at: www.wagner-group.com

VERSION 11/2018

1.4 ABBREVIATIONS

Order no. Order number Al Aluminum ET Spare part FFC Fine Flow Controller K Marking in the spare parts lists 2K Two components Pos Position POM Polyoxymethylene (Acetal) Qty Number of pieces PPS Polypropylene sulde DH Double stroke PTFE Polytetrauorethylene SSt Stainless steel UHMWPE Ultra-high molecular polyethylene

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning

agent.

Flushing Internal ushing of paint-wetted parts with ushing agent. Product pressure

generator

Personnel qualications

Trained person Is instructed in the tasks assigned to him/her, the potential risks

Electrically trained person

Electrician Can assess the work assigned to him/her and detect possible

Skilled person in accordance with TRBS 1203 (2010/Revision 2012)

Pump or pressure tank.

associated with improper behavior as well as the necessary protective devices and measures.

Is instructed by an electrician about the tasks assigned to him/ her, the potential risks associated with improper behavior as well as the necessary protective devices and measures.

hazards based on his/her technical training, knowledge and experience in relevant provisions.

A person, who, based on his/her technical training, experience and recent vocational experience, has sucient technical knowledge in the areas of explosion protection, protection from pressure hazards and electric hazards (if applicable) and is familiar with the relevant and generally accepted rules of technology so that he/she can inspect and assess the status of devices and coating systems based on workplace safety.

ORDER NUMBER DOC 2332848

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2 CORRECT USE

2.1 DEVICE TYPES

Pneumatic double diaphragm pumps with order number: A: Metallic versions in aluminium and stainless steel.

U760.00 (aluminum) U765.00 (stainless steel) U731.00 (aluminum)

B: Conductive acetal versions.

U773.00 (POM - acetal)

2.2 TYPE OF USE

The device is suitable for processing liquid products like paints and lacquers:

– Non-ignitable products. – Products in accordance with their classication in explosion class IIB.

WAGNER explicitly prohibits any other use! The device may only be operated under the following conditions:

Zip 52 Finishing

Use the device only to work with the products recommended by WAGNER. Do not deactivate safety xtures. Use only WAGNER original spare parts and accessories. The operating personnel must be trained on the basis of this operating manual.

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).

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2.4 PROCESSIBLE WORKING MATERIALS

Fluid materials like paints and lacquers.

Application Finishing Finishing SSt Eco-Finishing Finishing POM

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 not suitable

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NOTICE

Abrasive working materials and pigments!

Greater wear of product-wetted parts.

Use the application-oriented model (ow rate/cycle, product, valves, etc.) as indicated in Chapter 5.6.

Check if the uids and solvents used are compatible with the pump construction materials as indicated in Chapter 5.6.1.

Wear caused by abrasive working materials is not covered by the warranty.

Typical applications

Application Finishing

Furniture industry Kitchen manufacturers Joinery Window factories Steel-processing industry Construction of vehicles Shipbuilding

recommended limited suitability not suitable

2.5 MISUSE

Misuse can lead to physical injury and/or property damage! Special attention must be paid that:

no dry coating products, e.g., powder are processed. no food, medicine or cosmetics are processed.

It is important to note that the device's materials are not food-safe.

Finishing

SSt

Eco-

Finishing

POM

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3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

Device types: metallic versions in aluminum, stainless steel and in conductive acetal. Pneumatic double diaphragm pumps with Order no.

U760.00 (aluminum) U765.00 (stainless steel) U731.00 (aluminum)

U773.00 (POM - acetal) -- --

As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially explosive areas.

Manufacturer: Wagner S.p.A.

I - 23868 Valmadrera (LC)

CE European Communities Ex Symbol for explosion protection II Device class II 2 Category 2 (zone 1) G Ex-atmosphere gas Ex Ignition protection h Ignition protection for non-electrical devices IIB Explosion group T4 Maximum surface temperature < 135 °C; 275 °F (with drying protection

active) Gb Zone 1 high safety level X Special notes (see Chapter 3.2)

3.2 IDENTIFICATION "X"

The maximum surface temperature corresponds to the permissible product temperature. This and the permissible ambient temperature can be found in Chapter 5.6.2 (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; do not drop the device.

Maximum surface temperature

The maximum surface temperature of the pump depends on the operating conditions (heated product) and not on the device (frictional heat).

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.

VERSION 11/2018

Cleaning

If there are deposits on the surfaces, the device may form electrostatic charges. Flames or sparks can form during discharge.

Remove deposits from the surfaces to maintain conductivity. Use only a damp cloth to clean the device.

Air in the pump uid

Ignitable gas mixtures can form if air enters the pump uid.

Prevent the pump from taking in air and running dry. If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until

the air has escaped.

Air in the pumped uid can be caused by damaged diaphragms.

Avoid operating the pump with damaged diaphragms. Periodically check that the pump is working smoothly, paying special attention to

the presence of air in the pumped uid.

Filling and emptying

Ignitable gas mixtures can form in the uid section or product hoses if the pump must be emptied for maintenance and/or repair purposes.

Empty and ll the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

ORDER NUMBER DOC 2332848

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VERSION 11/2018

ORDER NUMBER DOC 2332848

4 BASIC SAFETY INSTRUCTIONS

4.1 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 operating mode and ambient inuences.

May only be maintained by skilled electricians or under their supervision. With open housings, the mains voltage poses a danger.

Operate device in accordance with the safety regulations and electrotechnical regulations.

Must be repaired immediately in the event of problems. Decommission if it poses a hazard or is damaged. Must be de-energized before work is commenced. Inform personnel about planned

work. Observe electrical safety regulations. Ground all devices to a common grounding point. Only operate the device with a properly installed socket with a protective ground

wire connection. Keep liquids away from electrical devices.

Zip 52 Finishing

4.1.2 A SAFE WORK ENVIRONMENT

Hazard due to dangerous uids or vapors!

Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with the skin or eyes.

Ensure that the oor in the working area is static dissipative in accordance with EN61340-4-1 (resistance must not exceed 100 M).

Paint mist extraction systems/ventilation systems must be tted on site according to local regulations.

Make sure that the ground connection and potential equalization of all system parts are reliable and continuous and can withstand the expected stress (e.g. mechanical stress, corrosion).

Ensure that product hoses / air hoses adapted to the working pressure are used. Ensure that personal protective equipment (see Chapter 4.2.1) is available and is

used. 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 M.

VERSION 11/2018

Ensure that during spraying, persons wear electrically conductive gloves. The grounding takes place via the spray gun handle or the trigger.

Protective clothing, including gloves, must comply with EN 1149-5. The measured insulation resistance must not exceed 100 M.

Ensure that there are no ignition sources such as naked ames, 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.).

- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g., daily before commissioning, at the end of work or weekly.

Ensure that maintenance and safety checks are performed regularly. In the event of defects, immediately bring the device or system to a stop and

arrange to have repairs carried out immediately.

4.1.3 PERSONNEL QUALIFICATIONS

ORDER NUMBER DOC 2332848

Zip 52 Finishing

Hazard due to incorrect use of device!

Risk of death due to untrained personnel.

Ensure that the operating personnel has been instructed by the operator in accordance with the operating manual and the operating instructions. The device must only be operated, maintained and repaired by trained personnel. Refer to the operating instructions for information about the required personnel qualications.

4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL

Always follow the information in this manual, particularly the safety instructions and the warning instructions.

Always follow local regulations concerning occupational safety and accident prevention.

In electrostatics applications: anyone who belongs to a risk group according to EMF Directive 2013/35/EU (e.g. those with active implants), must not enter the highvoltage area.

4.2.1 PERSONAL SAFETY EQUIPMENT

Hazard due to dangerous uids or vapors!

Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.

When preparing or working with lacquer and when cleaning the device, follow the working instructions of the manufacturer of the lacquers, solvents, and cleaning agents being used.

Take the specied protective measures. In particular wear safety goggles, protective clothing and gloves, as well as hand protection cream if necessary.

Use a mask or breathing apparatus if necessary. For sucient health and environmental safety: Operate the device in a spray booth

or on a spraying wall with the ventilation (extraction) switched on. Wear suitable protective clothing when working with hot products.

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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES

Hazard due to injection of lacquer or ushing agent into the skin!

The spray jet is under pressure and can cause dangerous injuries. Avoid injection of lacquer or ushing agents:

Never point the spray gun at people. Never reach into the spray jet. Before any work on the device, in the event of work interruptions and malfunctions:

– Switch o the energy/compressed air supply. – Relieve the pressure from the spray gun and device. – Secure the spray gun against actuation.

− Disconnect the control unit from the mains. – In the event of functional faults, remedy the fault as described in the "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).

− For shut-down devices, the check can be postponed until the next start-up.

