WAGNER ZIP52 Finishing Operational manual

B_07802
Pneumatic double diaphragm pump
ZIP52 - ZIP80
Translation of the Original Operating Manual
+  II2GExhIIBT4GbX
For professional use.
Always observe the information in this manual, particularly the safety
instructions and the warning instructions. Store the manual in a safe place. Edition: 09/2021

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
Table of Contents
Order number DOC 2330426 | Edition 09/2021 3
TABLE OF CONTENTS
1 About these instructions 5
1.1 Preface 5
1.2 Warnings, Notices and Symbols in these Instructions 5
1.3 General Characters and Symbols 5
1.4 Languages 6
1.5 Abbreviations 6
1.6 Terminology for the Purpose of this Manual 7
2 Using in accordance with the instructions 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 9
2.5 Misuse 10
3 Identification 11
3.1 Identification of Non-ignitable Products 11
3.2 Explosion Protection Identification 11
3.3 Identification "X" 11
3.4 Type Plate 12
4 Basic Safety Instructions 14
4.1 Safety Instructions for the Operator 14
4.2 Safety Instructions for the Personnel 15
5 Description 20
5.1 Components 20
5.2 Mode of Operation 20
5.3 Protective and Monitoring Equipment 20
5.4 Scope of Delivery 21
5.5 Data 21
6 Assembly and Commissioning 29
6.1 Training of Assembly/Commissioning Personnel 29
6.2 Storage Conditions 29
6.3 Installation Conditions 29
6.4 Transportation 29
6.5 Assembly and Installation 29
6.6 Grounding 33
6.7 Commissioning 35
7 Operation 37
7.1 Training the Operating Personnel 37
7.2 Emergency Stop 37
7.3 Tasks 37
7.4 Pressure Relief / Work Interruption 38
7.5 Basic Flushing 38
8 Cleaning and Maintenance 41
8.1 Cleaning 41
8.2 Maintenance 41
8.3 Replacing the Diaphragm (Preventive Maintenance) 46
8.4 Cleaning/Replacement of the Suction and Delivery Non-Return Valves 47
8.5 Replacement of the Reversing Valve 47

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
Table of Contents
4 Order number DOC 2330426 | Edition 09/2021
9 Troubleshooting and Rectification 48
10 Repairs 49
10.1 Repair Personnel 49
10.2 Repair Notes 49
10.3 Tools 50
10.4 Cleaning the Parts after Disassembly 50
10.5 Assembly of the Device 50
10.6 Replacing the Diaphragm (Due to Breakage) 50
11 Function Test after Repair Work 52
12 Disposal 53
12.1 Device 53
12.2 Consumable products 53
13 Accessories 54
14 Spare Parts 56
14.1 How to order spare parts 56
14.2 Notes on Using Spare Parts 56
14.3 ZIP52 Pump - Metallic - Universal Connections 57
14.4 ZIP52 Pump - Metallic - Independent Connections 59
14.5 ZIP52 Pump - Conductive Acetal 61
14.6 ZIP52 Pump - Polypropylene - Universal Connections 63
14.7 ZIP80 Pump - Aluminum - Universal Connections 65
14.8 ZIP Motor 67
14.9 Service Sets 68
15 Declaration of Conformity 70
15.1 EU Declaration of Conformity 70

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
1 About these instructions
Order number DOC 2330426 | Edition 09/2021 5
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 Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential danger.
Non-observance may result in death or serious injury.
CAUTION Potentially dangerous situation.
Non-observance may result in minor injury.
NOTICE Potentially dangerous situation.
Non-observance may result in damage to property.
Info Provides information about particular characteristics and how to
proceed.
Explanation of warning notice:
WARNING
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
4The measures for preventing the hazard and its consequences.
1.3 GENERAL CHARACTERS AND SYMBOLS
The characters and symbols in this operating manual indicate the following:
üRequirement that must be fulfilled before an action can be performed.
1. Step 1 of an action to be performed with several action steps.
4Second level action step
2. Step 2
ðIntermediate result of an action
ðResult of a complete action
4Action to be performed with an action step
1. Numbered list, first level
– Numbered list, second level

