"user manual"
Contents
1. To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences May only be maintained by skilled electricians or under their supervision Must be operated in accordance with the safety regulations and electrotechnical regu lations Must be repaired immediately in the event of problems Must be put out of operation if they pose a hazard Must be de energized before work is commenced on active parts Inform staff about planned work observe electrical safety regulations 2 1 2 PERSONNEL QUALIFICATIONS Ensure that the unit is operated and repaired only by trained persons 2 1 3 ASAFEWORK ENVIRONMENT 1 Ensure that the floor of the working area is anti static in accordance with EN 50053 Part 1 7 2 Ensure that all persons within the working area wear anti static shoes e g shoes with leather soles Ensure that during spraying persons wear anti static gloves so that they are earthed via the handle of the spray gun Customer to provide paint mist extraction systems conforming to local regulations Ensure that the following components of a safe working environment are available Material air hoses adapted to the working pressure Personal safety equipment breathing and skin protection Ensure that there are no ignition sources such as naked flame glowing wires or hot surfaces in the vicinity Do not smoke 2 2 SAFETY2. OPERATING MANUAL WAGNER Spare parts list T4005 00ALS Pos Description Qty Code 1 Filter body 1 B0259 01 2 Filter cover 1 B0127 01 3 Tank filter 1 T454 00 4 Stainless steel spring 1 H282 03 5 Filter tie rod 1 H1152 03 6 Filter lockring 1 B0128 03 7 Tank seal Joint reservoir 1 G605 07 60 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 8 3 7 SUCTION PIPE RE CYCLE PIPE COD T406 00 T406 00A 58 56 58 57 61 EDITION 01 2010 PART NO ZZBO12ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Spare parts list T406 00 T406 00A Pos Description Qty Code 1 Suction pipe spring 1 H206 03 2 Filter disk 1 H401 07 3 Hose clamp 2 R601 00 4 Solventresistant Suction tube T406 00 3811721 L 900 mm 1 S402 06A T406 00A 3811722 L 1200 mm 1 S402 06C 5 Metalsuction pipe 1 S637 03 6 Suction pipe filter 1 T453 03 7 STSuction pipe cup 1 F141 07 8 Suction pipe ST stiff part 1 T404 00 9 Suction pipe ST complete metallic part 1 T420 00 10 Contact clip 2 E0107 03 56 Suction pipe 1 T406 00 57 Re cycle pipe 1 401 00 58 Plastic clamp 4 R602 07A 62 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 63 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINIS
3. N 55 EDITION 01 2010 A WAGNER OPERATING MANUAL Spare parts list 2301837 2301838 2301832 2301836 Pos Description Qty Code Code Motor ZIP52 Without cycle counter 1 T6103 00 T6103 00S connection Motor ZIP52 With cycle counter 1 T6103 00C T6103 00G connection 1 Feeler pin 2 B0146 04 B0146 04 2 Inner diaphragm disk 2 B0147 71 0147 71 3 Shaft 1 0150 03 B0150 03S 4 Cover pressure side 1 F194 91 F194 91 5 Bushing guide rod 2 F829 07 F829 07 6 Cover discharge side 1 F830 07 F830 07 Motor block with safety valve 7 T6103 00 T6103 00S 1 T6103 00A T6103 00A T6103 00C T6103 00G 1 T6103 00F T6103 00F 8 Reversing valve gasket 1 G925 06 G925 06 9 Pressure cover gasket 1 G7020 06 G7020 06 10 Silencer 1 H618 07 H618 07 11 Screw 4 K1038 62 K1038 62 12 Screw 6 K1039 62 K1039 62 13 Lip gasket 2 L470 06 L470 06 14 Lip gasket 2 L471 06 L471 06 15 Reversing valve 1 P4003 00 3 4003 00 3 16 Safety valve 1 17 Side plate 546 00 546 00 18 Screw T6103 00C 0 T6103 00G 1 K174 62 K174 62 19 Washer T6103 00C 0 T6103 00G 1 K535 07 K535 07 The spare part includes the reversing valve gasket code G925 06 and pressure cover gasket code G7020 06 Not available separately See pos 7 A WAGNER EDITION 01 2010 OPERATING MANUAL 8 3 5 FINE FLOW CONTROLLER T0180 00A T0180 00Al 17 6 Nim
4. 14 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 4 3 2 TECHNICAL DATA Description Units 2301832 2301836 2301837 2301838 Transmission ratio 1 1 151 1 1 1 1 Fluid max flow rate l min 52 52 52 28 Max operating pressure MPa 8 8 8 8 bar 116 116 116 116 psi 1682 1682 1682 1682 Min Max air inlet pressure MPa 0 1 0 8 0 1 0 8 0 1 0 8 0 1 0 8 bar 1 8 1 8 1 8 1 8 psi 15 116 15 116 15 116 15 116 Q air inlet connection female BSP 1 4 1 4 1 4 1 4 Sound power at max flow rate dB A 99 99 97 99 feeding 8 bar 116 psi Sound pressure equivalent to max flow rate dB A 85 85 85 85 feeding 8 bar 116 psi Sound pressure equivalent to 50 cycles min dB A 76 76 73 76 feeding 5 bar 72 5 psi Material outlet connection female M16x1 5 Inch G 1 4 G 1 4 G 1 4 G 1 4 Weight kg 3 8 6 1 2 9 3 8 Ib 8 4 13 4 6 4 8 4 Max material pressure at pump inlet MPa 0 1 0 1 bar 1 1 psi 14 5 14 5 Range of material temperature G 4 40 39 104 4 905 39 176 Range of the ambient temperature G F 4 40 39 104 Allowable sloping position at work 3 t10 A rated sound pressure level measured at 1m distance according to UNI EN ISO 3744 NWARNING Outgoing air containing oil Risk of poisoning if inhaled Function problem airmotor Provide water free and oil free compressed air quality stan
5. Check the opening of any valves present on the suction and delivery lines Close the air on off valve and reopen it rapidly after having increased the pressure Only for FINISHING check the pressure value of the paint reducer The unit is working i e the pump is moving but not liquid is coming out Accurately clean the filter if installed Check liquid level Check suction pipe Poor spray pattern See gun instructions The product flow into the delivery is discontinuous Check that the suction pipe is not clogged Check that the pump is not cavitating There may be impurities on the valve seats The pump delivery decreases during work Partial obstruction on delivery line Slight variations of product characteristics such as viscosity Ice formation inside the air outlet pipes The pump delivery decreases during work up to the point when it stops Complete obstruction on delivery line Strong variations of product characteristics such as viscosity completely The unit stops Increase the air pressure frequently Adjust the lubricator output if installed Put antifreezer in the lubricator and put an efficient condensate separator on the air line if installed The equipment remains in operation even with the delivery on off valve closed Check the product cutoff valve and the outlet valve seals There may be impurities on
6. This line warns of the hazard Possible consequences of failing to observe the warning instruc tions The signal word points out the hazard level Warning possible danger Non observance can result in death serious injury and serious material damage The measures for preventing the hazard and its consequences SIHI 0103 GB Caution a possibly hazardous situation Non obser vance can result in minor injury CAUTION This line warns of the hazard Possible consequences of failing to observe the warning instruc tions The signal word points out the hazard level The measures for preventing the hazard and its consequences SIHI 0101 GB Caution a possibly hazardous situation Non obser vance can cause material damage CAUTION This line warns of the hazard Possible consequences of failing to observe the warning instructions The signal word points out the hazard level The measures for preventing the hazard and its consequences Note provide information on particular characteristics and how to proceed EDITION 01 2010 OPERATING MANUAL 2 GENERAL SAFETY INSTRUCTIONS A WAGNER 2 1 SAFETY INSTRUCTIONS FOR THE OPERATOR gt gt Keep these operating instructions to hand near the unit at all times Always follow local regulations concerning occupational safety and accident preven tion 2 1 1 ELECTRICAL EQUIPMENT Electrical plant and unit