In the event of skin injuries caused by lacquer or ushing agents:

Note the lacquer or ushing agent that you have been using. Consult a doctor immediately.

ORDER NUMBER DOC 2332848

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4.2.3 GROUNDING THE UNIT

Hazard due to electrostatic charge!

Explosion hazard and damage to the device. Friction, owing liquids and air or electrostatic coating processes create charges. Flames

or sparks can form during discharge. Correct grounding of the entire spraying system prevents electrostatic charges.

Ensure that all devices and tanks are grounded before each spraying process. Ground the work pieces to be coated. Ensure that all persons inside the working area are grounded, e.g., that they are

wearing static dissipative shoes. Wear static dissipative gloves when spraying. The grounding takes place via the

spray gun handle or the trigger.

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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 ushing agents used.

Ensure that the product hose and the ttings are suitable for the pressure generated.

Ensure that the following information can be seen on the hose used:

− manufacturer

− permissible operating pressure

− date of manufacture Make sure that the hoses are laid only in suitable places. Hoses should not be laid in

the following places under any circumstances:

− in high-trafﬁc areas

− on sharp edges

− on moving parts

− on hot surfaces Ensure that the hoses are never run over by vehicles (e.g., fork lift trucks), or that the

hoses are never put under pressure from the outside in any other way. Ensure that the hoses are never kinked. Observe maximum bending radii. Ensure that no work is ever performed with a damaged hose. Make sure that the hoses are never used to pull or move the equipment. The electrical resistance of the product hose, measured at both valves, must be less

than 1 M. Suction hoses may not be subjected to pressure.

Several liquids have a high expansion coecient. In some cases, their volume can rise with consequent damage to pipes, ttings, etc. and cause uid leakage.

When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank (squeeze) and can cause it to break. The tank would leak and the liquid would ow out.

ORDER NUMBER DOC 2332848

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VERSION 11/2018

4.2.5 CLEANING AND FLUSHING

Hazard due to cleaning and ushing!

Explosion hazard and damage to the device.

Preference should be given to non-ignitable cleaning and ushing agents. When carrying out cleaning work with ammable cleaning agents, make sure

that all equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or static dissipative and grounded.

Observe the specications of the lacquer manufacturer. Ensure that the ash point of the cleaning agent is at least 15 K above the ambient

temperature or that cleaning is undertaken at a cleaning station with technical ventilation.

Never use chloride or halogenated solvents (such as trichloroethane and methylene chloride) with units containing aluminium or galvanized and zinc-plated parts. They may react chemically thus producing an explosion danger.

Take measures for workplace safety (see Chapter 4.1.2). When commissioning or emptying the device, please note that an explosive

mixture may temporarily exist inside the lines and components of equipment:

−depending upon the coating product used,

−depending on the ushing agent (solvent) used. Only electrically conductive tanks may be used for cleaning and ushing agents. The tanks must be grounded.

An explosive gas/air mixture forms in closed tanks.

Never spray into a closed tank when using solvents for ushing.

External Cleaning

When cleaning the exterior of the device or its parts, also observe the following:

Relieve the pressure from the device. De-energize the device electrically. Disconnect the pneumatic supply line. Use only moistened cloths and brushes. Never use abrasive agents or hard objects,

and never spray cleaning agents with a spray gun. Cleaning the device must not damage it in any way.

Ensure that no electric component is cleaned with or immersed into solvent.

ORDER NUMBER DOC 2332848

Zip 52 Finishing

4.2.6 TOUCHING HOT SURFACES

Hazard due to hot surfaces because of hot coating products!

Risk of burn injuries

Only touch hot surfaces if you are wearing protective gloves. When operating the device with a coating product with a temperature of > 43 °C;

109 °F: – Identify the device with a warning label "Warning – hot surface".

Part no.

9998910 instruction label 9998911 protection label

Note: Order the two stickers together.

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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. Do not change or modify the device; if change is necessary, contact WAGNER. Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are

assigned to the unit. Do not use any defective components. Before all work on the device and in the event of work interruptions:

- Relieve the pressure from the spray gun, hoses and all devices.

- Secure the spray gun against actuation.

- Switch o the energy and compressed air supply.

- Disconnect the control unit from the mains. Secure the spray gun against actuation.

Observe the operating and service manual for all work.

ORDER NUMBER DOC 2332848

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4.2.8 PROTECTIVE AND MONITORING EQUIPMENT

Hazard due to removal of protective and monitoring equipment!

Danger to life and equipment damage.

Protective and monitoring equipment must not be removed, modied or rendered unusable.

Regularly check for perfect functioning. If defects are detected on protective and monitoring equipment, the system must

not be operated until these defects are remedied.

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ORDER NUMBER DOC 2332848

5 DESCRIPTION

5.1 COMPONENTS OF ZIP 52 FINISHING

Designation

Pump pressure regulator

Product pressure regulator

Atomizing air pressure regulator

Product return valve

Air cut-o valve

(precisely adjustable lter ow controller with integrated pulsation damper)

B_04050

Zip 52 Finishing

5.2 COMPONENTS OF ZIP 52 PF ECOFINISHING

Designation

Pump pressure regulator

Atomizing air pressure

regulator

Material lter

Product return valve

Compressed air connection

B_04051

5.3 MODE OF OPERATION

The double diaphragm pump is driven with compressed air. A pneumatic manifold alternates in supplying two diaphragms with compressed air. Diaphragm motion is created in this manner. The product is thus sucked in and displaced again. A series of four non-return valves prevents the liquid from owing back, thus producing the suction and delivery phases in each pumping chamber, and generating the pumping eect.

VERSION 11/2018

5.4 PROTECTIVE AND MONITORING EQUIPMENT

ORDER NUMBER DOC 2332848

Zip 52 Finishing

WARNING

Overpressure!

Danger to life from bursting device components.

Never change the safety valve setting.

The air motor is tted with a safety valve. The safety valve has been set and sealed at the factory. In case of pressures over and above the permissible operating pressure, the valve, which is held with a spring, automatically opens and releases the excess pressure.

5.5 INCLUDED ITEMS

Order no. Designation

1 -- Diaphragm pump ZIP 52 Finishing / ZIP 52 PF Eco-Finishing

Suction hose with lter Fine Flow Controller FFC (for Zip 52 Finishing)

1 see Chapter 14

The standard equipment includes:

1 see Chapter 15.3 Declaration of Conformity 1 2332847 Operating manual, in German 1 see Chapter 1.3 Operating manual in the local language

The delivery note shows the exact scope of delivery.

Product lter (for ZIP 52 Eco-Finishing) Frame (for ZIP 52 Eco-Finishing) Connection elements

5.6 DATA

5.6.1 MATERIALS OF PAINTWETTED PARTS

Type Pump body Diaphragm Diaphragm disc Valve seat Valve ball O-rings

ZIP52 Aluminum UHMWPE PPS Stainless steel Stainless steel PTFE ZIP52 Stainless steel UHMWPE PPS Stainless steel Stainless steel PTFE ZIP52 Acetal (POM) UHMWPE POM Stainless steel Stainless steel PTFE ZIP52 PF Aluminum UHMWPE PPS Stainless steel Stainless steel PTFE

Positions of the individual parts: see Chapter 14.

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5.6.2 TECHNICAL DATA

Pump body Al SSt Acetal Al Description Units Zip 52 Zip 52 Zip 52 ZIP 52 PF

Pump ratio 1:1

Volume ow per double stroke

Maximum operating pressure

Maximum speed DH/min 490

Maximum ow rate

Compressed air quality: free from oil and water

Minimum air inlet pressure

Maximum air inlet pressure

Air inlet connection (plug) BSP(G) 1/4" F ø 8 mm Maximum suction height (1) (2) m

Maximum solid body size (5) mm

Sound pressure equivalent 50 cycles/min. (5 bar) Sound pressure equivalent at max. ow rate (8 bar) Sound power at maximum ow rate (8 bar) (4)

Fluid connections (inlet & outlet bushing) BSP(G) 1/4" M Weight kg

Product temperature

Ambient temperature

Allowable inclination for operation ± 10

(1) PF = Perfect Flow = low pulsation pump with a shorter stroke (2) Pump with stainless steel valves (start condition: empty pump / dry valves) (3) LqA (10s) (4) ISO 3744 (5) Technical data applies to the pump without a lter connected

ORDER NUMBER DOC 2332848

cm

cu inch

MPa

bar

psi

(1) (5)

(3) (5) (3) (4)

(5)

l/min

GPM

Quality standard 7.5.4 according to ISO 8573.1: 2010

MPa

bar

psi

MPa

bar

psi

Inches

dB(A) 73

dB(A) 85

dB(A) 99

lb °C °F °C °F

7: Particle concentration 5–10mg/m³ 5: Humidity: pressure dew point: ≤ +7 °C 4: Oil content ≤ 5mg/m3

19.8 4 – 90

39 – 194

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108

6.59

0.8 8

116

13.7

0.15

1.5 22

0.8 8

116

4.8

15.7

2.0

0.08

11.8 26

8.9

19.6

4 – 80

39 – 176

4 – 40

39.2 – 104

39 – 194

3.78

7.4

0.10

1.0 15

2.8

9.2

7.9

17.4

4 – 90

WARNING

Exhaust air containing oil!