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
1 About these instructions
6 Order number DOC 2330426 | Edition 09/2021
– 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 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2330425
Translation of the original operating manual
Language Order no. Language Order no.
English 2330426 Swedish 2341252
French 2335553 Turkish 2372050
Italian 2332230 Hungarian 2353652
Spanish 2335555 Portuguese 2404241
Chinese 2373697 Romanian 2408586
Russian 2359663
Additional languages upon request or at: www.wagner-group.com
1.5 ABBREVIATIONS
Order no. Order number
ET Spare part
K Marking in the spare parts lists
Pos Position
Stk Number of pieces
DH Double stroke
SSt Stainless steel
2K Two components
Al Aluminum
FFC Fine-Flow Controller (precisely adjustable filter flow controller with inte-
grated pulsation damper)
PP Polypropylene
POM Polyoxymethylene (Acetal)
PPS Polypropylene sulfide
PTFE Polytetrafluorethylene
UHMWPE Ultra-high molecular polyethylene

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
1 About these instructions
Order number DOC 2330426 | Edition 09/2021 7
1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent.
Flushing Internal flushing of paint-wetted parts with flushing agent.
Product pressure
generator
Pump or pressure tank.
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.
Electrically
trained person
Is instructed by an electrician about the tasks assigned to him/her, the
potential risks associated with improper behavior as well as the neces-
sary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible hazards
based on his/her technical training, knowledge and experience in rele-
vant provisions.
Skilled person in
accordance with
TRBS 1203
(2010/Revision
2012)
A person, who, based on his/her technical training, experience and re-
cent vocational experience, has sufficient technical knowledge in the ar-
eas of explosion protection, protection from pressure hazards and elec-
tric 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.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
2 Using in accordance with the instructions
8 Order number DOC 2330426 | Edition 09/2021
2 USING IN ACCORDANCE WITH THE INSTRUCTIONS
2.1 DEVICE TYPE
Pneumatic double diaphragm pump with order no.:
A: Metallic versions in aluminum and stainless steel.
ZIP52 ZIP52 PF ZIP80
U550.ATRD7 U551.ATSS7 U555.ATSS7
U550.ATSS7 U551.303 --
U550.ATSS8 -- --
U550.STSS7 -- --
B: Conductive acetal versions.
ZIP52 ZIP52 PF
U552.GHSS7 U553.GTSS1
C: Non-conductive polypropylene versions.
ZIP52 ZIP52 PF
U552.PTSS7 U553.PHSD7
-- U553.PTSS7
2.2 TYPE OF USE
The device is suitable for processing liquid products like paints and lacquers:
A) Metallic versions (aluminum and stainless steel)
B) Conductive acetal versions
– Products in accordance with their classification in explosion class IIB.
– Non-ignitable products.
C) Non-conductive polypropylene versions
– Non-ignitable products.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
4Use the device only to work with the materials recommended by WAGNER.
4Do not deactivate safety fixtures.
4Use only WAGNER original spare parts and accessories.
4The operating personnel must be trained on the basis of this operating manual.
4Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
A) Metallic versions (aluminum and stainless steel)
B) Conductive acetal versions
The device can be employed in explosion hazard zones (Zone 1) (see Chapter Identification
[811]).

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
2 Using in accordance with the instructions
Order number DOC 2330426 | Edition 09/2021 9
C) Non-conductive polypropylene versions
The pneumatic double diaphragm pump must be employed outside of explosion hazard
zones.
2.4 PROCESSIBLE WORKING MATERIALS
Fluid materials like paints and lacquers.
Application ZIP80 ZIP52 ZIP52 PF
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 ↗↗↗
Signs and definitions: ↗recommended
→limited suitability
↘not suitable
NOTICE
Abrasive working materials and pigments!
Greater wear of product-wetted parts.
4Use the application-oriented model (flow rate/cycle, product, valves, etc.) as
indicated in the Chapter Technical Data.
4Check if the fluids and solvents being used are compatible with the pump
construction materials as indicated in the Chapter Materials of Paint-wetted Parts.
Wear caused by abrasive working materials is not covered by the warranty.
Typical applications
Application ZIP80 ZIP52 ZIP52 PF
Furniture industry ↗↗↗
Kitchen manufacturers ↗↗↗
Joinery ↗↗↗
Window factories ↗↗↗
Steel-processing industry ↗↗↗
Construction of vehicles ↗↗↗
Shipbuilding ↘↘↘
Signs and definitions: ↗recommended
→limited suitability
↘not suitable