7. Translation of the original WAGNER Operating Manual ZIP52 ALU SP ZIP 52 INOX SP ZIP 52 ACETAL SP ZIP 52 PERFECT FLOW SP Edition 01 2010 Diaphragms pump ZIP 52 FINISHING ZIP 52 PF 4 Ex 2G IIB T4 EDITION 01 2010 PART NO ZZBO12ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Contents 1 ABOUT THESE INSTRUCTIONS 1 1 Languages 1 2 Warnings notes and symbols in these instructions 2 GENERAL SAFETY INSTRUCTIONS 2 1 Safety instructions for the operator 2 1 1 Electrical equipment 2 1 2 Personnel qualifications 2 1 3 Asafe work environment 22 Safety instructions for staff 2 2 1 Safe handling of WAGNER spray units 222 Earth the unit 2 23 Material hoses 224 Cleaning 2 25 Handling hazardous liquids varnishes and paints 2 26 Touching hot surfaces 2 3 Correct use 2 4 Use in an explosion hazard area 24 1 Correct use 24 2 Explosion protection identification 2 4 3 surface temperature 244 Safety regulations NO iO iO 10 OO OO OO OO N JO Oh Oh Oh Oh A vu u 3 PRODUCT LIABILITY AND WARRANTY 7222 3 1 Scope of guarantee 11 3 2 Guarantee period and registration 3 2 11 3 3 Handling 11 3 4 Exclusion of guarantee 12 3 5 Additional regulations 12 3 6 CE conformity 13 4 DESCRIPTION 14 4 1 Field of application 14 4 1 1 Using in accordance with the instructions 14 4 2 Extent of delivery 14 4 3 Data 14 4 3 1 Materials of the parts transporting paint 14 4 3
8. These can cause sparks and flames upon discharge Ensure that the unit is earthed for every spraying operation Earth the workpieces to be coated Ensure that all persons inside the working area are earthed e g that they are wearing antistatic shoes When spraying wear antistatic shoes to earth yourself via the spray gun handle If gloves are used they must be antistatic 2 2 3 MATERIAL HOSES Ensure that the hose material is chemically resistant to the sprayed materials Ensure that the material hose is suitable for the pressure generated in the unit Ensure that the following information is visible on the high pressure hose Manufacturer Permissible operating overpressure Date of manufacture The electrical resistance of the complete high pressure hose must be less than 1 MOhm EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 2 2 4 CLEANING De energize the unit electrically Disconnect the pneumatic supply line Relieve the pressure from the unit Ensure that the flash point of the cleaning agent is at least 5 K above the ambient tem perature To clean use only solvent free cloths and brushes Never use hard objects or spray on cleaning agents with a gun An explosive gas air mixture forms in closed containers When cleaning units with solvents never spray into a closed container Earth the container 2 2 5 HANDLIN
9. installed The gun should be secured with safety catch if installed The air supply should be interrupted 5 2 2 EMERGENCY STOPPING Emergency stopping for 2301832 2301836 2301837 To stop the equipment in good time close the air on off valve 1 or release pressure through the regulator knob H thus stop ping the feeding air to the motor Carry out the pump priming operations correctly to prevent pressurized air babbles from being trapped Pneumatic pumps can keep all components connected to the delivery under pressure even when the driving air feed is clo sed To prevent harm to people as well as to avoid damaging things or the environment after stopping the pump it is best to release the pressure by keeping the delivery valve open or opening the recycling valve L Emergency stopping for 2301838 To stop the equipment in good time close the air on off valve on the feeding line or release pressure through the regulator knob A thus stopping the feeding air to the motor Carry out the pump priming operations correctly to prevent pressurized air babbles from being trapped Pneumatic pumps can keep all components connected to the delivery under pressure even when the driving air feed is clo sed To prevent harm to people as well as to avoid damaging things or the environment after stopping the pump it is best to release the pressure by keeping the delivery valve open or opening the recycling valve L 25
10. 56 Contact spring 1 H261 03 1 H261 03 1 H261 03 49 PART ZZB012ENG EDITION 01 2010 A WAGNER OPERATING MANUAL 8 3 2 PUMP COD 2301838 71 Du Ca EEN fH a Exploded view parts 18 in the following pages 50 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNERA NWARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe cially trained staff or a WAGNER service center Before all work on the unit and in the event of work interrup tions Switch off the energy compressed air supply Relieve the pressure from the spray gun and unit Secure the spray gun against actuation Observe the operating and service instructions when carrying out all work SIHI 0004 GB Spare parts list 2301838 Pos Description Qty Code 1 ZIP52 PF pump 1 U551 AHSS1 see explod view 2 Pump support 1 E3112 92 3 Leg 2 E111 92B 4 Finned push rod 4 R211 07 5 Air pressure reducer 1 4 2 P123 00E 6 Pressure gauge 2 P936 00 7 Rapid revolving connector L 1 4 x8 3 M336 00 8 Conical nipple 1 4 1 205 04 9 Fitting T MFM 1 4 1 M340 00 10 Flexible pipe holder 1 2 x16 1 M208 04 11 Cylindrical plug 12 1 M254 14A 12 Cock MF 1 4 lever 1 M109 00 13 Re cyle pipe 1 5401 00 14 Suction
11. F978 01 F192 03 F978 01 5 Product diaphragm 2 G921 07B G921 07B G921 07B G921 07B 7 Socket screw 4 K1076 62 K142 62 K142 62 K142 62 8 Screw 8 K128 62 K183 62 K142 62 K183 62 9 Nut 24 K311 62 K311 62 K311 62 K311 62 10 Washer 16 K508 62 K508 62 K508 62 K508 62 11 Self tapping screw 1 K1012 62 K1012 62 K1012 62 K1012 62 12 Screw 4 K1040 62 K1040 62 K1040 62 K1040 62 13 Rivet 2 K1041 62 K1041 62 K1041 62 K1041 62 14 Screw 12 K1043 62 K1044 62 K1042 03 K1044 62 15 Nut 8 K311 62 K311 62A K311 62 K311 62A 17 Motor 1 T6103 00 T6103 00 T6103 00 6103 005 18 Fluid valve unit 4 T6105 00 T6105 00 T6105 00 T6105 00 19 Lug 1 Y622 00A Y622 00A Y622 00A Y622 00A 20 Cover plate 1 Z535 00X Z535 00X Z535 00X Z535 00X 22 Cover round plate 2 Z543 00A Z543 00A Z543 00A Z543 00A 23 Nipple 1 B0177 14A B0177 14A B0177 14A 24 Contact washer 4 K564 72 K564 72 K564 72 K564 72 25 Ball guide insert 2 F856 07D 26 Washer 4 K505 62 Reversing valve set ZIP52 1 P4003 00 P4003 00 P4003 00 P4003 00 Fluid service set 1 T9080 00B T9080 00B T9080 00B T9080 00B Kit PE Diaphragms Gasket 1 T9083 00B Product o ring set 1 9077 00 T9077 00 T9077 00 T9077 00 54 EDITION 01 2010 OPERATING MANUAL WAGNER 8 3 4 AIR MOTOR PUMP ZIP52 ZN QN FN FR f d j N e e 9 N N x 2 N i N 1 UY N
12. T e 57 EDITION 01 2010 A WAGNER OPERATING MANUAL Spare parts list T0180 00A T0180 00Al Pos Description Qty Code 1 Paint diaphragm disk 1 A588 03 2 Air diaphragm disk 1 A590 03 3 Ball guide body 1 B0172 03 4 Reducer body fluid side T0180 00A 1 B0180 01 T0180 00Al 1 B0180 03 5 Valve stem 1 B391 03 6 Reducer body air side 1 B563 01 7 Complete ball seat body 1 T6007 00A 8 Lockring 1 F991 07 9 Cup 1 F992 07 10 PTFE paint pressure reducer diaphragm 725 05 11 Paint pressure reducer diaphragm G726 06 12 Gasket 1 G640 05B 13 Conical spring 1 H285 03 14 Self tightening nut 1 K311 62 15 Washer 6 K515 62 16 Ball 1 4 1 K811 03 17 TCEI M5x30 screw 6 K1055 62 18 O ring 1 L148 06 19 O ring 1 L118 06A 20 Filter with collar 1 T500 00A Service set FFC pos 10 11 12 16 18 19 1 T9086 00 58 A WAGNER NG PART NO ZZB012E OPERATING MANUAL 8 3 6 MATERIAL FILTER 1 2 ALUMINIUM COD T4005 00ALS FOR 2301838 D 2 2 Y SIS N mi Z PSV VV NSS AZ 1 4 RECYCL ING CONNECTED TO INLET SIDE paa 47 8 4 l ZIGRINATURA d dE CIRE a lt 17 p i III NN re 2 65 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF
13. compressed air delivery and discharge the pressure from the pump and pipes connected to it If necessary depending on the intervention disconnect the product and air side connection pipes remove the pump from the base or support it is faste ned to and turn it over on top of a container suitable for collecting any liquid it may contain After the pump has been reassembled following maintenance operations re set and check the efficiency of the earthing connection of the individual parts of the pump 1 Diaphragm replacement Preventive maintenance Mark the coupled parts with a felt tip pin so as to make subsequent reassembly easier a Remove the suction and delivery manifolds 6 1 b Disassemble the fastening nuts and remove the external covers 6 2 c Turn the two end nuts of the external diaphragm disks in contraposition with the appropriate spanners and disassemble one of them d Remove the freed diaphragm with its relative internal disk and extract the shaft from the motor block 6 3 e Lock the end of the shaft released from the diaphragm in a vice adopting the proper precautions to avoid damaging it and disassemble the external diaphragm disk from the opposite end Now remove the second diaphragm with its internal disk f Assemble the new diaphragm with its internal disk and opportunely tighten it with the relevant external disk g Free the shaft from the vice put it inside the motor block after lubricating i