Risk of poisoning if inhaled.

Provide compressed air free from oil and water.

VERSION 11/2018

ORDER NUMBER DOC 2332848

5.6.3 DIMENSIONS AND CONNECTIONS

mm; inch

A 280; 11.02 B 189; 7.44 C 15; 0.59

9; ø 0.35

E 360; 14.17

F 158; 6.22 G 21; 0.83 H 250; 9.84

B_04046

B C

A E

on trolley mm; inch

A 520; 20.47

B 481; 18.94

C 1015; 39.96 D 930; 36.61

E 720; 28.35

Zip 52 Finishing

D (x4)

FG G

B_04047

VERSION 11/2018

mm; inch

A 405; 15.94

B 335; 13.19

C 940; 37.01 D 602; 23.70

ORDER NUMBER DOC 2332848

Zip 52 Finishing

5.6.4 PERFORMANCE DIAGRAMS

Example

Stroke frequency /min

8 bar

6 bar

4 bar

B_00301

Product pressure bar (MPa) psi

Water ow rate l/min <gpm>

8 bar

6 bar

4 bar

B_04048

Air consumption nl/min <scfm>

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

Zip 52

bar (MPa)

<psi>

10 (1.0)

<145>

8.0 (0.8)

<116>

6.0 (0.6)

<87>

4.0 (0.4)

<58>

Product pressure

2.0 (0.2)

<29>

Stroke frequency /min

<13.21>

<15.85>

0 0

<2.64>

<5.28>

<7.92>

<10.56>

Flow rate (water) A = 6 bar; 0.6 MPa; 87 psi air pressure B = 5 bar; 0.5 MPa; 73 psi air pressure C = 4 bar; 0.4 MPa; 58 psi air pressure

nl/min

<scfm>

750

<26.9>

600

<21.4>

450

<16.1>

300

<10.7>

150

<5.4>

l/min

<gpm>

ZIP 52 PF

bar (MPa)

<psi>

10 (1.0)

<145>

8.0 (0.8)

<116>

6.0 (0.6)

<87>

4.0 (0.4)

Air consumption

<58>

Product pressure

2.0 (0.2)

<29>

Stroke frequency /min

<3.96>

<5.28>

0 0

<1.32>

<2.64>

Flow rate (water) A = 6 bar; 0.6 MPa; 87 psi air pressure B = 5 bar; 0.5 MPa; 73 psi air pressure C = 4 bar; 0.4 MPa; 58 psi air pressure

The charts above refer to the aluminium version with stainless steel valves without an attached lter.

5.6.5 OPERATING ELEMENTS

<6.60>

nl/min

<scfm>

250

<8.9>

200

<7.1>

150

<5.4>

100

<3.6>

Air consumption

<1.8>

l/min

<7.92>

<gpm>

B_06955

Designation

1 Return valve 2 Pump pressure regulator (Zip 52 PF) 3 Atomizing air pressure regulator 4 Pump pressure regulator (ZIP 52) 5 Product pressure regulator (ZIP 52) 6 Valve compressed air connection (ZIP 52)

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

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.

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned.

6.2 STORAGE CONDITIONS

Until the point of assembly, the device must be stored in a dry location, free from vibrations and with a minimum of dust. The device must be stored in closed rooms.

The air temperature at the storage location must be between -20 °C and 60 °C (-4 °F and 140 °F).

The relative air humidity at the storage location must be between 10 and 95% (without condensation).

6.3 INSTALLATION CONDITIONS

The air temperature at the installation site must be in a range between 0 °C and 40 °C (32 °F and 132 °F).

The relative air humidity at the installation site must be between 10 and 95% (without condensation).

6.4 TRANSPORTATION

The pump can be moved on a trolley or manually without lifting equipment e.g., a crane.

6.5 ASSEMBLY AND INSTALLATION

WARNING

Inclined ground!

Risk of accidents if the device rolls away/falls.

Position the trolley with the double diaphragm pump horizontally. If the oor is inclined, position the feet of the trolley towards the gradient. Secure the trolley.

National regulations

Ensure that the national explosion prevention rules and regulations are observed when setting up the device.

VERSION 11/2018

B_06947

6.5.1 POSITIONING

Procedure:

1. Mount the pump on a frame, trolley or wall mount.

2. Connect the suction system and air supply.

3. Connect the material and air supply in accordance with the superordinate operating manual.

Designation

1 Product outlet 2 Product return valve 3 Fine Flow Controller (Zip 52 - gure above)

Product lter (Zip 52 PF - gure below) 4 Compressed air connection 5 Atomizing air pressure regulator 6 Product pressure regulator (Zip 52 - gure above) 7 Pump pressure regulator 8 Air suction lter 9 Suction hose

10 Product inlet

Product connection:

Connect the suction hose (on the underside) and the lacquer/air double hose to the corresponding connections. Notice: Connect the product hose and air hose correctly. Connect a suitable spray gun to the other end of the double hose. For pumps installed in areas subject to explosion hazards, all hoses and pipes must be made of conductive material and must be grounded. All hoses, pipes and components connected to the supply line must be designed to operate at the pump’s maximum pressure with the pump working at a vigorous rate.

Compressed air connection:

Connect the device’s air inlet ttings to the distribution network. Caution: The connection must be carried out on the device's tting. Do not replace the original connection. Use a pipeline with a suitable diameter for the connection. Provide an external air cut-o valve for the ZIP52 PF Eco-Finishing. The pressure must not exceed the maximum value indicated on the type plate.

ORDER NUMBER DOC 2332848

Zip 52 Finishing

B_06944

B_06048

VERSION 11/2018

6.5.2 VENTILATION OF THE SPRAY BOOTH

Operate the device in a spray booth approved for the working materials.

- or -

Operate the device on an appropriate spraying wall with the ventilation (extraction) switched on.

Observe national and local regulations for the exhaust air speed.

6.5.3 AIR SUPPLY LINES

Ensure that only dry, clean atomizing air is used in the spray gun! Dirt and moisture in the atomizing air worsens the spraying quality and spray pattern.

ORDER NUMBER DOC 2332848

Zip 52 Finishing

WARNING

Hose connections!

Risk of injury and damage to the device.

Do not mix up hose connections of product hose and air hose.

6.5.4 PRODUCT SUPPLY LINES

DANGER

Bursting hose, bursting threaded joints!

Danger to life from injection of product.

Ensure that the hose material is chemically resistant to the sprayed products.

Ensure that the spray gun, ttings and product hose between the device and the spray gun are suitable for the pressure generated in the device.

Ensure that the following information can be seen on the hose:

- manufacturer,

- permissible operating pressure,

- date of manufacture.

6.6 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 insucient!

Danger of poisoning. Insucient paint application quality.

Ground all device components. Ground the work pieces to be coated.

VERSION 11/2018

Grounding scheme (example)

EX zone

Pump

ORDER NUMBER DOC 2332848

Work piece

Zip 52 Finishing

Conveyor

Product tank

R max < 1 MΩ

Spraying stand

B_06945

Floor, static dissipative

Part / workstation Cable cross section

Pump 4 mm; AWG 12 Paint tank 6 mm; AWG 10 Conveyor 16 mm; AWG 6 Booth 16 mm; AWG 6 Spraying stand 16 mm; AWG 6

Safe operation of the pump is only guaranteed with a grounding connection. Connect all grounding cables using a short and direct route.

Procedure

1. Remove the crimp connection delivered with the pump.

2. Attach crimp connection to the grounding cable and re-attach it to the pump.

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.

Ex zone

All devices and equipment must be suitable for use in potentially explosive areas.

All paints, ushing agents and waste tanks have to be electrically conductive. All tanks must be grounded.

B_04049

VERSION 11/2018

6.7 COMMISSIONING

ORDER NUMBER DOC 2332848

Zip 52 Finishing

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts.

Ensure that the pump and suction system are always completely ﬁlled with ushing agent or working medium.

Do not spray the device empty after cleaning.

NOTICE

Impurities in the spraying system!

Spray gun blockage.

Flush the spray gun and paint supply with a suitable ushing agent before commissioning.

Emergency stop, see Chapter 7.2.

Preparation

Before every start-up, the following points should be observed as laid down in the operating manual:

− Secure spray gun with safety lever.

− Check the permissible pressures.

− Check all connections for leaks.

− Check hoses for damage in accordance with Chapter 8.2.3.

