WAGNER ZIP52 Finishing User manual

B_04044
B_04043
B_04045
Pneumatic Double
Diaphragm Pump
Spray Pack
Version 12 / 2012
Translation of the Original
Operating Manual

3
OPERATING MANUAL
VERSION 12 / 2012 ORDER NUMBER DOC 2332848
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Preface 5
1.2 Warnings, Notes and Symbols in these Instructions 5
1.3 Languages 6
1.4 Abbreviations in the Text 6
2 CORRECT USE 7
2.1 Device Types 7
2.2 Type of Use 7
2.3 Use in Potentially Explosive Areas 7
2.4 Safety Parameters 8
2.5 Processible Materials 8
2.6 Reasonably Foreseeable Misuse 9
2.7 Residual Risks 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Maximum Surface Temperature 10
4 GENERAL SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Equipment 11
4.1.2 Personnel Qualications 11
4.1.3 Safe Work Environment 11
4.2 Safety Instructions for Sta 12
4.2.1 Safe Handling of WAGNER Spray Units 12
4.2.2 Earthing the Unit 12
4.2.3 Material Hoses 13
4.2.4 Cleaning 13
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 13
4.2.6 Touching Hot Surfaces 14
4.2.7 Explosion Azard 14
4.2.8 Noise Risk 14
4.2.9 Material Chemical Compatibility 14
4.2.10 Emergency Stop 14
4.2.11 Tightness Check 15
4.2.12 Maintenance 15
4.3 Use in Areas Subject to Explosion Hazards 15
4.3.1 Safety Regulations 15
4.3.2 Operation without Fluid 16
4.3.3 Maximum Surface Temperature 16
4.3.4 Maximum Surface Temperature - Exothermic Reactions 16
4.3.5 Connection Pipes 16
4.3.6 Pump Protection 16
5 DESCRIPTION 17
5.1 Areas of Application 17
5.2 Scope of Delivery 17

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OPERATING MANUAL
VERSION 12 / 2012 ORDER NUMBER DOC 2332848
Contents
5.3 Data 17
5.3.1 Materials of the Fluid Transporting Parts 17
5.3.2 Technical Data 18
5.3.3 Dimensions and Connections 20
5.3.4 Performance Diagrams 22
5.4 Mode of Operation 24
6 ASSEMBLY AND COMMISSIONING 25
6.1 Transportation 25
6.2 Storage 25
6.3 Assembly 25
6.4 Grounding 27
6.5 Commissioning 29
6.5.1 Safety Regulations 29
6.5.2 Preliminary Operations 30
6.5.3 Unit Pressure Tightness Test 31
7 OPERATION 32
7.1 Operation 32
7.2 Ending or Interrupting Work 33
7.3 Ending Work: Cleaning 34
7.4 Storage Over Longer Periods of Time 34
8 TROUBLE SHOOTING AND RECTIFICATION 35
9 CLEANING AND MAINTENANCE 36
9.1 Safety Instructions 37
9.2 Filter Cleaning 37
9.3 Diaphragm Replacement (Preventive Maintenance) 39
9.4 Diaphragm Replacement (Due to Breakage) 41
9.5 Cleaning / Replacement of the Suction and Delivery Ball Valves 42
9.6 Replacement of the Reversing Valve 42
9.7 Material Hoses 42
9.8 Decommisioning 43
10 ACCESSORIES 44
11 SPARE PARTS 46
11.1 How can Spare Parts be Ordered? 46
11.2 ZIP52 Finishing 47
11.3 ZIP52 PF Eco-Finishing – Aluminium 50
11.4 ZIP52 Pump – Metal 52
11.5 ZIP52 Pump - Conductive Acetal 54
11.6 ZIP Motor 56
11.7 Trolley, Stand Set, and Wheel Set 58
11.8 Fine Flow Controller 60
11.9 Material Filter 62
11.10 Service Sets 63
12 GUARANTEE AND CONFORMITY DECLARATIONS 64
12.1 Important Notes Regarding Product Liability 64
12.2 Guarantee Claim 64
12.3 CE Declaration of Conformity 65