14. make sure efficient filtering and con densate separation systems are installed on the air line All impurities and the eventual condensate that has built up inside the air filter on top of the pump must be drained daily NOTE Consult specific catalogues when choosing the pipes The driving air pipe must be properly di mensioned Procedure for 2301832 2301836 2301837 1 Mount the pump onto a basement 2 Connectthe air atomization and paint delivery hoses respectively to the corresponding attachments C air N paint carefully tightening the fittings Procedure for 2301838 1 Connectthe air to the pump in the H fitting installing an on off valve on the line to stop the feeding air in case of emergency 2 Connectthe spraying air to its fitting E Carry out the same operation for the paint delivery pipe to be connected to its fitting 1 L N e WARNING Inclined surface SIHI_0012_GB Risk of accidents if the unit rolls away falls Position the carriage with the piston pump horizontally Ifthe surface is inclined position the feet of the carriage towards the gradient Secure the carriage 21 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 5 1 2 EARTHING NWARNING Discharge of electrostatically charged components in atmo spheres containing solvents Explosion hazard from electrostatic spark
15. number 20 13 EDITION 01 2010 OPERATING MANUAL 4 DESCRIPTION A WAGNER 4 1 FIELD OF APPLICATION 4 1 1 USING IN ACCORDANCE WITH THE INSTRUCTIONS The pneumatic diaphragm pump is suitable for process liquid materials CAUTION see chapter 4 3 2 SIHC_0067_GB 4 2 EXTENT OF DELIVERY Abrasive fluids and pigments Greater wear of the parts carrying the material Pneumatic diaphragm pump consisting of Material pump Air motor Material regulator Antipulsator and or filter Support pump with regulators Suction hose Connections CE conformity see Operating manual in english Operating manual for the other language see The delivery note shows the exact scope of delivery Accessories see chapter 7 4 3 DATA 4 3 1 MATERIALS OF THE PARTS TRANSPORTING PAINT Use suitable pump model delivery per cycle material valves etc Chapter 3 Part No ZZBO12ENG Chapter 1 gt Verify that fluids and solvents used are compatible with the constrution material of the pump as described in chapter 4 3 1 2301832 2301836 2301837 2301838 Covers Manifolds Aluminium Stainless steel Acetal Aluminium side Balls Stainless steel Stainless steel Stainless steel Stainless steel Valve seats Stainless steel Stainless steel Stainless steel Stainless steel Diaphragms PE PE PE PE Static gaskets product PTFE PTFE PTFE PTFE
16. revolving connector L 4 M335 00 4 M335 00 4 M335 00 1 8 x4 16 Plug 1 4 1 826 03 1 259 00 1 826 03 17 Cock FF 1 4 lever 1 513 001 1 109 00 1 513 001 18 Fitting L MF 1 4 1 M881 03 1 M213 04 1 881 03 19 Conical nipple 1 4 1 M801 03C 1 M205 04 1 M801 03C 20 TCEI M6x20 screw 4 K107 62 4 K107 62 4 K107 62 48 EDITION 01 2010 OPERATING MANUAL WAGNER Spare parts list 2301837 2301832 2301836 Pos Description Qty Code Qty Code Qty Code 21 Washer 8 K505 62 8 K505 62 8 K505 62 22 Air manifold 1 T139 01 1 T139 01 1 T139 01 23 Hollow screw 1 4 3 M404 00 3 M404 00 3 M404 00 24 Reduction MF 3 8 x1 4 1 M250 00 1 M250 00 1 M250 00 25 Fitting D MF 1 4 1 M239 00 1 M239 00 1 M239 00 26 Throttle cock MF 1 4 1 M101 00 1 M101 00 1 M101 00 27 O ring 3 L212 06 3 L212 06 3 L212 06 28 Paint reducer air pipe 1 5455 07 1 5455 07 1 5455 07 29 Manometer reducer pipe 3 455 07 3 455 07 3 455 07 30 Rapid revolving connector L 1 M354 00 1 M354 00 1 M354 00 1 4 x4 31 Fitting L MM 1 4 1 M215 04 2 M215 04 1 M215 04 32 Extension MF 1 4 1 M204 04 1 M204 04 1 M204 04 33 Air pressure reducer 1 4 3 P123 00 3 P123 00 3 P123 00 34 Nut 4 K311 62A 4 K311 62A 4 K311 62A 35 Re cyle pipe 2mt S103 07N 2mt 5401 00 2mt 5103 07 36 Suction pipe 1 T406 00 1 T406 00 1 T406 00 37 Pump feeding air pipe 455 07B 1 455 07B 1 455 07B 38 Nipple 1 4 2 M801 03B 2 M801 03B 2 M801 03B
17. 2 technical data 15 4 3 3 Dimensions and connections 16 AA Functioning 18 44 1 Pump 18 4 4 2 Pressure regulator 19 4 4 2 1 Technical sheet fine flow controller cod 2301832 2301836 2301837 20 5 STARTING UP AND OPERATING 21 5 1 Installation and connection 2 5 1 1 Pump installation 21 5 1 2 Earthing 22 5 2 Start up 24 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Contents 5 2 1 Safety regulations 24 5 22 Emergency stopping 25 5 2 3 Washing 26 5 24 Unit pressure tightness test 26 5 3 Work 27 5 3 1 Spraying 27 5 3 2 Painting hints 28 5 3 3 Working breaks 28 5 34 Shutting down and cleaning 29 5 4 Storing for longer periods of time 29 6 FAULT LOCATION MAINTENANCE AND REPAIR 30 6 1 Trouble shooting and solution 30 6 2 Maintenance 31 6 3 Filter cleaning operations 32 6 4 Machine maintenance 33 7 ACCESSORIES 35 7 1 Accessories only for 2301832 2301836 2301837 35 7 2 Pump zip 52 finishing with wall supporting kit cod T760 00M 36 7 2 1 Overall dimensions cod T760 00M 37 7 3 Pump zip 52 finishing with stand kit cod 760 005 38 7 3 1 Overall dimensions cod T760 00S 39 7 4 Pump zip 52 finishing with handle wheels kit cod T760 00R for stand pumps cod T760 00S 40 7 4 1 Overall dimensions cod T760 00R 41 75 Pompa zip 52 finishing with trolley kit cod T760 00SR 42 7 5 1 Overall dimensions cod T760 00SR 43 8 SPARE PARTS 44 8 1 How to order spare parts 44 8 2 Overview modules 46 8 3 Exploded vie
18. 21 Praha 5 Zlicin Czechia Tel 42 2 579 50 412 Telefax 42 2 579 51 052 info wagner cz Wagner Spraytech UK Limited The Coach House 2 Main Road Middleton Cheney OX17 2ND Great Britain UK Helpline 0844 335 0517 5 pper minute landline Wagner Colora Via Fermi 3 20040 Burago di Molgora MI Italia Tel 39 039 625 021 Telefax 39 039 685 18 00 info wagnercolora com NL Wagner Spraytech Benelux b v Zonneban 10 3542 EC Utrecht Netherlands Tel 31 30 241 41 55 Telefax 31 30 241 17 87 info wagner wsb nl S Wagner Spraytech Scandinavia A S Helgeshgj All 28 2630 Taastrup Denmark Tel 45 43 21 18 18 Telefax 45 43 43 05 28 wagner wagner group dk 65 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 66 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL 67 Order number ZZB012ENG Germany J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 5050 Telefax 49 0 7544 505200 E Mail service standard wagner group com Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altst tten Telephone 41 0 71 757 2211 Telefax 41 0 71 757 2222 E Mail rep ch wagner group ch www wagner group com
19. ALL DIMENSIONS COD T760 00SR 1000 770 Altezza comandi pompa Pump control height Hauteur commandes pompe H he Pumpensteuerung WAGNER 43 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 8 SPAREPARTS 8 1 HOW TO ORDER SPARE PARTS Always supply the following information to ensure delivery of the right spare part Part Number description and quantity The quantity need not be the same as the number given in the Quantity column This number merely indicates how many of the respective parts are used in each subassembly 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 required air freight or mail sea route or overland route etc Marks in spare parts lists NWARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe cially trained staff or a WAGNER service center Before all work on the unit and in the event of work interrup tions Switch off the energy compressed air supply Relieve the pressure from the spray gun and unit Secure the spray gun against actuation Observe the operating and service instructions when carrying out all work SIHI 0004 GB 44 EDITION 01 2010 P