Fill the pump with ushing agent

The devices are tested during manufacturing with emulsifying oil, pure oil or solvent. Possible residues must be ushed out of the circuits with a solvent (ushing agent) before commissioning.

− Fill the empty device with ushing agent in accordance with Chapter 8.2.5.

Pressure tightness test

WARNING

Overpressure!

Risk of injury from bursting components.

The operating pressure must not exceed the value shown on the type plate.

− Gradually increase the pressure in pump with the pressure regulator until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points for leaks.

− Depressurization in accordance with Chapter 7.4.

Verifying a Safe Operational Condition

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned. This includes:

− Carry out safety checks in accordance with Chapter 8.2.3.

Filling with Working Material

− According to Chapter 8.2.5.

VERSION 11/2018

ORDER NUMBER DOC 2332848

7 OPERATION

7.1 TRAINING THE OPERATING PERSONNEL

The operating personnel must be qualied 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.

7.2 EMERGENCY STOP

In the case of unforeseen occurrences:

– Immediately close the air cut-o valve (4).

ZIP 52 Finishing: An air cut-o valve is installed. ZIP 52 PF Eco-Finishing: An air cut-o valve must be provided by the user.

– Open the return valve (5) and/or the delivery devices (valves or guns).

Zip 52 Finishing

7.3 TASKS

Ensure that:

commissioning is carried out in accordance with Chapter 6.7.

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Secure spray gun and insert nozzle into the spray gun.

3. Slowly open the shut-o valve (4).

4. The pump supplies the product (8) while the spray gun (9) is open.

5. Set the air pressure to 1–1.5 bar with the pump pressure regulator (1) and the product pressure regulator (2, for ZIP 52 Finishing), in order to reach the desired product amount and/or the desired product pressure.

6. Set the atomizing air pressure regulator (3) to 1.5–2 bar.

7. Start work process.

closed

open

B_06949

VERSION 11/2018

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. In this case, more lacquer must be supplied. If enough lacquer is available and the pump still shakes, the suction lter is clogged and must be cleaned.

In case air accidentally ows into the pump suction inlet, the compressed air pressure must be reduced to avoid the pump working at an excessive speed.

7.3.2 PRODUCT PRESSURE AND ATOMIZING AIR PRESSURE

The previously indicated values for the product pressure (1–1.5 bar), and for the atomizing air pressure (1.5–2 bar) should be considered reference values, since the pressure is dependent upon the characteristics of the lacquer to be used, above all on its viscosity. If paints or other very uid products are used, the product pressure should be set extremely low (to approximately 0.5 bar or even lower). On the other hand, highly viscous lacquers require a pressure as high as 3 bar or even higher. The atomizing air pressure must be set to 1–2.5 bar, depending on the lacquer characteristics. To obtain perfect atomization and to avoid spray mist, the lowest possible atomizing air pressure must be used. In some cases, the spray gun must be provided with a very low product pressure and a very high atomizing air pressure. Carefully choose the appropriate atomizing cap for the spray gun.

ORDER NUMBER DOC 2332848

Zip 52 Finishing

7.4 PRESSURE RELIEF/WORK INTERRUPTION

The pressure must always be relieved:

− after the spraying tasks are nished,

− before servicing or repairing the system,

− before carrying out cleaning tasks on the system,

− before moving the system to another location,

− before something needs to be checked on the system,

− before the nozzle or the lter is removed from the spray gun.

The components for pressure relief on a CE-compliant spraying system include:

− Outlet equipment (return valve) mounted between pump and spray gun.

Process for relieving pressure

1. Close the product delivery valve or any other device installed on the delivery line (such as outlet valves or spray guns).

2. Close the air cut-o valve. Relieve the pressure in the product line, by opening the return valve (if installed) or the dispensing device (valve or spray gun).

3. Close and secure return valve and dispensing device.

Note:

Control air pressure is still present. If the system will process 2K products:

NOTICE

Hardened working material in the spraying system when 2K product is processed!

Destruction of pump and injection system.

Observe the manufacturer's processing rules, particularly in regards to the pot life. Flush thoroughly before the end of the pot life. The pot life is decreased by warmth.

VERSION 11/2018

7.5 BASIC FLUSHING

Regular ushing

Regular ushing, cleaning and maintenance ensures the pump's high pumping and extraction capacity. The cleaning and ushing agents used must be compatible with the working material.

ORDER NUMBER DOC 2332848

WARNING

Incompatibility of ushing / cleaning agent with the working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the ushing and cleaning agents and working media on the basis of the safety data sheets.

Zip 52 Finishing

Procedure

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Place empty, grounded tank (7) under the return tube (6).

3. Place the suction hose in the grounded tank with ushing agent (8).

4. Completely close the pressure regulator (1) and atomizing air pressure regulator (3) (0 MPa; 0 bar; 0 psi).

Flushing via the return valve

5. Open return valve (5).

6. Slowly open the air cut-o valve (4).

7. Turn the pressure regulator (1) clockwise until the pump starts.

8. Flush the system until clean ushing agent ows into the tank (7).

9. Close the pressure regulator (1).

10. As soon as there is no pressure remaining in the system, close the return valve (5).

Flushing via the gun

11. Point the spray gun, without nozzle, into the tank (7) and

open it.

12. Slowly open pressure regulator (1).

13. Rinse until clean ushing agent ows from the spray gun.

14. Close the pressure regulator (1).

15. When there is no pressure remaining in the system, close the spray gun.

16. Secure the spray gun.

17. Dispose of the contents of the tank (7) according to the local regulations.

In case of start-up problems:

If the pump doesn't start up, carry out the following steps:

Close the air cut-o valve (4). Turn the pressure regulator (1) counterclockwise (0 bar pressure). Open the air cut-o valve (4). Turn the pressure regulator (1) clockwise until the pump starts.

If necessary, repeat the operation several times.

closed

open

B_06949

7.5.1 FILLING WITH WORKING MATERIAL

After basic ushing, the pump can be lled with working material. Proceed according to Chapter 8.2.5, but use working material instead of ushing agent.

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

8 CLEANING AND MAINTENANCE

8.1 CLEANING

8.1.1 CLEANING PERSONNEL

Cleaning work should be undertaken regularly and carefully by qualied and trained personnel. They should be informed of specic hazards during their training. The following hazards may arise during cleaning work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable cleaning tools and aids.

8.1.2 DECOMMISSIONING AND CLEANING

The device should be cleaned for maintenance purposes, etc. Ensure that no remaining product dries on and sticks to the device.

Procedure

1. Carry out work interruption Chapter 7.4.

2. Carry out the basic ushing Chapter 7.5.

3. Empty system in a controlled manner Chapter 8.2.4.

4. Service spray gun in accordance to its operating instructions.

5. Clean and check the suction system and the suction lter.

6. Clean the outside of the system.

7. Fully assemble the system.

8. Fill the system with ushing agent in accordance with Chapter 8.2.5.

8.1.3 LONGTERM STORAGE

If storing the system for a prolonged period of time, thorough cleaning and corrosion protection are necessary. Replace the water or solvent in the product pump with a suitable preserving oil.

Procedure

1. Carry out points 1 to 7 in Chapter 8.1.2 "Decommissioning and Cleaning".

2. Fill the system with preservative in accordance with Chapter 8.2.5.

3. Empty the system in a controlled manner in accordance with Chapter 8.2.4 and seal the openings.

VERSION 11/2018

8.2 MAINTENANCE

8.2.1 MAINTENANCE PERSONNEL

Maintenance work should be undertaken regularly and carefully by qualied and trained personnel. They should be informed of specic hazards during their training. The following hazards may arise during maintenance work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable tools and aids.

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

8.2.2 MAINTENANCE INSTRUCTIONS

ORDER NUMBER DOC 2332848

Zip 52 Finishing

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. Before all work on the device and in the event of work interruptions:

- Relieve the pressure from the spray gun, product hoses and all devices.

- Secure the spray gun against actuation.

- Switch o the energy and compressed air supply.

- Disconnect the control unit from the mains. Observe the operating and service manual for all work.

Prior to Maintenance

It should be ensured that the device is in the following state before carrying out any work on it:

− Flush and clean the system. Chapter 8.1.2

− Relieve the pressure from the pump, product hose and spray gun.

− Secure spray gun with safety lever.

− Interrupt the air supply.

− Depending on the operation, disconnect the product and air-side connection pipes.

− Remove the pump from the base or support it is fastened to.

After maintenance

− Carry out safety checks in accordance with Chapter 8.2.3.

− Put the system into operation and check for leaks as described in Chapter 6.7.

− Have the system checked for safe condition by an authorized person.

− Function test in accordance with Chapter 11.

VERSION 11/2018

8.2.3 SAFETY CHECKS AND MAINTENANCE INTERVALS

Every day

Check grounding: see Chapter 6.5. Check delivery and suction lters. Check hoses, tubes and couplings: see Chapter 8.2.3.1.

