mixing unit zip52 2k - producten en diensten op het gebied...

C_Z2_00001

II 2G IIB T4

Mixing unitZIP52 2K

ZIP52 2K

Edition 04 / 2011

Translation of the original

Operating Manual

3

ZIP52 2K.

OPERATING MANUAL

EDITION 04 /2011 PART NO. ZZB025ENG

Contents

1 ABOUT THESE INSTRUCTIONS 51.1 Languages 51.2 Warnings, notes and symbols in these instructions 5

2 GENERAL SAFETY INSTRUCTIONS 62.1 Safety instructions for the operator 62.1.1 Electrical equipment 62.1.2 Personnel qualifi cations 62.1.3 A safe work environment 62.2 Safety instructions for staff 62.2.1 Safe handling of WAGNER spray units 72.2.2 Earth the unit 72.2.3 Material hoses 72.2.4 Cleaning 82.2.5 Handling hazardous liquids, varnishes and paints 82.2.6 Touching hot surfaces 82.3 Correct use 82.4 Use in an explosion hazard area 92.4.1 Correct use 92.4.2 Explosion protection identifi cation 92.4.3 Max. surface temperature 92.4.4 Safety regulations 9

3 PRODUCT LIABILITY AND WARRANTY 113.1 Important notes on product liability 113.2 Warranty 113.3 CE-conformity 12

4 DESCRIPTION 134.1 Field of application 134.1.1 Using in accordance with the instructions 134.2 Extent of delivery 134.3 Data 134.3.1 Materials of the parts transporting paint 134.3.2 Technical data 144.3.3 Dimensions and connections 154.4 Functioning 16

5 STARTING UP AND OPERATING 195.1 Installation and connection 195.1.1 Set up the pump 195.1.2 Earthing 205.1.3 Initial fl ushing 215.2 Start up 225.2.1 Safety regulations 225.2.2 How to start working 245.2.3 Filling with working material 245.3 Work 255.3.1 Spraying 25

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OPERATING MANUAL


Contents5.3.2 Painting hints 255.3.3 Work stop 255.3.4 Finishing work and cleaning 275.3.5 Filters cleaning operations 285.4 Storing for longer periods of time 28

6 FAULT LOCATION, MAINTENANCE AND REPAIR 296.1 Trouble shooting and solution 296.2 Maintenance 30

7 ACCESSORIES 317.1 Accessories 31

8 SPARE PARTS 358.1 How to order spare parts 358.2 Overview modules 368.3 Connecting pipes 378.3.1 Air pipes 378.3.2 Product pipes unit U843.00 388.3.3 Product pipes unit U843.00A 398.4 Paint pump 408.5 Flushing solvent pump 438.6 ZIP52 motor 468.7 Compensator 488.8 Mixing head 508.8.1 Mixing head unit U843.00 508.8.2 Mixing head unit U843.00A 518.9 Air group 528.9.1 Air group U843.00 528.9.2 Air group U843.00A 538.10 Floor stand 548.10.1 Floor stand U843.00 548.10.2 Floor stand U843.00A 558.11 Antipulsator 56

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ZIP52 2K.

OPERATING MANUAL


1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS

1 ABOUT THESE INSTRUCTIONS

1.1 LANGUAGES

-- ZZB025ENG -- -- ZZB025ITA ZZB025SPA -- -- -- --

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ZIP52 2K.

OPERATING MANUAL


2 GENERAL SAFETY INSTRUCTIONS

2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

2.1.1 ELECTRICAL EQUIPMENT

2.1.2 PERSONNEL QUALIFICATIONS

2.1.3 A SAFE WORK ENVIRONMENT

2.2 SAFETY INSTRUCTIONS FOR STAFF

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 withleather soles.Ensure that during spraying, persons wear anti-static gloves so that they are earthed viathe 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 hotsurfaces in the vicinity. Do not smoke.

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ZIP52 2K.

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2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS

2.2.2 EARTH THE UNIT

2.2.3 MATERIAL HOSES

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 functionalfaults:– 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.

Electrostatic charges can occur on the unit due to the electrostatic charge and the flowspeed involved in spraying.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 wearingantistatic shoes.When spraying, wear antistatic shoes to earth yourself via the spray gun handle.If gloves are used, they must be antistatic

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ZIP52 2K.

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2.2.4 CLEANING

2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS

2.2.6 TOUCHING HOT SURFACES

2.3 CORRECT USE

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ZIP52 2K.

OPERATING MANUAL


2.4.1 CORRECT USE

2.4.2 EXPLOSION PROTECTION IDENTIFICATION

2.4.3 MAX. SURFACE TEMPERATURE

2.4.4 SAFETY REGULATIONS

2.4 USE IN AN EXPLOSION HAZARD AREA

As defined in the Directive 94/9/CE (ATEX 95), the unit is suitable for use in areas wherethere is an explosion hazard.

II 2G IIB T4CE: Communautés EuropéennesEx: Symbol for explosion protectionII: Unit class II 2: Category 2 (Zone 1) G: Ex-atmosphere gas IIB: Explosion class T4: Temperature class: maximum surface temperature < 135°C; 275°F.

Max. surface temperature: same as the permissible material temperaturePermissible ambient temperature: see under Technical data, Section 4.3.2

Safe handling of WAGNER spray units

The maximum surface temperature of the pump can be reached if it runs dry.Ensure that the pump is filled with sufficient working or cleaning medium.

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 pumped materialCheck that the ignition temperature of the pumped material is higher than the max. allowable surface temperature.