20. ART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 45 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 8 2 OVERVIEW MODULES ZIP52 FINISHING PF 2301832 2301836 2301837 2301838 Pos Description No Qty No Qty No Qty No Qty 1 Pump ZIP52 see the Aluminium 1 Inox 1 Plastic 1 Alluminium 1 exploded view 8 3 3 2 Fine Flow Controller T0180 00A 1 T0180 00Al 1 T0180 00A 1 see the exploded view T0180 00Al 8 3 1 8 3 5 3 Material tank filter see T4005 00ALS 1 the exploded view 8 3 6 4 Suction pipe see the T406 00 1 T406 00 1 T406 00 1 T406 00 1 exploded view 8 3 7 5 Leg See See See E111 92B 2 Accessories Accessories Accessories Pump equipped with protection panel air pressure supporttrestle reducers and manometers to adjust pump motor relevant gauges for feeding air fluid reducer controlling air atomising air pump feeding air re cycle pipe with lever valve support and atomising air recycling pipe with manual valve 2301838 46 PART ZZB012ENG EDITION 01 2010 A WAGNER OPERATING MANUAL 8 3 EXPLODED VIEW 8 3 1 PUMP COD 2301832 2301836 2301837 a Exploded view parts 1 3 36 in the following pages 47 A WAGNER EDITION 01 2010 OPERATING MANUAL
21. DITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 4 4 2 1 TECHNICAL SHEET FINE FLOW CONTROLLER COD 2301832 2301836 2301837 Part in contact with the product Regulator body p Konsistal for T0180 00A Regulator body p Stainless Stell for T0180 00A1 Antipulsation body q PP D Product diaphragm PTFE Shutter ball Stainless Stell Shutter seat Tungsten carbide Reducer section performances with fluids having a viscosity of 45 mPa s corresponding to about 20 s Ford 4 Inlet pressure 5 Bar 4 5 4 3 5 2 5 ssione uscita Outlet press Press a la Ausgangsdruck bar Portata How rate D bit F rderung Max allowed fluid temperature C Max inlet pressure Bar Guiding air inlet max pressure Bar Adjustment range Bar Product inlet connection BSP 2x Product outlet connection BSP 2 Air inlet connection BSP FILTER CARTRIDGE INCLUDED Mesh OPTIONAL Mesh Dimensions Diameter mm Height mm weight gr weight gr 40 14 8 0 5 8 1 4 Fem 1 4 Fem 1 8 Fem 100 60 and 150 90 165 850 for T0180 00A 1455 for T0180 00Al 20 EDITION 01 2010 OPERATING MANUAL 5 STARTING UP AND OPERATING A WAGNER 5 1 INSTALLATION AND CONNECTION 5 1 1 PUMP INSTALLATION Note The pneumatic motor must be supplied with clean industrial air
22. EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 5 2 3 WASHING The pump has been tested using mineral oil Before using it it is best to let it wash once using an adequate solvent To do this place the metallic side of the suction pipe M inside a container full of solvent Open the re cycle valve L Make sure that the pressure regulator knob H is turned fully anti clockwise 0 bar pressure Open the air cutoff valve I on the compressed air line for 2301838 and turn the motor air pres sure regulator H knob clockwise until the pump starts It is best 2301832 2301836 to keep the atomization air valve B closed during washing ope 2301837 rations Set the motor air pressure to 2 bar The pump sucks solvent and pours it back into the container through the re cycle system thus cleaning itself Let the solvent flow inside the pump for 2 or 3 minutes 2301838 NOTE In case the pump does not start check that the gauge C reads at least 2 bar close the delivery air on off valve discharge C the residual pressure by turning the knob of the relative regula tor anticlockwise and then reset the pressure using the regulator 2 bar and instantly reopen the air on off valve If necessary repeat the operation several times Keeping the gun on the solvent container pull the trigger and let the solvent re cycle for some minutes through the gun delivery pipe If the solvent flow comi
23. G HAZARDOUS LIQUIDS VARNISHES AND PAINTS When preparing or working with paint and when cleaning the unit follow the work ing instructions of the manufacturer of the paints solvents and cleaning agents being used Take the specified 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 sufficient health and environmental safety Operate the unit in a spray booth or on a spraying wall with the ventilation extraction switched on Wear suitable protective clothing when working with hot materials 4 2 2 6 TOUCHING HOT SURFACES Touch hot surfaces only if you are wearing protective gloves When operating the unit with a coating material with a temperature of gt 43 C 109 4 F Identify the unit with a warning label that says Warning hot surface Order No 9998910 Information label 9998911 Safety label 2 3 CORRECT USE WAGNER accepts no liability for any damage arising from incorrect use Use the unit only to work with the materials recommended by WAGNER Operate the unit only as an entire unit Do not deactivate safety equipment Use only WAGNER original spare parts and accessories vc p v EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 2 4 USE IN AN EXPLOSION HAZARD AREA 2 4 1 CORRECT USE The unit i
24. HING PF OPERATING MANUAL WAGNER 64 EDITION 01 2010 OPERATING MANUAL 9 EUROPEAN SERVICE NETWORK A WAGNER A CH J Wagner Ges m b H Ottogasse 2 20 2333 Leopoldsdorf Osterreich Tel 43 2235 44 158 Telefax 43 2235 44 163 office wagner group at Wagner Spraytech E Benelux b v Veilinglaan 56 1861 Meise Wolvertem Belgium Tel 32 2 269 46 75 Telefax 32 2 269 78 45 info wagner wsb nl Wagner International AG F Industriestrasse 22 9450 Altstatten Schweiz Tel 41 71 757 2211 Telefax 441 71 7 57 2222 wagner wagner group ch J Wagner GmbH Otto Lilienthal Stra e 18 D 88677 Markdorf Postfach 11 20 D 88669 Markdorf Deutschland Tel 49 75 44 505 664 Fax 49 75 44 505 155 wagner wagner group com www wagner group com CZ DK Wagner Spraytech GB Scandinavia A S Helgeshgj All 28 2630 Taastrup Denmark Tel 45 43 27 18 18 Telefax 45 43 43 05 28 wagner wagner group dk Wagner Spraytech Iberica S A P O Box 132 Crta N 340 08750 Molins de Rey Barcelona Espania Tel 34 93 6800028 Telefax 34 93 66800555 info wagnerspain com J Wagner France S A R L Parc de Gutenberg Batiment F 8 voie la Cardon 91127 Palaiseau Cedex France Tel 33 1 825 011 111 Telefax 33 1 698 172 57 division batiment wagner france fr Wagner spol s r o Nedasovsk str 345 155
25. ING If defects can be seen in the materials processing or performance of the device during the guarantee period guarantee claims must be made immediately or at the latest within a period of 2 weeks The authorised specialist shop that delivered the device is entitled to accept guarantee claims Guarantee claims may also be made to the service centres named in our operating instructions The product has to be sent without charge or presented together with the original purchase document that includes details of the purchase date and the name of the product In order to claim for an extension to the guarantee the guarantee certificate must be included The costs as well as the risk of loss or damage to the product in transit or by the centre that accepts the guarantee claims or who delivers the repaired product are the responsibility of the customer 11 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 3 4 EXCLUSION OF GUARANTEE Guarantee claims cannot be considered for parts that are subject to wear and tear due to use or other natural wear and tear as well as defects in the product that are a result of natural wear and tear or wear and tear due to use This includes in particular cables valves packaging jets cylinders pistons means carrying housing components filters pipes seals rotors stators etc Damage due to wear and tear that is caused in particular by sanded coating materials su