Weekly

Check system for damage.

Check and tighten fastening screws.

Check for air and liquid leakages. Check that the safety xtures function properly (see Chapter 5.4).

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.

– For shut down devices, the examination can be suspended until the next start-

up.

ORDER NUMBER DOC 2332848

Zip 52 Finishing

8.2.3.1 PRODUCT HOSES, PIPES AND COUPLINGS

The service life of the complete hoses between product pressure generator and application device is reduced due to environmental inuences even when handled correctly.

Check hoses, pipes, and couplings every day and replace if necessary. Before every commissioning, check all connections for leaks. Additionally, the operator must regularly check the complete hoses for wear and tear as well as for damage at intervals that he/she has set. Records of these checks must be kept. The complete hose is to be replaced as soon as one of the two following intervals has been exceeded:

−6 years from the date of the hose crimping (see tting embossing).

−10 years from the date of the hose imprinting.

Fitting embossing Meaning

xxx bar Pressure yymm Crimping date (year/month) XX Internal code

Hose imprinting Meaning

Wagner Name / Manufacturer yymm Date of manufacture (year/month) xxx bar (xx MPa) e.g., 270 bar (27 MPa) XX Internal code DNxx (e.g., DN10) Nominal diameter

Pressure

VERSION 11/2018

8.2.4 EMPTYING PUMP

ORDER NUMBER DOC 2332848

Zip 52 Finishing

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts. Ignition of potentially explosive surrounding atmosphere.

Empty the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

If the pumping product becomes heated, switch o all heaters and let the product cool o.

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Place an empty, grounded collection tank (7) under the return tube (6).

3. Place the suction hose in an empty, grounded tank (8).

4. Close the pump pressure regulator (1) and atomizing air pressure regulator (3) (0MPa; 0bar; 0psi).

Emptying via return line

5. Open return valve (5).

6. Slowly open the air cut-o valve (4).

7. Slowly turn air pressure up on the pressure regulator (1) and only until the pump is running normally (approx. 0.15 MPa; 1.5 bar; 21.75 psi).

8. Be ready for the switch from working material to air.

9. As soon as working material is no longer owing from the return tube (6), close pressure regulator (1).

10. Close return valve (5).

Empty up to the gun

11. Point the spray gun, without nozzle, into the tank (7) and open it.

12. Slowly open pressure regulator (1). Be ready for the switch from working material to air.

13. As soon as working material is no longer owing, close the pressure regulator (1).

14. Close and secure the spray gun.

15. Depressurization in accordance with Chapter 7.4.

16. Dispose of the contents of the tank (7) according to the local regulations.

closed

open

B_06949

VERSION 11/2018

8.2.5 FILLING THE EMPTY PUMP

ORDER NUMBER DOC 2332848

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts. Ignition of potentially explosive surrounding atmosphere.

Fill the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

Zip 52 Finishing

Procedure

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Place empty, grounded tank (7) under the return tube (6).

3. Place the suction hose in a grounded tank with working material (8).

4. Completely close the pump pressure regulator (1) and atomizing air pressure regulator (3) (0MPa; 0bar; 0psi).

5. Open return valve (5).

6. Slowly open the air cut-o valve (4).

7. Turn the pump pressure regulator (1) clockwise until the pump starts. Be ready to switch from air to working material and prevent back spray.

8. Close the pressure regulator (1) as soon as pure working material starts coming from the return tube (6).

9. Close return valve (5).

10. Point the spray gun, without nozzle, into the tank (7) and open it.

11. Slowly open pressure regulator (1). Be ready to switch from air to working material and prevent back spray.

12. As soon as pure working material without air bubbles is owing, close pressure regulator (1).

13. Close and secure the spray gun.

14. Depressurization in accordance with Chapter 7.4.

15. Dispose of the contents of the tank (7) according to the local regulations.

In case of start-up problems:

If the pump doesn't start up, carry out the following steps:

Close the air cut-o valve (4). Turn the pressure regulator (1) counterclockwise (0 bar pressure). Open the air cut-o valve (4). Turn the pressure regulator (1) clockwise until the pump starts.

If necessary, repeat the operation several times.

closed

open

B_06949

VERSION 11/2018

B_04059

ORDER NUMBER DOC 2332848

Zip 52 Finishing

8.3 CLEANING THE FILTER

This pump has one lter inside the suction tube and another inside the delivery circuit (ZIP52 Finishing: Fine Flow Controller - ZIP52 PF Eco-Finishing: product lter). The lters must be cleaned regularly. Clean the lter every time that the lacquer color is changed.

Before cleaning the lters, close the air cut-o valve and release the pressure contained inside the pump and the pipes attached to it.

8.3.1 SUCTION TUBE FILTER

To clean the suction tube lter, remove the spring, take out the suction lter and lter disc and place them in ushing agent. Then, blow them o with compressed air.

B_04060

8.3.2 FINE FLOW CONTROLLER ZIP52 FINISHING

To clean the lter of the Fine Flow Controller, unscrew the union nut (1) from the metal body and lift the lter cup (2). When doing so, pay attention to the PTFE seal on the edge. Remove the lter (3) from the base (4), pulling it upward, since it has a very simple clip xing. Place the lter cartridge in the ushing agent, then brush and blow it o. Make sure that the inside of the lter is cleaned with ushing agent and is blown out. Re-insert the lter by simply pushing it onto the lter seat until the xing clip audibly clicks into place. Do not push the lter downwards any further, to avoid damaging it. Reposition the lter cup making sure that the PTFE seal is in the perfect position. Then, screw the union nut tight.

8.3.3 FILTER ZIP52 ECOFINISHING

To clean the lter of the ZIP52 Eco-Finishing device, simply remove the upper cover (1) from the lter housing (2), by unscrewing it, then unscrew the lter’s lock-ring (3) and remove the lter element (4). Remove the internal spring (5) from the lter element. Place the lter cartridge and the internal spring in the ushing agent. Then brush them o and blow them out. Make sure that the inside of the lter is cleaned with ushing agent and is blown

out.

B_04052

Reassemble in reverse order, taking care not to damage the plastic seal (6).

B_04053

VERSION 11/2018

B_04067

12 Nm

8.8 lbft

B_04015

ORDER NUMBER DOC 2332848

Zip 52 Finishing

8.4 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!

B_04066

a) Remove the suction and delivery manifolds.

b) Disassemble the fastening nuts and remove the outer diaphragm covers. Dismount

the pressure side cover (1).

c) Hold the end nut of the outer diaphragm disc with a wrench. Loosen the end nut of

the other diaphragm disc and dismount it.

d) Remove the released diaphragm with its corresponding internal disc, and remove

the shaft from the motor block.

e) 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. Then remove the second diaphragm with its internal disc.

f) Assemble the new diaphragm with its internal disc and properly fasten it to the

relevant external disc.

g) Remove the shaft from the bench vice and put it in the motor block. Grease the

shaft inside and outside (beyond the underside of the motor block). Thereby move the shaft into dierent positions. See Chapter 14.

h) Mount the inner diaphragm disc, the diaphragm and the outer disc and tighten

them properly onto the nut of the opposite outer discs using two wrenches.

i) Attach the silencer and the pressure side cover. Check the correct positioning of

the cover and its seal.

k) Attach the outer diaphragm cover and the manifolds. Ensure correct position of

seals of the ball valves when doing so.

l) Screw on and tighten the cover screws. Fasten the manifold screws. Apply the

correct torque, in accordance with Chapter 14.

VERSION 11/2018

8.5 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. Replace if

worn.

d) Remove all dirt particles as well as hardened product residues. Check the balls and seats for excessive

wear. Clean or replace the components.

e) Clean the contact surfaces of the manifolds and the diaphragm cover and mount the components. Apply

the correct torque, in accordance with Chapter 14.

It is recommended that the static seals be replaced when reassembling.

8.6 REPLACEMENT OF THE REVERSING VALVE

a) Dismount 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).

c) Install the new reversing valve. When doing so, apply the correct torque (see picture in Chapter 10.6).

Mount the valve slider (6) on one of the stroke stop positions. There are four possible positions, each of them is suitable. Attach the pressure side cover.

During the performance of the operations described above, check the positioning of the valve's seals and cover including the seal. Apply the correct torque, in accordance with Chapter 14.

The reversing valve of the pump is lubricated at the factory and does not need any lubrication.

ORDER NUMBER DOC 2332848

Zip 52 Finishing

VERSION 11/2018

ORDER NUMBER DOC 2332848

9 TROUBLESHOOTING AND RECTIFICATION

Problem Cause Remedy

The device does not work.

The device is working (i.e., the pump is moving), but no uid is delivered.

The product ow is irregular or decreases during work.