Medium supporting atomizingTo atomize the material, use only weakly oxidizing gases, e.g. air.

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OPERATING MANUAL


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3 PRODUCT LIABILITY AND WARRANTY

3.1 IMPORTANT NOTES ON PRODUCT LIABILITY

3.2 WARRANTY

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ZIP52 2K.

II 2G IIB T4

OPERATING MANUAL


3.3 CE-CONFORMITY

Herewith we declare that the supplied version of:Pneumatic pumps with article no.

Complies with the following provisons applying to it

2006/42/CE 94/9/CE Atex

Applied standards, in particular:

UNI EN ISO 12100-1 UNI EN 809 UNI EN 1127-1

UNI EN ISO 12100-2 UNI EN 14121-1 EN 12621

UNI EN 563 UNI EN ISO 3746 UNI EN ISO 13463

Marking:

ZDI.21

Part no. Model

U843.00 Pump ZIP52 2K with fl ushing pump

U843.00A Pump ZIP52 2K without fl ushing pump

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ZIP52 2K.

OPERATING MANUAL


4 DESCRIPTION

4.1 FIELD OF APPLICATION

4.1.1 USING IN ACCORDANCE WITH THE INSTRUCTIONS

The pneumatic diaphragm pump is suitable for process liquid materials.

SIHC_0067_GB

CAUTIONAbrasive fluids and pigments !Greater wear of the parts carrying the material.

Use suitable pump model (delivery per cycle, material, valves, etc.)see chapter 4.3.2.

Verify that fluids and solvents used are compatible with the constrution material of the pump as described in chapter 4.3.1.

4.2 EXTENT OF DELIVERY

Mixing unit with 1:1 fi xed ratio, with pneumatic diaphragm pump composed of:

- Diaphragm pump with independent sections- Flushing diaphragm pump (if expected)- Connection elements

CE-conformity see Chapter 3Operating manual in english Part No. : ZZB025ENGOperating manual for the other language see Chapter 1

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

Pump body AluminiumDiaphragms UHMW-PE / PTFEValves balls Stainless steelValves seats Stainless steelO-rings PTFE / EPDMAntipulsatorsConnections

Nickel-plated steelNickel-plated steel/brass

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4.3.2 TECHNICAL DATA

Description Units ZIP52 2K

Pressure ratio 1:1

Mixing ratio (in volume) 1:1

Flow volume per double stroke (DS) cm³ 65

Max. operating pressure (Pump) MPabarpsi

0.88

116

Max. possible strokes in operation DS/minDC/min

60

Min. - Max. air inlet pressure MPabarpsi

0.88

116

Ø air inlet connection (female) BSP 1/4“

Sound pressure with 5 bar feeding air and 50 DS/min (LqA) frequency*

dB(A) 76

Material outlet connection BSP 1/4“

WeightModel with fl ushing pump cod. U843.00Model without fl ushing pump cod. U843.00A

kg; lb 30; 66,226; 57,3

Range of material temperature °C; F +5° ÷ +80°; (+41 ÷ +176)

Range of the ambient temperature °C; F +4° ÷ +40° ; (+39 ÷ +104)

Allowable sloping position at work <) ° ± 10

* A rated sound pressure level measured at 1m distance according to UNI EN ISO 3744.

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ZIP52 2K.

ZIP52 2Kmm; inch

A 470; 18,50B 440; 17,32 C 1100; 43,31 D BSP 1/4” ME BSP 1/4” M

A

C

B

D

E

C_Z2_00002

A

C

B

D

E

C_Z2_00003

U843.00

U843.00A

OPERATING MANUAL


4.3.3 DIMENSIONS AND CONNECTIONS

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ZIP52 2K.

15

6

8

3 19

10

2

5

7

a

b

c

4

13

14

11

12

C_Z2_00004

OPERATING MANUAL


UNIT ZIP52-2K - Model with fl ushing pump cod. U843.00

a Paint pump 7 A-component solvent valve b Flushing solvent pump 8 B-component solvent valvec Compensator 9 Main air on-off valve1 A-component suction pipe 10 Paint pump air pressure2 B-component suction pipe 11 Flushing pump air pressure3 A-comp. return pipe 12 Atomising air pressure4 B-comp. return pipe 13 Solvent suction pipe 5 A-component recycling valve 14 A-component antipulsator6 B-component recycling valve 15 B-component antipulsator

4.4 FUNCTIONING

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ZIP52 2K.

15

6

3

19

10

2

5

a

c

4

14

12

C_Z2_00005

OPERATING MANUAL


UNIT ZIP52-2K - Model without fl ushing pump cod. U843.00A

a Paint pump 9 Main air on-off valvec Compensator 10 Paint pump air pressure 1 A-component suction pipe 12 Atomising air pressure2 B-component suction pipe 14 A-component antipulsator 3 A-comp. return pipe 15 B-component antipulsator4 B-comp. return pipe 5 A-component recycling valve 6 B-component recycling valve

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ZIP52 2K.