26. INSTRUCTIONS FOR STAFF Always follow the information in these instructions particularly the general safety in structions and the warning instructions Always follow local regulations concerning occupational safety and accident preven tion HM ii EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 2 2 1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries Avoid injection of paint or cleaning agents Never point the spray gun at people Never reach into the spray jet Before all work on the unit in the event of work interruptions and functional faults Switch off the energy compressed air supply Secure the spray gun against actuation Relieve the pressure from the spray gun and unit By functional faults If possible remove the defect as described in chap Trouble shooting otherwise apply to an authorised after sale service point In the event of skin injuries caused by paint or cleaning agents Note down the paint or cleaning agent that you have been using Consult a doctor immediately Avoid danger of injury through recoil forces Ensure that you have a firm footing when operating the spray gun Only hold the spray gun briefly in any one position 2 2 2 EARTH THE UNIT Electrostatic charges can occur on the unit due to the electrostatic charge and the flow speed involved in spraying
27. NG PF OPERATING MANUAL WAGNER 7 4 PUMP ZIP 52 FINISHING WITH HANDLE WHEELS KIT COD T760 00R FOR STAND PUMPS COD 760 005 59 51 40 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Spare parts list T760 00R Pos Description Qty Code 34 Nut 2 K311 62A 46 Wheel 2 R118 00 47 Benzing ring 2 K607 02 48 Trolley handle 1 E3108 92 49 TCEI 6x50 screw 2 K159 62 50 Washer 4 K502 62 57 Contact washer 4 K564 72 7 4 1 OVERALL DIMENSIONS COD T760 00R 770 Altezza comandi pompa Pump control height MAA Hauteur commandes pompe H he Pumpensteuerung 41 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 7 5 POMPA ZIP 52 FINISHING WITH TROLLEY KIT COD T760 00SR S u Yen DET f 42 EDITION 01 2010 OPERATING MANUAL Spare parts list T760 005R Pos Description Qty Code 21 Washer 2 K505 62 34 Nut 5 K311 62A 38 Right stand 1 E3107 92 39 Left stand 1 E3107 92A 40 Stand pin 1 H1156 62 41 Finned push rod 4 R204 07 42 Plyers foot 4 R244 07 43 TCEI 6x45 screw 4 K184 62 44 TCEI 8x40 screw 2 K1015 62 45 Gun hook 1 H009 62 46 Wheel 2 R118 00 47 Benzing ring 2 K607 02 48 Trolley handle 1 E3108 92 49 TCEI 6x50 screw 2 K159 62 50 Washer 4 K502 62 57 Contact washer 7 K564 72 7 5 1 OVER
28. NWARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe SIHI 0004 GB tions out all work cially trained staff or a WAGNER service center Before all work on the unit and in the event of work interrup Switch off the energy compressed air supply Relieve the pressure from the spray gun and unit Secure the spray gun against actuation Observe the operating and service instructions when carrying Spare parts list 2301837 2301832 2301836 Pos Description Qty Code Qty Code Oty Code 1 ZIP 52 pump 1 seeexplod 1 5 explod 1 see explod view view view 2 Fine Flow controller 1 T0180 00Al 1 T0180 00Al 1 T0180 00Al 3 Pump support 1 E3105 92 1 E3105 92 1 E3105 92 4 Reducer support 1 E3106 92 1 E3106 92 1 E3106 92 5 Flexible pipe holder 1 2 x16 1 B274 03 1 B274 03 1 B274 03 stainless steel 6 Nipple 1 4 1 801 03 1 801 03 7 Fitting spec 1 2 1 B0264 03 1 M247 00 1 B0264 03 8 Paint hose 1 591 00C 1 591 00C 1 591 00C 9 Rapid revolving connector L 2 M336 00 2 M336 00 2 M336 00 1 4 x8 10 Fitting 1 4x8 1 057 07 11 Pressure gauge 3 P904 00 3 P904 00 3 P904 00 12 Rapid connector D1 8 x4 F 3 M286 00 3 M286 00 3 M286 00 13 Control plate 1 Z547 00 1 7547 00 1 7547 00 14 ZIP52 finishing label 1 2548 00 1 2548 00 1 2548 00 15 Rapid
29. TH WALL SUPPORTING KIT COD T760 00M VEDI DET a lt q mmm Oo 36 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Spare parts list T760 00M Pos Description Qty No 51 Right wall bracket 1 E3101 92B 52 Left wall bracket 1 E3101 92A 53 TCEI 8x20 screw 4 K120 62 54 RWasher 8 4 K509 62 55 Nut 4 K312 62 58 Washer 4 K572 62 7 2 1 OVERALL DIMENSIONS COD T760 00M 3 eri H CNE N 4 Fori Holes 234 235 Trous Bohrungen d 9 360 l 295 A 37 PART ZZB012ENG EDITION 01 2010 A WAGNER OPERATING MANUAL 7 3 PUMP ZIP 52 FINISHING WITH STAND KIT COD T760 00S 38 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Spare parts list T760 00S Pos Description Qty Code 21 Washer 5 K505 62 34 Nut 5 K311 62A 38 Right stand 1 E3107 92 39 Left stand 1 E3107 92A 40 Stand pin 1 H1156 62 41 Finned push rod 4 R204 07 42 Plyers foot 4 R244 07 43 TCEI 6x45 screw 4 K184 62 44 TCEI 8x40 screw 2 K1015 62 45 Gun hook 1 H009 62 57 Contact washer 4 K564 72 7 3 1 OVERALL DIMENSIONS COD T760 00S Hauteur commandes pompe H he Pumpensteuerung 755 Altezza comandi pompa Pump control height 39 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHI
30. UST BE CLEANED DAILY IT IS ALSO NECESSARY TO CLEAN THEM WHEN USING A DIFFERENT COLOUR PAINT FROM THE ONE PREVIOUSLY USED To clean the suction pipe M filter undo the spring take out the filte ring disk leave it in some solvent brush it and spray it with compres sed air To clean the antipulsation filter unscrew the plastic ring nut O from the reducer body P lift the cup Q paying attention to the PTFE gasket on the edge Remove the filter R from the seat S pul ling it upward since it has a very simple fixing clip Plunge the filtering cartridge into the solvent then brush and blow it Make sure to clean also the filter inner side with solvent and blow it with compressed air if necessary To reassemble the filter push it on the seat until hearing the fixing clip do not push the filter any further to avoid damaging it Reposition the cup making sure the gasket is in the perfect position then screw the ring nut 32 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 6 4 MACHINE MAINTENANCE The following instructions are general Refer to the specific diagrams of each pump model to operate correctly ATTENTION Before you perform any maintenance or cleaning operation Supply yourself with the proper equipment Wear the garments and specific protection devices with regard to the nature of the fluids with which you will come into contact Close the
31. ch as dispersions pla ster putty adhesives glazes quartz foundation in the event of errors in devices that are due to non compliance with the operating in structions unsuitable or unprofessional use incorrect assembly and or commissioning by the buyer or by a third party or utilisation other than is intended abnormal ambient con ditions unsuitable coating materials unsuitable operating conditions operation with the incorrect mains voltage supply frequency over operation or defective servicing or care and or cleaning for errors in the device that have been caused by using accessory parts additional com ponents or spare parts that are not original Wagner parts for products to which modifications or additions have been carried out for products where the serial number has been removed or is illegible for products to which attempts at repairs have been carried out by unauthorised per sons for products with slight deviations from the target properties which are negligible with regard to the value and usability of the device for products that have been partially or fully taken apart 3 5 ADDITIONAL REGULATIONS The above guarantees apply exclusively to products that have been bought by authorised specialist shops in the EU CIS Australia and are used within the reference country If the check shows that the case is not a guarantee case repairs are carried out at the expense of the buyer The above regulati