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OPERATING MANUAL
VERSION 12 / 2012 ORDER NUMBER DOC 2332848
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and
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 - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance can cause material damage.
Note - provides information about particular characteristics and how to proceed.
This information warns you of a hazard!
Here are the possible consequences of not observing the warning
instructions. The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
DANGER
This information warns you of a hazard!
Here are the possible consequences of not observing the warning
instructions. The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
WARNING
Here is information that warns you of a hazard!
Here are the possible consequences of not observing the warning
instructions. The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
CAUTION
This information warns you of a hazard!
Here are the possible consequences of not observing the warning instructions. The
signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
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 operating and service
sta.
The operating and service sta should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the denitions in this
operating manual.
1.1 PREFACE

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OPERATING MANUAL
VERSION 12 / 2012 ORDER NUMBER DOC 2332848
1.3 LANGUAGES
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Labeling in the spare parts lists
Order No. Order number
Double stroke
Fine-Flow Controller (precisely adjustable lter ow controller with lter
and integrated pulsation damper)
2K Two components
Materials:
POM Polyoxymethylen (Acetal)
PPS Polypropylene sulde
PTFE Polytetrafluorethylene
UHMWPE High molecular weight Polyethylene
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 2332847 English 2332848
Italian 2332849 French 2335763
Spanish 2335762

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OPERATING MANUAL
VERSION 12 / 2012 ORDER NUMBER DOC 2332848
2 CORRECT USE
2.1 DEVICE TYPES
2.2 TYPE OF USE
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
A) Metallic versions (aluminium and stainless steel):
Pneumatic double diaphragm pumps with order number
Aluminum Stainless steel Aluminum
U760.00 U765.00 U731.00
The unit is suitable for working liquid materials like paints and varnishes in accordance
with the classication into explosion classes IIA or IIB.
Metallic (aluminium and stainless steel) and conductive acetal versions:
The pneumatic double diaphragm pumps can be employed in explosion hazard zones
(Zone 1).
B) Conductive acetal versions:
Pneumatic double diaphragm pumps with order number
(POM) acetal
U773.00

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OPERATING MANUAL
VERSION 12 / 2012 ORDER NUMBER DOC 2332848
2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from incorrect use.
Use the unit only to work with the materials recommended by WAGNER.
Operate only the entire unit.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
2.5 PROCESSIBLE MATERIALS
Fluid materials like paints and varnishes.
Abrasive materials and pigments!
Greater wear of the parts carrying the material.
Use the application-oriented model (ow rate/cycle, material, valves, etc.) as
indicated in Section 5.3.2.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Section 5.3.1.
NOTICE
The operation of the pneumatic double diaphragm pump is only allowable under the
following conditions:
The operating sta have previously been trained on the basis of this operating
manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must
be observed.
The statutory requirements and accident prevention regulations standard in the
country of use must be observed.

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OPERATING MANUAL
VERSION 12 / 2012 ORDER NUMBER DOC 2332848
2.6 REASONABLY FORESEEABLE MISUSE
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences specic measures Lifecycle phase
Skin contact with
paints and cleaning
agents
Handling of paints
and cleaning agents
Skin irritations, Wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Paint in air outside
the dened working
area
Painting outside the
dened working
area
Inhalation of
substances which
are hazardous to
health
Observe working
and operating
instructions.
Operation,
maintenance
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modications to the device,
processing dry or similar coating materials, and
using defective components, spare parts or accessories other than those described
in Chapter 10 of this operating manual.
The forms of misuse listed below may result in health issues and/or damage to property:
use of powder as a coating material, and
incorrectly set values for processing.
Wagner double diaphragm pumps are not designed for pumping food.

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OPERATING MANUAL
VERSION 12 / 2012 ORDER NUMBER DOC 2332848
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
3.2 MAXIMUM SURFACE TEMPERATURE
Metallic (aluminium and stainless steel) and conductive acetal versions:
Pneumatic double diaphragm pumps with order number
As dened in the Directive 94/9/EC (ATEX 95), the unit is suitable for use in areas where
there is an explosion hazard.
+4°C Tamb +40°C
European Communities
Symbol for explosion protection
Unit class II
Category 2 (Zone 1)
Ex-atmosphere gas
Explosion group
Temperature class: maximum surface temperature < 135 °C; 275 °F
Tamb +4 °C to +40 °C: permissible ambient temperature area
Aluminium Stainless steel (POM) acetal Aluminum
U760.00 U765.00 U773.00 U731.00
U760.00 U765.00 U773.00 U731.00
Aluminium Stainless
steel
Conductive
acetal Aluminium
Maximum surface temperature °C +90 +90 +80 +90
°F +194 +194 +176 +194
Permissible ambient temperature: °C +4 ÷ +40
°F +39 ÷ +104