The device works even if the spray gun is closed.

The pump stops often.

The device has no compressed air.

The product pressure regulator is set to 0 (ZIP52 Finishing).

The pump is blocked near the reversal point.

Fine Flow Controller (or product lter on the ZIP52 PF EcoFinishing) is clogged.

No uid is available at the pump’s inlet.

Air suction lter clogged Carefully clean the lter. The suction tube is clogged or

leaking (is possibly sucking air in from the atmosphere).

Suction problems Check the suction tube to see if it is partially

Conveying problems Partial clogging of the delivery line or the paint

Non-return valves are leaking. Contamination or wear in the non-return valves.

The return valve is not closed properly.

Low air pressure to the pump. Increase the air pressure. Non-return valves' guides/stops

are worn.

Ice formation inside the air outlet pipes

Check the compressed air supply line and the air cut-o valve.

Check the compressed air maintenance device (if available).

Check the pressure setting on the product pressure regulator. If necessary, increase the pressure.

Close the air cut-o valve. Turn the pressure regulator knob approximately half a turn clockwise. Open the air cut-o valve again. Repeat until the pump starts.

Clean or replace the lter.

Check the uid level in the tank or container.

Check the suction tube. Replace it if necessary.

clogged. Replace it if necessary.

hose. Clean or replace.

Check the non-return valves and replace them if necessary.

Check the return valve to see if it is open or leaking.

Check the non-return valves. Replace the delivery manifold or pump cover if necessary. With the acetal pump, the ball-guide can be replaced.

Check the compressed air quality. Install a condensation separator in the air line.

Zip 52 Finishing

Install an air dryer if necessary. If necessary, install an oiler and ll it with special

de-icing uid.

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

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

10 REPAIR WORK

10.1 REPAIR PERSONNEL

Repair work must be carried out carefully and by qualied and trained personnel. They should be informed of specic hazards during their training. The following hazards may arise during repair work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable tools and aids.

A skilled person must check to ensure that the device is in a reliable state after it is repaired. Carry out function test in accordance with Chapter 11.

10.2 REPAIR NOTES

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. Before all work on the device and in the event of work interruptions:

- Relieve the pressure from the spray gun, hoses and all devices.

- Secure the spray gun against actuation.

- Switch o the energy and compressed air supply.

- Disconnect the control unit from the mains. Observe the operating and service manual for all work.

Before Repair Work

It should be ensured that the device is in the following state before carrying out any work on it:

− Flush and clean the system. Chapter 8.1.2

− Interrupt the air supply.

− Depending on the operation, disconnect the product and air-side connection pipes.

− Remove the pump from the base or support it is fastened to.

After Repair Work

− Carry out safety checks in accordance with Chapter 8.2.3.

− Commission the system according to Chapter 6.7.

− Have the system checked for safe condition by an authorized person.

− Function test in accordance with Chapter 11.

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

VERSION 11/2018

10.4 CLEANING THE PARTS AFTER DISASSEMBLY

ORDER NUMBER DOC 2332848

Zip 52 Finishing

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.

Please note:

Thoroughly clean all reusable parts with a suitable cleaning agent. All dismantled parts have to be clean and dry after cleaning. Care should be taken

that these parts remain free of solvents, grease or sweat from the hands (salt water). Perform cleaning and mounting tasks wearing gloves.

10.5 ASSEMBLY OF THE DEVICE

In Chapter 14 the order numbers for device spare parts can be found, as well as for wearing parts such as seals.

Defective parts, O-rings and seal sets must always be replaced. Use greases and glues in accordance with Chapter 14. Observe torque specications in Chapter 14.

Assembly Aids

Order no. Quantity Designation

9992590 1 pc ≙ 50 ml Loctite 222 9992831 1 pc ≙ 50 ml Loctite 542 Z125.00 1 pc ≙ 1 kg Grease

Brand notice

The brands specied in this document are property of the respective owners. Loctite , for example, is a registered brand of Henkel.

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

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 uid, must be checked. Mark the coupled parts (diaphragm covers, manifold, covers) with a felt-tip pen so as to make subsequent reassembly easier.

a) According to Chapter 8.4, points a), b), c) d) and e): b) Follow the disassembly procedure of the

diaphragms. c) Remove the reversing valve (2). d) Remove the shaft's plastic bushings (3) located at

each end of the motor block, the lip seals (4) and

the feeler pins (5). e) Clean all the components, openings and spaces

within the motor block. Blow the housing cavity

of the reversing valve out thoroughly with a jet of

compressed air (wear safety goggles). f) Check the condition of the reversing valve. If

necessary replace. g) Assemble all the parts described under point c)

paying attention to properly orient the seals lips

(see Chapter 11, exploded view). h) Grease feeler pins (5) with lip seal (4) once more

from outside.

i) Put the reversing valve back in its housing. When

B_04018

doing so, apply the correct torque. Position the

valve slider (6) on one of the stroke stop positions.

There are four possible positions, each of them is

suitable.

j) According to Chapter 8.4, points f), g), h), i) k) and

l):

Reassemble the remaining components.

3.5 Nm

2.6 lbft

2 Nm; 1.5 lbft

2 Nm

1.5 lbft

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

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.

Activity Means

1. EX-relevant inspections

− Check mass connection between grounding connection of the pump and the frame/trolley and between the individual components of the frame/ trolley: <100k

These inspections are − relevant!!

2. Testing for leaks

− Connect the pump to the air supply with a pressure of 6 bar. To perform a leak test on the device, the product pressure with the ushing agent is slowly increased in increments until the maximum pressure indicated on the type plate is reached. Close pump outlet. Allow to stand in this position for 0.5-1 minute and listen for audible blowing o. When the air supply is turned o, a drop in pressure must be watched for.

3. General inspections

− Check tightening torque of various screws. see Chapter 14. Torque wrench

− Check all ttings.

− Empty device (Chapter 8.2.4) and depressurize it (Chapter 7.4).

− Check function of frame or transport trolley. Check whether the pump is mounted horizontally on the frame.

Ohmmeter

Air motor: Test medium com-

pressed air Leak spray Fluid section:

Test medium: suitable ushing agent

Visual check

12 DISPOSAL

When the equipment must be scrapped, please dierentiate the disposal of the waste materials.

The following materials have been used:

Stainless steel Aluminum Elastomers Plastics Carbide

Consumable products

Consumable products (lacquers, adhesives, ushing and cleaning agents and solvents) must be disposed of in accordance with all legal requirements and provisions.

VERSION 11/2018

13 ACCESSORIES

ORDER NUMBER DOC 2332848

Zip 52 Finishing

1 2

6 7

B_04054

VERSION 11/2018

Order no. Designation

1 U760.00 ZIP52 Finishing, aluminium 1 U765.00 ZIP52 Finishing, stainless steel 1 U773.00 ZIP52 Finishing, (POM) acetal 2 U731.00 ZIP52 PF Eco-Finishing 3 S419.00G Low-pressure double hose 3 S419.00GI Low-pressure double hose, stainless steel 4 R950.xx Spray gun, SP5 4 V1061304xx3 Spray gun, Pilot Trend MP 4 V1060203xx3 Spray gun, Pilot Trend HP 4 V1070203xx3 Spray gun, Pilot Premium HP 4 V1070404xx3 Spray gun, Pilot Premium HVLP PLUS 4 V1070603xx3 Spray gun, Pilot Premium HVLP 5 T406.00 Suction hose, stainless steel, complete 6 H401.07 Filter disk 7 T453.03 Air suction lter 8 H206.03 Spring

9 S402.06A Solvent resistant suction hose 10 T420.00 Suction tube, stainless steel 11 E0107.03 Contact clamp, stainless steel 12 R601.00 Hose clamp 13 T760.00M Wall mount 14 T760.00S Frame set 15 T760.00R Wheel set with handle 16 T760.00SR Trolley, complete

ORDER NUMBER DOC 2332848

Zip 52 Finishing

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

14 SPARE PARTS

14.1 HOW CAN SPARE PARTS BE ORDERED?

Always supply the following information to ensure delivery of the right spare part:

Order number, designation and quantity

The quantity need not be the same as the number given in the quantity column " " on the list. This number merely indicates how many of the respective parts are used in each component.

The following information is also required to ensure smooth processing of your order:

− address for the invoice,

− address for delivery,

− name of the person to be contacted in the event of any queries,

− Type of delivery (normal mail, express delivery, air freight, courier etc.)

Identication in spare parts lists

Explanation of column " " (labeling) in the following spare parts lists:

Wearing parts/ Wearing parts are not included in the warranty terms. Included in service set

Notice

These parts are not covered by warranty terms.

Not part of standard equipment, available, however, as additional extra.

Explanation of order no. column

-- Item not available as spare part. / Position does not exist.