32. d reimburse the purchase price The costs for materials and working hours are our responsibility Replaced products or parts become our property 3 2 GUARANTEE PERIOD AND REGISTRATION 3 2 The guarantee period amounts to 36 months For industrial use or equal wear such as shift operations in particular or in the event of rentals it amounts to 12 months Systems driven by petrol or air are also guaranteed for a 12 month period The guarantee period begins with the day of delivery by the authorised specialist shop The date on the original purchase document is authoritative For all products bought in authorised specialist shops from 01 02 2009 the guarantee pe riod is extended to 24 months providing the buyer of these devices registers in accordan ce with the following conditions within 4 weeks of the day of delivery by the authorised specialist shop Registration can be completed on the Internet under www wagner group com profi gua rantee The guarantee certificate is valid as confirmation as is the original purchase docu ment that carries the date of the purchase Registration is only possible if the buyer is in agreement with having the data being stored that is entered during registration When services are carried out under guarantee the guarantee period for the product is neither extended nor renewed Once the guarantee period has expired claims made against the guarantee or from the guarantee can no longer be enforced 3 3 HANDL
33. dard 5 5 4 as per ISO 8573 1 5 5 4 40 um 7 5 mg m SIHI 0068 GB 15 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 4 3 3 DIMENSIONS AND CONNECTIONS EDITION 01 2010 OPERATING MANUAL WAGNER Mounting for wallfor 2301832 2301836 2301837 C 00041 2301832 2301836 2301837 2301838 2301832 2301836 2301837 2301838 mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch 295 11 6 295 11 6 280 11 09 20 35 09 20 35 09 0 35 280 11 280 11 280 11 N 38 3 1 5 38 3 1 5 38 3 1 5 189 7 44 189 7 44 189 7 44 O 80 3 2 80 3 2 80 3 2 9 0 35 9 0 35 9 0 35 P 189 7 4 189 7 4 189 7 4 360 14 1 360 14 1 360 14 1 Q d G1 4 1 4 1 4 1 4 1 4 R 940 37 158 6 2 158 6 2 158 6 2 5 1 4 1 4 G1 4 gt 816 16 16 250 9 8 250 9 8 260 10 2 250 9 8 360 14 1 335 13 1 405 15 9 B 17 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 4 4 FUNCTIONING 4 4 1 PUMP 2227 c Pa C A Diaphragms 19M B Connecting shaft J Je N C Check valves 2 Z d M Driving chambers l Bj P Pumping chambers A 22 KY Q Air motor R Inversion valv
34. e C V General information The principle lying behind the functioning of diaphragm pumps driven by compressed air is just as simple as it is effective Two diaphragms A which are connected to one another by means of a connecting shaft B so as to be integral divide two adjacent capacities into four chambers The inner ones function as driving chambers M while the outer ones func tion as pumping chambers P A pneumatic distributor alternately conveys compressed air into one of the driving chambers thus producing the diaphragms movement and conse quently causing one of the pumping chambers to empty as a result of volume decrease while at the same time the other fills up as a result of volume increase A series of check valves C prevents the liquid from flowing back thus producing the suction and delivery phases in each pumping chamber Max pressione fluido Max liquid fluid pressure Max pression liquide Max druck Fl ssiakeit Air motor Q The pneumatic motor must be powered at a pressure not exceeding the value giv en on the plate Each component linked A WAGNER Pump Type Tipo di Pompa to the pump outlet must have an operat WAGNER Max fluid press 1 N Burago di Molgora Max air press bar psi 8 318 ing pressure equal to or higher than the Ratio Rapporto di pressione pressure generated by the pump i
35. e suction pipe and wait until the pump is completely empty from the solvent previously pumped for the first washing NOTE The solvent used for the first washing may contain oil residues the refore avoid using it to dilute the paint Insert the suction pipe F into the paint container Wait until the pump is full Close the re cycle valve L If the product re quires a continuous agitation adjust the re cycle valve opening so as to obtain the desired delivery Set the motor air pressure A on the gauge C to 3 5 bar or even more if the paint viscosity requires it Open the gun T and drain the solvent contained inside the hose Close the gun T as soon as paint starts coming out The pump stops while it is still pressurized Adjust the atomising air pressure using the regulator B and make sure the pressure on manometer D is 1 5 2 bar You can now start painting 27 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 5 3 2 PAINTING HINTS If the pump speeds up suddenly and starts to shake it means that there is no paint left inside it and that it is sucking air you must therefore supply it with new paint If the pump starts shaking like it would do if there were no paint left but in fact there is you must clean the suction pipe filter see the Filter cleaning operations paragraph 6 3 NWARNING Overpressure Risk of injury from bursting components Frequently ch
36. eck for blocked recirculation pipe the pipeline must be completely free SIHC 0001 GB 5 3 3 WORKING BREAKS Each time you stop spraying close the motor input air valve H and open the re cycle valve to release the pressure When using catalized paints the interruption must be considerably shorter than the mix ture lifetime In case it is not so wash the system thoroughly If the system has been used with two component material NWARNING Hardened material in the spraying system when 2 component material is worked Destruction of the pump and injection system Follow the manufacturer s working instructions particularly re garding the pot life Rinse thoroughly before the end of the pot life The potlife time decreases at raising temperature SIHI 0069 GB 28 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 5 3 4 SHUTTING DOWN AND CLEANING Note The device should be cleaned for maintenance purposes etc Ensure that no remaining material dries and sticks Procedure Working breaks gt procedure on chapter 5 3 2 Basic cleaning gt procedure on chapter 5 2 3 Maintain the gun as laid down in the operating instructions Clean and check the suction system and in particular the suction filter When using a high pressure filter Clean and check the filter insert Clean the outside of the system Ox pue pa c NWARNING Brittle fil
37. essure regulator knob H clockwise until the pump starts Set the air pressure on the gauge D to 2 bar Open the re cycle valve L Lift the suction pipe and wait until the pump is completely empty from the solvent previously pumped for the first washing NOTE The solvent used for the first washing may contain testing fluid resi dues therefore avoid using it to dilute the paint Insert the suction pipe M into the paint container Wait until the pump is full Close the re cycle valve L If the product re quires a continuous agitation adjust the re cycle valve opening so as to obtain the desired delivery Set the motor air pressure H on the gauge D to 5 5 5 bar or even more if the paint viscosity requires it Open the gun T and drain the solvent contained inside the hose Close the gun T as soon as paint starts coming out The pump stops while it is still pressurized Set the paint pressure using the regulator G until obtaining a pressure of 1 1 5 bar on manometer E Adjust the atomising air pressure using the regulator B and make sure the pressure on manometer F is 1 5 2 bar You can now start painting for 2301838 Make sure that the pressure regulator knob A is turned fully anti clockwise 0 bar pressure Open the air cutoff valve and turn the motor air pressure regulator knob A clockwise until the pump starts Set the air pressure on the gauge C to 2 bar Open the re cycle valve L Lift th
38. gaskets g Reassemble the valve in its housing check that the shoe is in the end of stroke position both vertically and horizontally and then put the pressure side cover on As you are performing the operations described above check the positioning of the valves seals and cover h Reassemble the remaining components by following the instructions under paragraph 1 points f h 3 Cleaning and or replacement of the suction and delivery valves a Removethe suction and delivery manifolds b Extract the gaskets seats and ball valves from the external cover and manifold housings c Check the condition of wear of the ball guide stops inside the covers and manifold WAGNER 6 4 3 Sequenza d serraggio Torque sequence S quence de serrage Anzugsreihenfolge EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 7 ACCESSORIES 7 1 ACCESSORIES ONLY FOR 2301832 2301836 2301837 T760 00M 3825964 T760 00R 3825551 KIT SUPPORTO MURALE KIT MANIGLIA RUOTE WALL SUPPORT KIT HANDLE WHEELS KIT KIT SUPPORT MURAL KIT POIGNEE ROUES SET MAUERTRAGER SET GRIFF RAD S T760 008R 3825546 KIT CARRELLO CON RUOTE TROLLEY WITH WHEELS KIT T760 008 3825548 KIT CHARIOT AVEC ROUES KIT CAVALLETTO SET WAGEN MIT RADERN STAND KIT KIT CHEVALET SET ST NDER 35 PART ZZB012ENG EDITION 01 2010 A WAGNER OPERATING MANUAL 7 2 PUMP ZIP 52 FINISHING WI