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
2 Using in accordance with the instructions
10 Order number DOC 2330426 | Edition 09/2021
2.5 MISUSE
Misuse can lead to physical injury and/or property damage! Special attention must be paid
that:
4No dry coating products, e.g., powder are processed.
4No food, medicine or cosmetics are processed. It is important to note that the device's
materials are not food-safe.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
3 Identification
Order number DOC 2330426 | Edition 09/2021 11
3 IDENTIFICATION
3.1 IDENTIFICATION OF NON-IGNITABLE PRODUCTS
Device types: C) Non-conductive polypropylene versions
Pneumatic double diaphragm pumps with Order no.
ZIP52 ZIP52 PF
U552.PTSS7 U553.PHSD7
-- U553.PTSS7
3.2 EXPLOSION PROTECTION IDENTIFICATION
Device types: A) Metallic versions (aluminum and stainless steel)
B) Conductive acetal versions
Pneumatic double diaphragm pumps with Order no.
ZIP52 ZIP52 PF ZIP80
U550.ATRD7 U551.ATSS7 U555.ATSS7
U550.ATSS7 U551.303 --
U550.ATSS8 U553.GTSS1 --
U550.STSS7 -- --
U552.GHSS7 -- --
As defined in Directive 2014/34/EU(ATEX), the device is suitable for use in potentially
explosive areas.
Manufacturer Wagner International AG
9450 Altstätten
Switzerland
 II2GExhIIBT4GbX
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
Gb Zone1 high safety level
X Special notes (see Chapter Identification "X" [811])
3.3 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter Technical data.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
3 Identification
12 Order number DOC 2330426 | Edition 09/2021
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
4Knocking or pushing metal against metal is to be avoided.
4Do 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
4Ensure 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.
Electrostatic surface spraying
4Do not spray device parts using electrostatic equipment.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
4Remove deposits from the surfaces to maintain conductivity.
4Use only a damp cloth to clean the device.
Air in the pump fluid
Ignitable gas mixtures can form if air enters the pump fluid.
4Prevent the pump from taking in air and running dry.
4If air has been taken in, fix the leak. Then, fill slowly and in a controlled manner until the
air has escaped.
Air in the pumped liquid can be caused by damaged diaphragms.
4Avoid operating the pump with damaged diaphragms.
4Periodically check that the pump is working smoothly, paying special attention to the
presence of air in the pumped fluid.
Filling and emptying
Ignitable gas mixtures can form in the fluid section or product hoses if the pump must be
emptied for maintenance and/or repair purposes.
4Empty and fill the device slowly and in a controlled manner.
4Avoid potentially explosive atmosphere in the surroundings.
3.4 TYPE PLATE
For information on EX and non-EX versions, see chapter Declaration of Conformity [870].

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
3 Identification
Order number DOC 2330426 | Edition 09/2021 13
Type plate of EX versions
Übersetzungsverhältnis / Ratio
Fördermenge DH / Delivery DS
Art-Nr. / Part No.
Max. Temp. Material / Fluid
Baujahr - Serie Nr. / Year of manufacture - Serial No.
Vor Gebrauch Betriebs- anleitung beachten
Check manual before use
Wagner International AG
CH-9450 ALTSTÄTTEN
Assembled by WAGNER in Switzerland
ZIP52 Max. Fluid pressure: 8bar-0.8MPa-116psi
Max. Air pressure: 8bar-0.8MPa-116psi
II 2 G Ex h IIB T4 Gb X
1
3
5
6
27
8
9
10
11
12
13
B_07800
4
Example type plate ZIP52
1 Manufacturer 8 Pump ratio
2 Device Type 9 DH flow rate
3 CE and UKCA identification 10 Max. product temperature
4 Ex identification 11 Article number
5 Indication of origin 12 Model year - serial number
6 Max. product pressure 13 Read the operating manual before use
7 Max. air pressure
Type plate of non-EX versions
Übersetzungsverhältnis / Ratio
Fördermenge DH / Delivery DS
Art-Nr. / Part No.
Max. Temp. Material / Fluid
Baujahr - Serie Nr. / Year of manufacture - Serial No.
Vor Gebrauch Betriebs- anleitung beachten
Check manual before use
Wagner International AG
CH-9450 ALTSTÄTTEN Assembled by WAGNER in Switzerland
ZIP52 Max. Fluid pressure: 8bar-0.8MPa-116psi
Max. Air pressure: 8bar-0.8MPa-116psi
1
3
4
5
26
7
8
9
10
11
12
B_07898
Example type plate ZIP52
1 Manufacturer 7 Pump ratio
2 Device Type 8 DH flow rate
3 CE and UKCA identification 9 Max. product temperature
4 Indication of origin 10 Article number
5 Max. product pressure 11 Model year - serial number
6 Max. air pressure 12 Read the operating manual before use

