WAGNER ZIP52 Finishing User manual

Zip 52 Finishing
ZIP 52 PF Eco-Finishing
Pneumatic Double
Diaphragm Pump
Spraypack
Version 11/2018
B_04043
B_04045

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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

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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
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

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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

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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 Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential risk.
Non-observance can result in death or serious injury.
CAUTION Potentially hazardous situation.
Non-observance may result in minor injury.
NOTICE Potentially hazardous situation.
Non-observance may result in damage to property.
Notice Provides information about particular characteristics and
how to proceed.
Explanation of warning notice:
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

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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
Pump or pressure tank.
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated 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 necessary 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 relevant provisions.
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
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.

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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:
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
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 Finishing
SSt
Eco-
Finishing
Finishing
POM
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.

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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.