39. ng out from the gun is poor use the recycling valve lever L to obtain a higher pressure from the gun At this point all components have been through the first washing the equipment has no unwanted fluid inside and is ready for painting lift the suction pipe from the dirty solvent container and empty the pump completely Plunge the suction pipe and refill the pump with clean solvent the turn off the air using the motor air pressure regulator H NOTE In case you are pumping liquids such as catalyzed resins which are bound to harden up once you have finished using the pump you must wash it as well as anything that may be connected to it in a thorough way using a solvent suitable for the type of resin being used You must then leave the pump full of solvent until it is next used 5 2 4 UNIT PRESSURE TIGHTNESS TEST Close the gun close the re cycle valve L gradually increase the motor feeding air pressu re H and the reducer controlling air G until reaching the max acceptable value for the pump and connected equipment make sure there are no leaks from fittings or pipe as well as from pump and antipulsation tank reducer filter 26 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 5 3 WORK 5 3 1 SPRAYING for 2301832 2301836 2301837 Make sure that the pressure regulator knob H is turned fully anti clockwise 0 bar pressure Open the air cutoff valve I and turn the motor air pr
40. o atomize the material use only weakly oxidizing gases e g air EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Surface spraying electrostatic Donot spray unit parts with electrostatic e g electrostatic spray gun Cleaning If there are deposits on the surfaces the unit may form electrostatic charges Flames or P sparks can form if there is a discharge Remove deposits from the surfaces to maintain conductivity Use only a damp cloth to clean the unit 10 EDITION 01 2010 PART NO ZZBO12ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 3 PRODUCT LIABILITY AND WARRANTY rwus 2 9 3 1 SCOPE OF GUARANTEE All Wagner professional colour application devices hereafter referred to as products are carefully inspected tested and are subject to strict checks under Wagner quality assurance Wagner exclusively issues extended guarantees to commercial or professional users he reafter referred to as customer who have purchased the product in an authorised spe cialist shop and which relate to the products listed for that customer on the Internet under www wagner group com profi guarantee The buyer s claim for liability for defects from the purchase agreement with the seller as well as statutory rights are not impaired by this guarantee We provide a guarantee in that we decide whether to replace or repair the product or individual parts or take the device back an
41. ons manage the legal relationship to us concludingly Additional claims in particular for damages and losses of any type which occur as a result of the product or its use are excluded from the product liability act except with regard to the area of appli cation Claims for liability for defects to the specialist trader remain unaffected German law applies to this guarantee The contractual language is German In the event that the meaning of the German and a foreign text of this guarantee deviate from one another the meaning of the German text has priority J Wagner GmbH Division Professional Finishing Otto Lilienthal Strasse 18 88677 Markdorf Federal Republic of Germany 12 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 3 6 CE CONFORMITY Herewith we declare that the supplied version of Pneumatic pumps with article no 2301832 2301836 2301837 2301838 Complies with the following provisons applying to it 2006 42 EC 94 9 EC Atex Applied standards in particular UNI EN 12100 1 UNI EN 809 UNI EN 1127 1 UNI EN 12100 2 UNI EN ISO 14121 1 EN 12621 UNI EN 563 UNI EN ISO 3746 UNI EN ISO 13463 Marking C 112G IIB T4 EC Certificate of Conformity The certificate is enclosed with this product The certificate of conformity can be reordered from your WAGNER representative quoting the product and serial number Part
42. pipe ST 1 T406 00 15 Pipe 300 mm 5103 07 16 Fitting LMM 1 4 1 M215 04 17 Reduced nipple 1 M618 62 18 Material filter 1 T4005 00ALS 19 Nipple 1 M631 62 51 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Spare parts list 2301838 Pos Description Qty Code 20 Plug 1 4 1 M623 12 21 Fitting L 1 4 1 M213 04 22 TCE M6x20 screw 4 K107 62 23 Washer 8 K505 62 24 Self tightening nut 8 K311 62 25 Vite TCE M4x50 2 K166 62 26 Washer 4 K501 62 27 Nut 2 K302 62 28 TCEI M6x55 screw 4 K134 62 29 Contact washer 8 K564 72 52 2 5 Nm Plastica Plastic Plastique Kunstoff 4 5 Nm EDITION 01 2010 OPERATING MANUAL 8 3 3 PUMP ZIP 52 PART NO ZZBO12ENG ZIP52 FINISHING PF WAGNER i AYR MER ANS TRE AN 97 2 5 Nm Plastica Plastic Plastique Kunstoff ek E 53 EDITION 01 2010 PART NO ZZBO12ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Spare parts list 2301837 2301832 2301836 2301838 Pos Description Qty Code Code Code Code 1 Suction manifold 1 F833 07G A F184 01 F188 03 F184 01 2 Delivery manifold 1 F859 07G F185 01 F189 03 F185 01 3 Outer diaphragm disk 2 F834 07D F834 07R F834 07R F834 07R 4 Diaphragm cover 2 F831 07G A
43. s Clean the piston pump only with a damp cloth SIHI 0041 GB NWARNING Heavy paint mist if earthing is insufficient Risk of poisoning Insufficient paint application quality Earth all unit components Earth the workpieces being painted 5 0003 GB Earthing schema example Conveyor Workpiece Spraying stand Paint container B_00304 Anti static floor 22 EDITION 01 2010 PART NO ZZB012ENG OPERATING MANUAL Cable cross sections Pump 4 mm AWG 11 Paint container 6 mm AWG 10 Conveyor 16 mm AWG 5 Spraying booth 16 mm AWG 5 Spraying stand 16 mm AWG 5 Procedure 1 Screw on earthing cable with eye 2 Clamptheearthingcablecliptoaearth connection on site 3 Earth the material paint container to a local earth connection 4 Earth the other parts of the system to a local earth connection WAGNER 23 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 5 2 START UP 5 2 1 SAFETY REGULATIONS Every time before starting up the following points should be observed as laid down in the operating instructions That it is possible to observe the safety regulations in Chap 2 The starting up procedure has been carried out properly NWARNING High pressure spray jet Danger to life from injecting paint or solvent Never reach into the spray jet Never point the
44. s suitable for working liquid materials in accordance with the classification into explosion classes 2 4 2 EXPLOSION PROTECTION IDENTIFICATION As defined in the Directive 94 9 CE ATEX 95 the unit is suitable for use in areas where there is an explosion hazard C 9 Il 2G IIB TA CE Communaut s Europ ennes Ex Symbol for explosion protection Il Unit class Il 2 Category 2 Zone 1 G Ex atmosphere gas IIB Explosion class T4 Temperature class maximum surface temperature lt 135 C 275 F 2 4 3 MAX SURFACE TEMPERATURE Max surface temperature same as the permissible material temperature Permissible ambient temperature see under Technical data Section 4 3 2 2 4 4 SAFETY REGULATIONS Safe handling of WAGNER spray units The maximum surface temperature of the piston pump can be reached if it runs dry Ensure that the piston pump is filled with sufficient working or cleaning medium Ensure that the separating agent container is filled with sufficient separating agent Mechanical sparks can form if the unit comes into contact with metal In an explosive atmosphere Do not knock or push the unit against steel or rusty iron Do not drop the unit Use only tools that are made of a permitted material Ignition temperature of the coating material Ensure that the ignition temperature of the coating material is above the maximum surface temperature Medium supporting atomizing T