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. Before all work on the device and in the event of work interruptions:

- Relieve the pressure from the spray gun, hoses and all devices.

- Secure the spray gun against actuation.

- Switch o the energy and compressed air supply.

- Disconnect the control unit from the mains. Observe the operating and service manual for all work.

VERSION 11/2018

14.2 SPARE PARTS FOR ZIP 52 FINISHING

ORDER NUMBER DOC 2332848

(U765.00)

Zip 52 Finishing

20 21

1 9

(U765.00)

B_04055

VERSION 11/2018

Order no. Order no. Order no. Designation

1 1 U760.00 U765.00 U773.00 DDP ZIP52 2 1 T0180.00A T0180.00AI T0180.L0AI FFC 14/0.5-8 bar pneum., aluminium

3 1 E3105.92 E3105.92 E3105.92 Zip52 pump bracket 4 1 E3106.92 E3106.92 E3106.92 Mounting plate for FFC 5 1 M208.04 B274.03 B274.03 Hose connection, 1/2"x16 6 1 M247.00 -- -- MF Reducer, 1/2-1/4 7 1 9998039 -- -- Elbow tting, MM 1/4" 8 1 S591.00C S591.00C S591.00C Paint hose

9 2 9998253 9998253 9998253 Screw-in tting, 8-1/4" 10 2 M205.04A M801.03B M801.03B Fitting, 1/4" 11 3 P904.00 P904.00 P904.00 Pressure gauge 0-10 bar 12 3 M286.00 M286.00 M286.00 Quick tting, D F 1/8"x4 13 1 Z547.00 Z547.00 Z547.00 Controller plate 14 1 Z548.C0 Z548.C0 Z548.C0 Zip52 Finishing Label 15 4 M335.00 M335.00 M335.00 Fitting, L 1/8"x4 16 1 9904307 M826.03B M826.03B Plug, E 1/4" 17 1 M109.00 M513.00IA M513.00IA Ball valve, MF 1/4" 18 1 9992265 M881.03 M881.03 Fitting, L MF 1/4" 19 1 M205.04 M801.03C M801.03C Double tting, 1/4" 20 4 K107.62 K107.62 K107.62 Screw, M6x20 21 8 9920103 9920103 9920103 Washer, A6.4, DIN 125 22 1 T139.01 T139.01 T139.01 Air manifold 23 3 M404.00 M404.00 M404.00 Hollow screw 24 1 M250.00 M250.00 M250.00 MF reducer, 3/8"-1/4" 25 1 9985682 9985682 9985682 Reducing tting, 1/4"A-1/4"I 26 1 M101.00 M101.00 M101.00 Ball valve, FM 1/4" 27 3 L212.06 L212.06 L212.06 O-ring 28 1 S455.07A S455.07A S455.07A Paint reducer air pipe 29 3 S455.07 S455.07 S455.07 Pressure gauge reducer pipe 30 1 M354.00 M354.00 M354.00 Revolving quick tting, L 1/4"x4 31 1 M204.14A M204.14A M204.14A Extension, MF 1/4" 32 3 P123.00 P123.00 P123.00 Air pressure regulator, 1/4” 33 4 9910204 9910204 9910204 Self-locking nut, M6 34 1 S401.00 -- -- Return hose, BP MT 2 D 8 35 1 9998039 9998039 9998039 Screw tting elbow, MM 1/4" 36 1 S455.07B S455.07B S455.07B Pump feeding air tube 37 1 -- M801.03A M801.03B Fitting, 1/4" stainless steel 38 1 -- B0264.03 B0264.03 Fitting, 1/2" stainless steel 39 2 m -- S103.07N S103.07N Hose, nylon D8 40 1 -- M057.07 M057.07 Fitting, 1/4"x8 41 1 H261.03 H261.03 H261.03 Spring 42 3 M404.00G M404.00G M404.00G Seal 43 1 9992831 9992831 9992831 Loctite 542, 50ml; 50cc

ORDER NUMBER DOC 2332848

Zip 52 Finishing

Wearing part

VERSION 11/2018

14.3 ZIP 52 PF ECOFINISHING

ORDER NUMBER DOC 2332848

Zip 52 Finishing

5 26 27

B_04056

VERSION 11/2018

Order no. Designation

1 1 U731.00 ZIP52 PF Eco-Finishing 2 1 E3112.92 Mounting plate for Zip52 3 2 E111.92b Leg ZIP52 Eco 4 4 R211.07 Closure cap D20 5 2 P123.00E Compressed air regulator, 1/4" 6 2 P936.00 Pressure gauge, 0-10 bar D50x1/8" 7 3 M336.00 Male stud elbow, 8-1/4" 8 1 M205.04 Double tting, 1/4"

9 1 M340.00 Fitting, T MFM 1/4" 10 1 M208.04 Hose connection, 1/2"x16 11 1 M254.14A Plug, 1/2" 12 1 M109.00 Ball valve, MF 1/4" 13 1 S401.00 Return hose, D8 14 8 K564.72 Contact washer 15 0.3 m S103.07N Hose, nylon D8 16 1 M215.04 Screw tting elbow, MM 1/4" 17 1 M618.62 Fitting, 3/8"-1/4" 18 1 T4005.00ALS LP ZIP Filter, PN15 G1/4" CS 19 1 M631.62 Fitting, 1/2" 20 1 M623.12 Plug, 1/4" 21 1 M213.04 Male stud elbow, MF 1/4" 22 4 K107.62 Screw, M6x20 23 8 K505.62 Washer, A6.4, DIN 125 24 8 K311.62 Self-locking nut, M6 25 2 K166.62 Screw, M4x50 26 4 K501.62 Washer, A4.3 27 2 K302.62 Self-locking nut, M4 28 4 K134.62 Screw, M6x55 29 1 9992831 Loctite 542, 50ml; 50cc

ORDER NUMBER DOC 2332848

Zip 52 Finishing

VERSION 11/2018

14.4 ZIP 52 METAL PUMP

ORDER NUMBER DOC 2332848

5 Nm; 3.7 lbft

Zip 52 Finishing

12 Nm; 8.8 lbft

5 Nm; 3.7 lbft

B_04058

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

ZIP 52 –

Aluminum

Order no.

1 1 F184.01 F188.03 F184.01 Suction manifold - left

2 1 F185.01 F189.03 F185.01 Delivery manifold - left

3 2 F834.07R F834.07R F834.07R Outer diaphragm disc

4 2 F978.01 F192.03 F978.01 Diaphragm cover

5 2 G921.07B G921.07B G921.07B Product diaphragm

6 -- -- -- -- Support diaphragm

7 4 K142.62 K142.62 K142.62 Screw, M6x35

8 4 K183.62 -- K183.62 Screw, M6x30

8 4 -- K142.62 -- Screw, M6x35

9 12 K311.62 K311.62 K311.62 Self-locking nut, M6 10 8 9910204 9910204 9910204 Nut, M6 11 20 9920103 9920103 9920103 Washer, A6.4 12 1 K1012.62 K1012.62 K1012.62 Screw 13 2 K1041.62 K1041.62 K1041.62 Rivet 14 12 K1044.62 K1044.62 K1044.62 Screw 15 -- -- -- -- Plug, 1/2" 16 1 T6103.00 T6103.00 T6103.00S Motor 17 4 T6105.00 T6105.00 T6105.00 Zip52 valve unit 18 1 Y622.00A Y622.00A Y622.00A Cable lug 19 1 -- -- -- Zip52 ATEX cover label 20 2 -- -- -- Round type plate 21 1 -- -- B0177.14A Reducing nipple 22 4 K805.03 K805.03 K805.03 Ball, 3/4" 23 4 B0148.03A B0148.03A B0148.03A Seat 24 4 L206.05 L206.05 L206.05 O-ring 25 1 9992831 9992831 9992831 Loctite 542, 50ml; 50cc

1 T9080.00 T9080.00 T9080.00 Pump service set 1 T9077.00 T9077.00 T9077.00 O-ring set

ZIP 52 –

Stainless Steel

Order no.