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
4 Basic Safety Instructions
14 Order number DOC 2330426 | Edition 09/2021
4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4Keep this operating manual at hand near the device at all times.
4Always follow existing regulations concerning occupational safety and accident
prevention regulations.
4.1.1 Electrical Devices and Equipment
Danger of electric shock!
Danger to life from electric shock:
4Place and operate device in accordance with the existing safety requirements with
regard to the operating mode and ambient influences.
4May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
4Operate device in accordance with the safety regulations and electrotechnical
regulations.
4Do not disconnect any plug connections during operation.
4Label plug connections with the warning "Do not disconnect when energized".
4Must be repaired immediately in the event of problems.
4Decommission if device poses a danger or is damaged.
4Must be de-energized before work is commenced.
4Secure the device against being switched back on without authorization.
4Inform personnel about planned work.
4Observe electrical safety regulations.
4Ground all devices to a common grounding point.
4Only operate the device with a properly installed socket with a protective ground wire
connection.
4Keep liquids away from electrical devices.
4.1.2 A Safe Work Environment
Danger due to dangerous fluids or vapors!
Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with the
skin or eyes.
4Ensure that the floor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 MΩ).
4Paint mist extraction systems/ventilation systems must be fitted on site according to
local regulations.
4Make 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).
4Ensure that product hoses/air hoses adapted to the working pressure are used.
4Ensure that personal protective equipment is available and is used.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
4 Basic Safety Instructions
Order number DOC 2330426 | Edition 09/2021 15
4Make sure that all people within the work area wear static dissipative shoes. Footwear
must comply with EN 20344. The measured insulation resistance must not exceed 100
MΩ.
4Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun's handle or its trigger.
4Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 MΩ.
4Ensure that there are no ignition sources such as naked flames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
4Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
4Periodic preventative maintenance and service (replacing hoses, checking tightness
strength of connections, etc.)
4Regular monitoring of leaks and defects via visual inspection and odor testing, e.g.,
daily before commissioning, at the end of work or weekly.
4Ensure that maintenance and safety checks are performed regularly.
4In 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
Danger due to incorrect use of device!
Risk of death due to untrained personnel.
4Ensure 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 qualifications.
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
4Always observe the information in this manual, particularly the safety instructions and
the warning instructions.
4Always follow existing regulations concerning occupational safety and accident
prevention regulations.
Danger due to high-voltage field!
Danger to life from malfunction of active implants.
4Persons belonging to a risk group according to EMF guideline 2013/35/EU (e.g., carriers
of active implants), must not enter the high-voltage area.
4.2.1 Personal Safety Equipment
Danger due to dangerous fluids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
4When 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.
4Implement the prescribed safety measures, in particular the wearing of safety glasses,
safety clothing and protective gloves as well as the use of protective hand cream.
4Use a mask or breathing apparatus if necessary.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
4 Basic Safety Instructions
16 Order number DOC 2330426 | Edition 09/2021
4For sufficient health and environmental safety: Operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
4Wear suitable protective clothing when working with hot products.
Danger due to noise pollution!
Hearing damage due to noise pollution.
4Wear ear protection.
4.2.2 Safe Handling of WAGNER Spray Devices
Danger due to injection of lacquer or flushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of lacquer or flushing agents:
4Never point the spray gun at people.
4Never reach into the spray jet.
4Perform the following measures before any work on the device, in the event of work
interruptions and malfunctions:
4Switch off the energy/compressed air supply
4Relieve the pressure from the spray gun and device
4Securing the Spray Gun Against Actuation
4Disconnect the control unit from the mains
4In the event of functional faults, remedy the fault as described in the chapter on
troubleshooting and rectification.
4If 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.
4For shut down devices, the examination can be suspended until the next start-up.
In the event of skin injuries caused by lacquer or flushing agents:
4Note the lacquer or flushing agent that you have been using.
4Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby, the user can lose his balance
and injure himself when falling.
Avoid risk of injury from recoil forces:
4Ensure that you have firm footing when operating the spray gun.
4.2.3 Grounding the Device
Danger due to electrostatic charge!
Risk of injury, explosion hazard and damage to the device.
Friction, flowing 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.
4Ensure that all devices and tanks are grounded before each spraying process.
4Make sure that the ground and potential equalization of all system parts are performed
reliably and continuously and can withstand the expected stress (e.g., mechanical
stress, corrosion).

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
4 Basic Safety Instructions
Order number DOC 2330426 | Edition 09/2021 17
4Earth the workpieces being painted.
4Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
4Wear static dissipative gloves when spraying. The grounding takes place via the spray
gun's handle or its trigger.
4.2.4 Product Hoses
Danger due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
4Ensure that the hose material is chemically resistant to the sprayed products and the
flushing agents used.
4Ensure that the product hoses and the fittings are suitable for the pressure generated.
4Ensure that the following information can be seen on the high-pressure hose:
4Manufacturer
4permissible operating pressure
4Date of manufacture
4Make sure that the hoses are laid only in suitable places. Hoses should not be laid in the
following places under any circumstances:
4in high traffic areas
4on sharp edges
4on moving parts
4on hot surfaces
4Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses
are never put under pressure from the outside in any other way.
4Ensure that the hoses are never kinked. Observe maximum bending radii.
4Ensure that no work is ever performed with a damaged hose.
4Make sure that the hoses are never used to pull or move the device.
4The electrical resistance of the product hose, measured at both valves, must be less
than 1 MΩ.
4Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coefficient. In some cases, their volume can rise with
consequent damage to pipes, fittings, etc. and cause fluid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can enter
the tank. In this way 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 flow out.
The pressure created by the pump can be a multiple of the input air pressure.
4.2.5 Cleaning and Flushing
Danger due to cleaning and flushing!
Explosion hazard and damage to the device.
4Non-ignitable cleaning agents and flushing agents should preferably be used.
4When carrying out cleaning work with flammable cleaning agents, make sure that all
equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or
static dissipative and grounded.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
4 Basic Safety Instructions
18 Order number DOC 2330426 | Edition 09/2021
4Observe the specifications of the lacquer manufacturer.
4Ensure that the flash 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.
4Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with devices containing aluminium or galvanized/zinc-plated parts. They may
react chemically thus producing an explosion danger.
4Take measures for workplace safety.
4It should be noted that when the device is put into operation or emptied: depending
on the coating product used, depending on the rinsing agent (solvent) used, there may
briefly be a mixture inside the pipes and equipment which can ignite.
4Only use electrically conductive tanks for cleaning and flushing agents.
4The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
4Never spray into a closed tank when using solvents for flushing.
External Cleaning
When cleaning the exterior of the device or its parts, also observe the following:
4Relieve the pressure from the device.
4De-energize the device electrically.
4Disconnect the pneumatic supply line.
4Use only moistened cloths and brushes. Never use abrasive agents or hard objects and
never spray cleaning agents with a gun. Cleaning the device must not damage it in any
way.
4Ensure that no electric component is cleaned with or immersed into solvent.
4.2.6 Touching Hot Surfaces
Danger due to hot surfaces because of hot coating products!
Risk of burn injuries
4Only touch hot surfaces if you are wearing protective gloves.
4When operating the device with a coating product with a temperature of > 43 °C; 109
°F, apply a warning label to the device that says "Warning - Hot Surface."
Instruction label: Order no. 9998910
Protection label: Order no. 9998911
Info
Order the two labels together.
4.2.7 Maintenance and Repair
Danger due to improper maintenance and repair!
Danger to life and equipment damage.
4Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
4Repair or replacement of devices or parts of devices are only allowed to be performed
outside the hazard area by qualified personnel.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
4 Basic Safety Instructions
Order number DOC 2330426 | Edition 09/2021 19
4Use only WAGNER original spare parts and accessories.
4Do not change or modify the device; if change is necessary, contact WAGNER.
4Only repair and replace parts that are listed in Chapters Accessories and Spare Parts
[856] and that are assigned to the device.
4Do not use any defective components.
4Before all work on the device and in the event of work interruptions:
4Relieve the pressure from the spray gun, product hoses and all devices.
4Secure the spray gun against actuation.
4Switch off the energy and compressed air supply.
4Disconnect the control unit from the mains.
4Observe the operating and service manual for all work.
4.2.8 Protective and Monitoring Equipment
Danger due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
4Protective and monitoring equipment must not be removed, modified or rendered
unusable.
4Regularly check for perfect functioning.
4If defects are detected on protective and monitoring equipment, the system must not
be operated until these defects are remedied.

Operating manual Pneumatic double diaphragm pump ZIP52 - ZIP80
5 Description
20 Order number DOC 2330426 | Edition 09/2021
5 DESCRIPTION
5.1 COMPONENTS
12
5
4
3
4
3
6
B_06950
1 Delivery manifold 4 Product input
2 Air input 5 Product distributor
3 Product output 6 Grounding connection
5.2 MODE OF OPERATION
The double diaphragm pump is driven with compressed air. A pneumatic manifold
alternates in supplying two diaphragms with compressed air. 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 flowing back, thus producing the suction and delivery
phases in each pumping chamber, and generating the pumping effect.
5.3 PROTECTIVE AND MONITORING EQUIPMENT
WARNING
Overpressure!
Danger to life from bursting device components.
4Never change the safety valve setting.
The air motor is fitted 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.