45. spray gun at people Consulta doctor immediately in the event of skin injuries caused by paint or solvent Inform the doctor about the paint or solvent used Never seal defective high pressure parts instead relieve the pressure from them and replace SIHI 0016 GB NWARNING Toxic and or flammable vapor mixtures Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials or Operate the unit on an appropriate spraying wall with the venti lation extraction switched on Observe national and local regulations for the outgoing air speed SIHI 0028 GB NWARNING Gas mixtures can explode if there is an incompletely filled pump Danger to life from flying parts Ensure that the piston pump and suction system are always completely filled with cleaning agent or working medium Do not spray the unit empty after cleaning SIHI 0025 GB 24 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER Before every start up the following points should be observed as laid down in the operating manual If installed secure gun with safety catch Check the permissible pressures Check all connections for leaks Check hose for damage It should be ensured that the unit is in the following state before carrying out any work on it The pressure should be released from the pump and high pressure hose with gun if
46. t with grease assemble the internal diaphragm disk diaphragm and external disk and then properly tighten it by using two spanners in contraposition on the nuts of the external disks h Reassemble the external covers and then the manifolds while making sure you check the positioning of the suction and delivery valves the relative seals and proper tightening of the screws 6 4 2 Diaphragm replacement due to breakage In the case the diaphragms are replaced as a consequence of breaking it is ne 6 Y cessary to clean all the internal parts of the motor and check the condition of Ww J the seals and reversing valve which may have been damaged by contact with the pumped fluid a Follow the sequence described under paragraph 1 points a b c d and e b Disassemble the pressure side cover and extract the reversing valve 33 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL c Remove the rod guide bushings placed at the two ends of the motor block the shaft seals and feeler pin underneath and extract the feeler pins 6 4 d Clean all the components the lines and spaces inside the motor block Thoroughly blow the housing cavity of the safety valve with a jet of compressed air e Check the condition of the reversing valve and replace it if necessary f Reassemble all the parts described under point c while paying attention that you properly orient the seal lip of the
47. ter pressure regulator The container on the filter pressure regulator becomes brittle through contact with solvents and can burst Flying parts can cause injury Do not clean the container on the pressure regulator with sol vent SIHI 0014 GB 7 Putthe whole system back together 8 Fillthe system with solvent as laid down in Paragraph 5 2 3 NWARNING Gas mixtures can explode if there is an incompletely filled pump Danger to life from flying parts Ensure that the piston pump and suction system are always completely filled with cleaning agent or working medium Do not spray the unit empty after cleaning SIHI 0025 GB 5 4 STORING FOR LONGER PERIODS OF TIME When storing the device for longer periods of time it is necessary to thoroughly clean it and protect it from corrosion Replace solvent in the material pump with a suitable preser ving oil Procedure 1 Carry out Paragraph 5 3 4 Shutting down and cleaning points 1 through 8 2 Cleaning with preserving agent acc Paragraph 5 2 3 3 Protect the air motor with pneumatic oil connect an oiler to the compressed air inlet and run for a few double strokes 29 EDITION 01 2010 OPERATING MANUAL A WAGNER 6 FAULT LOCATION MAINTENANCE AND REPAIR 6 1 TROUBLE SHOOTING AND SOLUTION Problem Solution The pump does not start Check the line and the air cutoff valve Check the air treatment group if installed
48. the valve seats If the problem is not listed above consult your WAGNER Service Center 30 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 6 2 MAINTENANCE WARNING 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 Only repair and replace parts that are listed in the chapter Spare parts catalog Before all work on the unit and in the event of work interrup tions Disconnect the control unit from the mains Relieve the pressure from the spray gun and unit Secure the spray gun against actuation Observe the operating and service instructions when carrying out all work SIHI_0048_GB 1 Every shut down should be carried out as laid down in paragraph 5 3 3 2 Checkand replace if necessary hoses tubes couplings every days WAGNER recommends to check the whole spray system every year from a technical expert e g WAGNER service technician 31 EDITION 01 2010 PART NO ZZB012ENG ZIP52 FINISHING PF OPERATING MANUAL WAGNER 6 3 FILTER CLEANING OPERATIONS wi Before you clean the filters you must close the compressed air 7 input valve and release the pres sure contained inside the pump and the pipes attached to it This pump has one filter inside the suction pipe and another inside the delivery circuit ALL FILTERS M
49. tself CE UJ Serial No Matricola 26 TA Technicalfile File tecnico rrorwarex This fi nal pressure is given on WE EEGEN the plate see the picture on the right prima dell uso Max pressione aria Max air pressure Max pression Air Max druck Luft NWARNING Overpressure Risk of injury from bursting components Never change the safety valve setting SIHI 0026 GB 18 EDITION 01 2010 OPERATING MANUAL 4 4 2 PRESSURE REGULATOR Di Antipulsation Reducer Filter with pneum control FINE FLOW CONTROLLER Atomising air pressure reducer Atomising air connection Pump motor feeding air manometer Atomising air manometer PM motor feeding air pressure reducer On off and feeding air inlet valve Re cycle on off valve Fluid suction pipe Fluid delivery connection 53 am ANS Pump feeding air pressure reducer Atomising air pressure reducer Pump feeding air manometer Atomising air manometer Atomising air connection Fluid suction pipe Filter material Compressed air connection Fluid delivery connection Recycling valve tuo ch Doo o OD Controlling air manometer of pneumatic paint pressure reducer Controlling air pressure reducer of pneumatic paint reducer WAGNER Figure Pump 2301832 2301836 2301837 1 AN L D i 7 2 CU Ze SS TN Figure Pump 2301838 19 E
50. w 47 8 3 1 Pump cod 2301832 2301836 2301837 47 8 3 2 Pump cod 2301838 50 8 3 3 Pump ZIP 52 53 8 3 4 Air motor pump 52 55 8 3 5 Fine flow controller T0180 00A T0180 00Al 57 8 3 6 Material filter 1 2 aluminium cod T4005 00ALS for 2301838 59 8 3 7 Suction pipe re cycle pipe cod T406 00 T406 00A 61 9 EUROPEAN SERVICE NETWORK 65 EDITION 01 2010 PART NO ZZB012ENG OPERATING MANUAL WAGNER 1 ABOUTTHESE INSTRUCTIONS This operating manual contains information about the operation repair and maintenance of the unit Always follow these instructions when operating the unit 1 1 LANGUAGES This operating manual is available in the following languages Language Part No Language Part No German ZZB012GER English ZZB012ENG French ZZB012FRE Dutch Italian ZZBO12ITA Spanish Danish Swedish Portuguese Turkish 1 2 WARNINGS NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard These warning instructions fall into the follo A DANGER d e m Danger imminent danger Non observance will result Ec np dps Possible consequences of failing to observe the warning instruc in death serious injury and serious material damage tions The signal word points out the hazard level SIHI 0100 GB The measures for preventing the hazard and its consequences N WARNING
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