A1 – A2 B

D1 D2

C1 – C2

E

F

G1 G2 H

E

OPERATING MANUAL


General informationFluid section – Pump and compensatorThis unit has been designed to proportionate and pump two components (A) and (B) separately, with a 1:1 mixing ratio, avoiding the frequent and expensive maintenance required by piston mixing units, since the paints have a high content of extenders or coarse pigments. The working principle is both simple and effective: it is based on a diaphragm pump with independent pumping chambers, driven by compressed air.Two diaphragms (A

1 -

A

2) connected through the shaft (B)

divide two independent and adjoining volumes into four chambers. The two inner chambers are the driving chambers (C

1-C

2) while the outer chambers are the pumping ones (D

1-

D2); a pneumatic distributor conveys the compressed air

alternatively into the fi rst or the second driving chamber (C

1-C

2), provoking the diaphragm displacement and the

following emptying of one of the pumping chamber (due to volume reduction) as well as the contemporary fi lling of the other pumping chamber (due to volume increase); a series of check valves (E) prevents the fl uid fl owing back, caused by the suction and delivery phase in each pumping chamber. A compensator (F) composed of two chambers (G

1-G

2) and

(H) separated by a diaphragm, is assembled directly on the pump delivery inlets.During the given phase (shaft displacement to the right), the chamber (G

2) will be fi lled with a volume increase that

will move the diaphragm (H) to the left and consequently the chamber (G

1) will be emptied (with a volume decrease).

Due to the system pressure drop, part of the fl uid pumped into the chamber (G

1) will fl ow into the mixer, automatically

making up for the lack of the component which is not pumped during this phase; also in this case, a series of check valves (E) prevents the liquid re-fl owing. This phase is followed by a symmetric one.

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5 STARTING UP AND OPERATING

5.1 INSTALLATION AND CONNECTION

5.1.1 SET UP THE PUMP

1. Place the pump on a fl at and horizontal surface.2. Connect the double product/air pipe and the spraying gun, paying attention not to

reverse the atomizing air pipe with the product pipe.

WARNINGDischarge of electrostatically charged components in atmo-spheres containing solvents!Explosion hazard from electrostatic sparks.

Clean the pump only with a damp cloth.

SIHC_41_0041_GB

SIHC_41_0012_GB

WARNINGInclined surface!Risk of accidents if the unit rolls away/falls.

Place the frame with the pump horizontally.

Lock the frame.

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ZIP52 2K.

Ω

OPERATING MANUAL


5.1.2 EARTHING

Earthing schema (example)

Paint container

Anti-static fl oor

Conveyor

WorkpieceSpraying stand

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ZIP52 2K.

6

8

3 19

10

2

5

4

C_Z2_00006

OPERATING MANUAL


5.1.3 INITIAL FLUSHING

1. Turn off completely the atomising air on the spraying gun. Please refer to the manual.2. Put the suction pipes (1 and 2) with their recycling pipes into a container fi lled with

solvent.3. Turn on the recycling valves (5 and 6) and make sure the solvent valves (7 and 8) are

closed (if any – models with fl ushing pump).4. Slowly open the ball valve (9).

5. Adjust the pressure regulator (10) until the pump starts working.6. Wait until the solvents comes out from both the recycling pipes (3 and 4).7. Turn off the recycling valves (5 and 6).8. Point the gun to the solvent container and turn it on. Warning: risk of material‘s sprayback! Protect body and eyes!9. Wash the system until clean solvent comes out from the gun.10. Turn off the ball valve (9) and depressurise the motor, pulling the gun trigger into the

solvent container.11. When the system is depressurized, close the spray gun.12. Dispose of the container content in compliance with the local regulations in force.

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5.2 START UP

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.

WARNINGGas mixtures can explode if there is an incompletely filledpump!Danger to life from flying parts.

Ensure that the pump and suction system are alwayscompletely filled with cleaning agent or working medium. Do not spray the unit empty after cleaning.

SIHI_41_0025_GB

5.2.1 SAFETY REGULATIONS

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ZIP52 2K.

6

9

5

C_Z2_00007

OPERATING MANUAL


Emergency stop In the case of unforeseen occurrences close immediately the ball valve (9) and depressurise the pump opening the gun or the recycling valves (5 and 6).

During operation the pump must be in vertical position.

Before every start-up, the following points should be observed as laid down in the operating manual:- Make sure the gun is turned off- 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:- Depressurise the pump and the gun hose- Make sure the gun is turned off- The air supply should be interrupted

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ZIP52 2K.

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5.2.2 HOW TO START WORKING

Tips to prepare accelerated/catalysed polyester paints.Prepare two containers. Put half of the paint to be used into the fi rst container, and the other half in the second container. In case of a total quantity of 10 litres, put the accelerator required for all the 10 litres into a container and the catalyst required to catalyse all the 10 litres into the other container.

EXAMPLE: if a paint is to be catalysed at 2% and accelerated at 2% and 10 litres of paint are going to be prepared, put 5 litres into the fi rst container and 5 litres into the second one. Put the 200cc of accelerator into container A and 200cc of catalyst into container B. Mix well the content of the two containers making sure to use different tools, to avoid mixing accelerator traces with catalysed resin and vice-versa.

5.2.3 FILLING WITH WORKING MATERIAL

Turn off the gun atomising air. Please refer to the gun manual.Plunge the A-component suction pipe into the A-component container and the B-component suction pipe into the B-component container.

WARNING : Never reverse the suction pipes of the two components to avoid the risk of product hardening inside the equipment.

Place the valves (5) and (6) on the recycling. Open slowly the ball valve (9) of motor feeding air.Adjust the pressure regulator (10) until the pump starts working.Point the gun without nozzle to the waste container.Warning: risk of material‘s sprayback! Protect body and eyes!Acting on the pressure regulator (10), adjust the air pressure so that the pump can cycle regularly.When pure material is delivered without air bubbles, close the ball valve (9) and depressurize the motor by pushing the gun trigger directing it towards the container.When the system is depressurized, close the spray gun.Dispose of the container content in compliance with the local regulations.

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ZIP52 2K.

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5.3 WORK

5.3.1 SPRAYING

Wait until the two pumps are perfectly charged and make sure no air bubbles are coming out from the recycling (3) and (4).Make sure the recycling valves (5 and 6 ) are closed.Keep the gun open on a container used for the washing solvent (waste container) until all the solvent contained into the pipes comes out and the mixed paint starts fl owing. Adjust the motor air pressure (10) to the required value to have a good product supply. Pressure shall be proportional to product viscosity and to the size of the nozzle used for the gun. Adjust the atomising air pressure to 1,5-2 bar, using the regulator (12). Also in this case, the necessary pressure shall be proportional to the viscosity of the product being used. Adjust the fan width according to the needs and start painting.

5.3.3 WORK STOP

1. Close spray gun.2. Close ball valve (9). 3. Depressurise the system opening the recycling valves (5 and 6).4. Clean the equipment as described below, to prevent the mixed product from catalysing

into the circuit, blocking the equipment.

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 pipes fi lters (see the “Filter cleaning operations” paragraph).

If the pump works asymmetrically, with a fast phase and a slow phase, it means that one of the components has fi nished. A fi lling up is therefore required.

WARNING:Every time painting is stopped, close the motor air valve (9x) and at the same time put valves (5 and 6) in recycling position, to discharge pressure.

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ZIP52 2K.

OPERATING MANUAL


Intermediate fl ushing – Only for models with fl ushing pump

1. If painting is to be interrupted for a time similar to the reaction time of the product being used (always refer to the technical characteristics provided by the manufacturer), an intermediate fl ushing must be carried out, in the following way:

2. Close the motor feeding air (9).3. Put the levers of A-component valve (5) and B-component valve (6) in recycling

position.4. Close the atomising air (12), open the gun on the waste container and keep it open,

open the washing solvent valves (7 and 8) alternatively and repeatedly, until clean solvent comes out.

5. To resume work, make sure the washing solvent valves (7 and 8) are closed; open the motor feeding air valve (9) to start up the pump and let each product recycle, making sure there are no air bubbles coming out from the recycling.

6. As soon as the pumps are properly primed, put at the same time the two levers of the recycling valves (5 and 6) in working position.

7. Open the gun on the waste container and wait until the mixed paint comes out.8. Open the atomising air (11). Now the original working conditions have been restored.

Warning : In case of models without fl ushing pump, use the fi nal fl ushing procedure also for these short interruptions.

Final fl ushing – for all models.Wash carefully the equipment at the end of each job. After painting, close the motor feeding air (9).Put the levers of A-component (5) and of B-component (6) valves in recycling position. Reduce the motor feeding pressure to 1,5 – 2 bar, using the regulator (10).Close the atomising air (12).Open the motor air valve (9).Lift the suction pipes of the 2 components (1) and (2) from their containers and after emptying the pumps, plunge them into the solvent containers. Let them recycle for about a minute. Put the valves (5) and (6) in working position, keep the gun open and, if necessary, increase the motor feeding pressure, then let it recycle for a few minutes until clean solvent comes out. Close the motor feeding air (9). Only for models with fl ushing pump: Keep the gun open on the waste container, open the washing solvent valves (7) and (8) alternatively and repeatedly, until clean solvent comes out.Close the gun, put it on the washing solvent container, re-open it and let it recycle for about a minute. Close the gun. Close the washing solvent valves (7) and (8).

NOTE: After using it, it is necessary to leave the equipment full of solvent; any paint residue left after a hasty washing cannot harden and shall be discharged when resuming work.

The fi lters shall be cleaned at the end of each job.

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ZIP52 2K.

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5.3.4 FINISHING WORK AND CLEANING

NoteThe device should be cleaned for maintenance purposes, etc. Ensure that no remaining material dries and sticks.

Procedure:1. Working breaks -> procedure on chapter 5.3.3.2. Carry out the initial fl ushing operations ->procedure on chapter 5.1.3.3. Maintain the gun as laid down in the operating instructions.4. Clean and check the suction system and, in particular, the suction fi lter (see instructions

below).5. Clean and check the fi ltering cartridge of the antipulsators (see instructions below).6. Clean the outside of the system.7. Put the whole system back together.8. Fill the equipment with solvent as described in paragraph 5.2.3 „Filling with working

material“.

WARNINGGas mixtures can explode if there is an incompletely filledpump!Danger to life from flying parts.

Ensure that the pump and suction system are alwayscompletely filled with cleaning agent or working medium. Do not spray the unit empty after cleaning.

SIHI_41_0025_GB

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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. Fill separating fl uid cup with separating fl uid.

Procedure:1. Carry out Paragraph 5.3.4 “Finishing work and cleaning“, points 1 through 8.2. Cleaning with preserving agent acc. Paragraph 5.1.3.3. Protect the air motor with pneumatic oil: connect an oiler to the compressed air inlet

and run for a few double strokes.

5.3.5 FILTERS CLEANING OPERATIONS

WARNING:Before you clean the fi lters, you must close the compressed air input valve and release the pressure contained inside the pump and the pipes attached to it.

The equipment is supplied with fi lters on both suction and delivery pipes.

ALL FILTERS MUST BE CLEANED DAILY.IT IS ALSO NECESSARY TO CLEAN THEM WHEN USING A DIFFERENT COLOUR PAINT FROM THE ONE PREVIOUSLY USED.

To clean the fi lter of suction pipes (1), (3) and (13 if any) in models with fl ushing pump– loosen the spring, remove the fi ltering disk and put it into the solvent, then brush it and blow with compressed air. To clean the antipulsators fi lters (14) and (15), unscrew the cap and the locking nut, remove the fi ltering cartridge and put it into the solvent, then brush it and blow with compressed air. Make sure to clean also the fi lter inside part with solvent; if necessary, blow it with compressed air.

WARNING: Protect the eyes from any solvent splash.When reassembling the fi lter, make sure to position correctly the gasket.

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6 FAULT LOCATION, MAINTENANCE AND REPAIR

6.1 TROUBLE SHOOTING AND SOLUTION

Problem Cause Solution

The pump does not work

• Lack of air pressure to the pump (no reading on the manometer)

• Check the pressure in the feeding air circuit

• The pressure regulator does not work (no reading on the manometer)

• Repair or replace the pressure regulator

• The pump pneumatic motor does not start up

• Close/open the air valve to the pump or temporary cut the compressed air feeding

• Insuffi cient supply of compressed air

• Check compressed air supply

The pump works but the paints does not arrive to the gun and recycling

• Clogged circuit fi lters • Check the suction pipe fi lters, clean them carefully and replace them

• Clogged suction valves and/or pipes

• Make sure the suction pipes or valves are not clogged by hardened paint residue

The paint comes out from the gun with a discontinuous fl ow

• Air infi ltration in suction circuits • Make sure there are no air infi ltrations (tightening clamps, fi ttings, etc.)

Paint fl ow rate is poor and does not vary increasing the feeding pressure

• Partially clogged fi lters • Check and clean the fi lters

• Too high paint viscosity • Dilute the paint according to manufacturer’s instructions

Abnormal catalyst (anomalous dosing)

• Partially clogged suction pipe fi lters

• Check and clean the suction pipe fi lters

• Air infi ltration from suction pipes • Make sure there are no air infi ltrations (tightening clamps, fi ttings, etc.)

• Tightness problems of diaphragm pump valves

• Check the diaphragm pump valves. Replace if necessary

If the problem is not listed above consult your WAGNER Service Center.

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ZIP52 2K.

OPERATING MANUAL


6.2 MAINTENANCE

1. Check and clean the delivery and suction fi lters every day or whenever necessary.2. Every shut down should be carried out as laid down in paragraph 5.3.4!3. Check and 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).

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ZIP52 2K.

2 5

6

1

1

5

3

1

33

4

4

7

8

C_Z2_00019

OPERATING MANUAL


7 ACCESSORIES

7.1 ACCESSORIES

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List accessoriesZIP52 2K

Pos K Description No

1 Stainless steel ST suction hose T406.00

2 Suction pipe ST compl. met. part T420.00

3 Flexible pipe holder M208.04

4 SSt contact clip E0107.03

5 Hose clamp R601.00

6 Solvent resistant suction hose S402.00A

7 Double pipe PE 6x8 - 7,5 mt. with sheathing S419.00G

7 Double pipe PE 6x8 - 10 mt. with sheathing S419.00GA

8 SP5 manual gun - mm. 0,8 R950.08





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8 SPARE PARTS

8.1 HOW TO ORDER SPARE PARTS

36

ZIP52 2K.

a

dd

e e

h

f

gg

g

g

a

cc

b

C_Z2_00008

h hhh

OPERATING MANUAL


8.2 OVERVIEW MODULES

U843.00 U843.00A

Pos Description See pag. See pag.

a Paint pump Pag. 40 Pag. 40

b Flushing solvent pump Pag. 43 Pag. 43

c Compensator Pag. 48 Pag. 48

d Mixing head Pag. 50 Pag. 51

e Air group Pag. 52 Pag. 53

f Floor stand Pag. 54 Pag. 55

g Antipulsator Pag. 56 Pag. 56

h Suction pipe Pag. 31 Pag. 31

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ZIP52 2K.

12

4 4

1

C_Z2_00020

U843.00

U843.00A

OPERATING MANUAL


Air pipes Units U843.00 - U843.00A

Pos Description Q.ty (*) No.

1 Hose nylon d.8 black 300 mm S103.07N

2 Hose nylon d.8 black 420 mm S103.07N

(*) Unit total quantity

8.3 CONNECTING PIPES

8.3.1 AIR PIPES

38

ZIP52 2K.

2

1 1

2

3

35

4

C_Z2_00021

OPERATING MANUAL


Product pipes unit U843.00

Pos Description Q.ty No.

1 Antipulsator feeding pipe 2 S468.00

2 Delivery pipe to mixing head 2 S468.00A

3 Recycling pipe 2 S468.00B

4 Washing valves connecting pipe 1 S468.00C

5 Washing delivery pipe 1 S468.00D

8.3.2 PRODUCT PIPES UNIT U843.00

39

ZIP52 2K.

2

1 1

2

3

3

C_Z2_00022

OPERATING MANUAL


8.3.3 PRODUCT PIPES UNIT U843.00A

Product pipes unit U843.00A

Pos Description Q.ty No.

1 Antipulsator feeding pipe 2 S468.00

2 Delivery pipe to mixing head 2 S468.00A

3 Recycling pipe 2 S468.00B

40

ZIP52 2K.

10

7

6

1

3

8

11

5

4

9

2

C_Z2_00009

OPERATING MANUAL


8.4 PAINT PUMP

Spare parts list Paint pump

Pos K Description Q.ty No.

1 M6 low self-locking nut 4 K311.62A

2 Sleeve 1/4 1 M279.00

3 ZIP52 pump ind/ind 1 U551.ATSS8

4 Flexible pipe holder G1/2 2 M208.04

5 Fast swivel fi tting L 1/4x8 1 M336.00

6 L-shaped fi tting MF 1/2 2 M217.04

7 Washer d.6 4 K505.62

8 ZIP52 pump’s bracket 1 E3384.62

9 Antipulsator’s bracket 2 E3388.62

10 Socket screw M6x20 4 K107.62

11 Loctite 542 - -

41

ZIP52 2K.

4

6

1214

15

3

1

11

17

9

18

13

10

2

5

7

20

19

C_Z2_00024

8

21

23

22

5 Nm; 3.7 lbft

5 Nm; 3.7 lbft

24

3.5 Nm; 2.5 lbft

12 Nm; 8.8 lbft

5 Nm; 3.7 lbft

25 26

127

OPERATING MANUAL


42

ZIP52 2K.

OPERATING MANUAL


Spare parts list ZIP52 pump ind/ind U551.ATSS8


1 Suction manifold 2 F184.01D

2 Delivery manifold 2 F185.01D

3 Outer diaphragm disk 2 F834.07R

4 Diaphragm cover 2 F978.01

5 Product diaphragm 2 G921.05

6 Support diaphragm 2 G921.06



9 Self-locking nut M6 16 K311.62

10 Washer 6 20 K505.62

11 Self-tapping screw 1 K1012.62

12 Screw 4 K1040.62

13 Rivet 2 K1041.62

14 Screw 12 K1044.62

15 Self-locking nut M6 8 K311.62A

16 -

17 Motor 1 T6103.00S

18 Fluid valve unit 4 T6105.00

19 Lug 1 Y622.00A

20 Cover plate 1 Z535.00X

21 Side plate -

22 Cover round plate 2 Z543.00A

23 Nipple 1 B0177.14A

24 Contact washer 4 K564.72

25 Ball 4 K805.03

26 Ball seat 4 B0148.03A

27 O-ring 4 L206.05

Product o-ring set 1 T9077.00

Fluid service set 1 T9080.00

= Wearing parts = Included in service set

43

ZIP52 2K.

4

6

8

3

1

9

10

2

5

7

8

11

C_00010

OPERATING MANUAL


8.5 FLUSHING SOLVENT PUMP

Spare parts list Flushing solvent pump


1 Low self-locking nut M6 4 K311.62

2 Sleeve 1/4 1 M279.00

3 ZIP52 pump universal 1 U550.ATSS7

4 Flexible pipe holder G1/2 1 M208.04

5 Fast swivel fi tting L L 1/4x8 1 M336.00

6 L-shaped fi tting MM 1/4 1 M215.04

7 Reduction MF 1/2x1/4 1 M247.00

8 Washer d.6 8 K505.62

9 ZIP52 pump’s bracket 1 E3384.62


11 Loctite 542 - -

44

ZIP52 2K.

4

6

1214

15

3

1

17

9

13

10

2

5

7

20

19

C_Z2_00025

8

21

23

22

5 Nm; 3.7 lbft

5 Nm; 3.7 lbft

24

3.5 Nm; 2.5 lbft

12 Nm; 8.8 lbft

5 Nm; 3.7 lbft

11

18

16

25 2627

OPERATING MANUAL


45

ZIP52 2K.

OPERATING MANUAL


Spare parts list ZIP52 pump universal U550.ATSS7


1 Suction manifold 1 F184.01C

2 Delivery manifold 1 F185.01C

3 Outer diaphragm disk 2 F834.07R

4 Diaphragm cover 2 F978.01

5 Product diaphragm 2 G921.05

6 Support diaphragm 2 G921.06




10 Washer 6 20 K505.62

11 Self-tapping screw 1 K1012.62

12 Screw 4 K1040.62

13 Rivet 2 K1041.62

14 Screw 12 K1044.62

15 Self-locking nut M6 8 K311.62A

16 Plug 1/2 4 M254.14A

17 Motor 1 T6103.00

18 Fluid valve unit 4 T6105.00

19 Lug 1 Y622.00A

20 Cover plate 1 Z535.00X

21 Side plate -

22 Cover round plate 2 Z543.00A

23 Nipple 1 B0177.14

24 Contact washer 4 K564.72

25 Ball 4 K805.03

26 Ball seat 4 B0148.03A

27 O-ring 4 L206.05

Product o-ring set 1 T9077.00

Fluid service set 1 T9080.00


46

ZIP52 2K.

4

6

12

14

15

8

11

17

9

16

13

10

5

7

C_Z2_00023

2 Nm; 1.47 lbft

2

3

2 Nm; 1.47 lbft

1

OPERATING MANUAL


8.6 ZIP52 MOTOR

47

ZIP52 2K.

OPERATING MANUAL


Spare parts listZIP52 motor T6103.00 T6103.00S

Pos K Description Q.ty No. No.

1 Feeler pin 2 B0146.04 B0146.04

2 Inner diaphragm disk 2 B0147.71 B0147.71

3 Shaft 1 B0150.03 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

7 Motor block with safety valve 1 T6103.00A T6103.00A

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 P4003.00

16 Safety valve (**) 1 see pos. 7 see pos. 7

17 Side plate 1 Z546.00 Z546.00

Fluid service set 1 T9080.00 T9080.00

(*) Includes pos. 8 and 9

(**) Not available separately


48

ZIP52 2K.

4

6

11

12

13

8

3

10 15

9

14

16

2

5

7

18

17

1

19

19

C_Z2_00011

5 Nm; 3.7 lbft

5 Nm; 3.7 lbft

5 Nm; 3.7 lbft

5 Nm; 3.7 lbft

5 Nm; 3.7 lbft

5 Nm; 3.7 lbft

OPERATING MANUAL


8.7 COMPENSATOR

49

ZIP52 2K.

OPERATING MANUAL


Spare parts list Compensator

Pos K Description Q.ty No.1 Compensator supporting carter 1 E3387.622 Suction manifold ZIP52 independent 2 F184.01D3 Delivery manifold ZIP52 independent 2 F185.01D4 ZIP52 product cover 2 F978.015 Self-locking nut M6 10 K311.626 Low self-locking nut M6 12 K311.62A7 Diaphragm disk 2 B0474.078 Label for ZIP52 2K 1 Z5042.009 Product valve unit 4 T6105.00

10 Compensator diaphragm 1 G7037.0511 Conical nipple 1/2 2 M206.0412 O-ring 2 L179.06A13 Threaded pin 1 H1151.62A14 Washer d.6 33 K505.6215 Socket screw M6x20 7 K107.6216 Socket screw M6x30 4 K183.6217 Socket screw M6x35 4 K142.6218 Socket screw M6x40 6 K128.6219 Loctite 542 - -

50

ZIP52 2K.

4

6

12

14 15

8

3

1

11

916

13

10

2

5

7

C_Z2_00012

OPERATING MANUAL


8.8 MIXING HEAD

8.8.1 MIXING HEAD UNIT U843.00

Spare parts list Mixing head unit U843.00


1 Mixing body 1 B0284.03

2 Mixer valve body 2 A194.22


4 Nut G1/4 2 K341.04A

5 Line mixer 1 T678.00

6 Mixer paint valve shutter 2 T701.00SA

7 Fitting G1/4x10 2 M276.04


9 Fitting T FFM 1/4 2 M218.04

10 Fitting T MFM 1/4 1 M340.00

11 Right ball valve G1/4 1 M110.00DA

12 Left ball valve G1/4 1 M110.00SA

13 Dashboard 1 E3385.62

14 Plug 1/4 1 M623.12


16 Needle valve 1/4 2 M116.00

51

ZIP52 2K.

4

612

8

3

1

11

9

10

2

5

7

C_Z2_00013

OPERATING MANUAL


8.8.2 MIXING HEAD UNIT U843.00A

Spare parts list Mixing head unit U843.00A


1 Mixing body 1 B0284.03

2 Mixer valve body 2 A194.22


4 Line mixer 1 T678.00

5 Mixer paint valve shutter 2 T701.00SA

6 Fitting G1/4x10 2 M276.04


8 Right ball valve G1/4 1 M110.00DA

9 Left ball valve G1/4 1 M110.00SA


11 Plug 1/4 1 M623.12


52

ZIP52 2K.

4

6

12

15

16

8

3

1

11

11

9

14

10

2

5

7

C_Z2_00014

13

OPERATING MANUAL


8.9 AIR GROUP

8.9.1 AIR GROUP U843.00

Spare parts list Air group U843.00

Pos. Description Q.ty No.


2 Pressure regulator 1/4” 3 P123.00

3 Air manifold 1 T139.01

4 Spring 1 H261.03

5 O-ring 3 L159.06


7 Hollow screw 1/4” 3 M404.00

8 Pressure gauge 0-1 MPa 3 P936.00


10 Reduction MF 1/4x3/8 1 M250.00

11 Conical nipple 1/4 2 M205.04

12 Ball valve MF 1/4 1 M106.00


14 Flushing pump pressure label 1 Z5044.00

15 Paint pump pressure label 1 Z5043.00

16 Atomising air pressure label 1 Z5045.00

53

ZIP52 2K.

4

6

12

14

1415

8

3

1

11

18

9

3.5 Nm ; 2.58 lbft

17

19

13

10

2

5

7

C_Z2_00015

20

16

OPERATING MANUAL


8.9.2 AIR GROUP U843.00A

Spare parts list Air group U843.00A

Pos. Description Q.ty No.


2 Pressure regulator 1/4” 2 P123.00

3 Air manifold 1 T139.01

4 Spring 1 H261.03

5 O-ring 2 L159.06

6 Gasket 1 M404.00G


8 Hollow screw 1/4” 3 M404.00

9 Sleeve 1/4 1 M279.00

10 Plug 1/4 1 M623.12

11 Pressure gauge 0-1 MPa 2 P936.00


13 Reduction MF 1/4x3/8 1 M250.00

14 Conical nipple 1/4 2 M205.04

15 Ball valve MF 1/4 1 M106.00

16 L-shaped MM 1/4 1 M215.04

17 Cover plate 1 Z543.00B

18 Atomising air pressure label 1 Z5045.00

19 Paint pump pressure label 1 Z5043.00

20 Loctite 542 - -

54

ZIP52 2K.

11

10

76

34

4

1

9

8

25

4

5 Nm; 3.7 lbft

C_Z2_00016

OPERATING MANUAL


8.10 FLOOR STAND

8.10.1 FLOOR STAND U843.00

Spare parts list Floor stand U843.00


1 Right leg 1 T6167.00

2 Left leg 1 T6167.00A

3 Nut M6 1 K316.62

4 Washer 6 9 K505.62

5 Gun hook 1 H009.62

6 Support spacer 1 H1156.62



9 Contact washer d.6 4 K564.72


11 Spacer d.14 4 H1178.62

55

ZIP52 2K.

4

7

3

6

4

1

9

8

25

10

5 Nm; 3.7 lbft

5 Nm; 3.7 lbft

C_Z2_00017

OPERATING MANUAL


8.10.2 FLOOR STAND U843.00A

Spare parts list Floor stand U843.00A


1 Right leg 1 T6167.00

2 Left leg 1 T6167.00A

3 Nut M6 1 K316.62

4 Washer 6 5 K505.62

5 Gun hook 1 H009.62

6 Support spacer 1 H1156.62



9 Contact washer d.6 4 K564.72

10 Low self-locking nut M6 4 K311.62A

56

ZIP52 2K.

1

4

5

6

8

12

7

3

2

914

13

10

10

C_Z2_00018

11

OPERATING MANUAL


8.11 ANTIPULSATOR

Spare parts list Antipulsator

Pos K Description Q.ty No.1 Antipulsator body 1 A291.222 Screw 2 K136.623 Contact washer 2 K572.624 Antipulsator cap 1 A292.715 Antipulsator fi lter 1 T455.006 Filter support 1 A364.047 Nipple 3/8 BSP x 1/4 BSP 1 M618.628 Ball 9/16” AISI 420 1 K820.039 Antipulsator seal gasket 1 G605.07

10 Plug 1/4 BSP 2 M623.1211 L-shaped fi tting 1/4 BSP 1 B0462.0312 Antipulsator base 1 A290.2213 Antipulsator spanner 1 T803.6214 Carbon steel antipulsator fi lter T405.00

57

ZIP52 2K.

OPERATING MANUAL


58

ZIP52 2K.

OPERATING MANUAL


GermanyJ.WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 MarkdorfTelephone: ++49/ (0)7544 / 5050 Telefax: ++49/ (0)7544 / 505200 E-Mail:[email protected]

SwitzerlandJ.WAGNER AGIndustriestrasse 22 Postfach 663 CH- 9450 AltstättenTelephone: ++41/ (0)71 / 757 2211 Telefax: ++41/ (0)71 / 757 2222 E-Mail: [email protected]

BelgiumWAGNER Spraytech Benelux BVVeilinglaan 56 B- 1861 WolvertemTelephone: ++32/ (0)2 / 269 4675 Telefax: ++32/ (0)2 / 269 7845 E-Mail: [email protected]

DenmarkWAGNER Spraytech Scandinavia A/S Kornmarksvej 26 DK- 2605 BrøndbyTelephone: ++45/ 43 271 818 Telefax: ++45/ 43 43 05 28 E-Mail [email protected]

United KingdomWAGNER Spraytech (UK) Ltd.Haslemere WayTramway Industrial EstateGB- Banbury, OXON OX16 8TYTelephone: ++44/ (0)1295 / 265 353 Telefax: ++44/ (0)1295 / 269861 E-Mail: [email protected]

FranceJ.WAGNER France S.A.R.L. 5, Ave. du 1er Mai – BP 47 F- 91122 Palaiseau-Cedex

Telephone: ++33/ (0)1 / 69 19 46 76 Telefax: ++33/ (0)1 / 69 81 72 57 E-Mail: [email protected]

NetherlandsWAGNER SPRAYTECH Benelux BVZonnebaan 10 NL- 3542 EC UtrechtPO Box 1656 3600 BR MaarssenTelephone: ++31/ (0)30 / 241 4155 Telefax: ++31/ (0)30 / 241 1787 E-Mail: [email protected]

ItalyWAGNER COLORA S.r.lVia Fermi, 3 I- 20875 Burago di Molgora (MB)

Telephone: ++39/ 039 / 625021 Telefax: ++39/ 039 / 6851800 E-Mail: [email protected]

JapanWAGNER Spraytech Ltd.2-35, Shinden Nishimachi J- Daito Shi, Osaka, 574-0057

Telephone: ++81/ (0)720 / 874 3561 Telefax: ++81/ (0)720 / 874 3426 E-Mail: [email protected]

AustriaJ.WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 MarkdorfTelephone: ++49/ (0)7544 / 5050 Telefax: ++49/ (0)7544 / 505200 E-Mail:[email protected]

SwedenWAGNER SVERIGE AB Muskötgatan 19 S- 25466 HelsingborgTelephone: ++46/ (0)42 150 020 Telefax: ++46/ (0)42 150 035 E-Mail: [email protected]

SpainWAGNER Spraytech Iberica S.A. Ctra. N- 340, Km. 1245,4 E- 08750 Molins de Rei (Barcelona)Telephone: ++34/ (0)93/ 680 0028 Telefax: ++34/ (0)93/ 668 0156 E-Mail: [email protected]

CzechoslovakiaWAGNER s.r.o.Na Belidle 1/63 C- 15000 Praha 5 Telephone: ++420/ (0)2/ 573 123 24 Telefax: ++420/ (0)2/ 545 001 E-Mail: [email protected]

USAWalter Pilot North America46890 Continental DriveChesterfield, MI 48047 USA Telephone: ++1/ 877 / 925-8437 Telefax: ++1/ 586 / 598-1457 http://www.waltherpilotna.com

ZZB025ENG

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