ZIP 52 PF – Aluminum

Order no. Designation

Wearing part Included in service set Included in product’s O-ring set

VERSION 11/2018

14.5 ZIP 52 PUMP  CONDUCTIVE ACETAL

ORDER NUMBER DOC 2332848

4.5 Nm; 3.3 lbft

Zip 52 Finishing

(21*)

12 Nm; 8.8 lbft

7 Nm; 5.2 lbft

B_04063

4.5 Nm; 3.3 lbft

VERSION 11/2018

Order no. Designation

1 U773.00 DDP ZIP52 1 1 F833.07G-A Suction manifold - left 2 1 F859.07G Delivery manifold - left 3 2 F834.07D External diaphragm disc 4 2 F831.07G-A Conductive diaphragm cover 5 2 G921.07B Diaphragm 7 4 K128.62 Screw, M6x40 8 4 K1076.62 Screw, M6x75 9 20 K311.62 Self-locking nut, M6

10 4 9920103 Washer, 6 11 16 K508.62 Washer, 6x18 12 1 K1012.62 Screw 13 2 K1041.62 Rivet 14 12 K1043.62 Screw, M6x45 16 1 T6103.00 Motor 17 4 T6105.00 Valve unit 18 1 Y622.00A Cable lug 19 1 -- Cover type plate 20 2 -- Round type plate 21 1 -- Nipple 22 4 K805.03 Ball, 3/4" 23 4 B0148.03A Seat 24 4 L206.05 O-ring 25 2 F856.07D Ball guide 26 1 9992831 Loctite 542 27 1 K558.62 Washer

ORDER NUMBER DOC 2332848

Zip 52 Finishing

Wearing part Included in service set Included in product’s O-ring set

21* If the complete double diaphragm pump is ordered as a spare part, the tting (item

21) must be removed.

VERSION 11/2018

14.6 ZIP MOTOR

ORDER NUMBER DOC 2332848

3.5 Nm; 2.6 lbft

Zip 52 Finishing

2 Nm;

1.5 lbft

2 Nm; 1.5 lbft

B_04027

VERSION 11/2018

ORDER NUMBER DOC 2332848

Zip 52 Finishing

Zip 52

Order no.

1 T6103.00 T6103.00S Motor 1 2 B0146.04 B0146.04 Feeler pin 2 2 B0147.71 B0147.71 Inner diaphragm disc 3 1 B0150.03 B0150.03S Shaft 4 1 F194.91 F194.91 Cover (pressure side) 5 2 F829.07 F829.07 Shaft guide bushing 6 1 F830.07 F830.07 Cover (exhaust side) 7 1 T6103.00A T6103.00A Motor block with safety valve 8 1 G925.06 G925.06 Reversing valve seals 9 1 G7020.06 G7020.06 Pressure cover seals

10 1 H618.07 H618.07 Silencer 11 4 K1038.62 K1038.62 Screw 12 6 K1039.62 K1039.62 Screw 13 2 L470.06 L470.06 Lip seal 14 2 L471.06 L471.06 Lip seal 15 1 P4003.00 P4003.00 Reversing valve (*) 16 1 see pos. 7 see pos. 7 Safety valve (**) 17 1 Z546.C0 Z546.C0 Side label 18 4 K1040.62 K1040.62 Screw 19 4 K564.72 K564.72 Contact washer 20 4 K311.62 K311.62 Self-locking nut, M6

* Includes pos. 8 and 9.

** Not available separately

ZIP 52 PF Order

no. Designation

Wearing part included in pump's service set

VERSION 11/2018

ORDER NUMBER DOC 2332848

14.7 TROLLEY, FRAME SET, AND WHEEL SET

Zip 52 Finishing

B_04035

Sliding tables

Order no.

Frame set

Order no.

Wheel set

Order no. Designation

1 T760.00SR -- -- Sliding tables

1 T760.00S T760.00S -- Frame set

1 T760.00R -- T760.00R Wheel set with handle 1 1 E3108.92 -- -- 1 E3108.92 Trolley handle 2 1 E3107.92A 1 E3107.92A -- -- Frame, left 3 1 E3107.92 1 E3107.92 -- -- Frame, right 4 1 H1156.62 1 H1156.62 -- -- Frame pin 5 4 R204.07 4 R204.07 -- -- Plug 6 1 H009.62 1 H009.62 -- -- Spray gun hook 7 2 9900316 -- -- 2 9900316 Socket cap screw, M6x50 8 9 3155404 -- -- 4 3155404 Contact washer, M8 9 2 9900389 4 9900389 -- -- Socket cap screw, M6x45

10 2 9900309 2 9900309 -- -- Socket cap screw, M8x40 11 2 K607.02 -- -- 2 K607.02 Lock washer for shaft 12 4 9925011 -- -- 4 9925011 Washer 13 5 9910204 5 9910204 2 9910204 Self-locking nut, M6 14 2 R118.00 -- -- 2 R118.00 Wheel, D150 15 4 R244.07 4 R244.07 -- -- Saddle feet for round tubes 16 2 9920103 -- -- -- -- Washer, A6.4

VERSION 11/2018

14.8 MATERIAL FILTER

ORDER NUMBER DOC 2332848

Zip 52 Finishing

B_04057

Order no. Designation

1 T4005.00ALS Product lter: LP ZIP Filter, PN15 G1/4“ CS 1 1 B0259.01 Filter housing 2 1 B0127.01 Filter cap 3 1 T454.00 APS lter cartridge, 60 mesh 4 1 H282.03 Spring for lter, inox 5 1 H1152.03 Filter tension rod 6 1 B0128.03 Filter nut 7 1 G605.07 Seal 8 1 M623.12 Plug, 1/4" 9 1 M6016.12 Plug, 3/8"

10 1 9992831 Loctite 542, 50ml; 50cc

Wearing part

VERSION 11/2018

14.9 FINE FLOW CONTROLLER

ORDER NUMBER DOC 2332848

Zip 52 Finishing

40 Nm

5 Nm

6 Nm

B_04036

VERSION 11/2018

Order no. Order no. Designation

1 T0180.00A T0180.00AI Fine Flow Controller, 14/0.5-8 bar 1 1 A588.03 A588.03 Diaphragm disc - product side 2 1 A590.03 A590.03 Diaphragm disc - air side 3 1 B0172.03 B0172.03 Ball guide 4 1 B0180.01 B0180.03 Housing - product side 5 1 B391.03 B391.03 Shut-o needle 6 1 B563.01 B563.01 Housing - air side 7 1 T6007.00A T6007.00A Ball seat body, complete 8 1 F991.07 F991.07 Union nut 9 1 F992.07 F992.07 Filter cup

10 1 G725.05 G725.05 RVO PTFE Diaphragm 11 1 G726.06 G726.06 RVO Diaphragm 12 1 G640.05B G640.05B Seal 13 1 H285.03 H285.03 Conical spring 14 1 K311.62 K311.62 Self-locking nut, M6 15 6 K515.62 K515.62 Plain washer 16 1 K811.03 K811.03 Ball, 1/4" 17 6 K1055.62 K1055.62 Screw, M5x30 18 1 L148.06 L148.06 O-ring 19 1 L118.06A L118.06A O-ring 20 1 T500.00A T500.00A Filter insert, 100 mesh, white 20 1 T500.00 T500.00 Filter insert, 60 mesh, black 20 1 T500.00B T500.00B Filter insert, 150 mesh

T6193.00 T6193.00 FFC service set T9086.00 T9086.00 FFC sealing set

ORDER NUMBER DOC 2332848

Zip 52 Finishing

Wearing part included in FFC service set included in FFC sealing set

VERSION 11/2018

14.10 SERVICE SETS

Pump No. Diaphragm Valve seat Valve ball Service set O-ring set Air valve set

U731.00 UHMWPE Stainless

U760.00 UHMWPE Stainless

U765.00 UHMWPE Stainless

U773.00 UHMWPE Stainless

Service set consists of: see spare parts lists

O-ring set consists of:

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

ORDER NUMBER DOC 2332848

steel

Stainless

steel

Stainless

steel

Stainless

steel

Stainless

steel

T9080.00 T9077.00 P4003.00

Zip 52 Finishing

Service sets for Fine Flow Controller

Pump No. FFC service set FFC sealing set

U731.00 T6193.00 -U760.00 T6193.00 T9086.00 U765.00 T6193.00 T9086.00 U773.00 T6193.00 T9086.00

FFC service set consists of: see spare parts list FFC sealing set consists of: see spare parts list

VERSION 11/2018

ORDER NUMBER DOC 2332848

15 EU DECLARATION OF CONFORMITY

We hereby declare that the supplied version of diaphragm pumps and spray packs:

Aluminum Stainless steel (POM) acetal Aluminum

complies with the following guidelines:

2006/42/EC 2014/34/EU (ATEX Directive)

Applied standards, in particular:

EN ISO 12100:2010 EN 12621: 2006+A1: 2010 EN809: 1998+A1:2009+AC:2010 EN 1127-1:2011 EN ISO 4413:2010 EN ISO 80079-36:2016 EN ISO 4414:2010 EN ISO 80079-37:2016 EN ISO 13732-1:2008 EN ISO/IEC 80079-34:2011 EN14462:2015

Zip 52 Finishing

Applied national technical standards and specications, in particular:

Chapter 2.29 and Chapter 2.36

Identication:

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 no. 2332848 Edition 11/2018

ts-liquid@wagner-group.com

Document No. 11145910

Version B

www.wagner-group.com

WAGNER Zip 52 Finishing, ZIP 52 PF Eco-Finishing Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual